218230

Parts Manual Service Manual
Serial Serial Number Number Range Range
GTH-844
TM
from GTH0813-16606
Part No. 218230 Rev A1 March 2013
March 2013
Introduction
Important
Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual before attempting any maintenance or repair procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes 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 dealer service center.
Serial Number Information

Genie offers the following Service Manuals for these models:
Title Part No.
GTH-844A (from serial number 8418 to 16605) .................... 97487 GTH-844B (from serial number 6946 to 16605) .................... 97487
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.
Copyright 2012 by Terex Industries 218230 Rev A November 2012 Second Edition, First Printing "Genie" is a registered trademark of Terex South Dakota, Inc. in the USA and many other countries. "GTH" is a trademark of Terex South Dakota, Inc. Printed on recycled paper Printed in U.S.A.
Contact Us:
www.genielift.com e-mail: [email protected]
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Part No. 218230
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Revision History
Revision
A A1
Date
11/2012 03/13
Section
3
Procedure / Schematic Page / Description

New Release C-3
REFERENCE EXAMPLES: Kubota Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. 3-2, 6-4, 9-1_Section 4_Repair Procedure. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. Electronic Version Click on any procedure or page number highlighted in blue to view the update.
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REVISION HISTORY, CONTINUED
Revision
Date
Section
Procedure / Schematic Page / Description
REFERENCE EXAMPLES: Kubota Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. 3-2, 6-4, 9-1_Section 4_Repair Procedure. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. Electronic Version Click on any procedure or page number highlighted in blue to view the update.
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INTRODUCTION
Serial Number Legend
A TEREX BRAND
MODEL: GTH844 SERIAL NUMBER:GTH0810-12101 ATTACHMENT: MANUFACTURE DATE:04/12/10 TOTAL TRUCK WEIGHT(LBS): 22,600lbs / 10252kg MAX LIFT CAPACITY(LBS): 8000 LBS LIFT CAPACITY(LBS) AT MAX LIFT HEIGHT: 6000 LBS OUTRIGGERS UP: N/A OUTRIGGERS DOWN: N/A COUNTRY OF MANUFACTURE: United States MANUFACTURER: Terex South Dakota, Inc. 500 Oakwood Road Watertown, SD 57201 United States THIS FORKLIFT TRUCK COMPLIES WITH: ANSI/ITSDF B56.6-2011 CSA B335-04
GTH08 10
Model Year of manufacture
- 12101
Sequence number
Facility code
Serial label (located inside chassis frame plate on cab side) Serial number (stamped on chassis) Serial label (located inside fork frame) (models with quick attach frame)
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Section 1 Safety Rules
Safety Rules
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 symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates an 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.
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 operators 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: - manufacturers instructions and safety rules - employers safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop.
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Section 1 Safety Rules
March 2013
SAFETY RULES
Workplace Safety
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.
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Table of Contents
Introduction Important Information ......................................................................................... ii Serial Number Legend ....................................................................................... iii Section 1 Safety Rules General Safety Rules ........................................................................................ v Section 2 Specifications Machine Specifications ................................................................................ 2 - 1 Performance Specifications ......................................................................... 2 - 2 Hydraulic Specifications ............................................................................... 2 - 3 Hydraulic Component Specifications ............................................................ 2 - 4 Manifold Component Specifications ............................................................. 2 - 5 Air Conditoner Refrigerant Specification....................................................... 2 - 5 Deutz TCD3.6 Engine................................................................................... 2 - 6 Perkins 1104D-E44TA Engine ...................................................................... 2 - 7 Perkins 854-E34TA Engine .......................................................................... 2 - 8 Dana VDT12000 Transmission..................................................................... 2 - 9 Carraro 26.27M Drive Axle ........................................................................... 2 - 9 Hydraulic Hose and Fitting Torque Specifications....................................... 2 - 10 SAE and Metric Fasteners TorqueCharts .................................................. 2 - 11 Section 3 Scheduled Maintenance Procedures Introduction .................................................................................................. 3 - 1 Pre-delivery Preparation Report.................................................................... 3 - 3 Maintenance Inspection Report .................................................................... 3 - 5
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TABLE OF CONTENTS
Section 3
Scheduled Maintenance Procedures, continued Checklist A Procedures A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9 Inspect the Manuals and Decals ......................................................... 3 - 5 Perform Pre-operation Inspection........................................................ 3 - 6 Perform Function Tests ...................................................................... 3 - 6 Lubricate the Boom............................................................................. 3 - 6 Perform Engine Maintenance - All Models........................................... 3 - 7 Perform Transmission Maintenance.................................................... 3 - 8 Perform 30 Day Service...................................................................... 3 - 8 Perform Axle Maintenance.................................................................. 3 - 9 Perform Transmission Maintenance.................................................... 3 - 9
A-10 Perform Axle Maintenance.................................................................. 3 - 9 Checklist B Procedures B-1 B-2 B-3 B-4 B-5 B-6 B-7 B-8 B-9 Inspect the Battery ........................................................................... 3 - 10 Inspect the Electrical Wiring ............................................................. 3 - 11 Check the Exhaust System .............................................................. 3 - 12 Inspect the Engine Air Filter .............................................................. 3 - 13 Inspect the Tires, Wheels and LugNut Torque .................................. 3 - 13 Perform Hydraulic Oil Analysis ......................................................... 3 - 14 Inspect the Fuel and Hydraulic Tank Cap Venting Systems .............. 3 - 14 Perform Engine Maintenance - Deutz Models ................................... 3 - 15 Check the Boom Wear Pads ............................................................. 3 - 16
B-10 Perform Axle Maintenance................................................................ 3 - 17
GTH-844
Part No. 218230
March 2013
TABLE OF CONTENTS
Section 3
Scheduled Maintenance Procedures, continued Checklist C Procedures C-1 C-2 C-3 C-4 D-1 D-2 D-3 D-4 D-5 D-6 D-7 D-8 E-1 E-2 E-3 E-4 E-5 E-6 E-7 Perform Engine Maintenance - Deutz Models ................................... 3 - 18 Perform Engine Maintenance - PerkinsModels ................................. 3 - 18 Perform Engine Maintenance - PerkinsModels ................................. 3 - 19 Inspect and Lubricate the SequencingChains ................................... 3 - 19 Inspect the Forks .............................................................................. 3 - 21 Adjust the Boom Sequencing Chains ................................................ 3 - 21 Replace the Hydraulic Tank ReturnFilter Element ............................ 3 - 22 Perform Transmission Maintenance.................................................. 3 - 23 Perform Engine Maintenance - Deutz Models ................................... 3 - 23 Perform Engine Maintenance - PerkinsModels ................................. 3 - 24 Perform Axle Maintenance................................................................ 3 - 24 Perform Engine Maintenance - PerkinsModels ................................. 3 - 25 Test or Replace the Hydraulic Oil ...................................................... 3 - 26 Perform Engine Maintenance - PerkinsModels ................................. 3 - 27 Perform Engine Maintenance - PerkinsModels ................................. 3 - 27 Perform Engine Maintenance - Deutz Models ................................... 3 - 28 Perform Engine Maintenance - PerkinsModels ................................. 3 - 28 Perform Engine Maintenance - Deutz Models ................................... 3 - 29 Perform Engine Maintenance - PerkinsModels ................................. 3 - 29
Checklist D Procedures
Checklist E Procedures
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TABLE OF CONTENTS
Section 4
Repair Procedures Introduction .................................................................................................. 4 - 1 Boom Components 1-1 1-2 1-3 1-4 1-5 2-1 2-2 3-1 4-1 4-2 5-1 6-1 Boom Proximity Switches ................................................................... 4 - 2 Boom .................................................................................................. 4 - 3 Boom Lift Cylinder ............................................................................ 4 - 10 Boom Extension Cylinder ................................................................. 4 - 12 Fork Level Cylinder........................................................................... 4 - 12 Operator's Compartment ................................................................... 4 - 16 Machine Controls .............................................................................. 4 - 18 Fuel and Hydraulic Tanks ................................................................. 4 - 22 Engines ............................................................................................ 4 - 23 Engine Fault Codes .......................................................................... 4 - 32 Transmission .................................................................................... 4 - 24 Hydraulic Pump ................................................................................ 4 - 26
Operator's Compartment
Fuel and Hydraulic Tanks
Engines
Transmission
Hydraulic Pumps
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TABLE OF CONTENTS
Section 4
Repair Procedures, continued Manifolds 7-1 7-2 7-3 7-4 7-5 7-6 8-1 Primary Function Manifold Components Models with Single Joystick ............................................................. 4 - 30 Primary Function Manifold Components Models with Dual Joysticks .............................................................. 4 - 34 Secondary Function Manifold Components....................................... 4 - 38 Auxiliary Manifold (option) and BrakeManifold Components ............. 4 - 40 Valve Adjustments - Secondary Function Manifold ........................... 4 - 41 Valve Coils ....................................................................................... 4 - 45 Axles ................................................................................................ 4 - 47
Axle Components
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TABLE OF CONTENTS
Section 5
Fault Codes Introduction .................................................................................................. 5 - 1 Diagnostic Display ....................................................................................... 5 - 2 Engine Fault Codes - DeutzModels ............................................................. 5 - 3 Engine Fault Codes - Perki ns 1104D Models.............................................. 5 - 13
Section 6
Schematics Introduction .................................................................................................. 6 - 1 Fuse Panel Layout ....................................................................................... 6 - 2 Electrical Component & Wire ColorLegend .................................................. 6 - 3 Electrical and Hydraulic Symbols Legends................................................... 6 - 5 Electrical Schematic - View 1....................................................................... 6 - 8 Electrical Schematic - View 2....................................................................... 6 - 9 Hydraulic Schematic - Single Joystick ....................................................... 6 - 12 Hydraulic Schematic - Dual Joysticks ........................................................ 6 - 13
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Section 2 Specifications
Specifications
Machine Specifications
Fluid capacities Fuel tank Hydraulic tank Hydraulic system (including tank) 35 gallons 132.5 liters 40 gallons 151.4 liters 55 gallons 208.2 liters Tires and wheels Tire size Tire ply rating Weight, rough terrain tire (air filled) Weight, rough terrain tire (foam filled) Tire pressure (models with air-filled tires) Lug nut torque Lug pattern Wheel diameter Wheel width 13.00 x 24 12 315 lbs 142.9 kg 967 35 lbs 439 16 kg 62 psi 4.3 bar 295 ft-lbs 400 Nm 8 x 10.826 24 in 60.1 cm 9 in 22.9 cm
For operational specifications, refer to the Operator's Manual.
Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.
Part No. 218230
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November 2012
SPECIFICATIONS
Performance Specifications
Drive speed, maximum Deutz 3.6 TCD Engines Perkins 1104D Engine Perkins 854 Engine Draw bar pull Lift capacity, maximum 15 mph 24.1 km/h 14 mph 22.5 km/h 16 mph 25.7 mph 21,000 lbs 9525 kg 8000 lbs 3629 kg
Boom function speeds, maximum Boom up Boom down Boom extend Boom retract Fork rotate Fork tilt up Fork tilt down 12 to 14 seconds 9 to 11 seconds 13 to 15 seconds 8 to 10 seconds 3 to 6 seconds 6 to 8 seconds 5 to 7 seconds
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SPECIFICATIONS
Hydraulic Specifications
Hydraulic Oil Specifications Hydraulic oil type Viscosity grade Viscosity index Chevron Rando HD equivalent Multi-viscosity 200 15/13 200 ppm
Optional Fluids Biodegradable Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE-S UCON Hydrolube HP-5046 Quintolubric 822 Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron Aviation A Eni Arnica 32
Fire resistant Mineral based
Cleanliness level, minimum Water content, maximum
Chevron Rando HD oil is fully compatible and mixable with Shell Donax TG (Dexron III) oils. 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, corrosion inhibition, seal conditioning, and foam and aeration suppression properties.
Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32F / 0C may result in component damage. Note: Use Chevron Aviation A hydraulic fluid when ambient temperatures are consistently below 0F / -17C. Note: Use Shell Tellus S2 V46 hydraulic oil when oil temperatures consistently exceed 205F / 96C. Note: Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult the Genie Industries Service Department before use.
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SPECIFICATIONS
Hydraulic Components Specifications

Function Pump Type: Displacement Flow rate @ 2500 rpm Pump pressure, maximum Pressure compensator Standby pressure variable displacement piston pump 0 to 3.1 cu in 0 to 51 cc 34 gpm 128 L/min 3190 psi 220 bar 3190 psi 220 bar 450 psi 31 bar
Primary Function Manifold System relief valve pressure, maximum (measured at test port TP) Fork tilt relief valve pressure, maximum Flow regulator, Sway circuit Secondary Function Manifold Steer relief valve pressure, maximum (measured at test port TS) 2650 psi 182.7 bar 35000 psi 241 bar 3500 psi 241 bar 2 gpm 7.5 L/min
Parking brake relief valve pressure, maximum 350 psi (measured at test port TPB) 24.1 bar Diff lock relief valve pressure, maximum (measured at test port TJ) Rear lock-up relief valve pressure, maximum (measured at test port TR) 400 psi 27.5 bar 50 psi 3.4 bar
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Part No. 218230
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SPECIFICATIONS
Manifold Component Specifications

Plug torque SAE No. 2 SAE No. 4 SAE No. 6 SAE No. 8 SAE No. 10 SAE No. 12 50 in-lbs / 6 Nm 13 ft-lbs / 18 Nm 18 ft-lbs / 24 Nm 50 ft-lbs / 68 Nm 55 ft-lbs / 75 Nm 75 ft-lbs / 102 Nm
Air Conditioner Refrigerant Specifications

System Full Charge R134a 1 lb 14 oz
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SPECIFICATIONS
Deutz TCD3.6 L4 Engine

Displacement Number of cylinders Bore & stroke Horsepower Peak Torque Firing order Compression ratio Combustion Governor Low idle Frequency High idle Frequency Lubrication system Minimum oil pressure (warm, at low idle) Oil capacity (including filter) 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 requirements, refer to the Engine Operator's Manual on your machine. 23.5 psi 1.6 bar 9.5 quarts 9 liters 221 cu in 3.62 liters 4 3.86 x 4.72 inches 98 x 120 mm 99 @ 2300 rpm 73.8 kw @ 2300 rpm 288 lb-ft @ 1600 rpm 390 Nm @ 1600 rpm 1-3-4-2 17.2:1 Direct injection Electronic 1000 rpm 200 Hz 2400 rpm 500 Hz
Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Fuel injection pressure, maximum Engine coolant Capacity Type Alternator Output Starter Motor Normal load Relay max Relay continuous Cranking speed Glow Plugs Initial load (0-6 sec) Continuous load (>6 sec) Battery Type Group Quantity Cold cranking ampere @ 0F Reserve capacity @ 25A rate 12V DC C31 1 1000A 200 minutes 80 amps <40 amps 300-400 A 60 A 12 A >100 rpm 95 A, 12V DC 4.5 gallons 17 liters Extended Life 23200 psi 1600 bar
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Part No. 218230
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SPECIFICATIONS
Perkins 1104D-E44TA Engine

Displacement Number of cylinders Bore and stroke Horsepower Peak Torque Firing order Compression ratio Combustion Governor Low idle Frequency High idle Frequency Lubrication system Oil pressure (hot @ 2300 rpm) Minimum pressure Oil capacity (including filter) Oil viscosity requirements Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operation and Maintenance Manual on your machine. 43-58 psi 2.96-4 bar 7.1 psi 10 quarts 9.6 liters 269 cu in 4.4 liters 4 4.13 x 5 inches 105 x 127 mm 99 @ 2200 rpm 73.8 kW @ 2200 rpm 310 lb-ft @ 1400 rpm 420 Nm @ 1400 rpm 1-3-4-2 16.2:1 E-TVCS Electronic 1000 rpm 200 Hz 2500 rpm 500 Hz
Fuel requirement For fuel requirements, refer to the engine Operation Manual on your machine. Fuel injection pressure Engine coolant Capacity Type Alternator Output Starter Motor Normal load Relay max Relay continuous Cranking speed Glow Plugs Initial load (0-4 sec) Continuous load (>4 sec) Battery Type Group Quantity Cold cranking ampere @ 0F Reserve capacity @ 25A rate 12V DC C31 1 1000A 200 minutes 20 A (EA) 15 A (EA) 68 A 50 A 20 A 130 - 200 rpm 85 A, 14V DC 4.6 gallons 17.4 liters Extended Life 23700 psi 1635 bar
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SPECIFICATIONS
Perkins 854E-E34TA Engine

Displacement Number of cylinders Bore and stroke Horsepower Peak Torque Firing order Compression ratio Governor Low idle Frequency High idle Frequency Lubrication system Minimum oil pressure Maximum oil capacity (including filter) 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 requirements, refer to the Engine Operation and Maintenance Manual on your machine. 12 psi 0.83 bar 8.8 quarts 8.3 liters 207 cu in 3.4 liters 4 3.9 x 4.3 inches 99 x 110 mm 99 @ 2500 rpm 73.8 kW @ 2500 rpm 288 lb-ft @ 1400 rpm 390 Nm @ 1400 rpm 1-3-4-2 17:1 Electronic 1000 rpm 100 Hz 2700 rpm 270 Hz
Fuel requirement For fuel requirements, refer to the engine Operation Manual on your machine. Fuel Injection Pressure Engine coolant Capacity Type Alternator Output Starter Motor Normal load Relay max Relay continuous Cranking speed Glow Plugs Initial load (0-10 sec) Continuous load (>10 sec) Battery Type Group Quantity Cold cranking ampere @ 0F Reserve capacity @ 25A rate 12V DC C31 1 1000A 200 minutes 80 amps 40 amps 68 A 50 A 20 A 130 - 200 rpm 120 A, 12V DC 4.9 gallons 18.5 liters Extended Life 23000 psi 1585 bar
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November 2012
SPECIFICATIONS
Dana VDT12000 Transmission

Transmission Type Speeds, Forward Speeds, Reverse Torque Converter Maximum input Size Lubrication Oil capacity, transmission Oil capacity, drop box Oil viscosity requirements Units ship with Chevron Ursa Hydraulic 10W. Extreme operating temperatures may require the use of alternative transmission oils. For oil requirements, refer to the Dana VDT12000 Service Manual (Dana part number TSM-0022). Dana VDT12000 Service Manual Genie part number 218706 14.3 quarts 13.5 liters 1.1 quart 1 liter 3100 rpm 12 inches 3 speed powershift converter 3 3
Carraro 26.27M Drive Axle

Steering Joints Steering angle, maximum Front Axle Lubrication Front differential Axle planetary end (each) Rear Axle Lubrication Rear differential Axle planetary end (each) Oil viscosity requirements Differential Planetary ends Chevron Supreme 80W90 LS Chevron Supreme 80W90 LS 7.9 quarts 7.5 liters 0.8 quarts 0.8 liters 7.4 quarts 7 liters 0.8 quarts 0.8 liters Integrated steer cylinder Heavy duty double U-joints 45
For additional axle information, refer to the Carraro 26.27M Axle Maintenance and Repair Manual. Carraro 26.27M Axle Maintenance and Repair Instructions Genie part number 218710
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SPECIFICATIONS
Hydraulic Hose and Fitting Torque Specifications

Your machine is equipped with Parker Seal-Lok fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.
Seal-Lok fittings 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight. Note: The O-rings used in the Parker Seal Lok fittings and hose ends are custom-size O-rings. They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part number 49612). 2 Lubricate the O-ring before installation. 3 Be sure that the face seal O-ring is seated and 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 per given size as shown in the table. 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks.
SAE O-ring Boss Port

(tube fitting - installed into Aluminum) SAE Dash size -4 -6 -8 -10 -12 -16 -20 -24 Torque 11 ft-lbs / 14.9 Nm 23 ft-lbs / 31.2 Nm 40 ft-lbs / 54.2 Nm 69 ft-lbs / 93.6 Nm 93 ft-lbs / 126.1 Nm 139 ft-lbs / 188.5 Nm 172 ft-lbs / 233.2 Nm 208 ft-lbs / 282 Nm
SAE O-ring Boss Port

