Terex Genie GTH-1544 Operator'S Manual Download

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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

Summary of Contents for Genie GTH-1544

Page 1: ...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 ...

Page 2: ...nd 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 ...

Page 3: ...uck with a pivoting boom which maybeequippedwithvariousattachmentsforpicking 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 ...

Page 4: ...pplications and safety Standards and regulatory compliance information QuestionsregardingProductModifications 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 informati...

Page 5: ...and 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 Youread understandandobeythemanufacturer 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 employ...

Page 6: ...ds published by the American National Standards Institute and the IndustrialTruckStandardsDevelopmentFoundation 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 stan...

Page 7: ...azard 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 o2 N2 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...

Page 8: ...re 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 W...

Page 9: ...eath 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 DANGER237971 A Explosion Burn Hazard Fuel and fumes can explode and burn resulting in death or serious injury No smoking Keep all open flames and sparks away Stop engine before ...

Page 10: ...structions 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 Donotoperatethemachineiftheloadchartismissing Do not exceed the rated capacity for each configuration Do not raise the boom unless the machine is level The machine level indicatorshouldbeatzerodegrees Do not level the ...

Page 11: ... 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 posi...

Page 12: ...e 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 rev...

Page 13: ...aintenance 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 Immediatelytagandremovefromse...

Page 14: ...eep clear of elevated components Supportcomponentsbeforeperformingservice 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 Refue...

Page 15: ... 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 discon...

Page 16: ...es 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 ...

Page 17: ...vel 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 12 3 17 4 20 11 8 6 9 1 19 18 15 5...

Page 18: ...lock switch 12 Accelerator pedal 13 Brake pedal 14 Windshield washer switch if equipped 15 Windshield wiper 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 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 Shif...

Page 19: ...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 thegreythumbswitchandpushthecontrolhandle forward and the forks will tilt down Hold the grey finger switch and push the control handle to the right and th...

Page 20: ...C off 21 Cab heater fan switch if equipped Push the switch to turn the cab heater fan on first position for low speed and second position for high speed Release the switch to turn the cab heater fan off 22 DPF switch DEUTZ engine configuration Push the switch to enable the DPF regeneration 23 Shift on fly button Push and hold the button to shift from one gear to another when the machine is travell...

Page 21: ...t 7 Diesel particulate filter indicator light Deutz configuration 8 Not active 9 Not active 10 Engine air filter restricted indicator light 11 DPF Alert indicator light 12 Engine Critical Fault indicator light 13 2nd gear engaged indicator light 14 1st gear engaged indicator light 15 High engine coolant temperature gauge 16 Position light indicator light 17 Hour meter 18 Tachometer 19 High hydraul...

Page 22: ...n the supplemental operator s manual 10 Engine air filter restricted indicator light When this lamp comes on the engine air filter is clogged proceed with cleaning or changing the air filter cartridge 11 DPF Alert indicator light This light flashes to warn of a problem of the engine To identify the problem see the two sections Engine Lamp Logic 12 Engine Critical Fault indicator light This light c...

Page 23: ...ction is designed to discover if anything is apparentlywrongwithamachinebeforetheoperator performs the function tests Thepre operationinspectionalsoservestodetermine ifroutinemaintenanceproceduresarerequired Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unauthorized variation ...

Page 24: ...mage improperlyinstalledormissingpartsandunauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive motors and drive hubs Boom wear pads Tires and wheels Mirrors and rear object detection system if equipped Engine and related components Limit switches Lights alarms and beacons if equipped Pins nuts b...

Page 25: ... 5 Only use the machine as it was intended Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service Theoperatormustfollowthestep by stepinstructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine m...

Page 26: ...10 Step on the brake pedal Push the top of the parking brake switch to turn it off 11 Insert the key in the ignition switch 12 Turn the key to start the engine Result The engine should not start 13 Set the transmision control lever in gear 14 Push the bottom of the parking brake switch to turn it on 15 Insert the key in the ignition switch 16 Turn the key to start the engine Result The engine shou...

Page 27: ...rection Result The front wheels and the rear wheels should turn in the same direction as the steering wheel Test the Transmission and Brakes 29 Be sure the boom is fully lowered and retracted 30 Step on the brake pedal Push the top of the parking brake switch to turn it off 31 Move the transmission control lever to forward Slowly let up on the brake pedal As soon as the machine starts to move push...

