Genie GTH-644 manual

Operator’s Manual with Maintenance Information GTH-844 GTH-842 GTH-644 First Edition Second Printing Part No. 114 100[...]

SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY SECTION 1-1 Introduction 1 - 3 S tandards 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 P[...]

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 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 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, Fe[...]

ROUGH TERRAIN FORK LIFT SAFETY ST ANDARDS AND SYMBOLS 1 - 4 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 TERRAIN FORK LIFT SAFETY SAFETY 1 - 5 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 29CFR[...]

ROUGH TERRAIN FORK LIFT SAFETY OPERA T OR'S RESPONSIBILITIES 1 - 6 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 machin[...]

ROUGH TERRAIN FORK LIFT SAFETY MANAGEMENT'S RESPONSIBILITIES 1 - 7 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 [...]

ROUGH TERRAIN FORK LIFT SAFETY 1 - 8 MAINTENANCE AND REP AIR 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 th[...]

ROUGH TERRAIN FORK LIFT SAFETY OPERA TION SAFETY 1 - 9 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 su[...]

ROUGH TERRAIN FORK LIFT SAFETY 1 - 10 OPERA TION SAFETY e c n a t s i D h c a o r p p A e f a S m u m i n i M e g a t l o V e n i L r e w o Pe c n a r a e l C d e r i u q e R V k 0 5 o t 0) m 0 0 . 3 ( . t f 0 1 V k 0 0 2 o t 0 5) m 0 6 . 4 ( . t f 5 1 V k 0 5 3 o t 0 0 2) m 0 1 . 6 ( . t f 0 2 V k 0 0 5 o t 0 5 3) m 2 6 . 7 ( . t f 5 2 V k 0 5 7 o[...]

ROUGH TERRAIN FORK LIFT SAFETY 1 - 11 OPERA TION SAFETY 17 . Inspect the path of travel before beginning movement. A void holes and dropoffs. 1 8. T raveling 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. i v . A void tu[...]

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 SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. W ARNING AL W A YS wear eye protection and personal safety equipment. THE OPERA TOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the oper[...]

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 W ARNING Slips and falls can cause serious injury . When getting on and off the machine, always maintain a three [...]

GENERAL SAFETY HYDRAULIC SAFETY W ARNING 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). Before ANYONE works on the hydraulic system: 1 . Lower the boom to the horizontal position. 2 . Support the boom to avoid unintentional lowering. 3 . Shutdown the engin[...]

GENERAL SAFETY GENERAL SAFETY PROCEDURES CAUTION USE SEA T BELT 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 af fect machine life. AL W A YS use a safety support or brace when w[...]

GENERAL SAFETY A VOID ELECTRICAL POWER LINES DANGER REQUIRED CLEARANCE FOR NORMAL VOL T AGE IN OPERA TION NEAR HIGH VOL T AGE POWER LINES AND OPERA TION IN TRANSIT WITH NO LOAD AND BOOM OR MAST LOWERED. Normal V oltage, kV Minimum Required (Phase to Phase) Clearance, ft. (m) Operation Near High V oltage Power Lines t o 5 0 10 (3.05) Over 50 to 200 [...]

GENERAL SAFETY Location: The battery is located under the fuel tank / battery box cover (A). JUMP ST ARTING Jump starting at the battery or battery replacement is required when the battery is discharged to the point where the battery will not crank the starter . W ARNING Battery posts, terminals, and related accessories contain lead and lead compou[...]

GENERAL SAFETY PROPER LOAD CHAR T USE 2 - 9 NEVER raise a load and drive to position it. This can cause the machine to turnover . When placing a load, always move a loaded machine with the boom angle indicator (B) at 0 degrees or less. When the machine is as close as possible to where the load needs to be placed, set the parking brake, raise the lo[...]

GENERAL SAFETY PROPER LOAD CHART USE 2 - 10 PO Bo x 9703 0 1834 0 NE 76t h St Red m on d W A 9807 3 Ma nufa ctu rer' s reco mme nded capacity is p er ANSI B56.6 Stability T ests using standar d hom o ge ne ou s c ube s 4 x 4 x 4 ft / 1.2 x 1. 2 x 1 . 2 m. Load cap acit ie s at 24 in / 60 cm loa d ce nter with s tanda rd f ork frame . Rat ed l [...]