(tube fitting - installed into Steel) SAE Dash size -4 -6 -8 -10 -12 -16 -20 -24 Torque 16 ft-lbs / 21.7 Nm 35 ft-lbs / 47.5 Nm 60 ft-lbs / 81.3 Nm 105 ft-lbs / 142.4 Nm 140 ft-lbs / 190 Nm 210 ft-lbs / 284.7 Nm 260 ft-lbs / 352.5 Nm 315 ft-lbs / 427.1 Nm
Seal-Lok Fittings
(hose end) SAE Dash size -4 -6 -8 -10 -12 -16 -20 -24 Torque 18 ft-lbs / 24.4 Nm 27 ft-lbs / 36.6 Nm 40 ft-lbs / 54.2 Nm 63 ft-lbs / 85.4 Nm 90 ft-lbs / 122 Nm 120 ft-lbs / 162.7 Nm 140 ft-lbs / 190 Nm 165 ft-lbs / 223.7 Nm
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SPECIFICATIONS
SAE FASTENER TO RQ UE C HART

Thi s charti st o be used as a gui de onl y unl ess not ed el sew here i nt hi s m anual
SI ZE
TH READ
LUBED
i n-l bs
Gr ade 5
DRY
i n-l bs Nm
Gr ade 8
LUBED
i n-l bs Nm i n-l bs
DRY
Nm
A 574 Hi gh St rengt h Bl ack O xi de Bol t s LUBED

i n-l bs Nm
Nm
1/ 4
20 28
80 90
ft-l bs
9 10. 1
Nm
100 120 DRY

ft-l bs
11. 3 13. 5
Nm
110 120
ft-l bs
12. 4 13. 5
Nm
140 160 DRY

ft-l bs
15. 8 18
Nm
130 140 LUBED

ft-l bs
14. 7 15. 8
Nm
LUBED 5/ 16 3/ 8 7/ 16 1/ 2 9/ 16 5/ 8 3/ 4 7/ 8 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 13 14 23 26 37 41 57 64 80 90 110 130 200 220 320 350 480 530 590 670 840 930 1460 1640 17. 6 19 31. 2 35. 2 50. 1 55. 5 77. 3 86. 7 108. 4 122 149 176 271 298 433 474 650 718 800 908 1138 1260 1979 2223 17 19 31 35 49 55 75 85 110 120 150 170 270 300 430 470 640 710 790 890 1120 1240 1950 2190
LUBED 18 20 33 37 50 60 80 90 120 130 160 180 280 310 450 500 680 750 970 1080 1360 1510 2370 2670 24 27. 1 44. 7 50. 1 67. 8 81. 3 108. 4 122 162 176 217 244 379 420 610 678 922 1016 1315 1464 1844 2047 3213 3620 25 27 44 49 70 80 110 120 150 170 210 240 380 420 610 670 910 990 1290 1440 1820 2010 3160 3560
1 1 1/ 8 1 1/ 4 1 1/ 2
23 25. 7 42 47. 4 66. 4 74. 5 101. 6 115 149 162 203 230 366 406 583 637 867 962 1071 1206 1518 1681 2643 2969
33. 9 36. 6 59. 6 66. 4 94. 7 108. 4 149 162 203 230 284 325 515 569 827 908 1233 1342 1749 1952 2467 2725 4284 4826
21 24 38 43 61 68 93 105 130 140 180 200 320 350 510 560 770 840 1090 1220 1530 1700 2670 3000
28. 4 32. 5 51. 5 58. 3 82. 7 92. 1 126 142 176 189 244 271 433 474 691 759 1044 1139 1477 1654 2074 2304 3620 4067
M ETRI C FASTENER TO RQ UE C HART

Thi s charti st o be used as a gui de onl y unl ess not ed el sew here i nt hi s m anual
Si ze
( m m) 5 6 7
i n-l bs
Cl ass 4. 6
LUBED
Nm i n-l bs
4.6
Cl ass 8. 8
LUBED
8.8
Cl ass 10. 9
LUBED
10.9
Cl ass 12. 9
LUBED
12.9
DRY
Nm
DRY
Nm
DRY
Nm
DRY
Nm
16 19 45
ft-l bs
1. 8 3. 05 5. 12
Nm
21 36 60
ft-l bs
2. 4 4. 07 6. 83 DRY
Nm
41 69 116
ft-l bs
4. 63 7. 87 13. 2
Nm
54 93 155
ft-l bs
6. 18 10. 5 17. 6
Nm
58 100 167
ft-l bs
6. 63 11. 3 18. 9
Nm
78 132 223
ft-l bs
8. 84 15 25. 2
Nm
68 116 1. 95
ft-l bs
7. 75 13. 2 22. 1
Nm
91 155 260
ft-l bs
10. 3 17. 6 29. 4

Nm
LUBED 8 10 12 14 16 18 20 22 24 5. 4 10. 8 18. 9 30. 1 46. 9 64. 5 91 124 157 7. 41 14. 7 25. 6 40. 8 63. 6 87. 5 124 169 214
LUBED 14 27. 9 48. 6 77. 4 125 171 243 331 420 19. 1 37. 8 66 105 170 233 330 450 570
DRY 18. 8 37. 2 64. 9 103 166 229 325 442 562 25. 5 50. 5 88 140 226 311 441 600 762
LUBED 20. 1 39. 9 69. 7 110 173 238 337 458 583 27. 3 54. 1 94. 5 150 235 323 458 622 791
DRY 26. 9 53. 2 92. 2 147 230 317 450 612 778 36. 5 72. 2 125 200 313 430 610 830 1055
LUBED 23. 6 46. 7 81 129 202 278 394 536 682 32 63. 3 110 175 274 377 535 727 925
DRY 31. 4 62. 3 108 172 269 371 525 715 909 42. 6 84. 4 147 234 365 503 713 970 1233
7. 2 14. 4 25. 1 40 62. 5 86. 2 121 166 210
9. 88 19. 6 34. 1 54. 3 84. 8 117 165 225 285
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Part No. 218230
November 2012
Section 3 Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety warnings and step-by-step instructions.
Observe and Obey:

Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. Scheduled maintenance inspections shall be completed daily, quarterly, semi-annually, annually and every 2 years as specified on the Maintenance Inspection Report. The frequency and extent of periodical examinations and tests may also depend on national regulations.
Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following: Symbols Legend Safety alert symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates an 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. Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps.
Failure to perform each procedure as presented and scheduled could result in death, serious injury or substantial damage. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Use only Genie approved replacement parts. Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection. Unless otherwise specified, perform each maintenance procedure with the machine in the following configuration: Machine parked on a firm, level surface Boom in the stowed position Key switch in the off position with the key removed Wheels chocked
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SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Note: The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below.
Pre-delivery Preparation Report The pre-delivery preparation report contains checklists for each type of scheduled inspection. Make copies of the Pre-delivery Preparation report to use for each inspection. Store completed forms as required. Maintenance Schedule
Indicates that tools will be required to perform this procedure.
Indicates that new parts will be required to perform this procedure.
Indicates that a cold engine will be required to perform this procedure.
There are five types of maintenance inspections that must be performed according to a schedule daily, quarterly, semi-annually, annually, and two year. The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsectionsA, B, C, D, and E. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection.
Inspection Checklist A A+B A+B+C A+B+C+D A+B+C+D+E
Indicates that a warm engine will be required to perform this procedure.
Daily or every 8 hours Quarterly or every 250 hours
Indicates that dealer service will be required to perform this procedure.
Semi-annually or every 500 hours Annually or every 1000 hours Two year or every 2000 hours
Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years.
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Pre-Deliver y Preparation Pre-Delivery

Fundamentals
It is the responsibility of the dealer to perform the Pre-delivery Preparation. The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service. A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service. Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications. Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual.
Instructions
Use the operators manual on your machine. The Pre-delivery Preparation consists of completing the Pre-operation Inspection, the Maintenance items and the Function Tests. Use this form to record the results. Place a check in the appropriate box after each part is completed. Follow the instructions in the operators manual. If any inspection receives an N, remove the machine from service, repair and reinspect it. After repair, place a check in the R box. Legend Y = yes, completed N = no, unable to complete R = repaired Comments
Pre-Delivery Preparation Pre-operation inspection completed Maintenance items completed Function tests completed
Model Serial number Date Machine owner Inspected by (print) Inspector signature Inspector title Inspector company
Terex South Dakota, Inc USA 500 Oak Wood Road PO Box 1150 Watertown, SD 57201-6150 (605) 882-4000 Genie UK The Maltings, Wharf Road Grantham, Lincolnshire NG31- 6BH England (44) 1476-584333
Copyright 2011 Terex Corporation. Genie is a registered trademark of Terex South Dakota, Inc. 218230 Rev A
November 2012
Maintenance Inspection Report

Model Serial number Date Hour meter Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection. Select the appropriate checklist(s) for the type of inspection to be performed. Daily or 8 hour Inspection: Quarterly or 250 hour Inspection: Checklist A A-1 Manuals and decals A-2 Pre-operation inspect A-3 Function tests A-4 Lubricate boom A-5 Engine maintenance All models A-6 Transmission maintenance Perform after 40 hours: A-7 30 day service Perform after 50 hours: A-8 Axle maintenance Perform after 100 hours: A-9 Transmission Perform after 150 hours: A-10 Axle maintenance Checklist B B-1 Battery B-2 Electrical wiring B-3 Exhaust system A A+B B-4 Engine air filter B-5 Tires and wheels B-6 Hydraulic oil B-7 Tank venting systems B-8 Engine maintenance Deutz models B-9 Boom wear pads Perform every 300 hours: B-10 Axle maintenance Y N R Y N R Checklist C C-1 Engine maintenance Deutz models C-2 Engine maintenance Perkins models C-3 Engine maintenance Perkins models C-4 Inspect and lubricate sequencing chains Checklist D D-1 Forks D-2 Sequencing chains D-3 Hydraulic return filter D-4 Transmission D-5 Engine maintenance Deutz models D-6 Engine maintenance Perkins models Perform every 1500 hours: D-7 Axle maintenance D-8 Engine maintenance Perkins models Checklist E E-1 Hydraulic oil E-2 Engine maintenance Perkins models Perform every 3000 hours: E-3 Engine maintenance Perkins models E-4 Engine maintenance Deutz models Perform every 4000 hours: E-5 Engine maintenance Perkins models Perform every 5000 hours: E-6 Engine maintenance Deutz models Perform every 12,000 hours: E-7 Engine maintenance Perkins models Comments Y N R Y N R Y N R
Semi-annually or 500 hour Inspection: A+B+C Annually or 1000 hour Inspection: A+B+C+D 2 Year or 2000 hour Inspection: A+B+C+D+E Place a check in the appropriate box after each inspection procedure is completed. Use the step-by-step procedures in this section to learn how to perform these inspections. If any inspection receives an N, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the R box. Legend Y = yes, acceptable N = no, remove from service R = repaired
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Checklist A Procedures
A-1 Inspect the Manuals and Decals
Note: Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first. Maintaining the operators and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the operator's compartment. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition. In addition, maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using this machine. They also provide users with operation and maintenance information. An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions. 1 Check to make sure that the operator's and safety manuals are present and complete in the storage container in the operator's compartment. 2 Examine the pages of each manual to be sure that they are legible and in good condition. Result: The operator's manual is appropriate for the machine and all manuals are legible and in good condition. Result: The operator's manual is not appropriate for the machine or all manuals are not in good condition or is illegible. Remove the machine from service until the manual is replaced. 3 Open the operator's manual to the decals inspection section. Carefully and thoroughly inspect all decals on the machine for legibility and damage. Result: The machine is equipped with all required decals, and all decals are legible and in good condition. Result: The machine is not equipped with all required decals, or one or more decals are illegible or in poor condition. Remove the machine from service until the decals are replaced. 4 Always return the manuals to the storage container after use. Note: Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed.
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CHECKLIST A PROCEDURES
A-2 Perform Pre-operation Inspection

Note: Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first. Completing a Pre-operation Inspection is essential to safe machine operation. The Pre-operation Inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests. The Pre-operation Inspection also serves to determine if routine maintenance procedures are required. Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine.
A-4 Lubricate the Boom
Note: Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first. Greasing the specified locations is essential for good machine performance and service life. Operating the machine with little or no grease may cause the machine to perform poorly and continued use may cause component damage. 1 Fully extend and raise the boom, then retract the boom, checking to insure it operates smoothly. There should be a light film of lubricant on wear pad contact surfaces. Result: Boom operates smoothly and a thin film of lubricant is visible. Proceed to step 5. Result: Boom does not extend or retract smoothly and no lubricant is visible on wear pad contact surfaces. Proceed to step 2. 2 Apply a thin layer of grease to the underside of the number 3 boom tube where it makes contact with the number 2 boom tube lower wear pads.
A-3 Perform Function Tests

Note: Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first. Completing the function tests is essential to safe machine operation. Function tests are designed to discover any malfunctions before the machine is put into service. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service. Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine.
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3 Apply a thin layer of grease to the underside of the number 2 boom tube where it makes contact with the number 1 boom tube lower wear pads. 4 Lubricate the top and side boom tube wear pads. 5 Return the boom to the stowed position.
Grease specification EP NLGI 2 (lithium based) or equivalent Lube-A-Boom grease, 7 lb pail (recommended) Genie part number 110147 Chevron Ultra-Duty EP 2 grease (alternate)
A-5 Perform Engine Maintenance All Models
Note: Engine specifications require that this procedure be performed every 8 hours or daily, whichever comes first. Engine oil level - check Coolant level - check/add Fuel system filter/water separator - drain Engine tightness - check or leaks Exhaust system - check for leaks Required maintenance procedures and additional engine information is available in the Perkins 1100D Operation and Maintenance Manual (Perkins part number SEBU8172-00), Perkins 854 Operation and Maintenance Manual (Perkins part number SEBU8726-01), OR the Deutz TCD3.6 Operation Manual (Deutz part number 0312 3907).
Perkins 1100D Operation and Maintenance Manual Genie part number 123702 Perkins 854 Operation and Maintenance Manual Genie part number 218708 Deutz TCD3.6 Operation Manual Genie part number
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A-6 Perform Transmission Maintenance
A-7 Perform 30 Day Service
Note: Transmission specifications require that this procedure be performed every 8 hours or daily, whichever comes first. Transmission oil level - check/add* Drop box oil level - check/add* *check oil with engine running at idle and oil at 180200 F / 65-93 C Required maintenance procedures and additional transmission information is available in the Dana VDT12000 Service Manual (Dana part number TSM-0022).
Dana VDT12000 Service Manual Genie part number
The 30 day maintenance procedure is a one-time sequence of procedures to be performed after the first 30 days or 40 hours of usage. After this interval, refer to the maintenance checklists for continued scheduled maintenance. 1 Perform the following maintenance procedures: B-5 Inspect the Tires, Wheels and Lug Nut Torque D-3 Replace the Hydraulic Tank Return Filter Element Check belt tension Check the engine mounts Check hose clamps
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A-8 Perform Axle Maintenance
A-9 Perform Transmission Maintenance
Note: Axle specifications require that this procedure be performed after 50 hours. Oil level - check/add Required maintenance procedures and additional axle information is available in the Carraro 26.27M Axle Maintenance and Repair Manual (Carraro part number CA270077).
Carraro 26.27M Axle Maintenance and Repair Instructions Genie part number 218710
Note: Manufacturer specifications require that this one-time procedure be performed after 100 hours of operation. Change transmission filter Required maintenance procedures and additional axle information is available in the Dana VDT12000 Service Manual (Dana part number TSM-0022).
218706
A-10 Perform Axle Maintenance
Note: Axle specifications require that this one-time procedure be performed after 150 hours of operation. Change axle oil Clean magnetic oil plugs Oil breather - clean Grease axle (if required) Required maintenance procedures and additional axle information is available in the Carraro 26.27M Axle Maintenance and Repair Manual (Carraro part number CA270077).
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Checklist B Procedures
B-1 Inspect the Batteries
3 Be sure that the battery cable connections are free of corrosion. Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper battery condition is essential to good engine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions. Electrocution/burn hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water. Note: Perform this test after fully charging the batteries. Note: For a more accurate determination of the battery condition, fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize. 1 Put on protective clothing and eye wear. 2 Remove the cover from the auxiliary power unit batteries located at the ground controls side of the machine. Note: Perform the remaining steps on the auxiliary power unit batteries and the engine starting battery. 4 Be sure that the battery retainers and cable connections are tight. 5 Be sure that the battery separator wire connections are tight. 6 Fully charge the battery(s) and allow the battery(s) to rest at least 6 hours. 7 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. 8 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: Add 0.004 to the reading of each cell for every 10 / 5.5 C above 80 F / 26.7 C. Subtract 0.004 from the reading of each cell for every 10 / 5.5 C below 80 F / 26.7 C. Result: All battery cells display an adjusted specific gravity of 1.277 or higher. The battery is fully charged. Proceed to step 12. Result: One or more battery cells display a specific gravity of 1.217 or below. Proceed to step 9.
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CHECKLIST B PROCEDURES
9 Perform an equalizing charge OR fully charge the battery(s) and allow the battery(s) to rest at least 6 hours. 10 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. 11 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: Add 0.004 to the reading of each cell for every 10 / 5.5 C above 80 F / 26.7 C. Subtract 0.004 from the reading of each cell for every 10 / 5.5 C below 80 F / 26.7 C. Result: All battery cells display a specific gravity of 1.277 or greater. The battery is fully charged. Proceed to step 12. Result: The difference in specific gravity readings between cells is greater than 0.1 OR the specific gravity of one or more cells is less than 1.177. Replace the battery. 12 Check the battery acid level. If needed, replenish with distilled water to 1/8 inch / 3 mm below the bottom of the battery fill tube. Do not overfill. 13 Install the vent caps and neutralize any electrolyte that may have spilled.
B-2 Inspect the Electrical Wiring
Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage. Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Inspect the following areas for burnt, chafed, corroded and loose wires: Inside of the operator's compartment Underside of the chassis Boom assembly 2 Inspect for a liberal coating of dielectric grease in the following locations: All harness connectors 3 Start the engine and raise the boom so there is enough room to access and remove all the covers attached to the chassis.
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4 Attach a lifting strap from an overhead crane to the boom. Support the boom. Do not apply any lifting pressure. 5 Remove all engine covers, hydraulic tank covers and chassis covers. Crushing hazard. Death or serious injury could result if the boom should unexpectedly fall while working underneath the boom. Do not stand or work beneath a boom that is not properly supported. 6 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: Engine Transmission Manifolds Chassis 7 Inspect for a liberal coating of dielectric grease in all connections between the engine, transmission and the operator's compartment. 8 Install all covers removed in step 5. 9 Remove the lifting strap from the overhead crane. 10 Start the engine and lower the boom to the stowed position. Turn the machine off.
B-3 Check the Exhaust System
Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the exhaust system is essential to good engine performance and service life. Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Bodily injury hazard. Beware of hot engine components. Contact with hot engine components may cause severe burns. 1 Open the engine access cover. 2 Be sure that all fasteners are tight. 3 Inspect all welds for cracks. 4 Inspect for exhaust leaks; i.e., carbon buildup around seams and joints. 5 Close the engine access cover.
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B-4 Inspect the Engine Air Filter
B-5 Inspect the Tires, Wheels and Lug Nut Torque
Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Perform this procedure more often if dusty conditions exist. Maintaining the engine air filter in good condition is essential to good engine performance and service life. Failure to perform this procedure can lead to poor engine performance and component damage. Note: Perform this procedure with the engine off. 1 Release the latches on the front cover of the air cleaner assembly. Remove the cover. 2 Gently twist and pull out the external or primary filter element. 3 Remove the inner or secondary filter element. 4 Clean the inside of the canister and the gasket with a damp cloth. 5 Inspect the primary and secondary air filter elements. If needed, blow from the inside out using low pressure dry compressed air, or carefully tap out dust. 6 Install the secondary filter element first, then install the primary filter element. 7 Install the front cover onto the air cleaner assembly and secure the latches.
Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the tires and wheels in good condition, including proper wheel fastener torque, is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion. Bodily injury hazard. An overinflated tire can explode and could result in death or serious injury. Tip over hazard. Do not use temporary flat tire repair products. Note: The tires on some machines are foam filled and do not need air added to them. 1 Check all tire treads and sidewalls for cuts, cracks, punctures and unusual wear. 2 Check each wheel for damage, bends and cracks. 3 Check each lug nut for proper torque. Refer to Section 2, Specifications. 4 Check the air pressure in each tire. Refer to Section 2, Specifications.
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B-6 Perform Hydraulic Oil Analysis
B-7 Inspect the Fuel and Hydraulic Tank Cap Venting Systems
Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often. Refer to Section 2, Specifications. Note: Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. See E-1, Test or Replace the Hydraulic Oil.
Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Perform this procedure more often if dusty conditions exist. Free-breathing fuel and hydraulic tank caps are essential for good machine performance and service life. A dirty or clogged tank vent system may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the vent system be inspected more often. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Note: Perform this procedure with the engine off. 1 Identify the vent tube breather from the fuel tank under the chassis center cover. 2 Check for proper venting. Result: Air passes through the vent tube. Proceed to step 4. Result: If air does not pass through the vent tube, clean or replace the tube. Proceed to step 3. Note: When checking for positive tank cap venting, air should pass freely through the tube.
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3 Using a mild solvent, carefully wash the tube venting system. Dry using low pressure compressed air. Repeat this procedure beginning with step 2. 4 Install the fuel tank cap onto the fuel tank. 5 Remove the breather cap from the hydraulic tank. 6 Check for proper venting. The cap is pressureized to 3 psi. Result: Air passes through the hydraulic tank cap. Proceed to step 8. Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 7. Note: When checking for positive tank cap venting, air should pass freely through the cap. 7 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat this procedure beginning with step 6. 8 Install the breather cap onto the hydraulic tank.
B-8 Perform Engine Maintenance Deutz Models
Note: Engine specifications require that this procedure be performed every 250 hours. Engine oil and filter - change Engines with exhaust after-treatment system Deutz DQC II LA approved oil API CJ-4 low ash oil Deutz DQC III LA approved oil in extreme conditions. Engines without exhaust after-treatment system Deutz DQC II LA approved oil API CJ-4 low ash approved oil Deutz DQC III approved oil in extreme conditions Deutz DQC III LA approved oil in extreme conditions Required maintenance procedures and additional engine information is available in the Deutz TCD3.6 Operation Manual (Deutz part number 0312 3907).
Deutz TCD3.6 Operation Manual Genie part number
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B-9 Check the Boom Wear Pads

