Terex Genie GTH-636 Operator's Manual
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Terex Genie GTH-636 Operator's Manual

Terex Genie GTH-636 Operator's Manual

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Operator's Manual
GTH
-636
™
from GTH636E-11750
with
Maintenance
Information
Third Edition
Fifth Printing
Part No. 1286012GT

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Summary of Contents for Terex Genie GTH-636

  • Page 1 Operator's Manual -636 ™ from GTH636E-11750 with Maintenance Information Third Edition Fifth Printing Part No. 1286012GT...

  • Page 2: Table Of Contents

    Load Charts ............67 Copyright © 2014 by Terex Corporation Third Edition: Fifth Printing, January 2020 Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “GTH” is a trademark of Terex South Dakota, Inc.

  • Page 3: Introduction

    Third Edition • Fifth Printing Operator's Manual Introduction Intr oducti on About this manual Intended Use Genie appreciates your choice of our machine for A variable reach rough terrain forklift truck is your application. Our number one priority is user defined as a wheeled type truck with a pivoting safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Third Edition • Fifth Printing Introduction Contacting the Manufacturer At times it may be necessary to contact Genie. When you do, be ready to supply the model number and serial number of your machine, along with your name and contact information. At minimum, Genie should be contacted for: Danger Accident reporting...
  • Page 5 Third Edition • Fifth Printing Operator's Manual Introduction Hazard Classification Standards Many aspects of rough terrain forklift operation and Decals on this machine use symbols, color coding, testing are discussed in standards published by and signal words to identify the following: the American National Standards Institute and the Industrial Truck Standards Development Safety alert symbol—used to alert...

  • Page 6: Symbol And Hazard Pictorials Definitions

    Operator's Manual Third Edition • Fifth Printing Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Electrocution hazard Maintain required Crush hazard No people under load Read the operator’s clearance manual Injection hazard Use a piece of Maintain required Crush hazard Always wear seat belt...
  • Page 7 Third Edition • Fifth Printing Operator's Manual Symbol and Hazard Pictorials Definitions Refer to load charts Do not sway when Crush hazard Keep away from Access by trained and and manual. boom is elevated. moving parts authorized personnel only Explosion / Burn No smoking.

  • Page 8: General Safety

    Operator's Manual Third Edition • Fifth Printing General Safety Gener al Safety ™ -636 Part No. 1286012GT...
  • Page 9 Third Edition • Fifth Printing Operator's Manual General Safety ™ Part No. 1286012GT -636...

  • Page 10: Work Area Safety

    Operator's Manual Third Edition • Fifth Printing Work Area Safety Work Ar ea Safety Tip-over Hazards If the telehandler starts to tip over: Using the appropriate load chart - Do not jump for the machine configuration, confirm that the load is within - Brace yourself and stay the rated capacity of the in the seat...
  • Page 11 Third Edition • Fifth Printing Operator's Manual Work Area Safety Traveling on Slopes Hazards Do not raise a load and then drive to position it. When driving, keep the boom at When driving, keep the boom at or below horizontal and keep or below horizontal and keep the the load close to the ground.
  • Page 12 Operator's Manual Third Edition • Fifth Printing Work Area Safety Construction sites and roads will frequently change Collision Hazards slope from place to place, can be hard and soft, and change due to construction activities and Keep people, equipment and weather.
  • Page 13 Third Edition • Fifth Printing Operator's Manual Work Area Safety Always make sure that mirrors and cab glass are Falling Object Hazards clean and do not obstruct the operators view of the Operate the machine at speeds that will keep the travel path or load.
  • Page 14 Operator's Manual Third Edition • Fifth Printing Work Area Safety Bodily Injury Hazards Damaged Machine Hazards Do not use a damaged or malfunctioning machine. Always adjust the seat and fasten the seat belt before Conduct a thorough pre-operation inspection of the starting the engine.
  • Page 15 Third Edition • Fifth Printing Operator's Manual Work Area Safety Component Damage Hazards Crush Hazards Do not use any battery or charger greater than 12V Keep clear of moving parts during machine to jump-start the engine. operation and make sure personnel and bystanders are kept clear of moving parts during Do not use the machine as a ground for welding.
  • Page 16 Operator's Manual Third Edition • Fifth Printing Work Area Safety Burn Hazards Electrocution Hazards This machine is not electrically insulated and will Allow hot surfaces to cool before not provide protection from contact with or touching or servicing. proximity to electrical current. Obey all local and governmental regulations regarding required clearance...
  • Page 17 Third Edition • Fifth Printing Operator's Manual Work Area Safety Explosion Hazards Always contact the electrical power line owner. The electrical power shall be disconnected or the Keep sparks, flames, and power lines moved or insulated before machine lighted tobacco away from operations begin.

