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danger - BlueLine Rental

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4. i e E E ar 8 de GROUND SYMBOL T e eel Ep T COLOUR LEGEND sh 2 A ORANGE Z T B WHITE Poc in 5 5 C PINK D GREY Em a Ae 45 E GREEN x F BLUE T o o usus o 5 5 233938 p i G YELLOW L Bs 8n T E 58 28 PS f H LIGHT BLUE I 5 3 69 br Bo Bs Be D M BROWN th T T Sg N BLACK dL L amp K amp D AS 62 _ V PURPLE Page G 7 Document 57 0005 9200 12 2005 A TEREX COMPANY G 3 5 GENERAL WIRING DIAGRAM description Handler with telescopic boom GTH 5519 TABLES AND DOCUMENTS ENCLOSED 5 Ref Description Ref Description 1 WARNING LIGHTS FUEL GAUGE 37 HYDRAULIC OIL TEMPERATURE SENSOR 2 ENGINE OIL TEMPERATURE TRANSDUCER 38 AIR FILTER CLOGGING SENSOR 3 ENGINE OIL COOLING TEMPERATURE 39 ENGINE OIL PRESSURE TRANSDUCER INDICATOR 40 OIL TEMPERATURE INDICATOR SENSOR 4 MOVEMENT STOP SWITCH 41 WHEEL STEERING SOLENOID VALVE 5 REAR WORK LIGHT SWITCH 42 WHEEL STEERING SOLENOID VALVE 6 12 WAY CONNECTOR STEERING COLUMN 43 BACK UP HORN LINE CONNECTION TO CAB LINE 44 FUEL FLOAT 7 FRONT WORK LIGHT SWITCH 45 WORK LIGHT 8 CHANGEOVER OVER SWITCH 46 HORN 9 HO
5. G 3 1 WIRING DIAGRAM FUSES AND RELAYS ON FUSES 14 F28 F29 INT Ref Circuit Amp Mu m F1 Interior lamp power supply 2 F2 Frontwork light switch power supply 10 E5 F3 Rear work light switch power supply 10 F4 E1relay pickup E2 relay pickup relay pickup EE To Relay E6 power supply hydraulic stop EPA warning lights fuel gauge instrument air filter E3 soiled warning light preheating warning light m engine oil cooling temperature indicator light e E engine oil temperature indicator 5 E a F5 Power supply engine stop solenoid am m preheating control unit 10 F6 Horn switch power supply 10 F7 solenoid valve switch power supply 5 tol tol F8 Parking brake switch power supply 5 F9 Windscreen wiper washer motor power supply 15 F10 Windscreen wiper washer switch power supply 5 F11 Power supply beacon lighting warning lights fuel gauge engine oil temperature indicator engine oil cooling temperature indicator 7 5 E11 F30 F31 E12 F12 Power supply steering selector 7 5 F13 Relay E3 Relay 5 power supply 5 F14 Notused 5 F15 Not used 2 F16 Not used 10 F17 Notused 10 F18 Notused 5 F19 used 10 F20 used 10 F21 Notused 5 F22 Notused 5 RELAYS F23 used 15 F24 Not used 5 Rer F25 Notused 75 E1 Front rear work lights F26 used 75
6. GTH 5519 09 4618 064 lt Genie 5519 MEE 09 4618 0643 09 4618 0010 09 4618 0641 Genie 09 4618 0061 09 4618 0061 ES a 0 09 4618 0109 97674 97664 A 97668 97665 top of chassis boom rest m 09 4618 0644 5519 97672 97666 97669 97664 09 4618 0061 09 4618 0061 4 bar 4 4 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 GENERAL INFORMATION Code Description 82558 Fluid at pressure 97664 Risk of crushing hands 97665 Safety belts 97666 Read the user s manual 97667 Risk of burns and scalds 97668 Risk of overturning 97669 Risk due to falling objects 97670 Risk of crushing 97671 Risk of explosion burns 97672 Risk of crushing 97673 Prohibition to lift people 97674 Risk of crushing 97675 Risk of explosion burns 97676 Electrical hazard 97688 Emergency exit handle 09 4616 0051 Hydraulic oil 09 4616 0101 Machine data plate 09 4618
7. J r8 22 A 21 F6 F20 Goo J J P STER F15 Boo s B Fuses Ref Circuit Amp F1 Interior lamp power supply 2 F2 Frontwork light switch power supply 10 F3 Rear work light switch power supply 10 F4 E1 relay pickup E2 relay pickup E3 relay pickup Relay E6 power supply hydraulic stop warning lights fuel gauge instrument air filter soiled warning light preheating warning light engine oil cooling temperature indicator light engine oil temperature indicator 5 F5 Power supply engine stop solenoid preheating control unit 10 F6 Horn switch power supply 10 F7 Vse solenoid valve switch power supply 5 F8 Parking brake switch power supply 5 F9 Windscreen wiper washer motor power supply 15 F10 Windscreen wiper washer switch power supply 5 F11 Power supply beacon lighting warning lights fuel gauge engine oil temperature indicator engine oil cooling temperature indicator 7 5 F12 Power supply steering selector 7 5 F13 Relay E3 Relay 5 power supply 5 F14 Not used 5 F15 Not used 2 F16 Not used 10 F17 Not used 10 F18 Not used 5 F19 Not used 10 F20 Not used 10 F21 Not used 5 F22 Not used 5 F23 Not used 15 F24 Not used 5 F25 Not used 7 5 Page D 22 Document 57 0005 9200 12 2005 eis A TEREX COMPANY enie Handler with telescopic boom GTH
8. oh ok Nao Page A 13 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 GENERAL INFORMATION A TEREX COMPANY A 4 2 DESCRIPTION OF THE MAIN COMPONENTS Hydrostatic transmission This unit consists of parts which drive the machine shifting and namely variable displacement pump connected to the thermal engine by an elastic joint amotor with variable displacement and automatic adjustment in relation to the wheel torque required complete with power divider directly applied on the rear axle ahydraulic oil filter placed on the discharge line to the tank aheat exchanger to cool the circuit down Motion is transmitted to the rear axle from the power divider through a Cardan shaft Engine The thermal engine is equipped with a heat exchanger which uses the engine oil as cooling medium Steering axles front and rear differential gears The differential axles transmit the motion to the wheels The locking device acting on the front axle enables the machine to move also on low grip grounds Tyres The machine is equipped with tyres suitably sized for the maximum load allowed on the handler When worn they shall be replaced with new ones having the same dimensions and loading capacity Boom hydraulic circuit Telescopic boom The machine is equipped with a telescopic boom with hydraulic driven extension The telescopes slides on interchangeable pads made of wearpro
9. OPTIONAL ATTACHMENTS F 131 SHOVEL Application Quick coupling fitted attachment for moving soil sand debris cereals etc Code GTH 5519 Litres 500 59 0200 0000 Safely Strictly obey the general safety precautions given in section B SAFETY Operation When using a shovel load the material only when the boom is completely retracted and push against the heap with straight wheels To load unload the material operate the rotation lever of the attachment holding plate Maintenance Visually check the shovel for damage before using it Technical data Capacity litres 500 A Width mm 1850 B Length mm 760 H Height mm 700 Weight kg 290 ATTENTION Attachment suitable for moving loose material Do not use for digging operations Page F 3 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 e A TEREX COMPANY OPTIONAL ATTACHMENTS F 1 2 CEREAL SHOVEL Application Quick coupling attachment for loading cereals or inert materials etc Code GTH 5519 Litres 800 59 0200 1000 Safety Strictly obey the general safety precautions given in section B SAFETY Operation When using a shovel load the material only when the boom is completely retracted and push against the heap with straight wheels To load unload the material operate the rotation lever of the attachment holding plate Maintenance Visually check the shovel for damage before us
10. 1 Green area 2 Yellow area Normal condition Replace the filter as soon as possible 3 Red area Shut the engine down to prevent damage to the hydraulic system Change the filter and or check for the fault reasons To change the hydraulic oil filter element on the suction line proceed as follows 1 Stop the machine on a level ground and engage the parking brake 2 Placeacontainer of suitable size under the filter to collect any oil leaks then close cock Q 3 Remove the filtering element using a wrench 4 Change the filtering element then before fitting a new one thoroughly clean and grease both seat and gasket 5 Hand tighten and re open cock IMPORTANT Hydraulic oil filter cartridges cannot be cleaned or washed and refitted They must be replaced with new ones of the type recommended by the manufacturer see par D 5 2 2 PROTECT THE ENVIRONMENT The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres IMPORTANT When changing the oil drain it when it is still hot and the polluting substances are in suspension Page D 13 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 MAINTENANCE Ie A TEREX COMPANY D 3 10 2 Auxiliary circuits oil filter Tochangethe hydraulic oil filter cartridge of the service circuits proceed as follows 1 Stopthemachineonalevel ground and
11. NOSELECTION OF THESTEERING MODE Fuse F20 controlling the steering selection blown ROAD JOBSITE switch set to ROAD Sostituire il fusibile Set to JOBSITE ROAD FUNCTION ON EVEN WHEN SELECTING THE JOBSITE FUNCTION No ROAD JOBSITE selection Check and replace fuse F20 if necessary Page E 2 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 FAULTS AND TROUBLESHOOTING NO BOOM LOWERING AND EXTENSION NO HOLDING FRAME TILTING Fuse blown Replace fuses F2 and or F24 THE HYDRAULIC OIL THERMOMETER DOES NOT WORK This is normal when the outside temperature is low and or the machine is used for short periods since the hydraulic oil cannot warm up over 40 50 C THE PARKING BRAKE LIGHT DOES NOT LIGHT UP Fuse blown Replace fuse F15 BOOM DOES NOT MOVE Fuse blown ROAD JOBSITE switch set to ROAD Emergency button ON Check and replace fuse F22 if necessary Set to JOBSITE e Reset the button ATTENTION In case of faults not listed in this chapter address to the GENIE Technical Assistance your nearest authorised workshop or dealer Page E 3 Document 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 TE FAULTS TROUBLESHOOTING Page E 4 Document 57 0005 9200 12 2005 G io H
12. Neither stop nor carry out interventions under or between the machine wheels when engine is running When maintenance in this area is required stop the engine Do not carry out maintenance or repair works without a sufficient lighting When using the machine lights the beam should be oriented in order not to blind the personnel at Work Before applying voltage to electric cables or components check their connection and proper functioning Do not carry out interventions on electric components with voltage over 48V Do not connect wet plugs or sockets Plates and hazard warning stickers shall never be removed hidden or become unreadable Document 57 0005 9200 12 2005 enie Handler with telescopic boom GTH 5519 TE A TEREX COMPANY SAFETY e Except for maintenance purposes do not remove safety devices shields protection cases etc Should their removal be necessary stop the engine remove them with the greatest care and always remember to refit them before starting the engine and using the machine again e Before any maintenance or repair work stop the engine and disconnect the batteries e Do not lubricate clean or adjust moving parts Do not carry out operations manually when specific tools are provided for this purpose e Absolutely avoid to use tools in bad conditions or in an improper way i e pliers instead of adjustable wrenches etc Before carrying out operations on hydraulic lines under pres
13. 4 5 e a 16 _ 8 Document 57 0005 9200 12 2005 A TEREX COMPANY 3 2 ENGINE CONTROLS AND INSTRUMENTS C 3 2 1 Ignition switch Three position switch N Q No circuit under voltage key can be removed E and engine is stopped R Circuits under voltage presetting for the engine starting Board controls and instruments are on The warning light 6 signalling the glow plugs preheating comes on Wait until the light goes off before starting the engine Engine starting when released key springs back to pos automatically 9 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS 3 2 2 5 gear selector switch Three position switch with lock in neutral position Neutral position no gear engaged Shift lever to pos F to select the forward gear Shift lever to pos R to select the reverse gear v Document 57 0005 9200 12 2005 TEREX COMPANY 3 2 3 Brakes 11 Service brake pedal Gradually step on the brake pedal to decelerate and stop the machine The pedal operates on the front axle Fully depressing the brake pedal causes a reset of the displacement of the power drive pump and makes the braking action more powerful 18 Parking brake The parking brake of negative type eng
14. 6 D 5 2 2 Rear differential gear Oil 5 D 5 2 2 Front wheel reduction gears Oil 1 5 1 5 D 5 2 2 Rear wheel reduction gears Oil 0 7 0 7 D 5 2 2 Brake oil tank Hydraulic oil 0 1 D 5 2 2 D 5 2 PRODUCT SPECIFICATIONS D 5 2 1 Engine oil Use the oil recommended by the Diesel engine Manufacturer see the relevant handbook delivered with the machine At the delivery the machine is refilled with SHELL RIMULA 15W 40 D 5 2 2 Lubrication oils and relevant filtering elements Refill the machine with following lubricants Use Product Definition Power divider Differential gears Reduction gears FUCHS TITAN GEAR LS 85 W 90 API GL 5 LS GL 5 Hydraulic system and brakes SHELL TELLUS T 46 DENISON HF 1 DIN 51524 part Cat HV ATTENTION Never mix different oils this may result in troubles and component breaks Filtering elements Filter Flow 1 1 Filtering Code Transmission oil filter MPS 150 10 09 4604 0001 Auxiliary circuit oil filter inside the tank STR 100 1 60 09 4604 0004 0 24 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY D 5 2 3 Fuel Use only Diesel fuel with less than 0 596 sulphur content according to the specifications of the diesel engine operation handbook ATTENTION In cold climates temperature under 20 C use only Arctic type Diesel fuel or oil diesel fuel or oil diesel fuel mixtures The co
15. C 2 2 ADJUSTING THE SEAT A correct adjustment of the seat ensures the operator a safe and comfortable driving The handler seat is fitted with devices which allow for the adjustment of the springing the height and the distance from the controls e Seat distance from the controls The seat is equipped with an adjusting device to slide the same seat forward or back with respect to the steering column To adjust the seat pull lever 1 outwards and push the seat to the desired direction Then release the lever and make sure that the seat locks in position e Springing adjustment optional Rotate lever 2 clockwise or anticlockwise according to the springing degree required Rotate clockwise anticlockwise to increase reduce the seat springing To reverse this control pull out and rotate the lever knob by 180 In some seats height can be adjusted to three different positions Lift the seat until you hear the click signalling that the seat is locked in position To lower the seat raise to end of stroke to release the mechanism then release the seat it will return to the bottom position 2 3 FASTENING THE SEAT BELTS e Height adjustment optional Turn knob 3 clockwise to lift the seat turn it Sit correctly in the driving seat then counter clockwise to lower the seat The safety belts are equipped with reel retractor To fasten the belt pull tab 1 and push it into buckle 2 To release the belt push button 3 an
16. FRONT PART LEFT SIDE LOWER PART Page A 2 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 GENERAL INFORMATION e A TEREX COMPANY 1 2 LABELS AND WARNING PLATES APPLIED ON THE MACHINE This paragraph lists the labels and warning plates normally applied on standard machines or on special attachments coupled to the machine IMPORTANT The familiarisation with these labels is never a waste of time Make sure they are easy to read For this purpose clean them or replace those that become unreadable either graphic or text To clean labels use of a soft cloth water and soap Never use solvents petrol etc When a label is applied on a part to be replaced make sure that the replaced part is already labelled as required or apply a new label A 1 2 1 Position 09 4618 0109 09 4618 0109 09 4618 0109 Page A 3 Document 57 0005 9200 12 2005 enie Handler with telescopic boom GTH 5519 GENERAL INFORMATION 09 4616 0051 4 8 Genie 5519 09 4618 0643 AT z Ew 97667 97671 97675 97664 094618005 m a O
