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PN 57.0008.6200 - Genie Industries

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1. E 5 8 e a 8 a ATTACHEMNT 1 WHIYE WHIYEot SOLENOID VALVE CONTINUOUS olL 55 ATTACHEMNT 1 WHIOGo1 WHIOGo1 SOLENOID VALVE e JOYSTICK FORK 1 BUIEo1 BUNEo1 SOLENOID VALVE a 1 i 8 a i vmo 559 115 ER H f Biot i BEACON 5 8 venais 2 2 5 E WORK LIGHT WORK LIGHT 2 SWITCH 8 OPTIONAL 1 2 221 sd a a 8 Y o 8 8 8 11 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 e A TEREX COMPANY TABLES AND DOCUMENTS ENCLOSED G 3 1 1 Wiring diagram Components description Ref X Description Sheet Description Sheet 2 10 A FUSE K06 GEAR ENGAGEMENT FROM PARKING BRAKE LINE 10 AFUSE LOW PRESSURE BULB 1 FA 5AFUSE K11 START RELAY 1 F5 10AFUSE F6 10AFUSE M01 STARTER MOTOR 1 F7 5AFUSE M02 ALTERNATOR 1 F8 5AFUSE M03 WINDSCREEN WIPER MOTOR 5 F9 15AFUSE M04 WINDSCREEN WIPER WASHER MOTOR 5 0 5AFUSE M06 FAN MOTOR 7 11 7 5 A FUSE F12 7 5 AFUSE P01 WARNING LIGHTS FUEL GAUGE INSTRUMENT 5 F13 5A FUSE P02 ENGINE OIL TEMPERATURE INDICATOR 5 F14 2AFUSE P03 ENGINE OIL COOLING TEMPERATURE INDICATOR 5 F15 2
2. C 15 C 3 4 1 Function selection C 16 65 49 Uihiafioweritd 17 C 6 7 Machine 32 C 3 4 3 Pitching the attachment holding frame forwards backwards C 18 3 4 4 Extending retracting the telescope 19 C 3 4 5 Quick coupling the attachments C 20 Page C 1 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e 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 only a correctuse 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
3. 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 Emergency button ON THE PARKING BRAKE LIGHT DOES Fuse blown Replace fuse F15 NOT LIGHT UP BOOM DOES NOT MOVE Fuse blown Check and replace fuse F22 if necessary Resetthe button IMPORTANT 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 0008 6200 05 2007 Handler with telescopic boom GTH 5519 FAULTS AND TROUBLESHOOTING e A TEREX COMPANY Page E 4 Document 57 0008 6200 05 2007 A TEREX COMPANY F 1 1 F 1 2 F 1 3 F 1 4 F 1 5 Handler with telescopic boom GTH 5519 OPTIONAL ATTACHMENTS Section F OPTIONAL ATTACHMENTS TABLE OF CONTENTS Fixed hook on plate MIT ose cm Forks with hydraulic side shift Page F 1 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 OPTIONAL ATTACHMENTS INTRODUCTION This section provides information on the optional in terchangeab
4. 1 Single overcenter safety valve Boom functions hydraulic 270 bar 8915 psiy 4 piloting ratio 4 2 1 circuit test port T cracking pressure 350 bar 5075 psi functions main valve 4 sections Return filter with suction line pressurized at 0 5 bar 8 psi 1 Check valve 2 5 bar 36 psi Diesel engine cracking pressure 1 R 5 M r5 Hydrostatic transmission pump max displacement 56 cc rev Page G 15 Document 57 0008 6200 03 2009 Boom functions pump with integrated priority valve displacement 27 cc rev Ev1 18 5 Hydrostatic transmission TP 5 UN Flushing valve high pressure test port 2 Hydrostatic transmission motor max displacement 107 cc rev s Fa Fa Fe Cracking pressure Cracking press 25bar 4 14 362 psi MM LN MCI
5. 3840 mm 12ft 7 in 330 1in Overall cL 5040 mm 6 ft Lifting height tae ccrte ens 5790 mm 19 Liting capacity ucc ecce nicer eee eorura de eue eee eet 2500 kg 5500 16 Lift capacity at maximum height assoni 2000 kg 4400 Ibs Lift capacity at maximum 860 kg 1900 16 Forward reach 3350 11 ft Reach at maximum height a 605 mm 2ft Fork holder plate rotation 130 130 C ad eat 4450 kg 9810 lbs Load No Load With Fork Page A 15 Document 57 0008 6200 03 2009 Genie Handler with telescopic GTH 5519 n GENERAL INFORMATION Productivity Metric Imperial Lifting lowering speed 2 7 4 7 4 Extension retraction speed 7 4 5 7 4 5 Inside outside turning 1750mm 3000mm 5ft 9in 9ft 10in Break out force with 5001 shovel SAE 732 80 3700 kg 8157 lbs Towing capacity al dinamometro 4230 kg 3100 kg 9325 16 6835 Ibs Travel speed 24 km h 15 mph Chassis levelling on both 2 3
6. m n m a V 21111 D 27 Document 57 0008 6200 05 2007 8 5 Handler with telescopic boom GTH 5519 e A TEREX COMPANY MAINTENANCE 0 5 REFUELLING D 5 1 REFUELLING Product Capacity specifications Part Product litres see par Diesel engine Engine oil 11 3 5 D 5 2 1 Fuel tank Diesel fuel 60 D 5 2 3 Hydraulic system tank Hydraulic oil 62 D 5 2 2 Front differential gear with reduction gear Cil 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 0 7 0 7 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 3 Cat HV Never mix different oils this may result in troubles and component breaks Filtering elements Filter Flow Filtering Code Transmission oil filter MPS
7. 8 REVERSE SPEED 06 91 SOLENOID VALVE x E us o E a 8 Y E 5 lt Y a 202 Document 57 0008 6200 03 2009 Page G 5 Handler with telescopic boom GTH 5519 A TEREX COMPANY 5 8 a SOLENOID VALVE FENGINE STOP BK 15 WHIRD 1 5 zi 5 bl a poi BUL15 WHIRDLIS EMERGENCY a MUSHROOM HEAD PUSHBUTTON s 5 WHIRDLAS Bugis M 8 25 e E 10A WHIRD 15 Bd 1 hi 3 INTERMITTENCE LIGHT INDICATOR 4 BKot 5 gt lt amp WHIBKot 2 amp f e i 8 5 EMERGENCY INDICATOR e SWITCH 5 8 2 8 8 5 8 E e 1 An 84 gt E DIODE 4 DIODE BEL ose 5 1 M M 8 3 le 4 5 8 8 8 8 5 5 8 6 Document 57 0008 6200 03 2009 Genie A TEREX COMPANY Handler with telescopic GTH 5519 TABLES AND DOCUMENTS ENCLOSED HEAD LIGHT INDICATOR LIGHT RIGHT HEAD LIGHT INDICATOR LIGHT LEFT REAR AND STOP LIGHTS LEFT REAR
8. Working in potentially explosive areas Working in confined and non ventilated environments 3 3 RESIDUAL HAZARDS Although the machine has been designed and manufactured according to the latest technology and all expected hazards have been eliminated some operations performed by the machine operator can result in potentially hazardous situations Among them Hazards deriving from a too high work or transfer speed in relation to the load handled or the ground condition of the jobsite Hazards deriving from work procedures adopted during the check or replacement of a block valve residual pressure uncontrolled movements 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 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 0008 6200 03 2009 Handler with telescopic boom GTH 5519 GENERAL INFORMATION e A TEREX COMPANY A 3 4 APPLICABLE STANDARDS For the operator s safety the following standards were obeyed during the risk assessment of the handler fitted with telescopic boom Standard Title ANSI ASME B56 6 2002 part IIl where applicable Page A 11 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 GENERAL INFORMATION
9. is within the working range of the machine 2 To tilt the attachment holding frame forwards backwards e Press button and shift the lever to position to tilt the frame forwards or to position to tilt it backwards Page C 18 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e A TEREX COMPANY 3 4 4 Extending retracting the telescope Before operating the boom make sure that nobody is within the working range of the machine To extend or retract the boom telescope e Smoothly shift the lever to position 6 to extend the boom or to position to retract it Page C 19 Document 57 0008 6200 03 2009 Genie Handler with telescopic boom GTH 5519 M OPERATING INSTRUCTIONS 3 4 5 Quick coupling the attachments Before operating the boom make sure that nobody f J is within the working range of the machine To lock the attachments e 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 20 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e A TEREX COMPANY C 4 SETUP 41 BEFORE STARTING THE ENGINE To ensure safe conditions to the operators and the bystanders and a longer life to yo
10. ea ead nce need ee ITEMS SUP PE IED 5 e terre 1 Document 57 0008 6200 03 2009 Genie Handler with telescopic GTH 5519 1 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 RIGHT SIDE lt py FRONT PART LEFT SIDE LOWER PART Page A 2 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 GENERAL INFORMATION 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 cleanthemor replace those that become unreadable either graphic or text To clean labels use of a soft cloth water and soap Never use solvents petrol When a label is applied on a part to be replaced make sure that the replaced part is already labelled as
11. A 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 a jet of compressed air 7 Refit 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 Running in None Ordinary Every 1000 hours Lm 01 82 WAN l PROTECT THE ae ENVIRONMENT The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres Page D 16 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY D 3 11 CHANGING THE OIL FILTER CARTRIDGE To change the hydraulic oil filter element proceed as follows 1 Stopthe machine on alevel ground and engage the parking brake 2 Place a container of suitable size under the filter to collect any oil leaks 3 Removethefi
12. Every 50 working hours or weekly Jobs to be done in addition to those above 1 Check the tension of the alternator belt 2 Check the tyre inflation 3 Check the tightening of the wheel nuts 4 Check the 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 Check the condition of the canister of the engine air filter renew the canister if necessary 5 Checktheclamping ofthe cableheads tothe battery terminals 6 Check the air suction hose between engine and filter 7 Check the cylinder chromium plated rods 8 Check the hydraulic lines are 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 Check the wear of the sliding pads of the boom sections 11 A Agjust 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 Checkthe efficiency ofthe block valves see chap D 3 16 Every 500 working hours or every six months Jobs to be done in addition to those above 1 Visually check the smoke quantity e
13. The control lever shall be operated only when correctly seated in the driving place Before operating the control lever make sure that nobody is within the working range of the machine Page C 15 Document 57 0008 6200 03 2009 Genie Handler with telescopic GTH 5519 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 2277 Boom extraction retraction F tle 3 shift the control lever to 9 or Attachment back forward tilting 3 press button and shift the control lever to or TN e Attachment coupling release press button together with the dashboard enabling button and shift the lever to or Page C 16 Document 57 0008 6200 03 2009 Genie Handler with telescopic boom GTH 5519 M OPERATING INSTRUCTIONS C 3 4 2 Lifting lowering the boom Before operating the boom make sure that nobody is within the working range of the machine To lift or lower the boom e Smoothly shift the lever to position to lift the boom or to position to lower it Page C 17 Document 57 0008 6200 03 2009 Genie Handler with telescopic boom GTH 5519 M OPERATING INSTRUCTIONS C 3 4 3 Pitching the attachment holding frame forwards backwards A D Q Y Before operating the boom make sure that nobody 9
14. s 8 TN 2 2 m gt lt n 5 8 BNo25 GN BKo1 5 a lt 8 6015 acts of 9 aNBKots LIGHTS lt INDICATOR 25 4 GYIRDot 5 WIND SCREEN WIPER Pate 5 BN RDot ru o Bs gts 1 8 8 m WH BKo1 Jz 3 A g 8 3 5 WIND SCREEN WiPERMoToR T gt 5 8 E WIND SCREEN WIPER 1 ME BN RDo1 10A e BN RDei WASHER MOTOR tM amp 5 amp i AA LIGHTS 2 A SWITCHES 8 7 2 gt 8 Y Y 1 8 5 G 8 Document 57 0008 6200 03 2009 5 8 Genie Handler with telescopic GTH 5519 TABLES AND DOCUMENTS ENCLOSED 019 6 0196 DASHBOARD LIGHT INDICATOR WATER TEMPERATURE 4 WHIGNat WHIGNot WHIGNot SENSOR 5 4 BUIRDot ENGINE OIL PRESSURE GY RDo1 GY RDot GY RDo1 TRANSDUCER GY YEo1 GY YEo1 FUEL FLOAT GY WHo1 GNo1 GNo1 1 au WH BUG1 WHIBUo1 WHIBUo1 1 NEGATIVE BRAKE PRESSURE SWITCH RD BKot HYDRAULIC OIL TEMPERATURE GAUGE BK EE HYDRAULIC OIL TEMPERATURE TOW GN RDo1 SENSOR RD BKo1 YEBKo 4 ENGINE WATER TEMPERATURE
