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GTH-636
Genie GTH-636 Manuals
Manuals and User Guides for Genie GTH-636. We have
4
Genie GTH-636 manuals available for free PDF download: Service Manual, Service And Repair Manual, Maintenance Manual
Genie GTH-636 Service Manual (196 pages)
Brand:
Genie
| Category:
Front End Loaders
| Size: 4.32 MB
Table of Contents
Table of Contents
7
Introduction
2
Serial Number Legend
3
Safety Rules
5
Personal Safety
6
Table of Contents
7
Machine Specifications
15
Performance Specifications
17
Hydraulic Specifications
18
Manifold Component Specifications
20
John Deere 4045TF270 Engine
21
John Deere 4045TF275 Engine
22
Deutz BF4 2012 Engine
23
Perkins 1104C-44T Engine
24
Perkins 1104C-44TA Engine
25
Dana T12000 Transmission
26
Dana T20000 Transmission
26
Dana Planetary 212 Drive Axle
27
Dana Planetary 213 Drive Axle
27
Specifications
27
Hydraulic Hose and Fitting Torque Specifications
28
About this Section
31
Observe and Obey
31
Pre-Delivery Preparation Report
32
Maintenance Inspection Report
35
C Checklist a Procedures
37
Inspect the Manuals and Decals
37
Perform Pre-Operation Inspection
38
Perform Function Tests
38
Lubricate the Machine
39
Perform Engine Maintenance - John Deere and Perkins Models
41
Perform Transmission Maintenance
41
Perform Engine Maintenance - Deutz Models
42
Perform 30 Day Service
42
Perform Transmission Maintenance
43
And GTH-844 Models
43
Perform Engine Maintenance - Perkins Models
43
Perform Axle Maintenance
44
Perform Engine Maintenance - John Deere Models
44
And GTH-844 Models
44
Perform Transmission Maintenance
45
A-15 Perform Axle Maintenance
46
B Checklist B Procedures
47
Inspect the Battery
47
Inspect the Electrical Wiring
47
Check the Exhaust System
48
Inspect the Engine Air Filter
49
Inspect the Tires, Wheels and Lug Nut Torque
49
Perform Hydraulic Oil Analysis
50
Inspect the Fuel and Hydraulic Tank Cap Venting Systems
51
Check the Boom Wear Pads
52
Lubricate the Driveshafts
53
Perform Engine Maintenance - John Deere Models
53
B Checklist C Procedures
54
Perform Engine Maintenance - Deutz Models
54
Perform Engine Maintenance - John Deere Models
54
Perform Axle Maintenance
55
Perform Transmission Maintenance
55
Perform Engine Maintenance - Perkins Models
56
Perform Axle Maintenance
56
Perform Axle Maintenance
57
B Checklist D Procedures
58
Inspect the Forks
58
Adjust the Boom Sequencing Chains
58
Replace the Hydraulic Tank Return Filter Element
61
Perform Engine Maintenance - Deutz Models
62
Perform Transmission Maintenance
62
Perform Axle Maintenance
63
Perform Engine Maintenance - Perkins Models
63
Perform Engine Maintenance - Deutz Models
64
C Checklist E Procedures
65
Test or Replace the Hydraulic Oil
65
Perform Engine Maintenance - John Deere Models
66
Perform Engine Maintenance - Perkins Models
66
Perform Engine Maintenance - Perkins Models
67
Perform Engine Maintenance - John Deere Models
68
Perform Engine Maintenance - Perkins Models
68
Perform Engine Maintenance - Deutz Models
69
Perform Engine Maintenance - Perkins Models
69
Repair Procedures
71
Boom Components
72
Boom Angle Limit Switch (All Models Except GTH-636)
72
Boom
73
Bodily Injury Hazard. Spraying
76
Boom Lift Cylinder
85
Boom Extension Cylinder
87
Fork Level Cylinder
88
Fork Rotate Cylinder (Option)
