Terex Genie GTH-1056 Operator's Manual
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Terex Genie GTH-1056 Operator's Manual

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Operator's Manual
GTH-1056
Serial Number Range
from GTH1012-16292
with
Maintenance
Information
Fourth Edition
Fourth Printing
Part No. 214834

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Summary of Contents for Terex Genie GTH-1056

  • Page 1 Operator's Manual Serial Number Range GTH-1056 from GTH1012-16292 with Maintenance Information Fourth Edition Fourth Printing Part No. 214834...

  • Page 2: Table Of Contents

    Load Charts ............62 Copyright © 2012 by Terex Corporation Fourth Edition: Fourth Printing, August 2013 Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “GTH” is a trademark of Terex South Dakota, Inc.

  • Page 3: Introduction

    Fourth Edition • Fourth Printing Operator's Manual Introduction Introduction About this manual Intended Use Genie appreciates your choice of our machine for A variable reach rough terrain forklift truck is your application. Our number one priority is user defined as a wheeled type truck with a pivoting safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Fourth Edition • Fourth Printing Introduction Contacting the Manufacturer At times it may be necessary to contact Genie. When you do, be ready to supply the model number and serial number of your machine, along with your name and contact information. At minimum, Genie should be contacted for: Accident reporting Questions regarding product applications and...
  • Page 5 Fourth Edition • Fourth Printing Operator's Manual Introduction 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 machine operation contained in this operator’s manual.
  • Page 6 Operator's Manual Fourth Edition • Fourth Printing Introduction Hazard Classification Standards Many aspects of rough terrain forklift operation and Decals on this machine use symbols, color coding testing are discussed in standards published by and signal words to identify the following: the American National Standards Institute and the Industrial Truck Standards Development Safety alert symbol—used to alert...

  • Page 7: Symbol And Hazard Pictorials Definitions

    Fourth Edition • Fourth Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Electrocution hazard Maintain required Crush hazard No people under load Read the operator’s clearance manual Crush hazard Keep clear of moving Maintain required Crush hazard Always wear seat stabilizers...
  • Page 8 Operator's Manual Fourth Edition • Fourth Printing Symbol and Hazard Pictorials Definitions Only trained Explosion / Burn No smoking. No open Fall hazard Work platform use maintenance hazard flame. personnel should access compartments Tip-over hazard Tip-over hazard Sway operation Keep load low Refer to load charts and manual.

  • Page 9: General Safety

    Fourth Edition • Fourth Printing Operator's Manual General Safety General Safety Part No. 214834 GTH-1056...
  • Page 10 Operator's Manual Fourth Edition • Fourth Printing General Safety GTH-1056 Part No. 214834...
  • Page 11 Fourth Edition • Fourth Printing Operator's Manual General Safety Part No. 214834 GTH-1056...
  • Page 12 Operator's Manual Fourth Edition • Fourth Printing General Safety GTH-1056 Part No. 214834...

  • Page 13: Work Area Safety

    Fourth Edition • Fourth Printing Operator's Manual Work Area Safety Work Area Safety Do not use the swing carriage with 60-inch or Overturning Hazards 72-inch forks. Only use the swing carriage with 48-inch forks. Using the load chart, confirm that the load is within the rated Do not raise the boom unless capacity of the machine.
  • Page 14 Operator's Manual Fourth Edition • Fourth Printing Work Area Safety Do not operate the machine in strong or gusty Whether a machine will tip over during dynamic winds. Do not increase the surface area of the machine operation involves many factors that need carriage or load.
  • Page 15 Fourth Edition • Fourth Printing Operator's Manual Work Area Safety Do not raise the boom unless the parking brake is Fall Hazards set. Always wear a seat belt when Do not operate in conditions without fenders to operating the machine. protect debris from hitting the operator or accumulating on the cab windows.
  • Page 16 Operator's Manual Fourth Edition • Fourth Printing Work Area Safety Bodily Injury Hazards Damaged Machine Hazards Do not use a damaged or malfunctioning machine. Always adjust the seat and fasten the seat belt before Conduct a thorough pre-operation inspection of the starting the engine.
  • Page 17 Fourth Edition • Fourth Printing Operator's Manual Work Area Safety Crush Hazards Electrocution Hazards This machine is not electrically insulated and will Keep clear of moving stabilizers. not provide protection from contact with or proximity to electrical current. Obey all local and Keep clear of moving parts during machine governmental regulations operation.
  • Page 18 Operator's Manual Fourth Edition • Fourth Printing Work Area Safety For power lines over 1000kV, the minimum Explosion Hazards clearance distance must be established by the Keep sparks, flames and utility owner or operator or by a registered lighted tobacco away from professional engineer who is a qualified person batteries.

