Genie GTH-644 Operator'S Manual Download

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Operator’s Manual

with
Maintenance
Information

GTH-844
GTH-842
GTH-644

First Edition

Second Printing

Part No. 114100

Summary of Contents for GTH-644

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

Page 2: ...stick Control Functions Button Pushed 3 5 Service Brakes 3 6 Low Service Brake Pressure Light 3 6 Parking Brake 3 7 FrameSwayControl 3 8 Gauges 3 9 HydraulicPumpDestroke Button 3 9 Steering 3 10 Transmission 3 10 FrontAxle Differential Lock 3 11 SECTION 4 OPERATION 4 1 OperationAndSafetyGuidelines 4 3 Before Starting The Engine 4 4 StartingThe Engine 4 5 Before Operating The Forklift 4 7 Transport...

Page 3: ...SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY 1 1 ...

Page 4: ...N 1 ROUGH TERRAIN FORK LIFT SAFETY Introduction 1 3 StandardsAnd Symbols 1 4 Safety 1 5 TrainingAndKnowledge 1 5 Operator sResponsibilities 1 6 Management sResponsibilities 1 7 MaintenanceAndRepair 1 8 OperationSafety 1 9 1 2 ...

Page 5: ...pliedwiththismachine 3 Use Good Safe Work Practices in a common sense way 4 Only have trained certified operators directed by informed and knowledgeablesupervision runningthemachine NOTE OSHAprohibitsthealterationormodificationofthismachinewithoutwritten manufacturer s approval Use only factory approved parts to service or repair this machine Ifthereisanythinginthismanualthatisnotclearorwhichyoube...

Page 6: ...StandardsInstitute 25 West 43nd Street 4th Fl New York New York 10036 Tel 212 642 4900 Fax 212 398 0023 STANDARDS SYMBOLS DANGER Indicatesanimminentlyhazardoussituation which ifnotavoided willresultindeathorseriousinjury CAUTION Indicatesapotentiallyhazardoussituation which ifnotavoided mayresultinminorormoderate injury WARNING Indicatesapotentiallyhazardoussituation which if not avoided could res...

Page 7: ...stration OSHA standards including29CFR1910 178 andtheAmerican National Standards Institute ANSI B56 6 latest edition 4 Read and Understand all Decals and Warnings 5 Read and Understand the Rating Chart 6 Knowthatthemachinecansafetylifteachloadbeforeattemptingtolift These are general safety rules which must be followed You are also required to read and understand the Operator s Manual as there are ...

Page 8: ... 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 Bealert physicallyfitandfreefromtheinfluencesofalcohol drugsor medicationsthatmightaffecttheoperator seyesight hearing orreactions 11 Keep people equipment and material out of the work area 12 K...

Page 9: ...d 2 Have a supervisor at the job site to be responsible for job safety 3 Crewmembersgivenspecificsafetyresponsibilitiesandinstructedtoreportany unsafeconditionstothesupervisor 4 Supply the weight on the load to be lifted to the operator 5 VerifythatallcrewmembersarefamiliarwithOSHA ANSIB56 6requirements aswellasinstructionsinthemanuals ...

Page 10: ...chineisstationarypriortoperformingadjustmentsor lubrication 5 Replaceallshieldsandguardsafterperformingservice 6 Always use a piece of cardboard or paper to search for leaks 7 Whenperformingworkonthehydraulicsystem i Lower the boom to horizontal ii Support the boom with supports or braces iii Shutdowntheengine iv Relieveallpressurebeforedisconnectinglines v Ensureallconnectionsaretightbeforeapplyi...

Page 11: ...theenginebeforerefuelingthemachine ii Fillthefueltankoutdoors iii Handlefuelwithcare asitishighlyflammable Donotrefuel themachinewhilesmokingornearopenflames iv Alwayscleanupspilledfuel 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 handrailsprovided andalwaysmaintainathreepointcontac...