15. GENERAL INFORMATION A 1 3 EXPLANATION OF THE DIFFERENT SYMBOLS USED ON THE MACHINE This paragraph illustrates those symbols that are normally applied on the main control devices and RTA N instruments of a standard machine and those that can be applied on accessories or special attachments Spend the necessary time to become familiar with They are mainly ISO standardised symbols that are these symbols and to learn their meaning now part of the common life But we consider useful to explain them once again lt 3 gt S Symbol Description Description Hazard warning lights Steering mode switch Engine oil pressure SZ Windscreen wiper 57 Windscreen washer Boom down 55 Cab ventilation fan Boom out Hydraulic oil temperature FN Fuel gauge Attachment locked DE Position lights Attachment unlocked High beam Turn signals Fork pitching forward 5 Parking brake Battery charge Fork pitching back Oil filter clogged Air filter clogged Glow plug preheating 6 Document 57 0008 6200 03 2009 Genie Handler with telescopic GTH 5519 1 GENERAL INFORMATION Symbol Description Symbol Description Front optional work light Road jobsite selector switch Lifting point Fuel plug Engine oil filler Page A 7 Document 57 0008 6200 03
16. NN Wc 3 5 SAFETY DEVICES 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 Block valve on lifting cylinder Block valve on balance cylinder Block valve on boom extension cylinder Block valve on attachment pitching cylinder 12 Document 57 0008 6200 03 2009 Genie Handler with telescopic GTH 5519 GENERAL INFORMATION 4 GENERAL DESCRIPTION E A 4 1 LIST OF THE MAIN COMPONENTS Forks Attachment holding frame 2 boom section 15 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 OANODOABRWN 1 h 1 1 1 13 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 GENERAL INFORMATION e A TEREX COMPANY B A 4 2 DESCRIPTION OF THE MAIN COMPONENTS Hydrostatic transmission This unit consists of parts which drive the machine shifting and namely a variable displacement pump connected to the thermal engine by an elastic joint a motor with variable displacement and aut
17. A TEREX COMPANY D 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 When raising a component for maintenance purposes secure it in a safe way before any maintenance intervention 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 ifaccumulators 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 Before any operation on hydraulic lines or components make sure there is no residual pressure For this purpose stop the engine engage the parking brake and operate the 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 The qualified staff charged with the maintenance of the hydraulic circuit must clean all areas around with care before any intervention PROTECT THE 49 ENVIRONMENT The handling and disposing of used oils be ruled by local or national regulati
18. Genie A TEREX COMPANY Operator s Manual Serial number range From 16381 GTH 5519 17548 17565 17822 17825 18154 18168 18556 18586 Part 57 0008 6200 Rev B March 2009 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 s manual 57 0008 6200 GTH 5519 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 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Phone 82 25 587 267 Fax 8225 583 910
19. 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 without undertaking to give prior notice therefore also this publication may be subject to modifications Some photos or drawings have been used to illustrate a specific function as a result they may not refer to the machine treated in this manual Copyright 2007 TEREXLIFT 51 All rights reserved Produced by TEREXLIFT Technical Literature Dept Umbertide Perugia enig REVISED PAGE LIST A TEREX COMPANY Revision Revised Issued N Date pages by 03 2009 Section A Section C Section G Revision OIOI 5 GN e A o N e N N N A N 1 NJ Handler with telescopic boom GTH 5519 INTRODUCTION INTRODUCTION This manual 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
20. lower section of the same door 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 Insert the key and release lock 1 Press the pushbutton and open the door Door closing from inside Pullthe door with force it locks automatically Door opening from inside Lift lever 2 and release the lock to open the door completely e Rotate handle to open the upper section of the door and lock it against the special catch To unlock the door latched in open position Press button 4 to unlock the door from the catch close and latch the door to the lower section using handle 3 Page C 4 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS le 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
21. 82 1 Low speed 2 2 High speed zl 1 8 m C 3 3 INSTRUMENTS AND LIGHT INDICATORS C 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 13 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 e A TEREX COMPANY OPERATING INSTRUCTIONS C 3 32 Light indicators 60 63 64 Be P 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 engine air filter restricted When this lamp come on proceed with cleaning or changing the air filter cartridge see Maintenance section 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
22. HYDRAULIC SCHEME Drw 57 2201 3000 rev B Service brake pressure switch fg 1 activating pressure TP 2 8 6 3 bar Service brake 40 90 psi circuit test port Service brake circuit reservoir Service brake pedal pump max pressure 80 bar Front axle 2 6 P1 Rear axle P steering cylinder JA Eval XI 157 Steering mode 7 selector valve 4 ways 3 positions Anti shock valves cracking pressure 225 bar 3262 psi Front axle steering cylinder Steering rotating actuator displacement 125 rev 4 P Max relief valve cracking pressure 170 bar 2465 psi 1160 psi Boom functions control lever ma F1 Parking brake 4 valve Auxiliary continous flow metering valve fs l Parking brake minimum pressure of pressure switch 29 activating pressure 20 bar 290 psi Auxiliary continous flow selector valve Forks tilt cylinder T 5075 psi Double overcenter safety valve piloting ratio 4 2 1 cracking pressure 350 bar Quick connect disconnect attachment enabling valve
23. K02 STARTING ENABLING COMMAND 1 Y08 WHEEL STEERING SOLENOID VALVE 7 K03 FORWARD SPEED ENABLING COMMAND 2 09 WHEEL STEERING SOLENOID VALVE 7 K04 INHIBITION WITH SERVICE BRAKE ENGAGED 2 Y10 SOLENOID VALVE ATTACHMENT RELEASE 8 K05 REVERSE SPEED ENABLING COMMAND 2 Y11 SOLENOID VALVE ATTACHMENT COUPLING 8 Page G 12 Document 57 0008 6200 03 2009 1 Handler with telescopic boom GTH 5519 e A TEREX COMPANY Ref Y12 A01 A02 A03 A04 A05 A06 A07 X01 X02 X03 X04 X05 X06 X07 X08 X09 X10 X15 X16 TABLES AND DOCUMENTS ENCLOSED Description Sheet Ref Description SOLENOID VALVE FORK ROTATION 8 12V BATTERY PREHEATING CONTROL UNIT TURN SIGNALS FLASHING DIODE DIODE DIODE DIODE 1 4 4 WAY CONNECTOR ENGINE FUSES LINE 4 WAY CONNECTOR STEERING COLUMN 6 WAY CONNECTOR CAB 6 WAY CONNECTOR STEERING COLUMN 12 WAY CONNECTOR STFFRING COI LIMN 12 WAY CONNECTOR EN 15 WAY CONNECTOR STE 15 WAY CONNECTOR ENGINE 9 WAY CONNECTOR ENGINE 12 WAY CONNECTOR STEERING COLUMN 4 WAY CONNECTOR JOYSTICK 2 WAY CONNECTOR STEERING COLUMN Page G 13 Document 57 0008 6200 03 2009 Sheet Genie Handler with telescopic GTH 5519 TABLES AND DOCUMENTS ENCLOSED INTENTIONALLY BLANK PAGE Page G 14 Document 57 0008 6200 03 2009 Genie A TEREX COMPANY G 4 1 Handler with telescopic boom GTH 5519 TABLES AND DOCUMENTS ENCLOSED
24. set all switches within the cab to OFF To disconnect the battery disconnect the negative lead from the frame earth first e To connect the battery connect the positive lead first Recharge the battery far from the machine in well ventilated place Keep out of items which can produce sparks of naked flames or lit cigarettes Do not rest metal objects onto the battery This can result in a 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 A 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 25 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY D 4 2 FUSES AND RELAYS The electrical system is protected by fuses placed in the driving cab on the left Before replacing a blown fuse with a new one having the same amperage find out and rectify the fault Fuses Ref Circuit Amp e Donotuse fuses having a higher amperage than that recommended since they can damage the electric system seriously e Ifthe fuse blows after a short time look for the fault source by ch
25. 1 2 3 Fill tank with oil With the machine stopped step downonthe brake W 0 3 5 1 Checking the brake oil level pedal 5 6 time Hold the pedal pressed down and slowly unscrew valve Q Close the valve as soon as oil mixed with air starts flowing out Ease up the brake pedal Repeat steps 2 3 and 4 until oil without air bubbles starts flowing out of the valve Test the efficiency of the braking system The oil within the braking circuit must be at about 2 cm from the tank plug Page D 11 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 e A TEREX COMPANY MAINTENANCE D 3 6 ENGINE AIR FILTER Clean the engine air filter and replace the elements when necessary 1 Cleaning and changing the outer element Shut the engine down and engage the parking brake Unlatch the fasteners and remove cover Pull out the filter cartridge Clean the filter bowl Dry clean the cartridge at max 6 bar pressure and direct the air jet from inside to outside Check the filter element for cracks by introducing a lamp inside Refit the cartridge and make sure it is properly positioned Close cover and lock in place with fasteners As soonas the warning lamp 63 onthe cab dashboard switches on replace the outer element 2 Changing the inner element See step 1 for removing the outer element Extract the internal cartridge Cl
26. 2009 Handler with telescopic boom GTH 5519 GENERAL INFORMATION 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 E A 2 1 MACHINE MODEL AND Handler with telescopic boom Q model GTH 5519 O MODEL NUMBER SERIAL NUMBER 1 110 YEAR OF MANUFACTURE 2 2 U FACTU RER UNLADEN TRUCK MAXIMUN WEIGHT TEREXLIFT srl TRUCK CAPACITY Zona Industriale Ind Estate 06019 UMBERTIDE 7 LY THIS TRUCK IS COMPLIANT TO PART Ill OF ASME B56 6 2002 WHERE APPLICABLE MADE IN ITALY Enrolled in the register of companies at the Court of Perugia under no 4823 1 n 102886 Fiscal Code V A T no 00249210543 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 Page A 8 Document 57 0008 6200 03 2009 iQ Handler with telescopic boom GTH 5519 GENERAL INFORMATION TEREX TEREXLIFT s ZONA INDUSTRIALE 06019 UMBERTIDE PG ITALY Tel 39 0 75 94181 Fax 39 0 75 9415382 ASSIEME FORCHE FORKS ASSY GROUPE FOURCHES GABELGROUPPE JUNTO HORQUILLAS O F
27. 5 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 e A TEREX COMPANY OPERATING INSTRUCTIONS 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 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 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 Height adjustment optional Turn knob 3 clockwise to lift the seat turn it counter clockwise to lower the seat 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 Sit correctly in the driving seat then The safety belts
28. 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 58000 69600 45 3 90 6 127 153 M14x2 25800 51500 72500 86900 67 4 135 190 228 M 14 x 1 5 28000 56000 78800 94500 71 7 143 202 242 M 16 x2 35200 70300 98900 119000 102 205 288 346 M 16 x 1 5 37400 74800 105000 126000 107 214 302 362 M 18 x 2 5 43000 86000 121000 145000 142 283 398 478 M 18 x 1 5 48400 96800 136000 163000 154 308 434 520 M 20 x 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 M22 x 1 5 74600 149000 210000 252000 286 571 803 964 M24x3 79100 158000 222000 267000 345 691 971 1170 M24x2 86000 172000 242000 290000 365 731 1030 1230 M 27 x 3 103000 206000 289000 347000 505 1010 1420 1700 M27x2 111000 222000 312000 375000 534 1070 1500 1800 M 30 x 3 5 126000 251000 353000 424000 686 1370 1930 2310 M30 x2 139000 278000 391000 469000 738 1480 2080 2490 IMPORTANT Sensor maximum driving torque 15 Nm Page G 2 Document 57 0008 6200 03 2009 Genie Handler with telescopic GTH 5519 TABLES AND DOCUMENTS ENCLOSED G 2 1 LOAD CHART WITH FORKS G
29. BKot GAUGE GYIGNot GYIGNot BKot WATER GY GNo1 TEMPERATURE SENSOR 9055 8055 7055 8055 eI 1 9055 T 9 El 8X 1 oxl 2 5 1 0 8 y 8 Xu X 4X 01 LX 6 L E amp 4 9 Er 2 0190 Sr mmm mMm oa Y z G 9 Document 57 0008 6200 03 2009 Genie A TEREX COMPANY Handler with telescopic GTH 5519 TABLES AND DOCUMENTS ENCLOSED AIR VENTILATOR MOTOR WARM AIR VENTILATOR SWITCH WHEEL STEERING SOLENOID VALVE STEERING SELECTOR WHEEL STEERING SOLENOID VALVE 199 gt 2 5 e Y NS BNo2 5 15 amp 2 8 2 5 E 8 8 p 5 Ei m 8 75 4 9 08 80015 2 1 S 8 BUIRDO1 5 8 d 15 WHIBKo1 5 5 E T 58601 E E 5 gt 8 5 1 BN BKo1 Bn YEIRDOt gt 5 2 9 5 YEIRDo1 001 lt 5 a a 015 9 098 4 Document 57 0008 6200 03 2009 Page G 10 7 8 Genie Handler with telescopic GTH 5519 T E TABLES AND DOCUMENTS ENCLOSED 8 8
