Genie GTH 636 - 1056 - Service - Manual

Parts Manual
Service Manual
Serial Number
Serial Range
Number Range
GTH-636
GTH-844 from GTH0606A-8418 to
afterGTH0610A-13771
GTH05-12345
GTH-842
GTH-644 from GTH0606A-8418
after GTH05-12345
from GTH0606B-6271
GTH-644
GTH-842 from GTH0806A-8418
after GTH05-12345
from GTH0806B-6958
from GTH0806A-8418 to
GTH-844 GTH0812-16605
from GTH0806B-6956

GTH1007A-11442

GTH-1007A-11442
Part No. 97487

Rev D
June 2007
Introduction June 2007
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.
Copyright © 2006 by Genie Industries

Contact Us:
97487 Rev D June 2007
PO Box 97030 First Edition, Fourth Printing
Redmond, WA 98073-9730 USA
"Genie" is a registered trademark of Genie
www.genieindustries.com Industries in the USA and many other countries.
"GTH" is a trademark of Genie Industries.
e-mail: techsup@genieind.com
Printed on recycled paper
Printed in U.S.A.
ii GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487

June 2007
INTRODUCTION
Serial Number Legend
A TEREX COMPANY
Genie Industries
18340 NE 76th S treet
Redmond, WA 98052
USA
MODEL: GTH844
SERIAL NUMBER: GTH0806A-8454
ATTACHMENT:
MANUFACTURE DATE: 02/20/06
TOTAL TRUCK WEIGHT(LBS): 22,010lbs / 9,984kg
MAX LIFT CAPACITY(LBS):

8000 LBS
TH08 06 A - 1234
LIFT CAPACITY(LBS)
AT MAX LIFT HEIGHT: 6000 LBS Model
OUTRIGGERS UP: N/A Sequence
OUTRIGGERS DOWN: N/A number
Year of
manufacture
THIS FORKLIFT TRUCK COMPLIES
WITH:
ASME B56.6-2002 SAFETY STD FOR Facility code
ROUGH TERRAIN FORKLIFT TRUCK
Serial label
Serial label (located inside fork frame)
(located inside chassis (models with quick attach frame)
upright at cab side of machine)
Serial number
stamped on chassis
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 iii
June 2007
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iv GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487

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

Section 1 • Safety Rules June 2007
SAFETY RULES
Personal Safety Workplace Safety

Be sure to keep sparks, flames and
Any person working on or around a machine must
lighted tobacco away from flammable and
be aware of all known safety hazards. Personal
combustible materials like battery gases
safety and the continued safe operation of the
and engine fuels. Always have an
machine should be your top priority.
approved fire extinguisher within easy
Read each procedure thoroughly. This reach.
manual and the decals on the machine,
Be sure that all tools and working areas
use signal words to identify the following:
are properly maintained and ready for
Safety alert symbol—used to alert use. Keep work surfaces clean and free of
personnel to potential personal debris that could get into machine
injury hazards. Obey all safety components and cause damage.
messages that follow this symbol
Be sure any forklift, overhead crane or
to avoid possible injury or death.
other lifting or supporting device is fully
Indicates an imminently hazardous capable of supporting and stabilizing the
situation which, if not avoided, will weight to be lifted. Use only chains or
result in death or serious injury. straps that are in good condition and of
ample capacity.
Indicates a potentially hazardous
situation which, if not avoided, Be sure that fasteners intended for one
could result in death or serious time use (i.e., cotter pins and self-locking
injury. nuts) are not reused. These components
Indicates a potentially hazardous may fail if they are used a second time.
situation which, if not avoided, Be sure to properly dispose of old oil or
may cause minor or moderate other fluids. Use an approved container.
injury. Please be environmentally safe.
Indicates a potentially hazardous Be sure that your workshop or work area
situation which, if not avoided, is properly ventilated and well lit.
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.
vi GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487

June 2007
Table of Contents
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
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 vii
June 2007
TABLE OF CONTENTS
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
viii GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487
June 2007
TABLE OF CONTENTS
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
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-6 Perform Engine Maintenance - John Deere Models ......................... 3 - 38
E-8 Perform Engine Maintenance - Deutz Models .................................. 3 - 39
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 ix

June 2007
TABLE OF CONTENTS
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
x GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487

June 2007
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

7-6 Control Block Manifold Components ................................................ 4 - 53
7-7 Fork Tilt Manifolds Components ....................................................... 4 - 54
7-8 Rear Lock-up Manifold Components ................................................ 4 - 55
7-9 Parking Brake Manifold Components ............................................... 4 - 56
7-10 Differential Lock-up Manifold Components
(optional on GTH-636 and GTH-644) ............................................... 4 - 57
7-11 Sway Manifold Components ............................................................. 4 - 58
7-12 Fork Rotate Manifold Components (option) ...................................... 4 - 59
7-13 Sway Directional Manifold Components ........................................... 4 - 60
7-14 Outrigger Manifold Components -
GTH-1048 and GTH-1056 ................................................................ 4 - 61
7-15 Controller Relief (Drop Block) Manifold -
GTH-636, GTH-1048 and GTH-1056 ............................................... 4 - 62
7-16 Boom Lift and Boom Extension Cylinders Manifold Components ..... 4 - 63
7-17 Fork Level Cylinder Manifold Components ....................................... 4 - 64
7-18 Fork Rotate Cylinder Manifold Components (option) ........................ 4 - 65
7-19 Pump Destroke Manifold Components ............................................. 4 - 66
7-20 Extend Cylinder Relief Valve Manifold -
GTH-636, GTH-1048 and GTH-1056 ............................................... 4 - 67
7-21 Boom Activated Sway Lock-up Manifold Components ..................... 4 - 68
7-22 Valve Adjustments - Control Block Manifold ..................................... 4 - 69
7-23 Valve Adjustments - Tilt Limiter Manifold.......................................... 4 - 71
7-24 Valve Coils ....................................................................................... 4 - 72
D Axle Components
8-1 Axles ................................................................................................ 4 - 73
A Outriggers
9-1 Outriggers ........................................................................................ 4 - 76
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 xi

June 2007
TABLE OF CONTENTS
Section 5 Rev Troubleshooting

Introduction .................................................................................................. 5 - 1
A 1-1 Engine Fault Codes -
GTH-1048 and GTH-1056 .................................................................. 5 - 2
A 1-2 Hydraulic Pump .................................................................................. 5 - 4
B 1-3 Boom Functions ................................................................................. 5 - 6
A 1-4 Drive Functions ................................................................................ 5 - 13
A 1-5 Steer Functions ................................................................................ 5 - 14
A 1-6 Brake Functions ............................................................................... 5 - 17
A 1-7 Sway Functions ................................................................................ 5 - 18
xii GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487
June 2007
TABLE OF CONTENTS
Section 6 Rev Schematics

Introduction .................................................................................................. 6 - 1
A Electrical Component and Limit Switch Legends ......................................... 6 - 2
B Electrical and Hydraulic Symbols Legends .................................................. 6 - 3
C Electrical Schematic -
GTH-636 with John Deere Power ................................................................ 6 - 4
B Electrical Schematic -
GTH-636 with Perkins Power....................................................................... 6 - 6
GTH-644, GTH-842 and GTH-844 with John Deere Power ......................... 6 - 8
GTH-644, GTH-842 and GTH-844 with Perkins Power ............................. 6 - 10
GTH-644, GTH-842 and GTH-844 with Deutz Power ................................ 6 - 12
GTH-1048 and GTH-1056 with John Deere Power .................................... 6 - 14
GTH-1048 and GTH-1056 with Perkins Power .......................................... 6 - 16
C Hydraulic Schematic -
GTH-636 with Single Joystick .................................................................... 6 - 18
A Hydraulic Schematic -
GTH-636 with Dual Joysticks ..................................................................... 6 - 19
B Hydraulic Schematic -
GTH-644, GTH-842 and GTH-844 with Single Joystick ............................. 6 - 20
GTH-644, GTH-842 and GTH-844 with Dual Joysticks .............................. 6 - 21
C Hydraulic Schematic -
GTH-1048 and GTH-1056 with Single Joystick .......................................... 6 - 22
GTH-1048 and GTH-1056 with Dual Joysticks .......................................... 6 - 23
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 xiii
June 2007
xiv GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487
June 2007 Section 2 • Specifications
REV D
Specifications
Machine Specifications GTH-1048 and GTH-1056
Fluid capacities Fuel tank 30 gallons

113.6 liters
GTH-636, GTH-644, GTH-842 and GTH 844
Hydraulic tank 48 gallons
Fuel tank 30 gallons 181.7 liters
113.6 liters
Hydraulic system 66 gallons
Hydraulic tank 34 gallons (including tank) 249.8 liters
128.7 liters
Hydraulic system 50 gallons

(including tank) 189.3 liters Continuous improvement of our products is a
Genie policy. Product specifications are
For operational specifications, refer to the

Operator's Manual.
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 2-1
Section 2 • Specifications June 2007
SPECIFICATIONS REV D
Tires and wheels All models
Tire size 13.00 x 24 Tire pressure 50 psi

(models without foam filled tires) 3.45 bar
Tire ply rating 12
Lug nut torque 465 ft-lbs
Weight, rough terrain tire 270 lbs 630 Nm
(air filled) 122.5 kg
Lug pattern 10 x 13.189
Weight, rough terrain tire 815 ±35 lbs
(calcium chloride filled) 370 ±16 kg Wheel diameter 24 in
60.1 cm
(foam filled) 379 ±16 kg Wheel width 9 in
22.9 cm
Weight, rock lug tire 835 ±35 lbs
(calcium chloride filled) 379 ±16 kg

(foam filled) 402 ±16 kg
Continuous improvement of our products is a
Tire size 14.00 x 24
Tire ply rating 12
Weight, rough terrain tire 270 lbs

(air filled) 122.5 kg




2-2 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487
REV D SPECIFICATIONS
Performance Specifications Boom function speeds, maximum
Drive speed, maximum GTH-644, GTH-842 and GTH-844
GTH-636 and GTH-842 18 mph Boom up 14 to 16 seconds

29 km/h Boom down 10 to 12 seconds
GTH-644 and GTH-844 17 mph Boom extend 17 to 19 seconds
27.4 km/h
Boom retract 13 to 15 seconds
GTH-1048 and GTH-1056 19 mph
30.6 km/h Chassis sway 9 to 12 seconds
Draw bar pull Fork tilt up 7 to 9 seconds
GTH-636, GTH-644, 19,200 lbs
GTH-842 and GTH-844 8427 kg
GTH-1048
GTH-1048 and GTH-1056 26,500 lbs
12045 kg Boom up 12 to 14 seconds
Lift capacity, maximum Boom down 13 to 15 seconds
GTH-636 and GTH-644 6000 lbs Boom extend 16 to 18 seconds

2727 kg
Boom retract 15 to 17 seconds
GTH-842 and GTH-844 8000 lbs
3636 kg Fork rotate 19 to 21 seconds
GTH-1048 and GTH-1056 10,000 lbs Chassis sway 11 to 13 seconds

4545 kg Fork tilt up 11 to 13 seconds
GTH-1056
Boom function speeds, maximum Boom up 17 to 19 seconds
GTH-636 Boom down 23 to 25 seconds
Boom up 12 to 14 seconds Boom extend 14 to 16 seconds
Boom down 16 to 18 seconds Boom retract 13 to 15 seconds
Boom extend 6 to 8 seconds Chassis sway 11 to 13 seconds
Boom retract 9 to 11 seconds Fork tilt up 11 to 13 seconds
Chassis sway 11 to 13 seconds All models
Fork tilt up 11 to 13 seconds Fork tilt down 11 to 13 seconds
Fork rotate 19 to 21 seconds

Hydraulic Specifications Hydraulic Specifications

Hydraulic Oil Specifications Hydraulic Oil Specifications
GTH-636/644 before serial number GTH0607A-11526 GTH-636/644 after serial number GTH0607A-11525
GTH-842/844 before serial number GTH0807A-11526 GTH-842/844 after serial number GTH0807A-11525
GTH-1048/1056 before serial number GTH1007A-11443
Hydraulic oil type Chevron Rykon MV equivalent
Hydraulic oil type Chevron Rykon AW ISO viscosity grade Multi-viscosity
ISO46 equivalent Viscosity index 200
ISO viscosity grade 46
Viscosity index 97 Cleanliness level, minimum 15/13
Cleanliness level, minimum 15/13 Water content, maximum 200 ppm
Water content, maximum 200 ppm Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
Genie specifications require hydraulic oils which are systems, have the ability to perform over a wide
designed to give maximum protection to hydraulic temperature range, and the viscosity index should
systems, have the ability to perform over a wide exceed 140. They should provide excellent antiwear,
temperature range, and have a minimum viscosity index oxidation, corrosion inhibition, seal conditioning, and
rating of 97. They should provide excellent antiwear, foam and aeration suppression properties.
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties. Optional Fluids
Optional Fluids Biodegradable Petro Canada Environ MV46

Statoil Hydra Way Bio Pa 32
Biodegradable Petro Canada Environ MV46 BP Biohyd SE-S
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822 Mineral based Chevron Rykon MV
Shell Tellus T32
Mineral based Chevron Rykon MV Shell Tellus T46
Shell Tellus T32 Chevron Aviation A
Shell Tellus T46
Chevron Aviation A Continued use of Chevron
Aviation A hydraulic fluid when
Continued use of Chevron
ambient temperatures are
Aviation A hydraulic fluid when
consistently above 32°F / 0°C may
ambient temperatures are
result in component damage.
consistently above 32°F / 0°C may
result in component damage. Note: Use Chevron Aviation A hydraulic fluid when
ambient temperatures are consistently below
Note: Use Chevron Aviation A hydraulic fluid when 0°F / -17°C.
ambient temperatures are consistently below
0°F / -17°C. Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205°F / 96°C.
Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205°F / 96°C. Note: Genie specifications require additional
equipment and special installation instructions for
Note: Genie specifications require additional the approved optional fluids. Consult the Genie
equipment and special installation instructions for Industries Service Department before use.
the approved optional fluids. Consult the Genie
Industries Service Department before use.
Function Pump Main Valve Manifold (all models)
GTH-636 System relief valve pressure, maximum 3650 psi

251.7 bar
Type: Variable displacement piston pump
Flow rate @ 2500 rpm 0 to 35 gpm

0 to 132.5 L/min Control Block Manifold
Pump pressure 2800 psi GTH-636, GTH-644, GTH-842 and GTH-844

(measured at test port GP1) 193 bar
Steer relief valve pressure, maximum 2250 psi
GTH-644, GTH-842, GTH-844 and GTH-1056 (measured at test port GP2) 155 bar
Type: Variable displacement piston pump Pilot relief valve pressure, maximum 500 psi
(measured at test port GP3) 34.5 bar
0 to 132.5 L/min GTH-1048 and GTH-1056
Pump pressure 3000 psi Steer relief valve pressure, maximum 2250 psi
(measured at test port GP1) 206.9 bar (measured at test port GP2) 155 bar
GTH-1048 Pilot relief valve pressure, maximum 400 psi

Type: Variable displacement piston pump

0 to 132.5 L/min Tilt Limiter Manifold
Pump pressure 3500 psi GTH-636, GTH-644, GTH-842 and GTH-844

Tilt limiter relief valve pressure, maximum 1200 psi
GTH-1048 and GTH-1056

Continuous improvement of our products is a Tilt limiter relief valve pressure, maximum 1200 psi
Genie policy. Product specifications are (measured at test port GP6) 82.7 bar
Boom Extend Relief Manifold
GTH-636 (from serial number GTH0606A-8418 to

GTH0606A-9022)
Boom extend relief valve pressure, maximum 2000 psi

137.9 bar
Boom extend relief valve pressure, maximum 2500 psi

172.3 bar
Manifold Component Valve Coil Resistance

Specifications Description Specification
Plug torque Solenoid valve, 2 position 3 way 12V DC 8 to 10Ω

(schematic items DA, IA and JA)
SAE No. 2 50 in-lbs / 6 Nm
Solenoid valve, 2 position 4 way 12V DC 8 to 10Ω
SAE No. 4 13 ft-lbs / 18 Nm (schematic items GA and GB)
SAE No. 6 18 ft-lbs / 24 Nm Solenoid valve, 3 position 4 way 12V DC 4 to 6Ω
(schematic items LA and MA)
SAE No. 8 50 ft-lbs / 68 Nm
Solenoid valve, 2 position 2 way 12V DC 8 to 10Ω
SAE No. 10 55 ft-lbs / 75 Nm (schematic item OA)
SAE No. 12 75 ft-lbs / 102 Nm Solenoid valve, 2 position 2 way 12V DC 6.5 to 8.5Ω
Sauer pump (black)(schematic item TA)
Solenoid valve, 2 position 2 way 12V DC 7.5 to 9.5Ω

Rexroth pump (grey)(schematic item TA)

John Deere 4045TF270 Engine Injection system
GTH-636, GTH-644, GTH-842 and GTH-844 Injection pump make Stanadyne
Displacement 275 cu in Peak injection pressure 10,000 psi

4.5 liters 690 bar
Number of cylinders 4 Fuel requirement
Bore & stroke 4.19 x 5 inches For fuel requirements, refer to the engine Operator's
106 x 127 mm Manual on your machine.
Horsepower 99 @ 2500 rpm Engine coolant

73.8 kw @ 2500 rpm Capacity 2.6 gallons
Firing order 1-3-4-2 9.8 liters
Low idle 900 rpm Alternator

Frequency 180 Hz Output 95 A, 14V DC
High idle 2600 rpm Battery
Frequency 520 Hz
Type 12V DC
Compression ratio 17:1
Group C31
Valve clearances, cold
Quantity 1
Intake, allowable range 0.012 to 0.015 in
0.31 to 0.38 mm Cold cranking ampere @ 0°F 1000A
Exhaust, allowable range 0.016 to 0.019 in Reserve capacity @ 25A rate 200 minutes
0.41 to 0.48 mm
Intake, recommended setting 0.14 in

0.36 mm
Exhaust, recommended setting 0.18 in

0.46 mm Genie policy. Product specifications are
Lubrication system
Oil pressure 50±15 psi

(at rated speed with full load) 3.4±1 bar
Oil capacity 14 quarts

(including filter) 13.2 liters
Oil viscosity requirements
Units ship with John Deere Engine Break-In Oil.

During the break-in period, add John Deere Engine
Break-In Oil as needed to maintain the specified oil
level.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator's Manual on your machine.
John Deere 4045TF275 Engine Injection system
GTH-1048 and GTH-1056 Injection pump make Stanadyne
Displacement 275 cu in Peak injection pressure 10,000 psi

4.5 liters 690 bar
Bore & stroke 4.19 x 5 inches For fuel requirements, refer to the engine Operator's

85.8 kw @ 2500 rpm Capacity 7 gallons
Low idle 1000 rpm Alternator

Frequency 200 Hz Output 95 A, 14V DC
High idle 2600 rpm Battery
Frequency 520 Hz
Type 12V DC
Compression ratio 17:1
Group C31
Valve clearances, cold
Quantity 1
Intake, allowable range 0.012 to 0.015 in
0.31 to 0.38 mm Cold cranking ampere @ 0°F 1000A
Exhaust, allowable range 0.016 to 0.019 in Reserve capacity @ 25A rate 200 minutes
0.41 to 0.48 mm
Intake, recommended setting 0.14 in

0.36 mm
Exhaust, recommended setting 0.18 in

0.46 mm Genie policy. Product specifications are
Lubrication system
Oil pressure 50±15 psi

(at rated speed with full load) 3.4±1 bar

Units ship with John Deere Engine Break-In Oil.

During the break-in period, add John Deere Engine
Break-In Oil as needed to maintain the specified oil
level.
Engine Operator's Manual on your machine.
Deutz BF4 2012 Engine Injection system
GTH-644, GTH-842 and GTH-844 Injection pump make Bosch PFM
Displacement 246 cu in Injector pressure, minimum 3190 psi

4 liters 220 bar
Bore and stroke 3.97 x 4.96 inches For fuel requirements, refer to the engine Operation

74.6 kW @ 2500 rpm Capacity 3 gallons
Compression ratio 19:1 Alternator
Low idle 1000 rpm Output 95 A, 14V DC

Frequency 200 Hz Fan belt (pretension / retension) 101 / 67 ±11 lbf
High idle 2600 rpm 450 / 300 ±50 N
Frequency 520 Hz Battery
Valve clearance, cold Type 12V DC
Intake 0.01 in Group C31
0.3 mm
Quantity 1
Exhaust 0.02 in
0.5 mm Cold cranking ampere @ 0°F 1000A
Lubrication system Reserve capacity @ 25A rate 200 minutes
Oil pressure 20 to 43 psi
1.4 to 3 bar
Oil capacity 12.2 quarts

Oil viscosity requirements subject to change without notice.
Units ship with 15W-40.
Engine Operation Manual on your machine.
Perkins 1104C-44T Engine Injection system
GTH-636, GTH-644, GTH-842 and GTH-844 Injection pump make Delphi

4.4 liters 302 bar
Number of cylinders 4 Lift pump pressure 4.5 to 9.5 psi

0.31 to 0.66 bar
Bore and stroke 4.133 x 5 inches
105 x 127 mm Fuel requirement
Horsepower 99.9 @ 2500 rpm For fuel requirements, refer to the engine Operation
74.5 kW @ 2500 rpm Manual on your machine.
Firing order 1-3-4-2 Engine coolant
Compression ratio 18.2:1 Capacity 4.75 gallons

18 liters
Low idle 1000 rpm
Frequency 200 Hz Alternator
High idle 2520 rpm Output 85 A, 14V DC

Frequency 504 Hz Fan belt tension (new belt / used belt) 120 / 80 lbf
Valve clearance, cold 535 / 355 N
Intake 0.008 in Battery

0.2 mm Type 12V DC
Exhaust 0.018 in Group C31
0.45 mm
Quantity 1
Lubrication system
Cold cranking ampere @ 0°F 1000A
Oil pressure at high idle, minimum 43 psi
3 bar Reserve capacity @ 25A rate 200 minutes

Units ship with 15W-40. Genie policy. Product specifications are
Extreme operating temperatures may require the use of subject to change without notice.
Engine Operation and Maintenance Manual on your
machine.
2 - 10 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487

Perkins 1104C-44TA Engine Injection system
GTH-1048 and GTH-1056 Injection pump make Delphi

4.4 liters 302 bar
Number of cylinders 4 Lift pump pressure 4.5 to 9.5 psi

0.31 to 0.66 bar
Bore and stroke 4.133 x 5 inches
105 x 127 mm Fuel requirement
Horsepower 127 @ 2200 rpm For fuel requirements, refer to the engine Operation
94.7 kW @ 2200 rpm Manual on your machine.
Firing order 1-3-4-2 Engine coolant
Compression ratio 18.2:1 Capacity 5 gallons

18.9 liters
Low idle 1000 rpm
Frequency 200 Hz Alternator
High idle 2310 rpm Output 85 A, 14V DC

Frequency 462 Hz Fan belt tension (new belt / used belt) 120 / 80 lbf
Valve clearance, cold 535 / 355 N
Intake 0.008 in Battery

0.2 mm Type 12V DC
Exhaust 0.018 in Group C31
0.45 mm
Quantity 1
Lubrication system
Cold cranking ampere @ 0°F 1000A
Oil pressure at high idle, minimum 43 psi
3 bar Reserve capacity @ 25A rate 200 minutes
Oil capacity 8.3 quarts

Units ship with 15W-40. Genie policy. Product specifications are
Extreme operating temperatures may require the use of subject to change without notice.
Engine Operation and Maintenance Manual on your
machine.
Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 2 - 11

Dana T12000 Transmission Dana T20000 Transmission

GTH-636, GTH-644, GTH-842 and GTH-844 GTH-1048 and GTH-1056
Transmission Type 3 speed powershift converter Transmission Type 3 speed powershift converter
Speeds, Forward 3 Speeds, Forward 3
Speeds, Reverse 3 Speeds, Reverse 3
Torque Converter Torque Converter
Maximum input 3300 rpm Maximum input 3100 rpm
Size 11 inches Size 12 inches
Lubrication Lubrication
Oil capacity 13.6 quarts Oil capacity 20 quarts

12.9 liters 18.9 liters
Oil viscosity requirements Oil viscosity requirements
Units ship with Chevron RPM SAE 10W. Units ship with Chevron RPM SAE 10W.
Extreme operating temperatures may require the use Extreme operating temperatures may require the use
of alternative transmission oils. For oil requirements, of alternative transmission oils. For oil requirements,
refer to the Dana T12000 Maintenance Manual refer to the Dana T20000 Maintenance Manual
(Dana part number 0109). (Dana part number 0202).
Dana 0109 Maintenance Manual Dana 0202 Maintenance Manual

Genie part number 97489 Genie part number 115025


Dana Planetary 212 Drive Axle Dana Planetary 213 Drive Axle
GTH-636, GTH-644, GTH-842 and GTH-844 GTH-1048 and GTH-1056
Steering Intergrated steer cylinder Steering Intergrated steer cylinder
Joints Heavy duty double U-joints Joints Heavy duty double U-joints
Steering angle, maximum 55° Steering angle, maximum 55°
Front Axle Lubrication Front Axle Lubrication
Front differential 9 quarts Front differential 15 quarts

Axle planetary end (each) 1 quart Axle planetary end (each) 2 quarts
0.9 liter 1.9 liters
Rear Axle Lubrication Rear Axle Lubrication
Rear differential 6 quarts Rear differential 15 quarts

Axle planetary end (each) 1 quart Axle planetary end (each) 2 quarts
0.9 liter 1.9 liters
Oil viscosity requirements Oil viscosity requirements
Differential Chervron Supreme 80W90 LS Differential Chervron Supreme 80W90 LS
Planet ends Chervron Supreme 80W90 LS Planet ends Chervron Supreme 80W90 LS
For additional axle information, refer to the Dana 212 For additional axle information, refer to the Dana 213
Axle Maintenance and Repair Manual Axle Maintenance and Repair Manual
(Dana part number MO212S20). (Dana part number 0243).
Dana 212 Axle Maintenance and Repair Manual Dana 213 Axle Maintenance and Repair Manual


Hydraulic Hose and Fitting JIC 37° Fittings

(swivel nut or hose connection)
Torque Specifications
SAE Dash size Thread Size Flats
Your machine is equipped with 37° flared fittings
and hose ends. Genie specifications require that -4 7/16-20 2
fittings and hose ends be torqued to specification
-6 9/16-18 1 1/4
when they are removed and installed or when new
hoses or fittings are installed. -8 3/4-16 1
Torque Procedure -10 7/8-14 1
JIC 37° fittings -12 1 1/16-12 1
Use the JIC 37° Fittings table on -16 1 5/16-12 1

this page to determine the correct -20 1 5/8-12 1
number of flats for the proper
tightening position. -24 1 7/8-12 1
1 Align the tube flare (hex nut) against the nose of

the fitting body (body hex fitting) and tighten the 3 Working clockwise on the body hex fitting, make
hex nut to the body hex fitting to hand-tight, a second mark with a permanent ink marker to
approximately 30 in-lbs / 3.4 Nm. indicate the proper tightening position.
2 Make a reference mark on one of the flats of the The marks indicate that the correct
hex nut, and continue it on to the body hex tightening positions have been
fitting with a permanent ink marker. determined. Use the second mark
on the body hex fitting to properly
a tighten the joint after it has been
loosened.
c
d b
a
c
b
a hydraulic hose
b hex nut
a body hex fitting
c reference mark
b reference mark
d body hex fitting
c second mark
4 Tighten the hex nut until the mark on the hex

nut is aligned with the second mark on the body
hex fitting.
5 Operate all machine functions and inspect the
hoses and fittings and related components to

SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8
Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7

28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4

24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

in- lbs Nm in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
f t - lbs Nm f t -lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm ft - lbs Nm f t - lbs Nm f t - lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233


June 2007 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety

warnings and step-by-step instructions.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Safety alert symbol—used to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, semi-annually,
annually and every 2 years as specified on the Indicates an imminently hazardous
Maintenance Inspection Report. situation which, if not avoided, will
result in death or serious injury.
Failure to perform each procedure
as presented and scheduled could Indicates a potentially hazardous
result in death, serious injury or situation which, if not avoided,
substantial damage. could result in death or serious
injury.
Immediately tag and remove from service a
damaged or malfunctioning machine. Indicates a potentially hazardous
situation which, if not avoided,
Repair any machine damage or malfunction may cause minor or moderate
before operating the machine. injury.
Use only Genie approved replacement parts. Indicates a potentially hazardous
situation which, if not avoided,
Machines that have been out of service for a may result in property damage.
period longer than 3 months must complete the
quarterly inspection. Indicates that a specific result is expected after
performing a series of steps.
Unless otherwise specified, perform each
maintenance procedure with the machine in the Indicates that an incorrect result has occurred
following configuration: after performing a series of steps.
· Machine parked on a firm, level surface

· Boom in the stowed position
· Key switch in the off position with the key
removed
· Wheels chocked
Section 3 • Scheduled Maintenance Procedures June 2007
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

Note: The following symbols have been used in The pre-delivery preparation report contains
this manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appear at the beginning of a maintenance Make copies of the Pre-delivery Preparation report
procedure, it conveys the meaning below. to use for each inspection. Store completed forms
as required.
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, semi-annually, annually, and
two year. The Scheduled Maintenance Procedures
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
have been divided into five subsections—A, B, C,
D, and E. Use the following chart to determine
which group(s) of procedures are required to
Indicates that a cold engine will be perform a scheduled inspection.
required to perform this procedure.
Inspection Checklist
Indicates that a warm engine will be Daily or every 8 hours A

required to perform this procedure.
Quarterly or every 250 hours A+B
Semi-annually or every 500 hours A+B+C

Indicates that dealer service will be
required to perform this procedure. Annually or every 1000 hours A+B+C+D
Two year or every 2000 hours A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains

checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Store completed forms
for three years.
Pre-Delivery Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to the Pre-operation Inspection, the Maintenance items
each delivery. The inspection is designed to discover if and the Function Tests.
anything is apparently wrong with a machine before it
is put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be used. Follow the instructions in the operator’s manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and re-inspect it. After repair,
place a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be N = no, unable to complete
performed by qualified service technicians, according R = repaired
to the manufacturer's specifications and the Comments
requirements listed in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA Genie UK

18340 NE 76th Street The Maltings, Wharf Road
PO Box 97030 Grantham, Lincolnshire
Redmond, WA 98073-9730 NG31- 6BH England
(425) 881-1800 (44) 1476-584333
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie
Industries. Rev B
Maintenance Inspection Report

Model Checklist A - Rev C Y N R Checklist B - Rev B Y N R
A-1 Manuals and decals B-1 Battery
Serial number
A-2 Pre-operation inspect B-2 Electrical wiring
Date A-3 Function tests B-3 Exhaust system
A-4 Lubricate machine B-4 Engine air filter
Hour meter
A-5 Engine maintenance - B-5 Tires and wheels
JDeere/Perkins models B-6 Hydraulic oil
Machine owner
A-6 Transmission B-7 Tank venting systems
Inspected by (print) maintenance
B-8 Boom wear pads
A-7 Engine maintenance -
B-9 Lubricate driveshafts
Inspector signature Deutz models
B-10 Engine maintenance -
Perform after 40 hours:
Inspector title John Deere models
A-8 30 day service
Inspector company Perform after 50 hours:

Checklist C - Rev B Y N R
A-9 Transmission
C-1 Engine maintenance -
Instructions maintenance
Deutz models
· Make copies of this report to use for Perform every 50 hours:
C-2 Engine maintenance -
each inspection. A-10 Engine maintenance - John Deere models
· Select the appropriate checklist(s) for Perkins models
C-3 Axle maintenance
the type of inspection to be A-11 Axle maintenance
performed. C-4 Transmission
Perform after 100 hours: maintenance
Daily or 8 hour A-12 Engine maintenance - C-5 Engine maintenance -
Inspection: A John Deere models Perkins models
Quarterly or 250 hour A-13 Axle maintenance Perform every 700 hours:
Inspection: A+B A-14 Transmission C-6 Axle maintenance
Semi-annually or 500 hour maintenance
Perform every 800 hours:
Inspection: A+B+C Perform every 200 hours:
C-7 Axle maintenance
Annually or 1000 hour A-15 Axle maintenance
Inspection: A+B+C+D
2 Year or 2000 hour Comments
Inspection: A+B+C+D+E
· Place a check in the appropriate box

after each inspection procedure is
completed.
· Use the step-by-step procedures in
this section to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
MAINTENANCE INSPECTION REPORT
Model Checklist D - Rev B Y N R Checklist E - Rev C Y N R

