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PN 57.0009.0415

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2. 14 GTH 5519 GTH 5519 S Genie Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures A 14 CHECKTHEEFFICIENCY OFTHELIGHTING ELECTRIC SYSTEM If the LIGHTS KIT is installed check every day that the electrical system powering the lights of the machine is in efficient working order Use the assistance of a second technician to check that the front lights position lights low and high beams and turn signals and the rear lights position lights stop tail lights and turn signals are in excellent state of repair Also check beacon located on the cab roof If one lamp or more must be replaced use the table below as a reference TABLE A When switched on lamps get hot Before touching a lamp with your fingers let it cool down NOTICE Never touch the bulb of halogen lamps mount type H3 with your fingers this may damage the lamp use of a clean cloth or a paper tissue If you touch it accidentally thoroughly clean with a paper tissue and some ethyl alcohol Use Voltage Mount type Power e Front low high beam 12V P45t 45 40 W Front position lights 12V BA 9s 3 W Side tail turn signals 12V BA 15s 21W e Stop lights and rear position lights 12V BAY 15d 21 5 W Beacon Work lights OPTIONAL 12V H3 55W Dashboard indicators and cab lighting 12V W 2x4 6d 1 2
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5. a alo 5 ajojo AIN Po N fo DO an pe alol DN O to co A AIME A ola fN OD NIN Oo lol Ajo A 6 BIN 2v rs ee he Wyo Oyo 0 91 D 924 4 AJ QIN ON NIN O1 oj Ao gt k 2 4 A o N X D 4 GTH 5519 GTH 5519 S Section 2 Technical Specifications February 2009 TECHNICAL SPECIFICATION 2 15 HOISTING INSTRUCTIONS 4 DANGER All parts weighing more than 55 Ibs MUST COMPULSORILY be handled with suitable hoisting means In the Disassembly and Assembly section there is a clear indication of the weight of the part to handle while chapter A 12 contains a summary table with the weight of the single components Before removing parts of the machine make sure that fixing bolts have been removed all hydraulic and electrical parts have been disconnected the part to be removed is not blocked STRANDED ROPES e Use ropes or other hoisting accessories suitable to the wei
6. KD HH HH HS Section 2 Technical Specifications February 2009 _oO lt TECHNICAL SPECIFICATION 2 19 CHECKING THE CYLINDER MOVEMENT TIMES The check of the movement times of the cylinders check the engine speed the area easy to reach shall be done with the hydraulic oil at a temperature is the shaft of the CASAPPA pump of 60 Min engine speed 950 rpm Max engine speed 2600 rpm BOOM LIFTING LOWERING GTH 5519 5519 S Max engine speed Min engine speed BOOM EXTENSION RETRACTION Extend 5519 5519 5 Max engine speed Min engine speed ATTACHMENT DUMPING GTH 5519 5519 S Time s dumping roll back Max engine speed 4 3 Min engine speed 8 6 10 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 2 Technical Specifications 2 20 HYDRAULIC SETTINGS 1 PRELIMINARY OPERATIONS Check that the engine idle is set at 950 rpm and that the engine maximum speed is set at 2600 rpm Warm up the hydraulic oil to 140 F by keeping one of the elements of the b
7. TERMINALS AND GROUNDS nis Pedal control e O Ring gt Proximity control Ground M AG As_3p_motor es Lever control Terminal ELECTRONIC PARTS a Timed control Ground to frame Rectifier A9 Bo Resistance Resistor Potentiometer Variable resistance SIGNALS Intermittent lamp Whistle Lamp Buzzer Siren Bell Horn FUSES AND RELAYS Horizontal fuse Relay x tempu Geni Frame ground 2 COILS Coil Mechanical coupling coil Winding coil Coil with diode Winding with diode CONNECTORS Connector STATIC APPLICATIONS Auto transformer Transformer A E aa oL Em Condenser PUSHBUTTONS Manual NC contact Manual NO contact NC mushroom head pushbutton NO mushroom head pushbutton NC level NO level Pushbutton with NC return Pushbutton with NO return NC tie rod NO tie rod GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 6 Schemes SCHEMES CONTACTS Thermal A Normally open NO Le Normally closed NC NO limit switch cim NC limit switch ut Contactor DA Magneto thermal closure a Magn
8. Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 21 Section 4 Maintenance Procedures February 2009 TABLE B B 3 CHECK THE TYRE INFLATION 4 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 OKAY For the tyre inflation or substitution please refer to the table below STANDARD GTH 5519 5519 S Dimensions front and rear 12 16 5 Load index 10 pr Rim 9 75x16 5 Wheel disc 8 holes DIN 70361 Pressure Psi 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 Always use tyres having the dimensions indicated in the vehicle registration card Genie 22 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures J arcs P TABLE B 4 CHECK THE TIGHTENING OF THE WHEEL NUTS If you have to check the tightening of the wheel bolts or replace a wheel proceed as follows Raise the machine using a hydraulic jack Remove the wheel rolling it on the ground Line up the wheel with the axle and fit the 8 nuts Tighten the nuts following the alternate sequence showninthe picture A with a pneumatic screwdriving machine Lower the machine to the ground Re tighten all nuts
9. o rew e sr wee 7 memaseemgmdu Ls GTH 5519 GTH 5519 S Standard Dimensions ___ 12 16 5 A A 7091 Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 1 Section 2 Technical Specifications February 2009 TECHNICAL SPECIFICATION 2 3 LIMIT OF USE GTH 5519 GTH 5519 S Angle of approach machine front side Dsamreane macnewersu 5 2 4 WEIGHT GTH 5519 GTH 5519 S with fork 9810 2 5 SPEED GTH 5519 GTH 5519 S Travel speed max Traction to the dynamometer max load 9325 Traction to the dynamometer no load 6835 2 6 PAYLOAD AND REACH GTH 5519 GTH 5519 S 19 Max lifting height Max forward reach Reach at maximum height Fork holder plate rotation Max lifting capacity Lift capacity at maximum height Lift capacity at maximum reach Weight ft ft ft bs bs bs bs 2 GTH 5519 GTH 5519 S Document 57 0009 0415 2009 Section 2 Technical Specifications TECHNICAL SPECIFICATION 2 7 FORKS floating type GTH 5519 GTH 5519 S Weight Ibs 551 ea Dimensions 47 2 x 3 9 x 1 6 ow d 2 8 DIESEL ENGINE GTH 5519 GTH 5519 S eax Power Oust mum oao _______630 2800 Joan Torque Out 158
10. s O J MJ P Section 4 Maintenance Procedures TABLE C C 3 CHECK THE OIL LEVEL IN THE FOUR C 4 CHECK AND CLEAN THE ENGINE AIR WHEEL REDUCTION GEARS To check the oil level in the wheel reduction gears lt Stop machine a level ground and ensure the parking brake is engaged and plug A finds on the horizontal axis Clean the plug all around then remove it and check if oil is level with the hole If necessary add new oil through hole A until it is level Refit the plug PROTECT THE ENVIRONMENT Place container of suitable size under the plug FILTER To clean the engine air filter Stop the engine and engage the parking brake Unlatch the fasteners A and remove cover B Pull out the filter cartridge C Clean the filter bowl Dry clean the cartridge at max 87 psi 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 posi tioned Close cover B and lock in place with fasteners A As soon as the warning lamp on the cab dashboard switches on replace the outer element Document 57 0009 0415 Genie GTH 5519 GTH 5519 S 27 Section 4 Maintenance Procedures February 2009 TABLE C 5 CHECK THE CLAMPING OF THE CABLEH
11. Ratea Power mesimi 198 68 2600 132632500 jowwrmme O Load No Load With Fork 2 9 HYDRAULIC SYSTEM GTH 5519 GTH 5519 S Make DEUTZ PERKINS Hydtauicouput USgamin 21 Pressure 3916 2 10 ELECTRICAL SYSTEM GTH 5519 GTH 5519 S EN jm Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 3 Section 2 Technical Specifications February 2009 E TECHNICAL SPECIFICATION 2 11 MACHINE SOUND LEVELS Not applicable 2 12 VIBRATION LEVELS GTH 5519 GTH 55 9 S EE Mean assessed vibration level transmitted to arms Mean assessed vibration level transmitted to body Values calculated in accordance with standard prEN13059 This is a Class A device In a residential environment such device can cause radio disturbance In such cases the operator is required to take suitable measures 2 43 REFILLING GTH 5519 GTH 5519 S Diesel engine Front differential gear with reduction gear Rear differential gear Front wheel reduction gears usa ______ oa Rearwheerdudongens usa o Brake 9i P Engine coolant Products Engine oil SHELL RIMULA SAE 15W 40 API CH 4 CG 4 CF 4 CF ACEA E3 MB 228 3 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 DE