Page 28: ...fly button placed at the top end of the transmission control lever Result The machine should not shift from one gear to another Test the Drive and Sway Cutout 41 Raise the boom to 50 Do not extend the boom 42 Step on the brake pedal 43 Push the top of the parking brake switch The parking brake is off when the indicator light is off 44 Put the transmission control lever in forward Slowly let up on ...

Page 29: ...n helps the operator determineiftheworkplaceissuitableforsafemachine operation Itshouldbeperformedbytheoperatorprior to moving the machine to the workplace Itistheoperator sresponsibilitytoreadandremember theworkplacehazards thenwatchforandavoidthem while moving setting up and operating the machine Workplace Inspection Checklist Be aware of and avoid the following hazardous situations drop offs or...

Page 30: ...ion Burn Hazard Fueling 1 826345 Label Ultra Low Sulfur Fuel Only 1 09 4618 1399 Label Upper Door Unlock System 1 09 4618 1418 Label Emergency Exit 1 09 4618 1618 Cosmetic GTH 1544 1 Part No Decal Description Qty 09 4618 1619 Notice Driving Downhill 1 09 4618 1621 Cosmetic Genie 1 09 4618 1622 Danger Warning 7 Decal Combination 1 09 4618 1625 Cosmetic Genie 1 09 4618 1630 Cosmetic Genie 1 09 4618 ...

Page 31: ...971 28159 09 4618 1635 215268 09 4618 1630 237970 82366 215267 214418 09 4618 1618 09 4618 1631 09 4618 1625 09 4618 1655 97667 09 4618 1638 214418 28175 09 4618 1632 97602 82558 237601 237605 09 4618 1633 237598 237598 237970 97667 237606 214418 09 4618 1640 97667 09 4618 1646 09 4618 1672 826345 28236 09 4618 1998 09 4618 1834 Shading indicates decal is hidden from view i e under covers ...

Page 32: ...anuals A variable reach rough terrain forklift truck is defined as a wheeled type truck designated primarily as a fork truck with a pivoted boom which may be equipped with attachments for lifting material Using it for any other use is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use a machine at differe...

Page 33: ...conds before trying to start again Starting in Cold Condition In cold conditions 20 F 6 C and below warm the engine for 5 minutes before operating to prevent hydraulic system damage In extreme cold conditions 0 F 18 C and below machines should be equipped with optional cold start kits Attempting to start the engine when temperatures are below 0 F 18 C may require the use of a booster battery Steer...

Page 34: ...OFF the travelling speed is beyond the admissible speed range and by pressing the switch gear won t be shifted If the indicator light flashes there are errors or problems Try to modulate the machine speed and check if the light comes on with a solid light The speed engagement is signalled by the dedicated indicator lights according to the engaged speed While traveling less than 3 mph on slopes the...

Page 35: ...d traffic clear of fiammable material clear of explosive atmospheres iii Set the parking brake iv Move the transmission control lever to neutral v Warm up the engine the coolant temperature must reach at least 75 C vi Keep the engine on vii Activate the DPF regeneration pushing on the DPF switch indicator light 7 becomes a solid light and the enigne revs up to 1 500 1 600 rpm viii Keep clear of th...

Page 36: ...eneration Operating Instructions Perkins configuration In this configuration regeneration always starts automatically Only when temperature is below 18 C the system is not able to activate the regeneration by itself 11 Dpf Alert indicator light 11 starts blinking and the operator has to start the DPF regeneration following these instructions i Select a safe outdoor parking location firm level surf...

Page 37: ...oad will meet the load chart specifications 2 Divide the load into smaller pieces so that each piece meets the load chart specifications 3 Obtain a larger machine capable of handling the load within specifications Placing the load 1 Travel to the desired work site and carefully stop the machine 2 Put the transmission in neutral 3 Apply the parking brake 4 Level the frame if the left to right level...

Page 38: ...ntroller to lower and extend the boom into final position Lower the load until the weight is completely off the forks Do not apply a downward force with the forks Operating Instructions 7 Gradually move the controller to raise and retract the boom This will bring the forks out of the load 8 When the forks are clear of the load and the structure the boom can be lowered and retracted ...

