Service and Repair Manual

Serial Number Range

GTH-1056 from GTH1016E-11305 to

GTH1016E-11799
This manual includes:
Repair procedures
includes GTH1016E-11281 Fault Codes
GTH1016E-11282 Electrical and
GTH1016E-11286
Hydraulic Schematics
from GTH10E-11800

For detailed maintenance

procedures, refer to the
appropriate Maintenance
Manual for your machine.

Part No. 1278145

Rev A
December 2016
Service and Repair Manual December 2016

Introduction
Intr oducti on Intr oducti on

Important Technical Publications

Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Genie policy.
procedure. Therefore, product specifications are subject to
change without notice.
This manual provides troubleshooting and repair
procedures for qualified service professionals. Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
Basic mechanical, hydraulic and electrical skills are communications will be carefully considered for
required to perform most procedures. However, future printings of this and all other manuals.
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 Contact Us:
authorized Genie dealer service center.
Internet: www.genielift.com
E-mail: awp.techpub@terex.com

Compliance
Find a Manual for this Model
Machine Design Life Go to http://www.genielift.com
Unrestricted with proper operation, inspection and Use the links to locate Service Manuals,
scheduled maintenance. Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.

Copyright © 2016 by Terex Corporation

1278145 Rev A, December 2016
First Edition, First Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
"GTH" is a trademark of Terex South Dakota, Inc.

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Introduction

Revision History
Revision Date Section Procedure / Page / Description
A 3/2016 Initial Release

Reference Examples:
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics

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Introduction

Serial Number Legend

To August 31, 2016

1 Model 1 Serial label

2 Model year 2 Serial number (stamped on chassis)
3 Facility code 3 Serial label (located inside fork frame)
4 Sequence number
From September 1, 2016

1 Model 1 Serial label

2 Facility code 2 Serial number (stamped on chassis)
3 Sequence number 3 Serial label (located inside fork frame)

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Safety Rules
Section 1 Safety R ules

Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.

Do Not Perform Maintenance

Unless:
 You are trained and qualified to perform
maintenance on this machine.
 You read, understand and obey:
• manufacturer's instructions and safety rules
• employer's safety rules and worksite
regulations
• applicable governmental regulations
 You have the appropriate tools, lifting
equipment and a suitable workshop.

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Safety Rules

Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.

Be sure to keep sparks, flames and

lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.

Be sure that all tools and working areas

are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.
Please be environmentally safe.

Be sure that your workshop or work area

is properly ventilated and well lit.

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Table of Contents

Introduction Introduction........................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Serial Number Legend .......................................................................................... iv

Section 1 Safety Rules .......................................................................................................... v

General Safety Rules ............................................................................................. v

Section 2 Specifications ....................................................................................................... 1

Machine Specifications ........................................................................................... 1
Performance Specifications .................................................................................... 2
Hydraulic Oil Specifications .................................................................................... 2
Hydraulic Component Specifications...................................................................... 5
Manifold Component Specifications ....................................................................... 6
Air Conditioner Refrigerant Specifications ............................................................. 7
Deutz TCD3.6 L4 Engine Specifications ................................................................ 8
Deutz TCD3.6 L4 T4F Engine Specifications ......................................................... 9
Perkins 1104D-E44TA Engine Specifications ...................................................... 10
Perkins 1204E-E44TA Engine Specifications ...................................................... 11
ZF 4 WG-98 TC Transmission Specifications ...................................................... 12
Dana Planetary 213 Drive Axle Specifications ..................................................... 12
Hydraulic Hose and Fitting Torque Specifications ............................................... 13
Torque Procedure ................................................................................................ 14

Section 3 Repair Procedures ............................................................................................. 16

Introduction ........................................................................................................... 16

Boom Components ............................................................................................ 18

1-1 Boom Proximity Switch .................................................................................. 18
How to Test a Proximity Switch....................................................................... 18
How to Adjust the Boom Angle Proximity Switch ............................................ 19
How to Adjust the Boom Extend Proximity Switch .......................................... 19
1-2 Boom .............................................................................................................. 20
How to Replace the Boom Wear Pads ........................................................... 20
How to Remove the Lifting Fork Frame .......................................................... 20
How to Remove the Cable Bridge Assembly .................................................. 21

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Table of Contents

How to Replace the Retraction Chain .............................................................22

How to Replace the Extension Chains ............................................................24
How to Remove the Boom ..............................................................................26
How to Disassemble the Boom - GTH-1056 ...................................................28
1-3 Boom Lift Cylinder ..........................................................................................31
1-4 Boom Extension Cylinder ...............................................................................32
1-5 Fork Level Cylinder ........................................................................................33
1-6 Hydraulic Hoses .............................................................................................34
How to Replace the Fork Level and/or Auxiliary Cylinder Hoses, GTH-1056 .34

Operator's Compartment ...................................................................................36

2-1 Operator's Compartment ................................................................................36
2-2 Machine Controls ...........................................................................................38
How to Remove the Steering Column .............................................................38
How to Remove the Steering Wheel ...............................................................38
How to Remove the Steer Orbitral ..................................................................39
How to Remove the Joystick - Models with Single Joystick ............................39
How to Remove the Joystick - Models with Dual Joysticks ............................40
How to Remove the Brake Pedal Assembly ...................................................40
How to Remove the Gauge Cluster Assembly ................................................41
How to Remove the Diagnostic Display ..........................................................41

Fuel and Hydraulic Tanks ..................................................................................42

3-1 Fuel and Hydraulic Tanks...............................................................................42

Engines ................................................................................................................43
4-1 Engines...........................................................................................................43
How to Repair the John Deere 4045T Engine ................................................43
How to Repair the Perkins 1104D-E44TA Engine ..........................................43
How to Repair the Deutz TD3.6 L4 and TCD3.6 L4 Engines ..........................43
How to Remove the Engine.............................................................................43
4-2 Engine Fault Codes ........................................................................................44

Transmission ......................................................................................................45
5-1 Transmission ..................................................................................................45
How to Repair the Transmission .....................................................................45
How to Remove the Transmission ..................................................................45

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Table of Contents

Hydraulic Pump .................................................................................................. 47

6-1 Hydraulic Pump .............................................................................................. 47
How to Test the Function Pump ...................................................................... 47
How to Remove the Function Pump ............................................................... 48
How to Install the Function .............................................................................. 49
How to Prime the Function Pump ................................................................... 49
How to Adjust the Function Pump Standby Pressure ..................................... 50
How to Adjust the Function Pump Pressure Compensator ............................ 51

Manifolds ............................................................................................................. 53
7-1 Primary Function Manifold Components - Models with Single Joystick ........ 53
7-2 Primary Function Manifold Components - Models with Dual Joysticks ......... 57
7-3 Secondary Function Manifold Components ................................................... 61
7-4 Outrigger Manifold Components .................................................................... 63
7-5 Auxiliary Manifold Components (option) ........................................................ 65
7-6 Brake Manifold Components .......................................................................... 66
7-7 AC Hydraulic Manifold Components .............................................................. 67
7-8 Valve Adjustments - Secondary Function Manifold ....................................... 68
How to Set the Steer System Pressure .......................................................... 68
How to Set the Parking Brake System Pressure ............................................ 69
How to Set the Differential Lock/Joystick System Pressure ........................... 70
How to Set the Rear Lock-up System Pressure ............................................. 71
7-9 Valve Coils ..................................................................................................... 72

Axle ...................................................................................................................... 74
8-1 Axles ............................................................................................................... 74
How to Remove the Axle ................................................................................. 74
How to Repair the Axle ................................................................................... 74

Outriggers ........................................................................................................... 75
9-1 Outriggers....................................................................................................... 75
How to Remove an Outrigger.......................................................................... 75
How to Remove an Outrigger Cylinder ........................................................... 76

Section 4 Fault Codes ......................................................................................................... 78

Introduction ........................................................................................................... 78

Diagnostic Display ............................................................................................. 79

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Table of Contents

Deutz TCD3.6 Engine Fault Codes ....................................................................80

Perkins 1104 Engine Fault Codes ...................................................................104

Section 5 Schematics ........................................................................................................106

Introduction .........................................................................................................106
Proximity Switch Legend ....................................................................................107
Fuse Panel Layout ..............................................................................................108
Electrical Component Legend ............................................................................109
Wire Color Legend ..............................................................................................111
Telematics Connector Pin Legend .....................................................................112
Electrical Symbol Legend ...................................................................................114
Hydraulic Symbols Legend .................................................................................115
Harness Map - Control System- Single Joystick ................................................116
Harness Map - Control System- Dual Joystick ...................................................119
Harness Map - Deutz 3.6TCD T4F Engine ........................................................120
Harness Map - Perkins 1204 T4F Engine ..........................................................123
Harness Map - Work Lights ................................................................................124
Harness Map - Road Lights ................................................................................127
Harness Map - Enclosed Cab with Heat ............................................................128
Harness Map - Enclosed Cab with HVAC ..........................................................131
Harness Map - Auxiliary Hydraulics, Beacon and Top Gear Lockout ................132

Electrical Schematics .......................................................................................134

Electrical Schematic ...........................................................................................135

Hydraulic Schematics ......................................................................................138

Hydraulic Schematic - Models with Single Joystick............................................139
Hydraulic Schematic - Models with Dual Joystick ..............................................140

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Specifications
Section 2 Specific ati ons

Machine Specifications Fluid capacities

Tires and wheels Fuel tank 35 gallons

132.5 liters
Tire size 14.00 x 24
Tire ply rating 12 Hydraulic tank 44 gallons
166.5 liters
Weight, rough terrain tire 315 lbs
(air filled) 142.9 kg Hydraulic system 55 gallons
(including tank) 208.2 liters
Weight, rough terrain tire 967 ±35 lbs
(foam filled) 439 ±16 kg
Weight, rock lug tire 1013 ±35 lbs
(foam filled) 459 ±16 kg
Tire pressure 50 psi
(models with air-filled tires) 3.45 bar
Lug nut torque 465 ft-lbs
630 Nm
Lug Pattern 10 x 13.189
Wheel diameter 24 in
60.1 cm
Wheel width 9 in
22.9 cm

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Specifications

Performance Specifications Hydraulic Oil Specifications

Drive speed, maximum 18 mph Hydraulic Fluid Specifications
29 km/h
Genie specifications require hydraulic oils which are
Draw bar pull 29,000 lbs designed to give maximum protection to hydraulic
13,154 kg systems, have the ability to perform over a wide
Lift capacity, maximum 10,000 lbs temperature range, and the viscosity index should
4545 kg exceed 140. They should provide excellent antiwear,
oxidation prevention, corrosion inhibition, seal
Boom function speeds, maximum conditioning, and foam and aeration suppression
Boom up 17 to 19 seconds properties.
Boom down 23 to 25 seconds Cleanliness level, ISO 15/13
minimum
Boom extend 14 to 16 seconds
Water content, 250 ppm
Boom retract 13 to 15 seconds maximum
Fork rotate 3 to 6 seconds Recommended Hydraulic Fluid
Hydraulic oil type Chevron Rando HD Premium
Viscosity grade 32
Viscosity index 200
Optional Hydraulic Fluids
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable Petro Canada Environ MV 46
Fire resistant UCON Hydrolube HP-5046
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult Genie Product
Support before use.

Optional fluids may not have the

same hydraulic lifespan and
may result in component
damage.

Note: Extended machine operation can cause the

hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.

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Specifications

Do not top off with incompatible Chevron Rando HD Premium Oil

hydraulic fluids. Hydraulic fluids
may be incompatible due to the MV Fluid Properties
differences in base additive ISO Grade 32
chemistry. When incompatible
fluids are mixed, insoluble Viscosity index 200
materials may form and deposit Kinematic Viscosity
in the hydraulic system, cSt @ 200°F / 100°C 7.5
plugging hydraulic lines, filters, cSt @ 104°F / 40°C 33.5
control valves and may result in Brookfield Viscosity
component damage. cP @ -4°F / -20°C 1040
cP @ -22°F / -30°C 3310
Note: Do not operate the machine when the Flash point 375°F / 190°C
ambient air temperature is consistently above
Pour point -58°F / -50°C
120°F / 49°C.
Maximum continuous operating 171°F / 77°C
temperature
Hydraulic Fluid Temperature
Range Note: A hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.
Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.

Ambient air temperature

1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV

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Specifications

Chevron 5606A Hydraulic Oil Petro-Canada Environ MV 46

Fluid Properties Fluid Properties
ISO Grade 15 ISO Grade 46
Viscosity index 300 Viscosity index 154
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 5.5 cSt @ 200°F / 100°C 8.0
cSt @ 104°F / 40°C 15.0 cSt @ 104°F / 40°C 44.4
cSt @ -40°F / -40°C 510
Flash point 482°F / 250°C
Flash point 180°F / 82°C
Pour point -49°F / -45°C
Pour point -81°F / -63°C
Maximum continuous operating 180°F / 82°C
Maximum continuous operating 124°F / 51°C temperature
temperature

Note: Use of Chevron 5606A hydraulic fluid, or

equivalent, is required when ambient temperatures
are consistently below 0°F / -17°C unless an oil
heating system is used. Shell Tellus S4 VX Fluid
Properties
Continued use of Chevron
5606A hydraulic fluid, or ISO Grade 32
equivalent, when ambient Viscosity index 300
temperatures are consistently
above 32°F / 0°C may result in Kinematic Viscosity
cSt @ 200°F / 100°C 9
component damage
cSt @ 104°F / 40°C 33.8
Brookfield Viscosity
cSt @ -4°F / -20°C 481
cSt @ -13°F / -25°C 702.4
cSt @ -40°F / -40°C 2624
Flash point >100
Pour point -76°F / -60°C
Maximum continuous operating 103°F / 75°C
temperature

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Specifications

Hydraulic Component
UCON Hydrolube HP-5046 Fluid Specifications
Properties Function pump
ISO Grade 46 Type: variable displacement piston pump
Viscosity index 192 Displacement 0 to 3.66 cu in
0 to 60 cc
Kinematic Viscosity
cSt @ 149°F / 65°C 22 Flow rate @ 2400 rpm 38 gpm
cSt @ 104°F / 40°C 46 144 L/min
cSt @ 0°F / -18°C 1300 Pump pressure, maximum 3190 psi
Flash point None 220 bar
Pour point -81°F / -63°C Pressure compensator 3190 psi
220 bar
Maximum continuous operating 189°F / 87°C
temperature Standby pressure 464 psi
32 bar

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Specifications

Primary Function Manifold Manifold Component

System relief valve pressure, maximum
(measured at test port TP)
3500 psi
241 bar
Specifications
Boom extend relief valve pressure, 3500 psi Plug torque
maximum 241 bar SAE No. 2 50 in-lbs / 6 Nm
Fork tilt relief valve pressure, maximum 3500 psi SAE No. 4 13 ft-lbs / 18 Nm
241 bar
SAE No. 6 18 ft-lbs / 24 Nm
Flow regulator, Fork tilt circuit 14 gpm
53 L/min SAE No. 8 50 ft-lbs / 68 Nm
Flow regulator, Sway circuit 2 gpm SAE No. 10 55 ft-lbs / 75 Nm
7.5 L/min SAE No. 12 75 ft-lbs / 102 Nm
Flow regulator, Pilot pressure bleed circuit 0.1 gpm
1.4 L/min
Secondary Function Manifold
Steer relief valve pressure, maximum 2500 psi
(measured at test port TS) 172 bar
Parking brake relief valve pressure, 400 psi
maximum 27.5 bar
(measured at test port TPB)
Diff lock relief valve pressure, maximum 400 psi
(measured at test port TJ) 27.5 bar
Rear lock-up relief valve pressure, 50 psi
maximum 3.4 bar
(measured at test port TR)
Outrigger Manifold
Flow regulator, Outrigger circuit 6 gpm
22.7 L/min

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Specifications

Air Conditioner Refrigerant

Specifications
System Full Charge
R134a 1 lb 14 oz

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Specifications

Deutz TCD3.6 L4 Engine Fuel injection system

Injection pump pressure, maximum 23200 psi
Displacement 221 cu in 1600 bar
3.62 liters
Fuel requirement
Number of cylinders 4
For fuel requirements, refer to the engine Operator
Bore and Stroke 3.86 x 4.72 inches Manual for your engine.
98 x 120 mm
Engine coolant
Horsepower 100 @ 2300 rpm
74.6 kw @ 2300 rpm Capacity 4.5 gallons
17 liters
Peak Torque 302 lb-ft @ 1600 rpm
409 Nm @ 1600 rpm Type Extended Life
Firing order 1-3-4-2 Starter motor
Low idle 1000 rpm Normal load 300-400A

High idle 2400 rpm Relay max 60A

Compression ratio 17.2:1 Relay continuous 12A

Combustion Direct injection Cranking speed >100 rpm

Governor electronic Glow Plugs

Initial load (0-6 sec) 80 amps
Lubrication system
Continuous load (>6 sec) <40 amps
Minimum oil pressure 23.5 psi
(warm, at low idle) 1.6 bar Battery Specifications
Oil capacity (including filter) 9.5 quarts Type 12V DC
9 liters Group C31
Oil viscosity requirements Quantity 1
Unit ships with 15W-40 API CJ4 low ash oil. Battery capacity, maximum 1000A
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the Reserve capacity @ 25A rate 200 Minutes
Engine Operator Manual for your engine. Alternator output 95A @ 12V DC

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Specifications

Deutz TCD3.6 L4 T4F Fuel injection system

Injection pump pressure, maximum 23200 psi
1600 bar
Engine Fuel requirement
Displacement 221 cu in For fuel requirements, refer to the engine Operator
3.62 liters Manual for your engine.
Number of cylinders 4 Engine coolant
Bore and Stroke 3.86 x 4.72 inches Capacity 4.5 gallons
98 x 120 mm 17 liters
Horsepower 121 @ 2300 rpm Type Extended Life
90.2 kw @ 2300 rpm
Starter motor
Peak Torque 354 lb-ft @ 1600 rpm
Normal load 300-400A
480 Nm @ 1600 rpm
Relay max 60A
Firing order 1-3-4-2
Relay continuous 12A
Low idle 1000 rpm
Cranking speed >100 rpm
High idle 2300 rpm
Glow Plugs
Compression ratio 17.2:1
Initial load (0-6 sec) 80 amps
Combustion Direct injection
Continuous load (>6 sec) <40 amps
Governor electronic
Battery Specifications
Lubrication system
Type 12V DC
Minimum oil pressure 23.5 psi
(warm, at low idle) 1.6 bar Group C31

Oil capacity (including filter) 9.5 quarts Quantity 1

9 liters Battery capacity, maximum 1000A
Oil viscosity requirements Reserve capacity @ 25A rate 200 Minutes
Unit ships with 15W-40 API CJ4 low ash oil. Alternator output 120A @ 12V DC
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.

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Specifications

Perkins 1104D-E44TA Engine Fuel requirement

For fuel requirements, refer to the engine Operator
Displacement 269 cu. in Manual for your engine.
4.4 liters
Fuel injection pressure, minimum 23700 psi
Number of cylinders 4 1635 bar
Bore and Stroke 4.13 x 5 inches Starter motor
105 x 127 mm
Normal load 68A
Horsepower 125 @ 2400 rpm
93.2 kW @ 2400 rpm Relay max 50A

Valve clearance, cold Relay continuous 20A

Intake 0.013 in Cranking speed 130 - 200 rpm

0.35 mm Battery Specifications
Exhaust 0.013 in Type 12V DC, Group C31
0.35 mm
Quantity 1
Firing order 1-3-4-2 Battery capacity, maximum 1000A
Low idle 1000 rpm Reserve capacity @ 25A rate 200 Minutes
High idle 2500 rpm Engine coolant
Compression ratio 16.2:1 Capacity 4.6 gallons
Lubrication system 17.4 liters
Oil pressure at operating 43 to 58 psi Type Extended Life
temperature 2.9 to 4 bar Glow Plugs
Oil capacity (including filter) 10 quarts Initial load (0-4 sec) 20A (EA)
9.5 liters
Continuous load (>4 sec) 15A (EA)
Oil viscosity requirements
Alternator output 85A @ 14V DC
Unit ships with 15W-40. Extreme operating
temperatures may require the use of alternative engine
oils. For oil requirements, refer to the Engine Operator
Manual for your engine.

