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Terex Genie GTH-1256 Operator's Manual

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Operator's Manual
GTH™-1256
Serial Number Range
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Original Instructions
Third Edition
First Printing
Part No. 1310133GT

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Summary of Contents for Terex Genie GTH-1256

  • Page 1 Operator's Manual Serial Number Range GTH™-1256 ANSI/CSA North America South America Asia with Maintenance Information Original Instructions Third Edition First Printing Part No. 1310133GT...

  • Page 2: Table Of Contents

    Load Charts ............70 Copyright © 2012 by Terex Corporation Third Edition: First Printing, October 2022 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

    Third Edition • First Printing Operator's Manual Introduction Intr oducti on 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 Third Edition • First Printing Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 5 Third Edition • First Printing Operator's Manual Introduction Hazard Classification Decals on this machine use symbols, color coding, and signal words to identify the following: Safety alert symbol—used to alert you to potential personal injury hazards. Obey all safety Danger messages that follow this symbol to avoid possible injury or death.
  • Page 6 Operator's Manual Third Edition • First Printing Introduction Standards Safety Sign Maintenance Many aspects of rough terrain forklift operation Replace any missing or damaged safety signs. and testing are discussed in standards published Keep operator safety in mind at all times. Use mild by the American National Standards Institute and soap and water to clean safety signs.

  • Page 7: Symbol And Hazard Pictorials Definitions

    Third Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons 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 belt...
  • Page 8 Operator's Manual Third Edition • First Printing Symbol and Hazard Pictorials Definitions Burn hazard Allow surfaces to cool Crush hazard Keep away from Overturning hazard moving parts Access by trained Explosion / Burn No smoking. No open Fall hazard Only use an and authorized hazard flame.

  • Page 9: General Safety

    Third Edition • First Printing Operator's Manual General Safety Gener al Safety -1256 Part No. 1310133GT ™...
  • Page 10 Operator's Manual Third Edition • First Printing General Safety -1256 Part No. 1310133GT ™...
  • Page 11 Third Edition • First Printing Operator's Manual General Safety -1256 Part No. 1310133GT ™...
  • Page 12 Operator's Manual Third Edition • First Printing General Safety -1256 Part No. 1310133GT ™...
  • Page 13 Third Edition • First Printing Operator's Manual General Safety -1256 Part No. 1310133GT ™...
  • Page 14 Operator's Manual Third Edition • First Printing General Safety -1256 Part No. 1310133GT ™...

  • Page 15: Work Area Safety

    Third Edition • First Printing Operator's Manual Work Area Safety Electrocution Hazards Work Ar ea Safety Always contact the electrical power line owner. The electrical power shall be disconnected or the This machine is not electrically insulated and will power lines moved or insulated before machine not provide protection from contact with or operations begin.
  • Page 16 Operator's Manual Third Edition • First Printing Work Area Safety Tip-over Hazards Do not use the swing carriage with 60-inch (1.5 m) or 72-inch (1.8 m) forks. Only use the swing Using the appropriate load chart carriage with 48-inch (1.2 m) forks. for the machine configuration, Do not attempt to jump free of the machine during confirm that the load is within...
  • Page 17 Third Edition • First Printing Operator's Manual Work Area Safety Traveling on Slopes Hazards Do not raise a load and then drive to position it. When driving, keep the boom at When driving, keep the boom or below horizontal and keep at or below horizontal and keep the load close to the ground.
  • Page 18 Operator's Manual Third Edition • First Printing Work Area Safety Fall Hazards Do not drive the machine if visibility is obstructed. Use a signal person when visibility is obstructed, and keep the signal person in view at all times. Always wear a seat belt when Use prearranged hand signals to communicate.
  • Page 19 Third Edition • First Printing Operator's Manual Work Area Safety Falling Object Hazards Bodily Injury Hazards Operate the machine at speeds that will keep the Always adjust the seat and load under control. Start and stop movements fasten the seat belt before smoothly.
  • Page 20 Operator's Manual Third Edition • First Printing Work Area Safety Damaged Machine Hazards Component Damage Hazards Do not use a damaged or malfunctioning machine. Do not use any battery or charger greater than 12V to jump-start the engine. Conduct a thorough pre-operation inspection of the machine and test all functions before each Do not use the machine as a ground for welding.
  • Page 21 Third Edition • First Printing Operator's Manual Work Area Safety Burn Hazards Battery Safety Allow hot surfaces to cool before Burn Hazards touching or servicing. Batteries contain acid. Always wear protective clothing and eye wear when working with batteries. Explosion and Fire Hazards Avoid spilling or contacting battery acid.

