Terex Genie GTH-1544 Manuale utente

Operator’s Manual

Original Instructions

First Edition

Third Printing

April 2019

Part No. 57.0009.0733

Serial number range

GTH-1544 (Deutz Tier 4 Final)

From GTH15M-601

Contents

Introduction .......................................................... 1

Symbol and Hazard Pictorials Definitions............ 5

General Safety..................................................... 6

Work Area Safety ................................................. 8

Legend............................................................... 16

Controls ............................................................. 17

Inspections ........................................................ 22

Operating Instructions ....................................... 32

Transport and Lifting Instructions ...................... 44

Maintenance ...................................................... 47

Attachments....................................................... 51

Specifications .................................................... 62

Load Charts ....................................................... 64

First Edition: Third Printing, April 2019

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

SouthDakota, Inc.

Complies with ANSI/ITSDF B56.6, CSA B335

April 2019

GTH-1544 Part No. 57.0009.0733

First Edition - Third Printing

April 2019First Edition - Third Printing

Part No. 57.0009.0733 GTH-1544 1

Introduction

About This Manual

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.

This book is an operation and daily maintenance

manual for the user or operator of a Genie machine.

This manual,along with the AEM Rough Terrain Forklift

Safety Manual and the CCTV operator's manual (if

equipped), should be considered a permanent part of

your machine and should remain with the machine at

all times. If you have any questions, contact Genie.

Product Identification

The machine serial number is located on the serial

label.

Intended Use

A variable reach rough terrain forklift truck is defined

as a wheeled type truck with a pivoting boom, which

may be equipped with various attachments for picking,

transporting and placing loads with the established

load range charts.

Use of this product in any other way is prohibited

and contrary to its intended

use.

Bulletin Distribution and

Compliance

Safety of product users is of paramount importance

to Genie. Various bulletins are used by Genie

to communicate important safety and product

information to dealers and machine owners.

The information contained in the bulletins is tied to

specific machines using the machine model and

serial number.

Distribution of bulletins is based on the most current

owner on record along with their associated dealer,

so it is important to register your machine and keep

your contact information up to date.

To ensure safety of personnel and the reliable

continued operation of your machine, be sure to

comply with the action indicated in a respective

bulletin.

Serial number

stamp

Serial label

(located inside

chassis)

Serial label

(located inside

fork frame)

April 2019

2 GTH-1544 Part No. 57.0009.0733

First Edition - Third Printing

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 safety

• Standards and regulatory compliance

information

• Questions regarding Product Modifications

• Current owner updates, such as changes

in machine ownership or changes in

your contact information. See Transfer of

Ownership, below.

Transfer of Machine Ownership

Taking a few minutes to update owner information

will ensure that you receive important safety,

maintenance and operating information that applies

to your machine.

Please register your machine by visiting us on the

web at www.genielift.com or by calling us toll free

at 1-800-536-1800.

Introduction

April 2019First Edition - Third Printing

Part No. 57.0009.0733 GTH-1544 3

Introduction

Danger

Failure to obey the instructions and

safety rules in this manual will result

in death or serious injury.

Do Not Operate Unless:

R You learn and practice the principles of safe

machine operation contained in this operator’s

manual.

1. Avoid hazardous situations.

Know and understand the safety rules

before going on to the next section.

2. Always perform a pre-operation inspection.

3. Always perform function tests prior to use.

4. Inspect the workplace.

5. Only use the machine as it was intended.

R You read, understand and obey the manufacturer’s

instructions and the safety rules, the safety and

operator’s manuals, and the decals applied on

the machine.

R You read, understand and obey the employer’s

safety rules and worksite regulations.

R You read, understand and obey all applicable

governmental regulations.

R You are properly trained to safely operate the

machine.

April 2019

4 GTH-1544 Part No. 57.0009.0733

First Edition - Third Printing

Hazard Classification

Safety alert symbol - used to

alert you to potential personal

injury hazards. Obey all safety

messages that follow this

symbol to avoid possible injury

or death

DANGER

Indicates a hazardous situation

which, if not avoided, will result

in death or serious injury.

