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Genie GTH-636 Service Manual

Genie GTH-636
196 pages
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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

Table of Contents

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Genie GTH-636 Specifications

General IconGeneral
Operating Weight6, 350 kg
Rated Lift Capacity6, 000 lbs
Max Lift Height36 ft
Lift Height36 ft
Fuel Capacity90 L
Weight6, 350 kg

Summary

Safety Rules

General Safety Guidelines

Outlines conditions for performing maintenance and inherent hazards.

Specifications

Performance Specifications

Lists drive speed, lift capacity, and boom function speeds.

Hydraulic Specifications

Details hydraulic oil types, viscosity, and cleanliness requirements.

Scheduled Maintenance Procedures

Maintenance Inspection Report

Checklist A Procedures

A-1 Inspect Manuals and Decals

Verify manual and decal presence and legibility.

A-2 Pre-operation Inspection

Daily visual inspection before work shift.

A-3 Function Tests

Daily operational checks of machine functions.

A-4 Lubricate the Machine

Lubrication points for machine performance and longevity.

Checklist B Procedures

B-1 Inspect the Battery

Battery inspection for optimal performance and safety.

B-2 Inspect Electrical Wiring

Checks wiring for damage, corrosion, and integrity.

B-4 Inspect Engine Air Filter

Checks engine air filter condition for optimal performance.

B-5 Inspect Tires, Wheels, and Lug Nut Torque

Verifies tire condition and wheel fastener tightness.

B-6 Perform Hydraulic Oil Analysis

Analyzes hydraulic oil for contamination and wear particles.

Checklist C Procedures

Checklist D Procedures

D-1 Inspect the Forks

Inspects forks for wear, damage, and straightness.

D-2 Adjust Boom Sequencing Chains

Adjusts chains for proper boom extension and retraction.

D-3 Replace Hydraulic Tank Return Filter Element

Replaces the hydraulic filter for system health.

Checklist E Procedures

E-1 Test or Replace Hydraulic Oil

Checks or replaces hydraulic oil based on condition.

Repair Procedures

Observe and Obey

Critical safety and procedural rules for performing repairs.

Before Repairs Start

Preparatory steps and checks before commencing repairs.

Boom Components

1-1 Boom Angle Limit Switch Adjustment

Procedure for adjusting the boom angle limit switch.

1-2 Boom

Procedures related to the boom structure.

Boom Removal Procedures

Detailed steps for removing the boom assembly.

Boom Disassembly

Steps for taking the boom assembly apart.

Operator's Compartment

Operator's Compartment Overview

Details components within the operator's compartment.

Operator's Compartment Components

Details components within the operator's cabin.

2-2 Machine Controls

Information on machine control systems.

Fuel and Hydraulic Tanks

3-1 Fuel Tank

Information about the fuel tank.

3-2 Hydraulic Tank

Information about the hydraulic tank.

Engines

4-1 Engine Overviews and Repair

Repair procedures for Deutz, Perkins, and John Deere engines.

4-2 Engine Fault Codes - John Deere 4045TF275 Engine

Information on engine fault codes for John Deere engines.

Transmission

5-1 Transmission Overview

General information about the transmission system.

Hydraulic Pump

6-1 Hydraulic Pump Overview

General information about the hydraulic pump.

Function Pump Testing

Procedure for testing the function of the hydraulic pump.

Adjusting Function Pump Pressure

Procedure for setting the function pump pressure.

Manifolds

7-1 Main Valve Manifold Components

Details components of the main valve manifold.

7-2 Tilt Limiter Manifold Components

Components of the tilt limiter manifold.

7-3 Dual Pilot Check Manifold Components

Components of the dual pilot check manifold.

7-4 Boom Activated Rear Lock-up Manifold Components

Components for boom-activated rear lock-up manifold.

7-5 Fork Rotate Speed Manifold Components (Option)

Components for optional fork rotate speed manifold.

7-6 Control Block Manifold Components

Components of the control block manifold.

7-7 Fork Tilt Manifolds Components

Components for fork tilt manifolds.

7-8 Rear Lock-up Manifold Components

Components of the rear lock-up manifold.

7-9 Parking Brake Manifold Components

Components for the parking brake manifold.

7-10 Differential Lock-up Manifold Components (Optional)

Components for optional differential lock-up manifold.

7-11 Sway Manifold Components

Components of the sway manifold.

7-12 Fork Rotate Manifold Components (Option)

Components for optional fork rotate manifold.

7-13 Sway Directional Manifold Components

Components of the sway directional manifold.

7-14 Outrigger Manifold Components (GTH-1048/1056)

Outrigger manifold components for specific models.

7-15 Controller Relief (Drop Block) Manifold Components

Components of the controller relief manifold.

7-16 Boom Lift and Extension Cylinder Manifold Components

Manifold components for boom lift and extension cylinders.

7-17 Fork Level Cylinder Manifold Components

Manifold components for the fork level cylinder.

7-18 Fork Rotate Cylinder Manifold Components (Option)

Manifold components for optional fork rotate cylinder.

7-19 Pump Destroke Manifold Components

Components of the pump destroke manifold.

7-20 Extend Cylinder Relief Manifold Components

Relief manifold components for the extend cylinder.

7-22 Valve Adjustments - Control Block Manifold

Procedures for adjusting control block manifold valves.

Setting Steer System Pressure

Procedure for setting steer system pressure.

7-23 Valve Adjustments - Tilt Limiter Manifold

Procedures for adjusting tilt limiter manifold valves.

Axle

Outriggers

Troubleshooting

Before Troubleshooting

Preparatory steps and checks before troubleshooting.

Schematics

Observe and Obey

Critical safety rules for working with schematics.

Electrical Component and Limit Switch Legends

Electrical and Hydraulic Symbols Legend

California Proposition 65 Warning

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