  • Page 22: Legend

    Operator's Manual Third Edition • First Printing Legend Leg end Exterior rear view mirror 14 Backup camera (if equipped) Left to right level indicator 15 Engine (Side Mounted, inside the engine tray) Steering wheel 16 Rear proximity alarm sensor (if equipped) Control handle 17 Fuse panel Front to rear level indicator...

  • Page 23: Controls

    Third Edition • First Printing Operator's Manual Controls Controls Control Panel Steering wheel Horn button Turn the steering wheel to the right to turn the Press this button and the horn will sound. front wheels to the right. Turn the steering Release the button and the horn will stop.
  • Page 24 Operator's Manual Third Edition • First Printing Controls Turn signal lever (if equipped) 10 Auxiliary hydraulics thumb rocker Move the lever up to activate the left turn Push the auxiliary hydraulics thumb rocker to signal. Move the lever down to activate the the left and the carriage will swing or rotate to right turn signal.
  • Page 25 Third Edition • First Printing Operator's Manual Controls 16 Left stabilizer up/down switch 23 Transmission control lever Push the top of the rocker switch to lower the Move the transmission control lever toward left stabilizer. Push the bottom of the rocker you and move it up for forward gear.
  • Page 26 Operator's Manual Third Edition • First Printing Controls Instrument Panel Fuel level gauge with low fuel indicator light 12 Engine oil pressure low indicator light Turn signal indicator lights 13 Check engine indicator light Error code messaging 14 Engine stop indicator light DEF (diesel exhaust fluid) Level (if equipped) 15 Four-wheel steer indicator light Engine identification...

  • Page 27: Inspections

    Third Edition • First Printing Operator's Manual Inspections Ins pections 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 28 Operator's Manual Third Edition • First Printing Inspections Pre-operation Inspection Check the following components or areas for damage, improperly installed, or missing parts and unauthorized modifications:  Be sure that the operator’s and safety manuals are complete, legible and in the storage ...
  • Page 29 Third Edition • First Printing Operator's Manual Inspections Check entire machine for:  Cracks in welds or structural components  Dents or damage to machine  Excessive rust, corrosion or oxidation  Be sure that only 48-inch forks are used with swing carriage.
  • Page 30 Operator's Manual Third Edition • First 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 31 Third Edition • First Printing Operator's Manual Inspections Function Tests Test the Steering Select a test area that is firm, level and free of 12 Push the right side of the steer selector switch hazards. Be sure there is no load on the forks to select four-wheel steer.
  • Page 32 Operator's Manual Third Edition • First Printing Inspections Test the Ignition System 35 Move the transmission control lever to reverse. Slowly let up on the brake pedal. As soon as 20 Set the transmission control lever in neutral the machine starts to move, push the brake position.
  • Page 33 Third Edition • First Printing Operator's Manual Inspections Test the CVT Transmission (if equipped) Test the Drive and Sway Cutout 51 Fully retract the boom and lower it to the travel 41 Raise the boom above 50 degrees. Extend the position.
  • Page 34 Operator's Manual Third Edition • First Printing Inspections Test the Rear Proximity Alarm System 57 Place the transmission in forward and slowly drive away from the object. (if equipped) Result: The rear proximity display/monitor The system provides a visible and audible should show an orange light on, and the alarm indication of objects behind the machine, when should sound with decreased frequency as the...
  • Page 35 Third Edition • First 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 Do Not Operate Unless:  sloped surfaces  unstable or slippery surfaces ...
  • Page 36 Operator's Manual Third Edition • First Printing Inspections Inspection for Decals with Words Part No.Decal Description 1268754 Label – DEF Fill Deutz Determine whether the decals on your machine 1268755 Serial Plate have words or symbols. Use the appropriate inspection to verify that all decals are legible and 1269532 Label –...
  • Page 37 Third Edition • First Printing Operator's Manual Inspections 82558 1272242 38149 237605 1303808 1268755 214418 1280264 1280293 215268 1280264 97602 237601 237970 214418 1280294 301868 1263543 82366 1268754 1280264 237970 1304711 1285068 1258415 8.5 inches 16 inches 1303812 231155 28159 826345 237971 1280888...
  • Page 38 Operator's Manual Third Edition • First Printing Inspections Inspection for Decals with Part No.Decal Description Symbols 1268755 Serial Plate 1269532 Label – Exterior Emergency Exit Determine whether the decals on your machine 1272242 Label – Machine Registration/Owner have words or symbols. Use the appropriate Transfer inspection to verify that all decals are legible and 1284367 Label –...
  • Page 39 Third Edition • First Printing Operator's Manual Inspections 1272242 82560 1286018 237726 1303808 1268755 215646 1286019 1286018 237722 237722 215644 215646 1263542 1286020 301868 1268754 215648 1286018 215648 215644 1304711 1285069 1258415 8.5 inches 16 inches 231155 1303812 28159 215645 1286022 1286021 133206...

