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

April 2018 Service and Repair Manual
Specifications
Part No. 1287209GT GTH-636 1
Section 2 Speci fi c ati ons
Machine Specifications
Tires and wheels
Tire size
13.00 x 28
Tire ply
rating
12
Weight, rough terrain tire
(air filled)
335 lbs
151.9 kg
Weight, rough terrain tire
(foam filled)
780 +50/-
20 lbs
353 +23/-
9 kg
Tire pressure
(models with air
-filled tires)
58 psi
4.3 bar
Lug nut torque
465 ft-
lbs
630 Nm
Lug Pattern
8 x
10.826
Wheel diameter
28 in
71.12 cm
Wheel width
10 in
25.4 cm
Fluid capacities
Fuel tank
27 gallons
102.2 liters
Hydraulic tank
19 gallons
71.9 liters
Hydraulic system
(including tank)
31.5 gallons
119.2 liters
Performance Specifications
Drive speed, maximum
Deutz TD2.9 Engines
18 mph
29.0 km/h
Draw bar pull
15,100 lbs
6849 kg
Lift capacity, maximum
6000 lbs
2722 kg
Boom function speeds, maximum
Boom up
10 to 12 seconds
Boom down
8 to 10 seconds
Boom
extend
11 to 13 seconds
Boom retract
9 to 11 seconds
Fork rotate
3 to 6 seconds
Fork tilt up
6 to 8 seconds
Fork tilt down
5 to 7 seconds

Service and Repair Manual April 2018
Specifications
2 GTH-636 Part No. 1287209GT
Hydraulic Oil Specifications
Hydraulic Fluid Specifications
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 prevention, c
orrosion inhibition, seal
conditioning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 ppm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron Rando HD Premium
Viscosity grade
32
Viscosity index
200
Optional Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable
Petro Canada Environ MV
46
Fire resistant
UCON Hydrolube HP-
5046
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult Genie
Product Support before use.
Optional fluids may not have
the same hydraulic lifespan and
may result in
component
damage.
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.
Do not top off with incompatible
hydraulic fluids. Hydraulic fluids
may be incompatible due to the
differences in base additive
chemistry. When incompatible
fluids are mixed, insoluble
materials may form and deposit
in the hydraulic system,
plugging hydrau
lic lines, filters,
control valves and may result in
component damage.
Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.
Hydraulic Fluid Temperature
Range
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV

April 2018 Service and Repair Manual
Specifications
Part No. 1287209GT GTH-636 3
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
Viscosity index
200
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield
Viscosity
cP @
-4°F / -20°C
cP @
-22°F / -30°C
1040
3310
Flash point
375°F / 190°C
Pour point
-58°F / -
50°C
Maximum continuous operating
temperature
171°F / 77°C
Note: A hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.
Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index
300
Kinematic Viscosity
cSt @
200°F / 100°C
cSt @ 104°F / 40°C
cSt @
-40°F / -40°C
5.5
15.0
510
Flash point
180°F / 82°C
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
124°F / 51°C
Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
are consistently below 0°F / -17°C unless an oil
heating system is used.
Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage

Service and Repair Manual April 2018
Specifications
4 GTH-636 Part No. 1287209GT
Petro-Canada Environ MV 46
Fluid Properties
ISO Grade
46
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
8.0
44.4
Flash point
482°F / 250°C
Pour point
-49°F / -
45°C
Maximum continuous operating
temperature
180°F / 82°C
Shell Tellus S4 VX Fluid
Properties
ISO Grade
32
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
9
33.8
Brookfield Viscosity
cSt @
-4°F / -20°C
cSt @
-13°F / -25°C
cSt @
-40°F / -40°C
481
702.4
2624
Flash point
>100
Pour point
-76°F / -
60°C
Maximum continuous operating
temperature
103°F / 75°C
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
46
Viscosity index
192
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F /
-18°C
22
46
1300
Flash
point
None
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
189°F / 87°C

April 2018 Service and Repair Manual
Specifications
Part No. 1287209GT GTH-636 5
Hydraulic Component
Specifications
Function pump
Type: variable displacement piston pump
Displacement
2.3 cu in
0 to 38 cc
Flow rate @ 2600 rpm
26 gpm
99 L/min
Pump pressure, maximum
3190 psi
220 bar
Pressure compensator
3190 psi
220 bar
Standby pressure
650 psi
44.8 bar
Primary Function Manifold
System relief valve pressure, maximum
(measured at test port TP)
3200 psi
221 bar
Fork tilt relief valve pressure, maximum
3500 psi
241 bar
Flow regulator, Sway circuit
2 gpm
7.5 L/min
Secondary Function Manifold
Steer relief valve pressure, maximum
(measured at test port TS)
2650 psi
182.7 bar
Parking brake relief valve
pressure,
maximum
(measured at test port TPB)
350 psi
24.1 bar
Joystick relief valve pressure, maximum
(measured at test port TJ)
400 psi
27.5 bar
Manifold Component
Specifications
Plug torque
SAE No. 2
50 in-lbs / 6
Nm
SAE No. 4
13 ft-
lbs / 18 Nm
SAE No. 5
15 ft lbs / 20 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
Air Conditioner Refrigerant
Specifications
System Full Charge
R134a

