Terex Genie GTH-1544 Operator's Manual
  1. Manuals
  2. Brands
  3. Terex Manuals
  4. Construction Equipment
  5. Genie GTH-1544
  6. Operator's manual
Terex Genie GTH-1544 Operator's Manual

Terex Genie GTH-1544 Operator's Manual

Hide thumbs Also See for Genie GTH-1544:
Table of Contents

Advertisement

Quick Links

Operator's Manual
Serial number range
GTH-1544
(Deutz Tier 4 Final)
From GTH15M-601
Original Instructions
First Edition
Third Printing
April 2019
Part No. 57.0009.0733

Advertisement

Table of Contents
loading

Related Manuals for Terex Genie GTH-1544

Summary of Contents for Terex Genie GTH-1544

  • Page 1 Operator’s Manual Serial number range GTH-1544 (Deutz Tier 4 Final) From GTH15M-601 Original Instructions First Edition Third Printing April 2019 Part No. 57.0009.0733...

  • Page 2: Table Of Contents

    Copyright © 2019 by Terex Corporation 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 GTH-1544...

  • Page 3: Introduction

    First Edition - Third Printing April 2019 Introduction About This Manual Intended Use Genie appreciates your choice of our machine for A variable reach rough terrain forklift truck is defined your application. Our number one priority is user as a wheeled type truck with a pivoting boom, which safety, which is best achieved by our joint efforts.
  • Page 4 April 2019 First Edition - Third 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: •...
  • Page 5 First Edition - Third Printing April 2019 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 April 2019 First Edition - Third Printing Introduction Hazard Classification Standards Safety alert symbol - used to Many aspects of rough terrain forklift operation and alert you to potential personal testing are discussed in standards published by injury hazards. Obey all safety the American National Standards Institute and the messages that follow this Industrial Truck Standards Development Foundation.

  • Page 7: Symbol And Hazard Pictorials Definitions

    First Edition - Third Printing April 2019 Symbol and Hazard Pictorials Definitions Electrocution Maintain required Crush hazard No people under Read the operator's Injection hazard hazard clearance load manual Use a piece of cardboard or paper to search Maintain required Crush hazard Always wear seat Tip-over hazard...

  • Page 8: General Safety

    April 2019 First Edition - Third Printing General Safety GTH-1544 Part No. 57.0009.0733...
  • Page 9 First Edition - Third Printing April 2019 General Safety Part No. 57.0009.0733 GTH-1544...

  • Page 10: Work Area Safety

    April 2019 First Edition - Third Printing Work Area Safety Do not attemp to jump free of the machine during a Tip-over Hazards tip-over. The ROPS (Roll Over Protective Structure) is designed to protect you. Using the appropriate load chart for the machine configuration, confirm If the telehandler starts to that the load is within the rated...
  • Page 11 First Edition - Third Printing April 2019 Work Area Safety Traveling on Slopes Hazards Do not raise a load unless the load is properly positioned or secured on the forks or approved attachment. When driving, keep the boom at or below horizontal and keep the Do not operate the machine in strong or gusty winds.
  • Page 12 April 2019 First Edition - Third Printing Work Area Safety Do not raise the boom unless the brake is applied. Fall Hazards Do not operate, without fenders, in conditions where Always wear a seat belt when loose debris could hit the operator or accumulate on operating the machine.
  • Page 13 First Edition - Third Printing April 2019 Work Area Safety Falling Object Hazards Bodily Injury Hazards Operate the machine at speeds that will keep the Always adjust the seat and fasten load under control. Start and stop movements the seat belt before starting the smoothly.
  • Page 14 April 2019 First Edition - Third Printing Work Area Safety Damaged Machine Hazards Component Damage Hazards Do not use any battery or charger greater than 12V Do not use a damaged or malfunctioning machine. to jump-start the engine. Conduct a thorough pre-operation inspection of the Do not use the machine as a ground for welding.
  • Page 15 First Edition - Third Printing April 2019 Work Area Safety 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...
  • Page 16 April 2019 First Edition - Third Printing Work Area Safety Do not use the machine as a ground for welding. Electrocution Hazards Always contact the electrical power line owner. The This machine is not electrically insulated and will electrical power shall be disconnected or the power not provide protection from contact with or lines moved or insulated before machine proximity to electrical current.
  • Page 17 First Edition - Third Printing April 2019 Work Area Safety Electrocution Hazard Battery Safety Burn Hazards Avoid contact with electrical terminal. Batteries contain acid. During maintenance or repair works, and while Always wear protective welding, disconnect the battery turning the cut-out clothing and eye wear when switch (see Inspection for Decals section).

