Genie GTH-636 Maintenance Manual
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- Service manual (196 pages) ,
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Table of Contents
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Maintenance Manual -
Telehandlers
GTH-636
GTH-844
GTH-1056
GTH-1256
GTH-1544
GTH-5519
Refer to the inside cover for a list of models
included in this manual.
This manual includes detailed
procedures for each
maintenance inspection.
For Repair procedures, Fault
Codes, Electrical and Hydraulic
Schematics, refer to the
appropriate Service and Repair
Manual for your machine.
Part No. 1272858
Rev A1
September 2016
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Table of Contents
Related Manuals for Genie GTH-636
Summary of Contents for Genie GTH-636
- Page 1 Maintenance Manual - Telehandlers GTH-636 This manual includes detailed procedures for each GTH-844 maintenance inspection. GTH-1056 For Repair procedures, Fault Codes, Electrical and Hydraulic GTH-1256 Schematics, refer to the appropriate Service and Repair GTH-1544 Manual for your machine. GTH-5519 Refer to the inside cover for a list of models Part No.
- Page 2 Copyright © 2016 by Terex Corporation 1272858 Rev A, March 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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Page 3: Introduction
GTH0816E-10000 to GTH0816E-10699 from GTH08E-10700 • Adjust the Boom Sequencing Chains - GTH-1056 from GTH1010-14001 to GTH1014-20404 GTH-636 and GTH-844 from GTH1014E-10001 to GTH1016E-10799 from GTH10E-10800 • Adjust the Boom Sequencing Chains - GTH-1056 GTH-1256 from GTH1215M-101 to GTH1216M-249... -
Page 4: Revision History
Procedure / Description 3/2016 Initial Release 9/2016 Introduction Models Included Reference Examples: Electronic Version Section – Specifications Click on any content or procedure in the Table of Contents to view Section – Maintenance, (procedure) the update. Genie Telehandlers Part No. 1272858... - Page 5 Revision History (continued) Revision Date Section Procedure / Description Reference Examples: Section – Specifications Electronic Version Click on any content or procedure in the Table of Contents to view Section – Maintenance, (procedure) the update. Part No. 1272858 Genie Telehandlers...
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Page 6: Safety Rules
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. Genie Telehandlers Part No. 1272858... - Page 7 Be sure that your workshop or work area warrants it. is properly ventilated and well lit. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Part No. 1272858 Genie Telehandlers...
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Page 8: Table Of Contents
Transmission Specifications .................. 9 Axle Specifications ....................10 Hydraulic Specifications ................... 11 Hydraulic Relief Valves ..................11 Hydraulic Oil Specifications ................. 13 Hydraulic Hose and Fitting Torque Specifications ..........16 Torque Procedure ....................16 viii Genie Telehandlers Part No. 1272858... - Page 9 Q-8 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ......32 Q-9 Visual Inspection of the Hydraulic Oil............34 Q-10 Inspect the Engine Air Filter ................ 35 Q-11 Lubricate the Driveshaft ................35 Q-12 Inspect and Lubricate the Sequencing Chains ........... 36 Part No. 1272858 Genie Telehandlers...
- Page 10 Annual Maintenance Procedures ..............38 A-1 Inspect the Forks ................... 38 A-2 Adjust the Boom Sequencing Chains - GTH-636 and GTH-844 ....38 A-3 Adjust the Boom Sequencing Chains - GTH-1056........39 A-4 Adjust the Boom Sequencing Chains - GTH-1256 and GTH-1544 ....40 A-5 Replace Hydraulic Tank Return Filter Element ..........
