Genie GTH-636 User manual

Parts Manual
GTH-844
GTH-842
GTH-644
after GTH05-12345
after GTH05-12345
after GTH05-12345
Serial Number Range
Service Manual
GTH-636
GTH-644
GTH-842
Part No. 97487
Rev D
June 2007
from GTH0806A-8418
from GTH0806B-6958
Serial Number Range
from GTH0606A-8418 to
GTH0610A-13771
from GTH0606A-8418
from GTH0606B-6271
GTH-844
GTH-1048
GTH-1056
GTH-844
from GTH1006A-8418 to
GTH-1007A-11442
from GTH0806A-8418 to
GTH0812-16605
from GTH0806B-6956
from GTH1006A-8418 to
GTH1007A-11442

June 2007
GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487
ii
Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
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 and repair be
performed at an authorized Genie dealer
service center.
Technical Publications
Genie Industries 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:
PO Box 97030
Redmond, WA 98073-9730 USA
www.genieindustries.com
e-mail: [email protected]
Copyright © 2006 by Genie Industries
97487 Rev D June 2007
First Edition, Fourth Printing
"Genie" is a registered trademark of Genie
Industries in the USA and many other countries.
"GTH" is a trademark of Genie Industries.
Printed on recycled paper
Printed in U.S.A.
Introduction

June 2007
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 iii
Serial Number Legend
INTRODUCTION
TH08 06 A - 1234
Model
Year of
manufacture
Facility code
Sequence
number
MODEL:
Genie Industries
18340 NE 76th S treet
Redmond, WA 98052
USA
GTH844
A TEREX COMPANY
SERIAL NUMBER: GTH0806A-8454
ATTACHMENT:
MANUFACTURE DATE: 02/20/06
TOTAL TRUCK WEIGHT(LBS): 22,010lbs / 9,984kg
MAX LIFT CAPACITY(LBS):
8000 LBS
LIFT CAPACITY(LBS)
AT MAX LIFT HEIGHT:
OUTRIGGERS UP:
OUTRIGGERS DOWN: N/A
N/A
6000 LBS
THIS FORKLIFT TRUCK COMPLIES
WITH:
ASME B56.6-2002 SAFETY STD FOR
ROUGH TERRAIN FORKLIFT TRUCK
Serial label
(located inside fork frame)
(models with quick attach frame)
Serial label
(located inside chassis
upright at cab side of machine)
Serial number
stamped on chassis

June 2007
GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487
iv
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June 2007
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056
Safety Rules
Section 1 • Safety Rules
v
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.

June 2007
GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487
SAFETY RULES
vi
Section 1 • Safety Rules
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 an 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 lifting or
placing loads. Always wear approved
steel-toed shoes.
Workplace Safety
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 properly 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 stabilizing 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.

June 2007
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056
Table of Contents
vii
Introduction
Important Information ......................................................................................... ii
Serial Number Legend ...................................................................................... iii
Section 1 Safety Rules
General Safety Rules ........................................................................................ v
Section 2 Rev Specifications
D Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 3
Hydraulic Specifications ............................................................................... 2 - 4
Manifold Component Specifications ............................................................. 2 - 6
John Deere 4045TF270 Engine ................................................................... 2 - 7
John Deere 4045TF275 Engine ................................................................... 2 - 8
Deutz BF4 2012 Engine ............................................................................... 2 - 9
Perkins 1104C-44T Engine ........................................................................ 2 - 10
Perkins 1104C-44TA Engine ..................................................................... 2 - 11
Dana T12000 Transmission ....................................................................... 2 - 12
Dana T20000 Transmission ....................................................................... 2 - 12
Dana Planetary 212 Drive Axle .................................................................. 2 - 13
Dana Planetary 213 Drive Axle .................................................................. 2 - 13
Hydraulic Hose and Fitting Torque Specifications ...................................... 2 - 14
SAE and Metric Fasteners Torque Charts ................................................. 2 - 15
Section 3 Rev Scheduled Maintenance Procedures
Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................. 3 - 3
Maintenance Inspection Report ................................................................... 3 - 5

