Terex Genie GTH-844 Operator's Manual
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Terex Genie GTH-844 Operator's Manual

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Operator's Manual
GTH-844
with
Maintenance
Information
Third Edition
Sixth Printing
Part No. 237108

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Summary of Contents for Terex Genie GTH-844

  • Page 1 Operator's Manual GTH-844 with Maintenance Information Third Edition Sixth Printing Part No. 237108...

  • Page 2: Table Of Contents

    Load Charts ............64 Copyright © 2012 by Terex Corporation Third Edition: Sixth Printing, January 2015 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 • Sixth Printing Operator's Manual Introduction Introduction About this manual Intended Use Genie appreciates your choice of our machine for A variable reach rough terrain forklift truck is your application. Our number one priority is user defined as a wheeled type truck with a pivoting safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Third Edition • Sixth 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: Danger Accident reporting...
  • Page 5 Third Edition • Sixth Printing Operator's Manual Introduction Hazard Classification Standards Many aspects of rough terrain forklift operation and Decals on this machine use symbols, color coding testing are discussed in standards published by and signal words to identify the following: the American National Standards Institute and the Industrial Truck Standards Development Safety alert symbol—used to alert...
  • Page 6 Operator's Manual Third Edition • Sixth Printing Introduction 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.

  • Page 7: Symbol And Hazard Pictorials Definitions

    Third Edition • Sixth Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Electrocution hazard Maintain required Crush hazard No people under load Read the operator’s clearance manual Injection hazard Use a piece of Maintain required Crush hazard Always wear seat cardboard or paper...
  • Page 8 Operator's Manual Third Edition • Sixth Printing Symbol and Hazard Pictorials Definitions Explosion / Burn No smoking. No Keep load low Fall hazard Only use an hazard open flame. approved work platform Refer to load charts Sway operation and manual. GTH-844 Part No.

  • Page 9: General Safety

    Third Edition • Sixth Printing Operator's Manual General Safety General Safety 214418 214419 214418 237599 215268 237970 82558 214419 237599 97602 237601 237605 82558 215268 237598 214418 237598 237970 237598 214418 97667 237971 97667 237605 28175 237601 28175 1262614 97602 1262614 237971 237970...
  • Page 10 Operator's Manual Third Edition • Sixth Printing General Safety 215646 215647 215644 215648 237721 215646 215647 133031 237721 237726 237722 82560 215648 237720 215646 237720 215644 237720 237726 215646 133031 82473 237722 82473 82560 215645 1262615 1262615 237720 215645 215644 GTH-844 Part No.

  • Page 11: Work Area Safety

    Third Edition • Sixth Printing Operator's Manual Work Area Safety Work Area Safety Overturning Hazards Do not attempt to jump free of the machine during a tip-over. The ROPS (Roll Over Protective Using the appropriate load chart Structure) is designed to protect you. for the machine configuration, If the telehandler starts confirm that the load is within...
  • Page 12 Operator's Manual Third Edition • Sixth Printing Work Area Safety Traveling on Slopes Hazards Do not raise a load and then drive to position it. When driving, keep the boom When driving, keep the boom at at or below horizontal and keep or below horizontal and keep the the load close to the ground.
  • Page 13 Third Edition • Sixth Printing Operator's Manual Work Area Safety Fall Hazards Collision Hazards Always wear a seat belt when Keep people, equipment and operating the machine. material out of the work area. Do not operate the machine while people are under or near an elevated boom, whether it is Always remain completely inside the cab when loaded or unloaded.
  • Page 14 Operator's Manual Third Edition • Sixth Printing 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 15 Third Edition • Sixth Printing Operator's Manual 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 work Do not use the machine as a ground for welding.
  • Page 16 Operator's Manual Third Edition • Sixth Printing Work Area Safety Crush Hazards Burn Hazards Keep clear of moving parts during machine Allow hot surfaces to cool before operation and make sure personnel and touching or servicing. bystanders are kept clear of moving parts during operation.
  • Page 17 Third Edition • Sixth Printing Operator's Manual Work Area Safety Electrocution Hazards 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 18 Operator's Manual Third Edition • Sixth Printing Work Area Safety Battery Safety Employer's Responsibilities Employers are responsible for providing a safe Burn Hazards work environment and for complying with local and national governmental regulations. Batteries contain acid. Always wear protective clothing and eye wear when working with batteries.

