Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Genie GTH-636 GTH-644 GTH-842 GTH-844 GTH-1048 GTH-1056 Service Manual – PDF
$26.95
Genie GTH-636 GTH-644 GTH-842 GTH-844 GTH-1048 GTH-1056 Service Manual 97487 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Genie GTH-636 GTH-644 GTH-842 GTH-844 GTH-1048 GTH-1056 Service Manual 97487 – PDF DOWNLOAD
Language : English
Pages : 196
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie GTH-636 GTH-644 GTH-842 GTH-844 GTH-1048 GTH-1056 Service Manual 97487 – PDF DOWNLOAD
Table of Contents........................................................................................... 7 Important Information....................................................................................... 2 Section 1 • Safety Rules.................................................................................... 5 Safety Rules............................................................................................ 5 Section 2 • Specifications - Rev D.......................................................................... 15 Machine Specifications.................................................................................. 15 Performance Specifications.............................................................................. 17 Hydraulic Specifications................................................................................ 18 Manifold Component Specifications....................................................................... 20 John Deere 4045TF270 Engine............................................................................. 21 John Deere 4045TF275 Engine............................................................................. 22 Deutz BF4 2012 Engine................................................................................... 23 Perkins 1104C-44T Engine................................................................................ 24 Perkins 1104C-44TA Engine............................................................................... 25 Dana T-12000 Transmission............................................................................... 26 Dana T-20000 Transmission............................................................................... 26 Dana Planetary 212 Drive Axle........................................................................... 27 Dana Planetary 213 Drive Axle........................................................................... 27 Hydraulic Hose and Fitting Torque Specifications........................................................ 28 SAE and Metric Fasteners Torque Charts.................................................................. 29 Section 3 • Scheduled Maintenance Procedures................................................................ 31 Introduction............................................................................................ 31 Pre-delivery Preparation Report......................................................................... 33 Maintenance Inspection Report........................................................................... 35 Checklist A Procedures - Rev C.......................................................................... 37 A-1 Inspect the Manuals and Decals................................................................. 37 A-2 Perform Pre-operation Inspection............................................................... 38 A-3 Perform Function Tests......................................................................... 38 A-4 Lubricate the Machine.......................................................................... 39 A-5 Perform Engine Maintenance - John Deere and Perkins Models..................................... 41 A-6 Perform Transmission Maintenance............................................................... 41 A-7 Perform Engine Maintenance - Deutz Models...................................................... 42 A-8 Perform 30 Day Service......................................................................... 42 A-9 Perform Transmission Maintenance............................................................... 43 A-10 Perform Engine Maintenance - Perkins Models................................................... 43 A-11 Perform Axle Maintenance...................................................................... 44 A-12 Perform Engine Maintenance - John Deere Models................................................ 44 A-13 Perform Axle Maintenance...................................................................... 45 A-14 Perform Transmission Maintenance.............................................................. 45 A-15 Perform Axle Maintenance...................................................................... 46 Checklist B Procedures - Rev B.......................................................................... 47 B-1 Inspect the Battery............................................................................ 47 B-2 Inspect the Electrical Wiring.................................................................. 47 B-3 Check the Exhaust System....................................................................... 48 B-4 Inspect the Engine Air Filter.................................................................. 49 B-5 Inspect the Tires, Wheels and Lug Nut Torque................................................... 49 B-6 Perform Hydraulic Oil Analysis................................................................. 50 B-7 Inspect the Fuel and Hydraulic Tank Cap Venting Systems........................................ 51 B-8 Check the Boom Wear Pads....................................................................... 52 B-9 Lubricate the Driveshafts...................................................................... 53 B-10 Perform Engine Maintenance - John Deere Models................................................. 53 Checklist C Procedure - Rev B........................................................................... 54 C-1 Perform Engine Maintenance - Deutz Models....................................................... 54 C-2 Perform Engine Maintenance - John Deere Models.................................................. 54 C-3 Perform Axle Maintenance........................................................................ 55 C-4 Perform Transmission Maintenance................................................................ 55 C-5 Perform Engine Maintenance - Perkins Models.................................................... 56 C-6 Perform Axle Maintenance........................................................................ 56 C-7 Perform Axle Maintenance........................................................................ 57 Checklist D Procedures - Rev B.......................................................................... 58 D-1 Inspect the Forks............................................................................... 58 D-2 Adjust the Boom Sequencing Chains............................................................... 58 D-3 Replace the Hydraulic Tank Return Filter Element................................................ 61 D-4 Perform Engine Maintenance - Deutz Models....................................................... 62 D-5 Perform Transmission Maintenance................................................................ 62 D-6 Perform Axle Maintenance........................................................................ 63 D-7 Perform Engine Maintenance - Perkins Models.................................................... 63 D-8 Perform Engine Maintenance - Deutz Models....................................................... 64 Checklist E Procedure - Rev C........................................................................... 65 E-1 Test or Replace the Hydraulic Oil............................................................... 65 E-2 Perform Engine Maintenance - John Deere Models.................................................. 66 E-3 Perform Engine Maintenance - Perkins Models.................................................... 66 E-4 Perform Engine Maintenance - Perkins Models.................................................... 67 E-5 Perform Engine Maintenance - Perkins Models.................................................... 67 E-6 Perform Engine Maintenance - John Deere Models................................................. 68 E-7 Perform Engine Maintenance - Perkins Models.................................................... 68 E-8 Perform Engine Maintenance - Deutz Models....................................................... 