Genie GTH-2506 AU.3 User manual

Operator’s Manual
Original Instructions
Second Edition
Second Printing
Part No. 57.0009.0730
Serial number range
GTH-2506 AU.3 From serial n.: GTH250617-501

Contents
Introduction.......................................................... 1
Symbol and Hazard Pictorials Definitions............ 5
General Safety..................................................... 6
Work Area Safety ................................................. 8
Safety Precautions ............................................ 15
Legend............................................................... 18
Controls ............................................................. 19
Inspections ........................................................ 25
Operating Instructions ....................................... 34
Parking and Storage.......................................... 55
Transport and Lifting Instructions ...................... 57
Maintenance...................................................... 60
Attachments....................................................... 68
Specifications .................................................... 80
Load Charts....................................................... 81
Copyright © 2015 by Terex Corporation
Second Edition: Second Printing, March 2018
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.
March 2018 Second Edition - Second Printing
Terex Australia Pty Ltd
33 Kimberley St
Darra, QLD 4076
Australia
Parts and Service Support
1800 788 633
II GTH-2506 AU.3 Part No. 57.0009.0730

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Part No. 57.0009.0730 GTH-2506 AU.3 1
Introduction
About This Manual
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie machine.
This manual should be considered a permanent part
of your machine and should remain with the machine
at all times. If you have any questions, contact Genie.
Product Identification
The machine serial number is located on the serial
label.
Serial number
Serial number
stamp
stamp
Serial label
Serial label
(if present)
(if present)
Homologation
Homologation
plate
plate
(if present)
(if present)
Intended Use
This product is only intended to be used and operated
by qualified, trained, competent and authorized
personnel according to the instructions in this manual,
the safety and instructional decals, and any applicable
standards and regulations.
A variable reach rough terrain forklift truck is defined
as a wheeled type truck with a pivoting boom, which
may be equipped with various attachments for picking,
transporting and placing loads using the established
load range charts.
Use of this product in any other way is prohibited
and contrary to its intended use.

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Contacting the Manufacturer
At times it may be necessary to contact Genie.
When you do, be ready to supply the model number
and serial number of your machine, along with your
name and contact information. At minimum, Genie
should be contacted for:
• Accident reporting
• Questions regarding product applications and
safety
• Standards and regulatory compliance information
• Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that applies
to your machine.
Please register your machine by visiting us on the
web at www.genieindustries.com.au
Introduction
Bulletin Distribution and
Compliance
Safety of product users is of paramount importance
to Genie. Various bulletins are used by Genie
to communicate important safety and product
information to dealers and machine owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most current
owner on record along with their associated dealer,
so it is important to register your machine and keep
your contact information up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.

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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.
1.Avoid hazardous situations.
Know and understand the safety rules
before going on to the next section.
2. Always perform a pre-operation inspection.
3. Always perform function tests prior to use.
4. Inspect the workplace.
5. Only use the machine as it was intended.
You read, understand and obey the manufacturer’s
instructions and the safety rules, the safety and
operator’s manuals, and the decals applied on
the machine.
You read, understand and obey the employer’s
safety rules and work-site regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

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Hazard Classification
Safety alert symbol - used to
alert you to potential personal
injury hazards. Obey all safety
messages that follow this
symbol to avoid possible injury
or death
DANGER
Indicates a hazardous situation
which, if not avoided, will result
in death or serious injury.
WARNING
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
CAUTION
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
NOTICE
Indicates a property damage
message.
Introduction
Standards
The following standards and/or regulations apply to
this machine:
Directive
AS 1418.19-2007 Cranes, hoists and winches. Part
19: Telescopic handlers
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.

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Maintain required
clearance.
Read the
operator's manual.
Burn Hazard
Explosion/burn
hazard
No smoking.
No open flame.
Allow surfaces to
cool.
Crush Hazard Keep clear of
moving parts.
Only trained
maintenance
personnel
should access
compartments.
Electrocution
hazard
Refer to load
charts and manual
Tip-over hazard
Always wear seat
belt.
Keep load low
during travel
Crush hazard.
Crush hazard.
Do not ride
on forks
Injection Hazard Use cardboard to
search for leaks
Burn hazard. Do not loosen cap
until cool.
Keep away from
moving parts.
No smoking. No
open flame.
Tip-over hazard
Symbol and Hazard Pictorials Definitions
Explosion hazard
Do not use
starting aids
No people under
load
Apply maintenance
collar
Crush hazard.
Explosion/burn
hazard
Fall hazard
Crush hazard.
Tip-over hazard
Explosion hazard Do not use.