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Page 11: Specifications
September 2016 Maintenance Manual Specifications Section 2 Specific ati ons Machi ne Specific ations GTH-636 GTH-1056 Fluid capacities Fluid capacities Fuel tank 27 gallons Fuel tank 35 gallons 102.2 liters 132.5 liters Hydraulic tank 34 gallons Hydraulic tank 44 gallons 128.7 liters... -
Page 12: Air Conditioner Refrigerant Specifications
Specifications Air Condi tioner R efri ger ant Specific ati ons Air Conditioner Refrigerant Specifications System Full Charge R134a GTH-636, GTH-844 and GTH-1056 1 lb 14 oz GTH-1256, GTH-1544 2 lb 3 oz GTH-5519 1 lb 10 oz Genie Telehandlers... -
Page 13: Performance Specifications
September 2016 Maintenance Manual Performance Specifications Perfo rm ance Sp ecification s Performanc e Specific ati ons GTH-636 GTH-1056 Drive speed, maximum Drive speed, maximum Deutz TD2.9 Engines 18 mph All engines 19 mph 29.0 km/h 31.2 km/h Draw bar pull... -
Page 14: September
Boom extend 17 seconds Boom extend 7 seconds Boom retract 14 seconds Boom retract 4 seconds Fork tilt up 7 seconds Fork tilt up 4 seconds Fork tilt down 7 seconds Fork tilt down 3 seconds Genie Telehandlers Part No. 1272858... -
Page 15: Torque Specifications
September 2016 Maintenance Manual Torque Specifications Torque Sp ecification s Tires and W heels GTH-636 GTH-1544 Lug nut torque 465 ft-lb Lug nut torque 465 ft-lb 630 Nm 630 Nm Tire pressure 58 psi Tire pressure 87 psi (models with air-filled tires) 4.3 bar... -
Page 16: Powertrain Specifications
Operator and M aintenanc e M anuals Engine Operator and Maintenance Maintenance Manuals Manuals Carraro 26.27M Deutz TD 2.9 L4 Genie part number 218710 Genie part number 1251561 Deutz TCD3.6 L4 Dana Integral Gear Box Shift on Fly Genie part number... -
Page 17: Deutz Engine Models
Maintenance Manual Powertrain Specifications Deutz Engine M odels Deutz Engine Models TCD 4.1 L4, GTH-1256, GTH-1544 Low idle 920 rpm TD 2.9 L4, GTH-636 High idle 2300 rpm Standby idle 1000 rpm Oil capacity (including filter) 12.1 quarts Low idle 950 rpm 11.5 liters... -
Page 18: Perkins Engine Models
29 liters Engine coolant capacity 4.6 gallons Type: Extended Life 17.4 liters Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine. Genie Telehandlers Part No. 1272858... -
Page 19: Transmission Specifications
Oil capacity, gear box 1.1 quarts 1 liters Units ship with Chevron Ursa Hydraulic 10W. Extreme operating temperatures may require the use of alternative transmission oils. For oil requirements, refer to the Dana VDT12000 Service Manual. Part No. 1272858 Genie Telehandlers... -
Page 20: Axle Specifications
Chervron Supreme 80W90 LS 0.95 liters Planetary ends Chervron Supreme 80W90 LS Drop Box Lubrication Drop Box 1.04 quarts 0.98 liters Oil viscosity requirements Differential API GL5 (MIL L-2105) Planetary ends API GL5 (MIL L-2105) Genie Telehandlers Part No. 1272858... -
Page 21: Hydraulic Specifications
September 2016 Maintenance Manual Hydraulic Specifications H ydr aulic Sp ecification s Hydraulic R elief Valves GTH-636 GTH-1056 Primary Function Manifold Primary Function Manifold System pressure, maximum 3200 psi System pressure, maximum 3200 psi 221 bar 221 bar Fork tilt relief valve pressure, maximum... - Page 22 Steer relief valve pressure, maximum 2030 psi 140 bar Steer anti-shock relief valve pressure, 2900 psi maximum 200 bar Parking brake relief valve pressure, maximum 360 psi 25 bar Auxiliary line relief valve pressure, maximum 3915 psi 270 bar Genie Telehandlers Part No. 1272858...
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Page 23: Hydraulic Oil Specifications
Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry. When incompatible designed to give maximum protection to hydraulic fluids are mixed, insoluble systems, have the ability to perform over a wide... - Page 24 Note: Do not operate the machine when the 5606A hydraulic fluid, or ambient temperature is below -20°F / -29°C with equivalent, when ambient Rando HD Premium MV. temperatures are consistently above 32°F / 0°C may result in component damage Genie Telehandlers Part No. 1272858...
