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CE from SN GTH250614-101, GTH-2506 (PN

1. 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 When loading round shaped objects as petrol drums etc bind them with straps or ropes and travel at reduced speed Genie Part No 57 0009 0631 GTH 2506 69 July 2014 First Edition First Printing Attachments 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 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 Genie GTH 2506 Travelling 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 visibili
2. Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 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 Part No 57 0009 0631 First Edition First Printing July 2014 Scheduled Maintenance Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hours Inspection A Quarterly or 250 hours Inspection A B Semi annually or 500 hours Inspection A B C Annually or 1000 hours Inspection A B C D 2 Years or 2000 hours Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re in
3. Work lights switch if equipped Push the rocker switch to turn the work lights on first position for front amp boom working lights and second position for front boom amp rear working lights Steering column control Unlock the lever on the right bottom side and pull or push the steering wheel to the required position then re lock it A C switch Push the switch to turn the A C on Push the Switch to turn the A C off 23 July 2014 EEEE Controls 19 20 21 22 23 24 Cab heater fan switch Push the bottom of the switch to turn the cab heater fan on first position for low speed and second position for high speed Push the top of the switch to turn the cab heater fan off Auxiliary hydraulic circuit switch if equipped Push the button to switch the hydraulic directional flow between the two auxiliary lines Mixing bucket switch if equipped Push the bottom of the rocker switch to enable the hydraulic mixing bucket functioning Push the top of the switch to stop the hydraulic mixing bucket functioning Hazard warning lights switch if equipped Push the bottom of the switch to turn the hazard warning lights on Push the top of the switch to turn the hazard warning lights off Road lights switch Push the rocker switch to turn the road lights on first position for position lights and second position for low beams Hydraulic mixing bucket oil direction switch if equipped Pr
4. 12 GTH 2506 A Falling Object Hazards Operate the machine at speeds that will keep the load under control Start and stop movements smoothly a Be sure the load is secure before lifting it 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 Part No 57 0009 0631 First Edition First Printing July 2014 A Bodily Injury Hazards Always adjust the seat and fasten A 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 TR disconnecting hydraulic lines away leaks and holes Use a piece of cardboard 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 kK A Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning Stay clear of belts and fans when the engine is running 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
5. 4618 0390 09 4618 1670 237720 09 4616 0102 09 4618 0776 09 4618 1423 09 4618 1818 215646 09 4618 1375 09 4618 1681 09 4618 1645 237721 09 4618 1690B 09 4618 1681 09 4618 1781 09 4618 1691 09 4618 1398 09 4618 0922 09 4618 1782 09 4618 1458 09 4618 0390 09 4618 1687 09 4618 1713 09 4616 1679 09 4618 0924 09 4618 1742 09 4618 1678 AS 09 4618 0922 09 4618 0923 L dor i 09 4618 1458 237726 LE m 1258639 j g 222 215646 28159 DISS SS S 9 H EA Ve y 09 4618 1681 215645 NN 237720 gt 09 4618 0923 09 4618 0920 09 4618 1674 09 4618 0930 09 4618 1681 Shading indicates decal is hidden from view i e under covers Genio Part No 57 0009 0631 om July 2014 Inspections Inspection for Stage 3B Decals Determine whetherthe decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place Part No 215645 215646 09 4618 1818 82560 237720 237721 237726 09 4616 0102 09 4618 0776 09 4618 0920 09 4618 0922 09 4618 0924 09 4618 0923 09 4618 1691 09 4618 1375 09 4618 1398 09 4618 1025 09 4618 1742 09 4618 1419 09 4618 1423 09 4618 1687 09 4618 1689 09 4618 1458 09 4618 0390 09 4618 0930 1258639 Decal Description Danger Explosion Burn Hazard Fueling Warning Electrocution Hazard Danger N
6. Kit part number 55 0750 0086 GM 1 Floating Forks part number 55 0750 0088 Hydraulic Forks FEM2 Side Shift 100mm part number 59 0601 5013 Loading shovel 500 Lt part number 59 0201 9009 Loading shovel 800 Lt part number 59 0201 9010 Concrete bucket 500 Lt manual discharge part number 59 0401 2012 Concrete bucket 500 Lt hydraulic discharge part number 55 0401 2013 Concrete mixing bucket 250 Lt full hydraulic part number 59 0401 2018 Brick holder basket part number 59 0401 2017 Fixed hook on plate part number 59 0700 9008 Mechanical jib 2m length 2000kg capacity part number 59 0802 3016 Information for use of this attachment is described in the specific attachments operator s manual available on official Genie site www genielift com en service support manuals Part No 57 0009 0631 First Edition First Printing July 2014 A 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 Additional rules standard and regulations may apply Additional training may be required If a telehandler must be used to transport a 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 sus
7. Only use the machine as it was intended Part No 57 0009 0631 Genie GTH 2506 27 Inspections 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 July 2014 See Inspections Pre operation Inspection Be sure that the operator s and safety manual
8. Safety for Stage 3A 96 97991 89 819 60 6c60 819 60 91 819 60 979912 819760 979912 0 60 819 60 022 60 02607819760 022 60 922260 2260 819160 260 819 60 141 8197 60 922 60 62607819760 8SvL 8197 60 LZE819v 60 60 819 60 Ezt 89760 G GTH 2506 Part No 57 0009 0631 July 2014 First Edition First Printing 28 L 8L9 60 184L 819760 629L8L9 60 9794 2 122 60 022 60 oc60 819 60 General Safety for Stage 3A 89 819 60 6 91 819v 60 2819760 18 819760 976819760 8181 8197 60 122162 G L 8197 60 8181819760 979412 8SrL819v 60 260 819760 022 60 09528 enie GTH 2506 Part No 57 0009 0631 First Edition First Printing July 2014 General Safety for Stage 3B 96 97991 89t 819760 co60 819 60 260 819 60 LZE 819760 922262 62607819760 022 60 02607819760 8 9 60 60 819 60 6o 819 60 979915 0260 8197 60 6c60 819 60 91 819 60 979912 260 819v 60 022 60 922160 a 8SvL 8197 60 8197 60 G GTH 2506 Par
9. cartridge 11 Engine Alert indicator light This light flashes to warn of a problem with the engine To identify the problem see the two sections Engine Lamp Logic Genie t GTH 2506 12 Engine Critical Fault indicator light This light comes on to warn of a problem with the engine To identify the problem see the two sections Engine Lamp Logic 15 Engine coolant temperature gauge with high coolant temperature indicator light When gauge reaches red the engine coolant is too hot which can lead to engine damage Discontinue use and service the engine 19 High hydraulic oil temperature indicator light This indicates the temperature of the hydraulic oil in the tank which can lead to machine damage Discontinue use of the machine and service 22 Brake pressure low indicator light It lights when the pressure of the braking circuit is too low for a correct functioning which can lead to machine damage Discontinue use of the machine and service 25 Diagnostic light Part No 57 0009 0631 First Edition First Printing July 2014 Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operators 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
10. 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 Part No 57 0009 0631 First Edition First Printing July 2014 Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operators 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 Part No 57 0009 0631 Genie GTH 2506 z Inspections 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 July 2014 EEEE Inspections Function Tests 1 Select a test area that is firm l
11. correctly and in a responsible way emotional they shall keep calm and always be able to evaluate their own physical and mental conditions training they shall read and be familiar with this handbook its enclosed graphs and diagrams the identification and hazard warning plates They shall be skilled and trained about the machine use The operator shall have a licence or a driving licence when provided for by the laws enforced in the country where the machine works Please ask the competent bodies In Italy the operator must be at least 18 year old Part No 57 0009 0631 Genie GTH 2506 17 Safety Precautions A Requisites of the servicemen The personnel charged with the machine maintenance shall be qualified specialised in the maintenance of telehandlers and shall have the following prerequisites physical good eyesight acute hearing good co ordination and ability to carry out all required maintenance operations in a safe way according to this manual mental ability to understand and apply the enforced rules regulations and safety precautions They shall be careful and sensible for their own as well as for the others safety and shall desire to carry out the work correctly and in a responsible way training they shall read and be familiar with this handbook its enclosed graphs and diagrams the identification and warning plates They shall be skilled and trained about the machine functioning Fro