  • Page 40: Operating Instructions

    Operator's Manual Third Edition • First Printing Operating Instructions Operati ng Instr ucti ons 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 41 Third Edition • First Printing Operator's Manual Operating Instructions Battery Disconnect Switch Parking Brake (if equipped) Use the parking brake switch to apply the parking brake before raising the boom or leaving the The battery disconnect switch is located inside the machine.
  • Page 42 Operator's Manual Third Edition • First Printing Operating Instructions Starting the Engine Raising and Lowering the Stabilizers Be sure the parking brake is set and the transmission control lever is in the neutral Push the top of the rocker switch to lower the position.
  • Page 43 Third Edition • First Printing Operator's Manual Operating Instructions Fire Extinguisher The transmission control lever also controls the transmission speed. To operate an extinguisher: To choose a lower speed, rotate the control lever Pull the pin clockwise. Aim nozzle at base of fire To choose a higher speed, rotate the control lever Squeeze the handle counterclockwise.
  • Page 44 Operator's Manual Third Edition • First Printing Operating Instructions Frame Sway Control Raising and Placing a Load Before raising the boom, the machine must be Always center the load on the forks. Position the level. load so that it is completely against the back of the fork frame.
  • Page 45 Third Edition • First Printing Operator's Manual Operating Instructions Gradually move the controller to lower and Placing the load extend the boom into final position. Lower the load until the weight is completely off the forks. Travel to the desired work site and carefully Do not apply a downward force with the forks.
  • Page 46 Operator's Manual Third Edition • First Printing Operating Instructions Controller movements – Electronic Control Handle Yellow fork Black auxiliary Control handle with Control handle only tilt roller (1) rocker (2) white finger switch (3) -1256 Part No. 1310133GT ™...
  • Page 47 Third Edition • First Printing Operator's Manual Operating Instructions Rear Axle Lock Boom and fork functions continue to operate. To unlock the rear axle and to operate the frame If the boom is raised above 50° and extended until sway function, lower the boom. E is visible, the transmission will shift to neutral and the frame sway function will not operate.
  • Page 48 Operator's Manual Third Edition • First Printing Operating Instructions Engine Display Information SCR cleaning operation Deutz engine (if equipped, only for 120HP Be sure the machine is parked on a flat, level option) surface. Lower and retract the mast. Do not operate the machine while the SCR DEF light on: DEF level is low.
  • Page 49 Third Edition • First Printing Operator's Manual Operating Instructions After Each Use Jump Starting the Machine Select a safe parking location—firm level Jump starting at the battery or battery replacement surface, clear of obstruction and traffic. is required when the battery is discharged to the point where the battery will not crank the starter.
  • Page 50 Operator's Manual Third Edition • First Printing Operating Instructions Driving on a slope Additionally, tip over of a machine is dependent in large part upon operator inputs such as the speed When the machine is loaded, always travel with and smoothness of the operation as well as the the load uphill.
  • Page 51 Third Edition • First Printing Operator's Manual Operating Instructions Rear Proximity Alarm (if equipped) Always look in the direction of travel. When the rear proximity alarm sounds, bring the machine to The system is designed to supplement other a controlled stop and verify the location of the safety practices and systems such as signal obstacle.