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Specifications

Perkins 1204E-E44TA Engine Fuel requirement

For fuel requirements, refer to the engine Operator
Displacement 268.5 cu. in Manual for your engine.
4.4 liters
Fuel injection pressure, minimum 23000 psi
Number of cylinders 4 1585 bar
Bore and Stroke 4.13 x 4.99 inches Starter motor
105 x 124 mm
Normal load 155A
Horsepower 124 @ 2000 rpm
92.7 kW @ 2000 rpm Relay max 50A

Peak Torque 391 lb-ft @ 1400 rpm Relay continuous 15A

530 Nm @ 1400 rpm Cranking speed 200 - 300 rpm
Firing order 1-3-4-2 Battery Specifications
Compression ratio 16.5:1 Type 12V DC, Group C31
Low idle 800 rpm Quantity 1
High idle 2200 rpm Battery capacity, maximum 1000A
Lubrication system Reserve capacity @ 25A rate 200 Minutes

Pressure (Hot @ 2300 rpm) 28 - 64 psi Engine coolant

1.9 to 4.4 bar Capacity 4.9 gallons
Minimum oil pressure 7.1 psi 18.5 liters
0.49 bar Type Extended Life
Oil capacity (including filter) 8.8 quarts Glow Plugs
8.3 liters
Initial load (0-6 sec) 12A (EA)
Oil viscosity requirements
Continuous load (>6 sec) 16A (EA)
Units ship with 15W-40 API CJ4 low ash oil.
Extreme operating temperatures may require the use of Alternator output 120A @ 12V DC
alternative engine oils. For oil requirements, refer to the
Engine Operation and Maintenance Manual on your
machine.

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Specifications

ZF 4 WG-98 TC Transmission Dana Planetary 213 Drive Axle

Transmission Type 4 speed powershift converter Steering Integrated steer cylinder
Speeds, Forward 4 Joints Heavy duty double U-joints
Speeds, Reverse 3 Steering angle, maximum 45°
Torque Converter Front Axle Lubrication
Maximum input 2600 rpm Front differential 15 quarts
14.2 liters
Maximum torque 480 Nm
Lubrication Axle planetary end (each) 2 quarts
1.9 liters
Oil capacity 16.9 quarts
Rear Axle Lubrication
16 liters
Oil viscosity requirements Rear differential 15 quarts
14.2 liters
Units ship with Chevron Delo 400 LE SAE 15W40.
Axle planetary end (each) 2 quarts
Extreme operating temperatures may require the use of
1.9 liters
alternative transmission oils. For oil requirements, refer
to the ZF 4 WG-98 TC Maintenance Manual. Oil viscosity requirements
ZF 4 WG-98 TC Operating Manual Differential Chevron Supreme 80W90 LS
Genie part number 1258405 Planetary ends Chevron Supreme 80W90 LS
For additional axle information, refer to the Dana 213
Axle Maintenance and Repair Manual
Dana 213 Axle Maintenance and Repair Manual
Genie part number 115026

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Specifications

Hydraulic Hose and Fitting

Torque Specifications SAE O-ring Boss Port
Your machine is equipped with Parker Seal-Lok™ (tube fitting - installed into Aluminum)
(all types)
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends be SAE Dash Size Torque
torqued to specification when they are removed -4 14 ft-lbs / 19 Nm
and installed or when new hoses or fittings are -6 23 ft-lbs / 31.2 Nm
installed.
-8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
Seal-Lok™ Fittings -12 84 ft-lbs / 114 Nm
(hose end - ORFS)
-16 125 ft-lbs / 169.5 Nm
SAE Dash Size Torque
-20 151 ft-lbs / 204.7 Nm
-4 10 ft-lbs / 13.6 Nm
-24 184 ft-lbs / 249.5 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
Adjustable Fitting Non-adjustable fitting

1 jam nut
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash Size Thread Size Flats
SAE O-ring Boss Port
-4 7/16-20 2
(tube fitting - installed into Steel)
-6 9/16-18 1¼
SAE Dash Size Torque
-8 3/4-16 1
-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
-10 7/8-14 1 ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
-12 1 1/16-12 1 37° (Non-adj) 22 ft-lbs / 30 Nm
-16 1 5/16-12 1 -6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-20 1 5/8-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
-24 1 7/8-12 1 37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm

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Specifications

Torque Procedure
JIC 37° fittings
Seal-Lok™ fittings 1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
1 Replace the O-ring. The O-ring must be
the hex nut to the body hex fitting to hand tight,
replaced anytime the seal has been broken.
approximately 30 in-lbs / 3.4 Nm.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger 2 Using a permanent ink marker, make a
tight. reference mark on one the flats of the hex nut
and continue the mark onto the body of the hex
Note: The O-ring in Parker Seal Lok™ fittings and
fitting. Refer to Illustration 1.
hose end are custom-size O-rings. They are not
standard 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 the O-ring face seal 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.
Illustration 1
5 Tighten the nut or fitting to the appropriate
torque. Refer to the appropriate torque chart in 1 hex nut
this section. 2 reference mark
3 body hex fitting
6 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.

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Specifications

3 Working clockwise on the body hex fitting,

make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Illustration 2.
Note: Use the JIC 37° Fitting table in this section to
determine the correct number of flats, for the proper
tightening position.
Note: The marks indicate the correct tightening
positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
joint after it has been loosened.

Illustration 2
1 body hex fitting
2 reference mark
3 second mark

4 Tighten the hex nut until the mark on the hex

nut is aligned with the second mark on the
body hex fitting.
5 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.

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Repair Procedures

Machine Configuration:
Section 3 Repair Pr oc edures

 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
Observe and Obey:
• Key switch in the off position with the key
 Repair procedures shall be completed by a removed
person trained and qualified on the repair of this
machine. • Wheels chocked

 Immediately tag and remove from service a

damaged or malfunctioning machine.
 Repair any machine damage or malfunction
before operating the machine.

Before Repairs Start:

 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 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.

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Repair Procedures

About This Section

Most of the procedures in this section should only
be performed by trained service professional in a
suitably equipped workshop. Select the appropriate
repair procedure after troubleshooting the problem.
Perform disassembly procedures to the point where
repairs can be completed. Then to re-assemble,
perform the disassembly steps in reverse order.

Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.

Indicates a imminently hazardous

situation which, if not avoided, will
result in death or serious injury.

Indicates a potentially hazardous

situation which, if not avoided,
could result in death or serious
injury.

Indicates a potentially hazardous

situation which, if not avoided,
may cause minor or moderate
injury.

Indicates a potentially hazardous

situation which, if not avoided,
may result in property damage.

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.

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Boom Components

How to Test a Proximity Switch

How to T est a Pr oxi mity Switc h

1-1
1 Remove the switch from the machine. Do not
Boom Proximity Switch disconnect the switch wire harness from the
machine.
The boom angle switch is a proximity switch. This
switch functions by sensing a change in the 2 Start the engine.
electromagnetic field of the switch, due to the 3 Move the switch away from any ferrous or
introduction of metal into the field. A proximity metallic object
switch is, simply, a metal detector.
Result: The light of the limit switch assembly is
The switch generates an electromagnetic field at not illuminated.
the face of the switch. This field senses when steel
has been moved close to the switch as well as 4 Move the switch close to any ferrous or
when the steel has been moved away, which is how metallic object
the switch contacts open and close. Result: The light of the proximity switch
assembly turns on. The switch is functioning
These switches are of a fail-safe design. Should the
correctly.
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.

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Boom Components

How to Adjust the Boom Angle How to Adjust the Boom Extend
How to Adj ust the Boom Angle Proxi mity Swi tch How to Adj ust the Boom Extend Proxi mity Switc h

Proximity Switch Proximity Switch

The boom angle proximity switch is attached to a The boom extend proximity switch assembly is
mounting bracket, located between the boom and secured to the top surface of the number 0 boom
the chassis directly beneath the boom pivot pin. tube at the center of the boom. The proximity switch
The switch location is adjustable. assembly is fixed in position and is not 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. 1 boom angle proximity switch
2 boom extend proximity switch
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.

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Boom Components

1-2 How to Remove the Lifting Fork

How to R emove the Lifting F or k Fr ame

Boom Frame
1 With the boom in the stowed position, attach a
How to Replace the Boom Wear
How to R eplac e the Boom Wear Pads

lifting strap from an overhead crane to the top

Pads of the lifting fork frame at the front of the boom.
Support the frame. Do not apply any lifting
1 Lower wear pads: Using a lifting strap from an pressure.
overhead crane or a fork lift of sufficient
capacity, lift the boom tube just enough to 2 Working from the rear of the frame, lift the
remove the weight from the pads. spring-assisted handle of the lock securing the
lower fork frame lock pin to the fork frame
2 Remove the wear pad mounting fasteners and mount. Use a soft metal drift to remove the pin.
remove the wear pads from the boom.
3 Using the overhead crane, lift and remove the
3 Lubricate the wear surface of the new pads. fork frame from the boom.
Refer to Maintenance Procedure in the
appropriate Service or Maintenance Manual Crushing hazard. The fork frame
for your machine, Lubricate the Boom. could fall if not properly supported
when the lock pin is removed
Note: Do not lubricate the side wear pads.
from the machine.
4 Install the wear pads. Install and securely
tighten the fasteners. Do not over tighten.

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Boom Components

How to Remove the Cable Bridge

How to R emove the Cable Bridg e Ass embl y

4 Working at the pivot end of the boom, remove

Assembly the fasteners securing the hose roller
assembly to boom tube number 1. Remove the
Inside the four-section boom, a cable bridge is used hose roller assembly from the boom.
to route hydraulic lines through the boom assembly
5 Working at the fork end of the boom, remove
to the fork level cylinder and auxiliary connections
the fasteners securing the cable track mount
(if equipped).
bracket to boom tube number 3.
1 Remove the inspection cover at the pivot end 6 Working at the fork end of the boom, remove
of the boom. the fasteners securing the cable bridge slider
2 Working at the pivot end of the boom, remove to the cable bridge. Remove the slider from the
the fasteners securing the cable bridge rear boom.
mount bracket to the boom assembly. Remove Note: Pay attention to how the hoses are routed
the bracket from the boom. 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.
7 Working at the fork end of the boom, securely
attach the loose end of the cable track to the
cable bridge using a cable tie or similar device.
8 Working at the pivot end of the boom, carefully
remove the cable bridge from the boom.

1 cable bridge mount bracket

2 cable track mount bracket
3 cable bridge slider

3 Working at the pivot end of the boom, tag,

disconnect and plug the hydraulic hoses at the
hard lines of the cable bridge. Cap the fittings.

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Service and Repair Manual December 2016

Boom Components

How to Replace the Retraction

How to R eplac e the R etraction C hain

Chain
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 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 dual-chain
tensioner to the top of boom tube number 1.
After noting the orientation and assembly order
of the components, remove the fasteners and
pull the tensioner free of the boom.

1 tube 3 extension chains

2 dual-chain tensioner
3 tube 2 extension chains
4 single-chain tensioner
5 boom tube number 0
6 boom tube number 1
7 boom tube number 2
8 boom tube number 3

7 Working at the fork end of the boom, loosen

evenly the fasteners securing the single-chain
tensioners to the top of boom tube number 0.
After noting the orientation and assembly order
of the components, remove the fasteners and
pull the tensioners free of the boom.
8 Remove the inspection cover from the pivot
end of the boom.

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Boom Components
9 Locate the two chain anchors of the boom 14 Working at the fork end of the boom, securely
retraction chains where they attach to the connect a 30 foot / 10 m length of rope to the
chain anchor mount at the lower side of boom end of the chain. Securely tie off the other end
tube 2 and 3. of the rope to the boom structure.
15 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.
16 Remove the rope from the end of the chain and
securely attach the rope to the new chain.
17 Working at the fork end of the boom, use the
1 chain anchor - boom tube number 3
rope to carefully pull the chain through the
2 chain anchor - boom tube number 2 boom just until the end of the chain is
accessible. Remove the rope from the chain.
10 Select a chain anchor. Remove the fasteners
securing the chain anchor pivot pin to the 18 Working at the pivot end of the boom, install
anchor mount of the boom tube. Remove the the chain anchor into the chain anchor mount.
pivot pin and pull the chain anchor free of the Secure the chain anchor to the mount using
mount. the pivot pin and fasteners removed in step 10.
Securely tighten the fasteners. Do not over
11 Using a strap from an overhead crane, support
tighten.
the extend cylinder. Do not apply any lifting
pressure
12 Working at the fork end of the boom, remove
the fasteners securing the boom extend
cylinder pivot pin to the boom.
13 Use a soft metal drift to remove the pivot pin.
Lower the cylinder just enough for access to
the chain anchor bolts.

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Service and Repair Manual December 2016

Boom Components

How to Replace the Extension

How to R eplac e the Extension C hai ns

19 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
Chains
removed in step 10. Securely tighten the Note: Perform this procedure on a firm, level
fasteners. Do not over tighten. surface with the boom in the stowed position and
the wheels chocked.
20 Repeat this procedure, beginning with step 10,
for the remaining chain anchor. 1 Start the engine and allow the engine to idle.
21 Install the inspection cover, removed in step 8, 2 Raise the boom to a horizontal position.
onto the boom. Install and securely tighten the
fasteners. Do not over tighten. 3 Fully retract the boom.

22 Working at the fork end of boom tube number 4 Turn the machine off and remove the key from
1, install the dual-chain tensioner into the the key switch.
tensioner mount. Install the mounting 5 Working at the fork end of the boom, loosen
components, removed in step 6, and securely the fasteners securing the dual-chain
tighten the fasteners. tensioner to the top of boom tube number 1.
23 Install the chain tensioners into the tensioner After noting the orientation and assembly order
mount at the fork end of boom tube number 0. of the components, remove the fasteners and
Install the mounting components, removed in pull the tensioner free of the boom.
step 7. Evenly tighten the chain tensioners to
the top of the boom tube until they are securely
tightened.
24 Adjust the chains. Refer to Maintenance
Procedure in the appropriate Service or
Maintenance Manual for your machine, 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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Boom Components

7 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.
8 Repeat this procedure, beginning with step 8,
for the other chains.
9 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.
10 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
tubes 2 and 3.
11 Remove the fasteners securing the extension
chain anchors to the boom tubes.
12 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
1 tube 3 extension chains sure the rope is securely attached to the chain and
2 dual-chain tensioner boom structure before pulling the chain out of the
3 tube 2 extension chains boom.
4 single-chain tensioner
13 On a workbench, remove the bow tie clip
5 boom tube number 0
securing the chain anchor pin to the chain
6 boom tube number 1
assembly. Remove the pin and chain anchor
7 boom tube number 2
pin from the assembly.
8 boom tube number 3
14 Install the chain anchor, pin and clip onto the
6 Working at the fork end of the boom, loosen new chain.
evenly the fasteners securing the single-chain
15 Remove the rope from the end of the old chain
tensioners to the top of boom tube number 0.
and securely attach the rope to the new chain.
After noting the orientation and assembly order
of the components, remove the fasteners and
pull the tensioners free of the boom.

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Boom Components

How to Remove the Boom

How to R emove the Boom

16 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 Bodily injury hazard. This
accessible. procedure requires specific repair
skills, lifting equipment and a
17 Working at the pivot end of the boom and using suitable workshop. Attempting
the fasteners removed in step 11, install the this procedure without these skills
chain anchor onto the boom tube. Securely and tools could result in death or
tighten the fasteners. Do not over tighten. serious injury and significant
18 Remove the rope from the chain and install the component damage. Dealer
chain into the chain anchor of the tensioner service is strongly recommended.
assembly. Secure the chain to the chain
anchor using the pin and clip removed in step Note: When removing a hose assembly or fitting,
7. the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
19 Repeat this procedure, beginning with step 9, torqued to specification during installation. Refer to
for the other chains. Specifications, Hydraulic Hose and Fitting Torque
20 Install the inspection cover, removed in step 7, Specifications.
onto the boom. Install and securely tighten the 1 Remove the lifting fork and frame. Refer to
fasteners. Do not over tighten. Repair Procedure, How to Remove the Lifting
21 Working at the fork end of boom tube number Fork Frame.
1, install the dual-chain tensioner into the 2 Attach a lifting strap from an overhead 10 ton /
tensioner mount. Install the mounting 10,000 kg crane to the fork end of the boom.
components, removed in step 5, and securely Support the boom. Do not apply any lifting
tighten the fasteners. pressure.
22 Install the chain tensioners into the tensioner 3 Select a fork level cylinder. Remove the
mount at the fork end of boom tube number 0. fasteners securing the fork level cylinder
Install the mounting components, removed in rod-end pivot pin to the boom.
step 6. Evenly tighten the chain tensioners to
the top of the boom tube until they are securely 4 Using a lifting strap from another overhead
tightened. crane, support the rod-end of the fork level
cylinder. Do not apply any lifting pressure.
23 Adjust the chains. Refer to Maintenance
Procedure in the appropriate Service or 5 Use a soft metal drift to remove the fork level
Maintenance Manual for your machine, Adjust cylinder pivot pin.
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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Boom Components

6 Lower the fork level cylinder onto the chassis. 16 Use a soft metal drift to remove the boom pivot
pin.
Crushing hazard. Keep hands
clear of the cylinder manifold Crushing hazard. The boom will
when lowering the cylinder. fall if not properly supported
when the pivot pin is removed
7 Repeat this procedure beginning with step from the machine.
3 for the other fork level cylinder.
17 Carefully remove the boom assembly from the
8 Select a lift cylinder. Tag, disconnect and plug
machine and place it on a structure capable of
the hydraulic hoses at the lift cylinder manifold.
supporting it.
Cap the fittings on the cylinder manifold.
9 Remove the fasteners securing the lift cylinder Crushing hazard. The boom
barrel-end pivot pin to the chassis. could become unbalanced and
fall if not properly supported
10 Support and secure the barrel end of the lift when removed from the
cylinder to the boom. machine.
11 Use a soft metal drift to remove the lift cylinder
pivot pin. Component damage hazard. The
weight of the boom assembly
12 Repeat this procedure beginning with step may crush the hydraulic hard
8 for the other lift cylinder. lines under the boom. Use
13 Tag, disconnect and plug the hydraulic hoses caution when placing the boom
at the hydraulic hard line connections at the assembly onto a structure
pivot end of the boom. Cap the fittings. capable of supporting it.

14 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.

15 Remove the fasteners securing the boom pivot

pin to the chassis.

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Service and Repair Manual December 2016

Boom Components

How to Disassemble the Boom -

How to Dis ass embl e the Boom - GTH-1056

7 Remove the fastener securing the fork level

GTH1056 cylinder rod-end pivot pin to the fork frame
mount.
Bodily injury hazard. This 8 Use a soft metal drift to remove the rod-end
procedure requires specific repair pivot pin.
skills, lifting equipment and a
suitable workshop. Attempting 9 Attach a lifting strap from an overhead crane to
this procedure without these skills the barrel end of the fork level cylinder.
and tools could result in death or Support the cylinder. Do not apply any lifting
serious injury and significant pressure.
component damage. Dealer 10 Tag, disconnect and plug the fork level cylinder
service is strongly recommended. hoses from the cylinder manifolds. Cap the
fittings.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose Bodily injury hazard. Spraying
end must be replaced. All connections must be hydraulic oil can penetrate and
torqued to specification during installation. Refer to burn skin. Loosen hydraulic
Specifications, Hydraulic Hose and Fitting Torque connections very slowly to allow
Specifications. the oil pressure to dissipate
gradually. Do not allow oil to
1 Remove the extension cylinder. Refer to
squirt or spray.
Repair Procedure, How to Remove the
Extension Cylinder.
Component damage hazard.
2 Remove the boom. Refer to Repair Procedure, Hoses can be damaged if they
How to Remove the Boom. are kinked or pinched.
3 Select a lift cylinder. Remove the fasteners
11 Remove the fasteners securing the fork level
securing the lift cylinder rod-end pivot pin to
cylinder barrel-end pivot pin to the boom.
the boom.
12 Use a soft metal drift to remove the pivot pin.
4 Using a lifting strap from an overhead crane,
Remove the cylinder from the machine.
support the lift cylinder. Do not apply any lifting
pressure. Crushing hazard. The cylinder
5 Use a soft metal drift to remove the lift cylinder could fall if not properly
rod-end pivot pin. Remove the cylinder from supported when the pivot pin is
the boom. removed from the machine.