12. number 57 4700 0006 Part No 57 0009 0631 First Edition First Printing July 2014 A 6 Perform Axle Maintenance Axle specifications require that this procedure be performed after the first 100 hours Differential lubricating oil check add Planetary reduction lubricating oil check add Required maintenance procedures and additional axle information is available in the Comer Axle S128 Service Manual Comer Axle Service Manual Maintenance A 7 Perform Axle Maintenance Axle specifications require that this one time procedure be performed after the first 200 hours Differential lubricating oil change Planetary reduction lubricating oil change Magnetic plug clean Required maintenance procedures and additional axle information is available in the Comer Axle S128 Service Manual Genie part number 57 4700 0020 Comer Axle Service Manual Genie Instructions Library Genie part number 57 4700 0020 Genie Instructions Library Genie Part No 57 0009 0631 GTH 2506 65 July 2014 First Edition First Printing Attachments This machine can be equipped with several attachments Use only Genie approved attachments specified in this section Information abouthow to fit and replace attachments onthe machine can be found in section Quick Attach Instructions Genie 66 GTH 2506 Genie Approved Attachments List e Floating Forks part number 55 0750 0087 s FEM 2 Plate and Forks
13. part number 09 4693 0000 1 Fully extend and raise the boom then retract the boom checking to insure it operates smoothly There should be a light film of lubricant on wear pad contact surfaces Result Boom operates smoothly and a thin film of lubricant is visible Proceed to step 4 Result Boom does not extend or retract smoothly and no lubricant is visible on wear pad contact surfaces Proceed to step 2 2 Apply a thin layer of grease to the underside of the number 2 boom tube where it makes contact with the number 1 boom tube lower wear pads Lubricate the top and side boom tube wear pads Return the boom to the stowed position Reach the pivot end of the boom and lubricate the chain return pulley using a grease gun Genie 64 GTH 2506 A 5 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first Deutz TD 2 9 L4 Lubricating oil level check add Coolant level check add Visual inspection Suction air filter dry air filter check Fuel pre filter check empty water Only for Deutz TD 2 9 L4 Stage IIIB Exhaust system including exhaust aftertreatment components check for leaks Required maintenance procedures and additional engine information is available in the Deutz TD 2 9 L4 Operation and Maintenance Manual Deutz part number 0312 3893 Deutz TD 2 9 L4 Operation and Maintenance Manual Genie part
14. points down with other fingers closed TELESCOPING BOOM With hands to the front at waist level thumbs point outward with other fingers closed TRAVEL With all fingers pointing up arm is extended horizontally out and back to make a pushing motion in the direction of travel AND RAISE THE LOAD With arm extended horizontally to the side and thumb pointing down fingers open and close while load movement is desired hand is placed in front of the hand that is giving the action signal 72 Genie GTH 2506 Part No 57 0009 0631 First Edition First Printing July 2014 HR EE Hr M 9 Specifications GTH 2506 Height stowed 1 92 Length stowed at fork holder plate 3 84 m Width standard tires 1 81m Wheelbase 2 36 Ground clearance center 0 33 m Weight 4 580 kg height 579m Horizontal reach maximum 3 35 m Reach at maximum height 0 60 m Lift capacity maximum height 2 000 kg Lift capacity maximum reach 900 kg Maximum lift capacity 2 500 kg Drive speed maximum 23 km h Turning radius outside 4 wheel steer am Fuel tank capacity 60 L Maximum grade 50 a ii ede aoa 2 o4 ms Sound pressure level at the operator 78 dB position in accordance with EN12053 Guaranteed sound power level LwA 10
15. rated capacity for each configuration d Do not raise the boom unless the machine is level The machine level indicator should be no more than 0 5 degrees Do not work with the load limiting system cut out Genie t GTH 2506 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 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 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 Part No 57 0009 0631 First Edition First Printing July 2014 A Traveling on Slopes Hazards 9 When driving keep the boom at aA or below horizontal and keep the load close to the groun
16. system alarm mode should sound Test the Joystick Enabling Function Switch 34 Operatethe joystick without pressing this button Result the joystick shall not activate any movement Genie GTH 2506 Test the Emergency Stop Push button 35 Press the Emergency Stop Push button down during a movement Result the movements shall stop and engine should shut down Test the Seat Switch 36 Do not sit on the drive seat 37 Place transmission into forward or backward 38 Release parking and service brakes 39 Push down lightly on the accelerator pedal Result the machine shall not move Part No 57 0009 0631 First Edition First Printing July 2014 Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operators 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 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 Itis the operator s responsibility to read and remember the workplace hazards then watch for and avoid th
17. 06 11 Work Area Safety A Fall Hazards Always wear a seat belt when P 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 transport or lift personnel with this machine Do not allow riders on the machine or forks July 2014 First Edition First Printing Work Area Safety A Collision Hazards Do not put the transmission into gear unless the parking brake is set Do not drive the machine if visibility is obstructed Do not raise the boom unless the parking brake is set Do not operate in conditions without fenders to protect debris from hitting the operator or accumulating 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 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 If a radio and or mp3 player is equipped keep the volume low enough to hear surrounding environment i e traffic alarms people etc Do notadjustthe controls while driving or manoeuvring a load Genie
18. 1 dB in accordance with the Directive 2000 14 CE Floor loading information Tire load maximum 3 500 kg Occupied floor pressure 7 5 kPa Genie Part No 57 0009 0631 GTH 2506 73 July 2014 First Edition First Printing Load Charts GTH 2506 Standard Carriage GTH 2506 GTH 2506 Hook GTH 2506 LN AES ARENIS om Genie 74 GTH 2506 Part No 57 0009 0631 First Edition First Printing July 2014 Load Charts GTH 2506 2000 Kg Jib GTH 2506 GTH 2506 Bucket GTH 2506 Genie Part No 57 0009 0631 GTH 2506 75 July 2014 First Edition First Printing c Load Charts GTH 2506 MANITOU TFF 29 653340 Fork GTH 2506 GM 1 09 4618 1515 Genie 76 GTH 2506 Part No 57 0009 0631 First Edition First Printing July 2014 Test Diagrammatic Representation Of Lorry Trailer Condition Test Results r 12m 45 MASKING AREA 45 N D ue _ 2 ae uper Part No 57 0009 0631 Genie GTH 2506 77 July 2014 First Edition First Printing LESEN GNE re Diagrammatic Representation Of Lorry Trailer Condition Test Results y I MASKING A
19. Genie A TEREX BRAND Operator s Manual Serial number range G TH 2506 From serial n GTH250614 101 Stage 3A Stage 3B Original Instructions First Edition First Printing Part No 57 0009 0631 July 2014 First Edition First Printing E I Contents 1 Symbol and Hazard Pictorials Definitions 5 General 6 Work Area Safety 10 Safety Precautions 17 Leg nd uice dr e decedens 20 CONUIOIS RT 21 eter n 27 Operating Instructions 39 Parking and 53 Transport and Lifting Instructions 55 Maintenance 58 66 Specifications ccrtc it 73 Load In enn nenas 74 est 77 EC Declaration of Conformity 80 TEREX Global GmbH Copyright O 2014 by Terex Corporation Bleicheplatz 2 First Edition First Printing July 2014 8200 Schaffhausen Switzerland Genie is a registered trademark of Terex South Dakota Inc in the U S A and many other Technical Assistance Service countries GTH is a trademark of Terex
