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; DANGER
GENERAL SAFETY AVOID ELECTRICAL POWER LINES DANGER REQUIRED CLEARANCE FOR NORMAL VOLTAGE INOPERATION NEAR HIGH VOLTAGE POWER LINES ANDOPERATION IN TRANSIT WITH NO LOAD AND BOOMOR MAST LOWERED. Normal Voltage, kV Minimum Required (Phase to Phase) Clearance, ft. (m) Operation Near High Voltage Power L...
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 3 - ...
Page 27 - CONTROLS AND INSTRUMENTS; OPERATOR'S COMPARTMENT
CONTROLS AND INSTRUMENTS OPERATOR'S COMPARTMENT 3 - 3 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. In...
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 C D
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 31 - FRAME SWAY CONTROL
CONTROLS AND INSTRUMENTS SWAY CONTROL C 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 m...
Page 32 - GAUGES
CONTROLS AND INSTRUMENTS Depressing the pump destroke button while operating the machinewill cause an immediate loss of hydraulic power, possiblycreating a very dangerous situation. Hydraulic functions thatwill be affected are: FORK TILT, LIFT, BOOM EXTENDand RETRACT, PARKING BRAKE and SWAY. None of...
Page 33 - STEERING
CONTROLS AND INSTRUMENTS STEERING In addition to the steering wheel, the machine has anothersteering control, the steering selector switch. 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 a...
Page 36 - 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 37 - 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 38 - BEFORE STARTING THE ENGINE
OPERATION BEFORE STARTING THE ENGINE 4 - 4 WARNING Before starting the engine, be sure that all daily maintenanceitems have been performed. See Maintenance section. Walk around the machine and check for any parts that aremissing, worn, damaged, or leaking. Repair and/or replaceany missing, worn, dam...
Page 39 - STARTING THE ENGINE
OPERATION STARTING THE ENGINE 4 - 5 DANGER If the machine should start with the transmission control lever(C) in gear, stop operation at once or property damage, seriousinjury or death may occur. Have a qualified service technicianrepair the machine. DANGER NEVER attempt to start the machine without...
Page 41 - 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 45 - TRANSPORTING A LOAD
OPERATION TRANSPORTING A LOAD WARNING WARNING 4 - 11 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 ...
Page 47 - PLACING A LOAD
OPERATION PLACING A LOAD 4 - 13 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 rollover hazard which may result in injury or death. DANGER Always apply the parking brake (C) before lifting and/orplacing a load. Failure to ...
Page 50 - 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 51 - 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 52 - 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 53 - DAILY MAINTENANCE
MAINTENANCE PROCEDURES DAILY MAINTENANCE 5 - 5 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 t...
Page 56 - 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 57 - 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 58 - 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...