Page 12: ...usethemachinetooverturn iii Verify that the load is secured on the forks before performing a lift Rearrange the load if necessary iv Beforeloweringamaximumload alwaysretracttheboom 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 ...

Page 13: ...avelwiththeattachmentdownhill iv Avoidturning travelstraightupanddown 19 Alwayspositionallwheelsinlinewiththemachinebeforeswitchingthesteering 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 Donottransportorliftpersonnelintopositionwiththisforklift 23 Whenleavingtheoperator sstation i Placethedirectionalcontrolsinne...

Page 14: ...ROUGH TERRAIN FORK LIFT SAFETY NOTES 1 12 ...

Page 15: ...SECTION 2 GENERAL SAFETY 2 1 ...

Page 16: ...TABLE OFCONTENTS SECTION 2 GENERAL SAFETY General Safety Procedures 2 3 JumpStarting 2 8 Proper Load Chart Use 2 9 2 2 ...

Page 17: ...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...

Page 18: ...el 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 ne...

Page 19: ...aulic 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 Aserious infection or reaction can result without proper medical treatment SERVICE TIRES SAFELY An improperly...

Page 20: ...s 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 DANGERAREA under or around the boom when the forks are off the ground or while the engine is running Se...

Page 21: ...10 67 Over 750 to 1000 45 13 72 Operation in Transit With No Load and Boom Lowered to 0 75 4 1 22 Over 0 75 to 50 6 1 83 Over 50 to 345 10 3 05 Over 345 to 750 16 4 87 Over 750 to 1000 20 6 10 WARNING Always remain completely inside the cab enclosure while operating the machine WARNING Never operate this machine under the influence of drugs alcohol and or medication which can cause drowsiness WARN...

Page 22: ... another machine be certain that the machines are not touching Never jump start a frozen battery as it will explode Keep sparks and flames away from the battery Lead acid batteries generate explosive gases when charging Wear safety glasses when working near batteries The booster battery must be a 12 volt type The machine used for jump starting must have a negative ground electrical system To jump ...

Page 23: ...on The load chart shows the operating limits of a properly maintained and operated machine To use the load chart the operator must know the weight of the load and how far out and up it is to be placed If the load is heavier than stated on the load chart three options can be used 1 Move the machine closer to the load so that the weight of the load will fall within the load chart specifications 2 Di...

Page 24: ... 2 m Load capacities at 24 in 60 cm load center with standard fork frame Rated lift capacities shown are with machine on a firm level surface with undamaged properly inflated calcium chloride solution filled tires or optional foam filled tires Rear axle lock up engaged Load Limits Horizontal Boom Last Fully Visible Letter Retracted 6000 lbs A Letter Visible 4000 lbs B Letter Visible 3000 lbs C Let...

Page 25: ... capacities at 24 in 60 cm load center with standard fork frame Rated lift capacities shown are with machine on a firm level surface with undamaged properly inflated calcium chloride solution filled tires or optional foam filled tires Rear axle lock up engaged Load Limits Horizontal Boom Last Fully Visible Letter Retracted 8000 lbs A Letter Visible 6000 lbs B Letter Visible 4000 lbs C Letter Visib...

Page 26: ...GENERAL SAFETY NOTES 2 12 ...

Page 27: ...SECTION 3 CONTROLSAND INSTRUMENTS 3 1 ...

Page 28: ...3 JoystickControlFunctions 3 4 JoystickControlFunctions ButtonPushed 3 5 Service Brakes 3 6 Low Service Brake Pressure Light 3 6 ParkingBrake 3 7 Frame Sway Control 3 8 Gauges 3 9 HydraulicPumpDestrokeButton 3 9 Steering 3 10 Transmission 3 10 FrontAxleDifferential Lock 3 11 3 2 ...

Page 29: ...ires 3 Transmission Control Lever 10 Machine Level Gauge 17 Front Wiper Switch 24 Interior RearView Mirror 4 Steering Selector 11 Plug 12 Volt Access 18 Ignition Switch 25 Frt AxleDifferentialLock 5 Service Brake Pedal 12 Seat 19 Auxiliary Hydraulics 26 Low Brake Press Light 6 Rear Wiper Switch 13 Frame Level Switch 20 Steering Wheel 27 Work Lights Switch 7 Load Chart 14 Seat Belt 21 Headlight Swi...