Page 39: ...ond Edition Second Printing Part No 57 0009 0610 GTH 1544 37 Operating Instructions Controller movements Control handle only Control handle only with grey thumb switch A Control handle only with grey finger switch B ...

Page 40: ...lock of the new attachment 8 Retract and raise the attachment a small distance It will centre automatically on the quick coupling frame 9 Refit mechanical locking pin fixing it with its safety split pin 10 Re couple the connectors of the attachment if any Version with hydraulic locking optional 1 Drive to the place where you will release the mounted attachment when possible a solid and sheltered s...

Page 41: ... machine directly to the starter or the starter solenoid Serious injury or death could result from the machine moving forward or backward To avoid personal injury when jump starting with another machine be certain that the machines are not touching Never jump start a frozen battery as it will explode Keep sparks and flames away from the battery Lead acid batteries generate explosive gases when cha...

Page 42: ...achine will tip over during dynamic machine operation involves many variables 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 ...

Page 43: ...e in preparing loading and securing construction and lifting equipment for international shipment Only qualified operators should move the machine on or off the truck The transport vehicle must be parked on a level surface The transport vehicle must be secured to prevent rolling while the machine is being loaded Before loading for transport make sure the deck ramps and machine tires are free of mu...

Page 44: ...d Prior to loading level the telehandler and retract the boom Use a spotter to load and unload the telehandler Keep the boom as low as possible when loading and unloading Set the parking brake Securing the Chassis Use chains of ample load capacity Use a minimum of 6 chains There are 8 tie down points on the chassis two in the front and three on each side of the machine Fully lower the forks or att...

Page 45: ...tions Be sure the crane capacity loading surfaces and straps or lines are sufficient to withstand the machine weight See the serial label for the machine weight 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 Attach the rigging only to the designated lifting points on the mach...

Page 46: ...g of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine will be required to perform this procedure Diesel Fuel Requirements Satisfactory engine performance is dependent on the use of a good quality fuel The use of a good quality fuel wil...

Page 47: ...0 Maintenance Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure that the engine is off the frame is level and the boom is in the stowed ...

Page 48: ...ing cap and adding fluids Check the Tire Pressure Tip over hazard An over inflated tire can explode which may compromise machine stability and cause the machine to tip over Tip over hazard The use of temporary flat tire repair products may lead to tire failure which could compromise machine stability and cause the machine to tip over Bodily injury hazard An over inflated tire can explode and may c...

Page 49: ...rformance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills wi...

Page 50: ...ed regarding the specific hazards associated with using the telehandler with the work platform and utilize all means including those provided by the user or employer to avoid them Always perform a pre operation inspection of the platform per the manufacturer s instructions prior to use If damage or any unauthorized variation from factory delivered condition is discovered the platform must be tagge...

Page 51: ...it the platform Do not climb down from the platform when raised Do not place or attach overhanging loads to any part of this machine or platform Do not place ladders or scaffolds in the platform or against any part of this machine Do not tie the boom or platform to adjacent structures Do not place loads outside the platform perimeter Do not transport tools and materials unless they are evenly dist...

Page 52: ... 14m 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft 30 ft 35 ft 40 ft 45 ft 5 ft 10 67m 12 19m 13 72m 0 m 1 52 m 3 05m 4 57m 6 10m 7 62m 9 14m 1 52 m 0 ft 0 m 5 ft 1 52 m 10 ft 3 05m 15 ft 4 57m 20 ft 6 10m 25 ft 7 62m 30 ft 9 14m 60 50 20 0 10 30 40 A B C D E 70 75 5 5 10000 lbs 5000 lbs 3500 lbs 15000 lbs 7000 lbs 5000 lbs 2268 kg 10000 lbs 4536 kg 15000 lbs 6804 kg 3500 lbs 1588 kg 7000 lbs 3175 kg Occupant...

Page 53: ...rected by the occupants Always lift and lower personnel smoothly and with caution and only at their request Operating Instructions Preparation and Setup Read understand and obey all jobsite local state federal and provincial rules standards and regulations as they pertain to the use of a telehandler mounted personnel work platform In the USA and Canada reference ANSI ITSDF B56 6 and CSA B335 If th...

