to SN GTH0614H-10000, GTH-636 (PN 114104)
Contents
1. 4 6 OPERATION BEFORE OPERATING THE FORKLIFT A CAUTION If any gauge reading does not fall within the set tolerances the machine must be repaired before operation Check the dash mounted gauges for logical readings 1 Fuel 1 2 to Full O O QO 2 Transmission Oil Temp 180 F to 200 F 3 Transmission Oil PSI 240 to 280 PSI 9 O 4 Volt 12 to 14 d 5 Engine Water Temp 180 F to 200 F 6 Engine Oil PSI 40 to 80 PSI wander denn Men es smen st Oo EA STANDARD JOYSTICK FUNCTIONS Operate the joystick controller momentarily in all directions Boom Down Boom Up Boom Out Boom In Boom Down and Out Boom Up and In Boom Up and Out Boom Down and In COMMAS BUTTON DEPRESSED FUNCTIONS A Tilt Forward B Tilt Back 4 7 OPERATION CN A gt Operate the frame sway control A momentarily right and left A CXV ay I X CA YA 4 LY AY pe Check steering operation by turning steering wheel approximately 1 4 turn in each direction If the front and re2. Before ANYONE works on the hydraulic system A Lower the boom to the horizontal position Support the boom to avoid unintentional lowering Shutdown the engine Remove the key from the ignition Clean the area around the oil reservoir cap A Ne FLUIDS UNDER PRESSURE AN WARNING Escaping fluid under pressure can penetrate the skin and can cause serious personal injury Use a piece of cardboard or paper to search for leaks DO NOT use hands Before disconnecting hydraulic lines be sure to relieve all line pressure Before applying pressure to the system be sure that all connections are tight DO NOT apply pressure to a damaged line hose or fitting If injured by escaping fluid see a doctor at once Proper medical treatment must be administered immediately A serious infection or reaction can result without proper medical treatment SERVICE TIRES SAFELY AN WARNING An improperly mounted over pressurized tire can result in tire explosion causing possible personal injury An inflation cage or other safety device must be used during tire inflation DO NOT attempt to mount a tire unless you have the proper equipment and experience to perform the job If you do not have the proper qualifications to perform the job have your dealer or qualified repair service perform the repair 250 GENERAL SAFETY GENERAL SAFETY PR
3. N DANGER If the machine should start with the transmission control lever C in gear stop operation at once or property damage serious injury or death may occur Have a qualified service technician repair the machine Insert the ignition key in the ignition switch D Rotate the key clockwise until the engine starts Release the key when the engine starts 4 5 OPERATION AN CAUTION If the engine fails to start within 30 seconds release the key wait at least 2 minutes to allow the starter motor to cool before trying again If the engine fails to start after four attempts trouble shoot and correct the problem DO NOT turn the key if the engine is running This may cause damage to the starter motor IN CAUTION Attempting to start the engine by towing or pushing the machine will result in damage to the powershift transmission and will not start the engine It also is an unsafe practice that could cause personal injury
4. Lower the boom to the horizontal position Support the boom to avoid unintentional lowering Shutdown the engine Remove the key from the ignition Clean the area around the oil reservoir cap A E FLUID UNDER PRESSURE AN WARNING Escaping fluid under pressure can penetrate the skin and can cause serious personal injury Use a piece of cardboard or paper to search for leaks DO NOT use hands Before disconnecting hydraulic lines be sure to relieve all line pressure Before applying pressure to the system be sure that all connections are tight DO NOT apply pressure to a damaged line hose or fitting If injured by escaping fluid see a doctor at once Proper medical treatment must be administered immediately A serious infection or reaction can result without proper medical treatment WELDING PRECAUTIONS IN WARNING DO NOT weld on any structural member Any unauthorized welding can cause structural failure or possible personal injury All unauthorized welding or repair procedures will void the machine warranty Before performing any authorized welding be sure to discon nect the positive lead from the battery Properly attach the ground cable of the welder to the frame member that is being welded Failure to do so can cause electrical system damage 5 4 MAINTENANCE PROCEDURES DAILY MAINTENANCE SCHEDULED MAINTENANCE Maintenace performed quarter
5. IN WARNING Use the frame sway control to level the machine only when the boom angle indicator is at O degrees or less Using frame sway control when the angle indicator is more than degrees may cause the machine to overturn resulting in injury or death The frame sway control C 1s located on the dash panel The frame sway control is used in conjunction with the machine level indicator D located in the center of the cross support that the interior rear view mirror 15 mounted on The sway control switch is either toggled to the left or right depending on the particular requirement 3 7 CONTROLS AND INSTRUMENTS GAUGES The following gauges are used to monitor the machine 1 Fuel Level 2 Oil Temperature Powershift Transmission 3 Oil Pressure Powershift Transmission 4 Voltmeter 5 Water Temperature Engine 6 Oil Pressure Engine HYDRAULIC PUMP DESTROKE BUTTON A DANGER Depressing the pump destroke button while operating the machine will cause an immediate loss of hydraulic power possibly creating a very dangerous situation Hydraulic functions that will be affected are FORK TILT LIFT BOOM EXTEND and RETRACT PARKING BRAKE and SWAY None of these functions will operate as long as the button is depressed The service brakes will continue to funct