D-1 Forks E-1 Hydraulic oil
Serial number
D-2 Sequencing chains E-2 Engine maintenance -
Date D-3 Hydraulic return filter John Deere models
D-4 Engine maintenance - E-3 Engine maintenance -
Hour meter Deutz models Perkins models
D-5 Transmission Perform every 3000 hours:
Machine owner E-4 Engine maintenance -
D-6 Axle maintenance
Perkins models
Inspected by (print) D-7 Engine maintenance -
Perkins models Perform every 4000 hours:
Inspector signature Perform every 1500 hours: E-5 Engine maintenance -
Perkins models
D-8 Engine maintenance -
Inspector title Deutz models Perform every 4500 hours:
E-6 Engine maintenance -
Inspector company John Deere models
Perform every 6000 hours:
Instructions
· Make copies of this report to use for E-7 Engine maintenance -
each inspection. Perkins models
· Select the appropriate checklist(s) for Perform every 12,000 hours:

the type of inspection to be E-8 Engine maintenance -
performed. Deutz models
E-9 Engine maintenance -
Daily or 8 hour Perkins models
Inspection: A
Quarterly or 250 hour
Comments
Inspection: A+B
Semi-annually or 500 hour
Inspection: A+B+C
Annually or 1000 hour
Inspection: A+B+C+D
2 Year or 2000 hour
Inspection: A+B+C+D+E
· Place a check in the appropriate box

after each inspection procedure is
completed.
· Use the step-by-step procedures in
this section to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
REV C
Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Note: Genie specifications require that this and damage.
procedure be performed every 8 hours or daily, Result: The machine is equipped with all
whichever comes first. required decals, and all decals are legible and
Maintaining the operator’s and safety manuals in in good condition.
good condition is essential to safe machine Result: The machine is not equipped with all
operation. Manuals are included with each required decals, or one or more decals are
machine and should be stored in the container illegible or in poor condition. Remove the
provided in the operator's compartment. An machine from service until the decals are
illegible or missing manual will not provide safety replaced.
and operational information necessary for a safe
operating condition. 4 Always return the manuals to the storage
container after use.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory Note: Contact your authorized Genie distributor or
for safe machine operation. Decals alert operators Genie Industries if replacement manuals or decals
and personnel to the many possible hazards are needed.
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's and

safety manuals are present and complete in the
storage container in the operator's
compartment.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove the
machine from service until the manual is
replaced.
CHECKLIST A PROCEDURES REV C
A-2 A-3
Perform Pre-operation Inspection Perform Function Tests
Note: Genie specifications require that this Note: Genie specifications require that this
procedure be performed every 8 hours or daily, procedure be performed every 8 hours or daily,
whichever comes first. whichever comes first.
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The Pre-operation Inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the appropriate operator's manual.
Complete information to perform this procedure is Refer to the Operator's Manual on your machine.
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
REV C CHECKLIST A PROCEDURES
A-4 a b c d e f g
Lubricate the Machine
Note: Genie specifications require that this

procedure be performed every 8 hours or daily,
whichever comes first.
Greasing the specified locations is essential for

good machine performance and service life.
a fork frame pivot pin
Operating the machine with little or no grease b fork level cylinder rod-end pivot pin
may cause the machine to perform poorly and c number 2 boom tube lower wear pads
continued use may cause component damage. d number 1 boom tube lower wear pads
e lift cylinder barrel-end pivot pin
GTH-644, GTH-842 and GTH-844: f lift cylinder rod-end pivot pin
g boom pivot pin
1 Fully extend the boom. Raise the boom as
needed. 6 Locate a grease fitting at one of the locations
shown in the illustration.
2 Apply a thin layer of grease to the underside of
the number 3 boom tube where it makes 7 Pump grease into the fitting until the joint is
contact with the number 2 boom tube lower thoroughly lubricated.
wear pads. Refer to the illustration. 8 Repeat this procedure, beginning with step 6,
3 Apply a thin layer of grease to the underside of for each remaining grease fitting shown in the
the number 2 boom tube where it makes illustration.
contact with the number 1 boom tube lower
wear pads. Grease Specification
4 Lubricate the top and side boom tube wear Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
pads. or equivalent
5 Return the boom to the stowed position.
GTH-636, GTH-1048 and GTH-1056: a b c d e f g
1 Fully extend the boom. Raise the boom as

needed.
2 Locate the grease fittings at both sides of all
boom tubes except the innermost tube. Refer to
the illustration.
i
3 Pump grease into the fittings until the inner
boom rollers are thoroughly lubricated. h
4 Lubricate the top boom tube wear pads.

a fork frame pivot pin
Note: Do not lubricate the side wear pads at the b fork level cylinder rod-end pivot pin
c fork level cylinder barrel-end pivot pin
boom rollers, if equipped.
d boom grease fittings
e lift cylinder barrel-end pivot pin
5 Return the boom to the stowed position. f lift cylinder rod-end pivot pin
g boom pivot pin
6 Locate a grease fitting at one of the locations
h outrigger pivot pin
shown in the illustration. (GTH-1048 and GTH-1056)
i outrigger frame
7 Pump grease into the fitting until the joint is (GTH-1048 and GTH-1056)
thoroughly lubricated.
8 Repeat this procedure, beginning with step 6,
for each remaining grease fitting shown in the
illustration.
GTH-1048 and GTH-1056:
9 Locate the grease fittings on the stabilizer frame

at the front of the machine.
10 Pump grease into each fitting until the joints are
11 Locate the grease fittings on the outriggers at
the front of the machine.
12 Pump grease into each fitting until the joints are
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent

A-5 A-6
Perform Engine Maintenance - Perform Transmission
John Deere and Perkins Models Maintenance
Note: Engine specifications require that this Note: Transmission specifications require that this
procedure be performed every 8 hours or daily, procedure be performed every 8 hours or daily,
whichever comes first. whichever comes first.
Required maintenance procedures and additional GTH-636, GTH-644, GTH-842 and GTH-844:
engine information is available in the
John Deere 4045T270 Operator's Manual Required maintenance procedures and additional
(John Deere part number OMRG25204) OR the transmission information is available in the
John Deere 4045T275 Operator's Manual Dana T12000 Maintenance Manual
(John Deere part number OMRG33324) OR the (Dana part number 0109).
Perkins 1104 Operation and Maintenance Manual
(Perkins part number SEBU7833-01). Dana T12000 Maintenance Manual
Genie part number 97489
John Deere 4045T270 Operator's Manual
Genie part number 108444 Required maintenance procedures and additional
Transmission information is available in the
Perkins 1104 Operation and Maintenance Manual Dana T20000 Maintenance Manual
Genie part number 117765 (Dana part number 0202).
Dana T20000 Maintenance Manual


A-7 A-8
Perform Engine Maintenance - Perform 30 Day Service
Deutz Models
The 30 day maintenance procedure is a one-time

Note: Engine specifications require that this sequence of procedures to be performed after the
procedure be performed every 10 hours or daily, first 30 days or 40 hours of usage. After this
whichever comes first. interval, refer to the maintenance checklists for
continued scheduled maintenance.
Required maintenance procedures and additional
engine information is available in the 1 Perform the following maintenance procedures:
Deutz 2012 Operation Manual John Deere models:
(Deutz part number 0297 9912).
· A-12 Perform Engine Maintenance -
John Deere Models
Deutz 2012 Operation Manual
· B-5 Inspect the Tires, Wheels and
Lug Nut Torque
· D-3 Replace the Hydraulic Tank
Return Filter Element
Deutz models:

Lug Nut Torque
· D-4 Perform Engine Maintenance -
Deutz Models
Perkins models:

Lug Nut Torque

A-9 A-10
Perform Transmission Perform Engine Maintenance -
Maintenance Perkins Models
GTH-636, GTH-644, GTH-842 and GTH-844
Note: Engine specifications require that this

Note: Transmission specifications require that this procedure be performed every 50 hours or weekly,
one-time procedure be performed after 50 hours of whichever comes first.
operation.
Required maintenance procedures and additional engine information is available in the
transmission information is available in the Perkins 1104 Operation and Maintenance Manual
Dana T12000 Maintenance Manual (Perkins part number SEBU7833-01).
(Dana part number 0109).
Dana T12000 Maintenance Manual Genie part number 117765

A-11 A-12
Perform Axle Maintenance Perform Engine Maintenance -
John Deere Models
Note: Axle specifications require that this

procedure be performed every 50 hours or Note: Engine specifications requires that this one-
monthly, whichever comes first. time procedure be performed after 100 hours of
GTH-636, GTH-644, GTH-842 and GTH-844: operation.
Required maintenance procedures and additional Required maintenance procedures and additional
axle information is available in the engine information is available in the
Dana 212 Axle Maintenance and Repair Manual John Deere 4045T270 Operator's Manual
(Dana part number 0247). (John Deere part number OMRG25204) OR the
(John Deere part number OMRG33324).
Dana 212 Axle Maintenance and Repair Manual
Required maintenance procedures and additional Genie part number 108444
axle information is available in the


A-13 A-14
Perform Axle Maintenance Perform Transmission
Maintenance
GTH-636, GTH-644, GTH-842 and GTH-844
Note: Axle specifications require that this one-time

procedure be performed after 100 hours of
operation.
Note: Transmission specifications requires that this
GTH-636, GTH-644, GTH-842 and GTH-844: one-time procedure be performed after 100 hours
of operation.
axle information is available in the Required maintenance procedures and additional
Dana 212 Axle Maintenance and Repair Manual transmission information is available in the
(Dana part number 0247). Dana T12000 Maintenance Manual
Genie part number 97488 Dana T12000 Maintenance Manual



A-15
Perform Axle Maintenance
Note: Axle specifications requires that this

procedure be performed every 200 hours of
operation.
GTH-636, GTH-644, GTH-842 and GTH-844:





REV B
Checklist B Procedures
B-1 B-2
Inspect the Battery Inspect the Electrical Wiring
Note: Genie requires that this procedure be Note: Genie requires that this procedure be
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
Proper battery condition is essential to good Maintaining electrical wiring in good condition is
engine performance and operational safety. essential to safe operation and good machine
Damaged cables and connections can result in performance. Failure to find and replace burnt,
engine component damage and hazardous chafed, corroded or pinched wires could result in
conditions. unsafe operating conditions and may cause
component damage.
Electrocution hazard. Contact with
hot or live circuits could result in Electrocution hazard. Contact with
death or serious injury. Remove all hot or live circuits could result in
rings, watches and other jewelry. death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or 1 Inspect the following areas for burnt, chafed,
contacting battery acid. Neutralize corroded and loose wires:
battery acid spills with baking soda
· Inside of the operator's compartment
and water.
· Underside of the chassis
1 Put on protective clothing and eye wear.
· Boom assembly
2 Be sure that the battery cable connections are
2 Inspect for a liberal coating of dielectric grease
free of corrosion.
in the following locations:
Note: Adding terminal protectors and a corrosion
·All harness connectors
preventative sealant will help eliminate corrosion
on the battery terminals and cables. 3 Start the engine and raise the boom so there is
enough room to access and remove all the
3 Be sure that the battery hold-downs and cable covers attached to the chassis.
connections are tight.

CHECKLIST B PROCEDURES REV B
4 Attach a lifting strap from an overhead crane to B-3

the boom. Support the boom. Do not apply any
lifting pressure. Check the Exhaust System
5 Remove all engine covers, hydraulic tank
covers and chassis covers.
Crushing hazard. Death or serious Note: Genie requires that this procedure be
injury could result if the boom performed every 250 hours or quarterly, whichever
should unexpectedly fall while comes first.
working underneath the boom. Do
not stand or work beneath a boom Maintaining the exhaust system is essential to
that is not properly supported. good engine performance and service life. Running
the engine with a damaged or leaking exhaust
6 Inspect the following areas for burnt, chafed, system can cause component damage and unsafe
corroded, pinched and loose wires: operating conditions.
· Engine Bodily injury hazard. Do not
·Transmission inspect while the engine is
· Manifolds running. Remove the key to
secure from operation.
·Chassis
Bodily injury hazard. Beware of
7 Inspect for a liberal coating of dielectric grease
hot engine components. Contact
in all connections between the engine,
with hot engine components may
transmission and the operator's compartment.
cause severe burns.
8 Install all covers removed in step 5.
1 Remove the center engine cover and set aside.
9 Remove the lifting strap from the overhead
2 Open the right side engine access cover.
crane.
3 Be sure that all fasteners are tight.
10 Start the engine and lower the boom to the
stowed position. Turn the machine off. 4 Inspect all welds for cracks.
5 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
6 Close the right side engine access cover. Install
the center engine access cover.

REV B CHECKLIST B PROCEDURES
B-4 B-5
Inspect the Engine Air Filter Inspect the Tires, Wheels and
Lug Nut Torque
Note: Genie requires that this procedure be

performed every 250 hours or quarterly, whichever Note: Genie requires that this procedure be
comes first. Perform this procedure more often if performed every 250 hours or quarterly, whichever
dusty conditions exist. comes first.
Maintaining the engine air filter in good condition is Maintaining the tires and wheels in good
essential to good engine performance and service condition, including proper wheel fastener torque,
life. Failure to perform this procedure can lead to is essential to safe operation and good
poor engine performance and component damage. performance. Tire and/or wheel failure could result
Note: Perform this procedure with the engine off. in a machine tip-over. Component damage may
also result if problems are not discovered and
1 Release the latches on the front cover of the air repaired in a timely fashion.
cleaner assembly. Remove the cover.
Bodily injury hazard. An
2 Gently twist and pull out the external or primary overinflated tire can explode and
filter element. could result in death or serious
3 Remove the inner or secondary filter element. injury.
4 Clean the inside of the canister and the gasket Tip over hazard. Do not use
with a damp cloth. temporary flat tire repair products.
5 Inspect the primary and secondary air filter Note: The tires on some machines are foam filled
elements. If needed, blow from the inside and do not need air added to them.
out using low pressure dry compressed air, 1 Check all tire treads and sidewalls for cuts,
or carefully tap out dust. cracks, punctures and unusual wear.
6 Install the secodnary filter element first, then 2 Check each wheel for damage, bends and
install the primary filter element. cracks.
7 Install the front cover onto the air cleaner 3 Check each lug nut for proper torque. Refer to
assembly and secure the latches. Section 2, Specifications.

Models with air or calcium chloride filled tires: B-6

4 Put on protective clothing and eye wear. Perform Hydraulic Oil Analysis
5 Rotate the wheel until the tire stem is at the 12
o'clock position.

performed every 250 hours or quarterly, whichever
comes first.
a
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil may cause the machine to
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may require oil changes to be performed more
often. Refer to Section 2, Specifications.
Note: Before replacing the hydraulic oil, the oil may

be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
a valve stem
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
6 Check the air pressure in the tire. Refer to Replace the oil when it fails the test. See E-1,
Section 2, Specifications. Test or Replace the Hydraulic Oil.
Result - models with air-filled tires: The air
pressure meets specification. The tire is at the
correctly filled level.
Result - models with calcium chloride-filled
tires: The air pressure meets specification, and
a small amount of calcium chloride mixture
leaks from the valve stem when checking the
air pressure. The tire is at the correctly filled
level.
Result - models with air-filled tires: The air
pressure does not meet specification. Add air
until the air pressure meets specification.
Result - models with calcium chloride-filled
tires: The air pressure does not meet
specification OR the tire does not release any
calcium chloride mixture when checking the air
pressure. Add calcium chloride mix to the tire
as needed until it begins to leak out when
depressing the valve stem, and add air until the
air pressure meets specification.
7 Repeat this procedure beginning with step 5 for
each remaining tire.

B-7 3 Using a mild solvent, carefully wash the cap

venting system. Dry using low pressure
Inspect the Fuel and Hydraulic compressed air. Repeat this procedure
Tank Cap Venting Systems beginning with step 2.
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
tank.
performed every 250 hours or quarterly, whichever 6 Check for proper venting.
comes first. Perform this procedure more often if
Result: Air passes through the fuel tank cap.
dusty conditions exist.
Proceed to step 8.
Free-breathing fuel and hydraulic tank caps are
Result: If air does not pass through the cap,
essential for good machine performance and
clean or replace the cap. Proceed to step 7.
service life. A dirty or clogged tank cap may cause
the machine to perform poorly and continued use Note: When checking for positive tank cap venting,
may cause component damage. Extremely dirty air should pass freely through the cap.
conditions may require that the caps be inspected
more often. 7 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
Explosion and fire hazard. Engine compressed air. Repeat this procedure
fuels are combustible. Perform this beginning with step 6.
procedure in an open, well-
8 Install the breather cap onto the hydraulic tank.
ventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Note: Perform this procedure with the engine off.
1 Remove the cap from the fuel tank.

2 Check for proper venting.
Result: Air passes through the fuel tank cap.
Proceed to step 4.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
Note: When checking for positive tank cap venting,
air should pass freely through the cap.

B-8 2 Measure each lower wear pad.

Check the Boom Wear Pads Result: The measurement is within
GTH-644, GTH-842 and GTH-844 specification.
Result: The measurement is less than
specification. Replace both wear pads. Refer to
Repair Procedure 1-2, How to Replace the
Note: Genie specifications require that this Boom Wear Pads.
operation. Boom Wear Pad Specifications,
GTH-644, GTH-842 and GTH-844
1 Extend the boom until the wear pads are
accessible. Upper wear pad thickness, minimum 9/16 inch
14.3 mm
2 Measure each upper wear pad.
Result: The measurement is within Side wear pad thickness, minimum 3/8 inch
specification. 9.5 mm
Result: The measurement is less than Lower wear pad thickness, minimum 9/16 inch
specification. Replace both wear pads. Refer to 14.3 mm
Repair Procedure 1-2, How to Replace the
Boom Wear Pads.
2 Measure each side wear pad.
Result: The measurement is within
specification.
Result: The measurement is less than
specification. Replace all side wear pads. Refer
to Repair Procedure 1-2, How to Replace the
Boom Wear Pads.

B-9 B-10
Lubricate the Driveshafts Perform Engine Maintenance -
John Deere Models

performed every 250 hours or quarterly, whichever Note: Engine specifications require that this
comes first. procedure be performed every 250 hours of
Greasing the specified locations is essential for operation.
good machine performance and service life. Required maintenance procedures and additional
Operating the machine with little or no grease engine information is available in the
may cause the machine to perform poorly and John Deere 4045T270 Operator's Manual
continued use may cause component damage. (John Deere part number OMRG25204) OR the
1 Using a grease gun, thoroughly grease the John Deere 4045T275 Operator's Manual
driveshafts at each of the locations indicated in (John Deere part number OMRG33324).
the illustration.
Grease Specification Genie part number 97492
Chevron Ultra-duty grease, EP NLGI 2 (lithium based) John Deere 4045T275 Operator's Manual
or equivalent Genie part number 108444
b b b a a a
a rear driveshaft
b front driveshaft

Checklist C Procedures REV B
C-1 C-2
Perform Engine Maintenance - Perform Engine Maintenance -
Deutz Models John Deere Models
Note: Engine specifications require that this Note: Engine specifications require that this
procedure be performed every 500 hours or semi- procedure be performed every 500 hours or semi-
annually, whichever comes first. annually, whichever comes first.
engine information is available in the engine information is available in the
Deutz 2012 Operation Manual John Deere 4045T270 Operator's Manual
(Deutz part number 0297 9912). (John Deere part number OMRG25204) OR the
Deutz 2012 Operation Manual (John Deere part number OMRG33324).


REV B CHECKLIST C PROCEDURES
C-3 C-4
Perform Axle Maintenance Perform Transmission
Maintenance

procedure be performed after 500 hours of
operation.
Note: Transmission specifications require that this
GTH-636, GTH-644, GTH-842 and GTH-844: procedure be performed every 500 hours or semi-
annually, whichever comes first.
axle information is available in the Required maintenance procedures and additional
Dana 212 Axle Maintenance and Repair Manual transmission information is available in the
(Dana part number 0247). Dana T20000 Maintenance Manual
Genie part number 97488 Dana T20000 Maintenance Manual



CHECKLIST C PROCEDURES REV B
C-5 C-6
Perform Engine Maintenance - Perform Axle Maintenance
Perkins Models

Note: Engine specifications require that this procedure be performed every 700 hours of
procedure be performed every 500 hours or operation.
annually, whichever comes first. GTH-636, GTH-644, GTH-842 and GTH-844:
engine information is available in the axle information is available in the
Perkins 1104 Operation and Maintenance Manual Dana 212 Axle Maintenance and Repair Manual
(Perkins part number SEBU7833-01). (Dana part number 0247).
Perkins 1104 Operation and Maintenance Manual Dana 212 Axle Maintenance and Repair Manual



REV B CHECKLIST C PROCEDURES
C-7
Perform Axle Maintenance

operation.





Checklist D Procedures REV B
D-1 D-2
Inspect the Forks Adjust the Boom Sequencing
Chains

procedure be performed every 1000 hours or Note: Genie specifications require that this
annually, whichever comes first OR whenever procedure be performed every 1000 hours or
permanent deformation of the forks is suspected. annually, whichever comes first.
Maintaining the lifting forks in good condition is GTH-636, GTH-644, GTH-842, GTH-844 and
essential to safe operation and good machine GTH-1048:
performance. Failure to detect damage to the forks
could result in a hazardous operating condition. 1 Raise the boom to the horizontal position.
1 Thoroughly clean the lifting forks. 2 Extend the boom fully, then retract the boom
approximately 1 inch / 25 mm.
2 Inspect the forks for the following:
3 On either side of the middle boom section,
· Surface cracks estimate the center. Place one end of a
· Straightness of the blade and shank tape measure on the top surface of the
· Fork angle at 90 ± 3 degrees boom directly above the estimated center.
· Relative height of fork tips shall not differ 4 Select a reference point on the sequencing
more than 3% of blade length chain. Measure the distance between the chain
and the top surface of the boom. Note the
· Excessive wear to the forks, fork mount or
measurement (1). Refer to the following
legible markings
illustrations.
Result: If any of the above criteria are not met,
the fork shall be removed from service until it is 2
repaired or replaced.
1
a
a shank
b blade

REV B CHECKLIST D PROCEDURES
5 Move to the fork end of the same boom section GTH-1056:

that was just measured.
1 Raise the boom to the horizontal position.
6 Measure the distance between the top surface
of the boom and the same reference point used 2 Extend the boom fully, then retract the boom
on the sequencing chain in step 4. Note the approximately 1 inch / 25 mm.
measurement (2). 3 On either side of the number 2 boom tube,
Result: The difference between measurements estimate the center. Place one end of a
tape measure on the top surface of the
1 and 2 is 0.25 to 0.5 inch / 6.35 to 12.7 mm.
boom directly above the estimated center.
No adjustment to the chain is necessary.
Proceed to step 10. a b c d e f g h
Result: The difference between measurements
1 and 2 is less than a 0.25 inch / 6.35 mm OR
is greater than 0.5 inch / 12.7 mm. The chain GTH-1056
requires adjustment. Proceed to step 7.
Note: The measurements taken in step 4 and step
6 must be taken from the same plane on the boom.
7 Working at the fork end of the large boom tube,

locate the adjustable chain anchor on the top of
boom section.
l k j i j j i
a b c
a number 0 boom tube
b chain tensioner
c boom tube 2 extension chain
d number 1 boom tube
e boom tube 3 extension chain
f number 2 boom tube
g number 3 boom tube
h front cover
i chain roller (hidden from view)
a nut
j boom roller (hidden from view)
b spring
k support loop
c chain anchor
l extension cylinder
8 Place an adjustable wrench across the flat part

of the chain, just ahead of the chain anchor.
Tighten the wrench onto the chain.
9 Using a 1 7/16 inch wrench, adjust the nut as
required to tighten or loosen the chain. Repeat
this procedure beginning with step 4.
10 Using a feeler gauge, check the gap between
the coils of the spring. The gap should be no
less than 0.030 inch / 0.76 mm.
Note: The spring coils should never be collapsed
completely.

CHECKLIST D PROCEDURES REV B
4 Select a reference point on the extension chain. 6 Measure the distance between the top surface
Measure the distance between the chain and of the boom and the same reference point used
the top surface of the boom. Note the on the sequencing chain in step 4. Note the
measurement (1). Refer to the following measurement (2).
illustrations.
2
1 and 2 is 0.25 to 0.5 inch / 6.35 to 12.7 mm.
No adjustment to the chain is necessary.
1 Proceed to step 10.
1 and 2 is less than a 0.25 inch / 6.35 mm OR
is greater than 0.5 inch / 12.7 mm. The chain
requires adjustment. Proceed to step 7.
Note: The measurements taken in step 4 and step
6 must be taken from the same plane on the boom.
7 Working at the fork end of the boom tube,

locate the adjustable chain anchor on the top of
the boom section.
a b c
5 Move to the fork end of the same boom section

that was just measured.
a nut
b spring
c chain anchor
8 Place an adjustable wrench across the flat part

of the chain, just ahead of the chain anchor.
Tighten the wrench onto the chain.
9 Using a 1 7/16 inch wrench, adjust the nut as
required to tighten or loosen the chain. Repeat
this procedure beginning with step 5.
10 Using a feeler gauge, check the gap between
the coils of the spring. The gap should be no
less than 0.030 inch / 0.76 mm.
Note: The spring coils should never be collapsed
completely.

for each extension chain of the boom assembly.

D-3 4 Carefully push down and rotate the cover

clockwise to remove.
Replace Hydraulic Tank Return
5 Remove the cover spring and pull the filter
Filter Element element out using the swivel handle on the
element.
Note: Before installing the new filter element, make
sure both o-rings are in place inside the new filter
element, then transfer the bypass valve into the
procedure be performed every 1000 hours or
new filter element.
annually, whichever comes first
6 Install the new filter element, cover spring and
Replacing the hydraulic return filter element is
cover, making sure the o-ring is in place
essential to good machine performance and
between the cover and the return filter
service life. A dirty or clogged filter element may
assembly.
cause the machine to perform poorly and
continued use may cause component damage. 7 Securely tighten the four bolts that hold the fuel
Extremely dirty conditions may require that the filter assembly cover in place. Do not over
filter element be replaced more often. tighten.
Bodily injury hazard. Beware of 8 Tighten the filler/breather cap.
hot oil. Contact with hot oil may
9 Record the hours the filter element was
cause severe burns.
replaced and keep with your maintenance
Note: Perform this procedure with the engine off. records.
1 Start the engine. Retract the boom and lower 10 Start the engine.
the forks to the ground. Shut off the engine. 11 Inspect the filter assembly to be sure that there
2 Working from the rear of the machine, release are no leaks.
the pressure in the oil reservoir by loosening 12 Clean up any oil that may have spilled during
the filler/breather cap. the installation procedure.
3 Loosen, but do not remove, the four bolts on top
of the return filter assembly.
Bodily injury hazard. The return
filter assembly cover is spring
loaded. Do not remove the bolts.

D-4 D-5
Perform Engine Maintenance - Perform Transmission
Deutz Models Maintenance
Note: Engine specifications require that this Note: Transmission specifications require that this
procedure be performed every 1000 hours or procedure be performed every 1000 hours or
annually, whichever comes first. annually, whichever comes first.
Required maintenance procedures and additional GTH-636, GTH-644, GTH-842 and GTH-844:
Deutz 2012 Operation Manual Required maintenance procedures and additional
(Deutz part number 0297 9912). transmission information is available in the

transmission information is available in the


D-6 D-7
Perform Axle Maintenance Perform Engine Maintenance -
Perkins Models

procedure be performed every 1000 hours of Note: Engine specifications require that this
operation. procedure be performed every 1000 hours.
GTH-636, GTH-644, GTH-842 and GTH-844: Required maintenance procedures and additional
axle information is available in the Perkins 1104 Operation and Maintenance Manual
Dana 212 Axle Maintenance and Repair Manual (Perkins part number SEBU7833-01).
Dana 212 Axle Maintenance and Repair Manual Genie part number 117765



D-8
Perform Engine Maintenance -
Deutz Models
Note: Engine specifications require the valves to

be adjusted every 1500 hours of operation.
(Deutz part number 0297 9912).


REV C
Checklist E Procedures
E-1 3 Using an approved hand-operated pump, drain
the hydraulic tank into a suitable container.
Test or Replace the Hydraulic Oil Refer to Section 2, Specifications.
cause severe burns.
procedure be performed every 2000 hours or two 4 Remove the drain plug from the rear of the tank.
years, whichever comes first 5 Rinse out the inside of the tank using a mild
Replacement or testing of the hydraulic oil is solvent.
essential for good machine performance and 6 Install the drain plug and securely tighten. Do
service life. Dirty oil may cause the machine to not over tighten.
perform poorly and continued use may cause
component damage. Extremely dirty conditions 7 Fill the tank with hydraulic oil until the fluid level
may require oil changes to be performed more is in the center of the sight glass at the rear of
frequently. Refer to Section 2, Specifications. the tank.
Component damage hazard. The 8 Clean up any oil that may have spilled.
work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic
system.
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
1 Lower the boom to the stowed position.

2 Remove oil cap from top of hydraulic tank.

CHECKLIST E PROCEDURES REV C
E-2 E-3
John Deere Models Perkins Models
procedure be performed every 2000 hours or two procedure be performed every 2000 hours.
years, whichever comes first.
engine information is available in the Perkins 1104 Operation and Maintenance Manual
John Deere 4045T270 Operator's Manual (Perkins part number SEBU7833-01).
(John Deere part number OMRG25204) OR the
John Deere 4045T275 Operator's Manual Perkins 1104 Operation and Maintenance Manual
(John Deere part number OMRG33324). Genie part number 117765



REV C CHECKLIST E PROCEDURES
E-4 E-5
Perkins Models Perkins Models
procedure be performed every 3000 hours or two procedure be performed every 4000 hours.
years, whichever comes first.
engine information is available in the Perkins 1104 Operation and Maintenance Manual
Perkins 1104 Operation and Maintenance Manual (Perkins part number SEBU7833-01).
(Perkins part number SEBU7833-01).
Perkins 1104 Operation and Maintenance Manual Genie part number 117765

CHECKLIST E PROCEDURES REV C
E-6 E-7
John Deere Models Perkins Models
procedure be performed every 4500 hours or 60 procedure be performed every 6000 hours or every
months, whichever comes first. three years, whichever comes first.
engine information is available in the engine information is available in the
John Deere 4045T270 Operator's Manual Perkins 1104 Operation and Maintenance Manual
(John Deere part number OMRG25204) OR the (Perkins part number SEBU7833-01).
(John Deere part number OMRG33324). Perkins 1104 Operation and Maintenance Manual


REV C CHECKLIST E PROCEDURES
E-8 E-9
Deutz Models Perkins Models
procedure be performed every 12,000 hours. procedure be performed every 12,000 hours or
every six years, whichever comes first.
engine information is available in the Required maintenance procedures and additional
Deutz 2012 Operation Manual engine information is available in the
(Deutz part number 0297 9912). Perkins 1104 Operation and Maintenance Manual
(Perkins part number SEBU7833-01).
Genie part number 108746 Perkins 1104 Operation and Maintenance Manual


June 2007 Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. Then to
Repair procedures shall be completed by a
re-assemble, perform the disassembly steps in
person trained and qualified on the repair of this
reverse order.
machine.
Immediately tag and remove from service a Symbols Legend
damaged or malfunctioning machine. Safety alert symbol—used to alert
Repair any machine damage or malfunction personnel to potential personal
before operating the machine. injury hazards. Obey all safety
Before Repairs Start: to avoid possible injury or death.
Read, understand and obey the safety rules Indicates an imminently hazardous
and operating instructions in the appropriate situation which, if not avoided, will
operator’s manual on your machine. result in death or serious injury.
Be sure that all necessary tools and parts are Indicates a potentially hazardous
available and ready for use. situation which, if not avoided,
could result in death or serious
Use only Genie approved replacement parts. injury.
Read each procedure completely and adhere Indicates a potentially hazardous
to the instructions. Attempting shortcuts may situation which, if not avoided,
produce hazardous conditions. may cause minor or moderate
Unless otherwise specified, perform each injury.
repair procedure with the machine in the Indicates a potentially hazardous
following configuration: situation which, if not avoided,
· Machine parked on a firm, level surface may result in property damage.
· Boom in the stowed position Indicates that a specific result is expected after
performing a series of steps.
· Key switch in the off position with the key
removed Indicates that an incorrect result has occurred
· Wheels chocked after performing a series of steps.
Section 4 • Repair Procedures June 2007
Boom Components REV C
1-1 5 Securely tighten the collar set screws.

Boom Angle Limit Switch 6 Lower the boom approximately 6 feet / 2 m.
(all models except GTH-636) 7 GTH-1056: Raise the boom to 55°. Confirm with
a digital level.
How to Adjust the Limit Switch All other models: Raise the boom to 60°.
Confirm with a digital level.
Note: Perform this procedure on a firm, level
8 Place the transmission into reverse 3. Release
surface.
the parking brake.
1 Start the engine. Result: The machine should not move and the
2 GTH-1056: Raise the boom to 55°. Confirm with alarm should not sound. The limit switch is
a digital level. properly calibrated.
All other models: Raise the boom to 60°. Result: The machine moves and the alarm
Confirm with a digital level. sounds. The limit switch is not calibrated
3 Working at the pivot end of the boom, locate correctly. Repeat this procedure beginning with
and loosen the fasteners of the limit switch step 2.
collar on the boom pivot at the exhaust side of Result: The machine moves and the alarm
the machine. sounds. The limit switch is faulty. Replace the
limit switch and repeat this procedure beginning
a
with step 2.
9 Lower the boom 10°.
Result: The machine moves and the alarm
sounds. The limit switch is calibrated correctly.
Result: The machine does not move and the
alarm stops sounding. The limit switch collar is
not parallel to the side of the boom. Repeat this
procedure beginning with step 3.
a boom pivot
10 Continue to lower the boom in 10° increments
4 Rotate the collar until the bottom of the collar
and test the drive function until the boom is in
ramp just contacts the roller head of the limit
the stowed position.
switch. Refer to the illustration below.
Result: The machine moves and the alarm
Note: Be sure the collar is parallel to the side of the
sounds. The limit switch is calibrated correctly.
boom.
Result: The machine does not move and the
alarm stops sounding. The limit switch collar is
not parallel to the side of the boom. Repeat this
procedure beginning with step 3.
REV C BOOM COMPONENTS
1-2 How to Remove the Lifting Fork

Boom Frame
1 With the boom in the stowed position, attach a
How to Replace the lifting strap from an overhead crane to the top
Boom Wear Pads of the lifting fork frame at the front of the boom.
Support the frame. Do not apply any lifting
1 Extend the boom until the wear pads are pressure.
accessible.
2 Remove the fasteners securing the fork level
2 Lower wear pads (if equipped): Attach a cylinder pivot pin to the lifting fork.
lifting strap from an overhead crane to the fork
end of the boom. Lift the boom just enough to 3 Use a soft metal drift to remove the pivot pin.
remove the weight from the pads and allow the 4 Remove the fasteners securing the fork frame
pad to be replaced. pivot pin to the boom.
3 Remove the wear pad mounting fasteners and 5 Use a soft metal drift to remove the pivot pin.
remove the wear pads from the boom.
Crushing hazard. The fork frame
4 Lubricate the wear surface of the new pads with could fall if not properly supported
multipurpose grease. when the pivot pin is removed
5 Install the new wear pads. Install and securely from the machine.
tighten the fasteners. 6 Remove the fork frame from the boom.
How to Replace the Boom Rollers
(if equipped)
1 Extend the boom approximately half way out.
2 Attach a lifting strap from an overhead crane to
the fork end of the boom. Lift the boom just
enough to remove the weight from the lower
rollers.
3 Remove the fasteners securing the boom roller
pivot pin to the boom.
4 Use a soft metal drift to remove the pivot pin.
Remove and replace the boom rollers.
Crushing hazard. The boom rollers
could fall if not secured when the
pivot pin is removed from the
boom.
Note: Note the quantity and location of the thrust
washers when removing the boom rollers.
BOOM COMPONENTS REV C
How to Remove the Boom a b c
Bodily injury hazard. This

procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and f e d
tools could result in death or
3-section boom
serious injury and significant
component damage. Dealer a boom tube number 3
service is strongly recommended. b boom tube number 2
c boom tube number 1
Note: When removing a hose assembly or fitting, d extension cylinder retaining pin
the O-ring on the fitting and/or hose end must be e extension cylinder support loop
f extension cylinder rod end nut
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and GTH-636, GTH-1048 and GTH-1056:
Fitting Torque Specifications.
5 Tag, disconnect and plug the remaining boom
1 Remove the lifting fork. See 1-2, How to supply hoses at the respective manifolds. Cap
Remove the Lifting Fork. the fittings on the manifolds.
2 Tag, disconnect and plug the two large All models:
hydraulic hoses from the manifolds of the
extension cylinder. Cap the fittings on the 6 Attach a lifting strap from an overhead
manifolds. 10 ton / 10,000 kg crane to the boom. Support
the boom. Do not apply any lifting pressure.
GTH-644, GTH-842 and GTH-844:
7 Select a boom lift cylinder. Attach a lifting strap
3 Tag, disconnect and plug the hydraulic hoses from an overhead 1 ton / 1000 kg crane to the
from the hydraulic hard lines adjacent to the cylinder. Support the cylinder. Do not apply any
extension cylinder at the pivot end of the boom. lifting pressure.
Cap the fittings on the hard lines.
8 Remove the fasteners securing the lift cylinder
4 Remove the fasteners and clamps securing the rod end pivot pin to the boom.
hydraulic hoses, disconnected in steps 2 and 3,
to the boom. Lay the hoses off to the side. a b
Component damage hazard.

