Terex Genie GTH-636 User manual

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

Operator's Manual Third Edition • Fifth Printing
GTH™-636 Part No. 1286012GT
FrontMatter
Contents
Introduction ............................................................1
Symbol and Hazard Pictorials Definitions..............4
General Safety.......................................................6
Work Area Safety...................................................8
Legend................................................................ 16
Controls............................................................... 17
Inspections.......................................................... 21
Operating Instructions......................................... 32
Transport and Lifting Instructions ....................... 44
Maintenance ....................................................... 47
Attachments........................................................ 53
Specifications...................................................... 65
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.
Complies with ANSI/ITSDF B56.6, CSA B335

Third Edition • Fifth Printing Operator's Manual
Introduction
Part No. 1286012GT GTH™-636 1
Intr oduct io n
About this manual
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.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
machine.
This manual should be considered a permanent
part of your machine and should remain with the
machine at all times. If you have any questions,
contact Genie.
Product Indentification
The machine serial number is located on the serial
label.
Serial label
(located inside
fork frame)
(models with
quick
attach frame)
Serial
number
stamp Serial label located inside riser
Intended Use
A variable reach rough terrain forklift truck is
defined as a wheeled type truck with a pivoting
boom, which may be equipped with various
attachments for picking, transporting and placing
loads with the established load range charts.
Use of this product in any other way is prohibited
and contrary to its intended use.
Bulletin Distribution and
Compliance
Safety of product users is of paramount
importance to Genie. Various bulletins are used by
Genie to communicate important safety and
product information to dealers and machine
owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their
associated dealer, so it is important to register your
machine and keep your contact information up to
date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
To view any open bulletins for your machine, visit
us on the web at www.genielift.com.

Operator's Manual Third Edition • Fifth Printing
Introduction
2 GTH™-636 Part No. 1286012GT
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:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.
Danger
Failure to obey the instructions and
safety rules in this manual will result
in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1 Avoid hazardous situations.
Know and understand the safety rules
before going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety
rules—safety and operator’s manuals and
machine decals.
You read, understand and obey employer’s
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

Third Edition • Fifth Printing Operator's Manual
Introduction
Part No. 1286012GT GTH™-636 3
Hazard Classification
Decals on this machine use symbols, color coding,
and signal words to identify the following:
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
message.
Standards
Many aspects of rough terrain forklift operation and
testing are discussed in standards published by
the American National Standards Institute and the
Industrial Truck Standards Development
Foundation. These standards are updated on a
regular basis with addenda. It is recommended
that you purchase and refer to the following
standards.
ANSI/ITSDF B56.6 - Rough Terrain Forklift Trucks
The ANSI standard can be downloaded from
www.ITSDF.org
CSA B335 - Safety Standard for Lift Trucks
The CSA standard can be downloaded from
www.csa.ca
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.

Operator's Manual Third Edition • Fifth Printing
Symbol and Hazard Pictorials Definitions
4 GTH™-636 Part No. 1286012GT
Symb ol an d H az ard Pi ct orial s D efi niti ons
Electrocution hazard Maintain required
clearance Crush hazard No people under load Read the operator’s manual
Injection hazard Use a piece of
cardboard or paper to
search for leaks
Maintain required
clearance Crush hazard Always wear seat belt
Tip-over hazard Tip-over hazard Stay clear of moving telehandler Crush hazard
Keep away from
moving parts Fall hazard Only use an approved work
platform
Explosion / Burn
hazard No smoking. No open flame.

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Symbol and Hazard Pictorials Definitions
Part No. 1286012GT GTH™-636 5
Refer to load charts
and manual. Do not sway when boom is elevated. Crush hazard Keep away from moving parts Access by trained and authorized personnel
only
Explosion / Burn
hazard No smoking. No open flame. Keep load low Only use 24 in / 1.22 m forks or
shorter on swing
carriage.
Exterior emergency
exit. Twist to remove
security strip. Hit with
force to break glass.
Tip-over hazard Burn hazard Allow surfaces to
cool Burn hazard Do not loosen cap until cool.

