Terex Genie GTH-644 Operator's Manual
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Terex Genie GTH-644 Operator's Manual

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Summary of Contents for Terex Genie GTH-644

  • Page 2: Table Of Contents

    Copyright © 2010 by Genie Industries Second Edition:First Printing, December 2010 Internet: www.genielift.com "Genie" is a registered trademark of E-mail: awp.techpub@terex.com 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.

  • Page 3: Introduction

    3 Always perform function tests prior to use. contact us. 4 Inspect the workplace. Internet: www.genielift.com 5 Only use the machine as it was intended. E-mail: awp.techpub@terex.com You read, understand and obey the manufacturer's instructions and safety rules— safety and operator's manuals and machine decals.
  • Page 4 Operator's Manual Second Edition • First Printing Introduction Standards Hazard Classification Many aspects of rough terrain forklift operation and Genie uses symbols, color coding and signal words testing are discussed in standards published by the to identify the following: American National Standards Institute and the Safety alert symbol—used to alert Industrial Truck Standards Development you to potential personal injury...

  • Page 5: Symbol And Hazard Pictorials Definitions

    Second Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Hazard Pictorial Descriptions Electrocution Falling Object Maintain required No people under Fall Hazard Hazard Hazard clearance. load. Always wear seat Bodily Injury No riders. Operate from Crush Hazard belt.
  • Page 6 Operator's Manual Second Edition • First Printing Symbol and Hazard Pictorials Definitions Hazard Pictorial Descriptions Overturning Keep load low. Keep away from Crush Hazard Hazard moving parts. GTH-644 • GTH-844 Part No. T109021...

  • Page 7: General Safety

    Second Edition • First Printing Operator's Manual General Safety Safety signs and locations Part No. T109021 GTH-644 • GTH-844...
  • Page 8 Operator's Manual Second Edition • First Printing General Safety Safety signs and locations GTH-644 • GTH-844 Part No. T109021...
  • Page 9 Second Edition • First Printing Operator's Manual General Safety Safety signs and locations Part No. T109021 GTH-644 • GTH-844...
  • Page 10 Operator's Manual Second Edition • First Printing General Safety Safety signs and locations GTH-644 • GTH-844 Part No. T109021...
  • Page 11 Second Edition • First Printing Operator's Manual General Safety Safety signs and locations Part No. T109021 GTH-644 • GTH-844...
  • Page 12 Operator's Manual Second Edition • First Printing General Safety Safety signs and locations GTH-644 • GTH-844 Part No. T109021...

  • Page 13: Work Area Safety

    Second Edition • First Printing Operator's Manual Work Area Safety Operate the machine at speeds Overturning Hazards that will keep the load under control. Start and stop Using the load chart, confirm movements smoothly. that the load is within the rated capacity of the machine.
  • Page 14 Operator's Manual Second Edition • First Printing Work Area Safety Traveling on Slopes Fall Hazards When driving, keep the Always wear a seat belt when boom at or below operating the machine. horizontal and keep the Always remain completely inside load close to the the cab when operating the ground.
  • Page 15 Second Edition • First Printing Operator's Manual Work Area Safety Collision Hazards Falling Object Hazards Keep people, equipment and Operate the machine at speeds material out of the work area. Do that will keep the load under not operate the machine while control.
  • Page 16 Operator's Manual Second Edition • First Printing Work Area Safety Always operate the machine in a well-ventilated Component Damage Hazards area to avoid carbon monoxide poisoning. Do not use any battery or charger greater than 12V Improper contact with components under any cover to jump-start the engine.
  • Page 17 Second Edition • First Printing Operator's Manual Work Area Safety Electrocution Hazards Battery Safety Maintain an appropriate Burn Hazards clearance from electrical power lines. See the chart below for Batteries contain acid. Always wear protective required clearance. clothing and eye wear when working with batteries. Avoid spilling or contacting battery acid.

  • Page 18: Legend

    Operator's Manual Second Edition • First Printing Legend 1 Hand rail 10 Seat belt 18 Step 2 Machine level indicator 11 Cab 19 Differential lock switch 3 Interior rear view mirror 12 Engine (under cover) 20 Service brake pedal 4 Steering wheel 13 Fuse panel 21 Accelerator pedal 5 Control handle...