6. DANGER All tires require a calcium chloride ballast or an optional foam fill to be operated safely The loss of ballast can affect the machine s stability and cause a rollover hazard resulting in damage injury or death 5 6 SECTION 6 MATERIAL SAFETY DATA TABLE OF CONTENTS SECTION 6 MATERIAL SAFETY DATA Material Safety Data Sheets 6 3 California Proposition 65 Warnings 6 4 MATERIAL SAFETY DATA MATERIAL SAFETY DATA SHEETS MSDS The Federal Occupational Safety and Health Administration OSHA Standard 29 ctr 1910 1200 and in some cases State and local Right To Know laws may require specific MSDS be available to employees prior to operating this equipment This may include information on substances contained in the equipment such as antifreeze brake fluid battery acid and hydraulic fluid Genie will provide at no cost Material Safety Data Sheets which are applicable to their product line Simply request them from your local Genie dealer or contact us at Genie Industries PO Box 97030 Redmond WA 98073 9730 To ensure a prompt response please be sure to include your return address and zip code along with the machine model and serial number MATERIAL SAFETY DATA CALIFORNIA PROPOSITION 65 WARNINGS The following warnings are required on all off road equipment operating in the State of California If you are operating a Genie in the State of California and do not see the approved warning labels plea
7. Boom Down and In 3 4 CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS BUTTON PUSHED A Tilt Down B Tilt Back SH gt 3 5 CONTROLS AND INSTRUMENTS SERVICE BRAKES The brake pedal is the operator s control for the service brakes Pushing the service brake pedal A activates the service brakes for all four wheels The brakes should be applied during normal operation to stop machine movement PARKING BRAKE AN WARNING Failure to set the parking brake before leaving the machine may result in unintended machine movement and possible injury or death and or damage to the machine or property The parking brake should be engaged anytime the operator gets off the machine To engage the parking brake move handle B to the BRAKE ON position 3 6 CONTROLS AND INSTRUMENTS FRAME SWAY CONTROL A WARNING Always ensure that the machine level indicator D 1s at zero 0 degrees before raising the boom Raising the boom with an unlevel machine may cause the machine to overturn resulting in injury or death
8. A WARNING NEVER raise a load and drive to position 1t This can cause the machine to turnover When placing a load always move a loaded machine with the boom angle indicator B at O degrees or less When the machine is as close as possible to where the load needs to be placed set the parking brake raise the load then place the load into position The load chart shows the operating limits of a properly maintained and operated machine To use the load chart the operator must know the weight of the load and how far out and up it is to be placed If the load is heavier than stated on the load chart three options can be used 1 Move the machine closer to the load so that the weight of the load will fall within the load chart specifications 2 Divide the load into smaller pieces so that each piece falls into load chart specifications 3 Geta larger machine capable of handling the load within specifications 2 9 GENERAL SAFETY PROPER LOAD CHART USE A A TEREX COMPANY PO Box 97030 18340 NE 76th St Redmond WA 98073 Manufacturer s recommended capacity is per ANSI 56 6 Stability Tests using standard homogeneous cubes 4 x 4 x 4 ft 1 2x 1 2x 1 2 m Load capacities at 24 in 60 cm load center with standard fork frame Rated lift capacities shown are with machine on a firm level surface with undamaged properly inf
9. enie A TEREX COMPANY Operator s Manual GTH 636 with Maintenance Information First Edition Second Printing Part No 114104 TABLE OF CONTENTS SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY SECTION 1 1 Introduction 1 3 Standards And Symbols 1 4 Safety 1 5 Training And Knowledge 1 5 Operator s Responsibilities 1 6 Management s Responsibilities 1 7 Maintenance And Repair 1 8 Operation Safety 1 9 SECTION 2 GENERAL SAFETY 2 1 General Safety Procedures 2 3 Jump Starting 2 8 Proper Load Chart Use 2 9 SECTION 3 CONTROLS AND INSTRUMENTS 3 1 Operator s Compartment 3 3 Joystick Control Functions 3 4 Joystick Control Functions Button Pushed 3 5 Service Brakes 3 6 Parking Brake 3 6 Frame Sway Control 3 7 Gauges 3 8 Hydraulic Pump Destroke Button 3 8 Steering 3 9 Transmission 3 9 SECTION 4 OPERATION 4 1 Operation And Safety Guidelines 4 3 Before Starting The Engine 4 4 Starting The Engine 4 5 Before Operating The Forklift 4 7 Transporting A Load 4 11 Placing A Load 4 13 SECTION 5 MAINTENANCE PROCEDURES 5 1 General Safety Practices 5 3 Daily Maintenance 5 5 SECTION 6 MATERIAL SAFETY DATA SHEETS 6 1 SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY TABLE OF CONTENTS SECTION I ROUGH TERRAIN FORK LIFT SAFETY Introduction 1 3 Standards And Symbols 1 4 Safety 1 5 Training And Knowledge 1 5 Operator s Responsibilities 1 6 Management s Responsibilities 1 7 Maintenance And Repair 1 8 Operation Safety 1 9 ROUGH