upper wear pad groove
Note: Genie specifications require that this procedure be performed every 250 hours of operation. 1 Extend the boom until the wear pads are accessible. Note: It may be necessary to remove the wear pad retainer plates to expose the wear pads. 2 Inspect the end of each upper wear pad. Result: The wear pad grooves are visible on the end of the wear pad. Result: The grooves on the end of the wear pad are no longer visible. Replace both wear pads. Refer to Repair Procedure 1-2, How to Replace the Boom Wear Pads. 3 Repeat the procedure for the lower wear pads. 4 Measure each side wear pad. Result: The measurement is within specification. Result: The measurement is less than specification. Replace all side wear pads. Refer to Repair Procedure 1-2, How to Replace the Boom Wear Pads.
upper wear pad groove
Boom Wear Pad Specifications, GTH-844 Side wear pad thickness, minimum
3/8 inch 9.5 mm
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B-10 Perform Axle Maintenance
Note: Axle specifications requires that this procedure be performed every 300 hours of operation. Oil level - check/add Oil breather - clean Required maintenance procedures and additional axle information is available in the Carraro 26.27M Axle Maintenance and Repair Manual (Carraro part number CA270077).
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Checklist C Procedures
C-1 Perform Engine Maintenance Deutz Models C-2 Perform Engine Maintenance Perkins Models
Note: Engine specifications require that this procedure be performed every 500 hours. Engine oil and filter - change* Coolant (additive concentration) - check Intake pipes - check for damage V-belts - check Fuel pre-filter - clean (change insert if necessary) *Engines with exhaust after-treatment system Deutz DQC III LA approved oil Deutz DQC IV LA approved oil API CJ-4 LE low ash approved oil *Engines without exhaust after-treatment system Deutz DQC III approved oil Deutz DQC III LA approved oil Deutz DQC IV approved oil API CJ-4 low ash approved oil Required maintenance procedures and additional engine information is available in the Deutz TCD3.6 Operation Manual (Deutz part number 0312 3907).
Note: Engine specifications require that this procedure be performed every 500 hours. 1104 Engine V-belts - inspect/adjust/replace 854 Engine Engine oil and filter - change API CJ-4 low ash approved oil Fuel system primary filter (water separator) element - replace Fuel system secondary filter - replace Fan clearance - check Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual (Perkins part number SEBU7833-01) OR the, Perkins 854 Operation and Maintenance Manual (Perkins part number SEBU8726-01).
Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 854 Operation and Maintenance Manual Genie part number 218708 218707
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CHECKLIST C PROCEDURES
C-3 Perform Engine Maintenance Perkins Models
C-4 Inspect and Lubricate the Sequencing Chains
Note: Engine specifications require that this procedure be performed every 500 hours or annually. 1104 Engine Engine oil and filter - change API CH-4 or API CI-4 approved oil Fuel system primary filter (water separator) element - replace Fuel system secondary filter - replace Hoses and clamps - inspect/replace Radiator - clean 854 Engine Radiator - clean Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual (Perkins part number SEBU7833-01) OR the, Perkins 854 Operation and Maintenance Manual (Perkins part number SEBU8726-01).
Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 854 Operation and Maintenance Manual Genie part number 218708
Genie specifications require that this procedure be performed every 500 hours or semi-annually, whichever comes first. In extremely dusty or hostile environments, it may be necessary to lubricate the chains more often. Maintaining the sequencing chains in good condition is essential to safe operation and good machine performance. Failure to detect damage to the chains could result in a hazardous operating condition. Environments in which Genie Telehandlers operate can vary widely from outdoor moisture and temperature extremes, to mildly corrosive or highly corrosive industrial atmospheres, in addition to abrasive exposures such as sand and grit. In addition, dynamic shock loading can impose abnormal loads above the endurance limit of the chains. Examples of dynamic shock loading are: High velocity movement of load, followed by sudden abrupt stops. Carrying loads in suspension over irregular surfaces and rough terrain. Attempting to "inch" loads which are beyond the rated capacity of the vehicle.
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The load cycles and environmental conditions make it impossible to predict chain life. It is therefore necessary to conduct regular inspections. 1 Park the machine on a firm level surface, level the boom and engage the parking brake. 2 Fully extend the boom. 3 Inspect the chains for the following conditions: Elongation BL666 chain - Measure 16 pitches of the extend chain for machines using BL666 chain. Note: For identification, this chain typically measures 3/4 inch between pin centers when new. Note: Both the extend and retract chains should be measured. Note: Measurement should be taken in the area where the chain articulates most frequently over the sheaves. Result: The distance measures 12.36 inches / 313mm or less. The chain is within specifications. Continue with inspection. Result: If the distance is greater than 12.36 inches / 313mm, the machine shall be removed from service until the chain is replaced. Note: The boom chain's normal life expectancy can be expressed as a maximum percent of elongation of 3%.
Edge wear Check the chain for wear on the link plate edges caused by running back and forth over the sheave. The maximum reduction of material should not exceed 5%. Cracked plates Check link side plates for any cracks. These are generally a sign of chain fatigue. Turning pins Check the pins. The position of the riveting must be parallel with the top and bottom of the side plate. If any of these conditions are discovered during the inspection, the chain must be replaced. After inspection and before being returned to service, the chains must be lubricated with a quality chain lubricant. Note: Do not use grease to lubricate chains. The chain plates should be brushed with a wire brush prior to lubrication to clear the space between the plates. The lubricant must penetrate the chain joint to prevent wear. Applying lubricant to the external surfaces will prevent rust, but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links. Lubricant may be applied with a brush, sprayed or poured on, but the chain should be well flooded with lubricant and the boom should be extended and retracted to insure that the lubricant penetrates to the working surfaces. All excess lubricant should be wiped away from the external surfaces. Note: Do not use solvents to remove excess lubricant.
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Checklist D Procedures
D-1 Inspect the Forks D-2 Adjust the Boom Sequencing Chains
Note: Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first OR whenever permanent deformation of the forks is suspected. Maintaining the lifting forks in good condition is essential to safe operation and good machine performance. Failure to detect damage to the forks could result in a hazardous operating condition. 1 Thoroughly clean the lifting forks. 2 Inspect the forks for the following: Surface cracks Straightness of the blade and shank Fork angle at 90 3 degrees Relative height of fork tips shall not differ more than 3% of blade length Excessive wear to the forks, fork mount or legible markings Result: If any of the above criteria are not met, the fork shall be removed from service until it is repaired or replaced.
a
Note: Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first.
1 Raise the boom to the horizontal position. 2 Extend the boom fully, then retract the boom approximately 1 inch / 25 mm. 3 On either side of the middle boom section, estimate the center. Place one end of a tape measure on the top surface of the boom directly above the estimated center. 4 Select a reference point on the sequencing chain. Measure the distance between the chain and the top surface of the boom. Note the measurement (1). Refer to the following illustrations.
2 1
a b
shank blade
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CHECKLIST D PROCEDURES
5 Move to the fork end of the same boom section that was just measured. 6 Measure the distance between the top surface of the boom and the same reference point used on the sequencing chain in step 4. Note the measurement (2). Result: The difference between measurements 1 and 2 is 0.25 to 0.5 inch / 6.35 to 12.7 mm. No adjustment to the chain is necessary. Proceed to step 10. Result: The difference between measurements 1 and 2 is less than a 0.25 inch / 6.35 mm OR is greater than 0.5 inch / 12.7 mm. The chain requires adjustment. Proceed to step 7. Note: The measurements taken in step 4 and step 6 must be taken from the same plane on the boom. 7 Working at the fork end of the large boom tube, locate the adjustable chain anchor on the top of boom section. 8 Place an adjustable wrench across the flat part of the chain, just ahead of the chain anchor. Tighten the wrench onto the chain. 9 Using a 1 7/16 inch wrench, adjust the nut as required to tighten or loosen the chain. Repeat this procedure beginning with step 4. 10 The procedure is complete.
D-3 Replace Hydraulic Tank Return Filter Element
Note: Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first Replacing the hydraulic return filter element is essential to good machine performance and service life. A dirty or clogged filter element may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter element be replaced more often. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. Note: Perform this procedure with the engine off. 1 Start the engine. Raise the boom to allow access to the hydraulic tank. 2 Remove the access cover to the tank. 3 Release the pressure in the oil reservoir by loosening the filler/breather cap. 4 Unscrew the return filter. 5 Install the new filter element. 6 Tighten the filler/breather cap. 7 Record the hours the filter element was replaced and keep with your maintenance records. 8 Start the engine. 9 Inspect the filter assembly to be sure that there are no leaks. 10 Clean up any oil that may have spilled during the installation procedure.
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D-4 Perform Transmission Maintenance
D-5 Perform Engine Maintenance Deutz Models
Note: Transmission specifications require that this procedure be performed every 1000 hours. Transmission - change oil and filter Drop box - change oil and filter Required maintenance procedures and additional transmission information is available in the Dana VDT12000 Service Manual (Dana part number TSM-0022).
Note: Engine specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Charge air cooler entry area - drain lube oil/ condensate Cold starting device - check Engine mounts - check Hose clamps and hoses - check V-rib belt and tensioning pulley - check Fuel filter cartridge - replace Filter insert for fuel pre-filter - replace Required maintenance procedures and additional engine information is available in the Deutz TCD3.6 Operation Manual (Deutz part number 0312 3907).
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oil drain, drop box oil drain, transmission
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D-6 Perform Engine Maintenance Perkins Models
D-7 Perform Axle Maintenance
Note: Engine specifications require that this procedure be performed every 1000 hours. 1104 Engine Engine valve lash - inspect/adjust 854 Engine Water pump - inspect Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual (Perkins part number SEBU7833-01) OR the, Perkins 854 Operation and Maintenance Manual (Perkins part number SEBU8726-01).
Note: Axle specifications require that this procedure be performed every 1500 hours of operation. Change axle oil Clean magnetic oil plugs Required maintenance procedures and additional axle information is available in the Carraro 26.27M Axle Maintenance and Repair Manual (Carraro part number CA270077).
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D-8 Perform Engine Maintenance Perkins Models
Note: Engine specifications require that this procedure be performed every 1500 hours. 854 Engines Engine crankcase breather element - replace Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual (Perkins part number SEBU7833-01) OR the, Perkins 854 Operation and Maintenance Manual (Perkins part number SEBU8726-01).
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Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil
2 Remove oil cap from top of hydraulic tank. 3 Using an approved hand-operated pump, drain the hydraulic tank into a suitable container. Refer to Section 2, Specifications. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. 4 Remove the drain plug from the rear of the tank. 5 Rinse out the inside of the tank using a mild solvent. 6 Install the drain plug and securely tighten. Do not over tighten. 7 Fill the tank with hydraulic oil until the fluid level is in the center of the sight glass at the rear of the tank. 8 Clean up any oil that may have spilled.
Note: Genie specifications require that this procedure be performed every 2000 hours or two years, whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more frequently. Refer to Section 2, Specifications. Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system. Note: Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. 1 Lower the boom to the stowed position.
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CHECKLIST E PROCEDURES
E-2 Perform Engine Maintenance Perkins Models
Note: Engine specifications require that this procedure be performed every 2000 hours. 1104 Engine Aftercooler core - inspect Alternator - inspect Engine mounts - inspect Starting Motor - inspect Turbocharger - inspect Water pump - inspect 854 Engine Aftercooler core - inspect Engine mounts - inspect Starting motor - inspect Turbocharger - inspect Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual (Perkins part number SEBU7833-01) OR the, Perkins 854 Operation and Maintenance Manual (Perkins part number SEBU8726-01).
Note: Engine specifications require that this procedure be performed every 3000 hours . 1104 Engine Alternator Belt - Inspect/Adjust/Replace Fuel Injector - test/change 854 Engine Alternator - inspect Alternator and Fan Belts - replace Diesel Particulate Filter - clean Radiator Pressure Cap - clean/replace Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual (Perkins part number SEBU7833-01) OR the, Perkins 854 Operation and Maintenance Manual (Perkins part number SEBU8726-01).
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E-4 Perform Engine Maintenance Deutz Models
Note: Engine specifications require that this procedure be performed every 3000 hours. V-rib belt and tensioning pulley- replace Required maintenance procedures and additional engine information is available in the Deutz TCD3.6 Operation Manual (Deutz part number 0312 3907).
Note: Engine specifications require that this procedure be performed every 4000 hours. 854 Engine Aftercooler Core - Clean/Test Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual (Perkins part number SEBU7833-01) OR the, Perkins 854 Operation and Maintenance Manual (Perkins part number SEBU8726-01).
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E-6 Perform Engine Maintenance Deutz Models
Note: Engine specifications require that this procedure be performed every 5000 hours. General engine overhaul Required maintenance procedures and additional engine information is available in the Deutz TCD3.6 Operation Manual (Deutz part number 0312 3907).
Note: Engine specifications require that this procedure be performed every 12,000 hours or every three years, whichever comes first. 1104 and 854 Engines Cooling System Coolant (Extended life coolant) - change Required maintenance procedures and additional engine information is available in the Perkins 1104 Operation and Maintenance Manual (Perkins part number SEBU7833-01) OR the, Perkins 854 Operation and Maintenance Manual (Perkins part number SEBU8726-01).
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Section 4 Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.
Observe and Obey:

Repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine.
Perform disassembly procedures to the point where repairs can be completed. To re-assemble, perform the disassembly steps in reverse order. Symbols Legend Safety alert symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates an 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. Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps.
Before Repairs Start:

Read, understand and obey the safety rules and operating instructions in the appropriate operators manual on your machine. Be sure that all necessary tools and parts are available and ready for use. Use only Genie approved replacement parts. Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: Machine parked on a firm, level surface Boom in the stowed position Key switch in the off position with the key removed Wheels chocked
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Boom Components
1-1 Boom Proximity Switch
The boom angle switch is a proximity switch. This switch functions by sensing a change in the electromagnetic field of the switch, due to the introduction of metal into the field. A proximity switch is, simply, a metal detector. The switch generates an electromagnetic field at the face of the switch. This field senses when steel has been moved close to the switch as well as when the steel has been moved away, which is how the switch contacts open and close. These switches are of a fail-safe design. Should the 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. Both the drive and the chassis sway functions are disabled when the boom is raised to 60 or higher.
How to Test a Proximity Switch

1 Remove the switch from the machine. Do not disconnect the switch wire harness from the machine. 2 Start the engine. 3 Move the switch away from any ferrous or metallic object Result: The light of the limit switch assembly is not illuminated. 4 Move the switch close to any ferrous or metallic object Result: The light of the proximity switch assembly turns on. The switch is functioning correctly. a
boom angle proximity switch (located on engine side)
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BOOM COMPONENTS
How to Adjust the Boom Angle Proximity Switch

The boom angle proximity switch is attached to a mounting bracket, located between the boom and the chassis directly beneath the boom pivot pin. The switch location is adjustable. 1 Start the engine. 2 Raise the boom to 60. Confirm with a digital level. 3 Working at the pivot end of the boom, locate the boom angle proximity switch. Loosen the fasteners, securing the proximity switch assembly to the chassis, just enough to allow the bracket to move. 4 Move the proximity switch assembly until the light of the proximity switch turns on, then move the proximity switch assembly until the light of the proximity switch just turns off. 5 Securely 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 light of the proximity switch assembly is not illuminated. The proximity switch is properly calibrated. Result: The light of the proximity switch assembly is illuminated. The proximity switch is not calibrated correctly. Repeat this procedure beginning with step 4.
1-2 Boom How to Replace the Boom Wear Pads

1 Lower wear pads: Using a lifting strap from an overhead crane or a fork lift of sufficient capacity, lift the boom tube just enough to remove the weight from the pads. 2 Remove the wear pad retainer plates and remove the wear pads from the boom. 3 Lubricate the wear surface of the new pads. Refer to Maintenance Procedure A-4, Lubricate the Boom. Note: Do not lubricate the side wear pads. 4 Install the wear pads. Install and securely tighten the retainer plates. Do not over tighten.
How to Remove the Lifting Fork Frame

1 With the boom in the stowed position, attach a lifting strap from an overhead crane to the top of the lifting fork frame at the front of the boom. Support the frame. Do not apply any lifting pressure. 2 Working from the rear of the frame, lift the spring-assisted handle of the lock securing the lower fork frame lock pin to the fork frame mount. Use a soft metal drift to remove the pin.
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BOOM COMPONENTS
3 Using the overhead crane, lift and remove the fork frame from the boom. Crushing hazard. The fork frame could fall if not properly supported when the lock pin is removed from the machine. b a
How to Replace the Retraction Chain

Note: Perform this procedure on a firm, level surface with the boom in the stowed position and the wheels chocked. e 1 Start the engine and allow the engine to idle. 2 Raise the boom to a horizontal position. 3 Fully retract the boom. 4 Extend the boom approximately 1 inch / 2.5 cm. 5 Turn the machine off and remove the key from the key switch. 6 Working at the fork end of the boom, loosen the fasteners securing the single-chain tensioners to the top of boom tube number 1. After noting the orientation and assembly order of the components, remove the fasteners and pull the tensioners free of the boom. Refer to Illustration 1. 7 Remove the inspection cover from the pivot end of the boom. Locate the chain anchor of the boom retraction chain where it attaches to the chain anchor mount at the lower side of boom tube 3. Refer to Illustration 2.
Illustration 1 a b c d e extension chains single-chain tensioner boom tube number 1 boom tube number 2 boom tube number 3
c d
Illustration 2 a chain anchor
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BOOM COMPONENTS
8 Remove a cotter pin securing the chain anchor pivot pin to the anchor mount of the boom tube. Remove the pivot pin and pull the chain free of the mount. 9 Working at the fork end of the boom, securely connect a 30 foot / 10 m length of rope to the end of the chain. Securely tie off the other end of the rope to the boom structure. 10 Working at the pivot end of the boom, pull the chain out of the boom. Note: Rope coming loose from the chain during removal may result in a difficult reassembly. Be sure the rope is securely attached to the chain and boom structure before pulling the chain out of the boom. 11 Remove the rope from the end of the chain and securely attach the rope to the new chain. 12 Working at the fork end of the boom, use the rope to carefully pull the chain through the boom just until the end of the chain is accessible. Remove the rope from the chain. 13 Working at the pivot end of the boom, install the chain into the chain anchor mount. Secure the chain anchor to the mount using the pivot pin and cotter pin removed in step 8. Secure the cotter pin. 14 Working at the pivot end of the boom, route the chain over the roller and install the chain onto the boom assembly using the pivot pin removed in step 11. Securely tighten the fasteners. Do not over tighten.
15 Install the chain tensioners into the tensioner mount at the fork end of boom tube number 1. Install the mounting components, removed in step 8. Evenly tighten the chain tensioners to the top of the boom tube until they are securely tightened. 16 Adjust the chains. Refer to Maintenance Procedure D-2, Adjust the Boom Sequencing Chains. Component damage 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 Replace the Extension Chains