  • Page 18: Legend

    Operator's Manual Third Edition • Fifth Printing Legend Legend Interior rear view mirror 14 Backup camera (if equipped) Left to right level indicator 15 Rear proximity alarm sensor (if equipped) Steering wheel 16 Fuel fill Control handle 17 Fuse panel Front to rear level indicator 18 Forks Exterior emergency exit (Safe T Punch) (if...

  • Page 19: Controls

    Third Edition • Fifth Printing Operator's Manual Controls Controls Control Panel Steering wheel Horn button Turn the steering wheel to the right to turn the Press this button and the horn will sound. front wheels to the right. Turn the steering Release the button and the horn will stop.
  • Page 20 Operator's Manual Third Edition • Fifth Printing Controls Turn signal lever (if equipped) 11 Auxiliary hydraulics thumb rocker Move the lever up to activate the left turn Push the auxiliary hydraulics thumb rocker to signal. Move the lever down to activate the the left and the carriage will swing or rotate to right turn signal.
  • Page 21 Third Edition • Fifth Printing Operator's Manual Controls 17 Brake pedal 22 Transmission control lever 18 Tilt steering pedal Move the transmission control lever toward you and move it up for forward gear. Move the Push and hold the tilt steering pedal to release lever toward you and move it down for reverse the steering column.
  • Page 22 Operator's Manual Third Edition • Fifth Printing Controls Instrument Panel Fuel level gauge with low fuel indicator light 12 Engine oil pressure low indicator light Turn signal indicator lights 13 Check engine indicator light Error code messaging 14 Engine stop indicator light Not used 15 Four-wheel steer indicator light Engine identification...

  • Page 23: Inspections

    Third Edition • Fifth Printing Operator's Manual Inspections Ins pections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 24 Operator's Manual Third Edition • Fifth Printing Inspections Pre-operation Inspection  Fuel and hydraulic tanks  Axles and transmission  Be sure that the operator’s and safety manuals  Boom wear pads are complete, legible and in the storage container located in the cab. ...
  • Page 25 Third Edition • Fifth Printing Operator's Manual Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 26 Operator's Manual Third Edition • Fifth Printing Inspections Function Tests Test the Steering Select a test area that is firm, level and free of 12 Push the right side of the steer selector switch hazards. Be sure there is no load on the forks to select four-wheel steer.
  • Page 27 Third Edition • Fifth Printing Operator's Manual Inspections 33 Move the transmission control lever to forward. Test the Ignition System Slowly let up on the brake pedal. As soon as the machine starts to move, push the brake 20 Set the transmission control lever in neutral pedal.
  • Page 28 Operator's Manual Third Edition • Fifth Printing Inspections 44 Set the parking brake, place the transmission into neutral and start the engine. Press and Test the Lights (if equipped) hold the brake pedal and place the 39 Verify that all lights are functional. transmission in reverse.
  • Page 29 Third Edition • Fifth Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 30 Part No. Decal Description 1257445 Cosmetic – Genie GTH-636 Determine whether the decals on your machine 1257446 Cosmetic – Genie GTH-636, Small have words or symbols. Use the appropriate inspection to verify that all decals are legible and in 1257759 Label – Load Chart, Standard place.
  • Page 31 Third Edition • Fifth Printing Operator's Manual Inspections Shading indicates decal is hidden from view, i.e. under covers ™ Part No. 1286012GT -636...
  • Page 32 Inspections Inspection for Decals with Part No. Decal Description Symbols 1257446 Cosmetic – Genie GTH-636, Small 1257759 Label – Load Chart, Standard Determine whether the decals on your machine 1257760 Label – Load Chart, Rotate have words or symbols. Use the appropriate 1257762 Label –...
  • Page 33 Third Edition • Fifth Printing Operator's Manual Inspections Shading indicates decal is hidden from view, i.e. under covers ™ Part No. 1286012GT -636...

