Terex 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
Refer to the inside cover for a list of model serial
number
ranges included in this manual.
Original Instructions
Part No. 1305161GT
Rev
A
November 2022

Maintenance Manual November 2022
Introduction
ii Genie Telehandlers Part No. 1305161GT
Intr od ucti on Intr od ucti 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
1305161GT Rev A, November 2022
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.

November 2022 Maintenance Manual
Introduction
Part No. 1305161GT 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 GTH06T-13801
GTH-844 from GTH08T-14101
GTH-1056 from GTH10E-16000 to GTH10E-16500
from GTH10T-16501
GTH-1256 from GTH12T-10101
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, GTH-844
•Adjust the Boom Sequencing Chains -
GTH-1056, GTH-1256
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 November 2022
Introduction
iv Genie Telehandlers Part No. 1305161GT
Revision History
Revision Date Section Procedure / Description
A 11/2022 Initial Release
Reference Examples:
Section – Specifications Electronic Version
Click on any content or procedure in the Table of Contents to view the
update.
Section – Maintenance, (procedure)

November 2022 Maintenance Manual
Safety Rules
Part No. 1305161GT Genie Telehandlers v
Section 1 Safet y R ules
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 modify or alter a Telehandler without prior
written permission from the manufacturer.
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.

Maintenance Manual November 2022
Safety Rules
vi Genie Telehandlers Part No. 1305161GT
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 avo
ided,
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 hazar
ds
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 extingu
isher 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 an
d 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.

November 2022
Table of Contents
Part No. 1305161GT Genie Telehandlers vii
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 ..........................................................................................................v
General Safety Rules ............................................................................................. v
Section 2 Specifications .......................................................................................................1
Fluid Capacities ......................................................................................................1
Air Conditioner Refrigerant Specifications .............................................................1
Performance Specifications ................................................................................2
Performance Specifications....................................................................................2
Torque Specifications..........................................................................................4
Tires and Wheels ...................................................................................................4
Powertrain Specifications ...................................................................................5
Operator and Maintenance Manuals ......................................................................5
Deutz Engine Models .............................................................................................5
Transmission Specifications...................................................................................6
Axle Specifications .................................................................................................6
Hydraulic Specifications......................................................................................7
Hydraulic Relief Valves ..........................................................................................7
Hydraulic Oil Specifications....................................................................................8
Hydraulic Hose and Fitting Torque Specifications ...............................................11
Torque Procedure ................................................................................................12

November 2022
Table of Contents
viii Genie Telehandlers Part No. 1305161GT
Section 3 Maintenance Procedures .................................................................................. 14
Introduction .......................................................................................................... 14
Maintenance Schedule ........................................................................................ 16
Pre-Delivery Preparation Report.......................................................................... 17
Scheduled and Programmed Maintenance Inspection Report ............................ 18
Commissioning Procedures ............................................................................. 19
C-1 Perform 50 Hour Service............................................................................... 19
C-2 Perform Engine Maintenance – 50 Hours..................................................... 19
C-3 Perform 150 Hour Service............................................................................. 20
Quarterly Maintenance Procedures ................................................................. 21
Q-1 Check for Open Bulletins and Owner Registration ....................................... 21
Q-2 Battery inspection ......................................................................................... 22
Q-3 Inspect the Electrical Wiring.......................................................................... 22
Q-4 Check the Boom Wear Pads......................................................................... 23
Q-5 Check the Exhaust System........................................................................... 24
Q-6 Inspect the Tires, Wheels and Lug Nut Torque ............................................ 24
Q-7 Inspect the Fork Level and Auxiliary Hydraulic Hose Tension ..................... 25
Q-8 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ........................ 26
Q-9 Visual Inspection of the Hydraulic Oil ........................................................... 27
Q-10 Inspect the Engine Air Filter........................................................................ 28
Q-11 Lubricate the Driveshaft .............................................................................. 28
Q-12 Inspect and Lubricate the Sequencing Chains ........................................... 29
Annual Maintenance Procedures ..................................................................... 32
A-1 Inspect the Forks........................................................................................... 32
A-2 Adjust the Boom Sequencing Chains - GTH-636, GTH-844......................... 32
A-3 Adjust the Boom Sequencing Chains - GTH-1056, GTH-1256..................... 33
A-4 Replace Hydraulic Tank Return Filter Element ............................................. 34
A-5 Replace the Cab Air Intake Filter Element (if equipped) ............................... 35

November 2022
Table of Contents
Part No. 1305161GT Genie Telehandlers ix
Programmed Maintenance Procedures ...........................................................36
P0-1 Lubricate the Boom......................................................................................36
P0-2 Deutz Engine Maintenance – Under 1000 Hours ........................................37
P0-3 Axle Maintenance – Under 1000 Hours.......................................................38
P0-4 Transmission Maintenance – Under 1000 Hours ........................................39
P1-1 Perform Engine Maintenance – 1000 Hours ...............................................40
P1-2 PerformTransmission Maintenance – 1000 Hours ......................................40
P1-3 Perform Axle Maintenance – 1000 Hours....................................................41
P2-1 Test or Replace the Hydraulic Oil................................................................41
P3-1 Perform Engine Maintenance – 3000 Hours ...............................................42
P5-1 Perform Engine Maintenance – 5000 Hours ...............................................43
P6-1 Perform Engine Maintenance – 6000 Hours ...............................................43

Maintenance Manual November 2022
x Genie Telehandlers Part No. 1305161GT
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