  • Page 19: Legend

    Third Edition • Sixth Printing Operator's Manual Legend Legend Interior rear view mirror 10 Engine (on opposite side of machine) Left to right level indicator 11 Fuse panel Steering wheel 12 Forks Control handle 13 Exterior rear view mirror Front to rear level indicator 14 Seat belt Boom angle indicator 15 Seat...

  • Page 20: Controls

    Operator's Manual Third Edition • Sixth Printing Controls Controls Control Panel Steering wheel 12 Accelerator pedal Horn button 13 Brake pedal Heater and air conditioning controls (if equipped) 14 Tilt steering pedal Turn signal lever (if equipped) 15 Axle differential lock pedal 12V power port, 10A maximum 16 Windshield washer/wiper switch (if equipped) Steer select switch...
  • Page 21 Third Edition • Sixth Printing Operator's Manual Controls Steering wheel Ignition switch Turn the steering wheel to the right to turn the Turn the key to the left to turn on the front wheels to the right. Turn the steering accessories.
  • Page 22 Operator's Manual Third Edition • Sixth Printing Controls 13 Brake pedal 18 Lights switch (if equipped) 14 Tilt steering pedal Push the right side of the rocker switch to turn the road lights or the work lights on. Push the Push and hold the tilt steering pedal to release left side of the rocker switch to turn the road the steering column.
  • Page 23 Third Edition • Sixth Printing Operator's Manual Controls RPM x100 Instrument Panel Fuel level gauge with low fuel indicator light 14 Four-wheel steer indicator light Turn signal indicator lights 15 Two-wheel steer indicator light Tachometer 16 Crab steer indicator light Lights indicator light 17 Brake pressure low indicator light Engine coolant temperature gauge...

  • Page 24: Inspections

    Operator's Manual Third Edition • Sixth Printing Inspections Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 25 Third Edition • Sixth Printing Operator's Manual Inspections  Limit switches Pre-operation Inspection  Steer and axle sensors  Be sure that the operator’s and safety manuals  Lights, alarms and beacons (if equipped) are complete, legible and in the storage ...
  • Page 26 Operator's Manual Third Edition • Sixth Printing Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 27 Third Edition • Sixth Printing Operator's Manual Inspections Function Tests Test the Dual Control Handles (if Select a test area that is firm, level and free of equipped) obstruction. Be sure there is no load on the 11 Using the boom control handle, momentarily forks or attachment.
  • Page 28 Operator's Manual Third Edition • Sixth Printing Inspections 20 Push the left side of the steer selector switch Test the Steering to select crab steer. The crab steer indicator light on the instrument panel will be on. 14 Push the right side of the steer selector switch to select four-wheel steer.
  • Page 29 Third Edition • Sixth Printing Operator's Manual Inspections 26 Move the transmission control lever to neutral. Test the Lights (if equipped) 27 Push the top of the parking brake switch. 35 Verify that all lights are functional. Result: The red parking brake indicator light should come on, indicating the parking brake Test the 2-speed Transmission (if is on.
  • Page 30 Operator's Manual Third Edition • Sixth Printing Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 31 Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description 219703 Cosmetic – Genie GTH-844, Small Determine whether the decals on your machine 219626 Label – Genie Logo have words or symbols. Use the appropriate inspection to verify that all decals are legible and in 220271 Label –...
  • Page 32 Operator's Manual Third Edition • Sixth Printing Inspections 133206 1253091 load chart set 214418 214419 215652 237606 114090 822590 215384 114115 237600 216208 237599 236083 97602 237605 237601 82558 215268 237598 214418 237598 219703 237970 1257994 214418 97667 28175 236083 82366 Serial Label 220271...
  • Page 33 Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols 219703 Cosmetic – Genie GTH-844, Small 220271 Label – Boom Lettering Determine whether the decals on your machine 236083 Cosmetic – Genie GTH-844 have words or symbols. Use the appropriate 237606 Label –...
  • Page 34 Operator's Manual Third Edition • Sixth Printing Inspections 1253091 load chart set 215646 133206 215647 215652 114090 237606 822590 1253091 A 1253091 A 114115 237721 236083 237726 237722 82560 215648 237720 215646 237720 219703 215644 215646 1257994 133031 82473 236083 Serial Label 220271 237720...