  • Page 18: Legend

    April 2019 First Edition - Third Printing Legend ¢ £ £ ¡ § § ¡ ¢ © © ¤ ¦ ¨ ¨ ¡ ¡ ¦ ¢ ¥ ¡ ¥ ¡ ¡ ¤ 1. Left/right level indicator 15. Transmission control lever 2.

  • Page 19: Controls

    First Edition - Third Printing April 2019 Controls " " Control Panel 1. Steering wheel 14. Windshield wiper switch (if equipped) 2. Horn button 15. Windshield washer switch (if equipped) 3. Heater and Air conditioning controls (if equipped) 16. Road lights switch (if equipped) 4.
  • Page 20 April 2019 First Edition - Third Printing Controls Steering wheel handle back and the forks will tilt up. Hold down the grey thumb switch and push the Control Turn the steering wheel to the right to turn the handle forward and the forks will tilt down. Hold front wheels to the right.
  • Page 21 First Edition - Third Printing April 2019 Controls 18 Transmission control lever/Transmission mode Move the transmission control lever forward for forward gear. Move the lever toward you for reverse gear. Move the lever to the center position for neutral. Rotate the end of the lever to pos 1 to turn the transmission on first gear fixed;...
  • Page 22 April 2019 First Edition - Third Printing Controls & & 1230 & & & engine rpm & 000000.0 Instrument Panel 15. High engine coolant temperature gauge 16. Position light indicator light 1. Low engine oil pressure indicator light 17. Hour meter 2.
  • Page 23 First Edition - Third Printing April 2019 Controls 1 Low engine oil pressure indicator light 17 Hour meter When illuminated this light indicates that the engine The hour meter displays the engine operating hours. oil pressure is too low which can lead to machine When the machine speed exceeds 2 mph the hour damage.

  • Page 24: Inspections

    April 2019 First Edition - Third Printing Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection Do Not Operate Unless: performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator You learn and practice the principles of safe...
  • Page 25 First Edition - Third Printing April 2019 Inspections Pre-operation Inspection Be sure that the operator’s and safety manuals Boom wear pads are complete, legible and in the storage container Tires and wheels located in the cab. Mirrors and rear object detection system (if Be sure that all load charts are in place and legible.
  • Page 26 April 2019 First Edition - Third Printing Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 27 First Edition - Third Printing April 2019 Inspections Function Tests Test the Control handle 17 Start the machine with the parking brake on Select a test area that is firm, level and free of and the transmission control lever set to neutral obstruction.
  • Page 28 April 2019 First Edition - Third Printing Inspections Test the Steering Test the Transmission and Brakes 21 Rotate the steering mode selector to the right 29 Be sure the boom is fully lowered and retracted. side to select four-wheel steer. 30 Step on the brake pedal.
  • Page 29 First Edition - Third Printing April 2019 Inspections Test the Transmission mode 48 Set parking brake. Slowly sway the machine to the left and to the right. 36 Be sure the boom is retracted and in the transport position. Result: The sway function should not operate. 37 Be sure that the parking brake is on and the transmission control lever is in neutral position .
  • Page 30 April 2019 First Edition - Third Printing Inspections Test the Rear Proximity Alarm System As the machine moves away from the object, (if equipped) the display should show the green light on,and no alarm should be sounding. The system provides a visible and audible indication 56 Stop the machine, place the transmission in of objects behind the machine, when they are within neutral and turn off the engine.
  • Page 31 First Edition - Third Printing April 2019 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 You learn and practice the principles of safe unstable or slippery surfaces machine operation contained in this operator’s manual.
  • Page 32 April 2019 First Edition - Third Printing Inspections Inspection for Decals with Words Use the pictures on the next page to verify that all decals are legible and in place. Below is a numerical list with quantities and descriptions. Part No. Decal Description Part No.
  • Page 33 First Edition - Third Printing April 2019 Inspections 09.4618.1632 09.4618.2050 09.4618.1919 09.4618.1655 237601 237605 82558 09.4618.1638 09.4618.1625 09.4618.1646 09.4618.1633 97667 237598 09.4618.1631 214418 237598 237970 09.4618.1834 1263543 97667 28236 09.4618.1622 237606 1280819 1280820 load chart set 09.4618.1418 09.4618.1399 09.4618.2035 09.4618.1631 09.4618.2039 82366 09.4618.1618...

