Genie GTH-1048 Utility Vehicle User Manual
Contents
1. 2 Digit Code Definition 11 Analog Throttle Input High 12 Analog Throttle input Low 18 Engine Coolant Temperature Input High 19 Engine Coolant Temperature Input Low 21 Sensor Supply Voltage High 2 Sensor Supply Voltage Low 23 Engine Oil Pressure Input Voltage High 24 Engine Oil Pressure Input Voltage Low 25 Manifold Air Temperature Input Voltage High 26 Manifold Air Temperature Input Voltage Low 28 ECU Error 32 Signifies Start of Active Fault Codes 33 Signifies Start of Previously Active Fault Codes 37 Fuel Temperature Input Voltage High 38 Fuel Temperature Input Voltage Low 39 Crank Position Input Noise Pattern Error 42 Engine Overspeed 5 ECU Power Down Error 55 CAN Error 62 Engine Coolant Temperature High Least Sever 63 Engine Coolant Temperature High Moderately Severe 64 Engine Oil Pressure Moderately Low 65 Engine Oil Pressure Extremely Low 66 Manifold Air Temperature Moderately High 68 Fuel Derate 69 Engine Coolant Temperature High Most Severe 71 Pump Control Valve Closure Too Long 12 Pump Control Valve Closure Too Short 73 Pump Solenoid Circuit Open 74 Pump Solenoid Circuit Severely Shorted 75 Pump Control Valve Closure Not Detected 76 Pump Solenoid Circuit Moderately Shorted TI Pump Solenoid Current High 78 Security Violation 79 Internal ECU Error 81 Fuel Temperature Moderately High 82 Engine Protection Shutdown 83 Auxiliary Engine S2. TRANSMISSION SHIFT CONTROL amp __ FAN amp BACK UP ALARM amp BACK UP LIGHTS 7 HEATER 20A 20A DASH GAUGES 8 HEADLIGHTS amp HOURMETER LA TAIL LIGHTS FORKTUTRELAVE 5A 20A TURN SIGNALS amp 4 WAY ELECTRIC TILT VALVES amp ESSE arene rara CONTROLLER RELIEF VALVE amp _ Pd SERVICE BRAKE LIGHTS amp p Lb 10A 10A PARKING BRAKE DASH LIGHT amp WINDSHIELD WIPERS TRANSMISSION CUT OUT RELAY 5A TOA 4 TORNE ELECTRIC ETHER AID amp I 12 VOLT ACCESSORY PLUG HORN RELAY p e me 10A 10A PUMP DESTROKE BUTTON amp FRONT AXLE DIFFERENTIAL LOCK ELECTRIC SWAY CONTROL amp AM AUXILIARY HYDRAULICS 5A 5A STABILIZERS FUSE PANEL VIEW 3 3 CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS A Boom Down A B Boom Up D B C Boom Out D BoomIn e E Boom Down and Out F Boom Up and In G Boom Up and Out H Boom Down and In 3 4 CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS BUTTON PUSHED A Tilt Down B TiltBack wo SH gt e 3 5 CONTROLS AND INSTRUMENTS SERVICE BRAKES The brake pedal is the operator s control for the service brakes Pushing the service brake pedal A activates the service brakes for all four wheels Th
3. Rated lift capacities shown are with P E 36 ft machine on a firm level surface with dim undamaged properly inflated calcium chloride solution filled tires or optional foam 28 ft filled tires Rear axle lock up engaged 8 5m Load Limits Horizontal Boom 20 ft Front Stabilizers Up 61m Last Fully Visible Letter Retracted 10 000 Ibs 12f A Letter Visible 8000 Ibs 3 6m B Letter Visible 4000 Ibs C Letter Visible 2000 Ibs 4ft D Letter Visible 1000 Ibs 122m E Letter Visible 500 Ibs ou Front Stabilizers Down 4tt Last Fully Visible Letter 1 22m Retracted 10 000 Ibs 12ft A Letter Visible 8000 Ibs 3 6m aser Visible 5009 os 36ft 28ft 201 12i AM Of An 121 C Letter Visible 4000 Ibs 11m 854m 61m 366m 12m0m12m 36m 61m D Letter Visible 2000 Ibs E Letter Visible 2000 Ibs 2000 Ibs 907 kg 4000 Ibs 1814 kg 1000 Ibs 454 kg 2000 lbs 907 kg 10000 lbs 4535 kg 10900 Ibs 4535 kg 500 lbs 227 kg 2000 Ibs 907 kg S A TEREX COMPANY PO Box 97030 32 ft 24ft 16 ft 8ft 18340 NE 76th St 976m 732m 488m 244m Om1 2m Redmond WA 98073 52 ft Ma
4. To access the fault codes hold down the Shutdown Override Blink Code Enable button B for several seconds while turning the ignition key C to the ON Not Start position After a brief pause the engine Warning Stop Engine Blink Code Light A will begin to flash a code number For example flash three times short pause flash two times long pause This example is code 32 Fault codes are reported as active codes and stored codes When a code 32 is flashed it signifies the start of flashing Active Codes when a code 33 is flashed it signifies the start of flashing Stored Codes When a code 88 is flashed there are no fault codes to report For example if an engine had no Active Faults to report and stored codes 18 and 62 to report the following flash sequence would be observed Flash three times short pause Flash two times long pause Flash eight times short pause Flash eight times long pause Flash three times short pause Flash three times long pause Flash one time short pause Flash eight times long pause Flash six times short pause Flash two times long pause Repeat above sequence Turn ignition key C to the off position when recording of the fault codes is completed A list of fault codes and their brief description follow on the next page CONTROLS AND INSTRUMENTS ENGINE ELECTRONIC CONTROL UNIT Fault Codes and Descriptions
5. CONTROLS AND INSTRUMENTS GAUGES The following gauges are used to monitor the machine 1 Fuel Level 2 Oil Temperature Powershift Transmission 3 Oil Pressure Powershift Transmission 4 Voltmeter 5 Water Temperature Engine 6 Oil Pressure Engine E HYDRAULIC PUMP DESTROKE BUTTON IN DANGER Depressing the pump destroke button while operating the machine will cause an immediate loss of hydraulic power possibly creating a very dangerous situation Hydraulic functions that will be affected are FORK TILT LIFT BOOM EXTEND and RETRACT PARKING BRAKE and SWAY None of these functions will operate as long as the button is depressed The service brakes will continue to function if the accumulator backup has a sufficient gas charge The pump destroke button A is the black push button switch located on the dash panel For example when starting the machine for the first time on a 30 degree F day depress the pump destroke button while starting the engine Continue to depress the button for 15 to 20 seconds after the engine starts Once the engine is running smoothly release the button and the hydraulic pump will engage Depressing the pump destroke button will not be required for all other starts of the day unless the engine has been allowed to cool completely 3 8 STEERING In addition to the steering whe