20. REA Genie 78 GTH 2506 Part No 57 0009 0631 First Edition First Printing July 2014 a 9 e acre Test Overload Test Procedure Telehandler coupled to attachments with fixed centre of load Forks Bucket Clamps 1 33 x Q Ref Standard EN1459 Q Nominal Rated Load Capacity Telehandler coupled to attachments with oscillating centre of load Hook Jib Hoist 1 33 xQ 0 1x Fb ontires 1 25 x Q 0 1x Fb outriggers Ref Standard EN13000 Nominal Rated Load Capacity Fb Boom weight reduced i e equal overturning moment at boom tip Genie Part No 57 0009 0631 GTH 2506 79 July 2014 EC Declaration Of Conformity Contents of EC Declaration of Conformity First Edition First Printing TEREX Global GmbH hereby declares that the machinery described below complies with the provisions of the following Directives 1 EC Directive 2006 42 EC Machinery Directive The machinery described below is suitable for Genie telehandlers models specified in the user manual Model Type Description Serial Number Manufacture Date Country of Manufacture Manufacturer TEREX Global GmbH Bleicheplatz 2 8200 Schaffhausen Switzerland European representative Genie UK LTD The Maltings Wharf Road Grantham Lincolnshire NG31 6BH United Kingdom Empowered signatory Place of issue Date of issue 80 Genie GTH 2506 Part No 57 0009 0631 www geni
21. South Telephone 39 075 9418129 Dakota Inc 39 075 9418175 e mail UMB Service terex com Genie 2506 Part No 57 0009 0631 First Edition First Printing July 2014 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 atalltimes If you have any questions contact Genie For Options Manuals if equipped e Key Pad Unlocking Device Option part number 58 2513 1089 PLS visit our webpage at www genielift com en service support manuals Part No 57 0009 0631 Genie GTH 2506 1 Introduction Product Identification The machine serial number is located on the serial label Homologation plate if present Serial label if present Intended Use A variable reach rough terrain forklift truck is defined as a wheeled type truck 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 July 2014 First Edition First Printing Introduction Bulletin Distribution and Complia
22. a 5x 09 4616 0000 Genie Homologation Pate 38 GTH 2506 Part No 57 0009 0631 First Edition First Printing July 2014 Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operators manual 1 Avoid hazardous situations Always perform a pre operation inspection 2 3 Always perform function tests prior to use 4 Inspect the workplace 5 Always wear the seat belt before operating the machine 6 Only use the machine as it was intended Part No 57 0009 0631 Genie GTH 2506 39 Operating Instructions 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 purpose 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 responsibilit
23. achine transmission movements ifthe operatoris notcorrectly seated inthe driving seat Emergency Stop Push button This device have to be used to stop the machine during an emergency situation By pressing this button the engine shuts down while the Load Limiting System stays active Before restarting the machine itis necessary to reset the push button by rotating it clockwise Enabling Function Switch on Joystick The joystick is equipped with an enabling function switch This red finger switch must be held pressed down until the joystick functions have been completed if it is released the manoeuvre stops July 2014 First Edition First Printing Legend 9 CO 4 2 Q 1 Left right level indicator 7 Fuel filler 2 Operator s manual storage 8 Hydraulic oil level gauge door internal side 9 Engine on opposite side of 3 Left rear view mirror machine 4 Right rear view mirrors 10 Forks 5 Boom angle indicator 11 Seat belt 6 Maintenance collar on opposite side of machine Genie 20 GTH 2506 Part No 57 0009 0631 First Edition First Printing July 2014 Controls Genie Part No 57 0009 0631 GTH 2506 21 July 2014 EEE Controls Control Panel 1 Steering wheel 2 Emergency stop push button 3 Seat controls 18 4 Turn signal Wi
24. art No 57 0009 0631 First Edition First Printing July 2014 Operating Instructions Adjusting the mirrors The machine is fitted with five rear view mirrors To adjust their positions manually rotate them to the position s which provides optimal visibility 1 Allows checking the area behind the machine on the right hand side 2 Allows checking the carriageway behind the machine 3 Allows checking the area 9 behind the machine on the left hand side 4 Allows checking the area behind the machine as well as the rear part of the chassis aa Genie Part No 57 0009 0631 GTH 250 41 July 2014 First Edition First Printing Operating Instructions Parking Brake Use the parking brake switch to apply the parking brake before raising the boom or leaving the machine Always engage the parking brake before rising from the seat if not the Load Limiting system will sound an alarm Push the bottom of the rocker switch to turn the parking brake on Push the top 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 t
25. ation 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 job site variables and avoid exceeding the machine s or operator s capabilities for terrain and conditions Part No 57 0009 0631 First Edition First Printing July 2014 Operating Instructions Engine Condition Indicator Road or site transfer If the Alert indicator light and or the Engine Critical When travelling on public roads strictly obey the Fault indicator light switch on contact service local or national road traffic regulations personnel Before traveling on public roads ensure the following is precautions are taken e Start the engine After Each Use Align the rear wheels with the chassis 1 Selecta safe parking location firm level e Stow the floating forks as shown below surface
26. azardous situation which if notavoided could result in death or serious injury MACAUTION Indicates a hazardous situation which if notavoided could result in minor or moderate injury NOTICE Indicates a property damage message Genie 2506 Standards The following standards and or regulations apply to this machine Directive 2006 42 EC Machinery Directive 2008 104 EC Electromagnetic compatibility 2000 14 CE Environment Acoustic Emissions EN 1459 1998 A3 2012 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 Part No 57 0009 0631 First Edition First Printing Electrocution hazard F Crush hazard Crush hazard Explosion burn hazard Allow engine compartment access Tip over hazard July 2014 Symbol and Hazard Pictorials Definitions Keep away from moving parts No smoking No open flame Keep load low Crush Hazard No smoking No open flame Do not use starting aids Part No 57 0009 0631 Genie Always wear seat belt Keep clear of moving parts until cool Use cardboard to search for leaks Allow surfaces to cool Explosion hazard Tip over hazard GTH 2506 First Edition First Printing July 2014 General
27. b at www genielift co uk Part No 57 0009 0631 First Edition First Printing July 2014 Introduction Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless M 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 Youread understand and obey the manufacturer s instructions and the safety rules the safety and operator s manuals and the decals applied on the machine You read understand and obey the employer s safety rules and work site regulations You read understand and obey all applicable governmental regulations You are properly trained to safely operate the machine Genie Part No 57 0009 0631 GTH 2506 3 July 2014 First Edition First Printing Introduction Hazard Classification 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 A DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury AWARNING a h
28. clear of obstruction and traffic 2 Retract and lower the boom to the stowed position 3 Move the transmission control lever to neutral 4 Setthe parking brake 5 Turn the key switch to the off position and remove the key to secure from unauthorized use With the floating forks pitched back do not move the fork pitching cylinder as the machine could suffer from damage Retract and lower the boom e Setthe Job site Road Platformselector to Road mode e sure that lights horn and turn signals are in working order e transfer speed of the machine will depend on the engine rpm A Driving on public loads is only allowed with an unloaded machine Do not use the machine to tow trailers Genie Part No 57 0009 0631 GTH 2506 51 July 2014 First Edition First Printing Operating Instructions Moving a disabled machine Towthe machine only when no alternative is possible since this operation may result in serious damage to thetransmission When possible repairthe machine on site When the machine shall absolutely be towed 1 Disable the parking brake 2 Put the gear lever to neutral see next 3 Select the two wheel steer 4 Connect a rigid draw bar to one of the two tie down points present on the front axle 5 When possible start the engine and use the hydraulic drive and the braking system 6 Tow the machine for short distances and at low speed less t
29. d 2 FIDE 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 Part No 57 0009 0631 Genie GTH 25
30. d every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation 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 Part No 57 0009 0631 Genie GTH 2506 63 Maintenance A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service July 2014 First Edition First Printing Maintenance A 4 Lubricate the Boom Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Greasing the specified locations is essentialfor good machine performance and service life Operating the machine with little or no grease may cause the machine to perform poorly and continued use may cause component damage Grease Specification PTFE INTERFLON FIN GREASE LS 2 Genie