Service and Repair Manual April 2018
Specifications
6 GTH-636 Part No. 1287209GT
Deutz TD 2.9 L4 Engine
Displacement
177 cu. in
2.9 liters
Number of cylinders
4
Bore and Stroke
3.6 x 4.3 inches
92 x 110 mm
Horsepower net intermittent @
2600 rpm
74.2 hp
55 kW
Firing order
1 - 3 - 4 -
2
Standby idle
1000 rpm
Low idle
950 rpm
High idle
2600 rpm
Compression ratio
17.4:1
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder
Governor
electronic
Lubrication system
Oil pressure, hot (@ 2000 rpm)
40 to 60 psi
2.8 to 4.1 bar
Oil capacity (including filter)
9.4 quarts
8.9 liters
Oil viscosity requirements
-
22°F to 86°F / -30°C to 30°C 5W-
30
(synthetic)
-
4°F to 104°F / -20°C to 40°C 10W-
40
Above 5°F /
-15°C 15W-
40
Unit ships with 15W
-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
Oil temperature switch
Installation torque
8 - 18 ft-
lbs
11 -
24 Nm
Temperature switch point
275°F
135°C
Oil Pressure switch
Installation torque
8 - 18 ft-
lbs
11 -
24 Nm
Pressure switch point
20 psi
1.4 bar
Fuel injection system
Bosch
Injection pump pressure, maximum
23200 psi
1600 bar
Injector opening pressure
3046 psi
210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Starter motor
Current draw, normal load
400A
Battery
– Engine starting and control system
Type
12V DC
Quantity
1
Battery capacity, maximum
1000A
Reserve capacity @ 25A rate
200 Minutes
Alternator output
95A @ 12V DC
Fan belt deflection
3/8 to 1/2 inch
9 to 12 mm

April 2018 Service and Repair Manual
Specifications
Part No. 1287209GT GTH-636 7
Dana VDT12000 Transmission
Specifications
Transmission
Type
3 speed powershift converter
Speeds, Forward
3
Speeds, Reverse
3
Torque Converter
Maximum input
3100 rpm
Size
12 inches
Lubrication
Oil capacity, transmission
14.3 quarts
13.5 liters
Oil capacity, drop box
1.1 quart
1 liter
Oil viscosity
requirements
Units ship with Chevron Ursa Hydraulic 10W.
Extreme operating temperatures may require the
use of alternative transmission oils. For oil
requirements, refer to the Dana VDT12000 Service
Manual.
Dana VDT12000 Service Manual
Genie part
number
218706
Dana 212 Drive Axle
Specifications
Steering
Integrated steer cylinder
Joints
Heavy duty double U-
joints
Steering angle, maximum
45°
Front Axle Lubrication
Front differential
7.4 quarts
7 liters
Axle planetary end
(each)
0.8 quarts
0.8 liters
Rear Axle Lubrication
Rear differential
8.0 quarts
7.6 liters
Axle planetary end (each)
0.8 quarts
0.8 liters
Oil viscosity requirements
Differential
Chevron Supreme 85W90 (API GL5)
Planetary
ends
Chevron Supreme 85W90
(API GL5)
For additional axle information, refer to the
Dana 212 Axle Service Manual.
Dana 212 Axle Service Manual
Genie part number
1259569

Service and Repair Manual April 2018
Specifications
8 GTH-636 Part No. 1287209GT
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok™
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends be
torqued to specification when they are removed
and installed or when new hoses or fittings are
installed.
Seal-Lok™ Fittings
(hose end - ORFS)
SAE Dash Size Torque
-4 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash Size Thread Size Flats
-4 7/16-20 2
-6 9/16-18 1 ¼
-8 3/4-16 1
-10 7/8-14 1
-12 1 1/16-12 1
-16 1 5/16-12 1
-20 1 5/8-12 1
-24 1 7/8-12 1
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
(all types)
SAE Dash Size Torque
-4 14 ft-lbs / 19 Nm
-6 23 ft-lbs / 31.2 Nm
-8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
-16 125 ft-lbs / 169.5 Nm
-20 151 ft-lbs / 204.7 Nm
-24 184 ft-lbs / 249.5 Nm
Adjustable Fitting Non-adjustable fitting
1 jam nut
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash Size Torque
-4 ORFS / 37° (Adj)
ORFS (Non-adj)
37° (Non-adj)
15 ft-lbs / 20.3 Nm
26 ft-lbs / 35.3 Nm
22 ft-lbs / 30 Nm
-5 ORFS (Adj / Non adj) 32 ft lbs / 43.4 Nm
-6 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
35 ft-lbs / 47.5 Nm
29 ft-lbs / 39.3 Nm
-8 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
60 ft-lbs / 81.3 Nm
52 ft-lbs / 70.5 Nm
-10 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
100 ft-lbs / 135.6 Nm
85 ft-lbs / 115.3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm

April 2018 Service and Repair Manual
Specifications
Part No. 1287209GT GTH-636 9
Torque Procedure
Seal-Lok™ fittings
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
Note: The O-ring in Parker Seal Lok™ fittings and
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the
O-ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure the O-ring face seal is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut
finger tight.
5 Tighten the nut or fitting to the appropriate
torque. Refer to the appropriate torque chart in
this section.
6 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
the hex nut to the body hex fitting to hand tight,
approximately 30 in-lbs / 3.4 Nm.
2 Using a permanent ink marker, make a
reference mark on one the flats of the hex nut
and continue the mark onto the body of the
hex fitting. Refer to Illustration 1.
Illustration 1
1 hex nut
2 reference mark
3 body hex fitting

Service and Repair Manual April 2018
Specifications
10 GTH-636 Part No. 1287209GT
3 Working clockwise on the body hex fitting,
make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Illustration 2.
Note: Use the JIC 37° Fitting table in this section to
determine the correct number of flats, for the
proper tightening position.
Note: The marks indicate the correct tightening
positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
joint after it has been loosened.
Illustration 2
1 body hex fitting
2 reference mark
3 second mark
4 Tighten the hex nut until the mark on the hex
nut is aligned with the second mark on the
body hex fitting.
5 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.