Note: Perform this procedure on a firm, level surface with the boom in the stowed position and the wheels chocked. 1 Start the engine and allow the engine to idle. 2 Raise the boom to a horizontal position. 3 Fully retract the boom. 4 Turn the machine off and remove the key from the key switch. 5 Working at the fork end of the boom, loosen the fasteners securing the single-chain tensioners to the top of boom tube number 1. After noting the orientation and assembly order of the components, remove the fasteners and pull the tensioners free of the boom. Refer to Illustration 1.
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BOOM COMPONENTS
6 Select a chain tensioner. Remove the bow tie clip securing the chain anchor pin to the chain assembly. Remove the 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, select a chain. Securely connect a 30 foot / 10 m length of rope to the end of the chain. Securely tie off the other end of the rope to the boom structure. 9 Remove the inspection cover from the pivot end of the boom and locate the chain anchors of the extension chains at the top of boom tube 3. 10 Remove the fasteners securing the extension chain anchors to the boom tubes. 11 Working at the pivot end of the boom, pull the chain out of the boom. Note: Rope coming loose from the chain during removal may result in a difficult reassembly. Be sure the rope is securely attached to the chain and boom structure before pulling the chain out of the boom. 12 On a workbench, remove the bow tie clip securing the chain anchor pin to the chain assembly. Remove the pin and chain anchor pin from the assembly. 13 Install the chain anchor, pin and clip onto the new chain. 14 Remove the rope from the end of the old chain and securely attach the rope to the new chain.
15 Working at the fork end of the boom, use the rope to carefully pull the chain through the boom just until the end of the chain is accessible. 16 Working at the pivot end of the boom and using the fasteners removed in step 5, install the chain anchor onto the boom tube. Securely tighten the fasteners. Do not over tighten. 17 Remove the rope from the chain and install the chain into the chain anchor of the tensioner assembly. Secure the chain to the chain anchor using the pin and clip removed in step 6. 18 Repeat this procedure, beginning with step 5, for the other chains. 19 Install the inspection cover, removed in step 9, onto the boom. Install and securely tighten the fasteners. Do not over tighten. 20 Install the chain tensioners into the tensioner mount at the fork end of boom tube number 1. Install the mounting components, removed in step 6. Evenly tighten the chain tensioners to the top of the boom tube until they are securely tightened. 21 Adjust the chains. Refer to Maintenance Procedure D-2, Adjust the Boom Sequencing Chains. Component damage 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.
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How to Remove the Boom

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. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications.
1 Remove the lifting fork and frame. See 1-2, How to Remove the Lifting Fork Frame. 2 Attach a lifting strap from an overhead 10 ton / 10,000 kg crane to the fork end of the boom. Support the boom. Do not apply any lifting pressure. 3 Select a fork level cylinder. Remove the fasteners securing the fork level cylinder rod-end pivot pin to the boom. 4 Using a lifting strap from another overhead crane, support the rod-end of the fork level cylinder. Do not apply any lifting pressure. 5 Use a soft metal drift to remove the fork level cylinder pivot pin. 6 Lower the fork level cylinder onto the chassis. Crushing hazard. Keep hands clear of the cylinder manifold when lowering the cylinder. 7 Repeat this procedure beginning with step 3 for the other fork level cylinder.
b a
8 Identify the hydraulic hoses from the lift cylinder. Tag, disconnect and plug the hoses at the lift cylinder manifold. Cap the fittings on the cylinder manifold. 9 Remove the fasteners securing the lift cylinder barrel-end pivot pin to the chassis. c 10 Support and secure the barrel end of the lift cylinder to the boom.
a b c d e
extension chains single-chain tensioner boom tube number 1 boom tube number 2 boom tube number 3
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11 Use a soft metal drift to remove the lift cylinder pivot pin. 12 Tag, disconnect and plug the 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 cylinder will fall if not properly supported when the boom is raised. 14 Remove the fasteners securing the boom pivot pin to the chassis. 15 Using a suitable tool, remove the boom pivot pin. Note: This may require a hydraulic power unit. Crushing hazard. The boom will fall if not properly supported when the pivot pin is removed from the machine. 16 Carefully remove the boom assembly from the machine and place it on a structure capable of supporting it. Crushing hazard. The boom could become unbalanced and fall if not properly supported when removed from the machine. Component damage hazard. The weight of the boom assembly may crush the hydraulic hard lines under the boom. Use caution when placing the boom assembly onto a structure capable of supporting it.
How to Disassemble the Boom

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. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the extension cylinder. See 1-4, How to Remove the Extension Cylinder. 2 Remove the boom. See 1-2, How to Remove the Boom. 3 Select a lift cylinder. Remove the fasteners securing the lift cylinder rod-end pivot pin to the boom. 4 Using a lifting strap from an overhead crane, support the lift cylinder. Do not apply any lifting pressure. 5 Use a soft metal drift to remove the lift cylinder rod-end pivot pin. Remove the cylinder from the boom. 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 Remove the fastener securing the fork level cylinder rod-end pivot pin to the fork frame mount.
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8 Use a soft metal drift to remove the rod-end pivot pin. 9 Attach a lifting strap from an overhead crane to the barrel end of the fork level cylinder. Support the cylinder. Do not apply any lifting pressure. 10 Tag, disconnect and plug the fork level cylinder hoses from the cylinder manifolds. 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 dissipate gradually. Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched 11 Remove the fasteners securing the fork level cylinder barrel-end pivot pin to the boom. 12 Use a soft metal drift to remove the pivot pin. Remove the cylinder from the boom. Crushing hazard. The cylinder could fall if not properly supported when the pivot pin is removed from the machine.
13 Remove the inspection cover at the pivot end of the boom. 14 Remove the hose keepers from the hose roller assembly. Note: The hose keepers ensure that the hoses do not jump off the hose rollers. 15 Working at the pivot end of the boom, remove the clamps securing the hoses to the inside of boom tube number 3. 16 Working at the fork end of the boom, remove the clamps securing the hoses to the inside of boom tube number 3. 17 Working at the pivot end of the boom, pull the fork level hydraulic hoses from the boom and lay them to the side. 18 Working at the pivot end of the boom, remove the fasteners securing the hose roller assembly to boom tube number 2. Remove the hose roller assembly from the boom. 19 Working at the fork end of the boom, loosen evenly, then remove, the fasteners securing the chain tensioners to the top of boom tube number 1. 20 Working at the fork end of the boom, remove the fasteners securing the extension chain rollers to the top of boom tube number 2. Remove the chain rollers from the boom.
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21 Working at the pivot end of the boom, remove the fasteners securing the retraction chain block pivot 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 number 2. Remove the chain roller from the boom. 23 Working at the fork end of the boom, remove the wear pads from boom tube number 2. 24 Support and slide boom tube number 3 out of boom tube number 2. Place boom tube number 3 on a structure capable of supporting it. Crushing hazard. Boom tube number 3 could become unbalanced and fall when removed from the boom tube number 2 if not properly supported and attached to the overhead crane. Note: During removal, the overhead crane strap will need to be adjusted for proper balancing. 25 Working at the fork end of the boom, remove the wear pads from boom tube number 1. 26 Support and slide boom tube number 2 out of boom tube number 1. Place boom tube number 2 on a structure capable of supporting it. Crushing hazard. Boom tube number 2 could become unbalanced and fall when removed from the boom tube number 1 if not properly supported and attached to the overhead crane. Note: During removal, the overhead crane strap will need to be adjusted for proper balancing.
1-3 Boom Lift Cylinder How to Remove the Lift Cylinder

Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Attach a lifting strap from an overhead 10 ton / 10,000 kg crane to the fork end of the boom. Support the boom. Do not apply any lifting pressure. 2 Tag, disconnect and plug the hydraulic hoses at the lift cylinder manifold. 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 dissipate gradually. Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 3 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder. Support the cylinder. Do not apply any lifting pressure.
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4 Remove the fasteners securing the lift cylinder barrel-end pivot pin to the chassis. 5 Use a soft metal drift to remove the pivot pin. 6 Remove the fasteners securing the lift cylinder rod-end pivot pin to the boom. 7 Use a soft metal drift to remove the pivot pin. Crushing hazard. The boom will fall if not properly supported when the pivot pin is removed from the machine. 8 Using the overhead crane, raise the boom to a horizontal position. Remove the cylinder from the machine. Crushing hazard. The cylinder will fall if not properly supported when removed from the machine.
2 Tag, disconnect and plug the hydraulic hoses at the boom extension cylinder manifold. 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 dissipate gradually. Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 3 Remove the access covers on the number 1 boom and remove the bolts holding the extend cylinder support 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 of the support sockets. 5 Support the extension cylinder with a suitable lifting device and remove from the boom assembly. Note: During removal, the overhead crane strap will need to be adjusted for proper balancing.
1-4 Boom Extension Cylinder How to Remove the Extension Cylinder

Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the boom to a horizontal position.
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BOOM COMPONENTS
1-5 Fork Level Cylinder How to Remove the Fork Level Cylinder
Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the lifting fork frame. See 1-2, How to Remove the Lifting Fork Frame. 2 Remove the fastener securing the fork level cylinder rod-end pivot pin to the fork frame mount. 3 Use a soft metal drift to remove the pivot pin. 4 Attach a lifting strap from an overhead crane to the barrel end of the fork level cylinder. Support the cylinder. Do not apply any lifting pressure. 5 Tag, disconnect and plug the fork level cylinder hoses from the cylinder manifolds. 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 dissipate gradually. Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched 6 Remove the fasteners securing the fork level cylinder 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 pivot pin is removed from the machine.
How to Replace the Fork Level and/or Auxiliary Cylinder Hoses,

Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Fully retract the boom.
b a
c e d
a b c d e
extension chains single-chain tensioner boom tube number 1 boom tube number 2 boom tube number 3
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2 Fully lower the tips of the lifting forks. 3 Remove the covers from the pivot end of the boom. 4 Attach a lifting strap from an overhead crane to the top of the lifting fork frame. Support the frame. Do not apply any lifting pressure. 5 Tag, disconnect and plug the fork level cylinder supply hoses at the cylinder manifold. 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 dissipate gradually. Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 6 Working near the center of the boom assembly, tag, disconnect and plug the hydraulic hoses from the hydraulic hard lines under boom tube number number 1. Cap the hard lines. 7 Securely connect a 30 feet / 10 m length of rope to each end of the hoses disconnected in steps 5 and 6. Securely tie off the other end of each section of rope to the boom structure. 8 Working at the pivot end of the boom, select one of the hoses. Pull the hose out of the boom. Note: Rope coming loose from either end of the hose or the boom during hose removal may result in a difficult reassembly. Be sure each section of rope is securely attached to both the hose and the boom structure before pulling the hose out of the boom.
9 Remove the rope from each end of the hose. Discard the hose. 10 Securely install a section of rope onto each end of the new hose assembly. 11 Install 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. 12 Install both ends of the hose assembly onto the correct connection points. Torque to specification. Refer to Section 2, Specifications. 13 Repeat this procedure for the remaining hose to be replaced, beginning with step 8. 14 Remove the lifting strap from the fork frame. 15 Install the cover onto the rear of the boom. Install and securely tighten the retaining fasteners. Replace the upper hoses: 1 Fully retract the boom. 2 Fully lower the tips of the lifting forks. 3 Remove the covers from the pivot end of the boom. 4 Attach a lifting strap from an overhead crane to the top of the lifting fork frame. Support the frame. Do not apply any lifting pressure. 5 Working at the pivot end of the boom, remove the fasteners securing the cable bridge rear mount bracket to the boom assembly. Remove the bracket from the boom.
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BOOM COMPONENTS
6 Tag, disconnect and plug the hydraulic hoses at the hard lines of the cable bridge. 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 dissipate gradually. Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 7 Return the cable bridge to its original position. 8 Working at the fork end of the boom, tag, disconnect and plug the fork level cylinder hoses at the cylinder manifolds. Cap the fittings. 9 Models with auxiliary function: Working at the fork end of the boom, tag, disconnect and plug the auxiliary hoses at the fittings. Cap the fittings. 10 Working at the fork end of the boom, remove the fasteners securing the cable bridge slider to the cable bridge. Remove the slider from the boom. Note: Pay attention to how the hoses are routed before removing the slider from the boom. Note: During reassembly, it may be helpful to use tape to secure the bolts to the cable bridge when installing the cable bridge slider.
11 Remove the fasteners securing the cable track to the cable track mount bracket. 12 Remove the fasteners securing the cable track mount bracket to the cable bridge. Remove the bracket from the boom. 13 Carefully pull the cable track through the opening at the front of boom until the hose connections are accessible. 14 Tag, disconnect and plug the affected hoses. Cap the fitting. Remove the hose from the cable track. 15 Install the new hose assembly and torque to specification. Refer to Section 2, Specifications. 16 Install the cable bridge and cable track into the boom. 17 Install the cable track mount bracket and cable bridge slider. Securely tighten all fasteners. Do not over tighten. 18 Working at the pivot end of the boom, install the hydraulic hoses onto the hard lines of the cable bridge and torque to specification. Refer to Section 2, Specifications. 19 Install the cable bridge mount bracket onto the cable bridge and the boom assembly. Securely tighten all fasteners. Do not over tighten. 20 Install the cover onto the rear of the boom. Install and securely tighten the retaining fasteners.
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Part No. 218230
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BOOM COMPONENTS
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November 2012
Operator's Compartment
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 Service Department. 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 required. 1 Open the access door above the hydraulic tank. 2 Disconnect the battery from the machine. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 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. 4 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. 5 Working under the dashboard, locate the hydraulic hose at port L of the steering orbitral. 6 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. 7 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. 8 Tag, disconnect and plug the hydraulic hose at port SULS of the primary function manifold. Cap the fitting.
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Part No. 218230
November 2012
OPERATOR'S COMPARTMENT
9 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. 10 Tag, disconnect and plug the hydraulic hoses at ports J1, J2, J3 and J4 of the primary function manifold. Cap the fittings. 11 Models with dual joystick: Tag, disconnect and plug the hydraulic hoses at ports JT2, JT4, JS3 and JS1 of the primary function manifold. Cap the fittings. 12 Tag, disconnect and plug the hydraulic hoses at ports JE1, JE3, JL2and JL4 of the primary function manifold. Cap the fittings. 13 Remove the fasteners securing the joystick mount to the operator's compartment. Remove the joystick assembly. 14 Models with single joystick: With the base of the joystick above the top of the hydraulic tank, tag disconnect and plug the hydraulic hose at port T of the joystick. Cap the fitting. Note: Removing the hydraulic hose from port T of the joystick with the joystick 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 joystick if the joystick is below the hydraulic oil level in the hydraulic tank. 15 Models with dual joystick: Locate the tee fitting which joins together the hydraulic hoses from port T of both joysticks to the tank return hydraulic hose.
16 Models with dual joystick: With the tee fitting above the top of the hydraulic tank, tag, disconnect and plug the tank return hydraulic hose from the tee fitting. Cap the fitting. Note: Removing the hydraulic hose from the tee fitting 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 fitting is below the hydraulic oil level in the hydraulic tank. 17 Working inside the chassis, tag and disconnect the wire harnesses at the connectors next to the operator's compartment. 18 Support and secure the operator's compartment to an adjustable table capable of supporting the weight and that will allow the operator's compartment to remain in an upright and stable position. Component damage hazard. Wrapping a strap around the cab and lifting using an overhead crane can put excessive pressure on the glass windows of the cab, causing the windows to break. Do not lift the cab using a strap from an overhead crane if the strap contacts the windows. Note: Placing a wedge between the operator's compartment and the adjustable table may be required to keep the operator's compartment stable. 19 Remove the lower fasteners securing the operator's compartment to the chassis.
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20 Remove the upper fasteners securing the operator's compartment to the chassis. Crushing hazard. The operator's compartment will fall if not properly supported when the fasteners are removed from the machine. 21 Slowly move the operator's compartment away from the chassis while feeding all loose hoses, cables and wires through the opening of the chassis. Component damage hazard. Hoses, cables and wires can be damaged if they are kinked or pinched.
Bolt torque specification Operator's cab mounting bolts 750 ft-lbs 1017 Nm
2-2 Machine Controls How to Remove the Steering Column

1 Open the access door above the hydraulic tank. 2 Disconnect the battery from the machine. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Remove the fasteners securing the transmission control lever to the column. Carefully separate the lever from the column. 4 Remove the nut securing the key switch to the dash panel. Gently push the key switch through the opening. 5 Remove the fasteners securing the dash panel to the dashboard. 6 Carefully pull the dash panel towards the seat of the operator's compartment. 7 Tag and disconnect the wire harness from the componments of the dash panel. Remove the dash panel from the machine. 8 Loosen the two lower fasteners securing the dash frame to the operator's compartment. 9 Remove the two upper fasteners securing the dash frame to the operator's compartment. 10 Rotate the dash frame towards the seat of the operator's compartment.Remove the dashboard from the machine.
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11 Tag and disconnect the ground wire of the steer column. 12 Support and secure the steer orbitral to the dash frame. 13 Remove the fasteners securing the steer column and steer orbitral to the dash frame. 14 Lower the steer orbitral and remove the steer column from the machine.
3 Follow the hydraulic hose from port L of the steer orbitral to its connection at the front axle of the machine. Tag, disconnect and plug the hydraulic hose at the front axle. Cap the fitting. 4 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. 5 Tag, disconnect and plug the hydraulic hose at port SULS of 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 Remove the Steering Wheel

1 Open the access door above the hydraulic tank. 2 Disconnect the battery from the machine. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Remove the horn button from the steering wheel. Remove the nut securing the steering wheel to the column and remove the steering wheel.
How to Remove the Joystick Models with Single Joystick

1 Open the access door above the hydraulic tank. 2 Disconnect the battery from the machine. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Remove the fasteners securing the joystick mount panel to the side console.
How to Remove the Steer Orbitral

1 Remove the steering column. See 2-2, How to Remove the Steering Column. 2 Working under the dashboard, locate the hydraulic hose at port L of the steering orbitral.
LS L T R P
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4 Tag and disconnect the joystick wire harness from the machine. 5 Tag, disconnect and plug the hoses from ports 1, 2, 3, 4, P and T of the joystick. Cap the fittings. Note: Removing the hydraulic hose from port T of the joystick with the joystick 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 port if the joystick is below the hydraulic oil level in the hydraulic tank. 6 Remove the fasteners securing the joystick to the mount panel. Remove the joystick.
4 Tag and disconnect the joystick wire harness from the machine. 5 Tag, disconnect and plug the hoses from ports 1, 2, 3, 4 and P of the joystick. Cap the fittings. 6 Locate the tee fitting which joins together the hydraulic hoses from port T of both joysticks to the tank return hydraulic hose. 7 With the tee fitting above the top of the hydraulic tank, tag, disconnect and plug the tank return hydraulic hose from the tee fitting. Cap the fitting. Note: Removing the hydraulic hose from port T of the joystick with the joystick 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 port if the joystick is below the hydraulic oil level in the hydraulic tank. 8 Remove the fasteners securing the joystick to the mount panel. Remove the joystick.
2 3 4
T 1 P
Joystick port orientation
How to Remove the Brake Pedal Assembly

1 Open the access door above the hydraulic tank. 2 Disconnect the battery from the machine. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Fully press and release the brake pedal a minimum of 10 times to release the hydraulic pressure in the brake system.
How to Remove the Joystick Models with Dual Joysticks

