Genie GTH-636 User manual

Maintenance Manual -
Telehandlers
GTH-636
This manual includes detailed
procedures for each
maintenance inspection.
GTH-844
GTH-1056
For Repair procedures, Fault
Codes, Electrical and Hydraulic
Schematics, refer to the
appropriate Service and Repair
Manual for your machine.
GTH-1256
GTH-1544
GTH-5519
Refer to the
inside cover for a list of models
included in this manual.
Part No. 1272858
Rev A1
September 2016

Maintenance Manual September 2016
Introduction
ii Genie Telehandlers Part No. 1272858
Intr od ucti o n Intr od uct i o n
Impor tant In form ati on
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance be performed at an authorized Genie
dealer service center.
Compliance
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
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.

September 2016 Maintenance Manual
Introduction
Part No. 1272858 Genie Telehandlers iii
Models included in this manual
Use the following chart to identify the specific serial
number for models included in this manual.
Models
Serial number
GTH
-636 from GTH0615H-10001 to 16H-
10742
from GTH0615E-10000 to GTH0616E-
10999
from GTH06E-
11000
GTH
-844 from GTH0813-16606 to GTH0816-
21572
from GTH0816E-10000 to GTH0816E-
10699
from GTH08E-
10700
GTH
-1056 from GTH1010-14001 to GTH1014-
20404
from GTH1014E-10001 to GTH1016E-
10799
from GTH10E-
10800
GTH
-1256 from GTH1215M-101 to GTH1216M-
249
from GTH12M-
250
GTH
-1544 from GTH1513B-1 to 15B-
339
(includes 24273)
GTH
-5519 from GTH5514B-101 to GTH5516B-
4411
from GTH5516M-4411 to GTH5516M-
5799
from GTH55M-
5800
Identifying the Correct Procedure
for your Model
Unless otherwise noted, each procedure will apply
to all models. Procedures that only apply to specific
models or options will include the information in the
procedure title.
Examples of procedures that apply to specific
models:
• Adjust the Boom Sequencing Chains -
GTH-636 and GTH-844
• Adjust the Boom Sequencing Chains -
GTH-1056
Examples of procedures that apply to all models:
• Inspect the Electrical Wiring
• Inspect the Tires, Wheels and Lug Nut
Torque
Find additional Manuals for your
Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.

Maintenance Manual September 2016
Introduction
iv Genie Telehandlers Part No. 1272858
Revision History
Revision History
Revision
Date
Section
Procedure / Description
A 3/2016 Initial Release
A1 9/2016 Introduction Models Included
Reference Examples:
Section – Specifications Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Maintenance, (procedure)

September 2016 Maintenance Manual
Introduction
Part No. 1272858 Genie Telehandlers v
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
the update.
Section – Maintenance, (procedure)

Maintenance Manual September 2016
Safety Rules
vi Genie Telehandlers Part No. 1272858
Section 1 Safet y R ules Gener al Saf ety Rul es
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
 You are trained and qualified to perform
maintenance on this machine.
 You read, understand and obey:
• manufacturer's instructions and safety rules
• employer's safety rules and worksite
regulations
• applicable governmental regulations
 You have the appropriate tools, lifting
equipment and a suitable workshop.

September 2016 Maintenance Manual
Safety Rules
Part No. 1272858 Genie Telehandlers vii
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol
—
used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a
potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which,
if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lif
ting or
placing loads. Always wear approved
steel
-toed shoes.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are p
roperly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stab
ilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self
-locking
nuts) are not reused. These components
may fail if they are
used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

September 2016
Table of Contents
viii Genie Telehandlers Part No. 1272858
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 ......................................................................................................... vi
General Safety Rules ............................................................................................. vi
Section 2 Specifications ....................................................................................................... 1
Machine Specifications .......................................................................................... 1
Air Conditioner Refrigerant Specifications ............................................................. 2
Performance Specifications ................................................................................ 3
Performance Specifications ................................................................................... 3
Torque Specifications ......................................................................................... 5
Tires and Wheels ................................................................................................... 5
Powertrain Specifications ................................................................................... 6
Operator and Maintenance Manuals...................................................................... 6
Deutz Engine Models ............................................................................................. 7
John Deere Engine Models .................................................................................... 7
Perkins Engine Models .......................................................................................... 8
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

September 2016
Table of Contents
Part No. 1272858 Genie Telehandlers ix
Section 3 Maintenance Procedures ................................................................................... 19
Introduction ........................................................................................................... 19
Maintenance Schedule ......................................................................................... 21
Pre-Delivery Preparation Report .......................................................................... 22
Scheduled and Programmed Maintenance Inspection Report ............................ 23
Commissioning Procedures ............................................................................. 24
C-1 Perform 50 Hour Service ............................................................................... 24
C-2 Perform Engine Maintenance – 50 Hours ..................................................... 24
C-3 Perform 150 Hour Service ............................................................................. 25
Quarterly Maintenance Procedures.................................................................. 26
Q-1 Check for Open Bulletins and Owner Registration ....................................... 26
Q-2 Battery inspection .......................................................................................... 27
Q-3 Inspect the Electrical Wiring .......................................................................... 28
Q-4 Check the Boom Wear Pads ......................................................................... 29
Q-5 Check the Exhaust System ........................................................................... 31
Q-6 Inspect the Tires, Wheels and Lug Nut Torque ............................................ 31
Q-7 Inspect the Fork Level and Auxiliary Hydraulic Hoses Tension .................... 32
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

September 2016
Table of Contents
x Genie Telehandlers Part No. 1272858
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 ............................................. 41
A-6 Replace the Cab Air Intake Filter Element (if equipped) ............................... 41
Programmed Maintenance Procedures ........................................................... 42
P0-1 Lubricate the Boom ..................................................................................... 42
P0-2 Deutz Engine Maintenance – Under 1000 Hours........................................ 43
P0-3 Perkins Engine Maintenance – Under 1000 Hours ..................................... 44
P0-4 John Deere Engine Maintenance – Under 1000 Hours .............................. 45
P0-5 Axle Maintenance – Under 1000 Hours ...................................................... 46
P0-6 Transmission Maintenance – Under 1000 Hours ........................................ 48
P1-1 Perform Engine Maintenance – 1000 Hours ............................................... 49
P1-2 PerformTransmission Maintenance – 1000 Hours ...................................... 49
P1-3 Perform Axle Maintenance – 1000 Hours ................................................... 50
P2-1 Perform Engine Maintenance – 2000 Hours ............................................... 51
P2-2 Test or Replace the Hydraulic Oil ............................................................... 52
P3-1 Perform Engine Maintenance – 3000 Hours ............................................... 53
P4-1 Perform Engine Maintenance – 4000 Hours ............................................... 53
P6-1 Perform Engine Maintenance – 6000 Hours ............................................... 54
P12-1 Perform Engine Maintenance – 12000 Hours ........................................... 54