Terex Genie GTH-644 User manual

Operator's Manual
GTH-644•GTH-844 PartNo.T109021
Second Edition • First Printing
Copyright © 2010 by Genie Industries
Second Edition:First Printing, December 2010
"Genie" is a registered trademark of
Genie Industries in the U.S.A. and many other
countries. "GTH" is a trademark of Genie
Industries.
Printed on recycled paper
Printed in U.S.A.
Important
Read,understandandobeythesesafetyrulesand
operating instructions before operating this machine.
Only trained and authorized personnel shall be
permitted to operate this 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, call Genie Industries.
Contents
Page
Introduction ................................................................ 1
Symboland Hazard Pictorials Definitions................... 3
GeneralSafety........................................................... 5
Work Area Safety...................................................... 11
Legend ...................................................................... 16
Controls .................................................................... 17
Inspections ............................................................... 20
OperatingInstructions............................................... 34
TransportInstructions ............................................... 42
Maintenance ............................................................. 43
Specifications ........................................................... 46
Contact us:
Internet:www.genielift.com
E-mail:[email protected]

Operator'sManualSecond Edition • First Printing
PartNo.T109021 GTH-644•GTH-844 1
Introduction
Owners, Users and Operators:
Genieappreciates your choice of our machinefor
yourapplication.Ournumberonepriorityis user
safety, which is best achieved by our joint efforts.
We feel that you make a major contribution to
safety if you, as the equipment users and
operators:
1 Comply with employer, job site and
governmentalrules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices inacommon
sense way.
4 Be alert and free from the influences of alcohol,
drugs or medications that might affect eyesight,
hearing,reactionsorjudgement.
5 Onlyhavetrained/certifiedoperators,directed
byinformedandknowledgeablesupervision,
runningthemachine.
If there is anything in this manual that is not clear
orwhichyoubelieveshould be added, please
contact us.
Internet:www.genielift.com
E-mail:[email protected]
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
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Alwaysperformapre-operationinspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread,understandandobeythe
manufacturer'sinstructionsandsafetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperlytrainedtosafelyoperate the
machine.

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2 GTH-644•GTH-844 PartNo.T109021
Standards
Many aspects of rough terrain forklift operation and
testing are discussed in standards published by the
AmericanNationalStandardsInstituteandthe
IndustrialTruckStandardsDevelopment
Foundation.Thesestandardsareupdatedona
regularbasiswithaddenda.Genierecommends
that you obtain and refer to the following standards.
ANSI/ITSDF B56.6 – Rough Terrain Fork Lifts
ThisStandardcanbedownloadedfrom
www.ITSDF.org
ITSDF
1750 K Street NW
Site 460
WashingtonDC20006
Introduction
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-basedcleanersbecausetheymaydamage
the safety sign material.
Hazard Classification
Genie uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
youtopotentialpersonalinjury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicatesa hazardous situation
which, if not avoided, will result in
deathorseriousinjury.
Indicatesa hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicatesa hazardous situation
which, if not avoided, could result
inminoror moderateinjury.
Indicatesapropertydamage
message.
Red
Orange
Yellow
Blue
Intended Use
A variable reach rough terrain forklift truck is
defined as a wheeled type truck with a pivoting
boom,whichmaybeequippedwithvarious
attachmentsforpicking,transportingandplacing
loadswithin the established load range charts.

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PartNo.T109021 GTH-644•GTH-844 3
Symbol and Hazard Pictorials Definitions
Hazard Pictorial Descriptions
Bodily Injury
Hazard Always wear seat
belt.
CrushHazard Supportboom
whenperforming
maintenance.
Noriders.
FallHazard
Maintainrequired
clearance.
Electrocution
Hazard Nopeopleunder
load.
FallingObject
Hazard
InjectionHazard Usecardboardto
search for leaks. CrushHazard
Readthe
operator'smanual.
Keepawayfrom
movingparts.
BurnHazard
BurnHazard
Explosion/Burn
Hazard
Lower forks. Set
parkingbrake.
Nosmoking. No
openflame.
Keep clear of
movingparts.
Allow system to
cool.
Allow surfaces to
cool.
Overturning
Hazard Swayoperation
CrushHazard CrushHazard
Overturning
Hazard
Operatefrom
operator'sstation.
x
CrushHazard