90
Operator's Compartment
93
Electrocution Hazard. Contact with Electrically Charged Circuits Could Result in Death or Serious Injury
93
Machine Controls
102
Fuel and Hydraulic Tanks
108
Fuel Tank
108
Hydraulic Tank
109
Gradually. Do Not Allow Oil to Squirt
109
Engines
110
Engine Fault Codes - John Deere 4045TF275 Engine
111
Transmission
112
Hydraulic Pumps
114
Hydraulic Pump
114
Or Spray
116
Main Valve Manifold Components
118
Tilt Limiter Manifold Components
119
Dual Pilot Check Manifold Components
120
Boom Activated Rear Lock-Up Manifold Components
121
Fork Rotate Speed Manifold Components (Option)
122
Control Block Manifold Components
123
Fork Tilt Manifolds Components
124
Rear Lock-Up Manifold Components
125
Parking Brake Manifold Components
126
Differential Lock-Up Manifold Components (Optional on GTH-636 and GTH-644)
127
Sway Manifold Components
128
Fork Rotate Manifold Components (Option)
129
Sway Directional Manifold Components
130
Outrigger Manifold Components - GTH-1048 and GTH-1056
131
Controller Relief (Drop Block) Manifold
132
GTH-636, GTH-1048 and GTH-1056
132
Boom Lift and Boom Extension Cylinders Manifold Components
133
Fork Level Cylinder Manifold Components
134
Fork Rotate Cylinder Manifold Components (Option)
135
Pump Destroke Manifold Components
136
GTH-636, GTH-1048 and GTH-1056
137
Boom Activated Sway Lock-Up Manifold Components
138
Valve Adjustments - Control Block Manifold
139
Valve Adjustments - Tilt Limiter Manifold
141
Valve Coils
142
Remove All Rings, Watches and Other Jewelry
142
Axles
143
To Adjust Front Axle Service Brakes
144
To Adjust Parking Brakes
144
Outriggers
146
Immediately Tag and Remove from Service a Damaged or Malfunctioning Machine
149
Repair any Machine Damage or Malfunction before Operating the Machine
149
Troubleshooting and Repair Procedures Shall be Completed by a Person Trained and Qualified on the Repair of this Machine
149
Before Troubleshooting
149
Be Sure that All Necessary Tools and Test Equipment Are Available and Ready for Use
149
Read, Understand and Obey the Safety Rules and Operating Instructions in the Appropriate Operator's Manual on Your Machine
149
Malfunction Discovered
149
Return to Service
149
General Repair Process
149
Identify Symptoms
149
Engine Fault Codes - GTH-1048 and GTH-1056
150
Hydraulic Pump
152
Boom Functions
154
Drive Functions
161
Steer Functions
162
Brake Functions
165
Sway Functions
166
Connections very Slowly to Allow
169
Hydraulic Oil Can Penetrate and Burn Skin. Loosen Hydraulic
169
The Oil Pressure to Dissipate
169
Schematics
171
Electrical Component and Limit Switch Legends
172
Section 6 • Schematics
172
Electrical and Hydraulic Symbols Legends
173
Electrical Schematics
173
Hydraulic Schematics
173
Electrical Schematic - GTH-636 with John Deere Power
174
C Electrical Schematic
176
And GTH-844 with John Deere Power
178
Electrical Schematic - GTH-636 with Perkins Power
176
Electrical Schematic - GTH-644, GTH-842 and GTH-844 with Perkins Power
180
Electrical Schematic - GTH-644, GTH-842 and GTH-844 with Deutz Power
182
Electrical Schematic - GTH-1048 and GTH-1056 with John Deere Power
184
Electrical Schematic - GTH-1048 and GTH-1056 with Perkins Power
186
With Single Joystick
186
A Hydraulic Schematic
188
Hydraulic Schematic GTH-636 with Single Joystick