17. Low temperature starting Disconnecting the battery Starting the machine Stopping and parking the machine USING THE HANDLER Using the load charts aciei peer s t c M Adjusting the floating forks Working phases cesses chanics Changing the attachment TRANSPORTING THE MACHINE Moving a disabled machine Unlocking the negative brake Road or site transfer Lifting the machine Transporting the machine on other ie Parking and storage Short 45 5 Machine storage Cleaning and washing the machine Cleaning instructions Washing instructions Machine disposal Disposal of batteries Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS A TEREX COMPANY INTRODUCTION This section provides the operator a practical guide for the gradual learning of the machine use The operator should get into the driving cab and carry out the preliminary adjustments then memorise the position of the different controls and instruments The familiarisation with the controls ensures not onl
18. speed of the actuator CAUTION The control lever shall be operated only when correctly seated in the driving place CAUTION Before operating the control lever make sure that nobody is within the working range of the machine Page C 14 Document 57 0005 9200 12 2005 enie Handler with telescopic boom GTH 5519 TE UEM OPERATING INSTRUCTIONS C 3 4 1 Function selection The lever is enabled to carry out the following motions Boom lowering lifting shift the control lever to or Boom extraction retraction shift the control lever to 9 or Attachment back forward tilting press button and shift the control lever to or e Attachment coupling release press button together with the dashboard enabling button and shift the lever to or Page C 15 Document 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 TE T OPERATING INSTRUCTIONS BC 3 4 2 Lifting lowering the boom CAUTION Before operating the boom make sure that nobody is within the working range of the machine To lift or lower the boom Smoothly shift the lever to position to lift the boom or to position to lower it Page C 16 Document 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 TE OPERATING INSTRUCTIONS BC 3 A43 Pitching the attachment holding frame forwards backwards CAUTION Before operating the boom
19. 12 Battery Ah 100 IMPORTANT This is a device of Class A In a residential environment such device can cause radio disturbance In such cases the operator is required to take suitable measures Page A 16 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 GENERAL INFORMATION A TEREX COMPANY 6 LIFETIME The lifetime of the machine is 10 000 hours provided all checks service jobs and overhauls are done at the times scheduled After this time the machine must compulsorily be inspected and tested by the Manufacturer before being used again The following items are supplied together with the machine 7 ITEMS SUPPLIED Description GTH 5519 Spanner 19 X Allen wrench 6 x A 7 1 LITERATURE SUPPLIED The machines comes with the following literature Machine operator s handbook DEUTZ engine use and maintenance manual Page A 17 Document 57 0005 9200 12 2005 enie Handler with telescopic boom GTH 5519 GENERAL INFORMATION Intentionally blank page Page A 18 Document 57 0005 9200 12 2005 B 1 B 2 B 2 1 B 2 2 B 2 3 B 2 4 B 3 B 3 1 B 3 2 B 3 3 B 4 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 TE SAFETY Section B SAFETY TABLE OF CONTENTS GENERAL i acr dinde rur dee eei cet p B 2 PREREQUISITES OF THE PERSONNEL IN CHARGE
20. 2005 D 1 D 2 D 2 1 D 3 D 3 1 D 3 2 D 3 3 D 3 4 D 3 5 D 3 5 1 D 3 6 D 3 7 D 3 8 D 3 9 D 3 10 D 3 10 1 D 3 10 2 D 3 11 D 3 11 1 D 3 11 2 D 3 12 D 3 13 D 3 14 D 3 15 D 4 D 4 1 D 4 2 D 5 D 5 1 D 5 2 D 5 2 1 D 5 2 2 D 5 2 3 D 5 2 4 Handler with telescopic boom GTH 5519 MAINTENANCE Section D MAINTENANCE TABLE OF CONTENTS LUBRICANTS HEALTH AND SAFETY PRECAUTIONS D 2 ROUTINE MAINTENANCE besa naa RYR FX VHS E P PREX RR ERE Ko et IRSE D 3 CHAOS See crase a D 4 MAINTENANCE JOBS UR EE E pied DS RA D 5 Disc nneciing ihe Daey em D 5 Access to the engine and tanks compartments D 6 pcc D 7 D 8 zl mm D 9 Checking the brake oil 2 D 9 S e eio I eee eer Ea i Mu D 10 Cab air filter only with cabin closed or glass kit installed D 11 Engine cooling 2216 iri ecco ers URL ILI D 11 Checking the oll level in thi Tank recen D 12 Changing the oil filter canisters on the intake line D 13 gets 0 13 CANCUN We EIC ee ee
21. 5519 I MAINTENANCE B Engine compartment fuses and relays E11 F30 F31 E12 Ref Circuit Amp F30 Timer fuse 70 F31 Start up and main board fuse 50 E11 Glow plugs timer relay E12 Start relay B Fuse boxrelays Ref Circuit E1 Front rear work lights E2 Engine start with parking brake engaged ES Relay E4 enabling command 4 Forward speed enabling command 5 Reverse speed E6 Stop S S e Do not use fuses having a higher amperage than that recommended since they can damage the electric system seriously e If the fuse blows after a short time look for the fault source by checking the electric system e Always keep some spare fuses for an emergency e Never try to repair or short blown fuses e Make sure the contacts of fuses and fuse sockets ensure a good electric connection and are not oxidised r Ne eis Page D 23 Document 57 0005 9200 12 2005 enie Handler with telescopic boom GTH 5519 TE MAINTENANCE EE 0 5 REFUELLING D 5 1 REFUELLING Product Capacity specifications Part Product litres see par Diesel engine Engine oil 11 3 5 0 5 2 1 Fuel tank Diesel fuel 60 D 5 2 3 Hydraulic system tank Hydraulic oil 120 D 5 2 2 Front differential gear with reduction gear
22. GTH 5519 TABLES AND DOCUMENTS ENCLOSED G 3 4 WIRING DIAGRAM CHASSIS SYSTEM NO amp DFo1 amp amp NO No1 e PN 8 GRo1 5 ERo1 BAot Not 8 5 1 DRot A AES DEo1 A Aol on i Not I hd 1 Nes 4 1 CGo1 2 GR t 3 HEo1 4 DRot1 5 1 Aol 6 7 8 DFo1 Vol BFo1 3 Col 10 gt HEo1 11 ANo1 12 9 AGo1 18 1 ANo1 A 4 9 BEo1 5 BRot 6 DEo1 d 17 Fol E ILE Not B 19 9 20 9 21 t 001 5 T 22 0601 23 FR 1 247 1 5 25 VBo1 5 26 gt REo1 279 01 5 5 28 GRo1 5 amp 29 1 1 je 1 5
23. GTH 5519 A Overall height ft 6 3 60 B Height to the steering wheel ft 4 0 50 C Overall width ft 5 10 92 D Cab width ft 2 9 84 E Track ft 4 10 92 Wheel base ft 7 5 76 G Length to the front tyres ft 10 10 32 H Length to the attachment holding plate ft 12 2 40 Ground clearance ft 1 2 16 Internal steering radius ft 5 8 16 External steering radius ft 14 1 80 B A 5 2 RESTRICTIONS OF USE e Angle of approach 90 e Departure angle 70 Ambient temperature 20 40 A 5 3 WEIGHT e Weight in working order with forks Ib 9855 A 5 4 SPEED Travel speed mph 15 Max slope with full load 6096 Page A 15 Document 57 0005 9200 12 2005 enie Handler with telescopic boom GTH 5519 TE GENERAL INFORMATION A 5 5 PAYLOAD AND REACH GTH 5519 lifting height ft 18 10 32 Reach at max height ft 1 5 76 reach forward ft 10 11 52 Attachment holding plate rotation 135 Maximum payload Ib 5500 Payload at max height Ib 2600 Payload at max reach Ib 1700 B A 5 6 FORKS Floating type Dimensions ft 3 11 28 x 0 8 86 x 0 1 56 Weight Ib 114 114 5 7 DIESEL ENGINE Aspirated version Make DEUTZ AG Model Type FAM 2011 A Features Diesel 4 cylinders in line 4 strokes direct injection Bore x Stroke in 3 7 x 4 41 Total displacement cu in 189 65 Power at 2600 rpm ISO 3046 IFN kW 46 5 B A 5 8 ELECTRICAL SYSTEM Voltage V
24. GTH 5519 MAINTENANCE A TEREX COMPANY D 3 14 ADJUSTING THE SLIDING PADS OF THE BOOM SECTIONS Any boom section is fitted with adjustable pads located on the four sides of the profile These pads are secured to both fixed and mobile part of every section All pads can be adjusted by the special shims supplied by GENIE upon demand Adjusting the pads e Remove or loosen the screws fixing the pads in relation to type of shims used with or without slots e Fit the necessary amount of shims e If the residual thickness of the pad is insufficient or near the maximum wearing limit renew the pad e Tighten the screws fixing the pads at the recommended torque see below Use a dynamometric wrench Tightening torques of the pad screws in relation to the screw diameter Screws M10 Nm 30 Screws M14 Nm 50 Tightening torques higher than those recommended can cause the break of the pad or of the locking threaded bush ATTENTION Pads must compulsorily be replaced if the residual thickness of the plastic layer with respect to the iron bush fixing the block is equal or inferior to 1 mm Page D 18 Max wearing thickness Eni Minimum 1 mm f Document 57 0005 9200 12 2005 N P Es CU Exil A TEREX COMPANY E D 3 15 CHECKING THE SAFETY DEVICES B Checking the block valves every months The piloted blocking valves allow to held
25. HYDRAULIC SCHEME Hydraulic piloting line test port 2 Service brake Pressure reducing Parking brake circuit reservoir valve I SE P selector valve ijr T 2 2 Senice brake AGB Load handling e ei pum pst control lever TB zh R a Pedal pump i 128 bar X O ae thu cape e 0 02 in i 7 psi 0 5 4 Hydraulic valve v i Check valve collector 7 psi 0 5 bar T 1 3l 1 Front axle s j A Parking brake Ee e i 2 control valve P2 i x o 4 2 1 1 E Hh 4350 psi Forks attachment P1 T 53 bar quick coupling cylinder C 3 l N 1 Quick coupling i l ports E L LI Boom functions Rear axle g 1 4 T 3 2 piloting selector valve steering cylinder 8 Tit a IL cylinder B Pd T n r Steering mode selector valve A Piloted check valve 4 1 Slave pe om RESET Ed Front axle cylinder H 4 1 l steering cylinder g 4350 psi 300 3262 psi Bal iit 22008 d al Tammy 11 1 T Steerin Y y 4350 psi 1 X Iv rotating 300 E i Bi actuator w x TM T 1 1 Anti cavitation el li Boom lift valves Boom
26. a specific function as a result they may not refer to the machine treated in this manual Copyright 2005 TEREXLIFT srl All rights reserved Produced by vega Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 LIST OF THE REVISED PAGES A COM Ww Revised Issued No Wig Ww pages by Q Handler with telescopic boom GTH 5519 INTRODUCTION A TEREX COMPANY B INTRODUCTION This handbook provides information for a safe and proper operation and maintenance of the machine STRICTLY COMPLY WITH THE INSTRUCTIONS GIVEN IN THIS HANDBOOK READ AND UNDERSTAND THIS HANDBOOK BEFORE STARTING USING AND CARRYING OUT ANY OPERATION WITH AND ON THE MACHINE The handbook is divided into seven sections Sect A GENERAL INFORMATION Sect SAFETY Sect C OPERATING INSTRUCTIONS Sect D MAINTENANCE Sect E TROUBLESHOOTING Sect F OPTIONAL ATTACHMENTS Sect G TABLES AND ENCLOSURES Section A contains general concepts that are decisive for the knowledge of the main parts of the machine It also contains all necessary dat
27. and check that the machine is level on the inclinometer e Insert the forks under the load and raise the load some centimetres e Pitch the forks backwards and check the machine stability before handling a load Transfer phase e Do not start or brake abruptly e Drive to the unloading point cautiously and keep the load 20 30 cm from the ground e Suitthemachine speed to the ground conditions to avoid dangerous jumps side skids of the vehicle and possible load falls e When driving on slopes or ramps hold the load uphill Do not drive on slopes sideways this wrong manoeuvre is one ofthe main reasons for accidents due to vehicle overturning Unloading phase e Drive to the unloading point with straight wheels and bring the machine to a smooth stop leaving enough space to operate the boom Put the parking brake and set the transmission to neutral e Position the load some centimetres above the desired position and set the forks level e Lower the load and make sure it is level e Carefully withdraw the forks by operating the boom retraction control and if necessary raise or lower the boom as forks come out e When the forks are clear of the load set them to transfer position e Release the parking brake and start a new working cycle CAUTION Do not move off when the load is raised 20 30 cm above the ground Risk of machine overturning or load fall Page C 26 Document 57 0005 92
28. cabin C 4 2 closed or glass kit installed C 4 C 4 3 Adjusting the SOA sert 5 C 4 4 Fastening the seat belts 5 4 5 Adjusting the steering column C 6 C 4 6 Adjusting the rear view mirrors C 6 C 4 7 Switching on the cab interior lamp C 6 5 DRIVING PLACE iiiter pecho rela ded 7 5 1 Controls and instruments C 7 C 5 2 Engine controls and instruments G 9 C 5 2 4 Into susci sn hi ud ibn C 9 C 5 2 2 Forward reverse gear switch 9 5 3 i T C 10 C 6 Accelerator COMMON C 10 C 6 1 Pushbutton enabling the attachment C 6 1 1 coupling reledse oannes 11 6 2 Steering mode C 11 C 6 3 C 11 C 6 4 Auxiliary drive controls C 12 Instruments and light indicators C 12 C 6 5 C 12 C 6 5 1 Light Indi store anie acetic ns C 13 C 6 5 2 PoC CL gets ia C 14 C 6 6 Function SelectiDhi C 14 C 6 6 1 Lifting lowering the boom C 16 C 6 6 2 Pitching the attachment holding frame C 6 7 forwards backwards C 17 C 6 7 1 Extending retracting the telescope C 18 Page C 1 Before starting the engine Checks at the machine start up Starting the engine Jump starting the engine
29. centimetres and check its stability before raising it completely 20 15 10 ft 15 10 5 Forward reach ft 70 deg GTH 5519 CAPACITY CHART E D 24 Document 57 0005 9200 12 2005 A TEREX COMPANY C 5 2 HANDLING LOADS Handler with telescopic boom GTH 5519 TE OPERATING INSTRUCTIONS B C 5 2 1 Adjusting the floating forks VN CAUTI Forks shall be spaced to suit the load going to handled For this purpose e Loosen the nut of the locking screws e Raise the forks and slide them on the pivot until correct spacing e Lock the screws re tightening the nut Page C 25 The centre of gravity of the load must always be halfway between the forks Ensure you exactly know the weight of the load before handling it When extending the boom do not exceed the payload limit Refer to the payload limits given in the load chart applied in the cab or in the quick user s guide Space the forks as wide as possible to suit the load being handled Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS A TEREX COMPANY C 5 2 2 Working phases When forks are correctly spaced the handler is ready to use Work can be subdivided into three different phases loading transfer and unloading Loading phase e Approach the load to the handled perpendicularly
30. engage the parking brake 2 Remove the inspection hatch and unscrew the oil filter fitted inside the tank 3 Check the tank is clean then fit a new filtering element and refit the inspection hatch 4 Check the oil level within the tank Add new oil if necessary Page D 14 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 MAINTENANCE D 3 11 OIL LEVEL IN THE DIFFERENTIAL GEARS AND THE REDUCER D 3 11 1 Front and differential gears To check the oil level in the front and rear differential gears e Stopthemachineonalevel ground and engage the parking brake e Loosen level plug and check if oil is level with the hole e If necessary add new oil through the hole of the level plug until it comes out e Refit and tighten plug For the oil change e Place a container of suitable size under plug Loosen the drain plug and the level plug and allow oil to flow out from the differential gears e Refit and tighten drain plug e Add new oil through plug until it is level with the hole e Refit and tighten level filler plug D 3 11 2 Reducer To check the oil level in the reducer Stopthemachineonalevel ground and engage the parking brake e Loosen level plug and check if oil is level with the hole e If necessary add new oil through the hole of the level plug until it comes out e Refit and tighten plug For the oil ch