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GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487
TABLE OF CONTENTS
viii
Section 3 Rev Scheduled Maintenance Procedures, continued
CChecklist A Procedures
A-1 Inspect the Manuals and Decals ......................................................... 3 - 7
A-2 Perform Pre-operation Inspection ....................................................... 3 - 8
A-3 Perform Function Tests ...................................................................... 3 - 8
A-4 Lubricate the Machine ........................................................................ 3 - 9
A-5 Perform Engine Maintenance - John Deere and Perkins Models...... 3 - 11
A-6 Perform Transmission Maintenance ................................................. 3 - 11
A-7 Perform Engine Maintenance - Deutz Models .................................. 3 - 12
A-8 Perform 30 Day Service ................................................................... 3 - 12
A-9 Perform Transmission Maintenance -
GTH-636, GTH-644, GTH-842 and GTH-844 Models ...................... 3 - 13
A-10 Perform Engine Maintenance - Perkins Models ................................ 3 - 13
A-11 Perform Axle Maintenance ............................................................... 3 - 14
A-12 Perform Engine Maintenance - John Deere Models ......................... 3 - 14
A-13 Perform Transmission Maintenance -
GTH-636, GTH-644, GTH-842 and GTH-844 Models ..................... 3 -- 15
A-14 Perform Transmission Maintenance ................................................. 3 - 15
A-15 Perform Axle Maintenance ............................................................... 3 - 16
BChecklist B Procedures
B-1 Inspect the Battery ........................................................................... 3 - 17
B-2 Inspect the Electrical Wiring ............................................................. 3 - 17
B-3 Check the Exhaust System .............................................................. 3 - 18
B-4 Inspect the Engine Air Filter.............................................................. 3 - 19
B-5 Inspect the Tires, Wheels and Lug Nut Torque................................. 3 - 19
B-6 Perform Hydraulic Oil Analysis ......................................................... 3 - 20
B-7 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ............. 3 - 21
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

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TABLE OF CONTENTS
ix
Section 3 Rev Scheduled Maintenance Procedures, continued
BChecklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models .................................. 3 - 24
C-2 Perform Engine Maintenance - John Deere Models ......................... 3 - 24
C-3 Perform Axle Maintenance ............................................................... 3 - 25
C-4 Perform Transmission Maintenance -
GTH-1048 and GTH-1056 Models .................................................... 3 - 25
C-5 Perform Engine Maintenance - Perkins Models ................................ 3 - 26
C-6 Perform Axle Maintenance ............................................................... 3 - 26
C-7 Perform Axle Maintenance ............................................................... 3 - 27
BChecklist D Procedures
D-1 Inspect the Forks .............................................................................. 3 - 28
D-2 Adjust the Boom Sequencing Chains ............................................... 3 - 28
D-3 Replace the Hydraulic Tank Return Filter Element ........................... 3 - 31
D-4 Perform Engine Maintenance - Deutz Models .................................. 3 - 32
D-5 Perform Transmission Maintenance ................................................. 3 - 32
D-6 Perform Axle Maintenance ............................................................... 3 - 33
D-7 Perform Engine Maintenance - Perkins Models ................................ 3 - 33
D-8 Perform Engine Maintenance - Deutz Models .................................. 3 - 34
CChecklist E Procedures
E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 35
E-2 Perform Engine Maintenance - John Deere Models ......................... 3 - 36
E-3 Perform Engine Maintenance - Perkins Models ................................ 3 - 36
E-4 Perform Engine Maintenance - Perkins Models ................................ 3 - 37
E-5 Perform Engine Maintenance - Perkins Models ................................ 3 - 37
E-6 Perform Engine Maintenance - John Deere Models ......................... 3 - 38
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

June 2007
GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487
TABLE OF CONTENTS
x
Section 4 Rev Repair Procedures
Introduction .................................................................................................. 4 - 1
CBoom Components
1-1 Boom Angle Limit Switch (all models except GTH-636) ..................... 4 - 2
1-2 Boom ................................................................................................. 4 - 3
1-3 Boom Lift Cylinder ............................................................................ 4 - 15
1-4 Boom Extension Cylinder ................................................................. 4 - 17
1-5 Fork Level Cylinder .......................................................................... 4 - 18
1-6 Fork Rotate Cylinder (option) ........................................................... 4 - 20
BOperator's Compartment
2-1 Operator's Compartment .................................................................. 4 - 23
2-2 Machine Controls ............................................................................. 4 - 32
CFuel and Hydraulic Tanks
3-1 Fuel Tank ......................................................................................... 4 - 38
3-2 Hydraulic Tank ................................................................................. 4 - 39
BEngines
4-1 Engines ............................................................................................ 4 - 40
4-2 Engine Fault Codes - John Deere 4045TF275 Engine ..................... 4 - 41
CTransmission
5-1 Transmission .................................................................................... 4 - 42
BHydraulic Pumps
6-1 Hydraulic Pump ................................................................................ 4 - 44
CManifolds
7-1 Main Valve Manifold Components .................................................... 4 - 48
7-2 Tilt Limiter Manifold Components ..................................................... 4 - 49
7-3 Dual Pilot Check Manifold Components ........................................... 4 - 50
7-4 Boom Activated Rear Lock-up Manifold Components ...................... 4 - 51
7-5 Fork Rotate Speed Manifold Components (option)........................... 4 - 52

