Genie GTH-636 User Manual
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
T raining 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 S tarting The Engine 4-4
Starting The Engine 4-5
Before Operating The Forklift 4-7
T ransporting 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 MA TERIAL SAFETY DATA SHEETS 6-1
SECTION 1
ROUGH TERRAIN
FORK LIFT SAFETY
1 - 1
T ABLE OF CONTENTS
SECTION 1 - 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
1 - 2
ROUGH TERRAIN FORK LIFT SAFETY
INTRODUCTION
Owners, Users, and Operators:
Genie appreciates your choice of our machine for your application. Our number one
priority is user safety , which is best achieved by our joint efforts. W e feel that you make a
major contribution to safety if 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. Use Good Safe W ork 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.
1 - 3
ROUGH TERRAIN FORK LIFT SAFETY
STANDARDS
SYMBOLS
STANDARDS AND SYMBOLS
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. Genie recommends that you purchase and refer to the
following standards.
ANSI B56.6 – Rough T errain Fork Lifts
This Standard can be purchased from:
American National Standards Institute
25 West 43nd Street, 4th Fl.
New Y ork, New Y ork, 10036
T el. 212.642.4900
Fax. 212.398.0023
The symbols below are used to inform the operator of important information concerning
the operation of this machine.
DANGER – Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury .
W ARNING – Indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury .
CAUTION – Indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury .
A TTENTION – Indicates a situation which, if not avoided,
may result in property or equipment damage.
1 - 4
ROUGH TERRAIN FORK LIFT SAFETY
SAFETY
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 Safety 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 W arnings.
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
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 the 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. W ear 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 times, 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 is 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
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. V erify that all crewmembers are familiar with OSHA, ANSI B56.6 requirements
as well as instructions in the manuals.
1 - 7
ROUGH TERRAIN FORK LIFT SAFETY
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 is stationary prior to performing 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.
i i . Support the boom with supports or braces.
iii. Shut down the engine.
iv. Relieve all pressure before disconnecting lines.
v . Ensure all connections are tight before applying pressure.
v i. 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
OPERATION SAFETY
1. Always inspect 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. Inspect for 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 . Always stop the engine before refueling the machine.
i i . Fill the fuel tank outdoors.
iii. Handle fuel with care, as it is 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 is 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 is loaded or unloaded. Falling objects from the forks or
attachment may cause serious injury or death.
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ROUGH TERRAIN FORK LIFT SAFETY
OPERATION SAFETY
12. Maintain an appropriate clearance from electrical power lines. See the chart
below for minimum safe approach distances.
ecnatsiDhcaorppAefaSmuminiM
egatloVeniLrewoPecnaraelCderiuqeR
Vk05ot0)m00.3(.tf01
Vk002ot05)m06.4(.tf51
Vk053ot002)m01.6(.tf02
Vk005ot053)m26.7(.tf52
Vk057ot005)m76.01(.tf53
Vk0001ot057)m27.31(.tf54
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 i. Level the 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 sway control with the boom above
horizontal may cause the machine to overturn.
iii. Verify that the load is secured on the forks before performing a lift.
Rearrange the load if necessary .
i v . 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 . Move the machine closer to the load so that the weight of the load
will be within the allowable load chart specifications.
i i . Divide the load into smaller pieces.
iii. Get a larger machine capable of handling the load.
15. Always move a load so that you have maximum machine stability and visibility is
not obstructed. Keep the boom at or below horizontal, with the load close to the
ground.
16. Tilt the forks back towards the machine slightly during travel to ensure stability of
the load.
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ROUGH TERRAIN FORK LIFT SAFETY
OPERATION SAFETY
17. Inspect the path of travel before beginning movement. A void holes and dropoffs.
18. Traveling on slopes/grades.
i . Ascend and descend slowly and with caution.
i i . When loaded, always travel with the load uphill.
iii. When unloaded,travel with the attachment downhill.
iv. A void 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 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:
i . Place the directional controls in neutral.
i i . Apply the parking brake.
iii. Lower the attachment to the ground.
1 - 11
ROUGH TERRAIN FORK LIFT SAFETY
NOTES
1 - 12
SECTION 2
GENERAL SAFETY
2 - 1
T ABLE OF CONTENTS
SECTION 2 - GENERAL SAFETY
General Safety Procedures 2-3
Jump Starting 2-8
Proper Load Chart Use 2-9
2 - 2
GENERAL SAFETY
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.
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:
1. Controls
2. Instruments
3 . Indicator lights
4. Safety and instruction labels
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 with the
first-aid kit and fire extinguisher.
2 - 3
GENERAL SAFETY
GENERAL SAFETY PROCEDURES
WELDING PRECAUTIONS
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
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
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
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