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General Safety
6 GTH™-636 Part No. 1286012GT
Gener al Safety

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General Safety
Part No. 1286012GT GTH™-636 7

Operator's Manual Third Edition • Fifth Printing
Work Area Safety
8 GTH™-636 Part No. 1286012GT
Work Ar ea Safety Tip-over Hazards
Using the appropriate load chart
for the machine configuration,
confirm that the load is within
the rated capacity of the
machine. Do not exceed the
rated load.
The load center on the fork (if equipped) must be
equal to or less than the load center indicated on
the load chart. If the load center is further from the
fork face than shown on the load chart, refer to the
Load Chart section of this manual.
All loads shown on the load chart are based on the
machine being on firm, level ground, the frame
being level, the forks being positioned evenly on
the carriage, the load being centered on the forks,
the tires being properly sized and properly inflated,
and the telehandler being in good operating
condition.
If using accessories, read, understand and obey
the decals, instructions and manuals with the
accessory.
Do not raise the load unless the ground can
support all forces imposed by the machine.
Do not lower a load without retracting the boom
first.
Do not operate the machine if the load chart is
missing.
Do not exceed the rated capacity for each
configuration.
Do not attempt to jump free of the machine during
a tip-over. The ROPS (Roll Over Protective
Structure) is designed to protect you.
If the telehandler starts to
tip over:
- Do not jump
- Brace yourself and stay
in the seat
- Keep your seat belt
fastened
- Hold on firmly
- Lean away from the
point
of impact
- Keep head, arms, hands,
legs and all other body
parts inside the operator's
cab at all times.
Do not raise the boom unless
the machine is level. The
machine level indicator should
be at zero degrees.
Do not level the machine using the frame sway
control unless the boom angle indicator is at zero
degrees or less.
Do not use the sway control to
position an elevated load.

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Work Area Safety
Part No. 1286012GT GTH™-636 9
Do not raise a load and then drive to position it.
When driving, keep the boom
at or below horizontal and keep
the load close to the ground.
Operate the machine at speeds that will keep the
load under control. Start and stop movements
smoothly.
Do not raise a load unless the
load is properly positioned or
secured on the forks or
approved attachment.
Do not operate the machine in strong or gusty
winds. Do not increase the surface area of the
carriage or load. Increasing the area exposed to
the wind will decrease machine stability.
Use extreme care and slow speeds while driving
the machine in the travel position across uneven
terrain, steep grades, debris, unstable or slippery
surfaces and near holes and drop-offs.
Do not alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not replace factory-installed tires with tires of
different specification or ply rating, unless
approved by the factory.
If using accessories, read, understand and obey
the decals, instructions and manuals with the
accessory.
Traveling on Slopes Hazards
When driving, keep the boom at
or below horizontal and keep the
load close to the ground.
When the machine is loaded, always travel with
the load uphill. When the machine is unloaded,
travel with the forks or attachment downhill.
On steep terrain, drive only up and down a hill, and
always keep the machine in gear. Do not turn
across the slope when the machine is traveling up
or down a slope.
Limit travel path and speed according to the
condition of the ground surface, traction, slope,
location of personnel and any other factors which
may create a hazard. Never drive the machine
unless the mast and equipment are in their proper
travel position.
Whether a machine will tip over during dynamic
machine operation involves many factors that need
to be considered. Among these are
pavement/ground conditions, stability and slope,
as well as machine equipment, operator skill, load
position, tire inflation, machine speed, etc.
Additionally, tip-over of a machine is dependent in
large part upon operator inputs such as the speed
and smoothness of the operation, as well as the
position of the attachment and its load.

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Work Area Safety
10 GTH™-636 Part No. 1286012GT
Construction sites and roads will frequently change
slope from place to place, can be hard and soft,
and change due to construction activities and
weather.
Operators should be properly trained and use their
best judgment and experience to take the
necessary precautions to prevent a tip-over.
Operators must assess the job site variables and
avoid exceeding the machine's (or operator's)
capabilities for terrain and conditions.
Fall Hazards
Always wear a seat belt when
operating the machine.
Always remain completely inside the cab when
operating the machine.
When getting in and out of the cab, face the
machine, use the steps and handrails provided and
always maintain three-point contact.
Do not use the steering wheel or any other controls
as handrails.
Do not allow riders on the machine
or forks.
Do not lift personnel with this
machine unless it is equipped with
an approved work platform. See
Work Platform section.
Collision Hazards
Keep people, equipment and
material out of the work area.
Do not operate the machine
while people are under or near
an elevated boom, whether it is
loaded or unloaded.
Do not put the transmission into gear unless the
brake is applied and personnel and bystanders are
clear of the machine and load.
Do not drive the machine if visibility is obstructed.
Use a signal person when visibility is obstructed,
and keep the signal person in view at all times.
Use prearranged hand signals to communicate.
Do not raise the boom unless the brake is applied.
Do not operate, without fenders, in conditions
where loose debris could hit the operator or
accumulate on the cab windows.
Do not operate the machine with a faulty back-up
alarm. The back-up alarm should sound when the
machine is in reverse.
Do not operate the machine in low light conditions.
An optional work and road light package is
available.
Operators must comply with employer, job site,
and governmental rules regarding use of personal
protective equipment.
Do not drive the machine directly up to anyone.

