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Terex Genie GTH1048 Operator's Manual

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Summary of Contents for Terex Genie GTH1048

  • Page 2: Table Of Contents

    Copyright © 2007 by Genie Industries Second Edition: First Printing, May 2007 Internet: www.genielift.com Third Edition: Fourth Printing, August 2008 E-mail: AWP.techpub@terex.com "Genie" is a registered trademark of Genie Industries in the U.S.A. and many other countries. "GTH" is a trademark of Genie Industries.

  • Page 3: Introduction

    Third Edition • Fourth Printing Operator's Manual 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: Danger...
  • Page 4 Operator's Manual Third Edition • Fourth Printing Introduction Standards Hazard Classification Many aspects of rough terrain forklift operation and Genie uses symbols, color coding and signal words testing are discussed in standards published by the to identify the following: American National Standards Institute and the Safety alert symbol—used to alert Industrial Truck Standards Development you to potential personal injury...

  • Page 5: Symbol And Hazard Pictorials Definitions

    Third Edition • Fourth Printing Operator's Manual Symbol and Hazard Pictorials Definitions Hazard Pictorial Descriptions Electrocution Falling Object Maintain required No people under Fall Hazard Hazard Hazard clearance. load. Always wear seat Keep clear of Bodily Injury Crush Hazard No riders. belt.
  • Page 6 Operator's Manual Third Edition • Fourth Printing Symbol and Hazard Pictorials Definitions Hazard Pictorial Descriptions Overturning Keep load low. Keep away from Crush Hazard Hazard moving parts. inches inches inches Crush Hazard Operate from Only use 48 inch operator's station. forks.

  • Page 7: General Safety

    Third Edition • Fourth Printing Operator's Manual General Safety Safety signs and locations Part No. 133306 GTH-1048 • GTH-1056...
  • Page 8 Operator's Manual Third Edition • Fourth Printing General Safety Safety signs and locations WARNING 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 a piece of cardboard or paper to search for leaks.
  • Page 9 Third Edition • Fourth Printing Operator's Manual General Safety Safety signs and locations 82558 114374 114365 97675 WARNING WARNING WARNING WARNING Crush Hazard Crush Hazard Machine Moving parts can movement can crush or cut Injection Hazard cause serious Escaping fluid under pressure can causing severe injury or death.
  • Page 10 Operator's Manual Third Edition • Fourth Printing General Safety Safety signs and locations GTH-1048 • GTH-1056 Part No. 133306...
  • Page 11 Third Edition • Fourth Printing Operator's Manual General Safety Safety signs and locations Part No. 133306 GTH-1048 • GTH-1056...
  • Page 12 Operator's Manual Third Edition • Fourth Printing General Safety Safety signs and locations GTH-1048 • GTH-1056 Part No. 133306...

  • Page 13: Work Area Safety

    Third Edition • Fourth Printing Operator's Manual Work Area Safety Operate the machine at speeds Overturning Hazards that will keep the load under control. Start and stop Using the load chart, confirm movements smoothly. that the load is within the rated capacity of the machine.
  • Page 14 Operator's Manual Third Edition • Fourth Printing Work Area Safety Traveling on Slopes Fall Hazards When driving, keep the Always wear a seat belt when boom at or below operating the machine. horizontal and keep the Always remain completely inside load close to the the cab when operating the ground.
  • Page 15 Third Edition • Fourth Printing Operator's Manual Work Area Safety Collision Hazards Falling Object Hazards Keep people, equipment and Operate the machine at speeds material out of the work area. Do that will keep the load under not operate the machine while control.
  • Page 16 Operator's Manual Third Edition • Fourth Printing Work Area Safety Always operate the machine in a well-ventilated Component Damage Hazards area to avoid carbon monoxide poisoning. Do not use any battery or charger greater than 12V Improper contact with components under any cover to jump-start the engine.
  • Page 17 Third Edition • Fourth Printing Operator's Manual Work Area Safety Burn Hazards Electrocution Hazards Allow hot surfaces to cool before Maintain an appropriate touching or servicing. clearance from electrical power lines. See the chart below for required clearance. Explosion and Fire Hazards Do not start the engine if you smell or detect liquid petroleum gas (LPG), gasoline, diesel fuel...
  • Page 18 Operator's Manual Third Edition • Fourth Printing Work Area Safety Employer's Responsibilities Battery Safety Employers are responsible for providing a safe work Burn Hazards environment and for complying with local and national governmental regulations. Batteries contain acid. Always wear protective clothing and eye wear when working with batteries.

