Operator’s Manual
GTH-844 GTH-842 GTH-644
with
Maintenance
Information
First Edition
Second Printing
Part No. 114100
TABLE OF CONTENTS
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SECTION 5
SECTION 6
ROUGH TERRAIN FORK LIFT SAFETY SECTION |
1-1 |
Introduction |
1-3 |
StandardsAnd Symbols |
1-4 |
Safety |
1-5 |
TrainingAnd Knowledge |
1-5 |
Operator's Responsibilities |
1-6 |
Management's Responsibilities |
1-7 |
Maintenance And Repair |
1-8 |
Operation Safety |
1-9 |
GENERAL SAFETY |
2-1 |
General Safety Procedures |
2-3 |
Jump Starting |
2-8 |
Proper Load Chart Use |
2-9 |
CONTROLS AND INSTRUMENTS |
3-1 |
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 |
Transmission |
3-10 |
FrontAxle Differential Lock |
3-11 |
OPERATION |
4-1 |
Operation And Safety Guidelines |
4-3 |
Before Starting The Engine |
4-4 |
Starting The Engine |
4-5 |
Before Operating The Forklift |
4-7 |
TransportingA Load |
4-11 |
PlacingA Load |
4-13 |
MAINTENANCE PROCEDURES |
5-1 |
General Safety Practices |
5-3 |
Daily Maintenance |
5-5 |
MATERIAL SAFETY DATA |
6-1 |
Material Safety Data Sheets |
6-3 |
California Proposition 65 Warnings |
6-4 |
SECTION 1
ROUGH TERRAIN FORK LIFT SAFETY
1 - 1
TABLE OF CONTENTS
SECTION 1 - ROUGH TERRAIN FORK LIFT SAFETY
Introduction |
1-3 |
Standards And Symbols |
1-4 |
Safety |
1-5 |
TrainingAnd 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. We feel that you make a major contribution to safety if you, as the equipment users and operators:
1.Comply with OSHA, Federal, State, and Local Regulations.
2.Read, Understand, and Follow the instructions in this and other manuals supplied with this machine.
3.Use Good Safe Work Practices in a common sense way.
4.Only have trained/certified operators – directed by informed and knowledgeable supervision – running the machine.
NOTE: OSHA prohibits the alteration or modification of this machine without written manufacturer's approval. Use only factory approved parts to service or repair this machine.
If there is anything in this manual that is not clear or which you believe should be added, please contact us.
Internet: www.genieind.com Email: techpub@genieind.com
Thank you!
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
STANDARDS
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 Lifts
This Standard can be purchased from:
American National Standards Institute 25 West 43nd Street, 4th Fl.
New York, New York, 10036 Tel. 212.642.4900
Fax. 212.398.0023
SYMBOLS
The symbols below are used to inform the operator of important information concerning the operation of this machine.
DANGER – Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING – Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION – Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
ATTENTION – Indicates a situation which, if not avoided, may result in property or equipment damage.
1 - 4
ROUGH TERRAIN FORK LIFT SAFETY 
SAFETY
These are general safety rules, which must be followed. You are also required to read and understand the Operator's Manual as there are instructions, which are more detailed specific to this machine.
TRAINING AND KNOWLEDGE
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 29CFR1910.178; and the American National Standards Institute (ANSI) B56.6 latest edition.
4.Read and Understand all Decals and Warnings.
5.Read and Understand the Rating Chart.
6.Know that the machine can safety lift each load before attempting to lift.
1 - 5
ROUGH TERRAIN FORK LIFT SAFETY 
OPERATOR'S RESPONSIBILITIES
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 machine clean, including all instrumentation, windows, lights and other glazed surfaces.
5.Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, hard hats, safety glasses and ear protection where necessary.
6.Wear protective clothing that is snug and belted where required.
7.Store tools and other necessary items in the toolbox.
8.Never lift a load without a Load Rating Chart in the cab.
9.Know the load to be lifted.
10.Be alert, physically fit and free from the influences of alcohol, drugs or medications that might affect the operator’s eyesight, hearing, or reactions.
11.Keep people, equipment and material out of the work area.
12.Keep a fully charged fire extinguisher and first aid kit in the cab at all times, and be familiar with how to use these items.
13.Know about movements of other machinery, trucks and personnel at the jobsite.
14.Make sure everyone is in a safe place before moving the boom, forks, load or outriggers (if so equipped.)
15.Start and stop movements smoothly and swing at speeds that will keep the load under control.
1 - 6
ROUGH TERRAIN FORK LIFT SAFETY 
MANAGEMENT'S RESPONSIBILITIES
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.
4.Supply the weight on the load to be lifted to the operator.
5.Verify that all crewmembers are familiar with OSHA, ANSI B56.6 requirements as well as instructions in the manuals.
1 - 7
ROUGH TERRAIN FORK LIFT SAFETY 
MAINTENANCE AND REPAIR
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 the machine or forks.
3.Shut off the engine and lockout the machine while working on the machine unless instructions specifically require the engine to be running.
4.Always make sure the machine is stationary prior to performing adjustments or lubrication.
5.Replace all shields and guards after performing service.
6.Always use a piece of cardboard or paper to search for leaks.
7.When performing work on the hydraulic system:
i.Lower the boom to horizontal.
ii.Support the boom with supports or braces.
iii.Shut down the engine.
iv.Relieve all pressure before disconnecting lines.
v.Ensure all connections are tight before applying pressure.
vi.Repair or replace any damaged line, hose or fitting before applying pressure.