31. e 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 the final cable connection to the engine block or the furthest ground point away from the battery 5 Start the engine Genie j GTH 2506 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 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 oper
32. elift com
33. em while moving setting up and operating the machine Part No 57 0009 0631 Genie GTH 2506 Inspections 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 D D DO O 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 July 2014 Inspections Inspection for Stage 3A Decals Determine whetherthe decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place Part No 215645 215646 09 4618 1818 82560 237720 237721 237726 09 4616 0102 09 4618 0776 09 4618 0920 09 4618 0922 09 4618 0924 09 4618 0923 09 4618 1691 09 4618 1375 09 4618 1398 09 4618 1025 09 4618 1742 09 4618 1419 09 4618 1423 09 4618 1687 09 4618 1689 09 4618 1458 09 4618 0390 09 4618 0930 1258639 Decal Description Danger Explosion Burn Hazard Fueling Warning Electrocution Hazard Danger No Riders on Forks Warning Injection Hazard Warning Crush Hazard Moving Machine Warning Dress seat Belt Warning Burn Hazard Label 2500 kg Label Upp
34. en during the machine inactivity Pay particular attention to the fluid levels and to those parts subject to ageing Before re starting the machine carry out an extraordinary maintenance and carefully check all mechanical hydraulic and electrical components July 2014 First Edition First Printing Parking and Storage Cleaning and washing the machine Clean the machine in accordance with the following instructions Remove any oil or grease traces with a dry solvent or a volatile mineral alcohol Before assembling a new part remove any protection product rust preventer grease wax etc Remove any trace of rust from metal parts with some emery cloth before smearing the part with a protection product rust preventer paint oil etc Do not use water at high pressure for washing the machine and especially the main valve the solenoid valves and electrical parts External washing Before washing the machine check that the engine is shut down and the doors and windows are closed Do not at any times use fuel to clean the machine Use water or some steam In cold climates dry the locks after washing or smearthem with an antifreeze Before using the machine again checkits conditions Internal washing Wash the machine interior with some water and a sponge Do not use water at high pressure After washing dry with a clean cloth Washing the engine Before washing the engine protect the air intake filter t
35. ents 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 will be required to perform this procedure Genie 58 GTH 2506 Check the Tire Pressure A Tip over hazard An over inflated tire can explode which may compromise machine stability and cause the machine to tip over A 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 A 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 Wheel and Tire Specifications 12 165 Rim 9 75x16 5 8 holes DIN 70361 45 bar 65 psi Part No 57 0009 0631 First Edition First Printing July 2014 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 impr
36. er Door Internal Unlock Warning Engine Compartment Warning Crush Hazard Danger Explosion Burn Hazard Warning Burn Hazard Hot Parts Label Test Ports Warning Tip Over Respect Capacity Label Attachment Locking Pin Label External Door Unlock Label Emergency Exit Label Naturelle Hydraulic Oil Danger Explosion Burn Hazard Label Control Lever Label Control Lever with Lock Unlock if equipped Warning Tip Over Respect Capacity Cosmetic Genie GTH 2506 Cosmetic Genie GTH 2506 Cosmetic Genie 34 Qty Part No 09 4618 1645 09 4618 1670 28159 09 4618 1674 09 4618 1681 09 4618 1690 09 4618 1678 09 4618 1679 09 4618 1713 09 4618 1781 09 4618 1782 Part No 09 4618 1637 09 4618 0835 09 4618 0837 09 4618 1426 09 4618 1515 First Edition First Printing ee Decal Description Label Load Limiting System Disabling Label Hydraulic Oil Label Diesel Warning Crush Hazard Safety Collar Label Tyre Pressure 4 5 bar Label Anchoring amp Lifting Label Cut off Switch Warning 7 decals Warning Burn Hazard Warning Falling Object Hazard Danger Electrocution Hazard GTH 2506 Load Chart Set Description Label Fork on Tires Label Hook Label 2000 kg Jib Label Bucket Label MANITOU Fork Qty Qty Part No 57 0009 0631 First Edition First Printing July 2014 Inspections 82560 09
37. ess the switch to regulate the oil flow direction towards right or left push the top to direct the oil towards left push the bottom to direct the oil towards right 24 25 26 27 28 29 First Edition First Printing Hydraulic quick attach enabling switch if equipped Push and hold the switch to enable the coupling or the release of the attachment managed by the control handle Road Job site switch Push the bottom of the rocker switch to select job site mode Push the bottom of the rocker switch to select road transfer mode Transmission control lever Horn button Move the transmission control lever away from you for forward gear Move the lever toward you for reverse gear Move the lever to the center position for neutral Press the top end lever button and the horn will sound Release the button and the horn will stop Instrument panel Windshield washer reservoir Genie GTH 2506 Part No 57 0009 0631 First Edition First Printing July 2014 1212171 IL NINE REIT 717171717171 n LILILILILILIULIE Controls Instrument Panel 1 O o mw er amp I ln n CO N Low engine oil pressure indicator light Parking brake engaged indicator light Hydraulic oil filter clogged indicator light Low hydraulic oil level indicator light Not active Glow plugs preheating indicator light Not active Not active Not active E
38. evel and free of 8 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 9 4 Fastenandsecurethe seatbelt around your waist 5 Adjust the cab mounted mirror and the exterior right hand mirror if required 6 Be sure the parking brake is on and the transmission control is in neutral Start the engine See Starting the Engine in the 10 Operating Instructions section 11 12 Genie 30 GTH 2506 First Edition First Printing Test the Control Handle Using the control handle momentarily raise the boom and extend the boom tilt the forks up and down Result All functions should operate smoothly Using the left roller switch momentarily extend and retract the boom Result All functions should operate smoothly Test the Hydraulic Quick Coupling Lock Unlock if equipped While pressing the dedicated switch push and hold the white thumb switch and use the control handle momentarily lock unlock the hydraulic quick coupling Result All functions should operate smoothly Test the Steering Rotate the steer selector to the right side to select four wheel steer Check the steering operation by turning the steering wheel approximately 4 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 Part N
39. go Decal 3 GTH 2506 Load Chart Set Part No Description Qty 09 4618 1637 Label Fork on Tires 1 09 4618 0835 Label Hook 1 09 4618 0837 Label 2000 kg Jib 1 09 4618 1426 09 4618 1515 Label Bucket Label MANITOU Fork Part No 57 0009 0631 First Edition First Printing July 2014 Inspections 82560 09 4618 0390 09 4618 1670 237720 09 4616 0102 09 4618 0776 09 4618 1423 09 4618 1818 215646 09 4618 1375 09 4618 1681 09 4618 1645 237721 09 4618 1690B 09 4618 1681 09 4618 1781 09 4618 1691 09 4618 1398 09 4618 0922 09 4618 1782 09 4618 1458 09 4618 1822 09 4618 1829 09 4618 0390 09 4618 1687 09 4618 1713 09 4616 1679 09 4618 0924 09 4618 1742 09 4618 1678 IRA 09 4618 0922 09 4618 0923 we gt 09 4618 1458 09 4618 1829 PY 4 09 4618 1829 237726 09 4618 1671 1258639 215645 09 4618 1681 215646 237720 09 4618 0923 09 4618 0920 09 4618 1674 09 4618 0930 09 4618 0923 09 4618 1681 Shading indicates decal is hidden from view i e under covers Genio Part No 57 0009 0631 om July 2014 First Edition First Printing Inspections Inspection for Road Homologation Configuration Part Number uv Switzerland aereossg mer Speca zomm _ 0846160276 Retecing Yetow Desa 5600100020 Orange roteer 008080081 Dosso Fenice P
40. han 5 km h Parking brakes disable A Lock with mechanical system all wheels to prevent the vehicle moving once the parking brake is disabled To unlock the negative brake of a faulty machine 1 On both sides unscrew the nuts 5 2 Screw in the brake release bolts 6a and 6b 1 2 turn at a time in sequence until the torque drops off sharply the wheels are free Clear the area of any personnel before remove the locking from each of the four tires and tow the vehicle to a safe location Genie t GTH 2506 Parking brakes enable A Lock with mechanical system all four wheels to prevent the vehicle from moving before execute any operation To re activate the negative brake 1 Apply a 20 25 bar pressure to the parking brake release port B Unscrew brake release screws 6 on both sides Adjust the screws 6 to 19 5 1 mm Apply the B2 sealant on nuts 5 and tighten them to 45 Nm 4 Release the pressure at the brakes port B The parking brakes are now re activated and the wheels are locked Clear the area of any personnel and verify that parking brake works properly Part No 57 0009 0631 First Edition First Printing July 2014 Short inactivity Always parkthe machine in a safe way after a working day a shift and at night Take all precautions to prevent damage to those persons who will approach the machine while stationary e Parkthe machine so that it does not hinder other o
