Terex Genie GTH5516M-5338 User manual

Operator’s Manual
Original Instructions
Third Edition
First Printing
June 2016
Part No. 57.0009.0619
Serial number range
GTH-5519 From GTH5516M-5338
to GTH5516M-5799
From GTH55M-5800
to GTH55M-7008
Tier 4 Interim
Tier 4 Final

Contents
Introduction.......................................................... 1
Symbol and Hazard Pictorials Definitions............ 5
General Safety..................................................... 6
Work Area Safety ............................................... 10
Legend............................................................... 17
Controls ............................................................. 18
Inspections ........................................................ 23
Operating Instructions ....................................... 34
Transport and Lifting Instructions ...................... 43
Maintenance...................................................... 46
Attachments....................................................... 50
Specifications .................................................... 56
Load Charts....................................................... 57
Copyright © 2015 by Terex Corporation
Third Edition: First Printing, June 2016
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.
June 2016
GTH-5519 Part No. 57.0009.0619
Third Edition - First Printing

June 2016Third Edition - First Printing
Part No. 57.0009.0619 GTH-5519 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,along with the AEM Rough Terrain
Forklift Safety 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.
Intended Use
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 with the established
load range charts.
Use of this product in any other way is prohibited
and contrary to its intended use.
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.
Serial number
stamp
Serial label
(located inside chassis)

June 2016
2 GTH-5519 Part No. 57.0009.0619
Third Edition - First Printing
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
• Questions regarding Product Modifications
• 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.genielift.com or by calling us toll free
at 1-800-536-1800.
Introduction

June 2016Third Edition - First Printing
Part No. 57.0009.0619 GTH-5519 3
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 worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

June 2016
4 GTH-5519 Part No. 57.0009.0619
Third Edition - First Printing
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
Many aspects of rough terrain forklift operation and
testing are discussed in standards published by
the American National Standards Institute and the
Industrial Truck Standards Development Foundation.
These standards are updated on a regular basis with
addenda. It is recommended that you purchase and
refer to the following standards.
ANSI/ITSDF B56.6 - Rough Terrain Forklift Trucks
The ANSI standard can be downloaded from
www.ITSDF.org
CSA B335 - Safety Standard for Lift Trucks
The CSA standard can be downloaded from
www.csa.ca
Safety Sign Maintenance
Safety signs are designed and fitted to the machine
to warn of possible hazards. They must be replaced
immediately if they become unreadable or lost. If the
machine is repaired and parts have been replaced
on which safety signs were attached, be sure new
safety signs are installed before the machine is put
into service. Use mild soap and water to clean safety
signs. Do not use solvent based cleaners, which may
damage the safety sign material.

June 2016Third Edition - First Printing
Part No. 57.0009.0619 GTH-5519 5
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.
Allow engine
compartment
access
Electrocution
hazard
Refer to load charts
and manual
Tip-over hazard
Always wear seat
belt.
Keep load low
Crush hazard.
Crush hazard.
Work platform use
Burn hazard. Do not loosen cap
until cool.
Keep away from
moving parts.
No smoking. No
open flame.
Symbol and Hazard Pictorials Definitions
Explosion hazard
Do not use
starting aids
No people under
load
Injection hazard
Use a piece of
cardboard or paper
to search for leaks
Maintain required
clearance. Crush hazard.
Tip-over hazard
Explosion/burn
hazard
Fall hazard
Sway operation

June 2016
6 GTH-5519 Part No. 57.0009.0619
Third Edition - First Printing
General Safety for Tier 4 Interim
DANGER
Explosion / Burn Hazard Battery explosion and/or contact with corrosive acid will result in death or serious injury.
Wear personal protective equipment, including face shield, gloves and long sleeve
shirt. Read manuals. If you do not understand the information in the manuals, consult your
supervisor, the owner or the manufacturer.
237601 A
Keep all open flames and sparks away.
237601
97667 B
Burn Hazard Contact with hotsurfaces can cause burns. Do not touch. Allow surfaces to cool before servicing.
WARNING
97667
237598 A
Crush Hazard
Contact between wheel and chassis can result in death or serious injury.
Stayclearofmachine during operation.
WARNING
237598
97667
215268
237601
214418 28175 97667
214418
97602
237598
237605
237605
237605 A
WARNING
BurnHazard Releaseof hot fluidunder pressure can result in
deathor serious injury.
Do not loosen cap until cool.
Compartment access is restricted. Contact with components under any cover may result in serious injury.
Only trained maintenance personnel should access compartments. Access by operator is only advised when performing Pre-operation Inspection.All compartments must remain closed and
secured during operation.
28175 H
WARNING
28175
215268 A
FallHazard Falling can result in death or serious injury. When lifting personnel, only use a work platform that meets Terex requirements, along with associated machine load charts.
Besure toproperly secureplatform totelehandler
beforeuse. Readandunderstandoperator'smanual.
Wearapprovedpersonnelfallprotection equipmentandattach lanyard toanchor provided.
WARNING
215268
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June 2016Third Edition - First Printing
Part No. 57.0009.0619 GTH-5519 7
09.4618.1622
09.4618.1622
237598
82558
214418
09.4618.1622
DANGER
237971 A
Explosion/BurnHazard
Fueland fumes can explode andburn,
resulting in death or serious injury.
Nosmoking. Keep all open flames and sparks away.
Stopengine before addingfuel.
237971
Stay clear of raised boom or load.
WARNING
Crush Hazard Contact with falling load can result in death
or serious injury.
214418 A
DANGER
Electrocution Hazard Contact with electric power lines will result in
death or serious injury.
Stay clear of machine.
214418
82558 B
Injection Hazard Escaping fluid under pressure can penetrate skin, causing serious injury.
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 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.
WARNING
82558
237598 A
Crush Hazard Contact between wheel and chassis can result in death or serious injury.
Stayclear ofmachineduringoperation.
WARNING
237598
237598237971
General Safety for Tier 4 Interim