- Page 25 33.8 Brookfield Viscosity cSt @ -4°F / -20°C 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 Part No. 1272858 Genie Telehandlers...
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Page 26: Hydraulic Hose And Fitting Torque Specifications
Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed 23 ft-lbs / 31.2 Nm... -
Page 27: Torque Procedure
Note: The O-ring in Parker Seal Lok™ fittings and 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). Lubricate the O-ring before installation. Be sure the O-ring face seal is seated and retained properly. - Page 28 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting. Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks. Genie Telehandlers Part No. 1272858...
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Page 29: Maintenance Procedures
Repair any machine damage or malfunction before operating the machine. Use only Genie approved replacement parts. Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection. - Page 30 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. Genie Telehandlers Part No. 1272858...
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Page 31: Maintenance Schedule
Quarterly and Annually Example: If this box is empty: the maintenance checklist will include multiple time intervals, use this box to write in the specific interval for the inspection completed. Part No. 1272858 Genie Telehandlers... -
Page 32: Pre-Delivery Preparation Report
Maintenance Manual September 2016 Pre-Delivery Preparation Report Pre-Deliv ery Prepar ati on Repor t Fundamentals Instructions It is the responsibility of the owner or dealer to Use the operator’s manual on your machine. perform the Pre-delivery Preparation. The Pre-delivery Preparation consists of The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the each delivery. -
Page 33: Scheduled And Programmed Maintenance Inspection Report
Inspect the Forks ∅ ∅ ∅ ∅ ∅ ∅ Engines - all models, 3000 HRS P3-1 Adjust the Boom Chains - GTH-636, GTH-844 ∅ ∅ ∅ ∅ ∅ ∅ Adjust the Boom Chains - GTH-1056 Engines - all models, 4000 HRS P4-1 ∅... -
Page 34: Commissioning Procedures
Replace the Hydraulic Filters John Deere Models • Engine oil - replace • Engine filter - replace Required maintenance procedures and additional engine information are available in the manufacturer's manuals. Refer to Specifications, Engine Operator and Maintenance Manuals Genie Telehandlers Part No. 1272858... -
Page 35: Perform 150 Hour Service
150 hours of usage. After this interval, refer to the maintenance tables for continued scheduled maintenance. Perform the following maintenance procedures: Visual Inspection of the Hydraulic Oil Part No. 1272858 Genie Telehandlers... -
Page 36: Quarterly Maintenance Procedures
Select "Customer Login" to login or select your machine has no open bulletins is to frequently "Request New Access" to create a new check the serial number of your Genie machine account. against our bulletin database. Using the links below you can view any open bulletins for your machine(s) At the homepage, select "Unit Configuration"... -
Page 37: Battery Inspection
Put on protective clothing and eye wear. Remove the battery vent caps and check the specific gravity of each battery cell with a Genie specifications require that this procedure be hydrometer. Note the results. performed quarterly. Check the ambient air temperature and adjust... -
Page 38: Inspect The Electrical Wiring
• Add 0.004 to the reading of each cell for every 10° F / 5.5° C above 80° F / 26.7° C. Genie specifications require that this procedure be • Subtract 0.004 from the reading of each cell performed quarterly. -
Page 39: Check The Boom Wear Pads
Check the Boom Wear Pads Crushing hazard. Death or serious injury could result if the boom should unexpectedly fall Genie specifications require that this procedure be while working underneath the performed quarterly. boom. Do not stand or work beneath a boom that is not GTH-636, GTH-844, GTH-1056 properly supported. - Page 40 Side wear pad thickness, minimum 3/8 inch How to Replace the Boom Wear Pads 9.5 mm 1 Maximum wearing thickness 2 Minimum wearing thickness Boom Wear Pad Screws Tightening Specifications Screws M10 22 ft-lbs 30 Nm Genie Telehandlers Part No. 1272858...
