Operator’s Manual GTH-636 with Maintenance Information First Edition Second Printing Part No.
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 1-1 1-3 1-4 1-5 1-5 1-6 1-7 1-8 1-9 SECTION 2 GENERAL SAFETY General Safety Procedures Jump Starting Proper Load Chart Use 2-1 2-3 2-8 2-9 SECTION 3 CONTROLS AND INSTRUMENTS Operator's Compartment Joystick Control Functions Joystick Control Functions (Button Pushed) Service
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 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. 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.
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.
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.
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.
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.
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.
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.
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.
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.
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. 2. 3. 4.
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.
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. 2. 3. 4. 5. A Lower the boom to the horizontal position. Support the boom to avoid unintentional lowering. Shutdown the engine. Remove the key from the ignition. Clean the area around the oil reservoir cap (A).
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.
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 (Phase to Phase) Minimum Required Clearance, ft. (m) Operation Near High Voltage Power Lines to 50 Over 50 to 200 Over 200 to 350 Over 350 to 500 Over 500 to 750 Over 750 to 1000 10 (3.05) 15 (4.60) 20 (6.10) 25 (7.62) 35 (10.67) 45 (13.
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. A WARNING Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.
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. When the machine is as close as possible to where the load needs to be placed, set the parking brake, raise the load, then place the load into position. The load chart shows the operating limits of a properly maintained and operated machine.
GENERAL SAFETY PROPER LOAD CHART USE 2 - 10
SECTION 3 CONTROLS AND INSTRUMENTS 3-1
TABLE OF CONTENTS SECTION 3 - CONTROLS AND INSTRUMENTS Operator's Compartment 3-3 Joystick Control Functions 3-4 Joystick Control Functions (Button Pushed) 3-5 Service Brakes 3-6 Parking Brake 3-6 Frame Sway Control 3-7 Gauges 3-8 Hydraulic Pump Destroke Button 3-8 Steering 3-9 Transmission 3-9 3-2
CONTROLS AND INSTRUMENTS OPERATOR'S COMPARTMENT 1. Accelerator Pedal 8. Hourmeter 15. Parking Brake Handle 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. Windshield Wiper 24. Interior Rear View Mirror 4. Steering Selector 11. Plug / 12 Volt Access. 18. Ignition Switch 25. Frt.Axle Differential Lock (optional) 5. Service Brake Pedal 12. Seat 19. Auxiliary Hydraulics 6.
CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS A - Boom Down B - Boom Up B A C - Boom Out D - Boom In C D E - Boom Down and Out F - Boom Up and In G - Boom Up and Out H - Boom Down and In 3-4
CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS (BUTTON PUSHED) A - Tilt Down B - Tilt Back B A 3-5
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. A 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.
CONTROLS AND INSTRUMENTS FRAME SWAY CONTROL WARNING Always ensure that the machine level indicator (D) 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. FEET 28 METER (8.54) P.O . BO X 790 455 NORTH SUPERIOR A VEN UE BARAGA, M ICH IGAN 49908 PHON E 906-353-6675 FAX 906-353-7543 24 (7.32) 20 16 (6.10) (4.88) 12 12 (3.66) (3.66) 16 20 (4.88) (6.10) 48 BRAKE ON (14.64) 44 (13.
CONTROLS AND INSTRUMENTS GAUGES The following gauges are used to monitor the machine: 1 - Fuel Level BRAKE ON 2 - Oil Temperature, Powershift Transmission 3 - Oil Pressure, Powershift Transmission 1 2 3 6 5 4 PUMP OFF 4 - Voltmeter 5 - Water Temperature, Engine SWAY CONTROL 6 - Oil Pressure, Engine HEADLIGHT HEATER WIPER AUXILIARY HYDRAULICS HYDRAULIC PUMP DESTROKE BUTTON DANGER Depressing the pump destroke button while operating the machine will cause an immediate loss of hydraulic power,
CONTROLS AND INSTRUMENTS STEERING In addition to the steering wheel, the machine has another steering control, the steering selector switch. B The steering selector switch (B) 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 right of center 2-WHEEL Handle directly centered FEET 16 28 24 20 12 METER (8.54) (7.32) (6.10) (4.88) (3.66) P.O.