6. The load should be kept as low to the ground as possible while traveling Always move a loaded machine with the boom angle indicator arrow D at O degrees or less OPERATION TRANSPORTING A LOAD AN WARNING oW Slower speeds should be used whenever transporting a load A m Mu M Always bring the machine to a complete stop before reversing M the transmission control lever A Failure to do so can result in damage to the load the machine and or bystanders Always keep the boom retracted to ensure greater stability Always place the load in the center and completely against the back of the fork frame By doing so greater stability will result IMPORTANT Never attempt to use the forks and or attach ments for prying wedged or frozen loads free Damage to the load pallet and or machine could result OPERATION PLACING A LOAD IN WARNING B Do not sway the machine with the boom angle indicator arrow B at more than 0 degrees By doing so you could cause a roll over hazard which may result in injury or death A DANGER Always apply the parking brake C before lifting and or placing a load Failure to do so could allow the machine to roll over which may result in injury or death an CAUTION Always bring the machine to a complete stop before applying the parking brake C Failure to do so will damage t
7. goggles and ear protection when necessary Wear protective clothing that is snug and belted where required FIRE PREVENTION FIRST AID Install a first aid kit and fire extinguisher in the operator s cab KEEP THE FIRST AID KIT and FIRE EXTINGUISHER properly maintained Follow the instructions provided with the first aid kit and fire extinguisher 2 3 GENERAL SAFETY PROCEDURES WELDING PRECAUTIONS IN CAUTION Any unauthorized welding can cause structural failure or possible personal injury DO NOT weld on any structural member All unauthorized welding will void the warranty HAND HOLDS AND STEPS IN WARNING Slips and falls can cause serious injury When getting on and off the machine always maintain a three point contact with steps and hand rails while facing the machine DO NOT use the steering wheel or any other controls as handrails NEVER jump on or off the machine Be careful of slippery conditions on platforms steps and handrails when getting on and off the machine ALWAYS shut off the engine before leaving the operator s station REFUELING IN WARNING Fires can cause death or severe personal injury Handle fuel with care It is highly flammable DO NOT refuel the machine while smoking or when near open flames or sparks ALWAYS stop the engine before refueling the machine Fill the fuel tank outdoors Prevent fires by keeping the machine clean of trash grease and debri
8. 2 This machine must only be operated by trained personnel who have demonstrated their ability to do so safely 3 Comply with the requirements of current Occupational Safety and Health Administration OSHA standards including 29CFR1910 178 and the American National Standards Institute ANSI B56 6 latest edition 4 Readand Understand all Decals and Warnings 5 Readand Understand the Rating Chart 6 Know that the machine can safety lift each load before attempting to lift 1 5 A ROUGH TERRAIN FORK LIFT SAFETY 4 OPERATOR S RESPONSIBILITIES 1 Read and understand the Operator s Manual 2 Know the location and the purpose of the controls instruments and indicator lights 3 Make sure the machine is in proper order and all operational aids and warning signals are functional before operating 4 Keepthe machine clean including all instrumentation windows lights and other glazed surfaces 5 Use protective clothing and safety equipment Always use approved safety equipment such as gloves safety boots hard hats safety glasses and ear protection where necessary 6 Wear protective clothing that is snug and belted where required 7 Storetools and other necessary items in the toolbox 8 Neverliftaload without a Load Rating Chart in the cab 9 Know the load to be lifted 10 Bealert physically fit and free from the influences of alcohol drugs or medications that might affect the operator s e
9. The following warnings are required on all off road equipment operating in the State of California If you are operating a Genie in the State of California and do not see the approved warning labels please contact us for a replacement at no charge Our address is Genie Industries PO Box 97030 Redmond WA 98073 9730 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also contain other chemicals known to the State of California to cause cancer Wash hands after handling
10. can cause the machine to turnover When placing a load always move a loaded machine with the boom angle indicator B at 0 degrees or less When the machine is as close as possible to where the load needs to be placed set the parking brake raise the load then place the load into position The load chart shows the operating limits of a properly maintained and operated machine To use the load chart the operator must know the weight of the load and how far out and up it is to be placed If the load is heavier than stated on the load chart three options can be used l Move the machine closer to the load so that the weight of the load will fall within the load chart specifications 2 Divide the load into smaller pieces so that each piece falls into load chart specifications 3 Geta larger machine capable of handling the load within specifications 2 9 A GENERAL SAFETY 4 PROPER LOAD CHART USE A TEREX COMPANY PO Box 97030 an 36ft 28ft 20ft 12 18340 NE 76th St 134m 11m 854m 61m 366m Redmond WA 98073 60 ft 183m Manufacturer s recommended capacity is per ANSI B56 6 Stability Tests using 52 ft standard homogeneous cubes 4x 4x 4ft 158m E Genie GTH 1056 1 2x 1 2x 1 2 m Lift Capacity Load capacities at 24 in 60 cm load center 44ft with standard fork frame 13 4m
11. obstructed 15 ALWAYS level the machine as indicated on the machine level indicator before raising the boom Raising the boom with an unlevel machine may cause the machine to overturn causing injury or death 16 USE the frame sway control to level the machine only when the boom position is horizontal or lower Using the frame sway control when the boom is higher than a horizontal position may cause the machine to overturn causing injury or death 17 DO NOT depress the pump destroke button while operating the machine This button should be used only during cold start ups Depressing the button while operating the machine will cause an immediate loss of hydraulic power that will affect fork tilt lift boom extend and retract sway and all other hydraulic functions The brakes will continue to function if the accumulator backup has a sufficient gas charge OPERATION BEFORE STARTING THE ENGINE AN WARNING Before starting the engine be sure that all daily maintenance items have been performed See Maintenance section Walk around the machine and check for any parts that are missing worn damaged or leaking Repair and or replace any missing worn damaged or leaking parts d OPERATION STARTING THE ENGINE IN DANGER Any problems discovered in the steps prior to BEFORE STARTING ENGINE should be corrected before the machine is started a DANGER NEVER attempt to start the machin
