Terex Genie GTH1048 User manual

Operator's Manual
GTH-1048•GTH-1056 PartNo.133306
Third Edition • Fourth Printing
Copyright © 2007 by Genie Industries
Second Edition: First Printing, May 2007
Third Edition: Fourth Printing, August 2008
"Genie" is a registered trademark of
Genie Industries in the U.S.A. and many other
countries. "GTH" is a trademark of Genie
Industries.
Printed on recycled paper
Printed in U.S.A.
Important
Read,understandandobeythesesafetyrulesand
operating instructions before operating this machine.
Only trained and authorized personnel shall be
permitted to operate this machine. This manual
should be considered a permanent part of your
machine and should remain with the machine at all
times. If you have any questions, call Genie Industries.
Contents
Page
Introduction ................................................................ 1
Symboland Hazard Pictorials Definitions................... 3
GeneralSafety........................................................... 5
Work Area Safety...................................................... 11
Legend ...................................................................... 17
Controls .................................................................... 18
Inspections ............................................................... 22
OperatingInstructions............................................... 36
TransportInstructions ............................................... 44
Maintenance ............................................................. 45
Specifications ........................................................... 48
Contact us:
Internet:www.genielift.com
E-mail:[email protected]

Operator'sManualThird Edition • Fourth Printing
PartNo.133306 GTH-1048•GTH-1056 1
Introduction
Owners, Users and Operators:
Genieappreciates your choice of our machinefor
yourapplication.Ournumberonepriorityis 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 employer, job site and
governmentalrules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices inacommon
sense way.
4 Be alert and free from the influences of alcohol,
drugs or medications that might affect eyesight,
hearing,reactionsorjudgement.
5 Onlyhavetrained/certifiedoperators,directed
byinformedandknowledgeablesupervision,
runningthemachine.
If there is anything in this manual that is not clear
orwhichyoubelieveshould be added, please
contact us.
Internet:www.genielift.com
E-mail:[email protected]
Danger
Failure to obey the instructions and
safety rules in this manual will
result in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Alwaysperformapre-operationinspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread,understandandobey the
manufacturer'sinstructionsandsafetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperlytrainedtosafelyoperate the
machine.

Operator'sManual Third Edition • Fourth Printing
2 GTH-1048•GTH-1056 PartNo.133306
Standards
Many aspects of rough terrain forklift operation and
testing are discussed in standards published by the
AmericanNationalStandardsInstituteandthe
IndustrialTruckStandardsDevelopment
Foundation.Thesestandardsareupdatedona
regularbasiswithaddenda.Genierecommends
that you purchase and refer to the following
standards.
ANSI/ITSDF B56.6 – Rough Terrain Fork Lifts
ThisStandardcanbedownloadedfrom
www.ITSDF.org
ITSDF
1750 K Street NW
Site 460
WashingtonDC20006
Introduction
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-basedcleanersbecausetheymaydamage
the safety sign material.
Hazard Classification
Genie uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
youtopotentialpersonalinjury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicatesa hazardous situation
which, if not avoided, will result in
deathorseriousinjury.
Indicatesa hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicatesa hazardous situation
which, if not avoided, could result
inminorormoderate injury.
Indicatesa hazardous situation
which, if not avoided, could result
inpropertydamage.
Red
Orange
Yellow
Blue
Intended Use
A variable reach rough terrain forklift truck is
defined as a wheeled type truck with a pivoting
boom,whichmaybeequippedwithvarious
attachmentsforpicking,transportingandplacing
loadswithin the established load range charts.

Operator'sManualThird Edition • Fourth Printing
PartNo.133306 GTH-1048•GTH-1056 3
Symbol and Hazard Pictorials Definitions
Hazard Pictorial Descriptions
Bodily Injury
Hazard Always wear seat
belt.
CrushHazard Supportboom
whenperforming
maintenance.
Noriders.
FallHazard
CrushHazard Keep clear of
movingoutriggers.
Maintainrequired
clearance.
Electrocution
Hazard Nopeopleunder
load.
FallingObject
Hazard
InjectionHazard Usecardboardto
search for leaks. CrushHazard
Readthe
operator'smanual.
Keepawayfrom
movingparts.
BurnHazard
BurnHazard
Explosion/Burn
Hazard
Lower forks. Set
parkingbrake.
Nosmoking. No
openflame.
Keep clear of
movingparts.
Allow system to
cool.
Allow surfaces to
cool.
Overturning
Hazard Swayoperation
x
CrushHazard CrushHazard
Overturning
Hazard