Page 30: ...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 ...

Page 31: ...CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS BUTTON PUSHED 3 5 A Tilt Down B TiltBack B A ...

Page 32: ...op machine movement WARNING Insufficient hydraulic pressure to the service brakes may result in increased stopping distances causing possible injury or death and or damage to the machine or property The illumination of the LOW BRAKE PRESSURE light B when the machine is running indicates this potentially hazard ous condition Should this condition ever exist discontinue use of the machine immediatel...

Page 33: ...rake 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 To engage the parking brake toggle the parking brake switch C forward The red light in the upper part of the parking brake switch should illuminate ...

Page 34: ... right depending on the particular requirement 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 Using the frame sway control whe...

Page 35: ...raulic functions that will be affected are FORK TILT LIFT BOOM EXTEND and RETRACT PARKING BRAKE and SWAY None of these functions will operate as long as the button is depressed The service brakes will continue to function if the accumulator backup has a sufficient gas charge The pump destroke button C is the black push button switch located on the dash panel For example when starting the machine f...

Page 36: ...rd gear gently pull the lever toward you and move the lever upward To shift into Neutral move the lever to the center position To shift into Reverse gear gently pull the lever toward you and move the lever downward To shift into a lower speed rotate the lever clockwise To shift into a higher speed rotate the lever counter clockwise When shifting the transmission from forward to reverse while the m...

Page 37: ...the front axle 3 11 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 The front axle differential lock switch must be depressed and held in order to activate the axle d...

Page 38: ...CONTROLS AND INSTRUMENTS 3 12 NOTES ...

Page 39: ...SECTION 4 OPERATION 4 1 ...

Page 40: ...TABLE OFCONTENTS SECTION 4 OPERATION OperationAndSafetyGuidelines 4 3 BeforeStartingTheEngine 4 4 StartingTheEngine 4 5 BeforeOperatingTheForklift 4 7 TransportingALoad 4 11 PlacingALoad 4 13 4 2 ...

Page 41: ...ld occur from escaping hot pressurized coolant 8 ALWAYS wear the seat belt when operating this machine 9 ALWAYS inspect the machine daily Check for leaks worn hoses loose belts or anything out of the ordinary Repair and or replace any worn damaged or leaking parts immediately Failure to do so can cause injury or death 10 CHECK to be sure that all guards and screens are secure and in their proper p...

Page 42: ...ne 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 BEFORE STARTING THE ENGINE 4 4 ...

Page 43: ...d 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 Attempting to start the machine from outside the operator s compartment may result in property damage serious injury or death DANGER Any problems discovered in the steps prior to BEFORE STARTING THE ENGINE should be corrected before the machine is sta...

Page 44: ...t 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 Attempting to start the engine by towing or pushing the machine will result in damage to the powershift transmission and will not start the engine It also is an unsafe practice that could cause personal injury 4 6 STARTING THE ENGINE ...

Page 45: ...gs 1 FuelLevel 1 2 to Full 2 EngineWaterTemperature 180 F to 200 F 3 Engine Oil Pressure 40 to 80 PSI 4 Transmission Oil Temperature 180 F to 200 F 5 Transmission Oil Pressure 240 to 280 PSI 6 Voltmeter 12 to 14 Volts Operate the joystick controller momentarily in all directions STANDARD JOYSTICK FUNCTIONS BUTTONDEPRESSEDFUNCTIONS A Boom Down B Boom Up C Boom Out D Boom In E Boom Down and Out F Bo...

Page 46: ...rection 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 steering selector valve to the 2 wheel position Bring the front tires into alignment with the rear tires Place the steering selector valve back into the 4 wheel position BEFORE OPERATING THE FORKLIFT 4 8 A C B ...