  • Page 19: Legend

    Fourth Edition • Fourth Printing Operator's Manual Legend Legend 10 Engine (under cover) Interior rear view mirror 11 Fuse panel Left to right level indicator 12 Stabilizer Steering wheel 13 Forks Control handle 14 Exterior rear view mirror Front to rear level indicator 15 Seat belt Boom angle indicator 16 Seat...

  • Page 20: Controls

    Operator's Manual Fourth Edition • Fourth Printing Controls Controls Control Panel 13 Auxiliary hydraulics switch (if equipped) Steering wheel 14 Accelerator pedal Horn button 15 Brake pedal Heater and air conditioning controls (if equipped) 16 Tilt steering pedal Turn signal lever (if equipped) 17 Axle differential lock pedal 12V power port, 10A maximum 18 Windshield washer/wiper switch (if equipped)
  • Page 21 Fourth Edition • Fourth Printing Operator's Manual Controls Ignition switch Control Panel Turn the key to the left to turn on the Steering wheel accessories. Turn the key to the on position Turn the steering wheel to the right to turn the and hold until the glow plug light on the front wheels to the right.
  • Page 22 Operator's Manual Fourth Edition • Fourth Printing Controls 13 Auxiliary hydraulics switch (if equipped) 19 Skylight washer/wiper switch (if equipped) Push the left side of the auxiliary hydraulics Push the right side of the rocker switch to turn button and the carriage will swing or rotate to the wiper on.
  • Page 23 Fourth Edition • Fourth Printing Operator's Manual Controls RPM x100 Instrument Panel 14 Four-wheel steer indicator light Fuel level gauge with low fuel indicator light 15 Two-wheel steer indicator light Turn signal indicator lights 16 Crab steer indicator light Tachometer 17 Brake pressure low indicator light Lights indicator light 18 Rear wheels centered indicator light (if equipped)

  • Page 24: Inspections

    Operator's Manual Fourth Edition • Fourth Printing Inspections 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 performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 25 Fourth Edition • Fourth Printing Operator's Manual Inspections  Limit switches Pre-operation Inspection  Steer and axle sensors (if equipped)  Be sure that the operator’s, safety and  Lights, alarms and beacons (if equipped) responsibilities manuals are complete, legible ...
  • Page 26 Operator's Manual Fourth 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 malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 27 Fourth Edition • Fourth Printing Operator's Manual Inspections Test the Dual Control Handles Function Tests (if equipped) Select a test area that is firm, level and free of 11 Using the boom control handle, momentarily obstruction. Be sure there is no load on the raise the boom, extend the boom, retract the forks or attachment.
  • Page 28 Operator's Manual Fourth Edition • Fourth Printing Inspections Test the Steering Test the Transmission and Brakes 14 Push the right side of the steer selector switch 22 Be sure the boom is fully lowered and to select four-wheel steer. The four-wheel retracted.
  • Page 29 Fourth Edition • Fourth Printing Operator's Manual Inspections Test the Stabilizers Test the Lights 30 Push the right and left stabilizer buttons and 37 Verify that all lights are functional. fully lower and raise the stabilizers. Test the 2-speed Transmission Result: The stabilizers should operate (if equipped) smoothly.
  • Page 30 Operator's Manual Fourth Edition • Fourth Printing Inspections Workplace Inspection Fundamentals The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation. It should be performed by the operator prior to moving the machine to the workplace.
  • Page 31 Fourth Edition • Fourth Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions or debris  sloped surfaces  unstable or slippery surfaces  overhead obstructions and high voltage conductors ...
  • Page 32 Label – Steer Model Selector 237605 Warning – Burn Hazard, Hot Parts 114366 Danger – Crush Hazard, Stabilizers 237606 Label – Single Controller 114379 Cosmetic – Genie GTH-1056 237796 Cosmetic – Genie Logo 114461 Cosmetic – GTH-1056 237970 Warning – Crush Hazard, Tires 114470 Cosmetic –...
  • Page 33 Fourth Edition • Fourth Printing Operator's Manual Inspections load chart set 214418 133206 214419 215652 114090 237606 822590 114115 215384 237600 216208 237599 114379 Serial Label 215267 82558 231155 97667 215268 237970 214418 237598 114366 97602 114461 237605 114379 97667 237598 130770 141146...
  • Page 34 Label – Transmission Control 215652 Label – Dual Controller 114115 Label – Steer Model Selector 216244 Label – Tip-over Hazard, Truss Boom 114379 Cosmetic – Genie GTH-1056 216245 Label – Tip-over Hazard, Forks 114461 Cosmetic – GTH-1056 231155 Label – Boom Lettering 133031 Label –...
  • Page 35 Fourth Edition • Fourth Printing Operator's Manual Inspections Part No. 214834 GTH-1056...