30. Fully raise the cover by means of the special handle Page D 7 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE le A TEREX COMPANY 0 3 3 GREASING Before injecting 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 greasers As the fresh grease comes out stop the operation The greasing points are shown in the following figures e the symbol represents the points to be greased by a pump thesymbol represents the points to be greased by a brush Page D 8 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY E D 3 4 TYRES AND WHEELS N DANGER 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
31. NUMBER PLATE LIGHT REAR AND STOP LIGHTS RIGHT 1 GYo1 5 e 7 5A 9 L GYo1 5 e 75A e GYo1 80H LOH 1 71 1 1 90 9 99 SOH 208 1 71 809 4 1094834 C 0 1098 34 19 9 lt a te 017 5 a 1 e E 5A 01 5 641 108 a 103 5 YEoi ox GYot 2 GNot gt GNot GNo1 5 3 ex 1 1 TA GNo1 5 GY BKot 2 GYIBKoi e 1 5 v x a 1 YE 31 8 8 8 YE T 8 8 gt 1 8 5 m ES 5 m m 2 YEo1 e E e YEo1 5 2 015 78 x 1354 L 1 G 7 Document 57 0008 6200 03 2009 4 8 Handler with telescopic boom GTH 5519 A TEREX COMPANY 5 E 5 8 Y 8 8 1 8 1 Bo HORN z O VTot
32. Never distract the operator during working phases or crucial manoeuvres Donotcall an operator suddenly if unnecessary Donotfrighten an operator or throw objects by any means After work never leave the machine under potentially dangerous conditions B 3 3 MACHINE OPERATION HAZARDS Absolutely avoid the following work situations Donothandle loads beyond the maximum capacity of the machine Do not raise or extend the boom if the machine is not on a firm level surface Do not operate the machine in strong wind Do not increase the surface area of the machine or forked load exposed to the wind Increasing the area exposed to the wind will decrease machine stability Use extreme caution and slow speeds when the machine is driven across uneven or unstable grounds slippery surfaces or near trenches or drop offs Limit travel speed according to ground conditions slopes presence of personnel or other factors which may cause Collision Donotplace or attach overhanging loads to any part of the machine B 3 4 DAMAGED COMPONENT HAZARDS Do not use battery chargers or batteries with a voltage above 12V to start the engine Do not use the machine as a ground for welding B 3 5 EXPLOSION FIRE HAZARDS Do not start the engine if you smell or detect LPG gasoline diesel fule or other explosive substances Do not refuel the machine with the engine running Refuel the machine and charge the bat
33. THE S ENVIRONMENT Green used to draw the attention to important information on environment protection IMPORTANT Green used to indicate operation and maintenance information WHEN READING THIS MANUAL PAY THE GREATEST ATTENTION TO THESE SPECIAL SYMBOLS AND THE EXPLANATION OF THE SITUATIONS THEY EMPHASIZE Page 2 Document 57 0008 6200 05 2007 Genie Handler with telescopic boom GTH 5519 GENERAL INDEX A TEREX COMPANY GENERAL INDEX GENERAL INFORMATION SAFETY PRECAUTIONS OPERATING INSTRUCTIONS MAINTENANCE TROUBLESHOOTING OPTIONAL ATTACHMENTS TABLES AND DOCUMENTS ENCLOSED Page 3 Document 57 0008 6200 05 2007 Sect Sect Sect Sect Sect Sect Sect GQimimiuocijio u Handler with telescopic boom GTH 5519 INTENTIONALLY BLANK PAGE Page 4 Document 57 0008 6200 05 2007 A TEREX COMPANY 1 2 A 1 2 1 A 1 3 A 2 A 2 1 A 2 2 A 2 3 2 4 2 5 3 A 3 1 A 3 2 A 3 3 A 3 4 A 3 5 A 4 4 1 4 2 4 3 4 4 5 6 7 7 1 Handler with telescopic boom GTH 5519 GENERAL INFORMATION Section A GENERAL INFORMATION TABLE OF CONTENTS CONVENTIONAL REFERENCES 2 1 kii Machine DOSIUOR Labels and warning plates applied on the E E Explanation of the d
34. button 12 Selection button Pushbutton with orange glass cap with two Two position button with return to the neutral stable positions Press this button to switch the point Press this button every time you wish to hydraulic circuit feeding the attachments with couple release an attachment Hold the button auxiliary lines pressed down until the movement has been completed 0 1 Continuous oil delivery to the used attachment C 3 2 6 Steering mode selection 0 No oil flow 13 Steering mode switch Three position switch for the selection of the steering mode By turning the potentiometer clockwise the flow rate in the circuit feeding the attachments movement lines is increased 19 Continuous oil flow potentiometer 1 Crab steering 0 Two wheel steering 2 Four wheel steering IMPORTANT Clock wise rottation of the steering wheel steers the truck to the operator s right Page C 12 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e A TEREX COMPANY C 3 2 8 Auxiliary drive controls 14 Horn pushbutton 22 Windscreen washer button Pushbutton with green glass Press this button to operate the horn By holding this button pressed down a jet of water is sprayed on the windscreen and the rear window 23 Air conditioning fan switch only with cabin closed O Three position switch OFF
35. electrical power lines Always keep at a minimum safe distance from the telescopic boom and the lifted load Electrical 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 ae BEFORE MACHINE OPERATIONS POWER LINE VOLTAGE REQUIRED CLEARANCE 0 0 ft 300m 50 200 kV 15 ft 4 60 200 350 kV 20 ft 610m 350 500 kV 25 ft 7 62 500 750 kV 35 ft 750 1000 kV 45 ft 10 67 m 13 72 m hazards Keep away from the machine in case of contact with energized power lines Personnel on the ground must never touch or operate the machine until energized power lines are shut off N DANGER Do not at any time use the machine during a storm Page B 4 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 SAFETY PRECAUTIONS e A TEREX COMPANY 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 cm2 500x500mm plates are sufficient Look for the best route to the job site When the machine is running nobody can enter its working range While working keep the working area in order Never leave objects scattered they could h
36. 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 18 Document 57 0008 6200 03 2009
37. grease traces with a dry solvent or a volatile mineral alcohol Before assembling a new part remove any 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 Neveruse waterat pressure for washing components ofthe machine suchas main valve solenoid valves electric and electronic parts 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 fuelto 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 Ifthe machine shall be used in a marine or equivalent environment protect it against salt deposits with an adequate treatment against saltiness to prevent rust formation C 6 7 MACHINE DISPOSAL ae 4 ENVIRONMENT At the end of the machine life call in a specialised firm to dispose of itin compliance with the local or national regu
38. mm 760 H Height mm 700 Weight kg 290 Attachment suitable for moving loose material Do not use for digging operations Page F 3 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 OPTIONAL ATTACHMENTS e A TEREX COMPANY F 1 2 CEREAL SHOVEL Code GTH 5519 Litres 800 59 0200 1000 Technical data Capacity litres 800 A Width mm 1850 B Length mm 800 H Height mm 1150 Weight kg 350 Attachment suitable for moving loose material Do not use for digging operations Application Quick coupling attachment for loading cereals or inert materials etc 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 using it Page F 4 Document 57 0008 6200 05 2007 e A TEREX COMPANY F 1 3 FIXED HOOK ON PLATE Handler with telescopic boom GTH 5519 OPTIONAL ATTACHMENTS Payload Code 2500 kg 59 0700 0000 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
39. only as a mere example To define the payload limits refer to the load charts applied in the cab of our machine A The load charts applied on the cab windscreen refer to a stationary machine standing on a solid and level ground Raise the load some centimetres and check its stability before raising it completely Page C 25 Document 57 0008 6200 03 2009 e A TEREX COMPANY C 5 2 HANDLING LOADS C 5 2 1 Adjusting the floating forks Forks shall be spaced to suit the load going to be handled For this purpose Loosen the nut of the locking screws Raise the forks and slide them on the pivot until correct spacing Lock the screws re tightening the nut Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS centre of gravity of the load must always be halfway between the forks e Ensure you exactly know the weight of the load before handling it e When extending the boom do not exceed the payload limit e Refer to the payload limits given in the load chart applied in the cab or in the quick user s guide e Space the forks as wide as possible to suit the load being handled Page C 26 Document 57 0008 6200 03 2009 Genie Handler with telescopic boom GTH 5519 I OPERATING INSTRUCTIONS C 5 2 2 Working phases When forks are correctly spaced the handler is ready R to use Work can be subdivided i
40. position Release the parking brake and start a new working cycle Page C 27 Document 57 0008 6200 03 2009 e C 5 3 CHANGING THE ATTACHMENT Use only attachments directly manufactured or recommended by Terexlift and detailed in the 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 Retract and raise the attachment some centimetres It will centre automatically on the quick coupling frame Operate the control lever to lock the attachment Handler with telescopic boom GTH 5519 MEA OPERATING INSTRUCTIONS N DANGER After substitution visually check the attachment is correctly coupled to the boom before operating the machine A wrongly coupled attachment may result in damage to persons or things Page C 28 Document 57 0008 6200 03 2009 Handler
41. required or apply a new label A 1 2 1 Position 09 4618 0109 2 09 4618 0109 09 4618 0109 3 Document 57 0008 6200 03 2009 enie Handler with telescopic boom GTH 5519 GENERAL INFORMATION A TEREX COMPANY 09 4616 0051 5 isi gt 2 0 t 4 9 E L F 09 4618 0389 Senet Es ppl 09 4618 0782 b ges Genie 5519 NS 09 4618 0643 o 09 4618 0780 E 09 4618 1262 09 4618 0777 97675 97671 97667 09 4618 0205 97667 25 5 5519 09 4618 0644 lt _ Genie 5519 09 4618 0643 Nee 97664 09 4618 0641 Genie 09 4618 0061 09 4618 0061 97674 97664 97665 top of chassis boom rest 09 4618 0644 GTH 5519 09 4618 0776 97672 97666 97689 get 09 4618 0061 09 4618 0061 16 4 Document 57 0008 6200 03 20
42. switch on the cab interior lights e Switch 4 in pos cab interior lights OFF e Switch 4 in pos cab interior lights ON e Switch 4 in pos C courtesy lamp ON Page C 7 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e 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 re lease 13 Steering selection switch 14 Horn pushbutton 15 Gas pedal 16 Warning light engine filter soiled 17 Control lever 18 Negative brake on off switch 19 Continuous oil flow potentiometer 20 Flow reversal button 21 Air conditioning fan switch only with cabin closed 22 Windscreen washer pushbutton only with cabin closed 23 Storage tray 24 Storage pocket 25 Seat 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 FAWN A N
43. system boom telescopes sliding pads clean glasses lights and rear view mirrors engine and relevant components limit switches and horn e lights machine ignition control nuts bolts and other fasteners Check the entire machine for cracks on welds or structural components dents or damage to the machine Make sure that all structural and other critical components are present and the relevant fasteners and pins are fitted and properly tightened After inspection check that all the compartment covers are in place and latched If even one single item is damaged or defective do not start work Stop the machine and repair the fault Checking the tyres Check the correct inflation of the tyres see par Tyre inflation in the Maintenance section Make sure that the tyre plies are not cut or worn A A tyre burst may result in serious injury never use the machine if tyres are worn wrongly inflated or damaged Ifthe machine shall be used in a marine or equivalent environment protect it against salt deposits with an adequate treatment against saltiness to prevent rust formation Page C 3 Document 57 0008 6200 03 2009 Handler with telescopic GTH 5519 OPERATING INSTRUCTIONS 2 1 ENTERING THE ONLY WITH CABIN CLOSED OR GLASS The upper section of the door must be secured to KIT INSTALLED the rear part of the driving cab or latched to the