12. welding be sure to discon nect the positive lead from the battery Properly attach the ground cable of the welder to the frame member that is being welded Failure to do so can cause electrical system damage 5 4 MAINTENANCE PROCEDURES DAILY MAINTENANCE SCHEDULED MAINTENANCE Maintenace performed quarterly annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service PERFORM ENGINE MAINTENANCE Refer to engine operator s manual Check engine oil Check coolant level Check engine fan Open water separator PERFORM TRANSMISSION MAINTENANCE Refer to the transmission operator s manual Check transmission oil level DAILY MAINTENANCE CHECK HYDRAULIC OIL LEVEL Location Sight glass B Behind the rear panel To Check Move the machine to level ground Level the frame Completely retract the boom Position the forks level Lower the boom to the ground Oil should be visible 1 2 way in the sight glass NOTE Refer to page 5 24 of this manual for the proper oil specifications and capacities CHECK TIRE FOR PROPER INFLATION Location Wheel ends ToCheck Wi
13. 07 kg 3000 Ibs 1360 kg lo 2 10 SECTION 3 CONTROLS AND INSTRUMENTS TABLE OF CONTENTS SECTION 3 CONTROLS AND INSTRUMENTS Operator s Compartment 3 3 Joystick Control Functions 3 4 Joystick Control Functions Button Pushed 3 5 Service Brakes 3 6 Parking Brake 3 6 Frame Sway Control 3 7 Gauges 3 8 Hydraulic Pump Destroke Button 3 8 Steering 3 9 Transmission 3 9 Front Axle Differential Lock 3 10 Front Stabilizers 3 11 Engine Electronic Control Unit ECU 3 12 3 2 CONTROLS AND INSTRUMENTS OPERATOR S COMPARTMENT Accelerator Pedal 9 Gauges 17 Windshield Wiper 24 Interior Rear View Mirror Joystick 4 way Controller 10 Machine Level Gauge 18 Ignition Switch 25 Frt Axle Differential Lock Transmission Control Lever 1l Plug 12 Volt Access 19 Auxiliary Hydraulics 26 Stabilizer Switch LH Steering Selector 12 Seat 20 Steering Wheel 27 StabilizerSwitch RH Service Brake Pedal 13 FrameLevel Switch 21 Headlight Switch 28 Switch Blink Code Parking Brake Warning Light 14 Seat Belt 22 Heater Switch 29 Light Blink Code Load Chart 15 Parking Brake Handle 23 Plug Turn Signal Wires Hourmeter 16 Pump Off Button 4 28 29 6 9 SEEN 3 20 23 21 22 17 19 26 27 18 11
14. CE FOR NORMAL VOLTAGE IN OPERATION NEAR HIGH VOLTAGE POWER LINES AND OPERATION IN TRANSIT WITH NOLOAD AND BOOM OR MAST LOWERED Normal Voltage kV Minimum Required Phase to Phase Clearance ft m Operation Near High Voltage Power Lines to 50 10 3 05 Over 50 to 200 15 4 60 Over 200 to 350 20 6 10 Over 350 to 500 25 7 62 Over 500 to 750 35 10 67 Over 750 to 1000 45 13 72 Operation in Transit With No Load and Boom Lowered to 0 75 4 1 22 Over 0 75 to 50 6 1 83 Over 50 to 345 10 3 05 Over 345 to 750 16 4 87 Over 750 to 1000 20 6 10 IN WARNING Always remain completely inside the cab enclosure while operating the machine AN WARNING Never operate this machine under the influence of drugs alcohol and or medication which can cause drowsiness AN WARNING Never transport or lift personnel into position with this fo It is not designed as a personnel lifting device Location The battery is located under the fuel tank battery box cover A JUMP STARTING Jump starting at the battery or battery replacement is required when the battery is discharged to the point where the battery will not crank the starter AN WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also contain other c
15. Code Diagnostics Details and procedures regarding ECU fault detection engine protection and blink code diagnostics are outlined below Engine Protection When the engine is in operation and the engine ECU detects a Warning Condition the amber light A on the dash will begin flashing A Warning Condition is an engine fault in which a critical monitored engine parameter goes beyond normal operating values If the engine operating conditions are not improved or become more extreme the Warning Fault may become a Shutdown Fault At this point the amber light A on the dash will stay lit and the engine ECU may begin a sequence of power reduction The operator is responsible for shutting down the engine to prevent further damage to the engine The engine ECU will not detect all engine problems The engine protection feature is not a substitute for routine engine maintenance Normal machinery operating procedures should be adhered to CONTROLS AND INSTRUMENTS ENGINE ELECTRONIC CONTROL UNIT Blink Code Diagnostics When the engine ECU detects abnormal operating conditions it generates a fault code that is stored in the Engine ECU that can be accessed by service personnel later even after the condition that have caused the engine fault have ceased to exist Multiple fault codes can be stored simultaneously These codes can give insight into the problem area but won t necessarily specify the underlying problem
16. ES on the GTH 1048 or 55 DEGREES on the GTH 1056 all frame leveling and transmission functions are disabled and the rear axle stabilizing cylinders become locked This DOES NOT affect any boom or fork functions To unlock the rear axle stabilizing cylinders and enable the transmission functions lower the boom to a position less than 60 degrees on the GTH 1048 or 55 degrees on the GTH 1056 O 60 GTH 1048 55 GTH 1056 OPERATION NOTES SECTION 5 MAINTENANCE PROCEDURES TABLE OF CONTENTS SECTION 5 MAINTENANCE PROCEDURES General Safety Practices 5 3 Daily Maintenance 5 5 MAINTENANCE PROCEDURES GENERAL SAFETY PRACTICES BEFORE SERVICING Read the entire Maintenance Procedure Section Familiarize yourself with all the safety precautions listed in Sections 1 amp 2 Pay close attention to all the safety alert symbols Be sure you understand the procedures detailed in this section Wear personal protective equipment Remove rings and jewelry Move the machine to a safe level work place Lower the boom and support all raised equipment Shut down the machine Remove the key from the ignition Be careful not to spill fuels and lubricants Do not fill or refuel the fuel tank while the engine is running or hot Doing so could cause a fire and or an explosion Do not smoke while refueling or working with fuel to avoid a fire and or explosion IMP
