GENIE Telehandler MASTER Service Manual

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 from GTH0606A-8418 from GTH0606B-6271 GTH-844 GTH-1048 GTH-1056 GTH-844 from GTH1006A-8418 to GTH-1007A-11442 from GTH0806A-8418 from GTH0806B-6956 from GTH1006A-8418 to GTH1007A-11442

June 2007 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487 ii Introduction Important Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine before attempting any maintenance or repair procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting and repair procedures for qualified service professionals. 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 and repair be performed at an authorized Genie dealer service center. Technical Publications Genie Industries 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: PO Box 97030 Redmond, WA 98073-9730 USA www.genieindustries.com e-mail: techsup@genieind.com Copyright © 2006 by Genie Industries 97487 Rev D June 2007 First Edition, Fourth Printing "Genie" is a registered trademark of Genie Industries in the USA and many other countries. "GTH" is a trademark of Genie Industries. Printed on recycled paper Printed in U.S.A. Introduction

June 2007 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 iii Serial Number Legend INTRODUCTION TH08 06 A - 1234 Model Y ear of manufacture Facility code Sequence number MODEL: Genie Industries 18340 NE 76th S treet Redmond, WA 98052 USA GTH844 A TEREX COMPANY SERIAL NUMBER: GTH0806A-8454 ATTACHMENT: MANUFACTURE DATE: 02/20/06 TOTAL TRUCK WEIGHT(LBS): 22,010lbs / 9,984kg MAX LIFT CAPACITY(LBS): 8000 LBS LIFT CAPACITY(LBS) AT MAX LIFT HEIGHT: OUTRIGGERS UP: OUTRIGGERS DOWN: N/A N/A 6000 LBS THIS FORKLIFT TRUCK COMPLIES WITH: ASME B56.6-2002 SAFETY STD FOR ROUGH TERRAIN FORKLIFT TRUCK Serial label (located inside fork frame) (models with quick attach frame) Serial label (located inside chassis upright at cab side of machine) Serial number stamped on chassis

June 2007 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487 iv This page intentionally left blank.

June 2007 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Safety Rules Section 1 • Safety Rules v 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 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.

June 2007 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487 SAFETY RULES vi Section 1 • Safety Rules 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 an imminently hazardous situation which, if not avoided, 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 hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Workplace Safety 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 extinguisher 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 and 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.

June 2007 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Table of Contents vii Introduction Important Information ......................................................................................... ii Serial Number Legend ...................................................................................... iii Section 1 Safety Rules General Safety Rules ........................................................................................ v Section 2 Rev Specifications D Machine Specifications ................................................................................ 2 - 1 Performance Specifications ......................................................................... 2 - 3 Hydraulic Specifications ............................................................................... 2 - 4 Manifold Component Specifications ............................................................. 2 - 6 John Deere 4045TF270 Engine ................................................................... 2 - 7 John Deere 4045TF275 Engine ................................................................... 2 - 8 Deutz BF4 2012 Engine ............................................................................... 2 - 9 Perkins 1104C-44T Engine ........................................................................ 2 - 10 Perkins 1104C-44TA Engine ..................................................................... 2 - 11 Dana T12000 Transmission ....................................................................... 2 - 12 Dana T20000 Transmission ....................................................................... 2 - 12 Dana Planetary 212 Drive Axle .................................................................. 2 - 13 Dana Planetary 213 Drive Axle .................................................................. 2 - 13 Hydraulic Hose and Fitting Torque Specifications ...................................... 2 - 14 SAE and Metric Fasteners Torque Charts ................................................. 2 - 15 Section 3 Rev Scheduled Maintenance Procedures Introduction .................................................................................................. 3 - 1 Pre-delivery Preparation Report .................................................................. 3 - 3 Maintenance Inspection Report ................................................................... 3 - 5