Operator'sManual Third Edition • Fourth Printing
4 GTH-1048•GTH-1056 PartNo.133306
Hazard Pictorial Descriptions
CrushHazard Keepawayfrom
movingparts. Overturning
Hazard Keeploadlow.
Operatefrom
operator'sstation.
x
CrushHazard
Symbol and Hazard Pictorials Definitions
48
inches
60
inches
72
inches
Only use 48 inch
forks.

Operator'sManualThird Edition • Fourth Printing
PartNo.133306 GTH-1048•GTH-1056 5
General Safety
Safetysignsandlocations

Operator'sManual Third Edition • Fourth Printing
6 GTH-1048•GTH-1056 PartNo.133306
General Safety
Safetysignsandlocations
82558 B
Injection Hazard
Escaping fluid under pressure can
penetrate skin, causing serious injury.
Relieve pressure before disconnecting
hydraulic lines. Keep away from leaks
and pin holes. Use apiece of cardboard
or paper to search for leaks. Do not use
hand.
Fluid injected into skin must be
surgically removed within afew hours
by adoctor familiar with thistype of
injury or gangrene will result.
WARNING

Operator'sManualThird Edition • Fourth Printing
PartNo.133306 GTH-1048•GTH-1056 7
General Safety
Safetysignsandlocations
31788
114374 114366
114367
114365
82558
114374
97667
114374 A
WARNING
Crush Hazard
Moving parts can
crush or cut
causing severe
injury.
Keep all body
parts clear of
moving parts
during equipment
operation.
114366 A
Crush Hazard
Serious injury can
result from contact with
moving outriggers.
Keep clear of moving
outriggers.
DANGER
114374
114366
97667 B
Burn Hazard
Contact with
hot surfaces
can cause
burns.
Do not touch.
Allow surfaces
to cool before
servicing.
WARNING
114365 A
Crush Hazard
Machine
movement can
cause serious
injury or death.
Stay away from
machine.
WARNING
97667
82558 B
Injection Hazard
Escaping fluid under pressure can
penetrate skin, causing serious injury.
Relieve pressure before disconnecting
hydraulic lines. Keep away from leaks
and pin holes. Use apiece of cardboard
or paper to search for leaks. Do not use
hand.
Fluid injected into skin must be
surgically removed within afew hours
by adoctor familiar with thistype of
injury or gangrene will result.
WARNING
82558 114365
114367
31788
DANGER
28175
WARNING
28175
114367 B
Do not enter the
area under or
around the boom
when the forks are
off the ground or
the engine is
running.
WARNING
Falling Object
Hazard
Death or Serious
Injury can result from
falling objects.
97675
WARNING
97675
97664
141146
141146
97664 B
WARNING
Crush Hazard
Moving parts can
crush or cut
causing severe
injury.
Keep all body
parts clear of
moving parts
during equipment
operation.
WARNING
141146
97664

Operator'sManual Third Edition • Fourth Printing
8 GTH-1048•GTH-1056 PartNo.133306
General Safety
Safetysignsandlocations

Operator'sManualThird Edition • Fourth Printing
PartNo.133306 GTH-1048•GTH-1056 9
General Safety
Safetysignsandlocations

Operator'sManual Third Edition • Fourth Printing
10 GTH-1048•GTH-1056 PartNo.133306
General Safety
Safetysignsandlocations