1 Open the access door above the hydraulic tank. 2 Disconnect the battery from the machine. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Remove the fasteners securing the joystick mount panel to the side console.
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4 Tag, disconnect and plug the hydraulic hoses at ports BP and BT of the secondary hydraulic manifold. 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 dissipate gradually. Do not allow oil to squirt or spray. 5 Follow the hydraulic hose from port A of the brake pedal manifold to the brake manifold. Tag, disconnect and plug this hydraulic hose at the brake manifold. Cap the fitting. 6 Remove the fasteners securing the brake pedal assembly to the dash frame. 7 Gentley rotate the brake pedal in an upwards direction and slowly move the brake pedal assembly away from the dash frame while feeding all loose hoses through the opening of the chassis.
How to Remove the Gauge Cluster Assembly

1 Open the engine cover. 2 Disconnect the battery from the machine. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Remove the fasteners securing the transmission control lever to the column. Carefully separate the lever from the column. 4 Reach under the dashboard and gently push the dash cluster through the opening in the dashboard. 5 Tag and disconnect the wire harness from the dash cluster. Remove the dash cluster from the machine.
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Fuel and Hydraulic Tank

3-1 Fuel and Hydraulic Tank How to Remove the Fuel and Hydraulic Tank Assembly
Explosion and fire hazard. Engine fuels are combustible. Remove the fuel tank in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Explosion and fire hazard. Never drain or store fuel in an open container due to the possibility of fire. Explosion and fire hazard. When transferring fuel, connect a grounding wire between the machine and pump or container. 1 Open the access door to the engine. 2 Disconnect the battery from the machine. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. HYDRAULIC TANK 3 Remove the access cover to the hydraulic tank. 4 Remove the filler cap from the hydraulic tank. 5 Place a drain pan or other suitable container under the hydraulic tank. Refer to Section 2, Specifications. 6 Remove the drain plug from the hydraulic tank and completely drain the tank. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. 7 Tag, disconnect and plug the supply and return hoses from the hydraulic tank. Cap the fittings. 8 Proceed to step 14. FUEL TANK 9 Remove the access cover above the fuel tank and the access door above the filler cap. 10 Tag and disconnect the wire harness from the fuel level terminals. 11 Remove the filler cap from the fuel tank. 12 Using an approved hand-operated pump, drain the fuel tank into a container of suitable capacity. Refer to Section 2, 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 for use with gasoline and/or diesel fuel. 13 Tag, disconnect and plug the fuel supply and return hoses. Cap the fittings. 14 Remove the clamps holding the vent hose so the vent and hose can be removed with the tank. 15 Support and secure the tank assembly to an appropriate lifting device. 16 Remove the fasteners securing the tank assembly to the chassis. Remove the tank from the machine. Crushing hazard. The tank assembly could become unbalanced and fall if not properly supported when removed from the machine.
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Engines
4-1 Engines How to Repair the Perkins 1104D-E44TA Engine
Repair procedures and additional engine information is available in the Perkins 1100 Operation and Maintenance Manual (Perkins part number SEBU8172-00) and the Perkins 1104 Service Manual (Perkins part number RENR9401) and the Perkins 1100 Troubleshooting Manual (Perkins part number SENR9982-01).
Perkins 1100 Operation and Maintenance Manual Genie part number 123702 Perkins 1104 Service Manual Genie part number Perkins 1100 Troubleshooting Manual Genie part number 117764 123583
How to Repair the Deutz TCD3.6 Engine

Maintenance procedures and additional engine information is available in the Deutz TCD3.6 Workshop Manual (Deutz part number 0312 3965).
Deutz TCD3.6 Workshop Manual Genie part number
218704
4-2 Engine Fault Codes How to Retrieve Engine Fault Codes

When the engine Electronic Control Module (ECM) detects an abnormal operating condition, a fault code is immediately stored in the ECM memory. 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 and how to use the fault codes, refer to Section 5, Fault Codes.
How to Repair the Perkins 854E-34TA Engine

Repair procedures and additional engine information is available in the Perkins 854 Systems Operation Testing & Adjusting (Perkins part number UENR0623) or the Perkins 854 Disassembly & Assembly (Perkins part number UENR0624)
Perkins 854 Operation Manual Genie part number Perkins 854 Assembly Manual Genie part number
218711 218712
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Transmission
5-1 Transmission How to Repair the Transmission
Repair procedures and additional transmission information is available in the Dana VDT12000 Service Manual (Dana part number TSM-0022).
218706
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TRANSMISSION
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November 2012
Hydraulic Pump
6-1 Hydraulic Pump How to Test the Function Pump
Note: When removing a hose assembly or fitting, the fitting and/or hose end must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 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. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to port TP on the secondary function manifold. 2 Start the engine and fully retract the boom. Continue 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 fails to reach 3200 psi / 220 bar, the pump needs to be adjusted OR or the pump or pump coupling is faulty and will need to be serviced or replaced. Component damage hazard. There is no relief valve in the hydraulic pump and the pump can be damaged if the pressure is allowed to exceed specification. When testing the pump, crank the engine in one second intervals until the correct pressure is confirmed. Do not over-pressurize the pump. 3 Remove the pressure gauge and install plug onto port TP. Torque to specification. Refer to Section 2, Specifications. 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.
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November 2012
HYDRAULIC PUMP
How to Remove the Function Pump

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. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. Note: Perform this procedure with the engine off and cool. 1 Open the engine cover. 2 Disconnect the battery from the machine. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 4 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 will result in excessive hydraulic fluid leaking from the hose. Do not lower the open end of the case drain hose to below the fluid level of the hydraulic tank until the hose is plugged.
5 Tag, disconnect and plug the large hydraulic pump supply hose at the pump. Cap the fitting on the pump. Note: Placing the open end of the pump supply hose below the fluid level in the hydraulic tank will result in excessive hydraulic fluid leaking from the hose. Do not lower the open end of the pump supply hose to below the fluid level of the hydraulic tank until the hose is plugged. 6 Tag, disconnect and plug the high pressure hose at the pump. Cap the fitting on the pump. 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 Remove the fasteners securing the pump to the transmission. Remove the pump from the machine.
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HYDRAULIC PUMP
How to Install the Function Pump

1 Carefully install the hydraulic pump onto the transmission. Install the fasteners and tighten to finger tight. 2 Torque the fasteners evenly to 85 ft-lbs / 115 Nm. 3 Install the smaller high pressure hose onto the pump outlet. Torque the fasteners to 27-37 ft-lbs / 37-50 Nm. 4 Install the larger low pressure hose onto the pump outlet. Install the hose retaining rings and fasteners. Torque the fasteners to 55-66 ft-lbs / 74-90 Nm. 5 Working at the case drain at the top of the pump, fill the pump with hydraulic fluid until the fluid is at the top of the case drain fitting. 6 Install the case drain hose onto the pump and torque to specification. Refer to Section 2, Specifications. 7 Securely install the wire harness onto the pump. 8 Check the level of the hydraulic fluid in the hydraulic tank. Add fluid if needed. 9 Prime the pump. See 6-1, How to Prime the Function Pump. 10 Start the engine and inspect for leaks. 11 Turn the machine off. 12 Adjust the pump pressure. See 6-1, How to Adjust the Function Pump Standby Pressure and How to Adjust the Function Pump Pressure Pressure Compensator.
How to Prime the Function Pump

Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Install all hoses onto the hydraulic pump. Torque to specification. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 2 Locate the case drain filler plug at the side of the function pump. 3 Remove the plug and slowly fill the case drain port of the pump with hydraulic fluid until the oil level is even with the bottom of the hole. Install the plug and torque to 40 ft-lbs / 54 Nm. 4 Start the engine, allow the engine to run at low idle for 15 seconds then shut off the engine. Wait 15 seconds, then start the engine again. Allow the engine to run at low idle for 15 seconds and then shut off the engine. 5 Check for hydraulic leaks and clean up any oil that may have spilled.
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HYDRAULIC PUMP
How to Adjust the Function Pump Standby Pressure

1 Connect a 0 to 1000 psi / 0 to 100 bar pressure gauge to test port 'TP' on the primary function manifold. See 7-1 or 7-2, Primary Function Manifold Components. 2 Start the engine and allow the engine to run at low idle. 3 Observe the pressure reading on the pressure gauge. Result: The pressure gauge reads 450 25 psi / 31 1.7 bar. The pump is 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 pressure adjustment screw. 5 Adjust the function pump standby pressure. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. Tighten the set screw. 6 Turn the engine off and remove the pressure gauge. 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.
How to Adjust the Function Pump Pressure Compensator

Note: Two people will be required to perform this procedure. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to port 'M1' on the function pump. 2 Start the engine and allow the engine to run at low idle. 3 Fully retract the boom. 4 Continue to activate the boom retract function and observe the pressure reading on the pressure gauge. Result: The pressure gauge reads 320050 psi / 2203.4 bar. The pump is functioning correctly. Proceed to step 7. Result: The pressure gauge fails to read 320050 psi / 2203.4 bar. The pressure setting needs to be adjusted. Proceed to step 5. 5 Loosen the set screw for the pressure compensator adjustment screw. 6 Adjust the pressure compensator pressure. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. Tighten the set screw. Component damage hazard. Do not adjust the pressure compensator higher than specified. 7 Turn the engine off and remove the pressure gauge. 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.
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Manifolds
7-1 Primary Function Manifold Components Models with Single Joystick
The primary function manifold is located under the manifold inspection cover.
Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Description Schematic Item Function Torque
Solenoid valve, 2 position 4 way ... SV1 ......... Function select boom retract and sway right ..................... 2-3 ft-lbs / 3-4 Nm Directional valve,proportional ........ PE1 ......... Boom extend/retract ....................... 65-75 ft-lbs / 88-101 Nm Directional valve, proportional ....... PE2 ......... Boom up/down ............................... 65-75 ft-lbs / 88-101 Nm Solenoid valve, 2 position 4 way ... SV3 ......... Function select boom extend and sway left ....................... 2-3 ft-lbs / 3-4 Nm Directional valve, proportional ....... PE3 ......... Fork tilt up/down ............................... 33-37 ft-lbs / 45-50 Nm Relief valve, 3500 psi / 241 bar ..... RV3 ......... Fork tilt up relief .......................................... 20 ft-lbs / 27 Nm Check valve, pilot operated 100 psi / 6.9 bar .............................. CV9 ......... Fork tilt down circuit .................................... 25 ft-lbs / 34 Nm Check valve, pilot operated 100 psi / 6.9 bar .............................. CV8 ......... Fork tilt up circuit ......................................... 25 ft-lbs / 34 Nm Relief valve, 3500 psi / 241 bar ..... RV2 ......... Fork tilt down relief ..................................... 20 ft-lbs / 27 Nm Relief valve, 3500 psi / 241 bar ..... RV1 ......... System relief ............................................... 25 ft-lbs / 34 Nm Check valve, 5 psi / 0.3 bar ............ CV7 ......... Sway right circuit .............................. 12-14 ft-lbs / 16-19 Nm Check valve, 5 psi / 0.3 bar ............ CV1 ......... Boom retract circuit ........................... 12-14 ft-lbs / 16-19 Nm Check valve, 5 psi / 0.3 bar ............ CV3 ......... Boom down circuit ............................ 12-14 ft-lbs / 16-19 Nm Check valve, 5 psi / 0.3 bar ............ CV6 ......... Tilt down circuit ................................. 12-14 ft-lbs / 16-19 Nm Check valve, 5 psi / 0.3 bar ............ CV5 ......... Tilt up circuit ...................................... 12-14 ft-lbs / 16-19 Nm
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MANIFOLDS
SV1 PE1 PE2 SV3 PE3
23 22
SV9 SV2
1 2 3 4 5
View A
RV3 6
CV9
CV8 21 SV4 RV2 RV1
9 10
20
PE4
View B
CV7 11
19 18
FR1 FR2 17 16 15
CV2
CV1 CV3 CV6
12 13 14
CV4 CV5
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MANIFOLDS
Primary Function Manifold Components Models with Single Joystick, continued

16 17 18 19 20 21 22 23 Check valve, 5 psi / 0.3 bar ............ CV4 ......... Boom up circuit ................................. 12-14 ft-lbs / 16-19 Nm Check valve, 5 psi / 0.3 bar ............ CV2 ......... Boom extend circuit .......................... 12-14 ft-lbs / 16-19 Nm Flow regulator valve, 0.1 gpm / 0.4 L/min ......................... FR2 ......... Sway left circuit / load sense bleed ............ 20 ft-lbs / 27 Nm Flow control valve, adj., 2.0 gpm / 7.6 L/min ......................... FR1 ......... Sway left circuit ........................................... 20 ft-lbs / 27 Nm Directional valve, proportional 3 position 4 way, pilot operated ..... PE4 ......... Sway left/right ................................... 33-37 ft-lbs / 45-50 Nm Solenoid valve, 2 position 4 way ... SV4 ......... Function select boom up and fork tilt up ............................ 2-3 ft-lbs / 3-4 Nm Solenoid valve, 2 position 4 way ... SV2 ......... Function select boom down and fork tilt down .................. 2-3 ft-lbs / 3-4 Nm Solenoid valve, 2 position 2 way ... SV9 ......... Function select - sway circuit ...................... 20 ft-lbs / 27 Nm
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MANIFOLDS
23 22
SV9 SV2
SV1 PE1 PE2 SV3 PE3
1 2 3 4 5
View A
RV3 6
CV9
CV8 21 SV4 RV2 RV1
9 10
20
PE4
View B
CV7 11
19 18
FR1 FR2 17 16 15
CV2
CV1 CV3 CV6
12 13 14
CV4 CV5
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MANIFOLDS
7-2 Primary Function Manifold Components Models with Dual Joysticks

The primary function manifold is located under the manifold inspection cover.
Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Description Schematic Item Function Torque
Directional valve, proportional ....... Directional valve, proportional ....... Directional valve, proportional ....... Check valve, pilot operated 100 psi / 6.9 bar ..............................
PE1 ......... Boom extend/retract ....................... 65-75 ft-lbs / 88-101 Nm PE2 ......... Boom up/down ............................... 65-75 ft-lbs / 88-101 Nm PE3 ......... Fork tilt up/down ............................... 33-37 ft-lbs / 45-50 Nm PC2 ......... Fork tilt down circuit .................................... 25 ft-lbs / 34 Nm
Relief valve, 3500 psi / 241 bar ..... RV1 ......... System relief ............................................... 20 ft-lbs / 27 Nm Relief valve, 3500 psi / 241 bar ..... RV3 ......... Fork tilt down circuit .................................... 25 ft-lbs / 34 Nm Check valve, pilot operated 100 psi / 6.9 bar .............................. PC1 ......... Fork tilt up circuit ......................................... 25 ft-lbs / 34 Nm Relief valve, 3500 psi / 241 bar ..... RV2 ......... Fork tilt up relief .......................................... 20 ft-lbs / 27 Nm Relief valve, 3500 psi / 241 bar ..... CV7 ......... Sway right check valve ............................... 25 ft-lbs / 34 Nm Shuttle valve .................................... LS1 ......... Function select - sway left/right .................. 20 ft-lbs / 27 Nm Flow regulator valve, 0.1 gpm / .38 L/min ......................... FR2 ......... Sway left circuit / load sense bleed ............ 20 ft-lbs / 27 Nm Check valve, 5 psi / 0.3 bar ............ CV1 ......... Boom retract circuit ........................... 12-14 ft-lbs / 16-19 Nm Check valve, 5 psi / 0.3 bar ............ CV3 ......... Boom down circuit ............................ 12-14 ft-lbs / 16-19 Nm Check valve, 5 psi / 0.3 bar ............ CV2 ......... Boom extend circuit .......................... 12-14 ft-lbs / 16-19 Nm
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MANIFOLDS
PE1
20
PE4
PE2
View A
PE3
19
FR1
PC2 RV1 RV3
4 5 6 7 8
18
SV9
PC1 RV2
17 16 15 14 13 12 11
CV5 CV4 CV6 CV2 CV3 Cv1 FR2
CV7
LS1
10
View B
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MANIFOLDS
Primary Function Manifold Components Models with Dual Joysticks, continued

15 16 17 18 19 20 Check valve, 5 psi / 0.3 bar ............ CV6 ......... Tilt down circuit ................................. 12-14 ft-lbs / 16-19 Nm Check valve, 5 psi / 0.3 bar ............ CV4 ......... Boom up circuit ................................. 12-14 ft-lbs / 16-19 Nm Check valve, 5 psi / 0.3 bar ............ CV5 ......... Tilt up circuit ...................................... 12-14 ft-lbs / 16-19 Nm Solenoid valve, 2 pos, 2 way ......... SV9 ......... Function select- sway circuit ............ 12-14 ft-lbs / 16-19 Nm Flow control valve, 2.0 gpm ........... FR1 ......... Fork up/down circuit ......................... 12-14 ft-lbs / 16-19 Nm Directional valve, proportional ....... PE4 ......... Sway function select ......................... 33-37 ft-lbs / 45-50 Nm
4 - 36
GTH-844
Part No. 218230
November 2012
MANIFOLDS
PE1
20
PE4
PE2
View A
PE3
19
FR1
PC2 RV1 RV3
4 5 6 7 8
18
SV9
PC1 RV2
17 16 15 14 13 12 11
CV5 CV4 CV6 CV2 CV3 Cv1 FR2
CV7
LS1
10
View B
Part No. 218230
GTH-844
4 - 37
November 2012
MANIFOLDS
7-3 Secondary Function Manifold Components

The secondary function manifold is located under the manifold inspection cover.
Index No. 1 2 3 4 5 6 7 8 9 10 11 12 Description Schematic Item Function Torque
DO3 valve, 3 position 4 way ......... SVD1 ....... Steer left/right ............................................ 60 in-lbs / 6.8 Nm Pressure reducing/relief valve, 50 psi / 3.4 bar ................................ PR2 ......... Rear lock-up circuit ........................... 25-27 ft-lbs / 34-37 Nm Pressure reducing/relief valve, 400 psi / 27.5 bar ........................... PR1 ......... Differential lock-up circuit ................. 25-27 ft-lbs / 34-37 Nm Pressure reducing/relief valve, 2650 psi / 183 bar .......................... PR3 ......... Steer circuit ....................................... 25-27 ft-lbs / 34-37 Nm Pressure reducing/relief valve, 350 psi / 24.8 bar ........................... PR4 ......... Parking brake circuit ......................... 25-27 ft-lbs / 34-37 Nm Solenoid valve, 2 position 3 way ... SV5 ......... Parking brake release ................................ 20 ft-lbs / 27 Nm Check valve, 5 psi / 0.35 bar .......... CV9 ......... Brake circuit ................................................ 20 ft-lbs / 27 Nm Check valve, 5 psi / 0.35 bar .......... CV8 ......... Steering circuit ............................................ 20 ft-lbs / 27 Nm Pressure switch ............................... S23 ......... Brake warning switch Pressure switch ................................ S5 .......... Parking brake switch Solenoid valve, 2 position 3 way ... SV7 ......... Rear lock up select ................................... 2-3 ft-lbs / 3-4 Nm Solenoid valve, 2 position 3 way ... SV6 ......... Differential lock up select ......................... 2-3 ft-lbs / 3-4 Nm
4 - 38
GTH-844
Part No. 218230
November 2012
MANIFOLDS
(TR) (TB) (TP) (TPB)

12345 12345
SVD1
View A
SV6
12345 12345 (LS) 12345
(TS)
(TJ)
PR2
12
PR1 SV7 PR3
3 4
11
PR4 SV5
5 6
View B
CV9 CV8
7 8
S23 S5
9 10
Part No. 218230
GTH-844
4 - 39
November 2012
MANIFOLDS
7-4 Auxiliary Manifold (option) and Brake Manifold Components