  • Page 52: Transport And Lifting Instructions

    Operator's Manual Third Edition • First Printing Transport and Lifting Instructions Trans port and Lifti ng Instr ucti ons 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 53 Third Edition • First Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Determine the center of gravity of your machine using the picture on this page. Remove all loose items on the machine. Observe and Obey: Attach the rigging only to the designated lifting ...

  • Page 54: Maintenance

    Operator's Manual Third Edition • First Printing Maintenance Maintenanc e 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 55 Third Edition • First Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Check the Batteries Maintaining the hydraulic oil at the proper level is Proper battery condition is essential to good essential to machine operation. Improper hydraulic machine performance and operational safety. oil levels can damage hydraulic components.
  • Page 56 Operator's Manual Third Edition • First Printing Maintenance Check Mirrors and Rear Check the Tire Pressure Proximity Alarm System Tip-over hazard. An over-inflated tire can explode which may compromise machine Maintaining the indirect visual aids is essential to stability and cause the machine to tip over. workplace visibility.
  • Page 57 Third Edition • First Printing Operator's Manual Maintenance Drain the Fuel/Water Separator Check DEF Level Maintaining DEF (diesel exhaust fluid) at the Proper maintenance of the fuel filter/water proper level is essential to machine separator is essential for good engine operation.
  • Page 58 Operator's Manual Third Edition • First Printing Maintenance Remove the spring clips securing the pins to Loosen the drain plug located at the bottom of the chock, and remove the pins from the the bowl. Allow the water to drain into a chock.

  • Page 59: Attachments

    Third Edition • First Printing Operator's Manual Attachments Work Platform Hazards Attac hments Always perform a pre-operation inspection of the platform, per the manufacturer’s instructions, prior Work Area Safety to use. The telehandler shall not be used to lift people If damage or any unauthorized variation from unless there is no other practical option.
  • Page 60 Operator's Manual Third Edition • First Printing 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 61 Third Edition • First Printing Operator's Manual 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 62 Operator's Manual Third Edition • First Printing 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 63 Third Edition • First Printing Operator's Manual 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. If equipped with stabilizers: Lower the stabilizers. Properly secure the platform to the telehandler according to the manufacturer’s instructions.
  • Page 64 Operator's Manual Third Edition • First Printing Attachments Suspended Load Hazards Tip-over Hazards Do not lift a suspended load without the proper Work Area Safety and legible load capacity chart for the attachment/telehandler combination you are using. General Safety Do not lift a suspended load without first understanding the local, state, federal, or provincial rules, standards and regulations related to the activity.
  • Page 65 Third Edition • First Printing Operator's Manual Attachments Never drag or pull a load sideways. Collision Hazards Only lift a load vertically; do not pull a load Be sure that the load is clear of any adjacent horizontally as it could cause excessive swinging obstacles before lifting.
  • Page 66 Operator's Manual Third Edition • First Printing 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. Properly secure the attachment to the telehandler.
  • Page 67 Third Edition • First Printing Operator's Manual 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 68 Operator's Manual Third Edition • First Printing Attachments STOP. With arm EMERGENCY STOP. With both arms extended HOIST. With upper RAISE BOOM. With extended horizontally to horizontally to the side, palms down, arms are arm extended to the arm extended the side, palm down, swung back and forth.
  • Page 69 Third Edition • First Printing Operator's Manual 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 70: Specifications

    Operator's Manual Third Edition • First Printing Specifications Specific ati ons GTH-1256 Turning radius (inside), 15 ft 6 in 4.72 m 2 wheel steer Height, stowed 8 ft 8 in 2.64 m 7 ft 1 in 2.15 m Turning radius (inside), Length, stowed, without forks 22 ft 8 in 6.91 m...
  • Page 71 Third Edition • First Printing Operator's Manual Specifications Rear Proximity Sensor Range Horizontal Values Vertical Values 9.75 ft 3 m 16.25 ft 5 m 6.5 ft 13 ft 3.25 ft 1 m 9.75 ft 0 ft 6.25 ft 3.25 ft 1 m 3.25 ft 6.5 ft 0 ft...

