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Terex GTH08E-13522 Operator's Manual

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Operator's Manual
GTH
-844
™
Serial Number Range
from GTH08E-13522
from GTH08T-14101
with
Maintenance
Information
Original Instructions
Sixth Edition
First Printing
Part No. 1312131GT

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Summary of Contents for Terex GTH08E-13522

  • Page 1 Operator's Manual Serial Number Range -844 ™ from GTH08E-13522 from GTH08T-14101 with Maintenance Information Original Instructions Sixth Edition First Printing Part No. 1312131GT...

  • Page 2: Table Of Contents

    Load Charts ............74 Copyright © 2012 by Terex Corporation Sixth Edition: First Printing, October 2021 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

    Sixth Edition • First 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 Sixth Edition • First Printing Introduction Contacting the Manufacturer Transfer of Machine Ownership At times it may be necessary to contact Genie. Taking a few minutes to update owner information When you do, be ready to supply the model will ensure that you receive important safety, number and serial number of your machine, along maintenance and operating information that...
  • Page 5 Sixth Edition • First Printing Operator's Manual Introduction Hazard Classification Decals on this machine use symbols, color coding, and signal words to identify the following: Safety alert symbol—used to alert you to potential personal injury hazards. Obey all safety Danger messages that follow this symbol to avoid possible injury or death.
  • Page 6 Operator's Manual Sixth Edition • First Printing Introduction Standards Safety Sign Maintenance Many aspects of rough terrain forklift operation Replace any missing or damaged safety signs. and testing are discussed in standards published Keep operator safety in mind at all times. Use mild by the American National Standards Institute and soap and water to clean safety signs.

  • Page 7: Symbol And Hazard Pictorials Definitions

    Sixth Edition • First 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 belt cardboard or paper to...
  • Page 8 Operator's Manual Sixth Edition • First Printing Symbol and Hazard Pictorials Definitions Explosion / Burn No smoking. No open Keep load low Fall hazard Only use an hazard flame. approved work platform Refer to load charts Sway operation Exterior emergency Tip-over hazard Tip-over hazard and manual.

  • Page 9: General Safety

    Sixth Edition • First Printing Operator's Manual General Safety General Safety 97602 NOTICE Axle DifferentialLock Do not use ether or otherhigh energy Explosion Hazard starting aids on Death or se rious injury can machinesequipped result from the use of ethe r or with glow plugs or othe r high e nergy starting grid heater.
  • Page 10 Operator's Manual Sixth Edition • First Printing General Safety 1304217 1304217 A 1298724 1304217 ™ -844 Part No. 1312131GT...

  • Page 11: Work Area Safety

    Sixth Edition • First Printing Operator's Manual Work Area Safety Work Area Safety Tip-over Hazards If the telehandler starts to tip over: Using the appropriate load chart - Do not jump for the machine configuration, confirm that the load is within - Brace yourself and stay the rated capacity of the in the seat...
  • Page 12 Operator's Manual Sixth Edition • First Printing Work Area Safety Traveling on Slopes Hazards Do not raise a load and then drive to position it. When driving, keep the boom at When driving, keep the boom or below horizontal and keep at or below horizontal and keep the load close to the ground.
  • Page 13 Sixth Edition • First Printing Operator's Manual Work Area Safety Operators should be properly trained and use their Collision Hazards best judgment and experience to take the necessary precautions to prevent a tip-over. Keep people, equipment and material out of the work area. Operators must assess the job site variables and Do not operate the machine avoid exceeding the machine's (or operator's)
  • Page 14 Operator's Manual Sixth Edition • First Printing Work Area Safety Always make sure that mirrors and cab glass are Bodily Injury Hazards clean and do not obstruct the operators view of the travel path or load. Always adjust the seat and fasten the seat belt before Scan the area prior to operating the machine.
  • Page 15 Sixth Edition • First 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 Do not use the machine as a ground for welding.
  • Page 16 Operator's Manual Sixth Edition • First 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 Sixth Edition • First 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 Sixth Edition • First 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

    Sixth Edition • First Printing Operator's Manual Legend Legend Interior rear view mirror 14 Rear proximity alarm sensor (if equipped) Left to right level indicator 15 Fuse panel Steering wheel 16 Shackle lifting point Control handle 17 Forks Front to rear level indicator 18 SCR cleaning operation switch (under cover) (if equipped) Exterior emergency exit (Safe T Punch) (if...

