Genie GTH-1048 User manual

Operator’s Manual
with
Maintenance
Information
GTH-1048
GTH-1056
First Edition
Second Printing
Part No. 114101

SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY SECTION 1-1
Introduction 1-3
StandardsAnd Symbols 1-4
Safety 1-5
TrainingAnd Knowledge 1-5
Operator's Responsibilities 1-6
Management'sResponsibilities 1-7
MaintenanceAnd Repair 1-8
Operation Safety 1-9
SECTION 2 GENERALSAFETY 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'sCompartment 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
FrontAxle Differential Lock 3-10
Front Stabilizers 3-11
Engine Electronic Control Unit (ECU) 3-12
SECTION 4 OPERATION 4-1
OperationAnd 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
PlacingA Load 4-13
SECTION 5 MAINTENANCEPROCEDURES 5-1
General Safety Practices 5-3
Daily Maintenance 5-5
SECTION 6 MATERIAL SAFETY DATA SHEETS 6-1
TABLE OF CONTENTS

SECTION 1
ROUGHTERRAIN
FORK LIFT SAFETY
1-1

TABLEOFCONTENTS
SECTION 1 - ROUGH TERRAIN FORK LIFT SAFETY
Introduction 1-3
StandardsAndSymbols 1-4
Safety 1-5
TrainingAndKnowledge 1-5
Operator'sResponsibilities 1-6
Management'sResponsibilities 1-7
MaintenanceAnd Repair 1-8
OperationSafety 1-9
1-2

ROUGH TERRAIN FORK LIFT SAFETY
INTRODUCTION
Owners,Users,and Operators:
Genieappreciatesyourchoice ofourmachineforyour application.Ournumberone
priorityisusersafety,which is best achievedbyourjointefforts.Wefeelthatyou make a
majorcontributiontosafety ifyou,astheequipment users andoperators:
1. ComplywithOSHA,Federal,State,andLocal Regulations.
2. Read,Understand,andFollowthe instructionsinthisandother manuals
suppliedwiththismachine.
3. UseGoodSafeWork Practicesin a common sense way.
4. Onlyhavetrained/certifiedoperators–directed by informed and
knowledgeablesupervision–runningthemachine.
NOTE: OSHAprohibitsthealterationormodificationofthis machinewithoutwritten
manufacturer'sapproval.Useonlyfactory approved parts toserviceorrepairthis
machine.
Ifthereis anythinginthismanualthatisnotclearor whichyoubelieveshould beadded,
pleasecontactus.
Internet:www.genieind.com
Email:[email protected]
Thankyou!
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
STANDARDS AND SYMBOLS
1-4
Manyaspectsofrough terrainforkliftoperationandtesting arediscussedinstandards
publishedbytheAmericanNationalStandards Institute. These Standards areupdatedon
aregularbasiswithaddendas.Genie recommends that you purchaseandrefertothe
followingstandards.
ANSIB56.6–RoughTerrain Fork Lifts
ThisStandardcanbe purchased from:
AmericanNationalStandardsInstitute
25 West 43nd Street, 4th Fl.
New York, New York, 10036
Tel. [phone]
Fax. [phone]
STANDARDS
SYMBOLS
DANGER–Indicatesanimminentlyhazardoussituation
which,ifnotavoided,willresultindeathorseriousinjury.
CAUTION–Indicates apotentiallyhazardoussituation
which,ifnot avoided,mayresultinminorormoderate
injury.
WARNING–Indicatesapotentiallyhazardous situation
which,ifnot avoided, couldresultindeath orserious
injury.
ATTENTION–Indicates asituationwhich,ifnot avoided,
mayresultin propertyorequipmentdamage.
Thesymbolsbelowareusedto informtheoperatorof importantinformationconcerning
theoperationofthismachine.

ROUGH TERRAIN FORK LIFT SAFETY
SAFETY
1-5
1. Safety must alwaysbetheoperator'smostimportantconcern.
2. This machinemustonlybeoperated bytrainedpersonnel,whohave demonstrated
theirabilityto dososafely.
3. Complywiththerequirementsofcurrent OccupationalSafetyandHealth
Administration(OSHA)standards, including29CFR1910.178;andthe American
NationalStandardsInstitute(ANSI) B56.6 latestedition.
4. Read andUnderstandallDecalsandWarnings.
5. Read and UnderstandtheRatingChart.
6. Know thatthemachinecan safetylifteachload beforeattemptingtolift.
Thesearegeneralsafetyrules,whichmustbe followed. You are also required toread
andunderstandtheOperator'sManualas there are instructions,whicharemore
detailedspecifictothismachine.
TRAINING AND KNOWLEDGE