WARNING

Indicates a hazardous situation

which, if not avoided, could result

in death or serious injury.

CAUTION

Indicates a hazardous situation

which, if not avoided, could result

in minor or moderate injury.

NOTICE

Indicates a property damage

message.

Introduction

Standards

Many aspects of rough terrain forklift operation and

testing are discussed in standards published by

the American National Standards Institute and the

Industrial Truck Standards Development Foundation.

These standards are updated on a regular basis with

addenda. It is recommended that you purchase and

refer to the following standards.

ANSI/ITSDF B56.6 - Rough Terrain Forklift Trucks

The ANSI standard can be downloaded from

www.ITSDF.org

CSA B335 - Safety Standard for Lift Trucks

The CSA standard can be downloaded from

www.csa.ca

Safety Sign Maintenance

Replace any missing or damaged safety signs.

Keep operator safety in mind at all times. Use mild

soap and water to clean safety signs. Do not use

solvent-based cleaners because they may damage

the safety sign material.

April 2019First Edition - Third Printing

Part No. 57.0009.0733 GTH-1544 5

Symbol and Hazard Pictorials Definitions

Maintain required

clearance

Read the operator's

manual

Burn HazardExplosion/burn

hazard

No smoking

No open flame

Allow surfaces to

cool

Crush Hazard Keep clear of

moving parts

Access by

trained and

authorized

personnel only

Electrocution

hazard

Refer to load

charts and manual

Tip-over hazardAlways wear seat

belt

Keep load low

during travel

Crush hazard

Only use an

approved work

platform

Crush hazard Keep away from

moving parts

Burn hazard Do not loosen cap

until cool

Keep away from

moving parts

Explosion hazard

o

2

N

2

Use nitrogen.

Not use oxygen

No people under

load

Injection hazard

Use a piece of

cardboard or

paper to search

for leaks

Maintain required

clearance

Crush hazard

Tip-over hazard

Explosion/burn

hazard

Fall hazard

Do not level the

machine with an

elevated boom

No smoking. No

open flame

Do not operate

machine unless

area around

machine is clear

of people and

obstructions

April 2019

6 GTH-1544 Part No. 57.0009.0733

First Edition - Third Printing

General Safety

237605

DANGER

237601

WARNING

97667

WARNING

237598

WARNING

237970

82558

82558 B

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. Do not use

hand.

Fluid injected into skin must be

surgically removed within a few hours

by a doctor familiar with this type of

injury or gangrene will result.

WARNING

97667

215268

237601

214418

1263543

97667

214418

82558

237598

237970

237605

WARNING

215268

1263543

Improper operation or maintenance of

this equipment can result in death or

serious injury.

Access by trained and

authorized personnel only.

1263543

A

April 2019First Edition - Third Printing

Part No. 57.0009.0733 GTH-1544 7

General Safety

09.4618.1622

214418

237598

237970

237971

09.4618.1635

09.4618.1622

o

DANGER

2

N

2

09.4618.1635

28236

DANGER

237971

WARNING

DANGER

214418

28236

April 2019

8 GTH-1544 Part No. 57.0009.0733

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Work Area Safety

Tip-over Hazards

Using the appropriate load chart for

the machine configuration, confirm

that the load is within the rated

capacity of the machine.

Do not exceed the rated load.

The load center of the fork (if equipped) must be

equal to or less than the load center indicated on

the load chart. If the load center is further from the

fork face than shown on the load chart, refer to the

Load Chart section on this manual.

All loads shown on the load chart are based on

the machine being on firm level ground, the frame

being level, the forks being positioned evenly on the

carriage, the load being centered on the forks, the

tires being properly sized and properly inflated, and

the telehandler being in good operating condition.

If using accessories, read, understand and obey the

decals, instructions and manuals with the accessory.

Do not raise the load unless the ground can support

all forces imposed by the machine.