  • Page 20: Controls

    Operator's Manual Sixth Edition • First Printing Controls Controls Control Panel Steering wheel Horn button Turn the steering wheel to the right to turn the Press this button and the horn will sound. front wheels to the right. Turn the steering Release the button and the horn will stop.
  • Page 21 Sixth Edition • First Printing Operator's Manual Controls Turn signal lever (if equipped) 11 Auxiliary hydraulics thumb rocker Move the lever up to activate the left turn Push the auxiliary hydraulics thumb rocker to signal. Move the lever down to activate the the left and the carriage will swing or rotate to right turn signal.
  • Page 22 Operator's Manual Sixth Edition • First Printing Controls 17 Brake pedal 22 Transmission control lever 18 Tilt steering pedal Move the transmission control lever toward you and move it up for forward gear. Move the Push and hold the tilt steering pedal to release lever toward you and move it down for reverse the steering column.
  • Page 23 Sixth Edition • First Printing Operator's Manual Controls Instrument Panel Fuel level gauge with low fuel indicator light 12 Engine oil pressure low indicator light Turn signal indicator lights 13 Check engine indicator light Error code messaging 14 Engine stop indicator light DEF (diesel exhaust fluid) Level (if equipped) 15 Four-wheel steer indicator light Engine identification...

  • Page 24: Inspections

    Operator's Manual Sixth Edition • First 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 Sixth Edition • First Printing Operator's Manual Inspections Pre-operation Inspection  Fuel and hydraulic tanks  Axles and transmission  Be sure that the operator’s and safety manuals  Boom wear pads are complete, legible and in the storage container located in the cab. ...
  • Page 26 Operator's Manual Sixth Edition • First 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 Sixth Edition • First Printing Operator's Manual Inspections Function Tests Test the Electronic Joystick Handle Using the control handle, momentarily raise Select a test area that is firm, level and free of the boom, extend the boom, retract the boom hazards.
  • Page 28 Operator's Manual Sixth Edition • First Printing Inspections Test the Steering Test the Ignition System 12 Push the right side of the steer selector switch 20 Set the transmission control lever in neutral to select four-wheel steer. The four-wheel position. steer indicator light on the instrument panel Turn off the engine.
  • Page 29 Sixth Edition • First Printing Operator's Manual Inspections Test the Drive and Sway Cutout 30 Move the transmission control lever to reverse. Slowly let up on the brake pedal. As soon as 36 Raise the boom to 55°. Do not extend the the machine starts to move, push the brake boom.
  • Page 30 Operator's Manual Sixth Edition • First Printing Inspections Test the 3-speed Transmission (if 47 Set the parking brake, place the transmission equipped) into neutral and start the engine. Press and hold the brake pedal and place the 43 Fully retract the boom and lower it to the travel transmission in reverse.
  • Page 31 Sixth Edition • First Printing Operator's Manual Inspections Test the Back-up Cameral (if equipped) 51 Press and hold the brake pedal and place the transmission in reverse. Result: The monitor will switch to a full screen showing only the rear camera view. If the monitor does not show the rear camera view, the system needs to be repaired.
  • Page 32 Operator's Manual Sixth Edition • First 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 33 Sixth Edition • First Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description 826345 Label – Ultra Low Sulfur Fuel Only Determine whether the decals on your machine (diesel models) have words or symbols. Use the appropriate 1253091 Label –...
  • Page 34 Operator's Manual Sixth Edition • First Printing Inspections 133206 214418 *237684 1253091 *219648 114090 *1257919 1307976 *1261896 214419 1284367 1269532 1255823 215384 114115 1272926 237599 1280819 1280820 1268755 237605 237601 82558 215268 1280624 214418 1280264 237970 1280294 1263543 97602 1276041 1272242 220271 38149...
  • Page 35 Sixth Edition • First Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols 1253091 Label – Key Ignition 1255823 Label – 3-speed Transmission Determine whether the decals on your machine 1257919 Label – Load Chart, Quick Attach Lifting have words or symbols.
  • Page 36 Operator's Manual Sixth Edition • First Printing Inspections 133206 215646 1253091 *237684 *219648 1307976 *1257919 *1261896 215647 1284367 114090 1269532 1255823 114115 1272926 237721 237726 1268755 82560 237722 215648 1286018 215646 1286018 215644 1286020 1263542 1304217 1272242 220271 1285069 1286018 160482 *82366 *1266019...