Third Edition • Fifth Printing Operator's Manual
Work Area Safety
Part No. 1286012GT GTH™-636 11
Always make sure that mirrors and cab glass are
clean and do not obstruct the operators view of the
travel path or load.
Scan the area prior to operating the machine. Look
in the direction of travel. Use mirrors to assist in
checking all around the machine.
Keep windows and mirrors clean, adjusted and in
good repair.
Be aware of the machine load swing area.
Do not rely on the rear proximity alarm system to
determine if personnel or objects are behind the
machine. The system has limitations due to
maintenance practices, the size or shape of the
object, composition, environmental conditions and
operating range. This system is set up for
detection at a reverse speed of a maximum of
3 feet per second / 0.9 meters per second (walking
pace). Refer to the detection zone chart in the
back of this manual.
Falling Object Hazards
Operate the machine at speeds that will keep the
load under control. Start and stop movements
smoothly.
Keep people, equipment and
material out of the work area.
Do not operate the machine
while people are under or near
an elevated boom, whether it is
loaded or unloaded.
Be sure the load is secure before lifting it. Always
make sure the quick attach pin is inserted and
secured.

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Work Area Safety
12 GTH™-636 Part No. 1286012GT
Bodily Injury Hazards
Always adjust the seat and
fasten the seat belt before
starting the engine.
Do not operate the machine
with a hydraulic oil or air leak.
An air leak or hydraulic leak
can p
enetrate and/or burn skin.
Relieve pressure before
disconnecting hydraulic lines.
Keep away from leaks and pin
holes. Use a piece of
cardboard or paper to search
for leaks. Do not use your
hand.
Fluid injected into skin must be surgically removed
within a few hours by a doctor familiar with this
type of injury or gangrene will result.
Stay clear of belts and fans
when the engine is running.
Always operate the machine in a well-ventilated
area to avoid carbon monoxide poisoning.
Improper contact with components under any
cover will cause serious injury. Only trained
maintenance personnel should access
compartments. Access by the operator is only
advised when performing a pre-operation
inspection. All compartments must remain closed
and secured during operation.
Keep body parts, such as hand, fingers and arms,
away from moving components.
Always use provided latches and handles for
opening and closing doors and covers.
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Immediately tag and remove from service a
damaged or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the appropriate Genie
service manual.
Be sure all decals are in place and legible.
Be sure the operator's and safety manuals are
complete, legible and in the storage container
located in the cab.
Do not attempt to start the machine by towing or
pushing.
Do not attempt to use the forks or attachments for
prying wedged or frozen loads free.
Do not push or pull objects or loads with the forks,
attachment or boom.

Third Edition • Fifth Printing Operator's Manual
Work Area Safety
Part No. 1286012GT GTH™-636 13
Component Damage Hazards
Do not use any battery or charger greater than 12V
to jump-start the engine.
Do not use the machine as a ground for welding.
Do not steer the front tires on dry pavement when
the axle differential lock is activated.
Do not lock the axle differential when the machine
is moving.
For machines equipped with solid tires, do not
operate continuously for longer than one hour
without allowing the tires to cool down for
30 minutes.
Do not work under the boom without the cylinder
chock in place.
Crush Hazards
Keep clear of moving parts during machine
operation and make sure personnel and
bystanders are kept clear of moving parts during
operation.
Set the parking brake, put the transmission in
neutral and lower the carriage or the attachment to
the ground before leaving the machine.
Keep clear of elevated components.
Support components before performing service.
Keep clear of moving parts during machine
operation and make sure personnel and
bystanders are kept clear of moving parts during
operation.
Do not work under the boom without the cylinder
chock in place.

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Work Area Safety
14 GTH™-636 Part No. 1286012GT
Burn Hazards
Allow hot surfaces to cool before
touching or servicing.
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleum gas (LPG), gasoline, diesel fuel or other
explosive substances.
Do not refuel the machine with the engine running.
Refuel the mac
hine and charge
the battery only in an open,
well-ventilated area away from
sparks, flames and lighted
tobacco.
Do not operate the machine in hazardous locations
or locations where potentially flammable or
explosive gases or particles may be present.
Do not spray ether into engines equipped with
glow plugs or air intake grid heaters.
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Obey all local and
governmental regulations
regarding required clearance
from electrical power lines. At a
minimum, the required
clearance contained in the chart
below must be followed.
Line Voltage Required Clearance
0 to 50KV 10 ft 3.05 m
>50 to 200KV 15 ft 4.60 m
>200 to 350KV 20 ft 6.10 m
>350 to 500KV 25 ft 7.62 m
>500 to 750KV 35 ft 10.67 m
>750 to 1000KV 45 ft 13.72 m
over 1000kV see below
For power lines over 1000kV, the minimum
clearance distance must be established by the
utility owner or operator or by a registered
professional engineer who is a qualified person
with respect to electrical power transmission and
distribution.
Do not use the machine as a ground for welding.