188
GTH-636 with Dual Joysticks
189
B Hydraulic Schematic
189
Hydraulic Schematic GTH-636 with Dual Joysticks
189
And GTH-844 with Single Joystick
190
A Hydraulic Schematic
190
Hydraulic Schematic GTH-644, GTH-842 and GTH-844 with Single Joystick
190
GTH-644, GTH-842 and GTH-844 with Dual Joysticks
191
A Hydraulic Schematic
192
GTH-1048 and GTH-1056 with Dual Joysticks
193
Hydraulic Schematic - GTH-1048 and GTH-1056 with Single Joystick
192
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Genie GTH-636 Service And Repair Manual (187 pages)
Brand:
Genie
| Category:
Lifting Systems
| Size: 12.29 MB
Table of Contents
Find a Manual for this Model
2
April
4
Serial Number Legend
4
Safety Rules
5
April
6
Table of Contents
7
Specifications
13
Machine Specifications
13
Performance Specifications
14
Hydraulic Oil Specifications
15
Hydraulic Component Specifications
18
Manifold Component Specifications
19
Air Conditioner Refrigerant Specifications
19
DEF Storage Specifications
20
Deutz TCD3.6 L4 Engine Specifications
21
Deutz TCD3.6 L4 T4F Engine Specifications
22
Perkins 1104D-E44TA Engine Specifications
23
Perkins 854E-E34TA Engine Specifications
24
Dana VDT12000 Transmission Specifications
25
Carraro 26.27M Drive Axle Specifications
25
Hydraulic Hose and Fitting Torque Specifications
26
Torque Procedure
27
Repair Procedures
29
Introduction
29
Boom Components
31
Boom Proximity Switch
31
How to Test a Proximity Switch
31
How to Adjust the Boom Angle Proximity Switch
32
Boom
32
How to Replace the Boom Wear Pads
32
How to Remove the Lifting Fork Frame
33
How to Replace the Retraction Chain
33
April
34
How to Replace the Extension Chains
35
How to Remove the Boom
36
How to Disassemble the Boom
38
Boom Lift Cylinder
40
Boom Extension Cylinder
41
Fork Level Cylinder
41
Hydraulic Hoses
42
How to Adjust the Fork Level Cylinder And/Or Auxiliary Hose
42
How to Replace the Fork Level Cylinder And/Or Auxiliary Hoses
43
Operator's Compartment
45
Machine Controls
47
How to Remove the Steering Column
47
How to Remove the Steering Wheel
47
How to Remove the Steer Orbitral
48
How to Remove the Joystick - Models with Single Joystick
48
How to Remove the Joystick - Models with Dual Joysticks
49
How to Remove the Brake Pedal Assembly
49
How to Remove the Gauge Cluster Assembly
50
Fuel and Hydraulic Tanks
51
Engines
53
How to Repair the Perkins 1104D-E44TA Engine
53
How to Repair the Perkins 854E-34TA Engine
53
How to Repair the Deutz TCD3.6 Engine
53
Engine Fault Codes
54
Transmission
55
Hydraulic Pump
55
How to Test the Function Pump
55
How to Remove the Function Pump
56
How to Install the Function
57
How to Prime the Function Pump
57
How to Adjust the Function Pump Standby Pressure
58
April
58
How to Adjust the Function Pump Pressure Compensator
59
Manifolds
60
Primary Function Manifold Components - Models with Single Joystick
60
Primary Function Manifold Components - Models with Dual Joysticks
64
Secondary Function Manifold Components
66
Auxiliary Manifold (Option) and Brake Manifold Components
68
Valve Adjustments - Secondary Function Manifold
69
How to Set the Steer System Pressure
69
How to Set the Parking Brake System Pressure
70
How to Set the Differential Lock/Joystick System Pressure
71
How to Set the Rear Lock-Up System Pressure
72
Valve Coils