GENERAL SAFETY PROPER LOAD CHAR T USE 2 - 11 114071 A PO Bo x 9703 0 1834 0 NE 76t h St Red m on d W A 9807 3 Ma nufac ture r' s r eco mmen de d capacity is p er ANSI B56.6 Stability T ests using sta n dard hom o ge ne ou s c ubes 4 x 4 x 4 ft / 1.2 x 1. 2 x 1 . 2 m. Load cap acit ie s at 24 i n / 60 c m loa d ce nter with s tanda rd f ork fra[...]

GENERAL SAFETY NOTES 2 - 12[...]

SECTION 3 CONTROLS AND INSTRUMENTS 3 - 1[...]

T ABLE OF CONTENTS SECTION 3 - CONTROLS AND INSTRUMENTS Operator's Compartment 3 - 3 Joystick Control Functions 3 - 4 Joystick Control Functions (Button Pushed) 3 - 5 Service Brakes 3 - 6 Low Service Brake Pressure Light 3 - 6 Parking Brake 3 - 7 Frame Sway Control 3 - 8 Gauges 3 - 9 Hydraulic Pump Destroke Button 3 - 9 Steering 3-10 T ransmis[...]

CONTROLS AND INSTRUMENTS OPERA TOR'S COMP AR TMENT 3 - 3 1 . Accelerator Pedal 8 . Hourmeter 1 5 . Parking Brake Switch 2 2 . Heater Switch 2 . Joystick 4-way Controller 9 . Gauges 1 6 . Pump Off Button 2 3 . Plug / T urn Signal Wires 3 . Transmission Control Lever 1 0 . Machine Level Gauge 1 7 . Front W iper Switch 2 4 . Interior Rear V iew M[...]

CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS 3 - 4 A - Boom Down B - Boom Up C - Boom Out D - Boom In E - Boom Down and Out F - Boom Up and In G - Boom Up and Out H - Boom Down and In $ % & ' B A C D[...]

CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS (BUTTON PUSHED) 3 - 5 A - Tilt Down B - Tilt Back $ % B A[...]

CONTROLS AND INSTRUMENTS PUMP OFF LOW BRAKE PRESSURE HEADLIGHT S REAR WIPER FRONT WIPER WORKLIGHTS PARKING BRAKE The brake pedal is the operator's control for the service brakes. Pushing the service brake pedal (A) activates the service brakes for all four wheels. The brakes should be applied during normal operation to stop machine movement. W[...]

CONTROLS AND INSTRUMENTS PUMP OFF LOW BRAKE PRESSURE HEADLIGHTS REAR WIPER FRONT WIPER WORKLIGHTS PARKING BRAKE 3 - 7 C P ARKING BRAKE W ARNING Failure to set the parking brake before leaving the machine may result in unintended machine movement and possible injury or death and/or damage to the machine or property . The parking brake should be enga[...]

CONTROLS AND INSTRUMENTS The frame sway control (A) is located on the forward side of the right arm rest. The frame sway control is used in conjunction with the machine level indicator (B) located in the center of the cross support that the interior rear view mirror is mounted on. The sway control switch is either toggled to the left or right depen[...]

CONTROLS AND INSTRUMENTS The following gauges are used to monitor the machine: 1 - Fuel Level 2 - W ater T emperature, Engine 3 - Oil Pressure, Engine 4 - Oil T emperature, Powershift Transmission 5 - Oil Pressure, Powershift Transmission 6 - V oltmeter BRAKE PARKI NG PRES SURE LOW BRAK E OFF PUMP HE ADLI GHTS WORKL IGHTS WIPER FRONT WIPER REAR PUM[...]

