Genie GTH-1048, Operator'S Manual

Page 1: ...Operator s Manual with Maintenance Information GTH 1048 GTH 1056 First Edition Second Printing Part No 114101 ...

Page 2: ... 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 Transmission 3 9 Front Axle Differential Lock 3 10 Front Stabilizers 3 11 Engine Electronic Control Unit ECU 3 12 SECTION 4 OPERATION 4 1 Operation And Safety Guidelines 4 3 Before Starting The Engine 4 4 Starting The Eng...

Page 3: ...SECTION 1 ROUGH TERRAIN FORK LIFT SAFETY 1 1 ...

Page 4: ...N 1 ROUGH TERRAIN FORK LIFT SAFETY Introduction 1 3 StandardsAnd Symbols 1 4 Safety 1 5 TrainingAndKnowledge 1 5 Operator sResponsibilities 1 6 Management sResponsibilities 1 7 MaintenanceAndRepair 1 8 OperationSafety 1 9 1 2 ...

Page 5: ...pliedwiththismachine 3 Use Good Safe Work Practices in a common sense way 4 Only have trained certified operators directed by informed and knowledgeablesupervision runningthemachine NOTE OSHAprohibitsthealterationormodificationofthismachinewithoutwritten manufacturer s approval Use only factory approved parts to service or repair this machine Ifthereisanythinginthismanualthatisnotclearorwhichyoube...

Page 6: ...StandardsInstitute 25 West 43nd Street 4th Fl New York New York 10036 Tel 212 642 4900 Fax 212 398 0023 STANDARDS SYMBOLS DANGER Indicatesanimminentlyhazardoussituation which ifnotavoided willresultindeathorseriousinjury CAUTION Indicatesapotentiallyhazardoussituation which ifnotavoided mayresultinminorormoderate injury WARNING Indicatesapotentiallyhazardoussituation which if not avoided could res...

Page 7: ...stration OSHA standards including29CFR1910 178 andtheAmerican National Standards Institute ANSI B56 6 latest edition 4 Read and Understand all Decals and Warnings 5 Read and Understand the Rating Chart 6 Knowthatthemachinecansafetylifteachloadbeforeattemptingtolift These are general safety rules which must be followed You are also required to read and understand the Operator s Manual as there are ...

Page 8: ... protective clothing that is snug and belted where required 7 Store tools and other necessary items in the toolbox 8 Never lift a load without a Load Rating Chart in the cab 9 Know the load to be lifted 10 Bealert physicallyfitandfreefromtheinfluencesofalcohol drugsor medicationsthatmightaffecttheoperator seyesight hearing orreactions 11 Keep people equipment and material out of the work area 12 K...

Page 9: ...d 2 Have a supervisor at the job site to be responsible for job safety 3 Crewmembersgivenspecificsafetyresponsibilitiesandinstructedtoreportany unsafeconditionstothesupervisor 4 Supply the weight on the load to be lifted to the operator 5 VerifythatallcrewmembersarefamiliarwithOSHA ANSIB56 6requirements aswellasinstructionsinthemanuals ...

Page 10: ...chineisstationarypriortoperformingadjustmentsor lubrication 5 Replaceallshieldsandguardsafterperformingservice 6 Always use a piece of cardboard or paper to search for leaks 7 Whenperformingworkonthehydraulicsystem i Lower the boom to horizontal ii Support the boom with supports or braces iii Shutdowntheengine iv Relieveallpressurebeforedisconnectinglines v Ensureallconnectionsaretightbeforeapplyi...

Page 11: ...theenginebeforerefuelingthemachine ii Fillthefueltankoutdoors iii Handlefuelwithcare asitishighlyflammable Donotrefuel themachinewhilesmokingornearopenflames iv Alwayscleanupspilledfuel 6 Make sure the machine and access system is clean and free of dirt oil grease or debris 7 When getting on and off the machine face the machine use the steps and handrailsprovided andalwaysmaintainathreepointcontac...

Page 12: ...usethemachinetooverturn iii Verify that the load is secured on the forks before performing a lift Rearrange the load if necessary iv Beforeloweringamaximumload alwaysretracttheboom completely v Use proper attachments such as a truss boom to lift suspended loads 14 If the load to be lifted exceeds the capacity of the machine for the given configuration i Move the machine closer to the load so that ...