17. ORTANT Always clean up spilled fuel and or lubricants to avoid polluting the earth GENERAL SAFETY PRACTICES HYDRAULIC SAFETY AN WARNING Hot hydraulic oil can cause severe burns DO NOT work on the hydraulic system if the oil system temperature exceeds 120 degrees F 49 degrees C Before ANYONE works on the hydraulic system Lower the boom to the horizontal position Support the boom to avoid unintentional lowering Shutdown the engine Remove the key from the ignition Clean the area around the oil reservoir cap A AWN FLUID UNDER PRESSURE A WARNING Escaping fluid under pressure can penetrate the skin and can cause serious personal injury Use a piece of cardboard or paper to search for leaks DO NOT use hands Before disconnecting hydraulic lines be sure to relieve all line pressure Before applying pressure to the system be sure that all connections are tight DO NOT apply pressure to a damaged line hose or fitting If injured by escaping fluid see a doctor at once Proper medical treatment must be administered immediately A serious infection or reaction can result without proper medical treatment WELDING PRECAUTIONS as WARNING DO NOT weld on any structural member Any unauthorized welding can cause structural failure or possible personal injury All unauthorized welding or repair procedures will void the machine warranty Before performing any authorized
18. ath could occur 4 ABSOLUTELY NO RIDERS SHOULD BE ALLOWED ON MACHINE OR ATTACHMENTS 5 NEVER lower a maximum load before retracting it Machine turn over component damage injury or death could occur 6 INSPECT and clear the working area of any obstructions rocks fence wire etc that could cause machine damage If obstructions cannot be cleared mark the obstructions with a stake or other marker that will be clearly visible to the operator 7 DO NOT check the engine coolant level if the engine has recently been run Injury could occur from escaping hot pressurized coolant 8 ALWAYS wear the seat belt when operating this machine 9 ALWAYS inspect the machine daily Check for leaks worn hoses loose belts or anything out of the ordinary Repair and or replace any worn damaged or leaking parts immediately Failure to do so can cause injury or death 10 CHECK to be sure that all guards and screens are secure and in their proper place 11 CHECK to be sure that all safety devices such as parking brake service brake level gauge neutral start safety switch back up alarm and horn are functioning properly Always make sure mirrors are adjusted properly 12 DO NOT travel on terrain or in dangerous areas that could cause the machine to tip over 13 DO NOT attempt to start the engine by towing or pushing Damage to the powershift transmission could result 14 CARRY A LOAD so that you have maximum machine stability and visibility is not
19. ducting the daily inspection should be corrected immediately Failure to do so could result in injury or death Activate the transmission using the transmission control lever D As soon as the machine starts to move apply the service brake pedal The machine should stop immediately Apply the parking brake E The machine should not be able to be driven Release the parking brake OPERATION BEFORE OPERATING THE FORKLIFT IN DANGER Never operate the machine with a faulty backup alarm Doing so may result in serious injury or death Place the transmission control lever A in reverse The backup alarm should sound If it does not sound have the backup alarm repaired immediately Check and adjust both the interior rear view mirror B and the exterior right hand mirror C if required OPERATION TRANSPORTING A LOAD IN WARNING Transporting a load with the boom extended and the boom angle indicator arrow D reading more than 0 degrees could cause a roll over hazard A WARNING At no time should any load be suspended from the forks by use of chains ropes straps etc If a load must be suspended the use of a truss jib boom is mandatory Proper rigging procedures should always be followed The forks should always be tilted back slightly during trans portation to ensure stability of the load
20. e machine must be repaired before operation Check the dash mounted gauges for logical readings 1 Fuel 1 2to Full 2 Transmission Oil Temp 180 F to 200 F 3 Transmission Oil PSI 240 to 280 PSI 4 Volt 12 to 14 5 Engine Water Temp 180 F to 200 F 6 Engine Oil PSI 40 to 80 PSI STANDARD JOYSTICK FUNCTIONS Operate the joystick controller momentarily in all directions n A Boom Down B Boom Up C Boom Out D D C D Boom In E Boom Down and Out F Boom Up and In G Boom Up and Out H Boom Down and In BUTTON DEPRESSED FUNCTIONS A Tilt Forward B Tilt Back OPERATION BEFORE OPERATING THE FORKLIFT Operate the frame sway control A momentarily right and left Check the steering operation by turning the steering wheel B approximately 1 4 turn in each direction If the front and rear tires are not aligned properly straighten the rear wheels with the steering selector valve C in the 4 wheel position Move the steering selector valve to the 2 wheel position Bring the front tires into alignment with the rear tires Place the steering selector valve back into the 4 wheel position 4 8 OPERATION BEFORE OPERATING THE FORKLIFT A DANGER Any problems with the service brakes or the parking brake found while con
21. e brakes should be applied during normal operation to stop machine movement PARKING BRAKE MN WARNING Failure to set the parking brake before leaving the machine may result in unintended machine movement and possible injury or death and or damage to the machine or property The parking brake should be engaged anytime the operator gets off the machine To engage the parking brake move handle B to the BRAKE ON position 3 6 CONTROLS AND INSTRUMENTS FRAME SWAY CONTROL AN WARNING Always ensure that the machine level indicator D is at zero 0 degrees before raising the boom Raising the boom with an unlevel machine may cause the machine to overturn resulting in injury or death A WARNING Use the frame sway control to level the machine only when the boom angle indicator is at O degrees or less Using the frame sway control when the angle indicator is more than 0 degrees may cause the machine to overturn resulting in injury or death The frame sway control C is located on the dash panel The frame sway control is used in conjunction with the machine level indicator D located in the center of the cross support that the interior rear view mirror is mounted on The sway control switch is either toggled to the left or right depending on the particular requirement