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General Safety
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General Safety
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Work Area Safety
Overturning Hazards
Using the load chart, confirm that
the load is within the rated capacity
of the machine. Do not exceed the
rated load.
The load center of the fork (if equipped) must be
equal to or less than the load center indicated on
the load chart.
All loads shown on the load chart are based on
the machine being on firm ground, the frame being
level, the forks being positioned evenly on the
carriage, the load being centered on the forks, the
tires being properly sized and properly inflated, and
the telehandler being in good operating condition.
If using accessories, read, understand and obey the
decals, instructions and manuals with the accessory.
Do not raise the load unless the ground can support
all forces imposed by the machine.
Do not lower a load without retracting the boom first.
Do not use attachments which are not approved by
Genie.
Do not operate the machine if the load chart is missing.
Do not exceed the rated capacity for each
configuration.
Do not raise the boom unless the
machine is level. The machine level
indicator should be no more than
+/- 0,5 degrees.
Do not work with the load limiting system cut out.
Do not raise a load and then drive to position it.
When driving, keep the boom at
or below horizontal and keep the
load close to the ground.
Operate the machine at speeds that will keep the
load under control. Start and stop movements
smoothly.
Do not raise a load unless the load
is properly positioned or secured on
the forks or approved attachment.
Do not operate the machine in strong or gusty winds.
Do not increase the surface area of the carriage or
load. Increasing the area exposed to the wind will
decrease machine stability.
Use extreme care and slow speeds while driving the
machine in the travel position across uneven terrain,
debris, unstable or slippery surfaces and near holes
and drop-offs.
Do not alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to machine stability with
items of different weight or specification.
Do not replace factory-installed tires with tires of
different specification or ply rating.

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Work Area Safety
Traveling on Slopes Hazards
When driving, keep the boom at
or below horizontal and keep the
load close to the ground.
When the machine is unloaded, travel with the forks
or attachment downhill.
On steep terrain, drive only up and down a hill, and
always keep the machine in gear. Do not turn across
the slope when the machine is traveling up or down
a slope.
Limit travel path and speed according to the condition
of the ground surface, traction, slope, location of
personnel and any other factors which may create
a hazard. Never drive the machine unless the mast
and equipment are in their proper travel position.
Whether a machine will tip over during dynamic
machine operation involves many factors that need
to be considered. Among these are pavement/ground
conditions, stability and slope, as well as machine
equipment, operator skill, load position, tire inflation,
machine speed, etc.
Additionally, tip-over of a machine is dependent in
large part upon operator inputs such as the speed
and smoothness of the operation, as well as the
position of the attachment and its load.
Construction sites and roads will frequently change
slope from place to place, can be hard and soft, and
change due to construction activities and weather.
Operators should be properly trained and use their
best judgment and experience to take the necessary
precautions to prevent a tip-over.
Operators must assess the job site variables and
avoid exceeding the machine's (or operator's)
capabilities for terrain and conditions.
Fall Hazards
Always wear a seat belt when
operating the machine.
Always remain completely inside the cab when
operating the machine.
When getting in and out of the cab, face the machine,
use the steps and handrails provided and always
maintain three-point contact.
Do not use the steering wheel or any other controls
as handrails.
Do not allow riders on the machine
or forks.
Do not transport or lift personnel with
this machine.

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Falling Object Hazards
Operate the machine at speeds that will keep the
load under control. Start and stop movements
smoothly.
Keep people, equipment and
material out of the work area.
Do not operate the machine
while people are under or near
an elevated boom, whether it is
loaded or unloaded.
Be sure the load is secure before lifting it.
Collision Hazards
Do not put the transmission into gear unless the
parking brake is set.
Do not drive the machine if visibility is obstructed.
Do not raise the boom unless the parking brake is set.
Do not operate in conditions without fenders to protect
debris from hitting the operator or accumulating on
the cab windows.
Do not operate the machine with a faulty back-up/
reversing alarm. The back-up alarm should sound
when the machine is in reverse.
Do not operate the machine in low light conditions.
Operators must comply with employer, job site
and governmental rules regarding use of personal
protective equipment.
Do not drive the machine directly up to anyone.
If a radio and/or mp3 player is equipped, keep the
volume low enough to hear surrounding environment
(i.e. traffic, alarms, people etc.).
Do not adjust the controls while driving or manoeuvring
a load.
Scan the area prior to operating the machine. Look
in the direction of travel. Use mirrors and the camera
to assist in checking all around the machine.
Keep windows and mirrors clean, adjusted and in
good repair.
Be aware of the machine/load swing area.
Do not rely on the camera system to determine if
personnel/objects are behind the machine. The
system has limitations due to maintenance practices,
environmental and lighting conditions and operating
range.
Work Area Safety