Crushing hazard. The cylinder 13 Remove the inspection cover at the pivot end
could become unbalanced and of the boom.
fall if not properly supported
when removed from the
machine.

6 Repeat this procedure beginning with step

3 for the other lift cylinder.

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Boom Components

14 Working at the pivot end of the boom, remove 17 Working at the pivot end of the boom, remove
the hose keepers from the hose roller the fasteners securing the hose roller
assembly. assembly to boom tube number 1. Remove the
hose roller assembly from the boom.
Note: The hose keepers ensure that the hoses do
not jump off the hose rollers. 18 Working at the fork end of the boom, remove
the fasteners securing the cable track mount
bracket to boom tube number 3.

1 cable bridge mount bracket

2 cable track mount bracket
3 cable bridge slider

19 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
1 tube 3 extension chains boom.
2 dual-chain tensioner
Note: Pay attention to how the hoses are routed
3 tube 2 extension chains
before removing the slider from the boom.
4 single-chain tensioner
5 boom tube number 0 Note: During reassembly, it may be helpful to use
6 boom tube number 1 tape to secure the bolts to the cable bridge when
7 boom tube number 2 installing the cable bridge slider.
8 boom tube number 3
20 Working at the fork end of the boom, securely
15 Working at the pivot end of the boom, remove attach the loose end of the cable track to the
the fasteners securing the cable bridge rear cable bridge using a cable tie or similar device.
mount bracket to the boom assembly. Remove
the bracket from the boom.
16 Working at the pivot end of the boom, tag,
disconnect and plug the hydraulic hoses at the
hard lines of the cable bridge. Cap the fittings.

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Boom Components

21 Working at the pivot end of the boom, carefully 30 Working at the pivot end of the boom, remove
remove the cable bridge from the boom. the fasteners securing the chain roller to boom
tube number 2. Remove the chain roller from
22 Working at the fork end of the boom, remove
the boom.
the fasteners securing the dual-chain
tensioner to the top of boom tube number 1. 31 Working at the fork end of the boom, remove
the wear pads from boom tube number 1.
23 Working at the fork end of the boom, remove
the fasteners securing the extension chain 32 Support and slide boom tube number 2 out of
rollers to the top of boom tube number 2. boom tube number 1. Place boom tube
Remove the chain rollers from the boom. number 2 on a structure capable of supporting
it.
24 Working at the pivot end of the boom, remove
the fasteners securing the retraction chain Crushing hazard. Boom tube
block pivot pin to boom tube number 3. number 2 could become
Remove the pivot pin. unbalanced and fall when
25 Working at the fork end of the boom, remove removed from the boom tube
the wear pads from boom tube number 2. number 1 if not properly
supported and attached to the
26 Support and slide boom tube number 3 out of overhead crane.
boom tube number 2. Place boom tube
number 3 on a structure capable of supporting Note: During removal, the overhead crane strap will
it. need to be adjusted for proper balancing.
Crushing hazard. Boom tube 33 Working at the pivot end of the boom, remove
number 3 could become the fasteners securing the chain roller to boom
unbalanced and fall when tube number 1. Remove the chain roller from
removed from the boom tube the boom.
number 2 if not properly
34 Working at the fork end of the boom, remove
supported and attached to the
the wear pads from boom tube number 0.
overhead crane.
35 Support and slide boom tube number 1 out of
Note: During removal, the overhead crane strap will boom tube number 0. Place boom tube
need to be adjusted for proper balancing. number 1 on a structure capable of supporting
it.
27 Working at the fork end of the boom, loosen
evenly, then remove, the fasteners securing Crushing hazard. Boom tube
the chain tensioners to the top of boom tube number 1 could become
number 0. unbalanced and fall when
28 Working at the fork end of the boom, remove removed from the boom tube
the fasteners securing the extension chain number 0 if not properly
rollers to the top of boom tube number 1. supported and attached to the
Remove the chain rollers from the boom. overhead crane.

29 Working at the pivot end of the boom, remove Note: During removal, the overhead crane strap will
the fasteners securing the retraction chain need to be adjusted for proper balancing.
block pivot pin to boom tube number 2.
Remove the pivot pin.

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Boom Components

1-3 5 Use a soft metal drift to remove the pivot pin.

Boom Lift Cylinder 6 Remove the fasteners securing the lift cylinder
rod-end pivot pin to the boom.

How to Remove the Lift Cylinder 7 Use a soft metal drift to remove the pivot pin.

Note: When removing a hose assembly or fitting, Crushing hazard. The boom will
the O-ring (if equipped) on the fitting and/or hose fall if not properly supported
end must be replaced. All connections must be when the pivot pin is removed
torqued to specification during installation. Refer to from the machine.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 8 Using the overhead crane, raise the boom to a
horizontal position. Remove the cylinder from
1 Attach a lifting strap from an overhead 10 ton / the machine.
10,000 kg crane to the fork end of the boom.
Support the boom. Do not apply any lifting Crushing hazard. The cylinder
pressure. will fall if not properly supported
when removed from the
2 Tag, disconnect and plug the hydraulic hoses machine.
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.
4 Remove the fasteners securing the lift cylinder
barrel-end pivot pin to the chassis.

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Service and Repair Manual December 2016

Boom Components

1-4 4 Remove the extension cylinder support loop

Boom Extension Cylinder from the underside of the boom.
Note: The extension cylinder support loop is
located at the fork end of the boom.
How to Remove the Extension
Cylinder 5 Remove the fasteners securing the extension
cylinder pivot pins to the boom.
Note: When removing a hose assembly or fitting, 6 Use a soft metal drift to remove both pivot pins.
the O-ring (if equipped) on the fitting and/or hose Remove the cylinder from the machine.
end must be replaced. All connections must be
torqued to specification during installation. Refer to Crushing hazard. The boom will
Specifications, Hydraulic Hose and Fitting Torque fall if not properly supported
Specifications. when the pivot pins are removed
from the machine.
1 Raise the boom to a horizontal position.
2 Tag, disconnect and plug the hydraulic hoses Note: During removal, the overhead crane strap will
at the boom extension cylinder manifold. Cap need to be adjusted for proper balancing.
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 center point of the boom extension
cylinder. Support the cylinder. Do not apply
any lifting pressure.

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Boom Components

1-5 5 Tag, disconnect and plug the fork level cylinder

Fork Level Cylinder hoses from the cylinder manifolds. Cap the
fittings.

How to Remove the Fork Level

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Cylinder burn skin. Loosen hydraulic
connections very slowly to allow
Note: When removing a hose assembly or fitting, the oil pressure to dissipate
the O-ring (if equipped) on the fitting and/or hose gradually. Do not allow oil to
end must be replaced. All connections must be squirt or spray.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Component damage hazard.
Specifications.
Hoses can be damaged if they
1 Remove the lifting fork frame. Refer to Repair are kinked or pinched.
Procedure, How to Remove the Lifting Fork
Frame. 6 Remove the fasteners securing the fork level
cylinder barrel-end pivot pin to the boom.
2 Remove the fastener securing the fork level
cylinder rod-end pivot pin to the fork frame 7 Use a soft metal drift to remove the pivot pin.
mount. Remove the cylinder from the machine.

3 Use a soft metal drift to remove the pivot pin. Crushing hazard. The cylinder
could fall if not properly
4 Attach a lifting strap from an overhead crane to supported when the pivot pin is
the barrel end of the fork level cylinder. removed from the machine.
Support the cylinder. Do not apply any lifting
pressure.

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Service and Repair Manual December 2016

Boom Components

1-6 7 Working near the center of the boom

Hydraulic Hoses assembly, tag, disconnect and plug the
hydraulic hoses from the hydraulic hard lines
under boom tube number number 1. Cap the
How to Replace the Fork Level
How to R eplac e the F or k Level and/or Auxili ar y C yli nder H oses, GTH-1056

hard lines.
and/or Auxiliary Cylinder Hoses, 8 Securely connect a 30 feet / 10 m length of
GTH-1056 rope to the end of each hose disconnected in
steps 6 and 7. Securely tie off the other end of
Note: When removing a hose assembly or fitting, each section of rope to the boom structure.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 9 Working at the pivot end of the boom, select
torqued to specification during installation. Refer to one of the hoses. Pull the hose out of the
Specifications, Hydraulic Hose and Fitting Torque boom.
Specifications. Note: Rope coming loose from either end of the
Replace the lower hoses: hose or the boom during hose removal may result in
a difficult reassembly. Be sure each section of rope
1 Fully retract the boom. is securely attached to both the hose and the boom
structure before pulling the hose out of the boom.
2 Fully lower the tips of the lifting forks.
3 Remove the covers from the pivot end of the 10 Remove the rope from the hose. Discard the
boom. hose.

4 Attach a lifting strap from an overhead crane to 11 Securely install a section of rope onto the
the top of the lifting fork frame. Support the correct end of the new hose assembly.
frame. Do not apply any lifting pressure. 12 Install the new hose assembly into the boom
5 Working at the pivot end of the boom, remove by routing the hose under the roller at the pivot
the fasteners securing the cable bridge rear end of the boom. Using the rope, carefully pull
mount bracket to the boom assembly. Remove the hose through the boom until the end is
the bracket from the boom. accessible.

6 Tag, disconnect and plug the hydraulic hoses 13 Install both ends of the hose assembly onto the
at the hard lines of the cable bridge. Cap the correct connection points. Torque to
fittings. specification. Refer to Specifications.
14 Repeat this procedure for the remaining hose
Bodily injury hazard. Spraying
to be replaced, beginning with step 8.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic 15 Install the cable bridge rear mount bracket
connections very slowly to allow onto the cable bridge and the boom assembly.
the oil pressure to dissipate Securely tighten the fasteners. Do not over
gradually. Do not allow oil to tighten.
squirt or spray.
16 Remove the lifting strap from the fork frame.
Component damage hazard. 17 Install the cover onto the rear of the boom.
Hoses can be damaged if they Install and securely tighten the retaining
are kinked or pinched. fasteners.

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Boom Components

Replace the upper hoses: 10 Working at the fork end of the boom, remove
the fasteners securing the cable bridge slider
1 Fully retract the boom. to the cable bridge. Remove the slider from the
2 Fully lower the tips of the lifting forks. boom.
3 Remove the covers from the pivot end of the Note: Pay attention to how the hoses are routed
boom. before removing the slider from the boom.
4 Attach a lifting strap from an overhead crane to Note: During reassembly, it may be helpful to use
the top of the lifting fork frame. Support the tape to secure the bolts to the cable bridge when
frame. Do not apply any lifting pressure. installing the cable bridge slider.
5 Working at the pivot end of the boom, remove 11 Remove the fasteners securing the cable track
the fasteners securing the cable bridge rear to the cable track mount bracket.
mount bracket to the boom assembly. Remove
the bracket from the boom. 12 Remove the fasteners securing the cable track
mount bracket to the cable bridge. Remove the
6 Tag, disconnect and plug the hydraulic hoses bracket from the boom.
at the hard lines of the cable bridge. Cap the
fittings. 13 Carefully pull the cable track through the
opening at the front of boom until the hose
Bodily injury hazard. Spraying connections are accessible.
hydraulic oil can penetrate and
14 Tag, disconnect and plug the affected hoses.
burn skin. Loosen hydraulic
Cap the fitting. Remove the hose from the
connections very slowly to allow
cable track.
the oil pressure to dissipate
gradually. Do not allow oil to 15 Install the new hose assembly and torque to
squirt or spray. specification. Refer to Specifications.
16 Install the cable bridge and cable track into the
Component damage hazard.
boom.
Hoses can be damaged if they
are kinked or pinched. 17 Install the cable track mount bracket and cable
bridge slider. Securely tighten all fasteners. Do
7 Return the cable bridge to its original position. not over tighten.
8 Working at the fork end of the boom, tag, 18 Working at the pivot end of the boom, install
disconnect and plug the fork level cylinder the hydraulic hoses onto the hard lines of the
hoses at the cylinder manifolds. Cap the cable bridge and torque to specification. Refer
fittings. to Specifications.
9 Models with auxiliary function: Working at 19 Install the cable bridge mount bracket onto the
the fork end of the boom, tag, disconnect and cable bridge and the boom assembly. Securely
plug the auxiliary hoses at the fittings. Cap the tighten all fasteners. Do not over tighten.
fittings.
20 Install the cover onto the rear of the boom.
Install and securely tighten the retaining
fasteners.

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Service and Repair Manual December 2016

Operator's Compartment

4 Locate the brake manifold under the manifold

2-1 inspection cover. Tag, disconnect and plug the
Operator's Compartment hydraulic hose at the underside of the brake
manifold. Cap the fitting. Refer to Brake
Manifold Components.
How to Remove the Operator's 5 Working under the dashboard, locate the
Compartment hydraulic hose at port L of the steering orbitral.

The operator's compartment is used to activate 6 Working at the front axle, locate the hydraulic
machine functions while sitting in the operator's hose connected to the front axle steer cylinder
drivers seat. at the operator's compartment side of the
machine. Tag, disconnect and plug the
Within the operator's compartment there is a hydraulic hose. Cap the fitting.
transmission column shifter, steering selector,
4-way controller, accelerator pedal, brake pedal 7 Tag, disconnect and plug the hydraulic hoses
and a differential lock switch. All of these at ports SUP, SUR and SUT of the secondary
components are replaceable. function manifold. Cap the fitting.

For further information or assistance, consult the Bodily injury hazard. Spraying
Genie Product Support. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Bodily injury hazard. This connections very slowly to allow
procedure requires specific repair the oil pressure to dissipate
skills, lifting equipment and a gradually. Do not allow oil to
suitable workshop. Attempting squirt or spray.
this procedure without these skills
and tools could result in death or 8 Tag, disconnect and plug the hydraulic hose at
serious injury and significant port SULS of the primary function manifold.
component damage. Dealer Cap the fitting.
service is strongly recommended. 9 Tag, disconnect and plug the hydraulic hose at
port JP of the secondary function manifold.
1 Open the access door above the hydraulic Cap the fitting.
tank.
Bodily injury hazard. Spraying
2 Disconnect the battery from the machine. hydraulic oil can penetrate and
Electrocution/burn hazard. burn skin. Loosen hydraulic
Contact with electrically charged connections very slowly to allow
circuits could result in death or the oil pressure to dissipate
serious injury. Remove all rings, gradually. Do not allow oil to
watches and other jewelry. squirt or spray.

3 Locate the secondary function manifold under 10 Tag, disconnect and plug the hydraulic hoses
the manifold inspection cover. Tag, disconnect at ports J1, J2, J3 and J4 of the primary
and plug the hydraulic hoses at ports BP and function manifold. Cap the fittings.
BT of the secondary function manifold. Cap the
fittings. Refer to Secondary Function Manifold
Components.

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Operator's Compartment

11 Models with dual joystick: Tag, disconnect 17 Support and secure the operator's
and plug the hydraulic hoses at ports JT2, JT4, compartment to an adjustable table capable of
JS3 and JS1 of the primary function manifold. supporting the weight and that will allow the
Cap the fittings. operator's compartment to remain in an upright
and stable position.
12 Remove the fasteners securing the joystick
mount to the operator's compartment. Remove Component damage hazard.
the joystick assembly. Wrapping a strap around the cab
13 Models with single joystick: With the base of and lifting using an overhead
the joystick above the top of the hydraulic tank, crane can put excessive
tag disconnect and plug the hydraulic hose at pressure on the glass windows of
port T of the joystick. Cap the fitting. the cab, causing the windows to
break. Do not lift the cab using a
Note: Removing the hydraulic hose from port T of strap from an overhead crane if
the joystick with the joystick below the hydraulic oil the strap contacts the windows.
level in the hydraulic tank will result in excessive
hydraulic fluid leaking from the hose. Do not Note: Placing a wedge between the operator's
disconnect the hose from the joystick if the joystick compartment and the adjustable table may be
is below the hydraulic oil level in the hydraulic tank. required to keep the operator's compartment
stable.
14 Models with dual joystick: Locate the tee
fitting which joins together the hydraulic hoses 18 Remove the lower fasteners securing the
from port T of both joysticks to the tank return operator's compartment to the chassis.
hydraulic hose.
19 Remove the upper fasteners securing the
15 Models with dual joystick: With the tee fitting operator's compartment to the chassis.
above the top of the hydraulic tank, tag,
disconnect and plug the tank return hydraulic Crushing hazard. The operator's
hose from the tee fitting. Cap the fitting. compartment will fall if not
properly supported when the
Note: Removing the hydraulic hose from the tee fasteners are removed from the
fitting with the tee fitting below the hydraulic oil level machine.
in the hydraulic tank will result in excessive
hydraulic fluid leaking from the hose. Do not 20 Slowly move the operator's compartment away
disconnect the hose from the tee fitting if the tee from the chassis while feeding all loose hoses,
fitting is below the hydraulic oil level in the hydraulic cables and wires through the opening of the
tank. chassis.
16 Working inside the chassis, tag and disconnect Component damage hazard.
the wire harnesses at the connectors next to Hoses, cables and wires can be
the operator's compartment. damaged if they are kinked or
pinched.

Bolt torque specification

Operator's cab mounting bolts 750 ft-lbs
1017 Nm

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Service and Repair Manual December 2016

Operator's Compartment

2-2 How to Remove the Steering

How to R emove the Steering Wheel

Machine Controls Wheel

1 Open the access door above the hydraulic
How to Remove the Steering
How to R emove the Steering C olumn

tank.
Column 2 Disconnect the battery from the machine.
1 Disconnect the battery from the machine.
Electrocution/burn hazard.
Electrocution/burn hazard. Contact with electrically charged
Contact with electrically charged circuits could result in death or
circuits could result in death or serious injury. Remove all rings,
serious injury. Remove all rings, watches and other jewelry.
watches and other jewelry.
3 Remove the horn button from the steering
2 Remove the fasteners securing the wheel. Remove the nut securing the steering
transmission control lever and turn signal wheel to the column and remove the steering
shifter, if equipped, to the column. Carefully wheel.
separate the lever from the column.
3 Remove the nut securing the key switch to the
dash panel. Gently push the key switch
through the opening.
4 Remove the fasteners securing the dash panel
to the dashboard.
5 Carefully pull the dash panel towards the seat
of the operator's compartment.
6 Tag and disconnect the wire harness from the
componments of the dash panel. Remove the
dash panel from the machine.
7 Loosen the two lower fasteners securing the
dash frame to the operator's compartment.
8 Remove the two upper fasteners securing the
dash frame to the operator's compartment.
9 Rotate the dash frame towards the seat of the
operator's compartment.Remove the
dashboard from the machine.
10 Tag and disconnect the ground wire of the
steer column.
11 Support and secure the steer orbitral to the
dash frame.
12 Remove the fasteners securing the steer
column and steer orbitral to the dash frame.
13 Lower the steer orbitral and remove the steer
column from the machine.

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Operator's Compartment

How to Remove the Steer Orbitral How to Remove the Joystick -

How to R emove the Steer Or bitral How to R emove the Joystic k - Models with Si ngle Joys tic k

1 Remove the steering column. Refer to Repair Models with Single Joystick
Procedure, How to Remove the Steering 1 Disconnect the battery from the machine.
Column.
2 Working under the dashboard, locate the Electrocution/burn hazard.
hydraulic hose at port L of the steering orbitral. Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

2 Tag and disconnect the joystick wire harness

from the machine.
3 Remove the fasteners securing the joystick
mount panel to the side console.
4 Tag, disconnect and plug the hoses from ports
3 Follow the hydraulic hose from port L of the 1, 2, 3, 4, P and T of the joystick. Cap the
steer orbitral to its connection at the front axle fittings.
of the machine. Tag, disconnect and plug the
hydraulic hose at the front axle. Cap the fitting. Note: Removing the hydraulic hose from port T of
the joystick with the joystick below the hydraulic oil
4 Tag, disconnect and plug the hydraulic hoses level in the hydraulic tank will result in excessive
at ports SUP, SUR and SUT of the secondary hydraulic fluid leaking from the hose. Do not
function manifold. Cap the fitting. disconnect the hose from the port if the joystick is
below the hydraulic oil level in the hydraulic tank.
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 5 Remove the fasteners securing the joystick to
through the opening of the chassis. the mount panel. Remove the joystick.