  • Page 34: Operating Instructions

    Operator's Manual Third Edition • Fifth Printing Operating Instructions Operati ng Instr ucti ons Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety and responsibilities manuals.
  • Page 35 Third Edition • Fifth Printing Operator's Manual Operating Instructions Parking Brake Battery Disconnect Switch (if equipped) Use the parking brake switch to apply the parking brake before raising the boom or leaving the The battery disconnect switch is located on Inside machine.
  • Page 36 Operator's Manual Third Edition • Fifth Printing Operating Instructions Starting the Engine Emergency Exit (if equipped) Be sure the parking brake is set and the Rotate each retaining lever and push out the transmission control lever is in the neutral window.
  • Page 37 Third Edition • Fifth Printing Operator's Manual Operating Instructions Fire Extinguisher The transmission control lever also controls the transmission speed. To operate an extinguisher: To choose a lower speed, rotate the control lever Pull the pin clockwise. Aim nozzle at base of fire To choose a higher speed, rotate the control lever Squeeze the handle counterclockwise.
  • Page 38 Operator's Manual Third Edition • Fifth Printing Operating Instructions Frame Sway Control Models with 2-speed transmission Before raising the boom, the machine must be level. Check the left to right level indicator. The left to right level indicator should be 0 degrees before raising the boom.
  • Page 39 Third Edition • Fifth Printing Operator's Manual Operating Instructions Raising and Placing a Load Placing the load The load chart in the cab shows the operating Travel to the desired work site and carefully limits of a properly maintained and operated stop the machine.
  • Page 40 Operator's Manual Third Edition • Fifth Printing Operating Instructions Gradually move the controller to lower and When the forks are clear of the load and the extend the boom into final position. Lower the structure, the boom can be lowered and load until the weight is completely off the forks.
  • Page 41 Third Edition • Fifth Printing Operator's Manual Operating Instructions Controller movements – Electronic Control Handle Control handle only Yellow fork Black auxiliary Control handle with tilt roller (1) rocker (2) white finger switch (3) ™ Part No. 1286012GT -636...
  • Page 42 Operator's Manual Third Edition • Fifth Printing Operating Instructions Quick Attach Instructions Remove the quick attach lock pin. Tilt the forks forward to pivot the quick attach connector back. Position the boom so that the quick attach pin on the boom is below and centered between the hooks on the attachment.
  • Page 43 Third Edition • Fifth Printing Operator's Manual Operating Instructions After Each Use Jump Starting the Machine Select a safe parking location—firm level Jump starting at the battery or battery replacement surface, clear of obstruction and traffic. is required when the battery is discharged to the point where the battery will not crank the starter.
  • Page 44 Operator's Manual Third Edition • Fifth Printing Operating Instructions Driving on a slope Additionally, tip over of a machine is dependent in large part upon operator inputs such as the speed When the machine is loaded, always travel with and smoothness of the operation as well as the the load uphill.
  • Page 45 Third Edition • Fifth Printing Operator's Manual Operating Instructions Rear Proximity Alarm (if equipped) Always look in the direction of travel. When the rear proximity alarm sounds, bring the machine to The system is designed to supplement other safety a controlled stop and verify the location of the practices and systems such as signal person and obstacle.

  • Page 46: Transport And Lifting Instructions

    Operator's Manual Third Edition • Fifth Printing Transport and Lifting Instructions Trans port and Lifti ng Instr ucti ons  Before loading for transport, make sure the deck, ramps and machine tires are free of mud, snow and ice. Failure to do so could cause the machine to slide.
  • Page 47 Third Edition • Fifth Printing Operator's Manual Transport and Lifting Instructions Securing to Truck or Trailer for Transit Securing the Chassis Turn the key switch to the off position and remove Use chains of ample load capacity. the key before transporting. Use a minimum of 6 chains.
  • Page 48 Operator's Manual Third Edition • Fifth Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Determine the center of gravity of your machine using the picture on this page. Remove all loose items on the machine. Observe and Obey: Attach the rigging only to the designated lifting ...

  • Page 49: Maintenance

    Third Edition • Fifth Printing Operator's Manual Maintenance Maintenanc e Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level Observe and Obey: can damage engine components.
  • Page 50 Operator's Manual Third Edition • Fifth Printing Maintenance Check the Transmission Oil Level Diesel Fuel Requirements Satisfactory engine performance is dependent on Maintaining the proper transmission oil level is the use of a good quality fuel. The use of a good essential to good transmission performance and quality fuel will give the following result: long service life.
  • Page 51 Third Edition • Fifth Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Check the Batteries Maintaining the hydraulic oil at the proper level is Proper battery condition is essential to good essential to machine operation. Improper hydraulic machine performance and operational safety. oil levels can damage hydraulic components.
  • Page 52 Operator's Manual Third Edition • Fifth Printing Maintenance Check Mirrors and Rear Check the Tire Pressure Proximity Alarm System Tip-over hazard. An over-inflated tire can explode which may compromise machine Maintaining the indirect visual aids is essential to stability and cause the machine to tip over. workplace visibility.
  • Page 53 Third Edition • Fifth Printing Operator's Manual Maintenance Drain the Fuel/Water Separator Fuel/water separator Proper maintenance of the fuel filter/water separator is essential for good engine performance. Failure to perform this procedure can lead to poor engine performance and/or hard starting, and continued use may result in component damage.
  • Page 54 Operator's Manual Third Edition • Fifth Printing Maintenance Safety Chock for Cylinder Rod Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Before carrying out any maintenance or repair this machine according to the procedures found in procedures under a raised boom, install the the service manual for this machine.