Do not lower a load without retracting the boom first.

Do not use attachments wich are not approved by

Genie.

Do not operate the machine if the load chart is missing.

Do not exceed the rated capacity for each

configuration.

Do not attemp to jump free of the machine during a

tip-over. The ROPS (Roll Over Protective Structure)

is designed to protect you.

If the telehandler starts to

tip over:

- do not jump

- Brace yourself and stay

in the seat

- Keep your seatbelt

fastened

- Hold on firmly

- Lean away from the point

of impact

- Keep head, arms, hands,

legs and all other body

parts inside the operator's

cab at all times.

Do not raise the boom unless the

machine is level. The machine level

indicator should be at zero degrees.

Do not level the machine using the frame sway

control unless the boom angle indicator is at zero

degrees or less.

Do not use the sway control to position

an elevated load.

Do not raise a load and then drive to position it.

When driving, keep the boom at

or below horizontal and keep the

load close to the ground.

Operate the machine at speeds that will keep the

load under control. Start and stop movements

smoothly.

April 2019First Edition - Third Printing

Part No. 57.0009.0733 GTH-1544 9

Do not raise a load unless the load

is properly positioned or secured on

the forks or approved attachment.

Do not operate the machine in strong or gusty winds.

Do not increase the surface area of the carriage or

load. Increasing the area exposed to the wind will

decrease machine stability.

Use extreme care and slow speeds while driving the

machine in the travel position across uneven terrain,

steep grades, debris, unstable or slippery surfaces

and near holes and drop-offs.

Do not alter or disable machine components that in

any way affect safety and stability.

Do not replace items critical to machine stability with

items of different weight or specification.

Do not replace factory-installed tires with tires of

different specification or ply rating, unless approved

by the factory.

If using accessories, read, understand and obey the

decals, instructions and manuals with the accessory.

Traveling on Slopes Hazards

When driving, keep the boom at

or below horizontal and keep the

load close to the ground.

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 a hill, and

always keep the machine in gear. Do not turn across

the slope when the machine is traveling up or down

a slope.

Limit travel path and speed according to the condition

of the ground surface, traction, slope, location of

personnel and any other factors which may create

a hazard. Never drive the machine unless the mast

and equipment are in their proper travel position.

Whether a machine will tip over during dynamic

machine operation involves many factors that need

to be considered. Among these are pavement/ground

conditions, stability and slope, as well as machine

equipment, operator skill, load position, tire inflation,

machine speed, etc.

Additionally, tip-over of a machine is dependent in

large part upon operator inputs such as the speed

and smoothness of the operation, as well as the

position of the attachment and its load.

Construction sites and roads will frequently change

slope from place to place, can be hard and soft,

and change due to construction activities and

weather.

Operators should be properly trained and use their

best judgment and experience to take the

necessary precautions to prevent a tip-over.

Operators must assess the job site variables and

avoid exceeding the machine's (or operator's)

capabilities for terrain and conditions.

Work Area Safety

April 2019

10 GTH-1544 Part No. 57.0009.0733

First Edition - Third Printing

Fall Hazards

Always wear a seat belt when

operating the machine.

Always remain completely inside the cab when

operating the machine.

When getting in and out of the cab, face the machine,

use the steps and handrails provided and always

maintain three-point contact.

Do not use the steering wheel or any other controls

as handrails.

Do not allow riders on the machine

or forks.

Do not lift personnel with this

machine unless it is equipped with

an approved work platform. See

Work Platform section.

Collision Hazards

Keep people, equipment and

material out of the work area.

Do not operate the machine

while people are under or near

an elevated boom, whether it is

loaded or unloaded.

Do not put the transmission into gear unless the

brake is applied and personnel and bystanders are

clear of the machine and load.

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.

Use prearranged hand signals to communicate.

Do not raise the boom unless the brake is applied.

Do not operate, without fenders, in conditions where

loose debris could hit the operator or accumulate on

the cab windows.

