237108_36 GTH 844m 844 237108

User Manual: GTH-844

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Operator's Manual

GTH

844

with

Maintenance

Information

Third Edition

Sixth Printing

Part No. 237108

Operator's Manual Third Edition • Sixth Printing

GTH-844 Part No. 237108

Front Matter

Contents

Introduction ........................................................... 1

Symbol and Hazard Pictorials Definitions ............. 5

General Safety ...................................................... 7

Work Area Safety .................................................. 9

Legend ................................................................ 17

Controls ............................................................... 18

Inspections .......................................................... 22

Operating Instructions ......................................... 33

Transport and Lifting Instructions ....................... 44

Maintenance ....................................................... 47

Attachments ........................................................ 51

Specifications ...................................................... 63

Load Charts ........................................................ 64

Third Edition: Sixth Printing, January 2015

Genie is a registered trademark of Terex South Dakota, Inc. in

the U.S.A. and many other countries. “GTH” is a trademark of

Terex South Dakota, Inc.

Complies with ANSI/ITSDF B56.6, CSA B335

Third Edition • Sixth Printing Operator's Manual

Introduction

Part No. 237108 GTH-844 1

Introducti on

About this manual

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.

This book is an operation and daily maintenance

manual for the user or operator of a Genie

machine.

This manual should be considered a permanent

part of your machine and should remain with the

machine at all times. If you have any questions,

contact Genie.

Product Identification

The machine serial number is located on the serial

label.

Intended Use

A variable reach rough terrain forklift truck is

defined as a wheeled type truck with a pivoting

boom, which may be equipped with various

attachments for picking, transporting and placing

loads with the established load range charts.

Use of this product in any other way is prohibited

and contrary to its intended use.

Bulletin Distribution and

Compliance

Safety of product users is of paramount

importance to Genie. Various bulletins are used by

Genie to communicate important safety and

product information to dealers and machine

owners.

The information contained in the bulletins is tied to

specific machines using the machine model and

serial number.

Distribution of bulletins is based on the most

current owner on record along with their

associated dealer, so it is important to register your

machine and keep your contact information up to

date.

To ensure safety of personnel and the reliable

continued operation of your machine, be sure to

comply with the action indicated in a respective

bulletin.

Serial label

(located inside fork frame)

(models with quick attach frame)

Serial number stamp

Serial label

(located inside riser)

Operator's Manual Third Edition • Sixth Printing

Introduction

2 GTH-844 Part No. 237108

Contacting the Manufacturer

At times it may be necessary to contact Genie.

When you do, be ready to supply the model

number and serial number of your machine, along

with your name and contact information. At

minimum, Genie should be contacted for:

Accident reporting

Questions regarding product applications and

safety

Standards and regulatory compliance information

Current owner updates, such as changes in

machine ownership or changes in your contact

information. See Transfer of Ownership, below.

Transfer of Machine Ownership

Taking a few minutes to update owner information

will ensure that you receive important safety,

maintenance and operating information that

applies to your machine.

Please register your machine by visiting us on the

web at www.genielift.com or by calling us toll free

at 1-800-536-1800.

Danger

Failure to obey the instructions and

safety rules in this manual will result

in death or serious injury.

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s

manual.

1 Avoid hazardous situations.

Know and understand the safety rules

before going on to the next section.

2 Always perform a pre-operation inspection.

3 Always perform function tests prior to use.

4 Inspect the workplace.

5 Only use the machine as it was intended.

 You read, understand and obey the

manufacturer’s instructions and safety

rules—safety and operator’s manuals and

machine decals.

 You read, understand and obey employer’s

safety rules and worksite regulations.

 You read, understand and obey all applicable

governmental regulations.

 You are properly trained to safely operate the

machine.

Third Edition • Sixth Printing Operator's Manual

Introduction

Part No. 237108 GTH-844 3

Hazard Classification

Decals on this machine use symbols, color coding

and signal words to identify the following:

Safety alert symbol—used to alert

you to potential personal injury

hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Indicates a hazardous situation

which, if not avoided, will result in

death or serious injury.

Indicates a hazardous situation

which, if not avoided, could result

in death or serious injury.

Indicates a hazardous situation

which, if not avoided, could result

in minor or moderate injury.

Indicates a property damage

message.

Standards

Many aspects of rough terrain forklift operation and

testing are discussed in standards published by

the American National Standards Institute and the

Industrial Truck Standards Development

Foundation. These standards are updated on a

regular basis with addenda. It is recommended

that you purchase and refer to the following

standards.

ANSI/ITSDF B56.6 - Rough Terrain Forklift Trucks

The ANSI standard can be downloaded from

www.ITSDF.org

CSA B335 - Safety Standard for Lift Trucks

The CSA standard can be downloaded from

www.csa.ca

DANGER

WARNING

CAUTION

NOTICE

Operator's Manual Third Edition • Sixth Printing

Introduction

4 GTH-844 Part No. 237108

Safety Sign Maintenance

Replace any missing or damaged safety signs.

Keep operator safety in mind at all times. Use mild

soap and water to clean safety signs. Do not use

solvent-based cleaners because they may damage

the safety sign material.

Third Edition • Sixth Printing Operator's Manual

Symbol and Hazard Pictorials Definitions

Part No. 237108 GTH-844 5

Symbol and Hazard Pic torials Definiti ons

Electrocution hazard Maintain required

clearance

Crush hazard No people under load Read the operator’s

manual

Injection hazard Use a piece of

cardboard or paper

to search for leaks

Maintain required

clearance

Crush hazard Always wear seat

belt

Tip-over hazard Tip-over hazard Crush hazard Keep away from

moving parts

Crush hazard

Keep away from

moving parts

Burn hazard Do not loosen cap

until cool.

Explosion / Burn

hazard

No smoking. No open

flame.

Burn hazard Allow surfaces to

cool

Crush hazard Keep away from

moving parts

Only trained

maintenance

personnel should

access

compartments

Operator's Manual Third Edition • Sixth Printing

Symbol and Hazard Pictorials Definitions

6 GTH-844 Part No. 237108

Explosion / Burn

hazard

No smoking. No

open flame.

Keep load low Fall hazard Only use an

approved work

platform

Refer to load charts

and manual.

Sway operation

Third Edition • Sixth Printing Operator's Manual

General Safety

Part No. 237108 GTH-844 7

General Safety

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214418

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237971 237598

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214419

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237598

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97667

28175 237601

97602

237971 237605

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Operator's Manual Third Edition • Sixth Printing

General Safety

8 GTH-844 Part No. 237108

82560

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Third Edition • Sixth Printing Operator's Manual

Work Area Safety

Part No. 237108 GTH-844 9

Work Area Safety

Overturning Hazards

Using the appropriate load chart

for the machine configuration,

confirm that the load is within

the rated capacity of the

machine. Do not exceed the

rated load.

The load center on the fork (if equipped) must be

equal to or less than the load center indicated on

the load chart. If the load center is further from the

fork face than shown on the load chart, refer to the

Load Chart section of this manual.

All loads shown on the load chart are based on the

machine being on firm, level ground, the frame

being level, the forks being positioned evenly on

the carriage, the load being centered on the forks,

the tires being properly sized and properly inflated,

and the telehandler being in good operating

condition.

If using accessories, read, understand and obey

the decals, instructions and manuals with the

accessory.

Do not raise the load unless the ground can

support all forces imposed by the machine.

Do not lower a load without retracting the boom

first.

Do not operate the machine if the load chart is

missing.

Do not exceed the rated capacity for each

configuration.

Do not attempt to jump free of the machine during

a tip-over. The ROPS (Roll Over Protective

Structure) is designed to protect you.

If the telehandler starts

to tip over:

- Do not jump

- Brace yourself and

stay in the seat

- Keep your seat belt

fastened

- Hold on firmly

- Lean away from the

point of impact

Do not raise the boom unless

the machine is level. The

machine level indicator should

be at zero degrees.

Do not level the machine using the frame sway

control unless the boom angle indicator is at zero

degrees or less.

Do not use the sway control to

position an elevated load.

Operator's Manual Third Edition • Sixth Printing

Work Area Safety

10 GTH-844 Part No. 237108

Do not raise a load and then drive to position it.

When driving, keep the boom

at or below horizontal and keep

the load close to the ground.

Operate the machine at speeds that will keep the

load under control. Start and stop movements

smoothly.

Do not raise a load unless the

load is properly positioned or

secured on the forks or

approved attachment.

Do not operate the machine in strong or gusty

winds. Do not increase the surface area of the

carriage or load. Increasing the area exposed to

the wind will decrease machine stability.

Use extreme care and slow speeds while driving

the machine in the travel position across uneven

terrain, steep grades, debris, unstable or slippery

surfaces and near holes and drop-offs.

Do not alter or disable machine components that in

any way affect safety and stability.

Do not replace items critical to machine stability

with items of different weight or specification.

Do not replace factory-installed tires with tires of

different specification or ply rating, unless

approved by the factory.

Traveling on Slopes Hazards

When driving, keep the boom at

or below horizontal and keep the

load close to the ground.