12. PROBLEMS CAUSES SOLUTIONS February 2009 Problem Cause Solution The boom lifting is not not efficient The seals of the lifting cylinder are damaged Cylinder rod damaged Leakage in the cylinder block valve Fit a new kit of seals and check the tightness of the cylinder Check the rod condition Check the valve operation if necessary clean or replace the valve During the down movement the boom jerks Leakage in the cylinder block valve Check the valve operation if necessary clean or replace the valve Operating the joystick no function is activated Joystick damaged Valve of the main valve damaged Low pilot pressure Check the joystick efficiency replace if necessary Check the efficiency of the valve replace if necessary Check the supercharge pressure of the drive pump The steering wheel is slow and noisy Couplings damaged Hydraulic drive damaged Replace the couplings Replace the hydraulic drive Differential noisy and high temperature on the body No oil Bearings damaged Check the oil level and refill If trouble cannot be rectified dismantle the unit Replace the bearings The boom is hard to move in when it is fully extended in the horizontal position When moving out the second telescope the boom tends to move right and left Sliding blocks worn out Sliding blocks worn out Check all the front bottom pads and the rear top
13. and relays FUSES Ref Circuit Amp 201 FUSE 10 1 F02 FUSE 15 203 FUSE 15 204 15 F05 FUSE 10 rr mmm FO6 FUSE 5 gegen F07 FUSE 5 a 208 FUSE 10 Quam F09 FUSE 10 F10 FUSE 5 es 11 FUSE 25 12 FUSE 10 F13 FUSE 15 B F14 FUSE 10 Fis F15 FUSE 10 A F16 FUSE 10 F17 FUSE 10 r F18 FUSE 10 F19 FUSE 10 F20 FUSE 10 RELAYS Ref Circuit Gam FG1 MAXIFUSE FG2 MAXIFUSE ENGINE STARTER KO1 GLOW PLUGS PREHEATING 12 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 6 Schemes SCHEMES 6 5 POSITION OF THE ELECTRICAL AND HYDRAULICAL COMPONENTS ON THE MACHINE 6 5 1 Hydraulical components PERKINS ENGINE PERKINS ENGINE Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 13 Section 6 Schemes February 2009 SCHEMES DEUTZ ENGINE 5s DEUTZ ENGINE Genie 14 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 6 Schemes SCHEMES Document 57 0009 0415 GTH 5519 GTH 5519 S 15 Section 6 Sch
14. Oil level in the four reduction gears C 4 Cartridge of the engine air filter C 5 Clamping of the cableheads to the battery terminals C 6 Air suction hose between engine and filter C 7 Cylinder chromium plated rods C 8 Check the hydraulic lines C 9 Check the electric cables C 10 Wear of the sliding pads of the boom sections C 11 Play of the sliding pads of the boom sections C 12 Sliding parts of the boom sections C 13 Level of the battery electrolyte C 14 Efficiency of the block valves Table D Every 500 working hours D 1 Smoke from engine exhaust D 2 Tightening of the engine fixing screws D 3 Tightening of the cab fixing screws D 4 Backlash between pins and bushings in all joints D 5 Drive pump hydraulic filter tank return D 6 Hydraulic oil filter in the tank D 7 Efficiency of hydraulic system D 8 Cartridge of the engine air fil ter 0 9 Air filter in the cab B 3 Check the tyre inflation Use the maintenance tables in this sec tion and step by step procedures in 84 Tightening of the wheel nuts 0 10 Engine oil oil filter and fuel filter B 5 Tightening of the cardan shaft section 4 to learn how to perform these screws inspection If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair pl
