Genie GTH-636 Service And Repair Manual Download Page 4

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Service and Repair Manual

April 2018

Introduction

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)

Summary of Contents for GTH-636

Page 1: ...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 yo...

Page 2: ...Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvem...

Page 3: ...ry 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...

Page 4: ...ear 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 S...

Page 5: ...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...

Page 6: ...hing 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 m...

Page 7: ...cifications 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 Hy...

Page 8: ...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 3...

Page 9: ...ing 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 Displ...

Page 10: ...ness 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 O...

Page 11: ...attern 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...

Page 12: ...e 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...

Page 13: ...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...

Page 14: ...llus 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 Flas...

Page 15: ...lt 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 ba...

Page 16: ...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 M...

Page 17: ...ils 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 He...

Page 18: ...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 lb...

Page 19: ...d 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 approp...

Page 20: ...mber 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...

Page 21: ...rstand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Gen...

Page 22: ...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 r...

Page 23: ...Refer to Maintenance Procedure Lubricate the Boom Note Do not lubricate the side wear pads 4 Install the wear pads Install and securely tighten the retainer plates Do not over tighten How to Use the...

Page 24: ...y retract the boom 4 Extend the boom approximately 1 inch 2 5 cm to insure retract chain is slack It may be necessary to loosen the extend chain adjuster 5 Turn the machine off and remove the key from...

Page 25: ...tape from the chain 13 Now pull the chain carefully toward the pivot end until the mounting holes of the chain anchor line up with the holes on the boom tube Install the fasteners securing the chain...

Page 26: ...and remove the key from the key switch 5 Working at the fork end of the boom loosen the fasteners securing the single chain tensioners to the top of boom tube number 1 After noting the orientation and...

Page 27: ...in a difficult reassembly Be sure the rope is securely attached to the chain and boom structure before pulling the chain out of the boom 13 On a workbench remove the bow tie clip securing the chain a...

Page 28: ...cedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant compon...

Page 29: ...raulic hoses at the hydraulic hard line connections at the pivot end of the boom Cap the fittings 12 Using the overhead crane raise the boom to a horizontal position Crushing hazard The lift cylinder...

Page 30: ...oom pull the fork level hydraulic hoses from the boom and lay them to the side 7 Working at the pivot end of the boom remove the fasteners securing the hose roller assembly to boom tube number 2 Remov...

Page 31: ...a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic...

Page 32: ...ylinder Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer...

Page 33: ...retaining fastener 1 4 Fork Level Cylinder How to Remove the Fork Level Cylinder Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced A...

Page 34: ...inder barrel end pivot pin to the boom 7 Use a soft metal drift to remove the pivot pin Remove the cylinder from the machine Crushing hazard The cylinder could fall if not properly supported when the...

Page 35: ...4 Attach a lifting strap from an overhead crane to the top of the lifting fork frame Support the frame Do not apply any lifting pressure 5 Disconnect and plug the fork level cylinder supply hoses at...

Page 36: ...ope from each end of the hose Discard the hose 12 Securely install a section of rope onto each end of the new hose assembly Note Tag each hose before assembly 13 Install the new hose assembly into the...

Page 37: ...ion manifold Cap the fittings 3 Locate the brake manifold under the manifold inspection cover Tag disconnect and plug the hydraulic hose at the underside of the brake manifold Cap the fitting 4 Workin...

Page 38: ...specification Operator s cab mounting bolts 750 ft lbs 1017 Nm 2 2 Machine Controls How to R emove the Steering Col um n How to Remove the Steering Column 1 Disconnect the battery from the machine El...

Page 39: ...to Remove the Steering Column 2 Working under the dashboard locate the hydraulic hose at port L of the steering orbitral 3 Follow the hydraulic hose from port L of the steer orbitral to its connection...

Page 40: ...hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Fully press and release the brake pedal a minimum of 10 times to...

Page 41: ...ontact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Remove the fasteners securing the transmission control lever to the colum...