CONTROLS AND INSTRUMENTS PUMP OFF LOW BRAKE PRESSURE HEADLIGHTS REAR WIPER FRONT WIPER WORKL IGHTS PARKING BRAKE In addition to the steering wheel, the machine has another steering control, the steering selector switch. The steering selector switch (A) is a three-position switch. The three positions are: 4-wheel, 2-wheel , and oblique. Switch posit[...]

CONTROLS AND INSTRUMENTS Always bring the front tires to a complete stop before engaging the front axle differential lock. Failure to stop the front tires before engaging the front axle differential lock may result in damage to the front axle. Never steer the front tires while using the front axle differential lock. Steering while the front axle di[...]

CONTROLS AND INSTRUMENTS 3 - 12 NOTES[...]

SECTION 4 OPERA TION 4 - 1[...]

T ABLE OF CONTENTS SECTION 4 - OPERA TION Operation And Safety Guidelines 4 - 3 Before Starting 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 4 - 2[...]

OPERATION OPERATION AND SAFETY GUIDELINES Y our safety and the safety of those around you depends upon you using care and judgement in the operation of this equipment. Know the positions and functions of all controls before attempting to operate this machine. All equipment has limitations. Understand the speed, braking, steering, stability , and lo[...]

OPERATION W ARNING Before starting the engine, be sure that all daily maintenance items have been performed. See Maintenance section. W alk around the machine and check for any parts that are missing, worn, damaged, or leaking. Repair and/or replace damaged parts. BEFORE ST AR TING THE ENGINE 4 - 4[...]

OPERATION PUMP OFF LOW BRAKE PRESSURE HEADLIGHTS REA R WIPER FRONT WIPER WORKLIGHTS PARKING BRAKE DANGER If the machine should start with the transmission control lever (C) in gear , stop operation at once or property damage, serious injury or death may occur . Have a qualified service technician repair the machine. DANGER NEVER attempt to start th[...]

OPERATION CAUTION If the engine fails to start within 30 seconds release the key , wait at least 2 minutes to allow the starter motor to cool before trying again. If the engine fails to start after four attempts, trouble shoot and correct the problem. DO NOT turn the key if the engine is running. This may cause damage to the starter motor . CAUTION[...]

OPERATION BRAK E PARKI NG PRESSURE LOW B RAKE OFF PUMP HEADLIGHTS WORKLIGHTS WIPE R FRONT WIPER REAR BEFORE OPERA TING THE FORKLIFT CAUTION If any gauge reading does not fall within the set tolerances the machine must be repaired before operation. Check the dash mounted gauges for logical readings. (1) Fuel Level 1/2 to Full (2) Engine W ater T emp[...]

OPERATION Operate the frame sway control (A) momentarily right and left. Check the steering operation by turning the steering wheel (B) approximately 1/4 turn in each direction. If the front and rear tires are not aligned properly , straighten the rear wheels with the steering selector valve (C) in the "4 wheel" position. Move the steerin[...]

OPERATION PUMP OFF LOW BR AKE PRESSUR E HEAD LIGHTS REAR WIPER FRO NT WIPER WORKLIGHTS PARKING BRAKE DANGER Any problems with the service brakes or the parking brake found while conducting the daily inspection should be corrected immediately . Failure to do so could result in injury or death. Activate the transmission using the transmission control[...]

OPERATION PUMP OFF LOW BRAKE PRESSUR E HEA DLIGHTS REAR WIPER FRO NT WIPER WORKLIGHTS PARKING BRAKE DANGER Never operate the machine with a faulty backup alarm. Doing so may result in serious injury or death. Place the transmission control lever (A) in reverse. The backup alarm should sound. If it does not sound, have the backup alarm repaired imme[...]

OPERATION Transporting a load with the boom extended and the boom angle indicator arrow (D) reading more than 0 degrees could cause a roll over hazard. The load should be kept as low to the ground as possible while traveling. Always move a loaded machine with the boom angle indicator (D) at 0 degrees or less. The forks should always be tilted back [...]

OPERATION PUMP OFF LOW BR AKE PRESSUR E HEAD LIGHTS REAR WIPER FRO NT WIPER WORKLIGHTS PARKING BRAKE W ARNING Slower speeds should be used whenever transporting a load. Always bring the machine to a complete stop before reversing the transmission control lever (A). Failure to do so can result in damage to the load, the machine and/or bystanders. Al[...]