Hoses can be damaged if they are c
kinked or pinched.
a lift cylinder
b rod end pivot pin
c barrel end pivot pin
9 Use a soft metal drift to remove the rod end 16 Use a soft metal drift to remove the pivot pin.
pivot pin from the cylinder.
Crushing hazard. The boom will
Crushing hazard. The boom will fall if not properly supported when
fall if not properly supported when the pivot pin is removed from the
the lift cylinder pivot pin is machine.
removed from the machine.
17 Carefully remove the boom assembly from the
Crushing hazard. The cylinder will machine and place it on a structure capable of
fall if not properly supported when supporting it.
the pivot pin is removed.
Crushing hazard. The boom could
10 Using the crane, raise the cylinder slightly. become unbalanced and fall if not
properly supported when removed
11 Place a block measuring
from the machine.
3 x 3 x 3 inches / 7 x 7 x 7 cm between the
cylinder manifold and the chassis. Component damage hazard. The
weight of the boom assembly may
12 Lower the cylinder until the cylinder manifold
crush the hydraulic hard lines
rests on the block.
under the boom. Use caution
Crushing hazard. Keep hands when placing the boom assembly
clear of the cylinder manifold when onto a structure capable of
lowering the cylinder. supporting it.
for the other lift cylinder.
14 Using the crane, raise the boom to a horizontal
position.
15 Remove the fasteners securing the boom pivot
pin to the machine.
How to Disassemble the Boom 5 Remove the fasteners securing the fork level
cylinder pivot pin to the boom.
procedure requires specific repair 6 Use a soft metal drift to remove the pivot pin.
skills, lifting equipment and a Remove the cylinder from the machine.
suitable workshop. Attempting this Crushing hazard. The cylinder will
procedure without these skills and fall if not properly supported when
tools could result in death or the pivot pin is removed from the
serious injury and significant machine.
component damage. Dealer
service is strongly recommended. 7 Tag, disconnect and plug the hydraulic hoses
from the hydraulic hard lines at the top of the
Note: When removing a hose assembly or fitting, number 1 boom tube. Cap the hard lines.
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during a b c
installation. Refer to Section 2, Hydraulic Hose and
GTH-644, GTH-842 and GTH-844:
1 Remove the extension cylinder. See 1-4, How
to Remove the Boom Extension Cylinder.
2 Remove the boom. See 1-2, How to Remove
the Boom.
3 Tag, disconnect and plug the hydraulic hoses g f e d
from the fork level cylinder manifolds. Cap the
fittings. a boom tube number 3
b boom tube number 2
Bodily injury hazard. Spraying c boom tube number 1
d retraction chain
hydraulic oil can penetrate and
e extension chain
burn skin. Loosen hydraulic f fixed chain block
connections very slowly to allow g chain tensioner
the oil pressure to dissipate
gradually. Do not allow oil to 8 Remove the fasteners and clamps securing the
squirt or spray. hydraulic hard lines to the number 1 boom tube.
Remove the hard lines and set them to the side.
the barrel end of the fork level cylinder. Support Component damage hazard.
the cylinder. Do not apply any lifting pressure. Hoses can be damaged if they are
kinked or pinched.
9 Remove the fasteners securing the chain 16 Using the crane, raise the front end of the
tensioner of the number 3 extension chain to numbers 2 and 3 boom tube assembly slightly
the number 1 boom tube. and remove the bottom wear pads of the
number 1 boom tube.
10 Remove the fasteners securing the fixed chain
block of the number 3 retraction chain to the 17 Support and slide the numbers 2 and 3 boom
number 1 boom tube. tube assembly out of the number 1 boom tube.
Place the numbers 2 and 3 boom tube
Note: The fixed chain block of the number 3
assembly on a structure capable of supporting
retraction chain is secured to the inside of the
it.
number 1 boom tube and is hidden from view when
installed. Crushing hazard. The numbers 2
and 3 boom tube assembly may
11 Extend the number 2 boom tube assembly become unbalanced and fall when
enough to access the inner wear pads of the removed from the number 1 boom
number 1 boom tube. tube if not properly supported and
12 Remove the top and side wear pads of the attached to the overhead crane.
number 1 boom tube at the fork end of the Note: During removal, the overhead crane strap
boom. will need to be adjusted for proper balancing.
13 Using a chain of sufficient capacity, secure
18 Remove the fork level cylinder hydraulic hoses
together the numbers 2 and 3 boom tubes.
from the boom assembly.
19 Remove the fasteners securing the extension
the numbers 2 and 3 boom tube assembly at
chain pivot pin to the number 3 boom tube.
the fork end of the boom.
15 Support and slide the numbers 2 and 3 boom
Remove the chain and set it to the side.
tube assembly approximately halfway out of the
number 1 boom tube. Note: Do not allow the chain to become twisted or
dirty.
Crushing hazard. The boom
assembly may become 21 Extend the number 3 boom tube enough to
unbalanced and fall when the access the inner wear pads of the number 2
numbers 2 and 3 boom tubes are boom tube.
moved if not secured together.
22 Remove the top and side wear pads of the
number 2 boom tube at the fork end of the
boom.
23 Support and slide the number 3 boom tube GTH-636 and GTH-1048:
assembly approximately halfway out of the
number 2 boom tube. 1 Remove the extension cylinder. See 1-4, How
to Remove the Boom Extension Cylinder.
24 Using the crane, raise the fork end of the
number 3 boom tube assembly slightly and 2 Remove the boom. See 1-2, How to Remove
remove the bottom wear pads of the number 2 the Boom.
boom tube. 3 Remove the access cover from the fork of the
25 Support and slide the number 3 boom tube boom. Remove the clamp securing the
assembly out of the number 2 boom tube. hydraulic hoses to the top of the gooseneck at
Place the number 3 boom tube assembly on a the fork end of the boom (if equipped).
structure capable of supporting it. 4 Attach a lifting strap from an overhead crane to
Crushing hazard. The number 3 the rod end of the fork level cylinder.
boom tube could become 5 Raise the cylinder enough to access the
unbalanced and fall when manifolds of the fork level cylinder.
removed from the number 2 boom
tube if not properly supported and 6 Tag, disconnect and plug the hydraulic hoses
attached to the overhead crane. from the fork level cylinder manifolds. Cap the
fittings. Lower the cylinder.
Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing. Bodily injury hazard. Spraying
burn skin. Loosen hydraulic
connections very slowly to allow
gradually. Do not allow oil to
squirt or spray.
Crushing hazard. Keep hands
clear of the cylinder when
lowering.
Hoses can be damaged if they are
kinked or pinched.
the barrel end of the fork level cylinder.
cylinder barrel-end pivot pin to the boom.
9 Use a soft metal drift to remove the pivot pin. 11 Remove the fastener(s) securing the chain
Remove the cylinder from the machine. tensioner of the number 3 extension chain(s) to
the number 1 boom tube.
Crushing hazard. The cylinder will
fall if not properly supported when Note: The GTH-636 has one chain; the GTH-1048
the pivot pin is removed from the has two chains.
machine.
12 Remove the fasteners securing the fixed chain
10 Working at the top of the boom assembly, tag, block of the number 3 retraction chain to the
disconnect and plug the fork level hoses from number 1 boom tube.
the manifold at the top of the number 1 boom
tube. Note: The fixed chain block of the number 3
a b c d e f
installed.
GTH-636
GTH-1048 13 Attach a lifting strap from an overhead crane to
the extension cylinder. Support the cylinder. Do
not apply any lifting pressure.
14 Remove the nut securing the rod end of the
extension cylinder to the number 2 boom tube.
15 Extend the number 2 boom tube assembly
enough to access the inner wear pads of the
i h g g
number 1 boom tube.
a number 1 boom tube
b chain tensioner Crushing hazard. The extension
c extension chain cylinder could fall if not properly
d number 2 boom tube supported when the number 2
e number 3 boom tube
f front cover
boom tube assembly is extended.
g boom roller
16 Remove the wear pads of the number 1 boom
h support loop
i extension cylinder tube at the fork end of the boom.
together the numbers 2 and 3 boom tubes.
the numbers 2 and 3 boom tube assembly at
the fork end of the boom.
a b c d
a retraction chain
b extension chain
c fixed chain block
d chain tensioner
19 Support and slide the numbers 2 and 3 boom 25 Extend the number 3 boom tube assembly
tube assembly approximately halfway out of the enough to access the inner wear pads of the
number 1 boom tube. number 2 boom tube.
Crushing hazard. The boom 26 Remove the wear pads of the number 2 boom
assembly could become tube at the front end of the boom.
unbalanced and fall when the
numbers 2 and 3 boom tubes are
the number 3 boom tube assembly at the fork
end of the boom.
20 If equipped, remove the fasteners securing the
28 Support and slide the number 3 boom tube
side wear pads to the number 1 boom tube, and
assembly approximately halfway out of the
remove the wear pads.
number 2 boom tube.
21 Raise the front end of the numbers 2 and 3
29 If equipped, remove the fasteners securing the
boom tube assembly slightly and remove the
side wear pads to the number 2 boom tube, and
boom rollers from the number 1 boom tube.
22 Support and slide the numbers 2 and 3 boom
30 Raise the front end of the number 3 boom tube
tube assembly out of the number 1 boom tube.
assembly slightly and remove the boom rollers
Place the numbers 2 and 3 boom tube
of the number 2 boom tube.
assembly on a structure capable of supporting
it. 31 Support and slide the number 3 boom tube
assembly out of the number 2 boom tube.
Crushing hazard. The numbers 2
Place the number 3 boom tube assembly on a
and 3 boom tube assembly could
structure capable of supporting it.
become unbalanced and fall when
removed from the number 1 boom Crushing hazard. The number 3
tube if not properly supported and boom tube assembly could
attached to the overhead crane. become unbalanced and fall when
tube if not properly supported and
will need to be adjusted for proper balancing.
attached to the overhead crane.
chain pivot pin to the number 3 boom tube.
Remove the chain and set it to the side.
Note: Do not allow the chain to become twisted or
dirty.

GTH-1056: 9 Use a soft metal drift to remove the pivot pin.

Remove the cylinder from the machine.
1 Remove the extension cylinder. See 1-4, How
to Remove the Boom Extension Cylinder. Crushing hazard. The cylinder will
fall if not properly supported when
2 Remove the boom. See 1-2, How to Remove the pivot pin is removed from the
the Boom. machine.
3 Remove the access cover from the front of the
a b c d e f g h
boom. Remove the clamp securing the fork
level hoses to the number 3 boom tube.
4 Attach a lifting strap from an overhead crane to GTH-1056
the rod end of the fork level cylinder.
5 Raise the cylinder enough to access the
manifolds of the fork level cylinder.
6 Tag, disconnect and plug the fork level cylinder
hoses from the cylinder manifolds. Cap the
fittings. Lower the cylinder.
l k j i j j i
Bodily injury hazard. Spraying
hydraulic oil can penetrate and a number 0 boom tube
burn skin. Loosen hydraulic b chain tensioner
connections very slowly to allow c boom tube 2 extension chain
the oil pressure to dissipate d number 1 boom tube
e boom tube 3 extension chain
gradually. Do not allow oil to f number 2 boom tube
squirt or spray. g number 3 boom tube
h front cover
Crushing hazard. Keep hands i chain roller (hidden from view)
clear of the cylinder when j boom roller (hidden from view)
lowering. k support loop
l extension cylinder
Component damage hazard. m rear cover
n cable track
Hoses can be damaged if they are o boom tube 2 retraction chain
kinked or pinched p boom tube 3 retraction chain
m n o p c e
the barrel end of the fork level cylinder.
cylinder barrel-end pivot pin to the boom.
a d f g

10 Attach a lifting strap from an overhead crane to 19 Loosen evenly, then remove, the fasteners
the extension cylinder. Support the cylinder. Do securing the chain tensioners of the boom tube
not apply any lifting pressure. 2 extension chains to the number 0 boom tube.
11 Remove the nut securing the rod end of the 20 Remove the fasteners securing the fixed chain
extension cylinder to the number 1 boom tube. block of the boom tube 2 retraction chain to the
top of the number 0 boom tube near the front of
12 Extend the number 1 boom tube until the hose
the tube.
manifolds are accessible.
Note: The fixed chain block of the boom tube 2
assembly could fall when the
number 1 boom tube is extended if
installed.
not properly supported and
attached to the overhead crane. 21 Using a chain of sufficient capacity, secure
13 Tag, disconnect and plug the hydraulic hoses at together the numbers 1, 2 and 3 boom tubes.
the top of the hose manifolds at the top of the Note:To secure the boom tubes together, it may be
number 1 boom tube. Cap the fittings. helpful to loosen the boom roller fasteners at one
side of the boom, wrapping the chain around the
boom roller pin between the nut and the side of the
boom.
kinked or pinched.
Note: Do not remove the hose manifolds at this 22 Attach a lifting strap from an overhead crane to
time. the numbers 1, 2 and 3 boom tube assemblies
at the fork end of the boom.
tube at the front end of the boom. 23 Support and slide the numbers 1, 2 and 3 boom
tube assemblies approximately halfway out of
15 Manually return the boom tubes to the stowed the number 0 boom tube.
position.
16 Remove the access cover from the rear of the assembly could become
boom. unbalanced and fall when the
numbers 1, 2 and 3 boom tubes
17 Working with a screwdriver inside the rear of
are moved if not secured together.
the boom, carefully remove eight of the external
hinge link tabs from the end of the cable track 24 If equipped, remove the fasteners securing the
where it attaches to the number 3 boom tube. side wear pads to the number 0 boom tube, and
18 Using a screwdriver, carefully separate the
cable track from the cable track mount at the
rear of the number 3 boom tube.

25 Raise the fork end of the number 1 boom tube 32 Remove the hose manifolds from the top of the
assembly slightly and remove the boom rollers number 1 boom tube. Tag, disconnect and plug
from the number 0 boom tube. the hoses from the hose manifolds. Cap the
fittings.
26 Support and slide the numbers 1, 2 and 3 boom
tube assemblies out of the number 0 boom Component damage hazard.
tube. Place the numbers 1, 2 and 3 boom tube Hoses can be damaged if they are
assemblies on a structure capable of kinked or pinched.
supporting it.
33 Remove the fork level cylinder hoses from the
Crushing hazard. The numbers 1, boom assembly.
2 and 3 boom tube assemblies
34 Extend the number 2 boom tube approximately
could become unbalanced and fall
12 inches / 30 cm.
when removed from the number 0
boom tube if not properly 35 Remove the chain rollers from the top of the
supported and attached to the number 1 boom tube at the front of the boom.
overhead crane.
Note: During removal, the overhead crane strap tube at the front end of the boom.
37 Manually return the boom tubes to the stowed
27 Remove the chain tensioner from the end of position.
both number 2 boom tube extension chains.
28 Remove the cable track mount bracket from the together the numbers 2 and 3 boom tubes.
rear of the number 1 boom tube.
29 Remove the chain or device securing the the numbers 2 and 3 boom tube assemblies at
booms together. the fork end of the boom.
30 Evenly remove the fasteners securing the chain 40 Support and slide the numbers 2 and 3 boom
tensioners of the boom tube 3 extension chains tube assemblies approximately halfway out of
to the number 1 boom tube. the number 1 boom tube.
31 Remove the fasteners securing the fixed chain Crushing hazard. The boom
block of the number 3 boom tube retraction assembly could become
chain to the top of the number 1 boom tube unbalanced and fall when the
near the fork end of the tube. numbers 2 and 3 boom tubes are
Note: The fixed chain block of the number 3 boom
tube retraction chain is secured to the inside of the
installed.

41 If equipped, remove the fasteners securing the 49 Support and slide the number 3 boom tube
side wear pads to the number 1 boom tube, and assembly approximately halfway out of the
remove the wear pads. number 2 boom tube.
42 Raise the fork end of the number 2 boom tube 50 If equipped, remove the fasteners securing the
assembly slightly and remove the boom rollers side wear pads to the number 2 boom tube, and
from the number 1 boom tube. remove the wear pads.
43 Support and slide the numbers 2 and 3 boom 51 Raise the fork end of the number 3 boom tube
tube assemblies out of the number 1 boom assembly slightly and remove the boom rollers
tube. Place the numbers 2 and 3 boom tube of the number 2 boom tube.
assemblies on a structure capable of
52 Support and slide the number 3 boom tube
supporting it.
assembly out of the number 2 boom tube.
Crushing hazard. The numbers 2 Place the number 3 boom tube assembly on a
and 3 boom tube assemblies structure capable of supporting it.
could become unbalanced and fall
Crushing hazard. The number 3
when removed from the number 1
boom tube assembly could
boom tube if not properly
become unbalanced and fall when
supported and attached to the
overhead crane.
tube if not properly supported and
Note: During removal, the overhead crane strap attached to the overhead crane.
44 Remove the chain or device securing the will need to be adjusted for proper balancing.
booms together.
45 Extend the number 3 boom tube approximately
12 inches / 30 cm.
46 Remove the chain rollers from the top of the
number 2 boom tube at the fork end of the
boom.
tube at the fork end of the boom.
the number 3 boom tube assembly at the fork
end of the boom.

1-3 4 Use a soft metal drift to remove the pivot pin.

Boom Lift Cylinder Crushing hazard. The boom will
the pivot pin is removed from the
How to Remove a Lift Cylinder machine.
Note: When removing a hose assembly or fitting, 5 Using the overhead crane, raise the boom to a
the O-ring on the fitting and/or hose end must be horizontal position.
installation. Refer to Section 2, Hydraulic Hose and 6 Attach a lifting strap from an overhead crane to
Fitting Torque Specifications. the lift cylinder. Support the cylinder. Do not
apply any lifting pressure.
1 Attach an overhead 10 ton / 10,000 kg crane to
the boom. Support the boom. Do not apply any 7 Remove the fasteners securing the lift cylinder
lifting pressure. collar to the boom. Remove the collar.
2 Tag, disconnect and plug the two larger 8 Remove the cylinder from the machine.
hydraulic hoses at the lift cylinder and manifold. Crushing hazard. The cylinder will
Cap the fittings. fall if not properly supported when
Bodily injury hazard. Spraying removed from the machine.
squirt or spray.
kinked or pinched.
3 Remove the fasteners securing the lift cylinder
pivot pin to the chassis.

How to Bleed the Lift/Tilt Circuit

1 With the machine on a firm, level surface, start
the engine and allow the engine to idle.
2 Raise the boom to full height, then lower the
boom to the stowed position.
3 Repeat step 2.
4 Raise the tips of the lifting forks to full height,
then continue to activate the fork tilt up function
for a minimum of 60 seconds. Release the
joystick.
5 Stop the engine.
6 Select one of the boom lift cylinders. Locate the
bleed fitting at the top of the cylinder.
7 Securely install a clear hose onto the bleeder
fitting. Place the other end of the hose into a
suitable container to collect hydraulic fluid.
8 Using a wrench, carefully open the bleeder
fitting on the cylinder and allow the pressurized
fluid to drain through the hose and into the
container. Close the bleeder fitting.
squirt or spray.
9 Start the engine and allow the engine to idle.
10 Activate the fork tilt up function for
approximately 15 seconds.
11 Repeat this procedure beginning with step 8
until a steady stream of oil without air bubbles is
visible through the bleeder hose.
12 Repeat this procedure for the other cylinder,
beginning with step 6.

1-4 6 Place a wooden block, which measures

approximately 2 x 4 x 12 inches / 5 x 10 x 30
Boom Extension Cylinder cm, onto the top of the number 2 boom tube in
a way that will prevent the number 2 boom tube
How to Remove the from retracting into the number 1 boom tube.
Extension Cylinder 7 Retract the extension cylinder to the stowed
position. Turn the machine off.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be Crushing hazard. The extension
replaced and then torqued to specification during cylinder will fall if not properly
installation. Refer to Section 2, Hydraulic Hose and supported when the cylinder is
Fitting Torque Specifications. retracted.
1 Raise the boom to a horizontal position. 8 Tag, disconnect and plug the hydraulic hoses
from the extension cylinder manifolds. Cap the
2 Extend the boom approximately 1 foot / 30 cm. fittings on the manifolds.
3 Attach a lifting strap from an overhead crane to Bodily injury hazard. Spraying
the extension cylinder. Support the cylinder. Do hydraulic oil can penetrate and
not apply any lifting pressure. burn skin. Loosen hydraulic
a b c the oil pressure to dissipate
squirt or spray.
f e d kinked or pinched.
a boom tube number 3

b boom tube number 2 cylinder barrel end pivot pin to the boom.
d extension cylinder retaining pin 10 Use a soft metal drift to remove the pivot pin.
e extension cylinder support loop Remove the cylinder from the machine.
f extension cylinder rod end nut
Crushing hazard. The extension
4 Remove the nut securing the rod end of the cylinder will fall if not properly
extension cylinder to the number 2 boom tube. supported when the pivot pin is
5 Remove the extension cylinder support loop
from the number 3 boom tube.

1-5 6 Remove the fasteners securing the fork level

cylinder rod-end pivot pin to the boom.
Fork Level Cylinder
How to Remove the Fork Level Crushing hazard. The lifting fork
Cylinder frame could fall if not properly
supported when the pivot pin is
1 With the boom in the stowed position, fully lower removed from the machine.
the tips of the lifting forks.
2 Remove the access cover from the fork of the cylinder barrel-end pivot pin to the boom.
boom.
3 Attach a lifting strap from an overhead crane to Remove the cylinder from the machine.
the top of the lifting fork frame. Support the
Crushing hazard. The cylinder
frame. Do not apply any lifting pressure.
could fall if not properly supported
4 Attach a lifting strap from a second overhead when the pivot pin is removed
crane to the barrel end of the fork level cylinder. from the machine.
Support the cylinder. Do not apply any lifting
pressure.
hoses from the cylinder manifolds. Cap the
fittings.
squirt or spray.
kinked or pinched

How to Replace the Fork Level 7 Securely connect a 30 foot / 10 m length of rope
to each end of the hoses disconnected in steps
Cylinder Hoses 5 and 6. Securely tie off the other end of each
Note: When removing a hose assembly or fitting, section of rope to the boom structure.
the O-ring on the fitting and/or hose end must be 8 Working at the pivot end of the boom, select
replaced and then torqued to specification during one of the hoses. Pull the hose out of the boom.
Fitting Torque Specifications. Note: Rope coming loose from either end of the
hose or the boom during hose removal may result
1 Fully retract the boom. in a difficult reassembly. Be sure each section of
rope is securely attached to both the hose and the
2 Fully lower the tips of the lifting forks.
boom structure before pulling the hose out of the
3 Remove the covers from both ends of the boom.
boom.
9 Remove the rope from each end of the hose.
4 Attach a lifting strap from an overhead crane to Discard the hose.
frame. Do not apply any lifting pressure. 10 Securely install a section of rope onto each end
of the new hose assembly.
supply hoses at the cylinder manifold. Cap the 11 Install the new hose assembly into the boom by
fittings on the manifold. routing the hose over the roller at the pivot end
of the boom. Using the rope, carefully pull the
Bodily injury hazard. Spraying hose through the boom until each end is
hydraulic oil can penetrate and accessible.
connections very slowly to allow 12 Install both ends of the hose assembly onto the
the oil pressure to dissipate correct connection points. Torque to
gradually. Do not allow oil to specification. Refer to Section 2, Specifications.
squirt or spray. 13 Repeat this procedure for the remaining hose to
Component damage hazard. be replaced, beginning with step 8.
Hoses can be damaged if they are 14 Remove the lifting strap from the fork frame.
kinked or pinched.
15 Install the covers onto the front and rear of the
6 Tag, disconnect and plug the hydraulic hoses boom. Install and securely tighten the retaining
from the hydraulic hard lines at the top of the fasteners.
number 1 boom tube. Cap the hard lines.
16 Bleed the fork level circuit. See 1-3, How to
a b c
Bleed the Lift/Tilt Circuit.
a boom tube number 3


1-6 6 Use a soft metal drift to remove the pivot pin.

Fork Rotate Cylinder (option) 7 Remove the fasteners securing the fork rotate
cylinder barrel end pivot pin to the pivot frame.
How to Remove the Fork Rotate 8 Use a soft metal drift to remove the pivot pin.
Cylinder Remove the cylinder from the machine.
1 Fully retract the boom.
2 Fully lower the tips of the lifting fork. when the pivot pin is removed
from the machine.
the barrel end of the fork rotate cylinder. Note: When installing the cylinder mount plate onto
Support the cylinder. Do not apply any lifting the boom, torque the fasteners to specification.
pressure.
Torque specification
4 Tag, disconnect and plug the fork rotate
cylinder hoses at the cylinder manifolds. Cap Cylinder mount plate fasteners 380 ft-lbs
the fittings. 515 Nm

squirt or spray.
kinked or pinched
5 Remove the fasteners securing the fork rotate
cylinder rod end pivot pin to the fork frame.

How to Replace the Fork Rotate 9 Tag, disconnect and plug the fork rotate
cylinder supply hoses at the fittings inside the
Cylinder Hoses boom gooseneck. Cap the fittings.
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring on the fitting and/or hose end must be hydraulic oil can penetrate and
replaced and then torqued to specification during burn skin. Loosen hydraulic
installation. Refer to Section 2, Hydraulic Hose and connections very slowly to allow
Fitting Torque Specifications. the oil pressure to dissipate
1 Fully retract the boom.
squirt or spray.
2 Fully lower the tips of the lifting fork until they
rest on the ground.
3 Remove the covers from both ends of the kinked or pinched.
boom.
10 Remove the clamp securing the hoses to the
4 Attach a lifting strap from an overhead crane to front of the boom.
11 Tag, disconnect and plug the hydraulic hoses
frame. Do not apply any lifting pressure.
from the hydraulic hard lines at the bulkhead
5 Attach a lifting strap from a second overhead under the number 1 boom tube. Cap the hard
crane to the barrel end of the fork level cylinder. lines.
Support the cylinder. Do not apply any lifting
a b c
pressure.
6 Remove the fasteners securing the level
cylinder rod end pivot pin to the lifting fork
frame.
7 Use a soft metal drift to remove the pivot pin. a boom tube number 3
Crushing hazard. The cylinder c boom tube number 1
when the pivot pin is removed 12 Securely connect a 30 foot / 10 m length of rope
from the machine. to each end of the hoses disconnected in steps
9 and 11. Securely tie off the other end of each
Crushing hazard. The lifting fork section of rope to the boom structure.
frame could fall if not properly
supported when the pivot pin is 13 Working at the pivot end of the boom, select
removed from the machine. one of the hoses. Pull the hose out of the boom.
8 Raise the fork level cylinder enough to access Note: Rope coming loose from either end of the
the supply hoses at the inside of the boom hose or the boom during hose removal may result
gooseneck. in a difficult reassembly. Be sure each section of
rope is securely attached to both the hose and the
Note: It may be necessary to tilt the fork frame boom structure before pulling the hose out of the
away from the boom to provide room to raise the boom.
cylinder.

14 Remove the rope from each end of the hose. 27 Start the engine and activate the fork rotate
Discard the hose. counter clockwise function until a steady stream
of oil without air bubbles is flowing from the
15 Securely install a section of rope onto each end
bleeder hose.
of the new hose assembly.
Note: This removes residual air from the barrel end
16 Install the new hose assembly into the boom by
of the cylinder circuit.
routing the hose over the roller at the pivot end
of the boom. Using the rope, carefully pull the 28 Looking from the cab towards the front of the
hose through the boom until each end is boom, fully rotate the lifting fork frame in a
accessible. clockwise direction. Turn the engine off.
17 Install both ends of the hose assembly onto the 29 Remove the hose extension from the hose.
correct connection points. Torque to
specification. Refer to Section 2, Specifications. 30 Install the hose with the straight connector end
fitting onto the cylinder manifold. Torque to
18 Repeat this procedure for the remaining hose to specification. Refer to Section 2, Specifications.
be replaced, beginning with step 13.
31 Disconnect the hydraulic hose with the 90°
19 Install the fork level cylinder. Use a soft metal connector end fitting from the cylinder manifold.
drift to install the cylinder pivot pins.
32 Securely install a 24 inch / 60 cm hose
20 Install and securely tighten all pivot pin retaining extension into the hose disconnected in step
fasteners. 31. Place the other end of the hose into a
container to collect hydraulic fluid.
21 Remove the lifting strap from the fork frame and
fork level cylinder. 33 Start the engine and activate the fork rotate
clockwise function until a steady stream of oil
22 Install the covers onto the front and rear of the
without air bubbles is flowing from the bleeder
boom. Install and securely tighten the retaining
hose.
fasteners.
Note: This removes residual air from the rod end of
Bleed the Fork Rotate Circuit:
the cylinder circuit.
23 Start the engine and warm to operating
34 Looking from the cab towards the front of the
temperature.
boom, fully rotate the lifting fork frame in a
24 Looking from the cab towards the front of the counter clockwise direction. Turn the engine off.
boom, fully rotate the lifting fork frame in a
35 Remove the hose extension from the hose.
clockwise direction. Turn the engine off.
36 Install the hose with the 90° connector end
25 Disconnect the hydraulic hose with the straight
fitting onto the cylinder manifold. Torque to
connector end fitting from the cylinder manifold.
specification. Refer to Section 2, Specifications.
26 Securely install a 24 inch / 60 cm hose
extension into the hose disconnected in step 37 Remove the lifting strap from the fork frame.
25. Place the other end of the hose into a
suitable container to collect hydraulic fluid.

REV B
Operator's Compartment
2-1 a b c
Operator's Compartment
How to Remove the Operator's

Compartment
The operator's compartment is used to activate
machine functions while sitting in the operator's
drivers seat.
Within the operator's compartment there is a

transmission column shifter, steering selector,
4-way controller, accelerator pedal, brake pedal
and a differential lock switch. All of these
components are replaceable.
For further information or assistance, consult the

Genie Industries Service Department.
skills, lifting equipment and a d
suitable workshop. Attempting this f
procedure without these skills and e
tools could result in death or
Illustration 1
component damage. Dealer a transmission column shifter
service is required. b steering selector
c 4-way controller (joystick)
GTH-644, GTH-842 and GTH-844: d accelerator pedal
e brake pedal
1 Locate and open the battery access door. f differential lock switch
2 Disconnect the battery from the machine. 5 Using Illustration 2 as a guide, tag, disconnect
and plug the hoses from ports 1, 2, 3, 4 and P of
Electrocution hazard. Contact with the joystick. Cap the fittings.
electrically charged circuits could
result in death or serious injury. Bodily injury hazard. Spraying
Remove all rings, watches and hydraulic oil can penetrate and
other jewelry. burn skin. Loosen hydraulic
3 Working inside the operator's compartment, the oil pressure to dissipate
remove the fasteners securing the 4-way gradually. Do not allow oil to
controller (joystick) to the side console. squirt or spray.
4 Carefully lift the joystick away from the side Burn hazard. Contact with hot
console assembly. fluids or components may cause
severe burns.

OPERATOR'S COMPARTMENT REV B
6 Refering to Illustration 2, locate port T of the 8 Carefully lift the steering selector away from the
joystick. Tag, disconnect and plug the hose with side console assembly.
the straight connector from the tee fitting at port
9 Tag, disconnect and plug the hoses at ports C1,
T of the joystick. Cap the fitting.
C2 and R of the steering selector. Cap the
fittings.
T the oil pressure to dissipate
T
2
3 1
4 squirt or spray.
P
P
Burn hazard. Contact with hot
fluids or components may cause
severe burns.
STEERING SELECTOR
TOP VIEW
CYL 1 FRONT
STEERING
CYL.
P R
TO (T) PORT
LIFT UP ON FOOT BRAKE
VALVE
BOOM IN
CYL 2
LIFT DOWN T
2 T
BOOM OUT 3 1
4
P
P
MAIN VALVE
ASSEMBLY
PARKING BRAKE
VALVE
CONTROL BLOCK TO FRONT AXLE

PARKING BRAKE
CIRCUIT
T3
C C2
P R
BOTTOM
L R C1 VIEW
T P
TANK PORT #3
T2 T3 R
TANK PORT #1
T1
Illustration 2
CONTROL
ST
BLOCK
4-way Controller Circuit C
7 Remove the fasteners securing the steering S PR BK

selector to the side console. Set the fasteners
aside.
MANIFOLD
BLOCK
REAR
STEERING
CYL.
Illustration 3
Steer Circuit

REV B OPERATOR'S COMPARTMENT
10 Remove the fasteners securing the steering

orbitral inspection cover to the under side of the
dash. Set the fasteners aside and remove the a
access panel.
11 Working through the orbitral inspection opening, SEE 4-WAY CONTROLLER
tag, disconnect and plug the hoses at ports L, P CIRCUIT
b
and T of the steering orbitral. Cap the fittings.
hydraulic oil can penetrate and T
P
burn skin. Loosen hydraulic F
c
d
squirt or spray.
severe burns.
12 Remove the fasteners securing the pedal
assembly to the floor. Set the fasteners aside.
13 Carefully lift the pedal assembly and place in a
secure position, allowing access the underside SEE 4-WAY CONTROLLER CIRCUIT
CONTROL BLOCK
of the pedal assembly. ASSEMBLY
PR
T
P
BK
14 Tag and disconnect the throttle cable from the

F
accelerator pedal.
REAR AXLE FRONT AXLE
15 Tag and disconnect the wires at the clutch

cut-off switch and the brake pressure switch.
Refer to illustration 4.
Component damage hazard. TRANSMISSION
Wires can be damaged if they TO REAR
are kinked or pinched.