22. e without being seated in the operator s compartment the parking brake B in the on position and the transmission control C in the neutral position Attempting to start the machine from outside the operator s compartment may result in property damage serious injury or death A DANGER If the machine should start with the transmission control lever C in gear stop operation at once or property damage serious injury or death may occur Have a qualified service technician repair the machine Insert the ignition key in the ignition switch D Rotate the key clockwise until the engine starts Release the key when the engine starts 4 5 OPERATION STARTING THE ENGINE AS CAUTION If the engine fails to start within 30 seconds release the key wait at least 2 minutes to allow the starter motor to cool before trying again If the engine fails to start after four attempts trouble shoot and correct the problem DO NOT turn the key if the engine is running This may cause damage to the starter motor IN CAUTION Attempting to start the engine by towing or pushing the machine will result in damage to the powershift transmission and will not start the engine It also is an unsafe practice that could cause personal injury 4 6 OPERATION BEFORE OPERATING THE FORKLIFT AN CAUTION If any gauge reading does not fall within the set tolerances th
23. edium speed Medium torque Forward 3rd High speed Low torque 3 9 CONTROLS AND INSTRUMENTS FRONT AXLE DIFFERENTIAL LOCK The front axle differential lock switch A is located near the operator s left foot The purpose for this device is to lock the front axle differential to gain added traction under certain conditions The front axle differential lock switch must be depressed and held in order to activate the axle differential lock Releasing the switch disengages the axle differential lock Use this differential lock when you are unable to drive through certain types of terrain such as sand mud snow etc AS WARNING Always bring the front tires to a complete stop before engaging the front axle differential lock Failure to stop the front tires before engaging the front axle differential lock may result in damage to the front axle Never steer the front tires while using the front axle differential lock Steering while the front axle differential lock is engaged may result in damage to the front axle The stabilizer controls B and C are located on the dash panel The front stabilizers are used when there is a need for added machine stability when lifting or lowering a load While sitting in the operator s seat the left front stabilizer arm is lowered or raised using the left stabilizer control B and the right front stabilizer arm is lowered or raised using the right stabi
24. el the machine has another steering control the steering selector switch The steering selector switch B is a three position switch The three positions are 4 wheel 2 wheel and oblique Switch positions are selected and function as follows 4 WHEEL Handle right of center 2 WHEEL Handle directly centered OBLIQUE CRAB Handle left of center IN CAUTION Before changing steering selections make sure all four wheels are in line Failure to align the wheels to the proper settings Sees before changing steering positions may cause haphazard steering This may result in injury to personnel and or damage to the machine or property TRANSMISSION The transmission control C has one lever that controls both directional and speed requirements It is located on the left side of the steering column To shift into Forward gear gently pull the lever toward you and move the lever upward To shift into Neutral move the lever to the center position To shift into Reverse gear gently pull the lever toward you and olle move the lever downward oV o pr To shift into a lower speed rotate the lever clockwise To shift into a higher speed rotate the lever counter clockwise When shifting the transmission from forward to reverse while the machine is in motion the transmission control C must be in Ist or 2nd gear only Forward 1st Low speed High torque Forward 2nd M
25. enie A TEREX COMPANY Operator s Manual GTH 1048 ee Maintenance GTH 1056 Information First Edition Second Printing Part No 114101 TABLE OF CONTENTS SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY SECTION 1 1 Introduction 1 3 Standards And Symbols 1 4 Safety 1 5 Training And Knowledge 1 5 Operator s Responsibilities 1 6 Management s Responsibilities 1 7 Maintenance And Repair 1 8 Operation Safety 1 9 SECTION 2 GENERAL SAFETY 2 1 General Safety Procedures 2 3 Jump Starting 2 8 Proper Load Chart Use 2 9 SECTION 3 CONTROLS AND INSTRUMENTS 3 1 Operator s Compartment 3 3 Joystick Control Functions 3 4 Joystick Control Functions Button Pushed 3 5 Service Brakes 3 6 Parking Brake 3 6 Frame Sway Control 3 7 Gauges 3 8 Hydraulic Pump Destroke Button 3 8 Steering 3 9 Transmission 3 9 Front Axle Differential Lock 3 10 Front Stabilizers 3 11 Engine Electronic Control Unit ECU 3 12 SECTION 4 OPERATION 4 1 Operation And Safety Guidelines 4 3 Before Starting The Engine 4 4 Starting The Engine 4 5 Before Operating The Forklift 4 7 Transporting A Load 4 11 Placing A Load 4 13 SECTION 5 MAINTENANCE PROCEDURES 5 1 General Safety Practices 5 3 Daily Maintenance 5 5 SECTION 6 MATERIAL SAFETY DATA SHEETS 6 1 SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY TABLE OF CONTENTS SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY Introduction 1 3 Standards And Symbols 1 4 Safety 1 5 Training And Knowledge 1 5 Operator s R
26. esponsibilities 1 6 Management s Responsibilities 1 7 Maintenance And Repair 1 8 Operation Safety 1 9 A ROUGH TERRAIN FORK LIFT SAFETY 4 INTRODUCTION Owners Users and Operators Genie appreciates your choice of our machine for your application Our number one priority is user safety which is best achieved by our joint efforts We feel that you make a major contribution to safety if you as the equipment users and operators 1 Comply with OSHA Federal State and Local Regulations 2 Read Understand and Follow the instructions in this and other manuals supplied with this machine 3 Use Good Safe Work Practices in a common sense way 4 Only have trained certified operators directed by informed and knowledgeable supervision running the machine NOTE OSHA prohibits the alteration or modification of this machine without written manufacturer s approval Use only factory approved parts to service or repair this machine If there is anything in this manual that is not clear or which you believe should be added please contact us Internet www genieind com Email techpub genieind com Thank you THIS SYMBOL MEANS YOUR SAFETY IS INVOLVED READ UNDERSTAND AND FOLLOW ALL DANGER WARNING AND CAUTION DECALS ON YOUR ROUGH TERRAIN FORKLIFT 1 3 ROUGH TERRAIN FORK LIFT SAFETY 4 STANDARDS AND SYMBOLS STANDARDS Many aspects of rough terrain forklift operatio
