Page 1 Parts Manual Service Manual Serial Number Range Serial Number Range GTH-844 GTH-636 from GTH0606A-8418 to after GTH05-12345 GTH0610A-13771 GTH-842 GTH-644 from GTH0606A-8418 after GTH05-12345 from GTH0606B-6271 GTH-644 GTH-842 from GTH0806A-8418 after GTH05-12345 from GTH0806B-6958 from GTH0806A-8418 to GTH-844 GTH-844 GTH0812-16605...
Page 2: Introduction
"Genie" is a registered trademark of Genie Industries in the USA and many other countries. www.genieindustries.com "GTH" is a trademark of Genie Industries. e-mail: techsup@genieind.com Printed on recycled paper Printed in U.S.A. GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 3: Serial Number Legend
Serial label (located inside fork frame) Serial label (models with quick attach frame) (located inside chassis upright at cab side of machine) Serial number stamped on chassis Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056...
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Page 5: Safety Rules
- 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. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056...
Page 6: Personal Safety
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. GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 7: Table Of Contents
SAE and Metric Fasteners Torque Charts ..........2 - 15 Section 3 Scheduled Maintenance Procedures Introduction ....................3 - 1 Pre-delivery Preparation Report ..............3 - 3 Maintenance Inspection Report ..............3 - 5 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056...
Page 8 B-8 Check the Boom Wear Pads ............3 - 22 B-9 Lubricate the Driveshafts ..............3 - 23 B-10 Perform Engine Maintenance - John Deere Models ......3 - 23 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487 viii...
Page 9 E-7 Perform Engine Maintenance - Perkins Models ........ 3 - 38 E-8 Perform Engine Maintenance - Deutz Models ........3 - 39 E-9 Perform Engine Maintenance - Perkins Models ........ 3 - 39 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056...
Page 10 Repair Procedures Introduction ....................4 - 1 Boom Components Boom Angle Limit Switch (all models except GTH-636) ..... 4 - 2 Boom ....................4 - 3 Boom Lift Cylinder ................4 - 15 Boom Extension Cylinder ..............4 - 17 Fork Level Cylinder ................
Page 11 7-23 Valve Adjustments - Tilt Limiter Manifold.......... 4 - 71 7-24 Valve Coils ..................4 - 72 Axle Components Axles ....................4 - 73 Outriggers Outriggers ..................4 - 76 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056...
Page 12 Boom Functions ................. 5 - 6 Drive Functions ................5 - 13 Steer Functions ................5 - 14 Brake Functions ................5 - 17 Sway Functions ................5 - 18 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 13 Hydraulic Schematic - GTH-1048 and GTH-1056 with Single Joystick .......... 6 - 22 Hydraulic Schematic - GTH-1048 and GTH-1056 with Dual Joysticks .......... 6 - 23 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 xiii...
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Page 15: Machine Specifications
Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. For operational specifications, refer to the Operator's Manual. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 2 - 1...
Page 16 Weight, rock lug tire 982 ±35 lbs (calcium chloride filled) 445 ±16 kg Weight, rock lug tire 1013 ±35 lbs (foam filled) 459 ±16 kg 2 - 2 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 17: Performance Specifications
Fork rotate 19 to 21 seconds Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 2 - 3...
Page 18: Hydraulic Specifications
Industries Service Department before use. the approved optional fluids. Consult the Genie Industries Service Department before use. 2 - 4 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 19 Boom extend relief valve pressure, maximum 2000 psi 137.9 bar GTH-1048 and GTH-1056 Boom extend relief valve pressure, maximum 2500 psi 172.3 bar Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 2 - 5...
Page 20: Manifold Component Specifications
7.5 to 9.5Ω Rexroth pump (grey)(schematic item TA) Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 6 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 21: John Deere 4045Tf270 Engine
Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator's Manual on your machine. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 2 - 7...
Page 22: John Deere 4045Tf275 Engine
Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator's Manual on your machine. 2 - 8 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 23: Deutz Bf4 2012 Engine
Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operation Manual on your machine. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 2 - 9...
Page 24: Perkins 1104C-44T Engine
Extreme operating temperatures may require the use of subject to change without notice. alternative engine oils. For oil requirements, refer to the Engine Operation and Maintenance Manual on your machine. 2 - 10 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 25: Perkins 1104C-44Ta Engine
