Page 2 - 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 Procedur...
Page 4 - SECTION 1 - ROUGH TERRAIN FORK LIFT SAFETY
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
Page 5 - ROUGH TERRAIN FORK LIFT SAFETY; INTRODUCTION; supplied with this machine.
ROUGH TERRAIN FORK LIFT SAFETY INTRODUCTION Owners, Users, and Operators: Genie appreciates your choice of our machine for your application. Our number onepriority is user safety, which is best achieved by our joint efforts. We feel that you make amajor contribution to safety if you, as the equipmen...
Page 6 - STANDARDS AND SYMBOLS; ANSI B56.6 – Rough Terrain Fork Lifts; STANDARDS
ROUGH TERRAIN FORK LIFT SAFETY STANDARDS AND SYMBOLS 1 - 4 Many aspects of rough terrain forklift operation and testing are discussed in standardspublished by the American National Standards Institute. These Standards are updated ona regular basis with addendas. Genie recommends that you purchase an...
Page 7 - SAFETY; Safety must always be the operator's most important concern.; TRAINING AND KNOWLEDGE
ROUGH TERRAIN FORK LIFT SAFETY SAFETY 1 - 5 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 Admin...
Page 8 - OPERATOR'S RESPONSIBILITIES
ROUGH TERRAIN FORK LIFT SAFETY OPERATOR'S RESPONSIBILITIES 1 - 6 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 function...
Page 9 - MANAGEMENT'S RESPONSIBILITIES; Have a supervisor at the job site to be responsible for job safety.
ROUGH TERRAIN FORK LIFT SAFETY MANAGEMENT'S RESPONSIBILITIES 1 - 7 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 repo...
Page 10 - MAINTENANCE AND REPAIR
ROUGH TERRAIN FORK LIFT SAFETY 1 - 8 MAINTENANCE AND REPAIR 1. Practice safe maintenance procedures. Perform all maintenance and repairs in accordance with instructions provided by the manufacturer in the manuals. Alsoheed the warnings on the placards and decals on the machine. 2. Always use support...
Page 11 - OPERATION SAFETY
ROUGH TERRAIN FORK LIFT SAFETY OPERATION SAFETY 1 - 9 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...
Page 13 - i. Ascend and descend slowly and with caution.
ROUGH TERRAIN FORK LIFT SAFETY 1 - 11 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 wit...
Page 14 - NOTES
Page 16 - SECTION 2 - GENERAL SAFETY; General Safety Procedures
TABLE OF CONTENTS SECTION 2 - GENERAL SAFETY General Safety Procedures 2-3 Jump Starting 2-8 Proper Load Chart Use 2-9 2 - 2
Page 17 - GENERAL SAFETY; SAFETY ALERT SYMBOL; WARNING; THE OPERATOR; GENERAL SAFETY PROCEDURES
GENERAL SAFETY SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Followall 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 thismachine. Bef...
Page 18 - WELDING PRECAUTIONS; CAUTION; HAND HOLDS AND STEPS; REFUELING
GENERAL SAFETY WELDING PRECAUTIONS CAUTION Any unauthorized welding can cause structural failure orpossible personal injury. DO NOT weld on any structuralmember. All unauthorized welding will void the warranty. HAND HOLDS AND STEPS WARNING Slips and falls can cause serious injury. When getting on an...
Page 19 - HYDRAULIC SAFETY; FLUIDS UNDER PRESSURE; SERVICE TIRES SAFELY
GENERAL SAFETY HYDRAULIC SAFETY WARNING Hot hydraulic oil can cause severe burns. DO NOT work onthe hydraulic system if the oil temperature exceeds120 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 uni...
Page 20 - USE SEAT BELT; PRACTICE SAFE MAINTENANCE; BOOM SAFETY
GENERAL SAFETY GENERAL SAFETY PROCEDURES 2 - 6 CAUTION USE SEAT BELT Always wear the seat belt while operating the machine toreduce the risk of personal injury. CAUTION PRACTICE SAFE MAINTENANCE Unauthorized modifications to the machine may impair thesafety, machine function and/or affect machine li...