  • Page 34: Operating Instructions

    April 2019 First Edition - Third Printing Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety and responsibilities manuals. Do Not Operate Unless: A variable reach rough terrain forklift truck is defined as a wheeled type truck designated...
  • Page 35 First Edition - Third Printing April 2019 Operating Instructions Parking Brake Starting in Cold Condition Always use the parking brake switch to apply the In cold conditions, 20°F / -6°C and below, warm parking brake before raising the boom. the engine for 5 minutes before operating to prevent hydraulic system damage.
  • Page 36 April 2019 First Edition - Third Printing Operating Instructions Rear Object Detection System (if Transmission Control equipped) Use the transmission control lever to control the direction of machine travel. The RODS system is intended to only augment, not replace, the operator’s direct vision or Step on the service brake pedal before putting the indirect vision using the mirrors and to provide an transmission into gear.
  • Page 37 First Edition - Third Printing April 2019 Operating Instructions When the instrument panel shows the reset code RST 1: 1 turn the ignition switch off 2 turn the ignition swich on When the instrument panel shows the reset code RST 2: 1 bring the machine to a stop on a firm level surface and set the brake 2 set the transmission control lever to the...
  • Page 38 April 2019 First Edition - Third Printing Operating Instructions SCR Regeneration Don’t leave the machine unattended. Signpost the area. Based on the blinking combination of the "Regen. Required." label, proceed as below: xii The regeneration lasts 35 or 40 minutes on average.
  • Page 39 First Edition - Third Printing April 2019 Operating Instructions Transporting a Load Raising and Placing a Load Always center the load on the forks. Position the Always center the load on the forks. Position the load so that it is completely against the back of the load so that it is completely against the back of the fork frame.
  • Page 40 April 2019 First Edition - Third Printing Operating Instructions Placing the load Gradually move the controller to lower and extend the boom into final position. Lower the Travel to the desired work site and carefully load until the weight is completely off the forks. stop the machine.
  • Page 41 First Edition - Third Printing April 2019 Operating Instructions Control handle Control handle only Control handle only Control handle only with grey thumb switch with grey finger switch Part No. 57.0009.0733 GTH-1544...
  • Page 42 April 2019 First Edition - Third Printing Operating Instructions Rear Axle Lock Version with hydraulic locking (optional) If the boom is raised above 50°, the transmission will shift to neutral and the frame sway function will 1. Drive to the place where you will release the not operate.
  • Page 43 First Edition - Third Printing April 2019 Operating Instructions Engine Condition Indicator Jump Starting the Machine If the SCR warning light and/or the Engine Critical Jump starting at the battery or battery replacement Fault indicator light switch on, contact service is required when the battery is discharged to the personnel.
  • Page 44 April 2019 First Edition - Third Printing Operating Instructions Driving on a slope Rear Proximity Alarm When the machine is loaded, always travel with The system is designed to supplement other safety the load uphill. When the machine is unloaded, practices and systems such as signal person and travel with the forks or attachment downhill.
  • Page 45 First Edition - Third Printing April 2019 Operating Instructions Inactivity at Low Temperature In case of inactivity of the machine at low temperature, make sure to store it with the boom fully retracted in order to avoid any ice accretion on its upper surface.

  • Page 46: Transport And Lifting Instructions

    April 2019 First Edition - Third Printing Transport and Lifting Instructions Before loading for transport, make sure the deck, ramps and machine tires are free of mud, snow and ice. Failure to do so could cause the machine to slide. Be sure the vehicle capacity, loading surfaces and chains or straps are sufficient to withstand Observe and Obey:...
  • Page 47 First Edition - Third Printing April 2019 Transport and Lifting Instructions Securing to Truck or Trailer for Transit Securing the Chassis Turn the key switch to the off position and remove Use chains of ample load capacity. the key before transporting. Use a minimum of 6 chains.
  • Page 48 April 2019 First Edition - Third Printing 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 points on the machine.