Operator'sManualThird Edition • Fourth Printing
PartNo.133306 GTH-1048•GTH-1056 11
Work Area Safety
Overturning Hazards
Using the load chart, confirm
that the load is within the rated
capacity of the machine. Do not
exceedtheratedload.
Do not raise the load unless the
groundcansupportallforces
imposed by the machine.
Donotloweraloadwithout
retracting the boom first.
Do not operate the machine if
the load chart is missing.
Do not exceed the rated capacity
foreachconfiguration.
GTH-1056:Donotusetheswing
carriage with 60 inch or 72 inch
forks. Only use the swing
carriage with 48 inch forks.
Do not raise the boom unless the
machine is level. The machine
level indicator should be at zero
degrees.
Do not level the machine using
the frame sway control unless
the boom angle indicator is at
zero degrees or less.
Do not use the sway control to
positionanelevatedload.
Do not raise a load and then
drive to position it.
When driving, keep the boom at
orbelowhorizontal andkeepthe
load close to the ground.
Operatethemachineatspeeds
that will keep the load under
control. Start and stop
movements smoothly.
Do not raise a load unless the
loadisproperlypositioned or
securedontheforksorapproved
attachment.
Donotoperate the machine in
strong or gusty winds. Do not
increase the surface area of the
carriageortheload.Increasing
the area exposed to the wind will
decrease machine stability.
Useextreme care and slow
speedswhiledrivingthemachine
in the travel position across
uneventerrain,debris,unstable
orslipperysurfacesandnear
holesanddrop-offs.
Donot alter or disable machine
components that in any way
affect safety or stability.
Do not replace items critical to
machine stability with items of
differentweight or specification.
Donotreplacefactory-installed
tires with tires of different
specification or ply rating.

Operator'sManual Third Edition • Fourth Printing
12 GTH-1048•GTH-1056 PartNo.133306
Traveling on Slopes
Whendriving,keep the
boomatorbelow
horizontalandkeepthe
load close to the
ground.
When the machine is loaded, always travel with the
loaduphill. 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
ordownaslope.
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
unlessthe mast and equipment are in their proper
travelposition.
Whethera machine will tip over duringdynamic
machine operation involves many factors that need
tobeconsidered. Among these are pavement/
ground conditions, stability and slope, as well as
machineequipment,operatorskill,load position,
tire inflation, machine speed, etc.
Additionally, tip-over of a machine is dependent in
largepart upon operator inputs such as the speed
and smoothness of the operation, as well as the
position of the attachment and its load.
Constructionsitesandroadswillfrequentlychange
slope from place to place, can be hard and soft,
and change due to construction activities and
weather.
Operatorsshouldbeproperlytrainedandusetheir
best judgment and experience to take the
necessaryprecautions to prevent a tip-over.
Operators must assess the job site variables and
avoidexceedingthemachine's(oroperator's)
capabilitiesforterrainandconditions.
Fall Hazards
Always wear a seat belt when
operatingthemachine.
Always remain completely inside
thecabwhenoperatingthe
machine.
When getting in and out of the
cab, face the machine, use the
stepsandhandrailsprovidedand
alwaysmaintainthree-point
contact.
Do not use the steering wheel or
any other controls as handrails.
Do not allow riders on the
machine or forks.
Donot transport or lift personnel
with this machine.
x
Work Area Safety

Operator'sManualThird Edition • Fourth Printing
PartNo.133306 GTH-1048•GTH-1056 13
Collision Hazards
Keeppeople,equipmentand
material out of the work area. Do
notoperatethemachinewhile
peopleareunderornearan
elevated boom, whether it is
loadedorunloaded.
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.
Donotoperatethemachinewith
a faulty back-up alarm.
Operators must comply with
employer, job site and
governmentalrulesregardingthe
useof personal protective
equipment.
Falling Object Hazards
Operatethemachineatspeeds
that will keep the load under
control. Start and stop
movements smoothly.
Keeppeople,equipmentand
material out of the work area. Do
notoperatethemachinewhile
peopleareunderornearan
elevated boom, whether it is
loadedorunloaded.
Bodily Injury Hazard
Always adjust the seat and
fasten the seat belt before
startingtheengine.
Donotoperatethemachinewith
a hydraulic oil or air leak.
Escapingfluidunderpressure
can penetrate skin, causing
seriousinjury.Relievepressure
beforedisconnectinghydraulic
lines. Keep away from leaks and
pin holes. Use a piece of
cardboardorpapertosearchfor
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.
Work Area Safety