41. he 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 20 seconds before trying to start again Genie GTH 2506 Starting in Cold Condition In cold conditions 20 F 6 C and below warm the engine for 5 minutes before operating to prevent hydraulic system damage In extreme cold conditions 18 C and below machines should be equipped with optional cold start kits Attempting to start the engine when temperatures are below 0 F 18 C may require the use of a booster battery Steer Select Always position all wheels in line with the machine before switching the steering mode Do not realign the wheels while driving To align the rear wheels 1 Start the engine and move the Job Site Road Platform Select to the job site position 2 Rotate the steering wheel until the wheels are in line with the length of the chassis and the orange indicator light of the steer selector Switches on with a solid light When swapping from four wheel steer to crab steer or vice versa the machine will automatically aligned the rear wheels Part No 57 0009 0631 First Edition First Printing July 2014 Emergency Exit Lift up the two levers and remove the wing nuts securing
42. he threshold value the acoustic alarm quickly beeps and the machine movements are stopped but for those allowing to return the load within safety limits Genie E h L3 L2 L1 il Part No 57 0009 0631 Genie GTH 2506 47 Operating Instructions Description of the controls 1 Calibration button 2 Stability indicator with LED bar 3 Green light power OK 4 L8 functional led Operation When power is turned on the load limiting system runs a self test e LED bar 2 gradually lights from green to red e display buzzes e L8andthe Load limiting system generalalarm indicator light stay on e then LED bar 2 gradually switches off e L8andthe Load limiting system generalalarm indicator light switch off During operation the LED bar 2 lights up gradually depending on the variation of stability Alarm codes and resetting The limiter has diagnostic facilities to aid in the identification of failures of the transducers breakages of the cables or malfunction of the electronic system When a failure is signalled the limiter enters the safety mode blocking any dangerous manoeuvres Load limiting system general alarm indicator light stays on together with LED L8 which starts flashing representing an alarm code A Before using the machine make sure that the first green LED of the overload warning system is ON The overload warning system must no
43. ies manuals That means every new operator should perform a pre operation inspection function tests anda workplace inspection before using the machine Additionally everyone working on or near the product also needs to be familiar with the applicable safety precautions July 2014 First Edition First Printing Operating Instructions Adjusting the Seat Move the lever A and slide the seat forward or backward Release the bar and make sure the seat locks in position Rotate the knob B clockwise or counter clockwise until reaching the desired springing Once you are correctly seated check that the yellow indicator C is in the green field Operate lever D press your back firmly against the backrest and put the backrest at the angle you wish then release the lever Fastening the Seat Belts Sit correctly in the driving seat then safety belts are equipped with reel retractor e To fasten the belt pull tab 1 and push it into buckle 2 e To release the belt push button 3 and remove the tab from the buckle e Make sure that the buckle is correctly located at the hip point and not on the stomach e Operate the end adjusters to reach the length you wish and make sure the buckle is always in the middle Raise armrest E and turn wheel F to put the armrest at the height you want A The seat is for one person only Don t adjust the seat when the machine is moving Genie 40 GTH 2506 P
44. if equipped be sure the device works at 12 Volt and doesn t exceed 15 Ampere During maintenance or repair works and while welding disconnect the battery by turning the cut out switch see Inspection for Decals section After turning off the cut out switch wait for 60 seconds before starting the engine A Employer s Responsibilities Employers are responsible for providing a safe work environment and for complying with local and national governmental regulations A Personal Safety Be sure that everyone working on ornear this machine is familiar with the applicable safety precautions GTH 2506 Part No 57 0009 0631 First Edition First Printing July 2014 Requisites Of The Machine Operators The operators who use the machine regularly or occasionally i e for transport reasons shall have the following prerequisites health before and during any operation operators shall never take alcoholic beverages medicines or other substances that may alter their psycho physical conditions and consequently their working abilities physical good eyesight acute hearing good co ordination and ability to carry out all required operations in a safe way according to the instructions of this manual mental ability to understand and apply the enforced rules regulations and safety precautions They shall be careful and sensible for their own as well as for the others safety and shall desire to carry out the work
45. ight turn 13 signal Move the lever backward to activate the 14 left turn signal 15 Press the top button at the end of the lever to direct a jet of water onto the cab windscreen Rotate the lever tip to operate the windscreen wiper Push the lever down to turn the high beams on after pushing the Road lights switch 30 Push T6 the lever up to use high beams for intermittent signalling Steer select switch Rotate the steer selector to the right side to select four wheel steer Rotate the steer selector to the 17 middle position to select two wheel steer Rotate the steer selector to the left to select crab steer Load limiter disable selector See Load Limiting Indicator section 18 Load limiting indicator See Load Limiting Indicator section Instrument panel Genie Part No 57 0009 0631 GTH 2506 July 2014 Controls Parking brake switch Push the bottom of the rocker switch to turn the parking brake on Push the top of the switch to turn the parking brake off Control handle See Controller movements section Heater and air conditioning controls Diagnostic button Push the button to scroll the LCD screen menu Accelerator pedal Brake pedal Ignition switch Turn the key to the e position and hold until the glow plugs preheating indicator light turns off when released key springs back to pos 1 automatically Turn the key to position P to switch the control from the cab to platform
46. ine 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 44 GTH 2506 Part No 57 0009 0631 First Edition First Printing July 2014 Operating Instructions 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 Gradually move the controller to raise and extend the boom to the required height of the load 5 Gradually move the controller to lower and retracted 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 6 Gradually move the controller to raise and retract the boom This will bring the forks out 7 When the forks are clear of the load and the structure the boom can be lowered and Genio Part No 57 0009 0631 45 July 2014 First Edition First Printing Operating Instr
47. ine levelling or required clearance contained sag and beware of strong or gusty winds YN the chart below must be followed Keep away from the machine if it contacts energized T Line Voltage Required 0 to 50kV 10 ft gt 50 to 200kV 15 ft gt 200 to 350kV 20 ft gt 350 to 500kV 25 ft gt 500 to 750kV 35 ft gt 750 to 1000kV 45 ft over 1000kV Clearance 3 05 m 4 60 m 6 10 m 7 62 10 67 13 72 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 power lines Personnel on the ground or in the cab must nottouch or operate the machine until energized power lines are shut off Donotoperate the machine during lightning or storms Genie Part No 57 0009 0631 GTH 2506 15 July 2014 First Edition First Printing Work Area Safety A Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eye wear when working with batteries t 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 Genie Electrocution Hazard Avoid contact with electrical terminal Using the Charger