10. obstructions cannot be cleared mark the obstructions with a stake or other marker that will be clearly visible to the operator DO NOT check the engine coolant level if the engine has recently been run Injury could occur from escaping hot pressurized coolant ALWAYS wear the seat belt when operating this machine ALWAYS inspect the machine daily Check for leaks worn hoses loose belts or anything out of the ordinary Repair and or replace any worn damaged or leaking parts immediately Failure to do so can cause injury or death CHECK to be sure that all guards and screens are secure and in their proper place CHECK to be sure that all safety devices such as parking brake service brake level gauge neutral start safety switch back up alarm and horn are functioning properly Always make sure mirrors are adjusted properly DO NOT travel on terrain or in dangerous areas that could cause the machine to tip over DO NOT attempt to start the engine by towing or pushing Damage to the powershift transmission could result CARRY A LOAD so that you have maximum machine stability and visibility is not obstructed ALWAYS level the machine as indicated on the machine level indicator before raising the boom Raising the boom with an unlevel machine may cause the machine to overturn causing injury or death USE the frame sway control to level the machine only when the boom position is horizontal or lower Using the frame sway control when the boom
11. TERRAIN FORK LIFT SAFETY A INTRODUCTION Owners Users and Operators Genie appreciates your choice of our machine for your application Our number one priority is user safety which 1s best achieved by our joint efforts We feel that you make a major contribution to safety 1f you as the equipment users and operators 1 Comply with OSHA Federal State and Local Regulations 2 Read Understand and Follow the instructions in this and other manuals supplied with this machine 3 UseGood Safe Work Practices in a common sense way 4 Only have trained certified operators directed by informed and knowledgeable supervision running the machine NOTE OSHA prohibits the alteration or modification of this machine without written manufacturer s approval Use only factory approved parts to service or repair this machine If there is anything in this manual that is not clear or which you believe should be added please contact us Internet www genieind com Email techpub genieind com Thank you THIS SYMBOL MEANS YOUR SAFETY IS INVOLVED READ UNDERSTAND AND FOLLOW ALL DANGER WARNING AND CAUTION DECALS ON YOUR ROUGH TERRAIN FORKLIFT A ROUGH TERRAIN FORK LIFT SAFETY A STANDARDS AND SYMBOLS STANDARDS Many aspects of rough terrain forklift operation and testing are discussed in standards published by the American National Standards Institute These Standards are updated on a regular basis with addendas Geni
12. should be used whenever transporting a load Always bring the machine to a complete stop before reversing the transmission control lever A Failure to do so can result in damage to the load the machine and or bystanders Always keep the boom retracted to ensure greater stability Always place the load in the center and completely against the back of the fork frame By doing so greater stability will result IMPORTANT Never attempt to use the forks and or attach ments for prying wedged or frozen loads free Damage to the load pallet and or machine could result OPERATION PLACING A LOAD A WARNING Do not sway the machine with the boom angle indicator arrow B at more than O degrees By doing so you could cause a roll over hazard which may result in injury or death A DANGER Always apply the parking brake C before lifting and or placing a load Failure to do so could allow the machine to roll over which may result in injury or death CAUTION Always bring the machine to a complete st
13. tank outdoors 11 Handle fuel with care as itis highly flammable Do not refuel the machine while smoking or near open flames iv Always clean up spilled fuel 6 Make sure the machine and access system 15 clean and free of dirt oil grease or debris 7 When getting on and off the machine face the machine use the steps and handrails provided and always maintain a three point contact 8 Always remain completely inside the cab enclosure while operating the machine 9 Always wear the seat belt while operating the machine 10 Always completely lower the boom with the forks resting on the ground before any work is performed on or around the machine 11 Do not operate the machine while people are under or near an elevated boom whether the boom 15 loaded or unloaded Falling objects from the forks or attachment may cause serious injury or death MROUGH TERRAIN FORK LIFT SAFETY 4 12 Maintain an appropriate clearance from electrical power lines See the chart below for minimum safe approach distances Minimum Safe Approach Distance Power Line Voltage Required Clearance 0 to 50 kV 10 ft 3 00 m 50 to 200 kV 15 ft 4 60 m 13 Lifting Loads i Using the load chart confirm that the load is within the rated capacity of the machine for the required configuration i Levelthe machine using the level gauge before lifting loads Use the sway control to level the machine only when the boom is at horizontal or lower Using the sw