ROUGH TERRAIN FORK LIFT SAFETY
OPERATOR'S RESPONSIBILITIES
1-6
1. Read and understand the Operator’s Manual.
2. Know thelocationandthepurposeof thecontrols,instrumentsandindicator
lights.
3. Make sure themachineisinproperorder and all operationalaidsandwarning
signalsarefunctionalbeforeoperating.
4. Keepthemachineclean,includingallinstrumentation,windows,lightsandother
glazedsurfaces.
5. Useprotectiveclothing and safetyequipment. Alwaysuseapproved safety
equipmentsuchas:gloves,safety boots, hard hats,safetyglassesandear
protectionwherenecessary.
6. Wearprotectiveclothingthatis snugandbeltedwhererequired.
7. Store tools andothernecessaryitemsinthetoolbox.
8. Never lift aloadwithoutaLoadRatingChartin the cab.
9. Know the load to be lifted.
10. Bealert,physicallyfitandfreefromtheinfluences ofalcohol,drugs or
medicationsthatmight affecttheoperator’seyesight,hearing,orreactions.
11. Keep people,equipmentandmaterialoutoftheworkarea.
12. Keep afullychargedfire extinguisherandfirstaidkitinthecabat alltimes,and
befamiliarwith howtousetheseitems.
13. Know aboutmovementsofothermachinery,trucksandpersonnelatthejobsite.
14. Makesureeveryoneisinasafeplacebeforemovingtheboom,forks,loador
outriggers(ifsoequipped.)
15. Startandstopmovementssmoothlyandswing at speeds thatwillkeeptheload
undercontrol.

ROUGH TERRAIN FORK LIFT SAFETY
MANAGEMENT'S RESPONSIBILITIES
1-7
1. Ensure operatorsarecompetent,physically fit,trainedandif requiredlicensed.
2. Have a supervisor at the job site to beresponsibleforjob safety.
3. Crewmembersgivenspecificsafetyresponsibilities andinstructedtoreportany
unsafeconditionstothesupervisor.
4. Supply the weight on the loadtobeliftedtotheoperator.
5. Verify thatallcrewmembersare familiarwithOSHA,ANSIB56.6requirements
aswellasinstructionsinthemanuals.

ROUGH TERRAIN FORK LIFT SAFETY
1-8
MAINTENANCE AND REPAIR
1. Practicesafemaintenance procedures. Performallmaintenanceandrepairs in
accordancewithinstructionsprovidedbythe manufacturerinthemanuals. Also
heedthewarningsonthe placards and decalsonthemachine.
2. Always use supportsandbraceswhenworkingon,underor around the machine
orforks.
3. Shutofftheengineandlockoutthemachine whileworkingonthemachineunless
instructionsspecificallyrequiretheenginetoberunning.
4. Always makesurethemachine isstationarypriortoperformingadjustmentsor
lubrication.
5. Replaceallshieldsandguardsafterperformingservice.
6. Always use a piece of cardboard or paper to search for leaks.
7. Whenperformingworkonthehydraulicsystem:
i. Lower theboomtohorizontal.
ii. Support the boom with supports or braces.
iii. Shutdowntheengine.
iv. Relieveallpressurebeforedisconnectinglines.
v. Ensureallconnectionsaretightbeforeapplyingpressure.
vi. Repairorreplaceanydamaged line, hoseorfittingbefore
applyingpressure.
8. Always havetiresservicedandmountedby aqualifiedpersonwiththeproper
toolsandguards.
9. Alwaysuseaninflationcageduringtireinflation.
10. Onlyperformweldingonthemachinewithapprovalfromthemanufacturer.

ROUGH TERRAIN FORK LIFT SAFETY
OPERATION SAFETY
1-9
1. Always inspect the machinedaily. Checkforleaks,wornhoses,loosebelts,
brokenstructures,andlooseormissingbolts. Repairorreplaceanyworn,
damagedorleakingpartsprior to operationofthemachine.
2. Only inspectthecoolantlevelwhen theengineandcoolantare cool.
3. Be sure that all guards and screens aresecureand in the proper place.
4. Inspect for andcleartheworkareaofany obstructions that couldinterferewith
propermachineoperation. Anyobstructionsthatcannot be cleared should be
clearlymarkedand avoidedduringoperation.
5. Refueling:
i. Alwaysstoptheenginebeforerefuelingthemachine.
ii. Fillthefueltankoutdoors.
iii. Handlefuelwithcare,as itishighlyflammable. Donotrefuel
themachinewhilesmokingor nearopenflames.
iv. Alwayscleanupspilledfuel.
6. Make sure the machine and access systemiscleanandfreeofdirt,oil,greaseor
debris.
7. When gettingonandoffthemachine, facethemachine,usethe steps and
handrailsprovided,and alwaysmaintainathree pointcontact.
8. Alwaysremaincompletelyinsidethecabenclosurewhileoperatingthemachine.
9. Always weartheseatbelt whileoperatingthemachine.
10. Always completelylowertheboom withtheforksrestingon thegroundbefore
anyworkisperformedon or around themachine.
11. Do notoperatethemachinewhilepeopleareunderornearanelevatedboom
whethertheboomisloadedor unloaded. Falling objects fromtheforksor
attachmentmaycause seriousinjuryordeath.

