Genie GTH-644 User manual

Operator’s Manual
with
Maintenance
Information
GTH-844
GTH-842
GTH-644
First Edition
Second Printing
Part No. 114100

SECTION 1 ROUGHTERRAINFORKLIFTSAFETYSECTION 1-1
Introduction 1-3
StandardsAndSymbols 1-4
Safety 1-5
TrainingAndKnowledge 1-5
Operator'sResponsibilities 1-6
Management'sResponsibilities 1-7
MaintenanceAndRepair 1-8
OperationSafety 1-9
SECTION 2 GENERALSAFETY 2-1
GeneralSafetyProcedures 2-3
JumpStarting 2-8
ProperLoadChartUse 2-9
SECTION 3 CONTROLSANDINSTRUMENTS 3-1
Operator'sCompartment 3-3
JoystickControlFunctions 3-4
JoystickControlFunctions(Button Pushed) 3-5
Service Brakes 3-6
LowServiceBrake Pressure Light 3-6
Parking Brake 3-7
FrameSwayControl 3-8
Gauges 3-9
HydraulicPumpDestrokeButton 3-9
Steering 3-10
Transmission 3-10
FrontAxleDifferentialLock 3-11
SECTION 4 OPERATION 4-1
OperationAndSafetyGuidelines 4-3
BeforeStartingTheEngine 4-4
StartingTheEngine 4-5
BeforeOperatingTheForklift 4-7
TransportingA Load 4-11
PlacingA Load 4-13
SECTION 5 MAINTENANCEPROCEDURES 5-1
GeneralSafetyPractices 5-3
DailyMaintenance 5-5
SECTION 6 MATERIALSAFETYDATA 6-1
MaterialSafetyDataSheets 6-3
CaliforniaProposition65Warnings 6-4
TABLE OF CONTENTS

SECTION 1
ROUGHTERRAIN
FORK LIFT SAFETY
1-1

TABLEOFCONTENTS
SECTION 1 - ROUGH TERRAIN FORK LIFT SAFETY
Introduction 1-3
StandardsAndSymbols 1-4
Safety 1-5
TrainingAndKnowledge 1-5
Operator'sResponsibilities 1-6
Management'sResponsibilities 1-7
MaintenanceAndRepair 1-8
OperationSafety 1-9
1-2

ROUGH TERRAIN FORK LIFT SAFETY
INTRODUCTION
Owners,Users,andOperators:
Genieappreciates yourchoiceofourmachineforyour application.Ournumber one
priorityisuser safety,whichisbest achieved byourjoint efforts.Wefeelthat youmakea
majorcontribution tosafetyifyou, astheequipment usersandoperators:
1. ComplywithOSHA,Federal, State, andLocalRegulations.
2. Read,Understand,andFollowtheinstructionsinthisandothermanuals
suppliedwiththismachine.
3. UseGoodSafeWorkPractices in a common sense way.
4. Onlyhavetrained/certifiedoperators–directedbyinformedand
knowledgeablesupervision–runningthemachine.
NOTE: OSHAprohibitsthealterationormodificationofthismachinewithoutwritten
manufacturer'sapproval.Use only factoryapprovedpartsto service orrepairthis
machine.
Ifthere isanythingin thismanualthatisnotclearorwhich youbelieveshould beadded,
pleasecontactus.
Internet:www.genieind.com
Email:[email protected]
Thankyou!
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 AND SYMBOLS
1-4
Manyaspects ofroughterrainforklift operationandtesting arediscussedin standards
publishedbythe American NationalStandardsInstitute. TheseStandards are updatedon
aregularbasis with addendas.Genierecommendsthat you purchaseandreferto the
followingstandards.
ANSIB56.6–RoughTerrain Fork Lifts
ThisStandardcan bepurchasedfrom:
AmericanNationalStandardsInstitute
25 West 43nd Street, 4th Fl.
New York, New York, 10036
Tel. [phone]
Fax. [phone]
STANDARDS
SYMBOLS
DANGER–Indicatesanimminentlyhazardoussituation
which,ifnotavoided,willresultindeath orserious injury.
CAUTION– Indicatesapotentially hazardoussituation
which,if notavoided,mayresultinminoror moderate
injury.
WARNING–Indicatesa potentiallyhazardoussituation
which,if notavoided,could resultindeath orserious
injury.
ATTENTION– Indicatesasituation which,ifnot avoided,
mayresult inpropertyorequipmentdamage.
Thesymbols belowareusedtoinformtheoperator ofimportantinformationconcerning
theoperationofthismachine.