Do not operate the machine with a faulty back-up

alarm. The back-up alarm should sound when the

machine is in reverse.

Do not operate the machine in low light conditions.

An optional work and road light package is available.

Operators must comply with employer, job site

and governmental rules regarding use of personal

protective equipment.

Do not drive the machine directly up to anyone.

Always make sure that mirrors and cab glass are

clean and do not obstruct the operators view of the

travel path or load.

Scan the area prior to operating the machine. Look

in the direction of travel. Use mirrors to assist in

checking all around the machine.

Keep windows and mirrors clean, adjusted and in

good repair.

Be aware of the machine load swing area.

Do not rely on the rear proximity alarm system

to determine if personnel or objects are behind

the machine. The system has limitations due to

maintenance practices, the size or shape of the

object, composition, environmental conditions and

operating range. This system is set up for detection

at a reverse speed of a maximum of 3 feet per second

/ 0.9 meters per second (walking pace). Refer to the

detection zone chart in the back of this manual.

Work Area Safety

April 2019First Edition - Third Printing

Part No. 57.0009.0733 GTH-1544 11

Work Area Safety

Falling Object Hazards

Operate the machine at speeds that will keep the

load under control. Start and stop movements

smoothly.

Keep people, equipment and

material out of the work area.

Do not operate the machine

while people are under or near

an elevated boom, whether it is

loaded or unloaded.

Be sure the load is secure before lifting it. Always

make sure the quick attach pin is inserted and secured.

Bodily Injury Hazards

Always adjust the seat and fasten

the seat belt before starting the

engine.

Do not operate the machine with a

hydraulic oil or air leak.

An air leak or hydraulic leak can

penetrate and/or burn skin.

Relieve pressure before

disconnecting hydraulic lines.

Keep away from leaks and pin

holes. Use a piece of cardboard or

paper to search for leaks. Do not

use your hand.

Fluid injected into skin must be surgically removed

within a few hours by a doctor familiar with this type

of injury or gangrene will result.

Stay clear of belts and fans when the

engine is running.

Always operate the machine in a well-ventilated

area to avoid carbon monoxide poisoning.

Improper contact with components under any cover

will cause serious injury. Only trained maintenance

personnel should access compartments. Access by

the operator is only advised when performing a pre-

operation inspection. All compartments must remain

closed and secured during operation.

Keep body parts, such as hand, fingers annd arms,

away from moving components.

Always use provided latches and handles for opening

and closing doors and covers.

April 2019

12 GTH-1544 Part No. 57.0009.0733

First Edition - Third Printing

Damaged Machine Hazards

Do not use a damaged or malfunctioning machine.

Conduct a thorough pre-operation inspection of the

machine and test all functions before each work shift.

Immediately tag and remove from service a damaged

or malfunctioning machine.

Be sure all maintenance has been performed as

specified in this manual and the appropriate Genie

service manual.

Be sure all decals are in place and legible.

Be sure the operator's and safety manuals are

complete, legible and in the storage container located

in the cab.

Do not attempt to start the machine by towing or

pushing.

Do not attempt to use the forks or attachments for

prying wedged or frozen loads free.

Do not push or pull objects or loads with the forks,

attachment or boom.

Do not exceed 20 mph travelling speed when driving

downhill.

If engine display lights or engine condition indicator

lights are on, see the operating Instructions section.

Continued use when engine lights are on could result

in reduced torque and engine speed.

Component Damage Hazards

Do not use any battery or charger greater than 12V

to jump-start the engine.

Do not use the machine as a ground for welding.

Do not operate the machine when the SCR (selective

catalytic reduction) regeneration operation is running.

See Operating Instructions section.

Diesel exhaust fluid (DEF) is corrosive to metal

and paint. If DEF is spilled, it should be cleaned up

immediately with warm water.

Do not use high pressure water on the air filter grid.

Crush Hazards

Keep clear of moving parts during machine operation

and make sure personnel and bystanders are kept

clear of moving parts during operation.