44. to the special lugs on the machine marked with the decal below Handler with telescopic GTH 5519 OPERATING INSTRUCTIONS C 6 4 TRANSPORTING THE MACHINE ON OTHER VEHICLES To transport 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 30 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e A TEREX COMPANY 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 Takeall precautions to prevent 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 Leaving a battery connected can re
45. 000 Weight kg 180 Stroke mm 100 Fork attachments FEM 2 Page F 7 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 OPTIONAL ATTACHMENTS A TEREX COMPANY Intentionally blank page Page F 8 Document 57 0008 6200 05 2007 A TEREX COMPANY G 1 G 2 1 G 3 1 G 3 1 1 G 4 1 G 5 en 2 Handler with telescopic GTH 5519 DA TABLES AND DOCUMENTS ENCLOSED Section G TABLES AND DOCUMENTS ENCLOSED TABLE OF CONTENTS TORGUEWRENGESETTJIB t ian est G 2 Load seco G 3 88 9 4 Wiring diagram Components description iecit tnnc sd De scu G 12 ates Bre ret va ee cade etc Qu MO MEE G 15 ROUTINE CHECK SCEHEDUEE SAFET Y DEVICES riria iiia G 17 Page G 1 Document 57 0008 6200 03 2009 e A TEREX COMPANY Handler with telescopic boom GTH 5519 TABLES AND DOCUMENTS ENCLOSED C 1 TORQUE WRENCH SETTINGS raj Dxp Pre loading N Torque wrench setting Nm 4 8 8 8 10 9 12 9 4 8 8 8 10 9 12 9 4 0 7 1970 3930 5530 6640 1 5 3 1 4 3 5 2 5 0 8 3180 6360 8950 10700 3 6 8 5 10 1 M6x1 4500 9000 12700 15200
46. 09 e A TEREX COMPANY 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 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 5519 09 4618 0783 Load chart 09 4618 0782 Connect disconnect quick coupling 09 4618 0777 Testing ports TP2 TP3 09 4618 0776 Upper door unlock system 09 4618 1262 Flow reversal button 09 4618 0780 Continuous flow knob sticker Page A 5 Document 57 0008 6200 03 2009 Genie Handler with telescopic boom GTH 5519
47. 150 10 09 4604 0001 Auxiliary circuit oil filter inside the tank STR 100 1 60 09 4604 0004 Page D 28 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE A TEREX COMPANY D 5 2 3 Fuel Use only Diesel fuel with less than 0 5 sulphur content according to the specifications of the diesel engine operation handbook In cold climates temperature under 20 C use only Arctic type Diesel fuel or oil diesel fuel or oil diesel fuel mixtures The composition of the latter can vary in relation to the ambient temperature up to max 80 oil 0 5 2 4 Grease For the machine greasing use Lithium based Vanguard When greasing by pump LIKO grease type EP2 Graphitized SHELL grease type GR NG 3 When greasing by brush INTERFLON FIN GREASE LS 2 Avoid mixing greases of different type or features and do not use greases of lower quality For the telescopic boom sliding blocks D 5 2 5 Engine coolant Itis advisable to use an antifreeze mixture 50 water 5096 antifreeze At the delivery the machine is refilled with TEREX PRO COOL by VALVOLINE The use of this product guarantees protection to the circuit for 3 years or 7000 hours without having to add any dry coolant additive TEREX PRO COOL Protection against boiling freezing Product Freezing Boiling 96 point point 33 17 123 C 40 24 C 126 50 36 128 70 67 1
48. 2 3 Floating TONKS lenght 1200 mm 3ft 11in section 100 x 40 mm 3 9 in x 1 6 in Tyres DIN 7063 2h torte vestre ete 12 16 5 8 holes 12 16 5 8 holes Power Metric Imperial Engine Perkins 804C 33 Ie te Itin TOO 3 331 litres 203 in Cylinder arrangement Vertical in line Combustion System en eR In direct injection Max Power Output 2600 47 0 kW 63 0 hp Max Torque Output 1600 190 N m 140 Ib ft Aspiration Aspirated Oylinder s n mb6etr leac true eA eee LEER 4 4 Hydraulic Hydraulic 80 l min 270 bar 21 USgal min 3916 psi Tank Capacities Metric Imperial PE EET 60 litres 16 USgal edere EE 10 litres 2 5 USgal Hydraulic O 70 litres 18 5 USgal IMPORTANT This is a device of Class A Ina residential environment such device can cause radio disturbance In such cases the operator is required to take suitable measures Page A 16 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 GENERAL INFORMATION A TEREX COMPANY 6 LIFETIME The lifetime of the machine is 10000 hours provided all checks service jobs and overhauls are done at the times scheduled A After this time the machine
49. 35 Use an antifreeze mixture in the proportions recommended by the manufacturer in relation to the ambient temperature of the jobsite Page D 29 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY INTENTIONALLY BLANK PAGE Page D 30 Document 57 0008 6200 05 2007 Q Handler with telescopic boom GTH 5519 D FAULTS AND TROUBLESHOOTING Section E FAULTS AND TROUBLESHOOTING TABLE OF CONTENTS E 1 FAULTS AND TROUBLESHOOTING Ge 4144 43 2 E 1 1 Fault Cause 2 1 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 FAULTS AND TROUBLESHOOTING e A TEREX COMPANY 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 mustbe carried out by qualified technical engineers If you are unsure about anything do not carry out operations on the machine but call in skilled technician E 1 1 FAULT CAUSE SOLUTION 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 engaged and ignition key removed DASHBOA
50. 8 Document 57 0008 6200 03 2009 Genie Handler with telescopic GTH 5519 OPERATING INSTRUCTIONS 1 2 L fogs 420246 16 3 4 5 Sass 10 11 9 1 25 9 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e A TEREX COMPANY 32 ENGINE CONTROLS AND INSTRUMENTS C 3 2 1 Ignition switch Three position switch No circuit under voltage key can be removed and engine is stopped 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 m C 3 2 2 Forward reverse gear selector switch Three position switch with lock in neutral position N Neutral position no gear engaged F Shift lever to pos F to select the forward gear R Shift lever to pos R to select the reverse gear Once the reverse gear is engaged a sound allarm will be activated Page C 10 Document 57 0008 6200 03 2009 e A TEREX COMPANY B C 3 2 3 Brakes 11 Service brake pedal Gradually step onthe brake pedal to decele
51. AFUSE F16 20 AFUSE R01 GLOW PLUGS 1 F17 10AFUSE F18 5A FUSE SW01 IGNITION KEY 1 F19 20 AFUSE SW02 PARKING BRAKE SWITCH 2 F20 10 AFUSE SW03 CHANGE OVER SWITCH 1 F21 15AFUSE SW04 MUSHROOM HEAD BUTTON 3 F22 5A FUSE SW05 HAZARD WARNING LIGHT TURN SIGNALS SWITCH 3 23 15AFUSE SW06 LIGHT SWITCH TURN SIGNALS WINDSCREEN WIPER F24 5AFUSE WASHER 5 F25 7 5 AFUSE SW07 LIGHTS SELECTION SWITCH 5 F26 7 5 AFUSE SW08 STEERING SELECTOR 7 F27 5A FUSE SW09 HEATING FAN SWITCH 7 F28 5 F29 SPARE FUSES 15A 10A 7 5A 5A SW11 CONTINUOUS OIL SWITCH 8 F30 PREHEATING CONTROL UNIT MAXIFUSE SW12 OPTIONAL WORK LIGHT SWITCH 8 1 SYSTEM PROTECTION FUSE SW13 BATTERY CUTOFF 1 SW14 JOYSTICK 8 01 WARNING LIGHTS AIR FILTER SOILED PREHEATING GLOW PLUGS WARNING LIGHT 1 SS01 SERVICE BRAKE SENSOR 2 H03 BACK UP LAMPS 2 SS02 AIR FILTER CLOGGING SENSOR 1 H04 REAR RIGHT HAND LIGHT 4 5503 WATER TEMPERATURRE SENSOR 6 H05 LICENSE PLATE LAMP 4 SS04 ENGINE OIL PRESSURE SENSOR 6 H06 REAR LEFT HAND LIGHT 4 5505 NEGATIVE BRAKE PRESSURE SWITCH 6 H07 FRONT LIGHT LAMP LEFT TURN SIGNAL 4 5506 HYDRAULIC OIL TEMPERATURE SENSOR 6 H08 FRONT LIGHT LAMP RIGHT TURN SIGNAL 4 5507 WATER TEMPERATURE SENSOR 6 H09 WORK LIGHT 8 SS08 FUEL FLOAT 6 01 BACK UP HORN 2 FUEL ENRICHER SOLENOID 1 HA02 HORN 5 Y02 SOLENOID VALVE FWD SPEED 2 03 BEACON 8 Y03 SOLENOID VALVE PARKING BRAKE 2 Y04 SOLENOID VALVE REVERSE SPEED 2 K01 OPTIONAL WORK LIGHT 07 ENGINE STOP SOLENOID 3
52. EALTH AND SAFETY PRECAUTIONS Health Aprolonged 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 onthe 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 Incase of accidental contactwith the eyes wash with fresh water If the irritation persists seek medical advice Intake In case of oil intake do not induce vomiting but seek medical advice Skin In case of a prolonged contact wash with soap and water Fire Incase of fire use carbon dioxide dry chemical or foam extinguishers Do not use water Page D 3 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY D 2 ROUTINE MAINTENANCE Awrongor 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 mac
53. Forks tilt function enabling valve on SM 88 Forks attachment quick coupling cylinder 3 2 T 2 5 10 5 mm 0 02 in P Quick coupling EN en w ol hydraulic ports Forks levelling slave 2 Hydraulically piloted piloting ratio 4 1 Single overcenter safety valve cracking pressure lift cylinder Anticavitation valves 5 bar 72 psi NK Double overcenter safety valve piloting ratio 4 2 1 cracking pressure 5075 psi 3 piloting ratio 4 2 1 cracking pressure 350 bar 1 double check valve 1 1 5075 psi Boom telescoping cylinder 350 bar
54. IGHT AIR FILTER PREHEATING GLOW PLUGS AIR FILTER CLOGGING SENSOR GY BU81 Page G 4 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 TABLES AND DOCUMENTS ENCLOSED Genie A TEREX COMPANY 8 8 2 23 e So 8 eg vg 5 15 S 5 8 5 a 82 sre 06 6 1 5 8 0 ES ka T S 1 5 4 7 l 0691 FORWARD SPEED SOLENOID VALVE 9 21 0601 ox gs T Vs 5 4 A 001 1 1 SERVICE BRAKE SENSOR RD BKe1 8 GN RD 1 8 gt TA 5 S 4 Ox x 9 455834 Q gt ise ES ae 5 Je PARKING BRAKE SWITCH 5 T 222 559 w i FASTSPEED Bust oe ae SOLENOID VALVE ise EA e o 2e BN GN91 OA 2 5 gt gt 5 x S BUZZER 2 He 8 2 5 253 d S 28 m 19 91 5 42 E 15 REAR LIGHT lt gt 55 e 28
55. MACHINE The handbook is divided into seven sections Sect A GENERAL INFORMATION Sect B SAFETY PRECAUTIONS 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 data 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 those responsible for safety 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 those responsible for maintenance 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 enclo
56. RD DOES NOT SWITCH The 50A fuse F31 supplying power Replace the fuse ON to the dashboard is blown engine compartment Battery disconnected Connect the battery using the relevant switch Battery down Check the battery Battery cut out switch OFF Switch it on ENGINE DOES NOT START Parking brake not engaged Engage the parking brake and Starter does not run ensure the relevant indicator on the dashboard switches on Battery down Recharge or replace the battery Battery cut out switch OFF Switch it on ENGINE DOES NOT START Fuse F15 blown Check the fuse Starter runs but engine does not No fuel Refuel start Diesel fuel filter clogged Diesel fuel hose empty fuel used up Solenoid valve engine stop See engine operator manual Refuel then refer to engine operator manual Check the solenoid valve replace if necessary MACHINE DOES NOT MOVE Speed selector switch in neutral Parking brake engaged Fuse F3 blown Set the speed selector switch correctly Disengage Check the fuse replace if necessary THE MACHINE DRIVE IS NOT ENOUGH Hydraulic oil filter clogged Replace the filter NO SELECTION OF THE STEERING MODE Fuse F20 controlling the steering selection blown Replace the fuse 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 0008 6200 05 2007
57. TH 5519 I 5 ft 2000 Ibs ae 4400 Ibs ig Pr 7 o O UJ 15 ft 10 ft 5 ft 0 ft Page G 3 Document 57 0008 6200 03 2009 Genie Handler with telescopic GTH 5519 TABLES AND DOCUMENTS ENCLOSED G 3 1 WIRING DIAGRAM 5 12 o DISCONNECTION L T BATTERY STARTER 5 MOTOR CHIAVE AWIAMENTO ALTERNATOR BU RD 1 FUELENRICHER Ll oc oNet 019 7 2a s 19N9 90 BN BKo1 PREHEATING CONTROL UNIT MAXIFUSE SYSTEM PROTECTION FUSE CHANGE OVER SWITCH RELAY STARTING 4 PARKING BRAKE LINE PRESSURE SWITCH lt BN BK91 5 WH BUS1 2 01 5 28 0001 ME 18 v 8 168 PREHEATING 4 CONTROL UNIT at 4 WH RDS1 WH RD 1 I Whos GLOW PLUGS 8901 RD BK91 OIL FILTER CLOGGING 198 08 4 1018 9 168 Q4 34 WARNING L