ROUGH TERRAIN FORK LIFT SAFETY
1-10
OPERATION SAFETY
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13. LiftingLoads:
i. Using theloadchart,confirmthattheloadiswithin therated
capacityofthemachinefortherequiredconfiguration.
ii. Levelthemachineusingthelevelgaugebeforeliftingloads. Use
theswaycontrolto levelthemachineonlywhen theboomisat
horizontalorlower. Using theswaycontrolwiththe boomabove
horizontalmaycausethemachinetooverturn.
iii. Verifythattheload issecuredontheforks before performingalift.
Rearrangetheloadif necessary.
iv. Beforeloweringamaximumload,always retracttheboom
completely.
v. Useproperattachments,suchasatrussboom,toliftsuspended
loads.
14. Iftheloadtobeliftedexceeds the capacityofthemachineforthe given
configuration:
i. Move the machine closertotheloadsothattheweightoftheload
willbe withintheallowableloadchartspecifications.
ii. Dividetheloadintosmallerpieces.
iii. Getalarger machinecapableofhandlingtheload.
15. Alwaysmovealoadsothatyouhavemaximummachinestabilityandvisibilityis
notobstructed. Keeptheboom at or below horizontal, with the load close to the
ground.
16. Tilt theforksback towardsthemachineslightlyduringtraveltoensurestabilityof
theload.
12. Maintain anappropriateclearancefromelectrical powerlines.Seethechart
belowforminimumsafeapproachdistances.

ROUGH TERRAIN FORK LIFT SAFETY
1-11
OPERATION SAFETY
17. Inspect thepathoftravelbefore beginningmovement. Avoid holesanddropoffs.
18. Travelingonslopes/grades.
i. Ascend anddescendslowlyandwith caution.
ii. Whenloaded,alwaystravelwiththeloaduphill.
iii. Whenunloaded,travelwiththeattachmentdownhill.
iv. Avoid turning,travelstraight upanddown.
19. Alwayspositionallwheelsinlinewiththemachinebeforeswitchingthesteering
mode.
20. Always positionthemachineandset the parkbrakebeforeliftinga load.
21. Donotallowridersonthemachineor forks.
22. Donottransportorliftpersonnelintopositionwiththisforklift.
23. Whenleavingtheoperator'sstation:
i. Placethedirectionalcontrolsinneutral.
ii. Apply the parking brake.
iii. Lowertheattachmentto the ground.

ROUGH TERRAIN FORK LIFT SAFETY
NOTES
1-12

SECTION 2
GENERALSAFETY
2-1

TABLEOFCONTENTS
SECTION 2 - GENERAL SAFETY
GeneralSafetyProcedures 2-3
JumpStarting 2-8
Proper Load Chart Use 2-9
2-2

GENERAL SAFETY
SAFETY ALERT SYMBOL
Stop and take time to read ALLsafety alert messages. Follow
all safety messages to avoid injury and/or death.
WARNING
ALWAYS wear eye protection and personal safety equipment.
THE OPERATOR
The operator must be fully trained and qualified to operate this
machine.
Before start-up or machine operation, the operator must learn
the location and purpose of the:
1. Controls
2. Instruments
3. Indicator lights
4. Safety and instruction labels
ACCIDENT PREVENTION
Use protective clothing and safety equipment. Always use
approved safety equipment such as: gloves, safety boots,
safety hard hats, 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.
KEEPTHEFIRST-AIDKITandFIREEXTINGUISHER
properly maintained. Follow the instructions provided with the
first-aid kit and fire extinguisher.
GENERAL SAFETY PROCEDURES
2-3

GENERAL SAFETY
WELDING PRECAUTIONS
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
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.
NEVERjump onor offthe 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
WARNING
Fires can cause death or severe personal injury.
Handle fuel with care. It is highly flammable. DONOT 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
debris.ALWAYS clean up spilled fuel.
GENERAL SAFETY PROCEDURES
2-4

GENERAL SAFETY
HYDRAULICSAFETY
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).
BeforeANYONE works on the hydraulic system:
1. Lower the boom to the horizontal position.
2. Support the boom to avoid unintentional lowering.
3. Shutdown the engine.
4. Remove the key from the ignition.
5. Clean the area around the oil reservoir cap (A).
FLUIDS UNDER PRESSURE
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.Aserious
infection or reaction can result without proper medical
treatment.
SERVICE TIRES SAFELY
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 proper
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.
GENERAL SAFETY PROCEDURES
WARNING
2-5
A

GENERAL SAFETY
GENERAL SAFETY PROCEDURES
2-6
CAUTION
USE SEAT BELT
Always wear the seat belt while operating the machine to
reduce the risk of personal injury.
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.
DONOT adjust or lubricate the machine while it is in motion.
SHUTOFFthe engine andLOCKOUT theignition while
working on the machine unless maintenance instructions
require the engine to be running.
REPLACEall the shields and guards after servicing.
NEVERuse the machine as a platform for lifting personnel.
CAUTION
BOOM SAFETY
DONOTenter the DANGERAREA underoraround the boom
when the forks are off the ground or while the engine is running.
(SeediagramatrightforDANGERAREA).
Serious personal injury could result if the boom should
unexpectedly drop.
BeforeANY workis performedintheDANGERAREA
the boom mustbe COMPLETELYlowered and theforks
must be resting on the ground.
'$1* (5
DANGER