  • Page 19: Legend

    Third Edition • Fourth Printing Operator's Manual Legend 1 Interior rear view mirror and 8 Engine (under cover) 15 Accelerator pedal machine level indicator 9 Fuse panel 16 Service brake pedal 2 Steering wheel 10 Stabilizer 17 Transmission control lever 3 Control handle 11 Forks 4 Boom angle indicator...

  • Page 20: Controls

    Operator's Manual Third Edition • Fourth Printing Controls 1 Steer select switch 12 Left stabilizer switch 2 Steering wheel 13 Right stabilizer switch 3 Instrument panel 14 Auxiliary hydraulics switch 4 Windshield washer switch (if equipped) 15 Boom control handle (dual control handle option) 5 Windshield wiper switch (if equipped) 16 Tilt and sway control handle (dual control handle option)
  • Page 21 Third Edition • Fourth Printing Operator's Manual Controls 1 Steer selector switch 9 Axle differential lock switch (if equipped with dashboard switch) Push down the right side of the rocker switch to select four-wheel steer. Push the rocker switch Push and hold the axle differential lock switch to to the middle position to select two-wheel steer.
  • Page 22 Operator's Manual Third Edition • Fourth Printing Controls 15 Boom control handle 20 Engine condition indicators Pull the control handle back and the boom will 21 Transmission control lever raise. Push the control handle forward and the Move the transmission control lever toward you boom will lower.
  • Page 23 Third Edition • Fourth Printing Operator's Manual Controls Instrument panel 1 Fuel level gauge 10 Two-wheel steer indicator light 2 Turn signal indicator lights 11 Not used 3 Techometer and hour meter 12 Parking brake indicator light 4 Engine coolant temperature gauge 13 Transmission oil temperature indicator light 5 Not used 14 Transmission oil pressure indicator light...

  • Page 24: Inspections

    Operator's Manual Third Edition • Fourth Printing Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection Do Not Operate Unless: performed by the operator prior to each work shift. The inspection is designed to discover if anything You learn and practice the principles of safe is apparently wrong with a machine before the...
  • Page 25 Third Edition • Fourth Printing Operator's Manual Inspections Pre-operation Inspection Engine and related components Be sure that the operator’s and safety manuals are complete, legible and in the storage Limit switches container located in the operator's compartment. Steer and axle sensors Be sure that all decals are legible and in place.
  • Page 26 Operator's Manual Third Edition • Fourth Printing Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 27 Third Edition • Fourth Printing Operator's Manual Inspections Test the Single Control Handle (if equipped) Test the Steering 7 Using the control handle, momentarily raise the 13 Push the right side of the steer selector switch boom, extend the boom, retract the boom and to select four-wheel steer.
  • Page 28 Operator's Manual Third Edition • Fourth Printing Inspections Test the Transmission and Brakes Test the Stabilizers 21 Be sure the boom is fully lowered and retracted. 29 Push the right and left stabilizer buttons and fully lower and raise the stabilizers. 22 Step on the service brake pedal.
  • Page 29 Third Edition • Fourth Printing Operator's Manual Inspections Workplace Inspection Be aware of and avoid the following hazardous situations: · drop-offs or holes · bumps, floor obstructions or debris Do Not Operate Unless: · sloped surfaces You learn and practice the principles of safe ·...
  • Page 30 Operator's Manual Third Edition • Fourth Printing Inspections Inspection for Decals with Words Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No. Description Quantity Part No.
  • Page 31 Third Edition • Fourth Printing Operator's Manual Inspections 114449 114446 Load chart cards* 97673 97670 133207 133206 97669 97672 114352 114119 114444 114115 114090 114445 114452 114356 114116 or 114453 97676 97668 114093 97665 97666 *GTH-1056: 141117, 141118, 141119, 141120, 141121, 141122, 114124 141123, 141124, 141125, 141126, 141127, 141128 114125...
  • Page 32 Operator's Manual Third Edition • Fourth Printing Inspections Inspection for Decals with Words Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. This inspection is a continuation from the previous page.
  • Page 33 Third Edition • Fourth Printing Operator's Manual Inspections 114449 114446 Load chart cards* 97673 97670 133207 133206 97669 97672 114352 114119 114444 114115 114090 114445 114452 114356 114116 or 114453 97676 97668 114093 97665 97666 *GTH-1056: 141117, 141118, 141119, 141120, 141121, 141122, 114124 141123, 141124, 141125, 141126, 141127, 141128 114125...
  • Page 34 Operator's Manual Third Edition • Fourth Printing Inspections Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No. Description Quantity Part No.
  • Page 35 Third Edition • Fourth Printing Operator's Manual Inspections 114449 114446 Load chart cards* 133035 133207 133206 133028 133037 133039 114444 133043 133041 114115 114090 114445 114452 133045 114116 or 114453 133040 133045 133030 82487 *GTH-1056: 141117, 141118, 141119, 141120, 141121, 141122, 114124 141123, 141124, 141125, 141126, 141127, 141128 114125...
  • Page 36 Operator's Manual Third Edition • Fourth Printing Inspections Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. This inspection is a continuation from the previous page.
  • Page 37 Third Edition • Fourth Printing Operator's Manual Inspections 114449 114446 Load chart cards* 133035 133207 133206 133028 133037 133039 114444 133043 133041 114115 114090 114445 114452 133045 114116 or 114453 133040 133045 133030 82487 *GTH-1056: 141117, 141118, 141119, 141120, 141121, 141122, 114124 141123, 141124, 141125, 141126, 141127, 141128 114125...