48. ions Hydraulic Oil type GAZPROMNEFT HYDRAULIC HDZ 46 Fuel Type Diesel Genie Part No 57 0009 0631 GTH 2506 59 July 2014 First Edition First Printing Maintenance 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 1 Visually inspect the sight gauge located on the top side of the radiator Result The fluid level should be halfway in the sight gauge A Bodily Injury Hazard Fluids in the radiator are under pressure and extremely hot Use caution when removing cap and adding fluids Check Mirrors Maintaining the indirect visual aids is essential to workplace visibility 1 Visually inspect all mirrors to ensure they are working properly and clean and free from debris Genie 60 GTH 2506 Check the Battery 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 A Electrocution hazard Contact with hot or live circuits may result in death or serious injury Remove all rings watches and other jewellery A Bodily injury hazard Batteries contain acid
49. l 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 Genio Part No 57 0009 0631 om 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 55 July 2014 First Edition First Printing Transport and Lifting Instructions 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 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 a Ips kg Securing the Chassis Use chains of ample load capacity Use a minimum of 4 chains There are 4 tie down points on the chassis two in the front and two in the rear of
50. m a technical point of view the ordinary maintenance of the machine is not a complex intervention and can be carried out by the machine operator too provided he has a basic knowledge of mechanics July 2014 First Edition First Printing Safety Precautions Working clothes During work but especially when maintaining or repairing the machine operators must wear suitable protective clothing e Overalls or any other comfortable garments Operators should not wear clothes with large sleeves or objects that can get stuck in moving parts of the machine e Protective helmet e Protective gloves e Working shoes 2J ea OD BSCS A Personal protective equipment Under special working conditions the following personal protective equipment should be used Breathing set or dust mask Ear protectors or equivalent equipment e Goggles or facial masks Use only type approved working clothing in good condition Genie 18 GTH 2506 Part No 57 0009 0631 First Edition First Printing July 2014 A Control Indicators and Interlocks Several control indicators and interlocks have been fitted to the machine They must never be tampered with or removed Always perform a function test to check the proper operation of these devices Never operate a machine that is malfunctioning If the machine starts to malfunction immediately stop using it and have it re
51. n level of the boom can be checked with the help of the letters A B C D E painted on the same boom while the actual boom inclination degrees are shown by the angle indicator Load Limit Warning Light if equipped This device fitted on the cab roof is connected to the load limiting system and shows the same led sequence which appears on the load limiting display When it reaches the red area an acoustic alarm buzzes Part No 57 0009 0631 First Edition First Printing July 2014 Quick Attach Instructions Version with mechanical locking 1 Drive to the place where you will release the mounted attachment when possible a solid and sheltered site 2 Disconnectthe quick connectors of the attachment if any 3 Pulloutthe mechanical pin locking the attachment after removing the safety split pin at its end 4 Restthe attachment flat on the ground 5 Pitch the attachment holding frame forward and lower the boom to release the attachment upper lock 6 Move back with the machine and drive to the new attachment to be coupled 7 Hold the frame pitched forward and hook the upper lock of the new attachment 8 Retract and raise the attachment a small distance It will center automatically on the quick coupling frame 9 Refit mechanical locking pin fixing it with its safety split pin 10 Re couple the connectors of the attachment if any Part No 57 0009 0631 Genie GTH 2506 49 Operating Instr
52. nce 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 Genie 2 GTH 2506 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 e Accident reporting e Questions regarding product applications and safety Standards and regulatory compliance information e 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 we
53. ndshield washer wiper High 19 beams 20 5 Steer select switch 21 6 Load limiting disable selector 22 7 Load limiting indicator 23 8 Instruments panel 24 9 Parking brake switch 10 Control handle 25 11 Heater and air conditioning controls 26 12 Diagnostic button g 27 13 Accelerator pedal 28 14 Brake pedal 29 15 Ignition switch Genie 22 GTH 2506 16 17 First Edition First Printing Work lights switch if equipped Steering column control A C switch if equipped Cab heater fan switch Auxiliary hydraulic circuit switch if equipped Mixing bucket switch if equipped Hazard warning lights switch Road lights switch Hydraulic mixing bucket oil direction switch if equipped Hydraulic quick coupling enabling switch if equipped Road Job site switch Transmission control lever Horn button Load charts holder Windshield washer reservoir Part No 57 0009 0631 First Edition First Printing n ng Steering wheel 9 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 Emergency stop push button 10 See Control Indicators and Interlocks section Seat controls 11 See Adjusting the Seat section 12 Turn signal Windshield washer wiper High beams Move the lever forward to activate the r
54. ngine air filter restricted indicator light Engine Alert indicator light Engine Critical Fault indicator light Not active 14 15 16 17 18 19 20 21 22 23 24 25 Part No 57 0009 0631 Not active Engine coolant temperature gauge with high coolant temperature indicator light Position light indicator light Hour meter Tachometer High hydraulic oil temperature indicator light Turn signal indicator light Fuel level gauge with low fuel indicator light Brake pressure low indicator light High beam indicator light Battery voltage low indicator light Diagnostic light Genie GTH 2506 25 July 2014 First Edition First Printing Controls 1 Low engine oil pressure indicator light When illuminated this light indicates that the engine oil pressure is too low which can lead to machine damage Discontinue use ofthe machine and service 3 Hydraulic oil filter clogged indicator light When illuminated this light indicates that the hydraulic oil filter is clogged which can lead to machine damage Discontinue use of the machine and service 4 Low hydraulic oil level indicator light When illuminated this light indicates that the hydraulic oil level is too low which can lead to machine damage Replenish and eliminate any oil leaks 10 Engine air filter restricted indicator light When this lamp comes on the engine air filter is clogged proceed with cleaning or changing the air filter
55. o 57 0009 0631 First Edition First Printing 2 4 13 14 15 16 17 18 Straighten the wheels Rotate the steer selector to the middle position to select two wheel steer Check the steering operation by turning the steering wheel approximately 4 turn in each direction Result The front wheels should turn in the same direction as the steering wheel The rear wheels should not turn Straighten the wheels Rotate the steer selector to the left to select crab steer Check the steering operation by turning the steering wheel approximately 4 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 19 20 21 Be sure the boom is fully lowered and retracted Step on the brake pedal Push the top of the parking brake switch to turn it off Move the transmission control lever to the forward direction Push down lightly on the accelerator pedal to increase the RPM s and 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 Part No 57 0009 0631 Genie GTH 2506 22 23 24 25 July 2014 Inspections Move the transmission control lever to the reverse direction Push down lightly on the accelerator pedal to increase the RPM s and slowly let up on the brake pedal As so
56. o Riders on Forks Warning Injection Hazard Warning Crush Hazard Moving Machine Warning Dress seat Belt Warning Burn Hazard Label 2500 kg Label Upper Door Internal Unlock Warning Engine Compartment Warning Crush Hazard Danger Explosion Burn Hazard Warning Burn Hazard Hot Parts Label Test Ports Warning Tip Over Respect Capacity Label Attachment Locking Pin Label External Door Unlock Label Emergency Exit Label Naturelle Hydraulic Oil Danger Explosion Burn Hazard Label Control Lever Label Control Lever with Lock Unlock if equipped Warning Tip Over Respect Capacity Cosmetic Genie GTH 2506 Cosmetic Genie GTH 2506 Cosmetic Genie Qty 36 First Edition First Printing nE B I S BANI Part No Decal Description Qty 09 4618 1645 Limiting System 1 09 4618 1670 Label Hydraulic Oil 2 09 4618 1671 Label ULSD Fuel 1 09 4618 1674 Warning Crush Hazard Safety Collar 1 09 4618 1681 Label Tyre Pressure 4 5 bar 4 09 4618 1690B Label Anchoring amp Lifting 1 09 4618 1678 Label Cut off Switch 1 09 4618 1679 Warning 7 decals 1 09 4618 1713 Warning Burn Hazard 1 09 4618 1781 Warning Falling Object Hazard 1 09 4618 1782 Danger Electrocution Hazard 1 09 4618 1822 Label Sound Level 101 dB 1 09 4618 1829 Label EcoLo
