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Maintenance Manual -
Telehandlers
GTH
-636
™
GTH
-844
™
GTH
-1056
™
GTH
-1256
™
Refer to the inside cover for a list of model serial
number ranges 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.
Original Instructions
Part No. 1305161GT
Rev A
November 2022
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Table of Contents
Related Manuals for Terex Genie GTH-636
Summary of Contents for Terex Genie GTH-636
- Page 1 Maintenance Manual - Telehandlers -636 ™ This manual includes detailed procedures for each -844 ™ maintenance inspection. -1056 ™ For Repair procedures, Fault Codes, Electrical and Hydraulic -1256 ™ Schematics, refer to the appropriate Service and Repair Manual for your machine. Refer to the inside cover for a list of model serial Original Instructions number ranges included in this manual.
- Page 2 Unrestricted with proper operation, inspection and Second Edition, First Printing scheduled maintenance. 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. Genie Telehandlers...
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Page 3: Introduction
November 2022 Maintenance Manual Introduction Models included in this manual Identifying the Correct Procedure for your Model Use the following chart to identify the specific serial number for models included in this manual. Unless otherwise noted, each procedure will apply to all models. -
Page 4: Revision History
Maintenance Manual November 2022 Introduction Revision History Revision Date Section Procedure / Description 11/2022 Initial Release Reference Examples: Section – Specifications Electronic Version Click on any content or procedure in the Table of Contents to view the Section – Maintenance, (procedure) update. -
Page 5: Safety Rules
November 2022 Maintenance Manual 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. - Page 6 Maintenance Manual November 2022 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.
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Page 7: Table Of Contents
November 2022 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Models included in this manual ................iii Identifying the Correct Procedure for your Model ..........iii Find additional Manuals for your Model ..............iii Revision History..................... iv Section 1 Safety Rules ...................... - Page 8 November 2022 Table of Contents Section 3 Maintenance Procedures .................. 14 Introduction ......................14 Maintenance Schedule ..................16 Pre-Delivery Preparation Report ................17 Scheduled and Programmed Maintenance Inspection Report ......18 Commissioning Procedures ................19 C-1 Perform 50 Hour Service ................19 C-2 Perform Engine Maintenance –...
- Page 9 November 2022 Table of Contents Programmed Maintenance Procedures ............36 P0-1 Lubricate the Boom ..................36 P0-2 Deutz Engine Maintenance – Under 1000 Hours ........37 P0-3 Axle Maintenance – Under 1000 Hours ............38 P0-4 Transmission Maintenance – Under 1000 Hours ........39 P1-1 Perform Engine Maintenance –...
- Page 10 Maintenance Manual November 2022 This page intentionally left blank. Genie Telehandlers Part No. 1305161GT...
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Page 11: Specifications
November 2022 Maintenance Manual Specifications Section 2 Specific ati ons Fluid capacities Air Conditioner Refrigerant Specifications GTH-636 Fuel tank 27 gallons System Full Charge R134a 102,2 liters GTH-636 / 844 / 1056 / 1256 1 lb 14 oz Hydraulic tank 34 gallons 128,7 liters 46.5 gallons... -
Page 12: Performance Specifications
Maintenance Manual November 2022 Performance Specifications GTH-636 GTH-1056 Drive speed, maximum Drive speed, maximum Deutz TD 2.9 L4 18 mph Deutz TCD 3.6 L4, 121 hp 17 mph 29,0 km/h 27,4 km/h Deutz TCD 3.6 L4, 74 hp, 15 mph Draw bar pull 15100 lbs 3 speed... - Page 13 November 2022 Maintenance Manual Performance Specifications GTH-1256 Drive speed, maximum Deutz TCD 3.6 L4, 121 hp 17 mph 27,4 km/h Draw bar pull, 121 hp 25000 lbs 10206 kg Lift capacity, maximum 12000 lbs 5450 kg Boom function speeds, maximum Boom up 19 - 23 seconds Boom down...