Extreme operating temperatures may require the use of subject to change without notice. alternative engine oils. For oil requirements, refer to the Engine Operation and Maintenance Manual on your machine. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 2 - 11...
Page 26: Dana T12000 Transmission
Genie part number 97489 Genie part number 115025 Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 12 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 27: Specifications
Genie part number 97488 Genie part number 115026 Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 2 - 13...
Page 28: Hydraulic Hose And Fitting Torque Specifications
5 Operate all machine functions and inspect the hoses and fittings and related components to 2 - 14 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 29 84.4 18.9 25.6 25.1 34.1 48.6 64.9 69.7 94.5 92.2 30.1 40.8 54.3 77.4 46.9 63.6 62.5 84.8 64.5 87.5 86.2 1055 1233 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 2 - 15...
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Page 31: Observe And Obey
· Machine parked on a firm, level surface · Boom in the stowed position · Key switch in the off position with the key removed · Wheels chocked Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 1...
Page 32: Pre-Delivery Preparation Report
Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. 3 - 2 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 33 Genie UK 18340 NE 76th Street The Maltings, Wharf Road PO Box 97030 Grantham, Lincolnshire Redmond, WA 98073-9730 NG31- 6BH England (425) 881-1800 (44) 1476-584333 Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Rev B...
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Page 35: Maintenance Inspection Report
After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 5...
Page 36 After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired 3 - 6 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 37: C Checklist A Procedures
Remove the machine from service until the manual is replaced. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 7...
Page 38: Perform Pre-Operation Inspection
Complete information to perform this procedure is Refer to the Operator's Manual on your machine. available in the appropriate operator's manual. Refer to the Operator's Manual on your machine. 3 - 8 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 39: Lubricate The Machine
4 Lubricate the top and side boom tube wear Chevron Ultra-duty grease, EP NLGI 2 (lithium based) pads. or equivalent 5 Return the boom to the stowed position. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 9...
Page 40 12 Pump grease into each fitting until the joints are thoroughly lubricated. Grease Specification Chevron Ultra-duty grease, EP NLGI 2 (lithium based) or equivalent 3 - 10 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 41: Perform Engine Maintenance - John Deere And Perkins Models
Dana T20000 Maintenance Manual Perkins 1104 Operation and Maintenance Manual (Dana part number 0202). Genie part number 117765 Dana T20000 Maintenance Manual Genie part number 115025 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 11...
Page 42: Perform Engine Maintenance - Deutz Models
Deutz Models Perkins models: · B-5 Inspect the Tires, Wheels and Lug Nut Torque · D-3 Replace the Hydraulic Tank Return Filter Element 3 - 12 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 43: Perform Transmission Maintenance
Dana T12000 Maintenance Manual (Dana part number 0109). Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Dana T12000 Maintenance Manual Genie part number 97489 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 13...
Page 44: Perform Axle Maintenance
Dana 213 Axle Maintenance and Repair Manual (Dana part number 0243). Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 3 - 14 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 45: Perform Transmission Maintenance
Dana 213 Axle Maintenance and Repair Manual (Dana part number 0243). Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 15...
Page 46: A-15 Perform Axle Maintenance
Dana 213 Axle Maintenance and Repair Manual (Dana part number 0243). Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 3 - 16 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 47: B Checklist B Procedures
3 Be sure that the battery hold-downs and cable covers attached to the chassis. connections are tight. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 17...
Page 48: Check The Exhaust System
5 Inspect for exhaust leaks; i.e., carbon buildup around seams and joints. 6 Close the right side engine access cover. Install the center engine access cover. 3 - 18 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 49: Inspect The Engine Air Filter
7 Install the front cover onto the air cleaner 3 Check each lug nut for proper torque. Refer to assembly and secure the latches. Section 2, Specifications . Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 19...
Page 50: Perform Hydraulic Oil Analysis
7 Repeat this procedure beginning with step 5 for each remaining tire. 3 - 20 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 51: Inspect The Fuel And Hydraulic Tank Cap Venting Systems
Proceed to step 3. Note: When checking for positive tank cap venting, air should pass freely through the cap. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 21...
Page 52: Check The Boom Wear Pads