  • Page 35: Operating Instructions

    Third Edition • Sixth Printing Operator's Manual Operating Instructions Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety and responsibilities manuals.
  • Page 36 Operator's Manual Third Edition • Sixth Printing Operating Instructions Parking Brake Steer Select Use the parking brake switch to apply the parking Always position all wheels in line with the machine brake before raising the boom or leaving the before switching the steering mode. machine.
  • Page 37 Third Edition • Sixth Printing Operator's Manual Operating Instructions Transmission Control Models with 3-speed transmission Use the transmission control lever to control the speed and direction of machine travel. Step on the service brake pedal before putting the transmission into gear. To drive forward, move the transmission control lever toward you and move it up.
  • Page 38 Operator's Manual Third Edition • Sixth Printing Operating Instructions Frame Sway Control Models with 2-speed transmission Before raising the boom, the machine must be level. Check the left to right level indicator. The left to right level indicator should be 0 degrees before raising the boom.
  • Page 39 Third Edition • Sixth Printing Operator's Manual Operating Instructions Raising and Placing a Load The load chart in the cab 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, its load center and how far out and up it is to be placed.
  • Page 40 Operator's Manual Third Edition • Sixth Printing Operating Instructions Gradually move the controller to lower and When the forks are clear of the load and the extend the boom into final position. Lower the structure, the boom can be lowered and load until the weight is completely off the forks.
  • Page 41 Third Edition • Sixth Printing Operator's Manual Operating Instructions Controller movements – Single Control Handle Control handle only Control handle with red thumb switch Control handle with white finger switch (B) Controller movements - Dual Control Handle Boom control handle Tilt and sway control handle Part No.
  • Page 42 Operator's Manual Third Edition • Sixth Printing Operating Instructions Rear Axle Lock If the boom is raised above 55°, the transmission will shift to neutral and the frame sway function will not operate. Boom and fork functions continue to operate. To unlock the rear axle and to operate the frame sway function, lower the boom.
  • Page 43 Third Edition • Sixth Printing Operator's Manual Operating Instructions Quick Attach Instructions Remove the quick attach lock pin. Tilt the forks forward to pivot the quick attach connector back. Position the boom so that the quick attach pin on the boom is below and centered between the hooks on the attachment.
  • Page 44 Operator's Manual Third Edition • Sixth Printing Operating Instructions After Each Use To jump start the machine Select a safe parking location—firm level Connect the positive (+) jumper cable to the surface, clear of obstruction and traffic. positive (+) post of the discharged battery. Retract and lower the boom to the stowed Connect the other end of the same jumper position.
  • Page 45 Third Edition • Sixth Printing Operator's Manual 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 46: Transport And Lifting Instructions

    Operator's Manual Third Edition • Sixth Printing Transport and Lifting Instructions 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.
  • Page 47 Third Edition • Sixth Printing Operator's Manual Transport and Lifting Instructions Securing the Chassis Securing to Truck or Trailer for Transit Use chains of ample load capacity. Turn the key switch to the off position and remove the key before transporting. Use a minimum of 6 chains.
  • Page 48 Operator's Manual Third Edition • Sixth 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 ...

  • Page 49: Maintenance

    Third Edition • Sixth Printing Operator's Manual Maintenance Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level Observe and Obey: can damage engine components.
  • Page 50 Operator's Manual Third Edition • Sixth Printing Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
  • Page 51 Third Edition • Sixth Printing Operator's Manual Maintenance Check the Batteries Check the Engine Coolant Level – Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 52 Operator's Manual Third Edition • Sixth Printing Maintenance Check the Tire Pressure Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Tip-over hazard. An over-inflated tire can this machine according to the procedures found in explode which may compromise machine the service manual for this machine.