  • Page 36: Operating Instructions

    Operator's Manual Fourth Edition • Fourth Printing Operating Instructions 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.
  • Page 37 Fourth 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 38 Operator's Manual Fourth Edition • Fourth Printing Operating Instructions Models with 3-speed transmission Transmission Control Use the transmission control lever to control the speed and direction of machine travel. Step on the service brake pedal before putting the transmission into gear. To drive forward, move the transmission control lever toward you and move it up.
  • Page 39 Fourth Edition • Fourth Printing Operator's Manual Operating Instructions Axle Differential Lock Transporting a Load Use the axle differential lock switch to lock the axle Center the load on the forks. Position the load so differential and gain added traction in certain types that it is completely against the back of the fork of terrain such as sand, mud or snow.
  • Page 40 Operator's Manual Fourth Edition • Fourth Printing Operating Instructions Gradually move the controller to raise and Raising and Placing a Load extend the boom to the required height. The load chart in the cab shows the operating limits of a properly maintained and operated machine.
  • Page 41 Fourth Edition • Fourth Printing Operator's Manual Operating Instructions Gradually move the controller to raise and retract the boom. This will bring the forks out of the load. When the forks are clear of the load and the structure, the boom can be lowered and retracted.
  • Page 42 Operator's Manual Fourth Edition • Fourth Printing Operating Instructions Controller movements – Single Control Handle Control handle only Control handle with red thumb Control handle with white finger switch (A) switch (B) Controller movements - Dual Control Handle Boom control handle Tilt and sway control handle GTH-1056 Part No.
  • Page 43 Fourth Edition • Fourth Printing Operator's Manual Operating Instructions Rear Axle Lock If the boom is raised above 60° and extended until E is visible, the transmission will shift to neutral and the frame sway function will not operate. Boom and fork functions continue to operate. To unlock the rear axle and to operate the frame sway function, lower the boom.
  • Page 44 Operator's Manual Fourth Edition • Fourth Printing Operating Instructions Engine Condition Indicator Jump Starting the Machine If the engine diagnostic display indicates an engine Jump starting at the battery or battery replacement fault, contact service personnel. is required when the battery is discharged to the point where the battery will not crank the starter.
  • Page 45 Fourth 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 Fourth Edition • Fourth Printing Transport Instructions 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 Fourth Edition • Fourth Printing Operator's Manual Transport Instructions Securing the Chassis Use chains of ample load capacity. Use a minimum of 5 chains. There are 5 tie down points on the chassis. Adjust the rigging to prevent damage to the chains. Part No.

  • Page 48: Maintenance

    Operator's Manual Fourth Edition • Fourth Printing Maintenance 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.
  • Page 49 Fourth Edition • Fourth Printing Operator's Manual Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
  • Page 50 Operator's Manual Fourth Edition • Fourth Printing Maintenance Check the Batteries Check the Engine Coolant Level – Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 51 Fourth Edition • Fourth Printing Operator's Manual Maintenance Check the Tire Pressure Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Tip-over hazard. An over-inflated tire can this machine according to the procedures found in explode which may compromise machine the service manual for this machine.