Page 21 - AVOID ELECTRICAL POWER LINES
GENERAL SAFETY GENERAL SAFETY PROCEDURES AVOID ELECTRICAL POWER LINES DANGER REQUIRED CLEARANCE FOR NORMAL VOLTAGE INOPERATION NEAR HIGH VOLTAGE POWER LINES ANDOPERATION IN TRANSIT WITH NO LOAD AND BOOM ORMAST LOWERED. Normal Voltage, kV Minimum Required (Phase to Phase) Clearance, ft. (m) Operation...
Page 22 - JUMP STARTING
GENERAL SAFETY Location: The battery is located under the fuel tank / battery box cover (A). JUMP STARTING Jump starting at the battery or battery replacement is requiredwhen the battery is discharged to the point where the batterywill not crank the starter. WARNING Battery posts, terminals, and rel...
Page 23 - PROPER LOAD CHART USE
GENERAL SAFETY PROPER LOAD CHART USE 2 - 9 NEVER raise a load and drive to position it. This can cause themachine to turnover. When placing a load, always move aloaded machine with the boom angle indicator (B) at 0 degreesor less. When the machine is as close as possible to where theload needs to be...
Page 26 - SECTION 3 - CONTROLS AND INSTRUMENTS
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 Fron...
Page 27 - CONTROLS AND INSTRUMENTS; OPERATOR'S COMPARTMENT
CONTROLS AND INSTRUMENTS 1. Accelerator Pedal 9. Gauges 17. Windshield Wiper 24. Interior Rear View Mirror 2. Joystick 4-way Controller 10. Machine Level Gauge 18. Ignition Switch 25. Frt.Axle Differential Lock 3. Transmission Control Lever 11. Plug / 12 Volt Access 19. Auxiliary Hydraulics 26. Stab...
Page 28 - JOYSTICK CONTROL FUNCTIONS
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 D C
Page 29 - JOYSTICK CONTROL FUNCTIONS (BUTTON PUSHED)
CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS (BUTTON PUSHED) 3 - 5 A - Tilt Down B - Tilt Back B A
Page 30 - SERVICE BRAKES
CONTROLS AND INSTRUMENTS SERVICE BRAKES PARKING BRAKE 3 - 6 The brake pedal is the operator's control for the service brakes.Pushing the service brake pedal (A) activates the servicebrakes for all four wheels. The brakes should be applied during normal operation to stopmachine movement. WARNING Fail...
Page 31 - FRAME SWAY CONTROL
CONTROLS AND INSTRUMENTS WARNING Always ensure that the machine level indicator (D) is at zero (0)degrees before raising the boom. Raising the boom with anunlevel machine may cause the machine to overturn, resulting in injury or death. WARNING Use the frame sway control to level the machine only whe...
Page 32 - GAUGES
CONTROLS AND INSTRUMENTS 3 - 8 PU MP OFF BR AKE ON CONTROL SWAY HEATER HEADLIGHT HYDRAULICS WIPER AUXILIARY LEFT STABILIZER RIGHT STABILIZER The pump destroke button (A) is the black push buttonswitch located on the dash panel. For example, when starting the machine for the first time on a 30degree ...
Page 34 - FRONT AXLE DIFFERENTIAL LOCK
CONTROLS AND INSTRUMENTS FRONT AXLE DIFFERENTIAL LOCK 3 - 10 The front axle differential lock switch (A) is located near theoperator's left foot. The purpose for this device is to lock thefront axle differential to gain added traction under certainconditions. The front axle differential lock switch ...
Page 35 - FRONT STABILIZERS; UP
CONTROLS AND INSTRUMENTS FRONT STABILIZERS 3 - 11 BRA KE ON (C) L E TT E R VIS IBLE = 3 ,0 0 0 LBS(D ) L ET TE R VI SI BL E = 2,00 0 L BS P/N 3- 1483 0 (1.22) METER FEET ( 6.10) 28 (8.54) 24 (7.32) 20 4 !"#"$ & ' ( )*"#+ 455 NORTH SUPERIO R A VEN UE MACH INE ON A FI RM, LEVELS URFACE...
Page 36 - ENGINE ELECTRONIC CONTROL UNIT; John Deere Engine Electronic Control Unit
CONTROLS AND INSTRUMENTS ENGINE ELECTRONIC CONTROL UNIT John Deere Engine Electronic Control Unit The John Deere Electronic Control Unit (ECU) is capable of detecting, storing, and reactingto abnormal engine operating conditions or faults. The presence of a fault is reported to theoperator through t...