58. YES NO For the tyre inflation or substitution please refer to the table below GTH 5519 Dimensions 12 16 5 Load index pr 10 Rim 9 75x16 5 Wheel disc 8 fori 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 IMPORTANT Always use tyres having the dimensions indicated in the vehicle registration card Page D 9 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE A TEREX COMPANY D 3 5 CHECK THE EFFICIENCY OF BRAKING SYSTEM AND PARKING BRAKE 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 in the hydraulic circuit The braking system is equipped with two purge valves and to eliminate any air from the circuit The first valve is used to purge the service brake circuit the second valve is usedto purge the negative parking brake circuit Both valves can be easily reached through the slot located on the front part of the chassis To bleed the circuit of the service brake proceed as follows Make sure that compressor contains sufficient quantity of oil so you can proceed with the circuit bleeding e Connect the flexible hose of the compressor to the
59. afe distance Every week before starting working with the coolant cold check the coolant level through the glass cap of plug When necessary add clean water or an antifreeze mixture through cap Q Change the antifreeze mixture every two years To drain the antifreeze Letthe engine cool down Unscrew the plug atthe bottom of the radiator or disconnect the rubber hose if no plug is pre sent Allow the coolant to flow out into a special container Refit the hose and pour new antifreeze 5096 water antifreeze This proportion will provide protection up to 38 C e Daily clean the radiator grille using a brush with hard bristles or compressed air at a max pressure of 6 bar On delivery the machine is filled with a cooling mixture consisting of 50 water and 50 anti freeze Handler with telescopic GTH 5519 SERVICE INTERVAL None Every 50 hours TEREX PRO COOL Protection against boiling freezing Product Freezing Boiling 96 point point 33 17 123 C 40 24 C 126 C 50 36 128 70 67 135 Running in Ordinary Page D 14 Document 57 0008 6200 05 2007 E Handler with telescopic boom GTH 5519 MAINTENANCE D 3 9 ENGINE OIL LEVEL To check the engine oil level Park the machine on a flat ground stop the engine and check the parking brake is eng
60. aged Remove dipstick and check if oil reaches the max mark Q If oil is below this mark remove plug and pour new oil into the engine using the special appliance Remove dipstick once again and check if oil reaches the max mark Q Refit the plug f one of the connecting pipes of radiator breaks Stop the machine immediately if possible on a flat ground stop the engine and check the parking brake is engaged Change the damaged pipe Remove dipstick and check if oil reaches the max mark Q If oil is below this mark remove plug 9 and pour new oil into the engine using the special appliance Restart the machine and let oil circulate in the engine and the radiator Stop the machine and check again the oil level If necessary add new oil step by step until reaching the max level by starting and stopping the engine at every step Page D 15 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY D 3 10 CHECKING THE OIL LEVEL IN THE TANK Fine jets of hydraulic oil under pressure 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 fitted into the tank When necessary add new oil through filler ATTENTION Check the oil level with handler set to transfer position lowered boom and retracted telescopic element
61. and proper utilisation this handbook stresses these specific instructions by means of SPECIAL SYMBOLS There are seven 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 method 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 degree of a hazard Safely Alert symbol when you see this symbol be alert to the possibility of personal injury Strictly obey all the safety messages accompanying this symbol to avoid the risk of serious injury or death N DANGER Red used to indicate an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol used to indicate a potentially hazardous situation which if not avoided may result in minor or moderate injury Yellow without safety alert symbol used to indicate a potentially hazardous situation which if not avoided may result in damage to the machine or the systems 49 PROTECT
62. 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 and 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 6 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS le A TEREX COMPANY 2 4 ADJUSTING THE STEERING COLUMN C 2 5 ADJUSTING THE REAR VIEW MIRRORS Both steering column and dashboard can be set to a The machine is fitted with two rear view mirrors different angle For this purpose The right rear view mirror is located on a special Loosen lever 1 and adjust as required then re supporting bracket in advanced position and allows tighten lever 1 checking the area behind the machine on the right hand side To adjust its position manually rotate the joint it is fitted with The left rear view mirror is placed on the left upper post of the windscreen and allows checking the Before driving the machine ensure the steering area behind the machine on the left hand side To wheel is perfectly clamped adjust its position manually rotate the joint it is fitted with C 2 6 SWITCHING ON THE CAB LIGHTS The ceiling light fixture of the cab has an internal lamp and a courtesy lamp To
63. b or other raised parts always face the machine never turn the back Iur When carrying out operations at hazardous heights over 1 5 meters from the ground always use approved fall restraint or fall arrest devices Do not enter leave the machine while it is running Do not leave the driving place when the machine is running 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 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 Before any maintenance or repair work stop the engine and disconnect the batteries Do not lubricate clean or adjust moving parts Do not carry out operations manually when speci
64. djusting the steering C7 E 2112 C 2 5 Adjusting the rear view mirrors 7 C 2 6 Switching on the cab interior C 7 di endo Mos C4 DRIVING PLACE ie iss 8 5 2 loads 26 CE ud eaniibant TS UNE C 10 C 5 2 1 the floating forks C 26 C 3 2 1 Ignition switch We 3 2 2 Forward reverse gear switch C 10 in 553 23 C 11 THE iiia s Mini C 3 2 4 Accelerator control C 11 we C525 P shbuton enabling theattachment C 6 2 Road or site C 29 coupling release 12 C 6 3 Lifting the machine C 30 C 3 2 6 Steering mode selection C 12 64 Transporting the machine on other ce HR C 12 30 C 3 2 8 Auxiliary drive C 13 caa immanis C 13 C 6 5 1 E C 31 C 3 3 1 Instruments C 13 ida C 3 3 2 Eight Indiealols 2a ox oce erect cms C 14 iis NND m 34
65. e in a well ventilated area to avoid carbon monoxide poisoning Do not lower the boom if the area underneath is not clear of personnel or obstructions 4 SAFETY DEVICES N DANGER 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 16 Page B 8 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 e OPERATING INSTRUCTIONS Section OPERATING INSTRUCTIONS TABLE OF CONTENTS C 1 PRE OPERATION INSPECTION C 2 C 4 C 21 2 ENTERING THE MACHINE C 4 C 4 1 Before starting the engine C 21 C 2 1 Entering the cab only with cabin C 4 1 1 Checks at the machine start up C 21 closed or glass kit installed oe C 4 2 Starting the engine C 21 C 2 1 1 _ ddl 2 5 4 3 Jump starting the C 22 C 2 2 Adjusting the C 6 dud E SEEMS C 2 3 Fastening the seat belts C 6 un n pini C 24 A
66. ean the filter bowl Mountthenew element and make sure itis correctly positioned Fit the main filter and the cap as described in point 1 ATTENTION The inner element should be replaced every two times the outer element is replaced ATTENTION Never wash the cartridge with water or solvents SERVICE INTERVAL Running in None Cleaning Every 10 hours Filtering element substitution Every 500 hours Page D 12 Document 57 0008 6200 05 2007 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 Paper filters must never be cleaned using compressed air or washed with water and or solvents D 13 Document 57 0008 6200 05 2007 e A TEREX COMPANY MAINTENANCE D 3 8 ENGINE COOLING CIRCUIT N DANGER When the coolant is hot the cooling system is under pressure With warm engine loosen the radiator plug slowly and carefully without removing it to drain the pressure Use protection gloves and keep your face at a s
67. ecking the electric system e Always keep some spare fuses for an emergency Never 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 PAGE IN PREPARATION 0 p N EED INT ED Gee eo CHW can e F5 Ft9 CHrj Elle Cm an 2 W 79 Page D 26 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY B Engine compartment fuses and relays Ref Circuit Amp Fuse box relays Ref Circuit Donotuse fuses having a higher amperage than that recommended since they can damage the electric system seriously e Ifthe fuse blows after short time look for the fault source by checking the electric system 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 PAGE IN PREPARATION 13 1 F1 e 7 mn c n amp 7 e N
68. engaged Indicator light negative brake accumulator Not activated 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 rs 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 14 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e A TEREX COMPANY 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 El 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 speed of the actuator
69. fic tools are provided for this purpose Avoid the use of tools in bad condition or use in an improper way i e pliers instead of adjustable wrenches etc Applying loads in different points of the attachment holding plate is forbidden Before carrying out operations on hydraulic lines under pressure or disconnecting hydraulic components ensure the relevant line has been previously depressurised and does not contain any hot fluid Any intervention 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 Page B 6 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 SAFETY PRECAUTIONS e A TEREX COMPANY Do not empty catalytic mufflers or other vessels containing burning materials without taking the necessary precautions After any maintenance 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 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 Always pay due attention to the instructions given by the foreman
70. g 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 N DANGER Wear safety glasses Wear safety gloves Wear safety shoes Wear suitable working clothes Use guards againsi 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 D 23 Document 57 0008 6200 05 2007 Handler with telescopic GTH 5519 MAINTENANCE Attachment coupling cylinder Extension cylinder Balance cylinder Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY Checking the machine start control at every use Attempt to start the engine with the forward 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 D 3 17 CHECKING THE STATE OF THE STRUCTURE Five years after the first placing into operation of the machine or after 6000 hours whichever occurs first check the state of the structure paying attention to the welded supporting joints and the boom pin
71. gine flor uui D 12 D 3 7 air filter only with cabin closed glass kit installed te D 13 D 3 8 Engine cooling circuit D 14 D 3 9 Engine oil level acce D 15 D 3 10 Checking the oil level in the tank D 16 D 3 11 Changing the oil filter cartridge D 17 D 3 11 1 Auxiliary circuits oil filter D 18 D 3 12 Oil level in the differential gears and the rducer D 19 D 3 12 1 Front and rear differential gears D 19 D 3 12 2 siae pecia dr D 19 D 3 13 Oil level in the front rear wheel reduction 7 D 20 D 3 14 Shafting D 21 D 3 15 Adjusting the sliding pads of the boom Seife M M D 22 D 3 16 Checking the safety devices D 23 Page D 1 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY Observe and obey The operator can only perform the routine mainte nance operations envisaged in this manual Scheduled maintenance procedures shall be com pleted by qualified technical personnel according to the manufacturer s specifications Maintenance symbol legend IMPORTANT The following symbols are used in this manual to help you understand better the instructions provided When one or more symbols appear at the be