31. engaged Indicator light accumulator Not activated negative brake Indicator light turn signals Green indicator light that signals when turn signals are ON This indicator is active only when the lights kit is installed Indicator light glow plugs preheating Green light indicators which signal the preheating phase of the engine glow plugs Before starting the engine wait for these lights to go off Indicator light air filter soiled Orange light indicator which signals when the air intake filter of the engine is getting soiled Clean or replace the filtering cartridge immediately Page C 13 Document 57 0005 9200 12 2005 G Q Handler with telescopic boom 55 19 TE TEREX COMPANY OPERATING INSTRUCTIONS C 3 4 CONTROL LEVER Handlers are equipped with a hydraulically driven servo controlled lever The lever has two pushbuttons one for coupling releasing the attachments and the other for pitching the attachment frame forwards backwards Shifting the lever to one of the four directions right left forwards backwards moves the boom up and down and the telescope out and in IMPORTANT Seize the control lever correctly and move it gently The motion speed of the actuators depends on the lever position a small motion results in a slow motion of the actuators vice versa a full range motion of the lever corresponds to the max
32. longer life to your machine perform a walk around inspection before starting the engine e Remove any dirt or rubbish from the cab interior and especially from pedals and control levers e Remove oil grease and mud from pedals and control levers e Make sure that your hands and shoe soles are clean and dry Check the seat belts can be fastened properly e Check that lights indicators side tail lights hazard indicator lights wipers and horn are in working order e Adjust the driving seat so that you can reach all control levers comfortably and fully depress the brake pedal without moving your back from the driving seat e Adjust the rear view mirrors to give you a good view close behind the machine when you are correctly seated e Check the parking brake is engaged C 4 1 1 Checkthe efficiency ofthe safety devices as described in chap D 3 15 namely e machine start control Checks at the machine start up C 42 STARTING THE ENGINE Forthe low temperature starting see paragraph C 4 4 Engage the parking brake Put the forward reverse speed selection lever to neutral Step on the gas pedal To start the engine turn the ignition switch to position Release the switch when the engine starts If the engine does not start within 20 seconds release the key and wait at least 2 minutes before attempting again e After the start up let O the engine run at idle for some seconds bef
33. make sure that nobody is within the working range of the machine To tilt the attachment holding frame forwards backwards Press button and shift the lever to position to tilt the frame forwards or to position to tilt it backwards Page C 17 Document 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 TE OPERATING INSTRUCTIONS BC 3 44 Extending retracting the telescope CAUTION Before operating the boom make sure that nobody is within the working range of the machine To extend or retract the boom telescope Smoothly shift the lever to position to extend the boom or to position 9 to retract it Page C 18 Document 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS C 3 45 Quick coupling the attachments CAUTION 2 Before operating the boom make sure that nobody is within the working range of the machine To lock the attachments Press button together with the dashboard enabling button 12 and shift the lever to position Q to unlock the attachment or to position to lock the attachment Page C 19 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS A TEREX COMPANY C 4 SETUP B C 4 1 BEFORE STARTING THE ENGINE To ensure safe conditions to the operators and the bystanders and a
34. reach trucks Self propelled industrial trucks sit down rider controlled Rules for the construction and layout of pedals Safety of machinery Basic concepts general principles for design Basic terminology methodology Safety of machinery Basic concepts principlesfor design Technical principles and specification Electrical requirements General requirements of internal combustion engine powered trucks prEN ISO 13564 1996 Test method for measuring visibility ISO 2330 1995 ISO DIS 3287 ISO 3449 1992 EN 13510 2002 ISO 3776 1989 ISO 3795 1989 ISO 5053 1987 from self propelled trucks Fork lift trucks Fork arms Technical characteristics and testing Powered industrial trucks Pictorial signs Control symbols Earth moving machinery Falling object protective structures Laboratory tests and performance requirements Earth moving machinery Roll over protective structures Laboratory tests and performance requirements Tractors for agriculture Seat belt anchorages Road vehicles tractors and machinery for agriculture and forestry Determination of burning behaviour of interior materials Powered industrial trucks Terminology EN 50082 1 1997 EN 60204 1 1998 High lift rider trucks Overhead guards Specification and testing Powered industrial trucks and tractors Brake performance and component strength Earth moving machinery Machine mounted
35. referto the DEUTZ engine use and maintenance manual The machine is supplied with oil SAE 15W 40 40 Er 0 10 15 25 To start the engine from cold proceed as follows e Engage the parking brake e Turn the ignition switch to position and wait until the warning light 6 signalling the glow plugs preheating goes off Step down on the gas pedal and start the engine turning the ignition switch to Release as soon as the engine starts e Let the engine run at idle for a few seconds before putting a gear this allows for a gradual warm up of the engine oil and a better lubrication e Incase of engine jump starting remove the booster ables see chapter C 4 3 B C 45 DISCONNECTING THE BATTERY Before any maintenance or repair work and especially before welding any components on the machine remove the cables at the battery CAUTION Before disconnecting the battery set all switches within the cab to OFF To disconnect the battery disconnect the negative lead from the frame earth first To connect the battery connect the positive 4 lead first C 4 6 STARTING THE MACHINE When the engine reaches the running temperature ensure all parts are in transfer position and the gearbox lever is in neutral Then proceed as follows e Select the required steering mode Select the required gear forward or reverse Release the parking brake pressing button 18 the warning light on th
36. safe distance from the telescopic boom and the lifted load Electrical hazards A DANGER DEATH OR INJURY CAN RESULT FROM CONTACTING ELECTRIC POWER LINES ALWAYS CONTACT THE ELECTRIC POWER LINES OWNER THE ELECTRIC POWER SHALL BE DISCONNECTED OR THE POWER LINES MOVED OR INSULATED BEFORE MACHINE OPERATIONS BEGIN POWER LINE VOLTAGE REQUIRED CLEARANCE 0 to 50 kV 10 ft 300m 50 to 200 kV 200 350 kV 4 60 m 6 10 m 500 750 kV 750 1000 kV 10 67 m 13 72 m ft ft 350 500 kV ft 762m ft ft CAUTION Make sure the machine wheels and stabilisers rests on a firm ground to prevent hazardous unstable conditions If the ground is not firm enough position some supporting planks under the stabilisers or the wheels These plates must grant a specific pressure of 1 2 to 1 5 kg cm 500x500mm plates are sufficient Look for the best route to the job site e When the machine is running nobody can enter its working range e While working keep the working area in order Never leave objects scattered they could hinder the machine movements and represent a danger for personnel Do not at any time use the machine during a storm Page B 4 Document 57 0005 9200 12 2005 A TEREX COMPANY B B 3 2 GETTING READY TO WORK Before any operation following precautions should be taken e First of all make sure that the maintenance interventions have been carried out with care according to the es
37. 0 14 Oil level in the differential gears and the D 15 Front and rear differential koe D 15 em D 15 Oil level in the front rear wheel reduction gears D 16 e EN D 17 Adjusting the sliding pads of the boom sections D 18 Checking Ihe D 19 ELECTHIGAL SYS TEM iiic eod D 21 c C ere eee re D 21 Puses and roS nt D 22 I LIEU EE SU D 24 ae te a D 24 PCIE SG IT CMON MEE aA DS D 24 ee ee reenter emer eter eee eer ee ne eer ere D 24 Lubrication oils and relevant filtering elements D 24 FUE penrem D 25 LEE oa ie E M ee D 25 Page D 1 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 MAINTENANCE A TEREX COMPANY INTRODUCTION A thorough and regular maintenance keeps the machine in a safe and efficient working condition For this reason it is advisable to wash grease and service the machine properly especially after having worked under particular conditions muddy or dusty environments heavy operations etc Always ensure all machine components are in good condi
38. 00 12 2005 Q Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS CAUTION 5 3 CHANGING THE ATTACHMENT After substitution visually check the attachment is ATTENTION correctly coupled to the boom before operating Use only attachments directly manufactured or the machine A wrongly coupled attachment may Optional attachments section To change an attachment operate as follows Drive to the place where you will release the mounted attachment when possible a solid and sheltered site Disconnect the quick connectors of the attachment if any and connect the hydraulic locking pipes of the attachments to couplings A Rest the attachment flat on the ground Pitch the attachment holding frame forward and lower the boom to release the attachment upper lock Move back with the machine or with the boom and drive to the new attachment to be coupled Hold the frame pitched forward and hook the upper lock of the new attachment e Retract and raise the attachment some centimetres It will centre automatically on the quick coupling frame Operate the control lever to lock the attachment Page C 27 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS A TEREX COMPANY Couple the connectors of the attachment if any to the quick couplings of the frame Afterthe substitution of an attachment or after
39. 000 69600 45 8 90 6 127 153 14 2 25800 51500 72500 86900 67 4 135 190 228 14 1 5 28000 56000 78800 94500 71 7 143 202 242 16x2 35200 70300 98900 119000 102 205 288 346 M 16 x 1 5 37400 74800 105000 126000 107 214 302 362 M 18x 2 5 43000 86000 121000 145000 142 283 398 478 M 18 x 1 5 48400 96800 136000 163000 154 308 434 520 M 20x 2 5 54900 110000 154000 185000 200 400 562 674 M 20 x 1 5 60900 122000 171000 206000 216 431 607 728 M22x2 5 67900 136000 191000 229000 266 532 748 897 M 22 x 1 5 74600 149000 210000 252000 286 571 803 964 24x3 79100 158000 222000 267000 345 691 971 1170 M24x2 86000 172000 242000 290000 365 731 1030 1230 M27x3 103000 206000 289000 347000 505 1010 1420 1700 M27x2 111000 222000 312000 375000 534 1070 1500 1800 M 30x 3 5 126000 251000 353000 424000 686 1370 1930 2310 M 30 x 2 139000 278000 391000 469000 738 1480 2080 2490 IMPORTANT Sensor maximum driving torque 15 Nm Page G 2 Document 57 0005 9200 12 2005 G nio Handler with telescopic boom GTH 5519 A TEREX COMPANY TABLES AND DOCUMENTS ENCLOSED 2 1 LOAD CHART WITH FORKS GTH 5519 15 10 5 0 Forward reach ft Page G 3 Document 57 0005 9200 12 2005 enie Handler with telescopic boom GTH 5519 dA TABLES AND DOCUMENTS ENCLOSED
40. 0010 Prohibition to open with the engine running 09 4618 0061 Tyre inflation pressure 09 4618 0109 Sticker with various warnings 09 4618 0205 Boom tilting degree 09 4618 0389 Control lever controls 09 4618 0641 Sticker Genie 09 4618 0643 Sticker Genie GTH 5519 09 4618 0644 Sticker GTH 5519 09 4618 0645 Load chart Page A 5 Document 57 0005 9200 12 2005 enie Handler with telescopic boom GTH 5519 GENERAL INFORMATION B A 1 3 EXPLANATION OF THE DIFFERENT SYMBOLS USED ON THE MACHINE IMPORTANT This paragraph illustrates those symbols that are normally applied on the main control devices and instruments of a standard machine and those that can be applied on accessories or special attachments They are mainly ISO standardised symbols that are now part of the common life But we consider useful to explain them once again Spend the necessary time to become familiar with these symbols and to learn their meaning 3 c o Symbol Description Description Hazard warning lights Steering mode switch Engine oil pressure SZ Windscreen wiper 9 P xod T Q7 Windscreen washer Boom down ae Cab ventilation fan Boom out Fuel gauge i Boom in n Hydraulic oil temperature Attachment locked Position lights Attachment unlocked High beam Turn signals Fork pitching forward 5 Par
41. 2 Four wheel steering Handler with telescopic boom GTH 5519 TE OPERATING INSTRUCTIONS 3 2 7 Continuous flow selector 19 Selection button Button with two stable positions 1 Pressing this selector delivers a continuous flow of oil to the attachment in use The built in light switches on 2 Pressing this selector again lets the circuit returns to normal mode oil is delivered to the attachment only when the control lever is operated The built in light switches off RARER X C B E EL ET Page C 11 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS A TEREX COMPANY 3 2 8 Auxiliary drive controls 14 pushbutton Pushbutton with green glass Press this button to operate the horn 22 Windscreen washer button When pushed it sprays a jet of detergent solution on the windscreen and makes the wiper functioning easier 23 Air conditioning fan switch only with cabin closed Three position switch 0 OFF 1 Low speed 2 High speed 24 Cab heater control cock only with cabin closed To the right of the driving seat Turn the heated air regulator 24 counter clockwise so the air heating fluid starts circulating The amount of heated air will be proportional to the opening of the relevant regulator e Adjust the heated air operating switch 23 to sele
42. 3 1 G 3 2 G 3 3 G 3 4 G 3 5 G 4 1 G 5 Handler with telescopic boom GTH 5519 TABLES AND DOCUMENTS ENCLOSED Section G TABLES AND DOCUMENTS ENCLOSED TABLE OF CONTENTS TORQUE WRENCH SET TII Load Chart wit TONKS era Wiring diagram Fuses and Wiring diagram TOSbs SYSIOM a Wiring diagram dashboard SYST Wiring diagram chassis System General wiring diagram description UE Routine check schedule Safety devices Page G 1 Document 57 0005 9200 12 2005 G 2 G 4 G 5 G 6 G 7 Handler with telescopic boom GTH 5519 TABLES AND DOCUMENTS ENCLOSED 1 TORQUE WRENCH SETTINGS Dxp Pre loading N Torque wrench setting 4 8 8 8 10 9 12 9 4 8 8 8 10 9 12 9 M4x0 7 1970 3930 5530 6640 1 5 3 1 4 3 5 2 M5x0 8 3180 6360 8950 10700 3 6 8 5 10 1 M6x1 4500 9000 12700 15200 5 2 10 4 14 6 17 5 M 8 x 1 25 8200 16400 23100 27700 12 3 24 6 34 7 41 6 M8x1 8780 17600 24700 29600 13 26 36 6 43 9 M 10 x 1 5 13000 26000 36500 43900 25 1 50 1 70 5 84 6 M 10 x 1 25 13700 27400 38500 46300 26 2 52 4 73 6 88 4 M 12 x 1 75 18900 37800 53000 63700 42 4 84 8 119 143 M 12 x 1 25 20600 41300 58