Operator'sManual Third Edition • Fourth Printing
14 GTH-1048•GTH-1056 PartNo.133306
Component Damage Hazards
Do not use any battery or charger greater than 12V
tojump-starttheengine.
Do not use the machine as a ground for welding.
Do not steer the front tires on dry pavement when
the axle differential lock is activated.
Do not lock the axle differential when the machine
is moving.
Do not drive the machine unless the stabilizers are
fully retracted.
Crush Hazards
Keep clear of moving stabilizers.
Keep clear of moving parts
duringmachineoperation.
Set the parking brake, put the
transmissioninneutralandlower
the carriage or the attachment to
thegroundbeforeleavingthe
machine.
Keep clear of elevated
components.
Supportcomponentsbefore
performingservice.
Alwaysoperatethemachineinawell-ventilated
areatoavoidcarbonmonoxidepoisoning.
Impropercontactwithcomponentsunderany cover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operationinspection.Allcompartmentsmust
remainclosedandsecuredduringoperation.
Damaged Machine Hazards
Donotuseadamagedormalfunctioningmachine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besureallmaintenancehasbeenperformedas
specifiedinthismanualandtheappropriate Genie
servicemanual.
Be sure all decals are in place and legible.
Be sure the operator’s and safety manuals are
complete,legibleandinthestoragecontainer
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
pryingwedgedorfrozenloads free.
Work Area Safety

Operator'sManualThird Edition • Fourth Printing
PartNo.133306 GTH-1048•GTH-1056 15
Burn Hazards
Allow hot surfaces to cool before
touchingorservicing.
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
theenginerunning.
Refuelthemachineandcharge
the battery only in an open, well-
ventilatedareaawayfrom
sparks, flames and lighted
tobacco.
Donotoperate the machine in
hazardouslocationsorlocations
wherepotentiallyflammableor
explosive gases or particles may
bepresent.
Do not spray ether into engines
equippedwithglowplugsorair
intakegridheaters.
Electrocution Hazards
Maintainanappropriate
clearancefromelectricalpower
lines. See the chart below for
requiredclearance.
LineVoltage Required Clearance
0 to 50KV 10 ft 3.0 m
50 to 200KV 15 ft 4.6 m
200 to 350KV 20 ft 6.1 m
350 to 500KV 25 ft 7.6 m
500 to 750KV 35 ft 10.6 m
750 to 1000KV 45 ft 13.7 m
Do not use the machine as a ground for welding.
Always contact the electric power line owner. The
electricpowershallbedisconnectedorthepower
linesmovedorinsulatedbeforemachineoperations
begin.
Work Area Safety

Operator'sManual Third Edition • Fourth Printing
16 GTH-1048•GTH-1056 PartNo.133306
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothingandeyewearwhenworkingwithbatteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Explosion Hazard
Keep sparks, flames and lighted tobacco away
from batteries. Batteries emit explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.
Employer's Responsibilities
Employersareresponsibleforprovidingasafework
environmentandforcomplyingwithlocaland
nationalgovernmentalregulations.
Work Area Safety

Operator'sManualThird Edition • Fourth Printing
PartNo.133306 GTH-1048•GTH-1056 17
1 Interiorrearviewmirrorand
machinelevelindicator
2 Steeringwheel
3 Controlhandle
4 Boomangleindicator
5 Boom
6 Cab
7 Hydraulicoillevelgauge (on
oppositesideofmachine)
8 Engine(undercover)
9 Fusepanel
10 Stabilizer
11 Forks
12 Exteriorrearviewmirror
13 Seat belt
14 Seat
15 Acceleratorpedal
16 Servicebrakepedal
17 Transmissioncontrollever
Legend

Operator'sManual Third Edition • Fourth Printing
18 GTH-1048•GTH-1056 PartNo.133306
1 Steer select switch
2 Steeringwheel
3 Instrumentpanel
4 Windshieldwasherswitch(ifequipped)
5 Windshieldwiperswitch(ifequipped)
6 Notused
7 Worklightswitch(ifequipped)
8 Parkingbrakeswitch
9 Axle differential lock switch (if equipped with
dashboardswitch)
10 Loadchartholder
11 Controlhandle(singlecontrolhandleoption)
12 Left stabilizer switch
13 Right stabilizer switch
14 Auxiliary hydraulics switch
15 Boomcontrolhandle(dualcontrolhandleoption)
16 Tiltandswaycontrolhandle(dualcontrolhandle
option)
17 Heatercontrols(ifequipped)
18 Ignition switch
19 Roadlightslever
20 Engineconditionindicators
21 Transmissioncontrollever
Controls