  • Page 37: Operating Instructions

    Sixth Edition • First 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 38 Operator's Manual Sixth Edition • First Printing Operating Instructions Parking Brake Battery Disconnect Switch (if equipped) Use the parking brake switch to apply the parking brake before raising the boom or leaving the The battery disconnect switch is located on Inside machine.
  • Page 39 Sixth Edition • First Printing Operator's Manual Operating Instructions Starting the Engine Emergency Exit (if equipped) Be sure the parking brake is set and the Rotate each retaining lever and push out the transmission control lever is in the neutral window.
  • Page 40 Operator's Manual Sixth Edition • First Printing Operating Instructions Fire Extinguisher The transmission control lever also controls the transmission speed. To operate an extinguisher: To choose a lower speed, rotate the control lever Pull the pin clockwise. Aim nozzle at base of fire To choose a higher speed, rotate the control lever Squeeze the handle counterclockwise.
  • Page 41 Sixth Edition • First Printing Operator's Manual 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 42 Operator's Manual Sixth Edition • First Printing Operating Instructions Placing the load Raising and Placing a Load Travel to the desired work site and carefully Always center the load on the forks. Position the stop the machine. load so that it is completely against the back of the fork frame.
  • Page 43 Sixth Edition • First Printing Operator's Manual 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 44 Operator's Manual Sixth Edition • First Printing Operating Instructions Controller movements – Electronic Control Handle Control handle only Yellow fork Black auxiliary Control handle with tilt roller (1) rocker (2) white finger switch (3) ™ -844 Part No. 1312131GT...
  • Page 45 Sixth Edition • First Printing Operator's Manual 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 46 Operator's Manual Sixth Edition • First Printing 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 47 Sixth Edition • First Printing Operator's Manual Operating Instructions Engine Condition Indicator SCR cleaning operation If the engine diagnostic display indicates an Be sure the machine is parked on a flat, level engine fault, contact service personnel. surface. Lower and retract the mast. Do not operate the machine while the SCR Engine Display Information cleaning operation is running.
  • Page 48 Operator's Manual Sixth Edition • First Printing Operating Instructions Inactivity at Low Temperature Jump Starting the Machine In case of inactivity of the machine at low Jump starting at the battery or battery replacement temperature, make sure to store it with the boom is required when the battery is discharged to the fully retracted in order to avoid any ice accretion point where the battery will not crank the starter.
  • Page 49 Sixth Edition • First 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 50 Operator's Manual Sixth Edition • First Printing Operating Instructions Rear Proximity Alarm (if equipped) Always look in the direction of travel. When the rear proximity alarm sounds, bring the machine to The system is designed to supplement other a controlled stop and verify the location of the safety practices and systems such as signal obstacle.
  • Page 51 Sixth Edition • First Printing Operator's Manual Operating Instructions After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position and make sure forks are resting on the ground.

  • Page 52: Transport And Lifting Instructions

    Operator's Manual Sixth Edition • First 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 53 Sixth Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing to Truck or Trailer for Transit Securing the Chassis 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 54 Operator's Manual Sixth Edition • First 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 55: Maintenance