Page 40 - SECTION 4 - OPERATION
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
Page 41 - OPERATION; OPERATION AND SAFETY GUIDELINES
OPERATION OPERATION AND SAFETY GUIDELINES 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 t...
Page 44 - STARTING THE ENGINE
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 beforetrying again. If the engine fails to start after four attempts,trouble shoot and correct the problem. DO NOT tur...
Page 45 - BEFORE OPERATING THE FORKLIFT
OPERATION PUMP OFF BRAKE ON C ONTROL SWAY HEATER HEADLIGHT HYDRAULICS WIPER AUXILIARY LE FT STABILIZER RIGHT STABILIZER BEFORE OPERATING THE FORKLIFT CAUTION If any gauge reading does not fall within the set tolerances themachine must be repaired before operation. Check the dash mounted gauges for l...
Page 49 - TRANSPORTING A LOAD
OPERATION Transporting a load with the boom extended and the boomangle indicator arrow (D) reading more than 0 degrees couldcause a roll over hazard. The load should be kept as low to the ground as possible whiletraveling. Always move a loaded machine with the boom angleindicator arrow (D) at 0 degr...
Page 51 - PLACING A LOAD
OPERATION PLACING A LOAD 4 - 13 SWA Y CONTROL P UM P OFF BRAK E ON ( C) LE TT E R VI SI BL E = 3,000 LB S( D) L ET TE R VISI B LE = 2,000 L BS P /N 3-1483 0 ( 1.22) MET ER FE ET ( 6.10) 28 (8.54) 24 (7. 32) 20 4 !"#"$ & ' ( )*"#+ 455 NORTH S UPE RI OR AVE NUE MACHINE ON A FIRM, LE VE...
Page 56 - SECTION 5 - MAINTENANCE PROCEDURES; General Safety Practices
TABLE OF CONTENTS SECTION 5 - MAINTENANCE PROCEDURES General Safety Practices 5-3 Daily Maintenance 5-5 5 - 2
Page 57 - MAINTENANCE PROCEDURES; BEFORE SERVICING; GENERAL SAFETY PRACTICES
MAINTENANCE PROCEDURES BEFORE SERVICING Read the entire Maintenance Procedure Section. Familiarize yourself with all the safety precautions listed inSections 1 & 2. Pay close attention to all the safety alert symbols. Be sure you understand the procedures detailed in thissection. Wear personal p...
Page 58 - FLUID UNDER PRESSURE
MAINTENANCE PROCEDURES GENERAL SAFETY PRACTICES HYDRAULIC SAFETY WARNING Hot hydraulic oil can cause severe burns. DO NOT work onthe hydraulic system if the oil system temperature exceeds120 degrees F. (49 degrees C.) Before ANYONE works on the hydraulic system: 1. Lower the boom to the horizontal p...
Page 59 - DAILY MAINTENANCE
MAINTENANCE PROCEDURES DAILY MAINTENANCE SCHEDULED MAINTENANCE Maintenace performed quarterly, annually and everytwo years must be completed by a person trained andqualified to perform maintenance on this machineaccording to the procedures found in the service manualfor this machine.Machines that ha...
Page 62 - SECTION 6 - MATERIAL SAFETY DATA; Material Safety Data Sheets
TABLE OF CONTENTS SECTION 6 - MATERIAL SAFETY DATA Material Safety Data Sheets 6-3 California Proposition 65 Warnings 6-4 6 - 2
Page 63 - MATERIAL SAFETY DATA
MATERIAL SAFETY DATA 6 - 3 The Federal Occupational, Safety and Health Administration (OSHA) Standard 29 ctr 1910.1200, and in somecases state and local Right-To-Know laws, may require specific MSDS be available to employees prior tooperating this equipment. This may include information on substance...
Page 64 - CALIFORNIA; CALIFORNIA PROPOSITION 65 WARNINGS
MATERIAL SAFETY DATA 6 - 4 The following warnings are required on all off road equipment operating in the State of California. If you areoperating 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: Genie Ind...