Result: The measurement is less than specification. Replace all side wear pads. Refer to Repair Procedure 1-2, How to Replace the Boom Wear Pads . 3 - 22 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 53: Lubricate The Driveshafts
John Deere 4045T275 Operator's Manual Chevron Ultra-duty grease, EP NLGI 2 (lithium based) Genie part number 108444 or equivalent rear driveshaft front driveshaft Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 23...
Page 54: B Checklist C Procedures
Deutz 2012 Operation Manual Genie part number 108746 John Deere 4045T270 Operator's Manual Genie part number 97492 John Deere 4045T275 Operator's Manual Genie part number 108444 3 - 24 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 55: Perform Axle Maintenance
Dana 213 Axle Maintenance and Repair Manual (Dana part number 0243). Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 25...
Page 56: Perform Engine Maintenance - Perkins Models
Dana 213 Axle Maintenance and Repair Manual (Dana part number 0243). Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 3 - 26 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 57: Perform Axle Maintenance
Dana 213 Axle Maintenance and Repair Manual (Dana part number 0243). Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 27...
Page 58: B Checklist D Procedures
Result: If any of the above criteria are not met, the fork shall be removed from service until it is repaired or replaced. shank blade 3 - 28 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 59 The gap should be no less than 0.030 inch / 0.76 mm. Note: The spring coils should never be collapsed completely. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 29...
Page 60 Note: The spring coils should never be collapsed completely. 11 Repeat this procedure, beginning with step 4, for each extension chain of the boom assembly. 3 - 30 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 61: Replace The Hydraulic Tank Return Filter Element
3 Loosen, but do not remove, the four bolts on top of the return filter assembly. Bodily injury hazard. The return filter assembly cover is spring loaded. Do not remove the bolts. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 31...
Page 62: Perform Engine Maintenance - Deutz Models
Required maintenance procedures and additional transmission information is available in the Dana T20000 Maintenance Manual (Dana part number 0202). Dana T20000 Maintenance Manual Genie part number 115025 3 - 32 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 63: Perform Axle Maintenance
Dana 213 Axle Maintenance and Repair Manual (Dana part number 0243). Dana 213 Axle Maintenance and Repair Manual Genie part number 115026 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 33...
Page 64: Perform Engine Maintenance - Deutz Models
Deutz 2012 Operation Manual (Deutz part number 0297 9912). Deutz 2012 Operation Manual Genie part number 108746 3 - 34 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 65: C Checklist E Procedures
Replace the oil when it fails the test. 1 Lower the boom to the stowed position. 2 Remove oil cap from top of hydraulic tank. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 35...
Page 66: Perform Engine Maintenance - John Deere Models
(John Deere part number OMRG33324). Genie part number 117765 John Deere 4045T270 Operator's Manual Genie part number 97492 John Deere 4045T275 Operator's Manual Genie part number 108444 3 - 36 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 67: Perform Engine Maintenance - Perkins Models
(Perkins part number SEBU7833-01). Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 37...
Page 68: Perform Engine Maintenance - John Deere Models
Perkins 1104 Operation and Maintenance Manual Genie part number 117765 John Deere 4045T270 Operator's Manual Genie part number 97492 John Deere 4045T275 Operator's Manual Genie part number 108444 3 - 38 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 69: Perform Engine Maintenance - Deutz Models
Perkins 1104 Operation and Maintenance Manual (Perkins part number SEBU7833-01). Deutz 2012 Operation Manual Genie part number 108746 Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 3 - 39...
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Page 71: Repair Procedures
· Key switch in the off position with the key removed Indicates that an incorrect result has occurred after performing a series of steps. · Wheels chocked Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 1...
Page 72: Boom Components
The limit switch collar is not parallel to the side of the boom. Repeat this procedure beginning with step 3. 4 - 2 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 73: Boom
Note: Note the quantity and location of the thrust washers when removing the boom rollers. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 3...
Page 74 Component damage hazard. Hoses can be damaged if they are kinked or pinched. lift cylinder rod end pivot pin barrel end pivot pin 4 - 4 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 75 14 Using the crane, raise the boom to a horizontal position. 15 Remove the fasteners securing the boom pivot pin to the machine. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 5...
Page 76: Bodily Injury Hazard. Spraying