CONTROLS AND INSTRUMENTS NOTES 3 - 10
SECTION 4 OPERATION 4-1
TABLE OF CONTENTS SECTION 4 - OPERATION Operation And Safety Guidelines 4-3 Before Starting The Engine 4-4 Starting The Engine 4-5 Before Operating The Forklift 4-7 Transporting A Load 4-11 Placing A Load 4-13 4-2
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.
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 any missing, worn, damaged, or leaking parts.
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 (B) 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.
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. DO NOT turn the key if the engine is running. This may cause damage to the starter motor.
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. (1) Fuel 1/2 to Full BRAKE ON (2) Transmission Oil Temp. 180 F to 200 F (3) Transmission Oil PSI. 240 to 280 PSI (4) Volt 12 to 14 (5) Engine Water Temp.
OPERATION BEFORE OPERATING THE FORKLIFT Operate the frame sway control (A) momentarily right and left. SWAY CONTROL A C 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" position. Move the steering selector valve to the "2 wheel" position. Bring the front tires into alignment with the rear tires.
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). As soon as the machine starts to move, apply the service brake pedal. The machine should stop immediately. BRAKE ON PUMP OFF SWAY CONTROL HEADLIGHT D Apply the parking brake (E).
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. BRAKE ON PUMP OFF SWAY CONTROL HEADLIGHT A B Check and adjust both the interior rear view mirror (B) and the exterior right hand mirror (C) if required.
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. If a load must be suspended the use of a truss (jib) boom is mandatory. Proper rigging procedures should always be followed. The forks should always be tilted back slightly during transportation to ensure stability of the load.
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. BRAKE ON PUMP OFF SWAY CONTROL HEADLIGHT A 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.
OPERATION PLACING A LOAD B 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 (C) before lifting and/or placing a load. Failure to do so could allow the machine to roll over which may result in injury or death. CAUTION Always bring the machine to a complete stop before applying the parking brake (C).
OPERATION PLACING A LOAD A 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. 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.
SECTION 5 MAINTENANCE PROCEDURES 5-1
TABLE OF CONTENTS SECTION 5 - MAINTENANCE PROCEDURES General Safety Practices 5-3 Daily Maintenance 5-5 5-2
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. Wear personal protective equipment. Remove rings and jewelry. Move the machine to a safe level work place. Lower the boom and support all raised equipment. Shut down the machine.
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.) A Before ANYONE works on the hydraulic system: 1. 2. 3. 4. 5. Lower the boom to the horizontal position. Support the boom to avoid unintentional lowering. Shutdown the engine. Remove the key from the ignition. Clean the area around the oil reservoir cap (A).
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. PERFORM ENGINE MAINTENANCE Refer to engine operator's manual. Check engine oil.
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. B 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). NOTE: Refer to page 5-24 of this manual for the proper oil specifications and capacities. CHECK TIRE FOR PROPER INFLATION Location: Wheel ends.
SECTION 6 MATERIAL SAFETY DATA 6-1
TABLE OF CONTENTS SECTION 6 - MATERIAL SAFETY DATA Material Safety Data Sheets 6-3 California Proposition 65 Warnings 6-4 6-2
MATERIAL SAFETY DATA MATERIAL SAFETY DATA SHEETS (MSDS) The Federal Occupational, Safety and Health Administration (OSHA) Standard 29 ctr 1910.1200, and in some cases state and local Right-To-Know laws, may require specific MSDS be available to employees prior to operating this equipment. This may include information on substances contained in the equipment such as antifreeze, brake fluid, battery acid and hydraulic fluid.
MATERIAL SAFETY DATA 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.