Page 13: ...avelwiththeattachmentdownhill iv Avoidturning travelstraightupanddown 19 Alwayspositionallwheelsinlinewiththemachinebeforeswitchingthesteering mode 20 Always position the machine and set the park brake before lifting a load 21 Do not allow riders on the machine or forks 22 Donottransportorliftpersonnelintopositionwiththisforklift 23 Whenleavingtheoperator sstation i Placethedirectionalcontrolsinne...

Page 14: ...ROUGH TERRAIN FORK LIFT SAFETY NOTES 1 12 ...

Page 15: ...SECTION 2 GENERAL SAFETY 2 1 ...

Page 16: ...TABLE OFCONTENTS SECTION 2 GENERAL SAFETY General Safety Procedures 2 3 JumpStarting 2 8 Proper Load Chart Use 2 9 2 2 ...

Page 17: ...1 Controls 2 Instruments 3 Indicator lights 4 Safety and instruction labels ACCIDENT PREVENTION Use protective clothing and safety equipment Always use approved safety equipment such as gloves safety boots safety hard hats goggles and ear protection when necessary Wear protective clothing that is snug and belted where required FIRE PREVENTION FIRST AID Install a first aid kit and fire extinguisher...

Page 18: ...el or any other controls as handrails NEVER jump on or off the machine Be careful of slippery conditions on platforms steps and handrails when getting on and off the machine ALWAYS shut off the engine before leaving the operator s station REFUELING WARNING Fires can cause death or severe personal injury Handle fuel with care It is highly flammable DO NOT refuel the machine while smoking or when ne...

Page 19: ...aulic lines be sure to relieve all line pressure Before applying pressure to the system be sure that all connections are tight DO NOT apply pressure to a damaged line hose or fitting If injured by escaping fluid see a doctor at once Proper medical treatment must be administered immediately Aserious infection or reaction can result without proper medical treatment SERVICE TIRES SAFELY An improperly...

Page 20: ...it is in motion SHUT OFF the engine and LOCKOUT the ignition while working on the machine unless maintenance instructions require the engine to be running REPLACE all the shields and guards after servicing NEVER use the machine as a platform for lifting personnel CAUTION BOOM SAFETY DO NOT enter the DANGERAREA under or around the boom when the forks are off the ground or while the engine is runnin...

Page 21: ... 500 to 750 35 10 67 Over 750 to 1000 45 13 72 Operation in Transit With No Load and Boom Lowered to 0 75 4 1 22 Over 0 75 to 50 6 1 83 Over 50 to 345 10 3 05 Over 345 to 750 16 4 87 Over 750 to 1000 20 6 10 WARNING Always remain completely inside the cab enclosure while operating the machine WARNING Never operate this machine under the influence of drugs alcohol and or medication which can cause ...

Page 22: ... another machine be certain that the machines are not touching Never jump start a frozen battery as it will explode Keep sparks and flames away from the battery Lead acid batteries generate explosive gases when charging Wear safety glasses when working near batteries The booster battery must be a 12 volt type The machine used for jump starting must have a negative ground electrical system To jump ...

Page 23: ...on The load chart shows the operating limits of a properly maintained and operated machine To use the load chart the operator must know the weight of the load and how far out and up it is to be placed If the load is heavier than stated on the load chart three options can be used 1 Move the machine closer to the load so that the weight of the load will fall within the load chart specifications 2 Di...

Page 24: ... Visible 8000 lbs B Letter Visible 6000 lbs C Letter Visible 4000 lbs D Letter Visible 2000 lbs E Letter Visible 2000 lbs PO Box 97030 18340 NE 76th St Redmond WA 98073 Manufacturer s recommended capacity is per ANSI B56 6 Stability Tests using standard homogeneous cubes 4 x 4 x 4 ft 1 2 x 1 2 x 1 2 m Load capacities at 24 in 60 cm load center with standard fork frame Rated lift capacities shown a...

Page 25: ...SECTION 3 CONTROLSAND INSTRUMENTS 3 1 ...

Page 26: ...kControlFunctions 3 4 JoystickControlFunctions ButtonPushed 3 5 Service Brakes 3 6 ParkingBrake 3 6 Frame Sway Control 3 7 Gauges 3 8 HydraulicPumpDestrokeButton 3 8 Steering 3 9 Transmission 3 9 FrontAxleDifferentialLock 3 10 FrontStabilizers 3 11 EngineElectronicControlUnit ECU 3 12 3 2 ...