Page 42: ...could result in death or serious injury Remove all rings watches and other jewelry FUEL TANK 2 Remove the access cover above the fuel tank and the access door above the filler cap 3 Tag and disconnect...

Page 43: ...ine Specifications 12 Remove the drain plug from the hydraulic tank and completely drain the tank Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 13 Tag disconnect a...

Page 44: ...nic Control Module ECM detects an abnormal operating condition a fault code is immediately stored in the ECM memory At the same time a colored warning lamp is illuminated To view the fault code push a...

Page 45: ...ssion Part No 1287209GT GTH 636 35 5 1 Transmission How to Repair the Transmission Repair procedures and additional transmission information is available in the Dana VDT12000 Service Manual Dana VDT12...

Page 46: ...ontinue to hold the joystick in the boom retract position and observe the pressure gauge Result If the pressure gauge reads 3200 psi 220 bar immediately stop The pump is good Result If the pressure fa...

Page 47: ...r jewelry 3 Tag and disconnect the case drain hose at the top of the pump Cap the fitting on the pump Note Placing the open end of the case drain hose below the hydraulic oil level in the hydraulic ta...

Page 48: ...rt the engine and inspect for leaks 11 Turn the machine off 12 Adjust the pump pressure Refer to Repair Procedures How to Adjust the Function Pump Standby Pressure and How to Adjust the Function Pump...

Page 49: ...Result The pressure gauge fails to read 650 20 psi 44 8 1 4 bar The pressure setting needs to be adjusted Proceed to step 4 4 Loosen the set screw for the standby pressure adjustment screw 5 Adjust th...

Page 50: ...e pressure gauge fails to read 3200 150 psi 220 10 3 bar The pressure setting needs to be adjusted Proceed to step 5 5 Loosen the set screw for the pressure compensator adjustment screw 1 Standby Pres...

Page 51: ...ystick The PVG manifold is located under the manifold inspection cover Index No Description Function 1 Assembly lift Controls boom up down 2 Assembly auxiliary Controls auxiliary functions 3 Assembly...

Page 52: ...SVD1 Steer left right 60 in lbs 6 8 Nm 2 Pressure reducing relief valve 400 psi 27 5 bar PR2 Differential lock up circuit 50 ft lbs 68 Nm 3 Pressure reducing relief valve 350 psi 24 8 bar PR1 Parking...

Page 53: ...April 2018 Service and Repair Manual Manifolds Part No 1287209GT GTH 636 43...

Page 54: ...Service and Repair Manual April 2018 Manifolds 44 GTH 636 Part No 1287209GT...

Page 55: ...omponents The auxiliary manifold is located under the transmission inspection cover Index No Description Schematic Item Function Torque 1 Pressure switch 450 psi 31 bar S6 Clutch cut off pressure 11 f...

Page 56: ...Without operating any machine controls observe the reading on the pressure gauge Result The pressure gauge reads 650 20 psi 44 8 1 4 bar The pump is functioning correctly Result The pressure gauge fai...

Page 57: ...il pressure to dissipate gradually Do not allow oil to squirt or spray How to Set the Differ enti al Lock System Pressure How to Set the Differential Lock System Pressure Note Be sure that the hydraul...

Page 58: ...ath or serious injury Remove all rings watches and other jewelry 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance Result The resistance should be within specificat...

Page 59: ...the coil Resistor 10 Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9v DC battery 3 10 resistor 4 coil Note Dotted lines in illust...

Page 60: ...n Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Loosen the lug nuts of both wheels on the axle to be removed Do not re...

Page 61: ...stowed position Key switch in the off position with the key removed Wheels chocked Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operat...

Page 62: ...fault codes are detected scroll through them using the diagnostic button Active Codes vs Stored Codes Active fault codes indicating an engine condition or conditions which have not been corrected are...