When the machine is loaded, always travel with

the load uphill. When the machine is unloaded,

travel with the forks or attachment downhill.

On steep terrain, drive only up and down a hill, and

always keep the machine in gear. Do not turn

across the slope when the machine is traveling up

or down a slope.

Limit travel path and speed according to the

condition of the ground surface, traction, slope,

location of personnel and any other factors which

may create a hazard. Never drive the machine

unless the mast and equipment are in their proper

travel position.

Whether a machine will tip over during dynamic

machine operation involves many factors that need

to be considered. Among these are

pavement/ground conditions, stability and slope,

as well as machine equipment, operator skill, load

position, tire inflation, machine speed, etc.

Additionally, tip-over of a machine is dependent in

large part upon operator inputs such as the speed

and smoothness of the operation, as well as the

position of the attachment and its load.

Construction sites and roads will frequently change

slope from place to place, can be hard and soft,

and change due to construction activities and

weather.

Operators should be properly trained and use their

best judgment and experience to take the

necessary precautions to prevent a tip-over.

Operators must assess the job site variables and

avoid exceeding the machine's (or operator's)

capabilities for terrain and conditions.

Third Edition • Sixth Printing Operator's Manual

Work Area Safety

Part No. 237108 GTH-844 11

Fall Hazards

Always wear a seat belt when

operating the machine.

Always remain completely inside the cab when

operating the machine.

When getting in and out of the cab, face the

machine, use the steps and handrails provided and

always maintain three-point contact.

Do not use the steering wheel or any other controls

as handrails.

Do not allow riders on the machine

or forks.

Do not lift personnel with this

machine unless it is equipped with

an approved work platform. See

Work Platform section.

Collision Hazards

Keep people, equipment and

material out of the work area.

Do not operate the machine

while people are under or near

an elevated boom, whether it is

loaded or unloaded.

Do not put the transmission into gear unless the

brake is applied and personnel and bystanders are

clear of the machine and load.

Do not drive the machine if visibility is obstructed.

Do not raise the boom unless the brake is applied.

Do not operate, without fenders, in conditions

where loose debris could hit the operator or

accumulate on the cab windows.

Do not operate the machine with a faulty back-up

alarm. The back-up alarm should sound when the

machine is in reverse.

Do not operate the machine in low light conditions.

An optional work and road light package is

available.

Operators must comply with employer, job site and

governmental rules regarding use of personal

protective equipment.

Do not drive the machine directly up to anyone.

Always make sure that mirrors and cab glass are

clean and do not obstruct the operators view of the

travel path or load.

Operator's Manual Third Edition • Sixth Printing

Work Area Safety

12 GTH-844 Part No. 237108

Falling Object Hazards

Operate the machine at speeds that will keep the

load under control. Start and stop movements

smoothly.

Keep people, equipment and

material out of the work area.

Do not operate the machine

while people are under or near

an elevated boom, whether it is

loaded or unloaded.

Be sure the load is secure before lifting it. Always

make sure the quick attach pin is inserted and

secured.

Bodily Injury Hazards

Always adjust the seat and

fasten the seat belt before

starting the engine.

Do not operate the machine

with a hydraulic oil or air leak.

An air leak or hydraulic leak

can penetrate and/or burn skin.

Relieve pressure before

disconnecting hydraulic lines.

Keep away from leaks and pin

holes. Use a piece of

cardboard or paper to search

for leaks. Do not use your

hand.

Fluid injected into skin must be surgically removed

within a few hours by a doctor familiar with this

type of injury or gangrene will result.

Stay clear of belts and fans

when the engine is running.

Always operate the machine in a well-ventilated

area to avoid carbon monoxide poisoning.

Improper contact with components under any

cover will cause serious injury. Only trained

maintenance personnel should access

compartments. Access by the operator is only

advised when performing a pre-operation

inspection. All compartments must remain closed

and secured during operation.

Keep body parts, such as hand, fingers and arms,

away from moving components.

Always use provided latches and handles for

opening and closing doors and covers.

Third Edition • Sixth Printing Operator's Manual

Work Area Safety

Part No. 237108 GTH-844 13

Damaged Machine Hazards

Do not use a damaged or malfunctioning machine.

Conduct a thorough pre-operation inspection of the

machine and test all functions before each work

shift. Immediately tag and remove from service a

damaged or malfunctioning machine.

Be sure all maintenance has been performed as

specified in this manual and the appropriate Genie

service manual.

Be sure all decals are in place and legible.

Be sure the operator's and safety manuals are

complete, legible and in the storage container

located in the cab.

Do not attempt to start the machine by towing or

pushing.

Do not attempt to use the forks or attachments for

prying wedged or frozen loads free.

Do not push or pull objects or loads with the forks,

attachment or boom.

Component Damage Hazards

Do not use any battery or charger greater than 12V

to jump-start the engine.

Do not use the machine as a ground for welding.

Do not steer the front tires on dry pavement when

the axle differential lock is activated.

Do not lock the axle differential when the machine

is moving.

For machines equipped with solid tires, do not

operate continuously for longer than one hour

without allowing the tires to cool down for

30 minutes.

Operator's Manual Third Edition • Sixth Printing

Work Area Safety

14 GTH-844 Part No. 237108

Crush Hazards

Keep clear of moving parts during machine

operation and make sure personnel and

bystanders are kept clear of moving parts during

operation.

Set the parking brake, put the transmission in

neutral and lower the carriage or the attachment to

the ground before leaving the machine.

Keep clear of elevated components.

Support components before performing service.

Keep clear of moving parts during machine

operation and make sure personnel and

bystanders are kept clear of moving parts during

operation.

Burn Hazards

Allow hot surfaces to cool before

touching or servicing.

Explosion and Fire Hazards

Do not start the engine if you smell or detect liquid

petroleum gas (LPG), gasoline, diesel fuel or other

explosive substances.

Do not refuel the machine with the engine running.

Refuel the machine and charge

the battery only in an open,

well-ventilated area away from

sparks, flames and lighted

tobacco.

Do not operate the machine in hazardous locations

or locations where potentially flammable or

explosive gases or particles may be present.

Do not spray ether into engines equipped with

glow plugs or air intake grid heaters.

Third Edition • Sixth Printing Operator's Manual

Work Area Safety

Part No. 237108 GTH-844 15

Electrocution Hazards

This machine is not electrically insulated and will

not provide protection from contact with or

proximity to electrical current.

Obey all local and

governmental regulations

regarding required clearance

from electrical power lines. At a

minimum, the required

clearance contained in the chart

below must be followed.

Line Voltage Required Clearance

0 to 50KV 10 ft 3.05 m

>50 to 200KV 15 ft 4.60 m

>200 to 350KV 20 ft 6.10 m

>350 to 500KV 25 ft 7.62 m

>500 to 750KV 35 ft 10.67 m

>750 to 1000KV 45 ft 13.72 m

over 1000kV see below

For power lines over 1000kV, the minimum

clearance distance must be established by the

utility owner or operator or by a registered

professional engineer who is a qualified person

with respect to electrical power transmission and

distribution.

Do not use the machine as a ground for welding.

Always contact the electrical power line owner.

The electrical power shall be disconnected or the

power lines moved or insulated before machine

operations begin.

Allow for boom and attachment movement,

electrical line sway or sag, and beware of strong or

gusty winds.

Keep away from the machine if it contacts

energized power lines. Personnel on the ground or

in the cab must not touch or operate the machine

until energized power lines are shut off.

Do not operate the machine during lightning or

storms.

Operator's Manual Third Edition • Sixth Printing

Work Area Safety

16 GTH-844 Part No. 237108

Battery Safety

Burn Hazards

Batteries contain acid.

Always wear protective

clothing and eye wear when

working with batteries.

Avoid spilling or contacting

battery acid. Neutralize

battery acid spills with

baking soda and water.

Explosion Hazards

Keep sparks, flames and

lighted tobacco away from

batteries. Batteries emit

explosive gas.

Electrocution Hazard

Avoid contact with electrical terminals.

Employer's Responsibilities

Employers are responsible for providing a safe

work environment and for complying with local and

national governmental regulations.

Third Edition • Sixth Printing Operator's Manual

Legend

Part No. 237108 GTH-844 17

Legend

1 Interior rear view mirror

2 Left to right level indicator

3 Steering wheel

4 Control handle

5 Front to rear level indicator

6 Boom angle indicator

7 Boom

8 Cab

9 Hydraulic oil level gauge (under cover)

10 Engine (on opposite side of machine)

11 Fuse panel

12 Forks

13 Exterior rear view mirror

14 Seat belt

15 Seat

16 Brake pedal

17 Accelerator pedal

18 Transmission control lever

1 3 4

2 5

Operator's Manual Third Edition • Sixth Printing

Controls

18 GTH-844 Part No. 237108

Controls

Control Panel

1 Steering wheel

2 Horn button

3 Heater and air conditioning controls (if equipped)

4 Turn signal lever (if equipped)

5 12V power port, 10A maximum

6 Steer select switch

7 Parking brake switch

8 Ignition switch

9 Load charts

10 Control handle

11 Auxiliary hydraulics switch (if equipped)

12 Accelerator pedal

13 Brake pedal

14 Tilt steering pedal

15 Axle differential lock pedal

16 Windshield washer/wiper switch (if equipped)

17 Skylight washer/wiper switch (if equipped)

18 Lights switch (if equipped)

19 Transmission control lever

20 Not used

21 Not used

22 Instrument panel

1 2

Third Edition • Sixth Printing Operator's Manual

Controls

Part No. 237108 GTH-844 19

1 Steering wheel

Turn the steering wheel to the right to turn the

front wheels to the right. Turn the steering

wheel to the left to turn the front wheels to the

left.