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Service and Repair Manual December 2016

Operator's Compartment

How to Remove the Joystick - How to Remove the Brake Pedal

How to R emove the Joystic k - Models with D ual J oys tic ks How to R emove the Brake Pedal Ass embl y

Models with Dual Joysticks Assembly

1 Disconnect the battery from the machine. 1 Disconnect the battery from the machine.
Electrocution/burn hazard. Electrocution/burn hazard.
Contact with electrically charged Contact with electrically charged
circuits could result in death or circuits could result in death or
serious injury. Remove all rings, serious injury. Remove all rings,
watches and other jewelry. watches and other jewelry.

2 Remove the fasteners securing the joystick 2 Fully press and release the brake pedal a
mount panel to the side console. minimum of 10 times to release the hydraulic
pressure in the brake system.
3 Tag and disconnect the joystick wire harness
from the machine. 3 Tag, disconnect and plug the hydraulic hoses
at ports BP and BT of the secondary hydraulic
4 Tag, disconnect and plug the hoses from ports
manifold. Cap the fittings.
1, 2, 3, 4 and P of the joystick. Cap the fittings.
5 Locate the tee fitting which joins together the Bodily injury hazard. Spraying
hydraulic hoses from port T of both joysticks to hydraulic oil can penetrate and
the tank return hydraulic hose. burn skin. Loosen hydraulic
connections very slowly to allow
6 With the tee fitting above the top of the the oil pressure to dissipate
hydraulic tank, tag, disconnect and plug the gradually. Do not allow oil to
tank return hydraulic hose from the tee fitting. squirt or spray.
Cap the fitting.
Note: Removing the hydraulic hose from port T of 4 Follow the hydraulic hose from port A of the
the joystick with the joystick below the hydraulic oil brake pedal manifold to the brake manifold.
Tag, disconnect and plug this hydraulic hose at
level in the hydraulic tank will result in excessive
the brake manifold. Cap the fitting.
hydraulic fluid leaking from the hose. Do not
disconnect the hose from the port if the joystick is 5 Remove the fasteners securing the brake
below the hydraulic oil level in the hydraulic tank. pedal assembly to the dash frame.
6 Gently 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.

7 Remove the fasteners securing the joystick to

the mount panel. Remove the joystick.

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December 2016 Service and Repair Manual

Operator's Compartment

How to Remove the Gauge How to Remove the Gauge

How to R emove the Gaug e Cluster Ass embl y How to R emove the Diagnostic Displ ay

Cluster Assembly Cluster Assembly

1 Disconnect the battery from the machine. 1 Disconnect the battery from the machine.
Electrocution/burn hazard. Electrocution/burn hazard.
Contact with electrically charged Contact with electrically charged
circuits could result in death or circuits could result in death or
serious injury. Remove all rings, serious injury. Remove all rings,
watches and other jewelry. watches and other jewelry.

2 Remove the fasteners securing the 2 Reach under the dashboard and gently loosen
transmission control lever to the column. and remove the locknut securing the
Carefully separate the lever from the column. diagnostic display to the dashboard. Gently
push the diagnostic display through the
3 Grasp the edge of the dash cluster and pull the
opening in the dashboard.
cluster through the opening in the dashboard.
3 Tag and disconnect the wire harness from the
4 Tag and disconnect the wire harness from the
diagnostic display. Remove the diagnostic
dash cluster. Remove the dash cluster from
display from the machine.
the machine.

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Service and Repair Manual December 2016

Fuel and Hydraulic Tanks

5 Place a drain pan or other suitable container

3-1 under the hydraulic tank. Refer to
Fuel and Hydraulic Tanks Specifications, Machine Specifications.
6 Remove the drain plug from the hydraulic tank
and completely drain the tank.
How to Remove the Fuel and
Hydraulic Tank Assembly Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
Explosion and fire hazard. cause severe burns.
Engine fuels are combustible.
Remove the fuel tank in an 7 Remove the filler cap from the fuel tank.
open, well-ventilated area away 8 Using an approved hand-operated pump, drain
from heaters, sparks, flames the fuel tank into a container of suitable
and lighted tobacco. Always capacity. Refer to Specifications, Machine
have an approved fire Specifications.
extinguisher within easy reach.
Explosion and fire hazard. When
Explosion and fire hazard. transferring fuel, connect a
Never drain or store fuel in an grounding wire between the
open container due to the machine and pump or container.
possibility of fire.
Note: Be sure to only use a hand operated pump
suitable for use with gasoline and/or diesel fuel.
Explosion and fire hazard. When
transferring fuel, connect a 9 Tag, disconnect and plug the fuel supply and
grounding wire between the return hoses. Cap the fittings.
machine and pump or container.
10 Tag, disconnect and plug the supply and return
1 Disconnect the battery from the machine. hoses from the hydraulic tank. Cap the fittings.

Electrocution/burn hazard. 11 Support and secure the tank assembly to an

Contact with electrically charged appropriate lifting device.
circuits could result in death or 12 Remove the fasteners securing the tank
serious injury. Remove all rings, assembly to the chassis. Remove the tank
watches and other jewelry. from the machine.

2 Remove the battery from the machine. Crushing hazard. The tank
assembly could become
3 Tag and disconnect the wire harness from the unbalanced and fall if not properly
fuel level terminals. supported when removed from
4 Remove the filler cap from the hydraulic tank. the machine.

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Engines

How to Remove the Engine

How to R emove the Engine

4-1
Note: When removing a hose assembly or fitting,
Engines the O-ring (if equipped) on the fitting and/or hose
How to R epair the J ohn D eere 4045T Engine end must be replaced. All connections must be
How to Repair the Perkins
How to R epair the Per ki ns 1104D-E44T A Engi ne

torqued to specification during installation. Refer to

1104D-E44TA Engine Specifications, Hydraulic Hose and Fitting Torque
Specifications.
Repair procedures and additional engine
All Models:
information is available in the Perkins 1100
Operation and Maintenance Manual and the 1 Open the access door above the hydraulic
Perkins 1104 Service Manual and the Perkins 1100 tank.
Troubleshooting Manual.
2 Disconnect the battery from the machine.
Perkins 1100 Operation and Maintenance Manual
Electrocution/burn hazard.
Genie part number 123702 Contact with electrically charged
Perkins 1104 Service Manual circuits could result in death or
Genie part number 117764 serious injury. Remove all rings,
watches and other jewelry.
Perkins 1100 Troubleshooting Manual
Genie part number 123583 3 Remove the fasteners securing the engine
access cover from the rear of the machine.
Remove the cover from the machine.
How to Repair the Deutz TD3.6
How to R epair the D eutz TD 3.6 L4 and TCD 3.6 L4 Engines

4 Perkins models: Open the engine access

L4 and TCD3.6 L4 Engine cover at the tank side of the machine. Locate
the fuel supply line where it is attached to the
Repair procedures and additional engine fuel filter/water separator.
information is available in the Deutz TCD3.6 Tag, disconnect and plug the fuel supply hose
Operation Manual and the Deutz TD3.6 L4 and at the fuel filter/water separator. Cap the fitting.
TCD3.6 L4 Workshop Manual.
Locate the fuel return hose connection just
Deutz TCD3.6 Operation Manual above the fuel filter/water separator.
Genie part number 218707 Tag, disconnect and plug the fuel return hose
Deutz TD3.6 and TCD3.6 Workshop Manual at the fuel filter/water separator. Cap the fitting.
Genie part number 1251788

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Service and Repair Manual December 2016

Engines

4-2
All Mod els:

All Models
5 Open the transmission access cover at the top Engine Fault Codes
of the machine. Locate the transmission
cooler.
How to Retrieve Engine Fault
6 Tag, disconnect and plug the coolant hoses at
the transmission cooler. Cap the fittings. Codes
7 Tag and disconnect the engine wire harnesses When the engine Electronic Control Module (ECM)
near the operator's compartment. detects an abnormal operating condition, a fault
code is immediately stored in the ECM memory. At
8 Remove the air cleaner from the machine. the same time, a colored warning lamp is
Remove all intake and exhaust components illuminated and the fault code is shown on the
which would interfere with the removal of the engine diagnostic display, is located on the
engine from the chassis. dashboard in the operator's compartment.
9 Remove the fasteners securing the driveshaft To learn the specifics of and how to use the fault
to the transmission. Secure the bearing caps codes, refer to, Fault Codes Section.
onto the universal joint of the driveshaft.
Note: Using adhesive tape to secure the caps to the
universal joint may be helpful.
10 Remove the fasteners securing the engine tray
to the chassis.
11 Support and secure the engine tray to a forklift
of adequate capacity.
12 Remove the engine tray from the machine.

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Transmission

How to Remove the Transmission

5-1 Note: When removing a hose assembly or fitting,
Transmission the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
How to Repair the Transmission
How to R epair the Tr ans missi on

Specifications.

Repair procedures and additional transmission 1 Open the access door above the hydraulic
information is available in the Dana T12000 tank.
Transmission Maintenance and Repair Manual and
2 Disconnect the battery from the machine.
the Dana T20000 Maintenance Manual.
Electrocution/burn hazard.
Dana T12000 Service Manual Contact with electrically charged
Genie part number 97489 circuits could result in death or
Dana T20000 Service Manual serious injury. Remove all rings,
watches and other jewelry.
Genie part number 115025
3 Place a drain pan or other suitable container
under the hydraulic tank. Refer to
Specifications, Machine Specifications.
4 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.

5 Tag, disconnect and plug the transmission oil

cooler lines at the cooler. Cap the fittings.
Bodily injury hazard. Spraying
Dana T20000 transmission hydraulic oil can penetrate and
burn skin. Loosen hydraulic
1 transmission temperature sender (located
opposite side of trans) connections very slowly to allow
2 transmission pressure sender
the oil pressure to dissipate
gradually. Do not allow oil to
3 transmission shift coil 'F' (drive forward
function) (blue wire) squirt or spray.
4 transmission shift coil 'R' (drive reverse
function) (brown wire) Component damage hazard.
5 transmission shift coil '2' (gear reduction) Hoses can be damaged if they
(green wire) are kinked or pinched.
6 transmission shift coil '1' (gear reduction)
(yellow wire)

Note: refer to electrical schematic for additional

transmission shift coil information.

How to R emove the Trans mission

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Service and Repair Manual December 2016

Transmission

6 Tag, disconnect and plug the hydraulic pump

high pressure line at the 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.

Component damage hazard.

Hoses can be damaged if they
are kinked or pinched.

7 Tag, disconnect and plug the hydraulic pump

supply line at the pump. Cap the orifice on the
pump.
8 Remove the fasteners securing the
transmission mounting flange to the chassis.
9 Tag and disconnect the driveshafts from the
transmission.
Note: To avoid damage to the driveshaft universal
joints, secure the driveshafts to the chassis.
10 Tag and disconnect the wiring harness from
the transmission.
11 Attach a lifting strap from an overhead crane to
the center point of the transmission.
12 Remove the fasteners securing the
transmission mounting flange to the chassis.
Remove the transmission from the machine.
Crushing hazard. The
transmission will fall if not
properly supported when
removed from the machine.

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4 Observe the pressure gauge while cranking

6-1 the engine in one second intervals.
Hydraulic Pump Result: If the pressure gauge reads 3190 psi /
220 bar, immediately stop. The pump is good.
How to Test the Function Pump
How to T est the Func tion Pump

Result: If the pressure fails to reach 3190 psi /

Note: When removing a hose assembly or fitting, 220 bar, the pump needs to be adjusted OR or
the O-ring (if equipped) on the fitting and/or hose the pump or pump coupling is faulty and will
end must be replaced. All connections must be need to be serviced or replaced.
torqued to specification during installation. Refer to Component damage hazard.
Specifications, Hydraulic Hose and Fitting Torque There is no relief valve in the
Specifications. hydraulic pump and the pump
1 Tag, disconnect and plug the high pressure can be damaged if the pressure
hydraulic hose from the primary function is allowed to exceed
manifold. Cap the fitting on the main valve. specification. When testing the
pump, crank the engine in one
Bodily injury hazard. Spraying second intervals until the
hydraulic oil can penetrate and correct pressure is confirmed.
burn skin. Loosen hydraulic Do not over-pressurize the
connections very slowly to allow pump.
the oil pressure to dissipate
gradually. Do not allow oil to 5 Remove the pressure gauge and install the
squirt or spray. high pressure hose onto the pump. Torque to
specification. Refer to Specifications,
Note: The high pressure hose is the smaller of the Hydraulic Hose and Fitting Torque
two hoses. Specifications.
2 Connect a 0 to 5000 psi / 0 to 350 bar Bodily injury hazard. Spraying
pressure gauge to the high pressure hose hydraulic oil can penetrate and
disconnected in step 1. burn skin. Loosen hydraulic
connections very slowly to allow
3 Hold the manual fuel shut-off lever on the
the oil pressure to dissipate
engine in the closed position.
gradually. Do not allow oil to
squirt or spray.

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How to Remove the Function

How to R emove the Functi on Pump

5 Tag, disconnect and plug the large hydraulic

Pump pump supply hose at the pump. Cap the fitting
on the pump.
Bodily injury hazard. This Note: Placing the open end of the pump supply
procedure requires specific repair hose below the fluid level in the hydraulic tank will
skills, lifting equipment and a result in excessive hydraulic fluid leaking from the
suitable workshop. Attempting hose. Do not lower the open end of the pump
this procedure without these skills supply hose to below the fluid level of the hydraulic
and tools could result in death or tank until the hose is plugged.
serious injury and significant
component damage. Dealer 6 Tag, disconnect and plug the high pressure
service is strongly recommended. hose at the pump. Cap the fitting on the pump.

Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring (if equipped) on the fitting and/or hose hydraulic oil can penetrate and
end must be replaced. All connections must be burn skin. Loosen hydraulic
torqued to specification during installation. Refer to connections very slowly to allow
Specifications, Hydraulic Hose and Fitting Torque the oil pressure to dissipate
Specifications. gradually. Do not allow oil to
squirt or spray.
Note: Perform this procedure with the engine off
and cool. 7 Tag and disconnect the transmission cooler
hoses at the transmission cooler. Cap the
1 Open the access door above the hydraulic fittings.
tank.
Burn hazard. Contact with hot
2 Disconnect the battery from the machine.
engine components may cause
Electrocution/burn hazard. severe burns.
Contact with electrically charged
circuits could result in death or 8 Remove the fasteners securing the pump to
serious injury. Remove all rings, the transmission. Remove the pump from the
watches and other jewelry. machine.

3 Tag and disconnect the wire harness from the

pump.
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.

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How to Install the Function Pump How to Prime the Function Pump
How to Ins tall the F uncti on How to Prime the F uncti on Pump

1 Carefully install the hydraulic pump onto the Note: When removing a hose assembly or fitting,
transmission. Install the fasteners and tighten the O-ring (if equipped) on the fitting and/or hose
to finger tight. end must be replaced. All connections must be
torqued to specification during installation. Refer to
2 Torque the fasteners evenly to 85 ft-lbs / 115
Specifications, Hydraulic Hose and Fitting Torque
Nm.
Specifications.
3 Install the smaller high pressure hose onto the
pump outlet. Torque the fasteners to 1 Install all hoses onto the hydraulic pump.
27-37 ft-lbs / 37-50 Nm. Torque to specification.Refer to Specifications,
Hydraulic Hose and Fitting Torque
4 Install the larger low pressure hose onto the Specifications.
pump outlet. Install the hose retaining rings
and fasteners. Torque the fasteners to 2 Locate the case drain filler plug at the side of
55-66 ft-lbs / 74-90 Nm. the function pump.

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 Specifications,
Hydraulic 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. Refer to Repair Procedure,
How to Prime the Function Pump.
10 Start the engine and inspect for leaks.
11 Turn the machine off.
12 Adjust the pump pressure. Refer to Repair
Procedures, How to Adjust the Function Pump
Standby Pressure and How to Adjust the
Function Pump Pressure Pressure
Compensator.

1 case drain filler plug

2 case drain hose
3 hydraulic supply line (from tank)

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How to Adjust the Function Pump

How to Adj ust the Functi on Pump Standby Pr ess ure

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
Standby Pressure
the plug and torque to 40 ft-lbs / 54 Nm. 1 Connect a 0 to 1000 psi / 0 to 100 bar
pressure gauge to test port 'TP' on the primary
4 Start the engine, allow the engine to run at low
function manifold. Refer to Primary Function
idle for 15 seconds then shut off the engine.
Manifold Components.
Wait 15 seconds, then start the engine again.
Allow the engine to run at low idle for 2 Start the engine and allow the engine to run at
15 seconds and then shut off the engine. low idle.
5 Check for hydraulic leaks and clean up any oil 3 Observe the pressure reading on the pressure
that may have spilled. 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.

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How to Adjust the Function Pump

How to Adj ust the Functi on Pump Press ure Compens ator

4 Loosen the set screw for the standby pressure

adjustment screw.
Standby Pressure
Note: Two people will be required to perform this
procedure.
1 Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to test port 'TP' on the primary
function manifold. Refer to Primary Function
Manifold Components.
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
3190±50 psi / 220±3.4 bar. The pump is
functioning correctly. Proceed to step 7.
Result: The pressure gauge fails to read
3190±50 psi / 220±3.4 bar. The pressure
setting needs to be adjusted. Proceed to step
5.

1 standby pressure adjustment screw

2 set screw
3 hydraulic supply line (from tank)

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.

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5 Loosen the set screw for the pressure 6 Adjust the pressure compensator pressure.
compensator adjustment screw. 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.

1 pressure compensator adjustment screw

2 set screw
3 hydraulic supply line (from tank)

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7-1
Primary Function Manifold Components - Models with Single Joystick
The primary function manifold is located under the manifold inspection cover.

Index Schematic
Description Function Torque
No. Item
1 Solenoid valve, 2 position 4 way AA Function select -boom extend and 20 ft-lbs / 27 Nm
sway left
2 Directional valve, 3 position 4 way, AB Boom extend/retract 65-75 ft-lbs / 88-101 Nm
pilot operated
3 Directional valve, 3 position 4 way, AC Boom up/down 65-75 ft-lbs / 88-101 Nm
pilot operated
4 Solenoid valve, 2 position 4 way AD Function select -boom down and 20 ft-lbs / 27 Nm
fork tilt down
5 Directional valve, 3 position 4 way, AE Fork tilt up/down 46-54 ft-lbs / 61-72 Nm
pilot operated
6 Relief valve, 3500 psi / 241 bar AF Fork tilt up relief 20 ft-lbs / 27 Nm
7 Check valve, pilot operated 100 psi AG Fork tilt down circuit 25 ft-lbs / 34 Nm
/ 6.9 bar
8 Check valve, pilot operated 100 psi AH Fork tilt up circuit 25 ft-lbs / 34 Nm
/ 6.9 bar
9 Relief valve, 3500 psi / 241 bar AI Fork tilt down relief 20 ft-lbs / 27 Nm
10 Relief valve, 3500 psi / 241 bar AJ System relief 25 ft-lbs / 34 Nm
11 Diagnostic nipple AK Test port 'LS'
12 Flow regulator valve, 0.1 gpm / 0.4 AL Load sense drain circuit 20 ft-lbs / 27 Nm
L/min
13 Check valve, 5 psi / 0.3 bar AM Sway right circuit 12-14 ft-lbs / 16-19 Nm
14 Priority flow regulator valve, 2 gpm AN Sway left/right circuit 20 ft-lbs / 27 Nm
/ 7.6 L/min
15 Check valve, 5 psi / 0.3 bar AO Sway left circuit 12-14 ft-lbs / 16-19 Nm

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Primary Function Manifold Components - Models with Single Joystick

The primary function manifold is located under the manifold inspection cover.

