Terex GTH1215M-180 User manual

Operator’s Manual
Original Instructions
First Edition
Second Printing
April 2017
Part No. 57.0009.0662
Serial number range
GTH-1256 (Perkins Tier 4i)
GTH-1256 (Deutz Tier 4i)
From GTH1215M-101
To GTH1215M-180
From GTH1215M-101
To GTH1215M-180

Contents
Introduction.......................................................... 1
Symbol and Hazard Pictorials Definitions............ 5
General Safety..................................................... 6
Work Area Safety ................................................. 8
Legend............................................................... 16
Controls ............................................................. 17
Inspections ........................................................ 22
Operating Instructions ....................................... 31
Transport and Lifting Instructions ...................... 42
Maintenance...................................................... 45
Attachments....................................................... 49
Specifications .................................................... 60
Load Charts....................................................... 61
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.
April 2017
GTH-1256 Part No. 57.0009.0662
First Edition - Second Printing

April 2017First Edition - Second Printing
Part No. 57.0009.0662 GTH-1256 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 and the CCTV operator's
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)

April 2017
2 GTH-1256 Part No. 57.0009.0662
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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
• 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

April 2017First Edition - Second Printing
Part No. 57.0009.0662 GTH-1256 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.

April 2017
4 GTH-1256 Part No. 57.0009.0662
First Edition - Second 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
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.

April 2017First Edition - Second Printing
Part No. 57.0009.0662 GTH-1256 5
Symbol and Hazard Pictorials Definitions
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
Crush hazard Keep away from
moving parts
Burn hazard. Do not loosen cap
until cool.
Keep away from
moving parts.
Explosion hazard
o
2
N
2
Use nitrogen.
Not use oxygen.
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
Crush hazard.
Keep away from
stabilizers.
No smoking. No
open flame.
No people under
load

April 2017
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General Safety
237605 A
97667 B
Burn Hazard Contact with hotsurfaces can cause burns. Do not touch. Allow surfaces to cool before servicing.
WARNING
97667 B
237598 A
Crush Hazard Contact between wheel and chassis can result in death or serious injury.
Stayclear ofmachineduringoperation.
WARNING
237598 A
WARNING
Crush Hazard Contact between wheel and chassis can result in
death or serious injury.
Stay clear of machine during operation.
237970 A
237970 A 82558 B
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
97667 B
215268 A
214418 A 28175 H
97667 B
214418 A
82558 B 237598 A 237970 A 237605 A
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 H
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 to properly secure platformtotelehandler beforeuse. Readandunderstandoperator'smanual.
Wearapprovedpersonnelfallprotection equipmentandattachlanyardtoanchorprovided.
WARNING
215268 A
09.4618.1842
09.4618.1842
09.4618.1842
Contact with moving outriggers will result in death or serious injury.
Crush Hazard
Stay clear of moving outriggers.
WARNING

April 2017First Edition - Second Printing
Part No. 57.0009.0662 GTH-1256 7
General Safety
09.4618.1622
09.4618.1622
Explosion Hazard
Improper charging of an accumulator can
result in an explosion, which will result in
death or serious injury.
Use only dry nitrogen for charging an accumulator. Do not use air or oxygen. Wear apppropriate personal protective equipment. Read and understand manuals.
o
DANGER
09.4618.1635
2
N
2
09.4618.1635
28236 D
DANGER
237971 A
Explosion/BurnHazard
Fuelandfumes canexplodeand burn,
resulting in death or serious injury.
Nosmoking. Keep all open flames and sparks away.
Stopengine before adding fuel.
237971 A
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 A
214418 A 237598 A 237970 A 237971 A
09.4618.1635
09.4618.1622
28236 D

April 2017
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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 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 level the machine using the frame sway
control unless the boom angle indicator is at zero
degrees or less.
Do not use the sway control to position
an elevated load.
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.
If using accessories, read, understand and obey the
decals, instructions and manuals with the accessory.
Lateral inclination allowed during working
phase ± 0,5°

April 2017First Edition - Second Printing
Part No. 57.0009.0662 GTH-1256 9
Work Area Safety
Only use the machine on firm ground capable of
supporting the maximum combined load of the
machine and payload. If the subsoil collapses,
the machine could tip over. To avoid any risk of
overturning, the following precautions should be
taken:
• Ask your employer (site manager or manager
assistant) if there may be buried pipes, pits,
old tanks, cellar floor, dung yards, etc. under
the ground onto which the stabilizers shall be
lowered.
• A rough estimate of the ground consistency can
be done using the tables and picture in this page.
• The resistance of the subsoil is in relation
to the ground type and geomorphological
characteristics.
Table 1 indicates the superficial pressure which is
allowed under the stabilizers of the machine.
Type of ground,
geomorphological
features
Allowable
superficial pressure
kg/cm2N/mm2
loose, non-compact soil generally speaking,
not solid;
special precautions
needed
loamy, peaty,pasty soil
rippable, soft ground
non-cohesive, well com-
pact soil, sand, gravel 2.0 0.2
rippable
soil
solid 1.0 0.1
semi-
solid 2.0 0.2
hard 4.0 0.4
Rocks, concrete, heavy
traffic paved roads
above
10.0
above
1.0
Table 1
Make sure the machine (wheels and stabilizers)
rests on a firm ground to prevent hazardous unstable
conditions. If the ground is not firm enough, position
some support planks, capable of withstanding the
expected loads, under the stabilizers or the wheels.
In presence of trenches, lower the stabilizers at a
safe distance from the trench edge.
a
h
a& h= minimum distances
The distance (a) from the foot of the overhang
shall be adequate to height (h) of the same over-
hang.
If the ground fulfils the required conditions:
a : h = 1 : 1
(values with a grey background in table 1)
In the case of doubts:
a : h = 2 : 1

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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.
Work Area Safety

April 2017First Edition - Second Printing
Part No. 57.0009.0662 GTH-1256 11
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.
Do not drive the machine unless the stabilizers are
fully retracted.
Work Area Safety
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.