43. CNo1 5 13 Ro6 CGo1 4 Co1 5 N 25 r Ro4 6 Nod i Mo4 7 No25 1 1 9 DRo1 5 10 zi 601 DEot Grol DFoi 4e oy Heat DBoi DGoi 34 T MNot 6 DFol FRo1 16 BEo 17 Sf Brat VBoi5 je 9 Cot 10 HEo1 1 12 gt AGo1 13 gt ANo lt 14 gt BEo1 154 1 RE Not IH sn BNo15 7 17 1 Fol ras MRoi 20 21 4 01 5 2 DGot 231 1 24 1 1 5 251 VBot 5 261 REot A s GEot 5 1 GEo1 5 294 BAgt 1 2 VBo1 304 Ro1 5 3 Ro1 5 1 4 Nol 34 Not 5 61 1 5 1 Not5 GROUND SYMBOL FNo1 5 IL 1 5 COLOUR LEGEND FGot NI A ORANGE Not E B WHITE PINK Bho D GREY 1 E GREEN S 1 Ed F BLUE ig 11 H SH Be 2 2 G YELLOW 5 Sbe 9992 S 8588859282525 LARGE 1 6 pps po 8 87 6 8 T8 2 67 66 S 8 65 EN 63 N BLACK R RED V PURPLE Page G 5 Document 57 0005 9200 12 2005 Handler with telescopic boom 55 19 EE TABLES AND DOCUMENTS ENCLOSED G 3 3 WIRING DIAGRAM DASHBOARD SYSTEM
44. E2 Engine start with parking brake engaged F27 Notused 5 ES Relay E4 enabling command F28 used 5 E4 Forward speed enabling command F29 fuses E5 Reverse speed E6 Stop Engine compartment fuses E11 Glow plugs timer relay F30 Timer fuse 50 F31 Start up and main board fuse 50 Ela Page G 4 Document 57 0005 9200 12 2005 io Handler with telescopic boom GTH 5519 TABLES AND DOCUMENTS ENCLOSED G 3 2 WIRING DIAGRAM FUSES SYSTEM
45. Genie A TEREX COMPANY OPERATOR HANDBOOK Code 57 0005 9200 0 12 2005 Handler with telescopic boom GTH 5519 English CAUTION THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE CAUTION KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES Genie A TEREX COMPANY Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579 5042 Fax 3493 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 TECHNICAL SERVICES Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Operator Handbook 57 0005 9200 GTH 5519 All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means without prior written permission from TEREXLIFT srl In pursuing a policy of constant quality improvement TEREXLIFT srl reserves the right to make changes at any time and without undertaking to give prior notice therefore also this publication may be subject to modifications Some photos or drawings have been used to illustrate
46. NG FAULTS AND TROUBLESHOOTING Any repair work maintenance or troubleshooting must be carried out with machine stopped boom in rest position or laid on the ground parking brake E 1 1 Fault Cause Solution engaged and ignition key removed DASHBOARD DOES NOT SWITCH ON The 50A fuse F31 supplying power to the dashboard is blown engine compartment Battery disconnected Battery down Battery cut out switch OFF Replace the fuse Connect the battery using the relevant switch Check the battery Switch it on ENGINE DOES NOT START Starter does not run Parking brake not engaged Engage the parking brake and ensure the relevant indicator on the dashboard switches on ENGINE DOES NOT START Starter runs but engine does not start Battery down Recharge or replace the battery Battery cut out switch OFF e Switch it on Fuse F15 blown Check the fuse No fuel Refuel Diesel fuel filter clogged Diesel fuel hose empty fuel used up Solenoid valve engine stop See DEUTZ engine operator manual Refuel then refer to DEUTZ engine operator manual Check the solenoid valve replace if necessary MACHINE DOES NOT MOVE Speed selector switch in neutral Parking brake engaged Fuse F8 blown Set the speed selector switch correctly Disengage Check the fuse necessary replace if THE MACHINE DRIVE IS NOT ENOUGH Hydraulic oil filter clogged Replace the filter
47. RN SWITCH 47 HIGH SPEED SOLENOID VALVE 10 STEERING SELECTOR 48 ENGINE OIL COOLING TEMPERATURE 11 IGNITION KEY SWITCH SENSOR 12 PREHEATING GLOW PLUGS WARNING 49 ENGINE STOP SOLENOID LIGHT 50 PREHEATING CONTROL UNIT MAXIFUSE 13 AIR FILTER SOILED WARNING LIGHT 51 SYSTEM PROTECTION FUSE 14 6 WAY CONNECTOR STEERING COLUMN 52 ALTERNATOR LINE CONNECTION TO CAB LINE 53 STARTER MOTOR 15 18 WAY CONNECTOR STEERING COLUMN 54 12V BATTERY LINE CONNECTION TO CAB LINE 55 STARTING RELAY 16 HYDRAULIC STOP 56 PREHEATING CONTROL UNIT 17 PARKING BRAKE SWITCH 57 GLOW PLUGS 18 VSE SOLENOID VALVE CONTROL 58 ENGINE STOP SOLENOID VALVE 19 FUSES AND RELAYS BOX 59 SOLENOID VALVE REVERSE SPEED 20 WINDSCREEN WIPER WASHER SWITCH 60 VSE SOLENOID VALVE 21 FRONT WINDSCREEN WIPER WASHER 61 NEGATIVE BRAKE PRESSURE SWITCH MOTOR 22 REAR WINDSCREEN WIPER WASHER MOTOR 23 SEAT SWITCH 24 6 WAY CONNECTOR FUSES LINE CONNECTION TO CAB LINE 25 LIGHTING 26 BEACON 27 WORK LIGHT 28 OPTIONAL FLASHING CONNECTOR 29 JOYSTICK CONNECTOR 30 OPTIONAL 3 WAY CONNECTOR 31 31 WAY CONNECTOR FUSES LINE CONNECTION TO ENGINE LINE 32 4 WAY CONNECTOR FUSES LINE CONNECTION TO ENGINE LINE 33 SOLENOID VALVE ATTACHMENT RELEASE 34 SOLENOID VALVE ATTACHMENT COUPLING 35 SOLENOID VALVE FWD SPEED 36 COMPRESSED AIR COMPRESSOR Page G 8 Document 57 0005 9200 12 2005 io Handler with telescopic boom GTH 5519 TABLES AND DOCUMENTS ENCLOSED
48. RUCK MAXIMUN WEIGHT TRUCK CAPACITY THIS TRUCK IS COMPLIANT TO PART OF ASME 56 6 2002 WHERE APPLICABLE MADE IN ITALY Page A 8 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 GENERAL INFORMATION e A TEREX COMPANY A 2 4 CHASSIS SERIAL NUMBER The chassis serial number is punched on the front left part of the chassis side member A 2 5 IDENTIFICATION PLATES OF THE MAIN PARTS The plates of the main components not directly manufactured by TEREXLIFT srl for instance engines pumps etc are located where originally applied by the manufacturers Page A 9 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 GENERAL INFORMATION A TEREX COMPANY A 3 ALLOWED USE A 3 1 ALLOWED USE The handlers have been designed and manufactured for lifting handling and transporting agricultural or industrial products by means of specific attachments see section F manufactured by TEREXLIFT srl Any other useis considered contrary to that established and therefore improper The compliance with and the strict respect of the operation maintenance and repair conditions indicated by the Manufacturer represent an essential part of the allowed use The handler must be used and serviced only by operators knowing its characteristics and the safety procedures in depth It is also essential to comply with the safety
49. a for a correct identification of the machine the technical features of the machine etc Section B is especially addressed to the personnel who shall operate repair and service the machine and in case of companies with a wide fleet of machines to the safety responsible It describes the essential compulsory qualities of the personnel in charge and other important information for the safety of persons and things Section C is mainly addressed to the operators who operate the machine This section illustrates all control devices Additionally it contains the main use instructions i e engine starting machine parking machine storing Section D is addressed to the maintenance responsible and the servicemen The section describes the maintenance schedule and the relevant intervals Section E deals with the failure diagnostics Section F makes a list of the main interchangeable attachments that can be coupled to the machine dimensions weight application field and limits of use Section G contains tables and various enclosed documents like load charts wiring diagrams hydraulic schemes torque wrench setting table etc irs Sections are subdivided into chapters and paragraphs that are numbered progressively The quickest way to look for an information is the reference to the general index or the titles of the single chapters and paragraphs that represent keys for an easy consultation Take care of this handbook
50. ages automatically when the engine is stopped When the handler s engine is restarted pressing the pushbutton switch 18 unlocks the parking brake To stop the handler without shutting down the engine press the pushbutton switch 18 to engage the parking brake and push it once again to disengage the brake Every pressure of the pushbutton switches the warning light on and off When the red warning light is on the parking brake is engaged CAUTION Never use the parking brake to slow down the machine unless in an emergency It may reduce the brake efficiency Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS 3 2 4 Accelerator control 15 Gas pedal Its pressure controls the engine rpm and coupled to the gearbox the machine speed It is fitted with an adjustable stop in the lower part 4 EL EE Page C 10 Document 57 0005 9200 12 2005 A TEREX COMPANY B C 3 2 5 Pushbutton enabling the attachment coupling release 12 Selection button Two position button with return to the neutral point Press this button every time you wish to couple release an attachment Hold the button pressed down until the movement has been completed 3 2 6 Steering mode selection 13 Steering mode switch Three position switch for the selection of the steering mode 1 Crab steering Two wheel steering
51. and keep it in an accessible place within the machine even after its reading so that it will always be within reach if in doubt If you are unsure about anything please address to GENIE Assistance Service or to your agent dealer addresses phone and fax numbers are printed in the cover and in the title page of this manual IMPORTANT Any difference between the contents of this manual and the real functional character of the machine can be attributed to either a machine manufactured before the issue of this manual orto a manual going to be updated after some changed effected on the machine Always contact GENIE Assistance Service for any updated version of this manual and any additional information Page 1 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 INTRODUCTION A TEREX COMPANY SYMBOLS When using the machine operators could have to face some situations requiring special care and particular knowledge When these situations involve the safety of operators or bystanders the machine efficiency and proper utilisation this handbook stresses these specific instructions by means of SPECIAL SYMBOLS Thereare six special or safety symbols in this manual always combined with keywords that class the situations according to their danger degree The symbols are always followed by a text explaining the situation taken into account the attention to be paid to such situation the meth
52. andler with telescopic boom GTH 5519 TE A TEREX COMPANY OPTIONAL ATTACHMENTS Section OPTIONAL ATTACHMENTS TABLE OF CONTENTS F 1 1 RE TTL F 3 F 1 2 iEn m F 4 F 1 3 Fixed nol om plate a Ee MEE CPP Ln EAS F 5 F 1 4 Eten EIER ERA DERI F 6 F 1 5 Forks with hydraulic side shift iaces aco re oiii rosa suut ct F 7 Page F 1 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 OPTIONAL ATTACHMENTS e A TEREX COMPANY INTRODUCTION This section provides information on the optional interchangeable attachments especially manufactured for the handlers Use only genuine attachments described in this section after having read their features thoroughly and understood their use To install and remove the attachments follow the instructions supplied in the OPERATION section par C 5 4 When replacing interchangeable attachments keep any person clear of the working area Mounting optional attachments and especially the extension jib can change the centre of gravity of the machine Before handling a load check its weight and compare it with the values on the load charts The weight of the used attachment must always be deducted from the rated payload Page F 2 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 e A TEREX COMPANY
53. ange Place a container of suitable size under drain plug Loosen the drain plug 6 and the level plug 9 and allow oil to flow out from the reduction gear e Refit and tighten drain plug e Add new oil through plug Q until it is level with the hole e Refit and tighten plug Page D 15 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 e A TEREX COMPANY MAINTENANCE D 3 12 OIL LEVEL IN THE front rear WHEEL REDUCTION GEARS To check the oil level within the wheel reduction gears Stop the machine on a level ground and ensure the parking brake is engaged and plug finds on the horizontal axis Cleanthe plug all around then remove it and check if oil is level with the hole If necessary add new oil through hole until it is level Refit the plug For the oil change Stop the machine and ensure the plug is oriented along the vertical axis Place a container of suitable size under the reduction gear plug Unscrew plug and drain any oil from the reduction gear Rotate the wheel by 90 until the plug finds again on the horizontal axis Add new oil through hole Refit and tighten plug PROTECT THE ENVIRONMENT The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres IMPORTANT When changing the oil drain it when it is still hot and the polluting su
54. any coupling operation visually check the attachment Awrongly coupledattachment may result in damage to persons or things C 6 TRANSPORTING THE MACHINE C 6 1 MOVING A DISABLED MACHINE Tow the machine only when no alternative is possible since this operation may result in serious damage to the transmission When possible repair the machine site When the machine shall absolutely be towed e Unlock the negative brake see chap C 6 1 1 e Tow the machine for short distances and at a low speed only e Use arigid drawbar e Select the two wheel steer e Set the gearbox lever to neutral e When possible start the engine and use the hydraulic drive and the braking system e Raise the front wheels of the machine and remove the Cardan shaft of the transmission 6 1 1 Unlocking the negative brake To unlock the negative brake of a faulty machine proceed as follows e Loosen the two opposite screws located on the front axle in order to remove the washers e Remove the horseshoe shaped washers located under the two screws e Re tighten screws turning alternately the front screw and the rear screw 1 2 turn to unlock the brake To relock the nagetive brake loosen the screws turning alternately the front screw and the rear screw 1 2 turn refit the horseshoe washers and re tighten screws C 6 2 ROAD OR SITE TRANSFER When travelling on public roads strictly obey the local or nati
55. at work legislation the precautions concerning safety and industrial medicine as well as the local and national road traffic regulations Effecting changes or carrying out interventions on the machine other than those of routine maintenance is expressly forbidden Any modification of the machine not carried out by GENIE or an authorised assistance centre involves the automatic invalidation of the conformity of the machine to the Directive 98 37 EC A 3 2 IMPROPER USE Improper use means a utilisation of the handler following working criteria that do not comply with the instructions of this manual and that in general may result in risks for both operators and bystanders We list below some of the most frequent and hazardous situations of improper use Carrying passengers on the machine Not strictly complying with the operation and maintenance instructions of this handbook Working beyond the handler working limits Working on unstable edges of ditches Driving crosswise on slopes or hills Working during a storm Working on steep slopes Using attachments other than those recommended Using attachments not approved or directly manufactured by Terexlift Working in potentially explosive areas Working in confined and non ventilated environments A 3 3 RESIDUAL HAZARDS Although the machine has been designed and manufactured according to the latest technology and all expec