14. with the first aid kit and fire extinguisher 2 3 GENERAL SAFETY GENERAL SAFETY PROCEDURES WELDING PRECAUTIONS AN CAUTION Any unauthorized welding can cause structural failure or possible personal injury DO NOT weld on any structural member All unauthorized welding will void the warranty HAND HOLDS AND STEPS A WARNING Slips and falls can cause serious injury When getting on and off the machine always maintain a three point contact with steps and hand rails while facing the machine DO NOT use the steering wheel or any other controls as handrails NEVER jump on or off the machine Be careful of slippery conditions on platforms steps and handrails when getting on and off the machine ALWAYS shut off the engine before leaving the operator s station REFUELING AN WARNING Fires can cause death or severe personal injury Handle fuel with care It is highly flammable DO NOT refuel the machine while smoking or when near open flames or sparks ALWAYS stop the engine before refueling the machine Fill the fuel tank outdoors Prevent fires by keeping the machine clean of trash grease and debris ALWAYS clean up spilled fuel 2 4 A GENERAL SAFETY A GENERAL SAFETY PROCEDURES HYDRAULIC SAFETY A WARNING Hot hydraulic oil can cause severe burns DO NOT work on the hydraulic system if the oil temperature exceeds 120 degrees 49 degrees
15. 15 higher than a horizontal position may cause the machine to overturn causing injury or death DO NOT depress the pump destroke button while operating the machine This button should be used only during cold start ups Depressing the button while operating the machine will cause an immediate loss of hydraulic power that will affect fork tilt lift boom extend and retract sway and all other hydraulic functions The brakes will continue to function if the accumulator backup has a sufficient gas charge OPERATION BEFORE STARTING THE ENGINE AN WARNING Before starting the engine be sure that all daily maintenance items have been performed See Maintenance section Walk around the machine and check for any parts that are missing worn damaged or leaking Repair and or replace any missing worn damaged or leaking parts OPERATION STARTING THE ENGINE Any problems discovered in the steps prior to BEFORE STARTING THE ENGINE should be corrected before the machine is started A DANGER IN IN DANGER NEVER attempt to start the machine without being seated in the operator s compartment the parking brake B in the on position and the transmission control C in the neutral position Attempting to start the machine from outside the operator s compartment may result in property damage serious injury or death
16. 4 11 Placing A Load 4 13 OPERATION OPERATION AND SAFETY GUIDELINES AN WARNING Your safety and the safety of those around you depends upon you using care and judgement in the operation of this equipment Know the positions and functions of all controls before attempting to operate this machine All equipment has limitations Understand the speed braking steering stability and load chart characteristics of this machine before operating Read the Operator s Manual and ask questions of your supervisor until you know the machine s limitations It is very important to read fully understand and follow these operation and safety guidelines 1 W A 10 11 12 13 14 15 16 17 DO NOT operate this machine while people are under or near an elevated boom whether boom 15 loaded or unloaded Falling objects from the forks or attachment may cause serious injury or death ALWAYS remain completely within the cab enclosure while operating this machine Falling debris can cause serious personal injury or death NEVER extend a load beyond the load chart band Machine turn over component damage injury or death could occur ABSOLUTELY NO RIDERS SHOULD BE ALLOWED ON MACHINE OR ATTACHMENTS NEVER lower a maximum load before retracting it Machine turn over component damage injury or death could occur INSPECT and clear the working area of any obstructions rocks fence wire etc that could cause machine damage If
17. OCEDURES A CAUTION USE SEAT BELT Always wear the seat belt while operating the machine to reduce the risk of personal injury A CAUTION PRACTICE SAFE MAINTENANCE Unauthorized modifications to the machine may impair the safety machine function and or affect machine life ALWAYS use a safety support or brace when working on under or around the machine or forks DO NOT adjust or lubricate the machine while it is in motion SHUT OFF the engine and LOCKOUT the ignition while working on the machine unless maintenance instructions require the engine to be running REPLACE all the shields and guards after servicing NEVER use the machine as a platform for lifting personnel AN CAUTION BOOM SAFETY DO NOT enter the DANGER AREA under or around the boom when the forks are off the ground or while the engine 15 running See diagram at right for DANGER AREA Serious personal injury could result 1f the boom should unexpectedly drop Before ANY work is performed in the DANGER AREA the boom must be COMPLETEL Y lowered and the forks must be resting on the ground 2 6 DANGER r p TS N GENERAL SAFETY A GENERAL SAFETY PROCEDURES AVOID ELECTRICAL POWER LINES A DANGER REQUIRED CLEARANCE FOR NORMAL VOLTAGE IN OPERATION NEAR HIGH VOLTAGE POWER LINES AND OPERATION IN TRANSIT WITH NO LOAD AND BOOM OR MAST LOWERED Normal Voltag
