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Genie GTH-644 Operator's Manual

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See also: Service Manual
Operator's Manual
GTH-844
GTH-842
GTH-644
with
Maintenance
Information
First Edition
Second Printing
Part No. 114100

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Summary of Contents for Genie GTH-644

  • Page 1 Operator’s Manual GTH-844 with Maintenance GTH-842 Information GTH-644 First Edition Second Printing Part No. 114100...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY SECTION Introduction Standards And Symbols Safety Training And Knowledge Operator's Responsibilities Management's Responsibilities Maintenance And Repair Operation Safety SECTION 2 GENERAL SAFETY General Safety Procedures Jump Starting Proper Load Chart Use SECTION 3 CONTROLS AND INSTRUMENTS Operator's Compartment...
  • Page 3 SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY 1 - 1...
  • Page 4 TABLE OF CONTENTS SECTION 1 - ROUGH TERRAIN FORK LIFT SAFETY Introduction Standards And Symbols Safety Training And Knowledge Operator's Responsibilities Management's Responsibilities Maintenance And Repair Operation Safety 1 - 2...

  • Page 5: Introduction

    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.

  • Page 6: 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.

  • Page 7: Safety

    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.

  • Page 8: Operator's Responsibilities

    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.

  • Page 9: Management's Responsibilities

    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.

  • Page 10: Maintenance And Repair

    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.

  • Page 11: Operation Safety

    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.
  • Page 12 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. t s i a t l r i u . t f . t f 13.
  • Page 13 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.
  • Page 14 ROUGH TERRAIN FORK LIFT SAFETY NOTES 1 - 12...

  • Page 15: General Safety

    SECTION 2 GENERAL SAFETY 2 - 1...
  • Page 16 TABLE OF CONTENTS SECTION 2 - GENERAL SAFETY General Safety Procedures Jump Starting Proper Load Chart Use 2 - 2...

  • Page 17: General Safety Procedures

    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.
  • Page 18 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.
  • Page 19 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.
  • Page 20 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.
  • Page 21 GENERAL SAFETY GENERAL SAFETY PROCEDURES AVOID ELECTRICAL POWER LINES DANGER REQUIRED CLEARANCE FOR NORMAL VOLTAGE IN OPERATION NEAR HIGH VOLTAGE POWER LINES AND OPERATION IN TRANSIT WITH NO LOAD AND BOOM OR MAST LOWERED. Normal Voltage, kV Minimum Required (Phase to Phase) Clearance, ft.

  • Page 22: Jump Starting

    GENERAL SAFETY JUMP STARTING Location: The battery is located under the fuel tank / battery box cover (A). JUMP STARTING 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.

  • Page 23: Proper Load Chart Use

    GENERAL SAFETY PROPER LOAD CHART USE WARNING 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.
  • Page 24 GENERAL SAFETY PROPER LOAD CHART USE PO Box 97030 18340 NE 76th St Redmond WA 98073 Manufacturer's recommended capacity is per ANSI B56.6 Stability Tests using standard homogeneous cubes 4 x 4 x 4 ft / 1.2 x 1.2 x 1.2 m. Load capacities at 24 in / 60 cm load center with standard fork frame.
  • Page 25 GENERAL SAFETY PROPER LOAD CHART USE PO Box 97030 18340 NE 76th St Redmond WA 98073 Manufacturer's recommended capacity is per ANSI B56.6 Stability Tests using standard homogeneous cubes 4 x 4 x 4 ft / 1.2 x 1.2 x 1.2 m. Load capacities at 24 in / 60 cm load center with standard fork frame.
  • Page 26 GENERAL SAFETY NOTES 2 - 12...

  • Page 27: Controls And Instruments

    SECTION 3 CONTROLS AND INSTRUMENTS 3 - 1...
  • Page 28 TABLE OF CONTENTS SECTION 3 - CONTROLS AND INSTRUMENTS Operator's Compartment Joystick Control Functions Joystick Control Functions (Button Pushed) Service Brakes Low Service Brake Pressure Light Parking Brake Frame Sway Control Gauges Hydraulic Pump Destroke Button Steering 3-10 Transmission 3-10 Front Axle Differential Lock 3-11 3 - 2...

  • Page 29: Operator's Compartment

    CONTROLS AND INSTRUMENTS OPERATOR'S COMPARTMENT 1. Accelerator Pedal 8. Hourmeter 15. Parking Brake Switch 22. Heater Switch 2. Joystick 4-way Controller 9. Gauges 16. Pump Off Button 23. Plug / Turn Signal Wires 3. Transmission Control Lever 10. Machine Level Gauge 17.

  • Page 30: Joystick Control Functions

    CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS Boom Down Boom Up Boom Out Boom In Boom Down and Out Boom Up and In Boom Up and Out Boom Down and In 3 - 4...

  • Page 31: Joystick Control Functions (Button Pushed)

    CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS (BUTTON PUSHED) Tilt Down Tilt Back 3 - 5...

  • Page 32: Service Brakes

    CONTROLS AND INSTRUMENTS SERVICE BRAKES 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.

  • Page 33: Parking Brake

    CONTROLS AND INSTRUMENTS PARKING BRAKE WARNING 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 engaged anytime the operator gets off the machine.

  • Page 34: Frame Sway Control

    CONTROLS AND INSTRUMENTS FRAME SWAY CONTROL WARNING Always ensure that the machine level indicator (B) is at zero (0) degrees before raising the boom. Raising the boom with an unlevel machine may cause the machine to overturn, resulting in injury or death. WARNING Use the frame sway control to level the machine only when the boom angle indicator is at 0 degrees or less.