2 Horn button

Press this button and the horn will sound.

Release the button and the horn will stop.

3 Heater and air conditioning controls (if

equipped)

4 Turn signal lever (if equipped)

Move the lever up to activate the left turn

signal. Move the lever down to activate the

right turn signal. Turn the lever to turn on the

hazard lights.

5 12V power port, 10A maximum

6 Steer select switch

Push down the right side of the rocker switch

to select four-wheel steer. Push the rocker

switch to the middle position to select

two-wheel steer. Push down the left side of the

rocker switch to select crab steer.

7 Parking brake switch

Push the top of the rocker switch to turn the

parking brake on. The light will be on when the

parking brake is on. Push the bottom of the

rocker switch to turn the parking brake off. The

light will be off when the parking brake is off.

8 Ignition switch

Turn the key to the left to turn on the

accessories. Turn the key to the on position

and hold until the glow plug light on the

instrument panel turns off. Turn the key to the

start position to start the engine.

9 Load charts

10 Control handle (single)

Pull the control handle back and the boom will

raise. Push the control handle forward and the

boom will lower. Push the control handle to the

right and the boom will extend. Pull the control

handle to the left and the boom will retract.

Hold down the red thumb switch and pull the

control handle back and the forks will tilt up.

Hold down the red thumb switch and push the

control handle forward and the forks will tilt

down. Hold the white finger switch and push

the control handle to the right and the machine

will sway to the right. Hold the white finger

switch and pull the control handle to the left

and the machine sway to the left.

11 Auxiliary hydraulics switch (if equipped)

Push the left side of the auxiliary hydraulics

button and the carriage will swing or rotate to

the left. Push the right side of the auxiliary

hydraulics button and the carriage will swing or

rotate to the right.

12 Accelerator pedal

Operator's Manual Third Edition • Sixth Printing

Controls

20 GTH-844 Part No. 237108

13 Brake pedal

14 Tilt steering pedal

Push and hold the tilt steering pedal to release

the steering column. Move the steering wheel

to desired position and release the pedal.

15 Axle differential lock pedal

Push and hold the axle differential lock pedal

to lock the axle differential. Release the pedal

to unlock the axle differential.

16 Windshield washer/wiper switch (if equipped)

Push the right side of the rocker switch to turn

the wiper on. Push and hold the right side of

the rocker switch to turn the washer on.

Release the switch to turn the washer off.

Push the left side of the rocker switch to turn

the wiper off.

17 Skylight washer/wiper switch (if equipped)

Push the right side of the rocker switch to turn

the wiper on. Push and hold the right side of

the rocker switch to turn the washer on.

Release the switch to turn the washer off.

Push the left side of the rocker switch to turn

the wiper off.

18 Lights switch (if equipped)

Push the right side of the rocker switch to turn

the road lights or the work lights on. Push the

left side of the rocker switch to turn the road

lights or the work lights off.

19 Transmission control lever

Move the transmission control lever toward

you and move it up for forward gear. Move the

lever toward you and move it down for reverse

gear. Move the lever to the center position for

neutral. Turn the lever clockwise to shift to a

lower speed. Turn the lever counterclockwise

to shift to a higher speed.

20 Not used

21 Not used

22 Instrument panel

Third Edition • Sixth Printing Operator's Manual

Controls

Part No. 237108 GTH-844 21

Instrument Panel

1 Fuel level gauge with low fuel indicator light

2 Turn signal indicator lights

3 Tachometer

4 Lights indicator light

5 Engine coolant temperature gauge

6 Engine emissions regeneration disabled indicator

light

7 Engine emissions regeneration indicator light

8 Engine emissions system temperature

9 Urea level low indicator light (if equipped)

10 Battery voltage low indicator light

11 Engine oil pressure low indicator light

12 Check engine indicator light

13 Engine stop indicator light

14 Four-wheel steer indicator light

15 Two-wheel steer indicator light

16 Crab steer indicator light

17 Brake pressure low indicator light

18 Rear wheels centered indicator light (if equipped)

19 Transmission oil pressure low indicator light

20 Transmission oil temperature high indicator light

21 Not used

22 Hydraulic oil temperature indicator light (if

equipped)

23 Not used

24 Glow plug indicator light

25 Engine hour meter and fault code display

RPM x100

15 20

1 2 3 5

18 17 16 15 14 13 12 11

20 10

Operator's Manual Third Edition • Sixth Printing

Inspections

22 GTH-844 Part No. 237108

Inspections

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s

manual.

1 Avoid hazardous situations.

2 Always perform a pre-operation

inspection.

Know and understand the pre-operation

inspection before going on to the next

section.

3 Always perform function tests prior to use.

4 Inspect the workplace.

5 Only use the machine as it was intended.

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

performed by the operator prior to each work shift.

The inspection is designed to discover if anything

is apparently wrong with a machine before the

operator performs the function tests.

The pre-operation inspection also serves to

determine if routine maintenance procedures are

required. Only routine maintenance items specified

in this manual may be performed by the operator.

Refer to the list on the next page and check each

of the items.

If damage or any unauthorized variation from

factory delivered condition is discovered, the

machine must be tagged and removed from

service.

Repairs to the machine may only be made by a

qualified service technician, according to the

manufacturer’s specifications. After repairs are

completed, the operator must perform a

pre-operation inspection again before going on to

the function tests.

Scheduled maintenance inspections shall be

performed by qualified service technicians,

according to the manufacturer’s specifications and

the requirements listed in the responsibilities

manual.

Third Edition • Sixth Printing Operator's Manual

Inspections

Part No. 237108 GTH-844 23

Pre-operation Inspection

 Be sure that the operator’s and safety manuals

are complete, legible and in the storage

container located in the cab.

 Be sure that all decals are legible and in place.

See Inspections section.

 Check for hydraulic oil leaks and proper oil

level. Add oil if needed. See Maintenance

section.

 Check for battery fluid leaks and proper fluid

level. Add distilled water if needed. See

Maintenance section.

 Check the transmission oil level. Add oil if

needed. See Maintenance section.

 Check for engine oil leaks and proper oil level.

Add oil if needed. See Maintenance section.

 Air-filled tires models: Check for proper tire

pressure. Add air if needed. See Maintenance

section.

Check the following components or areas for

damage, improperly installed or missing parts and

unauthorized modifications:

 Electrical components, wiring and

electrical cables

 Hydraulic hoses, fittings, cylinders and

manifolds

 Fuel and hydraulic tanks

 Drive motors and drive hubs

 Boom wear pads

 Tires and wheels

 Engine and related components

 Limit switches

 Steer and axle sensors

 Lights, alarms and beacons (if equipped)

 Pins, nuts, bolts and other fasteners

Check entire machine for:

 Cracks in welds or structural components

 Dents or damage to machine

 Excessive rust, corrosion or oxidation

 Be sure that all structural and other critical

components are present and all associated

fasteners and pins are in place and properly

tightened.

 Be sure the windshield and windows (if

equipped) are clean and free of obstructions

that might limit visibility.

 After you complete your inspection, be sure

that all guards, screens and compartment

covers are in place and secured.

Operator's Manual Third Edition • Sixth Printing

Inspections

24 GTH-844 Part No. 237108

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s

manual.

1 Avoid hazardous situations.

2 Always perform a pre-operation inspection.

3 Always perform function tests prior to

use.

Know and understand the function tests

before going on to the next section.

4 Inspect the workplace.

5 Only use the machine as it was intended.

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

malfunctions are discovered, the machine must be

tagged and removed from service. Repairs to the

machine may only be made by a qualified service

technician, according to the manufacturer’s

specifications.

After repairs are completed, the operator must

perform a pre-operation inspection and function

tests again before putting the machine into service.

Third Edition • Sixth Printing Operator's Manual

Inspections

Part No. 237108 GTH-844 25

Function Tests

1 Select a test area that is firm, level and free of

obstruction. Be sure there is no load on the

forks or attachment.

2 Enter the cab and sit on the seat.

3 Adjust the seat and steering column, if

needed.

4 Fasten the seat belt.

5 Adjust the mirrors, if required.

6 Be sure the parking brake is on and the

transmission control is in neutral.

7 Start the engine. See Starting the Engine in

the Operating Instructions section.

Test the Single Control Handle (if

equipped)

8 Using the control handle, momentarily raise

the boom, extend the boom, retract the boom

and lower the boom.

Result: All functions should operate smoothly.