LOCK-UP BLOCK
16 Remove the fasteners securing the foot-

operated differential lock switch to the pedal
3
2
1
assembly mount plate. Remove the switch. Set

Illustration 4
the fasteners aside.
Brake/Differential Lock Circuit
a brake pedal
b service brake pressure switch
c clutch cut-off pressure switch
d brake pedal actuator body

17 Open the fuse block access panel located 25 Remove the grommet from the dash panel.
under the dash. Set the grommet aside and pull the connector
of the transmission control harness through the
18 Tag and disconnect the blue wire of the
opening.
differential lock switch from the 5 amp fuse in
the lower right corner of the fuse block. Component damage hazard.
Wires can be damaged if they
19 Tag, disconnect and plug the hoses at ports F
and P of the brake pedal actuator body. Cap the
fittings. 26 Tag and disconnect the connector with a red
and black wire of the column mounted shifter
harness, from the connector with two black
wires of the instrument panel harness.
connections very slowly to allow 27 Tag and disconnect the white wire of the
the oil pressure to dissipate column mounted shifter wire harness from the
gradually. Do not allow oil to parking brake relay.
squirt or spray.
28 Tag and disconnect the yellow wire from the
Burn hazard. Contact with hot parking brake relay.
29 Tag and disconnect the instrument panel
severe burns.
harness from the main power harness.
20 Tag and disconnect the red wire from the 20
Note: This harness connection is the quick
amp fuse in the top left corner of the fuse block.
disconnect screw type.
21 Tag and disconnect the yellow wire of the rear
lock-up switch from the white wire of the 30 Tag and disconnect the red 8 gauge wires from
parking brake relay. one another.
22 Remove the fasteners securing the steering 31 Tag and disconnect the white, black and yellow
column cover to the dash. Remove the covers. wires from the sway control switch at the side
Set the fasteners aside. console assembly.
23 Tag and disconnect the harness connector from Component damage hazard.
the transmission control lever. Wires can be damaged if they
24 Remove the fasteners securing the dash
panel to the operator's compartment. Carefully 32 Remove the fasteners securing the seat to the
move the dash panel towards the front of the operator's compartment. Remove the seat.
machine. Set the fasteners aside

33 Remove the engine air filter assembly from the GTH-636, GTH-1048 and GTH-1056:
machine.
1 Locate and open the battery access door.
34 Remove the fasteners securing the front and
middle engine covers in place. Remove the 2 Disconnect the battery from the machine.
covers. Set the fasteners aside. Electrocution hazard. Contact with
35 Support and secure the operator's compartment electrically charged circuits could
to an adjustable table capable of supporting the result in death or serious injury.
weight and that will allow the operator's Remove all rings, watches and
compartment to remain in an upright and stable other jewelry.
position. 3 Working inside the operator's compartment,
Note: Placing a wedge between the operator's remove the fasteners securing the 4-way
compartment and the adjustable table may help controller (joystick) access cover to the side
keep the operator's compartment stable. console.
36 Remove the bottom fasteners securing the a b

operator's compartment to the chassis.
37 Remove the top fasteners securing the
Crushing hazard. The operator's
compartment will fall if not properly g
supported when the fasteners are
38 Slowly move the operator's compartment away
from the chassis while feeding all lose hoses,
cables and wires through the opening of the
operator's compartment.
Hoses, cables and wires can
be damaged if they are kinked
or pinched. f c
Note: When installing the operator's compartment
e
onto the chassis, torque the fasteners to
specification. d
Illustration 1
Torque specification Operator's Compartment
Operator's compartment 750 ft-lbs a transmission control lever
mounting fasteners 1017 Nm b 4-way controller (joystick)
c parking brake
d accelerator pedal
e differential lock switch
f brake pedal
g steering selector

4 Tag, disconnect and plug the hoses from ports 5 Refering to Illustration 2, locate port T of the
1, 2, 3, 4 and P of the joystick. Cap the fittings. joystick. Tag, disconnect and plug the hose with
Refer to illustration 2. the straight connector from the tee fitting at port
T of the joystick. Cap the fitting.
hydraulic oil can penetrate and 6 Tag and disconnect all three red wires and the
burn skin. Loosen hydraulic grey wire from the tilt relay, located inside the
connections very slowly to allow side console.
squirt or spray.
7 Tag and disconnect the harness connector from
the transmission control lever.
severe burns.
BOOM OUT 8 Remove the fasteners securing the left side
LIFT UP
dash panel in place.
9 Remove the grommet from the left side dash
LIFT DOWN 2
T
panel and set the grommet aside.
3 1
BOOM IN TO PORT 3
10 Carefully move the left dash panel away from
4 P
P TEE FITTING
T ON BRAKING
BRAKE VALVE the dash weldment. Pull the transmission
control level harness connector through the
opening. Set the panel aside in a secure
TO PORT 2
ON BRAKING position.
BRAKE VALVE
TO CONTROLLER
RELIEF VALVE
Illustration 2
Bottom View of 4-way Controller

11 Tag, disconnect and plug the hoses from ports 12 Remove the fasteners securing the right side
C1, C2 and R of the steering selector. Cap the dash panel in place. Carefully move the dash
fittings. Refer to illustration 3. panel away from the dash support. Place the
dash panel in a secure position.
hydraulic oil can penetrate and 13 Tag and disconnect the dash panel harness
burn skin. Loosen hydraulic from the main power harness.
Note: This harness connector is of the quick
disconnect screw type.
squirt or spray. 14 Tag and disconnect the red 8 gauge wires from
Burn hazard. Contact with hot one another.
fluids or components may cause 15 GTH-1048 and GTH-1056: Tag and disconnect
severe burns. the harness connector from the blink code
enable switch.
CYL 1
FRONT
STEERING 16 GTH-1048 and GTH-1056: Tag and disconnect
the yellow, brown, purple, orange and green
CYLINDER
P R
CYL 2 wires from the left and right stabilizer control

TOP VIEW
switches.
STEERING SELECTOR
TOP VIEW
17 GTH-1048 and GTH-1056: Tag and disconnect
the yellow wire from the sway control switch.
C2
P R
L
T
R
P
C1 BOTTOM 18 Open the fuse block access panel located
FRONT OF
VIEW
under the dash.
MACHINE
the red wire from the 20 amp fuse in the upper
T2 T3 R left corner of the fuse block and the green wire
T1 CONTROL
BLOCK
ST
from the 5 amp fuse in lower left corner of the
G2
fuse block.
G4 C
20 Tag and disconnect the yellow wire of the rear

lock-up switch from the white wire of the
G1 G3
S PR BK
SEE BOOM
CIRCUIT parking brake relay.
(10 SERIES ONLY)
21 Tag, disconnect and plug the hoses from ports

L, P and T of the steering orbitral. Cap the
MANIFOLD REAR
BLOCK STEERING fittings. Refer to illustration 3.
CYLINDER
Illustration 3
Steer Circuit

22 Remove the fasteners securing the brake 25 Working inside the seat box, tag, disconnect
actuator covers in place. Set the covers and and plug the hoses from ports 1, 2 and 3 of the
fasteners aside. parking brake valve assembly. Cap the fittings.
Refer to illustration 5.
A, P and T of the brake actuator. Cap the Bodily injury hazard. Spraying
fittings. Refer to illustration 4. hydraulic oil can penetrate and
squirt or spray.
gradually. Do not allow oil to Burn hazard. Contact with hot
squirt or spray. fluids or components may cause
severe burns.
fluids or components may cause 26 Tag and disconnect the orange and red wires
severe burns. from the parking brake pressure switch.
27 Remove the fasteners securing the pedal
assembly to the floor.
P T
A 28 Carefully lift the pedal assembly and place in a

secure position, allowing access to the
underside of the accelerator pedal.
TO CONTROLLER RELIEF VALVE TO CLUTCH CUT-OFF

29 GTH-636: Tag and disconnect the throttle cable
SEE 4-WAY CONTROLLER CIRCUIT PRESSURE SWITCH from the accelerator pedal.
the wire harness connector from the accelerator
pedal.
TO BRAKE ACCUMULATOR /
CONTROL BLOCK 31 Remove the fasteners securing the foot
Illustration 4 operated differential lock switch in place and
Brake Actuator remove the switch.
24 Remove the fasteners securing the seat box 32 GTH-1048 and GTH-1056: Tag and
cover in place. Set the cover and fasteners disconnected the blue wire of the differential
aside. lock switch from the 5 amp fuse in the lower
right corner of the fuse block.

33 Remove the fasteners securing the front and

side hose covers in place. Remove the covers.
34 Remove the engine air filter assembly from the
TO "P" PORT machine.
ON 4-WAY CONTROLLER
TO "T" PORT
ON 4-WAY CONTROLLER 35 Remove the fasteners securing the top front
cover and the top rear cover in place. Remove
TO "TANK" TEE FITTING ON the covers.
CONTROLLER RELIEF VALVE
4-WAY CONTROLLER CIRCUIT
3
(10 SERIES ONLY) 36 Support and secure the operator's compartment
2 to an adjustable table capable of supporting the
1
weight and that will allow the operator's
compartment to remain in an upright and stable
position.
Placing a wedge between the
TO "PRESSURE" TEE FITTING operator's compartment and the
ON CONTROLLER RELIEF VALVE
4-WAY CONTROLLER CIRCUIT adjustable table may be required
to keep the operator's
compartment stable.
37 Remove the bottom fasteners securing the
38 Remove the top fasteners securing the
TO "P" PORT TO "T" PORT
Crushing hazard. The operator's

ON 4-WAY CONTROLLER ON 4-WAY CONTROLLER
compartment will fall if not properly

TO "TANK" TEE FITTING ON
CONTROLLER RELIEF VALVE
(10 SERIES ONLY)
3
2
1
39 Slowly move the operator's compartment away

from the chassis while feeding all loose hoses,
cables and wires through the opening of the
TO "PRESSURE" TEE FITTING
FRONT
AXLE operator's compartment.
ON CONTROLLER RELIEF VALVE

Hoses, cables and wires can
be damaged if they are kinked
or pinched.
Illustration 5 Note: When installing the operator's compartment
Parking Brake Valve Assembly
onto the chassis, torque the fasteners to
specification. See 2-1, How to Remove the
Operator's Compartment.

2-2 5 Remove the horn button from the steering

wheel. Remove the nut securing the steering
Machine Controls wheel to the column.
6 Separate the steering wheel from the steering
How to Remove the Steering column and set it aside.
Column and Orbitral
GTH-644, GTH-842 and GTH-844: column cover to the dash. Remove the covers.
1 Locate and open the battery access door. 8 Tag and disconnect the Deutsch connector
from the transmission control lever.
2 Disconnect the battery from the machine.
9 Tag and disconnect the black wire on the
Electrocution hazard. Contact with steering column, from the tan wire on the
electrically charged circuits could instrument panel harness.
Remove all rings, watches and 10 Remove the fasteners securing the
other jewelry. transmission control lever to the column.
Carefully separate the lever from the column.
orbitral inspection cover in place. Remove the 11 Remove the fasteners securing the dash panel
cover. to the operator's compartment.
4 Working through the orbitral inspection opening, 12 Remove the grommet from the dash panel and
tag, disconnect and plug the hoses at ports L, P, set the grommet aside.
R and T of the steering orbitral. Cap the fittings.
13 Carefully move the dash panel towards the front
Bodily injury hazard. Spraying of the machine and pull the Deutsch connector
hydraulic oil can penetrate and through the panel hole. Place the dash panel in
burn skin. Loosen hydraulic a secure position.
connections very slowly to allow Component damage hazard.
the oil pressure to dissipate Wires can be damaged if they are
gradually. Do not allow oil to kinked or pinched.
squirt or spray.
Burn hazard. Contact with hot column to the steering orbitral. Carefully
fluids or components may cause separate the components and remove them
severe burns. from the dash weldment.
Note: Assistance may be needed to perform this
step.

GTH-636, GTH-1048 and GTH-1056: 11 Tag and disconnect the black wire on the
steering column, from the tan wire on the
1 Locate and open the battery access door. instrument panel harness.
2 Disconnect the battery from the machine. 12 Tag, disconnect and plug the hoses at ports L,
Electrocution hazard. Contact with P, R and T of the steering orbitral. Cap the
electrically charged circuits could fittings.
result in death or serious injury. Bodily injury hazard. Spraying
Remove all rings, watches and hydraulic oil can penetrate and
other jewelry. burn skin. Loosen hydraulic
3 Remove the horn button from the steering connections very slowly to allow
wheel. Remove the nut securing the steering the oil pressure to dissipate
wheel to the column. gradually. Do not allow oil to
squirt or spray.
4 Separate the steering wheel from the steering
column and set it aside. Burn hazard. Contact with hot
5 Tag and disconnect the Deutsch connector severe burns.
from the transmission control lever.
6 Remove the fasteners securing the column to the steering orbitral. Carefully
transmission control lever to the column. separate the components and remove them
Carefully separate the lever from the column. from the dash weldment.
7 Remove the fasteners securing the left and right Note: Assistance may be needed to perform this
dash panels in place. step.
panel and set the grommet aside.
9 Carefully move the left dash panel away from
the dash weldment. Pull the Deutsch connector
through the panel hole and place the dash
panel in a secure position.
10 Carefully move the right dash panel away from
the dash weldment and place in a secure
position.

How to Remove the Steering GTH-636, GTH-1048 and GTH-1056:

Selector 1 Locate and open the battery access door.
GTH-644, GTH-842 and GTH-844: 2 Disconnect the battery from the machine.
1 Locate and open the battery access door. Electrocution hazard. Contact with
2 Disconnect the battery from the machine. result in death or serious injury.
Electrocution hazard. Contact with Remove all rings, watches and
electrically charged circuits could other jewelry.
result in death or serious injury. 3 Tag and disconnect the Deutsch connector
Remove all rings, watches and from the transmission control lever.
other jewelry.
4 Remove the fasteners securing the left side
3 Remove the fasteners securing the side dash panel in place.
console cover in place. Remove the cover.
4 Tag, disconnect and plug the hoses from ports panel and set the grommet aside.
C1, C2, P and R of the steering selector. Cap
the fittings. 6 Carefully move the left side dash panel away
from the dash weldment. Pull the Deutsch
Bodily injury hazard. Spraying connector through the panel hole and place the
hydraulic oil can penetrate and dash panel in a secure position.
connections very slowly to allow Component damage hazard.
the oil pressure to dissipate Wires can be damaged if they
gradually. Do not allow oil to are kinked or pinched.
squirt or spray. 7 Tag, disconnect and plug the hoses from ports
Burn hazard. Contact with hot C1, C2, P and R of the steering selector. Cap
fluids or components may cause the fittings.
severe burns. Bodily injury hazard. Spraying
5 Remove the fasteners securing the steering hydraulic oil can penetrate and
selector in place. Remove the steering selector. burn skin. Loosen hydraulic
squirt or spray.
severe burns.
selector in place. Remove the steering selector.

How to Remove the 4-way How to Remove the Accelerator

Controller (joystick) Pedal
1 Locate and open the battery access door. 1 Locate and open the battery access door.
2 Disconnect the battery from the machine. 2 Disconnect the battery from the machine.
Electrocution hazard. Contact with Electrocution hazard. Contact with
electrically charged circuits could electrically charged circuits could
result in death or serious injury. result in death or serious injury.
Remove all rings, watches and Remove all rings, watches and
other jewelry. other jewelry.
3 Remove the fasteners securing the 4-way 3 Remove the fasteners securing the pedal
controller (joystick) access cover to the side assembly to the floor.
console. Set the cover to the side.
4 Carefully lift the pedal assembly and place in a
4 Tag, disconnect and plug the hoses from ports secure position to allow access the underside
1, 2, 3, 4, P and T of the joystick. Cap the of the accelerator pedal.
fittings.
5 Tag and disconnect all three red wires and the the Deutsch connector from accelerator pedal.
grey wire from the tilt relay. All other models: Tag and disconnect the
throttle cable from accelerator pedal.
6 Remove the fasteners securing the joystick to
the side console. 6 Remove the fasteners securing the accelerator
pedal in place.
7 Remove the joystick from the side console.
7 Set the fasteners aside and remove the
accelerator pedal.

How to Remove the Brake GTH-632, GTH-1048 and GTH-1056:

Actuator Pedal 1 Locate and open the battery access door.
GTH-644, GTH-842 and GTH-844: 2 Disconnect the battery from the machine.
1 Locate and open the battery access door. Electrocution hazard. Contact with
2 Disconnect the battery from the machine. result in death or serious injury.
Electrocution hazard. Contact with Remove all rings, watches and
electrically charged circuits could other jewelry.
result in death or serious injury. 3 Remove the fasteners securing the brake
Remove all rings, watches and actuator covers in place. Set the covers to the
other jewelry. side.
3 Remove the fasteners securing the pedal 4 Tag, disconnect and plug the hoses from ports
assembly to the floor. A, P and T of the brake actuator. Cap the
4 Carefully lift the pedal assembly and place in a fittings.
secure position, to allow access to the Bodily injury hazard. Spraying
underside of the brake pedal. hydraulic oil can penetrate and
5 Tag and disconnect the wires at the clutch burn skin. Loosen hydraulic
cut-off switch and the brake pressure switch. connections very slowly to allow
6 Tag, disconnect and plug the hoses at ports F, gradually. Do not allow oil to
P and T of the brake pedal actuator body. Cap squirt or spray.
the fittings.
Bodily injury hazard. Spraying fluids or components may cause
hydraulic oil can penetrate and severe burns.
connections very slowly to allow 5 Remove the fasteners securing the brake
the oil pressure to dissipate actuator pedal in place. Remove the brake
gradually. Do not allow oil to actuator pedal.
squirt or spray.
severe burns.
7 Remove the fasteners securing the brake
actuator pedal in place. Remove the brake
actuator pedal.

How to Remove the Parking

Brake Valve Assembly
1 Locate and open the battery access door.

Remove all rings, watches and
other jewelry.
3 Remove the fasteners securing the seat box
cover in place. Set the cover to the side.
1, 2 and 3 of the parking brake valve assembly,
located inside the seat box. Cap the fittings.
squirt or spray.
severe burns.
5 Tag and disconnect the orange and red wires
from the parking brake pressure switch.
6 Remove the fasteners and the bracket securing
the parking brake valve assembly in place.
Remove the parking brake valve assembly.

Fuel and Hydraulic Tanks REV C
3-1 5 Using an approved hand-operated pump, drain

the fuel tank into a container of suitable
Fuel Tank capacity. Refer to Section 2, Specifications.
Explosion and fire hazard. When
How to Remove the Fuel Tank transferring fuel, connect a
Explosion and fire hazard. Engine grounding wire between the
fuels are combustible. Remove the machine and pump or container.
fuel tank in an open, well- Note: Be sure to only use a hand operated pump
ventilated area away from heaters, suitable for use with gasoline and/or diesel fuel.
sparks, flames and lighted
tobacco. Always have an 6 Tag, disconnect and plug the fuel supply hose.
approved fire extinguisher within
7 Remove the fuel tank hold-down strap retaining
easy reach.
fasteners. Remove the straps from the fuel
Explosion and fire hazard. Never tank.
drain or store fuel in an open
8 Support and secure the fuel tank to an
container due to the possibility of
appropriate lifting device.
fire.
9 Remove the fuel tank from the machine.
Explosion and fire hazard. When
transferring fuel, connect a Component damage hazard. The
grounding wire between the fuel tank is plastic and may
machine and pump or container. become damaged if allowed to fall.
1 Disconnect the battery from the machine. Note: Clean the fuel tank and inspect
for cracks and other damage before installing.
other jewelry.
2 Remove the engine air filter assembly from the
machine.
3 Remove the front portion of the engine
enclosure assembly from the machine.
4 Remove the fuel filler cap from the tank.

REV C FUEL AND HYDRAULIC TANKS
3-2 4 Remove oil cap from top of hydraulic tank.

Hydraulic Tank 5 Using an approved hand-operated pump, drain
the hydraulic tank into a suitable container.
The primary functions of the hydraulic tank are to Refer to Section 2, Specifications.
cool, clean and deaerate the hydraulic fluid during Bodily injury hazard. Beware of
operation. It has an internal return line filter with a hot oil. Contact with hot oil may
filter condition indicator. cause severe burns.
How to Remove the 6 Remove the fasteners securing the access
covers at the rear of the machine. Remove the
Hydraulic Tank access covers.
Component damage hazard. The 7 Tag, disconnect and plug the hoses at the
work area and surfaces where this hydraulic tank. Cap the fittings.
procedure will be performed must
be clean and free of debris that Bodily injury hazard. Spraying
could get into the hydraulic hydraulic oil can penetrate and
system. burn skin. Loosen hydraulic
Note: When removing a hose assembly or fitting, the oil pressure to dissipate
the O-ring on the fitting and/or hose end must be gradually. Do not allow oil to squirt
replaced and then torqued to specification during or spray.
Fitting Torque Specifications. 8 Attach a lifting strap from an overhead crane to
the top of the hydraulic tank. Support the tank.
1 Lower the boom to the stowed position. Do not apply any lifting pressure.
2 Raise the machine 15 inches / 40 cm. 9 Remove the tank mounting fasteners. Lower the
3 Using a lift with a 1 ton / 1 kg minimum tank through the chassis to remove the tank
capacity, remove the counterweight from under from the machine.
the hydraulic tank at the pivot end of the Crushing hazard. The hydraulic
machine. tank could become unbalanced
Tip over hazard. The and fall if not properly supported
counterweight is critical to when removed from the machine.
machine stability. If the
counterweight is not installed
during re-assembly of the
machine, the machine will become
unstable and tip over, resulting in
death or serious injury. Do not
operate the machine without the
counterweight installed onto the
machine.
Crushing hazard. The
counterweight is extremely heavy.
Keep your body clear when
removing the counterweight.

Engines REV B
4-1 How to Repair the

Engines John Deere 4045T Engine
Repair procedures and additional engine
How to Repair the information is available in the
Deutz BF4 2012 Engine John Deere 4045T270 Operator's Manual
(John Deere part number OMRG25204) and the
Repair procedures and additional engine John Deere 4045T275 Operator's Manual
information is available in the (John Deere part number OMRG33324) and the
Deutz 2012 Engine Operation Manual John Deere 4045T Workshop Manual
(Deutz part number 0297 9912) and the (John Deere part number CTM104) and the
Deutz 2012 Engine Workshop Manual John Deere 4045T Alternator Manual
(Deutz part number 0312 0361) (John Deere part number CTM77) and the
John Deere 4045T Fuel Systems Manual
Deutz 2012 Operation Manual (John Deere part number CTM207).
Deutz 2012 Workshop Manual John Deere 4045T270 Operator's Manual


How to Repair the
John Deere 4045T Workshop Manual
Perkins 1104C Engine Genie part number 108443
Repair procedures and additional engine John Deere 4045T Alternator Manual
information is available in the Genie part number 108502
(Perkins part number SEBU7833-01) and the John Deere 4045T Fuel Systems Manual
Perkins 1104 Service Manual
(Perkins part number RENR9401).

Perkins 1104 Service Manual


REV B ENGINES
a b c d e f g h 4-2
Engine Fault Codes -
John Deere 4045TF275 Engine
How to Retrieve Engine Fault

Codes
When an engine malfunction is detected by the
engine Electronic Control Module (ECM), a fault
code is recorded and the blink code light on the
dashboard in the operator's compartment will turn
on.
Perkins 1104C engine To learn the specifics of and how to use the fault
codes, refer to Section 5, Troubleshooting.
a coolant temperature sender
b injection pump advance sender
c oil pressure sender
d cold start circuit breaker
e fuel lift pump fuse
e cold start relay
g lift pump relay
h starter solenoid
a b c
John Deere 4045T engine
a engine coolant temperature sender

b engine oil pressure sender
c starter relay

Transmission REV C
5-1 4 Tag, disconnect and plug the water lines at the

heat exchanger. Cap the fittings.
Transmission
Note: Do not disconnect the transmission cooler
hoses from the heat exchanger.
How to Remove the Transmission
5 Tag, disconnect and plug the hydraulic line at
the top of the transmission. Cap the fitting.
skills, lifting equipment and a Bodily injury hazard. Spraying
suitable workshop. Attempting this hydraulic oil can penetrate and
procedure without these skills and burn skin. Loosen hydraulic
tools could result in death or connections very slowly to allow
serious injury and significant the oil pressure to dissipate
component damage. Dealer gradually. Do not allow oil to squirt
service is strongly recommended. or spray.
Note: When removing a hose assembly or fitting, 6 Tag and disconnect the wire harness from the
the O-ring on the fitting and/or hose end must be transmission.
7 Support and secure the rear of the engine to a
lifting device of suitable capacity. Do not apply
any lifting pressure.
Note: Perform this procedure with the engine off
and cool. a b c d e f

other jewelry.
2 Chock the tires. Remove the driveshafts from
the machine.
3 Remove the drain plug from the radiator and
completely drain the radiator into a container of
suitable capacity. Refer to Section 2,
Specifications. Dana T12000 transmission
a transmission temperature sender
Burn hazard. Contact with hot b transmission pressure sender
engine components or fluids may c transmission shift coil 'B'
cause severe burns. (drive reverse function)
d transmission shift coil 'A'
(drive forward function)
e transmission shift coil 'D'
(gear reduction)
f transmission shift coil 'E'
(gear reduction)
Note: refer to electrical schematic for additional
transmission shift coil information.

REV C TRANSMISSION
8 Attach a lifting strap from an overhead crane or How to Repair the Transmission
similar lifting device to the transmission for
support. Do not apply any lifting pressure. Repair procedures and additional transmission
information is available in the
9 Remove the fasteners securing the Dana T12000 Transmission Maintenance and
transmission to the chassis. Repair Manual (Dana part number 0109) and the
10 Remove the 2 inch / 5 cm access plug from the Dana T20000 Maintenance Manual
underside of the engine bellhousing. (Dana part number 0202).
11 Working through the access opening under the Dana T12000 Transmission Manual
bellhousing, remove the fasteners securing the Genie part number 97489
transmission drive plate to the engine flywheel.
Note: During reassembly, torque these fasteners to Genie part number 115025
26-29 ft-lbs / 36-39 Nm.
12 Remove the fasteners securing the

transmission to the engine. Remove the
transmission from the machine.
Crushing hazard. The
transmission will fall if not properly
removed.
Note: During reassembly, torque these fasteners to
60 ft-lbs / 81 Nm.
a b c d e f
Dana T20000 transmission

a transmission temperature sender
(located opposite side of trans)
b transmission pressure sender
c transmission shift coil 'F'
(drive forward function) (blue wire)
d transmission shift coil 'R'
(drive reverse function) (brown wire)
e transmission shift coil '2'
(gear reduction) (green wire)
f transmission shift coil '1'
(gear reduction) (yellow wire)
Note: refer to electrical schematic for additional
transmission shift coil information.

Hydraulic Pump REV B
6-1 4 Observe the pressure gauge while cranking the

engine.
Hydraulic Pump
Result:
GTH-636: If the pressure gauge reads
How to Test the Function Pump 2800 psi / 193 bar, immediately stop. The pump
Note: When removing a hose assembly or fitting, is good.
the fitting and/or hose end must be torqued to GTH-644, GTH-842, GTH-844 and GTH-1056:
specification during installation. Refer to Section 2, If the pressure gauge reads 3000 psi / 207 bar,
Hydraulic Hose and Fitting Torque Specifications. immediately stop. The pump is good.
GTH-1048: If the pressure gauge reads
1 Tag, disconnect and plug the high pressure 3500 psi / 241 bar, immediately stop. The pump
hydraulic hose from the main valve assembly. is good.
Cap the fitting on the main valve.
Result:
Bodily injury hazard. Spraying GTH-636: If the pressure fails to reach
hydraulic oil can penetrate and 2800 psi / 193 bar, the pump or pump coupling
burn skin. Loosen hydraulic is bad and will need to be serviced or replaced.
connections very slowly to allow GTH-644, GTH-842, GTH-844 and GTH-1056:
the oil pressure to dissipate If the pressure fails to reach
gradually. Do not allow oil to squirt 3000 psi / 207 bar, the pump or pump coupling
or spray. is bad and will need to be serviced or replaced.
Note: The high pressure hose is the smaller of the GTH-1048: If the pressure fails to reach
two hoses. 3500 psi / 241 bar, the pump or pump coupling
is bad and will need to be serviced or replaced.
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the high pressure hose disconnected
There is no relief valve in the
in step 1.
hydraulic pump and the pump can
3 Hold the manual fuel shut-off lever on the be damaged if the pressure is
engine in the closed position. allowed to exceed specification.
When testing the pump, crank the
engine in one second intervals
until the correct pressure is
confirmed. Do not over-pressurize
the pump.
5 Remove the pressure gauge and install the high
pressure hose onto the pump. Torque to
gradually. Do not allow oil to squirt
or spray.

REV B HYDRAULIC PUMP
How to Adjust the Function Pump 4 Fully press and release the brake pedal 3 times,
then observe the reading on the pressure
Pressure gauge. Note the pressure. Refer to Section 2,
1 Install a 0 to 3500 psi / 0 to 250 bar pressure Specifications.
gauge into test port 1 at the side of the Result: The pressure meets specification.
hydraulic tank. Securely tighten the set screw. Proceed to step
Note: GTH-636, GTH-644, GTH-842 and GTH- 6.
844: There are four test ports at the hydraulic tank. Result: The pressure fails to reach
Test port 1 is closest to the tank; test port 4 is specification. Proceed to step 5.
farthest from the tank.
5 Adjust the lower hex socket of the DFR valve.
Note: GTH-1048 and GTH-1056: There are six Turn it clockwise to increase the pressure or
test ports at the hydraulic tank. Test port 1 is counterclockwise to decrease the pressure.
closest to the tank; test port 6 is farthest from the Repeat this procedure beginning with step 4.
tank.
6 Turn the machine off. Remove the pressure
2 Start the engine. Allow the engine to idle after gauge.
warming the engine to operating temperature.
3 Working at the hydraulic pump, loosen the set hydraulic oil can penetrate and
screw securing the lower of the two hex burn skin. Loosen hydraulic
sockets of the DFR valve on the pump. connections very slowly to allow
Note: The hydraulic pump is located on the top of gradually. Do not allow oil to squirt
the transmission at the cab side. or spray.
a b
a pump
b DFR valve

HYDRAULIC PUMP REV B
How to Remove the 4 Remove the engine air filter assembly from the
machine.
Function Pump
5 Remove the front portion of the engine
Bodily injury hazard. This enclosure assembly from the machine.
skills, lifting equipment and a 6 Tag and disconnect the wire harness from the
suitable workshop. Attempting this pump.
procedure without these skills and 7 Tag and disconnect the case drain hose at the
tools could result in death or top of the pump. Cap the fitting on the pump.
component damage. Dealer 8 Tag, disconnect and plug the large hydraulic
service is strongly recommended. supply line at the pump. Cap the fitting on the
pump.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be 9 Tag, disconnect and plug the high pressure
replaced and then torqued to specification during hose at the pump. Cap the fitting on the pump.
installation. Refer to Section 2, Hydraulic Hose and Bodily injury hazard. Spraying
Fitting Torque Specifications. hydraulic oil can penetrate and
Note: Perform this procedure with the engine off burn skin. Loosen hydraulic
and cool. connections very slowly to allow
1 Disconnect the battery from the machine. gradually. Do not allow oil to squirt
or spray.
electrically charged circuits could 10 Remove the fasteners securing the heat
result in death or serious injury. exchanger from the chassis bulkhead and let
Remove all rings, watches and the heat exchanger hang down.
other jewelry.
2 Remove the oil cap from the top of the hydraulic engine components may cause
tank. severe burns.
3 Using an approved hand-operated pump, drain 11 Remove the fasteners securing the pump to the
the hydraulic tank into a suitable container. transmission. Remove the pump from the
Refer to Section 2, Specifications. machine.
cause severe burns.

REV B HYDRAULIC PUMP
How to Install the 11 Start the engine.

Function Pump 12 Release the PUMP OFF button for two seconds.
1 Carefully install the hydraulic pump onto the 13 Press and hold the PUMP OFF button for one
transmission. Install the fasteners and tighten to second, then release.
finger tight. 14 Repeat step 13.
2 Torque the fasteners evenly to 15 Turn the machine off.
85 ft-lbs / 115 Nm.
3 Install the smaller high pressure hose onto the
pump outlet. Torque the fasteners to
27-37 ft-lbs / 37-50 Nm.
4 Install the larger low pressure hose onto the
pump outlet. Install the hose retaining rings and
fasteners. Torque the fasteners to
55-66 ft-lbs / 74-90 Nm.
5 Working at the case drain at the top of the
pump, fill the pump with hydraulic fluid until the
fluid is at the top of the case drain fitting.
6 Install the case drain hose onto the pump and
torque to specification. Refer to Section 2,
Specifications.
7 Securely install the wire harness onto the pump.
8 Install the heat exchanger onto the chassis
bulkhead. Install and securely tighten the
fasteners. Do not over tighten.
9 Check the level of the hydraulic fluid in the
hydraulic tank. Add fluid if needed.
10 Working inside the cab, press and hold the PUMP
OFF button.
Note: The PUMP OFF button is located under the

steering wheel.

