Terex Genie GTH5516M-5338 Bedienungsanleitung

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

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.

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 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

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 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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