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4 GTH-644•GTH-844 PartNo.T109021
Hazard Pictorial Descriptions
CrushHazard Keep awayfrom
movingparts. Overturning
Hazard Keeploadlow.
Symbol and Hazard Pictorials Definitions

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PartNo.T109021 GTH-644•GTH-844 5
General Safety
Safetysignsandlocations

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General Safety
Safetysignsandlocations

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General Safety
Safetysignsandlocations

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General Safety
Safetysignsandlocations

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General Safety
Safetysignsandlocations

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10 GTH-644•GTH-844 PartNo.T109021
General Safety
Safetysignsandlocations

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PartNo.T109021 GTH-644•GTH-844 11
Work Area Safety
Overturning Hazards
Using the load chart, confirm
that the load is within the rated
capacity of the machine. Do not
exceedtheratedload.
Do not raise the load unless the
groundcansupportallforces
imposed by the machine.
Donotloweraloadwithout
retracting the boom first.
Do not operate the machine if
the load chart is missing.
Do not exceed the rated capacity
foreachconfiguration.
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
positionanelevatedload.
Do not raise a load and then
drive to position it.
When driving, keep the boom at
orbelowhorizontal andkeepthe
load close to the ground.
Do not push the hydraulic
disablebuttonwhiletraveling.An
immediate loss of hydraulic
powerwillresultand theparking
brakewillapply suddenly.
Operatethemachineatspeeds
that will keep the load under
control. Start and stop
movements smoothly.
Do not raise a load unless the
loadisproperly positionedor
securedontheforksorapproved
attachment.
Donotoperate the machine in
strong or gusty winds. Do not
increase the surface area of the
carriageortheload.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,debris,unstableor slippery surfaces and
nearholesanddrop-offs.
Do not alter or disable machine components that in
any way affect safety or 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.
Donotreplacefactory-installedballast-filled tires
with air-filled tires. Wheel weight is critical to
stability.
Air-filled tires must be factory-installed. Machine
equippedwithair-filledtiresarealsoequippedwith
additionalcounterweight.Donotreplacestandard
factory-installed tires with air-filled tires.

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12 GTH-644•GTH-844 PartNo.T109021
Traveling on Slopes
Whendriving,keep the
boomator below
horizontalandkeepthe
load close to the
ground.
When the machine is loaded, always travel with the
loaduphill. 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
ordownaslope.
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
unlesstheboom andequipmentareintheir proper
travelposition.
Whethera machine will tip over duringdynamic
machine operation involves many factors that need
tobeconsidered. Among these are pavement/
ground conditions, stability and slope, as well as
machineequipment,operatorskill, load position,
tire inflation, machine speed, etc.
Additionally, tip-over of a machine is dependent in
largepart upon operator inputs such as the speed
and smoothness of the operation, as well as the
position of the attachment and its load.
Constructionsitesandroadswillfrequentlychange
slope from place to place, can be hard and soft,
and change due to construction activities and
weather.
Operatorsshouldbeproperlytrainedandusetheir
best judgment and experience to take the
necessaryprecautions to prevent a tip-over.
Operators must assess the job site variables and
avoidexceedingthemachine's(oroperator's)
capabilitiesforterrainandconditions.
Fall Hazards
Always wear a seat belt when
operatingthemachine.
Always remain completely inside
thecabwhenoperatingthe
machine.
When getting in and out of the
cab, face the machine, use the
stepsandhandrailsprovidedand
alwaysmaintainthree-point
contact.
Do not use the steering wheel or
any other controls as handrails.
Do not allow riders on the
machine or forks.
Donot transport or lift personnel
with this machine.
x
Work Area Safety