  • Page 72: Load Charts

    Operator's Manual Third Edition • First Printing Load Charts Load Capacity Field Calculations To calculate the new reduced load capacity at a Load C harts load center greater than the standard 24 in/61 cm load center, multiply the zone capacity from the Always center the load on the forks.
  • Page 73 Third Edition • First Printing Operator's Manual Load Charts GTH-1256 Standard Carriage, Stabilizers Up Maximum Load Capacity 500 lbs 227 kg 7500 lbs 3402 kg 1000 lbs 454 kg 10000 lbs 4536 kg 2000 lbs 907 kg 12000 lbs 5444 kg 5000 lbs 2268 kg Horizontal Values...
  • Page 74 Operator's Manual Third Edition • First Printing Load Charts GTH-1256 Standard Carriage, Stabilizers Down Maximum Load Capacity 3500 lbs 1588 kg 7000 lbs 3176 kg 4000 lbs 1815 kg 8000 lbs 3629 kg 5000 lbs 2268 kg 10000 lbs 4536 kg 6000 lbs 2722 kg 12000 lbs...
  • Page 75 Third Edition • First Printing Operator's Manual Load Charts GTH-1256 Swing Carriage, Stabilizers Up Maximum Load Capacity 250 lbs 114 kg 4000 lbs 1815 kg 1000 lbs 454 kg 8000 lbs 3629 kg 2000 lbs 908 kg 12000 lbs 5444 kg Horizontal Values Vertical Values -5 ft...
  • Page 76 Operator's Manual Third Edition • First Printing Load Charts GTH-1256 Swing Carriage, Stabilizers Down Maximum Load Capacity 2000 lbs 907 kg 8000 lbs 3629 kg 4000 lbs 1815 kg 10000 lbs 4536 kg 6000 lbs 2722 kg 12000 lbs 5444 kg Horizontal Values Vertical Values -5 ft...
  • Page 77 Third Edition • First Printing Operator's Manual Load Charts GTH-1256 Rotating Carriage, Stabilizers Up Maximum Load Capacity 200 lbs 91 kg 5000 lbs 2268 kg 500 lbs 227 kg 7500 lbs 3402 kg 1000 lbs 454 kg 10000 lbs 4536 kg 2500 lbs 1134 kg 12000 lbs...
  • Page 78 Operator's Manual Third Edition • First Printing Load Charts GTH-1256 Rotating Carriage, Stabilizers Down Maximum Load Capacity 2000 lbs 908 kg 8000 lbs 3629 kg 4000 lbs 1815 kg 10000 lbs 4536 kg 5000 lbs 2268 kg 12000 lbs 5444 kg 6000 lbs 2722 kg Horizontal Values...
  • Page 79 Third Edition • First Printing Operator's Manual Load Charts GTH-1256 Quick Attach Lifting Point, Stabilizers Up Maximum Load Capacity 250 lbs 114 kg 4000 lbs 1815 kg 1000 lbs 454 kg 8000 lbs 3629 kg 2000 lbs 908 kg 12000 lbs 5444 kg Horizontal Values Vertical Values...
  • Page 80 Operator's Manual Third Edition • First Printing Load Charts GTH-1256 Quick Attach Lifting Point, Stabilizers Down Maximum Load Capacity 2000 lbs 908 kg 8000 lbs 3629 kg 4000 lbs 1815 kg 10000 lbs 4536 kg 6000 lbs 2722 kg 12000 lbs 5444 kg Horizontal Values Vertical Values...

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