The auxiliary manifold is located under the transmission inspection cover.
Index No. 1 2 3 4 5 6 Description Schematic Item Function Torque
Check valve, 5 psi / 0.3 bar ............ CV2 ......... Auxiliary 'A1' circuit ........................... 12-14 ft-lbs / 16-19 Nm DO3 valve, 3 position 4 way ......... SVD1 ....... Auxiliary function enable .......................... 60 in-lbs / 6.8 Nm Flow regulator valve ....................... NV1 ......... Function speed control ............................... 25 ft-lbs / 34 Nm Check valve, 5 psi / 0.3 bar ............ CV1 ......... Auxiliary 'A2' circuit ........................... 12-14 ft-lbs / 16-19 Nm Pressure switch, 450 psi / 31 bar ................................ S6 .......... Clutch cut-off pressure ............................ 11 ft-lbs / 14.9 Nm Pressure switch, 50 psi / 3.4 bar ................................. S16 ......... Brake light pressure (option) ................... 11 ft-lbs / 14.9 Nm
CV1
CV2
NV1
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SVD1
2 S6
S16 TO REAR AXLE
TO FRONT AXLE TO REAR AXLE
4 - 40
GTH-844
Part No. 218230
November 2012
MANIFOLDS
7-5 Valve Adjustments Secondary Function Manifold How to Set the Steer System Pressure
Note: Be sure that the hydraulic oil level is visible in the inspection glass of the hydraulic tank. 1 Install a 0 to 1000 psi / 0 to 100 bar pressure gauge into test port 'TP' at the top of the secondary function manifold. See 7-3, Secondary Function Manifold Components. 2 Start the engine. Allow the engine to idle after warming the engine to operating temperature. 3 Without operating any machine controls, observe the reading on the pressure gauge. Result: The pressure gauge reads 450 25 psi / 31 1.7 bar. The pump is functioning correctly. Result: The pressure gauge fails to read 450 25 psi / 31 1.7 bar. The pressure setting needs to be adjusted. See Repair Procedure 6-1, How to Adjust the Function Pump Pressure. 4 Turn the machine off. Remove the pressure gauge from the test port. 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.
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. See 7-3, Secondary Function Manifold Components. 6 Start the engine. Allow the engine to idle. 7 Fully turn and hold the steering wheel in the left direction and allow the wheels to fully turn to the left. Continue holding the steering while observing the pressure reading on the pressure gauge. Result: The pressure gauge reads 2650 psi / 183 bar. The pressure setting is correct. Proceed to step 12. Result: The pressure gauge fails to read 2650 psi / 183 bar. The pressure setting needs to be adjusted. Proceed to step 8. 8 Turn the machine off. Hold the steer pressure reducing/relief valve with a wrench and remove the cap (schematic item PR3). 9 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Component damage hazard. Do not adjust the relief valve pressures higher than specifications. 10 Install the relief valve cap. 11 Repeat this procedure beginning with step 6. 12 Turn the machine off. Remove the pressure gauge from the test port. 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.
Part No. 218230
GTH-844
4 - 41
November 2012
MANIFOLDS
How to Set the Parking Brake System Pressure

Note: Be sure that the hydraulic oil level is visible in the inspection glass of the hydraulic tank. 1 Install a 0 to 1000 psi / 0 to 100 bar pressure gauge into test port 'TP' at the top of the primary function manifold. See 7-1 or 7-2, Primary Function Manifold Components. 2 Start the engine. Allow the engine to idle after warming the engine to operating temperature. 3 Without operating any machine controls, observe the reading on the pressure gauge. Result: The pressure gauge reads 450 25 psi / 31 1.7 bar. The pump is functioning correctly. Result: The pressure gauge fails to read 450 25 psi / 31 1.7 bar. The pressure setting needs to be adjusted. See Repair Procedure 6-1, How to Adjust the Function Pump Pressure. 4 Turn the machine off. Remove the pressure gauge from the test port. 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.
5 Install a 0 to 1000 psi / 0 to 100 bar pressure gauge into test port 'TPB' at the top of the secondary function manifold. See 7-3, Secondary Function Manifold Components. 6 Start the engine. Allow the engine to idle. Result: The pressure gauge reads 350 psi / 24.1. The pressure setting is correct. Proceed to step 11. Result: The pressure gauge fails to read 350 psi / 24.1. The pressure setting needs to be adjusted. Proceed to step 7. 7 Turn the machine off. Hold the brake pressure reducing/relief valve with a wrench and remove the cap (schematic item PR4). 8 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Component damage hazard. Do not adjust the relief valve pressures higher than specifications. 9 Install the relief valve cap. 10 Repeat this procedure beginning with step 6. 11 Turn the machine off. Remove the pressure gauge from the test port. 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.
4 - 42
GTH-844
Part No. 218230
November 2012
MANIFOLDS
How to Set the Differential Lock/Joystick System Pressure

5 Install a 0 to 1000 psi / 0 to 100 bar pressure gauge into test port 'TJ' at the top of the secondary function manifold. See 7-3, Secondary Function Manifold Components. 6 Start the engine. Allow the engine to idle. Result: The pressure gauge reads 400 psi / 27.5. The pressure setting is correct. Proceed to step 11. Result: The pressure gauge fails to read 400 psi / 27.5 bar. The pressure setting needs to be adjusted. Proceed to step 7. 7 Turn the machine off. Hold the diff lock/joystick pressure reducing/relief valve with a wrench and remove the cap (schematic item PR1). 8 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Component damage hazard. Do not adjust the relief valve pressures higher than specifications. 9 Install the relief valve cap. 10 Repeat this procedure beginning with step 6. 11 Turn the machine off. Remove the pressure gauge from the test port. 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.
Part No. 218230
GTH-844
4 - 43
November 2012
MANIFOLDS
How to Set the Rear Lock-up System Pressure

5 Install a 0 to 500 psi / 0 to 50 bar pressure gauge into test port 'TR' at the top of the secondary function manifold (See 7-3, Secondary Function Manifold Components). 6 Start the engine. Allow the engine to idle. Result: The pressure gauge reads 50 psi / 3.4 bar. The pressure setting is correct. Proceed to step 11. Result: The pressure gauge fails to read 50 psi / 3.4 bar. The pressure setting needs to be adjusted. Proceed to step 7. 7 Turn the machine off. Hold the rear lockup pressure reducing/relief valve with a wrench and remove the cap (schematic item PR2). 8 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Component damage hazard. Do not adjust the relief valve pressures higher than specifications. 9 Install the relief valve cap. 10 Repeat this procedure beginning with step 6. 11 Turn the machine off. Remove the pressure gauge from the test port. 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.
4 - 44
GTH-844
Part No. 218230
November 2012
MANIFOLDS
7-6 Valve Coils How to Test a Coil

A properly functioning coil provides an electromagnetic force which operates the solenoid valve. Critical to normal operation is continuity within the coil. Zero resistance or infinite resistance indicates the coil has failed. Since coil resistance is sensitive to temperature, resistance values outside specification can produce erratic operation. When coil resistance decreases below specification, amperage increases. As resistance rises above specification, voltage increases. While valves may operate when coil resistance is outside specification, maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Note: If the machine has been in operation, allow the coil to cool at least 3 hours before performing this test. 1 Tag and disconnect the wiring from the coil to be tested. 2 Test the coil resistance using a multimeter set to resistance (. Refer to the Valve Coil Resistance Specification table. Result: If the resistance is not within the adjusted specification, plus or minus 10%, replace the coil.
Valve Coil Resistance Specification

Note: The following coil resistance specifications are at an ambient temperature of 68F / 20C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18F / 20C that your air temperature increases or decreases from 68F / 20C.
Description DO3 valve, 3 position 4 way 12V DC with diode (schematic items SVD1) Solenoid valve, 2 position 2 way 12V DC with diode (schematic items SV9) Solenoid valve, 2 position 3 way 12V DC with diode (schematic items SV5, SV7, SV6) Solenoid valve, 2 position 4 way 12V DC with diode (schematic items SV1, SV2, SV3, SV4) Specification 5.6
8.8
8.8
8.8
Part No. 218230
GTH-844
4 - 45
November 2012
MANIFOLDS
How to Test a Coil Diode

Genie incorporates spike suppressing diodes in all of its coils. Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Test the coil for resistance. See 7-8, How to Test a Coil. 2 Connect a 10 resistor to the negative terminal of a known good 9V DC battery. Connect the other end of the resistor to a terminal on the coil. Note: The battery should read 9V DC or more when measured across the terminals.
Resistor, 10 Genie part number
4 Connect the negative lead to the other terminal on the coil. Note: If testing a single-terminal coil, connect the negative lead to the internal metallic ring at either end of the coil.
COIL
MULTI METER
+
b
10 W RESISTOR 9V BATTERY
a b c d multimeter 9V DC battery 10 resistor coil
Note: Dotted lines in illustration indicate a reversed connection as specified in step 6
27287
5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery. Note and record the current reading. 6 At the battery or coil terminals, reverse the connections. Note and record the current reading. Result: Both current readings are greater than 0 mA and are different by a minimum of 20%. The coil is good. Result: If one or both of the current readings are 0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced.
3 Set a multimeter to read DC amperage. Note: The multimeter, when set to read DC amperage, should be capable of reading up to 800 mA.
4 - 46
GTH-844
Part No. 218230
November 2012
Axle
8-1 Axles How to Remove the Axle
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 required. 1 Chock the wheels. 2 Remove the fasteners securing the driveshaft to the transmission. Lower the end of the driveshaft to the ground. 3 Remove the fasteners securing the driveshaft to the axle. remove the driveshaft from the machine. 4 Tag and remove the hydraulic hoses from the axle. 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. 5 Loosen the lug nuts of both wheels on the axle to be removed. Do not remove the lug nuts. 6 Raise the end of the machine until the tires are off the ground. Place blocks under the chassis for support. Crushing hazard. The chassis will fall if not properly supported. 7 Remove the lug nuts. Remove the tire and wheel assembly from both ends of the axle. 8 Support and secure the axle to an appropriate lifting device. 9 Remove the fasteners securing the sway cylinder rod-end pivot pin to the chassis. 10 Use a soft metal drift to remove the pivot pin. 11 Remove the fasteners securing the axle to the chassis. Remove the axle from the machine. Crushing hazard. The axle will fall if not properly supported when the fasteners are removed from the machine.
Bolt torque specification Axle mounting bolts 380 ft-lbs 515 Nm
Part No. 218230
GTH-844
4 - 47
November 2012
4 - 48
GTH-844
Part No. 218230
November 2012
Section 5 Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine before attempting any maintenance or repair procedure.
Observe and Obey:

Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: Machine parked on a firm, level surface Boom in the stowed position Key switch in the off position with the key removed Wheels chocked
Be sure that all necessary tools and test equipment are available and ready for use. Read each appropriate fault code thoroughly. Attempting shortcuts may produce hazardous conditions. Be aware of the following hazards and follow generally accepted safe workshop practices. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Note: Two persons will be required to safely perform some troubleshooting procedures.
Part No. 218230
GTH-844
5-1
November 2012
Diagnostic Display
When the engine Electronic Control Module (ECM) detects an abnormal operating condition, a fault code is immediately stored in the ECM memory. The fault code is displayed on the LCD display which is located on the gauge cluster in the operator's compartment. The gauge cluster also includes two warning lights. They are an amber colored light which signals an abnormal engine condition which should be corrected as soon as possible and a red colored light which signals an engine condition which requires the operator to shut down the engine as soon as possible. The ECM will, in some cases, automatically shut down the engine when the red light is displayed. Active Fault Codes Active Fault Codes will be displayed on the gauge cluster whenever a fault is detected. If multiple fault codes are detected, the fault 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 detected. Stored fault codes are the cumulative history of fault codes which the ECM has detected. These fault codes may be recalled by service personnel at a later time even if the condition which caused the engine fault has ceased to exist. Note: Additional hardware will be necessary to access stored codes.
Decoding Fault Codes The Suspect Parameter Number (SPN) and the Failure Mode Identifier (FMI), when combined, are the basis for an engine fault code. The SPN number indicates the affected component; the FMI number reveals the type of failure that has occurred. Comparing the combination of numbers to the fault code chart on the following pages will help to determine the exact engine fault and a corrective course of action. For additional information, refer to the engine operator's manual which came with your machine.
Gauge Cluster a b c LCD screen red stop engine light amber warning light
5-2
GTH-844
Part No. 218230
November 2012
Deutz Engine Fault Codes

SPN = Suspect Parameter Number FMI = Failure Mode Identifier
SPN 29
FMI 3 4
Description Hand throttle error, short circuit to battery on idle validation switch or sensor error Hand throttle error, short circuit to ground on idle validation switch or sensor error Temperature to high for power stage of EGR-Valve (2.9;3.6) / Throttle-Valve (6.1,7.8) or position sensor error Open load actuator EGR-Valve (2.9;3.6) / Throttle-Valve (6.1,7.8) or position sensor error Target range to low for actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8) Target range to high for actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8) The actuator position for EGR-Valve (2.9,3.6) or Throttle-Valve (6.1,7.8) is not plausible Open load actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8) Target range to high for accelerator pedal sensor Target range to low for accelerator pedal sensor PWM signal accelerator pedal out of target range, to high Plausibility check between APP1 and APP2 or APP1 and idle switch Low fuel pressure is out of target range; system reaction generated Target range to high for low fuel pressure sensor Target range to low for low fuel pressure sensor Water in Fuel Sensor - Short Circuit to U-Batt Water level in fuel prefilter above maximum value High oil pressure; system reaction generated Low oil pressure; system reaction generated Target range to high for oil pressure sensor Target range to low for oil pressure sensor Target range to high for ambient air pressure sensor Target range to low for ambient air pressure sensor Coolant temperature is out of target range; system reaction generated Target range to high for coolant temperature sensor Target range to low for coolant temperature sensor
51
3 4 5 6 7 12
91
3 4 8 11 1 3 4 3 12 0 1 3 4 3 4 0 3 4
94
97 100
108 110
Part No. 218230
GTH-844
5-3
November 2012

SPN 111 157 168
FMI 1 3 4 0 1 2 3 4 2 3 4 0 0 1 2 3 4 0 2 8 11 12 14 0 1 3 4 9 2
Description Coolant level underneath the allowed minimum Target range to high for rail pressure sensor Target range to low for rail pressure sensor Battery voltage is out of the target range (to high) Battery voltage is out of the target range (to low) Battery voltage is out of the target range; warning condition is generated Target range to high for battery voltage sensor Target range to low for battery voltage sensor Ambient air temperature sensor value is not plausible Target range to high for intake air sensor Target range to low for intake air sensor Low fuel temperature is out of target range; system reaction generated Oil temperature is out of target range; system reaction generated Physical Range Check low for Oil Temperature Oil temperature value is not plausible Target range to high for oil temperature sensor Target range to low for oil temperature sensor Engine speed target range exceeded; FOC-range 1 Speed sensor of crankshaft and camshaft signals are out of phase Speed sensor signal not plausible Engine speed target range exceeded; FOC-range 2 Speed sensor no signal Engine speed target range exceeded; overrun mode Differential pressure sensor value (AGR) out of target range, to high Differential pressure sensor value (AGR) out of target range, to low SRC high for EGR cooler downstream temperature sensor SRC low for EGR cooler downstream temperature sensor Timeout Error of CAN-Receive-Frame TSC1TR Break Lever Main switch and Break Lever Redundancy switch status not plausible
172
174 175
190
412
520 597
5-4
GTH-844
Part No. 218230
November 2012

SPN 624
FMI 3 4 5 12 12 14 3 5 3 5 3 5 3 5 3 5 3 5 3 4 5 12 5 13 2
Description Short circuit to battery on SVS lamp Short circuit to ground on SVS lamp No load error SVS lamp Temperature to high for power stage of SVS lamp Access error EEPROM memory CAN-Bus 0 "BusOff"-Status General short circuit injector 1 Interruption of electric connection injector 1 General short circuit injector 2 Interruption of electric connection injector 2 General short circuit injector 3 Interruption of electric connection injector 3 General short circuit injector 4 Interruption of electric connection injector 4 General short circuit injector 5 Interruption of electric connection injector 5 General short circuit injector 6 Interruption of electric connection injector 6 Short circuit on high side starter relay Short circuit on low side starter relay No load error starter relay Over load ECU power stage for Starter (overtemp.) Air Heater not connected. Sensor supply voltage monitor error Engine off request ignored
630 639 651 652 653 654 655 656 677
729 1079 1109
Part No. 218230
GTH-844
5-5
November 2012

SPN 1180
FMI 3 4 11 14 14 1 0 1 1 9 9 11 1 0 1 2 3 4 3 4 7 3 4 11 0 1 11 11
Description Target range to high for exhaust gas temperature sensor Target range to low for exhaust gas temperature sensor Exhaust gas temperature value before turbine (upstream) not plausible CAN-Bus 1 "BusOff"-Status CAN-Bus 2 "BusOff"-Status Urea tank temperature sensor value is out of the target range (to low); warning condition is generated Urea tank temperature sensor value out of the target range (to high) Urea tank temperature sensor value is out of the target range (to low); warning condition is generated Plausibility error Min for NOx sensor upstream of SCR Cat Timeout Error of CAN-Receive-Frame AT1IG1Vol; AT1O1; AT1OG1Vol Timeout Error of CAN-Receive-Frame AT1IG1Vol; AT1O1; AT1OG1Vol Nox sensor value downstream not plausible "stuck in range" Target range to low for SCR catalyst upstream temperature sensor Differential pressure sensor value (DPF) out of target range, to high Differential pressure sensor value (DPF) out of target range, to low Differential pressure sensor signal (DPF) not plausible Target range to high for differential pressure sensor (DPF) Target range to low for differential pressure sensor (DPF) Short circuit to battery at powerstage of Urea dosing valve Short circuit to ground at powerstage of Urea dosing valve Dosing valve blocked Target range to high for urea tank level sensor Target range to low for urea tank level sensor Urea heating procedure not successful Target range to high for urea pump module pressure sensor before pressure build up Physical range check low for urea pump module pressure sensor General pressure check error (SCR) General backflow line plausibility error (SCR)
1231 1235 1761 3031
3224 3234 3241 3251 3253
3361
3532 4243 4334 4343 4345
5-6
GTH-844
Part No. 218230
November 2012

SPN 4360 4361 4365
FMI 0 1 3 4 0 3 4 5 13 3 4 5 3 4 5 0 1 0 1 2 3 4 2 3 4
Description Urea catalyst upstream temperature out of the target range (to high) Urea catalyst upstream temperature out of the target range (to low) Target range to high for urea catalyst exhaust gas temperature sensor upstream Target range to low for urea catalyst exhaust gas temperature sensor upstream Urea tank temperature too high Short circuit to battery error on urea tank sensor Short circuit to ground error on urea tank sensor SCR main relay short circuit or open load Pressure stabilization error dosing valve (SCR) Short circuit to battery on powerstage for urea pump motor Short circuit to ground on powerstage for urea pump motor No load error on powerstage for urea pump motor Short circuit to battery on SCR reversal valve Short circuit to ground on SCR reversal valve No load error SCR reversal valve Exhaust gas temperature sensor value upstream (DOC) out of target range, to high Exhaust gas temperature sensor value upstream (DOC) out of target range, to low Exhaust gas temperature sensor value downstream (DOC) out of target range, to high Exhaust gas temperature sensor value downstream (DOC) out of target range, to low Exhaust gas temperature sensor signal upstream (DOC) not plausible Exhaust gas temperature sensor voltage to high Exhaust gas temperature sensor voltage to low Exhaust gas temperature sensor signal downstream (DOC) not plausible Target range to high for exhaust gas temperature sensor downstream (DOC) Target range to low for exhaust gas temperature sensor downstream (DOC)
4366 4374 4375
4376
4765 4766 4768
4769
Part No. 218230
GTH-844
5-7
November 2012