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Page 41: Check The Exhaust System
Q-6 Ins pect the Tir es, W heels and Lug N ut T orque Check the Exhaust System Inspect the Tires, Wheels and Lug Nut Torque Genie specifications require that this procedure be performed quarterly. Maintaining the exhaust system is essential to good engine performance and service life. -
Page 42: Inspect The Fork Level And Auxiliary Hydraulic Hoses Tension
Inspect the Fork Level and Inspect the Fuel and Hydraulic Auxiliary Hydraulic Hoses Tank Cap Venting Systems Tension Genie specifications require that this procedure be performed quarterly. Genie specifications require that this procedure be performed quarterly. Perform this procedure more often if dusty conditions exist. - Page 43 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat this procedure beginning with step 2. Install the breather cap onto the hydraulic tank. Part No. 1272858 Genie Telehandlers...
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Page 44: Visual Inspection Of The Hydraulic Oil
• Color: oil should be a clear, light-honey colored • Appearance, oil should be clear and not Genie specifications require that this procedure be cloudy or visibly distorts the view through performed quarterly. the sight glass or container Replacement or testing of the hydraulic oil is •... -
Page 45: Inspect The Engine Air Filter
Q-11 Lubricate the Driv es haft Q-11 Inspect the Engine Air Filter Lubricate the Driveshaft Genie specifications require that this procedure be Genie specifications require that this procedure be performed quarterly. performed quarterly. Perform this procedure more often if dusty Greasing the specified locations is essential for conditions exist. -
Page 46: Inspect And Lubricate The Sequencing Chains
GTH-844 and GTH-1056 GTH-636, GTH-844 and GTH-1056 models • Elongation • BL666 chain - Measure 16 pitches of the Genie specifications require that this procedure be extend chain for machines using performed quarterly. BL666 chain. In extremely dusty or hostile environments, it may be necessary to lubricate the chains more often. -
Page 47: September
All excess lubricant should be wiped away from the external surfaces. Note: Do not use solvents to remove excess lubricant. Part No. 1272858 Genie Telehandlers... -
Page 48: Annual Maintenance Procedures
Maintenance Manual September 2016 Annual Maintenance Procedures Annu al Mainten ance Pro cedur es A-2 Adj ust the Boom Sequencing C hai ns - GTH-636 and GTH-844 A-1 Ins pect the F orks Adjust the Boom Sequencing Inspect the Forks... -
Page 49: Adjust The Boom Sequencing Chains - Gth-1056
4. Note the measurement (2). Genie specifications require that this procedure be Result: The difference between performed annually. measurements 1 and 2 is 0.25 to 0.5 inch / 6.35 to 12.7 mm. -
Page 50: Adjust The Boom Sequencing Chains - Gth-1256 And Gth-1544
Repeat this procedure beginning with step 4 until the gap is between 0.25 to 0.5 inch / 6.35 to Genie specifications require that this procedure be 12.7 mm. performed annually. Note: If the adjusting bolt runs out of threads before... -
Page 51: Replace Hydraulic Tank Return Filter Element
Replace Hydraulic Tank Return Replace the Cab Air Intake Filter Filter Element Element (if equipped) Genie specifications require that this procedure be Genie specifications require that this procedure be performed annually. performed annually. Perform this procedure more often if dusty Perform this procedure more often if dusty conditions exist. -
Page 52: Programmed Maintenance Procedures
1 boom tube lower wear pads. Lubricate the top and side boom tube wear pads. Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes Return the boom to the stowed position. first. -