9 Using the control handle and the red thumb

switch, momentarily tilt the forks up and tilt the

forks down.

Result: All functions should operate smoothly.

10 Using the control handle and the white finger

switch, momentarily sway the machine to the

right and to the left.

Result: The frame level function should

operate smoothly.

Test the Dual Control Handles (if

equipped)

11 Using the boom control handle, momentarily

raise the boom, extend the boom, retract the

boom and lower the boom.

Result: All functions should operate smoothly.

12 Using the tilt and sway control handle,

momentarily tilt the forks up and tilt the forks

down.

Result: All functions should operate smoothly.

13 Using the tilt and sway control handle,

momentarily sway the machine to the right and

to the left.

Result: All functions should operate smoothly.

Operator's Manual Third Edition • Sixth Printing

Inspections

26 GTH-844 Part No. 237108

Test the Steering

14 Push the right side of the steer selector switch

to select four-wheel steer. The four-wheel

steer indicator light on the instrument panel will

be on.

15 Check the steering operation by turning the

steering wheel approximately ¼ turn in each

direction.

Result: The front wheels should turn in the

same direction as the steering wheel. The rear

wheels should turn in the opposite direction.

16 Straighten the wheels.

17 Push the steer selector switch to the middle

position to select two-wheel steer. The

two-wheel steer indicator light on the

instrument panel will be on.

18 Check the steering operation by turning the

steering wheel approximately ¼ turn in each

direction.

Result: The front wheels should turn in the

same direction as the steering wheel. The rear

wheels should not turn.

19 Straighten the wheels.

20 Push the left side of the steer selector switch

to select crab steer. The crab steer indicator

light on the instrument panel will be on.

21 Check the steering operation by turning the

steering wheel approximately ¼ turn in each

direction.

Result: The front wheels and the rear wheels

should turn in the same direction as the

steering wheel.

Test the Transmission and Brakes

22 Be sure the boom is fully lowered and

retracted.

23 Step on the brake pedal. Push the bottom of

the parking brake switch to turn it off.

24 Move the transmission control lever to forward.

Slowly let up on the brake pedal. As soon as

the machine starts to move, push the brake

pedal.

Result: The machine should move forward,

and then come to an abrupt stop.

25 Move the transmission control lever to reverse.

Slowly let up on the brake pedal. As soon as

the machine starts to move, push the brake

pedal.

Result: The machine should move in reverse,

and then come to an abrupt stop. The back-up

alarm should sound when the transmission

control lever is in reverse.

Third Edition • Sixth Printing Operator's Manual

Inspections

Part No. 237108 GTH-844 27

26 Move the transmission control lever to neutral.

27 Push the top of the parking brake switch.

Result: The red parking brake indicator light

should come on, indicating the parking brake

is on.

28 Move the transmission control lever forward,

and then in reverse.

Result: The machine should not move.

Test the Drive and Sway Cutout

29 Raise the boom to 55°. Do not extend the

boom.

30 Step on the brake pedal.

31 Push the bottom of the parking brake switch.

The parking brake is off when the indicator

light is off.

32 Put the transmission control lever in forward.

Slowly let up on the brake pedal.

Result: The drive function should not operate.

33 Put the transmission control lever in neutral.

34 Push the top of the parking brake switch.

Slowly sway the machine to the left and to the

right.

Result: The sway function should not operate.

Test the Lights (if equipped)

35 Verify that all lights are functional.

Test the 2-speed Transmission (if

equipped)

36 Retract and lower the boom to the stowed

position.

37 Drive the machine forward. Rotate the control

lever to shift the transmission to second gear.

Result: The machine should shift to second

gear.

38 Rotate the control lever to shift the

transmission to third gear.

39 Result: The transmission should not shift to

third gear.

Operator's Manual Third Edition • Sixth Printing

Inspections

28 GTH-844 Part No. 237108

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s

manual.

1 Avoid hazardous situations.

2 Always perform a pre-operation inspection.

3 Always perform function tests prior to use.

4 Inspect the workplace.

Know and understand the workplace

inspection before going on to the next

section.

5 Only use the machine as it was intended.

Workplace Inspection

Fundamentals

The workplace inspection helps the operator

determine if the workplace is suitable for safe

machine operation. It should be performed by the

operator prior to moving the machine to the

workplace.

It is the operator’s responsibility to read and

remember the workplace hazards, then watch for

and avoid them while moving, setting up and

operating the machine.

Workplace Inspection Checklist

Be aware of and avoid the following hazardous

situations:

 drop-offs or holes

 bumps, floor obstructions or debris

 sloped surfaces

 unstable or slippery surfaces

 overhead obstructions and high voltage

conductors

 hazardous locations

 inadequate surface support to withstand all

load forces imposed by the machine

 wind and weather conditions

 the presence of unauthorized personnel

 other possible unsafe conditions

Third Edition • Sixth Printing Operator's Manual

Inspections

Part No. 237108 GTH-844 29

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.

Part No. Decal Description Qty

28159 Label – Diesel 1

28175 Warning – Compartment Access 1

82366 Label – Chevron Rando 1

82558 Warning – Skin Injection Hazard 1

97602 Warning – Explosion Hazard 1

97667 Warning – Burn Hazard 1

114090 Label – Transmission Control 1

114115 Label – Steer Model Selector 1

133206 Label – Emergency Exit 1

160482 Label – Transport and Lifting 1

214418 Danger/Warning – 2 Decal

Combination

214419 Danger/Warning – 6 Decal

Combination

215267 Label – Product Registration 1

215268 Warning – Fall Hazard, Work

Platform

215384 Label – FOPS/ROPS 1

215652 Label – Dual Controller 1

216208 Label - LED Chart 1

219648 Label – Load Chart, Rotate Carriage 1

Part No. Decal Description Qty

219703 Cosmetic – Genie GTH-844, Small 1

219626 Label – Genie Logo 1

220271 Label – Boom Lettering 1

236083 Cosmetic – Genie GTH-844 2

237598 Warning – Crush Hazard, Moving

Machine

237599 Warning – Bodily Injury Hazard 1

237600 Notice – Axle Differential Lock 1

237601 Danger – Explosion/Burn Hazard 1

237605 Warning – Burn Hazard, Hot Parts 1

237606 Label – Single Controller 1

237684 Label - Load Chart, Standard

Carriage

237863 Label – Angle Indicator 1

237970 Warning – Crush Hazard, Tires 3

237971 Danger – Explosion/Burn Hazard,

Fueling

826345 Label – Ultra Low Sulfur Fuel Only

(diesel models)

822590 Label – 2-speed Transmission 1

1253091 Label – Key Ignition 1

1257919 Label – Load Chart, Quick Attach

Lifting Point

1257994 Cosmetic – Genie 1

1261896 Label – Load Chart, Swing 1

1262614 Warning – Tip-over, Swing Carriage 2

Operator's Manual Third Edition • Sixth Printing

Inspections

30 GTH-844 Part No. 237108

Shading indicates decal is hidden from view, i.e. under covers

114090

237600

114115

load chart set 214418

237599

215384

237606

215652

133206

214419

82558

237598

237605

236083

215268

237601

97602

97667

214418

28175

Serial Label

236083

220271

23797128159

82366

215267

237598

237970

216208

214418

219703

160482

237970

822590

826345

1253091

1257994

1262614

Third Edition • Sixth Printing Operator's Manual

Inspections

Part No. 237108 GTH-844 31

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.

Part No. Decal Description Qty

28159 Label – Diesel 1

82473 Label – Compartment Access 1

82560 Label – Skin Injection Hazard 1

133031 Label – Burn Hazard 1

114090 Label – Transmission Control 1

114115 Label – Steer Model Selector 1

133206 Label – Emergency Exit 1

160482 Label – Transport and Lifting 1

215644 Label – Crush Hazard, Tires 3

215645 Label – Explosion/Burn Hazard 1

215646 Label – 2 Decal Combination 3

215647 Label – 6 Decal Combination 1

215648 Label – Fall Hazard 1

215652 Label – Dual Controller 1

219648 Label – Load Chart, Rotate Carriage 1

Part No. Decal Description Qty

219703 Cosmetic – Genie GTH-844, Small 1

220271 Label – Boom Lettering 1

236083 Cosmetic – Genie GTH-844 2

237606 Label – Single Controller 1

237720 Label – Crush Hazard, Moving

Machine

237721 Label – Bodily Injury Hazard 1

237722 Label – Explosion/Burn Hazard 1

237726 Label – Burn Hazard, Hot

Components

237863 Label – Angle Indicator 1

237684 Label - Load Chart, Standard

Carriage

822590 Label – 2-speed Transmission 1

1253091 Label – Key Ignition 1

1257919 Label – Load Chart, Quick Attach

Lifting Point

1257994 Cosmetic – Genie 1

1261896 Label – Load Chart, Swing 1

1262615 Label – Tip-over, Swing Carriage 2

Operator's Manual Third Edition • Sixth Printing

Inspections

32 GTH-844 Part No. 237108

Shading indicates decal is hidden from view, i.e. under covers

160482

114090

114115

load chart set 215646

237721

237606

215652

133206

215647

82560

237720

215644

237726

236083

215648

237722

133031

215646

82473

Serial Label

236083

220271

215645 28159

237720

215644

215646

219703

822590

1253091

1253091 A1253091 A

1257994

1262615

Third Edition • Sixth Printing Operator's Manual

Operating Instructions

Part No. 237108 GTH-844 33

Operating Ins tructions

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s

manual.