Third Edition • Fifth Printing Operator's Manual
Work Area Safety
Part No. 1286012GT GTH™-636 15
Always contact the electrical power line owner.
The electrical power shall be disconnected or the
power lines moved or insulated before machine
operations begin.
Allow for boom and attachment movement,
electrical line sway or sag, and beware of strong or
gusty winds.
Keep away from the machine if it contacts
energized power lines. Personnel on the ground or
in the cab must not touch or operate the machine
until energized power lines are shut off.
Do not operate the machine during lightning or
storms.
Battery Safety
Burn Hazards
Batteries contain acid.
Always wear protective
clothing and eye wear when
working with batteries.
Avoid spilling or contacting
battery acid. Neutralize
battery acid spills with
baking soda and water.
Explosion Hazards
Keep sparks, flames, and
lighted tobacco away from
batteries. Batteries emit
explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.
Employer's Responsibilities
Employers are responsible for providing a safe
work environment and for complying with local and
national governmental regulations.

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Legend
16 GTH™-636 Part No. 1286012GT
Legend
1 Interior rear view mirror
2 Left to right level indicator
3 Steering wheel
4 Control handle
5 Front to rear level indicator
6 Exterior emergency exit (Safe T Punch) (if
equipped)
7 Operator's manual
8 Battery Disconnect Switch
9 Boom angle indicator
10 Boom
11 Cab
12 Hydraulic oil level gauge
13 Engine (on opposite side of machine)
14 Backup camera (if equipped)
15 Rear proximity alarm sensor (if equipped)
16 Fuel fill
17 Fuse panel
18 Forks
19 Suspended load lifting point
20 Exterior rear view mirror
21 Manual storage container
22 Seat belt
23 Seat
24 Brake pedal
25 Accelerator pedal
26 Transmission control lever
27 Monitor, backup camera (if equipped)

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Controls
Part No. 1286012GT GTH™-636 17
Contr ols
Control Panel
1 Steering wheel
Turn the steering wheel to the right to turn the
front wheels to the right. Turn the steering
wheel to the left to turn the front wheels to the
left.
2 Rear proximity display and alarm (if equipped)
3 Horn button
Press this button and the horn will sound.
Release the button and the horn will stop.
4 Heater and air conditioning controls
(if equipped)

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Controls
18 GTH™-636 Part No. 1286012GT
5 Turn signal lever (if equipped)
Move the lever up to activate the left turn
signal. Move the lever down to activate the
right turn signal. Turn the lever to turn on the
hazard lights.
6 12V power port, 10A maximum
7 Steer select switch
Push down the right side of the rocker switch
to select four-wheel steer. Push the rocker
switch to the middle position to select
two-wheel steer. Push down the left side of the
rocker switch to select crab steer.
8 Axle differential lock switch
Push and hold the axle differential lock switch
to lock the axle differential. Release the switch
to unlock the axle differential.
9 Yellow roller
Pull the yellow roller down/back and the forks
will tilt up. Push the yellow roller up/forward
and the forks will tilt down.
10 White finger switch
Hold the white finger switch and push the
control handle to the right and the machine will
sway to the right. Hold the white finger switch
and pull the control handle to the left and the
machine sway to the left.
11 Auxiliary hydraulics thumb rocker
Push the auxiliary hydraulics thumb rocker to
the left and the carriage will swing or rotate to
the left. Push the auxiliary hydraulics thumb
rocker to the right and the carriage will swing
or rotate to the right.
12 Load charts
13 Control handle (electronic)
Pull the control handle back and the boom will
raise. Push the control handle forward and the
boom will lower. Push the control handle to the
right and the boom will extend. Pull the control
handle to the left and the boom will retract.
14 Ignition switch
Turn the key to the left to turn on the
accessories. Turn the key to the on position
and hold until the glow plug light on the
instrument panel turns off. Turn the key to the
start position to start the engine.
15 Parking brake switch
Push the top of the rocker switch to turn the
parking brake on. The light will be on when the
parking brake is on. Push the bottom of the
rocker switch to turn the parking brake off. The
light will be off when the parking brake is off.
16 Accelerator pedal