Page 63: ...Valve signal range check low 51 5 Actuator EGR Valve open load 51 6 Actuator error EGR Valve signal range check high SPN FMI Description 51 6 Actuator error EGR Valve signal range check high 51 6 Act...

Page 64: ...eded 105 3 Sensor error charged air temperature signal range check high 105 4 Sensor error charged air temperature signal range check low SPN FMI Description 108 3 Sensor error ambient air press signa...

Page 65: ...Sensor ambient air temperature plausibility error 172 2 Intake air sensor plausibility error 172 3 Sensor error intake air signal range check high 172 4 Sensor error intake air sensor signal range che...

Page 66: ...signal range check high 411 4 Physical range check low for EGR differential pressure 411 4 Sensor error differential pressure Venturiunit EGR signal range check low SPN FMI Description 412 3 Sensor er...

Page 67: ...e injector 4 in firing order 654 5 Injector 4 in firing order interruption of electric connection 676 11 Cold start aid relay error 676 11 Cold start aid relay open load SPN FMI Description 677 3 Star...

Page 68: ...st gas temperature upstream turbine warning threshold exceeded 1180 1 Physical range check low for exhaust gas temperature upstream turbine 1180 1 Turbocharger Wastegate CAN feedback shut off threshol...

Page 69: ...sor has burn off not performed 2797 4 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 0 SPN FMI Description 2798 4 Injector diagnostics timeout error of short circui...

Page 70: ...exhaust gas temperature downstream DOC signal range check low 23006 3 Controller mode switch short circuit to battery 23006 4 Controller mode switch short circuit to ground 23008 1 Manipulation contr...

Page 71: ...r of CAN Receive Frame TSC1AR Retarder 23612 12 Internal software error ECU injection cut off 23612 12 Internal ECU monitoring detection reported error SPN FMI Description 23612 12 Internal ECU monito...

Page 72: ...ceeded RailMeUn3 23613 2 Setpoint of metering unit in overrun mode not plausible 23615 3 Metering unit Fuel System short circuit to battery highside SPN FMI Description 23615 3 Metering unit Fuel Syst...

Page 73: ...heck of missing injector adjustment value programming IMA injector 1 in firing order 23896 13 check of missing injector adjustment value programming IMA injector 2 in firing order SPN FMI Description...

Page 74: ...e Control integrator injector 4 in firing order maximum value exceeded 23932 1 Fuel Balance Control integrator injector 4 in firing order minimum value exceeded 23935 12 Timeout Error of CAN Transmit...

Page 75: ...r temp 23998 4 Injector cylinder bank 2 slave short circuit 23999 12 Injector powerstage output Slave defect 24014 1 Air pressure glow plug flush line below limit SPN FMI Description 24016 2 Amount of...

Page 76: ...ive Frame ComRxEGRMsFlw1 24107 9 Timeout error of CAN Receive Frame ComRxEGRMsFlw2 SPN FMI Description 24108 9 Timeout error of CAN Transmit Frame ComEGRTVActr 24109 9 Timeout error of CAN Receive Fra...

Page 77: ...fety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There...

Page 78: ...ir Manual April 2018 Fuse Panel Layout 68 GTH 636 Part No 1287209GT Circuit Breakers located on the Battery Tray CB1 Telehandler Control System Power CB2 Engine Power ECM CB3 Glow Plugs Fuse Board loc...

Page 79: ...e Enable CR11 Parking Brake Latch CR12 Sway Left Right Enable CR13 Tilt Up Down Enable CR14 Boom Angle Monitor CR15 HVAC Blower L CR16 HVAC Blower M CR17 HVAC Blower H Item Description D Diode EMS Eng...

Page 80: ...ft ON L25 Parking Brake Release OFF L26 Brake Light Power ON L27 Hazard Power ON L28 Not Used M Motor R Resistor Item Description S Switch S1 Key Start Switch S4 Boom Extend Switch S5 Parking Brake Pr...