56. ations C 6 7 1 Battery disposal PROTECT THE ENVIRONMENT Used lead acid batteries cannot be disposed of as normal industrial solid wastes Because of the presence of harmful substances they must be collected eliminated and orrecycled in accordance with the laws of the UE In Italy used or discarded batteries have been classified as Toxic wastes in accordance with Presidential decree n 397 of 09 09 1988 and Law n 475 O G n 18 of 09 11 1988 because they contain lead and sulphuric acid Their disposal through recycling must be done only through companies authorised and belonging to the Consorzio Obbligatorio Batterie Esauste dei rifiuti piombosi Cobat which collect and dispose of used lead acid batteries throughout the national territory Used batteries must be kept in a dry and confined place Make sure the battery is dry and the cell plugs are tight Place a sign on the battery to warn of not using it If before disposal the battery is left in the open air it will be necessary to dry smearthe box and the elements with a coat of grease and tighten the plugs Do not rest the battery on the it is always advisable to rest it on a pallet and cover it The disposal of batteries shall be as rapid as possible Page C 31 Document 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS Intentionally blank page Page C 32 Document 57 0005 9200 12
57. ble to evaluate their own physical and mental conditions training they shall read and familiarise with this handbook its enclosed graphs and diagrams the identification and hazard warning plates They shall be skilled and trained about the machine use IMPORTANT The operator shall have a licence or a driving licence when provided for by the laws enforced in the country where the machine works Please ask the competent bodies In Italy the operator must be at least 18 year old Page B 2 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 SAFETY e A TEREX COMPANY B B 2 2 REQUISITES OF THE SERVICEMEN The personnel charged with the machine maintenance shall be qualified specialised in the maintenance of earth moving machines and shall have the following prerequisites physical good eyesight acute hearing good co ordination and ability to carry out all required maintenance operations in a safe way according to this manual mental ability to understand and apply the enforced rules regulations and safety precautions They shall be careful and sensible for their own as well as for the others safety and shall desire to carry out the work correctly and in a responsible way training they shall read and familiarise with this handbook its enclosed graphs and diagrams the identification and warning plates They shall be skilled and trained about the machine functioning IMPORTANT From a te
58. bstances are in suspension Page D 16 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 MAINTENANCE 0 3 13 SHAFTING ALIGNMENT During operation the alignment of the front and rear S axles of the machine be subject to variations This e M can depend on an oil blow by from the steering control circuit or a steering of both axles when front and rear wheels are not perfectly aligned To fix this problem rather than checking the alignment visually follow the procedure below 1 Move to a solid and level ground 2 Setthesteering selection switch 13 to four wheel steer pos 2 3 Rotatethe steering up to its stop either to the right or to the left 4 Set the steering selection switch to two wheel steer pos 0 5 Rotate the steering up to its stop turn in the same direction as above 6 Resetthe steering selection switch to four wheel steer pos 2 7 Rotate the steering to the side opposite to point 3 so that the rear axle reaches its stop 8 Reset the steering selection switch to two wheel steer pos 0 9 Rotate the steering to the same side as in point 7 so that the front axle reaches its stop 10 Reset the steering selection switch to four wheel steer pos 2 Now the wheels should be re aligned Page D 17 Document 57 0005 9200 12 2005 Handler with telescopic boom
59. chnical point of view the ordinary maintenance of the machine is not a complex intervention and can be carried out by the machine operator too provided he has a basic knowledge of mechanics B 23 WORKING CLOTHES During work but especially when maintaining or repairing the machine operators must wear suitable protective clothing e Overalls or any other comfortable garments Operators should wear neither clothes with large sleeves nor objects that can get stuck in moving parts of the machine Protective helmet Protective gloves e Working shoes IMPORTANT Use only type approved working clothing in good condition irs B 2 4 PERSONAL PROTECTIVE EQUIPMENT Under special working conditions the following personal protective equipment should be used e Breathing set or dust mask Ear protectors or equivalent equipment e Goggles or facial masks IMPORTANT Use only type approved protective equipment in good condition 9 8 Page B 3 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 SAFETY A TEREX COMPANY B 3 SAFETY PRECAUTIONS 3 1 JOBSITE Always take into account the features of the job site where you are going to work e Always examine the working area and compare it with the machine dimensions in the different configurations ELECTRICAL DANGER Pay the greatest attention to overhead electric lines Always keep at a minimum
60. ct one of the three available speeds Open the air flaps and adjust their position to direct the air as you want Turn the heated air regulator clockwise to switch off heated air af C 3 3 INSTRUMENTS AND LIGHT INDICATORS 3 3 1 Instruments 54 Engine coolant temperature indicator Signals the engine coolant temperature engine oil Fuel gauge Signals the fuel level within the tank Hour meter Signals the total operating hours of the machine 51 Hydraulic oil temperature indicator Signals the temperature of the hydraulic oil within the reservoir Page C 12 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 A TEREX COMPANY OPERATING INSTRUCTIONS BC 3 3 2 Light indicators 60 68 Indicator light high beam Blue indicator light that signals when high beam is ON This indicator is active only when the lights kit is installed Indicator light position lights Green indicator light that signals when position lights are ON This indicator is active only when the lights kit is installed Indicator light air filter soiled Not activated Indicator light low battery charge Signals a low charge by the alternator Indicator light low engine oil pressure It lights when the engine oil pressure is too low Indicator light parking brake engaged When ON this light indicates that the parking brake is
61. d remove the tab from the buckle Make sure that the buckle is correctly located at the hip point and not on the stomach Operate the end adjusters to reach the length you wish and make sure the buckle is always in the middle Page C 5 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS A TEREX COMPANY C 24 ADJUSTING THE STEERING COLUMN Both steering column and dashboard can be set to a different angle For this purpose e Loosen lever 1 and adjust as required then re tighten lever 1 Before driving the machine ensure the steering wheel is perfectly clamped E 2 5 ADJUSTING THE REAR VIEW MIRRORS The machine is fitted with two rear view mirrors e The right rear view mirror is located on a special supporting bracket in advanced position and allows checking the area behind the machine on the right hand side To adjust its position manually rotate the joint it is fitted with e left rear view mirror is placed on the left upper post of the windscreen and allows checking the area behind the machine on the left hand side To adjust its position manually rotate the joint it is fitted with C 26 SWITCHING ON THE CAB LIGHTS The ceiling light fixture of the cab has an internal lamp and a courtesy lamp To switch on the cab interior lights Switch 4 in pos cab interior lights OFF e Switch 4 in pos B cab in
62. damage to those persons who will approach the machine while stationary Park the machine so that it does not hinder other operations Lower the boom fitted with attachment on the ground Remove the key from the ignition switch Leave the driving cab and lock the cab door Disconnect the battery see chapter C 4 5 C 6 5 2 Machine storage In case of extended inactivity of the machine follow the above precautions Additionally e Wash the machine thoroughly For a better cleaning remove grills and protection casings Carefully dry all machine parts by blowing some compressed e Lubricate the machine thoroughly Do walk around inspection and replace any worn or damaged part Re paint any worn or damaged part Remove the battery smear its terminals with vaseline and store it in a dry place Battery can be used for other purposes Otherwise periodically check its charge level Refuel the tank to prevent internal oxidation Store the machine in a sheltered and well ventilated place e Start the engine for about 10 minutes at least once a month IMPORTANT Always remember that the ordinary maintenance must be carried out even during the machine inactivity Pay particular attention to the fluid levels and to those parts subject to ageing Before re starting the machine carry out an extraordinary maintenance and carefully check all mechanical hydraulic and electrical compon
63. diator if necessary Check the hydraulic oil level in the tank Check the greasing of the boom section pads Grease the attachment holding frame Grease all joints of the boom the rear axle shaft joint the transmission shafts the front and rear axles and any equipment of the machine Check the efficiency of the lighting electric system 9 Checktheefficiency of braking system and parking brake 10 Check the efficiency of the steering selection system 11 Checkthe efficiency of the fork balancing system 12 Makesurethe safety devices installed are in efficient working order see procedure in chap D 3 14 NO Every 50 working hours or weekly Jobs to be done in addition to those above 1 Check the tension of the alternator belt 2 Checkthe tyre inflation 3 Checkthe tightening of the wheel nuts 4 Checkthe tightening of the Cardan shaft screws Every 250 working hours or monthly Jobs to be done in addition to those above 1 Change the engine oil and relevant filter 2 Check the oil level in the front and rear differential gears and the reducer 3 Check the oil level in the four wheel reduction gears 4 Checkthe condition of the canister of the engine air filter renew the canister if necessary 5 Check the clamping of the cableheads to the battery terminals 6 Check the air suction hose between engine and filter 7 Checkthe cylinder chromium plated rods 8 Check the hydraulic lines are
64. dvice Intake In case of oil intake do not induce vomiting but seek medical advice Skin n case of a prolonged contact wash with soap and water Fire In case of fire use carbon dioxide dry chemical or foam extinguishers Do not use water Page D 2 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 MAINTENANCE A TEREX COMPANY D 2 ROUTINE MAINTENANCE A wrong or neglected maintenance can result in possible risks for both operator and bystanders Make sure maintenance and lubrication are carried out according to the manufacturer s instructions to keep the machine safe and efficient The maintenance interventions are based on the machine working hours Regularly check the hour meter and keep it in good conditions to define the maintenance intervals correctly Make sure any defect detected during the maintenance is promptly rectified before using the machine All marked operations must be carried out by a skilled technician During the first 10 working hours 1 Check the oil level within reduction gears power divider and differential gears 2 Regularly check the tightening of the wheel bolts 3 Checkthe tightening of all bolts and nuts 4 Checkthe couplings for oil leaks Within the first 50 working hours 1 Change the oil for the first time Every 10 working hours or daily Check the engine oil level Clean the air suction filter Clean the ra
65. e pushbutton must be off Slowly step on the gas pedal to start moving off CAUTION Donot operate the forward reverse gear leverwhen the machine is running The machine would reverse the running direction abruptly and you could seriously be injured Page C 22 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e A TEREX COMPANY B C 4 7 STOPPING AND PARKING THE MACHINE When possible stop the machine on a dry level and solid ground Then e Bring the machine to a smooth stop by easing up the gas pedal and stepping down on the brake pedal e Set the forward back speed lever to neutral position e Engage the parking brake pressing button 18 the warning light on the pushbutton must be on e Release the service brake pedal e Rest the attachment coupled to the boom flat on the ground e Rotate the ignition key to 0 and remove the key e Leave the driving cab and lock the cab door e Disconnect the battery see chapter C 4 5 Always face the machine when getting off the driving cab make sure that your hands and shoe soles are clean and dry and hold to the handholds to prevent falls or slips Always engage the parking brake after stopping the machine to prevent possible accidental motions of the vehicle C 5 USING THE HANDLER This chapter describes some techniques and provides instructions for a safe use of the machine fitted wi
66. ease the joints using the greasing gun Page F 6 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 OPTIONAL ATTACHMENTS A TEREX COMPANY F 1 5 FORKS WITH HYDRAULIC SIDE SHIFT Application Quick coupling fitted attachment for handling palletised loads with possibility of shifting the load to the side by x 100 mm Safety Strictly obey the general safety precautions given in section B SAFETY Do not load loose materials not move superposed pallets Operation To adjust the tilting operate the rotation lever of the attachment holding plate To side shift operate the attachment locking lever after connecting the feeding lines of the new attachment to the quick couplings See page F 2 Maintenance Visually check the attachment for damage before using it Check for hydraulic oil leaks Daily grease the joints using a greasing gun and smear the sliding guides with graphitized grease Machine GTH 5519 Code 59 0600 0000 Technical data Payload kg 2600 Width mm 1240 Length mm 1600 Height with protection mm 1000 Weight kg 180 Stroke mm 100 Fork attachments FEM 2 Page F 7 Document 57 0005 9200 12 2005 G io Handler with telescopic boom GTH 5519 A TEREX COMPANY OPTIONAL ATTACHMENTS Intentionally blank page Page F 8 Document 57 0005 9200 12 2005 G 1 G 2 1 G
67. el reduction gears 3 Change the hydraulic oil 0 21 OIL CHANGE SCHEDULE operating service Cil type hours interval Oil level check 10 daily SHELL RIMULA 15W 40 First change Subsequent changes monthly Axles and Oil level check monthly FUCHS TITAN GEAR LS 85 W 90 Poa First change API GL 5 LS GL 5 divider Subsequent changes 1000 yearly Hydraulic Oil level check monthly SHELL TELLUS T 46 all Subsequent changes 1000 yearly DENISON HF 1 DIN 51524 part 3 Cat HV whichever occurs first Page D 4 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY 0 3 MAINTENANCE JOBS All maintenance interventions must be carried out with engine stopped parking brake engaged working attachments flat on the ground and gear lever in neutral CAUTION When raising component for maintenance purposes secure it in a safe way before any maintenance intervention CAUTION Any intervention on the hydraulic circuit must be carried out by skilled personnel The hydraulic circuit of this machine is fitted with pressure accumulators You and others could be seriously injured if accumulators are not completely depressurised To depressurise the accumators just steer the machine wheels some times with engine shut down until noticing a gradual binding of the handwheel CAUTION Before any operation on hydraulic lines or components
