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.

ROUGH TERRAIN FORK LIFT SAFETY
OPERATION SAFETY
1-9
1. Always inspect themachinedaily. Check for leaks,wornhoses,loose belts,
brokenstructures,andloose or missing bolts. Repairorreplaceanyworn,
damagedorleaking partspriortooperation of themachine.
2. Only inspectthecoolant levelwhentheengineandcoolantare cool.
3. Be sure that all guards and screens are secure and in theproperplace.
4. Inspect forandclearthe work areaofanyobstructions that couldinterferewith
propermachineoperation. Any obstructions thatcannotbecleared should be
clearlymarked andavoidedduring operation.
5. Refueling:
i. Alwaysstoptheenginebeforerefuelingthemachine.
ii. Fillthefueltankoutdoors.
iii. Handlefuelwithcare,asitishighlyflammable. Donotrefuel
themachinewhilesmokingornearopenflames.
iv. Alwayscleanupspilledfuel.
6. Make sure themachineandaccesssystemis clean and free ofdirt,oil,greaseor
debris.
7. When gettingonand offthemachine,face themachine,use thestepsand
handrailsprovided, andalwaysmaintainathree pointcontact.
8. Alwaysremaincompletelyinsidethecabenclosurewhileoperatingthemachine.
9. Always weartheseatbeltwhile operatingthemachine.
10. Always completelylowerthe boomwiththe forksrestingonthegroundbefore
anyworkis performed onoraroundthe machine.
11. Donotoperatethemachine while people are under ornearanelevatedboom
whethertheboom is loadedorunloaded.Falling objects from theforksor
attachmentmay causeseriousinjury ordeath.

ROUGH TERRAIN FORK LIFT SAFETY
1-10
OPERATION SAFETY
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13. LiftingLoads:
i. Using theloadchart, confirmthattheloadiswithintherated
capacityofthemachinefortherequiredconfiguration.
ii. Levelthemachineusingthelevelgaugebeforeliftingloads. Use
thesway controltolevelthe machineonlywhen theboomis at
horizontalor lower. Using theswaycontrol withtheboom above
horizontalmaycausethemachinetooverturn.
iii. Verifythat theloadis securedontheforks beforeperforminga lift.
Rearrangethe loadifnecessary.
iv. Beforeloweringamaximum load,alwaysretracttheboom
completely.
v. Useproperattachments,such as a truss boom, to liftsuspended
loads.
14. If theloadto be liftedexceedsthe capacity ofthemachine for thegiven
configuration:
i. Move the machineclosertothe load so thattheweightofthe load
willbewithintheallowableloadchartspecifications.
ii. Dividetheloadintosmallerpieces.
iii. Geta largermachinecapable ofhandlingthe load.
15. Alwaysmovealoadsothatyouhavemaximummachinestabilityandvisibilityis
notobstructed. Keeptheboomatorbelowhorizontal,withtheloadclose to the
ground.
16. Tilttheforksbacktowardsthemachineslightlyduringtraveltoensurestabilityof
theload.
12. Maintain anappropriateclearance fromelectricalpower lines.Seethechart
belowforminimumsafeapproachdistances.

ROUGH TERRAIN FORK LIFT SAFETY
1-11
OPERATION SAFETY
17. Inspect thepathof travelbeforebeginning movement. Avoid holesanddropoffs.
18. Travelingonslopes/grades.
i. Ascend anddescendslowly andwithcaution.
ii. Whenloaded,alwaystravelwiththeloaduphill.
iii. Whenunloaded,travelwiththeattachmentdownhill.
iv. Avoid turning,travel straightupanddown.
19. Alwayspositionallwheelsinlinewiththemachinebeforeswitchingthesteering
mode.
20. Always positionthemachine andsetthepark brakebeforelifting aload.
21. Donotallowriders on themachineorforks.
22. Donot transportor liftpersonnel intoposition withthis forklift.
23. Whenleavingtheoperator's station:
i. Placethedirectionalcontrolsinneutral.
ii. Applythe parking brake.
iii. Lowertheattachment totheground.

ROUGH TERRAIN FORK LIFT SAFETY
NOTES
1-12

SECTION 2
GENERALSAFETY
2-1

TABLEOFCONTENTS
SECTION 2 - GENERAL SAFETY
GeneralSafety Procedures 2-3
JumpStarting 2-8
Proper Load Chart Use 2-9
2-2

GENERAL SAFETY
SAFETY ALERT SYMBOL
Stop and take time to read ALLsafety 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.
KEEPTHEFIRST-AIDKITandFIREEXTINGUISHER
properly maintained. Follow the instructions provided with the
first-aid kit and fire extinguisher.
GENERAL SAFETY PROCEDURES
2-3

GENERAL SAFETY
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.
NEVERjump on oroffthemachine.
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. DONOT 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.
GENERAL SAFETY PROCEDURES
2-4

GENERAL SAFETY
HYDRAULICSAFETY
WARNING
Hot hydraulic oil can cause severe burns. DO NOT work on
the hydraulic system if the oil temperature exceeds
120 degrees F. (49 degrees C).
BeforeANYONEworks on the hydraulic system:
1. Lower the boom to the horizontal position.
2. Support the boom to avoid unintentional lowering.
3. Shutdown the engine.
4. Remove the key from the ignition.
5. Clean the area around the oil reservoir cap (A).
FLUIDS UNDER PRESSURE
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.Aserious
infection or reaction can result without proper medical
treatment.
SERVICE TIRES SAFELY
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.
GENERAL SAFETY PROCEDURES
WARNING
2-5
A

GENERAL SAFETY
GENERAL SAFETY PROCEDURES
CAUTION
USESEATBELT
Always wear the seat belt while operating the machine to
reduce the risk of personal injury.
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.
DONOT adjust or lubricate the machine while it is in motion.
SHUTOFFtheengineandLOCKOUTthe ignition while
working on the machine unless maintenance instructions
require the engine to be running.
REPLACEall the shields and guards after servicing.
NEVERuse the machine as a platform for lifting personnel.
CAUTION
BOOMSAFETY
DONOTenter the DANGERAREAunder or around the boom
when the forks are off the ground or while the engine is running.
(SeediagramatrightforDANGERAREA).
Serious personal injury could result if the boom should
unexpectedly drop.
BeforeANYworkis performedintheDANGERAREA
the boom mustbe COMPLETELYloweredandtheforks
must be resting on the ground. 2-6
'$1* (5
DANGER