1 Avoid hazardous situations.

2 Always perform a pre-operation inspection.

3 Always perform function tests prior to use.

4 Inspect the workplace.

5 Only use the machine as it was

intended.

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,

safety and responsibilities manuals.

A variable reach rough terrain forklift truck is

defined as a wheeled type truck designated

primarily as a fork truck with a pivoted boom, which

may be equipped with attachments for lifting

material. Using it for any other use is unsafe and

dangerous.

Only trained and authorized personnel should be

permitted to operate a machine. If more than one

operator is expected to use a machine at different

times in the same work shift, they must all be

qualified operators and are all expected to follow

all safety rules and instructions in the operator’s,

safety and responsibilities manuals. That means

every new operator should perform a pre-operation

inspection, function tests, and a workplace

inspection before using the machine.

Operator's Manual Third Edition • Sixth Printing

Operating Instructions

34 GTH-844 Part No. 237108

Parking Brake

Use the parking brake switch to apply the parking

brake before raising the boom or leaving the

machine.

Push the top of the rocker switch to turn the

parking brake on.

Push the bottom of the switch to turn the parking

brake off.

Brake Pedal

Use the brake pedal to control the machine speed

and to stop the machine motion.

Push and hold the brake pedal to stop the

machine.

Push and release the brake pedal to control the

machine speed.

Starting the Engine

1 Be sure the parking brake is set and the

transmission control lever is in the neutral

position.

2 Insert the key in the ignition switch.

3 Turn the key until the engine starts.

If the engine fails to start after 30 seconds of

cranking, determine the cause and repair any

malfunction. Wait 120 seconds before trying to

start again.

Steer Select

Always position all wheels in line with the machine

before switching the steering mode.

Do not realign the wheels while driving.

Steer selector switch

Emergency Exit (if equipped)

Rotate each retaining lever and push out the

window.

Third Edition • Sixth Printing Operator's Manual

Operating Instructions

Part No. 237108 GTH-844 35

Transmission Control

Use the transmission control lever to control the

speed and direction of machine travel.

Step on the service brake pedal before putting the

transmission into gear.

To drive forward, move the transmission control

lever toward you and move it up.

To drive in reverse, move the transmission control

lever toward you and move it down.

To return to neutral, move the transmission control

lever to the center position.

The transmission control lever also controls the

transmission speed.

To choose a lower speed, rotate the control lever

clockwise.

To choose a higher speed, rotate the control lever

counterclockwise.

Models with 3-speed transmission

Come to a complete stop before shifting the

transmission from forward to reverse. The

transmission control lever must be in 1st or 2nd

gear only.

Forward / 1st gear: Low speed / high torque

Forward / 2nd gear: Medium speed / medium

torque

Forward / 3rd gear: High speed / low torque

Operator's Manual Third Edition • Sixth Printing

Operating Instructions

36 GTH-844 Part No. 237108

Models with 2-speed transmission

Come to a complete stop before shifting the

transmission from forward to reverse. The

transmission control lever must be in 1st or 2nd

gear only.

Forward / 1st gear: Low speed / high torque

Forward / 2nd gear: Medium speed / medium

torque

Axle Differential Lock

Use the axle differential lock switch to lock the axle

differential and gain added traction in certain types

of terrain such as sand, mud or snow.

Come to a complete stop before activating the axle

differential lock. Do not lock the axle when the

machine is moving.

Step on the pedal and hold it to activate the axle

differential lock. Release the pedal to release the

differential lock.

Frame Sway Control

Before raising the boom, the machine must be

level.

1 Check the left to right level indicator. The left to

right level indicator should be 0 degrees before

raising the boom.

2 If the machine is not level, use the frame sway

control function to level the machine.

Only use the frame sway control function if the

boom angle indicator is at 0 degrees or less.

See Controller Movements section.

Transporting a Load

Center the load on the forks. Position the load so

that it is completely against the back of the fork

frame.

The load should be kept as low to the ground as

possible while traveling. Always move a loaded

machine with the boom angle indicator at

0 degrees or less.

Tilt the forks back slightly to help keep the load

secure.

Always bring the machine to a complete stop

before applying the parking brake.

Third Edition • Sixth Printing Operator's Manual

Operating Instructions

Part No. 237108 GTH-844 37

Raising and Placing a Load

The load chart in the cab 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, its load center and

how far out and up it is to be placed.

This machine has more than one load chart. Be

sure you are using the load chart that corresponds

to the attachment on the machine.

If you determine that the weight of the load cannot

be placed at the height and angle you want, these

options can be used:

1 Move the machine closer to the loading or pick

point so that the weight of the load will meet

the load chart specifications.

2 Divide the load into smaller pieces so that

each piece meets the load chart specifications.

3 Obtain a larger machine capable of handling

the load within specifications.

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 left to right level

indicator or the front to back level indicator is

not at 0 degrees.

5 Gradually move the controller to raise and

extend the boom to the required height.

Operator's Manual Third Edition • Sixth Printing

Operating Instructions

38 GTH-844 Part No. 237108

6 Gradually move the controller to lower and

extend the boom into final position. Lower the

load until the weight is completely off the forks.

Do not apply a downward force with the forks.

7 Gradually move the controller to raise and

retract the boom. This will bring the forks out of

the load.

8 When the forks are clear of the load and the

structure, the boom can be lowered and

retracted.

Third Edition • Sixth Printing Operator's Manual

Operating Instructions

Part No. 237108 GTH-844 39

Controller movements – Single Control Handle

Control handle only Control handle with red thumb switch

(A)

Control handle with white finger switch (B)

Controller movements - Dual Control Handle

Boom control handle Tilt and sway control handle

Operator's Manual Third Edition • Sixth Printing

Operating Instructions

40 GTH-844 Part No. 237108

Rear Axle Lock

If the boom is raised above 55°, the transmission

will shift to neutral and the frame sway function will

not operate.

Boom and fork functions continue to operate.

To unlock the rear axle and to operate the frame

sway function, lower the boom. When the boom is

at or below 0°, the frame sway function will

operate.

Third Edition • Sixth Printing Operator's Manual

Operating Instructions

Part No. 237108 GTH-844 41

Quick Attach Instructions

Remove the quick attach lock pin.

Tilt the forks forward to

pivot the quick attach

connector back.

Position the boom so that the quick attach pin on

the boom is below and centered between the

hooks on the attachment.

Raise the boom until the

pin is secured in the

hooks on the

attachment.

Tilt the forks back to

pivot the quick attach

into the attachment.

Insert the quick attach lock pin all the way through

the attachment and be sure the quick attach lock

lever is secured in the notch on the pin.

a quick attach pin

b quick attach lock pin

c quick attach lock lever

d quick attach connector

e attachment hooks

Engine Condition Indicator

If the engine diagnostic display indicates an engine

fault, contact service personnel.

abde

Operator's Manual Third Edition • Sixth Printing

Operating Instructions

42 GTH-844 Part No. 237108

After Each Use

1 Select a safe parking location—firm level

surface, clear of obstruction and traffic.

2 Retract and lower the boom to the stowed

position.

3 Move the transmission control lever to neutral.

4 Set the parking brake.

5 Turn the key switch to the off position and

remove the key to secure from unauthorized

use.

Jump Starting the Machine

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.

Never jump start the machine directly to the starter

or the starter solenoid. Serious injury or death

could result from the machine moving forward or

backward.

To avoid personal injury when jump starting with

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 12V. The machine

used for jump starting must have a negative

ground electrical system.

To jump start the machine

1 Connect the positive (+) jumper cable to the

positive (+) post of the discharged battery.

2 Connect the other end of the same jumper

cable to the positive (+) post of the booster

battery.

3 Connect one end of the second jumper cable

to the negative (-) post of the booster battery.

4 Make the final cable connection to the engine

block or the furthest ground point away from

the battery.

5 Start the engine.

Third Edition • Sixth Printing Operator's Manual

Operating Instructions

Part No. 237108 GTH-844 43

Driving on a slope

When the machine is loaded, always travel with

the load uphill. When the machine is unloaded,

travel with the forks or attachment downhill.

On steep terrain, drive only up and down hill, and

always keep the machine in gear. Do not turn

across slope when machine is traveling up or down

a slope. To avoid overspeeding the engine and

transmission when driving down slopes, downshift

to a lower gear and use the service brake as

necessary to maintain a slow speed.

Limit travel path and speed according to the

condition of the ground surface, traction, slope,

location of personnel and any other factors which

may create a hazard. Never drive the machine

unless the mast and equipment are in their proper

travel position.

Whether a machine will tip over during dynamic

machine operation involves many variables that

need to be considered. Among these are

pavement/ground conditions, stability and slope,

as well as machine equipment, operator skill, load

position, tire inflation, machine speed, etc.