Index Schematic
Description Function Torque
No. Item
16 Check valve, 5 psi / 0.3 bar AP Boom extend circuit 12-14 ft-lbs / 16-19 Nm
17 Check valve, 5 psi / 0.3 bar AQ Boom down circuit 12-14 ft-lbs / 16-19 Nm
18 Check valve, 5 psi / 0.3 bar AR Fork tilt up circuit 12-14 ft-lbs / 16-19 Nm
19 Check valve, 5 psi / 0.3 bar AS Steer left/right circuit 12-14 ft-lbs / 16-19 Nm
20 Check valve, 5 psi / 0.3 bar AT Fork tilt down circuit 12-14 ft-lbs / 16-19 Nm
21 Check valve, 5 psi / 0.3 bar AU Boom up circuit 12-14 ft-lbs / 16-19 Nm
22 Check valve, 5 psi / 0.3 bar AV Boom retract circuit 12-14 ft-lbs / 16-19 Nm
23 Directional valve, 3 position 4 way, AW Sway left/right 33-37 ft-lbs / 45-50 Nm
pilot operated
24 Flow regulator valve, 14 gpm / 53 AX Fork tilt up/down circuit 20 ft-lbs / 27 Nm
L/min
25 Solenoid valve, 2 position 4 way AY Function select -boom up and 20 ft-lbs / 27 Nm
fork tilt up
26 Diagnostic nipple AAA Test port 'TP'
27 Solenoid valve, 2 position 4 way AAB Function select -boom extend 20 ft-lbs / 27 Nm
and sway right
28 Solenoid valve, 2 position 2 way AAC Function select - sway left/right 20 ft-lbs / 27 Nm

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7-2
Primary Function Manifold Components - Models with Dual Joysticks
The primary function manifold is located under the manifold inspection cover.

Index Schematic
Description Function Torque
No. Item
1 Directional valve, 3 position 4 way, pilot BA Sway left/right 33-37 ft-lbs / 45-50 Nm
operated
2 Directional valve, 3 position 4 way, pilot BB Boom extend/retract 65-75 ft-lbs / 88-101 Nm
operated
3 Directional valve, 3 position 4 way, pilot BC Boom up/down 65-75 ft-lbs / 88-101 Nm
operated
4 Directional valve, 3 position 4 way, pilot BD Fork tilt up/down 46-54 ft-lbs / 61-72 Nm
operated
5 Relief valve, 3500 psi / 241 bar BE Fork tilt up relief 20 ft-lbs / 27 Nm
6 Check valve, pilot operated 100 psi / 6.9 bar BF Fork tilt down circuit 25 ft-lbs / 34 Nm
7 Check valve, pilot operated 100 psi / 6.9 bar BG Fork tilt up circuit 25 ft-lbs / 34 Nm
8 Relief valve, 3500 psi / 241 bar BH Fork tilt down relief 20 ft-lbs / 27 Nm
9 Relief valve, 3500 psi / 241 bar BI System relief 25 ft-lbs / 34 Nm
10 Shuttle valve BJ Function select - sway 20 ft-lbs / 27 Nm
left/right
11 Diagnostic nipple BK Test port 'LS'
12 Flow regulator valve, 14 gpm / 53 L/min BL Fork tilt up/down circuit 20 ft-lbs / 27 Nm
13 Flow regulator valve, 0.1 gpm / 0.4 L/min BM Pilot pressure drain circuit 20 ft-lbs / 27 Nm
14 Check valve, 5 psi / 0.3 bar BN Sway left circuit 12-14 ft-lbs / 16-19 Nm
15 Priority flow regulator valve, 2 gpm / 7.6 BO Sway left/right circuit 20 ft-lbs / 27 Nm
L/min

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7-2
Primary Function Manifold Components - Models with Dual Joysticks
The primary function manifold is located under the manifold inspection cover.

Index Schematic
Description Function Torque
No. Item
16 Check valve, 5 psi / 0.3 bar BP Sway right circuit 12-14 ft-lbs / 16-19 Nm
17 Check valve, 5 psi / 0.3 bar BQ Boom extend circuit 12-14 ft-lbs / 16-19 Nm
18 Check valve, 5 psi / 0.3 bar BR Boom down circuit 12-14 ft-lbs / 16-19 Nm
19 Check valve, 5 psi / 0.3 bar BS Fork tilt down circuit 12-14 ft-lbs / 16-19 Nm
20 Check valve, 5 psi / 0.3 bar BT Steer left/right circuit 12-14 ft-lbs / 16-19 Nm
21 Check valve, 5 psi / 0.3 bar BU Fork tilt up circuit 12-14 ft-lbs / 16-19 Nm
22 Check valve, 5 psi / 0.3 bar BV Boom up circuit 12-14 ft-lbs / 16-19 Nm
23 Check valve, 5 psi / 0.3 bar BW Boom retract circuit 12-14 ft-lbs / 16-19 Nm
24 Directional valve, 2 position 2 way, pilot BX Fork tilt circuit 25 ft-lbs / 34 Nm
operated
25 Diagnostic nipple BZ Test port 'TP'
26 Solenoid valve, 2 position 2 way BAA Function select - sway 20 ft-lbs / 27 Nm
left/right

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7-3
Secondary Function Manifold Components
The secondary function manifold is located under the manifold inspection cover.

Index Schematic
Description Function Torque
No. Item
1 DO3 valve, 3 position 4 way CA Steer left/right 60 in-lbs / 6.8 Nm
2 Pressure reducing/relief valve, 50 psi / CB Rear lock-up circuit 25-27 ft-lbs / 34-37 Nm
3.4 bar
3 Pressure reducing/relief valve, 400 psi / CC Differential lock-up circuit 25-27 ft-lbs / 34-37 Nm
27.5 bar
4 Pressure reducing/relief valve, 2500 psi / CD Steer circuit 25-27 ft-lbs / 34-37 Nm
172 bar
5 Pressure reducing/relief valve, 400 psi / CE Drive brake circuit 25-27 ft-lbs / 34-37 Nm
27.5 bar
6 Solenoid valve, 2 position 3 way CF Parking brake select 20 ft-lbs / 27 Nm
7 Solenoid valve, 2 position 4 way CG Rear axle fast oscillate 25 ft-lbs / 34 Nm
select
8 Check valve, 4 psi / 0.3 bar CH Rear lock-up extend circuit 20 ft-lbs / 27 Nm
9 Check valve, 25 psi / 1.7 bar CI Drive brake circuit 20 ft-lbs / 27 Nm
10 Pressure switch, 350 psi / 24 bar PS7 Low brake pressure 11 ft-lbs / 14.9 Nm
11 Pressure switch, 250 psi / 17.2 bar PS6 Parking brake pressure 11 ft-lbs / 14.9 Nm
12 Orifice, 0.059 in / 1.5 mm CJ Rear lock-up extend circuit
13 Orifice, 0.051 in / 1.3 mm CK Rear lock-up retract circuit
14 Check valve, 4 psi / 0.3 bar CL Rear lock-up retract circuit 20 ft-lbs / 27 Nm
15 Diagnostic nipple CM Test port 'TB'
16 Diagnostic nipple CN Test port 'TPB'
17 Solenoid valve, 2 position 3 way CO Rear axle oscillate enable 20 ft-lbs / 27 Nm
select
18 Solenoid valve, 2 position 3 way CP Differential lock-up select 20 ft-lbs / 27 Nm
19 Diagnostic nipple CQ Test port 'TJ'
20 Diagnostic nipple CR Test port 'TS'
21 Diagnostic nipple CS Test port 'TR'

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7-4
Outrigger Manifold Components
The outrigger manifold is located under the outrigger inspection cover.

Index Schematic
Description Function Torque
No. Item
1 Solenoid valve, 3 position 4 way DA Left outrigger 25 ft-lbs / 34 Nm
extend/retract
2 Solenoid valve, 3 position 4 way DB Right outrigger 25 ft-lbs / 34 Nm
extend/retract
3 Flow regulator valve, 6 gpm / 22.7 L/min DC Right outrigger circuit 25 ft-lbs / 34 Nm
4 Flow regulator valve, 6 gpm / 22.7 L/min DD Left outrigger circuit 25 ft-lbs / 34 Nm
5 Check valve, 5 psi / 0.3 bar DE Left outrigger extend circuit 12-14 ft-lbs / 16-19 Nm
6 Check valve, 5 psi / 0.3 bar DF Right outrigger extend 12-14 ft-lbs / 16-19 Nm
circuit
7 Check valve, 5 psi / 0.3 bar DG Left outrigger retract circuit 12-14 ft-lbs / 16-19 Nm
8 Check valve, 5 psi / 0.3 bar DH Right outrigger retract 12-14 ft-lbs / 16-19 Nm
circuit

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7-5
Auxiliary Manifold Components (option)
The auxiliary manifold is located under the transmission inspection cover.

Index Schematic
Description Function Torque
No. Item
1 Check valve, 5 psi / 0.3 bar EA Auxiliary 'A1' circuit 12-14 ft-lbs / 16-19 Nm
2 DO3 valve, 3 position 4 way EB Auxiliary function enable 60 in-lbs / 6.8 Nm
3 Flow regulator valve EC Function speed control 25 ft-lbs / 34 Nm
4 Check valve, 5 psi / 0.3 bar ED Auxiliary 'A2' circuit 12-14 ft-lbs / 16-19 Nm

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7-6
Brake Manifold Components
The brake manifold is located under the manifold inspection cover.

Index Schematic
Description Function Torque
No. Item
1 Pressure switch, 450 psi / 31 bar PS4 Clutch cut-off pressure 11 ft-lbs / 14.9 Nm
2 Pressure switch, 50 psi / 3.4 bar PS5 Brake light pressure (option) 11 ft-lbs / 14.9 Nm

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7-7
AC Hydraulic Manifold Components
The AC Hydraulic manifolds are located under the manifold inspection cover.

Index Schematic
Description Function Torque
No. Item
1 Solenoid valve, 2 position 2 way FA Controls motor 20 ft-lbs / 27.1 Nm
2 Flow control valve, 3 gpm/ 11.3 lpm FB Regulates flow 33-37 ft-lbs / 45-50 Nm

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7-8 6 Start the engine. Allow the engine to idle.

Valve Adjustments - Secondary 7 Fully turn and hold the steering wheel in the left
Function Manifold direction and allow the wheels to fully turn to
the left. Continue holding the steering while
observing the pressure reading on the
How to Set the Steer System
How to Set the Steer System Pres sur e

pressure gauge.
Pressure Result: The pressure gauge reads 2500 psi /
Note: Be sure that the hydraulic oil level is visible in 172 bar. The pressure setting is correct.
the inspection glass of the hydraulic tank. Proceed to step 12.

1 Install a 0 to 1000 psi / 0 to 100 bar pressure Result: The pressure gauge fails to read
gauge into test port 'TP' at the top of the 2500 psi / 172 bar. The pressure setting needs
secondary function manifold, refer to to be adjusted. Proceed to step 8.
Secondary Function Manifold Components. 8 Turn the machine off. Hold the steer pressure
2 Start the engine. Allow the engine to idle after reducing/relief valve with a wrench and
warming the engine to operating temperature. remove the cap.

3 Without operating any machine controls, 9 Adjust the internal hex socket. Turn it
observe the reading on the pressure gauge. clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Result: The pressure gauge reads 450 ±25 psi
/ 31 ±1.7 bar. The pump is functioning Component damage hazard. Do
correctly. not adjust the relief valve
pressures higher than
Result: The pressure gauge fails to read 450 specifications.
±25 psi / 31 ±1.7 bar. The pressure setting
needs to be adjusted. Refer to Repair 10 Install the relief valve cap.
Procedure, How to Adjust the Function Pump
Pressure. 11 Repeat this procedure beginning with step 6.
4 Turn the machine off. Remove the pressure 12 Turn the machine off. Remove the pressure
gauge from the test port. gauge from the test port.

Bodily injury hazard. Spraying Bodily injury hazard. Spraying

hydraulic oil can penetrate and hydraulic oil can penetrate and
burn skin. Loosen hydraulic burn skin. Loosen hydraulic
connections very slowly to allow connections very slowly to allow
the oil pressure to dissipate the oil pressure to dissipate
gradually. Do not allow oil to gradually. Do not allow oil to
squirt or spray. squirt or spray.

5 Install a 0 to 3500 psi / 0 to 250 bar pressure

gauge into test port 'TS' at the top of the
secondary function manifold. Refer to
Secondary Function Manifold Components.

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How to Set the Parking Brake

How to Set the Par ki ng Br ake System Pr ess ure

6 Start the engine. Allow the engine to idle.

System Pressure Result: The pressure gauge reads 400 psi /
27.5 bar. The pressure setting is correct.
Note: Be sure that the hydraulic oil level is visible in
Proceed to step 11.
the inspection glass of the hydraulic tank.
Result: The pressure gauge fails to read
1 Install a 0 to 1000 psi / 0 to 100 bar pressure 400 psi / 27.5 bar. The pressure setting needs
gauge into test port 'TP' at the top of the to be adjusted. Proceed to step 7.
primary function manifold, Refer to Primary
Function Manifold Components. 7 Turn the machine off. Hold the brake pressure
reducing/relief valve with a wrench and
2 Start the engine. Allow the engine to idle after remove the cap.
warming the engine to operating temperature.
8 Adjust the internal hex socket. Turn it
3 Without operating any machine controls, clockwise to increase the pressure or
observe the reading on the pressure gauge. counterclockwise to decrease the pressure.
Result: The pressure gauge reads 450 ±25 psi
Component damage hazard. Do
/ 31 ±1.7 bar. The pump is functioning
not adjust the relief valve
correctly.
pressures higher than
Result: The pressure gauge fails to read 450 specifications.
±25 psi / 31 ±1.7 bar. The pressure setting
needs to be adjusted. Refer to Repair 9 Install the relief valve cap.
Procedure, How to Adjust the Function Pump 10 Repeat this procedure beginning with step 6.
Pressure.
11 Turn the machine off. Remove the pressure
4 Turn the machine off. Remove the pressure gauge from the test port.
gauge from the test port.
Bodily injury hazard. Spraying
Bodily injury hazard. Spraying hydraulic oil can penetrate and
hydraulic oil can penetrate and burn skin. Loosen hydraulic
burn skin. Loosen hydraulic connections very slowly to allow
connections very slowly to allow the oil pressure to dissipate
the oil pressure to dissipate gradually. Do not allow oil to
gradually. Do not allow oil to squirt or spray.
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, Refer to
Secondary Function Manifold Components.

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How to Set the Differential

How to Set the Differ enti al Loc k/J oysti c k System Press ure

6 Start the engine. Allow the engine to idle.

Lock/Joystick System Pressure Result: The pressure gauge reads 400 psi /
27.5 bar. The pressure setting is correct.
Note: Be sure that the hydraulic oil level is visible in
Proceed to step 11.
the inspection glass of the hydraulic tank.
Result: The pressure gauge fails to read
1 Install a 0 to 1000 psi / 0 to 100 bar pressure 400 psi / 27.5 bar. The pressure setting needs
gauge into test port 'TP' at the top of the to be adjusted. Proceed to step 7.
primary function manifold, Refer to Primary
Function Manifold Components. 7 Turn the machine off. Hold the differential
lock/joystick pressure reducing/relief valve
2 Start the engine. Allow the engine to idle after with a wrench and remove the cap.
warming the engine to operating temperature.
8 Adjust the internal hex socket. Turn it
3 Without operating any machine controls, clockwise to increase the pressure or
observe the reading on the pressure gauge. counterclockwise to decrease the pressure.
Result: The pressure gauge reads 450 ±25 psi
Component damage hazard. Do
/ 31 ±1.7 bar. The pump is functioning
not adjust the relief valve
correctly.
pressures higher than
Result: The pressure gauge fails to read 450 specifications.
±25 psi / 31 ±1.7 bar. The pressure setting
needs to be adjusted. Refer to Repair 9 Install the relief valve cap.
Procedure, How to Adjust the Function Pump 10 Repeat this procedure beginning with step 6.
Pressure.
11 Turn the machine off. Remove the pressure
4 Turn the machine off. Remove the pressure gauge from the test port.
gauge from the test port.
Bodily injury hazard. Spraying
Bodily injury hazard. Spraying hydraulic oil can penetrate and
hydraulic oil can penetrate and burn skin. Loosen hydraulic
burn skin. Loosen hydraulic connections very slowly to allow
connections very slowly to allow the oil pressure to dissipate
the oil pressure to dissipate gradually. Do not allow oil to
gradually. Do not allow oil to squirt or spray.
squirt or spray.

5 Install a 0 to 1000 psi / 0 to 100 bar pressure

gauge into test port 'TJ' at the top of the
secondary function manifold, Refer to
Secondary Function Manifold Components.

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Manifolds

How to Set the Rear Lock-up

How to Set the R ear Loc k-up Sys tem Pressur e

6 Start the engine. Allow the engine to idle.

System Pressure Result: The pressure gauge reads 50 psi /
3.4 bar. The pressure setting is correct.
Note: Be sure that the hydraulic oil level is visible in
Proceed to step 11.
the inspection glass of the hydraulic tank.
Result: The pressure gauge fails to read 50 psi
1 Install a 0 to 1000 psi / 0 to 100 bar pressure / 3.4 bar. The pressure setting needs to be
gauge into test port 'TP' at the top of the adjusted. Proceed to step 7.
primary function manifold. Refer to Primary
Function Manifold Components. 7 Turn the machine off. Hold the rear lockup
pressure reducing/relief valve with a wrench
2 Start the engine. Allow the engine to idle after and remove the cap.
warming the engine to operating temperature.
8 Adjust the internal hex socket. Turn it
3 Without operating any machine controls, clockwise to increase the pressure or
observe the reading on the pressure gauge. counterclockwise to decrease the pressure.
Result: The pressure gauge reads 450 ±25 psi
Component damage hazard. Do
/ 31 ±1.7 bar. The pump is functioning
not adjust the relief valve
correctly.
pressures higher than
Result: The pressure gauge fails to read 450 specifications.
±25 psi / 31 ±1.7 bar. The pressure setting
needs to be adjusted. Refer to Repair 9 Install the relief valve cap.
Procedure, How to Adjust the Function Pump 10 Repeat this procedure beginning with step 6.
Pressure.
11 Turn the machine off. Remove the pressure
4 Turn the machine off. Remove the pressure gauge from the test port.
gauge from the test port.
Bodily injury hazard. Spraying
Bodily injury hazard. Spraying hydraulic oil can penetrate and
hydraulic oil can penetrate and burn skin. Loosen hydraulic
burn skin. Loosen hydraulic connections very slowly to allow
connections very slowly to allow the oil pressure to dissipate
the oil pressure to dissipate gradually. Do not allow oil to
gradually. Do not allow oil to squirt or spray.
squirt or spray.

5 Install a 0 to 500 psi / 0 to 50 bar pressure

gauge into test port 'TR' at the top of the
secondary function manifold, Refer to
Secondary Function Manifold Components.

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Manifolds

7-9 Valve Coil Resistance

Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
A properly functioning coil provides an temperature, the coil resistance will typically
electromotive force which operates the solenoid increase or decrease by 4% for each 18°F / 10°C
valve. Critical to normal operation is continuity that your air temperature increases or decreases
within the coil that provides this force field. from 68°F / 20°C.
Since coil resistance is sensitive to temperature, Valve Coil Resistance Specification
resistance values outside specification can produce
Description Specification
erratic operation. When coil resistance decreases
below specification, amperage increases. As Solenoid valve, 2 position 4 way 12V DC 8.9Ω
resistance rises above specification, voltage with diode (schematic items AA, AD, AY,
increases. AAB and BAA)

While valves may operate when coil resistance is Solenoid valve, 2 position 2 way 12V DC with 8.9Ω
outside specification, maintaining coils within diode (schematic items AAC and EA)
specification will help ensure proper valve function DO3 valve, 3 position 4 way 12V DC with 5.6Ω
over a wide range of operating temperatures. diode (schematic items CA and EB)
Solenoid valve, 2 position 2 way 12V DC with 8.8Ω
Electrocution/burn hazard.
diode (schematic items FA)
Contact with electrically charged
circuits could result in death or Solenoid valve, 2 position 3 way 12V DC with 8.9Ω
serious injury. Remove all rings, diode
(schematic items CF, CO and CP)
watches and other jewelry.
Solenoid valve, 2 position 4 way 12V DC with 7.3Ω
1 Tag and disconnect the wiring from the coil to diode (schematic items CG )
be tested. Solenoid valve, 3 position 4 way 12V DC with 7.3Ω
diode (schematic items DA and DB)
2 Test the coil resistance.
Result: The resistance should be within
specification, plus or minus 30%.
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.