Page 54: ...se and secure the entry point gate or railing before signaling to be lifted Attach PFPE to the designated lanyard anchor Occupants should use the guardrail to help stabilize themselves during movement Be aware of crushing hazards when grasping the platform guardrail Lifting and lowering the platform Set the parking brake and place the transmission into neutral Only allow personnel to enter and exi...

Page 55: ...ry As a suspended load moves the load center can change As a result extreme caution in transporting and lifting or placing the load must be observed to minimize the potential for the load to move Overturning Hazards Do not lift a suspended load without the proper and legible load capacity chart for the attachment telehandler combination you are using Do not permit the load to swing freely Always p...

Page 56: ...s as the load center will move towards the tipping line thereby reducing stability Only climb or descend inclines with extreme care as the load center will move towards the tipping line thereby reducing stability Do not park on a slope Fall Hazards Do not lift or suspend personnel Collision Hazards Be sure that the load is clear of any adjacent obstacles before lifting When visibility is or could ...

Page 57: ...y and gradually raise the boom and load making sure to keep the load and boom as low to the ground as practical Be sure that all boom and attachment movements are performed as slow as practical to avoid swinging of the load Travelling Be sure that the path of travel is level and capable of supporting the telehandler with its load Keep the boom and load as low as practical while maintaining visibil...

Page 58: ... rigging and tethers can be removed 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 When the equipment is traveling the view in the direction of travel is obstructed Due to site specific safety concerns either the operator or the person handl...

Page 59: ...osed RAISE THE BOOM AND LOWER THE LOAD With arm extended horizontally to the side and thumb pointing up fingers open and close while load movement is desired DOG EVERYTHING Hands held together at waist level LOWER With arm and index finger pointing down hand and finger make small circles LOWER BOOM With arm extended horizontally to the side thumb points down with other fingers closed EXTENDED TELE...

Page 60: ...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 prevent unintentional displacement Hooks with self closing latches or their equivalent must be used Exception J hooks are permitted to be used for setting wooden trusses The materials must be rigged by a qualified rigge...

Page 61: ...m load center 10 000 lbs 4 536 kg Lift capacity maximum reach with 24 in 61 cm load center 3 500 lbs 1 587 kg Maximum lift capacity 15 000 lbs 6 804 kg Drive speed maximum Deutz engines 18 mph 29 km h Drive speed maximum Perkins engines 18 mph 29 km h Frame sway 7 Tire size 17 5 x 25 in 20 ply Turning radius outside 2 wheel steer 22 ft 10 in 6 98 m Turning radius outside 4 wheel steer 14 ft 7 in 4...

Page 62: ...D E 70 75 5 5 10000 lbs 5000 lbs 3500 lbs 15000 lbs 7000 lbs 5000 lbs 2268 kg 10000 lbs 4536 kg 15000 lbs 6804 kg 3500 lbs 1588 kg 7000 lbs 3175 kg GTH 1544 Standard Carriage 0 ft 0 m 5 ft 1 52 m 10 ft 3 05 m 15 ft 4 57 m 20 ft 6 10 m 25 ft 7 62 m 30 ft 9 14 m 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft 30 ft 35 ft 40 ft 45 ft 5 ft 10 67 m 12 19 m 13 72 m 0 m 1 52 m 3 05 m 4 57 m 6 10 m 7 62 m 9 14 m 1 52 m...

Page 63: ...30 ft 9 14 m 0 ft 0 m 5 ft 1 52 m 10 ft 3 05 m 15 ft 4 57 m 20 ft 6 10 m 25 ft 7 62 m 30 ft 9 14 m 4400 lbs 1996 kg 3500 lbs 1587 kg 3 000 lbs 1360 kg GTH 1544 7 ft Truss Boom 0 ft 0 m 5 ft 1 52 m 10 ft 3 05 m 15 ft 4 57 m 20 ft 6 10 m 25 ft 7 62 m 30 ft 9 14 m 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft 30 ft 35 ft 40 ft 45 ft 5 ft 10 67 m 12 19 m 13 72 m 0 m 1 52 m 3 05 m 4 57 m 6 10 m 7 62 m 9 14 m 1 52 ...

Page 64: ...April 2017 62 GTH 1544 Part No 57 0009 0610 Second Edition Second Printing Load Charts GTH 1544 Shackle 09 4618 1868 GTH 1544 ...

Page 65: ... t u b i r t s i D www genielift com California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

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