Manifolds REV C
7-1
Main Valve Manifold Components
The main valve manifold is located on the front of the hydraulic tank at the tailpipe side of the machine.
Index Schematic
No. Description Item Function Torque
1 Directional valve, pilot operated ....... AA .......... Boom extend/retract .................................... 88 in-lbs / 10 Nm
2 Directional valve, pilot operated ....... AB .......... Lifting fork level ........................................... 88 in-lbs / 10 Nm
3 Directional valve, pilot operated ...... AC .......... Boom up/down ............................................ 88 in-lbs / 10 Nm
4 Relief valve, 3650 psi / 251 bar ....... AD .......... Manifold relief ............................................ 73 ft-lbs / 100 Nm
AA
1
AB
2
AC
3
AD
4
Note: 'alpha' callouts refer

IC
to corresponding notes on
UL
the hydraulic schematic
D RAANK
HY T

REV C MANIFOLDS
7-2
Tilt Limiter Manifold Components
The tilt limiter manifold is located on the front of the hydraulic tank at the tailpipe side of the machine.
Index Schematic
1 Relief valve, 1250 psi / 86.2 bar ....... BA .......... Fork level circuit ................................ 30-35 ft-lbs / 45-50 Nm
BA
1

IC
UL
D RAANK
HY T

MANIFOLDS REV C
7-3
Dual Pilot Check Manifold Components
The dual pilot check manifold is located on the front of the hydraulic tank at the tailpipe side of the machine
Index Schematic
1 Check valve, pilot operated ............. CA .......... Boom lift circuit .................................. 30-35 ft-lbs / 45-50 Nm
2 Check valve, pilot operated ............. CB .......... Boom lift circuit .................................. 30-35 ft-lbs / 45-50 Nm
CB
2
CA
1

IC
UL
D RAANK
HY T

REV C MANIFOLDS
7-4
Boom Activated Rear Lock-up Manifold Components
The rear lock-up manifold is located on the front of the hydraulic tank at the cab side of the machine.
Index Schematic
1 Solenoid valve, 2 position 3 way ..... DA .......... Deactivates chassis sway

circuit when boom is
above 60° .................................................... 20 ft-lbs / 27 Nm
Coil nut .................................................................................................................................. 40 in-lbs / 4.5 Nm
DA
1
Y69

IC
UL
the hydraulic schematic;
D RAANK
alphanumeric callouts refer HY T
to the electrical schematic

MANIFOLDS REV C
7-5
Fork Rotate Speed Manifold Components (option)
The fork rotate speed manifold is located on the front of the hydraulic tank at the cab side of the machine.
Index Schematic
1 Adjustable needle valve ................... EA .......... Fork rotate speed .............................. 30-35 ft-lbs / 40-47 Nm
Adjustment nut ..................................................................................................................... 108 in-lbs / 12 Nm
EA
1

IC
UL
D RAANK
H Y T

REV C MANIFOLDS
7-6
Control Block Manifold Components
The control block manifold is located on the front of the hydraulic tank at the cab side of the machine.
Index Schematic
1 Adjustable needle valve ................... FA .......... Chassis sway speed ......................... 30-35 ft-lbs / 40-47 Nm
Adjustment nut ..................................................................................................................... 108 in-lbs / 12 Nm
2 Pressure reducing/relief valve,
pilot operated, 500 psi / 34.5 bar ...... FB .......... Pilot pressure for boom up/down,
boom extend/retract and parking
brake circuits ..................................... 30-35 ft-lbs / 40-47 Nm
3 Pressure reducing/relief valve,
pilot operated, 2250 psi / 155 bar ..... FC .......... Steer left/right and
fork rotate (option) circuits ................ 30-35 ft-lbs / 40-47 Nm
4 Check valve ...................................... FD .......... Brake circuit ...................................... 30-35 ft-lbs / 40-47 Nm
FA FB
1 2
FC
3
FD
4

IC
UL
D RAANK
H Y T

MANIFOLDS REV C
7-7
Fork Tilt Manifolds Components
The fork tilt manifolds, used only on machines with single joystick, are located on the front of the hydraulic
tank at the cab side of the machine.
Index Schematic
— Coil nut (items GA and GB) ................................................................................................... 40 in-lbs / 4.5 Nm

1 Solenoid valve, 2 position 4 way ..... GA .......... Tilts lifting forks down ................................. 20 ft-lbs / 27 Nm
2 Solenoid valve, 2 position 4 way ..... GB .......... Tilts lifting forks up ...................................... 20 ft-lbs / 27 Nm
GA Y72A Y72B GB
1 2

IC IC
UL UL
D RAANK D RAANK
alphanumeric callouts refer H Y T HY T

REV C MANIFOLDS
7-8
Rear Lock-up Manifold Components
The rear lock-up manifold is located on top of the rear axle support bulkhead.
Index Schematic
1 Check valve, pilot operated ............. HA .......... Left rear cylinder retract circuit ......... 35-40 ft-lbs / 47-54 Nm
2 Check valve, pilot operated ............. HB .......... Left rear cylinder extend circuit ......... 35-40 ft-lbs / 47-54 Nm
3 Check valve, pilot operated ............. HC .......... Right rear cylinder retract circuit ....... 35-40 ft-lbs / 47-54 Nm
4 Check valve, pilot operated ............. HD .......... Right rear cylinder extend circuit ...... 35-40 ft-lbs / 47-54 Nm
5 Shuttle valve, 2 position 3 way ........ HE .......... Chassis sway circuit ......................... 25-30 ft-lbs / 34-40 Nm
6 Directional valve, pilot operated ....... HF .......... Activates rear sway function ............. 35-40 ft-lbs / 47-54 Nm
7 Directional valve, pilot operated ...... HG .......... Opens check valves .......................... 35-40 ft-lbs / 47-54 Nm
8 Relief valve, pilot operated,
500 psi / 34.5 bar ............................. HH .......... Controls fluid pressure to cylinders .. 35-40 ft-lbs / 47-54 Nm
1 HA HB 2
HC
Note: 'alpha' callouts refer 2
HD
2
HH
5
HE
HG 2
4
HF
3

MANIFOLDS REV C
7-9
Parking Brake Manifold Components
GTH-644, GTH-842 and GTH-844: The parking brake manifold is the outboard of the two similar
manifolds located on the chassis main tube next to the cab, mounted directly to the chassis.
GTH-636, GTH-1048 and GTH-1056: The parking brake manifold located inside the cab, just to the left of
the operator's seat.
Index Schematic
1 Solenoid valve, 2 position 3 way

(644, 842 and 844 models) .............. IA ........... Activates/releases parking brake ................ 20 ft-lbs / 27 Nm
Coil nut .................................................................................................................................. 40 in-lbs / 4.5 Nm
2 Manually-activated valve,
2 position 3 way
(636, 1048 and 1056 models) .......... IA ........... Activates/releases parking brake ............... 20 ft-lbs / 27 Nm
1 2
IA IA
Y67
3 GTH-636
GTH-1048
GTH-1056
2
GTH-644
GTH-842
GTH-844

alphanumeric callouts refer

REV C MANIFOLDS
7-10
Differential Lock-up Manifold Components
(optional on GTH-636 and GTH-644)
The differential lock-up manifold is the inboard of the two similar manifolds located on the chassis main
tube next to the cab, mounted closest to the centerline of the machine.
Index Schematic
1 Solenoid valve, 2 position 3 way ...... JA .......... Releases parking brake .............................. 20 ft-lbs / 27 Nm
Coil nut .................................................................................................................................. 40 in-lbs / 4.5 Nm
1
JA
Y68


MANIFOLDS REV C
7-11
Sway Manifold Components
The sway manifolds are located under an inspection cover on the front axle support bulkhead with the left
sway manifold mounted on the cab side of the machine and the right sway manifold mounted on the
exhaust side of the machine.
Index Schematic
1 Check valve, pilot operated .............. KA .......... Left front cylinder extend circuit ........ 30-35 ft-lbs / 40-47 Nm
2 Check valve, pilot operated .............. KB .......... Left front cylinder retract circuit ......... 30-35 ft-lbs / 40-47 Nm
3 Check valve, pilot operated ............. KC .......... Right front cylinder retract circuit ...... 30-35 ft-lbs / 40-47 Nm
4 Check valve, pilot operated ............. KD .......... Right front cylinder extend circuit ..... 30-35 ft-lbs / 40-47 Nm
KB KC
2 3
1 4
KA KD
CAB SIDE EXHAUST SIDE


REV C MANIFOLDS
7-12
Fork Rotate Manifold Components (option)
If equipped with the fork rotate option, the fork rotate manifold is located under the rear lock-up manifold
on the rear axle support bulkhead at the cab side of the machine.
Index Schematic

with manual override ........................ LA .......... Rotate forks clockwise or
counterclockwise
Coil nut .................................................................................................................................. 30 in-lbs / 3.4 Nm
LA
1


MANIFOLDS REV C
7-13
Sway Directional Manifold Components
The sway directional manifold is located under the rear lock-up manifold on the rear axle support bulkhead
at the exhaust side of the machine.
Index Schematic

with manual override
(models with single joystick) ............ MA .......... Rotate chassis clockwise or
counterclockwise
Coil nut .................................................................................................................................. 30 in-lbs / 3.4 Nm
2 Pilot-operated directional valve
(models with dual joysticks) ............. MA .......... Rotate chassis clockwise or
counterclockwise
MODELS WITH
SINGLE
Y71
JOYSTICK
MA
2
Y70
MA
1
MODELS WITH
DUAL
JOYSTICKS


REV C MANIFOLDS
7-14
Outrigger Manifold Components -
The outrigger manifold is located under the inspection cover on the front axle support bulkhead.
Index Schematic
— Coil nut .................................................................................................................................. 30 in-lbs / 3.4 Nm

with manual override ....................... NA .......... Outrigger extend/retract circuit, cab side
with manual override ....................... NB .......... Outrigger extend/retract circuit, exhaust side
Y75 Y73
Y76 Y74
1 2
NA NB


MANIFOLDS REV C
7-15
Controller Relief (Drop Block) Manifold Components
The controller relief valve manifold is located inside the frame rail between the cab and the rear axle
support bulkhead on the cab side of the machine.
Index Schematic

with manual override ....................... OA .......... Disengages hydraulic pump ....................... 20 ft-lbs / 27 Nm
Coil nut .................................................................................................................................. 40 in-lbs / 4.5 Nm
Y77
OA
1


REV C MANIFOLDS
7-16
Boom Lift and Boom Extension Cylinders Manifold Components
The manifolds are located on the respective cylinder(s).
Index Schematic
1 Counterbalance valve ....................... PA .......... Left boom up/down circuit

(cab side) .......................................... 45-50 ft-lbs / 61-67 Nm
2 Counterbalance valve ....................... PB .......... Right boom up/down circuit
(exhaust side) ................................... 45-50 ft-lbs / 61-67 Nm
3 Counterbalance valve ...................... QA .......... Boom extend circuit
(barrel end) ....................................... 45-50 ft-lbs / 61-67 Nm
4 Counterbalance valve ...................... QB .......... Boom retract circuit
(rod end) ........................................... 45-50 ft-lbs / 61-67 Nm
PA
1
PB
Boom Lift
Cylinder Manifold
QA
2
QB
Boom Extension
Cylinder Manifold


MANIFOLDS REV C
7-17
Fork Level Cylinder Manifold Components
If equipped with the fork rotate option, the fork rotate cylinder manifold is located on the cylinder.
Index Schematic
1 Check valve, pilot operated ............. RA .......... Fork up circuit ................................... 30-35 ft-lbs / 40-47 Nm
2 Counterbalance valve ...................... RB .......... Fork up circuit ................................... 30-35 ft-lbs / 40-47 Nm
3 Check valve, pilot operated ............. RC .......... Fork down circuit ............................... 30-35 ft-lbs / 40-47 Nm
RA
1
RB
2
RC
3


REV C MANIFOLDS
7-18
Fork Rotate Cylinder Manifold Components (option)
The manifolds are located on the cylinder.
Index Schematic
1 Check valve, pilot operated .............. SA .......... Rotate clockwise circuit .................... 30-35 ft-lbs / 40-47 Nm
2 Check valve, pilot operated .............. SB .......... Rotate counterclockwise circuit ........ 30-35 ft-lbs / 40-47 Nm
SA
1
SB
2


MANIFOLDS REV C
7-19
Pump Destroke Manifold Components
The pump destroke manifold is located on the hydraulic pump next to the DFR valve.
Index Schematic
1 Solenoid valve, 2 position 2 way ...... TA .......... Disengages hydraulic pump ....................... 20 ft-lbs / 27 Nm
Coil nut .................................................................................................................................. 40 in-lbs / 4.5 Nm
USED ON SAUER PUMP

(BLACK MANIFOLD ON BLACK PUMP)
TA Y66
1
USED ON REXROTH PUMP

(SILVER MANIFOLD ON GREY PUMP)
Y66 TA
2


REV C MANIFOLDS
7-20
Extend Cylinder Relief Manifold Components -
The extend cylinder relief manifold is located on the dump block at the front of the hydraulic tank.
Index Schematic
1 Relief valve, 2000 psi / 137.9 bar

(GTH-636 from serial number
GTH0606A-8418 to
GTH0606A-9022) ............................ UA .......... Boom extend relief ...................................... 20 ft-lbs / 27 Nm
— Relief valve, 2500 psi / 172.3 bar
(GTH-1048 and GTH-1056) ............. UA .......... Boom extend relief ...................................... 20 ft-lbs / 27 Nm
UA
1

IC
UL
D RAANK
HY T

MANIFOLDS REV C
7-21
Boom-activated Sway Lock-up Manifold Components
(models with dual joysticks except GTH-636)
The boom-activated sway lock-up manifold, used on all machines with dual joysticks except the GTH-636,
is mounted on the pilot operated sway directional valve.
Index Schematic
— Coil nut .................................................................................................................................. 40 in-lbs / 4.5 Nm

1 Solenoid valve, 2 position 2 way ...... VA .......... GTH-644, GTH-842 and GTH-844:
Stops fluid flow to chassis sway circuit
when boom is above 60° ............................. 20 ft-lbs / 27 Nm
1 Solenoid valve, 2 position 2 way ...... VA .......... GTH-1048 and GTH-1056:
Stops fluid flow to chassis sway circuit
when boom is above 55° ............................. 20 ft-lbs / 27 Nm
VA
1
Y84


REV C MANIFOLDS
7-22 2 Start the engine. Allow the engine to idle after

Valve Adjustments -
3 Without operating any machine controls,
Control Block Manifold observe the reading on the pressure gauge.
How to Set the Steer System Result: The pressure gauge reads
2250 psi / 155 bar. The pressure setting is
Pressure correct.
Note: Be sure that the hydraulic oil level is visible Result: The pressure gauge fails to read
in the inspection glass of the hydraulic tank. 2250 psi / 155 bar. The pressure setting needs
to be adjusted. Continue to step 4.
1 Install a 0 to 3500 psi / 0 to 250 bar pressure
gauge into test port 2 at the side of the 4 Locate the boom lift/extend relief valve
hydraulic tank. (schematic item FC) of the control block on the
front of the hydraulic tank. Loosen the jam nut
Note: There are four test ports at the hydraulic
at the top of the valve. Turn the adjustment
tank. Test port 1 is closest to the tank; test port 4 is
screw clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Tighten the jam nut and repeat this procedure
beginning with step 3.
FA
FB
FC
GTH-636
GTH-1048 GTH-644
GTH-1056 GTH-842
GTH-844
b
a test port 6
b test port 4
c test port 3 c
a b c d d test port 1 b c d
a hydraulic tank
b boom lift/extend relief valve
c control block manifold

MANIFOLDS REV C
How to Set the Boom System 3 Start the engine. Allow the engine to idle after
Pilot Pressure
Note: Be sure that the hydraulic oil level is visible observe the reading on the pressure gauge.
in the inspection glass of the hydraulic tank.
Result:
1 GTH-636, GTH-644, GTH-842 and GTH-844: GTH-636, GTH-644, GTH-842 and GTH-844:
Install a 0 to 3500 psi / 0 to 250 bar pressure The pressure gauge reads 500 psi / 34.5 bar.
gauge into test port 3 at the side of the The pressure setting is correct.
hydraulic tank. GTH-1048 and GTH-1056: The pressure
gauge reads 400 psi / 27.6 bar. The pressure
setting is correct.
farthest from the tank. Result:
2 GTH-1048 and GTH-1056: Install a The pressure gauge fails to read
0 to 3500 psi / 0 to 250 bar pressure gauge into 500 psi / 34.5 bar. The pressure setting needs
test port 5 at the side of the hydraulic tank. to be adjusted. Continue to step 5.
Note: There are six test ports at the hydraulic tank. GTH-1048 and GTH-1056: The pressure
Test port 1 is closest to the tank; test port 6 is gauge fails to read 500 psi / 34.5 bar. The
farthest from the tank. pressure setting needs to be adjusted. Continue
to step 5.
5 Locate the pilot pressure relief valve (schematic
item FB) of the control block on the front of the
hydraulic tank. Loosen the jam nut at the top of
the valve. Turn the adjustment screw clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Tighten the jam nut and
repeat this procedure beginning with step 4.
GTH-636 a
GTH-1048 GTH-644
GTH-1056 GTH-842 FA
GTH-844
FB
a test port 6 FC
b test port 4
c test port 3
a b c d d test port 1 b c d b
a hydraulic tank
b pilot pressure relief valve
c control block manifold

REV C MANIFOLDS
7-23 3 Start the engine. Allow the engine to idle after

Valve Adjustments -
4 Activate the fork level up function until the fork
Tilt Limiter Manifold level cylinder is fully retracted, then continue to
activate the function while observing the
How to Set the Tilt Limiter pressure on the gauge.
Pressure Result: The pressure gauge reads
1250 psi / 86.2 bar. The pressure setting is
Note: Be sure that the hydraulic oil level is visible
correct.
in the inspection glass of the hydraulic tank.
Result: The pressure gauge fails to read
Note: Two technicians are required to perform this
1250 psi / 86.2 bar. The pressure setting needs
procedure.
to be adjusted. Continue to step 5.
1 GTH-636, GTH-644, GTH-842 and GTH-844: 5 Locate the tilt limiter relief valve (schematic item
Install a 0 to 3500 psi / 0 to 250 bar pressure BA) of the tilt limiter manifold on the front of the
gauge into test port 4 at the side of the hydraulic tank. Loosen the jam nut at the top of
hydraulic tank. the valve. Turn the adjustment screw clockwise
Note: There are four test ports at the hydraulic to increase the pressure or counterclockwise to
tank. Test port 1 is closest to the tank; test port 4 is decrease the pressure. Tighten the jam nut and
farthest from the tank. repeat this procedure beginning with step 4.
2 GTH-1048 and GTH-1056: Install a Note: It may be necessary to perform this

0 to 3500 psi / 0 to 250 bar pressure gauge into adjustment 5 or 6 times to ensure a correct
test port 6 at the side of the hydraulic tank. pressure setting.
Note: There are six test ports at the hydraulic tank.

a
Test port 1 is closest to the tank; test port 6 is
BA
c
GTH-636
GTH-1048 GTH-644
GTH-1056 GTH-842
GTH-844 a hydraulic tank
b tilt limiter manifold
a test port 6 c tilt limiter relief valve
b test port 4
c test port 3

MANIFOLDS REV C
7-24
Valve Coils
How to Test a Coil

A properly functioning coil provides an
electromotive force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil that provides this force field.

other jewelry.
1 Start the engine.
2 While activating the appropriate machine
function, apply a steel wrench to the tip of the
solenoid valve. Release the wrench.
Result: The wrench sticks to the tip of the valve.
The valve coil is functioning correctly.
Result: The wrench does not stick to the valve.
The valve coil is not functioning correctly.
3 Disconnect the wire harness from the valve coil.
4 Using a multimeter set to read DC voltage,
attach the positive lead to one of the terminals
of the valve coil connector.
5 Attach the negative lead to a ground point on
the chassis.
Result: The multimeter displays approximately
13V DC. The wire harness is good. Replace the
valve coil.
Result: The multimeter displays 0V DC. The
valve coil is good; the wire harness is faulty.
Repair or replace the wire harness.

REV D
Axle
8-1 7 Working at one side of the machine, tag,
disconnect and plug the fork level cylinder
Axles hoses at the cylinder manifold. Cap the fittings.
How to Remove the Axle hydraulic oil can penetrate and
Bodily injury hazard. This burn skin. Loosen hydraulic
procedure requires specific repair connections very slowly to allow
skills, lifting equipment and a the oil pressure to dissipate
suitable workshop. Attempting this gradually. Do not allow oil to
procedure without these skills and squirt or spray.
tools could result in death or Component damage hazard.
serious injury and significant Hoses can be damaged if they are
component damage. Dealer kinked or pinched.
service is required.
1 Remove the fasteners securing the driveshaft to the barrel end of the axle level cylinder. Support
the transmission. Lower the end of the the cylinder. Do not apply any lifting pressure.
driveshaft to the ground.
9 Remove the fasteners securing the axle level
2 Remove the fasteners securing the driveshaft to cylinder barrel-end pivot pin to the chassis.
the axle. remove the driveshaft from the
machine. 10 Use a soft metal drift to remove the pivot pin.
Lower the cylinder onto the axle.
3 Loosen the lug nuts of both wheels on the axle
to be removed. Do not remove the lug nuts. Crushing hazard. The cylinder will
4 Raise the end of the machine until the tires are the pivot pin is removed from the
off the ground. Place blocks under the chassis machine.
for support.
Crushing hazard. The chassis will for the other side of the axle.
fall if not properly supported.
12 Remove the fasteners securing the axle to the
5 Remove the lug nuts. Remove the tire and chassis. Remove the axle from the machine.
wheel assembly from both ends of the axle.
Crushing hazard. The axle will fall
6 Support and secure the axle to an appropriate if not properly supported when the
lifting device. fasteners are removed from the
machine.
Note: When installing the axle onto the chassis,
torque the fasteners to specification.
Torque specification
Axle mounting fasteners 380 ft-lbs

515 Nm

AXLE REV D
How to Adjust the Front Axle How to Adjust the Parking Brakes
Service Brakes GTH-636, GTH-644, GTH-842 and GTH-844
GTH-1048 and GTH-1056 1 Chock the tires.
When using the GTH-1048 and GTH-1056, most of 2 Start the engine and allow the engine to idle.
the braking is performed by the front axle. As a
result, the rear axle service brakes will rarely need 3 Release the parking brake.
to be adjusted. Should adjustment of the rear axle 4 Remove the top inspection cover from the
service brakes be required, contact the Genie chassis at the fork end of the machine. Locate
Industries Service Dept. the parking brake cylinder on top of the drive
axle.
1 Chock the tires.
5 Loosen the lock nut securing the threaded
portion of the parking brake adjustment rod.
3 Release the parking brake.
6 Turn the threaded rod of the cylinder out of the
4 At the front axle, locate and remove the covers cylinder several turns.
over the service brake adjustment screws.
7 Turn the threaded rod into the cylinder just until
Refer to the following illustrations.
there is zero clearance between the bushing of
the threaded rod, the lever actuator and the
lever bracket.
Note: Turning the threaded rod too far into the
cylinder will move the parking brake lever, resulting
in a parking brake which does not function
correctly. Do not over tighten the rod.
8 While holding the cylinder rod in position,
securely tighten the cylinder rod jam nut.
9 Inspect the parking brake lever to confirm that
the lever is not binding or in contact with axle
5 Turn both of the four-sided service brake casting.
adjustment screws in a counter clockwise 10 Set the parking brake and stop the engine.
direction until a slight resistance is detected.
6 Turn both of the four-sided service brake
adjustment screws 3.75 turns in a clockwise
direction.
7 Install the covers over the service brake
adjustment screws. Securely tighten the
fasteners. Do not over tighten.

REV D AXLE
How to Manually Release the 3 Turn the parking brake release bolts equally
into the differential housing until the parking
Parking Brake brake is released.
GTH-636, GTH-644, GHT-842 and GTH-844 Component damage hazard.
Turning the parking brake release
1 Remove the top inspection cover from the
bolts into the housing in unequal
chassis at the fork end of the machine. Locate
amounts may damage the parking
the parking brake cylinder on top of the drive
brake internally. Do not turn the
axle.
parking brake release bolts into
2 Loosen the lock nut securing the threaded the housing in unequal amounts.
portion of the parking brake adjustment rod.
4 To reset the parking brake, turn the bolts in
3 Turn the threaded rod out of the cylinder until equal amounts out of the differential housing
the parking brake is released, counting the until the top of each bolt is 32 ±1 mm from the
number of revolutions the rod is turned. differential case. Securely tighten the jam nut.
Do not over tighten.
Note: For ease in recalibrating the parking brake
cylinder rod, it is helpful to keep an accurate count
of revolutions that the rod is turned when releasing
32±1 mm
the brake.

In the rare event of an engine failure, it may be
necessary to release the brakes before moving the
machine.
1 Chock the tires.

2 Working at the front axle, locate the four parking
brake release bolts with jam nuts at the
locations shown in the illustration. Fully loosen How to Repair the Axle
the jam nuts which secures the bolts in position.
GTH-636, GTH-644, GHT-842 and GTH-844:
Repair procedures and additional axle information

is available in the Dana 212 Axle Maintenance and
Repair Manual (Dana part number 0247).

Repair procedures and additional axle information

is available in the Dana 213 Axle Maintenance and
Repair Manual (Dana part number 0243).


Outriggers REV A
9-1 6 Raise the outrigger assembly to a vertical

position.
Outriggers
7 Remove the fasteners securing the outrigger
pivot pin to the machine.
How to Remove an Outrigger
1 Extend the outrigger until the pad just touches Remove the outrigger assembly from the
the ground. Do not rest the weight of the machine.
machine on the outrigger.
Crushing hazard. The outrigger
2 Tag, disconnect and plug the hydraulic supply will fall if not properly supported
hoses at the outrigger cylinder. Cap the fittings. when the pivot pin is removed
Bodily injury hazard. Spraying from the machine.
squirt or spray.
kinked or pinched.
the outrigger assembly. Raise the outrigger to
approximately 80°.
cylinder rod-end pivot pin to the machine.
Lower the cylinder onto the outrigger.
may become unbalanced and fall
if not properly supported when the
pivot pin is removed from the
machine.

REV A OUTRIGGERS
How to Remove an Outrigger 5 Use a soft metal drift to remove the pivot pin.
Cylinder Crushing hazard. The cylinder will
Note: When removing a hose assembly or fitting, the pivot pin is removed from the
the O-ring on the fitting and/or hose end must be machine.
installation. Refer to Section 2, Hydraulic Hose and 5 Raise the cylinder to a vertical position.
Fitting Torque Specifications. 6 Remove the fasteners securing the outrigger
1 Extend the outrigger until the pad just touches cylinder rod-end pivot pin to the machine.
the ground. Do not rest the weight of the 7 Use a soft metal drift to remove the pivot pin.
machine on the outrigger. Remove the cylinder from the machine.
2 Tag, disconnect and plug the two hydraulic Crushing hazard. The cylinder will
supply hoses at the outrigger cylinder. Cap the fall if not properly supported when
fittings. the pivot pin is removed from the
Bodily injury hazard. Spraying machine.
squirt or spray.
kinked or pinched.
the barrel end of the outrigger cylinder. Support
the cylinder. Do not apply any lifting pressure.
cylinder barrel-end pivot pin to the chassis.


June 2007 Section 5 • Troubleshooting
Troubleshooting
Before Troubleshooting:
Read, understand and obey the safety 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.
Observe and Obey:
Be aware of the following hazards and follow
Troubleshooting and repair procedures shall be generally accepted safe workshop practices.
completed by a person trained and qualified on
Crushing hazard. When testing
the repair of this machine.
or replacing any hydraulic
Immediately tag and remove from service a component, always support
damaged or malfunctioning machine. the structure and secure it
from movement.
Repair any machine damage or malfunction
before operating the machine. Electrocution hazard. Contact
with electrically charged circuits
Unless otherwise specified, perform each could result in death or serious
repair procedure with the machine in the injury. Remove all rings, watches
following configuration: and other jewelry.
· Machine parked on a firm, level surface
· Boom in the stowed position hydraulic oil can penetrate and
· Key switch in the off position with the key burn skin. Loosen hydraulic
removed connections very slowly to allow
· Wheels chocked
squirt or spray.
General Repair Process
Malfunction Identify Troubleshoot

discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Section 5 • Troubleshooting June 2007
TROUBLESHOOTING REV A
1-1 Fault Code Diagnostics

Engine Fault Codes - When the engine ECM detects an abnormal
GTH-1048 and GTH-1056 operating condition, the ECM generates a fault
code that is stored in the ECM which may be
recalled by service personnel at a later time even if
When an engine malfunction is detected by the
the condition which caused the engine fault has
engine Electronic Control Module (ECM), a fault
ceased to exist. Multiple fault codes can be stored
code is recorded and the blink code light, located
simultaneously. These codes can give insight into
on the dashboard in the operator's compartment,
the problem area, but won’t necessarily specify the
will turn on.
underlying problem.
Warning Lamp
Access the Fault Codes
The ECM for the John Deere 4045T engine is
To access the fault codes, begin by turning the key
capable of detecting, storing and reacting to
switch to the off position. Then, press and hold the
abnormal engine operating conditions or faults.
Blink Code Enable button. While activating the
The presence of a fault is reported to the operator
BCE button, turn the key switch to the on position,
through the amber colored Warning Stop Engine
though do not activate the engine starter. Continue
Blink Code (BC) light located on the dash.
to activate the BCE button until the BC light begins
Depending upon the severity of the engine fault
to flash, approximately 7 seconds.
detected, the ECM may take steps to minimize
engine damage by reducing power output. Faults The BC light will begin to flash in a sequence
are also stored in the ECM and can be accessed which corresponds to the fault code stored the
by service personnel at a later time using the BC ECM memory. Once the service tech has noted all
light. the codes, turn the key switch to the off position.
Engine Protection Active Codes vs Stored Codes
When the engine is in operation and the ECM To aid the service tech over time, fault codes are
detects a warning condition, the BC light on the reported as active codes and stored codes. Active
dash will begin to flash. A warning condition is an fault codes indicate an engine condition or
engine fault in which a critical monitored engine conditions which have not been corrected; stored
parameter exceeds its normal operating values. If fault codes are the history of fault codes stored in
the engine operating conditions are not improved the ECM. Active fault codes are preceded by code
or if the conditions become more extreme, the 32; stored fault codes are preceded by code 33. If
warning condition may become a shutdown there are no engine faults being stored by the
condition. At this point, the BC light will no longer ECM, code 88 will also be displayed.
flash, but will remain brightly lit and the ECM may
begin a sequence of power reduction. The operator
is responsible for shutting down the machine to
prevent further damage to the engine.
The ECM will not detect all engine problems, nor is
the fault detection capability a substitute for regular
engine maintenance. Normal machinery operating
procedures should always be observed.
REV A TROUBLESHOOTING
How to Read the Fault Codes Example: If the ECM had no active faults to report,
though had stored codes 18 and 62 in memory, the
The flashing BC light, when combined with short or following flash sequence would be observed:
long pauses between the flash, tells the service
technician the specific fault coded detected by the Three quick flashes followed by a short pause…
ECM, if any. Code 32, for example, would appear two quick flashes followed by a long pause… eight
as three quick flashes followed by a short pause of quick flashes followed by a short pause… eight
two seconds, then two more quick flashes followed quick flashes followed by a long pause… three
by a long pause of four seconds. Code 33 would quick flashes followed by a short pause… three
appear as three quick flashes followed by a short quick flashes followed by a long pause... one quick
pause, then three more quick flashes followed by a flash followed by a short pause… eight quick
long pause. flashes followed by a long pause… six quick
flashes followed by a short pause… two quick
flashes followed by a long pause… the ECM would
then repeat the previous sequence.
Code and Description Code and Description

11 Analog throttle input high 63 Engine coolant temp high – moderately severe
12 Analog throttle input low 64 Engine oil pressure moderately low
18 Engine coolant temperature high 65 Engine oil pressure extremely low
19 Engine coolant temperature low 66 Manifold air temperature moderately high
21 Sensor supply voltage high 68 Fuel derate
22 Sensor supply voltage low 69 Engine coolant temperature high – most severe
23 Engine oil pressure input voltage high 71 Pump control valve closure too long
24 Engine oil pressure input voltage low 72 Pump control valve closure too short
25 Manifold air temperature input voltage high 73 Pump solenoid circuit open
26 Manifold air temperature input voltage low 74 Pump solenoid circuit severely shorted
28 ECM error 75 Pump control valve closure not detected
32 Signifies start of active fault codes 76 Pump solenoid circuit moderately shorted
33 Signifies start of previously active fault codes 77 Pump solenoid current high
37 Fuel temperature input voltage high 78 Security violation
38 Fuel temperature input voltage low 79 Internal ECM error
39 Crank position input noise/pattern error 81 Fuel temperature moderately high
42 Engine overspeed 82 Engine protection shutdown
54 ECM power down error 83 Auxiliary engine shutdown switch active
55 Can error 84 ECM power down error/external derate active
62 Engine coolant temperature high – least severe 88 Signifies that no fault codes are stored
1-2 Check the Main Valve