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Page 14: Torque Specifications
Maintenance Manual November 2022 Torque Specifications Tires and wheels Torque values are listed as dry. Note: The tires on some machines are foam-filled or solid rubber and do not need air added to them. GTH-636 Lug nut torque 465 ft-lb 630 Nm Tire pressure 72 psi... -
Page 15: Powertrain Specifications
November 2022 Maintenance Manual Powertrain Specifications Deutz Engine Models Engine Operator and Maintenance Manuals TD 2.9 L4 T4F Low idle 1000 rpm Deutz TD 2.9 L4 High idle 2600 rpm Genie part number 1251561GT Oil capacity (including filter) 9.4 quarts Deutz TCD 3.6 L4 9 liters Genie part number... -
Page 16: Transmission Specifications
Maintenance Manual November 2022 Powertrain Specifications Dana Transmission Models Dana Axle Models Dana VDT12004 Dana 212 drive axle Transmission type: 3 speed powershift Front axle lubrication Oil capacity, transmission 14.3 quarts Front differential 7.4 quarts 13,5 liters 7 liters 1.1 quarts 0.8 quarts Oil capacity, drop box Axle planetary end (each) -
Page 17: Hydraulic Specifications
November 2022 Maintenance Manual Hydraulic Specifications GTH-636 GTH-1056 Primary Function Manifold Primary Function Manifold 3200 psi 3200 psi System relief valve pressure, maximum System relief valve pressure, maximum 221 bar 221 bar 3500 psi 2611 psi Fork tilt relief valve pressure, maximum Boom extend relief valve pressure, 241 bar maximum... -
Page 18: Hydraulic Oil Specifications
Maintenance Manual November 2022 Hydraulic Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. 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 19 November 2022 Maintenance Manual Hydraulic Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index, maximum Viscosity index, maximum Kinematic Viscosity, maximum Kinematic Viscosity, maximum cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5...
- Page 20 Maintenance Manual November 2022 Hydraulic Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index, maximum Viscosity index, maximum Kinematic Viscosity, maximum Kinematic Viscosity, maximum cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C...
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Page 21: Hydraulic Hose And Fitting Torque Specifications
November 2022 Maintenance Manual Hydraulic Specifications Hydraulic Hose and Fitting ORFS Hose End Torque Specifications SAE Dash Size Torque 10 - 12 ft-lbs / 14 - 16 Nm Your machine is equipped with Ryco ORFS or 37° JIC fittings and hose ends. Manufactures 18 - 20 ft-lbs / 24 - 27 Nm specifications require that fittings and hose ends 32 - 35 ft-lbs / 43 - 47 Nm... -
Page 22: Torque Procedure
Maintenance Manual November 2022 Hydraulic Specifications Torque Procedure SAE Flange Clamp Bolts Code 61 Seal-Lok™ fittings SAE Dash Size Torque Replace the O-ring. The O-ring must be 15 - 18 ft lbs / 20 - 25 Nm replaced anytime the seal has been broken. 21 - 29 ft lbs / 28 - 40 Nm The O-ring cannot be re-used if the fitting or 27 - 35 ft lbs / 37 - 48 Nm... - Page 23 November 2022 Maintenance Manual Hydraulic Specifications JIC 37° fittings Working clockwise on the body hex fitting, make a second mark with a permanent ink Align the tube flare (hex nut) against the nose marker to indicate the proper tightening of the fitting body (body hex fitting) and position.
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Page 24: Maintenance Procedures
Maintenance Manual November 2022 Maintenance Procedures Machine Configuration: Section 3 Maintenanc e Proc edures Unless otherwise specified, perform each procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Boom in the stowed position Observe and Obey: •... - Page 25 November 2022 Maintenance Manual Maintenance Procedures About This Section Maintenance Symbols Legend Note: The following symbols have been used in This section contains detailed procedures for each this manual to help communicate the intent of the scheduled maintenance inspection. instructions. When one or more of the symbols Each procedure includes a description, safety appear at the beginning of a maintenance warnings and step-by-step instructions.