  • Page 55: Attachments

    Third Edition • Fifth Printing Operator's Manual Attachments Attac hments Work Platform Hazards Always perform a pre-operation inspection of the platform, per the manufacturer’s instructions, prior Work Area Safety to use. If damage or any unauthorized variation from The telehandler shall not be used to lift people factory delivered condition is discovered, the unless there is no other practical option.
  • Page 56 Operator's Manual Third Edition • Fifth Printing Attachments Do not place or attach overhanging loads to any part of this machine or platform. Occupying the Platform Do not place ladders or Do not carry materials directly on platform railing scaffolds in the platform or unless approved by Genie.
  • Page 57 Third Edition • Fifth Printing Operator's Manual Attachments Telehandler Operation Lifting Personnel Be certain that the platform is securely attached to Occupants, equipment and the telehandler, lifting carriage and forks. materials shall not exceed the maximum platform Be certain that the lifting carriage and forks are capacity.
  • Page 58 Operator's Manual Third Edition • Fifth Printing Attachments Keep bystanders away while operating. Operating Instructions Do not place boom or platform against any structure to steady the platform or to support the Preparation and Setup structure. Read, understand and obey all jobsite, local, state, Do not use the controls to free a platform that is federal and provincial rules, standards and caught, snagged or otherwise prevented from...
  • Page 59 Third Edition • Fifth Printing Operator's Manual Attachments Installing and securing the Lifting and lowering the platform platform Set the parking brake and place the transmission into neutral. Center the platform on the telehandler. If equipped with stabilizers: Lower the stabilizers. Properly secure the platform to the telehandler according to the manufacturer’s instructions.
  • Page 60 Operator's Manual Third Edition • Fifth Printing Attachments Suspended Load Hazards A single shackle lifting point is rated for the maximum lifting capacity referenced on the load chart. It can be used as a single lift point, or both Work Area Safety lifting points can be used to suspend a load.
  • Page 61 Third Edition • Fifth Printing Operator's Manual Attachments In addition to ground personnel, the two chassis Identify the proper lifting points of the load, taking tie-down points in the front of the machine can be into consideration the center of gravity and load used to help externally stabilize the load.
  • Page 62 Operator's Manual Third Edition • Fifth Printing Attachments Collision Hazards Lifting a Suspended Load Be sure that the load is clear of any adjacent Verify that landing point is level and can safely obstacles before lifting. support the load. When visibility is or could be obstructed, near or at Properly secure the attachment to the telehandler.
  • Page 63 Third Edition • Fifth Printing Operator's Manual Attachments Traveling Placing the Load Be sure that the path of travel is level and capable Ask a signal person to assist with placing the load of supporting the telehandler with its load. if visibility will be obstructed at the point of operation.
  • Page 64 Operator's Manual Third Edition • Fifth Printing Attachments Signal Person (from 1926.1419) Per OSHA CFR 1926.1419, a signal person is required when: The point of operation, meaning the load travel or the area near or at load placement, is not in full view of the operator.
  • Page 65 Third Edition • Fifth Printing Operator's Manual Attachments STOP. With arm EMERGENCY STOP. With both arms extended HOIST. With upper arm RAISE BOOM. With extended horizontally to horizontally to the side, palms down, arms are extended to the side, arm extended the side, palm down, swung back and forth.
  • Page 66 Operator's Manual Third Edition • Fifth Printing Attachments Suspended Load Hazards Rigger Requirements (from OSHA CFR 1926.404) When employees are engaged in hooking, unhooking, or guiding the load, or in the initial connection of a load to a component or structure and are within the fall zone, all of the following criteria must be met: The materials being hoisted must be rigged to...

  • Page 67: Specifications

    Third Edition • Fifth Printing Operator's Manual Specifications Specific ati ons GTH-636 Tire size 13 x 28 Height, stowed 7 ft 10 in 2.39 m Turning radius (outside), 2 wheel steer 21 ft 1 in 6.43 m Length, stowed, without 17ft 10 in 5.44 m forks...
  • Page 68 Operator's Manual Third Edition • Fifth Printing Specifications Rear Proximity Sensor Range Approximate detection range. Minimum rear proximity sensor detection height is 2 ft/0.6 m. ™ -636 Part No. 1286012GT...

  • Page 69: Load Charts

    Third Edition • Fifth Printing Operator's Manual Load Charts Load Charts All Genie telehandler fork carriage load charts are Load Capacity Field Calculations based on a horizontal load center that is 24 in/61 cm from the front vertical surface of the Always center the load on the forks.
  • Page 70 Operator's Manual Third Edition • Fifth Printing Load Charts GTH-636 Standard Carriage GTH-636 Quick Attach Lifting Point GTH-636 Rotate Carriage GTH-636 Swing Carriage GTH™-636 Part No. 1286012GT Operator's M anual Third Edi tion • Fi fth Pri nting ™ -636 Part No.

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