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Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056
TABLE OF CONTENTS
xi
Section 4 Rev Repair Procedures, continued
7-6 Control Block Manifold Components ................................................ 4 - 53
7-7 Fork Tilt Manifolds Components ....................................................... 4 - 54
7-8 Rear Lock-up Manifold Components ................................................ 4 - 55
7-9 Parking Brake Manifold Components ............................................... 4 - 56
7-10 Differential Lock-up Manifold Components
(optional on GTH-636 and GTH-644) ............................................... 4 - 57
7-11 Sway Manifold Components............................................................. 4 - 58
7-12 Fork Rotate Manifold Components (option) ...................................... 4 - 59
7-13 Sway Directional Manifold Components ........................................... 4 - 60
7-14 Outrigger Manifold Components -
GTH-1048 and GTH-1056 ................................................................ 4 - 61
7-15 Controller Relief (Drop Block) Manifold -
GTH-636, GTH-1048 and GTH-1056 ............................................... 4 - 62
7-16 Boom Lift and Boom Extension Cylinders Manifold Components ..... 4 - 63
7-17 Fork Level Cylinder Manifold Components ....................................... 4 - 64
7-18 Fork Rotate Cylinder Manifold Components (option) ........................ 4 - 65
7-19 Pump Destroke Manifold Components ............................................. 4 - 66
7-20 Extend Cylinder Relief Valve Manifold -
GTH-636, GTH-1048 and GTH-1056 ............................................... 4 - 67
7-21 Boom Activated Sway Lock-up Manifold Components ..................... 4 - 68
7-22 Valve Adjustments - Control Block Manifold ..................................... 4 - 69
7-23 Valve Adjustments - Tilt Limiter Manifold.......................................... 4 - 71
7-24 Valve Coils ....................................................................................... 4 - 72
DAxle Components
8-1 Axles ................................................................................................ 4 - 73
AOutriggers
9-1 Outriggers ........................................................................................ 4 - 76

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GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487
xii
Section 5 Rev Troubleshooting
Introduction .................................................................................................. 5 - 1
A 1-1 Engine Fault Codes -
GTH-1048 and GTH-1056 .................................................................. 5 - 2
A 1-2 Hydraulic Pump .................................................................................. 5 - 4
B 1-3 Boom Functions ................................................................................. 5 - 6
A 1-4 Drive Functions ................................................................................ 5 - 13
A 1-5 Steer Functions ................................................................................ 5 - 14
A 1-6 Brake Functions ............................................................................... 5 - 17
A 1-7 Sway Functions ................................................................................ 5 - 18
TABLE OF CONTENTS

June 2007
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056
Section 6 Rev Schematics
Introduction .................................................................................................. 6 - 1
A Electrical Component and Limit Switch Legends ......................................... 6 - 2
B Electrical and Hydraulic Symbols Legends .................................................. 6 - 3
C Electrical Schematic -
GTH-636 with John Deere Power ................................................................ 6 - 4
B Electrical Schematic -
GTH-636 with Perkins Power....................................................................... 6 - 6
C Electrical Schematic -
GTH-644, GTH-842 and GTH-844 with John Deere Power ......................... 6 - 8
B Electrical Schematic -
GTH-644, GTH-842 and GTH-844 with Perkins Power ............................. 6 - 10
B Electrical Schematic -
GTH-644, GTH-842 and GTH-844 with Deutz Power ................................ 6 - 12
C Electrical Schematic -
GTH-1048 and GTH-1056 with John Deere Power .................................... 6 - 14
B Electrical Schematic -
GTH-1048 and GTH-1056 with Perkins Power .......................................... 6 - 16
C Hydraulic Schematic -
GTH-636 with Single Joystick .................................................................... 6 - 18
A Hydraulic Schematic -
GTH-636 with Dual Joysticks ..................................................................... 6 - 19
B Hydraulic Schematic -
GTH-644, GTH-842 and GTH-844 with Single Joystick ............................. 6 - 20
A Hydraulic Schematic -
GTH-644, GTH-842 and GTH-844 with Dual Joysticks .............................. 6 - 21
C Hydraulic Schematic -
GTH-1048 and GTH-1056 with Single Joystick.......................................... 6 - 22
A Hydraulic Schematic -
GTH-1048 and GTH-1056 with Dual Joysticks .......................................... 6 - 23
TABLE OF CONTENTS
xiii