    Sixth Edition • First 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 56 Operator's Manual Sixth Edition • First Printing Maintenance Check the Transmission Oil Level Diesel Fuel Requirements Satisfactory engine performance is dependent on Maintaining the proper transmission oil level is the use of a good quality fuel. The use of a good essential to good transmission performance and quality fuel will give the following result: long service life.
  • Page 57 Sixth Edition • First Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Check the Batteries Maintaining the hydraulic oil at the proper level is Proper battery condition is essential to good essential to machine operation. Improper hydraulic machine performance and operational safety. oil levels can damage hydraulic components.
  • Page 58 Operator's Manual Sixth Edition • First Printing Maintenance Check Mirrors and Rear Check the Engine Coolant Level – Proximity Alarm System Liquid Cooled Models Maintaining the indirect visual aids is essential to Maintaining the engine coolant at the proper level workplace visibility.
  • Page 59 Sixth Edition • First Printing Operator's Manual Maintenance Check the Tire Pressure Check DEF Level (if equipped) Tip-over hazard. An over-inflated tire can Maintaining DEF (diesel exhaust fluid) at the explode which may compromise machine proper level is essential to machine stability and cause the machine to tip over.
  • Page 60 Operator's Manual Sixth Edition • First Printing Maintenance Loosen the drain plug located at the bottom of Drain the Fuel/Water Separator the bowl. Allow the water to drain into a suitable container until fuel starts to come out. Immediately tighten the drain plug. Proper maintenance of the fuel filter/water Tighten the vent plug and clean up any spills separator is essential for good engine...
  • Page 61 Sixth Edition • First Printing Operator's Manual Maintenance Install the safety chock on the lifting cylinder Scheduled Maintenance rod. Properly position the chock onto the Maintenance performed quarterly, annually and cylinder as show in the figures below. Secure every two years must be completed by a person the chock on to the cylinder using the lock pins trained and qualified to perform maintenance on and the spring clips in step 1.

  • Page 62: Attachments

    Operator's Manual Sixth Edition • First Printing 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. The telehandler shall not be used to lift people If damage or any unauthorized variation from unless there is no other practical option.
  • Page 63 Sixth Edition • First Printing Operator's Manual 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 scaffolds in the platform or Be certain that materials and tools are protected against any part of this...
  • Page 64 Operator's Manual Sixth Edition • First Printing 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 65 Sixth Edition • First Printing Operator's Manual 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, state, federal and provincial rules, standards and Do not use the controls to free a platform that is regulations as they pertain to the use of a...
  • Page 66 Operator's Manual Sixth Edition • First Printing 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 67 Sixth Edition • First Printing Operator's Manual Attachments Suspended Load Hazards A single shackle lifting point is rated for the maximum lifting capacity referenced on the load chart. It can be used as a single lift point, or both Work Area Safety lifting points can be used to suspend a load.
  • Page 68 Operator's Manual Sixth Edition • First Printing Attachments In addition to ground personnel, the two chassis Identify the proper lifting points of the load, taking tie-down points in the front of the machine can be into consideration the center of gravity and load used to help externally stabilize the load.
  • Page 69 Sixth Edition • First Printing Operator's Manual 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.
  • Page 70 Operator's Manual Sixth Edition • First Printing 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 of supporting the telehandler with its load. if visibility will be obstructed at the point of operation.
  • Page 71 Sixth Edition • First Printing Operator's Manual 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 72 Operator's Manual Sixth Edition • First 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, side, forearm and index horizontally to the side,...
  • Page 73 Sixth Edition • First Printing Operator's Manual 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 74: Specifications

    Operator's Manual Sixth Edition • First Printing Specifications Specifications GTH-844 Tire size 13 x 28, 12 ply Height, stowed 7 ft 10 in 2.39 m Turning radius (outside), 2 wheel steer 25 ft 7 in 7.80 m Length, stowed, without 20 ft 3 in 6.17 m forks...
  • Page 75 Sixth Edition • First Printing Operator's Manual Specifications Rear Proximity Sensor Range Horizontal Values Vertical Values 9.75 ft 3 m 16.25 ft 5 m 6.5 ft 13 ft 3.25 ft 1 m 9.75 ft 0 ft 6.25 ft 3.25 ft 1 m 3.25 ft 6.5 ft 0 ft...

  • Page 76: Load Charts

    Operator's Manual Sixth Edition • First Printing Load Charts Load Charts To calculate the new reduced load capacity at a Load Capacity Field Calculations load center greater than the standard 24 in/61 cm Always center the load on the forks. Position the load center, multiply the zone capacity from the load chart by the appropriate reduction factor listed load so that it is completely against the back of the...
  • Page 77 Sixth Edition • First Printing Operator's Manual Load Charts GTH-844 Standard Carriage GTH-844 Quick Attach Lifting Point GTH-844 Rotate Carriage GTH-844 Swing Carriage GTH™-844 Part No. 1312131GT Operator's Manual Sixth Edition • First Printing ™ Part No. 1312131GT -844...

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