68. element Tighten wingnut C close cover B and tighten with wingnut A As soon as the warning lamp on the cab dashboard switches on replace the outer element Page D 10 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY D 3 7 CAB AIR FILTER ONLY WITH CABIN CLOSED OR GLASS KIT INSTALLED Every six months clean the air filter in the cab Replace the cartridge if the filtering cloth is damged 1 Cleaning and changing the cartridge Shut the engine down and engage the parking brake Pull out the filter A located to the left of the driving place Clean the filter bowl Clean the filter cartridge and replace in case of damage Do not atany times dry clean the filters Use some water and or solvent D 3 8 ENGINE COOLING CIRCUIT The cooling radiator is lubricated with the engine oil and does not need any maintenance Page D 11 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 MAINTENANCE A TEREX COMPANY B D 3 9 CHECKING THE OIL LEVEL IN THE TANK Fine jets of hydraulic oil under pressure can penetrate the skin Do not use your fingers but a piece of cardboard to detect oil leaks Check the hydraulic oil level visually through the special level Q fitted into the tank When necessary add new oil through filler Check the oil leve
69. ents Page C 30 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS A TEREX COMPANY C 6 6 CLEANING AND WASHING THE MACHINE C 6 6 1 Cleaning instructions Clean the machine in accordance with the following instructions Remove any oil or grease traces with a dry solvent or a volatile mineral alcohol Before assembling a new part remove protection product rust preventer grease wax etc Remove any trace of rust from metal parts with some emery cloth before smearing the part with a protection product rust preventer paint oil etc C 6 6 2 Washing instructions External washing Before washing the machine check that the engine is shut down and the doors and windows are closed Do not at any times use fuel to clean the machine Use water or some steam In cold climates dry the locks after washing or smear them with an antifreeze Before using the machine again check its conditions Internal washing Wash the machine interior with some water and a sponge Do not use water at high pressure After washing dry with a clean cloth Washing the engine Before washing the engine protect the air intake filter to prevent water from entering the circuit C 6 7 MACHINE DISPOSAL PROTECT THE ENVIRONMENT At the end of the machine life call in a specialised firm to dispose of it in compliance with the local or national regul
70. est port exchanger Page G 9 Document 57 0005 9200 12 2005 G 5 ROUTINE CHECK SCHEDULE SAFETY DEVICES COMPONENT Result Notes Block Valve 1 Block Valve 2 Block Valve 3 Block Valve 4 Block Valve 5 Block Valve 6 Block Valve 7 Block Valve 8 Block Valve 9 Positive Negative D JOJO enie A TEREX COMPANY Handler with telescopic boom GTH 5519 TABLES AND DOCUMENTS ENCLOSED Table key explanation Block valve 1 Block valve 2 Block valve 3 Block valve 4 Block valve 5 Block valve 6 Block valve 7 Block valve 8 Block valve 9 Block valve on lifting cylinder Block valve on fork balance cylinder Block valve on telescope extension cylinder Block valve on attachment moving cylinder Block valve on attachment locking cylinder Page G 10 Document 57 0005 9200 12 2005
71. extend 4205 psi A x cylinder 72 psi 5 bar retract cylinder 290 nee B IHR Y3 p IE lll 4350 psi S 2i 300 bar Xj Ya Hi P 2465psi i i xX Lg E x LM tI 170 bar i Accumulator 1 a 1 capacity 0 13 gallons 0 5 Liters pre charge pressure 725 psi 50 bar T i H H i Pei i i c E Load handling Boom functions hydraulic 3915 psi E controls circuit test port TP4 270 bar main valve i i LEN Hydrostatic transmission i high pressure test port pm ii valve Hydrostatic R Fa Fe transmission Check valve Denn E motor H 1 36psi 2 5 bar hl il T T j 9525 psi_______ _ _ 725 psi dX 450 _ 1 ar i i ei ES a d T HH pg Function pump OWNYYN iant i with integrated 9 priority valve BE 21 7 gpm 82 L min 7 362 psi _ 25 bar i i 6525 ps i 450 bari i i i 6235psi Hydrostatio 430 i transmission 4 LL pump x X G MH n Fa a i Check valve L LA Suction Check valve 4 Suction OF filter 7 psi 0 5 bar oi is 36 psi 2 5 bar Thank X filter Check valve TP J Heat 1 7 psi 0 5 bar Hydrostatic t saat X ea i 1 Ter boost pressure t
72. forward and reverse audible warning alarm Sound test method Safety of industrialtrucks Test methods for measuring vibration Electromagnetic compatibility Generic requirements on emissions Part 1 Electromagnetic compatibility Generic requirements on immunity Part 1 Safety of machinery Electrical equipment of machines Part 1 ANSI ASME B56 6 2002 part III where applicable Page A 11 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 GENERAL INFORMATION B A 3 5 SAFETY DEVICES e The machine is equipped with a negative brake on the front axle which engages automatically when the engine stops When this brake is disengaged the engine start up is inhibited Block valves fitted to all cylinders A Block valve on attachment coupling cylinder B Block valve on lifting cylinder C Block valve on balance cylinder D Block valve on boom extension cylinder E Block valve on attachment pitching cylinder Page A 12 Document 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 TE GENERAL INFORMATION 4 GENERAL DESCRIPTION A 4 1 LIST OF THEMAIN COMPONENTS Forks Attachment holding frame 2 boom section 1 boom section Engine hood Driving cab Left rear view mirror Front axle Chassis Left front wheel mud guard Left front wheel reduction gear Left rear wheel reduction gear
73. iiit deteriore bea perraro B 2 Requisites of the machine operators B 2 Reguisites of the sert B 3 Wonn ee B 3 Personal protective e Er re E Ela E EPFL HM RE B 3 SAFET PREC AUTONG E B 4 E A T E E B 4 Geno road O WOK arare aE aa B 5 During work or eT B 5 SAFETY DEVI ES oui ciu MUI s B 7 Page B 1 Q Handler with telescopic boom GTH 5519 SAFETY A TEREX COMPANY 1 GENERAL REMARKS Most accidents occurring while working repairing or maintaining operation machines are caused by not complying with the basic safety precautions Therefore it is necessary to pay steady attention to the potential hazards and the effects that may come of operations carried out on the machine IMPORTANT If you recognise hazardous situations you can prevent accidents For instance this handbook makes use of special safety symbols to stress any potentially hazardous situation CAUTION The instructions given this handbook are the ones established by GENIE They do not exclude other safe and most convenient ways for the machine installation operation and maintenance that take into account the available spaces and means If you decide to follow instructions other than those given in this manual you shall absolutely sure that the operations you are going to carry out are not e
74. ing it Technical data Capacity litres 800 A Width mm 1850 B Length mm 800 H Height mm 1150 Weight kg 350 ATTENTION Attachment suitable for moving loose material Do not use for digging operations Page F 4 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 TE OPTIONAL ATTACHMENTS F 1 3 FIXED HOOK ON PLATE Payload Code 2500 kg 59 0700 0000 Technical data Payload kg 2500 Width Length Height Weight mm 970 mm 620 mm 600 kg 105 Application Quick coupling fitted attachment for lifting loads by means of special slings Safety Strictly obey the general safety precautions given in section B SAFETY Do not oscillate the load Do not drag hooked loads Lift the load before extending the boom Operation Fork the hook and hold it in position by means of the locking cylinder All loads must be bridled with special textile slings or chains in compliance with all pertinent regulations To handle the load raise and rotate the telescopic boom of the handler Maintenance Visually check the hook for damage before using it Check the safety catch is in good working order IMPORTANT The fixed hook has been designed to support a load of 2500 kg The max payload corresponds to the nominal capacity rating of the handler on which itis installed and is indicated o
75. intenance or repair work make sure that no tool cloth or other object has been left within machine compartments fitted with moving parts or where suction and cooling air circulates e When working do not give instructions or signs to several people at the same time Instructions and signs must be given by one person only e Always pay the due attention to the instructions given by the foreman e Never distract the operator during working phases or crucial manoeuvres e Do not call an operator suddenly if unnecessary e Do not frighten an operator or throw objects by no means e After work never leave the machine under potentially dangerous conditions Page B 7 Document 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 SAFETY Intentionally blank page Page B 8 Document 57 0005 9200 12 2005 A TEREX COMPANY C 1 2 C 2 1 C 2 1 1 2 2 2 3 2 4 2 5 2 6 C 3 C 3 1 C 3 2 C 3 2 1 C 3 2 2 C 3 2 3 C 3 2 4 C 3 2 5 C 3 2 6 C 3 2 7 C 3 2 8 C 3 3 C 3 3 1 C 3 3 2 C 3 4 C 3 4 1 C 3 4 2 C 3 4 3 C 3 4 4 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS Section C OPERATING INSTRUCTIONS TABLE OF CONTENTS BEFORE ENTERING THE MACHINE C 2 C 3 4 5 ENTERING THE MACHINE C 3 C 4 Entering the cab only with cabin C 4 1 closed or glass kit installed C 3 C 4 1 1 Emergency exit way only with
76. ir PLE EHE Fed a dea Identification plates of the maim PANTS isis m erp bol soa axe Allowed SEES Residnal hazala e m stand ar errr eer reer T GENERAL laici vj Listor Ine 5120 sacs NUES dA Description or the mal componens Gpional MH Kiis s pplied om regue ST LE TECHNICAL DATA AND PERFORMANGE Man RETE ERES osa perpeti c per E SERE HERR ie EO oiii isum LM MeL E ME B T ir Literature Supple d m EE Page A 1 Document 57 0005 9200 12 2005 enie Handler with telescopic boom GTH 5519 TE GENERAL INFORMATION 1 CONVENTIONAL REFERENCES A 1 1 MACHINE POSITION Conventionally the machine should be considered positioned as shown in the figure This convention is necessary to make any reference of this handbook to different machine parts front rear etc clear and unmistakable Any exception to this rule will always be specified UPPER PART REAR PART ce A lt RIGHT SIDE
77. king brake Battery charge Fork pitching back Oil filter clogged Air filter clogged Glow plug preheating Oe bereketle 6 Document 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 TE OUT GENERAL INFORMATION Symbol Description Symbol Description zb Front optional work light Road jobsite selector switch Lifting point Fuel plug Engine oil filler Page A 7 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 GENERAL INFORMATION e A TEREX COMPANY A 2 MACHINE IDENTIFICATION IMPORTANT Check that the operator handbook refers to the delivered machine When asking for information or technical assistance always specify model type and serial number of the machine A 2 1 MACHINE MODEL AND TYPE Handler with telescopic boom Cl model GTH 5519 A 2 2 MANUFACTURER TEREXLIFT srl Zona Industriale Ind Estate 1 06019 UMBERTIDE PG ITALY Enrolled in the register of companies at the Court of Perugia under no 4823 n 102886 Fiscal Code V A T no 00249210543 A 2 3 MACHINE IDENTIFICATION PLATES Machine data plate At the front on the right side of the chassis The identification plate contains the main identification data of the machine like model serial number and year of manufacture O O TEREX MODEL NUMBER SERIAL NUMBER YEAR OF MANUFACTURE E UNLADEN T
78. l switches within the cab to OFF To disconnect the battery disconnect the negative lead from the frame earth first Toconnect the battery connect the positive lead first Recharge the battery far from the machine in a well ventilated place Keep out of items which can produce sparks of naked flames or lit cigarettes Donot rest metal objects onto the battery This canresult dangerous short especially during a recharge e Because the electrolyte is highly corrosive it must never come in contact with the frame of the handler or electric electronic parts If the electrolyte comes in contact with these parts contact the nearest authorised assistance centre Risk of explosion or shorts During the recharge an explosive mixture with release of hydrogen gas forms Do not add sulphuric acid add only distilled water Page D 21 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 TE MAINTENANCE D 4 2 FUSES AND RELAYS Ref Circuit Amp The electrical system is protected by fuses placed in Feo Matused fm the driving cab on the left Before replacing a blown F27 Not used 5 fuse with a new one having the same amperage find F28 Not used 5 out and rectify the fault F29 Spare fuses I CF14 F28 CAs r2 Fm
79. l with handler set to transfer position lowered boom and retracted telescopic element SERVICE INTERVAL Running in Within the first 10 hours Ordinary Every 50 hours If oil must be changed proceed as follows 1 Stop the machine on a level ground and make sure the parking brake is engaged 2 Release the pressure from the hydraulic circuit 3 Place a container of suitable size under the drain plug placed in the lower part of the reservoir and collect any oil leaks 4 Remove the drain plug and allow oil to flow out into the container 5 Remove the inspection cover of tank 6 Carefully wash the tank with Diesel oil and blow jet of compressed air 7 the drain plug and the inspection cover 8 Add new oil by making sure that it matches the recommended type indicated in paragraph D 5 2 2 until it is level with SERVICE INTERVAL None Every 1000 hours Running in Ordinary The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres Page D 12 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 MAINTENANCE A TEREX COMPANY D 3 10 CHANGING THE OIL FILTER CANISTERS ON THE INTAKE LINE D 3 10 1 Transmission oil filter Every 50 hours check the clogging degree of the filtering element using the vacuometer The indexed scale of the vacuometer is divided into 3 areas
80. make sure there is no residual pressure Forthis purpose stop the engine engage the parking brake and operate the control levers of the distributors in both working directions alternately to depressurise the hydraulic circuit High pressure lines must be replaced by qualified personnel only Any foreign matters entering the closed circuit may result in a sudden deterioration of the transmission ATTENTION The qualified staff charged with the maintenance of the hydraulic circuit must clean all areas around with care before any intervention PROTECT THE ENVIRONMENT The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres D 3 1 DISCONNECTING THE BATTERY Before any maintenance or repair work and especially before welding any components on the machine remove the cables at the battery CAUTION Before disconnecting the battery set all switches within the cab to OFF To disconnect the battery disconnect the negative lead from the frame earth first To connect the battery connect the positive 4 lead first Page D 5 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 MAINTENANCE A TEREX COMPANY D 3 2 ACCESS TO THE ENGINE AND TANKS COMPARTMENTS E Engine compartment For any operation within the engine compartment open the protection bonnet Hood is equipped with l