  • Page 19: Controls

    Second Edition • First Printing Operator's Manual Controls 1 Heater controls 14 Tilt and sway control handle (dual control handle option) 2 Transmission control lever 15 Auxiliary hydraulics switch 3 Fuel gauge 16 Not used 4 Engine water temperature gauge 17 Sway control switch (single control handle 5 Engine oil pressure gauge option)
  • Page 20 Operator's Manual Second Edition • First Printing Controls 1 Heater controls 11 Control handle with thumb switch (single control handle option) 2 Transmission control lever Pull the control handle back and the boom will Move the transmission control lever toward you raise.
  • Page 21 Second Edition • First Printing Operator's Manual Controls 15 Auxiliary hydraulics switch 22 Parking brake switch Push and hold the auxiliary hydraulics switch to Push the top of the rocker switch to turn the provide hydraulic flow to powered attachments. parking brake on.

  • Page 22: Inspections

    Operator's Manual Second Edition • First Printing Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection Do Not Operate Unless: performed by the operator prior to each work shift. The inspection is designed to discover if anything You learn and practice the principles of safe is apparently wrong with a machine before the...
  • Page 23 Second Edition • First Printing Operator's Manual Inspections Pre-operation Inspection Engine and related components Be sure that the operator’s and safety manuals are complete, legible and in the storage Limit switches container located in the operator's compartment. Steer and axle sensors Be sure that all decals are legible and in place.
  • Page 24 Operator's Manual Second Edition • First Printing Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 25 Second Edition • First Printing Operator's Manual Inspections Test the Single Control Handle (if equipped) Test the Sway Control (if equipped with single control handle) 7 Using the control handle, momentarily raise the boom, extend the boom, retract the boom and 12 Push the right side of the sway control rocker lower the boom.
  • Page 26 Operator's Manual Second Edition • First Printing Inspections Test the Transmission and Brakes Test Auxilliary Hydraulics (if equipped with swing or rotate carriage) 22 Be sure the boom is fully lowered and retracted. 29 Using the auxiliary hydraulics switch, 23 Step on the service brake pedal. momentarily rotate the carriage to the right and to the left.
  • Page 27 Second Edition • First Printing Operator's Manual Inspections Workplace Inspection Be aware of and avoid the following hazardous situations: · drop-offs or holes · bumps, floor obstructions or debris Do Not Operate Unless: · sloped surfaces You learn and practice the principles of safe ·...
  • Page 28 GTH-644 97676 Danger - Electrocution Hazard 130693 Load Chart Card, CAT Attachment, 114057 Cosmetic - Genie GTH-844 GTH-644 114059 Cosmetic - Genie GTH-644 130701 Load Chart Card, Standard Forks, 114062 Cosmetic - GTH-844 GTH-844 114083 Cosmetic - Genie Logo 114087...
  • Page 29 Second Edition • First Printing Operator's Manual Inspections Part No. T109021 GTH-644 • GTH-844...
  • Page 30 Operator's Manual Second Edition • First Printing Inspections Inspection for Decals with Words Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. This inspection is a continuation from the previous page.
  • Page 31 Second Edition • First Printing Operator's Manual Inspections Part No. T109021 GTH-644 • GTH-844...
  • Page 32 Load Chart Card, CAT Attachment, 82560 Warning - Injection Hazard GTH-644 114057 Cosmetic - Genie GTH-844 130701 Load Chart Card, Standard Forks, 114059 Cosmetic - Genie GTH-644 GTH-844 114062 Cosmetic - GTH-844 130702 Load Chart Card, Swing Carriage, GTH-844 114083 Cosmetic - Genie...
  • Page 33 Second Edition • First Printing Operator's Manual Inspections Part No. T109021 GTH-644 • GTH-844...
  • Page 34 Operator's Manual Second Edition • First Printing Inspections Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. This inspection is a continuation from the previous page.
  • Page 35 Second Edition • First Printing Operator's Manual Inspections Part No. T109021 GTH-644 • GTH-844...