73
Axle
75
Axles
75
Fault Codes
76
Introduction
76
Section 4 Fault Codes
76
Diagnostic Display
77
Deutz TCD3.6 Engine Fault Codes
78
Perkins 1104 Engine Fault Codes
102
Schematics
104
Introduction
104
Section 5 Schematics
104
Fuse Panel Layout (to 20629)
105
Fuse Panel Layout (from 20630 to 21535)
106
Deutz TCD3.6 T4F Module (from 21536, 16E-10000)
107
Electrical Component & Wire Color Abbreviation Legend
108
Telematics Connector Pin Legend
111
Electrical Symbol Legend
113
Hydraulic Symbols Legend
114
Electrical Schematics - Harness Maps
115
April
115
Harness Map - Control System Power Single Joystick (to 15-20661)
116
Harness Map - Control System Ground Single Joystick (to 15-20661)
117
Harness Map - Control System Power Single Joystick (from 15-20662 to 21535)
120
Harness Map - Control System Ground Single Joystick (from 15-20662 to 21535)
121
Harness Map - Control System Power Single Joystick (from 15-21536, 16E-10000)
124
Harness Map - Control System Ground Single Joystick (from 15-21536, 16E-10000)
125
Harness Map - Control System Power Dual Joystick (to 15-20661)
128
Harness Map - Control System Ground Dual Joystick (to 15-20661)
129
Harness Map - Control System Power Dual Joystick (from 15-20662 to 21535)
132
Harness Map - Control System Ground Dual Joystick (from 15-20662 to 21535)
133
Harness Map - Control System Power Dual Joystick (from 15-21536, 16E-10000)
136
Harness Map - Control System Ground Dual Joystick (from 15-21536, 16E-10000)
137
Harness Map - Deutz TCD3.6 T3_T4I Engine Battery Power and Ground
140
Harness Map - Deutz TCD3.6 T4F Engine Battery Power and Ground
141
Harness Map - Perkins 1104D Engine Battery Power and Ground
144
Harness Map - Perkins 854E T4I Engine Battery Power and Ground
145
Harness Map - Perkins 854E T4I Engine Battery Power and Ground
148
Harness Map - Options Auxiliary Hydraulics, Beacon and 3Rd Gear Lockout
149
Harness Map - Options Work Lights (to 15-21456)
152
Harness Map - Options Work Lights (from 15-21457, 16E-10000)
153
Harness Map - Options Road Lights (to 15-20456)
156
Harness Map - Options Road Lights (from 15-21457, 16E-10000)
157
Harness Map - Options Enclosed Cab with Heater
160
Harness Map - Options Enclosed Cab with HVAC
161
Electrical Schematics
163
Electrical Schematic - View 1 (to 15-20661)
164
Electrical Schematic - View 2 (to 15-20661)
165
Electrical Schematic - View 1 (from 15-20662 to 21456)
168
Electrical Schematic - View 2 (from 15-20662 to 21456)
169
Electrical Schematic - View 1 (from 15-21457 to 21535)
172
Electrical Schematic - View 2 (from 21457 to 21535)
173
Electrical Schematic - View 1 (from 15-21536, 16E-10000)
176
Electrical Schematic - View 2 (from 21536, 16E-10000)
177
Hydraulic Schematics
179
Hydraulic Schematic - Single Joystick (to 19528)
180
Hydraulic Schematic - Single Joystick (from 19529, 16E-10000)
181
Hydraulic Schematic - Dual Joystick (to 19528)
184
Hydraulic Schematic - Dual Joystick (from 19529, 16E-10000)
185
Genie GTH-636 Service And Repair Manual (109 pages)
Brand:
Genie
| Category:
Lifting Systems
| Size: 4.58 MB
Table of Contents
Table of Contents
7
Introduction
2
Find a Manual for this Model
2
Read, Understand and Obey the Safety Rules and Operating Instructions in the Appropriate Operator's Manual on Your Machine
2
Serial Number Legend