18. Switch Plug Turn Signal Wires Interior Rear View Mirror Frt Axle Differential Lock optional 4 8 18 O FUSE PANEL OQ 5 25 1 TRANSMISSION SHIFT CONTROL amp amp BACK UP ALARM amp BACK UP LIGHTS X HEATER DASH GAUGES amp L 20A 20A _ __ HEADLIGHTS amp HOURMETER gt TAIL LIGHTS FORK TILT RELAY amp 5A __20 TURN SIGNALS amp 4 WAY ELECTRIC TILT VALVES amp amp CONTROLLER RELIEF VALVE amp dee SERVICE BRAKE LIGHTS amp 10A 10A PARKING BRAKE DASH LIGHT amp WINDSHIELD WIPERS TRANSMISSION CUT OUT RELAY cm ELECTRIC ETHER AID amp HORN amp 12 VOLT ACCESSORY PLUG HORN RELAY 7 10 10 PUMP DESTROKE BUTTON 8 FRONT AXLE DIFFERENTIAL LOCK ELECTRIC SWAY CONTROL amp 9 di AUXILIARY HYDRAULICS 5A FUSE PANEL VIEW 3 3 CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS A Boom Down A Boom Up 5 B C Boom D Boom In D D en H E E Boom Down and Out Boom Up and In G Boom Up and
19. ar tires are not aligned properly straighten the rear wheels with the steering selector valve C in the 4 wheel position Move the steering selector valve to the 2 wheel position Bring the front tires into alignment with the rear tires Place the steering selector valve back into the 4 wheel position H R Gp IT OPERATION BEFORE OPERATING THE FORKLIFT AN DANGER Any problems with the service brakes or the parking brake found while conducting the daily inspection should be corrected immediately Failure to do so could result in injury or death Activate the transmission using the transmission control lever D As soon as the machine starts to move apply the service brake pedal The machine should stop immediately BS Qua gt 1 4 2 Apply parking brake The machine should not be able to be driven Release the parking brake OPERATION BEFORE OPERATING THE FORKLIFT AN DANGER Never operate the machine with a faulty backup alarm Doin
20. ay control with the boom above horizontal may cause the machine to overturn m Verify that the load 1s secured on the forks before performing a lift Rearrange the load if necessary iv Before lowering a maximum load always retract the boom completely v Use proper attachments such as a truss boom to lift suspended loads 14 If the load to be lifted exceeds the capacity of the machine for the given configuration i Movethe machine closer to the load so that the weight of the load will be within the allowable load chart specifications i Divide the load into smaller pieces in Getalarger machine capable of handling the load 15 Always move aload so that you have maximum machine stability and visibility 15 not obstructed Keep the boom at or below horizontal with the load close to the eround 16 Tiltthe forks back towards the machine slightly during travel to ensure stability of the load ROUGH TERRAIN FORK LIFT SAFETY A OPERATION SAFETY 17 Inspect the path of travel before beginning movement Avoid holes and dropofts 18 Traveling on slopes grades i Ascend and descend slowly and with caution i When loaded always travel with the load uphill When unloaded travel with the attachment downhill iv Avoid turning travel straight up and down 19 Always position all wheels in line with the machine before switching the steering mode 20 Always position the machine and set the park brake before lifting a
21. e kV Minimum Required Phase to Phase Clearance ft m Operation Near High Voltage Power Lines to 50 10 3 05 Over 50 to 200 15 4 60 Over 200 to 350 20 6 10 Over 350 to 500 25 7 62 Over 500 to 750 35 10 67 Over 750 to 1000 45 13 72 Operation in Transit With No Load and Boom Lowered to 0 75 4 1 22 Over 0 75 to 50 6 1 83 Over 50 to 345 10 3 05 Over 345 to 750 16 4 87 Over 750 to 1000 20 6 10 IN WARNING Always remain completely inside the cab enclosure while operating the machine IN WARNING Never operate this machine under the influence of drugs alcohol and or medication which can cause drowsiness AN WARNING Never transport or lift personnel into position with this forklift It is not designed as a personnel lifting device 59 2 7 GENERAL SAFETY JUMP STARTING Location The battery is located under the fuel tank battery box cover A JUMP STARTING Jump starting at the battery or battery replacement is required when the battery is discharged to the point where the battery will not crank the starter AN WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also co