  • Page 38: Operating Instructions

    Operator's Manual Third Edition • Fourth Printing Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator's responsibility to follow all the safety rules and instructions in the operator's, safety and responsibilities manuals. Do Not Operate Unless: A variable reach rough terrain forklift truck is defined as a wheeled type truck designed primarily...
  • Page 39 Third Edition • Fourth Printing Operator's Manual Operating Instructions Parking Brake Steer Select Use the parking brake switch to apply the parking Always position all wheels in line with the machine brake before raising the boom or leaving the before switching the steering mode. machine.
  • Page 40 Operator's Manual Third Edition • Fourth Printing Operating Instructions Transmission Control When shifting the transmission from forward to reverse while the machine is in motion, the transmission control lever must be in 1st or 2nd Use the transmission control lever to control the gear only.
  • Page 41 Third Edition • Fourth Printing Operator's Manual Operating Instructions Frame sway with single control handle Raising and Placing a Load Hold the white finger switch The load chart in the cab shows the operating limits (B) and push the control of a properly maintained and operated machine.
  • Page 42 Operator's Manual Third Edition • Fourth Printing Operating Instructions Placing the load 1 Travel to the desired work site and carefully stop the machine. 2 Put the transmission in neutral. 3 Apply the parking brake. 4 Lower the stabilizers, if your configuration requires it.
  • Page 43 Third Edition • Fourth Printing Operator's Manual Operating Instructions Controller movements - Single Controller movements - Dual Control Handle Control Handles Control handle only Boom control handle Control handle with red thumb switch (A) Tilt and sway control handle Control handle with white finger switch (B) Part No.
  • Page 44 Operator's Manual Third Edition • Fourth Printing Operating Instructions Rear Axle Lock - GTH-1056 Jump Starting the Machine If the boom is raised above 60° and extended until Jump starting at the battery or battery replacement E is visible, the transmission will shift to neutral is required when the battery is discharged to the and the frame sway function will not operate.
  • Page 45 Third Edition • Fourth Printing Operator's Manual Operating Instructions Driving on a slope When the machine is loaded, always travel with the load uphill. When the machine is unloaded, travel with the forks or attachment downhill. On steep terrain, drive only up and down hill, and always keep the machine in gear.

  • Page 46: Transport Instructions

    Operator's Manual Third Edition • Fourth Printing Transport Instructions Securing to Truck or Trailer for Transit Turn the key switch to the off position and remove the key before transporting. Inspect the entire machine for loose or unsecured Observe and Obey: items.

  • Page 47: Maintenance

    Third Edition • Fourth Printing Operator's Manual Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level Observe and Obey: can damage engine components. Check the oil level with the engine off.
  • Page 48 Operator's Manual Third Edition • Fourth Printing Maintenance Check the Hydraulic Oil Level Check the Batteries Proper battery condition is essential to good engine Maintaining the hydraulic oil at the proper level is performance and operational safety. Improper fluid essential to machine operation. Improper hydraulic levels or damaged cables and connections can oil levels can damage hydraulic components.
  • Page 49 Third Edition • Fourth Printing Operator's Manual Maintenance Check the Engine Coolant Level Check the Tire Pressure - Liquid Cooled Models Tip-over hazard. An overinflated tire can explode which may compromise machine Maintaining the engine coolant at the proper level is stability and cause the machine to tip over.