4
Safety Rules
5
Table of Contents
7
Specifications
11
Machine Specifications
11
Performance Specifications
11
Hydraulic Oil Specifications
12
Hydraulic Component Specifications
15
Manifold Component Specifications
15
Air Conditioner Refrigerant Specifications
15
Deutz TD 2.9 Engine Specifications
16
Dana VDT12000 Transmission Specifications
17
Dana 212 Drive Axle
17
Hydraulic Hose and Fitting Torque Specifications
18
Torque Procedure
19
Repair Procedures
21
Introduction
21
Immediately Tag and Remove from Service a
21
Observe and Obey
21
About this Section
22
Boom Components
23
Boom
23
How to Replace the Boom Wear Pads
23
How to Use the Quick Attachment
23
How to Replace the Retraction Chain
24
How to Replace the Extension Chains
26
How to Remove the Boom
28
How to Disassemble the Boom
30
Boom Lift Cylinder
31
April
31
Bodily Injury Hazard. Spraying
31
Boom Extension Cylinder
32
Fork Level Cylinder
33
Hydraulic Hoses
34
How to Adjust the Fork Level Cylinder And/Or Auxiliary Hose
34
How to Replace the Fork Level Cylinder And/Or Auxiliary Hoses
35
Operator's Compartment
37
Machine Controls
38
How to Remove the Steering Column
38
How to Remove the Steer Orbitral
39
How to Remove the Steering Wheel
39
How to Remove the Brake Pedal Assembly
40
How to Remove the Joystick - Models with Electronic Joystick
40
How to Remove the Gauge Cluster Assembly
41
Fuel and Hydraulic Tanks
42
Engines
44
Engine Fault Codes
44
Transmission
45
Hydraulic Pump
46
How to Test the Function Pump
46
How to Remove the Function Pump
47
How to Install the Function
48
How to Prime the Function Pump
48
How to Adjust the Function Pump Standby Pressure
49
How to Adjust the Function Pump Pressure Compensator
50
Manifolds
51
PVG Manifold Components - Electronic Joystick
51
April
51
Secondary Function Manifold Components
52
Brake Manifold Components
55
Valve Adjustments - Secondary Function Manifold
56
How to Set the Parking Brake System Pressure
56
How to Set the Differential Lock System Pressure
57
Valve Coils
58
Axle
60
Axles
60
Connections very Slowly to Allow
60
Gradually. Do Not Allow Oil to
60
Hydraulic Oil Can Penetrate and Burn Skin. Loosen Hydraulic
60
Squirt or Spray
60
The Oil Pressure to Dissipate
60
Fault Codes
61
Introduction
61
Be Sure that All Necessary Tools and Test Equipment Are Available and Ready for Use
61
Before Troubleshooting
61
Contact with Electrically Charged Circuits Could Result in Death or Serious Injury. Remove All Rings, Watches and Other Jewelry
61
Damaged or Malfunctioning Machine
61
Electrocution/Burn Hazard
61
Repair any Machine Damage or Malfunction before Operating the Machine
61
Troubleshooting and Repair Procedures Shall be Completed by a Person Trained and Qualified on the Repair of this Machine
61
Diagnostic Display
62
Deutz TD 2.9 L4 Engine Fault Codes
63
Schematics
77
Introduction
77
Fuse Panel Layout
78
Electrical Component & Wire Color Abbreviation Legend
79
Telematics Connector Pin Legend
82
Electrical Symbol Legend
84
Hydraulic Symbols Legend
85
Harness Map Legend
86
Electrical Schematics - Harness Maps
87
April
87
Harness Map - Control System Power Electronic Joystick
88
Harness Map - Deutz TD2.9 Engine Battery Power and Ground
90
Harness Map - Options Auxiliary Hydraulics, Beacon and 3Rd Gear Lockout
91