Page 27: ...er 11 Plug 12 VoltAccess 19 Auxiliary Hydraulics 26 Stabilizer Switch LH 4 Steering Selector 12 Seat 20 Steering Wheel 27 Stabilizer Switch RH 5 Service Brake Pedal 13 Frame Level Switch 21 Headlight Switch 28 Switch Blink Code 6 Parking Brake Warning Light 14 Seat Belt 22 Heater Switch 29 Light Blink Code 7 Load Chart 15 Parking Brake Handle 23 Plug Turn Signal Wires 8 Hourmeter 16 Pump Off Butto...

Page 28: ...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 ...

Page 29: ...CONTROLS AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS BUTTON PUSHED 3 5 A Tilt Down B TiltBack B A ...

Page 30: ... The brakes should be applied during normal operation to stop machine movement WARNING Failure to set the parking brake before leaving the machine may result in unintended machine movement and possible injury or death and or damage to the machine or property The parking brake should be engaged anytime the operator gets off the machine To engage the parking brake move handle B to the BRAKE ON posit...

Page 31: ...ED TIRES CHLORIDE SOLUTION FILLEDTIRES RATEDLIFT CAPACITIES ARE WITH LAST FULLY VISIBLE LETTER A LETTER VISIBLE 6 000 LBS RETRACTED 8 000 LBS REAR AXLE LOCK UP ENGAGED 61 METERS LOADCENTER WITH MANUFACTURER SRECOMMENDED STABILITY TESTS USING STANDARD 1 22x1 22x1 22 METERS LOAD HOMOGENEOUS CUBES4x4x4 FT P O BOX 790 PHONE 906 353 6675 FAX906 353 7543 CAPACITIES AT 24 INCH STANDARD FORK FRAME BARAGA ...

Page 32: ... allowed to cool completely HEATER HEADLIGHT HYDRAULICS WIPER AUXILIARY LEFT STABILIZER RIGHT STABILIZER PUMP OFF BRAKE ON CONTROL SWAY The following gauges are used to monitor the machine 1 Fuel Level 2 Oil Temperature Powershift Transmission 3 Oil Pressure Powershift Transmission 4 Voltmeter 5 Water Temperature Engine 6 Oil Pressure Engine GAUGES HYDRAULIC PUMP DESTROKE BUTTON DANGER Depressing ...

Page 33: ...sion control C must be in 1st or 2nd gear only Forward 1st Low speed High torque Forward 2nd Medium speed Medium torque Forward 3rd High speed Low torque BRAKE ON SWAY CONTROL PUMP OFF HEATER HEADLIGHT LEFT STABILIZER RIGHT STABILIZER BLIN ENGINE In addition to the steering wheel the machine has another steering control the steering selector switch The steering selector switch B is a three positio...

Page 34: ... Releasing the switch disengages the axle differential lock Use this differential lock when you are unable to drive through certain types of terrain such as sand mud snow etc WARNING Always bring the front tires to a complete stop before engaging the front axle differential lock Failure to stop the front tires before engaging the front axle differential lock may result in damage to the front axle ...

Page 35: ... 10 20 SWAY CONTROL PUMP OFF HEATER HEADLIGHT LEFT STABILIZER RIGHT STABILIZER BLIN ENGINE LEFT STABILIZER RIGHT STABILIZER LEFT FRONT STABILIZER DOWN LEFT FRONT STABILIZER UP The stabilizer controls B and C are located on the dash panel The front stabilizers are used when there is a need for added machine stability when lifting or lowering a load While sitting in the operator s seat the left fron...

Page 36: ...he dash will stay lit and the engine ECU may begin a sequence of power reduction The operator is responsible for shutting down the engine to prevent further damage to the engine The engine ECU will not detect all engine problems The engine protection feature is not a substitute for routine engine maintenance Normal machinery operating procedures should be adhered to 1 22x1 22x1 22 METERS LOAD STAN...

Page 37: ... flash three times short pause flash two times long pause This example is code 32 Fault codes are reported as active codes and stored codes When a code 32 is flashed it signifies the start of flashing Active Codes when a code 33 is flashed it signifies the start of flashing Stored Codes When a code 88 is flashed there are no fault codes to report For example if an engine had no Active Faults to re...