ROUGH TERRAIN FORK LIFT SAFETY
SAFETY
1-5
1. Safety mustalwaysbethe operator's mostimportantconcern.
2. This machinemustonly beoperatedbytrainedpersonnel,whohave demonstrated
theirability todoso safely.
3. Complywiththerequirements ofcurrentOccupationalSafetyandHealth
Administration(OSHA) standards,including29CFR1910.178;andthe American
NationalStandardsInstitute (ANSI)B56.6latest edition.
4. Read andUnderstandallDecals andWarnings.
5. Read andUnderstandtheRating Chart.
6. Know thatthemachine cansafetylifteachload beforeattemptingtolift.
Thesearegeneral safety rules, whichmustbefollowed. You are also requiredtoread
andunderstandthe Operator's Manualasthereare instructions, whicharemore
detailedspecifictothismachine.
TRAINING AND KNOWLEDGE

ROUGH TERRAIN FORK LIFT SAFETY
OPERATOR'S RESPONSIBILITIES
1-6
1. Read and understandtheOperator’sManual.
2. Know thelocationandthe purposeofthe controls,instrumentsand indicator
lights.
3. Make surethemachineis in properorderand all operationalaidsand warning
signalsarefunctionalbeforeoperating.
4. Keepthemachineclean,includingallinstrumentation,windows,lightsandother
glazedsurfaces.
5. Useprotective clothingandsafety equipment. Alwaysuseapproved safety
equipmentsuchas: gloves,safetyboots,hard hats, safetyglassesandear
protectionwhere necessary.
6. Wearprotectiveclothing thatissnug andbeltedwhererequired.
7. Store tools andothernecessaryitems in thetoolbox.
8. Never liftaloadwithout a Load RatingChartinthe cab.
9. Know the load tobelifted.
10. Bealert,physicallyfit andfree fromtheinfluencesofalcohol,drugsor
medicationsthat mightaffecttheoperator’s eyesight,hearing,orreactions.
11. Keeppeople,equipmentandmaterial out of the work area.
12. Keep afullychargedfireextinguisherandfirstaid kitinthe cabatalltimes,and
befamiliar withhowtousetheseitems.
13. Know aboutmovementsof other machinery,trucksand personnel atthejobsite.
14. Makesureeveryoneisin a safe place before movingtheboom,forks,loador
outriggers(if soequipped.)
15. Startandstopmovements smoothly andswingatspeeds that willkeeptheload
undercontrol.

ROUGH TERRAIN FORK LIFT SAFETY
MANAGEMENT'S RESPONSIBILITIES
1-7
1. Ensure operatorsarecompetent, physicallyfit,trainedandif requiredlicensed.
2. Have a supervisor at the job site toberesponsibleforjobsafety.
3. Crewmembers givenspecific safetyresponsibilitiesandinstructedto reportany
unsafeconditionstothe supervisor.
4. Supply the weightontheloadto be lifted to theoperator.
5. Verify thatallcrewmembersarefamiliar withOSHA,ANSIB56.6requirements
aswellasinstructionsinthemanuals.

ROUGH TERRAIN FORK LIFT SAFETY
1-8
MAINTENANCE AND REPAIR
1. Practicesafemaintenanceprocedures. Performall maintenanceandrepairs in
accordancewith instructionsprovidedbythemanufacturerinthe manuals. Also
heedthewarnings on theplacardsand decals onthemachine.
2. Always usesupportsandbraces when workingon,underor around themachine
orforks.
3. Shutofftheengineandlockoutthemachinewhileworkingonthemachineunless
instructionsspecificallyrequiretheenginetoberunning.
4. Alwaysmake surethemachineisstationary priorto performingadjustmentsor
lubrication.
5. Replaceallshieldsand guardsafter performingservice.
6. Always use a piece of cardboard or paper to search for leaks.
7. Whenperformingworkonthehydraulicsystem:
i. Lower theboomto horizontal.
ii. Support the boom with supports or braces.
iii. Shutdowntheengine.
iv. Relieveallpressurebeforedisconnectinglines.
v. Ensureallconnectionsaretightbeforeapplying pressure.
vi. Repairorreplace anydamagedline, hoseorfittingbefore
applyingpressure.
8. Always havetiresservicedand mountedbya qualifiedpersonwiththe proper
toolsandguards.
9. Alwaysuseaninflationcageduringtireinflation.
10. Onlyperform weldingonthemachinewithapprovalfromthemanufacturer.