Support Hoses can be damaged if they are the cylinder. Do not apply any lifting pressure. kinked or pinched. 4 - 6 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 77 22 Remove the top and side wear pads of the number 2 boom tube at the fork end of the boom. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 7...
Page 78 8 Remove the fasteners securing the fork level cylinder barrel-end pivot pin to the boom. 4 - 8 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 79 2 and 3 boom tube assembly at the fork end of the boom. retraction chain extension chain fixed chain block chain tensioner Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 9...
Page 80 24 Use a soft metal drift to remove the pivot pin. Remove the chain and set it to the side. Note: Do not allow the chain to become twisted or dirty. 4 - 10 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 81 8 Remove the fasteners securing the fork level cylinder barrel-end pivot pin to the boom. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 11...
Page 82 18 Using a screwdriver, carefully separate the cable track from the cable track mount at the rear of the number 3 boom tube. 4 - 12 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 83 Note: The fixed chain block of the number 3 boom tube retraction chain is secured to the inside of the number 1 boom tube and is hidden from view when installed. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 13...
Page 84 48 Attach a lifting strap from an overhead crane to the number 3 boom tube assembly at the fork end of the boom. 4 - 14 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 85: Boom Lift Cylinder
Hoses can be damaged if they are kinked or pinched. 3 Remove the fasteners securing the lift cylinder pivot pin to the chassis. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 15...
Page 86 12 Repeat this procedure for the other cylinder, beginning with step 6. 4 - 16 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 87: Boom Extension Cylinder
5 Remove the extension cylinder support loop from the number 3 boom tube. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 17...
Page 88: Fork Level Cylinder
Do not allow oil to squirt or spray. Component damage hazard. Hoses can be damaged if they are kinked or pinched 4 - 18 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 89 16 Bleed the fork level circuit. See 1-3, How to Bleed the Lift/Tilt Circuit . boom tube number 3 boom tube number 2 boom tube number 1 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 19...
Page 90: Fork Rotate Cylinder (Option)
Hoses can be damaged if they are kinked or pinched 5 Remove the fasteners securing the fork rotate cylinder rod end pivot pin to the fork frame. 4 - 20 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 91 Note: It may be necessary to tilt the fork frame boom structure before pulling the hose out of the away from the boom to provide room to raise the boom. cylinder. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 21...
Page 92 25. Place the other end of the hose into a suitable container to collect hydraulic fluid. 4 - 22 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 93: Operator's Compartment
4 Carefully lift the joystick away from the side Burn hazard. Contact with hot console assembly. fluids or components may cause severe burns. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 23...
Page 94 7 Remove the fasteners securing the steering selector to the side console. Set the fasteners aside. MANIFOLD BLOCK REAR STEERING CYL. Illustration 3 Steer Circuit 4 - 24 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 95 Remove the switch. Set Illustration 4 the fasteners aside. Brake/Differential Lock Circuit brake pedal service brake pressure switch clutch cut-off pressure switch brake pedal actuator body Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 25...
Page 96 Carefully operator's compartment. Remove the seat. move the dash panel towards the front of the machine. Set the fasteners aside 4 - 26 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 97 750 ft-lbs transmission control lever mounting fasteners 1017 Nm 4-way controller (joystick) parking brake accelerator pedal differential lock switch brake pedal steering selector Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 27...
Page 98 Set the panel aside in a secure TO PORT 2 position. ON BRAKING BRAKE VALVE TO CONTROLLER RELIEF VALVE Illustration 2 Bottom View of 4-way Controller 4 - 28 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 99 L, P and T of the steering orbitral. Cap the MANIFOLD REAR fittings. Refer to illustration 3. BLOCK STEERING CYLINDER Illustration 3 Steer Circuit Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 29...
Page 100 5 amp fuse in the lower right corner of the fuse block. Component damage hazard. Wires can be damaged if they are kinked or pinched. 4 - 30 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 101 Note: When installing the operator's compartment Parking Brake Valve Assembly onto the chassis, torque the fasteners to specification. See 2-1, How to Remove the Operator's Compartment . Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 31...
Page 102: Machine Controls
Note: Assistance may be needed to perform this step. 4 - 32 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 103 10 Carefully move the right dash panel away from the dash weldment and place in a secure position. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 33...