22. e recommends that you purchase and refer to the following standards ANSI B56 6 Rough Terrain Fork Lifts This Standard can be purchased from American National Standards Institute 25 West 43nd Street 4th Fl New York New York 10036 Tel 212 642 4900 Fax 212 398 0023 SYMBOLS The symbols below are used to inform the operator of important information concerning the operation of this machine DANGER Indicates an imminently hazardous situation DANGER _ which if not avoided will result in death or serious injury WARNING WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation CAUTION which if not avoided may result in minor or moderate injury ATTENTION Indicates a situation which 1f not avoided ATTENTION may result in property or equipment damage 1 4 ROUGH TERRAIN FORK LIFT SAFETY A SAFETY AN These are general safety rules which must be followed You are also required to read and understand the Operator s Manual as there are instructions which are more detailed specific to this machine TRAINING AND KNOWLEDGE 1 Safety must always be the operator s most important concern 2 This machine must only be operated by trained personnel who have demonstrated their ability to do so safely 3 Comply with the requirements of current Occupational Sa
23. fety and Health Administration OSHA standards including 29CFR1910 178 and the American National Standards Institute ANSI B56 6 latest edition 4 Read and Understand all Decals and Warnings 5 Read and Understand the Rating Chart 6 Know that the machine can safety lift each load before attempting to lift 1 5 ROUGH TERRAIN FORK LIFT SAFETY A OPERATOR S RESPONSIBILITIES 1 Read and understand the Operator s Manual 2 Know the location and the purpose of the controls instruments and indicator lights 3 Make sure the machine is in proper order and all operational aids and warning signals are functional before operating 4 Keep machine clean including all instrumentation windows lights and other glazed surfaces 5 Use protective clothing and safety equipment Always use approved safety equipment such as gloves safety boots hard hats safety glasses and ear protection where necessary 6 Wear protective clothing that is snug and belted where required 7 Store tools and other necessary items in the toolbox 8 Never lift a load without a Load Rating Chart in the cab 9 Know the load to be lifted 10 Be alert physically fit and free from the influences of alcohol drugs or medications that might affect the operator s eyesight hearing or reactions 11 Keep people equipment and material out of the work area 12 Keep a fully charged fire extinguisher and first aid kit in the cab at all t
24. g so may result in serious injury or death Place the transmission control lever A in reverse The backup alarm should sound If it does not sound have the backup alarm repaired immediately Check and adjust both the interior rear view mirror B and the exterior right hand mirror C if required OPERATION TRANSPORTING A LOAD AN WARNING Transporting a load with the boom extended and the boom angle indicator arrow D reading more than 0 degrees could cause a roll over hazard A WARNING At no time should any load be suspended from the forks by use of chains ropes straps etc If a load must be suspended the use of a truss jib boom is mandatory Proper rigging procedures should always be followed The forks should always be tilted back slightly during trans portation to ensure stability of the load The load should be kept as low to the ground as possible while traveling Always move a loaded machine with the boom angle indicator D at 0 degrees or less 4 11 OPERATION A WARNING Slower speeds
25. imes and be familiar with how to use these items 13 Know about movements of other machinery trucks and personnel at the jobsite 14 Make sure everyone 15 in a safe place before moving the boom forks load or outriggers if so equipped 15 Start and stop movements smoothly and swing at speeds that will keep the load under control 1 6 ROUGH TERRAIN FORK LIFT SAFETY A MANAGEMENT S RESPONSIBILITIES 1 Ensure operators are competent physically fit trained and if required licensed 2 Have a supervisor at the job site to be responsible for job safety 3 Crew members given specific safety responsibilities and instructed to report any unsafe conditions to the supervisor 4 Supply the weight on the load to be lifted to the operator 5 Verify that all crewmembers are familiar with OSHA ANSI B56 6 requirements as well as instructions in the manuals AMROUGH TERRAIN FORK LIFT SAFETY A MAINTENANCE AND REPAIR 1 Practice safe maintenance procedures Perform all maintenance and repairs in accordance with instructions provided by the manufacturer in the manuals Also heed the warnings on the placards and decals on the machine 2 Always use supports and braces when working on under or around the machine or forks 3 Shut off the engine and lockout the machine while working on the machine unless instructions specifically require the engine to be running 4 Always make sure the machine 15 stationary prior to perfor
26. ion if the accumulator backup has a sufficient gas charge gt O The pump destroke button A is the black push button switch located on the dash panel For example when starting the machine for the first time on a 30 degree F day depress the pump destroke button while starting the engine Continue to depress the button for 15 to 20 seconds after the engine starts Once the engine is running smoothly release the button and the hydraulic pump will engage Depressing the pump destroke button will not be required for all other starts of the day unless the engine has been allowed to cool completely ee CONTROLS AND INSTRUMENTS STEERING In addition to the steering wheel the machine has another steering control the steering selector switch The steering selector switch B is a three position switch The three positions are 4 wheel 2 wheel and oblique Switch positions are selected and function as follows 4 WHEEL Handle right of center 879 2 WHEEL Handle directly centered OBLIQUE CRAB Handle left of center A CAUTION Before changing steering selections make su