81. mposition of the latter can vary in relation to the ambient temperature up to max 8090 oil D 5 2 4 Grease For the machine greasing use e Lithium based When greasing by pump Vanguard LIKO grease type EP2 Graphitized SHELL When greasing by brush grease type GR NG 3 INTERFLON FIN For the telescopic boom GREASE LS 2 sliding blocks ATTENTION Avoid mixing greases of different type or features and do not use greases of lower quality Page D 25 Document 57 0005 9200 12 2005 enie Handler with telescopic boom GTH 5519 MAINTENANCE Intentionally blank page Page D 26 Document 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 TE FAULTS TROUBLESHOOTING Section E FAULTS AND TROUBLESHOOTING TABLE OF CONTENTS E 1 FAULTS AND TROUBLESHOOTING 2 1 1 Fault Cause nixa cose tasa rv teri E 2 Page E 1 Document 57 0005 9200 12 2005 TEREX COMPANY EN E 1 This chapter represents a practical guide for the operator for fixing the most common failures and at the same time detecting those interventions which must be carried out by qualified technical engineers If you are unsure about anything do not carry out operations on the machine but call in a skilled technician Handler with telescopic boom GTH 5519 FAULTS AND TROUBLESHOOTI
82. n the load charts supplied with the equipment IMPORTANT Make sure this attachment can be used in the destination country of the machine In Italy this attachment must be enrolled at ISPESL and submitted to yearly test Application must be submitted directly by the user Page F 5 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 OPTIONAL ATTACHMENTS F 1 4 EXTENSION JIB Application Code 400 kg GTH 5519 59 0800 0000 Characteristics Payload kg 400 A Length mm 2100 B Wiath mm 920 H Height mm 630 Weight kg 115 IMPORTANT Make sure this attachment can be used in the destination country of the machine In Italy this attachment must be enrolled at ISPESL and submitted to yearly test Application must be submitted directly by the user Quick coupling fitted attachment for maintenance interventions at high working heights Safety Strictly obey the general safety precautions given in section B SAFETY Never lift wrongly slung loads Avoid abrupt acceleration or deceleration Avoid load oscillations and especially do not move the load from the vertical pull line Do not pull crosswise and do not tow Operation To change the working height operate the rotation lever of the attachment holding plate Maintenance Visually check the jib for damage before using it Check the safety catch is in good working order Daily gr
83. nd valve 9 for the negative parking brake circuit To bleed the circuit of the service brake e Makesurethatthe oil is level within the feeding tank Step on the brake pedal repeatedly Slowly unscrew valve and re close it as soon as oil mixed with air bubbles comes out e Repeat the operation until bubble free oil comes out e Bleed from both sides of the machine To bleed the circuit of the negative parking brake Press the parking brake button 9 As soon as the light indicator on the button goes off start bleeding through valve Q until air free oil comes out D 3 5 1 Checking the brake oil level The oil within the braking circuit must be at about 2 cm from the tank plug Page D 9 Document 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 MAINTENANCE D 3 6 ENGINE AIR FILTER Clean the engine air filter every 10 hours replace the filtering element if necessary 1 Cleaning and changing the external element Stop the engine and engage the parking brake Unscrew wingnut A and remove cover B Unscrew wingnut C and remove the outer element D Clean the filter bowl Clean the cartridge by beating it some times on the ground paying attention not to damage the filtering element Do not dry clean the filtering element Check for cracks in the filtering element by introducing a lamp inside Smearthe seal with grease then refit the
84. not worn because of rubbing against the frame or other mechanical components 9 Check the electric cables do not rub against the frame or other mechanical components 10 A Checkthe wear of the sliding pads of the boom sections 11 A Adjust the play of the sliding pads of the boom sections 12 Remove any grease from the boom then re grease the sliding parts of the boom sections 13 Check the level of the battery electrolyte Every 3 working months 1 Check the efficiency of the block valves see chap D 3 14 Every 500 working hours or every six months Jobs to be done in addition to those above 1 Visually checkthe smoke quantity evacuated from the engine exhaust 2 Check the tightening of the engine fixing screws 3 Checkthe tightening of the cab fixing screws 4 Check the backlash between pins and bushings in all joints 5 Change the hydraulic oil filter of the transmission 6 Change the hydraulic oil filter in the tank Page D 3 Document 57 0005 9200 12 2005 enie Handler with telescopic boom GTH 5519 MAINTENANCE 7 Have the hydraulic system checked by a skilled technician 8 Change the main cartridge of the engine air filter 9 Cleanorreplace if nececessary the air filter in the cab Every 1000 working hours or yearly Jobs to be done in addition to those above 1 Changetheoilinthe front and rear differential units and in the power divider 2 Change the oil in the four whe
85. ock amp key and a supporting rod that holds it in position From the engine compartment you get access to e Thermal engine Engine air filter 9 e Hydraulic oil tank plug e Radiator fluid compensation cup e Battery To get access to the engine compartment Shut the engine down and put the parking brake e Unlock the bonnet lock e Lift the bonnet using the special handle until it latches in the gas spring e To close the bonnet press on the green locking device on the gas spring and lower the bonnet Take all precautions when approaching the engine compartment Some parts of the engine may be very hot Always use protective gloves Diesel fuel tank compartment To gain access to the fuel tank open the rear cover of the machine as follows Shut the engine down and put the parking brake e Fully raise the cover by means of the special handle Page D 6 Document 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 TE MAINTENANCE B D 3 3 GREASING ATTENTION Beforeinjecting grease into the greasers thoroughly clean them to avoid that mud dust or other matters can mix with the lubricant and reduce or annihilate the lubrication effect Remove any old grease with a degreaser from the telescopes before smearing them with new grease Regularly grease the machine to grant it efficient conditions and a long life By means of a pump inject grease into the special g
86. od and the behaviour to be adopted When necessary it stresses prohibitions or supplies instructions to prevent dangers Sometimes it can be followed by illustrations We list below the special or safety symbols according to the relative seriousness of the hazard situation Draws the attention to situations that involve your own as well as the others safety and that can result in serious or lethal injury DANGER Draws the attention to situations that involve your own as well as the others safety and that can result in serious injury or lethal injury CAUTION Draws the attention either to situations that involve your own as well as the others safety and that can result in minor or moderate injury or to situations that involve the machine efficiency ATTENTION Draws the attention to situations that involve the machine efficiency IMPORTANT Draws the attention to important technical information or practical advice that allows for a safer and more efficient use of the machine PROTECT THE ENVIRONMENT Draws the attention to important environment related information WHEN READING THIS MANUAL PAY THE GREATEST ATTENTION TO THESE SPECIAL SYMBOLS AND THE EXPLANATION OF THE SITUATIONS THEY EMPHASIZE The manual in electronic format also contains the following symbol which enables the user to return to the table of contents Page 2 Documen
87. of material Driving cab Type approved driving cab in compliance with standards ANSI ASME B56 6 2002 B A 4 3 OPTIONAL ACCESSORIES The machine can be fitted with a wide range of optional accessories please address to Genie sales network IMPORTANT Please check the accessories available for your machine 4 4 KITS SUPPLIED REQUEST The machine is prepared for the installation of the following assembly kits Driving cab glasses including door Heater Air conditioning Work lights including courtesy lamp in the cab Beacon It consists of a gear pump connected to the thermal engine which through a special valve dispenses oil to the hydraulic drive and a distributor for the following functions boom lifting lowering telescopic boom extension retraction attachment rotation attachment locking Braking circuit It consists of an independent circuit the pedal directly acts on the brake pump which dispenses oil to the front axle braking unit with discs in oil bath The parking brake of negative type acts on the braking unit of the service brake This brake is engaged every time the handler s engine is stopped or pressing down the light pushbutton located to the right of the driving place Page 14 Document 57 0005 9200 12 2005 enie Handler with telescopic boom GTH 5519 TE LL GENERAL INFORMATION 5 TECHNICAL DATA AND PERFORMANCE A 5 1 MAIN DIMENSIONS
88. onal road traffic regulations Page C 28 Document 57 0005 9200 12 2005 A TEREX COMPANY B C 6 3 LIFTING THE MACHINE When the machine shall be lifted use only means having a suitable capacity The characteristic data are detailed in the relevant chapter of this manual and on the identification plate Forthe machine lifting anchorthe chains to the special lugs on the machine marked with the decal below enie Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS E C 6 4 TRANSPORTING THE MACHINE ON OTHER VEHICLES Totransport the machine on another vehicle follow the steps below Put chocks at the machine wheels Ensure ramps are correctly positioned Retract the boom to transfer position Carefully drive the machine onto the transporting vehicle Put the parking brake and rest the attachment flat on the vehicle platform Ensure the overall dimensions do not exceed the allowed limits Shut the engine down and close the driving cab of the machine Secure the machine to the vehicle platform by wheel chocks Anchor the machine to the transporting vehicle with suitable chains Page C 29 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS A TEREX COMPANY C 6 5 PARKING AND STORAGE C 6 5 1 Short inactivity Always park the machine in a safe way after a working day a shift and at night Take all precautions to prevent
89. ore engaging gear this allows for a gradual warm up ofthe engine oil and a better lubrication In case of engine jump starting remove the booster cables see following chapter ATTENTION If the light indicators do not switch off on when engine is running immediately stop the machine and find and rectify the fault IMPORTANT Engine cannot be started if the parking brake is not engaged After the start up when leaving the driving place the engine continues to run DO NOT LEAVE THE DRIVING PLACE BEFORE HAVING SHUT THE ENGINE DOWN LOWERED THE BOOM TO THE GROUND AND ENGAGED THE PARKING BRAKE Page C 20 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e A TEREX COMPANY C 4 3 JUMP STARTING THE ENGINE ATTENTION Do not start the engine using a quick charge booster to avoid any damage to the electronic boards When ump starting the engine through the battery ofanothermachine make sure that the two vehicles cannot collide to prevent formation of sparks Batteries give off a flammable gas and sparks may burn it and cause an explosion Do not smoke when checking the electrolyte level Keep any metal object like buckles watch straps etc clear of the battery positive terminal These elements can short between the terminal and nearby metal work and the operator can get burned The booster supply must have the same rated voltage and output of
90. reasers As the fresh grease comes out stop the operation The greasing points are shown in the following figures thesymbol represents the points to be greased by a pump the symbol represents the points to be greased by a brush Page D 7 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 MAINTENANCE D 3 4 TYRES AND WHEELS Over inflated or overheated tyres can burst Do not flame cut or weld the wheel rims For any repair work call in a qualified technician YES NO For the tyre inflation or substitution please refer to the table below GTH 5519 Dimensions 12 16 5 EM14 Load index pr 10 Rim 9 75x16 Wheel disc 8 holes DIN 70361 Pressure 4 5 65 On new machines and when a wheel has been disassembled or replaced check the nut torque of the wheels every 2 hours until they stay correct ATTENTION Always use tyres having the dimensions indicated in the vehicle registration card Page D 8 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 MAINTENANCE MS D 3 5 BRAKES e For any intervention on the braking system adjustment and or substitution of the brake discs call in a specialised technician The malfunctioning of the braking system may depend on the presence of air within the hydraulic circuit The braking system has two bleeding valves valve forthe service brake circuit a
91. rward or reverse gear put The engine must not start If the engine starts contact the GENIE Technical Service Repeat the operation putting first one gear then the other Page D 20 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY 0 4 ELECTRICAL SYSTEM All maintenance interventions must be carried out with engine stopped parking brake engaged working attachments on the ground and gearbox lever in neutral When raising a component for maintenance purposes secure it in a safe way before carrying out any maintenance D 4 1 BATTERY e Check the electrolyte level every 250 working hours if necessary add distilled water Ensure the fluid is 5 6 mm above the plates and the cell levels are correct Check the cable clips are well secured to the battery terminals To tighten the clips always use a box wrench never pliers Protect the terminals smearing them with pure vaseline Remove the battery and store it in a dry place when the machine is not used for a long time e Battery electrolyte contains sulphuric acid It can burn you if it touches your skin and eyes Always wear goggles and protective gloves and handle the battery with caution to prevent spillage Keep metal objects watch straps rings necklaces clear of the battery leads since they can short the terminals and burn you Before disconnecting the battery set al