Page 104 Burn hazard. Contact with hot fluids or components may cause severe burns. 8 Remove the fasteners securing the steering selector in place. Remove the steering selector. 4 - 34 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 105 6 Remove the fasteners securing the accelerator pedal in place. 7 Remove the joystick from the side console. 7 Set the fasteners aside and remove the accelerator pedal. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 35...
Page 106 7 Remove the fasteners securing the brake actuator pedal in place. Remove the brake actuator pedal. 4 - 36 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 107 6 Remove the fasteners and the bracket securing the parking brake valve assembly in place. Remove the parking brake valve assembly. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 37...
Page 108: Fuel And Hydraulic Tanks
3 Remove the front portion of the engine enclosure assembly from the machine. 4 Remove the fuel filler cap from the tank. 4 - 38 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 109: Hydraulic Tank
Crushing hazard. The counterweight is extremely heavy. Keep your body clear when removing the counterweight. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 39...
Page 110: Engines
Perkins 1104 Service Manual (Perkins part number RENR9401). Perkins 1104 Operation and Maintenance Manual Genie part number 117765 Perkins 1104 Service Manual Genie part number 117764 4 - 40 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 111: Engine Fault Codes - John Deere 4045Tf275 Engine
John Deere 4045T engine engine coolant temperature sender engine oil pressure sender starter relay Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 41...
Page 112: Transmission
'D' (gear reduction) transmission shift coil 'E' (gear reduction) Note: refer to electrical schematic for additional transmission shift coil information. 4 - 42 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 113 (gear reduction) (green wire) transmission shift coil '1' (gear reduction) (yellow wire) Note: refer to electrical schematic for additional transmission shift coil information. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 43...
Page 114: Hydraulic Pumps
Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 44 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 115 Note: The hydraulic pump is located on the top of gradually. Do not allow oil to squirt the transmission at the cab side. or spray. pump DFR valve Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 45...
Page 116: Or Spray
Remove the pump from the Refer to Section 2, Specifications . machine. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. 4 - 46 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 117 Add fluid if needed. 10 Working inside the cab, press and hold the PUMP button. Note: The button is located under the PUMP OFF steering wheel. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 47...
Page 118: Main Valve Manifold Components
Relief valve, 3650 psi / 251 bar ..AD ..Manifold relief ..........73 ft-lbs / 100 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic 4 - 48 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 119: Tilt Limiter Manifold Components
Relief valve, 1250 psi / 86.2 bar ..BA ..Fork level circuit ........ 30-35 ft-lbs / 45-50 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 49...
Page 120: Dual Pilot Check Manifold Components
Check valve, pilot operated ..... CB ..Boom lift circuit ........30-35 ft-lbs / 45-50 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic 4 - 50 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 121: Boom Activated Rear Lock-Up Manifold Components
Coil nut ..........................40 in-lbs / 4.5 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer to the electrical schematic Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 51...
Page 122: Fork Rotate Speed Manifold Components (Option)
Adjustable needle valve ....EA ..Fork rotate speed ......30-35 ft-lbs / 40-47 Nm Adjustment nut ........................108 in-lbs / 12 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic 4 - 52 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 123: Control Block Manifold Components
Check valve ........FD ..Brake circuit ........30-35 ft-lbs / 40-47 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 53...
Page 124: Fork Tilt Manifolds Components
Solenoid valve, 2 position 4 way ..GB ..Tilts lifting forks up ........20 ft-lbs / 27 Nm Y72A Y72B Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer to the electrical schematic 4 - 54 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 125: Rear Lock-Up Manifold Components
500 psi / 34.5 bar ......HH ..Controls fluid pressure to cylinders .. 35-40 ft-lbs / 47-54 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 55...
Page 126: Parking Brake Manifold Components
GTH-644, GTH-842 and GTH-844: The parking brake manifold is the outboard of the two similar manifolds located on the chassis main tube next to the cab, mounted directly to the chassis. GTH-636, GTH-1048 and GTH-1056: The parking brake manifold located inside the cab, just to the left of the operator's seat.
Page 127: Differential Lock-Up Manifold Components (Optional On Gth-636 And Gth-644)