June 2016
8 GTH-5519 Part No. 57.0009.0619
Third Edition - First Printing
General Safety for Tier 4 Final
DANGER
Explosion / Burn Hazard Battery explosion and/or contact with corrosive acid will result in death or serious injury.
Wear personal protective equipment, including face shield, gloves and long sleeve
shirt. Read manuals. If you do not understand the information in the manuals, consult your
supervisor, the owner or the manufacturer.
237601 A
Keep all open flames and sparks away.
237601
97667 B
Burn Hazard Contact with hotsurfaces can cause burns. Do not touch. Allow surfaces to cool before servicing.
WARNING
97667
237598 A
Crush Hazard
Contact between wheel and chassis can result in death or serious injury.
Stayclearofmachine during operation.
WARNING
237598
97667
215268
237601
214418 28175 97667
214418
97602
237598
237605
237605
237605 A
WARNING
BurnHazard Releaseof hot fluidunder pressure can result in
deathor serious injury.
Do not loosen cap until cool.
Compartment access is restricted. Contact with components under any cover may result in serious injury.
Only trained maintenance personnel should access compartments. Access by operator is only advised when performing Pre-operation Inspection.All compartments must remain closed and
secured during operation.
28175 H
WARNING
28175
215268 A
FallHazard Falling can result in death or serious injury. When lifting personnel, only use a work platform that meets Terex requirements, along with associated machine load charts.
Besure toproperly secureplatform totelehandler
beforeuse. Readandunderstandoperator'smanual.
Wearapprovedpersonnelfallprotection equipmentandattach lanyard toanchor provided.
WARNING
215268
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June 2016Third Edition - First Printing
Part No. 57.0009.0619 GTH-5519 9
09.4618.1622
09.4618.1622
237598
82558
214418
09.4618.1622
DANGER
237971 A
Explosion/BurnHazard
Fueland fumes can explode andburn,
resulting in death or serious injury.
Nosmoking. Keep all open flames and sparks away.
Stopengine before addingfuel.
237971
Stay clear of raised boom or load.
WARNING
Crush Hazard Contact with falling load can result in death
or serious injury.
214418 A
DANGER
Electrocution Hazard Contact with electric
power lines will result in
death or serious injury.
Stay clear of machine.
214418
82558 B
Injection Hazard Escaping fluid under pressure can penetrate skin, causing serious injury.
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 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.
WARNING
82558
237598 A
Crush Hazard Contact between wheel and chassis can result in death or serious injury.
Stayclear ofmachineduringoperation.
WARNING
237598
237598237971
General Safety for Tier 4 Final

June 2016
10 GTH-5519 Part No. 57.0009.0619
Third Edition - First Printing
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 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 at zero degrees.
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.

June 2016Third Edition - First Printing
Part No. 57.0009.0619 GTH-5519 11
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 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 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 lift personnel with this
machine unless it is equipped with
an approved work platform.

June 2016
12 GTH-5519 Part No. 57.0009.0619
Third Edition - First Printing
Work Area Safety
Collision Hazards
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.
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
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.
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.

June 2016Third Edition - First Printing
Part No. 57.0009.0619 GTH-5519 13
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.

June 2016
14 GTH-5519 Part No. 57.0009.0619
Third Edition - First Printing
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.
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.

June 2016Third Edition - First Printing
Part No. 57.0009.0619 GTH-5519 15
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.
Work Area Safety
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 platform movement, electrical line sway 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 platform must not touch or operate the
machine until energized power lines are shut off.
Do not operate the machine during lightning or
storms.

June 2016
16 GTH-5519 Part No. 57.0009.0619
Third Edition - First Printing
Work Area Safety
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.
Electrocution Hazard
Avoid contact with electrical terminal.
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.

June 2016Third Edition - First Printing
Part No. 57.0009.0619 GTH-5519 17
Legend
1. Left/right level indicator
2. Steering wheel
3. Control handle
4. Left rear view mirror
5. Boom angle indicator
6. Boom
7. Cab
8. Hydraulic oil level gauge
9. Engine
10. Forks
11. Seat belt
12. Seat
13. Brake pedal
14. Accelerator pedal
15. Transmission control lever
16. Right rear view mirror
17. Operators manual storage
12
3
11
8
6
9
1
4
16
15
5
13
2
10
14
7
17

June 2016
18 GTH-5519 Part No. 57.0009.0619
Third Edition - First Printing
Controls
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