57. o prevent water from entering the circuit A If the machine shall be used in a marine or equivalent environment protect it against salt deposits with an adequate treatment to prevent rust formation Genie i GTH 2506 Machine disposal A At the end of the machine life call in a specialized firm to dispose of it in compliance with the local or national regulations Battery disposal A Used lead acid batteries cannot be disposed of as normal industrial solid wastes Because of the presence of harmful substances they must be collected eliminated and or recycled in accordance with the laws of the EU Used batteries must be kept in a dry and confined place Make sure the battery is dry and the cell plugs are tight Place a sign on the battery to warn of not using it If before disposal the battery is left in the open air it will be necessary to dry smear the box and the elements with a coat of grease and tighten the plugs Do not rest the battery on the ground it is always advisable to rest it on a pallet and cover it The disposal of batteries shall be as rapid as possible Part No 57 0009 0631 First Edition First Printing July 2014 Transport and Lifting Instructions Observe and Obey 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 internationa
58. on 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 Move the transmission control lever to neutral Push the bottom of the parking brake switch Result The red parking brake indicator light should come on indicating the parking brake is on Move the transmission control lever forward and then in reverse while increasing the RPM s with the accelerator pedal Result The machine should not move Test the Parking Brake 26 27 Push the bottom of the rocker switch to turn the parking brake on the parking brake warning light should come on Push down lightly on the accelerator pedal Result The machine should not move 31 July 2014 First Edition First Printing Inspections Test the Road Transfer Mode 28 Setthe steer select switch to road transfer mode 29 Attempt to operate the boom Result None of these functions should operate Test the Lights 30 Verify that all equipped working and road lights are functional Test the Load Limiting System 31 Loada known weight of approximately 1000 kg 32 Raise the boom about 30 cm above the ground 33 Extend the boom and check if the system enters the alarm mode once it has reached the distance as indicated in the load charts for the attachment fitted to the machine Result the
59. oper oil level can damage engine components Note Check the oil level with the engine off and on a level surface 1 Check the oil level dipstick Add oil as needed Deutz TD 2 9 L4 STAGE B EU model Oil type SHELL RIMULA R4 L 15W 40 Deutz TD 2 9 L4 STAGE III A Oil type SHELL RIMULA R4 L 15W 40 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 The Stage III B diesel engine must be operated using only Ultra Low Sulfur Fuel The sulphur content of this fuel must be lower than 15 PPM Tank 60L 13 gal Deutz TD 2 9 L4 STAGE 3 B EU model Fuel Type Ultra Low Sulfur Fuel ULSD Deutz TD 2 9 L4 STAGE Maintenance 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 Besure 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 left 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 specificat
60. paired Load Limiting system The Load Limiting System has been developed to help the operator to maintain the machine longitudinal stability Audible and visual messages are provided when the limits of longitudinal stability are being approached However this device cannot replace the experience of the operator It is up to the user to adopt the necessary safety measures to work within the rated limits of the machine The Load Limiting System is designed to function only when the truck is static e when the truck is on consolidated stable and level ground e when the truck is performing loading or placing functions e when the Load Limiting System is activated not overridden The Load Limiting System will only warn the operator in the event of inadequate stability in the longitudinal plane in the forward direction The Load Limiting System is not intended for warning of the risk of overturning in the case of e a sudden overload e travelling with the load in the elevated position e travelling on rough terrain or on grounds with obstacles and holes e travelling across a slope or turning on a slope e driving in bends too fast or too sharp Adjustments affecting the setting of the Load Limiting System shall be performed only by authorised personnel Part No 57 0009 0631 Genie GTH 2506 19 Safety Precautions Seat Interlock This micro switch is located inside the seat cushion anditprevents any m
61. pending loads Only a properly designed tested and approved attachment should be used to carry 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 Part No 57 0009 0631 Genie GTH 2506 67 Attachments Overturning Hazards Do not lift a suspended load without the proper and legible load capacity chart for the attachment telehandler combination you are using A Do not permit i A the load to swing freely Always Mc properly tether loads to restrict 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 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 July 2014 Fir
62. perations Retract and lower the boom fitted with attachment on the ground e Disengage the transmission and set the parking brake Remove the key from the ignition switch and lock the cab door A Leaving a battery connected can result in shorts and as a consequence in a fire Disconnect the battery by turning the cut out switch placed inside the engine housing to OFF position see Inspection for Decals section Vea 09 4618 1678 Part No 57 0009 0631 Genie GTH 2506 53 Parking and Storage Machine storage In case of extended inactivity of the machine follow the above precautions Additionally e Wash the machine thoroughly For a better cleaning remove grills and protection casings e Carefully dry all machine parts by blowing some compressed air e Lubricate the machine thoroughly Do a walk around inspection and replace any worn or damaged part e Re paint any worn or damaged part e Remove the battery smear its terminals with vaseline and store it in a dry place Battery can be used for other purposes Otherwise periodically check its charge level e Refuel the tank to prevent internal oxidation e Store the machine a sheltered and well ventilated place e Start the engine for about 10 minutes at least once a month e When weather is particularly cold empty the radiator Always remember that the ordinary maintenance must be carried out ev
63. rator 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 The hand signal chart below may be used as reference July 2014 Attachments First Edition First Printing 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 DOG EVERYTHING Hands held together at waist level LOWER With arm and index finger pointing down hand and finger make small circles desired 2 LOWER BOOM With EXTENDED TRAVEL TOWER LOWER THE BOOM MOVE SLOWLY A arm extended horizontally to the side thumb
64. remain closed and secured during operation Part No 57 0009 0631 Genie GTH 2506 13 Work Area Safety A Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conduct a thorough pre operation inspection of the machine 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 operators and safety manuals are complete legible andin 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 July 2014 First Edition First Printing Work Area Safety A 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 A Crush Hazards Keep clear of moving parts during machine operation Set the parking brake put the transmission in neutral and lower the carriage or the attachmentto the ground before leaving the machine Keep clear of elevated components Support componen
65. s 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 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 Checkthe 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 Mirrors Ooooo g Engine and related components 28 First Edition First Printing Limit switches Lights alarms and beacons Pins nuts bolts and other fasteners Check entire machine for Genie GTH 2506 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 Besurethe windshield and windows if equipped are
66. spect it After repair place a check in the R box Part No 57 0009 0631 GTH 2506 Maintenance Checklist A A 1 Manuals and decals A 2 Pre operation inspect A 3 Function tests A 4 Lubricate the boom A 5 Engine maintenance Perform after 100 hours A 6 Axle maintenance Perform after 200 hours A 7 Axle maintenance Interlocks Spare Parts LMI Display amp Board 56 0016 0132 Enabling Function Switch on Joystick Emergency Stop Switch 56 0016 0091 Seat Switch 07 0703 0484 07 0741 0225 61 July 2014 First Edition First Printing Maintenance A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operators and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the operator s compartment An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to aler