Hydraulic Pump 5 Tag and disconnect the 1.5 inch main valve
hose from the collector manifold at the top of
Symptom: the hydraulic tank. Drain the hose into a
Laboring engine; pump is constantly trying to build container.
pressure.
6 Place open end of hose into 5 gallon container.
Check the Pump 7 Start the engine.
1 Tag, disconnect and plug the smaller JIC hose Result: No fluid is draining from the hose. The
at the top of the hydraulic pump. main valve is good. Proceed to step 10.
Bodily injury hazard. Spraying Result: Fluid is draining from the hose. Inspect
hydraulic oil can penetrate and the main valve Y-plug. Proceed to the next
burn skin. Loosen hydraulic step.
the oil pressure to dissipate 8 Stop the engine. Remove the Y-plug from the
gradually. Do not allow oil to top of the main valve. Inspect for cracks, cuts
squirt or spray. or breaks in the o-ring or teflon ring.
2 Install a hose onto the open port and tighten. Result: Cracks, cuts or breaks are not
Place open end of hose into 5 gallon container. observed. The Y-plug is in good condition.
Proceed to the next step.
3 Start the engine and run for 1 minute.
Result: Cracks, cuts or breaks are observed.
4 Stop the engine. Measure the fluid. Replace the o-ring or teflon ring.
Result: Fluid volume is one gallon or less. The Bodily injury hazard. Spraying
pump is good. Proceed to step 5. hydraulic oil can penetrate and
Result: Fluid volume is greater than one gallon. burn skin. Loosen hydraulic
The pump is faulty. Replace the pump. connections very slowly to allow
squirt or spray.
9 Remove the manifold relief valve (schematic
item AD) from the main valve manifold. Inspect
for cracks, cuts or breaks in the seals.
Result: Cracks, cuts or breaks are not
observed. Replace the relief valve.
Result: Cracks, cuts or breaks are observed.
Replace the seals.
squirt or spray.
Check the Control Block Check the Pilot Pressure

10 Install a 0 to 3500 psi / 0 to 250 bar pressure 13 Stop the engine.
gauge into test port 2 at the side of the
14 GTH-636, GTH-644, GTH-842 and GTH-844:
hydraulic tank.
Install a 0 to 3500 psi / 0 to 250 bar pressure
Note: GTH-636, GTH-644, GTH-842 and gauge into test port 3 at the side of the
GTH-844: There are four test ports at the hydraulic hydraulic tank.
tank. Test port 1 is closest to the tank; test port 4 is GTH-1048 and GTH-1056: Install a
farthest from the tank. 0 to 3500 psi / 0 to 250 bar pressure gauge into
test port 5 at the side of the hydraulic tank.
Note: GTH-1048 and GTH-1056: There are six
test ports at the hydraulic tank. Test port 1 is 15 Check the pilot pressure. Start the engine and
closest to the tank; test port 6 is farthest from the allow the engine to idle.
tank.
Result:
The pressure gauge reads 500 psi / 34.5 bar.
The pressure setting is correct.
GTH-1048 and GTH-1056: The pressure
gauge reads 400 psi / 27.6 bar. The pressure
setting is correct.
Result: The pressure gauge shows a fluctuating
pressure reading. Proceed to the next step.
GTH-1048
GTH-636
GTH-644
Result: The pressure reading is
GTH-1056 GTH-842 200 psi / 13.8 bar or lower OR the pressure
GTH-844
reading is 1000 psi / 69 bar or higher. The
pressure reducing/relief valve (schematic item
a test port 6
b test port 4
FB) is faulty. Replace the valve.
c test port 3
d test port 1
16 Turn the engine off.
a b c d b c d
17 Tag, disconnect and plug the hydraulic hose
11 Check the steer pressure. Start the engine and from port C of the control block. Cap the fitting.
allow the engine to idle.
observe the reading on the pressure gauge. Result: The pressure gauge shows a fluctuating
pressure reading. The pressure reducing/relief
Result: The pressure gauge reads valve (schematic item FB) is faulty. Replace the
2250 psi / 155 bar. The pressure setting is valve.
correct.
Result: The pressure reading does not
Result: The pressure gauge shows a fluctuating fluctuate. Troubleshoot the parking brake or the
pressure reading. The steer relief valve joystick circuits.
(schematic item FC) is faulty. Replace the
valve.
Result: The pressure gauge reads less than
1000 psi / 69 bar. The steer relief valve
(schematic item FC) is faulty. Replace the
valve.
TROUBLESHOOTING REV B
1-3 3 Check the pilot pressure. Start the engine and

allow the engine to idle.
Boom Functions
Result:
Joystick (4-way) Circuit The pressure gauge reads 500 psi / 34.5 bar.
Symptom: The pressure setting is correct. Proceed to step
Slow or no boom functions 4.
GTH-1048 and GTH-1056: The pressure
Check the Pilot Pressure gauge reads 400 psi / 27.6 bar. The pressure
setting is correct. Proceed to step 4.
1 GTH-636, GTH-644, GTH-842 and GTH-844:
Install a 0 to 3500 psi / 0 to 250 bar pressure Result:
gauge into test port 3 at the side of the GTH-636, GTH-644, GTH-842 and GTH-844:
hydraulic tank. The pressure gauge fails to read
500 psi / 34.5 bar. Adjust or replace the
pressure reducing/relief valve (schematic item
FB). Refer to Repair Procedure 7-18, How to
Set the Boom System Pilot Pressure.
2 GTH-1048 and GTH-1056: Install a GTH-1048 and GTH-1056: The pressure
0 to 3500 psi / 0 to 250 bar pressure gauge into gauge fails to read 400 psi / 27.6 bar. Adjust or
test port 5 at the side of the hydraulic tank. replace the pressure reducing/relief valve
(schematic item FB). Refer to Repair Procedure
Note: There are six test ports at the hydraulic tank. 7-18, How to Set the Boom System Pilot
Test port 1 is closest to the tank; test port 6 is Pressure.
Result: The pressure reading is
200 psi / 13.8 bar or lower. The pressure
reducing/relief valve (schematic item FB) is
faulty. Replace the valve.
4 GTH-636, GTH-1048 and GTH-1056: Stop the
engine. Proceed to step 5.
GTH-644, GTH-842 and GTH-844: Stop the
engine. Proceed to step 13.
GTH-636
GTH-1048 GTH-644
GTH-1056 GTH-842
GTH-844
a test port 6
b test port 4
c test port 3
REV B TROUBLESHOOTING
Check the Controller Relief (drop block) 9 Tag and disconnect the two smaller hydraulic
Manifold hoses at the controller relief manifold. Connect
the hoses together and torque to specification.
5 Turn the key switch to the on position. Do not Refer to Section 2, Specifications.
start the engine.
Note: Do not remove the three larger hoses from
6 Using a wrench, check for magnetism in the the manifold.
solenoid valve of the controller relief manifold.
Touch a wrench to the end of the valve. 10 Start the engine and allow the engine to idle.
Test a boom function.
Result: The wrench sticks to the valve. The coil
is good. Proceed to step 9. Result: The boom functions correctly. The
controller relief valve (schematic item OA) is
faulty. Replace the valve.
Proceed to step 7.
Result: The boom does not function correctly.
Note: The controller relief manifold is secured to
The controller relief valve is good. Proceed to
the hoses inside the frame rail next to the
step 11.
operator's compartment.
11 Stop the engine.
Note: A fast way to determine if a valve coil is
functioning correctly is to touch a wrench to the 12 Install the hoses, disconnected in step 9, into
end of the valve when the coil is activated. When the controller relief manifold. Torque to
energized, the valve will magnetize and the wrench specification. Refer to Section 2, Specifications.
will stick to the valve; turn the power off and the Check the Joystick
wrench will fall.
13 Locate the hose installed into port P of the
7 Using a multimeter, check for power at the joystick. Tag the hose.
valve coil.
14 Tag, disconnect and plug all hydraulic hoses
Result: Power is present at the coil. Proceed to installed into the joystick except for the hose at
step 8. port P of the joystick.
Result: Power is not present at the coil. Repair 15 Start the engine and allow the engine to idle. Do
the wire circuit to the coil. not move the joystick.
8 Check for continuity in the ground wire circuit Result: Oil does not flow from any port. The
from the controller relief valve coil to ground. joystick is functioning correctly.
Result: The ground circuit has continuity. Result: Oil flows from one or more ports of the
Replace the valve coil. joystick. The joystick is faulty. Repair or replace
Result: The ground circuit does not have the joystick.
continuity. Repair the ground wire circuit to the
coil.
Check the Tilt Function 20 Using a multimeter, check for power at the
valve coils.
16 Stop the engine.
Result: Power is present at the coils. Proceed to
17 Turn the key switch to the on position. Do not step 21.
start the engine.
Result: Power is not present at the coil(s).
18 Locate the control relay under the joystick. Repair the wire circuit to the coil(s).
Check the relay for functionality.
21 Check for continuity in the ground wire circuit
Note: A fast way to determine if a relay is from the fork tilt valve coils to ground.
functioning correctly is to listen carefully when
activating the relay. When activated, the relay will Result: The ground circuit has continuity.
make a distinctive 'click' as the relay contacts Replace the valve coil(s).
switch internally.
Result: The ground circuit does not have
19 Activate the fork level functions and, using a continuity. Repair the ground wire circuit to the
wrench, check for magnetism in the solenoid coil(s).
valves of both fork tilt manifolds (schematic
items GA and GB). Touch a wrench to the end
of the valve.
is good. Replace the valve(s).
Result: The wrench does not stick to the
valve(s). Proceed to step 20.
Note: The fork tilt manifolds are the two manifolds
on the hydraulic tank located closest to the bottom
of the tank.

functioning correctly is to touch a wrench to the
end of the valve when the coil is activated. When
energized, the valve will magnetize and the wrench
will stick to the valve; turn the power off and the
wrench will fall.
Lift Not Functional 4 Lower the boom to the stowed position. Stop
the engine.
1 Tag and disconnect the hydraulic hoses at the
dual pilot check manifold. Cap the fittings on the 5 Replace the check valve at the barrel end of the
manifold. Connect together both hoses from the fork level cylinder (schematic item RA) OR
CA side of the manifold AND connect together troubleshoot the dual pilot check circuit.
both hoses from the CB side of the manifold. Bodily injury hazard. Spraying
Torque to specification. Refer to Section 2, hydraulic oil can penetrate and
Specifications. burn skin. Loosen hydraulic
Bodily injury hazard. Spraying connections very slowly to allow
hydraulic oil can penetrate and the oil pressure to dissipate
burn skin. Loosen hydraulic gradually. Do not allow oil to
connections very slowly to allow squirt or spray.
squirt or spray.
3 Activate the boom up function.
Result: The machine functions correctly.
Replace the check valves of the dual pilot
check valve manifold (schematic items CA and
CB) OR replace the dual pilot check valve
manifold.
Result: The machine does not function
correctly. Proceed to step 4.
Crushing Hazard. The load on the
forks could fall when lowering the
boom due to bypassing the fork
self-leveling function, resulting in
death or serious injury and
property damage. Do not allow
anyone to stand anywhere near
the area below or in front of the
boom when performing this
procedure.
Fork Rotate Function 4 Activate the fork rotate switch in the opposite
direction from step 3 and use a wrench to
Symptom: check for magnetism in the solenoid valve of
Fork rotates in one direction only (if equipped). the fork rotate manifold. Touch a wrench to the
valve.
1 Turn the key switch to the on position. Start the
engine. Result: The wrench sticks to the valve. The coil
is good. Replace the valve (schematic item LA).
2 Operate the manual over ride at both ends of
the fork rotate valve. Result: The wrench does not stick to the valve.
Repair or replace the wire circuit from the fork
Result: The machine functions correctly. tilt switch to the fork tilt valve coil OR replace
Proceed to step 3. the fork tilt switch OR replace the valve coil.
correctly. Remove air from the fork rotate
circuit. Refer to Repair Procedure 1-6, How to
Replace the Fork Rotate Cylinder Hoses.
3 Troubleshoot the fork rotate electrical circuit.
While activating the fork rotate function in one
direction, use a wrench to check for magnetism
in the solenoid valve of the fork rotate manifold.
Touch a wrench to the valve.
is good.
Repair or replace the wire circuit from the fork
tilt switch to the fork tilt valve coil OR replace
the fork tilt switch OR replace the valve coil.
functioning correctly is to touch a wrench to the
end of the valve when the coil is activated. When
energized, the valve will magnetize and the wrench
wrench will fall.

Fork Level Function Symptom B:

Forks self-level at a faster rate than the boom is
Symptom A: descending.
Forks self-level at slower rate than boom is
descending 1 Remove the load from the forks.
Check the Tilt Relief Valve 2 Start the engine and allow the engine to idle.
3 Level the forks.
4 Stop the engine.
2 Level the forks.
5 Tag and disconnect the two hydraulic hoses of
3 Stop the engine.
the boom from the tee fittings at ports C1 and
4 Tag and disconnect the hydraulic hoses at the C2 of the dual pilot check manifold. Cap the
tilt limiter manifold. Cap the fittings on the fittings.
manifold. Connect the hoses together and
Specifications.
6 Tag and disconnect the hydraulic hoses from
the fittings at ports V1 and V2 of the dual pilot
squirt or spray.
check manifold. Cap the fittings.
6 Activate the boom up and boom down hydraulic oil can penetrate and
functions. burn skin. Loosen hydraulic
Result: The machine functions correctly. the oil pressure to dissipate
Replace the relief valve of the tilt limiter gradually. Do not allow oil to
manifold (schematic item BA). squirt or spray.
Result: The machine does not function 7 Connect the hydraulic hose of port C1 to the
correctly. Troubleshoot the fork level cylinder hydraulic hose of port V1. Torque to
manifold components (schematic items RA, RB specification. Refer to Section 2, Specifications.
and RC) OR check the cylinder for internal
leakage. 8 Connect the hydraulic hose of port C2 to the
hydraulic hose of port V2. Torque to

10 Activate the boom up and boom down Fork Level Hose Blowout
functions.
1 Remove the load from the forks.
Result: The machine functions correctly.
Replace the check valves of the dual pilot 2 Tag and disconnect the hydraulic hoses from
check manifold (schematic items CA and CB). the boom at ports C1 and C2 of the dual pilot
check manifold. Plug the hoses.
correctly. Proceed to step 11. 3 Using a jumper hose, connect together ports C1
and C2 and torque to specification. Refer to
11 Separate the hoses connected together in steps Section 2, Specifications.
7 and 8, and install them into the correct ports
of the dual pilot check manifold. Torque to Bodily injury hazard. Spraying
specification. Refer to Section 2, Specifications. hydraulic oil can penetrate and
gradually. Do not allow oil to 4 Start the engine and allow the engine to idle.
squirt or spray.
5 Activate the boom down function and lower the
12 Start the engine and allow the engine to idle. boom to the stowed position.
13 Lower the boom to the stowed position. Note: Once the hoses are replaced, the circuit
must be bled. Refer to Repair Procedure 1-3, How
14 Stop the engine. to Bleed the Lift/Tilt Circuit.
15 Tag and disconnect the lower supply hose to
the lift cylinder at the exhaust side of the
machine.
squirt or spray.
17 Activate the boom down function.
Result: Fluid is leaking from the open port of the
cylinder. The cylinder has internal leakage.
Replace the seals inside the cylinder.

1-4 Symptom:
Back-up alarm doesn't work when transmission in
Drive Functions reverse.
Symptom: • Troubleshoot the back-up alarm and alarm

Machine won't drive. wiring.
If the back-up alarm operates:
• Troubleshoot ground wire connection on the

transmission mount at the cab side of the
machine.
• Troubleshoot clutch cut-off switch and switch
wiring. Remove black wires from clutch cut-off
pressure switch (under cab floor) and connect
together.
• Troubleshoot transmission shift coils and wiring.
If the back-up alarm does not operate:
• Check for faulty 20A fuse at top left of fuse

block.
If the sway function operates:
• Troubleshoot the parking brake relay and relay
wiring OR parking brake pressure switch and
wiring.
• Troubleshoot transmission controller and wiring.
If the sway function does not operate:
• Troubleshoot the boom limit switch and limit
switch wiring. With boom in stowed position,
look for 12V at yellow wire on the switch (to
calibrate the boom limit switch, refer to Repair
Procedure 1-1, How to Adjust the Limit Switch).

1-5 Check the Steer Selector Valve

Steer Functions 5 Start the engine.
Result: The wheels at one or both ends of the
How to Troubleshoot the Steering machine 'drift' after releasing the steering
wheel.
Check the Steer Orbitral
6 Adjust the wheels so that all wheels are parallel
1 Tag, disconnect and plug the hoses at orbitral with the length of the chassis.
ports T, R and L. Do not cap the fittings.
7 Turn off the engine.
hydraulic oil can penetrate and 8 Working inside the operator's compartment,
burn skin. Loosen hydraulic remove the fasteners securing the joystick
connections very slowly to allow inspection cover to the side console.
9 Remove the fasteners securing the steer
selector to the side console.
squirt or spray.
10 Tag and disconnect the hoses from the steer
2 Install the hose from port P into port L and
selector valve. Cap the fittings on the valve.
Specifications. Bodily injury hazard. Spraying
3 Start the engine. Do not move the steering
wheel.
Result: There is no flow from the open ports of the oil pressure to dissipate
the orbitral. The steer orbitral is functioning gradually. Do not allow oil to
correctly. squirt or spray.
Result: There is fluid flow from one or more of 11 Connect together the hoses from port EXH and
the ports of the orbitral. The steer orbitral is CYL 1, and torque to specification. Refer to
faulty and must be repaired or replaced. Section 2, Specifications.
4 Turn the machine off. Install the hoses onto the 12 Connect together the hoses from port PSI and
correct orbitral fitting and torque to CYL 2, and torque to specification. Refer to
specification. Refer to Section 2, Specifications. Section 2, Specifications.
13 Start the engine.

14 Activate the drive forward function. 24 Turn the steering wheel to the right, then turn
the machine off.
Result: The wheels at one or both ends of the
machine 'drift' and the machine will not drive in Result: Fluid does not flow from the open fitting
a straight line without steering correction. The on the steer cylinder. The cylinder is operating
steer selector valve is operating correctly. correctly.
Result: The wheels do not 'drift' and the Result: Fluid flows from the open fitting on the
machine drives in a straight line. The steer steer cylinder. The cylinder is faulty and must
selector valve is faulty and must be repaired or be repaired or replaced.
replaced.
25 Install the hose, disconnected in step 22, onto
15 Turn off the engine. the cylinder and torque to specification. Refer to
Section 2, Specifications.
16 Disconnect the steer selector valve hose from
one another and install them into the correct 26 Start the engine.
ports of the steer selector valve, and torque to
27 Turn the steering wheel to the left until the
wheels turn fully to the left, then turn the
17 Install the steer selector into the side console. machine off.
Install and securely tighten the fasteners.
28 Tag, disconnect and plug the return hose at the
18 Install the joystick inspection cover to the side cylinder. Do not cap the fitting.
console. Install and securely tighten the
fasteners.
30 Turn the steering wheel to the left, then turn the
Check the Front Steer Cylinder
machine off.
Result: Fluid does not flow from the open fitting
20 Move the steer selector to two-wheel steer. on the steer cylinder. The cylinder is operating
correctly.
21 Turn the steering wheel to the right until the
wheels turn fully to the right, then turn the Result: Fluid flows from the open fitting on the
machine off. steer cylinder. The cylinder is faulty and must
be repaired or replaced.
cylinder. Do not cap the fitting. 31 Install the hose, disconnected in step 28, onto
the cylinder and torque to specification. Refer to
23 Start the engine. Section 2, Specifications.

Check the Rear Steer Cylinder 43 Turn the steering wheel to the left, then turn the
machine off.
33 Move the steer selector to oblique steer. on the steer cylinder. The cylinder is operating
34 Turn the steering wheel to the right until the correctly.
wheels turn fully to the right, then turn the Result: Fluid flows from the open fitting on the
machine off. steer cylinder. The cylinder is faulty and must
35 Tag, disconnect and plug the return hose at the be repaired or replaced.
cylinder. Do not cap the fitting. 44 Install the hose, disconnected in step 41, onto
36 Start the engine. the cylinder and torque to specification. Refer to
37 Turn the steering wheel to the right, then turn
the machine off.
on the steer cylinder. The cylinder is operating
correctly.
Result: Fluid flows from the open fitting on the
steer cylinder. The cylinder is faulty and must
be repaired or replaced.
38 Install the hose, disconnected in step 35, onto
the cylinder and torque to specification. Refer to
40 Turn the steering wheel to the left until the
wheels turn fully to the left, then turn the
machine off.
cylinder. Do not cap the fitting.

1-6 Parking Brake

Brake Functions Symptom:
Parking brake does not hold OR does not release
Service Brakes 1 Locate the parking brake manifold.
Symptom:
Note: The parking brake manifold is the outboard
Brakes dragging (not releasing)
of the two manifolds located inside the frame rail
1 Tee in a 0 to 1000 psi / 0 to 100 bar pressure next to the operator's compartment.
gauge at port A of the brake actuator at the
2 Tag, disconnect and plug the hydraulic hoses at
brake pedal assembly.
ports 1 and 2 of the parking brake manifold.
2 Start the engine and allow the engine to idle. Do Cap the fittings.
not touch the brake pedal.
Result: The gauge indicates 0 psi / 0 bar. The hydraulic oil can penetrate and
actuator is good. burn skin. Loosen hydraulic
Result: The gauge indicates more than the oil pressure to dissipate
0 psi / 0 bar. The actuator is faulty. Replace the gradually. Do not allow oil to
brake actuator. squirt or spray.
Symptom: 3 Install a hose measuring 3 feet / 1 m into each
Brakes slow to apply OR apply too quickly port and tighten.
1 Tee in a 0 to 1000 psi / 0 to 100 bar pressure 4 With the open ends of both hoses into a 5
gauge at port A of the brake actuator at the gallon container, start the engine.
brake pedal assembly.
3 Press down on the brake pedal.
Result: The gauge indicates
600 to 650 psi / 41.4 to 44.8 bar. The actuator
is good.
Result: The gauge indicates less than
600 psi / 41.4 bar. The actuator is faulty.
Replace the brake actuator.
Result: The gauge indicates more than
650 psi / 44.8 bar. The actuator is faulty.
Replace the brake actuator.

Parking brake does not hold: 1-7

5 Activate the parking brake (parking brake on). Sway Functions
Result: Oil passes through port 2 and does not
Symptom:
pass through port 1. The manifold is functioning
When activating the sway function, the rear axle
correctly.
won’t move.
Result: Oil passes through port 1 and does not
pass through port 2. The manifold is faulty. Check the Boom Angle Limit Switch
Replace the manifold (schematic item IA). The GTH-636 is not equipped with
Parking brake does not release: a boom angle limit switch. To
troubleshoot the sway function on
6 Deactivate the parking brake (parking brake a GTH-636, begin this procedure
off). with step 7.
Result: Oil passes through port 1 and does not 1 Remove all weight from the forks.
pass through port 2. The manifold is functioning
correctly. The pilot pressure setting is too low. 2 GTH-1056: Lower the boom to below 55°. Turn
Calibrate the pilot pressure. the machine off.
All other models: Lower the boom to below
Result: Oil passes through port 2 and does not 60°. Turn the machine off.
pass through port 1. The manifold is faulty.
Replace the manifold (schematic item IA). 3 Turn the key switch to the on position. Do not
start the engine.
Note: Required maintenance procedures and
additional axle information is available in the Dana
212 Axle Maintenance and Repair Manual
(Dana part number MO212S20) OR the

(GTH-636, GTH-644, GTH-842 and GTH-844)

(GTH-1048 and GTH-1056)

4 Using a wrench, check for magnetism in the 6 Using a multimeter, check for power at the
solenoid valve of the boom activated rear terminal closest to the roller arm of the limit
lock-up manifold. Touch a wrench to the end of switch (grey wire).
the valve.
Result: Power is not present at the terminal.
Result: The wrench sticks to the valve. The The switch is functioning correctly. Repair or
boom angle limit switch wiring is reversed OR replace the grey wire of the limit switch wire
the switch is faulty. Proceed to step 5. harness from the limit switch to the boom
activated rear lock-up valve coil.
The wiring is functioning correctly. Proceed to Result: Power is present at the terminal. The
step 7. limit switch is not calibrated correctly OR the
limit switch is faulty. Calibrate the switch OR
Note: The boom activated rear lock-up manifold is
replace and calibrate the switch.
mounted on the hydraulic tank and is located
closest to the top of the tank at the cab side of the Check the Rear Lock-up Valve
machine.
7 Tag and disconnect the hydraulic hoses from
Note: A fast way to determine if a valve coil is ports 1 and 2 of the boom activated rear lock-
functioning correctly is to touch a wrench to the up manifold. Connect the hoses together and
end of the valve when the coil is activated. When torque to specification. Refer to Section 2,
energized, the valve will magnetize and the wrench Specifications.
wrench will fall.
5 Confirm that the yellow wire of the limit switch burn skin. Loosen hydraulic
wire harness is attached to the center terminal connections very slowly to allow
of the limit switch, and that the grey wire of the the oil pressure to dissipate
limit switch wire harness is attached to the gradually. Do not allow oil to
terminal closest to the roller arm. squirt or spray.
9 Activate the sway function.
Result: The machine functions correctly. Repair
or replace the boom activated rear lock-up
valve (schematic item DA).
correctly. Proceed to step 10.

10 Stop the engine. 13 Start the engine and allow the engine to idle.
11 Separate the hoses connected together in step Result:
7, and install them into the correct ports of the GTH-644, GTH-842 and GTH-844 and
boom activated rear lock-up manifold. Torque GTH-1056: The pressure gauge reads
to specification. Refer to Section 2, 3000 psi / 207 bar. The pressure setting is
Specifications. correct. Proceed to step 14.
GTH-1048: The pressure gauge reads
3500 psi / 241 bar. The pressure setting is
correct. Proceed to step 14.
connections very slowly to allow Result: The pressure is low. There is blockage
the oil pressure to dissipate in the hoses. Troubleshoot the hoses until
gradually. Do not allow oil to blockage is found.
squirt or spray.
14 Stop the engine.
Check the Rear Lock-up Manifold
15 Tee in a 0 to 3500 psi / 0 to 250 bar pressure
12 Tee in a 0 to 3500 psi / 0 to 250 bar pressure gauge at port C1 of the boom activated rear
gauge at port P of the boom activated rear lock-up manifold. Torque to specification. Refer
lock-up manifold. Torque to specification. Refer to Section 2, Specifications.
to Section 2, Specifications.
Bodily injury hazard. Spraying hydraulic oil can penetrate and
hydraulic oil can penetrate and burn skin. Loosen hydraulic
burn skin. Loosen hydraulic connections very slowly to allow
connections very slowly to allow the oil pressure to dissipate
the oil pressure to dissipate gradually. Do not allow oil to
gradually. Do not allow oil to squirt or spray.
squirt or spray.


Result: The pressure gauge is reads
500 psi / 34.5 bar. The pressure setting is
correct. Proceed to step 17.
Result: The pressure is less than
500 psi / 34.5 bar. The rear lock-up relief valve
(schematic item HH) is failing. Adjust the valve
OR replace the valve.
Result: The pressure is greater than
500 psi / 34.5 bar. Replace the rear lock-up
relief valve (schematic item HH).
17 Stop the engine.
18 Remove both pilot operated directional valves
(schematic items HF and HG) from the rear
lock-up manifold. Inspect the valves.
squirt or spray.
Result: Both valves do not have broken springs,
or damaged seals. Install the valves. Proceed
to step 19.
Result: The valve has a broken spring or a
damaged seal. The valve is faulty. Replace the
valve.
19 Remove all four check valves (schematic items
HA, HB, HC and HD) from the rear lock-up
manifold. Repair or replace the faulty valve(s).
squirt or spray.


June 2007 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey: Electrocution hazard. Contact with

Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
gradually. Do not allow oil to squirt
Read, understand and obey the safety rules
or spray.
and operating instructions in the appropriate
operator's manual on your machine. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction Identify Troubleshoot
discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Section 6 • Schematics June 2007
Electrical Component and Limit Switch Legends

REV A
ABBREVIATION LEGEND ABBREVIATION LEGEND ABBREVIATION LEGEND

Item Description Item Description Item Description
B1 Battery KS3 Key switch SW Switch
BN Button L Light or LED SW23 = Transmission control
BN3 = Cold start L30 = Head lights SW24 = Parking brake
BN5 = Horn L31 = Left rear turn/brake SW34 = Sway control
BN77 = Front axle differential lock L32 = Right rear turn/brake SW35 = Auxiliary control
BN99 = Pump destroke L59 = Right front turn signal SW36 = Wiper
BN100 = Fork level L60 = Left front turn signal SW37 = Turn switch
BN101 = Blink code enable L61 = Back-up SW38 = Heater
CB2 Circuit breaker, system power, 40A L62 = Brake/tail light SW39 = Outrigger - RF
CR Control relay L63 = Low brake pressure SW40 = Outrigger - LF
CR1 = Engine start L64 = Parking brake “On” TS Toggle switch
CR5 = Horn relay L65 = Blink code TS18 = Head light
CR22 = Head light LS2 Boom limit switch U Electronic component
CR88 = Fuse block M Motor U31 = Engine ECM
CR89 = Parking brake M3 = Engine starter U34 = Turn flasher
CR90 = Fork tilt M4 = Fuel pump U35 = 12V accessory plug
D1 Alternator M9 = Heater fan Y Solenoid valve coil
F Fuse M10 = Front wiper Y66 = Pump destroke
F18 = Power to blink code light M11 = Circulation fan Y67 = Parking brake
F19 = Power to ECM Q Solenoid Y68 = Front axle differential lock
FB1 Flashing beacons (option) Q7 = Fuel enrichment Y69 = Boom actuated lock-up
G Gauge Q8 = Fuel shut-off Y70 = Sway left
G1 = Volt meter PS Pressure switch Y71 = Sway right
G2 = Engine oil pressure PS4 = Clutch cut-off Y72 = Fork level
G3 = Engine coolant temperature PS5 = Brake light Y73 = Stabilizer right front down
G6 = Hour meter PS6 = Parking brake Y74 = Stabilizer right front up
G9 = Transmission oil pressure PS7 = Service brake low pressure Y75 = Stabilizer left front down
G10 = Transmission temperature S Sensor Y76 = Stabilizer left front up
G11 = Fuel level S1 = Engine coolant temperature Y77 = Controller relief
H Horn or alarm S2 = Engine oil pressure
H2 = Auto-style horn S11 = Transmission temperature
H3 = Back-up alarm S12 = Transmission pressure
S13 = Fuel level
a boom limit switch (all models except GTH-636)

(hidden from view)
(located on boom pivot between boom and chassis)
Electrical and Hydraulic Symbols Legend

REV B
Electrical Schematic Symbols Hydraulic Schematic Symbols
+ - NC
NO
COM
X
P
L 2 position 4 way
Battery solenoid valve
Boom up Flasher 3 position 4 way
limit switch solenoid valve with
1
manual override
2
3
2 position 3 way
Button 12V DC accessory solenoid valve
recepticle 2 position 2 way
Motors solenoid valve
40A
Relief valve
Circuit breaker
3 position 7 way
Pressure switch Diode steering valve
87
85
Pilot operated
86
30 check valve
BAT ACC
Relay Sensor ST
IGN
Pump
Counterbalance
Key switch vavle
T P
Flashing beacon, Hydraulic cylinder

Switch
LED or light 2 4 3 1
Joystick 1 2 3 4
Solenoid valves
Toggle switch Test ports

Gauge Pressure switch
D1 Adjustable orifice
10A Horn or alarm
Alternator
10 Amp fuse
Check valve
Accumulator
Electrical Schematic -
GTH-636 with John Deere Power REV C
Page 1 of 2
ALTERNATOR BATTERY
2/0 RED 2/0 BLK
12 RED
D1 16 RED + B1 - 16 WHT
12 RED
16 GRY
16 BRN 16 BRN
B 12 BLK 16 BLK 16 BLU

16 YEL
8 RED
16 GRN
16 RED 12 RED 16 BLU
16 WHT
FUEL PUMP A 12 BLK 16 BLK 12 BLK 12 BLK
M3 STARTER
M4 PS4
8 BLK 12 RED 16 YEL CLUTCH CUT-OFF
12 WHT
PRESSURE SWITCH
8 RED D 12 BLK 16 BLK
12 WHT TRANSMISSION SHIFT COILS
DESTROKE COIL COILS
12 RED 16 GRN DIRECTION GEAR
ACTIVATED
E 12 BLK 16 BLK 1 ADE
CR1 FORWARD 2 AE
Y66
12 GRN
12 PUR
STARTER
TRANSMISSION 3 A
RELAY
SHIFT COILS 1 BDE
REVERSE 2 BE
12 PUR 3 B
12 BLK 12 BLK
8 RED
WIRE COLOR 12 WHT
LEGEND 16 GRN
S12 TRANSMISSION PRESSURE SENDER
16 ORN
WHT / WHITE 16 GRN

16 BLU
RED / RED S1 ENGINE COOLANT TEMPERATURE SENDER 16 BLU
BLK / BLACK 16 GRY
16 GRY
BLU / BLUE
YEL / YELLOW
S2 ENGINE OIL PRESSURE SENDER 16 YEL
16 BRN 16 BRN
BRN / BROWN
GRN / GREEN
S11 TRANSMISSION TEMPERATURE SENDER
ORN / ORANGE
GRY / GRAY
PUR / PURPLE 12 RED
TAN / TAN 16 TAN
16 PINK
12 RED
16 WHT
16 GRY
LT BLU / LIGHT BLUE

16 PUR
16 BRN/WHT 16 BRN/WHT
12 PUR
12 GRY (UNUSED) 12 GRY
12 BLU (UNUSED) 12 BLU
16 BLK 16 BLK
BACK-UP
ALARM 16 WHT
H3 16 WHT
16 WHT 16 WHT
16 BRN/WHT
16 GRY
BACK-UP
LIGHT 16 RED 16 WHT
L61 16 BLK
16 BLK 16 BLK
16 BLK
16 PUR
16 RED
16 TAN
16 YEL
Y70 SWAY LEFT

