Genie GTH-1048 manual

Operator’s Manual with Maintenance Information GTH-1048 GTH-1056 First Edition Second Printing Part No. 114 101[...]

SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY SECTION 1-1 Introduction 1-3 S tandards And Symbols 1-4 Safety 1-5 T raining 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 Procedur es 2-3 Jump S tarting 2-8 Proper Load[...]

SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY 1 - 1[...]

T ABLE OF CONTENTS SECTION 1 - ROUGH TERRAIN FORK LIFT SAFETY Introduction 1 - 3 Standards And Symbols 1 - 4 Safety 1 - 5 T raining And Knowledge 1 - 5 Operator's Responsibilities 1 - 6 Management's Responsibilities 1 - 7 Maintenance And Repair 1 - 8 Operation Safety 1 - 9 1 - 2[...]

ROUGH TERRAIN FORK LIFT SAFETY 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. W e feel that you make a major contribution to safety if you, as the equipment users and operators: 1. Comply with OSHA, Fe[...]

ROUGH TERRAIN FORK LIFT SAFETY ST ANDARDS AND SYMBOLS 1 - 4 Many aspects of rough terrain forklift operation 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 LIFT SAFETY SAFETY 1 - 5 1. Safety must always be the operator's most important concern. 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 29CFR[...]

ROUGH TERRAIN FORK LIFT SAFETY OPERA T OR'S RESPONSIBILITIES 1 - 6 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 . Keep the machi[...]

ROUGH TERRAIN FORK LIFT SAFETY MANAGEMENT'S RESPONSIBILITIES 1 - 7 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 [...]

ROUGH TERRAIN FORK LIFT SAFETY 1 - 8 MAINTENANCE AND REP AIR 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 th[...]

ROUGH TERRAIN FORK LIFT SAFETY OPERA TION SAFETY 1 - 9 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 su[...]

ROUGH TERRAIN FORK LIFT SAFETY 1 - 10 OPERA TION SAFETY e c n a t s i D h c a o r p p A e f a S m u m i n i M e g a t l o V e n i L r e w o Pe c n a r a e l C d e r i u q e R V k 0 5 o t 0) m 0 0 . 3 ( . t f 0 1 V k 0 0 2 o t 0 5) m 0 6 . 4 ( . t f 5 1 V k 0 5 3 o t 0 0 2) m 0 1 . 6 ( . t f 0 2 V k 0 0 5 o t 0 5 3) m 2 6 . 7 ( . t f 5 2 V k 0 5 7 o[...]

ROUGH TERRAIN FORK LIFT SAFETY 1 - 11 OPERA TION SAFETY 17 . Inspect the path of travel before beginning movement. A void holes and dropoffs. 1 8. T raveling on slopes/grades. i . Ascend and descend slowly and with caution. i i . When loaded, always travel with the load uphill. iii. When unloaded,travel with the attachment downhill. i v . A void tu[...]

ROUGH TERRAIN FORK LIFT SAFETY NOTES 1 - 12[...]

SECTION 2 GENERAL SAFETY 2 - 1[...]

T ABLE OF CONTENTS SECTION 2 - GENERAL SAFETY General Safety Procedures 2 - 3 Jump Starting 2 - 8 Proper Load Chart Use 2 -9 2 - 2[...]

GENERAL SAFETY SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. W ARNING AL W A YS wear eye protection and personal safety equipment. THE OPERA TOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the oper[...]

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 W ARNING Slips and falls can cause serious injury . When getting on and off the machine, always maintain a three [...]

GENERAL SAFETY HYDRAULIC SAFETY W ARNING 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: 1 . Lower the boom to the horizontal position. 2 . Support the boom to avoid unintentional lowering. 3 . Shutdown the engin[...]

GENERAL SAFETY GENERAL SAFETY PROCEDURES 2 - 6 CAUTION USE SEA T 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 af fect machine life. AL W A YS use a safety support or brace [...]

GENERAL SAFETY GENERAL SAFETY PROCEDURES A VOID ELECTRICAL POWER LINES DANGER REQUIRED CLEARANCE FOR NORMAL VOL T AGE IN OPERA TION NEAR HIGH VOL T AGE POWER LINES AND OPERA TION IN TRANSIT WITH NO LOAD AND BOOM OR MAST LOWERED. Normal V oltage, kV Minimum Required (Phase to Phase) Clearance, ft. (m) Operation Near High V oltage Power Lines to 50 1[...]

GENERAL SAFETY Location: The battery is located under the fuel tank / battery box cover (A). JUMP ST ARTING 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 . W ARNING Battery posts, terminals, and related accessories contain lead and lead compou[...]