27. lated calcium chloride solution filled tires or optional foam filled tires Load Limits Horizontal Boom Last Fully Visible Letter Retracted 6000 Ibs A Letter Visible 5000 lbs B Letter Visible 4000 155 C Letter Visible 3000 Ibs D Letter Visible 2000 16 24 ft 16 ft 8 ft 0 ft 8 ft 16 ft 4 88 m 2 44m 2 44 m 4 88 m Genie GTH 636 Lift Capacity Chart IN AL 3000 lbs 1360 kg A SE N L 4000 lbs 1810 kg ASS 24 ft 16 ft 8 ft 0 ft 8 ft 7 32m 4 88 m 2 44 m 2 44 m 4 88 m SECTION 3 CONTROLS AND INSTRUMENTS TABLE OF CONTENTS SECTION 3 CONTROLS AND INSTRUMENTS Operator s Compartment 3 3 Joystick Control Functions 3 4 Joystick Control Functions Button Pushed 3 5 Service Brakes 3 6 Parking Brake 3 6 Frame Sway Control 3 7 Gauges 3 8 Hydraulic Pump Destroke Button 3 8 Steering 3 9 Transmission 3 9 CONTROLS AND INSTRUMENTS Accelerator Pedal Joystick 4 way Controller Transmission Control Lever Steering Selector Service Brake Pedal Parking Brake Warning Light Load Chart OPERATOR S COMPARTMENT 8 Hourmeter 9 Gauges 10 Machine Level Gauge 17 11 Plug 12 Volt Access 18 12 Seat 19 13 Frame Level Switch 20 14 Seat Belt 21 Parking Brake Handle 22 Pump Off Button 29 Windshield Wiper 24 Ignition Switch 25 Auxiliary Hydraulics Steering Wheel Headlight Switch Heater
28. load 21 Do not allow riders on the machine or forks 22 Do not transport or lift personnel into position with this forklift 23 When leaving the operator s station 1 Place the directional controls in neutral i Apply the parking brake Lower the attachment to the ground A ROUGH TERRAIN FORK LIFT SAFETY A SECTION 2 GENERAL SAFETY TABLE OF CONTENTS SECTION 2 GENERAL SAFETY General Safety Procedures 2 3 Jump Starting 2 8 Proper Load Chart Use 2 9 GENERAL SAFETY PROCEDURES SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages Follow all safety messages to avoid injury and or death AN WARNING ALWAYS wear eye protection and personal safety equipment THE OPERATOR The operator must be fully trained and qualified to operate this machine Before start up or machine operation the operator must learn the location and purpose of the Controls Instruments Indicator lights Safety and instruction labels psu ACCIDENT PREVENTION Use protective clothing and safety equipment Always use approved safety equipment such as gloves safety boots safety hard hats goggles and ear protection when necessary Wear protective clothing that is snug and belted where required FIRE PREVENTION FIRST AID Install a first aid kit and fire extinguisher in the operator s cab KEEP THE FIRST AID KIT and FIRE EXTINGUISHER properly maintained Follow the instructions provided
29. ly annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service PERFORM ENGINE MAINTENANCE Refer to engine operator s manual Check engine oil Check coolant level Check engine fan Open water separator PERFORM TRANSMISSION MAINTENANCE Refer to the transmission operator s manual Check transmission oil level MAINTENANCE PROCEDURES DAILY MAINTENANCE CHECK HYDRAULIC OIL LEVEL Location Sight glass B Behind the rear panel To Check Move the machine to level ground Level the frame Completely retract the boom Position the forks level Lower the boom to the ground Oil should be visible 1 2 way in sight glass NOTE Refer to page 5 24 of this manual for the proper oil specifications and capacities CHECK TIRE FOR PROPER INFLATION Location Wheel ends To Check With the valve stem C positioned to the top of the tire check the tire pressure with the tire cold and a properly functioning air pressure gauge Setting 50 PSI
30. ming adjustments or lubrication 5 Replace all shields and guards after performing service 6 Always use a piece of cardboard or paper to search for leaks 7 When performing work on the hydraulic system i Lower the boom to horizontal Support the boom with supports or braces Shut down the engine Iv Relieve all pressure before disconnecting lines v Ensure all connections are tight before applying pressure vi Repair or replace any damaged line hose or fitting before applying pressure 8 Always have tires serviced and mounted by a qualified person with the proper tools and guards 9 Always use an inflation cage during tire inflation 10 Only perform welding on the machine with approval from the manufacturer 1 8 ROUGH TERRAIN FORK LIFT SAFETY A OPERATION SAFETY 1 Alwaysinspect the machine daily Check for leaks worn hoses loose belts broken structures and loose or missing bolts Repair or replace any worn damaged or leaking parts prior to operation of the machine 2 Only inspect the coolant level when the engine and coolant are cool 3 Be sure that all guards and screens are secure and in the proper place 4 Inspectfor and clear the work area of any obstructions that could interfere with proper machine operation Any obstructions that cannot be cleared should be clearly marked and avoided during operation 5 Refueling i Alwaysstop the engine before refueling the machine i Fill the fuel