72. gine is stopped or pressing down the light pushbutton located to the right of the driving place Telescopic boom The machine is equipped with a telescopic boom with hydraulic driven extension The telescopes slides on interchangeable pads made of wearproof material Driving cab Type approved driving cabin compliance with standards ANSI ASME B56 6 2002 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 ON 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 Page 14 Document 57 0008 6200 03 2009 Genie Handler with telescopic boom GTH 5519 GENERAL INFORMATION 5 TECHNICAL DATA AND PERFORMANCE Measurements Metric Imperial TGQ Mt ee trn io d eod 1935 mm 6 ft 4in B Height at steering whell sem 1250 mm 4 ft 1 in WIGID 1810 5ft 11 in D Inside cab width 750 mm 2ft 6in E 1500 4ft 11in 2320 7ft G Length at fork holder
73. ginning of a maintenance procedure they indicate the following M o Indicates that tools are required to perform the procedure Indicates that new parts are required to perform the procedure Indicates that a cold engine is required to perform the procedure Indicates the time interval for the maintenance jobs expressed in working hours INTRODUCTION Athorough 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 condition 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 Page D 2 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY 0 1 LUBRICANTS H
74. he others safety and shall desire to carry out the work correctly and in a responsible way emotional they shall keep calm and always be able to evaluate their own physical and mental conditions training they shall read and be familiar 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 B 22 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 be familiar 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 technical point of
75. heel reduction gears e 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 f necessary add new oil through hole until it is level e Refit the plug For the oil change Stop the machine and ensure the plug is oriented along the vertical axis e Place acontainer of suitable size under the reduction gear plug Unscrew plug and drain any oil from the reduction gear e 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 ae 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 20 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY D 3 14 SHAFTING ALIGNMENT During operation the alignment of the front and rear axles of the machine can be subject to variations This can depend on an oil blow by from the steering control circuit or on a steering of both axles when front and rear wheels are not perfectly aligned To fix this problem rather than checking the alignment visually fol
76. hine 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 A 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 radiator 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 8 Check the efficiency of the lighting electric sy stem 9 Checkthe efficiency of braking system and parking brake 10 Check the efficiency of the steering selection sy stem 11 Check the efficiency of the fork balancing sy stem 12 Makesurethe safety devices installed are in efficient working order see procedure in chap D 3 16
77. hout slots Fit the necessary amount of shims fthe residual thickness of the pad is insufficient or near the maximum wearing limit renew the pad Tightenthe screws fixing the pads atthe 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 Pads must compulsorily be replaced if the residual thickness ofthe plastic layer with respectto the iron bush fixing the block is equal or inferior to 1 mm Page D 22 lt Max wearing thickness _Y Minimum 1 mm Document 57 0008 6200 05 2007 Sul D 3 16 CHECKING THE SAFETY DEVICES Checking the block valves every 3 months The piloted blocking valves allow to held the load in position in case of burst of a flexible hose To check the efficiency of a valve proceed as follows Load a weight near the maximum payload 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 Loosen the oil hoses to the cylinder of which you are checking the valve with caution Durin
78. ifferent symbols used on the MACHINE IDENTIFICATION Machine modeland Rio m 541 444585 SESS senno EY ooo een eee nett pee Chassis senalmUmbel 4 54525858 52 558252 c A e Identification plates of the main parts ALLOWED USE EET 956 88 2 doctiss dotate deoa du ct undc en terre rere Improper USE 220338 46 4388 8 5 0 1 25 errr ent tee 20 0028 orae E GENERALE DESCRIPTION 42851 a LISHOFINE main componens 4 5444558525542055545542415248432454824 AA Description Of The main 2 96606501660 5 41 5 5 1 5 A 8550 aba da Kits supplied OM TECHNICAL DATA AND
79. inder the machine movements and represent a danger for personnel B 3 2 OPERATION OR MAINTENANCE HAZARDS Before any operation following precautions should be taken First of all make sure that the maintenance interventions have been carried out with care according to the established schedule see section D Maintenance Set the machine to working configuration and sway it Use the special inclinometer to the right of the driving place to check that the machine is level before operating it Ensure you have enough fuel to avoid a sudden stop of the engine especially during a crucial manoeuvre Clean instruments data plates lights and the cab windscreen thoroughly Check the correct functioning of all the safety devices installed on the machine and in the job site n case of troubles or difficulties inform the foreman at once Never start working under unsafe conditions Donotcarry out any repair work in a makeshift way to start working During work and especially maintenance always pay the greatest attention Do not walk or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only Keep the machine handholds and access steps always clean from oil grease or dirt to prevent falls or slips Page B 5 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 e A TEREX COMPANY SAFETY PRECAUTIONS When entering leaving the ca
80. ine Turn any users off by the special control levers e Putthe gear lever to neutral and engage the parking brake 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 Ifthe booster supply is installed on a second vehicle make sure that the latter does not touch the handler To avoid damage to the electronic instruments of the machine the engine of the machine where the booster supply is installed must be stopped 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 N DANGER Use only a 12V battery other devices like battery chargers etc may causean explosion ofthe battery or result in damage to the electrical system Page C 22 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e 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 P
81. ion inspection 3 Always test the machine functions prior to use 4 Inspect the work place 5 Only use the machine for the intended application Read understand and obey the manufacturer s instructions and the safety rules the safety and operator s manuals and the decals applied on the machine Read understand and obey the employer s safety rules and worksite regulations Read understand and obey the applicable national regulations Only trained personnel informed on the safety rules can operate the machine B 1 GENERAL REMARKS Most accidents occurring while working repairing or maintaining 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 N DANGER The instructions given in 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 be sure that the operations you are going to car
82. iques and provides instructions for a safe use of the machine fitted with standard forks Before using different attachments thoroughly read the chapter Optional attachments 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 N DANGER Pay the greatest attention when working close to electric lines Check their position and ensure that no part ofthe machine operates atless than 6 meters from the power lines 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 24 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e 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 ofthe machine under safe conditions To operate under safe conditions always refer to these charts The extension level of the boom can be checked with the help of the letters A A B C painted on the same boom and compared with the load chart while the actual degrees of inclination of the boom are shown by the angle indicator B IMPORTANT The load charts illustrated in this manual are given
83. lations Page C 32 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 A TEREX COMPANY MAINTENANCE Section D MAINTENANCE TABLE OF CONTENTS D 1 LUBRICANTS HEALTH AND SAFETY D 3 17 Checking the state of the structure D 24 PRECAUTIONS icto ie tard D 3 D 4 ELECTRICAL SYSTEM D 25 D 2 ROUTINE MAINTENANCE D 4 IO eet D 25 D 2 1 Oil change D 5 D 4 2 Fuses and D 26 D 3 MAINTENANCE JOBS D 6 D 5 REFUELING 0 28 D 3 1 Disconnecting the battery D 6 D 5 1 Refueling 0 28 D 3 2 Access to the engine and tanks D 5 2 Product specifications D 28 44 9 D 7 45524 Engine oil D 28 0 8 D 5 2 2 Lubrication oils and relevant filtering D 3 4 Tyres and D 9 0 28 D 3 5 Check the efficiency of braking system and 055 2 3 29 parking brake D 10 524 Grease D 29 D 3 5 1 Checking the brake oil level 0 11 D 5 2 5 Engine D 29 D 3 6 En
84. le 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 3 N DANGER When replacing interchangeable attachments keep any person clear of the working area N DANGER 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 0008 6200 05 2007 Handler with telescopic boom GTH 5519 e A TEREX COMPANY OPTIONAL ATTACHMENTS B F 1 1 SHOVEL Application Quick coupling fitted attachment for moving soil sand debris cereals etc Code GTH 5519 Safety Litres 500 59 0200 0000 iis 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
85. lease refer to the engine use and maintenance manual The machine is supplied with oil SAE 15W 40 40 31 0 10 15 25 To start the engine from cold proceed as follows Engage the parking brake 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 Il 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 Incase of engine jump starting remove the booster ables see chapter C 4 3 4 5 DISCONNECTING THE BATTERY Before any maintenance or repair work and especially before welding any components onthe machine remove the cables at the battery 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 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 Select the required steering mode Select the required gear forward or reverse Release the parking brake pressing button 18 the warning light on the pushbutton m
86. low the procedure below D P amp o OR RE DE 1 Move to asolid and level ground 2 Setthe steering selection switch 13 to four wheel Steer pos 2 3 Rotate the 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 Reset the steering selection switch to four wheel steer pos 2 1 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 21 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE le A TEREX COMPANY 0 3 15 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 Remove or loosen the screws fixing the pads in relation to type of shims used with or wit
87. lter cover B per accedere alla cartuccia A 4 Change the filter element then before fitting a new one thoroughly clean and grease both seat and gasket 5 Refit and tighten the filter cover ATTENTION Hydraulic oil filter canisters 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 ae ENVIRONMENT The handling and disposing of used oils may be ruled by local or national regulations Address to authorised centres D SERVICE INTERVAL Running in None Ordinary Every 500 hours Page D 17 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY D 3 11 1 Auxiliary circuits oil filter To change the hydraulic oil filter cartridge of the service circuits proceed as follows 1 Stop the machine on a level ground and 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 18 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY D 3 12 LEVEL IN THE DIFFERENTIAL GEARS AND THE REDUCER D 3 12 1 Front and differential gears To check the oil level in the f