69 E-9 Perform Engine Maintenance - Perkins Models..................................................... 69 Section 4 • Repair Procedures............................................................................... 71 Introduction............................................................................................ 71 Boom Components - Rev C................................................................................. 72 1-1 Boom Angle Limit Switch (all models except GTH-636)............................................. 72 1-2 Boom............................................................................................ 73 1-3 Boom Lift Cylinder.............................................................................. 85 1-4 Boom Extension Cylinder......................................................................... 87 1-5 Fork Level Cylinder............................................................................. 88 1-6 Fork Rotate Cylinder (option)................................................................... 90 Operator's Compartment - Rev B.......................................................................... 93 2-1 Operators Compartment........................................................................... 93 2-2 Machine Controls................................................................................102 Fuel and Hydraulic Tanks - Rev C........................................................................108 3-1 Fuel Tank.......................................................................................108 3-2 Hydraulic Tank..................................................................................109 Engines - Rev B.........................................................................................110 4-1 Engine..........................................................................................110 4-2 Engine Fault Codes - John Deere 4045TF275 Engine................................................111 Transmission - Rev C....................................................................................112 5-1 Transmission....................................................................................112 Hydraulic Pump - Rev B..................................................................................114 6-1 Hydraulic Pump..................................................................................114 Manifolds - Rev C.......................................................................................118 7-1 Main Valve Manifold Components..................................................................118 7-2 Tilt Limiter Manifold Components................................................................119 7-3 Dual Pilot Check Manifold Components............................................................120 7-4 Boom Activated Rear Lock-up Manifold Components.................................................121 7-5 Fork Rotate Speed Manifold Components...........................................................122 7-6 Control Block Manifold Components...............................................................123 7-7 Fork Tilt Manifolds Components..................................................................124 7-8 Rear Lock-up Manifold Components................................................................125 7-9 Parking Brake Manifold Components...............................................................126 7-10 Differential Lock-up Manifold Components (optional on GTH-636 and GTH-644).....................127 7-11 Sway Manifold Components.......................................................................128 7-12 Fork Rotate Manifold Components (option).......................................................129 7-13 Sway Directional Manifold Components...........................................................130 7-14 Outrigger Manifold Components..................................................................131 7-15 Controller Relief (Drop Block) Manifold Components.............................................132 7-16 Boom Lift and Boom Extension Cylinders Manifold Components.....................................133 7-17 Fork Level Cylinder Manifold Components........................................................134 7-18 Fork Rotate Cylinder Manifold Components (option)..............................................135 7-19 Pump Destroke Manifold Components..............................................................136 7-20 Extend Cylinder Relief Manifold Components.....................................................137 7-21 Boom-activated Sway Lock-up Manifold Components (models with dual joysticks except GTH-636)....138 7-22 Valve Adjustments - Control Block Manifold.....................................................139 7-23 Valve Adjustments - Tilt Limiter Manifold......................................................141 7-24 Valve Coils....................................................................................142 Axle - Rev D............................................................................................143 8-1 Axles...........................................................................................143 Outriggers - Rev A......................................................................................146 9-1 Outriggers......................................................................................146 Section 5 • Troubleshooting - Rev A.........................................................................149 Introduction............................................................................................149 1-1 Engine Fault Codes - GTH-1048 and GTH-1056..........................................................150 1-2 Hydraulic Pump......................................................................................152 1-3 Boom Functions......................................................................................154 1-4 Drive Functions.....................................................................................161 1-5 Steer Functions.....................................................................................162 1-6 Brake Functions.....................................................................................165 1-7 Sway Functions......................................................................................166 Section 6 • Schematics......................................................................................171 Introduction............................................................................................171 Electrical Component and Limit Switch Legends - Rev A...................................................172 Electrical and Hydraulic Symbols Legend - Rev B.........................................................173 Electrical Schematics...................................................................................174 GTH-636 with John Deere Power - Rev C...............................................................174 GTH-636 with Perkins Power - Rev B..................................................................176 GTH-644, GTH-842 and GTH-844 with John Deere Power - Rev C..........................................178 GTH-644, GTH-842 and GTH-844 with Perkins Power - Rev B.............................................180 GTH-644, GTH-842 and GTH-844 with Deutz Power - Rev B...............................................182 GTH-1048 and GTH-1056 with John Deere Power - Rev C.................................................184 GTH-1048 and GTH-1056 with Perkins Power - Rev B....................................................186 Hydraulic Schematics....................................................................................188 GTH-636 with Single Joystick - Rev C................................................................188 GTH-636 with Dual Joysticks - Rev A.................................................................189 GTH-644, GTH-842 and GTH-844 with Single Joystick - Rev B...........................................190 GTH-644, GTH-842 and GTH-844 with Dual Joysticks - Rev A............................................191 GTH-1048 and GTH-1056 with Single Joystick - Rev C..................................................192 GTH-1048 and GTH-1056 with Dual Joysticks - Rev A...................................................193 Return to Index............................................................................................. 0
S.S 04/24