8.Always have tires serviced and mounted by a qualified person with the proper tools and guards.
9.Always use an inflation cage during tire inflation.
10.Only perform welding on the machine with approval from the manufacturer.
1 - 8
ROUGH TERRAIN FORK LIFT SAFETY 
OPERATION SAFETY
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 sure that all guards and screens are secure and in the proper place.
4.Inspect for and clear the work area of any obstructions that could interfere with proper machine operation. Any obstructions that cannot be cleared should be clearly marked and avoided during operation.
5.Refueling:
i.Always stop the engine before refueling the machine.
ii.Fill the fuel tank outdoors.
iii.Handle fuel with care, as it is highly flammable. Do not refuel the machine while smoking or near open flames.
iv.Always clean up spilled fuel.
6.Make sure the machine and access system is clean and free of dirt, oil, grease or debris.
7.When getting on and off the machine, face the machine, use the steps and handrails provided, and always maintain a three point contact.
8.Always remain completely inside the cab enclosure while operating the machine.
9.Always wear the seat belt while operating the machine.
10.Always completely lower the boom with the forks resting on the ground before any work is performed on or around the machine.
11.Do not operate the machine while people are under or near an elevated boom whether the boom is loaded or unloaded. Falling objects from the forks or attachment may cause serious injury or death.
1 - 9
ROUGH TERRAIN FORK LIFT SAFETY 
OPERATION SAFETY
12.Maintain an appropriate clearance from electrical power lines. See the chart below for minimum safe approach distances.
Minimum Safe Approach Distance
Power Line Voltage |
Required Clearance |
|
|
0 to 50 kV |
10 ft. (3.00 m) |
50 to 200 kV |
15 ft. (4.60 m) |
200 to 350 kV |
20 ft. (6.10 m) |
350 to 500 kV |
25 ft. (7.62 m) |
500 to 750 kV |
35 ft. (10.67 m) |
750 to 1000 kV |
45 ft. (13.72 m) |
13.Lifting Loads:
i.Using the load chart, confirm that the load is within the rated capacity of the machine for the required configuration.
ii.Level the machine using the level gauge before lifting loads. Use the sway control to level the machine only when the boom is at horizontal or lower. Using the sway control with the boom above horizontal may cause the machine to overturn.
iii.Verify that the load is secured on the forks before performing a lift. Rearrange the load if necessary.
iv.Before lowering a maximum load, always retract the boom completely.
v.Use proper attachments, such as a truss boom, to lift suspended loads.
14.If the load to be lifted exceeds the capacity of the machine for the given configuration:
i.Move the machine closer to the load so that the weight of the load will be within the allowable load chart specifications.
ii.Divide the load into smaller pieces.
iii.Get a larger machine capable of handling the load.
15.Always move a load so that you have maximum machine stability and visibility is not obstructed. Keep the boom at or below horizontal, with the load close to the ground.
16.Tilt the forks back towards the machine slightly during travel to ensure stability of the load.
1 - 10
ROUGH TERRAIN FORK LIFT SAFETY 
OPERATION SAFETY
17.Inspect the path of travel before beginning movement. Avoid holes and dropoffs.
18.Traveling on slopes/grades.
i.Ascend and descend slowly and with caution.
ii.When loaded, always travel with the load uphill.
iii.When unloaded,travel with the attachment downhill.
iv.Avoid turning, travel straight up and down.
19.Always position all wheels in line with the machine before switching the steering mode.
20.Always position the machine and set the park brake before lifting a load.
21.Do not allow riders on the machine or forks.
22.Do not transport or lift personnel into position with this forklift.
23.When leaving the operator's station:
i.Place the directional controls in neutral.
ii.Apply the parking brake.
iii.Lower the attachment to the ground.
1 - 11
ROUGH TERRAIN FORK LIFT SAFETY 
NOTES
1 - 12
SECTION 2
GENERAL SAFETY
2 - 1
TABLE 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 
GENERAL SAFETY PROCEDURES
SAFETY ALERT SYMBOL
Stop and take time to read ALL safety 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.
2 - 3
GENERAL SAFETY
GENERAL SAFETY PROCEDURES
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.
NEVER jump on or off the machine.
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. DO NOT 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.
2 - 4
GENERAL SAFETY 
GENERAL SAFETY PROCEDURES
HYDRAULIC SAFETY
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).
Before ANYONE works on the hydraulic system: |
A |
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. A serious infection or reaction can result without proper medical treatment.
SERVICE TIRES SAFELY
WARNING
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.
2 - 5
GENERAL SAFETY
GENERAL SAFETY PROCEDURES
CAUTION
USE SEAT 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 affect machine life.
ALWAYS use a safety support or brace when working on, under, or around the machine or forks.
DO NOT adjust or lubricate the machine while it is in motion.
SHUT OFF the engine and LOCKOUT the ignition while working on the machine unless maintenance instructions require the engine to be running.
REPLACE all the shields and guards after servicing.
NEVER use the machine as a platform for lifting personnel.
CAUTION |
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BOOM SAFETY |
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DO NOT enter the DANGER AREA under or around the boom |
DANGER'$1* (5 |
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when the forks are off the ground or while the engine is running. |
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(See diagram at right for DANGERAREA). |
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Serious personal injury could result if the boom should |
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unexpectedly drop. |
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Before ANY work is performed in the DANGERAREA |
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the boom must be COMPLETELY lowered and the forks |
|
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must be resting on the ground. |
2 - 6 |
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