Additionally, tip over of a machine is dependent in

large part upon operator inputs such as the speed

and smoothness of the operation as well as the

position of the attachment and its load.

Construction sites and roads will frequently change

slope from place to place, can be hard and soft,

and change due to the construction activities and

weather.

Operators should be properly trained and use their

best judgment and experience to take the

necessary precautions to prevent tip over.

Operators must assess the jobsite variables and

avoid exceeding the machine's (or operator's)

capabilities for terrain and conditions.

Operator's Manual Third Edition • Sixth Printing

Transport and Lifting Instructions

44 GTH-844 Part No. 237108

Transport and Lif ting Instructions

Observe and Obey:

 Genie provides this securement information as

a recommendation. Drivers are solely

responsible for making sure machines are

properly secured and the correct trailer is

selected pursuant to US Department of

Transportation regulations, other localized

regulations, and their company policy.

 Genie customers needing to containerize any

lift or Genie product should source a qualified

freight forwarder with expertise in preparing,

loading and securing construction and lifting

equipment for international shipment.

 Only qualified operators should move the

machine on or off the truck.

 The transport vehicle must be parked on a

level surface.

 The transport vehicle must be secured to

prevent rolling while the machine is being

loaded.

 Before loading for transport, make sure the

deck, ramps and machine tires are free of mud,

snow and ice. Failure to do so could cause the

machine to slide.

 Be sure the vehicle capacity, loading surfaces

and chains or straps are sufficient to withstand

the machine weight. Genie telehandlers are

very heavy relative to their size. See the serial

label for the machine weight. See the

Inspections section for the serial label location.

Third Edition • Sixth Printing Operator's Manual

Transport and Lifting Instructions

Part No. 237108 GTH-844 45

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

items.

Be sure the door and the door windows are latched

and secured (if equipped).

Prior to loading, level the telehandler and retract

the boom.

Use a spotter to load and unload the telehandler.

Keep the boom as low as possible when loading

and unloading.

Set the parking brake.

Securing the Chassis

Use chains of ample load capacity.

Use a minimum of 6 chains. There are 6 tie down

points on the chassis, two in the front and two on

each side of the machine.

Fully lower the forks or attachment onto the truck

bed. Secure the forks or attachment with a suitable

strap or chain to prevent movement.

Adjust the rigging to prevent damage to the chains.

102 in / 2.6 m

44 in /

1.1 m

Operator's Manual Third Edition • Sixth Printing

Transport and Lifting Instructions

46 GTH-844 Part No. 237108

Observe and Obey:

 Only qualified riggers should rig the machine.

 Only certified crane operators should lift the

machine and only in accordance with the

applicable crane regulations.

 Be sure the crane capacity, loading surfaces

and straps or lines are sufficient to withstand

the machine weight. See the serial label for the

machine weight.

Lifting Instructions

Fully lower and retract the boom.

Determine the center of gravity of your machine

using the picture on this page.

Remove all loose items on the machine.

Attach the rigging only to the designated lifting

points on the machine.

Adjust the rigging to prevent damage to the

machine and to keep the machine level.

102 in / 2.6 m

44 in /

1.1 m

Third Edition • Sixth Printing Operator's Manual

Maintenance

Part No. 237108 GTH-844 47

Maintenance

Observe and Obey:

 Only routine maintenance items specified in

this manual shall be performed by the

operator.

 Scheduled maintenance inspections shall be

completed by qualified service technicians,

according to the manufacturer’s specifications

and the requirements specified in the

responsibilities manual.

Maintenance Symbols Legend

The following symbols have been used in this

manual to help communicate the intent of the

instructions. When one or more of the symbols

appear at the beginning of a maintenance

procedure, it conveys the meaning below.

Indicates that tools will be required to

perform this procedure.

Indicates that new parts will be required to

perform this procedure.

Indicates that a cold engine is required

before performing this procedure.

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

can damage engine components.

Note: Check the oil level with the engine off.

1 Check the oil level dipstick. Add oil as needed.

Perkins 1104D-E44T Engine

Oil type 15W-40

Perkins 854E-E34TA Engine

Oil type API CJ-4 15W-40

Low Ash Oil

Deutz TCD 3.6 L4 Tier 3 Engine

Oil type 15W-40

Deutz TCD 3.6 L4 Tier 4i Engine

Oil type API CJ-4 15W-40

Low Ash Oil

Operator's Manual Third Edition • Sixth Printing

Maintenance

48 GTH-844 Part No. 237108

Diesel Fuel Requirements

Satisfactory engine performance is dependent on

the use of a good quality fuel. The use of a good

quality fuel will give the following result: long

engine life and acceptable exhaust emissions

levels.

Minimum diesel fuel requirements for each engine

are listed below.

Perkins 1104D-E44T Engine

Fuel Type Low Sulfur Diesel (LSD)

Perkins 854E-E34TA Engine

Fuel Type Ultra Low Sulfur Diesel (ULSD)

Deutz TCD 3.6 L4 Tier 3 Engine

Fuel Type Low Sulfur Diesel (LSD)

Deutz TCD 3.6 L4 Tier 4i Engine

Fuel Type Ultra Low Sulfur Diesel (ULSD)

Check the Hydraulic Oil Level

Maintaining the hydraulic oil at the proper level is

essential to machine operation. Improper hydraulic

oil levels can damage hydraulic components. Daily

checks allow the inspector to identify changes in oil

level that might indicate the presence of hydraulic

system problems.

1 Be sure that the engine is off, the frame is level

and the boom is in the stowed position.

2 Visually inspect the sight gauge located on the

side of the hydraulic oil tank.

Result: The hydraulic oil level should be

halfway in the sight gauge.

3 Add oil as needed. Do not overfill.

Hydraulic oil specifications

Hydraulic oil type Chevron Rando HD equivalent

Third Edition • Sixth Printing Operator's Manual

Maintenance

Part No. 237108 GTH-844 49

Check the Batteries

Proper battery condition is essential to good

machine performance and operational safety.

Improper fluid levels or damaged cables and

connections can result in component damage and

hazardous conditions.

Electrocution hazard. Contact with hot or live

circuits may result in death or serious injury.

Remove all rings, watches and other jewelry.

Bodily injury hazard. Batteries contain acid.

Avoid spilling or contacting battery acid.

Neutralize battery acid spills with baking soda

and water.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections are

tight and free of corrosion.

3 Be sure that the battery hold-down brackets

are in place and secure.

Note: Adding terminal protectors and a corrosion

preventative sealant will help eliminate the

corrosion on the battery terminals and cables.

Check the Engine Coolant Level –

Liquid Cooled Models

Maintaining the engine coolant at the proper level

is essential to engine service life. Improper coolant

level will affect the engine’s cooling capability and

damage engine components. Daily checks will

allow the inspector to identify changes in coolant

level that might indicate cooling system problems.

Perkins Engines:

1 Check the fluid level in the radiator.

Result: The fluid level should be at the bottom

of the filler neck.

Bodily Injury Hazard. Fluids in the radiator are

under pressure and extremely hot. Use caution

when removing cap and adding fluids.

Deutz Engines:

1 Check the fluid level in the sight glass located

on the radiator expansion tank.

Result: The fluid level should be at the half

way mark of the sight glass when the engine is

cold.

Coolant Specification

Perkins and Deutz engines Extended Life Coolant

(ELC)

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Maintenance

50 GTH-844 Part No. 237108

Check the Tire Pressure

Tip-over hazard. An over-inflated tire can

explode which may compromise machine

stability and cause the machine to tip over.

Tip-over hazard. The use of temporary flat tire

repair products may lead to tire failure which

could compromise machine stability and cause

the machine to tip over.

Bodily injury hazard. An over-inflated tire can

explode and may cause death or serious

injury.

Note: This procedure does not need to be

performed on machines equipped with foam-filled

tires.

1 Check each tire with an air pressure gauge.

Add air as needed.

Tire pressure 62 psi 4.3 bar

Scheduled Maintenance

Maintenance 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.

Third Edition • Sixth Printing Operator's Manual

Attachments

Part No. 237108 GTH-844 51

Attachments

Work Platform Hazards

Work Area Safety

The telehandler shall not be used to lift people

unless there is no other practical option. If a

telehandler must be used to lift people, the

following precautions for the protection of

occupants shall be taken.

Use only a Genie approved personnel work

platform which complies with the design

requirements of ANSI/ITSDF B56.6.

Do not lift personnel with a

telehandler unless it is equipped

with an approved work platform.

The user or employer and the operator shall further

investigate, and comply with, all applicable jobsite,

local, state, provincial, or federal rules, regulations,

and standards related to the use of the telehandler

with a work platform.

Read, understand and obey all warnings and

instructions provided with the attachment that is

approved for elevating personnel.

The operator and the platform occupants must be

instructed regarding the specific hazards

associated with using the telehandler with the work

platform, and utilize all means, including those

provided by the user or employer, to avoid them.

Always perform a pre-operation inspection of the

platform, per the manufacturer’s instructions, prior

to use.