Coil nut ..........................40 in-lbs / 4.5 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer to the electrical schematic Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 57...
Page 128: Sway Manifold Components
Check valve, pilot operated ..... KD ..Right front cylinder extend circuit ..30-35 ft-lbs / 40-47 Nm CAB SIDE EXHAUST SIDE Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic 4 - 58 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 129: Fork Rotate Manifold Components (Option)
......LA ..Rotate forks clockwise or counterclockwise Coil nut ..........................30 in-lbs / 3.4 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 59...
Page 130: Sway Directional Manifold Components
JOYSTICK MODELS WITH DUAL JOYSTICKS Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer to the electrical schematic 4 - 60 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 131: Outrigger Manifold Components - Gth-1048 And Gth-1056
....... NB ..Outrigger extend/retract circuit, exhaust side Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer to the electrical schematic Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 61...
Page 132: Controller Relief (Drop Block) Manifold
Coil nut ..........................40 in-lbs / 4.5 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer to the electrical schematic 4 - 62 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 133: Boom Lift And Boom Extension Cylinders Manifold Components
(rod end) ........... 45-50 ft-lbs / 61-67 Nm Boom Lift Cylinder Manifold Boom Extension Cylinder Manifold Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 63...
Page 134: Fork Level Cylinder Manifold Components
Check valve, pilot operated ..... RC ..Fork down circuit ....... 30-35 ft-lbs / 40-47 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic 4 - 64 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 135: Fork Rotate Cylinder Manifold Components (Option)
Check valve, pilot operated ....SB ..Rotate counterclockwise circuit ..30-35 ft-lbs / 40-47 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 65...
Page 136: Pump Destroke Manifold Components
(SILVER MANIFOLD ON GREY PUMP) Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic; alphanumeric callouts refer to the electrical schematic 4 - 66 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 137: Gth-636, Gth-1048 And Gth-1056
(GTH-1048 and GTH-1056) ..... UA ..Boom extend relief ........20 ft-lbs / 27 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 67...
Page 138: Boom Activated Sway Lock-Up Manifold Components
REV C 7-21 Boom-activated Sway Lock-up Manifold Components (models with dual joysticks except GTH-636) The boom-activated sway lock-up manifold, used on all machines with dual joysticks except the GTH-636, is mounted on the pilot operated sway directional valve. Index Schematic...
Page 139: Valve Adjustments - Control Block Manifold
GTH-842 GTH-844 test port test port 4 test port 3 d test port 1 hydraulic tank boom lift/extend relief valve control block manifold Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 69...
Page 140 GTH-842 GTH-844 test port test port 4 test port 3 d test port 1 hydraulic tank pilot pressure relief valve control block manifold 4 - 70 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 141: Valve Adjustments - Tilt Limiter Manifold
GTH-842 hydraulic tank GTH-844 tilt limiter manifold tilt limiter relief valve test port test port 4 test port 3 d test port 1 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 71...
Page 142: Valve Coils
Result: The multimeter displays 0V DC. The valve coil is good; the wire harness is faulty. Repair or replace the wire harness. 4 - 72 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 143: Axles
Note: When installing the axle onto the chassis, torque the fasteners to specification. Torque specification Axle mounting fasteners 380 ft-lbs 515 Nm Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 73...
Page 144: To Adjust Front Axle Service Brakes
3.75 turns in a clockwise direction. 7 Install the covers over the service brake adjustment screws. Securely tighten the fasteners. Do not over tighten. 4 - 74 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 145 Dana 213 Axle Maintenance and Repair Manual (Dana part number 0243). Dana 212 Axle Maintenance and Repair Manual Genie part number 115026 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 75...
Page 146: Outriggers
Lower the cylinder onto the outrigger. Crushing hazard. The cylinder may become unbalanced and fall if not properly supported when the pivot pin is removed from the machine. 4 - 76 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 147 Support the cylinder. Do not apply any lifting pressure. 4 Remove the fasteners securing the outrigger cylinder barrel-end pivot pin to the chassis. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 4 - 77...
Page 148 Section 4 • Repair Procedures June 2007 This page intentionally left blank. 4 - 78 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 149: Troubleshooting And Repair Procedures Shall Be Completed By A Person Trained And Qualified On The Repair Of This Machine
General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Inspect Perform service and test repair problem solved Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 5 - 1...