Set the parking brake, put the transmission in neutral

and lower the carriage or the attachment to the ground

before leaving the machine.

Keep clear of elevated components.

Support components before performing service.

Burn Hazards

Allow hot surfaces to cool before

touching or servicing

Work Area Safety

April 2019First Edition - Third Printing

Part No. 57.0009.0733 GTH-1544 13

Explosion and Fire Hazards

Do not start the engine if you smell or detect liquid

petroleum gas (LPG), gasoline, diesel fuel or other

explosive substances.

Do not refuel the machine with the engine running.

Refuel the machine and charge

the battery only in an open,

well-ventilated area away from

sparks, flames and lighted

tobacco.

Do not operate the machine in hazardous locations

or locations where potentially flammable or explosive

gases or particles may be present.

Do not spray ether into engines equipped with glow

plugs or air intake grid heaters.

Do not use air or oxygen for charging the accumulators.

Work Area Safety

April 2019

14 GTH-1544 Part No. 57.0009.0733

First Edition - Third Printing

Electrocution Hazards

This machine is not electrically insulated and will

not provide protection from contact with or

proximity to electrical current.

Obey all local and governmental

regulations regarding required

clearance from electrical power

lines. At a minimum, the

required clearance contained in

the chart below must be

followed.

Line Voltage Required Clearance

0 to 50kV 10 ft 3.05 m

>50 to 200kV 15 ft 4.60 m

>200 to 350kV 20 ft 6.10 m

>350 to 500kV 25 ft 7.62 m

>500 to 750kV 35 ft 10.67 m

>750 to 1000kV 45 ft 13.72 m

over 1000kV see below

For power lines over 1000kV, the minimum

clearance distance must be established by the

utility owner or operator or by a registered

professional engineer who is a qualified person

with respect to electrical power transmission and

distribution.

Do not use the machine as a ground for welding.

Always contact the electrical power line owner. The

electrical power shall be disconnected or the power

lines moved or insulated before machine

operations begin.

Allow for boom and attachment movement, electrical

line sway or sag, and beware of strong or gusty winds.

Keep away from the machine if it contacts

energized power lines. Personnel on the ground or

in the platform must not touch or operate the

machine until energized power lines are shut off.

Do not operate the machine during lightning or

storms.

Work Area Safety

April 2019First Edition - Third Printing

Part No. 57.0009.0733 GTH-1544 15

Battery Safety

Burn Hazards

Batteries contain acid.

Always wear protective

clothing and eye wear when

working with batteries.

Avoid spilling or contacting

battery acid. Neutralize

battery acid spills with baking

soda and water.

Explosion Hazards

Keep sparks, flames and

lighted tobacco away from

batteries. Batteries emit

explosive gas.

Electrocution Hazard

Avoid contact with electrical terminal.

During maintenance or repair works, and while

welding, disconnect the battery turning the cut-out

switch (see Inspection for Decals section).

After turning off the engine, wait for 120 seconds

before activate the cut-out switch.

Employer's Responsibilities

Employers are responsible for providing a safe

work environment and for complying with local and

national governmental regulations.

Personal Safety

Be sure that everyone working on or near this machine

is familiar with the applicable safety precautions.

Work Area Safety

April 2019

16 GTH-1544 Part No. 57.0009.0733

First Edition - Third Printing

Legend

1. Left/right level indicator

2. Steering wheel

3. Control handle

4. Rear convex mirror

5. Boom angle indicator

6. Boom

7. Cab

8. Hydraulic oil level gauge

9. Engine (on opposite side of machine)

10. Forks

11. Seat belt

12. Seat

13. Brake pedal

14. Accelerator pedal

15. Transmission control lever

16. Load charts

17. Front/rear level indicator

18. Right rear view mirror

19. Left rear view mirror

20. Fire extinguisher (if equipped)

21. Operator’s manual location

(canopy version)

22. Operator’s manual location

(closed cab version)