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PartNo.T109021 GTH-644•GTH-844 13
Collision Hazards
Keeppeople,equipmentand
material out of the work area. Do
notoperatethemachinewhile
peopleareunderornearan
elevated boom, whether it is
loadedorunloaded.
Do not put the transmission into
gear unless the parking brake is
set.
Do not drive the machine if
visibility is obstructed.
Do not raise the boom unless the
parking brake is set.
Donotoperatethemachinewith
a faulty back-up alarm.
Operators must comply with
employer, job site and
governmentalrulesregardingthe
useof personal protective
equipment.
Donotoperatehydraulicdisable
buttonafter engine has started.
Falling Object Hazards
Operatethemachineatspeeds
that will keep the load under
control. Start and stop
movements smoothly.
Keeppeople,equipmentand
material out of the work area. Do
notoperatethemachinewhile
peopleareunderornearan
elevated boom, whether it is
loadedorunloaded.
Do not push the hydraulic
disablebuttonwhiletraveling.An
immediate loss of hydraulic
powerwillresultand theparking
brakewillapply suddenly.
Bodily Injury Hazard
Always adjust the seat and
fasten the seat belt before
startingtheengine.
Donotoperatethemachinewith
a hydraulic oil or air leak.
Escapingfluidunderpressure
can penetrate skin, causing
seriousinjury.Relievepressure
beforedisconnectinghydraulic
lines. Keep away from leaks and
pin holes. Use a piece of
cardboardorpapertosearchfor
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.
Work Area Safety

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14 GTH-644•GTH-844 PartNo.T109021
Component Damage Hazards
Do not use any battery or charger greater than 12V
tojump-starttheengine.
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.
Explosion and Fire Hazards
Do not start the engine if you
smell or detect gasoline, diesel
fuel or other explosive
substances.
Do not refuel the machine with
theenginerunning.
Refuelthemachineandcharge
the battery only in an open, well-
ventilatedareaawayfrom
sparks, flames and lighted
tobacco.
Donotoperate the machine in
hazardouslocationsor locations
wherepotentiallyflammableor
explosive gases or particles may
bepresent.
Do not spray ether into engines
equippedwithglowplugsorair
intakegridheaters.
Alwaysoperatethemachineinawell-ventilated
areatoavoidcarbonmonoxidepoisoning.
Impropercontactwithcomponentsunder any cover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operationinspection.Allcompartmentsmust
remainclosedandsecuredduringoperation.
Damaged Machine Hazards
Donotuseadamagedormalfunctioningmachine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besureallmaintenancehasbeenperformedas
specifiedinthismanualandthe appropriate Genie
servicemanual.
Be sure all decals are in place and legible.
Be sure the operator’s and safety manuals are
complete,legibleandinthestoragecontainer
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
pryingwedgedorfrozenloadsfree.
Burn Hazards
Allow hot surfaces to cool before
touchingorservicing.
Work Area Safety

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PartNo.T109021 GTH-644•GTH-844 15
Electrocution Hazards
Maintainanappropriate
clearancefromelectricalpower
lines. See the chart below for
requiredclearance.
LineVoltage Required Clearance
0 to 50KV 10 ft 3.0 m
50 to 200KV 15 ft 4.6 m
200 to 350KV 20 ft 6.1 m
350 to 500KV 25 ft 7.6 m
500 to 750KV 35 ft 10.6 m
750 to 1000KV 45 ft 13.7 m
Do not use the machine as a ground for welding.
Always contact the electric power line owner. The
electricpowershallbedisconnectedorthepower
linesmovedorinsulatedbeforemachineoperations
begin.
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothingandeye wearwhenworkingwith batteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Explosion Hazard
Keep sparks, flames and lighted tobacco away
from batteries. Batteries emit explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.
Employer's Responsibilities
Employersareresponsibleforprovidingasafework
environmentandforcomplyingwithlocaland
nationalgovernmentalregulations.
Work Area Safety