Page 150: Engine Fault Codes - Gth-1048 And Gth-1056
The ECM will not detect all engine problems, nor is the fault detection capability a substitute for regular engine maintenance. Normal machinery operating procedures should always be observed. 5 - 2 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 151 84 ECM power down error/external derate active 62 Engine coolant temperature high – least severe 88 Signifies that no fault codes are stored Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 5 - 3...
Page 152: Hydraulic Pump
Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 5 - 4 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 153 Result: The pressure gauge reads less than 1000 psi / 69 bar. The steer relief valve (schematic item FC) is faulty. Replace the valve. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 5 - 5...
Page 154: Boom Functions
Proceed to step 13. GTH-636 GTH-1048 GTH-644 GTH-1056 GTH-842 GTH-844 test port test port 4 test port 3 d test port 1 5 - 6 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 155 The joystick is faulty. Repair or replace the joystick. Result: The ground circuit does not have continuity. Repair the ground wire circuit to the coil. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 5 - 7...
Page 156 When energized, the valve will magnetize and the wrench will stick to the valve; turn the power off and the wrench will fall. 5 - 8 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 157 Do not allow anyone to stand anywhere near the area below or in front of the boom when performing this procedure. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 5 - 9...
Page 158 When energized, the valve will magnetize and the wrench will stick to the valve; turn the power off and the wrench will fall. 5 - 10 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 159 V2. Torque to specification. Refer to Section 2, Specifications. 9 Start the engine and allow the engine to idle. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 5 - 11...
Page 160 17 Activate the boom down function. Result: Fluid is leaking from the open port of the cylinder. The cylinder has internal leakage. Replace the seals inside the cylinder. 5 - 12 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 161: Drive Functions
12V at yellow wire on the switch (to calibrate the boom limit switch, refer to Repair Procedure 1-1, How to Adjust the Limit Switch). Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 5 - 13...
Page 162: Steer Functions
, and torque to specification. Refer to correct orbitral fitting and torque to CYL 2 Section 2, Specifications. specification. Refer to Section 2, Specifications. 13 Start the engine. 5 - 14 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 163 31 Install the hose, disconnected in step 28, onto cylinder. Do not cap the fitting. the cylinder and torque to specification. Refer to 23 Start the engine. Section 2, Specifications. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 5 - 15...
Page 164 41 Tag, disconnect and plug the return hose at the cylinder. Do not cap the fitting. 42 Start the engine. 5 - 16 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 165: Brake Functions
Replace the brake actuator. Result: The gauge indicates more than 650 psi / 44.8 bar. The actuator is faulty. Replace the brake actuator. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 5 - 17...
Page 166: Sway Functions
(GTH-636, GTH-644, GTH-842 and GTH-844) Genie part number 97488 Dana 213 Axle Maintenance and Repair Manual (GTH-1048 and GTH-1056) Genie part number 115026 5 - 18 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 167 Result: The machine functions correctly. Repair or replace the boom activated rear lock-up valve (schematic item DA). Result: The machine does not function correctly. Proceed to step 10. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 5 - 19...
Page 168 Do not allow oil to the oil pressure to dissipate squirt or spray. gradually. Do not allow oil to squirt or spray. 5 - 20 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 169: Hydraulic Oil Can Penetrate And Burn Skin. Loosen Hydraulic
Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 5 - 21...
Page 170 Section 5 • Troubleshooting June 2007 This page intentionally left blank. 5 - 22 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 171 Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Inspect Perform service and test repair problem solved Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 6 - 1...
Page 172: Electrical Component And Limit Switch Legends
H3 = Back-up alarm S13 = Fuel level boom limit switch (all models except GTH-636) (hidden from view) (located on boom pivot between boom and chassis) 6 - 2 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 173: Electrical And Hydraulic Symbols Legends
1 2 3 4 Solenoid valves Toggle switch Test ports Gauge Pressure switch Adjustable orifice Horn or alarm Alternator 10 Amp fuse Check valve Accumulator Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 6 - 3...
Page 174: Electrical Schematic - Gth-636 With John Deere Power
SWITCH BN100 FORK TILT CR90 HORN BUTTON FORK TILT 20 RED FORK TILT 20 BLK COILS 16 BLK CONTROLLER Y72A Y72B RELIEF ES0447A 6 - 4 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 175: June 2007