27. he parking brake disc packs which may void the axle warranty Before placing a load the frame should be leveled This can be done by the use of the switch labeled sway control D located on the lower right hand side of the dash panel in front of the operator Adjust the sway control D until the indicator ball on the level gauge E is on the 0 degree mark O OPERATION PLACING A LOAD IN DANGER Traveling with a reading of more than 0 degress on the boom angle indicator arrow A may cause a rollover hazard Gradually move the 4 way controller towards the letter B to lift the load vertically Hold the controller back until the A required height has been achieved Gradually move the 4 way controller towards the letter E to bring the load DOWN and OUT into final position Lower the load until the weight is completely off the forks B Gradually move the 4 way controller towards the letter F to bring the boom UP and IN This will bring the forks out of the load Once the forks are clear of the load the boom can be lowered OPERATION PLACING A LOAD GTH 1048 amp GTH 1056 When placing a load with the Model GTH 1048 or the GTH 1056 the rear axle stabilizing cylinders need to be taken into consideration When the boom reaches an angle of 60 DEGRE
28. hemicals known to the State of California to cause cancer Wash hands after handling L N WARNING 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 AN WARNING To avoid personal injury when jump starting with another machine be certain that the machines are not touching Never jump start a frozen battery as it will explode Keep sparks and flames away from the battery Lead acid batteries generate explosive gases when charging Wear safety glasses when working near batteries The booster battery must be a 12 volt type The machine used for jump starting must have a negative ground electrical system To jump start the machine proceed as follows 1 Connect the positive jumper cable to the positive post of the discharged battery 2 Connect the other end of the same jumper cable to the positive post of the booster battery 3 Connect one end of the second jumper cable to the negative post of the booster battery 4 Make the final cable connection to the engine block or the furthest ground point away from the battery 5 Start the engine 6 Remove the jumper cables in the reverse order of their connection i e negative cable ground connection first etc 2 8 Ay GENERAL SAFETY A PROPER LOAD CHART USE AN WARNING NEVER raise a load and drive to position it This
29. hutdown Switch Active 84 ECU Power Down Error External Derate Active 88 Signifies that No Fault Codes are Stored SECTION 4 OPERATION TABLE OF CONTENTS SECTION 4 OPERATION Operation And Safety Guidelines Before Starting The Engine Starting The Engine Before Operating The Forklift Transporting A Load Placing A Load 4 3 4 4 4 7 4 11 4 13 OPERATION OPERATION AND SAFETY GUIDELINES AN WARNING Your safety and the safety of those around you depends upon you using care and judgement in the operation of this equipment Know the positions and functions of all controls before attempting to operate this machine All equipment has limitations Understand the speed braking steering stability and load chart characteristics of this machine before operating Read the Operator s Manual and ask questions of your supervisor until you know the machine s limitations It is very important to read fully understand and follow these operation and safety guidelines 1 DO NOT operate this machine while people are under or near an elevated boom whether the boom is loaded or unloaded Falling objects from the forks or attachment may cause serious injury or death 2 ALWAYS remain completely within the cab enclosure while operating this machine Falling debris can cause serious personal injury or death 3 NEVER extend a load beyond the load chart band Machine turn over component damage injury or de
30. lizer control C To lower the left front stabilizer arm press the lower part of the left stabilizer control To raise the left front stabilizer press the upper part of the left stabilizer control To lower the right front stabilizer arm press the lower part of the right stabilizer control To raise the right front stabilizer press the upper part of the right stabilizer control To lower both the left and the right front stabilizers at the same time press the lower part of both the left stabilizer control and the right stabilizer control LEFT FRONT STABILIZER UP RIGHT FRONT STABILIZER UP B C d o A MM Ya LEFT FRONT RIGHT FRONT STABILIZER DOWN STABILIZER DOWN CONTROLS AND INSTRUMENTS ENGINE ELECTRONIC CONTROL UNIT John Deere Engine Electronic Control Unit The John Deere Electronic Control Unit ECU is capable of detecting storing and reacting to abnormal engine operating conditions or faults The presence of a fault is reported to the operator through the amber colored lamp A located on the dash Depending upon the severity of the engine fault detected the ECU may take steps to minimize engine damage by reducing power output Faults are also stored in the ECU and can be accessed by service personnel later These stored faults can be viewed using the same amber colored lamp A located on the machine s dash using a system known as Blink