  • Page 53: Attachments

    Third Edition • Sixth Printing Operator's Manual Attachments Attachments Work Platform Hazards Always perform a pre-operation inspection of the platform, per the manufacturer’s instructions, prior Work Area Safety to use. 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 Operator's Manual Third Edition • Sixth Printing Attachments Do not place or attach overhanging loads to any part of this machine or platform. Occupying the Platform Do not place ladders or Do not carry materials directly on platform railing scaffolds in the platform or unless approved by Genie.
  • Page 55 Third Edition • Sixth 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 56 Operator's Manual Third Edition • Sixth Printing Attachments Keep bystanders away while operating. Operating Instructions Do not place boom or platform against any structure to steady the platform or to support the Preparation and Setup structure. Read, understand and obey all jobsite, local, state, Do not use the controls to free a platform that is federal and provincial rules, standards and caught, snagged or otherwise prevented from...
  • Page 57 Third Edition • Sixth 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 58 Operator's Manual Third Edition • Sixth Printing Attachments Suspended Load Hazards Overturning Hazards Work Area Safety Do not lift a suspended load without the proper and legible load capacity chart for the General Safety attachment/telehandler combination you are using. Do not lift a suspended load without first Do not permit understanding the local, state, federal, or the load to...
  • Page 59 Third Edition • Sixth Printing Operator's Manual Attachments All movements of the load must be accomplished Do not leave the telehandler unattended with a gradually and at the slowest practical speed to suspended load. prevent the load from swinging. Keep the boom and load as low as practical while Keep the heavy part of the load closest to the maintaining visibility in the direction of travel.
  • Page 60 Operator's Manual Third Edition • Sixth Printing Attachments Collision Hazards Lifting a Suspended Load Be sure that the load is clear of any adjacent Verify that landing point is level and can safely obstacles before lifting. support the load. When visibility is or could be obstructed, near or at Properly secure the attachment to the telehandler the load placement, the operator shall use Level the frame on the telehandler.
  • Page 61 Third Edition • Sixth Printing Operator's Manual Attachments Traveling Placing the Load Be sure that the path of travel is level and capable Ask a signal person to assist with placing the load if visibility will be obstructed at the point of of supporting the telehandler with its load.
  • Page 62 Operator's Manual Third Edition • Sixth Printing Attachments Signal Person (from 1926.1419) Per OSHA CFR 1926.1419, a signal person is required when: The point of operation, meaning the load travel or the area near or at load placement, is not in full view of the operator.
  • Page 63 Third Edition • Sixth Printing Operator's Manual Attachments STOP. With arm EMERGENCY STOP. With both arms extended HOIST. With upper arm RAISE BOOM. With extended horizontally to horizontally to the side, palms down, arms are extended to the side, arm extended the side, palm down, swung back and forth.
  • Page 64 Operator's Manual Third Edition • Sixth Printing Attachments Suspended Load Hazards Rigger Requirements (from OSHA CFR 1926.404) When employees are engaged in hooking, unhooking, or guiding the load, or in the initial connection of a load to a component or structure and are within the fall zone, all of the following criteria must be met: The materials being hoisted must be rigged to...

  • Page 65: Specifications

    Third Edition • Sixth Printing Operator's Manual Specifications Specifications GTH-844 Tire size 13 x 24, 12 ply Height, stowed 7 ft 10 in 2.39 m Turning radius (outside), 2 wheel steer 21 ft 9 in 6.63 m Length, stowed, without 20 ft 3 in 6.17 m forks...

  • Page 66: Load Charts

    Operator's Manual Third Edition • Sixth Printing Load Charts Load Charts GTH-844 Standard Carriage GTH-844 Quick Attach Lifting Point 0 ft 35 ft 30 ft 20 ft 10 ft 10.7 m 9.1 m 6.1 m 3.0 m 45 ft 70° 13.7 m 60°...
  • Page 67 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. www.genielift.com...

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