23. Rear proximity display and alarm

(if equipped)

24. Rear proximity alarm sensor

(if equipped)

April 2019First Edition - Third Printing

Part No. 57.0009.0733 GTH-1544 17

Controls

Control Panel

1. Steering wheel

2. Horn button

3. Heater and Air conditioning controls (if equipped)

4. Turn signal lever/Hazard warning lights (if

equipped)

5. Steer select switch

6. Parking brake switch

7. Ignition switch

8. Instrument panel

9. Control handle

10. Auxiliary hydraulics switch

11. Diagnostic button

12. Accelerator pedal

13. Brake pedal

14. Windshield wiper switch (if equipped)

15. Windshield washer switch (if equipped)

16. Road lights switch (if equipped)

17. Work light switch (if equipped)

18. Transmission control lever/Transmission mode

19. Lock/unlock enabling switch (if equipped)

20. A/C switch (if equipped)

21. Cab heater fan switch (if equipped)

22. SCR switch

23. Steering column tilt adjustment lock

24. Not active

25. Rear Object Detection System (if equipped)

26. Diagnostic button

P

April 2019

18 GTH-1544 Part No. 57.0009.0733

First Edition - Third Printing

Controls

1 Steering wheel

Turn the steering wheel to the right to turn the

front wheels to the right. Turn the steering wheel

to the left to turn the front wheels to the left.

2 Horn button

Press this button and the horn will sound. Release

the button and the horn will stop.

3 Heater and air conditioning controls (if equipped)

4 Turn signal lever/Hazard warning lights (if

equipped)

Move the lever forward to activate the left turn

signal. Move the lever backward to activate the

right turn signal.

Rotate the end of the lever backward to activate

the hazard warning lights. Rotate the end of the

lever forward to deactivate the hazard warning

lights.

5 Steering mode selector

Rotate the steer selector to the right side to select

four-wheel steer. Rotate the steer selector to the

middle position to select two-wheel steer. Rotate

the steer selector to the left to select crab steer.

6 Parking brake switch

Push the bottom of the rocker switch to turn the

parking brake on. Push the top of the switch to

turn the parking brake off.

7 Ignition switch

Turn the key until the engine starts; when

released, key springs back to pos. I automatically.

Position P is not active.

8 Instrument panel

9 Control handle

Pull the Control handle back and the boom will

raise. Push the Control handle forward and the

boom will lower. Push the Control handle to the

right and the boom will extend. Pull the Control

handle to the left and the boom will retract. Hold

down the grey thumb switch and pull the Control

handle back and the forks will tilt up. Hold down

the grey thumb switch and push the Control

handle forward and the forks will tilt down. Hold

the grey finger switch and push the Control

handle to the right and the machine will sway

to the right. Hold the grey finger switch and pull

the Control handle to the left and the machine

sway to the left.

10 Auxiliary hydraulics switch

Push the left side of the auxiliary hydraulics button

and the carriage will swing or rotate to the left.

Push the right side of the auxiliary hydraulics

button and the carriage will swing or rotate to

the right.

Push and Hold the Lock/unlock enabling switch 19

and push the left side of the auxiliary hydraulics

button to lock the attachment; Push and Hold

the Lock/unlock enabling switch 19 and push

the right side of the auxiliary hydraulics button

to unlock the attachment.

11 Diagnostic button

Push the button to scroll the LCD screen menu.

12 Accelerator pedal

13 Brake pedal

14 Windshield wiper switch (if equipped)

Push the switch to turn the wiper on: first position

for low speed and second position for high speed.

Push the top of the switch to turn the wiper off.

15 Windshield washer switch (if equipped)

Push and hold the switch to turn the washer on.

Release the switch to turn the washer off.

16 Road lights switch (if equipped)

Push the bottom of the switch to turn the road

lights on. Push the top of the switch to turn it off.

17 Work light switch (if equipped)

Push the bottom of the switch to turn the boom

working light on. Push the top of the switch to

turn it off.

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