31. n and testing are discussed in standards published by the American National Standards Institute These Standards are updated on a regular basis with addendas Genie recommends that you purchase and refer to the following standards ANSI B56 6 Rough Terrain Fork Lifts This Standard can be purchased from American National Standards Institute 25 West 43nd Street Ath Fl New York New York 10036 Tel 212 642 4900 Fax 212 398 0023 SYMBOLS The symbols below are used to inform the operator of important information concerning the operation ofthis machine DANGER Indicates an imminently hazardous situation A DANGER which if not avoided will result in death or serious injury MEZENNE WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation VY CAUTION which if not avoided may result in minor or moderate injury ATTENTION Indicates a situation which if not avoided ATTENTION may result in property or equipment damage 1 4 A ROUGH TERRAIN FORK LIFT SAFETY 4 SAFETY A Ei These are general safety rules which must be followed You are also required to read and understand the Operator s Manual as there are instructions which are more detailed specific to this machine TRAINING AND KNOWLEDGE NY 1 Safety must always be the operator s most important concern
32. n unloaded travel with the attachment downhill iv Avoid turning travel straight up and down 19 Always position all wheels in line with the machine before switching the steering mode 20 Always position the machine and set the park brake before lifting a load 21 Do not allow riders on the machine or forks 22 Do not transport or lift personnel into position with this forklift 23 When leaving the operator s station i Place the directional controls in neutral i Apply the parking brake ii Lower the attachment to the ground A ROUGH TERRAIN FORK LIFT SAFETY 4 NOTES j SECTION 2 GENERAL SAFETY TABLE OF CONTENTS SECTION 2 GENERAL SAFETY General Safety Procedures 2 3 Jump Starting 2 8 Proper Load Chart Use 2 9 Ay GENERAL SAFETY A GENERAL SAFETY PROCEDURES SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages Follow all safety messages to avoid injury and or death A WARNING ALWAYS wear eye protection and personal safety equipment THE OPERATOR The operator must be fully trained and qualified to operate this machine Before start up or machine operation the operator must learn the location and purpose of the Controls Instruments Indicator lights Safety and instruction labels Ponm ACCIDENT PREVENTION Use protective clothing and safety equipment Always use approved safety equipment such as gloves safety boots safety hard hats
33. nufacturer s recommended capacity is 15 8 m 795 Genie GTH per ANSI B56 6 Stability Tests using cara standard homogeneous cubes 4 x 4 x 4 ft E pacity 44 ft Chart 12x1 2x1 2m 134m Load capacities at 24 in 60 cm load center with standard fork frame 36 ft Rated lift capacities shown are with 11m machine on a firm level surface with undamaged properly inflated calcium 28 ft chloride solution filled tires or optional foam 85m filled tires Rear axle lock up engaged Load Limits Horizontal Boom Front Stabilizers Up Fast Fully Visible Letter Retracted 10 000 Ibs A Letter Visible 8000 Ibs B Letter Visible 6000 Ibs C Letter Visible 4000 Ibs D Letter Visible 2500 Ibs E Letter Visible 2000 Ibs Front Stabilizers Down Last Fully Visible Letter Retracted 10 000 Ibs A Letter Visible 9000 Ibs 32 ft 24ft 16 ft 8tt Oft 4ft 12ft 20 ft B Letter Visible 7000 lbs 976m 732m 488m 244m Om1 2m 3 6m 6 1m C Letter Visible 6000 Ibs D Letter Visible 4000 Ibs E Letter Visible 3000 Ibs Da Q 4000 Ibs 1814 kg 6000 Ibs 2721 kg 8000 Ibs 3629 kg 9000 Ibs 4082 kg e 10 000 Ibs 4536 kg 10 000 Ibs 4536 kg 2500 Ibs 1133 kg 4000 Ibs 1814 kg 6000 Ibs 2721 kg 7000 Ibs 3175 kg LH 2000 Ibs 9
34. obstructions that cannot be cleared should be clearly marked and avoided during operation 5 Refueling i Always stop the engine before refueling the machine i Fill the fuel tank outdoors ii Handle fuel with care as it is highly flammable Do not refuel the machine while smoking or near open flames iv Always clean up spilled fuel 6 Make sure the machine and access system is clean and free of dirt oil grease or debris 7 When getting on and off the machine face the machine use the steps and handrails provided and always maintain a three point contact 8 Always remain completely inside the cab enclosure while operating the machine 9 Always wear the seat belt while operating the machine 10 Always completely lower the boom with the forks resting on the ground before any work is performed on or around the machine 11 Do not operate the machine while people are under or near an elevated boom whether the boom is loaded or unloaded Falling objects from the forks or attachment may cause serious injury or death A ROUGH TERRAIN FORK LIFT SAFETY N OPERATION SAFETY 12 Maintain an appropriate clearance from electrical power lines See the chart below for minimum safe approach distances Minimum Safe Approach Distance 0 to 50 kV 50 to 200 kV 200 to 350 kV 350 to 500 kV 500 to 750 kV 451 13 772m id 750 to 1000 kV 45 ft 13 72 m 13 Lifting Loads i Usingthe load chart confirm that
35. ockout the machine while working on the machine unless instructions specifically require the engine to be running 4 Always make sure the machine is stationary prior to performing adjustments or lubrication 5 Replace all shields and guards after performing service 6 Always use a piece of cardboard or paper to search for leaks 7 Whenperforming work on the hydraulic system i Lowerthe boom to horizontal i Support the boom with supports or braces i Shut down the engine iv Relieveall pressure before disconnecting lines v Ensure all connections are tight before applying pressure vi Repair or replace any damaged line hose or fitting before applying pressure 8 Always have tires serviced and mounted by a qualified person with the proper tools and guards 9 Alwaysusean inflation cage during tire inflation 10 Only perform welding on the machine with approval from the manufacturer A ROUGH TERRAIN FORK LIFT SAFETY 4 OPERATION SAFETY 1 Always inspect the machine daily Check for leaks worn hoses loose belts broken structures and loose or missing bolts Repair or replace any worn damaged or leaking parts prior to operation of the machine 2 Only inspect the coolant level when the engine and coolant are cool 3 Be sure that all guards and screens are secure and in the proper place 4 Inspect for and clear the work area of any obstructions that could interfere with proper machine operation Any