  • Page 52: Attachments

    Operator's Manual Fourth Edition • Fourth Printing Attachments Attachments Always perform a pre-operation inspection of the Work Platform Hazards platform, per the manufacturer’s instructions, prior to use. Work Area Safety If damage or any unauthorized variation from The telehandler shall not be used to lift people factory delivered condition is discovered, the unless there is no other practical option.
  • Page 53 Fourth Edition • Fourth Printing Operator's Manual Attachments Do not place or attach overhanging loads to any Occupying the Platform part of this machine or platform. Do not carry materials directly on platform railing Do not place ladders or unless approved by Genie. scaffolds in the platform or Be certain that materials and tools are protected against any part of this...
  • Page 54 Operator's Manual Fourth Edition • Fourth Printing Attachments Telehandler Operation Lifting Personnel Be certain that the platform is securely attached to Occupants, equipment and the telehandler, lifting carriage and forks. materials shall not exceed the maximum platform Be certain that the lifting carriage and forks are capacity.
  • Page 55 Fourth Edition • Fourth Printing Operator's Manual Attachments Keep bystanders away while operating. Operating Instructions Do not place boom or platform against any Preparation and Setup structure to steady the platform or to support the structure. Read, understand and obey all jobsite, local, state, federal and provincial rules, standards and Do not use the controls to free a platform that is regulations as they pertain to the use of a...
  • Page 56 Operator's Manual Fourth Edition • Fourth Printing Attachments Installing and securing the Lifting and lowering the platform platform Set the parking brake and place the transmission into neutral. Center the platform on the telehandler. Lower the stabilizers. Properly secure the platform to the telehandler according to the manufacturer’s instructions.
  • Page 57 Fourth Edition • Fourth Printing Operator's Manual Attachments Suspended Load Hazards Overturning Hazards Do not lift a suspended load without the proper and Work Area Safety legible load capacity chart for the attachment/telehandler combination you are using. General Safety Do not permit Do not lift a suspended load without first the load to understanding the local, state, federal, or...
  • Page 58 Operator's Manual Fourth Edition • Fourth Printing Attachments Identify the proper lifting points of the load, taking Collision Hazards into consideration the center of gravity and load stability. Be sure that the load is clear of any adjacent obstacles before lifting. Do not attempt to use the telehandler When visibility is or could be obstructed, near or at frame-leveling to compensate for a swinging load...
  • Page 59 Fourth Edition • Fourth Printing Operator's Manual Attachments Lifting a Suspended Load Traveling Verify that landing point is level and can safely Be sure that the path of travel is level and capable support the load. of supporting the telehandler with its load. Keep the boom, and load, as low as practical while Properly secure the attachment to the telehandler maintaining visibility in the direction of travel.
  • Page 60 Operator's Manual Fourth Edition • Fourth Printing Attachments Placing the Load Signal Person (from 1926.1419) Ask a signal person to assist with placing the load Per OSHA CFR 1926.1419, a signal person is if visibility will be obstructed at the point of required when: operation.
  • Page 61 Fourth Edition • Fourth Printing Operator's Manual Attachments STOP. With arm EMERGENCY STOP. With both arms extended HOIST. With upper arm RAISE BOOM. With extended horizontally to horizontally to the side, palms down, arms are extended to the side, arm extended the side, palm down, swung back and forth.
  • Page 62 Operator's Manual Fourth Edition • Fourth Printing Attachments Suspended Load Hazards Rigger Requirements (from OSHA CFR 1926.404) When employees are engaged in hooking, unhooking, or guiding the load, or in the initial connection of a load to a component or structure and are within the fall zone, all of the following criteria must be met: The materials being hoisted must be rigged to...

  • Page 63: Specifications

    Fourth Edition • Fourth Printing Operator's Manual Specifications Specifications GTH-1056 Height, stowed 8 ft 6 in 2.6 m Length, stowed, without 22 ft 6.7 m forks Width, standard tires 8 ft 6 in 2.6 m Wheelbase 10 ft 8 in 3.3 m Ground clearance, center 1 ft 10 in...

  • Page 64: Load Charts

    Operator's Manual Fourth Edition • Fourth Printing Load Charts Load Charts GTH-1056 Standard Carriage, GTH-1056 Swing Carriage, Stabilizers Up Stabilizers Up GTH-1056 Swing Carriage, Stabilizers Down GTH-1056 Standard Carriage, Stabilizers Down GTH-1056 Part No. 214834...
  • Page 65 Fourth Edition • Fourth Printing Operator's Manual Load Charts GTH-1056 Rotating Carriage, GTH-1056 Truss Boom Stabilizers Up Attachment, Stabilizers Up GTH-1056 Rotating Carriage, GTH-1056 Truss Boom Stabilizers Down Attachment, Stabilizers Down Part No. 214834 GTH-1056...
  • Page 66 Operator's Manual Fourth Edition • Fourth Printing Load Charts GTH-1056 Rubbish Bucket GTH-1056 Cat Attachment, Attachment, Stabilizers Up Stabilizers Up GTH-1056 Rubbish Bucket GTH-1056 Cat Attachment, Attachment, Stabilizers Down Stabilizers Down GTH-1056 Part No. 214834 Operator's Manual Fourth Edition • Fourth Printing GTH-1056 Part No.
  • Page 67 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. www.genielift.com...

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