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Manifolds

How to Test a Coil Diode

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/burn 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. Refer to Repair 1 multimeter

Procedure, How to Test a Coil. 2 9v DC battery
3 10Ω resistor
2 Connect a 10W resistor to the negative
4 coil
terminal of a known good 9V DC battery.
Connect the other end of the resistor to a Note: Dotted lines in illustration indicate a reversed
terminal on the coil. connection as specified in step 6.
Resistor 10Ω 3 Set a multimeter to read DC current.
Genie part number 27287
Note: The multimeter, when set to read DC current,
should be capable of reading up to 800 mA.
Note: The battery should read 9V DC or more when
measured across the terminals. 4 Connect the negative lead to the other terminal
on the coil.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V
DC 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.

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Axle

7 Support and secure the axle to an appropriate

8-1 lifting device.
Axles 8 Remove the fasteners securing the sway
cylinder rod-end pivot pin to the chassis.
How to Remove the Axle
How to R emove the Axl e

9 Use a soft metal drift to remove the pivot pin.

Bodily injury hazard. This 10 Remove the fasteners securing the axle to the
procedure requires specific repair chassis. Remove the axle from the machine.
skills, lifting equipment and a
suitable workshop. Attempting Crushing hazard. The axle will
this procedure without these skills fall if not properly supported
and tools could result in death or when the fasteners are removed
serious injury and significant from the machine.
component damage. Dealer
service is strongly recommended. Bolt torque specification
Axle mounting bolts 380 ft-lbs
1 Chock the wheels. 515 Nm
2 Remove the fasteners securing the driveshaft
to the transmission. Lower the end of the How to R epair the Axle

driveshaft to the ground.

3 Remove the fasteners securing the driveshaft How to Repair the Axle
to the axle. remove the driveshaft from the
Repair procedures and additional axle information
machine.
is available in the Dana 213 Axle Maintenance and
4 Loosen the lug nuts of both wheels on the axle Repair Manual.
to be removed. Do not remove the lug nuts.
Dana 213 Axle Maintenance and Repair Manual
5 Raise the end of the machine until the tires are
off the ground. Place blocks under the chassis Genie part number 115026
for support.
Crushing hazard. The chassis
will fall if not properly supported.

6 Remove the lug nuts. Remove the tire and

wheel assembly from both ends of the axle.

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Outriggers

5 Use a soft metal drift to remove the outrigger

9-1 cylinder barrel-end pivot pin. Lower the
Outriggers cylinder onto the outrigger.
Crushing hazard. The cylinder
How to Remove an Outrigger
How to R emove an Outrigger

may become unbalanced and fall

if not properly supported when
1 Extend the outrigger until the pad just touches the pivot pin is removed from the
the ground. Do not rest the weight of the machine.
machine on the outrigger.
2 Tag, disconnect and plug the hydraulic supply 6 Attach a lifting strap from an overhead crane to
hoses at the outrigger cylinder. Cap the the outrigger assembly. Support the outrigger.
fittings. Do not apply any lifting pressure.

Bodily injury hazard. Spraying 7 Remove the fasteners securing the outrigger
hydraulic oil can penetrate and pivot pin to the machine.
burn skin. Loosen hydraulic 8 Use a soft metal drift to remove the pivot pin.
connections very slowly to allow Remove the outrigger assembly from the
the oil pressure to dissipate machine.
gradually. Do not allow oil to
squirt or spray. Crushing hazard. The outrigger
will fall if not properly supported
Component damage hazard. when the pivot pin is removed
Hoses can be damaged if they from the machine.
are kinked or pinched.

3 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.
4 Remove the fasteners securing the outrigger
cylinder barrel-end pivot pin to the machine.

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Outriggers

How to Remove an Outrigger

How to R emove an Outrigger Cyli nder

4 Remove the fasteners securing the outrigger

Cylinder cylinder barrel-end pivot pin to the chassis.
5 Use a soft metal drift to remove the pivot pin.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose Crushing hazard. The cylinder
end must be replaced. All connections must be will fall if not properly supported
torqued to specification during installation. Refer to when the pivot pin is removed
Specifications, Hydraulic Hose and Fitting Torque from the machine.
Specifications.
6 Raise the cylinder to a vertical position.
1 Extend the outrigger until the pad just touches
the ground. Do not rest the weight of the 7 Remove the fasteners securing the outrigger
machine on the outrigger. cylinder rod-end pivot pin to the machine.
2 Tag, disconnect and plug the two hydraulic 8 Use a soft metal drift to remove the pivot pin.
supply hoses at the outrigger cylinder. Cap the Remove the cylinder from the machine.
fittings.
Crushing hazard. The cylinder
Bodily injury hazard. Spraying will fall if not properly supported
hydraulic oil can penetrate and when the pivot pin is removed
burn skin. Loosen hydraulic from the machine.
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 barrel end of the outrigger cylinder.
Support the cylinder. Do not apply any lifting
pressure.

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Fault Codes
Section 4 Faul t Codes

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
Observe and Obey: equipment are available and ready for use.
 Troubleshooting and repair procedures shall be  Read each appropriate fault code thoroughly.
completed by a person trained and qualified on Attempting short cuts may produce hazardous
the repair of this machine conditions.
 Immediately tag and remove from service a  Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.
 Repair any machine damage or malfunction Electrocution/burn hazard.
before operating the machine. Contact with electrically charged
circuits could result in death or
 Unless otherwise specified, perform each serious injury. Remove all rings,
procedure with the machine in the following watches and other jewelry.
configuration:
• Machine parked on a firm, level surface Note: Two persons will be required to safely
perform some troubleshooting procedures.
• Boom in the stowed position
• Key switch in the off position with the key
removed
• Wheels chocked

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Diagnostic Display

When the engine Electronic Control Module (ECM) Stored fault codes are the cumulative history of
detects an abnormal operating condition, a fault fault codes which the ECM has detected. These
code is immediately stored in the ECM memory. fault codes may be recalled by service personnel at
a later time even if the condition which caused the
The fault code is displayed on the LCD display engine fault has ceased to exist.
which is located on the gauge cluster in the
operator's compartment. Note: Additional hardware will be necessary to
access stored codes.
The gauge cluster also includes two warning lights.
Decoding Fault Codes
They are an amber colored light which signals an
abnormal engine condition which should be The Suspect Parameter Number (SPN) and the
corrected as soon as possible and a red colored Failure Mode Identifier (FMI), when combined, are
light which signals an engine condition which the basis for an engine fault code. The SPN number
requres the operator to shut down the engine as indicates the affected component; the FMI number
soon as possible. reveals the type of failure that has occurred.
Comparing the combination of numbers to the fault
The ECM will, in some cases, automatically shut code chart on the following pages will help to
down the engine when the red light is displayed. determine the exact engine fault and a corrective
course of action. For additional information, refer to
Active Fault Codes the engine operator's manual which came with your
Active Fault Codes will be displayed on the gauge machine.
cluster whenever a fault is detected. If multiple fault
codes are detected, the fault codes will scroll on the
display.

1 FMI Code
2 SPN Code
3 amber warning light
4 red stop engine light

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.

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Deutz TCD3.6 Engine Fault Codes

SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
29 3 Handthrottle; signal out of range, short circuit to battery
4 Handthrottle; signal out of range, short circuit to ground
51 3 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error
4 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error
5 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error
6 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error
7 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error
11 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error
12 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error
84 2 Sensor vehicle speed; plausibility error
91 3 Sensor error accelerator pedal; signal range check high
4 Sensor error accelerator pedal; signal range check low
11 Plausibility error between APP1 and APP2 or APP1 and idle switch
94 1 Low fuel pressure; system reaction initiated
3 Sensor error low fuel pressure; signal range check high
4 Sensor error low fuel pressure; signal range check low
97 3 Sensor error water in fuel; signal range check high
4 Sensor error water in fuel; signal range check low
12 Water in fuel level prefilter; maximum value exceeded
100 0 High oil pressure; system reaction initiated
1 High oil pressure; system reaction initiated
3 Sensor error oil pressure; signal range check high
4 Sensor error oil pressure sensor; signal range check low
102 2 Charged air pressure; system reaction initiated
3 Sensor error charged air pressure; signal range check high
4 Sensor error charged air pressure; signal range check low
105 0 Charged air cooler temperature; system reaction initiated
3 Sensor error charged air temperature; signal range check high
4 Sensor error charged air temperature; signal range check low

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
107 0 Air filter differential pressure; system reaction initiated
3 Sensor error airfilter differential pressure; short circuit to battery
4 Sensor error airfilter differential pressure; short circuit to ground
108 3 Sensor error ambient air pressure; signal range check high
4 Sensor error ambient air pressure; signal range check low
110 0 Coolant temperature; system reaction initiated
3 Sensor error coolant temperature; signal range check high
4 Sensor error coolant temperature; signal range check low
111 1 Coolant level too low
132 11 Air flow sensor; sensor error
157 3 Sesnor error rail pressure; signal range check high
4 Sensor error rail pressure; signal range check low
164 2 Rail pressure safety function is not executed correctly
168 0 Physikal range check high for battery voltage
1 Physikal range check low for battery voltage
2 High battery voltate; warning threshold exceeded
2 Battery voltage; system reaction initiated
3 Sensor error battery voltage; signal range check high
3 Sensor error battery voltage; signal range check high
4 Sensor error battery voltage; signal range check low
4 Sensor error battery voltage; signal range check low
171 3 Sensor error environment temperature; signal range check high
4 Sensor error environment temperature; signal range check low
172 0 Physical range check high for intake air temperature
1 Physical range check low for intake air temperature
2 Intake air sensor; plausibility error
3 Sensor error intake air; signal range check high
4 Sensor error intake air sensor; signal range check low
Sensor ambient air temperature; plausibility error
174 0 High Low fuel temperature; shut off threshold exceeded
High low fuel temperature; warning threshold exceeded

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
175 0 Oil temperature; out of range, system reaction initiated
1 Physical range check low for oil temperature
2 Oil temperature; plausibility error
3 Sensor error oil temperature; signal range check high
4 Sensor error oil temperature; signal range check low
190 0 Engine speed above warning threshold (FOC-Level 1)
2 Offset angle between crank- and camshaft sensor is too large
8 Speed detection; out of range, signal disrupted
11 Engine speed above warning threshold (FOC-Level 2)
12 Speed detection; out of range, signal disrupted
14 Speed detection; out of range, signal disrupted
411 0 Physical range check high for differential pressure Venturiunit (EGR)
1 Physical range check low for differential pressure Venturiunit (EGR)
3 Sensor error differential pressure Venturiunit (EGR); signal range check high
4 Physical range check low for EGR differential pressure
Sensor error differential pressure Venturiunit (EGR); signal range check low
412 3 Sensor error EGR cooler downstream temperature; signal range check high
4 Sensor error EGR cooler downstream temperature; signal range check low
520 9 Timeout Error of CAN-Receive-Frame TSC1TR; Setpoint
597 2 Break lever mainswitch and break lever redundancyswitch status not plausible
624 3 SVS lamp; short circuit to battery
4 SVS lamp; short circuit to ground
5 SVS lamp; open load
12 SVS lamp; powerstage over temperature
630 12 Access error EEPROM
639 14 CAN-Bus 0 "BusOff-Status"

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
651 3 Injector 1 (in firing order); short circuit
4 High side to low side short circuit in the injector 1 (in firing order)
5 Injector 1 (in firing order); interruption of electric connection
652 3 Injector 2 (in firing order); short circuit
4 High side to low side short circuit in the injector 2 (in firing order)
5 Injector 2 (in firing order); interruption of electric connection
653 3 Injector 3 (in firing order); short circuit
4 High side to low side short circuit in the injector 3 (in firing order)
5 Injector 3 (in firing order); interruption of electric connection
654 3 Injector 4 (in firing order); short circuit
4 High side to low side short circuit in the injector 4 (in firing order)
5 Injector 4 (in firing order); interruption of electric connection
655 3 Injector 5 (in firing order); short circuit
4 High side to low side short circuit in the injector 5 (in firing order)
5 Injector 5 (in firing order); interruption of electric connection
656 3 Injector 6 (in firing order); short circuit
4 High side to low side short circuit in the injector 6 (in firing order)
5 Injector 6 (in firing order); interruption of electric connection
676 11 Cold start aid relay; open load, relay error.
677 3 Starter relay; short circuit
4 Starter relay; short circuit
5 Starter relay; no load error
12 Starter relay; powerstage over temperature
703 3 Engine running lamp; short circuit to battery
4 Engine running lamp; short circuit to ground
5 Engine running lamp; open load
12 Engine running lamp; powerstage over temperature

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Deutz TCD3.6 Engine Fault Codes

SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
729 5 Cold start aid relay open load
12 Cold start aid relay; over temperature error
898 9 Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint
975 3 Fan control; short circuit to battery
4 Fan control; short circuit to ground
5 Fan control; open load
12 Fan control; internal error
1079 13 Sensor supply voltage monitor 1 error (ECU)
1080 13 Sensor supply voltage monitor 2 error (ECU)
1109 2 Engine shut off demand ignored
1136 0 Physikal range check high for ECU temperature
1 Physikal range check low for ECU temperature
3 Sensor error ECU temperature; signal range check high
4 Sensor error ECU temperature; signal range check low
1176 3 Sensor error pressure sensor upstream turbine; signal range check high
4 Sensor error pressure sensor downstream turbine; signal range check high
1180 0 Exhaust gas temperature turbine upstream; out of range, system reaction initiated
1 Exhaust gas temperature turbine upstream; out of range, system reaction initiated
3 Sensor error exhaust gas temperature upstream turbine; signal range check high
4 Sensor error exhaust gas temperature upstream turbine; signal range check low
11 Sensor exhaust gas temperature upstream turbine; plausibility error
Exhaust gas temperature upstream turbine; out of range, system reaction initiated
Exhaust gas temperature upstream turbine; out of range, system reaction initiated

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
1188 2 Wastegate; status message from ECU missing
7 Wastegate actuator; blocked
11 Turbo charger wastegate actuator; internal error
13 Wastegate actuator calibration deviation too large, recalibration required
1231 14 CAN-Bus 1 "BusOff-Status"
1235 14 CAN-Bus 2 "BusOff-Status"
1237 2 Override switch; plausibility error
1322 12 Too many recognized misfires in more than one cylinder
1323 12 Too many recognized misfires in cylinder 1 (in firing order)
12 Too many recognized misfires in cylinder 1 (in firing order)
1324 12 Too many recognized misfires in cylinder 2 (in firing order)
1325 12 Too many recognized misfires in cylinder 3 (in firing order)
1326 12 Too many recognized misfires in cylinder 4 (in firing order)
1327 12 Too many recognized misfires in cylinder 5 (in firing order)
1328 12 Too many recognized misfires in cylinder 6 (in firing order)
1639 0 Sensor error fan speed; signal range check high
1 Sensor error fan speed; signal range check low
1761 14 Urea tank level; warning threshold exceeded
2621 3 Flush valve burner (EPV DPF-System); short circuit to battery
4 Flush valve burner (EPV DPF-System); short circuit to ground
5 Flush valve burner (EPV DPF-System); open load
12 Flush valve burner (EPV DPF-System); powerstage over temperature
2659 0 Physical range check high for EGR exhaust gas mass flow
1 Physical range check low for EGR exhaust gas mass flow
2 AGS sensor temperature exhaust gas mass flow; plausibility error
12 Exhaust gas recirculation; AGS sensor has "burn off" not performed
Exhaust gas recirculation AGS sensor; plausibility error

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
2791 0 EGR actuator, temperature critical high
2 EGR actuator, CAN error
3 EGR actuator supply voltage is above the maximum threshold
4 EGR actuator supply voltage is below minimum threshold
6 EGR actuator current is above maximum threshold
7 EGR actuator, actuator blocked or broken spring detected
12 EGR actuator, internal electrical fault
13 EGR actuator, EOL calibration error or learning process aborted or learning process out of
range
16 EGR actuator, temperature high
2797 4 Injector diagnostics; timeout error of short circuit to ground measurement cyl. Bank 0
2798 4 Injector diagnostics; short circuit Bank 0, Bank 1
Injector diagnostics; timeout error of short circuit to ground measurement cyl. Bank 1
3031 0 AdBlue-Tank temperature: maximum exceeded
1 DEF-Tank temperature: below minimum
3 Sensor error urea tank temperature; short circuit to battery
4 Sensor error urea tank temperature; short circuit to ground
3224 1 Nox sensor upstream of SCR Catalysator; low signal not plausible
2 NOx Sensor; CAN DLC error
9 NOx Sensor; CAN Timeout
3234 2 NOx Sensor; CAN DLC error
9 NOx Sensor; CAN Timeout
11 Nox Sensor downstream of SCR Catalysator; plausibility error "stuk in range"
3241 0 Sensor SCR catalyst upstream temperature too high; plausibility error
1 Sensor SCR catalyst upstream temperature too low; plausibility error

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
3248 0 Exhaust gas temperature particulate filter downstream; out of range, system reaction initiated
1 Exhaust gas temperature particulate filter downstream; out of range, system reaction initiated
2 Sensor exhaust gas temperature downstream DPF; plausibility error
4 Sensor error particle filter downstream temperature; signal range check low
3251 0 Physical range check high for differential pressure (DPF); shut off regeneration
1 Physical range check low for differential pressure (DPF); shut off regeneration
3253 2 Sensor differential pressure (DPF); plausibility error
3 Sensor error differential pressure (DPF); signal range check high
4 Sensor error differential pressure (DPF); signal range check low
3361 3 Urea dosing valve; short circuit to battery
4 Urea dosing valve; short circuit to ground
7 AdBlue dosing valve blocked (SCR)
3519 3 DEF quality sensor, internal temperature sensor short circuit to battery or open lead
4 DEF quality sensor, internal temperature sensor short circuit to ground
12 DEF tank temperature, temperature too high
13 Temperature at UQS invalid
3520 3 DEF quality sensor, short circuit to battery or open load
4 DEF quality sensor, short ciruit to ground
13 Urea quality at UQS invalid
3532 3 DEF level at UQS out of max. physical range
3 Sensor error urea tank level; signal range check high
4 Quality at UQS of of min. physical range
4 Sensor error urea tank level; signal range check low
3699 2 DPF differential pressure sensor and a further sensor or actuator CRT system defective
14 Maximum stand-still-duration reached; oil exchange required
Temperature sensor us. and ds. DOC simultaneously defect
3711 12 Regeneration temperature (PFltRgn LigtOff) not reached; regeneration aborted
3936 14 Standstill request ignored too long

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
4243 11 SCR system heater diagnostic reports error; shut off SCR-system
4334 0 Urea pump pressure; out of range
1 Urea pump pressure; out of range
3 Sensor error urea pump pressure; signal range check high
4 Sensor error urea pump pressure; signal range check low
4341 3 SCR-heater urea supplyline; short circuit to battery
4 SCR-heater urea supplyline; short circuit to ground
5 SCR heater relay urea supplyline; open load
4343 3 SCR heater urea pressureline; short circuit to battery
4 SCR heater urea pressureline; short circuit to ground
5 SCR heater relay urea pressureline; open load
11 General pressure check error (SCR)
4345 3 SCR heater urea returnline; short circuit to battery
4 SCR heater urea returnline; short circuit to ground
5 SCR heater relay urea returnline; open load
11 Sensor backflow line pressure (SCR); plausibility error
4360 0 Physical range check high for urea catalyst upstream temperature
1 Physical range low for urea catalyst upstream temperature
3 Sensor error urea catalyst exhaust gas temperature upstream; signal range check high
4 Sensor error urea catalyst exhaust gas temperature upstream; signal range check low
4365 0 Urea tank temperature too high
4366 3 SCR Tank heating valve; short circuit to battery
4 SCR Tank heating valve; short circuit to ground
5 SCR main relay (secondary side): open load
12 SCR-heater relay urea tank powerstage output; over temperature
SCR main relay; short circuit
SCR Tank heating valve; open load
4374 13 Pressure stabilisation error dosing valve (SCR)