67. st Edition First Printing Attachments 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 levelling 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 When driving on a rise with loaded material proceed in forward gear and travel with load in the lowest possible position When sloping downward with loaded material proceed into reverse Genie GTH 2506 When driving on a rise with empty shovel proceed into reverse When sloping downward with empty shovel proceed in forward gear Do no
68. t No 57 0009 0631 July 2014 First Edition First Printing 28 L 8L9 60 184L 819760 629L8L9 60 9794 2 122 60 022 60 oc60 819 60 General Safety for Stage 3B 89 819 60 6 91 819v 60 2819760 18 819760 976819760 8181 8197 60 122162 G L 8197 60 8181819760 979412 8SrL819v 60 260 819760 022 60 09528 enie GTH 2506 Part No 57 0009 0631 July 2014 First Edition First Printing Work Area Safety A Overturning Hazards Using the load chart confirm that the load is within the rated capacity of the machine Do not exceed the rated load The load center of the fork if equipped must be equal to or less than the load center indicated on the load chart All loads shown on the load chart are based on the machine being on firm 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 Donotoperate the machine if the load chartis missing Do not exceed the
69. t allow suspended loads to oscillate Do not drag loads when they are hooked up A suspended load has a dynamic and therefore an unpredictable effect on machine stability operate with caution The fixed hook has been designed to support the load declared beside The maximum payload corresponds to the nominal capacity rating of the handler on which it is installed and is indicated on the load charts supplied with the equipment Fall Hazards Do not lift or suspend personnel Don t use the shovel for rising or transporting people Part No 57 0009 0631 First Edition First Printing July 2014 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 Before any maintenance on the mixing bucket rest the bucket on the ground stop the machine remove the starter key and lock the cab door to prevent anybody from gaining access to the control panel Attachments Falling Object Hazards Do not raise the load into the fall zone shown
70. t be used to check the load going to be lifted it has only been designed to signal possible unbalances of the machine along its motion axis Such unbalances may also be caused by an abrupt operation of the levers during the load handling If during work several indicators light up operate the levers more smoothly July 2014 First Edition First Printing Operating Instructions Load Limiting Disable Selector This selector allows to override the load limiting system in order to recover the machine e when it is stuck after the load limiting system has triggered e incase of main machine failures requesting the unlock of all the machine movements In order to prevent any misuse of this device ie working outside the load and stability limits of the machine the control system is provided with a timer calibrated at 10 seconds which after this time is expired restores automatically the lock out functions When the load limiter disable selector is switched on the L8 functional led lights with a solid red light The load limiting system disable selector is active only in the Job site mode In the Platform mode the load limiting system cannot be deactivated Genie GTH 2506 Using The Load Charts The load charts installed on the cab indicate the maximum allow loadin relation to the boom extension and the type of attachment To operate under safe conditions always refer to these charts The extensio
71. t personnel of a procedure or hazard and could result in unsafe operating conditions 1 Checkto make sure that the operator s and safety manuals are present and complete in the storage container in the operator s compartment 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced Genie GTH 2506 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Part No 57 0009 0631 First Edition First Printing July 2014 A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performe
72. the levers to the frame Genie Operating Instructions Transmission Control Use the transmission control lever to control the 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 the back up alarm sounds and the rear working light turns on if equipped To return to neutral move the transmission control lever to the center position Forward Neutral Reverse Part No 57 0009 0631 GTH 2506 43 July 2014 First Edition First Printing Operating Instructions 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 Genie 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 mach
73. 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 Genie j GTH 2506 Part No 57 0009 0631 First Edition First Printing July 2014 Transport and Lifting Instructions 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 EN Ibs kg 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 Part No 57 0009 0631 Gonio GTH 2506 July 2014 First Edition First Printing 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 requirem
74. ts before performing service Keep clear of moving parts during machine operation A Burn Hazards 72 7 Allow hot surfaces to cool before touching or servicing Genie 14 GTH 2506 A 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 R ki 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 Donotuse air or oxygen for charging the accumulators Part No 57 0009 0631 First Edition First Printing July 2014 A Electrocution Hazards Work Area Safety This machine is not electrically insulated and will not Do not use the machine as a ground for welding provide protection from contact with or proximity to electrical current Always contact the electrical power line owner The electrical power shall be disconnected or the power Obey all local and governmental lines moved or insulated before machine operations regulations regarding required begin 564 clearance from electrical power lines At a minimum the Allow for boom movement electrical l
75. ty 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 lt 2 mph 3 2 km h Part No 57 0009 0631 First Edition First Printing July 2014 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 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 Part No 57 0009 0631 Genie GTH 2506 71 Attachments Signal Person A signal person is recommended 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 ope
76. uctions Controller movements Single Control Handle Control handle only Control handle only with red finger switch with red finger switch B B and with yellow roller switch C Hydraulic quick coupling if equipped While pressing the hydraulic quick coupling lock unlock control handle with red finger switch B and with white thumb switch A Genie 46 GTH 2506 Part No 57 0009 0631 First Edition First Printing July 2014 Load Limiting Indicator Atthe back of the driving place there is a unit which lets you manage the load limiting system of the machine The collected data processed in relation to the attachmentused are continuously compared with the data stored in the program memory The processing of these data results in three different situations which are displayed by the warning lights located at the left side of the display 1 Green LED ON Stability condition L1 L2 L3 during normal operation when the percentage of overturning moment is between 0 and 79 these LED s are ON 2 Yellow LED ON Pre alarm condition L4 and L5 they light up when the machine tends to overturn and the percentage of overturning moment with respect to the threshold value is between 80 and 99 the boom movements are slowed down and the acoustic alarm slowly beeps 3 Red LED Alarm condition L6 and L7 risk of overturning The percentage of overturning moment is from 100 with respect to t
77. uctions Version with hydraulic locking optional 1 Drive to the place where you will release the mounted attachment when possible a solid and sheltered site 2 Disconnect the quick connectors of the attachment if any 3 Rest the attachment flat on the ground 4 Press the Lock Unlock Enabling Switch and keep it pressed up to the end of Step 5 5 Free the attachment moving the control handle 6 Pitch the attachment holding frame forward and lower the boom to release the attachment upper lock 7 Move back with the machine and drive to the new attachment to be coupled 8 Hold the frame pitched forward and hook the upper lock of the new attachment 9 Retract and raise the attachment a small distance It will center automatically on the quick coupling frame 10 Coupling the attachment moving the control handle with the Lock Unlock Enabling Switch 11 Re couple the connectors of the attachment if any July 2014 First Edition First Printing Operating Instructions 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 ar

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