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Page 26: Maintenance Schedule
Maintenance Manual November 2022 Maintenance Procedures Maintenance Schedule Programmed Example (under 1000 HRS): The maintenance procedures have been divided into subsections that include: Commissioning, Quarterly, Annually and Programmed maintenance intervals. The maintenance inspection report has been divided into general areas of the machine that include: Drive Chassis, Booms and Fork, Functions and Controls and Powertrain. -
Page 27: Pre-Delivery Preparation Report
November 2022 Maintenance Manual Pre-Delivery Preparation Report 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 28: Scheduled And Programmed Maintenance Inspection Report
Scheduled and Programmed November 2022 Maintenance Inspection Report – Telehandlers Model Hour meter Date Serial number Inspector company Machine owner Inspected by (print) Inspector signature Scheduled Maintenance: Legend Make copies of this report to use Programmed Maintenance: Inspection Type for each inspection. Programmed maintenance will be completed based Y = yes, acceptable Q = quarterly or frequent... -
Page 29: Commissioning Procedures
November 2022 Maintenance Manual Commissioning Procedures Perform Engine Maintenance - 50 Perform 50 Hour Service Hours The 50 hour maintenance procedure is a one time sequence of procedures to be performed after the The 50 hour maintenance procedure is a one time first 50 hours of usage. -
Page 30: Perform 150 Hour Service
Maintenance Manual November 2022 Commissioning Procedures Perform 150 Hour Service The 150 hour maintenance procedure is a one time sequence of procedures to be performed after the first 150 hours of usage. After this interval, refer to the maintenance tables for continued scheduled maintenance. -
Page 31: Quarterly Maintenance Procedures
November 2022 Maintenance Manual Quarterly Maintenance Procedures Machines purchased in ASIA, North America and Latin America: Check for Open Bulletins and Owner Registration Go to ASIA, North America and Latin America Bulletins (https://www.gogenielift.com/en/support/safety Genie specifications require that this procedure be performed quarterly. -
Page 32: Battery Inspection
Maintenance Manual November 2022 Quarterly Maintenance Procedures Battery Inspection Inspect the Electrical Wiring Genie specifications require that this procedure be Genie specifications require that this procedure be performed quarterly. performed quarterly. Proper battery condition is essential to good Maintaining electrical wiring in good condition is engine and machine performance and operational essential to safe operation and good machine safety. -
Page 33: Check The Boom Wear Pads
November 2022 Maintenance Manual Quarterly Maintenance Procedures Remove all engine covers, hydraulic tank covers and chassis covers. 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. -
Page 34: Check The Exhaust System
Maintenance Manual November 2022 Quarterly Maintenance Procedures 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. Genie specifications require that this procedure be Operating the engine with a damaged or leaking performed quarterly. -
Page 35: Inspect The Fork Level And Auxiliary Hydraulic Hose Tension
November 2022 Maintenance Manual Quarterly Maintenance Procedures All models: Inspect the Fork Level and Inspect the hydraulic hoses for the following: Auxiliary Hydraulic Hose Tension • Chafing • Kinked, pinched or crushed hoses • Proper routing Genie specifications require that this procedure be •... -
Page 36: Inspect The Fuel And Hydraulic Tank Cap Venting Systems
Maintenance Manual November 2022 Quarterly Maintenance Procedures GTH-1056, GTH-1256: Inspect the Fuel and Hydraulic Remove the fuel filler cap from the tank. Tank Cap Venting Systems Check for proper venting. Result: Air passes through the fuel tank cap. Proceed to step 4. Result: If air does not pass through the cap, Genie specifications require that this procedure be clean or replace the cap. -
Page 37: Visual Inspection Of The Hydraulic Oil
November 2022 Maintenance Manual Quarterly Maintenance Procedures Collect a sample of hydraulic oil and place in a clear container. Visually inspect the Visual Inspection of the Hydraulic hydraulic oil for the following: • Color: oil should be a clear, light-honey colored •... -
Page 38: Inspect The Engine Air Filter
Maintenance Manual November 2022 Quarterly Maintenance Procedures Q-10 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 good machine performance and service life. -
Page 39: Inspect And Lubricate The Sequencing Chains
November 2022 Maintenance Manual Quarterly Maintenance Procedures Q-12 Park the machine on a firm level surface, level the boom and engage the parking brake. Inspect and Lubricate the Sequencing Chains Fully extend the boom. Inspect the chains for the following conditions: GTH-636, GTH-844: Genie specifications require that this procedure be •... - Page 40 Maintenance Manual November 2022 Quarterly Maintenance Procedures GTH-1056: GTH-1256: • Elongation • Elongation • Measure 16 pitches of the extend / retract • Measure 16 pitches of the extend / retract chains chains Note: The pitch of the boom BL666 chains is Note: The pitch of the boom BL866 chains is 0.75 inches / 19,5 mm.
- Page 41 November 2022 Maintenance Manual Quarterly Maintenance Procedures All models: • Edge wear: Check the chains for wear on the link plate edges caused by running back and forth over the sheave. The maximum reduction of material should not exceed 5%. •...