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REV D
Section 2 • Specifications
June 2007
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 2 - 1
Specifications
Machine Specifications
Fluid capacities
GTH-636, GTH-644, GTH-842 and GTH 844
Fuel tank 30 gallons
113.6 liters
Hydraulic tank 34 gallons
128.7 liters
Hydraulic system 50 gallons
(including tank) 189.3 liters
For operational specifications, refer to the
Operator's Manual.
GTH-1048 and GTH-1056
Fuel tank 30 gallons
113.6 liters
Hydraulic tank 48 gallons
181.7 liters
Hydraulic system 66 gallons
(including tank) 249.8 liters
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

REV D
Section 2 • Specifications June 2007
2 - 2 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487
SPECIFICATIONS
Tires and wheels
Tire size 13.00 x 24
Tire ply rating 12
Weight, rough terrain tire 270 lbs
(air filled) 122.5 kg
Weight, rough terrain tire 815 ±35 lbs
(calcium chloride filled) 370 ±16 kg
Weight, rough terrain tire 836 ±35 lbs
(foam filled) 379 ±16 kg
Weight, rock lug tire 835 ±35 lbs
(calcium chloride filled) 379 ±16 kg
Weight, rock lug tire 886 ±35 lbs
(foam filled) 402 ±16 kg
Tire size 14.00 x 24
Tire ply rating 12
Weight, rough terrain tire 270 lbs
(air filled) 122.5 kg
Weight, rough terrain tire 965 ±35 lbs
(calcium chloride filled) 438 ±16 kg
Weight, rough terrain tire 967 ±35 lbs
(foam filled) 439 ±16 kg
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
All models
Tire pressure 50 psi
(models without foam filled tires) 3.45 bar
Lug nut torque 465 ft-lbs
630 Nm
Lug pattern 10 x 13.189
Wheel diameter 24 in
60.1 cm
Wheel width 9 in
22.9 cm
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

REV D
Section 2 • Specifications
June 2007
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 2 - 3
Performance Specifications
Drive speed, maximum
GTH-636 and GTH-842 18 mph
29 km/h
GTH-644 and GTH-844 17 mph
27.4 km/h
GTH-1048 and GTH-1056 19 mph
30.6 km/h
Draw bar pull
GTH-636, GTH-644, 19,200 lbs
GTH-842 and GTH-844 8427 kg
GTH-1048 and GTH-1056 26,500 lbs
12045 kg
Lift capacity, maximum
GTH-636 and GTH-644 6000 lbs
2727 kg
GTH-842 and GTH-844 8000 lbs
3636 kg
GTH-1048 and GTH-1056 10,000 lbs
4545 kg
Boom function speeds, maximum
GTH-636
Boom up 12 to 14 seconds
Boom down 16 to 18 seconds
Boom extend 6 to 8 seconds
Boom retract 9 to 11 seconds
Chassis sway 11 to 13 seconds
Fork tilt up 11 to 13 seconds
SPECIFICATIONS
Boom function speeds, maximum
GTH-644, GTH-842 and GTH-844
Boom up 14 to 16 seconds
Boom down 10 to 12 seconds
Boom extend 17 to 19 seconds
Boom retract 13 to 15 seconds
Chassis sway 9 to 12 seconds
Fork tilt up 7 to 9 seconds
GTH-1048
Boom up 12 to 14 seconds
Boom down 13 to 15 seconds
Boom extend 16 to 18 seconds
Boom retract 15 to 17 seconds
Fork rotate 19 to 21 seconds
Chassis sway 11 to 13 seconds
Fork tilt up 11 to 13 seconds
GTH-1056
Boom up 17 to 19 seconds
Boom down 23 to 25 seconds
Boom extend 14 to 16 seconds
Boom retract 13 to 15 seconds
Chassis sway 11 to 13 seconds
Fork tilt up 11 to 13 seconds
All models
Fork tilt down 11 to 13 seconds
Fork rotate 19 to 21 seconds
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