Page 53: P0-2 Deutz Engine Maintenance - Under 1000 Hours
Air filter - replace ∅ ∅ Valve clearance - check/adjust ∅ ∅ Engine coolant - test/add ∅ ∅ Air intake pipes - inspect ∅ ∅ V-belts - inspect ∅ ∅ Fuel filter / separator - replace ∅ ∅ Part No. 1272858 Genie Telehandlers... -
Page 54: P0-3 Perkins Engine Maintenance - Under 1000 Hours
∅ ∅ Engine oil and filter – replace ∅ ∅ Fuel system filter(s) - replace ∅ ∅ Radiator – clean ∅ ∅ Air cleaner element - clean/replace ∅ ∅ Fan clearance - check ∅ ∅ Genie Telehandlers Part No. 1272858... -
Page 55: P0-4 John Deere Engine Maintenance - Under 1000 Hours
Air intake system - inspect ∅ Cooling system - check ∅ Engine ground - check ∅ Air filter - replace ∅ Engine belts - check/adjust/replace ∅ Fuel system - check ∅ Fuel filter - replace ∅ Part No. 1272858 Genie Telehandlers... -
Page 56: P0-5 Axle Maintenance - Under 1000 Hours
Magnetic plug - clean (initial, one-time interval) ∅ ∅ Axle - grease ∅ ∅ Differential lubricating oil - check/add ∅ ∅ Planetary reduction lubricating oil - check/add ∅ ∅ Oil breather - clean ∅ ∅ Genie Telehandlers Part No. 1272858... - Page 57 Planetary reduction lubricating oil - check/add ∅ ∅ ∅ ∅ ∅ Service brake - adjust ∅ ∅ ∅ ∅ ∅ Differential oil - change ∅ ∅ ∅ ∅ ∅ Differential lubricating oil - change ∅ ∅ ∅ ∅ ∅ Part No. 1272858 Genie Telehandlers...
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Page 58: P0-6 Transmission Maintenance - Under 1000 Hours
Drop box oil level - check/add ∅ Transmission filter - replace (initial, one-time interval) ∅ Transmission oil - replace (initial, one-time interval) ∅ *check oil with engine running at idle and oil at 180-200° F / 65-93° C Genie Telehandlers Part No. 1272858... -
Page 59: P1-1 Perform Engine Maintenance - 1000 Hours
• Battery and cable connectors - check • Cold starting device (if equipped) - check Perkins Models 854E-E34TA, 1204E-E44TA • Water pump - inspect • Engine crankcase breather element - replace 1104D-E44TA • Engine valve lash - inspect/adjust Part No. 1272858 Genie Telehandlers... -
Page 60: P1-3 Perform Axle Maintenance - 1000 Hours
Carraro 26.27M Models • Change axle oil 1500 hrs • Clean magnetic oil plugs 1500 hrs Comer Models • Differential lubricating oil - change • Planetary reduction lubricating oil - change • Magnetic plug - clean Genie Telehandlers Part No. 1272858... -
Page 61: P2-1 Perform Engine Maintenance - 2000 Hours
• Thermostats - test • Exhaust gas recirculation, rods clearance - check/adjust • Engine valve clearance check and adjust • Fuel pre-filter - replace • Cooling system - flush and refill • Coolant - replace Part No. 1272858 Genie Telehandlers... -
Page 62: P2-2 Test Or Replace The Hydraulic Oil
If the hydraulic oil passes testing at the 2000 hour maintenance interval, the oil must Genie requires that this procedure be performed be tested every quarter by an oil distributor every 2000 hours. until the oil fails the test and is replaced. -
Page 63: P3-1 Perform Engine Maintenance - 3000 Hours
John Deere 4045HF485 - 4500 Hours • Diesel Particulate Filter - clean • Crankshaft damper - replace • Radiator Pressure Cap - clean/replace 1204E-E44TA • Radiator Pressure Cap - clean/replace • Belt tensioner - inspect Part No. 1272858 Genie Telehandlers... -
Page 64: P6-1 Perform Engine Maintenance - 6000 Hours
Perkins Models TCD 4.1 L4 854E-E34TA, 1104D-E44TA, 1204E-E44TA • Crankcase breather valve - replace • Cooling System Coolant (Extended life coolant) - change Genie Tel ehandl ers Part No. 1272858 Maintenanc e M anual September 2016 Genie Telehandlers Part No. 1272858... - Page 65 California Proposition 65 WARNING Operating, servicing and maintaining this equipment, passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.