SPN 523006 523009 523212 523350 523352 523450
FMI 3 4 9 10 9 4 4 2 3 4 2 3 4
Description Short circuit to battery on Controller Mode Switch (Engine Speed or Fuel-Delivery Control) Short circuit to ground on Controller Mode Switch (Engine Speed or Fuel-Delivery Control) Incidence of PRV open occurs too often Opening period of PRV is too long or opening occurs to often Timeout Error of CAN-Receive-Frame ComEngPrt Short circuit injector cylinder bank 1 Short circuit injector cylinder bank 2 Injector high current output defect Multiple Stage Switch constant speed Voltage value to the switch setting not plausible Short circuit to battery on Multiple Stage Switch constant speed Short circuit to ground on Multiple Stage Switch constant speed Multiple Stage Switch engine speed control parameter Voltage value to the switch setting not plausible Short circuit to battery on Multiple Stage Switch engine speed control parameter Short circuit to ground on Multiple Stage Switch engine speed control parameter Multiple Stage Switch engine torque limitation curve Voltage value to the switch setting not plausible Short circuit to battery on Multiple Stage Switch engine torque limitation curve Short circuit to ground on Multiple Stage Switch engine torque limitation curve PRV forced to open Maximum rail pressure exceeded (PRV) Rail pressure out of tolerance range Open PRV; system reaction generated Pressure relief valve (PRV) is open T50 Starter switch too long actively Sensor supply voltage 3 error Timeout Error of CAN-Receive-Frame TSC1AE; TSC1AR Internal ECU monitoring detection reported error Softwarereset CPU
523354 12
523451
523452
2 3 4
523470
2 7 11 12 14
523550 12 523601 13 523605 9 523612 12 14
5-8
GTH-844
Part No. 218230
November 2012

SPN 523613
FMI 0 1 2 3 4 5 12 0 1 3 4 16 18
Description Rail pressure is out of target range Minimum rail pressure exceeded (Metering Unit) Setpoint of metering unit not plausible Short circuit to battery Metering Unit Short circuit to ground Metering Unit Open load of metering unit Temperature to high for power stage of fuel metering unit Pressure overload at SCR-System Error pressure build-up SCR Voltage of urea pump module pressure sensor is out of the target range (to high) Voltage of urea pump module pressure sensor is out of the target range (to low) Pump pressure SCR during metering to high Pump pressure SCR during metering to low Nox conversion rate insufficient (SCR-Cat defect, bad AdBule quality) Shutoff request from supervisory monitoring Urea Heater Relay Error - Relay not connected Plausibility error urea supply module heater temperature sensor Supply Module temperature Duty cycle in failure range plausibility error urea supply module temperature sensor (normal condition) Supply Module temperature Duty cycle in failure range Supply Module Temperature measurement not available Timeout message send TrbCH Timeout Error of CAN-Receive-Frame RxEngPres Timeout Error of CAN-Transmit-Frame UAA1 on CAN A check of missing injector adjustment value programming (IMA) check of missing injector adjustment value programming (IMA) check of missing injector adjustment value programming (IMA) check of missing injector adjustment value programming (IMA)
523615
523632
523633 11 523698 11 523718 523720 523721 5 2 8 2 8 11 9
523788 12 523803 523867 12 523895 13 523896 13 523897 13 523898 13
Part No. 218230
GTH-844
5-9
November 2012

SPN
FMI
Description check of missing injector adjustment value programming (IMA) check of missing injector adjustment value programming (IMA) Air pump doesn't achieved air mass flow setpoint Short circuit to battery on a powerstage of burner dosing valve (DV2) Short circuit to ground on a powerstage of burner dosing valve (DV2) Short circuit error in the high side powerstage of burner dosing valve (DV2) Burner dosing valve (DV2) pressure downstream to high, regeneration disabled Burner dosing valve (DV2) pressure downstream to low, regeneration disabled Burner dosing valve (DV2) pressure sensor signal downstream not plausible Target range to high for Burner dosing valve (DV2) pressure sensor downstream Target range to low for Burner dosing valve (DV2) pressure sensor downstream Voltage of glow plug control diagnostic line to high Voltage of glow plug control diagnostic line to low Short circuit to battery on glow plug control Short circuit to ground on glow plug control Open load glow plug control Internal error glow plug control Short circuit to battery on a powerstage of HCI dosing valve (DV1) Short circuit to ground on a powerstage of HCI dosing valve (DV1) Short circuit in the high side powerstage of HCI dosing valve (DV1) HCI dosing valve (DV1) pressure value downstream out of target range, to high HCI dosing valve (DV1) pressure value downstream out of target range, to low HCI dosing valve (DV1) pressure sensor signal downstream not plausible Target range to high for HCI dosing valve (DV1) pressure sensor downstream Target range to low for HCI dosing valve (DV1) pressure sensor downstream Pressure sensor value upstream DV1 & DV2 out fo target range, to high Pressure sensor value upstream DV1 & DV2 out fo target range, to low Pressure sensor signal upstream DV1 & DV2 not plausible Target range to high for pressure sensor upstream DV1 & DV2 Target range to low for pressure sensor upstream DV1 & DV2
523899 13 523900 13 523910 14 523911 3 4 11 0 1 2 3 4 3 4 3 4 5 11 3 4 11 0 1 2 3 4 0 1 2 3 4
523912
523913 523914
523915
523916
523917
5 - 10
GTH-844
Part No. 218230
November 2012

SPN 523918
FMI 0 1 2 3 4 0 1 2 3 4 0 1 2 3 4 0 1 3 4 11 3 4 5 12 0 1
Description Temperature sensor value upstream DV1 & DV2 out of target range, to high Temperature sensor value upstream DV1 & DV2 out of target range, to low Temperature sensor signal upstream DV1 & DV2 not plausible Temperature sensor voltage upstream DV1 & DV2 to high Temperature sensor voltage upstream DV1 & DV2 to low Airpump pressure sensor value out of target range, to high Airpump pressure sensor value out of target range, to low Airpump pressure sensor signal not plausible Target range to high for airpump pressure sensor Target range to low for airpump pressure sensor Exhaust gas back pressure sensor value out of target range, to high Exhaust gas back pressure sensor value out of target range, to low Exhaust gas back pressure sensor signal not plausible Target range to high for exhaust gas back pressure sensor Target range to low for exhaust gas back pressure sensor Burner temperature sensor value out of target range, to high Burner temperature sensor value out of target range, to low Burner Temperature sensor voltage to high Burner Temperature sensor voltage to low Burner temperature sensor signal not plausible Short circuit to battery on shut of valve Short circuit to ground on shut of valve Open load shut off valve Temperature to high for shut of valve Timeout Error of CAN-Receive-Frame EE3CVOL1; EEC3VOL2 Zerofuel calibration during low idle injector 0 out of target range (to high) Zerofuel calibration during low idle injector 0 out of target range (to low)
523919
523920
523921
523922
523935 12 523946
Part No. 218230
GTH-844
5 - 11
November 2012

SPN 523947 523948 523949 523950 523951
FMI 0 1 0 1 0 1 0 1 0 1
Description Zerofuel calibration during low idle injector 1 out of target range (to high) Zerofuel calibration during low idle injector 1 out of target range (to low) Zerofuel calibration during low idle injector 2 out of target range (to high) Zerofuel calibration during low idle injector 2 out of target range (to low) Zerofuel calibration during low idle injector 3 out of target range (to high) Zerofuel calibration during low idle injector 3 out of target range (to low) Zerofuel calibration during low idle injector 4 out of target range (to high) Zerofuel calibration during low idle injector 4 out of target range (to low) Zerofuel calibration during low idle injector 5 out of target range (to high) Zerofuel calibration during low idle injector 5 out of target range (to low) Tamper detection derating timer below limit 1 Tamper detection derating timer below limit 2 Urea quality derating timer below limit 1 Urea qulaity derating timer below limit 2 Urea tank level derating timer below limit 1 Urea tank level derating timer below limit 2 Bad quality of reduction agent detected Burner flame unintentional killed DPF wasn't regenerated, power reduction phase 1 (manuell regeneration request) Engine power reduction due to low lambda DPF wasn't regenerated, power reduction phase 2 (manuell regeneration request) DPF wasn't regenerated, warning condition (manuell regeneration mode)
523973 14 523974 14 523975 14 523976 14 523977 14 523978 14 523980 14 524013 7 524018 14 524020 14 524022 14 524023 14
5 - 12
GTH-844
Part No. 218230
November 2012
Perkins 1104D Engine Fault Codes

SPN 91
FMI 2 3 4 8 3 4 3 4 10 3 4 3 4 3 4 3 4 0 1 2 3 4 2 8 15 0 5 6 2 2 11
Description Incorrect throttle switch inputs Throttle position sensor: voltage above normal or shorted high Throttle position sensor: voltage below normal or shorted low Throttle position sensor: abnormal frequency, pulse width or period Engine oil pressure sensor: voltage above normal or shorted high Engine oil pressure sensor :voltage below normal or shorted low Boost pressure sensor voltage: voltage above normal or shorted high Boost pressure sensor voltage: voltage below normal or shorted low No 5V to sender Intake manifold temperature sensor: temperature above normal or shorted high Intake manifold temperature sensor: temperature below normal or shorted low Intake manifold air temperature open/short to battery positive (+) Intake manifold air temperature short to ground Engine coolant temperature open/short to battery positive (+) Engine coolant temperature short to ground Fuel rail pressure open/short to battery positive (+) Fuel rail pressure short to ground System voltage high System voltage low ECM battery power intermittent/erratic Air inlet temperature voltage high Air inlet temperature voltage low Fuel temperature sensor: data erratic/intermittent or incorrect Engine speed signal abnormal Engine speed: overspeed WARNING Engine overspeed Ether start aid current low Ether start aid current high System parameters incorrect Personality module mismatch Engine timing calibration invalid For further engine fault code troubleshooting and diagnostic information, refer to the Perkins 1100 Troubleshooting Manual (Perkins part number SENR9982-01).
Perkins 1100 Troubleshooting Manual Genie part number
100 102
105 105 110 157 168
172 174 190 190 626 630 631 637
123583
Part No. 218230
GTH-844
5 - 13
November 2012
Perkins 1104D Engine Fault Codes

SPN 637 639 651
FMI 139 9 12 2 5 6 7 2 5 6 7 2 5 6 7 2 5 6 7 3 4 8 5 9 5 6 7 2 3 4
Description Engine timing calibration required J1939 data link communications J1939 data link malfunction Cylinder #1 injector data incorrect Cylinder #1 injector open circuit Cylinder #1 injector short Cylinder #1 injector not responding Cylinder #2 injector data incorrect Cylinder #2 injector open circuit Cylinder #2 injector short Cylinder #2 injector not responding Cylinder #3 injector data incorrect Cylinder #3 injector open circuit Cylinder #3 injector short Cylinder #3 injector not responding Cylinder #4 injector data incorrect Cylinder #4 injector open circuit Cylinder #4 injector short Cylinder #4 injector not responding 8V DC supply short to battery positive (+) 8V DC supply shorted to ground Secondary engine speed signal abnormal Turbo wastegate drive current low Machine security system module non-communication Fuel rail pump output current low Fuel rail pump output current high Fuel rail pressure valve solenoid not responding Mode selector switch: data erratic/intermittent or incorrect 5V DC power supply sensor short to battery positive (+) 5V DC power supply sensor short to ground
652
653
654
678 723 1188 1196 1347
2882 3509 3509
For further engine fault code troubleshooting and diagnostic information, refer to the Perkins 1100 Troubleshooting Manual (Perkins part number SENR9982-01).
Perkins 1100 Troubleshooting Manual Genie part number
123583
5 - 14
GTH-844
Part No. 218230
November 2012
Section 6 Schematics
Schematics
About This Section
There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics
Observe and Obey:

Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine.
Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Hydraulic Schematics 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. General Repair Process
Before Troubleshooting:
Read, understand and obey the safety 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.
Malfunction discovered
Identify symptoms
problem still exists
Troubleshoot
Return to service
problem solved
Inspect and test
Perform repair
Part No. 218230
GTH-844
6-1
November 2012
Fuse Panel Layout
RN1
R10
RN3
RN2
R2 R3 R4
C6
ENCLOSED CAB HARNESS
C7
L10
L2
L1
L4
L5
L7
L11
L6
L9
L3
L8
L13
L12
L14
BEACON LT HARNESS
60 Amp CB3
50 Amp CB1
CB2*
C8
DOME LT HARNESS
L24
L23
L22
L25
L28
L27
L15
L21
L26
L16
L17
L20
L19
L18
C5
DASHBOARD HARNESS
F15 1A SWITCH PWR F3 10A
F14 10A PWR PORT F6 5A
F11 10A
F8 5A
DEFROST FAN DOME/BEACON F17 10A MAX SPARE F10 15A F7 5A GAUGE CLS PWR F16 1A
Circuit Breakers located on the Battery Tray

CB1 and CB3 on all engines CB2 30A Deutz T3 or T4i Perkins T3 30A CB2 50A Perkins T4i CB1- Telehandler Control System Power CB2- Engine Power / ECM CB3- Glow Plugs
REAR AXLE OSCSTEER/DIFF SW F4 10A F1 15A
CR14 SPARE
+
D14
C4
D3 + D1 + D2 +
SWAY/TILT F20 10A MAX SPARE F5 5A HORN
BRAKE/SHIFT WIPER/WASHER GAUGE CLS ECU F2 10A AUX HYD F18 10A MAX SPARE F12 20A LIGHTS F9 25A HVAC F19 10A MAX SPARE F13 15A IGNITION CR4 FLASHER
+ D5 + D4
C2
ROAD/WORK LIGHT HARNESS
D8
CR8 BOOM EXTEND

D9
CR9 FORWARD ENABLE

D10
D13
D12
D6
D11
D18
D19
CAP1
D15
D16
D17
C1
TRANSMISSION HARNESS
R1
CR1 MAIN POWER
CR2 OPTIONS POWER
D7
SECONDARY MANIF. HARNESS
C3
PRIMARY MANIF. HARNESS
CR11 P .BRAKE LATCH
CR12 SWAY L/R ENBL

+
CR13 TILT U/D ENABLE
CR10 REVERSE ENABLE
CR5 LIGHTS OPTION

+ +
CR6 SWAY ENABLE

+
CR7 BOOM ANGLE
CR3 SERVICE HORN
C9
JOYSTICK HARNESS
PCB Board Fuse Panel located in the Cab
6-2
GTH-844
Part No. 218230
November 2012
Electrical Component Legend
Electrical Component & Wire Color Abbreviation Legend

ALT B CB Alternator Battery B1 Main Battery Circuit Breaker CB1 50 Amp Circuit Breaker CB2 30 Amp Circuit Breaker CB3 60 Amp Circuit Breaker Capacitor C1 4700 uf Control Relay CR1 Main Power CR2 Options Power CR3 Service Horn CR4 Flasher CR5 Lights Option CR6 Sway Enable CR7 Boom Angle CR8 Boom Extend CR9 Forward Enable CR10 Reverse Enable CR11 Parking Brake Latch CR12 Sway Left/Right Enable CR13 Tilt Up/Down Enable CR15 HVAC Blower L CR16 HVAC Blower M CR17 HVAC Blower H Diode Engine Management System Fuse F1 15 Amp - Break/Shift F2 10 Amp - Aux Hydraulics F3 10 Amp Rear Axle Oscillate F4 10 Amp Sway/Tilt F5 5 Amp - Horn F6 5 Amp - Steer/Differential Switch F7 5 Amp - Gauge Cluster Power F8 5 Amp - Dome/Beacon Light F9 25 Amp HVAC F10 15 Amp Windshield Wiper/Washer F11 10 Amp Defrost Fan F12 20 Amp Lights F13 15 Amp Ignition F14 10 Amp Power Port F15 1 Amp - Switch Power F16 1 Amp Gauge Cluster ECU F17 Not Used F18 Not Used F21 HVAC Control Panel
C CR
D EMS F
M R S
LED Light L1 Ignition Power L2 Options Power Relay L3 Horn Relay L4 Turn Signal L5 Road Lights, Work Lights L6 Sway Enable Coil Power L7 Boom Angle L8 Boom Extend L9 Brake Pressure L10 Backup Light, Alarm L11 Parking Brake Latch L12 Sway Enable L13 Tilt Circuit Power L14 Horn Power L15 Cab, Tail Light Power L16 Rear Axle Float Coil Power L17 Rr Ax Fast Power (GTH1056) L18 Parking Brake Power L19 Forward Coil Power L20 Reverse Coil Power L21 PB Release Coil Power L22 Sway L/R Enable Coil Power L23 Tilt U/D Enable Coil Power L24 Forward Shift L25 Parking Brake Release L26 Brake Light Power L27 Hazard Power L28 Not Used Motor Resistor Switch S1 Key Start Switch S2 Parking Brake Switch S3 Boom Angle Switch S4 Boom Extend Switch S5 Parking Brake Pressure Switch S6 Service Brake Pressure Switch S7 Sway Enable Pressure Switch S8 Sway Enable Switch S9 Tilt Enable Switch S10 Steer Select Switch S11 Left Stabilizer Switch S12 Right Stabilizer Switch S13 Differential Lock Switch S14 Auxiliary Cont. Switch S15 Horn Switch S16 Brake Light Pressure Switch S17A Windshield Wiper Motor Switch S17B Windshield Washer Switch S18A Windshield Wiper Motor Switch S18B Windshield Washer Switch S19 Dome Light Switch S21 Enclosed Cab Fan Switch S22 Road / Work Light Switch S23 Brake Pressure Warning Switch S24 Transmission Oil Pressure Switch S25 Transmission Oil Temp. Switch
ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF ON ON
Part No. 218230
GTH-844
6-3
November 2012
Electrical Component Legend
Electrical Component & Wire Color Abbreviation Legend

TP TSS Y Throttle Pedal Turn Signal Shifter Valve Coil Y1 Sway Left Enable SV1 Y2 Tilt Up Enable SV2 Y3 Sway Right Enable SV3 Y4 Tilt Down Enable SV4 Y5 Parking Brake Release SV5 Y6 Differential Lock SV6 Y7 Rear Axle Float SV7 Y8 Rear Axle Fast SV8 Y9 Sway Enable SV9 YA Auxiliary 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 YRD Right Stabilizer Down YRU Right Stabilizer Up
Wire Color Legend

BL BL/BK BL/RD BL/WH BK BK/RD BK/WH BK/YL BR GR GR/BK GR/WH RD RD/BK RD/WH OR OR/BK OR/RD WH WH/BK WH/RD Blue Blue/Black Blue/Red Blue/White Black Black/Red Black/White Black/Yellow Brown Green Green/Black Green/White Red Red/Black Red/White Orange Orange/Black Orange/Red White White/Black White/Red
6-4
GTH-844
Part No. 218230
November 2012
Electrical and Hydraulic Symbols Legend
Electrical Schematic Symbols

BAT ACC
Hydraulic Schematic Symbols
KS1
KEY SWITCH
IGN
START
STARTER
M3
Pressure switch Hydraulic cylinder
Axle
Key switch
86 85 30 87 87A
Engine start
D1
ALT G B
Orifice
Adjustable orifice
Filter
Control relay
Alternator Check valve Flow regulator Relief valve
Fuse
Circuit breaker 2 position 3 way solenoid valve 2 position 3 way directional valve, pilot-operated
Horn or Alarm
Light
3 position 4 way solenoid valve
Valve coil with diode
Valve coil
Diode Switch
P T
Proximity switch
Joystick Limit switch Counterbalance valve
Temperature switch
Fuel level sender
Pressure switch
-
Battery
Part No. 218230
GTH-844
6-5
November 2012
6-6
GTH-844
Part No. 218230
November 2012
Electrical Schematic - View 1
6-7
6-8
November 2012

A 1
NO
C
CAN H YL CAN L GR
E
C10-10 C10-11
H
CAN H YL CAN L GR
K
C13-3 C13-2
L
GAUGE CLUSTER
NO
120 F1 10 AMP D16 C3-8

CR1
C5-11
F15 1 AMP RD BRN C24-1
F13 15 AMP
S1 KEY SWITCH ACC WH C5-8
CR2
S3 BOOM ANGLE SW. (N.O.) BLU C24-2 RD/BK C3-10
L7
F3 10 AMP
F4 10 AMP
F5 5 AMP
F14 10 AMP
F2 10 AMP
F6 5 AMP
F7 5 AMP
F16 1 AMP
L17 L16 L19
DPF (PERKINS T4i) DPF DISABLED (PERKINS T4i) HEST (PERKINS T4i) L9 ENGINE WARNING ENGINE STOP L10 ENGINE OIL PRESSURE TACHOMETER LCD/HOURMETER
D7
CR7 NO
RD
BAT
DUAL JOYSTICK OPTION