Page 38: ...k Position Input Noise Pattern Error 42 Engine Overspeed 54 ECUPowerDownError 55 CANError 62 Engine Coolant Temperature High Least Sever 63 Engine Coolant Temperature High Moderately Severe 64 Engine Oil Pressure Moderately Low 65 Engine Oil Pressure Extremely Low 66 ManifoldAir Temperature Moderately High 68 Fuel Derate 69 Engine Coolant Temperature High Most Severe 71 Pump Control Valve Closure ...

Page 39: ...SECTION 4 OPERATION 4 1 ...

Page 40: ...TABLE OFCONTENTS SECTION 4 OPERATION OperationAndSafetyGuidelines 4 3 BeforeStartingTheEngine 4 4 StartingTheEngine 4 5 BeforeOperatingTheForklift 4 7 TransportingALoad 4 11 PlacingALoad 4 13 4 2 ...

Page 41: ...r from escaping hot pressurized coolant 8 ALWAYS wear the seat belt when operating this machine 9 ALWAYS inspect the machine daily Check for leaks worn hoses loose belts or anything out of the ordinary Repair and or replace any worn damaged or leaking parts immediately Failure to do so can cause injury or death 10 CHECK to be sure that all guards and screens are secure and in their proper place 11...

Page 42: ...t all daily maintenance items have been performed See Maintenance section Walk 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 STARTING THE ENGINE 4 4 ...

Page 43: ...44 13 42 40 36 10 98 12 20 0 4 88 4 88 12 3 66 8 16 6 10 20 4 1 22 2 44 4 88 12 3 66 16 6 10 20 HEATER HEADLIGHT LEFT STABILIZER RIGHT STABILIZER BLIN ENGINE BRAKE ON SWAY CONTROL PUMP OFF HEATER HEADLIGHT LEFT STABILIZER RIGHT STABILIZER BLIN ENGINE DANGER If the machine should start with the transmission control lever C in gear stop operation at once or property damage serious injury or death ma...

Page 44: ...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 starter motor CAUTION Attempting to start the engine by towing or pushing the machine will result in damage to the powershift transmission and will not start the engine It also is an unsafe practice that could cause personal injury 4 6 ...

Page 45: ...ted gauges for logical readings 1 Fuel 1 2 to Full 2 Transmission Oil Temp 180 F to 200 F 3 Transmission Oil PSI 240 to 280 PSI 4 Volt 12 to 14 5 EngineWaterTemp 180 F to 200 F 6 Engine Oil PSI 40 to 80 PSI Operate the joystick controller momentarily in all directions STANDARD JOYSTICK FUNCTIONS BUTTON DEPRESSED FUNCTIONS A Boom Down B Boom Up C Boom Out D Boom In E Boom Down and Out F Boom Up and...

Page 46: ...20 4 455 NORTH SUPERIOR AVENUE MACHINE ON A FIRM LEVEL SURFACE WITH UNDAMAGED PROPERLY INFLATED CALCIUM CAPACITY IS PER ANSI B56 6 LOAD LIMITS HORIZONTAL BOOM B LETTER VISIBLE 4 000 LBS OR OPTIONAL FOAMFILLED TIRES CHLORIDE SOLUTION FILLED TIRES RATED LIFTCAPACITIES ARE WITH LAST FULLY VISIBLE LETTER A LETTER VISIBLE 6 000 LBS RETRACTED 8 000 LBS REAR AXLELOCK UP ENGAGED 61 METERS LOAD CENTER WITH...

Page 47: ...th Activate the transmission using the transmission control lever D As soon as the machine starts to move apply the service brake pedal The machine should stop immediately Apply the parking brake E The machine should not be able to be driven Release the parking brake BRAKE ON SWAY CONTROL PUMP OFF HEATER HEADLIGHT LEFT STABILIZER RIGHT STABILIZER BLIN ENGINE BEFORE OPERATING THE FORKLIFT 4 9 D E ...

Page 48: ...y 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 repaired immediately Check and adjust both the interior rear view mirror B and the exterior right hand mirror C if required BEFORE OPERATING THE FORKLIFT 4 10 C B A ...

Page 49: ...e a loaded machine with the boom angle indicator arrow D at 0 degrees or less The forks should always be tilted back slightly during trans portation to ensure stability of the load TRANSPORTING A LOAD WARNING At no time should any load be suspended from the forks by use of chains ropes straps etc If a load must be suspended the use of a truss jib boom is mandatory Proper rigging procedures should ...

