Genie GTH-844, GTH-644, GTH-842 User Manual

Operator’s Manual

GTH-844
GTH-842
GTH-644

with
Maintenance
Information

First Edition

Second Printing

Part No. 114100

TABLE OF CONTENTS

SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY SECTION 1-1

Introduction 1-3
Standards And Symbols 1-4
Safety 1-5
Training 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
Proper Load Chart Use 2-9

SECTION 3 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 DestrokeButton 3-9
Steering 3-10
Transmission 3-10
Front Axle Differential Lock 3-11

SECTION 4 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
T ransporting A Load 4-11
Placing A Load 4-13

SECTION 5 MAINTENANCE PROCEDURES 5-1

General Safety Practices 5-3
Daily Maintenance 5-5

SECTION 6 MATERIAL SAFETY DA T A 6-1

Material Safety Data Sheets 6-3
California Proposition 65 W arnings 6-4

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

Training 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, 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 W ork 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: [e-mail]

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

SYMBOLS

STANDARDS AND SYMBOLS

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 T errain Fork Lifts

This Standard can be purchased from:

American National Standards Institute
25 W est 43nd Street, 4th Fl.
New Y ork, New Y ork, 10036
T el. 212.642.4900
Fax. [phone]

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 .

W ARNING – 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 .

A TTENTION – 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 W arnings.

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. W ear 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. V erify 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.

i i . 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.

v i. 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.

i i . 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.

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Vk05ot0)m00.3(.tf01

Vk002ot05)m06.4(.tf51

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Vk005ot053)m26.7(.tf52
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Vk0001ot057)m27.31(.tf54

13. Lifting Loads:

i . Using the load chart, confirm that the load is within the rated

capacity of the machine for the required configuration.

i i. 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 .

i v . 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.

i i. 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. A void holes and dropoffs.

18. Traveling 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.
iv. A void 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.

i i . 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

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

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.

KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER
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. AL WA YS 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:

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.

A

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 BEL T

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.

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

BOOM SAFETY

DO NOT enter the DANGER AREA under or around the boom
when the forks are off the ground or while the engine is running.
(See diagram at right for DANGER AREA) .

Serious personal injury could result if the boom should
unexpectedly drop.

Before ANY work is performed in the DANGER AREA
the boom must be COMPLETEL Y lowered and the forks
must be resting on the ground.

2 - 6

DANGER

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