Harness Map - Options Work Lights
94
Harness Map - Options Road Lights
95
Harness Map - Options Enclosed Cab with Heater
98
Harness Map - Options Enclosed Cab with HVAC
99
Electrical Schematics
101
Electrical Schematic - View 1
102
Electrical Schematic - View 2
103
Electrical Schematic - Deutz T4F Eng Harness
106
Hydraulic Schematic
107
Hydraulic Schematics
108
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Genie GTH-636 Maintenance Manual (65 pages)
Telehandlers
Brand:
Genie
| Category:
Forklifts
| Size: 1.04 MB
Table of Contents
Introduction
3
Models Included in this Manual
3
Identifying the Correct Procedure for Your Model
3
Find Additional Manuals for Your Model
3
Revision History
4
Safety Rules
6
Table of Contents
8
Specifications
11
Machine Specifications
11
Air Conditioner Refrigerant Specifications
12
September
12
Performance Specifications
13
September
14
Torque Specifications
15
Tires and Wheels
15
September
15
Powertrain Specifications
16
Operator and Maintenance Manuals
16
September
16
Deutz Engine Models
17
John Deere Engine Models
17
Perkins Engine Models
18
Transmission Specifications
19
Axle Specifications
20
Hydraulic Specifications
21
Hydraulic Relief Valves
21
Hydraulic Oil Specifications
23
Hydraulic Hose and Fitting Torque Specifications
26
Torque Procedure
27
September
27
Maintenance Procedures
29
Introduction
29
Section 3 Maintenance Procedures
29
Maintenance Schedule
31
Pre-Delivery Preparation Report
32
Scheduled and Programmed Maintenance Inspection Report
33
Commissioning Procedures
34
Perform 50 Hour Service
34
Perform Engine Maintenance - 50 Hours
34
Perform 150 Hour Service
35
Quarterly Maintenance Procedures
36
Check for Open Bulletins and Owner Registration
36
Battery Inspection
37
Inspect the Electrical Wiring
38
Check the Boom Wear Pads
39
Check the Exhaust System
41
Inspect the Tires, Wheels and Lug Nut Torque
41
Inspect the Fork Level and Auxiliary Hydraulic Hoses Tension
42
Inspect the Fuel and Hydraulic Tank Cap Venting Systems
42
Visual Inspection of the Hydraulic Oil
44
Inspect the Engine Air Filter
45
Lubricate the Driveshaft
45
Inspect and Lubricate the Sequencing Chains
46
September
47
Annual Maintenance Procedures
48
Inspect the Forks
48
Adjust the Boom Sequencing Chains - GTH-636 and GTH-844
48
Adjust the Boom Sequencing Chains - GTH-1056
49
Adjust the Boom Sequencing Chains - GTH-1256 and GTH-1544
50
Replace Hydraulic Tank Return Filter Element
51
Replace the Cab Air Intake Filter Element (if Equipped)
51
Programmed Maintenance Procedures
52
P0-1 Lubricate the Boom
52
P0-2 Deutz Engine Maintenance - under 1000 Hours
53
P0-3 Perkins Engine Maintenance - under 1000 Hours
54
P0-4 John Deere Engine Maintenance - under 1000 Hours
55
P0-5 Axle Maintenance - under 1000 Hours
56
P0-6 Transmission Maintenance - under 1000 Hours
58
P1-1 Perform Engine Maintenance - 1000 Hours
59
P1-2 Performtransmission Maintenance - 1000 Hours
59
P1-3 Perform Axle Maintenance - 1000 Hours
60
P2-1 Perform Engine Maintenance - 2000 Hours
61
P2-2 Test or Replace the Hydraulic Oil
62
P3-1 Perform Engine Maintenance - 3000 Hours
63
P4-1 Perform Engine Maintenance - 4000 Hours
63
P6-1 Perform Engine Maintenance - 6000 Hours
64
P12-1 Perform Engine Maintenance - 12000 Hours
64
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