31. ntain other chemicals known to the State of California to cause cancer Wash hands after handling AN WARNING Never jump start the machine directly to the starter or the starter solenoid Serious injury or death could result from the machine moving forward or backward AN WARNING To avoid personal injury when jump starting with another machine be certain that the machines are not touching Never jump start a frozen battery as it will explode Keep sparks and flames away from the battery Lead acid batteries generate explosive gases when charging Wear safety glasses when working near batteries The booster battery must be a 12 volt type The machine used for jump starting must have a negative ground electrical system To jump start the machine proceed as follows 1 Connect the positive jumper cable to the positive post of the discharged battery 2 Connect the other end of the same jumper cable to the positive post of the booster battery 3 Connect one end of the second jumper cable to the negative post of the booster battery 4 Make the final cable connection to the engine block or the furthest ground point away from the battery 5 Start the engine 6 Remove the jumper cables in the reverse order of their connection 1 e negative cable ground connection first etc 2 8 N GENERAL SAFETY A PROPER LOAD CHART USE
32. op before applying the parking brake C Failure to do so will damage the parking brake disc packs which may void the axle warranty Before placing a load the frame should be leveled This can be done by the use of the switch labeled sway control D located on the lower right hand side of the dash panel in front of the operator Adjust the sway control D until the indicator ball on the level gauge E 1s on the O degree mark OPERATION PLACING A LOAD AN DANGER Traveling with a reading of more than degress on the boom angle indicator arrow A may cause a rollover hazard Gradually move the 4 way controller towards the letter B to lift the load vertically Hold the controller back until the A required height has been achieved Gradually move the 4 way controller towards the letter E to bring load DOWN and OUT into final position Lower D a 2 C load until weight is completely off forks Gradually move the 4 way controller towards the letter F to bring the boom UP and IN This will bring the forks
33. out of the load Once the forks are clear of the load the boom can be lowered UJ SECTION 5 MAINTENANCE PROCEDURES TABLE OF CONTENTS SECTION 5 MAINTENANCE PROCEDURES General Safety Practices 5 3 Daily Maintenance 5 5 MAINTENANCE PROCEDURES GENERAL SAFETY PRACTICES BEFORE SERVICING Read the entire Maintenance Procedure Section Familiarize yourself with all the safety precautions listed in Sections amp 2 Pay close attention to all the safety alert symbols Be sure you understand the procedures detailed in this section Wear personal protective equipment Remove rings and jewelry Move the machine to a safe level work place Lower the boom and support all raised equipment Shut down the machine Remove the key from the ignition Be careful not to spill fuels and lubricants Do not fill or refuel the fuel tank while the engine is running or hot Doing so could cause a fire and or an explosion Do not smoke while refueling or working with fuel to avoid a fire and or explosion IMPORTANT Always clean up spilled fuel and or lubricants to avoid polluting the earth 5 3 MAINTENANCE PROCEDURES GENERAL SAFETY PRACTICES HYDRAULIC SAFETY AN WARNING Hot hydraulic oil can cause severe burns DO NOT work on the hydraulic system if the oil system temperature exceeds 120 degrees F 49 degrees C Before ANYONE works on the hydraulic system
34. re all four wheels are in line Failure to align the wheels to the proper settings before changing steering positions may cause haphazard steering This may result in injury to personnel and or damage to the machine or property TRANSMISSION The transmission control C has one lever that controls both directional and speed requirements It is located on the left side of the steering column To shift into Forward gear gently pull the lever toward you and move the lever upward To shift into Neutral move the lever to the center position To shift into Reverse gear gently pull the lever toward you move the lever downward 0 70 To shift into a lower speed rotate lever clockwise To shift into a higher speed rotate the lever counter clockwise When shifting the transmission from forward to reverse while the machine is in motion the transmission control C must be in Ist or 2nd gear only Forward 1lst Low speed High torque Forward 2nd Medium speed Medium torque Forward 3rd High speed Low torque 3 9 NOTES SECTION 4 OPERATION TABLE OF CONTENTS SECTION 4 OPERATION Operation And Safety Guidelines 4 3 Before Starting The Engine 4 4 Starting The Engine 4 5 Before Operating The Forklift 4 7 Transporting A Load
35. se contact us for a replacement at no charge Our address 1s Genie Industries PO Box 97030 Redmond WA 98073 9730 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also contain other chemicals known to the State of California to cause cancer Wash hands after handling
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