88. machine operators FE QUISKES 01 16 56 re A Personal protective edulpITIelit A Res DEDE DL CUM SAFETY PRECAUTIONS Hazards On iie 48635844 8 8 Operation or 6 Pads Machine operation hazards cete Reuse ecco tene dE E Ede an ERU EVER Damaged comporett Mam nee cave canted Explosion OF fire eR Damaged machine 5 ae tim ades und ca saan Personal injury 57420 22 SAEETTIDEVIGES tte c initia tut 1 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 SAFETY PRECAUTIONS e A TEREX COMPANY DANGER Not observing the instructions and safety rules in this manual may result in death or serious injury Do not operate the machine unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Read and understand the safety instructions before going on to the next chapter 2 Always perform a pre operat
89. mini socket TP4 placed inside the engine compartment Connect the compressor to an air source and pressurise the system Unscrew valve to help air flow out of the braking circuit Open the cap of the feeding tank e Open the tap of the compressor which has been previously connected to mini socket TP4 1 S Page D 10 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 le A TEREX COMPANY MAINTENANCE Check the air flows out of valve As soon as oil TO BLEED THE CIRCUIT OF THE PARKING BRAKE without air bubbles starts flowing out of this valve DO THE FOLLOWING close the same Start the diesel engine Check that the fluid in tank reaches the e Press pushbutton to unlock the parking brake recommended level e Slowly unscrew valve and close the same as soon as oil mixed with air bubbles starts flowing out e Repeat until oil without air bubbles starts flowing out of the valve e Test the efficiency of the braking system 12 Close the tap of the compressor Disconnect the hose from mini socket TP4 Test the efficiency of the braking system A In order to bleed the service brake circuit WITHOUT Once the circuit has been bled make sure the brake A COMPRESSOR for this operation two service circuit is in efficient working order technicians are needed one in the driving place and the other near the drain valve
90. must compulsorily be inspected and tested by the Manufacturer before being used again IMPORTANT Five years or 6000 hours after the first placing into operation of the machine whichever occurs first check the state of the structure paying an extreme attention to the welded supporting joints and the pins of both boom and platform see chap D 3 20 7 ITEMS SUPPLIED The following items are supplied together with the machine Description GTH 5519 Spanner CH 19 x for fork positioning Allen wrench CH 6 x for fork positioning 12 V lamps x spare A 7 1 LITERATURE SUPPLIED The machines comes with the following literature Machine operator s handbook PERKINS engine use and maintenance manual Spare parts catalogue Warranty and handing over certificate Page A 17 Document 57 0008 6200 03 2009 Genie Handler with telescopic GTH 5519 GENERAL INFORMATION Intentionally blank page Page A 18 Document 57 0008 6200 03 2009 A TEREX COMPANY B 1 B 2 B 2 1 2 2 2 3 2 4 3 B 3 1 B 3 2 B 3 3 B 3 4 B 3 5 B 3 6 B 3 7 B 4 Handler with telescopic GTH 5519 SAFETY PRECAUTIONS Section B SAFETY PRECAUTIONS TABLE OF CONTENTS GENERALIREMARKS ee Psi ema EDI PREREQUISITES OF THE PERSONNEL IN Requisites of the
91. 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 Technical data Payload 2500 IMPORTANT Width 970 The fixed hook has been designed to support a Length mm 620 load of 2500 kg The max payload corresponds to the nominal capacity rating of the handler on which Height 600 it is installed and is indicated on the load charts Weight kg 105 supplied with the equipment Page F 5 Document 57 0008 6200 05 2007 e A TEREX COMPANY 1 4 EXTENSION JIB Handler with telescopic boom GTH 5519 Code GTH 5519 400 kg 59 0800 0000 Characteristics Payload kg 400 A Length mm 2100 B Wiath mm 920 Height mm 630 Weight kg 115 OPTIONAL ATTACHMENTS Application 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 es
92. nsporting agricultural or industrial products by means of specific attachments see section F manufactured by TEREXLIFT srl Any other use is 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 Thehandler mustbe used and serviced only by operators knowing its characteristics and the safety procedures in depth It is also essential to comply with the safety at work legislation the precautions concerning safety and industrial medicine as well as the local and national road traffic regulations E 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 N DANGER 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
93. nto three different phases loading transfer and unloading Do not move off when the load is raised 20 30 cm above the ground Risk of machine overturning or load fall Loading phase Approach the load to the handled perpendicularly and check that the machine is level on the inclinometer Insert the forks under the load and raise the load some centimetres Pitch the forks backwards and check the machine stability before handling a load Transfer phase Do not start or brake abruptly Drivetothe unloading point cautiously and keep the load 20 30 cm from the ground Suitthe machine speed to the ground conditions to avoid dangerous jumps side skids of the vehicle and possible load falls When driving on slopes or ramps hold the load uphill N DANGER Do drive on slopes sideways this wrong manoeuvre is one of the main reasons for accidents due to vehicle overturning Unloading phase Drivetothe unloading point with straight wheels and bring the machine to a smooth stop leaving enough space to operate the boom e Put the parking brake and set the transmission to neutral Position the load some centimetres above the desired position and set the forks level Lower the load and make sure it is level Carefully withdraw the forks by operating the boom retraction control and if necessary raise or lower the boom as forks come out When the forks are clear of the load set them to transfer
94. omatic adjustment in relation to the wheel torque required complete with power divider directly applied on the rear axle hydraulic oil filter placed on the discharge line to the tank a heat 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 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 en
95. ons Address to authorised centres 0 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 A 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 lead first Page D 6 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE D 3 2 ACCESS TO THE ENGINE AND TANKS COMPARTMENTS Engine compartment For any operation within the engine compartment open the protection bonnet Hood is equipped with lock amp key and a supporting rod that holds it in position From the engine compartment you get access to Thermal engine Engine air filter 9 Hydraulic oil tank plug Radiator fluid compensation cup Battery To get access to the engine compartment Shutthe engine down and put the parking brake Unlock and raise the hatch Q with handle The gas springs will help the operation N DANGER 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 Q as follows Shutthe engine down and put the parking brake
96. ork data plate MODELLO TYPE DESIGNATION Placed on the left side of the fork frame This plate shows the identification data of fork such as model Ne BASTIDOR serial number year of manufacture weight nominal ANNO DI COSTRUZIONE payload centre of the load and model of the machine ANN E DE CONSTRUCTION 0 which the forks installed MASSA MASS MASSE MASSE MASA CENTRO DI GRAVITA CENTER OF GRAVITY CENTRE DE GRAVIT SCHWERPUNKT CENTRO DE GRAVEDAD PORTATA NOMINALE PAY LOAD PORTEE NOMINALL NENN TRAGFAHIGKEIT CARGA NOMINAL CENTRO DI CARICO LOAD CENTER CENTRE DE CHARGE LASTPUNKT CENTRO DE CARGA MODELLO MACCHINA MACHINE MODEL DESOGNATION MACHINE MASCHINEN MODELL MODELO MAQUINA A 2 4 CHASSIS SERIAL NUMBER The chassis serial number is punched on the front left part of the chassis side member 55 19 13545 SIL 9320 5500 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 0008 6200 03 2009 Handler with telescopic boom GTH 5519 GENERAL INFORMATION e A TEREX COMPANY 3 ALLOWED USE 3 1 ALLOWED USE Thehandlers have been designed and manufactured for lifting handling and tra
97. ows for a gradual warm up of the engine oil and a better lubrication In case of engine jump starting remove the booster cables see following chapter 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 A 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 21 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e A TEREX COMPANY 4 3 JUMP STARTING THE ENGINE Donotstart the engine using a quick charge booster to avoid any damage to the electronic boards When jump starting the engine through the battery ofanother machine 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 the battery installed on the handler To jump start the eng
98. pecially 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 grease the joints using the greasing gun Page F 6 Document 57 0008 6200 05 2007 e A TEREX COMPANY Handler with telescopic boom GTH 5519 OPTIONAL ATTACHMENTS 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 100 mm Safety Strictly obey the general safety precautions given in section B SAFETY Do not load loose materials Do 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 Machine GTH 5519 the sliding guides with graphitized grease Code 59 0600 0000 Technical data Payload kg 2600 Width mm 1240 Length 1600 Height with protection mm 1
99. rate 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 engages 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 Never use the parking brake to slow down the machine unless in an emergency It may reduce the brake efficiency Handler with telescopic GTH 5519 OPERATING INSTRUCTIONS m 3 2 4 Accelerator control 15 Gas pedal Its pressure controls the engine rom and coupled to the gearbox the machine speed It is fitted with an adjustable stop in the lower part 2 2 11 Document 57 0008 6200 03 2009 1 Handler with telescopic GTH 5519 INSTRUCTIONS 3 2 5 Pushbutton enabling the attachment 3 2 7 Continuous oil flow coupling release ping 20 Flow reversal
100. re operation inspection before testing the machine functions Scheduled maintenance procedures must be performed by qualified technical personnel according to the technical specifications of the manufacturer and the requirements envisaged in the responsibilities manual Page C 2 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e A TEREX COMPANY Pre operation inspection Make sure the operator s manuals are intact legible and placed inside the machine Make sure all decals are present and legible See Decals chapter Check for engine oil leaks and proper oil level Top up if necessary See Maintenance chapter Check for axle oil leaks and proper oil level Top up if necessary See Maintenance chapter Check for hydraulic oil leaks and proper oil level Top up if necessary See Maintenance chapter Check for engine coolant leaks and proper coolant level Add coolant if necessary See Maintenance chapter Check for battery fluid leaks and proper fluid level Add distilled water if necessary See Maintenance chapter Check the following components or zones for damage missing or wrongly fitted parts or non authorised modifications electrical components wiring and electrical cables hydraulic hoses fittings cylinders and distributors fuel and hydraulic oil tanks drive pump and motor and transmission axles Steering system braking