OPERATION PUMP OFF LOW BRAKE PRESSURE HEADLIGHTS REAR WIPER FRONT WIPER WORKLIGHTS PARKING BRAKE W ARNING Do not sway the machine with the boom angle indicator arrow (B) at more than 0 degrees. By doing so you could cause a roll over hazard which may result in injury or death. DANGER Always apply the parking brake by toggling the parking brake swit[...]

OPERATION PLACING A LOAD DANGER Traveling with a reading of more than 0 degress on the boom angle indicator arrow (A) may cause a rollover hazard. Gradually move the 4-way controller towards the letter (B) to lift the load vertically . Hold the controller back until the required height has been achieved. Gradually move the 4-way controller towards [...]

OPERATION PLACING A LOAD 4 - 15 !" # When placing a load with the Model GTH-644, GTH-842, or the GTH-844 the rear axle stabilizing cylinders need to be taken into consideration. When the boom reaches an angle of 60 DEGREES , all frame leveling and transmission functions are disabled and the rear axle stabilizing cylinders become locked. This D[...]

OPERATION 4 - 16 NOTES[...]

SECTION 5 MAINTENANCE PROCEDURES 5 - 1[...]

T ABLE OF CONTENTS SECTION 5 - MAINTENANCE PROCEDURES General Safety Practices 5 - 3 Daily Maintenance 5 - 5 5 - 2[...]

MAINTENANCE PROCEDURES BEFORE SERVICING Read the entire Maintenance Procedure Section. Familiarize yourself with all the safety precautions listed in Sections 1 & 2. Pay close attention to all the safety alert symbols. Be sure you understand the procedures detailed in this section. W ear personal protective equipment. Remove rings and jewelry .[...]

MAINTENANCE PROCEDURES GENERAL SAFETY PRACTICES HYDRAULIC SAFETY W ARNING Hot hydraulic oil can cause severe burns. DO NOT work on the hydraulic system if the oil system temperature exceeds 120 degrees F . (49 degrees C.) Before ANYONE works on the hydraulic system: 1 . Lower the boom to the horizontal position. 2 . Support the boom to avoid uninte[...]

MAINTENANCE PROCEDURES PERFORM ENGINE MAINTENANCE Refer to engine operator's manual. Check engine oil. Check coolant level. Check engine fan. Open water separator . PERFORM TRANSMISSION MAINTENANCE Refer to the transmission operator's manual. Check transmission oil level. DAIL Y MAINTENANCE SCHEDULED MAINTENANCE Maintenace performed quart[...]

MAINTENANCE PROCEDURES CHECK HYDRAULIC OIL LEVEL Location: Sight glass (B). Behind the rear panel. T o Check: Move the machine to level ground. Level the frame. Completely retract the boom. Position the forks level. Lower the boom to the ground. Oil should be visible 1/2 way in sight glass (B). DAIL Y MAINTENANCE 5 - 6 B CHECK TIRE FOR PROPER INFLA[...]

SECTION 6 MA TERIAL SAFETY DA T A 6 - 1[...]

T ABLE OF CONTENTS SECTION 6 - MA TERIAL SAFETY DA T A Material Safety Data Sheets 6 - 3 California Proposition 65 W arnings 6 - 4 6 - 2[...]

MA TERIAL SAFETY DA T A 6 - 3 The Federal Occupational, Safety and Health Administration (OSHA) Standard 29 ctr 1910.1200, and in some cases state and local Right-T o-Know laws, may require specific MSDS be available to employees prior to operating this equipment. This may include information on substances contained in the equipment such as antifre[...]

MA TERIAL SAFETY DA T A 6 - 4 The following warnings are required on all off road equipment operating in the State of California. If you are operating a Genie in the State of California and do not see the approved warning labels, please contact us for a replacement at no charge. Our address is: Genie Industries PO Box 97030 Redmond, W A 98073-9730 [...]