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GTH-636
Genie GTH-636 Service And Repair Manual
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Service and Re
pair Manual
Serial Num
ber Range
GTHâ„¢
-
636
from GTH06
E
-
11750
This m
anual
includ
es:
Repair pr
ocedures
Fault Codes
Elect
rical an
d
Hydrau
lic Sc
hema
tics
For deta
iled ma
intenan
ce
procedures, refer to the
appropriate Maintenanc
e
Manual for your machine.
Part N
o. 1287209G
T
Rev A
April
2018
2
Table of Contents
Table of Contents
7
Introduction
2
Find a Manual for this Model
2
Read, Understand and Obey the Safety Rules and Operating Instructions in the Appropriate Operator's Manual on Your Machine
2
Serial Number Legend
4
Safety Rules
5
Table of Contents
7
Specifications
11
Machine Specifications
11
Performance Specifications
11
Hydraulic Oil Specifications
12
Hydraulic Component Specifications
15
Manifold Component Specifications
15
Air Conditioner Refrigerant Specifications
15
Deutz TD 2.9 Engine Specifications
16
Dana VDT12000 Transmission Specifications
17
Dana 212 Drive Axle
17
Hydraulic Hose and Fitting Torque Specifications
18
Torque Procedure
19
Repair Procedures
21
Introduction
21
Immediately Tag and Remove from Service a
21
Observe and Obey
21
About this Section
22
Boom Components
23
Boom
23
How to Replace the Boom Wear Pads
23
How to Use the Quick Attachment
23
How to Replace the Retraction Chain
24
How to Replace the Extension Chains
26
How to Remove the Boom
28
How to Disassemble the Boom
30
Boom Lift Cylinder
31
April
31
Bodily Injury Hazard. Spraying
31
Boom Extension Cylinder
32
Fork Level Cylinder
33
Hydraulic Hoses
34
How to Adjust the Fork Level Cylinder And/Or Auxiliary Hose
34
How to Replace the Fork Level Cylinder And/Or Auxiliary Hoses
35
Operator's Compartment
37
Machine Controls
38
How to Remove the Steering Column
38
How to Remove the Steer Orbitral
39
How to Remove the Steering Wheel
39
How to Remove the Brake Pedal Assembly
40
How to Remove the Joystick - Models with Electronic Joystick
40
How to Remove the Gauge Cluster Assembly
41
Fuel and Hydraulic Tanks
42
Engines
44
Engine Fault Codes
44
Transmission
45
Hydraulic Pump
46
How to Test the Function Pump
46
How to Remove the Function Pump
47
How to Install the Function
48
How to Prime the Function Pump
48
How to Adjust the Function Pump Standby Pressure
49
How to Adjust the Function Pump Pressure Compensator
50
Manifolds
51
PVG Manifold Components - Electronic Joystick
51
April
51
Secondary Function Manifold Components
52
Brake Manifold Components
55
Valve Adjustments - Secondary Function Manifold
56
How to Set the Parking Brake System Pressure
56
How to Set the Differential Lock System Pressure
57
Valve Coils
58
Axle
60
Axles
60
Connections very Slowly to Allow
60
Gradually. Do Not Allow Oil to
60
Hydraulic Oil Can Penetrate and Burn Skin. Loosen Hydraulic
60
Squirt or Spray
60
The Oil Pressure to Dissipate
60
Fault Codes
61
Introduction
61
Be Sure that All Necessary Tools and Test Equipment Are Available and Ready for Use
61
Before Troubleshooting
61
Contact with Electrically Charged Circuits Could Result in Death or Serious Injury. Remove All Rings, Watches and Other Jewelry
61
Damaged or Malfunctioning Machine
61
Electrocution/Burn Hazard
61
Repair any Machine Damage or Malfunction before Operating the Machine
61
Troubleshooting and Repair Procedures Shall be Completed by a Person Trained and Qualified on the Repair of this Machine
61
Diagnostic Display
62
Deutz TD 2.9 L4 Engine Fault Codes
63
Schematics
77
Default Chapter
77
Introduction
77
Fuse Panel Layout
78
Electrical Component & Wire Color Abbreviation Legend
79
Telematics Connector Pin Legend
82
Electrical Symbol Legend
84
Hydraulic Symbols Legend
85
Harness Map Legend
86
Electrical Schematics - Harness Maps
87
April
87
Harness Map - Control System Power Electronic Joystick
88
Harness Map - Deutz TD2.9 Engine Battery Power and Ground
90
Harness Map - Options Auxiliary Hydraulics, Beacon and 3Rd Gear Lockout
91
Harness Map - Options Work Lights
94
Harness Map - Options Road Lights
95
Harness Map - Options Enclosed Cab with Heater
98
Harness Map - Options Enclosed Cab with HVAC
99
Electrical Schematics
101
Electrical Schematic - View 1
102
Electrical Schematic - View 2
103
Electrical Schematic - Deutz T4F Eng Harness
106
Hydraulic Schematic
107
Hydraulic Schematics
108
Other manuals for Genie GTH-636
Service Manual
196 pages
Maintenance Manual
65 pages
4
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Genie GTH-636 Specifications
General
Operating Weight
6, 350 kg
Rated Lift Capacity
6, 000 lbs
Max Lift Height
36 ft
Lift Height
36 ft
Fuel Capacity
90 L
Weight
6, 350 kg
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