92. sert the key and release lock 1 e Press the pushbutton and open the door Door closing from inside e Pull the door with force it locks automatically Door opening from inside e Lift lever 2 and release the lock to open the door completely e Rotate handle 3 to open the upper section of the door and lock it against the special catch To unlock the door latched in open position e Press button 4 to unlock the door from the catch close and latch the door to the lower section using handle 3 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS CAUTION The upper section of the door must be secured to the rear part of the driving cab or latched to the lower section of the same door Page C 3 Document 57 0005 9200 12 2005 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS Ie A TEREX COMPANY C 2 1 1 Leaving the cab in an emergency ONLY WITH CABIN CLOSED OR GLASS KIT INSTALLED In an emergency the operator can use he front or the rear window as safety exit ways The rear window has handles for partially opening the glass Such handles are locked in position by some wing nuts 5 which if driven out allow opening the glass completely The front window has two handles 6 which if turned enable the operator to pass through Page C 4 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS A TEREX COMPANY
93. sure or disconnecting hydraulic components ensure the relevant line has been previously depressurised and does not contain any hot fluid Any intervention on the hydraulic circuit must be carried out by authorised personnel The hydraulic circuit of this machine is fitted with pressure accumulators You and others could be seriously injured if accumulators are not completely depressurised For this purpose shut the engine down and step on the brake pedal 8 10 times e Neither smoke nor use open flames in areas subject to fire dangers and in presence of fuel oil or batteries asm Page B 6 Document 57 0005 9200 12 2005 enie Handler with telescopic boom GTH 5519 SAFETY e Do not leave fuel cans or bottles in unsuitable B 4 SAFETY DEVICES places Do not empty catalytic mufflers or other vessels containing burning materials without taking the necessary precautions e Carefully handle all flammable or dangerous substances Several safety devices have been fitted to the machine They must never be tampered with or removed see chap A 3 5 Regularly check the efficiency of such devices see check card chap G 5 In case of faults stop working immediately and proceed in replacing the defective device For the checking procedures read chap D 3 14 e Do not tamper with fire extinguishers or pressure accumulators explosion hazard e After any ma
94. t 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 GENERAL INDEX GENERAL INDEX GENERAL INFORMATION SAFETY OPERATING INSTRUCTIONS MAINTENANCE TROUBLESHOOTING OPTIONAL ATTACHMENTS TABLES AND DOCUMENTS ENCLOSED Page 3 Document 57 0005 9200 12 2005 Sect Sect Sect Sect Sect Sect Sect gt Genie Handler with telescopic boom GTH 5519 Intentionally blank page Page 4 Document 57 0005 9200 12 2005 A 1 A 1 1 A 1 2 A 1 2 1 A 1 3 A 2 A 2 1 A 2 2 A 2 3 A 2 4 A 2 5 A 3 A 3 1 A 3 2 A 3 3 A 3 4 A 3 5 A 4 A 4 1 A 4 2 A 4 3 A 4 4 A 5 A 5 1 A 5 2 A 5 3 A 5 4 A 5 5 A 5 6 A 5 7 A 5 8 A 6 A 7 A 7 1 Handler with telescopic boom GTH 5519 GENERAL INFORMATION Section A GENERAL INFORMATION TABLE OF CONTENTS CONVENTIONAL REFERENCES Machine siiis M H Labels and warning plates applied on the machine rie vencer ql ERE IE ENE T HERE HARE Qe ee RARE Explanation of the different symbols used on the machine MAGHINE IDENTIFICATION ET ii ssepe REST ELE lek B cc Machine eai Ghas k eral NUDO o cai r
95. tablished schedule see section D Maintenance CAUTION Set the machine to working configuration and sway it checking the special water level in the driving cab at the top on the strut e Ensure you have enough fuel to avoid a sudden stop of the engine especially during a crucial manoeuvre e Clean instruments data plates lights and the cab windscreen thoroughly e Check the correct functioning of all the safety devices installed on the machine and in the job site e Incase of troubles or difficulties inform the foreman at once Never start working under unsafe conditions Do not carry out any repair work in a makeshift way to start working B 3 3 DURING WORK OR MAINTENANCE During work and especially maintenance always pay the greatest attention e Donot walk or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only e Keep the machine handholds and access steps always clean from oil grease or dirt to prevent falls or slips Page B 5 Handler with telescopic boom GTH 5519 TE SAFETY When entering leaving the cab or other raised parts always face the machine never turn the back When carrying out operations at hazardous heights over 1 5 meters from the ground always use type approved safety belts or fall preventing devices uj al Do not enter leave the machine while it is running Do not leave the driving place when the machine is running
96. ted hazards have been eliminated some operations performed by the machine operator can result in potentially hazardous situations Among them e Hazards deriving from a too high work or transfer speed in relation to the load handled or the ground condition of the jobsite e Hazards deriving from work procedures adopted during the check or replacement of a block valve residual pressure uncontrolled movements e Hazards deriving from work procedures adopted while disassembling parts of the machine e g the cylinders without supporting mobile parts suitably risk of uncontrolled fall of the mobile part e Hazard deriving from an accidental overturning of the machine in the event the operator has not fastened the safety belts Page A 10 Document 57 0005 9200 12 2005 GENERAL INFORMATION A 3 4 APPLICABLE STANDARDS ISO 6055 1997 Forthe operator s safety the following standards were ISO 6292 1996 obeyed during the risk assessment of the handler fitted with telescopic boom Directive Title ISO 9533 1989 98 37 CE Machinery Directive 89 336 CEE Electromagnetic compatibility 73 23 CEE Low Voltage prEN 13059 1997 2000 14 CE Environment Acoustic Emissions Title EN 50081 1 1997 EN 1459 1988 EN 281 1988 EN 292 1 1991 EN 292 2 1991 EN 1175 2 1998 Handler with telescopic boom GTH 5519 Harmonised standard Safety of industrial trucks Self propelled variable
97. terior lights ON Switch 4 in pos C courtesy lamp ON Page C 6 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS A TEREX COMPANY C 3 DRIVING PLACE C 3 1 CONTROLS AND INSTRUMENTS Dashboard Water level Brake oil tank Ignition switch Fresh air flap Warning light glow plugs preheating Warning light air filter clogged Fuse compartment Forward reverse speed selection lever Steering column locking lever Brake pedal Pushbutton enabling the attachment coupling release 13 Steering selection switch 14 Horn pushbutton 15 Gas pedal 16 Seat 17 Control lever 18 Negative brake on off switch 19 Continuous flow selector 20 Storage tray 21 Storage pocket 22 Windscreen washer pushbutton only with cabin closed 23 Airconditioning fan switch only with cabin closed 24 Cab heater cock only with cabin closed IMPORTANT The warning lights controls and instruments not indicated in this list or in the drawings on the following pages are part of the optional assembly kits When looking for one of such devices please refer to the pages of the specific assembly kit at the end of this manual or to the specific installation instructions AN N Page C 7 Document 57 0005 9200 12 2005 Genie Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS 1 2 L 420246
98. th standard forks Before using different attachments thoroughly read the chapter Optional attachments CAUTION Before using the machine inspect the job site and check for possible hazardous conditions Make sure that there are no holes moving banks or debris that may cause you to lose the control of the machine ELECTRICAL DANGER Pay the greatest attention when working close to electric lines Check their position and ensure that no part of the machine operates at less than 6 meters from the power lines CAUTION For a safe use of the machine always check the weight of the loads going to be handled Always refer to the load charts applied in the cab Page C 23 Document 57 0005 9200 12 2005 A TEREX COMPANY C 5 1 USING THE LOAD CHARTS On the cab windscreen there are the load charts that indicate the operator how far a load can be extended The load chart indicates the payload limits of the machine under safe conditions To operate under safe conditions always referto these charts CAUTION The load charts illustrated in this manual are given only as a mere example To define the payload limits refer to the load charts applied in the cab of your machine Q Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS rs CAUTION The load charts applied on the cab windscreen refer to a stationary machine standing on a solid and level ground Raise the load some
99. the battery installed on the handler To jump start the engine e Turn any users off by the special control levers e Putthe gear lever to neutral and engage the parking brake e Ensure the machine battery A is connected to the frame earth the terminals are well tightened and the electrolyte level is regular Connect the two batteries as shown in the figure Connect first the positive terminals of the two batteries then the negative terminal of the booster supply B to the machine frame earth f the booster supply is installed on a second vehicle make sure that the latter does not touch the handler then start the vehicle and reach an rpm corresponding to 1 4 of full throttle Turn the ignition key and start the handler then follow the procedure explained in chapter C 4 2 Starting the engine e Disconnect the cables Remove first the negative terminal from the frame earth then from the booster supply Disconnect the positive terminal from the machine battery then from the booster supply Use only a 12V battery other devices like battery chargers etc may cause an explosion of the battery or result in damage to the electrical system Page C 21 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS A TEREX COMPANY C 4 4 LOW TEMPERATURE STARTING In case of cold starting use an oil with a SAE viscosity adequate to the ambient temperature Please
100. the load in position in case of burst of a flexible hose To check the efficiency of a valve proceed as follows e Load a weight near the maximum payload 2400 kg roughly onto the boom Raise the load some centimetres above the ground max 10 cm To check the valve on the telescope extension cylinder move the boom to maximum height and extend it some centimetres e Loosen the oil hoses to the cylinder of which you are checking the valve with caution During the check the oil will flow out of the hoses and the load shall remain blocked in position Should that not be the case the valve must be replaced Contact GENIE Technical Service Wear safety glasses Wear safety gloves Wear safety shoes Wear suitable working clothes Use guards against leaks of oil at high pressure Do the check in a free space with barriers all around to keep non authorised people away During the check proceed with extreme caution Ensure that the part to be checked is in safe condition and that the action generated does not result in an uncontrolled movement of the machine Attachment pitching cylinder Handler with telescopic boom GTH 5519 MAINTENANCE Attachment coupling cylinder I Balance cylinder Page D 19 Document 57 0005 9200 12 2005 Q Handler with telescopic boom GTH 5519 MAINTENANCE Checking the machine start control at every use Attempt to start the engine with the fo
101. tion Check for oil leaks or loosening of guards and make sure that the safety devices are efficient In case of defects find and rectify them before using the machine again The maintenance interventions are based on the machine working hours Regularly check the hour meter and keep it in good condition to define the maintenance intervals correctly Not respecting the ordinary maintenance schedule of this manual automatically voids GENIE warranty IMPORTANT For the engine maintenance please refer to the specific Operator handbook supplied with the machine LUBRICANTS HEALTH AND SAFETY PRECAUTIONS EN D 1 Health A prolonged skin contact with oil can cause irritation Use rubber gloves and protective goggles After handling oil carefully wash your hands with soap and water Storage Always keep lubricants in a closed place out of the children s reach Never store lubricants on the open air and without a label indicating their contents Disposal New or exhausted oil is always polluting Never drain oil on the ground Store new oil in a suitable warehouse Pour exhausted oil into cans and deliver them to specialised firms for disposal Oil leaks In case of accidental oil leaks cover with sand or type approved granulate Then scrape off and dispose of it as chemical waste First aid Eyes n case of accidental contact with the eyes wash with fresh water If the irritation persists seek medical a
102. xplicitly forbidden be sure that the methods are safe say in compliance with the rules and provisions given in this section e be sure that the methods cannot damage the machine directly or indirectly or make it unsafe contact GENIE Assistance Service for any suggestion and the necessary written permission IMPORTANT If in doubt it is always better to ask For this purpose contact GENIE the assistance service is atyour disposal Addresses phone andfax numbers are given in the cover and in the title page of this manual B 2 REQUISITES OF THE PERSONNEL IN CHARGE B B 21 REQUISITES OF THE MACHINE OPERATORS The operators who use the machine regularly or occasionally i e for transport reasons shall have the following prerequisites health before and during any operation operators shall never take alcoholic beverages medicines or other substances that may alter their psycho physical conditions and consequently their working abilities physical good eyesight acute hearing good co ordination and ability to carry out all required operations in a safe way according to the instructions of this manual mental ability to understand and apply the enforced rules regulations and safety precautions They shall be careful and sensible for their own as well as for the others safety and shall desire to carry out the work correctly and in a responsible way emotional they shall keep calm and always be a
103. y a correct use during the working phases but also a prompt and timely intervention of the operator when he shall carry out sudden manoeuvres to safeguard his safety and the machine integrity It is necessary to learn how to use and foresee the machine reactions Learn how to operate the machine controls in a safe and open place without obstacles and anybody standing around Do not ram the controls Operate them slowly to understand their effect on the machine BEFORE ENTERING THE MACHINE Checks and cleaning Clean glasses lights and rear view mirrors Check that pins joints and bolts are well tightened in position e Check for oil fuel or coolant leaks C 1 Checking the tyres e Check the correct inflation of the tyres see par Tyre inflation in the Maintenance section e Make sure that the tyre plies are not cut or worn A tyre burst may result in serious injury never use the machine if tyres are worn wrongly inflated or damaged Page C 2 Document 57 0005 9200 12 2005 EE C 2 ENTERING THE MACHINE C 2 1 ENTERING THE CAB ONLY WITH CABIN CLOSED OR GLASS KIT INSTALLED CAUTION Always make sure that your hands and shoe soles are clean and dry before getting into the driving cab Always face the machine when entering and leaving it and hold to the suitable handles The handler cab is equipped with an access door on the left hand side Door opening from outside e In

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