  • Page 36: Operating Instructions

    Operator's Manual Second Edition • First Printing Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator's responsibility to follow all the safety rules and instructions in the operator's and safety manuals. Do Not Operate Unless: A variable reach rough terrain forklift truck is defined as a wheeled type truck designed primarily...
  • Page 37 Second Edition • First Printing Operator's Manual Operating Instructions Parking Brake Steer Select Use the parking brake switch to apply the parking Always position all wheels in line with the machine brake before raising the boom or leaving the before switching the steering mode. machine.
  • Page 38 Operator's Manual Second Edition • First Printing Operating Instructions Transmission Control When shifting the transmission from forward to reverse while the machine is in motion, the transmission control lever must be in 1st or 2nd Use the transmission control lever to control the gear only.
  • Page 39 Second Edition • First Printing Operator's Manual Operating Instructions Frame Sway Control Transporting a Load Before raising the boom, the machine must be Center the load on the forks. Position the load so level. that it is completely against the back of the fork frame.
  • Page 40 Operator's Manual Second Edition • First Printing Operating Instructions Placing the load 1 Travel to the desired work site and carefully stop the machine. 2 Put the transmission in neutral. 3 Apply the parking brake. 4 Level the frame, if the machine angle indicator is not at 0.
  • Page 41 Second Edition • First Printing Operator's Manual Operating Instructions Controller movements - Single Controller movements - Dual Control Handle Control Handles Control handle only Boom control handle Control handle with thumb switch Tilt and sway control handle Part No. T109021 GTH-644 •...
  • Page 42 Operator's Manual Second Edition • First Printing Operating Instructions Rear Axle Lock Jump Starting the Machine If the boom is raised above 60°, the transmission Jump starting at the battery or battery replacement will shift to neutral and the frame sway function will is required when the battery is discharged to the not operate.
  • Page 43 Second Edition • First Printing Operator's Manual Operating Instructions Additionally, tip over of a machine is dependent in Driving on a slope large part upon operator inputs such as the speed and smoothness of the operation as well as the When the machine is loaded, always travel with the position of the attachment and its load.

  • Page 44: Transport Instructions

    Operator's Manual Second Edition • First Printing Transport Instructions Securing to Truck or Trailer for Transit Turn the key switch to the off position and remove the key before transporting. Inspect the entire machine for loose or unsecured Observe and Obey: items.

  • Page 45: Maintenance

    Second Edition • First Printing Operator's Manual Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level Observe and Obey: can damage engine components. Check the oil level with the engine off.
  • Page 46 Operator's Manual Second Edition • First Printing Maintenance Check the Hydraulic Oil Level Check the Batteries Proper battery condition is essential to good engine Maintaining the hydraulic oil at the proper level is performance and operational safety. Improper fluid essential to machine operation. Improper hydraulic levels or damaged cables and connections can oil levels can damage hydraulic components.
  • Page 47 Second Edition • First Printing Operator's Manual Maintenance Check the Engine Coolant Level Check the Tire Pressure - Liquid Cooled Models Tip-over hazard. An overinflated tire can explode which may compromise machine Maintaining the engine coolant at the proper level is stability and cause the machine to tip over.

  • Page 48: Specifications

    Operator's Manual Second Edition • First Printing Specifications GTH-644 GTH-844 Height, stowed 8 ft 11 in 2.5 m Height, stowed 8 ft 11 in 2.5 m Length, stowed, without forks 19 ft 10 in 6.0 m Length, stowed, without forks 20 ft 6.1 m Width, standard tires...
  • Page 49 Second Edition • First Printing Operator's Manual Load Charts GTH-644 Standard Carriage GTH-644 Swing Carriage GTH-644 Pin-on Bucket GTH-644 Pin-on Truss Boom Part No. T109021 GTH-644 • GTH-844...
  • Page 50 Operator's Manual Second Edition • First Printing Load Charts GTH-644 Quick Attach Bucket GTH-644 Quick Attach Truss Boom GTH-644 CAT Attachment GTH-644 Quick Attach Swing Carriage GTH-644 • GTH-844 Part No. T109021...
  • Page 51 Second Edition • First Printing Operator's Manual Load Charts GTH-844 Standard Carriage GTH-844 Swing Carriage GTH-844 Pin-on Bucket GTH-844 Pin-on Truss Boom Part No. T109021 GTH-644 • GTH-844...
  • Page 52 Operator's Manual Second Edition • First Printing Load Charts GTH-844 Quick Attach Bucket GTH-844 Quick Attach Truss Boom GTH-844 CAT Attachment GTH-844 Quick Attach Swing Carriage GTH-644 • GTH-844 Part No. T109021...
  • Page 53 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie Scandinavia...

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