  • Page 50: Specifications

    Operator's Manual Third Edition • Fourth Printing Specifications GTH-1048 GTH-1056 Height, stowed 8 ft 6 in 2.6 m Height, stowed 8 ft 6 in 2.6 m Length, stowed, without forks 22 ft 6.7 m Length, stowed, without forks 22 ft 6.7 m Width, standard tires 8 ft 6 in...
  • Page 51 Third Edition • Fourth Printing Operator's Manual Load Charts GTH-1048 Standard Carriage, Stabilizers Up 35 ft 30 ft 20 ft 10 ft 0 ft 10.67 m 9.14m 6.10m 3.05 m 50 ft 70° 15.24 m 60° 40 ft 50° 12.20 m 40°...
  • Page 52 Operator's Manual Third Edition • Fourth Printing Load Charts GTH-1048 Rotating Carriage, Stabilizers Up 35 ft 30 ft 20 ft 10 ft 0 ft 10.67 m 9.14m 6.10m 3.05 m 50 ft 70° 15.24 m 60° 40 ft 50° 12.20 m 40°...
  • Page 53 Third Edition • Fourth Printing Operator's Manual Load Charts GTH-1048 Swing Carriage, Stabilizers Up 35 ft 30 ft 20 ft 10 ft 0 ft 10.67 m 9.14 m 6.10 m 3.05 m 50 ft 70° 15.20 m 4000 lbs / 2500 lbs / 60°...
  • Page 54 Operator's Manual Third Edition • Fourth Printing Load Charts GTH-1048 CAT Attachment, Stabilizers Up 35 ft 30 ft 20 ft 10 ft 0 ft 10.67 m 9.14m 6.10m 3.05 m 50 ft 70° 15.24 m 60° 40 ft 50° 12.20 m 40°...
  • Page 55 Third Edition • Fourth Printing Operator's Manual Load Charts GTH-1048 Truss Boom Attachment, Stabilizers Up First Second Fourth Third Truss Position 1500 lbs / 680 kg 1000 lbs / 454 kg 1000 lbs / 454 kg 750 lbs / 340 kg 2000 lbs / 907 kg 1500 lbs / 680 kg 40 ft...
  • Page 56 Operator's Manual Third Edition • Fourth Printing Load Charts GTH-1048 Rubbish Bucket Attachment, Stabilizers Up 40 ft 40 ft 30 ft 30 ft 20 ft 20 ft 10 ft 10 ft 0 ft 0 ft 12.20 m 12.20 m 9.14 m 9.14 m 6.10 m 6.10 m...
  • Page 57 Third Edition • Fourth Printing Operator's Manual Load Charts GTH-1056 Standard Carriage, Stabilizers Up 50 ft 40 ft 30 ft 20 ft 10 ft 0 ft 15.24 m 12.20 m 9.14 m 6.10 m 3.05 m 60 ft 18.29 m 70°...
  • Page 58 Operator's Manual Third Edition • Fourth Printing Load Charts GTH-1056 Rotating Carriage, Stabilizers Up 50 ft 40 ft 30 ft 20 ft 10 ft 0 ft 15.24 m 12.20 m 9.14 m 6.10 m 3.05 m 60 ft 18.29 m 70°...
  • Page 59 Third Edition • Fourth Printing Operator's Manual Load Charts GTH-1056 Swing Carriage, Stabilizers Up Approved for 48” Forks Only 50 ft 40 ft 30 ft 20 ft 10 ft 0 ft 15.24 m 12.20 m 9.14 m 6.10 m 3.05 m 60 ft 3500 lbs / 1500 lbs /...
  • Page 60 Operator's Manual Third Edition • Fourth Printing Load Charts GTH-1056 CAT Attachment, Stabilizers Up 50 ft 40 ft 30 ft 20 ft 10 ft 0 ft 15.24 m 12.20 m 9.14 m 6.10 m 3.05 m 60 ft 18.29 m 70°...
  • Page 61 Third Edition • Fourth Printing Operator's Manual Load Charts GTH-1056 Truss Boom Attachment, Stabilizers Up Fourth First Second Third Truss Position 400 lbs / 181 kg 400 lbs / 181 kg 400 lbs / 181 kg 400 lbs / 181 kg 1000 lbs / 454 kg 1000 lbs / 454 kg 1000 lbs / 454 kg...
  • Page 62 Operator's Manual Third Edition • Fourth Printing Load Charts GTH-1056 Rubbish Bucket Attachment, Stabilizers Up 50 ft 40 ft 30 ft 20 ft 10 ft 0 ft 15.24 m 12.20 m 9.14 m 6.10 m 3.05 m 60 ft 18.29 m 70°...
  • Page 63 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie China...

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