GENERAL SAFETY PROPER LOAD CHAR T USE 2 - 9 NEVER raise a load and drive to position it. This 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 lo[...]

GENERAL SAFETY PROPER LOAD CHART USE 2 - 10 PO Box 97030 18340 NE 76th St Redmond WA 98073 Manufact urer's recommended capaci ty is per ANSI B56.6 Stabi lity T est s using standard homogeneous cubes 4 x 4 x 4 ft / 1.2 x 1.2 x 1.2 m. Load capaciti es at 24 i n / 60 c m load cent er with standar d fork frame. Rated lif t capacities shown are w i[...]

SECTION 3 CONTROLS AND INSTRUMENTS 3 - 1[...]

T ABLE 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 T ransmission 3 - 9 Front Axle Differential Loc[...]

CONTROLS AND INSTRUMENTS 1 . Accelerator Pedal 9 . Gauges 1 7 . W indshield W iper 2 4 . Interior Rear V iew Mirror 2 . Joystick 4-way Controller 1 0 . Machine Level Gauge 1 8 . Ignition Switch 2 5 . Frt.Axle Differential Lock 3 . Transmission Control Lever 1 1 . Plug / 12 V olt Access 1 9 . Auxiliary Hydraulics 2 6 . Stabilizer Switch / LH 4 . Ste[...]

CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS 3 - 4 A - Boom Down B - Boom Up C - Boom Out D - Boom In E - Boom Down and Out F - Boom Up and In G - Boom Up and Out H - Boom Down and In     B A D C[...]

CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS (BUTTON PUSHED) 3 - 5 A - Tilt Down B - Tilt Back   B A[...]

CONTROLS AND INSTRUMENTS SERVICE BRAKES P ARKING BRAKE 3 - 6 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. The brakes should be applied during normal operation to stop machine movement. W ARNING Failure to set the parking brake before leav[...]

CONTROLS AND INSTRUMENTS W ARNING 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. W ARNING Use the frame sway control to level the machine only when the boom angle indicator is at 0 degrees or [...]

CONTROLS AND INSTRUMENTS 3 - 8 PUMP OFF BRAK E ON CONTROL SWAY HEATER HEADLIGHT HYDRAULICS WIPER AUXILIARY LEFT STABILIZER RIGHT STABILIZER 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 [...]

CONTROLS AND INSTRUMENTS BRAK E ON SWAY CONTROL PUMP OFF HEATER HEADLIGH T LE FT STABILIZ ER RIGH T STAB ILIZE R BLIN ENGI NE 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. T o shift into Forward gear gently pull the lever toward you and move t[...]

CONTROLS AND INSTRUMENTS FRONT AXLE DIFFERENTIAL LOCK 3 - 10 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 act[...]

CONTROLS AND INSTRUMENTS FRONT ST ABILIZERS 3 - 11 BRAKE ON (C) LETTER VISIB LE = 3,000 L BS (D) LE TTER VISIB LE = 2,0 00 LBS P/N 3-1483 0 (1.22) METER FEET ( 6. 10) 28 (8.54) 24 (7.32) 20 4 !" #" $ &'() * " #+ 455 NORT H SUPERIOR AVEN UE MACH INE ON A FIRM, LEVEL SURFAC E WITH UNDAMAGED, PROPE RLY INF LATED CA LCIUM CAPACI[...]

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. D[...]

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 c[...]

CONTROLS AND INSTRUMENTS 3 - 14 ENGINE ELECTRONIC CONTROL UNIT Fault Codes and Descriptions 2-Digit Code Definition 1 1 Analog Throttle Input High 1 2 Analog Throttle input Low 1 8 Engine Coolant T emperature Input High 1 9 Engine Coolant T emperature Input Low 2 1 Sensor Supply V oltage High 2 2 Sensor Supply V oltage Low 2 3 Engine Oil Pressure I[...]

SECTION 4 OPERA TION 4 - 1[...]

T ABLE OF CONTENTS SECTION 4 - OPERA TION Operation And Safety Guidelines 4 - 3 Before Starting The Engine 4 - 4 Starting The Engine 4 - 5 Before Operating The Forklift 4 - 7 T ransporting A Load 4 - 1 1 Placing A Load 4-13 4 - 2[...]

OPERA TION OPERA TION AND SAFETY GUIDELINES Y our 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 [...]

OPERA TION W ARNING Before starting the engine, be sure that all daily maintenance items have been performed. See Maintenance section. W alk 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. BEFORE ST AR TING THE ENGINE 4 - 4[...]