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
4375 3 Urea pump motor; short circuit to battery
4 Urea pump motor; short circuit to ground
5 Urea pump motor; open load
4376 3 SCR reversing valve; short circuit to battery
4 SCR reversing valve; short circuit to ground
5 SCR reversing valve; open load
12 SCR reversing valve; over temperature
4765 0 Physical range check high for exhaust gas temperature upstream (DOC)
1 Physical range check low for exhaust gas temperature upstream (DOC)
4766 0 Physical range check high for exhaust gas temperature downstream (DOC)
1 Physical range check low for exhaust gas temperature downstream (DOC)
4768 2 Sensor exhaust gas temperature upstream (DOC); plausibility error
3 Sensor error exhaust gas temperature upstream (DOC); signal range check high
4 Sensor error exhaust gas temperature upstream (DOC); signal range check low
4769 2 Sensor exhaust gas temperature (DOC) downstream; plausibility error
3 Sensor error exhaust gas temperature downstream (DOC); signal range check high
4 Sensor error exhaust gas temperature downstream (DOC); signal range check low
Sensor exhaust gas temperature downstream (DOC); plausibility error
5763 0 Warning threshold for an internal actuator error exceeded, <4L EGR actuator and >4L Air Intake
Flap
1 Shutoff threshold for an internal actuator error exceeded, <4L EGR actuator and >4L Air Intake
Flap
3 Position sensor error of actuator EGR-Valve (2.9; 3.6) Signal range check high
3 Actuator EGR-Valve (2.9; 3.6); short circuit to battery
4 Actuator EGR-Valve (2.9; 3.6); short circuit to ground; Voltage below threshold
5 Actuator EGR-Valve (2.9; 3.6); Open load on ECU output is detected
6 Actuator error EGR-Valve; signal range check high
7 Actuator position for EGR-Valve (2.9; 3.6)
11 Power stage over temperature due to high current
20521 5 Actuator error EGR-Valve (2.9;3.6) Signal range check low

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
23006 64254 3 Controller mode switch; short circuit to battery
4 Controller mode switch; short circuit to ground
23008 64256 1 Manipulation control was triggered
2 Timeout error in Manipulation control
23009 64257 9 Pressure Relief Valve (PRV) reached maximun allowed opening count
10 Pressure relief valve (PRV) reached maximun allowed open time
23090 2 Engine Brake Pre-Selection switch; Plausibiliy Error
23212 64460 9 Timeout Error of CAN-Receive-Frame ComEngPrt; Engine Protection
23216 64464 9 Timeout Error of CAN-Receive-Frame PrHtEnCmd; pre-heat command, engine command
23240 64488 9 Timeout CAN-message FunModCtl; Function Mode Control
23330 64578 14 Immobilizer status; fuel blocked
23350 64598 4 Injector cylinder-bank 1; short circuit
23352 64600 4 Injector cylinder-bank 2; short circuit
23354 64602 12 Injector powerstage output defect
23450 64698 2 Multiple Stage Switch constant speed; plausibility error
3 Multiple Stage Switch constant speed; short circuit to battery
4 Multiple Stage Switch constant speed; short circuit to ground
23451 64699 2 Multiple Stage Switch engine speed control parameter; plausibility error
3 Multiple Stage Switch engine speed control parameter; short circuit to battery
4 Multiple Stage Switch engine speed control parameter; short circuit to ground
23452 64700 2 Multiple Stage Switch engine torque limitation curve; plausibility error
3 Multiple Stage Switch engine torque limitation curve; short circuit to battery
4 Multiple Stage Switch engine torque limitation curve; short circuit to ground

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
23470 64718 2 Pressure Relief Valve (PRV) forced to open
7 Maximum rail pressure in limp home mode exceeded (PRV)
11 Pressure Relief Valve (PRV) error; Rail pressure out of tolerance range
12 Pressure Relief Valve (PRV) forced to open; system reaction initiated
14 Pressure Relief Valve (PRV) is open
Rail pressure out of tolerance range
23550 64798 12 T50 start switch active for too long
23601 64849 13 Sensor supply voltage monitor 3 error (ECU)
23602 64850 0 Fan control; out of range, system reaction initiated
23603 64851 9 Timeout Error of CAN-Receive-Frame AMB; Ambient Temperature Sensor
23605 64853 9 Timeout Error of CAN-Receive-Frame TSC1AE; Traction Control
23606 64854 9 Timeout Error of CAN-Receive-Frame TSC1AR; Retarder
23612 64860 12 ECU reported internal software error
14 Softwarereset CPU
Internal software error ECU
23613 64861 0 Rail pressure disrupted
1 Minimum rail pressure exceeded (RailMeUn3)
2 Setpoint of metering unit in overrun mode not plausible
23615 64863 3 Metering unit (Fuel-System); short circuit to battery
4 Metering unit (Fuel-System); short circuit to ground
5 Metering unit (Fuel-System); open load
12 Metering unit (Fuel-System); powerstage over temperature
23619 64867 2 Physical range check high for exhaust gas temperature upstrem (SCR-CAT)
23632 64880 0 Pressure overload of SCR-System
1 Pressure build-up error SCR-System
2 Metering control is not performed in time error
16 Pump pressure SCR metering unit too high
18 Pump pressure SCR metering unit too low
23633 64881 11 Nox conversion rate insufficient

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
23698 64946 11 Shut off request from supervisory monitoring function
23704 12 Timeout Error of CAN-Transmit_Frame EEC3
23717 64965 12 Timeout Error of CAN-Transmit-Frame AmbCon; Weather environments
23718 64966 3 SCR main relay (primary side); short circuit to battery
4 SCR main relay (primary side); short circuit to ground
5 SCR main relay (primary side); open load
12 SCR mainrelay; powerstage over temperature (only CV56B)
SCR mainrelay; short circuit to battery (only CV56B)
SCR mainrelay; short circuit to ground (only CV56B)
SCR mainrelay; open load (only CV56B)
23719 64967 3 SCR heater urea supplymodule; short circuit to battery
4 SCR heater urea supplymodule; short circuit to ground
5 SCR heater relay urea supply module; open load
23720 64968 2 Urea supply module heater temperature; plausibility error
8 Urea supply module heater temperature; signal disrupted
23721 64969 2 Urea supply module heater temperature; plausibility error
8 Urea supply module temperature; signal disrupted
11 Urea supply module temperature measurement not available
23722 64970 8 Urea supply module PWM signal; signal disrupted

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
23723 64971 11 Detection of AdBlue filled SCR system in Init-State
23766 65014 9 Timeout Error of CAN-Receive-Frame Active TSC1AE
23767 65015 9 Timeout Error of CAN-Receive-Frame Passive TSC1AE
23768 65016 9 Timeout Error of CAN-Receive-Frame Active TSC1AR
23769 65017 9 Timeout Error of CAN-Receive-Frame Passive TSC1AR
23770 65018 9 Timeout Error of CAN-Receive-Frame Passive TSC1DE
23776 65024 9 Timeout Error of CAN-Receive-Frame TSC1TE - active
23777 65025 9 Passive Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint
23778 65026 9 Active Timeout Errorof CAN-Receive-Frame TSC1TR
23779 65027 9 Passive Timeout Error of CAN-Receive-Frame TSC1TR
23788 65036 0 Turbo charger wastegate; CAN Fehler
12 Timeout Error of CAN-Transmit-Frame TrbCH; Status Wastegate
23793 65041 9 Timeout Error of CAN-Receive-Frame UAA10; AGS sensor service message
23794 65042 9 Timeout Error of CAN-Receive-Frame UAA11; AGS sensor data
23803 65051 9 Timeout Error of CAN-Receive-Frame RxEngPres; Status burner airpump
23867 65115 12 Timeout Error of CAN-Transmit-Frame UAA1 on CAN 2; Burner Air Pump Control
23895 65143 13 Check of missing injector adjustment value programming (IMA) injector 1 (in firing order)
23896 65144 13 check of missing injector adjustment value programming (IMA) injector 2 (in firing order)
23897 65145 13 check of missing injector adjustment value programming (IMA) injector 3 (in firing order)
23898 65146 13 check of missing injector adjustment value programming (IMA) injector 4 (in firing order)
23899 65147 13 check of missing injector adjustment value programming (IMA) injector 5 (in firing order)
23900 65148 13 check of missing injector adjustment value programming (IMA) injector 6 (in firing order)
23910 65158 0 Air Pump; internal error
6 Air Pump; over current
7 Air pump; CAN communication interrupted no purge function available
9 Air Pump; CAN communication lost
12 Air Pump; internal error
14 Air pump doesn´t achieve air mass flow setpoint

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
23911 65159 0 Burner dosing valve (DV2); overcurrent at the end of the injection phase
3 Burner dosing valve (DV2); short circuit to battery
4 Burner dosing valve (DV2); short circuit to ground
7 Burner dosing valve (DV2); blocked closed
11 Burner dosing valve (DV2); short circuit high side powerstage
12 Burner dosing valve (DV2); powerstage over temperature
23912 65160 0 Physical range check high for burner dosing valve (DV2) downstream pressure; shut off
regeneration
1 Physical range check low for burner dosing valve (DV2) downstream pressure; shut off
regeneration. When burner injector is actuated, the measured pressure does not rise above ca.
1250mbar abs (expected: ca. 2400mbar).
2 Burner dosing valve (DV2) downstream pressure sensor; plausibility error
3 Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range check high
4 Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range check low
23913 65161 3 Sensor error glow plug control diagnostic line voltage; signal range check high
4 Sensor error glow plug control diagnostic line voltage; signal range check low
23914 65162 3 Glow plug control; short circuit to battery
4 Glow plug control; short circuit to ground
5 Glow plug control; open load
11 Glow plug control; internal error
12 Glow plug control; powerstage over temperature
23915 65163 0 HCI dosing valve (DV1); overcurrent at the end of the injection phase
3 HCI dosing valve (DV1); short circuit to battery
4 HCI dosing valve (DV1); short circuit to ground
7 HCI dosing valve (DV1); blocked
11 HCI dosing valve (DV1); short circuit high side powerstage
12 HCI dosing valve (DV1); powerstage over temperature
23916 65164 0 Physical range check high for HCI dosing valve (DV1) downstream pressure; shut off
regeneration
1 Physical range check low for HCI dosing valve (DV1) downstream pressure; shut off
regeneration
2 Sensor HCI dosing valve (DV1) downstream pressure; plausibility error
3 Sensor error HCI dosing valve (DV1) downstream pressure; signal range check high
4 Sensor error HCI dosing valve (DV1) downstream pressure; signal range check low

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
23917 65165 0 Physical range check high for DV1 & DV2 upstream pressure; shut off regeneration
1 Physical range check low for DV1 & DV2 upstream pressure; shut off regeneration
2 Sensor DV1 & DV2 upstream pressure; plausibility error
3 Sensor error DV1 & DV2 upstream pressure; signal range check high
4 Sensor error DV1 & DV2 upstream pressure; signal range check low
23918 65166 0 Physical range check high for DV1 & DV2 upstream temperature; shut off regeneration
1 Physical range check low for DV1 & DV2 upstream temperature; shut off regeneration
2 Sensor DV1 & DV2 upstream temperature; plausibility error
3 Sensor error DV1 & DV2 upstream temperature; signal range check high
4 Sensor error DV1 & DV2 upstream temperature; signal range check low
23919 65167 0 Physical range check high for airpump pressure; shut off regeneration
1 Physical range check low for airpump pressure; shut off regeneration
2 Sensor airpump pressure; plausibility error
3 Sensor error airpump pressure; signal range check high
4 Sensor error airpump pressure; signal range check low
23920 65168 0 Physical range check high for exhaustgas back pressure burner; shut off regeneration
1 Physical range check low for exhaustgas back pressure burner; shut off regeneration
2 Sensor exhaustgas back pressure; plausibility error
3 Sensor error exhaustgas back pressure burner; signal range check high
4 Sensor error exhaustgas back pressure burner; signal range check low
23921 65169 0 Physical range check high for burner temperature
1 Physical range check low for burner temperature
2 Sensor burner temperature; plausibility error
3 Sensor error burner temperature; signal range check high
4 Sensor error burner temperature; signal range check low
11 Sensor burner temperature; plausibility error
23922 65170 3 Burner shut of valve; short circuit to battery
4 Burner shut of valve; short circuit to ground
5 Burner shut off valve; open load
7 Shut off valve: blocked
12 Over temperature error on burner shut of valve

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
23924 4 Short circuit to ground actuator relay 2
23925 3 Short cicuit to battery error of actuator relay 3
4 Short circuit to ground actuator relay 3
23926 4 Short cirucit to dround actuator relay 4
23927 3 Short cicuit to battery error of actuator relay 5
23929 65177 0 Fuel Balance Control integrator injector 1 (in firing order); maximum value exceeded
1 Fuel Balance Control integrator injector 1 (in firing order); minimum value exceeded
23930 65178 0 Fuel Balance Control integrator injector 2 (in firing order); maximum value exceeded
1 Fuel Balance Control integrator injector 2 (in firing order); minimum value exceeded
23931 65179 0 Fuel Balance Control integrator injector 3 (in firing order); maximum value exceeded
1 Fuel Balance Control integrator injector 3 (in firing order); minimum value exceeded
23932 65180 0 Fuel Balance Control integrator injector 4 (in firing order); maximum value exceeded
1 Fuel Balance Control integrator injector 4 (in firing order); minimum value exceeded
23933 65181 0 Fuel Balance Control integrator injector 5 (in firing order); maximum value exceeded
1 Fuel Balance Control integrator injector 5 (in firing order); minimum value exceeded
23934 65182 0 Fuel Balance Control integrator injector 6 (in firing order); maximum value exceeded
1 Fuel Balance Control integrator injector 6 (in firing order); minimum value exceeded
23935 65183 12 Timeout Error of CAN-Transmit-Frame EEC3VOL1; Engine send messages
23936 65184 12 Timeout Error of CAN-Transmit-Frame EEC3VOL2; Engine send messages
23938 65186 9 Timeout Error (BAM to packet) for CAN-Receive-Frame AT1IGCVol1 information; factors &
Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPF- system downstream cat)
23939 65187 9 Timeout Error (BAM to BAM) for CAN-Receive-Frame AT1IGCVol1 information; factors &
Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPF- system downstream cat)
23940 65188 9 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1IGCVol1 information; factors &
Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPF-system downstream cat)
23941 65189 9 Timeout Error (BAM to packet) for CAN-Receive-Frame AT1OGCVol2 information; factors &
Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPF- system downstream
cat)
23942 65190 9 Timeout Error (BAM to BAM) for CAN-Receive-Frame AT1OGCVol2 information; factors &
Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPF- system downstream
cat)

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
23943 65191 9 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1OGCVol2 information; factors &
Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPF- system downstream
cat)
23946 65194 0 Zerofuel calibration injector 1 (in firing order); maximum value exceeded
1 Zerofuel calibration injector 1 (in firing order); minimum value exceeded
23947 65195 0 Zerofuel calibration injector 2 (in firing order); maximum value exceeded
1 Zerofuel calibration injector 2 (in firing order); minimum value exceeded
23948 65196 0 Zerofuel calibration injector 3 (in firing order); maximum value exceeded
1 Zerofuel calibration injector 3 (in firing order); minimum value exceeded
23949 65197 0 Zerofuel calibration injector 4 (in firing order); maximum value exceeded
1 Zerofuel calibration injector 4 (in firing order); minimum value exceeded
23950 65198 0 Zerofuel calibration injector 5 (in firing order); maximum value exceeded
1 Zerofuel calibration injector 5 (in firing order); minimum value exceeded
23951 65199 0 Zerofuel calibration injector 6 (in firing order); maximum value exceeded
1 Zerofuel calibration injector 6 (in firing order); minimum value exceeded
23960 65208 0 EGR cooler downstream temperature; out of range, system reaction initiated
1 EGR cooler downstream temperature; out of range, system reaction initiated
Exhaust gas temperature EGR downstream; out of range, system reaction initiated
Exhaust gas temperature EGR downstream; out of range, system reaction initiated
23973 65221 14 SCR Tamper detection; derating timer below limit 1
23974 65222 14 SCR Tamper detection; derating timer below limit 2
23975 65223 14 Urea quality; derating timer below limit 1
23976 65224 14 Urea qulaity; derating timer below limit 2
23977 65225 14 Urea tank level; derating timer below limit 1
23978 65226 14 Urea tank level; derating timer below limit 2
23980 65228 14 Bad quality of reduction agent detected
23981 65229 11 Urea-tank without heating function (heating phase)
23982 65230 0 Powerstage diagnosis disabled; high battery voltage
1 Powerstage diagnosis disabled; low battery voltage

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
23984 3 UB6; Short circuit to battery error of actuator relay 6
23986 4 Actuator relay 5; voltage measured by ECU is out of target range
23987 4 Actuator relay 6; voltage measured by ECU is out of target range
23988 65236 3 Charging lamp; short circuit to battery
4 Charging lamp; short circuit to ground
5 Charging lamp; open load
12 Charging lamp; over temperature
23989 65237 0 Fuel Balance Control integrator injector 7 (in firing order); maximum value exceeded
1 Fuel Balance Control integrator injector 7 (in firing order); minimum value exceeded
23990 65238 0 Fuel Balance Control integrator injector 8 (in firing order); maximum value exceeded
1 Fuel Balance Control integrator injector 8 (in firing order); minimum value exceeded
23992 65240 9 Timeout Error of CAN-Receive-Frame DM19Vol1; NOX sensor upstream
23993 65241 9 Timeout Error of CAN-Receive-Frame DM19Vol2; NOX sensor downstream
23995 65243 13 check of missing injector adjustment value programming (IMA) injector 7 (in firing order)
23996 65244 13 check of missing injector adjustment value programming (IMA) injector 8 (in firing order)
23998 65246 4 Injector cylinder bank 2 slave; short circuit
23999 65247 12 Injector powerstage output Slave defect
24000 65248 3 Injector 7 (in firing order); short circuit
4 High side to low side short circuit in the injector 7 (in firing order)
5 Injector 7 (in firing order); interruption of electric connection
24001 65249 3 Injector 8 (in firing order); short circuit
4 High side to low side short circuit in the injector 8 (in firing order)
5 Injector 8 (in firing order); interruption of electric connection
24004 65252 12 Too many recognized misfires in cylinder 7 (in firing order)
24005 65253 12 Too many recognized misfires in cylinder 8 (in firing order)

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
24011 65259 0 Zerofuel calibration injector 7 (in firing order); maximum value exceeded
1 Zerofuel calibration injector 7 (in firing order); minimum value exceeded
24012 65260 0 Zerofuel calibration injector 8 (in firing order); maximum value exceeded
1 Zerofuel calibration injector 8 (in firing order); minimum value exceeded
24013 65261 7 Burner operation disturbed
24014 65262 1 Air pressure glow plug flush line; below limit
24016 65264 2 Air Pump; air flow is not plausible
11 HFM sensor; electrical fault
24017 65265 12 Spark plug control unit (SPCU); internal error
24018 65266 14 DPF wasn´t regenerated, power reduction phase 1 (manuell regeneration request)
24019 65267 11 Air Pump; air lines blocked
24020 65268 14 Engine power; Not enough oxygen for regeneration
24021 65269 11 Burner fuel line pipe leak behind Shut Off Valve
24022 65270 14 DPF wasn´t regenerated, power reduction phase 2 (manuell regeneration request)
24023 65271 14 DPF wasn´t regenerated, warning condition (manuell regeneration mode)
24024 65272 11 Deviation of the exhaust gas temperature setpoint to actual value downstream (DOC) too high
24025 65273 5 DPF system; operating voltage error
14 Particulate filter; regeneration not succesful
24028 65276 2 CAN message PROEGRActr; plausibility error
24029 65277 2 Timeout Error of CAN-Receive-Frame ComEGRActr - exhaust gas recirculation positioner
24030 65278 7 EGR actuator; internal error
24031 65279 13 EGR actuator; calibration error
24032 65280 2 EGR actuator; status message "EGRCust" is missing
24033 65281 7 EGR actuator; due to overload in Save Mode
24034 65282 3 Disc separator; short circuit to battery
4 Disc separator; short circuit to ground
5 Disc Separator; open load
12 Disc Separator; powerstage over temperature