PS5
16 PUR
16 PUR
BRAKE/TAIL LIGHT (WHT WIRE)
L62 16 RED 16 GRY

BRAKE LIGHTS
PRESSURE
MODELS 16 BLK Y71 SWAY RIGHT
(BLK WIRE)
16 BLK 16 BRN/WHT
SWITCH
WITH
CR5 MODELS
SINGLE JOYSTICK
16 ORG
16 RED
HORN
30 WITH
S13
SINGLE
12 RED
12 RED
12 RED
85 87A
FUEL
PS6 86
JOYSTICK
SENDER 87
16 BLK
PARKING BRAKE
PRESSURE
SWITCH
16 PINK
12 RED
12 RED
12 BLK
12 BLK
12 BLK
BN100 H2
12 RED
12 RED
FORK TILT
CR90
HORN
BUTTON
FORK TILT
30 20 RED
Y77 FORK TILT
85 20 BLK
CONTROLLER COILS 16 BLK 87A
RELIEF
Y72A Y72B 87
86
ES0447A
REV C GTH-636 with John Deere Power
Page 2 of 2
L30
HEAD LIGHTS
12 YEL 16 RED
16 BRN 14 WHT TS18 CR22 16 BLK
16 BLU 16 BLK 12 BLK HEAD LIGHT HEAD LIGHT RELAY 12 YEL
SWITCH
16 YEL 16 RED 12 BLK 12 BLK 16 BRN/WHT 12 YEL 16 RED
16 RED
16 GRN 87 16 BLK
85 16 GRN
CR88 16 YEL 86
FUSE BLOCK 30
RELAY
1 7 8 CB2
3
2 6
5 +
87
M9 HEATER FAN
SW38 HEATER
14 WHT
16 BLK
SW23 8 RED 12 RED BAT ACC 16 WHT 16 RED (LOW) 16 PUR
BAT.
40A ACC.
ST 86 85 16 BRN
TRANS 16 ORN (HIGH) 16 ORN
16 BLK
IGN 30
CONTROL 12 GRN
KS3 CAB HEATER
CR89
12 WHT
KEY SWITCH
(OPTION) 16 RED 16 BRN
8 YEL PARKING
BRAKE M11
16 ORN RELAY 8 RED CIRCULATION FAN
87A
16 BLK 16 ORN 16 BLK
86 85
L64 12 WHITE
20A 20A
16 BRN
PARKING BRAKE “ON” 30
12 BLK 16 RED 12 YEL
5A 20A
8 RED 12 RED 16 PUR
16 RED
16 RED
16 RED
16 RED
10A 10A
12 WHT G9 G3 G2 G6 16 PUR
5A 10A
16 ORN
TP ET EP HM
16 ORN 12 GRY 16 YEL
10A 10A
16 GRN 12 BLU
5A
16 BLU
16 BLK
FUSE BOX
16 RED
16 GRY FR AXLE
16 YEL 16 RED 12 PUR BN77 DIFF LOCK
U35
16 YEL
G10 G11
16 BRN 12 BLK
16 RED
TT FL 12V 16 BLK
ACCESSORY
G1 Y68
V 16 WHT
FRONT AXLE
12 RED TILT RELAY / 4-WAY ELEC. / DROP BLOCK / BRAKE LIGHT DIFFERENTIAL 16 BLK BN3
LOCK (OPTION) COLD START
16 TAN HORN BN5 16 BLK
16 PUR HORN RELAY COLD START (ETHER AID)

(JOHN DEERE MODELS)
16 BRN/WHT TAIL-LIGHT 16 BRN/WHT
12 PUR PUMP DESTROKE BN99 16 GRY / WHT M10
FRONT WIPER
12 GRY
16 GRY SW36
12 BLU AUXILIARY CONTROL SW35 P H L 16 GRY WIPER
12 GRY
16 BRN 16 ORN
16 BLK 16 BLU
16 GRY
16 WHT SWAY CONTROL SW34 FB1
16 RED 16 PUR
STROBE LIGHT 16 BLK
FROM MAIN HARNESS

X U34
“BRAKE LIGHTS PRESSURE SWITCH” P FLASHER
L
16 GRY - HOT
16 BLU
16 YEL
PS5 16 GRY/BLK
BRAKE LIGHTS
PRESSURE
SWITCH
SW37 6 2 3
TURN SWITCH
L31 5 8 7 4
LEFT REAR L60
16 GRN
16 RED
16 GRY
16 BLK
TURN/BRAKE LIGHT LEFT FRONT

TURN SIGNAL
16 RED
16 BLK
16 RED
16 BLK
MODELS 16 BRN/WHT
WITH
16 RED
16 RED
16 BLK
16 BLK
SINGLE
JOYSTICK L59
RIGHT FRONT
L32 TURN SIGNAL
RIGHT REAR
TURN/BRAKE LIGHT
ES0447A
GTH-636 with Perkins Power REV B
Page 1 of 2
Q7
COLD START ADVANCE
U32
16 ORN
8 RED
ALTERNATOR BATTERY
2/0 RED 2/0 BLK GLOW PLUGS
12 RED
D1 16 RED + B1 - S1B
16 WHT
12 RED
16 GRY
16 BRN 16 BRN
12 RED/WHT
INJECTION PUMP
16 RED/WHT
ADVANCE SENDER B 12 BLK 16 BLK 16 BLU
16 YEL
8 RED CR94 CR15 16 GRN
16 RED
LIFT PUMP COLD START 12 RED 16 BLU

STARTER 87 87
FUEL PUMP 85 RELAY 85 RELAY A 12 BLK 16 BLK 12 BLK 12 BLK
M3 86 86
M4 30 30
PS4
F9 CLUTCH CUT-OFF
8 BLK
12 RED 16 YEL
12 WHT
CR1 16 RED/BLK
20A
D 12 BLK 16 BLK
PRESSURE SWITCH
STARTER 16 GRN/WHT
CB3 TRANSMISSION SHIFT COILS
16 RED/BLK
RELAY
COILS
12 YEL 12 RED 16 GRN DIRECTION GEAR
ACTIVATED
50A
M4 FORWARD 2 AE
FUEL LIFT PUMP TRANSMISSION 3 A

SHIFT COILS
Y66
12 PUR
1 BDE
12 PUR
12 GRN
DESTROKE REVERSE 2 BE
COIL 3 B
12 BLK 12 BLK
8 RED 8 RED
12 WHT 12 WHT
16 RED/WHT
WIRE COLOR 16 WHT 16 ORN
LEGEND 16 GRN 16 GRN
WHT / WHITE S12 S1

16 BLU 16 BLU
TRANSMISSION 16 GRY
RED / RED PRESSURE
ENGINE COOLANT
TEMPERATURE SENDER
S2 16 GRY
BLK / BLACK SENDER ENGINE OIL PRESSURE SENDER 16 YEL
S11
BLU / BLUE 16 BRN 16 BRN
YEL / YELLOW TRANSMISSION
BRN / BROWN TEMPERATURE
SENDER
GRN / GREEN
16 PINK
ORN / ORANGE 16 BLU/WHT

GRY / GRAY
PUR / PURPLE
TAN / TAN
LT BLU / LIGHT BLUE
16 BLK 16 GRY 12 RED

BACK-UP
16 TAN
12 RED
ALARM
H3 16 WHT
16 PUR
16 WHT 16 WHT
12 PUR 12 PUR
BACK-UP
LIGHT 16 WHT 12 GRY
16 RED
L61 16 BLK
12 BLU
PS5
BRAKE LIGHTS
PRESSURE SWITCH 16 BLK
BRAKE/TAIL LIGHT 16 WHT

L62 16 RED 16 GRY
16 RED
16 YEL
16 BLK 16 BRN/WHT
MODELS
16 PUR
16 BLK
12 GRY (UNUSED) WITH

SINGLE JOYSTICK
16 ORG
16 RED
12 BLU (UNUSED)
16 PUR
16 PUR
16 TAN
16 BLK 16 BLK
S13 16 BLK
12 RED
12 RED
12 RED
FUEL
PS6 SENDER
PARKING BRAKE CR5 Y70

PRESSURE HORN SWAY LEFT (WHT WIRE)
SWITCH Y71
16 PINK
30
12 RED
12 RED
12 BLK
12 BLK
12 BLK
85 SWAY RIGHT (BLK WIRE)

BN100
87A
FORK TILT 87
86
MODELS
CR90 BUTTON
WITH
16 BLK
FORK TILT
Y77
12 RED
85
30 20 RED
SINGLE
CONTROLLER 16 BLK 87A 20 BLK
JOYSTICK
RELIEF
Y72A Y72B 87
86
H2
FORK TILT FORK TILT HORN
COIL COIL
ES0445A
REV B GTH-636 with Perkins Power
Page 2 of 2
L30
HEAD LIGHTS
12 YEL 16 RED
SWITCH
16 RED
16 GRN 87 16 BLK
85 16 GRN
CR88 16 YEL 86
FUSE BLOCK 30
RELAY
1 7 8 CB2
3
2 6
5 +
87
M9 HEATER FAN
SW38 HEATER
14 WHT
16 BLK
BAT.
40A ACC.
ST 86 85 16 BRN
16 BLK
IGN 30
CONTROL 12 GRN
KS3 CAB HEATER
CR89
12 WHT
KEY SWITCH
(OPTION) 16 RED 16 BRN
8 YEL PARKING
BRAKE M11
16 ORN RELAY 8 RED CIRCULATION FAN
87A
86 85
L64 12 WHITE
20A 20A
16 BRN
PARKING BRAKE “ON” 30
5A 20A
8 RED 12 RED 16 PUR
10A 10A
12 WHT 16 PUR 16 ORN
5A 10A
16 RED/WHT 12 GRY 16 YEL
16 RED
16 RED
16 RED
16 RED
10A 10A
G9 G3 G2 G6 5A
12 BLU
TP ET EP HM
16 ORN
FUSE BOX
16 GRN FR AXLE
16 BLU
12 PUR BN77 DIFF LOCK
16 BLK
U35
16 YEL
12 BLK
16 RED
16 GRY
12V 16 BLK
16 YEL 16 RED
ACCESSORY
16 BRN
G10 G11 Y68
16 RED
FRONT AXLE
TT FL
DIFFERENTIAL 16 BLK BN3
G1 LOCK (OPTION) 16 BLU/WHT COLD
V START
16 BLU/WHT 16 BLU/WHT
16 BRN/WHT
M10
FRONT WIPER
SW36
P H L 16 GRY WIPER
16 BRN 16 ORN
12 RED TILT RELAY / 4-WAY ELEC. / DROP BLOCK / BRAKE LIGHT 16 BLU
16 TAN HORN BN5 16 BLK 16 RED 16 PUR
16 PUR HORN RELAY
FB1 16 BLK
STROBE LIGHT
16 BRN/WHT TAIL-LIGHT FROM MAIN HARNESS
X U34
12 PUR PUMP DESTROKE BN99 16 GRY / WHT “BRAKE LIGHTS PRESSURE SWITCH”
L
P FLASHER
12 GRY 16 GRY - HOT

16 GRY
SW35
16 BLU
12 BLU AUXILIARY CONTROL 16 YEL

12 GRY PS5 16 GRY/BLK
BRAKE LIGHTS
PRESSURE
SW37
16 BLK SWITCH 6 2 3
16 GRY
16 WHT SWAY CONTROL SW34 TURN SWITCH
L31 5 8 7 4
LEFT REAR L60
16 GRN
16 RED
16 GRY
16 BLK

TURN SIGNAL
16 RED
16 BLK
16 RED
16 BLK
16 BRN/WHT
16 RED
16 RED
16 BLK
16 BLK
L59
RIGHT FRONT
L32 TURN SIGNAL
RIGHT REAR
TURN/BRAKE LIGHT
MODELS
WITH
SINGLE
JOYSTICK
ES0445A
GTH-644, GTH-842 and GTH-844 with John Deere Power REV C
Page 1 of 2
ALTERNATOR BATTERY
2/0 RED 2/0 BLK
12 RED
D1 16 RED + B1 - 16 WHT
12 RED
16 GRY
16 BRN 16 BRN

16 YEL
8 RED
16 GRN
16 RED 12 RED 16 BLU
16 WHT
FUEL PUMP A 12 BLK 16 BLK 12 BLK 12 BLK
M3 STARTER
M4 PS4
8 BLK 12 RED 16 YEL CLUTCH CUT-OFF
12 WHT
PRESSURE SWITCH
8 RED D 12 BLK 16 BLK
DESTROKE COIL COILS
ACTIVATED
CR1 FORWARD 2 AD
Y66
12 GRN
12 PUR
STARTER
TRANSMISSION 3 A
RELAY
SHIFT COILS 1 BDE
REVERSE 2 BD
12 PUR 3 B
12 BLK 12 BLK
8 RED
WIRE COLOR 12 WHT
LEGEND 16 GRN
16 ORN
WHT / WHITE 16 GRN

16 BLU
BLK / BLACK 16 GRY
16 GRY
BLU / BLUE
YEL / YELLOW
16 BRN 16 BRN
BRN / BROWN
GRN / GREEN
S11 TRANSMISSION TEMPERATURE SENDER 16 LT BLU
ORN / ORANGE
GRY / GRAY
PUR / PURPLE 12 RED
TAN / TAN 16 TAN
16 WHT
16 GRY
LT BLU / LIGHT BLUE

16 PUR
16 BRN/WHT
12 PUR
12 GRY (UNUSED)
12 BLU (UNUSED)
16 BLK
BACK-UP
ALARM 16 PINK
H3 16 WHT 12 YEL
16 PUR
16 WHT 16 WHT
16 ORG
16 RED
16 GRY
16 WHT
BACK-UP
12 BLK
16 BLK
16 YEL
16 TAN
LIGHT 16 RED
L61
16 PUR
16 PUR
16 BLK
16 BLK PS6
16 BLK PARKING BRAKE
BRAKE LIGHTS
PRESSURE SWITCH
CR5 PRESSURE
16 BLK HORN SWITCH
PS5
12 BLK
L63
30
S13
12 RED
12 RED
12 BLK
85
FUEL 87A
LOW
SENDER 86 16 PINK BRAKE
BRAKE/TAIL LIGHT 87
L62 16 RED 16 GRY
Y70 SWAY LEFT
(WHT WIRE)
PRESSURE
16 BLK
16 BLK
Y71 SWAY RIGHT
16 LT BLU
16 BLK 16 BRN/WHT
(BLK WIRE)
16 WHT
12 GRY
16 RED
16 RED
12 BLU
16 BLK
12 YEL
Y67
H2 PARKING BRAKE
VALVE
HORN
PS7
SERVICE BRAKE
MODELS WITH SINGLE JOYSTICK LOW PRESSURE
SWITCH
12 RED
12 RED
12 RED
12 RED
12 BLK
12 BLK
BN100
FORK TILT CR90
FORK TILT
87
SW35
86 AUXILIARY
FORK TILT 20 BLK 16 BLK
COILS
87A CONTROL
Y72A Y72B
20 RED
30
85
SW34
SWAY
CONTROL
ES0446A
REV C GTH-644, GTH-842 and GTH-844 with John Deere Power
Page 2 of 2
L30
HEAD LIGHTS
12 YEL 16 RED
SWITCH
16 RED
16 GRN 87 16 BLK
85 16 GRN
CR88 16 YEL 86
FUSE BLOCK 30
RELAY
1 7 8 CB2
3
2 6
5 +
87
M9 HEATER FAN
SW38 HEATER
14 WHT
16 BLK
BAT.
40A ACC.
ST 86 85 16 BRN
16 BLK
IGN 30
CONTROL 12 GRN
12 WHT
KS3 CAB HEATER
KEY SWITCH CR89 (OPTION) 16 RED 16 BRN
8 YEL PARKING
BRAKE M11
RELAY 8 RED CIRCULATION FAN
87A
16 ORN 16 BLK
86 85
12 RED 16 BRN
30 20A 20A
5A 20A
8 RED 12 RED 16 PUR
16 RED
16 RED
16 RED
16 RED
10A 10A
5A 10A
16 ORN
TP ET EP HM
10A 10A
12 WHT
16 GRN 12 BLU
5A
16 BLU
16 BLK
FUSE BOX
16 RED
16 GRY FR AXLE
BN77 DIFF LOCK
12 YEL
16 YEL 16 RED 12 PUR
U35
16 YEL
G10 G11
16 BRN 12 BLK
16 RED
16 LT BLU TT FL 12V 16 BLK

ACCESSORY
G1 Y68
V 16 WHT
FRONT AXLE
12 RED TILT RELAY / 4-WAY ELEC. / SWAY / AUXILLIARY / BRAKE LIGHT DIFFERENTIAL LOCK 16 BLK BN3
(STANDARD ON 842,844) COLD START
16 TAN HORN BN5 16 BLK (OPTIONAL ON 644)

(JOHN DEERE MODELS)
12 PUR PUMP DESTROKE BN99 16 GRY / WHT 12 GRY M10
FRONT WIPER
SW24 12 BLK
SW36
P H L 16 GRY WIPER
PARKING BRAKE SWITCH/LIGHT
16 BLK 12 BLK 16 BRN 16 ORN
16 BLU
(INTERNAL CONNECTION)
16 GRY / WHT 16 RED 16 PUR
16 PINK FB1 16 BLK
STROBE LIGHT
U34
12 YEL
X
FROM MAIN HARNESS
L
16 GRY - HOT
PS5
16 BLU
16 YEL
BRAKE LIGHTS 16 GRY/BLK
PRESSURE
SWITCH
SW37 6 2 3
TURN SWITCH
L31 5 8 7 4
LEFT REAR L60
16 GRN
16 RED
16 GRY
16 BLK

TURN SIGNAL
16 RED
16 BLK
16 RED
16 BLK
12 GRY 12 GRY 16 BRN/WHT

12 BLK 12 BLK
16 RED
16 RED
16 BLK
16 BLK
Y84 Y69
BOOM ACTUATED BOOM ACTUATED L59
SWAY LOCK-UP LOCK-UP VALVE RIGHT FRONT
L32 TURN SIGNAL
(MODELS WITH DUAL JOYSTICKS) RIGHT REAR
12 RED
12 GRY
12 YEL
TURN/BRAKE LIGHT
LS2
NO
NC COM
BOOM LIMIT SWITCH
ES0446A
GTH-644, GTH-842 and GTH-844 with Perkins Power REV B
Page 1 of 2
Q7
COLD START ADVANCE
U32
16 ORN
8 RED
ALTERNATOR BATTERY
2/0 RED 2/0 BLK GLOW PLUGS
12 RED
D1 16 RED + B1 - S1B
16 WHT
12 RED
16 GRY
16 BRN 16 BRN
12 RED/WHT
INJECTION PUMP
16 RED/WHT
ADVANCE SENDER B 12 BLK 16 BLK 16 BLU
16 YEL
8 RED CR94 CR15 16 GRN
16 RED
LIFT PUMP COLD START 12 RED 16 BLU

STARTER 87 87
16 WHT
FUEL PUMP 85 RELAY 85 RELAY A 12 BLK 16 BLK 12 BLK 12 BLK
M3 86 86
M4 30 30
PS4
F9 CLUTCH CUT-OFF
8 BLK
12 RED 16 YEL
12 WHT
CR1 16 RED/BLK
20A
D 12 BLK 16 BLK
PRESSURE SWITCH
STARTER 16 GRN/WHT
CB3 TRANSMISSION SHIFT COILS
16 RED/BLK
RELAY
COILS
12 YEL 12 RED 16 GRN DIRECTION GEAR
ACTIVATED
50A
M4 FORWARD 2 AD
FUEL LIFT PUMP TRANSMISSION 3 A

SHIFT COILS
Y66
12 PUR
1 BDE
12 PUR
12 GRN
DESTROKE REVERSE 2 BD
COIL 3 B
12 BLK 12 BLK
8 RED 8 RED
12 WHT 12 WHT
16 RED/WHT
WIRE COLOR 16 WHT 16 ORN
LEGEND 16 GRN 16 GRN
WHT / WHITE S12 S1

16 BLU 16 BLU
TRANSMISSION 16 GRY
RED / RED PRESSURE
ENGINE COOLANT
TEMPERATURE SENDER
S2 16 GRY
BLK / BLACK SENDER ENGINE OIL PRESSURE SENDER 16 YEL
S11
BLU / BLUE 16 BRN 16 BRN
YEL / YELLOW 16 LT BLU
TRANSMISSION
BRN / BROWN TEMPERATURE
SENDER
GRN / GREEN
ORN / ORANGE 16 BLU/WHT
GRY / GRAY
PUR / PURPLE
TAN / TAN 16 GRY 12 RED
LT BLU / LIGHT BLUE 16 TAN
16 PUR
16 BLK
12 PUR 12 PUR
BACK-UP
ALARM
H3 16 WHT
16 RED
16 WHT 16 WHT
BACK-UP
LIGHT 16 RED 16 WHT
L61 16 BLK
PS5
BRAKE LIGHTS
16 PUR
PRESSURE SWITCH 16 PINK

12 YEL
BRAKE/TAIL LIGHT
16 ORG
16 RED
L62 16 RED 16 GRY

16 PUR
16 PUR
16 TAN
16 WHT
L63
16 BLK
16 BLK 16 BRN/WHT
LOW
CR5
BRAKE
PS6
16 LT BLU
PRESSURE
12 GRY
12 RED
16 RED
12 BLU
12 BLK
16 YEL
HORN
16 BLK
12 GRY (UNUSED) 30 PARKING BRAKE
16 BLK PRESSURE
16 BLK 85
SWITCH
PS7
87A
12 BLU (UNUSED)
86
87
16 PINK
SERVICE BRAKE
Y70
16 BLK
LOW PRESSURE
SWAY LEFT S13 16 BLK SWITCH
(WHT WIRE) FUEL SW35
Y71 SENDER AUXILIARY
Y67 CONTROL
H2
SWAY RIGHT
(BLK WIRE) PARKING BRAKE
HORN VALVE
12 BLK
12 BLK
MODELS WITH SINGLE JOYSTICK

16 WHT
16 RED
16 BLK
12 YEL
12 RED
BN100 CR90
FORK TILT FORK TILT
87
Y72A Y72B 20 BLK
86
87A
16 BLK SW34
FORK TILT FORK TILT 85 SWAY
20 RED
COIL COIL 30 CONTROL
ES0444A

REV B GTH-644, GTH-842 and GTH-844 with Perkins Power
Page 2 of 2
L30
HEAD LIGHTS
12 YEL 16 RED
SWITCH
16 RED
16 GRN 87 16 BLK
85 16 GRN
CR88 16 YEL 86
FUSE BLOCK 30
RELAY
1 7 8 CB2
3
2 6
5 +
87
M9 HEATER FAN
SW38 HEATER
14 WHT
16 BLK
BAT.
40A ACC.
ST 86 85 16 BRN
16 BLK
IGN 30
CONTROL
12 WHT 12 GRN
KS3 CAB HEATER
8 YEL PARKING
BRAKE M11
87A
16 ORN 16 BLK
86 85
12 RED 16 BRN
30 20A 20A
5A 20A
8 RED 12 RED 16 PUR
10A 10A
12 WHT 16 PUR 16 ORN
5A 10A
16 RED/WHT 12 GRY 16 YEL
16 RED
16 RED
16 RED
16 RED
10A 10A
12 WHT
G9 G3 G2 G6 5A
12 BLU
TP ET EP HM
16 ORN
FUSE BOX
16 GRN FR AXLE
BN77 DIFF LOCK
12 YEL
12 PUR
16 BLU
16 BLK
U35
16 YEL
12 BLK
16 RED
16 GRY
12V 16 BLK
16 YEL 16 RED
ACCESSORY
16 BRN
G10 G11 Y68
16 RED
16 LT BLU FRONT AXLE

TT FL
DIFFERENTIAL LOCK 16 BLK BN3
G1 (STANDARD ON 842,844) 16 BLU/WHT COLD
V (OPTIONAL ON 644) START
16 BLU/WHT 16 BLU/WHT
16 BRN/WHT
12 RED TILT RELAY / 4-WAY ELEC. / SWAY / AUXILLIARY / BRAKE LIGHT
M10
16 TAN HORN BN5 16 BLK FRONT WIPER
16 PUR HORN RELAY
SW36
P H L 16 GRY WIPER
16 BRN/WHT TAIL-LIGHT 16 BRN 16 ORN
12 PUR PUMP DESTROKE BN99 16 GRY / WHT 12 GRY 16 BLU
16 RED 16 PUR
FB1 16 BLK
STROBE LIGHT
FROM MAIN HARNESS

X U34
SW24 12 BLK L
PARKING BRAKE SWITCH/LIGHT 16 GRY - HOT
16 BLK 12 BLK
16 BLU
16 YEL
PS5 16 GRY/BLK
(INTERNAL CONNECTION) BRAKE LIGHTS
16 GRY / WHT
PRESSURE
16 PINK
12 YEL
SWITCH
SW37 6 2 3
TURN SWITCH
L31 5 8 7 4
LEFT REAR L60
16 GRN
16 RED
16 GRY
16 BLK

TURN SIGNAL
16 RED
16 BLK
16 RED
16 BLK
12 GRY 12 GRY
16 BRN/WHT
12 BLK 12 BLK
16 RED
16 RED
16 BLK
16 BLK
Y84 Y69
BOOM ACTUATED
SWAY LOCK-UP
BOOM ACTUATED
LOCK-UP VALVE L59
RIGHT FRONT
(MODELS WITH DUAL JOYSTICKS) L32 TURN SIGNAL
12 RED
12 GRY
12 YEL
RIGHT REAR
TURN/BRAKE LIGHT
LS2
NO
NC COM
BOOM LIMIT SWITCH
ES0444A

GTH-644, GTH-842 and GTH-844 with Deutz Power REV B
Page 1 of 2
ALTERNATOR BATTERY
2/0 RED 2/0 BLK
12 RED
D1 16 RED + B1 - 16 WHT
12 RED
16 GRY
16 BRN 16 BRN

16 YEL
8 RED
16 GRN
16 RED STARTER
12 RED 16 BLU
A
12 WHT
FUEL SHUT OFF 12 BLK 16 BLK 12 BLK 12 BLK
M3 FUEL
Q8 12 BLK 12 BLK
ENRICHMENT PS4
1 CLUTCH CUT-OFF
Q7
12 RED 16 YEL
12 BLK PRESSURE SWITCH
2 D 12 BLK 16 BLK
8 BLK
DESTROKE COIL COILS

ACTIVATED
8 RED
CR1 FORWARD 2 AD
Y66
12 GRN
12 PUR
STARTER
TRANSMISSION 3 A
RELAY
SHIFT COILS 1 BDE
REVERSE 2 BD
12 PUR 3 B
12 BLK 12 BLK
8 RED
WIRE COLOR 12 WHT
LEGEND 16 GRN
16 ORN
WHT / WHITE 16 GRN

16 BLU
BLK / BLACK 16 GRY
16 GRY
BLU / BLUE
YEL / YELLOW
16 BRN 16 BRN
BRN / BROWN
GRN / GREEN
S11 TRANSMISSION TEMPERATURE SENDER 16 LT BLU
ORN / ORANGE
GRY / GRAY
PUR / PURPLE 12 RED
TAN / TAN 16 TAN
16 WHT
16 GRY
LT BLU / LIGHT BLUE

16 PUR
16 BRN/WHT
12 PUR
12 GRY (UNUSED)
12 BLU (UNUSED)
16 BLK
BACK-UP
ALARM 16 PINK
H3 16 WHT 12 YEL
16 PUR
16 WHT 16 WHT
16 ORG
16 RED
16 GRY
16 WHT
BACK-UP
12 BLK
16 BLK
16 YEL
16 TAN
LIGHT 16 RED
L61
16 PUR
16 PUR
16 BLK
16 BLK PS6
16 BLK PARKING BRAKE
BRAKE LIGHTS
PRESSURE SWITCH
CR5 PRESSURE
16 BLK HORN SWITCH
PS5
12 BLK
L63
30
S13
12 RED
12 RED
12 BLK
85
FUEL 87A
LOW
SENDER 86 16 PINK BRAKE
BRAKE/TAIL LIGHT 87
L62 16 RED 16 GRY
Y70 SWAY LEFT
(WHT WIRE)
PRESSURE
16 BLK
16 BLK
Y71 SWAY RIGHT
16 LT BLU
16 BLK 16 BRN/WHT
(BLK WIRE)
16 WHT
12 GRY
16 RED
16 RED
12 BLU
16 BLK
12 YEL
Y67
H2 PARKING BRAKE
VALVE
HORN
PS7
SERVICE BRAKE
MODELS WITH SINGLE JOYSTICK LOW PRESSURE
SWITCH
12 RED
12 RED
12 RED
12 RED
12 BLK
12 BLK
BN100
FORK TILT CR90
FORK TILT
87
SW35
86 AUXILIARY
FORK TILT 20 BLK 16 BLK
COILS
87A CONTROL
Y72A Y72B
20 RED
30
85
SW34
SWAY
CONTROL
ES0448A

REV B GTH-644, GTH-842 and GTH-844 with Deutz Power
Page 2 of 2
L30
HEAD LIGHTS
12 YEL 16 RED
SWITCH
16 RED
16 GRN 87 16 BLK
85 16 GRN
CR88 16 YEL 86
FUSE BLOCK 30
RELAY
1 7 8 CB2
3
2 6
5 +
87
M9 HEATER FAN
SW38 HEATER
14 WHT
16 BLK
BAT.
40A ACC.
ST 86 85 16 BRN
16 BLK
IGN 30
CONTROL 12 GRN
12 WHT
KS3 CAB HEATER
8 YEL PARKING
BRAKE M11
87A
16 ORN 16 BLK
86 85
12 RED 16 BRN
30 20A 20A
5A 20A
8 RED 12 RED 16 PUR
16 RED
16 RED
16 RED
16 RED
10A 10A
5A 10A
16 ORN
TP ET EP HM
10A 10A
12 WHT
16 GRN 12 BLU
5A
16 BLU
16 BLK
FUSE BOX
16 RED
16 GRY FR AXLE
BN77 DIFF LOCK
12 YEL
16 YEL 16 RED 12 PUR
U35
16 YEL
G10 G11
16 BRN 12 BLK
16 RED
16 LT BLU TT FL 12V 16 BLK

ACCESSORY
G1 Y68
V
FRONT AXLE
12 RED TILT RELAY / 4-WAY ELEC. / SWAY / AUXILLIARY / BRAKE LIGHT DIFFERENTIAL LOCK
(STANDARD ON 842,844)
16 TAN HORN BN5 16 BLK (OPTIONAL ON 644)
16 PUR HORN RELAY

12 PUR PUMP DESTROKE BN99 16 GRY / WHT 12 GRY M10
FRONT WIPER
SW24 12 BLK
SW36
P H L 16 GRY WIPER
PARKING BRAKE SWITCH/LIGHT
16 BLK 12 BLK 16 BRN 16 ORN
16 BLU
(INTERNAL CONNECTION)
16 GRY / WHT 16 RED 16 PUR
16 PINK FB1 16 BLK
STROBE LIGHT
U34
12 YEL
X
FROM MAIN HARNESS
L
16 GRY - HOT
PS5
16 BLU
16 YEL
BRAKE LIGHTS 16 GRY/BLK
PRESSURE
SWITCH
SW37 6 2 3
TURN SWITCH
L31 5 8 7 4
LEFT REAR L60
16 GRN
16 RED
16 GRY
16 BLK

TURN SIGNAL
16 RED
16 BLK
16 RED
16 BLK
12 GRY 12 GRY 16 BRN/WHT

12 BLK 12 BLK
16 RED
16 RED
16 BLK
16 BLK
Y84 Y69
BOOM ACTUATED BOOM ACTUATED L59
SWAY LOCK-UP LOCK-UP VALVE RIGHT FRONT
L32 TURN SIGNAL
(MODELS WITH DUAL JOYSTICKS) RIGHT REAR
12 RED
12 GRY
12 YEL
TURN/BRAKE LIGHT
LS2
NO
NC COM
BOOM LIMIT SWITCH
ES0448A

GTH-1048 and GTH-1056 with John Deere Power REV C
Page 1 of 2
TRANSMISSION SHIFT COILS

16 YEL 14 WHT
16 GRN 16 BLK
FWD REV 2 ND 1 ST
16 BRN 16 RED
16 BLU
16 BLU
16 BRN
16 YEL
16 GRN
UNSWITCHED ECU POWER PS4 3 2 8
16 BLK
CLUTCH 7 6
CUT-OFF 1 5
PRESSURE SW23
16 BLK
16 BLK
16 BLK
ALTERNATOR SWITCH TRANS
2/0 RED 2/0 BLK CONTROL
12 RED 12 BLK 12 BLK
D1 16 RED + -
B1
16 GRY
10 RED
BATTERY
10 BLK
8 RED
TRANSMISSION SHIFT COILS 16 GRN/WHT
16 WHT
COILS
M3 STARTER DIRECTION GEAR
ACTIVATED
16 BLU/WHT
1 F21 390 OHM

RESISTOR
FORWARD 2 F2 16 BRN/WHT
8 BLK
F19 10 AMP
FUSE
3 F 16 GRY/WHT
1 R21
8 RED 10A 16 ORN/WHT
REVERSE 2 R2
WIRE COLOR DESTROKE COIL 3 R
12 RED/BLK
LEGEND U31 R 390 OHM

12 RED/WHT
ENGINE RESISTOR
CR1
UR
WHT / WHITE
Y66 ECM S 16 WHT
12 GRN
12 PUR
16 P
RED / RED
STARTER
12 PUR
12 RED
BLK / BLACK RELAY C 16 YEL/WHT

BLU / BLUE L 16 GRN/WHT
YEL / YELLOW M 16 BLU/WHT
BRN / BROWN
P 16 BRN/WHT
GRN / GREEN
N 16 GRY/WHT
ORN / ORANGE
GRY / GRAY H 16 ORN/WHT
12 RED D
PUR / PURPLE G 12 RED/BLK SWITCHED & FUSED ECU POWER
16 RED J
TAN / TAN D 12 RED/WHT
LT BLU / LIGHT BLUE J 16 RED/WHT 16 RED/WHT
ENGINE ECU HARNESS
8 RED
16 GRN
16 ORN
16 GRN
16 BLU
S1 ENGINE COOLANT TEMPERATURE SENDER 16 BLU
16 GRY 16 GRY
16 BRN 16 BRN
S11 TRANSMISSION TEMPERATURE SENDER
12 RED
16 TAN
12 RED
16 PUR
16 BRN/WHT
12 PUR
12 GRY 12 GRY
12 BLU 12 BLU
16 BLK
BACK-UP 16 BLK 16 BLK
16 PUR
16 TAN
16 YEL
ALARM
16 ORG
16 RED
H3 16 WHT
16 WHT
16 WHT 16 WHT
MODELS
16 GRY
16 PUR
16 PUR
S13
BACK-UP
LIGHT
L61
16 RED 16 WHT PS6 FUEL WITH
SENDER
SINGLE
PARKING BRAKE
16 BLK CR5
PS5 PRESSURE
HORN
JOYSTICK
SWITCH
BRAKE LIGHTS 30
PRESSURE SWITCH
BRAKE/TAIL 86
87A
LIGHT
16 RED 16 GRY 85
L62 16 BLK 16 BRN/WHT
12 BLK
BN100 87 16 BLK
FORK TILT 16 BLK
12 RED
12 RED
16 PNK
12 BLK
12 BLK
16 BLK
BUTTON 16 BLK
CR90
Y77 FORK TILT
CONTROLLER
12 RED 30 20 RED
H2 Y70 SWAY LEFT
(WHT WIRE)
RELIEF VALVE FORK TILT 16 BLK 86 20 BLK HORN
Y71 SWAY
87A
COILS RIGHT
85
12 BLK
87 (BLK WIRE)
Y72A Y72B 12 RED