Page 47: ...er D As soon as the machine starts to move apply the service brake pedal The machine should stop immediately Apply the parking brake by toggling the parking brake switch E forward The red light in the upper part of the parking brake switch should illuminate The machine should not be able to be driven with the parking brake in the forward on position Release the parking brake by toggling the parkin...

Page 48: ...ackup 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 Check and adjust both the interior rear view mirror B and the exterior right hand mirror C if required BEFORE OPERATING THE FORKLIFT 4 10 C B A ...

Page 49: ... move a loaded machine with the boom angle indicator D at 0 degrees or less The forks should always be tilted back slightly during transportation to ensure stability of the load TRANSPORTING A LOAD WARNING At no time should any load be suspended from the forks by use of chains ropes straps etc If a load must be suspended the use of a truss jib boom is mandatory Proper rigging procedures should alw...

Page 50: ...ver A Failure to do so can result in damage to the load the machine and or bystanders Always keep the boom retracted to ensure greater stability Always place the load in the center and completely against the back of the fork frame By doing so greater stability will result IMPORTANT Never attempt to use the forks and or attach ments for prying wedged or frozen loads free Damage to the load pallet a...

Page 51: ...of the switch labeled sway control D located on the forward side of the right arm rest The frame sway control is used in conjunction with the machine level indicator E located in the center of the cross support that the interior rear view mirror is mounted on The sway control switch is either toggled left or right depending on the particular require ment Adjust the sway control D until the indicat...

Page 52: ...Hold the controller back until the required height has been achieved Gradually move the 4 way controller towards the letter E to bring the load DOWN and OUT into final position Lower the load until the weight is completely off the forks Gradually move the 4 way controller towards the letter F to bring the boom UP and IN This will bring the forks out of the load Once the forks are clear of the load...

Page 53: ...en 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 DOES NOT affect any boom or fork functions To unlock the rear axle stabilizing cylinders and enable the transmission functions lower the boom to a position less than 60 degrees GTH 644 GTH 842 GTH 844 60 degrees ...

Page 54: ...OPERATION 4 16 NOTES ...

Page 55: ...SECTION 5 MAINTENANCE PROCEDURES 5 1 ...

Page 56: ...TABLE OF CONTENTS SECTION 5 MAINTENANCE PROCEDURES GeneralSafetyPractices 5 3 DailyMaintenance 5 5 5 2 ...

Page 57: ...gs and jewelry Move the machine to a safe level work place Lower the boom and support all raised equipment Shut down the machine Remove the key from the ignition Be careful not to spill fuels and lubricants Do not fill or refuel the fuel tank while the engine is running or hot Doing so could cause a fire and or an explosion Do not smoke while refueling or working with fuel to avoid a fire and or e...

Page 58: ...re 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 WELDING PREC...

Page 59: ...Check transmission oil level DAILY MAINTENANCE SCHEDULEDMAINTENANCE 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 befo...

Page 60: ... glass B DAILY MAINTENANCE 5 6 B CHECK TIRE FOR PROPER INFLATION Location Wheel ends To Check With the valve stem C positioned to the top of the tire check the tire pressure with the tire cold and a properly functioning air pressure gauge Setting 50 PSI All tires require a calcium chloride ballast or an optional foam fill to be operated safely The loss of ballast can affect the machine s stability...

Page 61: ...SECTION 6 MATERIAL SAFETY DATA 6 1 ...

Page 62: ...TABLE OFCONTENTS SECTION 6 MATERIAL SAFETY DATA Material Safety Data Sheets 6 3 CaliforniaProposition 65 Warnings 6 4 6 2 ...

Page 63: ...iononsubstancescontainedintheequipmentsuchas antifreeze brakefluid batteryacidandhydraulicfluid 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 GenieIndustries PO Box 97030 Redmond WA98073 9730 To ensure a prompt response please be sure to include your return address and zip code ...

Page 64: ... 9730 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories containleadandleadcompounds chemicals known to the State of California to cause cancer andreproductiveharm Batteriesalsocontainother...

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