36. r equipment and experience to perform the job If you do not have the proper qualifications to perform the job have your dealer or qualified repair service perform the repair 2 5 GENERAL SAFETY PROCEDURES A CAUTION USE SEAT BELT Always wear the seat belt while operating the machine to reduce the risk of personal injury IN CAUTION PRACTICE SAFE MAINTENANCE Unauthorized modifications to the machine may impair the safety machine function and or affect machine life ALWAYS use a safety support or brace when working on under or around the machine or forks DO NOT adjust or lubricate the machine while it is in motion SHUT OFF the engine and LOCKOUT the ignition while working on the machine unless maintenance instructions require the engine to be running REPLACE all the shields and guards after servicing NEVER use the machine as a platform for lifting personnel IN CAUTION BOOM SAFETY DO NOT enter the DANGER AREA under or around the boom when the forks are off the ground or while the engine is running See diagram at right for DANGER AREA Serious personal injury could result if the boom should unexpectedly drop Before ANY work is performed in the DANGERAREA the boom mustbe COMPLETELY lowered and the forks must be resting on the ground 2 6 Ay GENERAL SAFETY A GENERAL SAFETY PROCEDURES AVOID ELECTRICAL POWER LINES IN DANGER REQUIRED CLEARAN
37. s ALWAYS clean up spilled fuel te Ay GENERAL SAFETY A GENERAL SAFETY PROCEDURES HYDRAULIC SAFETY IN WARNING Hot hydraulic oil can cause severe burns DO NOT work on the hydraulic system if the oil temperature exceeds 120 degrees F 49 degrees C Before ANYONE works on the hydraulic system Lower the boom to the horizontal position Support the boom to avoid unintentional lowering Shutdown the engine Remove the key from the ignition Clean the area around the oil reservoir cap A ABR WN FLUIDS UNDER PRESSURE AN WARNING Escaping fluid under pressure can penetrate the skin and can cause serious personal injury Use a piece of cardboard or paper to search for leaks DO NOT use hands Before disconnecting hydraulic lines be sure to relieve all line pressure Before applying pressure to the system be sure that all connections are tight DO NOT apply pressure to a damaged line hose or fitting If injured by escaping fluid see a doctor at once Proper medical treatment must be administered immediately A serious infection or reaction can result without proper medical treatment SERVICE TIRES SAFELY AS WARNING An improperly mounted over pressurized tire can result in tire explosion causing possible personal injury An inflation cage or other safety device must be used during tire inflation DO NOT attempt to mount a tire unless you have the prope
38. th the valve stem C positioned to the top of the tire check the tire pressure with the tire cold and a properly functioning air pressure gauge Setting 50 PSI A All tires require a calcium chloride ballast or an optional foam fill to be operated safely The loss of ballast can affect the machine s stability and cause a rollover hazard resulting in damage injury or death 5 6 SECTION 6 MATERIAL SAFETY DATA TABLE OF CONTENTS SECTION 6 MATERIAL SAFETY DATA Material Safety Data Sheets 6 3 California Proposition 65 Warnings 6 4 MATERIAL SAFETY DATA MATERIAL SAFETY DATA SHEETS MSDS The Federal Occupational Safety and Health Administration OSHA Standard 29 ctr 1910 1200 and in some cases state and local Right To Know laws may require specific MSDS be available to employees prior to operating this equipment This may include information on substances contained in the equipment such as antifreeze brake fluid battery acid and hydraulic fluid Genie will provide at no cost Material Safety Data Sheets which are applicable to their product line Simply request them from your local Genie dealer or contact us at Genie Industries PO Box 97030 Redmond WA 98073 9730 To ensure a prompt response please be sure to include your return address and zip code along with the machine model and serial number MATERIAL SAFETY DATA CALIFORNIA PROPOSITION 65 WARNINGS
39. the load is within the rated capacity of the machine for the required configuration i Levelthe machine using the level gauge before lifting loads Use the sway control to level the machine only when the boom is at horizontal or lower Using the sway control with the boom above horizontal may cause the machine to overturn ii Verify that the load is secured on the forks before performing a lift Rearrange the load if necessary iv Before lowering a maximum load always retract the boom completely v Use proper attachments such as a truss boom to lift suspended loads 14 Ifthe load to be lifted exceeds the capacity of the machine for the given configuration i Movethe machine closer to the load so that the weight of the load will be within the allowable load chart specifications i Divide the load into smaller pieces ii Geta larger machine capable of handling the load 15 Always move a load so that you have maximum machine stability and visibility is not obstructed Keep the boom at or below horizontal with the load close to the ground 16 Tilt the forks back towards the machine slightly during travel to ensure stability of the load A ROUGH TERRAIN FORK LIFT SAFETY 4 OPERATION SAFETY 17 Inspect the path of travel before beginning movement Avoid holes and dropoffs 18 Traveling on slopes grades i Ascend and descend slowly and with caution i When loaded always travel with the load uphill ii Whe
40. yesight hearing or reactions 11 Keep people equipment and material out of the work area 12 Keep a fully charged fire extinguisher and first aid kit in the cab at all times and be familiar with how to use these items 13 Know about movements of other machinery trucks and personnel at the jobsite 14 Make sure everyone is in a safe place before moving the boom forks load or outriggers if so equipped 15 Start and stop movements smoothly and swing at speeds that will keep the load under control A ROUGH TERRAIN FORK LIFT SAFETY 4 1 Ensure operators are competent physically fit trained and if required licensed 2 Have a supervisor at the job site to be responsible for job safety 3 Crew members given specific safety responsibilities and instructed to report any unsafe conditions to the supervisor 4 Supplythe weight on the load to be lifted to the operator 5 Verify that all crewmembers are familiar with OSHA ANSI B56 6 requirements as well as instructions in the manuals 1 7 A ROUGH TERRAIN FORK LIFT SAFETY 4 MAINTENANCE AND REPAIR 1 Practice safe maintenance procedures Perform all maintenance and repairs in accordance with instructions provided by the manufacturer in the manuals Also heed the warnings on the placards and decals on the machine 2 Always use supports and braces when working on under or around the machine or forks 3 Shut off the engine and l
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