ES0450A

REV C GTH-1048 and GTH-1056 with John Deere Power
Page 2 of 2
14 WHT
16 BLK 12 RED/WHT
16 RED 12 RED/WHT
ACCELERATOR
PEDAL
A
B
C
16 YEL/WHT
16 GRN/WHT L30
HEADLIGHTS
16 BLU/WHT
TS18 CR22
12 YEL 16 RED
16 BLK
16 BRN/WHT HEAD LIGHT HEAD LIGHT RELAY 12 YEL
SWITCH
16 GRY/WHT
16 BRN/WHT 12 YEL 16 RED
16 ORN/WHT 16 RED
16 GRY/WHT
16 BRN/WHT
87 16 BLK
85 16 GRN
12 RED/BLK 16 BRN/WHT
F18
86
FUSE BLOCK 16 YEL 30
12 RED/WHT
10 AMP RELAY
16 ORN/WHT
FUSE 10A CR88 M9 HEATER FAN

SW38 HEATER
CB2 BN101
16 RED
87 16 RED (LOW) 16 PUR

12 RED + 12 RED BAT ACC 16 WHT 16 BLK BLINK
CODE 16 ORN (HIGH) 16 ORN
16 BRN
16 BLK
BAT.
40A ACC.
ST 86 85
IGN 12 RED/BLK ENABLE
30
16 RED/WHT KS3 BLINK
CODE L65
CAB HEATER
(OPTION)
8 RED
CR89 16 RED 16 BRN

14 WHT
KEY SWITCH LIGHT

8 YEL PARKING
BRAKE
8 RED M11
16 ORN CIRCULATION FAN
RELAY 87A
L64 86 85
12 RED 16 BRN
PARKING BRAKE “ON” 30 20A 20A
16 RED 12 YEL
16 RED/WHT 5A 20A
12 RED 16 PUR
16 RED
16 RED
16 RED
16 RED
10A 10A
8 RED G9 G3 G2 G6 16 PUR
5A 10A
16 ORN
TP ET EP HM
10A 10A
12 WHT
16 GRN 12 GRN 12 BLU

5A
16 BLU
16 BLK
FUSE BOX
16 RED
16 GRY FR AXLE
G10 TT G11
U35 16 YEL
16 RED
16 BRN 12 BLK
12 YEL
FL
G1 12V
ACCESSORY
16 BLK
V
Y68 16 WHT
12 RED TILT RELAY / 4-WAY ELEC. / DROP BLOCK / BRAKE LIGHT

FRONT AXLE
DIFFERENTIAL
16 BLK
BN3
16 TAN HORN BN5 16 BLK LOCK (OPTION) COLD START

(JOHN DEERE MODELS)
12 PUR PUMP DESTROKE 16 GRY / WHT M10

12 GRY
BN99 FRONT WIPER
SW36
16 GRY P H L 16 GRY WIPER
12 BLU AUX. CONTROL
SW35 12 GRY 16 BRN 16 ORN
16 BLU
16 GRY
SW34
16 BLK
12 YEL FB1 16 RED 16 PUR
16 WHT SWAY CONTROL STROBE LIGHT 16 BLK
FROM MAIN HARNESS X U34
SW39 "BRAKE PRESSURE SWITCH" P FLASHER
16 BRN R.F. STABILIZER CONTROL L
16 GRN 16 GRY - HOT
16 PUR
16 ORN L.F. STABILIZER CONTROL
16 GRN
PS5 16 YEL
16 BLU
SW40 BRAKE LIGHTS 16 GRY/BLK

SW40 12 GRY 12 GRY
PRESSURE LEFT FRONT
TURN SIGNAL
SWITCH
Y69 Y84 SW37 L60

L31 6 2 3
16 BRN/WHT
12 BLK 12 BLK LEFT REAR

BOOM ACTUATED BOOM ACTUATED TURN/BRAKE LIGHT TURN SWITCH
LOCK-UP VALVE SWAY LOCK-UP 5 8 7 4
16 RED
16 BLK
16 BRN
16 GRN
16 RED
16 GRY
16 BLK
16 RED
(MODELS WITH DUAL JOYSTICKS)

16 BLK
16 BLK
Y75 Y73
L.F. DOWN R.F. DOWN
12 RED
12 GRY
12 YEL
16 ORN 16 BLK
16 BLK
16 RED
16 PUR 16 BLK
LS2
16 BLK
16 BLK
16 RED
NO
Y76 Y74
NC COM
STABILIZER BOOM LIMIT SWITCH
L.F. UP VALVES R.F. UP
16 BLK
16 YEL L32 RIGHT REAR L59
TURN/BRAKE LIGHT RIGHT FRONT
ES0450A TURN SIGNAL

GTH-1048 and GTH-1056 with Perkins Power REV B
Page 1 of 2
Q7 TRANSMISSION SHIFT COILS

16 YEL 14 WHT
COLD START ADVANCE
U32
16 ORN
8 RED
16 GRN 16 BLK
ALTERNATOR BATTERY FWD REV 2 ND 1 ST
2/0 RED 2/0 BLK GLOW PLUGS 16 BRN 16 RED
12 RED
D1 16 RED + - S1B 16 BLU
16 BLU
16 BRN
16 YEL
16 GRN
B1
12 RED/WHT
INJECTION PUMP
16 RED/WHT
ADVANCE SENDER
3 2 8
16 BLK
7 6
CR94 CR15 1 5
8 RED
LIFT PUMP RELAY COLD START RELAY SW23
16 BLK
16 BLK
16 BLK
16 RED
STARTER TRANS
87 87 12 BLK 12 BLK CONTROL
FUEL PUMP 85 85
M3
PS4
16 WHT 86 86
M4 F9
30 30
CLUTCH
8 BLK
CR1 16 RED/BLK
20A CUT-OFF
PRESSURE
STARTER
16 GRN/WHT
CB3
16 RED/BLK
RELAY SWITCH
12 YEL
TRANSMISSION SHIFT COILS
16 GRY
50A
COILS
DIRECTION GEAR
ACTIVATED
12 RED M4 1 F21
FUEL
LIFT PUMP FORWARD 2 F2
Y66
16 WHT
12 PUR
12 PUR
12 GRN
3 F
DESTROKE
COIL 1 R21
REVERSE 2 R2
3 R
16 BLU/WHT
12 BLK 12 BLK
8 RED 8 RED
12 WHT 12 WHT
16 RED/WHT
WIRE COLOR 16 ORN

LEGEND 16 GRN
16 GRN
WHT / WHITE
S12 S1
16 BLU 16 BLU
RED / RED TRANSMISSION 16 GRY
BLK / BLACK PRESSURE
ENGINE COOLANT
TEMPERATURE SENDER
S2 16 GRY
SENDER ENGINE OIL PRESSURE 16 YEL

BLU / BLUE
SENDER 16 BRN
S11
16 BRN
YEL / YELLOW
BRN / BROWN TRANSMISSION
GRN / GREEN TEMPERATURE
SENDER
ORN / ORANGE
GRY / GRAY 12 RED
PUR / PURPLE 16 TAN
12 RED
TAN / TAN
16 PUR
LT BLU / LIGHT BLUE
16 BRN/WHT
12 PUR
12 GRY 12 GRY
12 BLU 12 BLU
16 BLK
BACK-UP 16 BLK 16 BLK
16 PUR
16 TAN
16 YEL
ALARM
16 ORG
16 RED
H3 16 WHT
16 WHT
16 WHT 16 WHT
MODELS
16 GRY
16 PUR
16 PUR
S13
BACK-UP
LIGHT
L61
16 RED 16 WHT PS6 FUEL WITH
SENDER
SINGLE
PARKING BRAKE
16 BLK CR5
PS5 PRESSURE
HORN
JOYSTICK
SWITCH
BRAKE LIGHTS 30
PRESSURE SWITCH
BRAKE/TAIL 86
87A
LIGHT
16 RED 16 GRY 85
L62 16 BLK 16 BRN/WHT
12 BLK
BN100 87 16 BLK
FORK TILT 16 BLK
12 RED
12 RED
16 PNK
12 BLK
12 BLK
16 BLK
BUTTON 16 BLK
CR90
Y77 FORK TILT
CONTROLLER
12 RED 30 20 RED
H2 Y70 SWAY LEFT
(WHT WIRE)
RELIEF VALVE FORK TILT 16 BLK 86 20 BLK HORN
Y71 SWAY
87A
COILS RIGHT
85
12 BLK
87 (BLK WIRE)
Y72A Y72B 12 RED

ES0449A

REV B GTH-1048 and GTH-1056 with Perkins Power
Page 2 of 2
14 WHT
16 BLK 12 BLK
16 RED 12 BLK
L30
HEADLIGHTS
TS18 CR22
12 YEL 16 RED
16 BLK
HEAD LIGHT HEAD LIGHT RELAY 12 YEL
SWITCH
16 BRN/WHT 12 YEL 16 RED
16 RED
87 16 BLK
85 16 GRN
8 RED 16 BRN/WHT
86
16 BLU/WHT 16 YEL 30
12 BLK KS3 CR88

CB2
KEY SWITCH FUSE BLOCK
87 RELAY
M9 HEATER FAN
SW38 HEATER
16 RED (LOW) 16 PUR
8 RED + 12 RED BAT ACC 16 WHT 16 BLK
16 ORN (HIGH) 16 ORN
16 BRN
16 BLK
BAT.
40A ACC.
ST 86 85
IGN
30
12 WHT 12 GRN CAB HEATER
CR89 (OPTION) 16 RED 16 BRN
14 WHT
16 RED/WHT 16 RED/WHT
8 YEL PARKING
BRAKE
M11
16 ORN CIRCULATION FAN
RELAY 87A 8 RED
L64 86 85
12 RED 16 BRN
PARKING BRAKE “ON” 30 20A 20A
16 RED 12 YEL
5A 20A
12 RED 16 PUR
16 RED
16 RED
16 RED
16 RED
10A 10A
G9 G3 G2 G6 16 PUR
5A 10A
16 ORN
TP ET EP HM
10A 10A
12 WHT
16 GRN 12 GRN 12 BLU

5A 5A
16 BLU
16 BLK
FUSE BOX
16 RED
16 GRY FR AXLE
G10 TT G11
U35 16 YEL
16 RED
16 BRN 12 BLK
Y68
12 YEL
FL
G1 FRONT AXLE
12V
ACCESSORY
16 BLK
V DIFFERENTIAL
LOCK (OPTION)
16 BLU/WHT
12 RED TILT RELAY / 4-WAY ELEC. / DROP BLOCK / BRAKE LIGHT
16 TAN HORN BN5 16 BLK 16 BLU/WHT
BN3
16 PUR HORN RELAY COLD
START
12 PUR PUMP DESTROKE 16 GRY / WHT M10

12 GRY
BN99 FRONT WIPER
SW36
16 GRY P H L 16 GRY WIPER
12 BLU AUX. CONTROL
SW35 12 GRY 16 BRN 16 ORN
16 BLU
16 GRY
SW34
16 BLK
12 YEL FB1 16 RED 16 PUR
16 WHT SWAY CONTROL STROBE LIGHT 16 BLK
FROM MAIN HARNESS X U34
SW39 "BRAKE PRESSURE SWITCH" P FLASHER
16 BRN R.F. STABILIZER CONTROL 16 GRN L
16 GRY - HOT
16 PUR
16 ORN L.F. STABILIZER CONTROL
16 GRN
PS5 16 YEL
16 BLU
SW40 BRAKE LIGHTS

PRESSURE
16 GRY/BLK
LEFT FRONT
12 GRY 12 GRY SWITCH TURN SIGNAL
Y69 Y84 SW37 L60

L31 6 2 3
16 BRN/WHT
12 BLK 12 BLK LEFT REAR

BOOM ACTUATED BOOM ACTUATED TURN/BRAKE LIGHT TURN SWITCH
LOCK-UP VALVE SWAY LOCK-UP 5 8 7 4
16 RED
16 BLK
16 BRN
16 GRN
16 RED
16 GRY
16 BLK
16 RED
(MODELS WITH DUAL JOYSTICKS)

16 BLK
16 BLK
Y75 Y73
L.F. DOWN R.F. DOWN
12 RED
12 GRY
12 YEL
16 ORN 16 BLK
16 BLK
16 RED
16 PUR 16 BLK
LS2
16 BLK
16 BLK
16 RED
NO
Y76 Y74
NC COM
STABILIZER BOOM LIMIT SWITCH
L.F. UP VALVES R.F. UP
16 BLK
16 YEL L32 RIGHT REAR L59
TURN/BRAKE LIGHT RIGHT FRONT
ES0449A TURN SIGNAL

P
6 - 18
TRANSMISSION DIFFERENTIAL
LOCK
T P
TILT JA
EXTENSION 4-WAY CONTROL 1
CYLINDER QA
CYLINDER (JOYSTICK) T 2
T1
RA 3
2 4 3 1 PARKING BRAKE
PS6 PARKING BRAKE
PRESSURE SWITCH
BOOM IA 250 psi / 17 bar
3 1
NORMALLY CLOSED
RB QB 2
RC UA AA 2
2000 psi GA T P P T
Section 6 • Schematics
BA 137.9 bar
1 FRONT AXLE
B A A B
TILT GB PS4
CA CB BRAKE CLUTCH CUTOFF
4 ACTUATOR PRESSURE SWITCH
AB 350 psi / 24 bar
NORMALLY CLOSED
(4) = 1200 psi / 82.7 bar
BRAKE
GTH-636 with Single Joystick
OA
ACCUMULATOR
Hydraulic Schematic -
P A
LIFT CONTROLLER
LIFT RELIEF T
CYLINDERS (DROP BLOCK)
AC
PA PB PS5
BRAKE LIGHTS
PRESSURE SWITCH
(1)= 2800 psi / 193 bar REAR AXLE NORMALLY OPEN
(2)= 2250 psi / 155 bar 1 2 3 (OPTION)
AD (3)= 500 psi / 34.5 bar
ROTATE HOSE REEL ROTATE
VALVE SA CYLINDER
P1 3650 psi
251 bar
MAIN VALVE MANIFOLD 0.040 in
EA LA
1 mm SB
G1
ROTATE SPEED
S FB G4
FA
PR C FORK ROTATE (OPTION)
FD
G3 G2
PRESSURIZED ST
FILTER/BREATHER
3 psi / 0.2 bar BK
FC R
TA
T1
RETURN FILTER T3 T2
PUMP
2800 psi
193 bar
HYDRAULIC
TANK
T A P
0.060 in STEERING
STEERING
PUMP CASE DRAIN MA 1.5 mm WHEEL
ORBITRAL
FRONT
SWAY 0.060 in STEER CYLINDER
DIRECTIONAL 1.5 mm
VALVE
NOTE: RT LT
ITEM ‘UA’ WAS REMOVED FROM
THE MACHINE AFTER SERIAL NUMBER
GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056

KA GTH0606A-9022 P T
KD STEER SELECTOR
STEER LEGEND
C1 C2
P TO T = 2WS
P TO C2 = 4WS
KB KC P TO C1 = OBLIQUE
SWAY
CYLINDERS REAR
STEER CYLINDER
P1-1846
REV C
June 2007
Part No. 97487

T P P
4-WAY CONTROL
REV A
(JOYSTICK) LOCK
TILT JA
CYLINDER EXTENSION T P 1
2 4 3 1
June 2007
QA 2
CYLINDER T1 4-WAY CONTROL T
RA 3
(JOYSTICK)
PARKING BRAKE
Part No. 97487

PS6 PARKING BRAKE
PRESSURE SWITCH
2 4 3 1
3 1
NORMALLY CLOSED
RB QB 2
RC UA AA 2
2000 psi
BA 137.9 bar
1 FRONT AXLE
TILT PS4
CA CB BRAKE CLUTCH CUTOFF
4 ACTUATOR PRESSURE SWITCH
AB 350 psi / 24 bar
NORMALLY CLOSED
(4) = 1200 psi / 82.7 bar
OA BRAKE
ACCUMULATOR P A
LIFT CONTROLLER
LIFT RELIEF T
CYLINDERS (DROP BLOCK)
AC
PA PB PS5
BRAKE LIGHTS
PRESSURE SWITCH
(1)= 2800 psi / 193 bar REAR AXLE NORMALLY OPEN
(2)= 2250 psi / 155 bar 1 2 3 (OPTION)
AD (3)= 500 psi / 34.5 bar
ROTATE HOSE REEL ROTATE
VALVE SA CYLINDER
P1 3650 psi
251 bar
MAIN VALVE MANIFOLD 0.040 in
EA LA
1 mm SB
G1
ROTATE SPEED
S FB G4
FA
PR C FORK ROTATE (OPTION)
FD
G3 G2
PRESSURIZED ST
FILTER/BREATHER
3 psi / 0.2 bar BK
FC R
TA
T1
RETURN FILTER T3 T2
PUMP
2800 psi
193 bar
HYDRAULIC
TANK
T A P
STEERING
0.060 in STEERING
PUMP CASE DRAIN MA WHEEL
1.5 mm ORBITRAL
FRONT
0.060 in STEER CYLINDER
1.5 mm
SWAY NOTE: RT LT
DIRECTIONAL ITEM ‘UA’ WAS REMOVED FROM
VALVE
THE MACHINE AFTER SERIAL NUMBER

KA GTH0606A-9022 P T
KD STEER SELECTOR
STEER LEGEND
C1 C2
P TO T = 2WS
P TO C2 = 4WS
KB KC P TO C1 = OBLIQUE
SWAY
CYLINDERS REAR
STEER CYLINDER
P1-1846
GTH-636 with Dual Joysticks

6 - 19
P
6 - 20
LOCK
T P
4-WAY CONTROL JA
EXTENSION 1
QA (JOYSTICK) 2
CYLINDER T
RA 3
TILT T1
2 4 3 1
CYLINDER PARKING BRAKE PARKING BRAKE
PS6 PRESSURE SWITCH
1 NORMALLY CLOSED
RB 2
QB 3
RC AA
GA T P P T
BA
FRONT AXLE
B A A B LOW BRAKE PRESSURE

TILT GB PRESSURE SWITCH
1000 psi / 69 bar BRAKE
CA CB NORMALLY CLOSED ACTUATOR
AB PS7
BRAKE
ACCUMULATOR P A
LIFT LIFT T
CYLINDERS PS4 PS5
CLUTCH CUTOFF PRESSURE SWITCH BRAKE LIGHTS
AC PRESSURE SWITCH
350 psi / 24 bar
NORMALLY CLOSED NORMALLY OPEN (OPTION)
PA PB
(1)= 3000 psi / 207 bar REAR AXLE

(2)= 2250 psi / 155 bar 1 2 3 4
GTH-844
AD (3)= 500 psi / 34.5 bar
(4)= 1250 psi / 86.2 bar
MODELS ROTATE HOSE REEL ROTATE
VALVE SA CYLINDER
P1 3650 psi
251 bar
0.040 in
MAIN VALVE MANIFOLD CONTROL BLOCK G4 LA
ROTATE 1 mm SB
MANIFOLD SPEED
S FA FB
C EA
PR
FD FORK ROTATE (OPTION)
G2
G3 ST
GTH-644, GTH-842 and GTH-844 with Single Joystick
PRESSURIZED R
FILTER/BREATHER
3 psi / 0.2 bar FC
T1
TA
BK G1 T3 T2
PUMP RETURN FILTER
3000 psi
207 bar
HYDRAULIC
CA CB TANK DA
T A P
0.060 in STEERING
STEERING
PUMP CASE DRAIN MA 1.5 mm WHEEL
ORBITRAL
B P C1 C2
FRONT
SWAY 0.060 in STEER CYLINDER
DIRECTIONAL 1.5 mm HD HC
VALVE
RT LT
T HF
NA HG
TANK
KA P T
S1 STEER SELECTOR

KD
STEER LEGEND
HH HB HA C1 C2
GTH-644 • GTH-842 HE P TO T = 2WS
MODELS C4 P TO C2 = 4WS
KB KC REAR LOCK-UP P TO C1 = OBLIQUE
S2 MANIFOLD C3
SWAY
CYLINDERS REAR
REAR
LOCK-UP
STEER CYLINDER
CYLINDERS
P1-1971
P1-1962
P1-1940
REV B
June 2007
Part No. 97487

P
T P
4-WAY CONTROL DIFFERENTIAL
TRANSMISSION
(JOYSTICK) LOCK
REV A
JA
EXTENSION T P 1
QA 2 4 3 1 2
CYLINDER 4-WAY CONTROL T
June 2007
RA 3
(JOYSTICK)
TILT T1
CYLINDER PARKING BRAKE PARKING BRAKE
PS6 PRESSURE SWITCH
Part No. 97487

2 4 3 1 IA
BOOM 250 psi / 17 bar
1 NORMALLY CLOSED
RB 2
QB 3
RC AA
BA
FRONT AXLE
LOW BRAKE PRESSURE
TILT PRESSURE SWITCH
1000 psi / 69 bar BRAKE
CA CB NORMALLY CLOSED ACTUATOR
AB PS7
BRAKE
ACCUMULATOR P A
LIFT LIFT T
CYLINDERS PS4 PS5
CLUTCH CUTOFF PRESSURE SWITCH BRAKE LIGHTS
AC PRESSURE SWITCH
350 psi / 24 bar
NORMALLY CLOSED NORMALLY OPEN (OPTION)
PA PB
(1)= 3000 psi / 207 bar REAR AXLE

(2)= 2250 psi / 155 bar 1 2 3 4
GTH-844
AD (3)= 500 psi / 34.5 bar
(4)= 1250 psi / 86.2 bar
MODELS ROTATE HOSE REEL ROTATE
VALVE SA CYLINDER
P1 3650 psi
251 bar
0.040 in
MAIN VALVE MANIFOLD CONTROL BLOCK G4 LA
ROTATE 1 mm SB
MANIFOLD SPEED
S FA FB
C EA
PR
FD FORK ROTATE (OPTION)
G2
G3 ST
PRESSURIZED R
FILTER/BREATHER
3 psi / 0.2 bar FC
T1
TA
BK G1 T3 T2
PUMP RETURN FILTER
3000 psi
207 bar
HYDRAULIC
CA CB TANK DA
T A P
STEERING
0.060 in STEERING
PUMP CASE DRAIN MA WHEEL
1.5 mm ORBITRAL
B P C1 C2
FRONT
VA
0.060 in STEER CYLINDER
1.5 mm HD HC
SWAY DIRECTIONAL VALVE
RT LT
T HF
NA HG
TANK
KA P T
KD S1 STEER SELECTOR

STEER LEGEND
HH HB HA C1 C2
GTH-644 • GTH-842 HE P TO T = 2WS
MODELS C4 P TO C2 = 4WS
KB KC REAR LOCK-UP P TO C1 = OBLIQUE
S2 MANIFOLD C3
SWAY
CYLINDERS REAR
REAR
LOCK-UP
STEER CYLINDER
CYLINDERS
P1-1971
P1-1962
P1-1940
GTH-644, GTH-842 and GTH-844 with Dual Joysticks

6 - 21
6 - 22
JA
DIFFERENTIAL
LOCK
EXTENSION
QA
CYLINDER T1 T P
TILT RA PARKING BRAKE
CYLINDER 4-WAY CONTROL
PRESSURE SWITCH
(JOYSTICK)
250 psi / 17 bar
PARKING
NORMALLY CLOSED
2 4 3 1 BRAKE
BOOM
RB QB 2 IA PS6
AA 3 1
RC UA
GA 2
2500 psi T P P T
172.4 bar 1
BA
FRONT AXLE
B A A B BRAKE
TILT FORK
GB OA ACCUMULATOR CLUTCH CUTOFF
CA CB 6 LEVEL BRAKE PRESSURE SWITCH
AB ACTUATOR 350 psi / 24 bar
NORMALLY CLOSED
(6) = 1200 psi / 82.7 bar CONTROLLER
RELIEF
(DROP BLOCK) PS4
LIFT P A
CYLINDERS LIFT T
AC
PS5
BRAKE LIGHTS
PRESSURE SWITCH
(1a)= 3500 psi / 241.3 bar GTH-1048 NORMALLY OPEN
(1b)= 3000 psi / 206.8 bar GTH-1056 REAR AXLE (OPTION)
12 3 4 5 6
(2)= 2250 psi / 155 bar
AD (3a)= 3500 psi / 241.3 bar GTH-1048
PA PB (3b)= 3000 psi / 206.8 bar GTH-1056
P1 (5)= 400 psi / 27.6 bar ROTATE HOSE REEL ROTATE
VALVE SA CYLINDER
3650 psi
GTH-1048 and GTH-1056 with Single Joystick
OUTRIGGERS 251 bar

0.040 in
MAIN VALVE MANIFOLD 1 mm
LA SB
G1 G4 ROTATE
SPEED
S FB
FA
EA
PR C
NA FORK ROTATE (OPTION)
PRESSURIZED FD
G3 G2
FILTER/BREATHER FC
3 psi / 0.2 bar ST
BK
TANK R
NB T1
TA T3 T2
RETURN FILTER
PUMP
T A P
STEERING STEERING
HYDRAULIC WHEEL
GTH-1048 ORBITRAL
TANK DA
3500 psi / 241 bar
GTH-1056 MA FRONT
3000 psi / 207 bar 0.060 in
STEER CYLINDER
PUMP CASE DRAIN 1.5 mm
B P C1 C2
RT LT
SWAY 0.060 in
DIRECTIONAL 1.5 mm
VALVE HD HC
P T

T HF STEER SELECTOR
STEER LEGEND
HG C1 C2
KA KD TANK P TO T = 2WS
P TO C2 = 4WS
S1 HA P TO C1 = OBLIQUE
HH HB
HE
KB KC
REAR
SWAY S2 C3 C4
STEER CYLINDER
CYLINDERS REAR LOCK-UP MANIFOLD
REAR LOCK-UP
CYLINDERS
P1-1871
REV C
June 2007
Part No. 97487

T P
REV A
4-WAY CONTROL JA
(JOYSTICK) DIFFERENTIAL
LOCK
June 2007
EXTENSION T P
QA 2 4 3 1
CYLINDER T1 4-WAY CONTROL
TILT RA PARKING BRAKE
(JOYSTICK)
Part No. 97487

CYLINDER PRESSURE SWITCH
250 psi / 17 bar
PARKING
NORMALLY CLOSED
2 4 3 1 BRAKE
BOOM
RB QB 2 IA PS6
AA 3 1
RC UA
2
2500 psi
172.4 bar 1
BA
FRONT AXLE
BRAKE
TILT OA ACCUMULATOR CLUTCH CUTOFF
CA CB 6 BRAKE PRESSURE SWITCH
AB ACTUATOR 350 psi / 24 bar
NORMALLY CLOSED
(6) = 1200 psi / 82.7 bar CONTROLLER
RELIEF
(DROP BLOCK) PS4
LIFT P A
CYLINDERS LIFT T
AC
PS5
BRAKE LIGHTS
PRESSURE SWITCH
(1a)= 3500 psi / 241.3 bar GTH-1048 NORMALLY OPEN
(1b)= 3000 psi / 206.8 bar GTH-1056 REAR AXLE (OPTION)
12 3 4 5 6
(2)= 2250 psi / 155 bar
AD (3a)= 3500 psi / 241.3 bar GTH-1048
PA PB (3b)= 3000 psi / 206.8 bar GTH-1056
P1 (5)= 400 psi / 27.6 bar ROTATE HOSE REEL ROTATE
VALVE SA CYLINDER
3650 psi
OUTRIGGERS 251 bar
0.040 in
MAIN VALVE MANIFOLD 1 mm
LA SB
G1 G4 ROTATE
SPEED
S FB
FA
EA
PR C
NA FORK ROTATE (OPTION)
PRESSURIZED FD
G3 G2
FILTER/BREATHER FC
3 psi / 0.2 bar ST
BK
TANK R
NB T1
TA T3 T2
RETURN FILTER
PUMP
T A P
STEERING STEERING
HYDRAULIC WHEEL
GTH-1048 ORBITRAL
TANK DA
3500 psi / 241 bar
GTH-1056 VA FRONT
3000 psi / 207 bar MA 0.060 in STEER CYLINDER
PUMP CASE DRAIN 1.5 mm
B P C1 C2
RT LT
0.060 in
1.5 mm
SWAY DIRECTIONAL VALVE HD HC
P T
T HF

STEER SELECTOR
STEER LEGEND
HG C1 C2
KA KD TANK P TO T = 2WS
P TO C2 = 4WS
S1 HA P TO C1 = OBLIQUE
HH HB
HE
KB KC
REAR
SWAY S2 C3 C4
STEER CYLINDER
CYLINDERS REAR LOCK-UP MANIFOLD
REAR LOCK-UP
CYLINDERS
P1-1871
GTH-1048 and GTH-1056 with Dual Joysticks

6 - 23

California Proposition 65
Warning
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
Genie North America

Phone 425.881.1800
Toll Free USA and Canada
Distributed By:
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.

Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie Scandinavia
Phone +46 31 575100 Genie China
Fax +46 31 579020 Phone +86 21 53852570
Fax +86 21 53852569
Genie France
Phone +33 (0)2 37 26 09 99 Genie Malaysia
Fax +33 (0)2 37 26 09 98 Phone +65 98 480 775
Fax +65 67 533 544
Genie Iberica
Phone +34 93 579 5042 Genie Japan
Fax +34 93 579 5059 Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Germany
Phone 0800 180 9017 Genie Korea
Phone +49 422 149 1818 Phone +82 25 587 267
Fax +49 422 149 1820 Fax +82 25 583 910
Genie U.K. Genie Brasil

Phone +44 (0)1476 584333 Phone +55 11 41 665 755
Fax +44 (0)1476 584334 Fax +55 11 41 665 754
Genie Mexico City Genie Holland

Phone +52 55 5666 5242 Phone +31 183 581 102
Fax +52 55 5666 3241 Fax +31 183 581 566
(GTH-636 from serial number GTH0606A-8418)
Service Manual
Part No.
97487
Rev D
(GTH-844 from serial number GTH0806B-6956)
GTH-636 • GTH-842•GTH-1048 (GTH-644 from serial number GTH0606B-6271)
(GTH-1048 from serial number GTH1006A-8418 to GTH1007A-11442)
GTH-644 • GTH-844•GTH-1056 (GTH-842 from serial number GTH0806A-8418)
(GTH-842 from serial number GTH0806B-6958)
(GTH-1056 from serial number GTH1006A-8418 to GTH1007A-11442)

Genie GTH 636 - 1056 - Service - Manual

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Parts Manual

GTH-1048 from GTH1006A-8418 to

GTH-1056 from GTH1006A-8418 to

Part No. 97487

Copyright © 2006 by Genie Industries

ii GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487

Serial Number Legend

SERIAL NUMBER: GTH0806A-8454

MANUFACTURE DATE: 02/20/06

TOTAL TRUCK WEIGHT(LBS): 22,010lbs / 9,984kg

MAX LIFT CAPACITY(LBS):

This page intentionally left blank.

iv GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487

Do Not Perform Maintenance

Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 v

Personal Safety Workplace Safety

vi GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487

Section 1 Safety Rules

Section 2 Rev Specifications

Section 3 Rev Scheduled Maintenance Procedures

Section 3 Rev Scheduled Maintenance Procedures, continued

Section 3 Rev Scheduled Maintenance Procedures, continued

Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 ix

Section 4 Rev Repair Procedures

x GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 Part No. 97487

Section 4 Rev Repair Procedures, continued

Part No. 97487 GTH-636 • GTH-644 • GTH-842 • GTH-844 • GTH-1048 • GTH-1056 xi

Section 5 Rev Troubleshooting

Section 6 Rev Schematics

This page intentionally left blank.

Fluid capacities Fuel tank 30 gallons

Hydraulic system 50 gallons

For operational specifications, refer to the

Tires and wheels All models

Tire size 13.00 x 24 Tire pressure 50 psi

Weight, rock lug tire 886 ±35 lbs

Tire ply rating 12

Weight, rough terrain tire 270 lbs

Weight, rough terrain tire 965 ±35 lbs

Weight, rough terrain tire 967 ±35 lbs

Weight, rock lug tire 982 ±35 lbs

Weight, rock lug tire 1013 ±35 lbs

Performance Specifications Boom function speeds, maximum

Drive speed, maximum GTH-644, GTH-842 and GTH-844

GTH-636 and GTH-842 18 mph Boom up 14 to 16 seconds

Lift capacity, maximum Boom down 13 to 15 seconds

GTH-636 and GTH-644 6000 lbs Boom extend 16 to 18 seconds

GTH-1048 and GTH-1056 10,000 lbs Chassis sway 11 to 13 seconds

Fork rotate 19 to 21 seconds

Continuous improvement of our products is a

Hydraulic Specifications Hydraulic Specifications

Cleanliness level, minimum 15/13 Water content, maximum 200 ppm

Optional Fluids Biodegradable Petro Canada Environ MV46

Function Pump Main Valve Manifold (all models)

GTH-636 System relief valve pressure, maximum 3650 psi

Flow rate @ 2500 rpm 0 to 35 gpm

Pump pressure 2800 psi GTH-636, GTH-644, GTH-842 and GTH-844

GTH-1048 Pilot relief valve pressure, maximum 400 psi

Flow rate @ 2500 rpm 0 to 35 gpm

Pump pressure 3500 psi GTH-636, GTH-644, GTH-842 and GTH-844

GTH-1048 and GTH-1056

Boom Extend Relief Manifold

GTH-636 (from serial number GTH0606A-8418 to