101. ront and rear differential gears Stop the machine on a level ground and engage the parking brake e Loosen level plug and check if oil is level with the hole f necessary add new oil through the hole of the level plug until it comes out Refit and tighten plug For the oil change Place a container of suitable size under drain plug Loosen the drain plug and the level plug and allow oil to flow out from the differential gears Refit and tighten drain plug Add new oil through plug until it is level with the hole e Refit and tighten level filler plug D 3 12 2 Reducer To check the oil level in the reducer e Stop the machine on a level ground and engage the parking brake e Loosen level plug and check if oil is level with the hole f necessary add new oil through the hole of the level plug until it comes out Refit and tighten plug For the oil change Place a container of suitable size under drain plug Loosen the drain plug and the level plug 9 and allow oil to flow out from the reduction gear Refit and tighten drain plug Add new oil through plug Q until it is level with the hole Refit and tighten plug Page D 19 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY D 3 13 OILLEVELIN THE FRONT REAR WHEEL REDUCTION GEARS To check the oil level within the w
102. ry out are not explicitly forbidden besurethatthe methods are safe say in compliance with the rules and provisions given in this section 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 theassistance service is at your disposal Addresses phone and fax numbers are given in the cover and in the title page of this manual Page B 2 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 SAFETY PRECAUTIONS e A TEREX COMPANY 2 REQUISITES OF THE PERSONNEL IN CHARGE 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 t
103. s After the first 5 years repeat this check every 2 years Page D 24 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE A TEREX COMPANY D 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 component for maintenance purposes secure it in a safe way before carrying out any maintenance A Any intervention on the electrical system unless performed by authorized personnel is expressly forbidden D 4 1 BATTERY 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
104. sed documents like load charts wiring diagrams hydraulic schemes torque wrench setting table etc Sections are subdivided into chapters and paragraphs that are numbered progressively The quickest way to look for 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 manual and keep it in an accessible place within the machine even after its reading so that it willalways 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 or to 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 0008 6200 05 2007 Q IQ Handler with telescopic boom GTH 5519 SYMBOLS A TEREX COMPANY SYMBOLS When using the machine operators could have to face some situations requiring special care and particular knowledge Whenthese situations involve the safety of operators or bystanders the machine efficiency
105. sult in shorts and as a consequence in a fire 6 5 2 Machine storage In case of extended inactivity of the machine follow the above precautions Additionally Washthe machine thoroughly For a better cleaning remove grills and protection casings Carefully dry all machine parts by blowing some compressed air Lubricate the machine thoroughly Doawalk 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 Storethe machine in a sheltered and well ventilated place Startthe engine for about 10 minutes at least once a month Always remember that the ordinary maintenance 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 components Page C 31 Document 57 0008 6200 03 2009 Handler with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e A TEREX COMPANY 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
106. tery only in a well ventilated area away from sparks naked flames and lighted cigarettes Do not operate the machine in dangerous environments or in places with flammable or explosive gases or materials Do not inject ether in engines equipped with glow plugs Do not leave fuel cans or bottles in unsuitable places Neither smoke nor use open flames in areas subject to fire dangers and in presence of fuel oil or batteries Carefully handle all flammable or dangerous substances Do not tamper with fire extinguishers or pressure accumulators explosion hazard B 7 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 e A TEREX COMPANY SAFETY PRECAUTIONS B 3 6 DAMAGED MACHINE HAZARDS Do not use a damaged or defective machine Do a thorough pre operation inspection of the machine and test all functions before each work shift Tag and remove from service a damaged or defective machine Make sure that all maintenance jobs have been carried out as specified in this manual and the appropriate service manual Make sure that all decals are in place and legible Make sure that the operator s safety and responsibilities manuals are intact legible and placed in the special container located in the machine B 3 7 PERSONAL INJURY HAZARDS Do not operate the machine in case of hydraulic oil or air leak Air or hydraulic oil leaks can penetrate or burn the skin Always operate the machin
107. the machine 1 PRE OPERATION INSPECTION Do not operate the machine unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Read and understand the safety rules before going on to the next chapter 2 Always perform a pre operation inspection Read and understand the safety rules before going on to the next chapter 3 Always test the machine functions prior to use 4 Inspect the work place 5 Only use the machine for the intended application Fundamentals It is the operator responsibility to perform a pre operation inspection and routine maintenance Pre operation inspection means a visual inspection performed by the operator prior to each work shift The inspection has to be carried out on the machine to detect possible faults before the operator starts testing the machine functions The pre operation inspection also helps understand if some routine maintenance procedures are required The operator can only perform the routine maintenance procedures envisaged in this manual See the list on the next page and check each single component If the machine is damaged or a non authorized modification has been done the machine must be tagged and removed from service Repairs must be carried out by qualified technical personnel according to the manufacturer s specifications After any repair the operator should repeat the p
108. um Cracking press Hydrostatic transmission Check 1 boost pressure test port Fae ca si TP 116 psi 1 HYDRAULIC CIRCUIT COLORS LEGENDA Open circuits high pressure lines Hydrostatic transmission high pressure lines Functions driving lines Low pressure and transmission charge pressure lines Load sensing and piloting lines Suction lines Tank lines Oil tank capacity 75 liters 20 gallons Genie Handler with telescopic boom GTH 5519 m TABLES AND DOCUMENTS ENCLOSED INTENTIONALLY BLANK PAGE Page G 16 Document 57 0008 6200 03 2009 Genie Handler with telescopic boom GTH 5519 TE TABLES AND DOCUMENTS ENCLOSED 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 Positive Negative Block Valve 8 Block Valve 9 oO 17 Document 57 0008 6200 03 2009 e A TEREX COMPANY Handler with telescopic boom GTH 5519 TABLES AND DOCUMENTS ENCLOSED Table key
109. ur machine perform a walk around inspection before starting the engine 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 Make sure that your hands and shoe soles are clean and dry e Check the seat belts can be fastened properly Check that lights indicators side tail lights hazard indicator lights wipers and horn are in working order 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 Adjustthe 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 Checks at the machine start up Check the efficiency of the safety devices as described in chap D 3 16 namely machine start control 4 2 STARTING THE ENGINE For the low temperature starting see paragraph C 4 4 Engage the parking brake Put the forward reverse speed selection lever to neutral Stepon the gas pedal Tostartthe 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 After the start up let the engine run at idle for some seconds before engaging a gear this all
110. ust be off Slowly step on the gas pedal to start moving off Do not operate the forward reverse gear lever when the machine is running The machine would reverse the running direction abruptly and you could seriously be injured Page C 23 Document 57 0008 6200 03 2009 Handler with telescopic GTH 5519 OPERATING INSTRUCTIONS 4 7 STOPPING AND PARKING THE MACHINE When possible stop the machine on a dry level and solid ground Then Bring the machine to a smooth stop by easing up the gas pedal and stepping down on the brake pedal Set the forward back speed lever to neutral position Engage the parking brake pressing button 18 the warning light on the pushbutton must be on Release the service brake pedal Rest the attachment coupled to the boom flat on the ground Rotate the ignition key to 0 and remove the key Leave the driving cab and lock the cab door 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 A Always engage the parking brake after stopping the machine to prevent possible accidental motions of the vehicle Leaving a battery connected can result in shorts and as a consequence in a fire C 5 USING THE HANDLER This chapter describes some techn
111. vacuated from the engine exhaust 2 Checkthe tightening of the engine fixing screws Check the tightening of the cab fixing screws 4 Checkthe backlash between pins and bushings in all joints Change the hydraulic oil filter of the transmission Change the hydraulic oil filter in the tank 0 4 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE e A TEREX COMPANY 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 Change the oil in the front and rear differential units and in the power divider 2 Change the oil in the four wheel 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 50 Subsequent changes 250 monthly Axles and Oil level check 250 monthly FUCHS TITAN GEAR LS 85 W 90 powa First change GL 5 LS GL 5 divider Subsequent changes 1000 yearly Hydraulic Oil level check 250 monthly SHELL TELLUS T 46 Subsequent changes 1000 yearly DENISON HF 1 DIN 51524 part 3 Cat HV whichever occurs first Page D 5 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 MAINTENANCE
112. 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 Page B 3 Document 57 0008 6200 05 2007 Handler with telescopic boom GTH 5519 SAFETY PRECAUTIONS e A TEREX COMPANY 2 3 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 not wear clothes with large Sleeves or objects that can get stuck in moving parts of the machine Protective helmet Protective gloves Working shoes IMPORTANT Use only type approved working clothing in good condition B 2 4 PERSONAL PROTECTIVE EQUIPMENT Under special working conditions the following personal protective equipment should be used Breathing set or dust mask Ear protectors or equivalent equipment Goggles or facial masks IMPORTANT Use only type approved protective equipment in good condition 3 SAFETY PRECAUTIONS B 3 1 HAZARDS ON THE JOBSITE Always take into account the features of the job site where you are going to work Always examine the working area and compare it with the machine dimensions in the different configurations N DANGER The machine is not electrically insulated and does not provide protection from contact with or proximity to
113. with telescopic boom GTH 5519 OPERATING INSTRUCTIONS e A TEREX COMPANY Couple the connectors of the attachment if any to the quick couplings of the frame N DANGER After the substitution of an attachment or after any coupling operation visually check the attachment A wrongly coupled attachment may result in damage to persons or things m 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 on site When the machine shall absolutely be towed Tow the machine for short distances and at low speed only Use a rigid drawbar Select the two wheel steer Setthe gearbox lever to neutral When possible start the engine and use the hydraulic drive and the braking system Raise the front wheels of the machine and remove the Cardan shaft of the transmission 6 2 ROAD OR SITE TRANSFER When travelling on public roads strictly obey the local or national road traffic regulations Page C 29 Document 57 0008 6200 03 2009 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 For the machine lifting anchor the chains

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