  • Page 49: Maintenance

    First Edition - Third Printing April 2019 Maintenance Diesel Fuel Requirements Satisfactory engine performance is dependent on the use of a good quality fuel. The use of a good quality fuel will give the following result: long engine life and acceptable exhaust emissions Observe and Obey: levels.
  • Page 50 April 2019 First Edition - Third Printing Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential Visually inspect the DEF indicator light on the to good engine performance and service life. dashboard. Operating the machine with an improper oil level Result: Light flashing indicates DEF level is low.
  • Page 51 First Edition - Third Printing April 2019 Maintenance Check the Engine Coolant Level - Check the Tire Pressure Liquid Cooled Models Tip-over hazard. An over-inflated tire can explode which may compromise machine Maintaining the engine coolant at the proper level stability and cause the machine to tip over.
  • Page 52 April 2019 First Edition - Third Printing Maintenance Check the Battery Drain the Fuel/Water Separator Proper battery condition is essential to good Proper maintenance of the fuel filter/water machine performance and operational safety. separator is essential for good engine Improper fluid levels or damaged cables and performance.

  • Page 53: Attachments

    First Edition - Third Printing April 2019 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 54 April 2019 First Edition - Third 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 unless approved by Genie. Do not place ladders or Be certain that materials and tools are protected scaffolds in the platform or from falling out of the platform.
  • Page 55 First Edition - Third Printing April 2019 Attachments Telehandler Operation Lifting Personnel Be certain that the platform is securely attached to Occupants, equipment and GTH-1544 the telehandler, lifting carriage and forks. materials shall not exceed the maximum platform capacity. Be certain that the lifting carriage and forks are Distribute loads evenly on the secured to prevent them from pivoting freely.
  • Page 56 April 2019 First Edition - Third 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, Do not use the controls to free a platform that is state, federal and provincial rules, standards caught, snagged or otherwise prevented from...
  • Page 57 First Edition - Third Printing April 2019 Attachments Installing and securing the platform Lifting and lowering the platform Center the platform on the telehandler. Set the parking brake and place the transmission into neutral. Properly secure the platform to the telehandler according to the manufacturer’s instructions.
  • Page 58 April 2019 First Edition - Third Printing Attachments Overturning Hazards Suspended Load Hazards Work Area Safety Do not lift a suspended load without the proper and legible load capacity chart for the attachment/ General Safety telehandler combination you are using. Do not permit Do not lift a suspended load without first the load to swing...
  • Page 59 First Edition - Third Printing April 2019 Attachments All movements of the load must be accomplished Fall Hazards gradually and at the slowest practical speed to Do not lift or suspend personnel. prevent the load from swinging. Keep the heavy part of the load closest to the Collision Hazards attachment.
  • Page 60 April 2019 First Edition - Third Printing Attachments Lifting a Suspended Load Travelling 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 61 First Edition - Third Printing April 2019 Attachments Placing the Load Signal Person (from 1926.1419) Ask a signal person to assist with placing the Per OSHA CFR 1926.1419, a signal person is load if visibility will be obstructed at the point of required when: operation.
  • Page 62 April 2019 First Edition - Third 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 63 First Edition - Third Printing April 2019 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 64: Specifications

    April 2019 First Edition - Third Printing Specifications GTH-1544 Height, stowed 8 ft 7 in 2.62 m Length, stowed, without 20 ft 4 in 6.20 m forks Width, standard tires 7 ft 11 in 2.41 m Wheelbase 11 ft 6 in 3.51 m Ground clearance, center 1 ft 3 in...
  • Page 65 First Edition - Third Printing April 2019 Specifications Rear proximity Sensor Range Approximate detection range. Minimum rear proximity sensor detection height is 2 ft / 0.6 m. Part No. 57.0009.0733 GTH-1544...

  • Page 66: Load Charts

    April 2019 First Edition - Third Printing Load Charts Load Capacity Field Calculations To calculate the new reduced load capacity at a load center greater than the standard 24 in / 61 cm load center, multiply the zone capacity from Always center the load on the forks.
  • Page 67 First Edition - Third Printing April 2019 Load Charts GTH-1544, Standard Carriage GTH-1544, Rotating Carriage Part No. 57.0009.0733 GTH-1544...
  • Page 68 April 2019 First Edition - Third Printing Load Charts GTH-1544, 7 ft Truss Boom GTH-1544, Rubbish Bucket GTH-1544 Part No. 57.0009.0733...
  • Page 69 First Edition - Third Printing April 2019 Load Charts GTH-1544, Shackle Part No. 57.0009.0733 GTH-1544...
  • Page 70 California Proposition 65 WARNING Operating, servicing and maintaining this equipment, passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.

Table of Contents