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Related Manuals for Terex GTH1215M-180
Summary of Contents for Terex GTH1215M-180
- Page 1 Operator’s Manual Serial number range GTH-1256 From GTH1215M-101 (Perkins Tier 4i) To GTH1215M-180 GTH-1256 From GTH1215M-101 (Deutz Tier 4i) To GTH1215M-180 Original Instructions First Edition Second Printing April 2017 Part No. 57.0009.0662...
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Page 2: Table Of Contents
Copyright © 2017 by Terex Corporation First Edition: Second Printing, April 2017 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. GTH-1256 Part No. -
Page 3: Introduction
First Edition - Second Printing April 2017 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 2017 First Edition - Second 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 - Second Printing April 2017 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 2017 First Edition - Second 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.
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Page 7: Symbol And Hazard Pictorials Definitions
First Edition - Second Printing April 2017 Symbol and Hazard Pictorials Definitions Maintain required Electrocution Crush hazard. No people under Injection hazard Read the operator's clearance. manual. hazard load Use a piece of Maintain required cardboard or paper Always wear seat Tip-over hazard Tip-over hazard Crush hazard. -
Page 8: General Safety
April 2017 First Edition - Second Printing General Safety GTH-1256 Part No. 57.0009.0662... - Page 9 First Edition - Second Printing April 2017 General Safety Part No. 57.0009.0662 GTH-1256...
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Page 10: Work Area Safety
April 2017 First Edition - Second Printing Work Area Safety Overturning Hazards Do not use the sway control to position Using the load chart, confirm that an elevated load. the load is within the rated capacity of the machine. Do not exceed the rated load. - Page 11 First Edition - Second Printing April 2017 Work Area Safety Only use the machine on firm ground capable of Make sure the machine (wheels and stabilizers) supporting the maximum combined load of the rests on a firm ground to prevent hazardous unstable machine and payload.
- Page 12 April 2017 First Edition - Second Printing Work Area Safety Traveling on Slopes Hazards Operators should be properly trained and use their best judgment and experience to take the necessary precautions to prevent a tip-over. When driving, keep the boom at or below horizontal and keep the Operators must assess the job site variables and load close to the ground.
- Page 13 First Edition - Second Printing April 2017 Work Area Safety Falling Object Hazards Collision Hazards Operate the machine at speeds that will keep the Keep people, equipment and load under control. Start and stop movements material out of the work area. smoothly.
- Page 14 April 2017 First Edition - Second Printing Work Area Safety Bodily Injury Hazards Damaged Machine Hazards Always adjust the seat and fasten Do not use a damaged or malfunctioning machine. the seat belt before starting the engine. Conduct a thorough pre-operation inspection of the machine and test all functions before each work shift.
- Page 15 First Edition - Second Printing April 2017 Work Area Safety Component Damage Hazards Explosion and Fire Hazards Do not use any battery or charger greater than 12V Do not start the engine if you smell or detect liquid to jump-start the engine. petroleum gas (LPG), gasoline, diesel fuel or other explosive substances.
- Page 16 April 2017 First Edition - Second Printing Work Area Safety Electrocution Hazards Do not use the machine as a ground for welding. 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 - Second Printing April 2017 Work Area Safety Battery Safety Electrocution Hazard 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).
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Page 18: Legend
April 2017 First Edition - Second Printing Legend 1. Left/right level indicator 14. Accelerator pedal 2. Steering wheel 15. Transmission control lever 3. Control handle 16. Load charts 4. Rear convex mirror 17. Front/rear level indicator 5. Boom angle indicator 18. -
Page 19: Controls
First Edition - Second Printing April 2017 Controls 22 14 20 Control Panel 14. Windshield wiper switch (if equipped) 15. Windshield washer switch (if equipped) 1. Steering wheel 16. Work lights switch (if equipped) 2. Horn button 17. Hazard warning lights switch (if equipped) 3. - Page 20 April 2017 First Edition - Second Printing Controls Steering wheel Control handle (single) Turn the steering wheel to the right to turn the Pull the control handle back and the boom will front wheels to the right. Turn the steering wheel raise.
- Page 21 First Edition - Second Printing April 2017 Controls 17 Hazard warning lights switch (if equipped) 22 DPF switch (DEUTZ engine configuration) Push the switch to turn the hazard warning Push the switch to enable the DPF regeneration. lights on. Release the switch to turn the hazard 23 “Shift-on-fly”...
