Genie GTH-636 Installation and operating manual

Service and Repair Manual
Serial Number Range
GTH™-636
from GTH06E-
11750
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1287209GT
Rev A
April 2018

Service and Repair Manual April 2018
Introduction
ii GTH-636 Part No. 1287209GT
Intr od ucti o n Intr od ucti o n
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual 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.
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.
Find a Manual for this 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.
Copyright © 2016 by Terex Corporation
1287209GT Rev A, April 2018
Second 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.

April 2018 Service and Repair Manual
Introduction
Part No. 1287209GT GTH-636 iii
Revision History
Revision
Date
Section
Procedure / Page / Description
A 4/2018 Initial Release
Reference Examples:
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual April 2018
Introduction
iv GTH-636 Part No. 1287209GT
Serial Number Legend
To August 31,
2016
1 Model
2 Model year
3 Facility code
4 Sequence number
1 Serial label (located inside riser, cab side)
2 Serial number (stamped on chassis)
3 Serial label (inside fork frame)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
1 Serial label (located inside riser, cab side)
2 Serial number (stamped on chassis)
3 Serial label (located inside fork frame)

April 2018 Service and Repair Manual
Safety Rules
Part No. 1287209GT GTH-636 v
Section 1 Safet y R ul 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.

Service and Repair Manual April 2018
Safety Rules
vi GTH-636 Part No. 1287209GT
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 lifting 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 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 int
ended 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.

April 2018
Table of Contents
Part No. 1287209GT GTH-636 vii
Introduction Introduction...........................................................................................................ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules ..........................................................................................................v
General Safety Rules ............................................................................................. v
Section 2Specifications .......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications....................................................................................1
Hydraulic Oil Specifications....................................................................................2
Hydraulic Component Specifications......................................................................5
Manifold Component Specifications .......................................................................5
Air Conditioner Refrigerant Specifications .............................................................5
Deutz TD 2.9 Engine Specifications.......................................................................6
Dana VDT12000 Transmission Specifications .......................................................7
Dana 212 Drive Axle ..............................................................................................7
Hydraulic Hose and Fitting Torque Specifications .................................................8
Torque Procedure ..................................................................................................9
Section 3 Repair Procedures .............................................................................................11
Introduction...........................................................................................................11
Boom Components ............................................................................................13
1-1 Boom ..............................................................................................................13
How to Replace the Boom Wear Pads ...........................................................13
How to Use the Quick Attachment ..................................................................13
How to Replace the Retraction Chain.............................................................14
How to Replace the Extension Chains............................................................16
How to Remove the Boom ..............................................................................18
How to Disassemble the Boom .......................................................................20

April 2018
Table of Contents
viii GTH-636 Part No. 1287209GT
1-2 Boom Lift Cylinder ..........................................................................................21
1-3 Boom Extension Cylinder ...............................................................................22
1-4 Fork Level Cylinder ........................................................................................23
1-5 Hydraulic Hoses .............................................................................................24
How to Adjust the Fork Level Cylinder and/or Auxiliary Hose.........................24
How to Replace the Fork Level Cylinder and/or Auxiliary Hoses....................25
Operator's Compartment ...................................................................................27
2-1 Operator's Compartment................................................................................27
2-2 Machine Controls ...........................................................................................28
How to Remove the Steering Column.............................................................28
How to Remove the Steering Wheel ...............................................................29
How to Remove the Steer Orbitral ..................................................................29
How to Remove the Joystick - Models with Electronic Joystick......................30
How to Remove the Brake Pedal Assembly ...................................................30
How to Remove the Gauge Cluster Assembly................................................31
Fuel and Hydraulic Tanks ..................................................................................32
3-1 Fuel and Hydraulic Tanks...............................................................................32
Engines................................................................................................................34
4-1 Engines...........................................................................................................34
4-2 Engine Fault Codes........................................................................................34
Transmission ......................................................................................................35
5-1 Transmission ..................................................................................................35
Hydraulic Pump ..................................................................................................36
6-1 Hydraulic Pump ..............................................................................................36
How to Test the Function Pump ......................................................................36
How to Remove the Function Pump ...............................................................37
How to Install the Function ..............................................................................38
How to Prime the Function Pump ...................................................................38
How to Adjust the Function Pump Standby Pressure .....................................39
How to Adjust the Function Pump Pressure Compensator.............................40

April 2018
Table of Contents
Part No. 1287209GT GTH-636 ix
Manifolds.............................................................................................................41
7-1 PVG Manifold Components - Electronic Joystick...........................................41
7-2 Secondary Function Manifold Components ...................................................42
7-3 Brake Manifold Components..........................................................................45
7-4 Valve Adjustments - Secondary Function Manifold .......................................46
How to Set the Parking Brake System Pressure ............................................46
How to Set the Differential Lock System Pressure .........................................47
7-5 Valve Coils .....................................................................................................48
Axle ......................................................................................................................50
8-1 Axles...............................................................................................................50
Section 4 Fault Codes .........................................................................................................51
Introduction...........................................................................................................51
Diagnostic Display .............................................................................................52
Diagnostic Display ................................................................................................52
Deutz TD 2.9 L4 Engine Fault Codes................................................................53
Section 5 Schematics..........................................................................................................67
Introduction...........................................................................................................67
Fuse Panel Layout ...............................................................................................68
Electrical Component & Wire Color Abbreviation Legend ...................................69
Telematics Connector Pin Legend .......................................................................72
Electrical Symbol Legend.....................................................................................74
Hydraulic Symbols Legend...................................................................................75
Harness Map Legend ...........................................................................................76

April 2018
Table of Contents
x GTH-636 Part No. 1287209GT
Electrical Schematics - Harness Maps.............................................................77
Harness Map - Control System Power Electronic Joystick ..................................78
Harness Map - Deutz TD2.9 Engine Battery Power and Ground.........................80
Harness Map - Options Auxiliary Hydraulics, Beacon and 3rd Gear Lockout......81
Harness Map - Options Work Lights ....................................................................84
Harness Map - Options Road Lights ....................................................................85
Harness Map - Options Enclosed Cab with Heater..............................................88
Harness Map - Options Enclosed Cab with HVAC...............................................89
Electrical Schematics.........................................................................................91
Electrical Schematic - View 1 ...............................................................................92
Electrical Schematic - View 2 ...............................................................................93
Electrical Schematic - Deutz T4F Eng Harness ...................................................96
Hydraulic Schematic.............................................................................................97
Hydraulic Schematics ........................................................................................99