Terex GTH1516M-340 User manual

Operator’s Manual
Original Instructions
Second Edition
Second Printing
April 2017
Part No. 57.0009.0610
Serial number range
GTH-1544 (Perkins Tier 4i)
GTH-1544 (Deutz Tier 4i)
From GTH1516M-340
to GTH1516M-599
From GTH1516M-340
to GTH1516M-599

Contents
Introduction.......................................................... 1
Symbol and Hazard Pictorials Definitions............ 5
General Safety..................................................... 6
Work Area Safety ................................................. 7
Legend............................................................... 15
Controls ............................................................. 17
Inspections ........................................................ 21
Operating Instructions ....................................... 30
Transport and Lifting Instructions ...................... 41
Maintenance...................................................... 44
Attachments....................................................... 48
Specifications .................................................... 59
Load Charts....................................................... 60
Copyright © 2017 by Terex Corporation
Second 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-1544 Part No. 57.0009.0610
Second Edition - Second Printing

April 2017Second Edition - Second Printing
Part No. 57.0009.0610 GTH-1544 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)

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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 2017Second Edition - Second Printing
Part No. 57.0009.0610 GTH-1544 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.

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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
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.

April 2017Second Edition - Second Printing
Part No. 57.0009.0610 GTH-1544 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
Crush hazard Keep away from
moving parts
Burn hazard. Do not loosen cap
until cool.
Keep away from
moving parts.
No smoking. No
open flame.
Explosion hazard
o
2
N
2
Use nitrogen.
Not use oxygen.
Symbol and Hazard Pictorials Definitions
Explosion hazard
No 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

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General Safety
237605 A
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 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.
Stay clearofmachine during operation.
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
237601 A
214418 A 28175 H
97667 B
214418 A
97602 C
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 secureplatform to telehandler beforeuse. Readandunderstandoperator'smanual.
Wearapprovedpersonnelfallprotection equipmentandattachlanyardtoanchorprovided.
WARNING
215268 A

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Part No. 57.0009.0610 GTH-1544 7
09.4618.1622
09.4618.1622 214418 A
237598 A 237970 A 237971 A
09.4618.1635
09.4618.1622
Explosion Hazard Death or serious injury can result from the use of ether or other high energy starting aids. 97602 C
WARNING
Do not use ether or
other high energy
starting aids on
machines equipped with glow plugs or
gridheater.
97602 C
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
Fueland fumes canexplode and 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
28236 D
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 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.