If damage or any unauthorized variation from

factory delivered condition is discovered, the

platform must be tagged and removed from

service.

Do not modify the platform without written approval

by Genie and the platform manufacturer.

Do not use the telehandler with a work platform

attached for any purpose other than positioning

personnel with their tools, materials and

equipment.

Provide overhead protection as required by the

operating conditions.

Platform Occupant

Fall Protection

Personal fall protection equipment (PFPE) is

required for all occupants of the work platform.

Occupants must wear a

safety belt or harness in

accordance with

governmental regulations.

Attach the lanyard to the

anchor provided in the

platform.

All PFPE must comply with applicable

governmental regulations, and must be inspected

and used in accordance with the PFPE

manufacturer’s instructions.

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52 GTH-844 Part No. 237108

Occupying the Platform

Do not carry materials directly on platform railing

unless approved by Genie.

Be certain that materials and tools are protected

from falling out of the platform.

Be aware of crushing

hazards when grasping

the platform guard rail.

During movement of the

platform, occupants must

keep all body parts inside

the platform railing.

Do not sit, stand or climb

on the platform guard

rails. Maintain a firm

footing on the platform

floor at all times.

Do not enter or exit the platform unless the

machine is in the stowed position and the platform

is at ground level.

Occupants shall not climb on any part of the

telehandler in attempting to enter and exit the

platform.

Do not climb down from the

platform when raised.

Do not place or attach overhanging loads to any

part of this machine or platform.

Do not place ladders or

scaffolds in the platform or

against any part of this

machine.

Do not tie the boom or platform to adjacent

structures.

Do not place loads outside the platform perimeter.

Do not transport tools and materials unless they

are evenly distributed and can be safely handled

by person(s) in the platform.

Keep the platform floor clear of debris.

Never use ladders, boxes, steps, planks or similar

items on the platform to provide additional reach.

Be certain that required personnel fall protection

devices, such as guard rails and full body harness

with lanyard, are in place and properly used.

Use the hand rails to maintain balance while the

platform is in motion.

Do not increase the surface area of the platform or

the load. Increasing the area exposed to the wind

will decrease machine stability.

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Part No. 237108 GTH-844 53

Telehandler Operation

Be certain that the platform is securely attached to

the telehandler, lifting carriage and forks.

Be certain that the lifting carriage and forks are

secured to prevent them from pivoting freely.

Do not drive the telehandler

when occupants are in the

platform.

Always fully lower the platform and have

occupants leave the platform before driving the

telehandler.

Before elevating personnel, the area shall be

marked to warn of work by elevated personnel.

Prior to lifting personnel, platform occupants and

telehandler operator must establish a means of

communication for positioning of the platform.

Be sure that operators of other overhead and floor

level machines are aware of the machine’s

presence.

Lifting Personnel

Occupants, equipment and

materials shall not exceed

the maximum platform

capacity. Distribute loads

evenly on the platform floor.

The combined weight of the platform, load, and

personnel shall not exceed one-third of the

capacity at the related load center position

(24 inches / 60 cm) as indicated on the load charts

of the telehandler on which the platform is used.

Be certain that the path of platform travel is clear of

hazards such as storage racks, scaffolds,

overhead obstructions, and electrical wires.

Do not level the machine

with the frame sway

function when the platform

is occupied.

Be certain that the platform

is horizontal before lifting,

and do not tilt the platform

forward or backward when

the occupied platform is

elevated.

When equipped, always lower the stabilizers prior

to raising personnel.

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54 GTH-844 Part No. 237108

Keep bystanders away while operating.

Do not place boom or platform against any

structure to steady the platform or to support the

structure.

Do not use the controls to free a platform that is

caught, snagged or otherwise prevented from

normal motion by an adjacent structure. All

personnel must be removed from the platform

before attempting to free the platform using the

controls.

Check the work area for

overhead obstructions or

other possible hazards.

Be certain that the path of platform travel is clear of

hazards, such as storage racks, scaffolds,

overhead obstructions, and electrical wires.

Do not allow personnel or bystanders to tamper

with or operate the machine from the cab when

occupants are in the platform except in an

emergency or when directed by the occupants.

Always lift and lower personnel smoothly and with

caution, and only at their request.

Operating Instructions

Preparation and Setup

Read, understand and obey all jobsite, local, state,

federal and provincial rules, standards and

regulations as they pertain to the use of a

telehandler mounted personnel work platform (In

the USA and Canada, reference ANSI/ITSDF

B56.6 and CSA B335).

If the personnel work platform is equipped with

safety instructions, make sure a copy is placed in

the cab as well as in the work platform, if it is

equipped with a manual holder.

Cordon off the area to warn of work by elevated

personnel. Keep the area under the platform free

of personnel.

Be sure the telehandler is on a firm level surface

capable of supporting all forces imposed by the

machine.

Without personnel in the platform, perform a

simulated lift with the designated signal person on

the ground as a spotter, to assure adequate

telehandler range and attachment clearances and

that the telehandler lifting mechanism is operating

smoothly.

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Attachments

Part No. 237108 GTH-844 55

Installing and securing the

platform

Center the platform on the telehandler.

Properly secure the platform to the telehandler

according to the manufacturer’s instructions.

Be sure that the forks supporting the platform are

secured to prevent them from pivoting forward.

If mounted to a rotating attachment, center the

rotation of the attachment and then deactivate its

rotation capability.

Level the platform, both side to side (frame sway

function) and front to rear (attachment tilt function).

Entering, occupying and exiting

the platform

Use three-point contact when entering or exiting a

work platform.

Only enter and exit the platform when it is at

ground level.

Only enter and exit the platform at the designated

entry and exit locations.

Close and secure the entry point gate or railing

before signaling to be lifted.

Attach PFPE to the designated lanyard anchor.

Occupants should use the guardrail to help

stabilize themselves during movement. Be aware

of crushing hazards when grasping the platform

guardrail.

Lifting and lowering the platform

Set the parking brake and place the transmission

into neutral.

If equipped with stabilizers: Lower the stabilizers.

Only allow personnel to enter and exit the platform

when it is at ground level.

Establish and maintain a means of communication

with the occupants.

Only move the platform at the request of a single

designated occupant. Never tilt the platform

forward or backward, or attempt to level the

machine when the platform is occupied.

Sound the horn to alert occupants prior to lifting or

lowering the platform.

Move the platform slowly, smoothly and with

caution.

Keep hands and feet clear of all controls other than

those in use.

When the platform is occupied, the telehandler

operator must remain seated in the cab with the

occupants in direct line of sight.

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56 GTH-844 Part No. 237108

Suspended Load Hazards

Work Area Safety

General Safety

Do not lift a suspended load without first

understanding the local, state, federal, or

provincial rules, standards and regulations related

to the activity. In the USA requirements are set

forth in ANSI/ITSDF B56.6 and OSHA 29 CFR

1926.1400-1442. Additional rules, standard and

regulations may apply. Additional training may be

required.

If a telehandler must be used to transport a

suspended load, the following precautions for the

protection of the operator shall be taken.

Read, understand and obey all warnings and

instructions provided with the attachment that is

approved for suspending loads.

Only properly designed, tested and approved

attachments, designated lifting points, and lifting

accessories should be used to support a

suspended load.

The telehandler load charts are designed for loads

where the load center is stationary. As a

suspended load moves, the load center can

change. As a result, extreme caution in

transporting and lifting, or placing, the load must

be observed to minimize the potential for the load

to move.

Overturning Hazards

Do not lift a suspended load without the proper and

legible load capacity chart for the

attachment/telehandler combination you are using.

Do not permit

the load to

swing

freely. Always

properly tether

loads to restrict

movement. In

addition to

ground

personnel, the

two chassis

tie-down points

in the front of

the machine

can be used to

help externally

stabilize the

load. Always

cross the

tethers to

opposite sides

of the load to

minimize load

movement.

Driving across

grades, sudden

starts, stops,

and turns can

cause the load

to swing and

create a hazard

if not externally

stabilized.

Keep the boom retracted as much as practical.

Do not lift suspended loads when wind speeds can

cause an unsafe situation.

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Part No. 237108 GTH-844 57

All movements of the load must be accomplished

gradually and at the slowest practical speed to

prevent the load from swinging.

Keep the heavy part of the load closest to the

attachment.

Never drag or pull a load sideways.

Only lift a load vertically; do not pull a load

horizontally as it could cause excessive swinging

of the load.

The weight of all rigging (slings, shackles etc.)

must be included as part of the load.

Identify the proper lifting points of the load, taking

into consideration the center of gravity and load

stability.

Do not attempt to use the telehandler

frame-leveling to compensate for a swinging load

or to adjust the load after it has been raised.

Do not try to move fixed or obstructed loads.

Do not leave the telehandler unattended with a

suspended load.

Keep the boom and load as low as practical while

maintaining visibility in the direction of travel.

Do not exceed walking speed (2 mph / 3.2 km/h)

with a suspended load.

Start, travel, turn and stop slowly to prevent the

load from becoming unstable or swinging.

Do not use any controls to re-position the load

when traveling. Come to a gradual and complete

stop before attempting to re-position the load.