June 2007 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487 TABLE OF CONTENTS viii Section 3 Rev Scheduled Maintenance Procedures, continued C Checklist A Procedures A-1 Inspect the Manuals and Decals ......................................................... 3 - 7 A-2 Perform Pre-operation Inspection ....................................................... 3 - 8 A-3 Perform Function Tests ...................................................................... 3 - 8 A-4 Lubricate the Machine ........................................................................ 3 - 9 A-5 Perform Engine Maintenance - John Deere and Perkins Models ...... 3 - 11 A-6 Perform Transmission Maintenance ................................................. 3 - 11 A-7 Perform Engine Maintenance - Deutz Models .................................. 3 - 12 A-8 Perform 30 Day Service ................................................................... 3 - 12 A-9 Perform Transmission Maintenance - GTH-636, GTH-644, GTH-842 and GTH-844 Models ...................... 3 - 13 A-10 Perform Engine Maintenance - Perkins Models ................................ 3 - 13 A-11 Perform Axle Maintenance ............................................................... 3 - 14 A-12 Perform Engine Maintenance - John Deere Models ......................... 3 - 14 A-13 Perform Transmission Maintenance - GTH-636, GTH-644, GTH-842 and GTH-844 Models ..................... 3 -- 15 A-14 Perform Transmission Maintenance ................................................. 3 - 15 A-15 Perform Axle Maintenance ............................................................... 3 - 16 B Checklist B Procedures B-1 Inspect the Battery ........................................................................... 3 - 17 B-2 Inspect the Electrical Wiring ............................................................. 3 - 17 B-3 Check the Exhaust System .............................................................. 3 - 18 B-4 Inspect the Engine Air Filter .............................................................. 3 - 19 B-5 Inspect the Tires, Wheels and Lug Nut Torque ................................. 3 - 19 B-6 Perform Hydraulic Oil Analysis ......................................................... 3 - 20 B-7 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ............. 3 - 21 B-8 Check the Boom Wear Pads ............................................................ 3 - 22 B-9 Lubricate the Driveshafts .................................................................. 3 - 23 B-10 Perform Engine Maintenance - John Deere Models ......................... 3 - 23

June 2007 Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 TABLE OF CONTENTS ix Section 3 Rev Scheduled Maintenance Procedures, continued B Checklist C Procedures C-1 Perform Engine Maintenance - Deutz Models .................................. 3 - 24 C-2 Perform Engine Maintenance - John Deere Models ......................... 3 - 24 C-3 Perform Axle Maintenance ............................................................... 3 - 25 C-4 Perform Transmission Maintenance - GTH-1048 and GTH-1056 Models .................................................... 3 - 25 C-5 Perform Engine Maintenance - Perkins Models ................................ 3 - 26 C-6 Perform Axle Maintenance ............................................................... 3 - 26 C-7 Perform Axle Maintenance ............................................................... 3 - 27 B Checklist D Procedures D-1 Inspect the Forks .............................................................................. 3 - 28 D-2 Adjust the Boom Sequencing Chains ............................................... 3 - 28 D-3 Replace the Hydraulic Tank Return Filter Element ........................... 3 - 31 D-4 Perform Engine Maintenance - Deutz Models .................................. 3 - 32 D-5 Perform Transmission Maintenance ................................................. 3 - 32 D-6 Perform Axle Maintenance ............................................................... 3 - 33 D-7 Perform Engine Maintenance - Perkins Models ................................ 3 - 33 D-8 Perform Engine Maintenance - Deutz Models .................................. 3 - 34 C Checklist E Procedures E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 35 E-2 Perform Engine Maintenance - John Deere Models ......................... 3 - 36 E-3 Perform Engine Maintenance - Perkins Models ................................ 3 - 36 E-4 Perform Engine Maintenance - Perkins Models ................................ 3 - 37 E-5 Perform Engine Maintenance - Perkins Models ................................ 3 - 37 E-6 Perform Engine Maintenance - John Deere Models ......................... 3 - 38 E-7 Perform Engine Maintenance - Perkins Models ................................ 3 - 38 E-8 Perform Engine Maintenance - Deutz Models .................................. 3 - 39 E-9 Perform Engine Maintenance - Perkins Models ................................ 3 - 39

June 2007 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487 TABLE OF CONTENTS x Section 4 Rev Repair Procedures Introduction .................................................................................................. 4 - 1 C Boom Components 1-1 Boom Angle Limit Switch (all models except GTH-636) ..................... 4 - 2 1-2 Boom ................................................................................................. 4 - 3 1-3 Boom Lift Cylinder ............................................................................ 4 - 15 1-4 Boom Extension Cylinder ................................................................. 4 - 17 1-5 Fork Level Cylinder .......................................................................... 4 - 18 1-6 Fork Rotate Cylinder (option) ........................................................... 4 - 20 B Operator's Compartment 2-1 Operator's Compartment .................................................................. 4 - 23 2-2 Machine Controls ............................................................................. 4 - 32 C Fuel and Hydraulic Tanks 3-1 Fuel Tank ......................................................................................... 4 - 38 3-2 Hydraulic Tank ................................................................................. 4 - 39 B Engines 4-1 Engines ............................................................................................ 4 - 40 4-2 Engine Fault Codes - John Deere 4045TF275 Engine ..................... 4 - 41 C Transmission 5-1 Transmission .................................................................................... 4 - 42 B Hydraulic Pumps 6-1 Hydraulic Pump ................................................................................ 4 - 44 C Manifolds 7-1 Main Valve Manifold Components .................................................... 4 - 48 7-2 Tilt Limiter Manifold Components ..................................................... 4 - 49 7-3 Dual Pilot Check Manifold Components ........................................... 4 - 50 7-4 Boom Activated Rear Lock-up Manifold Components ...................... 4 - 51 7-5 Fork Rotate Speed Manifold Components (option) ........................... 4 - 52

GENIE Telehandler MASTER Service Manual

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