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Work Area Safety
Bodily Injury Hazards
Always adjust the seat and fasten
the seat belt before starting the
engine.
Do not operate the machine with a
hydraulic oil or air leak.
An air leak or hydraulic leak can
penetrate and/or burn skin.
Relieve pressure before
disconnecting hydraulic lines.
Keep away from leaks and pin
holes. Use a piece of cardboard or
paper to search for leaks. Do not
use your hand.
Fluid injected into skin must be surgically removed
within a few hours by a doctor familiar with this type
of injury or gangrene will result.
Stay clear of belts and fans when the
engine is running.
Always operate the machine in a well-ventilated area
to avoid carbon monoxide poisoning.
Improper contact with components under any cover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access by
the operator is only advised when performing a pre-
operation inspection. All compartments must remain
closed and secured during operation.
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work shift.
Immediately tag and remove from service a damaged
or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the appropriate Genie
service manual.
Be sure all decals are in place and legible.
Be sure the operator's and safety manuals are
complete, legible and in the storage container located
in the cab.
Do not attempt to start the machine by towing or
pushing.
Do not attempt to use the forks or attachments for
prying wedged or frozen loads free.
Do not push or pull objects or loads with the forks,
attachment or boom.

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Work Area Safety
Component Damage Hazards
Do not use any battery or charger greater than 12V
to jump-start the engine.
Do not use the machine as a ground for welding.
Do not steer the front tires on dry pavement when
the axle differential lock is activated.
Crush Hazards
Keep clear of moving parts during machine operation.
Set the parking brake, put the transmission in neutral
and lower the carriage or the attachment to the ground
before leaving the machine.
Keep clear of elevated components.
Support components before performing service. Keep
clear of moving parts during machine operation.
Burn Hazards
Allow hot surfaces to cool before
touching or servicing.
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleum gas (LPG), gasoline, diesel fuel or other
explosive substances.
Do not refuel the machine with the engine running.
Refuel the machine and charge the
battery only in an open, well-
ventilated area away from sparks,
flames and lighted tobacco.
Do not operate the machine in hazardous locations
or locations where potentially flammable or explosive
gases or particles may be present.
Do not spray ether into engines equipped with glow
plugs or air intake grid heaters.
Do notuse airor oxygenforcharging theaccumulators.

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Electrocution Hazards
This machine is not electrically insulated and will not
provide protection from contact with or proximity to
electrical current.
Obey all local and governmental
regulations regarding required
clearance from electrical power
lines. At a minimum, the
required clearance contained in
the chart below must be
followed.
Line Voltage Required Clearance
0 to 50kV 10 ft 3.05 m
>50 to 200kV 15 ft 4.60 m
>200 to 350kV 20 ft 6.10 m
>350 to 500kV 25 ft 7.62 m
>500 to 750kV 35 ft 10.67 m
>750 to 1000kV 45 ft 13.72 m
over 1000kV see below
For power lines over 1000kV, the minimum
clearance distance must be established by
the utility owner or operator or by a registered
professional engineer who is a qualified person
with respect to electrical power transmission and
distribution.
Do not use the machine as a ground for welding.
Always contact the electrical power line owner. The
electrical power shall be disconnected or the power
lines moved or insulated before machine operations
begin.
Allow for boom movement, electrical line levelling or
sag, and beware of strong or gusty winds.
Keep away from the machine if it contacts energized
power lines. Personnel on the ground or in the cab
must not touch or operate the machine until energized
power lines are shut off.
Do not operate the machine during lightning or storms.
Work Area Safety

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Battery Safety
Burn Hazards
Batteries contain acid.
Always wear protective
clothing and eye wear when
working with batteries.
Avoid spilling or contacting
battery acid. Neutralize
battery acid spills with baking
soda and water.
Explosion Hazards
Keep sparks, flames and
lighted tobacco away from
batteries. Batteries emit
explosive gas.
Work Area Safety
Electrocution Hazard
Avoid contact with electrical terminal.
Using the Charger (if equipped), be sure the device
works at 12 Volt and doesn't exceed 15 Ampere.
During maintenance or repair works, and while
welding, disconnect the battery by turning the cut-out
switch (see Inspection for Decals section).
After turning off the cut-out switch, wait for 60 seconds
before starting the engine.
Employer's Responsibilities
Employers are responsible for providing a safe
work environment and for complying with local and
national governmental regulations.
Personal Safety
Be sure that everyone working on or near this machine
is familiar with the applicable safety precautions.