OPERA TION SWAY CON TROL PUMP OFF BRAKE ON (C) LE TT ER VISIBL E = 3, 0 0 0 L BS (D) LE TT ER VISIBLE = 2 , 000 LBS P/N 3-1483 0 (1.22) METER FEET (6.10) 28 (8.54) 24 (7. 3 2) 20 4 ! " #" $ &'() * " #+ 455 NORTH SUPERIOR AVENUE MACHINE ON A FIRM, LEVEL SURFACE WITH U NDAMAGED, PROPERLY INFLATED C ALCIUM CAPACITY IS PER ANSI [...]

OPERA TION ST A R TING THE ENGINE 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[...]

OPERA TION PUMP OFF BRAKE ON CONTROL SWAY HEATER HEADLIGHT HYDRAULICS WIPER AUXILI ARY LEFT STABILIZER RIGHT STABILIZER BEFORE OPERA TING THE FORKLIFT CAUTION If any gauge reading does not fall within the set tolerances the machine must be repaired before operation. Check the dash mounted gauges for logical readings. (1) Fuel 1/2 to Full (2) T rans[...]

OPERA TION BEFORE OPERA TING THE FORKLIFT 4 - 8 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 [...]

OPERA TION DANGER Any problems with the service brakes or the parking brake found while conducting 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 mach[...]

OPERA TION BRAKE O N SWAY CONTROL PUMP OFF HEATER HEADLIGHT LEFT STABILIZ ER RI GHT STABILIZ ER BLIN ENGINE 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 repai[...]

OPERA TION 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. 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 0 degrees or less. The forks should always be tilte[...]

OPERA TION BRAK E ON SWAY CONTROL PUMP OFF HE ATER HEADLIG HT LEFT STABILIZE R RIGHT STABILIZ ER BLIN ENGINE W ARNING Slower speeds should be used whenever transporting a load. Always bring the machine to a complete stop before reversing the transmission control lever (A). Failure to do so can result in damage to the load, the machine and/or bystan[...]

OPERA TION PLACING A LOAD 4 - 13 SWAY CONTROL PUMP OFF BRA KE O N (C) LETTER VISIBLE = 3, 000 L B S (D) LE TTER VI SIBLE = 2,0 00 LBS P/N 3-1483 0 (1.2 2) METER FEET (6.10) 28 (8.54) 24 (7.32 ) 20 4 ! "#" $ &'()*" #+ 455 NORTH SUPERIOR AVENUE MACHINE ON A FIRM, LEVEL SURFACE WITH UNDAMAGED, PROP ERLY IN F LATED CA LCIUM CAPA[...]

OPERA TION PLACING A LOAD 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 required height has been achieved. Gradually move the 4-way controller towards[...]

OPERA TION PLACING A LOAD 4 - 15 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 DEGREES on the GTH-1048 or 55 DEGREES on the GTH-1056, all frame leveling and transmission functions are disabled and the rear axle stabilizing cyl[...]

OPERA TION 4 - 16 NOTES[...]

SECTION 5 MAINTENANCE PROCEDURES 5 - 1[...]

T ABLE OF CONTENTS SECTION 5 - MAINTENANCE PROCEDURES General Safety Practices 5 - 3 Daily Maintenance 5 - 5 5 - 2[...]

MAINTENANCE PROCEDURES BEFORE SERVICING Read the entire Maintenance Procedure Section. Familiarize yourself with all the safety precautions listed in Sections 1 & 2. Pay close attention to all the safety alert symbols. Be sure you understand the procedures detailed in this section. W ear personal protective equipment. Remove rings and jewelry .[...]

MAINTENANCE PROCEDURES GENERAL SAFETY PRACTICES HYDRAULIC SAFETY W ARNING 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: 1 . Lower the boom to the horizontal position. 2 . Support the boom to avoid uninte[...]

MAINTENANCE PROCEDURES DAIL Y 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 [...]

MAINTENANCE PROCEDURES DAIL Y MAINTENANCE CHECK HYDRAULIC OIL LEVEL Location: Sight glass (B). Behind the rear panel. T o 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 ma[...]

SECTION 6 MA TERIAL SAFETY DA T A 6 - 1[...]

T ABLE OF CONTENTS SECTION 6 - MA TERIAL SAFETY DA T A Material Safety Data Sheets 6 - 3 California Proposition 65 W arnings 6 - 4 6 - 2[...]

MA TERIAL SAFETY DA T A 6 - 3 The Federal Occupational, Safety and Health Administration (OSHA) Standard 29 ctr 1910.1200, and in some cases state and local Right-T o-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 antifre[...]

MA TERIAL SAFETY DA T A 6 - 4 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, W A 98073-9730 [...]