- Page 22 April 2017 First Edition - Second Printing Controls °c 1230 engine rpm 000000.0 Instrument Panel 13. 2nd gear engaged indicator light 1. Low engine oil pressure indicator light 14. 1st gear engaged indicator light 2. Parking brake engaged indicator light 15.
- Page 23 First Edition - Second Printing April 2017 Controls indicator light 1 Low engine oil pressure indicator light 11 DPF Alert When illuminated this light indicates that the engine This light flashes to warn of a problem of the engine. oil pressure is too low which can lead to machine To identify the problem, see the two sections “Engine damage.
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Page 24: Inspections
April 2017 First Edition - Second 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 ... - Page 25 First Edition - Second Printing April 2017 Inspections Pre-operation Inspection Be sure that the operator’s, safety and Engine and related components responsibilities manuals are complete, legible Limit switches and in the storage container located in the platform. ...
- Page 26 April 2017 First Edition - Second 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 - Second Printing April 2017 Inspections Function Tests Test the Control Handle Select a test area that is firm, level and free of obstruction. Be sure there is no load on the forks 17 Start the machine with the parking brake on or attachment.
- Page 28 April 2017 First Edition - Second Printing Inspections Test the Steering Test the Transmission and Brakes 21 Rotate the steer selector to the right side to select 29 Be sure the boom is fully lowered and retracted. four-wheel steer. 30 Step on the brake pedal. Push the top of the 22 Check the steering operation by turning the parking brake switch to turn it off.
- Page 29 First Edition - Second Printing April 2017 Inspections Test the “Shift-on-fly” System Test the Stabilizers 36 Be sure the boom is fully lowered and retracted. 47 Push the top of each stabilizers switch and fully extend and lower the stabilizers. Push the bottom 37 Step on the brake pedal.
- Page 30 April 2017 First Edition - Second Printing 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 ...
- Page 31 First Edition - Second Printing April 2017 Inspections Inspection for Decals with Words Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No. Decal Description Part No.
- Page 32 April 2017 First Edition - Second Printing Inspections 09.4618.1765 09.4618.1919 09.4618.1655 97667 237605 09.4618.1638 09.4618.1834 82558 09.4618.1625 09.4618.1646 09.4618.1768 97667 237598 09.4618.1672 09.4618.1767 214418 237598 28175 237970 97667 28236 09.4618.1622 09.4618.1418 load chart set 09.4618.1399 09.4618.1845 237606 09.4618.1767 09.4618.1619 82366 237598 826345 237970...
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Page 33: Operating Instructions
First Edition - Second Printing April 2017 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 34 April 2017 First Edition - Second Printing Operating Instructions Parking Brake Starting in Cold Condition Use the parking brake switch to apply the parking In cold conditions, 20°F / -6°C and below, warm brake before raising the boom or leaving the the engine for 5 minutes before operating to machine.
- Page 35 First Edition - Second Printing April 2017 Operating Instructions Emergency Exit (if equipped) Transmission Control Extract the retaining levers and push out the Use the transmission control lever to control the window. direction of machine travel. Step on the service brake pedal before putting the transmission into gear.
- Page 36 April 2017 First Edition - Second Printing Operating Instructions DPF Regeneration When the indicator light is OFF, the travelling speed is beyond the admissible speed range and, (Deutz configuration) by pressing the switch, gear won’t be shifted. Based on the blinking combination of the DPF Shift to 1st gear before ascending steep slopes.
- Page 37 First Edition - Second Printing April 2017 Operating Instructions DPF Regeneration (Perkins configuration) Machine must remain parked outdoors for 30 minutes approximately. In this configuration regeneration always starts automatically. In case of need, regeneration can be stopped by pushing the DPF switch and Only when temperature is below -18°C, the system then restarted.
- Page 38 April 2017 First Edition - Second Printing Operating Instructions Transporting a Load Raising and Placing a Load Center the load on the forks. Position the load so The load chart in the cab shows the operating that it is completely against the back of the fork limits of a properly maintained and operated frame.
- Page 39 First Edition - Second Printing April 2017 Operating Instructions Placing the load load until the weight is completely off the forks. Do not apply a downward force with the forks. Travel to the desired work site and carefully stop the machine. Put the transmission in neutral.