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Section 2 • Specifications June 2007
2 - 4 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487
SPECIFICATIONS
Hydraulic Specifications
Hydraulic Oil Specifications
GTH-636/644 before serial number GTH0607A-11526
GTH-842/844 before serial number GTH0807A-11526
GTH-1048/1056 before serial number GTH1007A-11443
Hydraulic oil type Chevron Rykon AW
ISO46 equivalent
ISO viscosity grade 46
Viscosity index 97
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and have a minimum viscosity index
rating of 97. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional Fluids
Biodegradable Petro Canada Environ MV46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Chevron Rykon MV
Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Continued use of Chevron
Aviation A hydraulic fluid when
ambient temperatures are
consistently above 32°F / 0°C may
result in component damage.
Note: Use Chevron Aviation A hydraulic fluid when
ambient temperatures are consistently below
0°F / -17°C.
Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.
Hydraulic Specifications
Hydraulic Oil Specifications
GTH-636/644 after serial number GTH0607A-11525
GTH-842/844 after serial number GTH0807A-11525
Hydraulic oil type Chevron Rykon MV equivalent
ISO viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional Fluids
Biodegradable Petro Canada Environ MV46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Chevron Rykon MV
Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Continued use of Chevron
Aviation A hydraulic fluid when
ambient temperatures are
consistently above 32°F / 0°C may
result in component damage.
Note: Use Chevron Aviation A hydraulic fluid when
ambient temperatures are consistently below
0°F / -17°C.
Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.

REV D
Section 2 • Specifications
June 2007
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 2 - 5
Function Pump
GTH-636
Type: Variable displacement piston pump
Flow rate @ 2500 rpm 0 to 35 gpm
0 to 132.5 L/min
Pump pressure 2800 psi
(measured at test port GP1) 193 bar
GTH-644, GTH-842, GTH-844 and GTH-1056
Type: Variable displacement piston pump
Flow rate @ 2500 rpm 0 to 35 gpm
0 to 132.5 L/min
Pump pressure 3000 psi
(measured at test port GP1) 206.9 bar
GTH-1048
Type: Variable displacement piston pump
Flow rate @ 2500 rpm 0 to 35 gpm
0 to 132.5 L/min
Pump pressure 3500 psi
(measured at test port GP1) 206.9 bar
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Main Valve Manifold (all models)
System relief valve pressure, maximum 3650 psi
251.7 bar
Control Block Manifold
GTH-636, GTH-644, GTH-842 and GTH-844
Steer relief valve pressure, maximum 2250 psi
(measured at test port GP2) 155 bar
Pilot relief valve pressure, maximum 500 psi
(measured at test port GP3) 34.5 bar
GTH-1048 and GTH-1056
Steer relief valve pressure, maximum 2250 psi
(measured at test port GP2) 155 bar
Pilot relief valve pressure, maximum 400 psi
(measured at test port GP5) 27.6 bar
Tilt Limiter Manifold
GTH-636, GTH-644, GTH-842 and GTH-844
Tilt limiter relief valve pressure, maximum 1200 psi
(measured at test port GP4) 82.7 bar
GTH-1048 and GTH-1056
Tilt limiter relief valve pressure, maximum 1200 psi
(measured at test port GP6) 82.7 bar
Boom Extend Relief Manifold
GTH-636 (from serial number GTH0606A-8418 to
GTH0606A-9022)
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
SPECIFICATIONS

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2 - 6 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487
SPECIFICATIONS
Manifold Component
Specifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 13 ft-lbs / 18 Nm
SAE No. 6 18 ft-lbs / 24 Nm
SAE No. 8 50 ft-lbs / 68 Nm
SAE No. 10 55 ft-lbs / 75 Nm
SAE No. 12 75 ft-lbs / 102 Nm
Valve Coil Resistance
Description Specification
Solenoid valve, 2 position 3 way 12V DC 8 to 10Ω
(schematic items DA, IA and JA)
Solenoid valve, 2 position 4 way 12V DC 8 to 10Ω
(schematic items GA and GB)
Solenoid valve, 3 position 4 way 12V DC 4 to 6Ω
(schematic items LA and MA)
Solenoid valve, 2 position 2 way 12V DC 8 to 10Ω
(schematic item OA)
Solenoid valve, 2 position 2 way 12V DC 6.5 to 8.5Ω
Sauer pump (black)(schematic item TA)
Solenoid valve, 2 position 2 way 12V DC 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.