  • Page 35: Gauges

    CONTROLS AND INSTRUMENTS GAUGES The following gauges are used to monitor the machine: 1 - Fuel Level 2 - Water Temperature, Engine 3 - Oil Pressure, Engine PUMP LOW BRAKE PARKING FRONT REAR WORKLIGHTS HEADLIGHTS PRESSURE BRAKE WIPER WIPER 4 - Oil Temperature, Powershift Transmission 5 - Oil Pressure, Powershift Transmission 6 - Voltmeter HYDRAULIC PUMP DESTROKE BUTTON...

  • Page 36: Steering

    CONTROLS AND INSTRUMENTS STEERING 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 positions are selected and function as follows: 4-WHEEL Handle rotated forward 2-WHEEL...

  • Page 37: Front Axle Differential Lock

    CONTROLS AND INSTRUMENTS FRONT AXLE DIFFERENTIAL LOCK The front axle differential lock switch (C) is located near the operator's left foot. It is a standard feature on all GTH-842 & GTH-844 models. The purpose for this device is to lock the front axle differential to gain added traction under certain conditions.
  • Page 38 CONTROLS AND INSTRUMENTS NOTES 3 - 12...

  • Page 39: Operation

    SECTION 4 OPERATION 4 - 1...
  • Page 40 TABLE OF CONTENTS SECTION 4 - OPERATION Operation And Safety Guidelines Before Starting The Engine Starting The Engine Before Operating The Forklift Transporting A Load 4-11 Placing A Load 4-13 4 - 2...

  • Page 41: Operation And Safety Guidelines

    OPERATION OPERATION AND SAFETY GUIDELINES WARNING Your 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 load chart characteristics of this machine before operating.

  • Page 42: Before Starting The Engine

    OPERATION BEFORE STARTING THE ENGINE WARNING Before starting the engine, be sure that all daily maintenance items have been performed. See Maintenance section. Walk around the machine and check for any parts that are missing, worn, damaged, or leaking. Repair and/or replace damaged parts.

  • Page 43: Starting The Engine

    OPERATION STARTING THE ENGINE DANGER Any problems discovered in the steps prior to "BEFORE STARTING THE ENGINE" should be corrected before the machine is started. DANGER NEVER attempt to start the machine without being seated in the operator's compartment, the parking brake switch (B) toggled forward in the on position and the transmission control (C) in the neutral position.
  • Page 44 OPERATION STARTING THE ENGINE 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.

  • Page 45: Before Operating The Forklift

    OPERATION BEFORE OPERATING 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. Fuel Level 1/2 to Full Engine Water Temperature 180 F to 200 F Engine Oil Pressure 40 to 80 PSI...
  • Page 46 OPERATION BEFORE OPERATING THE FORKLIFT 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"...
  • Page 47 OPERATION BEFORE OPERATING THE FORKLIFT 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 lever (D).
  • Page 48 OPERATION BEFORE OPERATING THE FORKLIFT 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 immediately.

  • Page 49: Transporting A Load

    OPERATION TRANSPORTING A LOAD WARNING 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. WARNING At no time should any load be suspended from the forks by use of chains, ropes, straps etc.
  • Page 50 OPERATION TRANSPORTING A LOAD WARNING 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. PUMP LOW BRAKE PAR KING...

  • Page 51: Placing A Load

    OPERATION PLACING A LOAD WARNING 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 switch (C) forward before lifting and/or placing a load.
  • Page 52 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.
  • Page 53 OPERATION PLACING A LOAD GTH-644, GTH-842, GTH-844 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.
  • Page 54 OPERATION NOTES 4 - 16...

  • Page 55: Maintenance Procedures

    SECTION 5 MAINTENANCE PROCEDURES 5 - 1...
  • Page 56 TABLE OF CONTENTS SECTION 5 - MAINTENANCE PROCEDURES General Safety Practices Daily Maintenance 5 - 2...

  • Page 57: General Safety Practices

    MAINTENANCE PROCEDURES GENERAL SAFETY PRACTICES 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.
  • Page 58 MAINTENANCE PROCEDURES GENERAL SAFETY PRACTICES HYDRAULIC SAFETY WARNING 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.

  • Page 59: Daily Maintenance

    MAINTENANCE PROCEDURES DAILY MAINTENANCE SCHEDULED MAINTENANCE Maintenace performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine. Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service.
  • Page 60 MAINTENANCE PROCEDURES DAILY MAINTENANCE CHECK HYDRAULIC OIL LEVEL Location: Sight glass (B). Behind the rear panel. To 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).

  • Page 61: Material Safety Data

    SECTION 6 MATERIAL SAFETY DATA 6 - 1...
  • Page 62 TABLE OF CONTENTS SECTION 6 - MATERIAL SAFETY DATA Material Safety Data Sheets California Proposition 65 Warnings 6 - 2...

  • Page 63: Material Safety Data Sheets

    This may include information on substances contained in the equipment such as antifreeze, brake fluid, battery acid and hydraulic fluid. Genie will provide, at no cost, Material Safety Data Sheets which are applicable to their product line. Simply request them from your local Genie dealer or contact us at:...

  • Page 64: California Proposition 65 Warnings

    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:...

This manual is also suitable for:

Gth-842Gth-844

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