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Page 42: Annual Maintenance Procedures
Maintenance Manual November 2022 Annual Maintenance Procedures Adjust the Boom Sequencing Inspect the Forks Chains - GTH-636, GTH-844 Genie specifications require that this procedure be performed annually. OR whenever permanent deformation of the forks is suspected. Genie specifications require that this procedure be performed annually. -
Page 43: Adjust The Boom Sequencing Chains - Gth-1056, Gth-1256
November 2022 Maintenance Manual Annual Maintenance Procedures Move to the fork end of the same boom section that was just measured. Adjust the Boom Sequencing Chains - GTH-1056, GTH-1256 Measure the distance between the top surface of the boom and the same reference point used on the sequencing chain in step 4. -
Page 44: Replace Hydraulic Tank Return Filter Element
Maintenance Manual November 2022 Annual Maintenance Procedures Move to the fork end of the same boom section that was just measured. Replace Hydraulic Tank Return Filter Element Measure the distance between the surface of the boom and the same reference point used on the sequencing chain in step 4. -
Page 45: Replace The Cab Air Intake Filter Element (If Equipped)
November 2022 Maintenance Manual Annual Maintenance Procedures Replace the Cab Air Intake Filter (if equipped) Genie specifications require that this procedure be performed annually. Perform this procedure more often if dusty conditions exist. Note: Location of the air intake access cover will vary, depending on specific models. -
Page 46: Programmed Maintenance Procedures
Maintenance Manual November 2022 Programmed Maintenance Procedures All models: P0-1 Lubricate the Boom Apply a thin layer of grease to the underside of the number 3 boom tube where it makes contact with the number 2 boom tube lower wear pads. Genie specifications require that this procedure be Apply a thin layer of grease to the underside performed every 8 hours or daily, whichever... -
Page 47: P0-2 Deutz Engine Maintenance - Under 1000 Hours
November 2022 Maintenance Manual Programmed Maintenance Procedures P0-2 Deutz Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals. -
Page 48: P0-3 Axle Maintenance - Under 1000 Hours
Maintenance Manual November 2022 Programmed Maintenance Procedures P0-3 Axle Maintenance – Under 1000 Hours Additional axle maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional axle information are available in the manufacturer's manuals. -
Page 49: P0-4 Transmission Maintenance - Under 1000 Hours
November 2022 Maintenance Manual Programmed Maintenance Procedures P0-4 Transmission Maintenance – Under 1000 Hours Additional transmission maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional transmission information are available in the manufacturer's manuals. -
Page 50: P1-1 Perform Engine Maintenance - 1000 Hours
Maintenance Manual November 2022 Programmed Maintenance Procedures P1-1 P1-2 Perform Engine Maintenance – Perform Transmission 1000 Hours Maintenance – 1000 Hours Engine specifications require that this procedure Transmission specifications require that this be performed every 1000 hours. procedure be performed every 1000 hours. Required maintenance procedures and additional Required maintenance procedures and additional engine information are available in the... -
Page 51: P1-3 Perform Axle Maintenance - 1000 Hours
November 2022 Maintenance Manual Programmed Maintenance Procedures P1-3 P2-1 Perform Axle Maintenance – 1000 Test or Replace the Hydraulic Oil Hours Genie requires that this procedure be performed every 2000 hours. Axle specifications require that this procedure be performed every 1000 hours. Replacement or testing of the hydraulic oil is essential for good machine performance and Required maintenance procedures and additional... -
Page 52: P3-1 Perform Engine Maintenance - 3000 Hours
Maintenance Manual November 2022 Programmed Maintenance Procedures P3-1 Testing the oil: Perform Engine Maintenance – Complete the hydraulic oil testing with an oil 3000 Hours distributor. If the hydraulic oil passes testing at the 2000 hour maintenance interval, the oil must be tested every quarter by an oil distributor Engine specifications require that this procedure until the oil fails the test and is replaced. -
Page 53: P5-1 Perform Engine Maintenance - 5000 Hours
November 2022 Maintenance Manual Programmed Maintenance Procedures P5-1 P6-1 Perform Engine Maintenance – Perform Engine Maintenance – 5000 Hours 6000 Hours Engine specifications require that this procedure Engine specifications require that this procedure be performed every 5000 hours. be performed every 6000 hours. Required maintenance procedures and additional Required maintenance procedures and additional engine information are available in the...