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Safety Precautions
Requirements for Machine
Operators
The operators who use the machine regularly or
occasionally (i.e. for transport reasons) shall have
the following prerequisites:
health:
before and during any operation, operators shall
never take alcoholic beverages, medicines or other
substances that may alter their psycho-physical
conditions and, consequently, their working abilities.
physical:
good eyesight, acute hearing, good co-ordination
and ability to carry out all required operations in
a safe way, according to the instructions of this
manual.
mental:
ability to understand and apply the enforced rules,
regulations and safety precautions. They shall be
careful and sensible for their own as well as for the
others’ safety and shall desire to carry out the work
correctly and in a responsible way.
emotional:
they shall keep calm and always be able to evaluate
their own physical and mental conditions.
training:
they shall read and be familiar with this handbook,
its enclosed graphs and diagrams, the identification
and hazard warning plates. They shall be skilled and
trained about the machine use.
The operator shall have a licence (or a driving
licence) when provided for by the laws enforced in
the country where the machine is operated. Please,
ask the competent bodies.
Requirements for service
personnel
Personnel in charge of machine maintenance
shall be qualified, specialised in the maintenance
of telehandlers, and shall have the following
prerequisites:
physical:
good eyesight, acute hearing, good co-ordination
and ability to carry out all required maintenance
operations in a safe way, according to this manual.
mental:
ability to understand and apply the enforced rules,
regulations and safety precautions. They shall be
careful and sensible for their own as well as for the
others’ safety and shall desire to carry out the work
correctly and in a responsible way.
training:
they shall read and be familiar with this handbook,
its enclosed graphs and diagrams, the identification
and warning plates. They shall be skilled and trained
about the machine functioning.
From a technical point of view, routine maintenance
of the machine is not a complex procedure and can
be carried out by the machine operator too, provided
he has a basic knowledge of mechanics.

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Safety Precautions
Working clothes
During work, but especially when maintaining or
repairing the machine, operators must wear suitable
protective clothing:
• Overalls or any other comfortable garments.
Operators should not wear clothes with large
sleeves or objects that can get stuck in moving
parts of the machine.
• Protective helmet.
• Protective gloves.
• Working shoes.
Use only approved safety workwear in good
condition.
Personal protective equipment
Under special working conditions, the following
personal protective equipment should be used:
• Breathing set (or dust mask).
• Ear-protectors or equivalent equipment.
• Goggles or facial masks.

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Safety Precautions
Control Indicators and
Interlocks
Several control indicators and interlocks have been
fitted to the machine. They must never be tampered
with or removed.
Always perform a function test to check the proper
operation of these devices.
Never operate a machine that is malfunctioning. If
the machine starts to malfunction, immediately stop
using it and have it repaired.
Load Management System (LMS)
The Load Management System has been developed
to help the operator to maintain longitudinal
stability of the machine. Audible and visual messages
are provided when the limits of longitudinal stability
are being approached.
However this device cannot replace the experience
of the operator. It is up to the user to adopt the
necessary safety measures to work within the rated
limits of the machine.
The LMS is designed to function only:
• when the truck is static;
• when the truck is on consolidated, stable and
level ground;
• when the truck is performing loading or placing
functions;
• when the LMS is activated (not overridden).
The LMS will only warn the operator in the event of
inadequate stability in the longitudinal plane in the
forward direction.
The LMS is not intended for warning of the risk of
overturning in the case of:
• a sudden overload;
• travelling with the load in the elevated position;
• travelling on rough terrain or on grounds with
obstacles and holes;
• travelling across a slope or turning on a slope;
• driving in bends too fast or too sharp;
Adjustments affecting the setting of the Load
Management System shall be performed only by
authorised personnel.
Seat Interlock
This micro switch is located inside the seat cushion,
and it prevents any machine transmission movements
if the operator is not correctly seated in the driving seat.
Emergency Stop Push-button
This device may be used to stop the machine during
an emergency situation.
By pressing this button, the engine shuts down while
the Load Management System stays active.
Before restarting the machine, it is necessary to reset
the push-button by rotating it clockwise.
Enabling Function Switch on Joystick
The joystick is equipped with an enabling function
switch. This red finger switch must be held pressed
down until the joystick functions have been completed;
if it is released, the manoeuvre stops.

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Legend
1. Left/right level indicator
2. Operator’s manual storage
(door internal side)
3. Left rear view mirror
4. Right rear view mirrors
5. Boom angle indicator
6. Maintenance collar (on
opposite side of machine)
7. Fuel filler
8. Hydraulic oil level gauge
9. Engine (on opposite side of
machine)
10.Forks
11.Seat belt
12.Reversing Camera
8
11
6
1
4 9
5
2
3
10
7
12