- Page 40 April 2017 First Edition - Second Printing Operating Instructions Controller movements Control handle only Control handle only Control handle only with grey thumb switch with grey finger switch GTH-1256 Part No. 57.0009.0662...
- Page 41 First Edition - Second Printing April 2017 Operating Instructions Rear Axle Lock If the boom is raised above 50°, the transmission Version with hydraulic locking (optional) will shift to neutral and the frame sway function will 1. Drive to the place where you will release the not operate.
- Page 42 April 2017 First Edition - Second Printing Operating Instructions Engine Condition Indicator Jump Starting the Machine If the DPF Alert indicator light and/or the Engine Jump starting at the battery or battery replacement Critical Fault indicator light switch on, contact is required when the battery is discharged to the service personnel.
- Page 43 First Edition - Second Printing April 2017 Operating Instructions Driving on a slope 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 hill, and always keep the machine in gear.
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Page 44: Transport And Lifting Instructions
April 2017 First Edition - Second 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. ... - Page 45 First Edition - Second Printing April 2017 Transport and Lifting Instructions Securing to Truck or Trailer for Transit Set the parking brake. Securing the Chassis Turn the key switch to the off position and remove the key before transporting. Use chains of ample load capacity. Inspect the entire machine for loose or unsecured Use a minimum of 6 chains.
- Page 46 April 2017 First Edition - Second Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Retract the stabilizers. Determine the center of gravity of your machine using the picture on this page. Observe and Obey: Remove all loose items on the machine. ...
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Page 47: Maintenance
First Edition - Second Printing April 2017 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 48 April 2017 First Edition - Second Printing Maintenance Check the Engine Oil Level Check the Hydraulic Oil Level Maintaining the proper engine oil level is essential Maintaining the hydraulic oil at the proper level is to good engine performance and service life. essential to machine operation.
- Page 49 First Edition - Second Printing April 2017 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 50 April 2017 First Edition - Second Printing Maintenance Check the Battery Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Proper battery condition is essential to good this machine according to the procedures found in machine performance and operational safety.
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Page 51: Attachments
First Edition - Second Printing April 2017 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 52 April 2017 First Edition - Second Printing Attachments Occupying the Platform Do not place or attach overhanging loads to any 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 53 First Edition - Second Printing April 2017 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. 30 ft 25 ft 20 ft 15 ft 10 ft 5 ft...
- Page 54 April 2017 First Edition - Second Printing Attachments Operating Instructions Keep bystanders away while operating. 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 55 First Edition - Second Printing April 2017 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 56 April 2017 First Edition - Second 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 57 First Edition - Second Printing April 2017 Attachments Collision Hazards Identify the proper lifting points of the load, taking into consideration the center of gravity and load Be sure that the load is clear of any adjacent stability. obstacles before lifting. Do not attempt to use the telehandler frame- When visibility is or could be obstructed, near leveling to compensate for a swinging load or to...
- Page 58 April 2017 First Edition - Second 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 Keep the boom, and load, as low as practical while maintaining visibility in the direction of travel.
- Page 59 First Edition - Second Printing April 2017 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 60 April 2017 First Edition - Second 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 61 First Edition - Second Printing April 2017 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...
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Page 62: Specifications
April 2017 First Edition - Second Printing Specifications GTH-1256 Rear Object Detection System Refer to supplemental Height, stowed 8 ft 9 in 2.67 m manuals Length, stowed, without 21 ft 6.40 m Floor loading information forks Tire load, maximum 18,518 lbs 11,100 kg Width, standard tires 7 ft 11 in... -
Page 63: Load Charts
First Edition - Second Printing April 2017 Load Charts GTH-1256, Standard Carriage GTH-1256, Rotating Carriage stabilizers up stabilizers up GTH-1256, Standard Carriage GTH-1256, Rotating Carriage stabilizers down stabilizers down Part No. 57.0009.0662 GTH-1256... - Page 64 April 2017 First Edition - Second Printing Load Charts GTH-1256, 7 ft Truss Boom G T H - 1 2 5 6 , R u b b i s h B u c k e t stabilizers up stabilizers up 45 ft 40 ft 35 ft...
- Page 65 First Edition - Second Printing April 2017 Load Charts GTH-1256, Shackle stabilizers up GTH-1256, Shackle stabilizers down Part No. 57.0009.0662 GTH-1256...
- Page 66 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...