Page 50: ... lever A Failure to do so can result in damage to the load the machine and or bystanders Always keep the boom retracted to ensure greater stability Always place the load in the center and completely against the back of the fork frame By doing so greater stability will result IMPORTANT Never attempt to use the forks and or attach ments for prying wedged or frozen loads free Damage to the load palle...

Page 51: ...0 28 8 54 24 7 32 20 32 20 24 7 32 8 54 28 9 76 44 13 42 40 36 10 98 12 20 0 4 88 4 88 12 3 6 6 8 16 6 10 20 4 1 22 2 44 4 88 12 3 6 6 16 6 10 20 HEATER HEADLIGHT LEFT STABILIZER RIGHT STABILIZER BLIN ENGINE SWAY CONTROL WARNING Do not sway the machine with the boom angle indicator arrow B at more than 0 degrees By doing so you could cause a roll over hazard which may result in injury or death DAN...

Page 52: ...Hold the controller back until the required height has been achieved Gradually move the 4 way controller towards the letter E to bring the load DOWN and OUT into final position Lower the load until the weight is completely off the forks Gradually move the 4 way controller towards the letter F to bring the boom UP and IN This will bring the forks out of the load Once the forks are clear of the load...

Page 53: ...55 DEGREES on the GTH 1056 all frame leveling and transmission functions are disabled and the rear axle stabilizing cylinders become locked This DOES NOT affect any boom or fork functions To unlock the rear axle stabilizing cylinders and enable the transmission functions lower the boom to a position less than 60 degrees on the GTH 1048 or 55 degrees on the GTH 1056 GTH 1048 GTH 1056 0 1 2 34 55 0 ...

Page 54: ...OPERATION 4 16 NOTES ...

Page 55: ...SECTION 5 MAINTENANCE PROCEDURES 5 1 ...

Page 56: ...TABLE OF CONTENTS SECTION 5 MAINTENANCE PROCEDURES GeneralSafetyPractices 5 3 DailyMaintenance 5 5 5 2 ...

Page 57: ...gs and jewelry Move the machine to a safe level work place Lower the boom and support all raised equipment Shut down the machine Remove the key from the ignition Be careful not to spill fuels and lubricants Do not fill or refuel the fuel tank while the engine is running or hot Doing so could cause a fire and or an explosion Do not smoke while refueling or working with fuel to avoid a fire and or e...

Page 58: ...re disconnecting hydraulic lines be sure to relieve all line pressure Before applying pressure to the system be sure that all connections are tight DO NOT apply pressure to a damaged line hose or fitting If injured by escaping fluid see a doctor at once Proper medical treatment must be administered immediately A serious infection or reaction can result without proper medical treatment WELDING PREC...

Page 59: ...ures found in the service manual for this machine Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service 5 5 PERFORM ENGINE MAINTENANCE Refer to engine operator s manual Check engine oil Check coolant level Check engine fan Open water separator PERFORM TRANSMISSION MAINTENANCE Refer to the transmission operator ...

Page 60: ...o page 5 24 of this manual for the proper oil specifications and capacities 5 6 B CHECK TIRE FOR PROPER INFLATION Location Wheel ends To Check With the valve stem C positioned to the top of the tire check the tire pressure with the tire cold and a properly functioning air pressure gauge Setting 50 PSI All tires require a calcium chloride ballast or an optional foam fill to be operated safely The l...

Page 61: ...SECTION 6 MATERIAL SAFETY DATA 6 1 ...

Page 62: ...TABLE OFCONTENTS SECTION 6 MATERIAL SAFETY DATA Material Safety Data Sheets 6 3 CaliforniaProposition 65 Warnings 6 4 6 2 ...

Page 63: ...iononsubstancescontainedintheequipmentsuchas antifreeze brakefluid batteryacidandhydraulicfluid Genie will provide at no cost Material Safety Data Sheets which are applicable to their product line Simply request them from your local Genie dealer or contact us at GenieIndustries PO Box 97030 Redmond WA98073 9730 To ensure a prompt response please be sure to include your return address and zip code ...

Page 64: ... 9730 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories containleadandleadcompounds chemicals known to the State of California to cause cancer andreproductiveharm Batteriesalsocontainother...