Do not attempt to cross inclines as the load center

will move towards the tipping line, thereby reducing

stability.

Only climb or descend inclines with extreme care

as the load center will move towards the tipping

line, thereby reducing stability

Do not park on a slope.

Fall Hazards

Do not lift or suspend personnel.

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58 GTH-844 Part No. 237108

Collision Hazards

Be sure that the load is clear of any adjacent

obstacles before lifting.

When visibility is or could be obstructed, near or at

the load placement, the operator shall use

alternative or additional means to safely lift the

load, such as a qualified signal person.

Signal persons must remain in constant

communication (verbal or hand) and be in visual

contact with the operator at all times.

Crush Hazards

Never allow the signal person to come between

the suspended load and another object (such as

the telehandler itself).

Falling Object Hazards

Do not raise the load into

the fall zone shown.

Do not operate the machine while people are

under the load or in the fall zone.

Do not suspend loads using slings or chains from

the forks or fork carriage.

Avoid lifting double tiered loads.

Lifting a Suspended Load

Verify that landing point is level and can safely

support the load.

Properly secure the attachment to the telehandler

Level the frame on the telehandler.

Rig the load as outlined in OSHA 29 CFR

1926.1401, 1926.1404, 1926.1425, keeping the

heaviest part of the load as close to the attachment

as practical.

Tether the load to restrict movement.

Ask a signal person to assist with lifting the load if

visibility will be obstructed at the point of operation.

Make sure that the signal person remains in

constant communication and is in visual contact at

all times.

With the boom retracted as far as practical, slowly

and gradually raise the boom and load, making

sure to keep the load and boom as low to the

ground as practical.

Be sure that all boom and attachment movements

are performed as slow as practical to avoid

swinging of the load.

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Attachments

Part No. 237108 GTH-844 59

Traveling

Be sure that the path of travel is level and capable

of supporting the telehandler with its load.

Keep the boom, and load, as low as practical while

maintaining visibility in the direction of travel.

Ask a signal person to assist with your travel if

visibility will be obstructed in the direction of travel.

Crush or Collision Hazard. Make sure that the

signal person remains in constant communication

and be in visual contact at all times.

Only make adjustments to the load after bringing

the telehandler to a complete stop.

Start, stop, travel and turn slowly to prevent the

load from becoming unstable or swinging.

Do not travel faster than walking speed (<2 mph /

3.2 km/h).

Placing the Load

Ask a signal person to assist with placing the load

if visibility will be obstructed at the point of

operation.

Make sure that the signal person remains in

constant communication and be in visual contact at

all times.

Come to a complete stop near the landing point.

If equipped with stabilizers: Lower the stabilizers.

Set the parking brake and place the transmission

into neutral.

Slowly, and gradually, place the load over the

landing point and lower the load until it is safely

supported.

Once the load has been landed, continue to lower

the boom until the rigging and tethers can be

removed.

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Attachments

60 GTH-844 Part No. 237108

Signal Person (from 1926.1419)

Per OSHA CFR 1926.1419, a signal person is

required when:

The point of operation, meaning the load travel or

the area near or at load placement, is not in full

view of the operator.

When the equipment is traveling, the view in the

direction of travel is obstructed.

Due to site specific safety concerns, either the

operator or the person handling the load

determines that it is necessary.

Signal persons must remain in constant

communication (verbal or hand) and be in visual

contact with the operator at all times.

When using hand signals, follow the requirements

set forth in OSHA CFR 1926.1419-1926.1422.

The hand signal chart below may be used in place

of the Standard Method in Appendix A of Subpart

CC of Part OSHA CFR 1926.

Third Edition • Sixth Printing Operator's Manual

Attachments

Part No. 237108 GTH-844 61

STOP. With arm

extended horizontally to

the side, palm down,

arm is swung back and

forth.

EMERGENCY STOP. With both arms extended

horizontally to the side, palms down, arms are

swung back and forth.

HOIST. With upper arm

extended to the side,

forearm and index

finger pointing straight

up, hand and finger

make small circles.

RAISE BOOM. With

arm extended

horizontally to the side,

thumb points up with

other fingers closed.

SWING. With arm

extended horizontally,

index finger points in

direction that boom is to

swing.

RETRACT

TELESCOPING BOOM.

With hands to the front

at waist level, thumbs

point at each other with

other fingers closed.

RAISE THE BOOM

AND LOWER THE

LOAD. With arm

extended horizontally to

the side and thumb

pointing up, fingers

open and close while

load movement is

desired.

DOG EVERYTHING.

Hands held together at

waist level.

LOWER. With arm and

index finger pointing

down, hand and finger

make small circles.

LOWER BOOM. With

arm extended

horizontally to the side,

thumb points down with

other fingers closed.

EXTENDED

TELESCOPING BOOM.

With hands to the front

at waist level, thumbs

point outward with other

fingers closed.

TRAVEL/TOWER

TRAVEL. With all

fingers pointing up, arm

is extended horizontally

out and back to make a

pushing motion in the

direction of travel.

LOWER THE BOOM

AND RAISE THE

LOAD. With arm

extended horizontally to

the side and thumb

pointing down, fingers

open and close while

load movement is

desired.

MOVE SLOWLY. A

hand is placed in front

of the hand that is

giving the action signal.

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Attachments

62 GTH-844 Part No. 237108

Suspended Load Hazards

Rigger Requirements (from OSHA CFR 1926.404)

When employees are engaged in hooking,

unhooking, or guiding the load, or in the initial

connection of a load to a component or structure

and are within the fall zone, all of the following

criteria must be met:

The materials being hoisted must be rigged to

prevent unintentional displacement. Only approved

lifting accessories should be used.

Hooks with self-closing latches or their equivalent

must be used. Exception: "J" hooks are permitted

to be used for setting wooden trusses.

The materials must be rigged by a qualified rigger.

Third Edition • Sixth Printing Operator's Manual

Specifications

Part No. 237108 GTH-844 63

Specificati ons

GTH-844

Height, stowed 7 ft 10 in 2.39 m

Length, stowed, without

forks

20 ft 3 in 6.17 m

Width, standard tires 7 ft 11 in 2.41 m

Wheelbase 11 ft 4 in 3.45 m

Ground clearance, center 1 ft 3 in 38 cm

Ground clearance, axle 1 ft 5 in 43 cm

Weight 22,600 lbs 10251 kg

Working fork height,

maximum

43 ft 10 in 13.36 m

Horizontal reach, maximum 28 ft 2 in 8.59 m

Reach at maximum height 2 ft 1 in 64 cm

Lift capacity, maximum

height with 24 in / 61 cm

load center

6000 lbs 2722 kg

Lift capacity, maximum

reach with 24 in / 61 cm

load center

2000 lbs 907 kg

Maximum lift capacity 8000 lbs 3629 kg

Drive speed, maximum, Deutz engines

3-speed transmission 15 mph 24.1 km/h

2-speed transmission 6 mph 10.5 km/h

Drive speed, maximum, Perkins 854 engines

3-speed transmission 16 mph 25.7 km/h

2-speed transmission 6 mph 10.5 km/h

Drive speed, maximum, Perkins 1104 engines

3-speed transmission 14 mph 22.5 km/h

2-speed transmission 5.5 mph 9.7 km/h

Tire size 13 x 24, 12 ply

Turning radius (outside),

2 wheel steer 21 ft 9 in 6.63 m

Turning radius (outside),

4 wheel steer 13 ft 9 in 4.19 m

Frame leveling (each side) 10 degrees

Fuel tank capacity 35 gal 132.5 liter

Maximum grade 50%

Horn sound level,

manufacturer's rating

113 dB

Backup alarm sound level,

manufacturer's rating

107 dB

Floor loading information

Tire load maximum 15,100 lbs 6849 kg

Occupied floor pressure 184 psf 8.8 kPa

Operator's Manual Third Edition • Sixth Printing

Load Charts

64 GTH-844 Part No. 237108

Load Charts

GTH-844 Standard Carriage

GTH-844 Rotate Carriage

GTH-844 Quick Attach Lifting

Point

GTH-844 Swing Carriage

GTH-844 Part No. 237108 Oper ator's Manual Third Edition • Sixth Printing

10 ft

3.0 m

30 ft

9.1 m

35 ft

10.7 m

0 ft

0 m

-5 ft

1.5 m

10 ft

3.0 m

30 ft

9.1 m

40 ft

12.2 m

20 ft

6.1 m

1600 lbs / 726 kg

0 ft

0 m

0 ft

0 m

10 ft

3.0 m

20 ft

6.1 m

30 ft

9.1 m

35 ft

10.7 m

20 ft

6.1 m

45 ft

13.7 m 70°

60°

50°

40°

30°

20°

10°

0°

-8°

3000 lbs / 1361 kg

4000 lbs / 1814 kg

6000 lbs / 2722 kg

8000 lbs / 3629 kg

<15 ft

<4.5 m

< 2 mph / 3.2 km/h

Distributed By:

www.genielift.com

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.

237108_36 GTH 844m 844 237108

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