C4-6
C9-2
C9-1
C4-9 OR/RD
C4-10 RD/WH
C3-12 YL
C5-4
C5-6
C5-1
C5-5
L2 WH/RD START IGN RD/BK C5-9 BK C15-2 S2 PARK BRAKE SW. L1
D15
SINGLE JOYSTICK OPTION S8 SWAY ENABLE SW. S9 TILT ENABLE SW.
C15-6
WH
C12-6
NO
PCB BAT+
RD
F-N-R SHIFTER
C27-A S5 PARKING BRAKE PRESS. SW. (N.O.) 2 1 S6 SERVICE BRAKE PRESS. SW. (N.C.) C27-B
GR
C27-A C27-B
11
1 L14 L3
12
WHITE
RED
50 AMP CB 1
C10-6 3 WH
C12-3 C12-2 C12-1 C5-2 BL/WH C15-1 BL/WH C15-8 C15-9 C15-4 BL/RD RD/BK
S14 AUX. CONT. SW.
S13 DIFF. LOCK SW.
S10 STEER SELECT SW.
GAUGE CLUSTER CPU
C5-7
D17
CR3
L18
S7 SWAY ENABLE PS.
AUX. HYD. OPTION
RD
WH/RD
WH/RD
GR
L8
WH/RD C12-8
C28-1
C14-2
GR/BK
C55-2
C11-4 RD/WH
RD/BK
3
C44-7 C44-8 A 120 CB 2 ECU PWR 60 AMP CB 3
RED BATTERY CABLE
C29-1
C5-3 C12-7 GR/WH
C9-3 C12-5 C9-4
12V POWER PORT
L1 L2
C55-4 C55-1 C28-2
C13-7 C13-24 C13-22
RD/WH OR/BK BL BL/WH
S25 S24
TRANS OIL TEMP SW.(N.O.) TRANS OIL PRESS SW.(N.C.) FUEL SENDER
C14-4 GR/WH
C14-1 GR/BK
C44-5 CAN L CAN H IGN EMS ENGINE MANAGEMENT SYSTEM D5

C44-4 OR C38-5 IVS VCC C44-3 BL/WH C38-3 C44-2 YL/WH C38-2 GND C44-1 GR/WH C38-1 APS GND ALT
START
C44-6
RD/WH
C5-12 C5-10
BR C5-8
RD/WH
C29-2
WH
L12
C1-3 OR/BK BL BR
C13-1 L4 C13-5
C4-8 BL/BK
C13-8
S23
L24
CR6 NO
BRAKE PRESS WARN SW.(N.C.)
D19 D12
CR12 NO CR13 NO
C4-7
YL
GR
WH
D13 L13
ENGINE COOLANT TEMP C13-21 BACKLIGHT L6 2WS LIGHT L5 L7 L21 L20 CRAB STEER LIGHT 4WS LIGHT HEADLIGHTS ON TURN SIGNAL
RD
C10-8
GLOW PLUG PWR
D1 L25
CR11 NO CR10 NO
C1-2
ST
L11 D11 R1 0.1 D6
BL
D10
STARTER
L10
CR9 NO
C1-1
D9 L9 L16
C4-4 C10-3 C12-2
D2 L6 L22
C3-5 C3-4 C3-6 C3-3 C3-7
C3-11
B+ ALT G
D+
C1 4700 F
L23
S15 HORN SW.
C13-13 C11-3
GR/WH
C2-2
C13-4 C13-17 C13-16
C57-1
C56-1
C4-5 BL/WH
L21
RD/WH
BL/BK
BL/BK
RD/WH
BK/RD
BK/WH
OR/RD
YL
BL
YL
GR
B1
A B C D
C84 Y67 BR
PARKING BRAKE LATCH RELAY
C30-1
WORK/ ROAD LIGHT OPTION
WH
L20
L19 C41-1 Y6
C11-2 C32-1 Y68 C32-2

DIFFERENTIAL LOCK COIL SV6
GR/BK
C18-1 Y5
C40-1
C43-1 Y81 C43-2

FORWARD COIL E TRANS COIL CR9 FORWARD ENABLE RELAY
C42-1 Y80 C42-2

D TRANS COIL CR7 BOOM ANGLE RELAY
C31-1 Y55 Y82 C31-2

REAR AXLE FLOAT COIL SV7
C19-1
C21-1 Y70
C20-1 Y71 C20-2

SWAY LEFT ENABLE COIL SV1 SWAY RIGHT ENABLE COIL SV3
C23-1 Y72A
C22-1 Y72B
Y77B
C57-2 BK
Y77A
C56-2 GR
C33-1 Y78 C33-2
C34-1 Y79 C34-2
THROTTLE PEDAL
IVS VCC GND APS
C30-2
BACKUP LIGHT
C18-2
CR1 MAIN POWER RELAY PARKING BRAKE LIGHT BACKUP ALARM CR2 OPTIONS POWER RELAY
C40-2
REVERSE COIL CR10 REVERSE ENABLE RELAY
C41-2
C19-2
CR12 SWAY FUNCTION RELAY CR6 SWAY ENABLE RELAY SWAY ENABLE COIL SV9
C21-2
C23-2
TILT UP ENABLE COIL SV2
C22-2
HORN CR3 HORN RELAY 12V POWER PORT CR13 TILT FUNCTION RELAY TILT DOWN ENABLE COIL SV4
BR
C13-6
AUX COIL B
AUX COIL A
BEACON LIGHT OPTION
12 VOLT BATTERY
PARKING BRAKE RELEASE COIL SV5
4WS COIL SVD1A
CRAB STEER COIL SVD1B
STARTER SOLENOID & RELAY
STARTER MOTOR
PERKINS T4 50AMP PERKINS T3 30AMP DEUTZ,T3/T4 30AMP
BL/RD BL C10-7 BL
ENCLOSED CAB OPTION
WORK/ROAD LIGHT OPTION
ROAD LIGHT OPTION L4 C1-5

CR4
F8 5 AMP
F9 25 AMP
F11 5 AMP
F10 10 AMP
F12 20 AMP
C2-4
C2-3
X L26 D4 P
TURN SIGNAL SHIFTER
L 2 3
3-4 3-5 4-3 4-5 5-3 5-4 6-8
C48-2
C49-1
C2-1 C2-10 YL BL RD OR/BK GY GR GR/BK 2 3 4 5 6 7 8
C7-1
C8-1
WH
C6-1
C6-2
C6-5
RD
C6-3
C6-4
2 S22 ROAD/WORK 4 LIGHT SW.
C48-4
S16 BRAKE LIGHT PRESS SW. (N.O.)
FLASHER L27
2-3 2>7 2>4 3-7 3-2 3>7 3-8 3>4
R H N
OR/BK BL/RD
RD/BK
C49-2
RD C2-11 C2-12
4 5 6 7 8
C65-1 C7-1
RD BK
WH S19 HEATER/HVAC OPTION S21 FAN SWITCH
C61-1
RD S17B WINDSHIELD WASH SW. S17A WINDSHIELD WIPER MOTOR SW. 4

OR
2 4
OR
RD S18B SKYLIGHT WASH SW.
C2-5
CR5 NO
5-6 5-6 5-8 6-5 6-5 6-8 7-3 7-8 8-3 8-5 8-6 8-7 8-6
5-6 5-8 6-5 6-8 8-5 8-6
RD
RD
RD
BK
2 4
OR
L5
C7-1
BK C65-2 C61-2
BR
1 2
RD BL
1 2
RD
S18A WINDSHIELD WIPER MOTOR SW. 4

OR BL
D18
L15
UNLESS OTHERWISE SPECIFIED
C2-7
RD
C2-6
RD
C2-9
RD/BK BK
C2-6
RD
C2-7
RD
C2-8
OR
C2-9
OR C51-A
BK
BK
GND
C47-1
C46-1
C51-A
C51-B
C46-1
C47-1
C52-A
C52-B
C51-B
C53-1
C54-1
C7-2
C8-2
C6-6
BK
C47-2 BR STROBE LIGHT DOME LIGHT HVAC MOTOR DEFROSTER FAN WINDSHIELD WIPER WINDSHIELD WHASHER WINDSHIELD WIPER WINDSHIELD WHASHER RIGHT CAB LIGHT WORK LIGHTS
C46-2
C51-C
C46-2
C47-2
C52-C
C51-C
C53-2
C54-2
LEFT CAB LIGHT
RIGHT TAILIGHT
LEFT CAB LIGHT ROAD LIGHTS
RIGHT CAB LIGHT
LEFT TAILIGHT
RIGHT TAILIGHT
LEFT FRONT BLINKER
RIGHT FRONT BLINKER
ES0459A
6-8
GTH-844
Part No. 218230
November 2012

N M L K J I H G F E D C B A 1
HVAC OPTION DETAILS CONTROL PANEL 26-1397 HEAT VALVE POTENTIOMETER 10KW BL CCW C76-A ACTUATOR SEALED HEATER VALVE GND M IGN SIG C81-D C81-C C81-A CW BK WH C77-4 C77-3 22 20 C76-C 32 WH WH WH WH 31 WH WH 16 15 F21 INLINE 4 AMP A1 A2 B 18 RD C6-1 RD C6-2 BK GND WH C83-1 SEE PAGE 1 FOR DETAILS RD BK/WH WHC80-B WHC80-C WHC80-A WH WH WH THERMOSTAT
CR16 NO
HEATER OPTION DETAILS NOTE: CIRCLED NUMBERS PRINTED ON WIRES A/C SWITCH (ON/OFF) C77-1 BLOWER SWITCH SPEED CONTROL B C78-B BLOWER SPEED SWITCH INFO: OFF - UNIT OFF L - BLOWER LOW SPEED M - BLOWER MEDIUM SPEED H - BLOWER HIGH SPEED HEATER VALVE POT INFO: CCW - COOL SETTING CW - HOT SETTING A/C SWITCH INFO: ON - A/C ON OFF - A/C OFF CONTROL PANEL 56-0048 HEAT VALVE POTENTIOMETER 10KW BL CCW CW BK BLOWER SWITCH SPEED CONTROL B C78-B NOTE: CIRCLED NUMBERS PRINTED ON WIRES BLOWER SPEED SWITCH INFO: OFF - UNIT OFF L - BLOWER LOW SPEED M - BLOWER MEDIUM SPEED H - BLOWER HIGH SPEED HEATER VALVE POT INFO: CCW - COOL SETTING CW - HOT SETTING
WH
WH C76-B
C OFF L M H WH C78-C WH C80-E WH WHC80-D C78-H C78-M C78-L 5 WHC79-A 21 1 WHC79-B WHC80-F 5 21 WH WH 1 WH WH 4 10
CR17 NO
C OFF L M H C78-H C78-M C78-L
C76-A
C76-B
C76-C YL K BK WH BL RD I YL C80-C
3
OR RD A H G E RD C6-1 RD C6-2 BK GND SEE PAGE 1 FOR DETAILS
22 17 18 25 26 27
C85-1
L WHC80-E
F RD C80-B
B OR C80-A
X 10 WHC80-D WHC80-F
A/C DRIER SWITCH
WHC79-C HVAC CORE 13-2537
C85-2 BK L I YL F RD B OR X 10 WH WH
HEATER CORE 13-2541
22 17 18 25 26 27
C82-1 12 2 WH A/C CONTROL VALVE Y84 C82-2 BK
COLD CUT-OUT: -3.0C1.0C
23
29
11
30
R2 82KW
28 24 WH WH WH
CR15 NO
3 11 13 M
ACTUATOR SEALED RED N HEATER VALVE 4 GND M IGN BLOWER SIG C81-D C81-C C81-A
R2 82K W F 8 WH WH WH I
6
B D
BLOWER
ES0459A
Part No. 218230
GTH-844
6-9
November 2012
6-9
6 - 10
November 2012
Hydraulic Schematic - Single Joystick
6 - 11
6 - 12
November 2012
Hydraulic Schematic - Single Joystick

A 1
SERVICE BRAKE PRESSURE SWITCH 450 psi 31 bar BRAKE LIGHTS (OPTION) PRESSURE SWITCH 50 psi 3.5 bar
DIFF LOCK SERVICE BRAKE MANIFOLD BRAKE PEDAL PARKING BRAKE FRONT AXLE 1
H
T 3
I
P 2
J
4-WAY CONTROL
4
FRONT STEER
6 gpm 22.8 L/min L R
REAR STEER
EXTEND / RETRACT
31 / 14 gpm 117.4 / 53 L/min
6 gpm 22.8 L/min L R REAR AXLE
31 / 19 gpm 117.4 / 72 L/min
LIFT
14 / 10 gpm 53 / 37.9 L/min 2.2 gpm 8.4 L/min
TILT
SWAY
2
P STRG. WHL. T
15.3 cid / 250 cc
STEERING UNIT
REAR LOCK-UP
5 gpm 19 L/min
L R LS BRAKE WARNING LIGHT PRESSURE SWITCH A P TB BP
0-640 psi / 0-44.2 bar

PARKING BRAKE PRESSURE SWITCH P DL TJ JP TR LU LUP J1 R ER EE E J3 J2 R LD LU E J4
E E R 15 gpm 56.8 L/min A1 A2 ALS ALS CV7 CV2 CV1
3
SUP TS SUT SULS
350 psi 24.1 bar
T BT
250 psi / 17.3 bar

TPB PBS
AUX HYD
SUR
SRF b
SLR
SRR
BS BA
PB
MASTER TD TU
CV8
SVD1
SL #6
SR
SV5
SV6 CV1 CV2 CV3 CV4 SV2 SV3 SV4 PE2 SV1 PR2 50 psi 3.5 bar
CV9 CV6 PE3
CV8 CV5
0.1 gpm 0.8 L/min

FR2
SVD1
a
4
PR3
PE1
PE4
2.0 gpm 7.6 L/min
FR1
SV7
NV1
2650 psi 183 bar
PR4
350 psi 24.1 bar PR1 400 psi 28 bar

TP P2 LS2 P2
SV9
AUX MANIFOLD (OPTION)
AP
AT
5
CV9
RV1
LS2
RV2 3500 psi 241.4 bar 3500 psi 241.4 bar
RV3 3500 psi 241.4 bar
AP
SECONDARY FUNCTION MANIFOLD

LS PLS
T2
T2
AT
MAIN FUNCTION MANIFOLD

P T
HS0205B
E BREATHER / FILLER
3 psi / 0.3 bar
L1 L2 L S FUNCTION PUMP 3250/450 PSI PC/LS SETTING 3.11 CID (51 CC) 2370-2580 RPM MAX
RESERVOIR
6 - 12
GTH-844
Part No. 218230
November 2012
Hydraulic Schematic - Dual Joystick

N M L K J I H G F
T P
E
4-WAY CONTROL
4
D
T P 4 2 1
C
4-WAY CONTROL
3
A 1
SERVICE BRAKE PRESSURE SWITCH

450 psi 31 bar
BRAKE LIGHTS (OPTION) PRESSURE SWITCH

50 psi 3.5 bar
FRONT STEER
6 gpm 22.8 L/min
REAR STEER
EXTEND / RETRACT
31 / 14 gpm 117.4 / 53 L/min
6 gpm 22.8 L/min
31 / 19 gpm 117.4 / 72 L/min
LIFT
14 / 10 gpm 53 / 37.9 L/min
TILT
DIFF LOCK SERVICE BRAKE MANIFOLD PARKING BRAKE FRONT AXLE
15.3 cid / 250 cc
STEERING UNIT
REAR LOCK-UP
5 gpm 19 L/min
2.2 gpm 8.4 L/min
SWAY
R REAR AXLE
P STRG. WHL. T LS SUP TS SUT SULS SUR SRF b SLR L R
BRAKE WARNING LIGHT PRESSURE SWITCH 350 psi 24.1 bar SRR BS BA TB
BRAKE PEDAL 0-640 psi / 0-44.2 bar A P BP T BT PARKING BRAKE PRESSURE SWITCH 250 psi / 17.3 bar TPB PBS PB DL TJ JP #4 TR LU P LUP JE1 R ER EE E JE3 JL2 R LD LU E
E E R
15 gpm 56.8 L/min A1 A2
AUX HYD
MASTER
JL4 JT4 TD TU JT2 JS1 SL SR JS3 ALS ALS
CV8
SVD1 SV5 SV6
CV1 CV2
a
CV3 CV4 PE2
PC1 CV5 PE3
PC2 CV6 PE4
0.1 gpm 0.8 L/min
FR2
CV7
CV2 CV1 SVD1 a b
PE1 PR2 50 psi 3.5 bar SV7
PR3
2650 psi 183 bar
PR4 350 psi 24.1 bar PR1

CV9
2.0 gpm 7.6 L/min
FR1
LS1
50 psi / 3.5 bar
SWAY ENABLE PRESSURE SWITCH
NV1 AP AT
400 psi 28 bar
SV9
TP P2 LS2 P2
SS
AUX MANIFOLD (OPTION)
RV1
LS2
RV2 3500 psi 241.4 bar 3500 psi 241.4 bar
RV3 3500 psi 241.4 bar
AP
6
T2 T2 AT
SECONDARY FUNCTION MANIFOLD

LS PLS P T
MAIN FUNCTION MANIFOLD

HS0206C
E BREATHER / FILLER
3 psi / 0.3 bar
L S FUNCTION PUMP 3250/450 PSI PC/LS SETTING 3.11 CID (51 CC) 2370-2580 RPM MAX L1 L2
RESERVOIR
Part No. 218230
GTH-844
6 - 13
November 2012
Hydraulic Schematic - Dual Joystick
6 - 13
6 - 14
California Proposition 65
Warning
The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
Genie North America
Genie Australia Pty Ltd.

Phone +61 7 3375 1660 Fax +61 7 3375 1002
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Phone +46 31 575100 Fax +46 31 579020
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Phone +86 21 53852570 Fax +86 21 53852569
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Phone +33 (0)2 37 26 09 99 Fax +33 (0)2 37 26 09 98
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Phone +65 98 480 775 Fax +65 67 533 544
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Phone +34 93 579 5042 Fax +34 93 579 5059
Genie Japan
Phone +81 3 3453 6082 Fax +81 3 3453 6083
Genie Germany
Phone Phone Fax 0800 180 9017 +49 422 149 1818 +49 422 149 1820
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Phone +82 25 587 267 Fax +82 25 583 910
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Phone +44 (0)1476 584333 Fax +44 (0)1476 584334
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Phone +55 11 41 665 755 Fax +55 11 41 665 754
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Phone +52 55 5666 5242 Fax +52 55 5666 3241
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Phone +31 183 581 102 Fax +31 183 581 566
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Parts Manual Service Manual

Serial Serial Number Number Range Range

Part No. 218230 Rev A1 March 2013

Serial Number Information

Part No. 218230

Procedure / Schematic Page / Description

Part No. 218230

REVISION HISTORY, CONTINUED

Procedure / Schematic Page / Description

Part No. 218230

Serial Number Legend

Part No. 218230

This page intentionally left blank.

Part No. 218230

Section 1 Safety Rules

Do Not Perform Maintenance Unless:

Part No. 218230

Section 1 Safety Rules

Part No. 218230

Part No. 218230

B-10 Perform Axle Maintenance................................................................ 3 - 17

Part No. 218230

Part No. 218230

Fuel and Hydraulic Tanks

Part No. 218230

Part No. 218230

Part No. 218230

For operational specifications, refer to the Operator's Manual.

Part No. 218230

Part No. 218230

Fire resistant Mineral based

Cleanliness level, minimum Water content, maximum

Part No. 218230

Hydraulic Components Specifications

Part No. 218230

Manifold Component Specifications

Air Conditioner Refrigerant Specifications

Part No. 218230

Deutz TCD3.6 L4 Engine

Part No. 218230

Perkins 1104D-E44TA Engine

Part No. 218230

Perkins 854E-E34TA Engine

Part No. 218230

Dana VDT12000 Transmission

Carraro 26.27M Drive Axle

Part No. 218230

Hydraulic Hose and Fitting Torque Specifications

SAE O-ring Boss Port

SAE O-ring Boss Port

Part No. 218230

SAE FASTENER TO RQ UE C HART

A 574 Hi gh St rengt h Bl ack O xi de Bol t s LUBED

100 120 DRY

140 160 DRY

130 140 LUBED

M ETRI C FASTENER TO RQ UE C HART

10. 3 17. 6 29. 4

7. 2 14. 4 25. 1 40 62. 5 86. 2 121 166 210

9. 88 19. 6 34. 1 54. 3 84. 8 117 165 225 285