April 2017
12 GTH-1256 Part No. 57.0009.0662
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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.
Do not exceed 22mph travelling speed when driving
downhill.
Do not use the joystick during DPF regeneration.
(only for Deutz Configuration)

April 2017First Edition - Second Printing
Part No. 57.0009.0662 GTH-1256 13
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.
Do not lock the axle differential when the machine
is moving.
Crush Hazards
Do not operate the stabilizers while people are in the
path of movement.
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 notuse air or oxygenfor charging the accumulators.

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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 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.
Work Area Safety

April 2017First Edition - Second Printing
Part No. 57.0009.0662 GTH-1256 15
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.
During maintenance or repair works, and while
welding, disconnect the battery 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 (only for Deutz
Configuration).
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.
Work Area Safety

April 2017
16 GTH-1256 Part No. 57.0009.0662
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Legend
1. Left/right level indicator
2. Steering wheel
3. Control handle
4. Rear convex mirror
5. Boom angle indicator
6. Boom
7. Cab
8. Hydraulic oil level gauge
9. Engine (on opposite side of machine)
10. Forks
11. Seat belt
12. Seat
13. Brake pedal
14. Accelerator pedal
15. Transmission control lever
16. Load charts
17. Front/rear level indicator
18. Right rear view mirror
19. Left rear view mirror
20. Fire extinguisher (if equipped)
21. Operator’s manual location (canopy
version)
22. Operator’s manual location (closed
cab version)
23. Outrigger
12
3
17
4
20
11
8
6
9
1
19
18
15
5
13
2
10
14
7
16
22
21
23

April 2017First Edition - Second Printing
Part No. 57.0009.0662 GTH-1256 17
Controls
Control Panel
1. Steering wheel
2. Horn button
3. Heater and Air conditioning controls (if equipped)
4. Turn signal lever (if equipped)
5. Steer select switch
6. Parking brake switch
7. Ignition switch
8. Instrument panel
9. Control handle
10. Auxiliary hydraulics switch
11. Axle differential lock switch
12. Accelerator pedal
13. Brake pedal
14. Windshield wiper switch (if equipped)
15. Windshield washer switch (if equipped)
16. Work lights switch (if equipped)
17. Hazard warning lights switch (if equipped)
18. Transmission control lever
19. Lock/unlock enabling switch (if equipped)
20. A/ C switch (if equipped)
21. Cab heater fan switch (if equipped)
22. DPF switch (DEUTZ engine configuration)
23. “Shift-on-fly” button
24. “Shift-on-fly” indicator light
25. Rear Object Detection System (if equipped)
26. Diagnostic button
27. Stabilizers switches
P
3
8 5
10
12
19
23
2
9
611
13
7
15
22 14 20
21
16
17
4
1
18
24
25
26
27

April 2017
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Controls
1 Steering wheel
Turn the steering wheel to the right to turn the
front wheels to the right. Turn the steering wheel
to the left to turn the front wheels to the left.
2 Horn button
Press this button and the horn will sound. Release
the button and the horn will stop.
3 Heater and air conditioning controls (if equipped)
4 Turn signal lever (if equipped)
Move the lever up to activate the right turn signal.
Move the lever down to activate the left turn signal.
5 Steer select switch
Rotate the steer selector to the right side to select
four-wheel steer. Rotate the steer selector to the
middle position to select two-wheel steer. Rotate
the steer selector to the left to select crab steer.
6 Parking brake switch
Push the bottom of the rocker switch to turn the
parking brake on. Push the top of the switch to
turn the parking brake off.
7 Ignition switch
Turn the key to the position and hold until
the glow plugs preheating indicator light turns
off; when released, key springs back to pos. I
automatically. Position Pis not active.
8 Instrument panel
9 Control handle (single)
Pull the control handle back and the boom will
raise. Push the control handle forward and the
boom will lower. Push the control handle to the
right and the boom will extend. Pull the control
handle to the left and the boom will retract. Hold
down the grey thumb switch and pull the control
handle back and the forks will tilt up. Hold down
the grey thumb switch and push the control handle
forward and the forks will tilt down. Hold the grey
finger switch and push the control handle to the
right and the machine will sway to the right. Hold
the grey finger switch and pull the control handle
to the left and the machine sway to the left.
10 Auxiliary hydraulics switch
Push the left side of the auxiliary hydraulics button
and the carriage will swing or rotate to the left.
Push the right side of the auxiliary hydraulics
button and the carriage will swing or rotate to
the right.
11 Axle differential lock switch
Push the switch to activate the axle differential
lock. Release the switch to release the axle
differential lock.
12 Accelerator pedal
13 Brake pedal
14 Windshield wiper switch (if equipped)
Push the switch to turn the wiper on: first position
for low speed and second position for high speed.
Release the switch to turn the wiper off.
15 Windshield washer switch (if equipped)
Push and hold the switch to turn the washer on.
Release the switch to turn the washer off.
16 Work lights switch (if equipped)
Push the top of the rocker switch to turn the front
& boom working lights on. Push the bottom of
the switch to turn them of.