Page 81: ...liary B YD D Transmission YE E Transmission YF Transmission Forward YR Transmission Reverse YD1A 4Wheel Steer SVD1A YD1B Crab Steer SVD1B YLD Left Stabilizer Down YLU Left Stabilizer Up YRD Right Stab...

Page 82: ...0 VDC Battery Negative Device Ground 3 Digital Output 1 12 VDC Engine Run Hour Meter 12V engine run 0V engine off Monitor Engine Hours 4 Digital Output 2 12 VDC Boom Angle Status 12V boom 55 0V 55 Mo...

Page 83: ...h Schematic standard wiring Telematics Active Low Schematic optional wiring 1 Ignition Start Input 2 Relay 3 Telematics with Active High input 4 Telematics with Active Low input Wireless Certification...

Page 84: ...al T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor Hor...

Page 85: ...3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically a...

Page 86: ...ght Option Harnesses Item Part Description 20 1258527 Harness Light Led Clear 5 Round 21 1258775 Harness Cab Light Power 22 1256520 Harness Boom Light Power 23 237934 Harness Backup Light 24 1258528 H...

Page 87: ...April 2018 Service and Repair Manual 77 Harness Map Control System Electronic Joystick...

Page 88: ...Service and Repair Manual April 2018 78 GTH 636 Part No 1287209GT Harness Map Control System Electronic Joystick...

Page 89: ...April 2018 Service and Repair Manual 79 Harness Map Deutz TD2 9 Engine Battery Power and Ground...

Page 90: ...Service and Repair Manual April 2018 80 GTH 636 Part No 1287209GT Harness Map Deutz TD2 9 Engine Battery Power and Ground...

Page 91: ...April 2018 Service and Repair Manual Part No 1287209GT GTH 636 81 Harness Map Options Auxiliary Hydraulics Beacon and 3rd Gear Lockout...

Page 92: ...Service and Repair Manual April 2018 82 Harness Map Options Auxiliary Hydraulics Beacon and 3rd Gear Lockout...

Page 93: ...April 2018 Service and Repair Manual 83 Harness Map Options Work Lights...

Page 94: ...Service and Repair Manual April 2018 84 GTH 636 Part No 1287209GT Harness Map Options Work Lights...

Page 95: ...April 2018 Service and Repair Manual Part No 1287209GT GTH 636 85 Harness Map Options Road Lights...

Page 96: ...Service and Repair Manual April 2018 86 Harness Map Options Road Lights...

Page 97: ...April 2018 Service and Repair Manual 87 Harness Map Options Enclosed Cab with Heater...

Page 98: ...Service and Repair Manual April 2018 88 GTH 636 Part No 1287209GT Harness Map Options Enclosed Cab with Heater...

Page 99: ...April 2018 Service and Repair Manual Part No 1287209GT GTH 636 89 Harness Map Options Enclosed Cab with HVAC...

Page 100: ...Service and Repair Manual April 2018 90 Harness Map Options Enclosed Cab with HVAC...

Page 101: ...April 2018 Service and Repair Manual 91 Electrical Schematic View 1...

Page 102: ...Service and Repair Manual April 2018 92 GTH 636 Part No 1287209GT Electrical Schematic View 1...

Page 103: ...April 2018 Service and Repair Manual Part No 1287209GT GTH 636 93 Electrical Schematic View 2...

Page 104: ...Service and Repair Manual April 2018 94 Electrical Schematic View 2...

Page 105: ...April 2018 Service and Repair Manual 95 Electrical Schematic Deutz T4F Eng Harness...

Page 106: ...Service and Repair Manual April 2018 96 GTH 636 Part No 1287209GT Electrical Schematic Deutz T4F Eng Harness...

Page 107: ...April 2018 Service and Repair Manual Part No 1287209GT GTH 636 97 Hydraulic Schematic...

Page 108: ...Service and Repair Manual April 2018 98 Hydraulic Schematic...

Page 109: ...GTH 636 Part No 1287209GT Service and R epair M anual April 2018...

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