LEFT REAR TURN/BRAKE LIGHT LEFT FRONT TURN SIGNAL MODELS 16 BRN/WHT WITH SINGLE JOYSTICK RIGHT FRONT TURN SIGNAL RIGHT REAR TURN/BRAKE LIGHT ES0447A Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 6 - 5...
Page 176: Electrical Schematic - Gth-636 With Perkins Power
FORK TILT SINGLE 12 RED 20 RED JOYSTICK 20 BLK 16 BLK CONTROLLER Y72A Y72B RELIEF FORK TILT FORK TILT HORN COIL COIL ES0445A 6 - 6 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 177 LEFT REAR LEFT FRONT TURN/BRAKE LIGHT TURN SIGNAL 16 BRN/WHT RIGHT FRONT TURN SIGNAL RIGHT REAR TURN/BRAKE LIGHT MODELS WITH SINGLE JOYSTICK ES0445A Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 6 - 7...
Page 178: And Gth-844 With John Deere Power
CR90 FORK TILT FORK TILT SW35 AUXILIARY 20 BLK 16 BLK FORK TILT CONTROL COILS SW34 20 RED Y72A Y72B SWAY CONTROL ES0446A 6 - 8 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 179 BOOM ACTUATED BOOM ACTUATED SWAY LOCK-UP LOCK-UP VALVE RIGHT FRONT TURN SIGNAL (MODELS WITH DUAL JOYSTICKS) RIGHT REAR TURN/BRAKE LIGHT BOOM LIMIT SWITCH ES0446A Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 6 - 9...
Page 180: Electrical Schematic - Gth-644, Gth-842 And Gth-844 With Perkins Power
CR90 FORK TILT FORK TILT SW34 Y72A Y72B 20 BLK 16 BLK FORK TILT FORK TILT SWAY 20 RED CONTROL COIL COIL ES0444A 6 - 10 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 181 BOOM ACTUATED BOOM ACTUATED SWAY LOCK-UP LOCK-UP VALVE RIGHT FRONT TURN SIGNAL (MODELS WITH DUAL JOYSTICKS) RIGHT REAR TURN/BRAKE LIGHT BOOM LIMIT SWITCH ES0444A Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 6 - 11...
Page 182: Electrical Schematic - Gth-644, Gth-842 And Gth-844 With Deutz Power
CR90 FORK TILT FORK TILT SW35 AUXILIARY 20 BLK 16 BLK FORK TILT CONTROL COILS SW34 20 RED Y72A Y72B SWAY CONTROL ES0448A 6 - 12 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 183 BOOM ACTUATED BOOM ACTUATED SWAY LOCK-UP LOCK-UP VALVE RIGHT FRONT TURN SIGNAL (MODELS WITH DUAL JOYSTICKS) RIGHT REAR TURN/BRAKE LIGHT BOOM LIMIT SWITCH ES0448A Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 6 - 13...
Page 184: Electrical Schematic - Gth-1048 And Gth-1056 With John Deere Power
FORK TILT RELIEF VALVE 16 BLK 20 BLK HORN SWAY RIGHT COILS (BLK WIRE) Y72A Y72B 12 RED MODELS WITH SINGLE JOYSTICK ES0450A 6 - 14 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 185 16 BLK BOOM LIMIT SWITCH STABILIZER L.F. UP R.F. UP VALVES 16 BLK 16 YEL RIGHT REAR RIGHT FRONT TURN/BRAKE LIGHT ES0450A TURN SIGNAL Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 6 - 15...
Page 186: Electrical Schematic - Gth-1048 And Gth-1056 With Perkins Power
FORK TILT RELIEF VALVE 16 BLK 20 BLK HORN SWAY RIGHT COILS (BLK WIRE) Y72A Y72B 12 RED MODELS WITH SINGLE JOYSTICK ES0449A 6 - 16 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 187 16 BLK BOOM LIMIT SWITCH STABILIZER L.F. UP R.F. UP VALVES 16 BLK 16 YEL RIGHT REAR RIGHT FRONT TURN/BRAKE LIGHT ES0449A TURN SIGNAL Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 6 - 17...
Page 188: A Hydraulic Schematic
Section 6 • Schematics June 2007 Hydraulic Schematic - GTH-636 with Single Joystick REV C P1-1846 6 - 18 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 189: Gth-636 With Dual Joysticks
June 2007 Section 6 • Schematics Hydraulic Schematic - GTH-636 with Dual Joysticks REV A P1-1846 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 6 - 19...
Page 190: And Gth-844 With Single Joystick
Section 6 • Schematics June 2007 Hydraulic Schematic - GTH-644, GTH-842 and GTH-844 with Single Joystick REV B P1-1940 P1-1962 P1-1971 6 - 20 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 191: Gth-644, Gth-842 And Gth-844 With Dual Joysticks
June 2007 Section 6 • Schematics Hydraulic Schematic - GTH-644, GTH-842 and GTH-844 with Dual Joysticks REV A P1-1940 P1-1962 P1-1971 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 6 - 21...
Page 192: Hydraulic Schematic - Gth-1048 And Gth-1056 With Single Joystick
Section 6 • Schematics June 2007 Hydraulic Schematic - GTH-1048 and GTH-1056 with Single Joystick REV C P1-1871 6 - 22 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 193: Gth-1048 And Gth-1056 With Dual Joysticks
June 2007 Section 6 • Schematics Hydraulic Schematic - GTH-1048 and GTH-1056 with Dual Joysticks REV A P1-1871 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 6 - 23...
Page 194 Section 6 • Schematics June 2007 This page intentionally left blank. 6 - 24 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487...
Page 195 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie Scandinavia Genie China Phone +46 31 575100 Fax +...
Page 196 Part No. 97487 Rev D...

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Gth-842 Gth-644 Gth-1048 Gth-1056 Gth-844

Genie GTH-636 Service Manual

Table of Contents

Introduction

Safety Rules

C Checklist a Procedures

B Checklist B Procedures

B Checklist C Procedures

B Checklist D Procedures

C Checklist E Procedures

Repair Procedures

Boom Components

Operator's Compartment

Fuel and Hydraulic Tanks

Transmission

Hydraulic Pumps

Schematics

Quick Links

Chapters

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Summary of Contents for Genie GTH-636

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Table of Contents