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16 GTH-644•GTH-844 PartNo.T109021
Legend
1 Handrail
2 Machinelevelindicator
3 Interiorrearviewmirror
4 Steeringwheel
5 Controlhandle
6 Operator'smanualstorage
container
7 Sway control switch
8 Auxiliary hydraulics switch
9 Seat
10 Seat belt
11 Cab
12 Engine(undercover)
13 Fusepanel
14 Fork
15 Externalrearviewmirror(on
oppositesideofmachine)
16 Boom
17 Boomangleindicator
18 Step
19 Differential lock switch
20 Servicebrakepedal
21 Acceleratorpedal
22 Steer selector switch
23 Loadcharts
24 Transmissioncontrollever

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PartNo.T109021 GTH-644•GTH-844 17
1 Heatercontrols
2 Transmissioncontrollever
3 Fuelgauge
4 Enginewatertemperaturegauge
5 Engineoilpressuregauge
6 Transmissionoiltemperaturegauge
7 Transmissionoilpressuregauge
8 Voltmeter
9 Frontwindowwiper/washerswitch
10 Turnsignalandemergencyflasherlever (if
equipped)
11 Controlhandlewiththumbswitch (single control
handleoption)
12 Steer selector switch
13 Boomcontrolhandle(dualcontrolhandleoption)
14 Tiltandswaycontrolhandle(dualcontrolhandle
option)
15 Auxiliary hydraulics switch
16 Notused
17 Sway control switch (single control handle
option)
18 Glowplugbutton(ifequipped)
19 Roadlightswitch (ifequipped)
20 Worklightswitch(ifequipped)
21 Ignition switch
22 Parkingbrakeswitch
23 Lowbrakepressureindicatorlight
24 Hydraulicdisablebutton
25 Etherstartingaidbutton (ifequipped)
26 Steeringwheel
Controls

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18 GTH-644•GTH-844 PartNo.T109021
Controls
1 Heatercontrols
2 Transmissioncontrollever
Move the transmission control lever toward you
and move it up for forward gear. Move the lever
toward you and move it down for reverse gear.
Move the lever to the center position for neutral.
Turn the lever clockwise to shift to a lower
speed. Turn the lever counterclockwise to shift
toa higher speed.
If the boom is raised above 60°, the
transmission will shift to neutral and the frame
sway function will not operate.
3 Fuelgauge
4 Enginewatertemperaturegauge
5 Engineoilpressuregauge
6 Transmissionoiltemperaturegauge
7 Transmissionoilpressuregauge
8 Voltmeter
9 Frontwindowwiper/washerswitch
Turn the switch clockwise one click for slow
speedwiperoperation.Turntheswitch
clockwise two clicks for fast speed wiper
operation.Turn the switch counterclockwise to
slow down or turn off the wiper.
10 Turnsignalandemergencyflasherlever (if
equipped)
Move the lever away from you and move it up
for the left turn signal. Move the lever toward
you and move it down for right turn signal. Turn
the lever clockwise to turn on the emergency
flashers. Turn the lever counterclockwise to turn
off the emergency flashers.
11 Controlhandlewiththumbswitch (single control
handleoption)
Pull the control handle back and the boom will
raise.Pushthecontrolhandleforwardandthe
boom will lower. Push the control handle to the
right and the boom will extend. Pull the control
to the left and the boom will retract. Hold down
the thumb switch and pull the control handle
back and the forks will tilt up. Hold down the
thumb switch and push the control handle
forward and the forks will tilt down.
12 Steer selector switch
Move the steer selector switch forward to select
four-wheel steer. Move the steer selector switch
to the center to select two-wheel steer. Move
the steer selector switch backward to select
crabsteer.
13 Boomcontrolhandle(dualcontrolhandleoption)
Pull the control handle back and the boom will
raise.Pushthecontrolhandleforwardandthe
boom will lower. Push the control handle to the
right and the boom will extend. Pull the control
to the left and the boom will retract.
14 Tiltandswaycontrolhandle(dualcontrolhandle
option)
Pull the control handle back and the forks will tilt
up.Pushthecontrolhandleforwardandthe
forks will tilt down. Push the control handle to
the right and the machine will sway to the right.
Pull the control handle to the left and the
machine will sway to the left.