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
24035 65283 12 Injector diagnostics; time out error in the SPI communication
24036 65284 12 Injector diagnostics Slave; time out error in the SPI communication
24037 65285 3 Ashlamp; short circuit to battery
4 Ashlamp; short circuit to ground
5 Ashlamp; open load
24038 65286 9 Timeout error of CAN-Receive-Frame ComMS_Sys1TO (error memory Slave); Master-Slave
internal CAN message
24039 65287 9 Timeout error of CAN-Receive-Frame ComMS_Sys2TO (error memory Slave); Master-Slave
internal CAN message
24040 65288 9 Timeout error of CAN-Receive-Frame ComMS_Sys3TO (error memory Slave); Master-Slave
internal CAN message
24041 65289 9 Timeout error of CAN-Receive-Frame ComMS_Sys4TO (error memory Slave); Master-Slave
internal CAN message
24042 65290 9 Timeout error of CAN-Receive-Frame ComMS_Sys5TO (error memory Slave); Master-Slave
internal CAN message
24043 65291 9 Timeout error of CAN-Receive-Frame ComMS_Sys6TO (error memory Slave); Master-Slave
internal CAN message
24044 65292 9 CAN message ComMS_Sys7 not received from slave
24045 65293 9 Master-Slave CAN; Message-Counter-Error of CAN-Receive-Frame ComMSMoFOvR
24046 65294 9 Master-Slave CAN; Checksum-Error of CAN-Receive-Frame ComMSMoFOvR
24047 65295 9 Master-Slave CAN; Messsage-Length-Error of CAN-Receive-Frame ComMSMoFOvR
24048 65296 9 Timeout error CAN message ComMSMoFOvR1TO error memory Slave
24049 65297 9 Message copy error in the Master / Slave data transfer
24052 65300 11 MS ECU reported internal error
24055 65303 4 Spark Plug Control Unit (SPCU); short circuit to ground
24057 65305 2 Electric fuel pump; fuel pressure build up error
24062 65310 12 EAT-system HMI disrupted
24063 3 SCR main relay; short circuit to battery
4 SCR heater main relay load side (K31 on heating valve (Y31)
5 SCR heater return line; open load or SCR main relay not connected; or SCR heater
pressureline; open load or SCR or SCR relay for suction line not connected or SCR heater
supply module; open load or SCR heater tank; open loac
12 DEF supply module, time for defrosting too long or DEF tank, time for defrosting too long

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
24065 0 Pressure sensor upstream SCR-CAT, pressure above upper physical threashold
1 Pressure sensor upstream SCR-CAT, pressure below lower physical threashold
2 Pressure sensor upstream SCR-CAT, plausibility error
3 Pressure sensor upstream SCR-CAT, short circuit battery or open load
4 Pressure sensor upstream SCR-CAT, short circuit ground
24067 0 DEF supply module, heater temperature above upper physical threshold
1 DEF supply module, heater temperature below lower physical threshold
2 Supply module heather temperature, plausibility error
24068 65316 2 Master ECU and Slave ECU have been identified as the same types
24069 65317 9 Timeout Error of CAN-Receive-Frame MSMon_FidFCCTO; Master-Slave CAN communication
faulty
24074 9 NOx sensor downstream SCR-CAT, sensor internally open load
24075 11 NOx sensor downstream SCR-CAT, sensor internally short circuit
24076 9 NOx sensor downstream SCR-CAT, sensor internally open line
24077 11 NOx sensor upstream SCR-CAT, sensor internally short circuit
24078 9 NOx sensor downstream SCR-CAT, lambda value above upper physical threshold
24079 9 NOx sensor downstream SCR-CAT, lambda value below lower physical threshold
24080 9 NOx sensor upstream SCR-CAT, lambda value above upper physical threshold
24081 9 NOx sensor upstream SCR-CAT, lambda value below lower physical threshold
24083 9 NOx sensor downstream SCR-CAT, NOx value below minimum value
24085 9 NOx sensor upstream SCR-CAT, NOx value below lower physical threshold

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SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
24097 65345 9 Timeout error of CAN-Transmit-Frame DPFBrnAirPmpCtl
24098 65346 9 Timeout error of CAN-Transmit-Frame ComDPFBrnPT
24099 65347 9 Timeout error of CAN-Transmit-Frame ComDPFC0
24100 65348 9 Timeout error of CAN-Transmit-Frame ComDPFHisDat
24101 65349 9 Timeout error of CAN-Transmit-Frame ComDPFTstMon
24102 65350 9 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmpCtl
24103 65351 9 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp
24104 65352 9 Timeout error of CAN-Receive-Frame ComRxDPFCtl
24105 65353 9 Timeout error of CAN-Transmit-Frame ComEGRMsFlw
24106 65354 9 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw1
24107 65355 9 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw2
24108 65356 9 Timeout error of CAN-Transmit-Frame ComEGRTVActr
24109 65357 9 Timeout error of CAN-Receive-Frame ComRxEGRTVActr
24110 65358 9 Timeout error of CAN-Transmit-Frame ComETVActr
24111 65359 9 Timeout error of CAN-Receive-Frame ComRxETVActr
24112 65360 9 Timeout ComITVActr
24113 65361 9 Timeout error of CAN-Receive-Frame ComRxITVActr
24114 65362 9 Timeout error of CAN-Transmit-Frame A1DOC
24115 65363 9 Timeout error of CAN-Transmit-Frame AT1S

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Deutz TCD3.6 Engine Fault Codes

SPN = Suspect Parameter Number

ASPN = Alternate Suspect Parameter Number
FMI = Failure Mode Identifier
SPN ASPN FMI Description
24116 65364 9 Timeout error of CAN-Transmit-Frame SCR2
24117 65365 9 Timeout error of CAN-Transmit-Frame SCR3
24118 65366 9 Timeout error of CAN-Receive-Frame ComRxCM0
24119 65367 9 Timeout error of CAN-Receive-Frame ComRxCustSCR2
24120 65368 9 Timeout error of CAN-Receive-Frame ComRxSCRHtDiag
24121 65369 9 Timeout error of CAN-Receive-Frame ComRxTrbChActr
24122 65370 9 Timeout error of CAN-Receive-Frame ComRxUQSens
24123 65371 9 Timeout error of CAN-Receive-Frame ComSCRHtCtl
24124 65372 9 Timeout error of CAN-Receive-Frame ComTxAT1IMG
24125 65373 9 Timeout error of CAN-Receive-Frame ComTxTrbChActr
24141 7 DEF dosing valve, dosing valve blocked
24147 7 SCR System, reverting valve blocked
13 SCR System, pressure build up not possible
24152 2 Urea Quality Sensor, Timout CAN message
24153 2 Urea tank level & urea tank temperature via CAN bus, timeout of CAN message
24156 9 Timeout error of CAN-Receive-Frame ComRxEBC2
24175 0 SCR-CAT, Nox emissions above minimum threshold
24177 7 SCR System, DEF suction line blocked
24178 7 SCR System, DEF pressure ot of range
24190 14 Not enough urea in tank or low urea quality or hardware tampering failure is detected or
hardware failure is detected
24191 14 A low DEF tank level or a low DEF quality is detected or hardware tampering or hardware
failures
24193 8 The standstill-regeneration mode time exceeds the long limit threshold; Vehicle was too long or
too often in standstill mode; Change oil and reset counter
24194 8 The standstill-regeneration mode time exceeds the short limit threshold; Vehicle was too long or
too often within a short time in standstill mode; Change oil and reset counter
24195 14 Standstill request due to crystalization ignored too long

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Perkins 1104 Engine Fault Codes

SPN FMI Description

SPN = Suspect Parameter Number
157 3 Fuel rail pressure open/short to battery
FMI = Failure Mode Identifier
positive (+)
SPN FMI Description 4 Fuel rail pressure short to ground
91 2 Incorrect throttle switch inputs
168 0 System voltage high
3 Throttle position sensor: voltage above
normal or shorted high 1 System voltage low

4 Throttle position sensor: voltage below 2 ECM battery power intermittent/erratic

normal or shorted low 172 3 Air inlet temperature voltage high
8 Throttle position sensor: abnormal 4 Air inlet temperature voltage low
frequency, pulse width or period
100 3 Engine oil pressure sensor: voltage above 174 2 Fuel temperature sensor: data
normal or shorted high erratic/intermittent or incorrect

4 Engine oil pressure sensor :voltage below 190 8 Engine speed signal abnormal
normal or shorted low 15 Engine speed: overspeed WARNING
102 3 Boost pressure sensor voltage: voltage 190 0 Engine overspeed
above normal or shorted high
626 5 Ether start aid current low
4 Boost pressure sensor voltage: voltage
below normal or shorted low 6 Ether start aid current high

10 No 5V to sender 630 2 System parameters incorrect

105 3 Intake manifold temperature sensor: 631 2 Personality module mismatch

temperature above normal or shorted high 637 11 Engine timing calibration invalid
4 Intake manifold temperature sensor: 637 139 Engine timing calibration required
temperature below normal or shorted low
639 9 J1939 data link communications
105 3 Intake manifold air temperature open/short
12 J1939 data link malfunction
to battery positive (+)
4 Intake manifold air temperature short to 651 2 Cylinder #1 injector data incorrect
ground 5 Cylinder #1 injector open circuit
110 3 Engine coolant temperature open/short to 6 Cylinder #1 injector short
battery positive (+)
7 Cylinder #1 injector not responding
4 Engine coolant temperature short to
ground 652 2 Cylinder #2 injector data incorrect
5 Cylinder #2 injector open circuit
6 Cylinder #2 injector short
7 Cylinder #2 injector not responding

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Perkins 1104 Engine Fault Codes

SPN = Suspect Parameter Number

FMI = Failure Mode Identifier
SPN FMI Description
653 2 Cylinder #3 injector data incorrect
5 Cylinder #3 injector open circuit
6 Cylinder #3 injector short
7 Cylinder #3 injector not responding
654 2 Cylinder #4 injector data incorrect
5 Cylinder #4 injector open circuit
6 Cylinder #4 injector short
7 Cylinder #4 injector not responding
678 3 8V DC supply short to battery positive
(+)
4 8V DC supply shorted to ground
723 8 Secondary engine speed signal
abnormal
1188 5 Turbo wastegate drive current low
1196 9 Machine security system module
non-communication
1347 5 Fuel rail pump output current low
6 Fuel rail pump output current high
7 Fuel rail pressure valve solenoid not
responding
2882 2 Mode selector switch: data
erratic/intermittent or incorrect
3509 3 5V DC power supply sensor short to
battery positive (+)
4 5V DC power supply sensor short to
ground

Perkins 1100 Troubleshooting Manual

Genie part number 123583

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Schematics

About This Section

Section 5 Schematics

There are two groups of schematics in this section.

Electrical Schematics
Electrocution/burn hazard.
Contact with electrically charged
Observe and Obey: circuits could result in death or
serious injury. Remove all rings,
 Troubleshooting and repair procedures shall be watches and other jewelry.
completed by a person trained and qualified on
the repair of this machine
Hydraulic Schematics
 Immediately tag and remove from service a
damaged or malfunctioning machine. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
 Repair any machine damage or malfunction burn skin. Loosen hydraulic
before operating the machine.
connections very slowly to allow
the oil pressure to dissipate
Before Troubleshooting: gradually. Do not allow oil to
squirt or spray.
 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.

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Proximity Switch Legend

1 Boom Angle Proximity Switch PX2 (under boom pivot

pin)
2 Boom Extend Proximity Switch PX1 (under plate at
top of boom tube, GTH-1056 only)

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Fuse Panel Layout

Perkins Engine Circuit Breakers

Located in Tank Assembly

PCB Board Fuse Panel located in the Cab

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Electrical Component Legend

Item Description Item Description
ALT Alternator F Fuse
B Battery F1 15 Amp - Break/Shift
B1 Main Battery F2 10 Amp - Aux Hydraulics
CB Circuit Breaker F3 10 Amp – Rear Axle Oscillate
CB1 50 Amp Circuit Breaker F4 10 Amp – Sway/Tilt
CB2 30 Amp Circuit Breaker F5 5 Amp - Horn
CB3 60 Amp Circuit Breaker F6 5 Amp - Steer/Differential Switch
C Capacitor F7 5 Amp - Gauge Cluster Power
C1 4700 uf F8 5 Amp - Dome/Beacon Light
CR Control Relay F9 25 Amp – HVAC
CR1 Main Power F10 15 Amp – Windshield Wiper/Washer
CR2 Options Power F11 10 Amp – Defrost Fan
CR3 Service Horn F12 20 Amp – Lights
CR4 Flasher F13 15 Amp – Ignition
CR5 Lights Option F14 10 Amp – Power Port
CR6 Sway Enable F15 1 Amp - Switch Power
CR7 Boom Angle F16 1 Amp – Gauge Cluster ECU
CR8 Boom Extend F17 Spare
CR9 Forward Enable F18 Spare
CR10 Reverse Enable F21 HVAC Control Panel
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
D Diode
ECU Engine Control Unit

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Electrical Component Legend

Item Description Item Description

L LED Light M Motor
L1 Ignition Power ON R Resistor
L2 Options Power Relay ON S Switch
L3 Horn Relay ON S1 Key Start Switch
L4 Turn Signal ON S2 Parking Brake Switch
L5 Road Lights, Work Lights ON S3 Boom Angle Switch
L6 Sway Enable Coil Power ON S4 Boom Extend Switch
L7 Boom Angle ON S5 Parking Brake Pressure Switch
L8 Boom Extend ON S6 Service Brake Pressure Switch
L9 Brake Pressure ON S7 Sway Enable Pressure Switch
L10 Backup Light, Alarm ON S8 Sway Enable Switch
L11 Parking Brake Latch ON S9 Tilt Enable Switch
L12 Sway Enable ON S10 Steer Select Switch
L13 Tilt Circuit Power ON S11 Left Stabilizer Switch
L14 Horn Power ON S12 Right Stabilizer Switch
L15 Cab, Tail Light Power ON S13 Differential Lock Switch
L16 Rear Axle Float Coil Power ON S14 Auxiliary Cont. Switch
L17 Rr Ax Fast Power (GTH1056) ON S15 Horn Switch
L18 Parking Brake Power ON S16 Brake Light Pressure Switch
L19 Forward Coil Power ON S17A Windshield Wiper Motor Switch
L20 Reverse Coil Power ON S17B Windshield Washer Switch
L21 PB Release Coil Power ON S18A Windshield Wiper Motor Switch
L22 Sway L/R Enable Coil Power ON S18B Windshield Washer Switch
L23 Tilt U/D Enable Coil Power ON S19 Dome Light Switch
L24 Forward Shift ON S21 Enclosed Cab Fan Switch
L25 Parking Brake Release OFF S22 Road / Work Light Switch
L26 Brake Light Power ON S23 Brake Pressure Warning Switch
L27 Hazard Power ON S24 Transmission Oil Pressure Switch
L28 Not Used S25 Transmission Oil Temp. Switch

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Wire Color Legend

Item Description Wire Color Legend

TP Throttle Pedal Item Description
TSS Turn Signal Shifter BL Blue
Y Valve Coil BL/BK Blue/Black
Y70 Sway Left Enable SV1 BL/RD Blue/Red
Y72A Tilt Up Enable SV2 BL/WH Blue/White
Y71 Sway Right Enable SV3 BK Black
Y72B Tilt Down Enable SV4 BK/RD Black/Red
Y67 Parking Brake Release SV5 BK/WH Black/White
Y68 Differential Lock SV6 BK/YL Black/Yellow
Y55 Rear Axle Float SV7 BR Brown
Y83 Rear Axle Fast SV8 GR Green
Y82 Sway Enable SV9 GR/BK Green/Black
Y77A Auxiliary A GR/WH Green/White
Y77B Auxiliary B RD Red
Y80 D Transmission RD/BK Red/Black
Y81 E Transmission RD/WH Red/White
Y6 Transmission Forward OR Orange
Y5 Transmission Reverse OR/BK Orange/Black
Y78 4Wheel Steer SVD1A OR/RD Orange/Red
Y79 Crab Steer SVD1B WH White
Y75 Left Stabilizer Down WH/BK White/Black
Y76 Left Stabilizer Up WH/RD White/Red
Y73 Right Stabilizer Down
Y74 Right Stabilizer Up
Y84 AC Control

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Telematics Connector Pin Legend

Genie installed Telematics connector is wired with an Active High digital input.

Pin Circuit Type Circuit Properties Genie Machine Function(s) Telematics Use Case
1 System Power 12 VDC Battery Positive – constant power Supply power to device
5 Amp Max. allowed
draw
2 System Ground 0 VDC Battery Negative Device Ground
3 Digital Output 1 12 VDC Engine Run Hour Meter Monitor Engine Hours
12V = engine run, 0V = engine off
4* Digital Output 2 12 VDC Boom Angle Status Monitor Machine Utilization
12V = boom >55°, 0V <55°
5 Digital Output 3 12 VDC Parking Brake Monitor Machine Utilization
12V = active, 0V = inactive
6 Digital Input 1 12 VDC (standard) Remote Disable Engine Start Remotely Prevent Engine
or Ground (optional) Start
7 CAN HIGH J1939 Databus HIGH J1939 Receive J1939 Engine Data
8 CAN LOW J1939 Databus LOW J1939 Receive J1939 Engine Data

* Not available on GTH-636

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Telematics Connector Pin Legend

Remote Disable Engine Start Relay Configuration

Telematics Active High - Schematic Telematics Active Low - Schematic

(standard wiring) (optional wiring)

1 Ignition Start Input

2 Relay
3 Telematics with Active High input
4 Telematics with Active Low input

Wireless Certifications
Telematic device(s) should comply with specific wireless carrier certifications where applicable and comply
with the following:
N. America – PTCRB, FCC/IC
Europe – CE, R&TTE

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Electrical Symbol Legend

Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge

Diode Hour meter LED Fuse with amperage Foot switch

T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid

T-circuits connect at Circuits crossing - no Quick disconnect Circuit breaker with

Connection - no terminal
terminal connection terminal amperage

Key switch Toggle switch DPDT Toggle switch SPDT Pump or Motor Tilt sensor

Horn button - normally Emergency stop button -

Resistor with ohm value Battery seperator Gauge sending unit
open normally closed

Oil temperature switch Coolant temperature Oil pressure switch Control relay contact Diode starting aid, glow
normally open switch - normally open normally closed normally open plug or flame ignitor

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Hydraulic Symbols Legend

Orifice with size Check valve Shut off valve Brake

Pump, bi-directional Motor, 2 speed

Pump, fixed displacement Motor, bi-directional
variable displacement bi-directional

Pump, prime mover (engine Shuttle valve. 2 position,

Double acting cylinder Differential sensing valve
or motor) 3 way

Filter with bypass relief Relief valve with pressure Solenoid operated
Priority flow regulator valve
valve setting proportional valve

Solenoid operated
Directional valve Pilot operated 3 position,
Flow divider/combiner valve 2 position, 3 way directional
(mechanically activated) 3 way shuttle valve
valve

Solenoid operated
Solenoid operated
Counterbalance valve with 3 position, 4 way 2 position, 2 way solenoid
3 position, 4 way directional
pressure and pilot ratio proportional directional valve
valve
valve

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Harness Map - Control System - Single Joystick

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Harness Map - Control System Ground Single Joystick

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Harness Map - Control System - Dual Joystick

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Harness Map - Control System - Dual Joystick

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Harness Map - Deutz TCD3.6 T4F Engine

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Harness Map - Deutz 3.6TCD T4F Engine

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Harness Map - Perkins 1204 T4F Engine

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Harness Map - Perkins 1204 T4F Engine

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Harness Map - Work Lights

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Harness Map - Work Lights

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Harness Map - Road Lights

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Harness Map - Road Lights

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Harness Map - Enclosed Cab with Heat

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Harness Map - Enclosed Cab with Heat

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Harness Map - Enclosed Cab with HVAC

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Harness Map - Enclosed Cab with HVAC

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Harness Map - Auxiliary Hydraulics, Beacon and Top Gear Lockout

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Harness Map - Auxiliary Hydraulics, Beacon and Top Gear Lockout

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Electrical Schematic

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Electrical Schematic

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Electrical Schematic

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Electrical Schematic

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Hydraulic Schematic - Models with Single Joystick

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Hydraulic Schematic - Models with Single Joystick

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Hydraulic Schematic - Models with Dual Joystick

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Hydraulic Schematic - Models with Dual Joystick

GTH-1056 Part No. 1278145 Ser vic e and R epair M anual December 2016

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