15. E X QO e y OUS Schemes Combined non return and throttle valve Switching valve Pressure relief valve with direct control Pressure relief valve with hydraulic control Pressure reducing valve Sequence valve Adjustable throttle valve Two way flow regulator Cut out cock POWER SOURCES Electric motor Thermal engine OTHER EQUIPMENT Accumulator Water tank Compressor Filter Cooler Pressure gauge Thermometer Flowmeter Pressure switch Drain to tank indication Section 6 Schemes SCHEMES DISTRIBUTION SETTING ELEMENTS Two position and two way distributor with manual lever control and spring return Three way and two position distributor with hydraulic control Two position three way distributor with electro magnetic control and spring return Distributor with mechanical control and span proportional to the action of the same control Two position three way distributor with representation of transient connection during passage phase Electro hydraulic single acting servo valve Geni February 2009 GTH 5519 GTH 5519 S Document 57 0009 0415 Section 6 Schemes SCHEMES HYDRAULIC SCHEMES GTH 5
16. Refit and tighten plug A Recommended oil FUCHS TITAN GEAR LS 85 W 90 GL 5 LS GL 5 Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures TABLE E E 3 CHANGE THE OIL IN THE FOUR WHEEL REDUCTION GEARS To change the oil in the wheel reduction gears Stop the machine on a level ground and ensure the parking brake is engaged and plug A is oriented along the vertical axis 9 PROTECT THE ENVIRONMENT Place a container of suitable size under the plug Unscrew plug A and drain any oil from the reduction gear Rotate the wheel by 90 until the plug finds again on the horizontal axis Add new oil through hole A Refit and tighten plug A Recommended oil FUCHS TITAN GEAR LS 85 W 90 GL 5 LS GL 5 gt Document 57 0009 0415 GTH 5519 GTH 5519 S 47 Section 4 Maintenance Procedures February 2009 TABLE E 4 CHANGE THE HYDRAULIC OIL To change the hydraulic oil Stop the machine on a level ground and make sure the parking brake is engaged Release the pressure from the hydraulic circuit Place a container of suitable size under the drain plug placed in the lower part of the reservoir and collect a
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18. 6 Securethe cooler with a textile bridle connected to the swing hoist 7 Hoist with caution by tilting the cooler forward to prevent damage to the fixed fan of the engine VIEW OF THE MACHINE FROM THE BOTTOM 24 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Procedures TABLE 008 Operation Main valve disassembly table 008 GTH5519 5519 5 Standard tools 7 PROTECT THE Ge ENVIRONMENT Before disconnecting the hydraulic piping place containers of suitable size underneath to prevent oil spillage Carefully clean the area around the piping to be disconnected plug all disconnected parts with connectors clothes or adhesive tape to prevent dust or impurities from entering the circuit They can cause serious damage Before disconnecting the hydraulic piping ensure the line is not under pressure Release the pressure if necessary by operating the control levers with the engine stopped In any case disconnect the hydraulic piping with extreme caution and always wear suitable personal protection equipment e g goggles gloves facial screen etc Wrap up the end of the pipe to be disconnected with some rags and slowly loosen the pipe connector so that air comes out as slow as possible TEREX COMPANY Document 57 0009 0415 GTH 5519 GTH 5519 S 25 Section 7 Repair Procedures February 2009 TABLE 008 Operation Main valve disassembly Table 008 GTH5519
19. GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures 4 6 TABLE D PROCEDURES D 1 VISUALLY CHECK THESMOKE QUANTITY EVACUATED FROM THE ENGINE EXHAUST Tocheck the quantity of smoke evacuated from the engine exhaust proceed as follows Start the engine of the machine Wait for a few minutes so the engine can warm up correctly Visually check that the amount of smoke coming out of the exhaust is normal repeat the check while accelerating the engine NOTICE Do this check outdoors or use an adequate smoke extraction system In case of excess smoke strictly obey the instruc tions provided in the relevant Use and maintenance manual enclosed with the technical literature of the machine TABLE D D 2 CHECKTHETIGHTENING OF THE ENGINE FIXING SCREWS Every 6 months check that the screws fixing the engine to the machine chassis are tight For this operation use a torque wrench and tighten the screws to a torque of 91 Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 37 Section 4 Maintenance Procedures February 2009 TABLE D D 3 CHECK THE TIGHTENING OF THE CAB FIXING SCREWS Every 6 months check that the screws fixing the cab to the machine chassis are tight For this operation use a torque wrench and tighten the Screws to a torque of 138 38 GTH 5519 GTH 5519 S 0 4 CHECK THE BACKLASH
20. Timer enabling antioverload system switch 24 X59 Plug in Connector Emergency switch K100 Relay fans air conditionig 22 X6 Plug in Connector 12 way In Out relay card K101 Relay air conditionig compressor 14 X61p Plug in Connector Steering unit bridge MT Starter engine 11 615 Plug in Connector Steering unit Mn Heating fan 53 xi Plug in Connector way In Out relay card M12 Windscreen washer pump 4 4 M21 Air conditioning 14 M22 Windscreen washer motor 43 M60 LMI setting 23 M106 Air conditioning fan motor 22 COLOR WIRE LEGEND M196 Air conditioning fan motor 22 P25 Main gauges cluster 12 LIGHT BLUE R36 Glow plugs M B WHITE 51 Parking brake switch 34 C ORANGE 52 Continuous flow enabling switch 35 D YELLOW 55 Switch light m H GREY 56 Work spotlight switch 53 L BLUE 59 Fan switch 52 M BROWN 510 Air condition switch 51 N BLACK 511 Windscreen washer pump switch 33 R RED 513 Steering selector 3 S PINK 518 Microswitch stop light 45 GREEN 520 LMI bypass key 24 Z PURPLE S24 Start up panel 11 557 Road light switch AA REMARK Two colorwires are indicated through a 558 Forward reverse switch 22 combination of the aforesaid initials as follows 559 Warning switch 24 G V YELLOW GREEN crosswise colouring G V YELLOW GREEN lengthswise colouring Document 57 0009 0415 enie A TEREX COMPANY GTH 5519 GTH 5519 S 11 Section 6 Schemes February 2009 SCHEMES REV A 6 4 2
21. checking the pressure of the drive pump checking the pressure of the hydraulic drive unit checking the pressure of the braking system checking all hydraulic components and their movements In case of need please contact the GENIE Service Centre Document 57 0009 0415 GTH 5519 GTH 5519 S 41 Section 4 Maintenance Procedures February 2009 TABLE D D 8 CHANGE THE MAIN CARTRIDGE OF THE ENGINE AIR FILTER Changing the external element Stop the engine and engage the parking brake Unlatch the fasteners A and remove cover B Pull out the filter cartridge C Clean the filter bowl Mount the new cartridge D and make sure it is cor rectly positioned Close cover B and lock in place with fasteners A As soon as the warning lamp on the cab dashboard switches on replace the outer element 42 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures TABLE D D 9 CLEAN THE CAB AIR FILTER If the machine comes with a closed cab clean the air filter in the cab every six months Replace the cartridge if the filtering cloth is damaged Cleaning and changing the cartridge Shut the engine down and engage the parking brake Pull out the filter A located to the right of the driving place Clean the filter bowl Clean the filter cartridge and replace in case of damage Paper filters must never b
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23. 5 Pull out the motor from the power divider fitted to the front axle 6 Protect the engine compartment to prevent the entrance of impurities Genie 20 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Procedures TABLE 006 Operation Cylinder disassembly Table 006 GTH5519 GTH 5519 S Boom extension cylinder Bridge crane payload 2000 Ibs Standard tools Textile bridles or chains with hooks Operation 1 Set the boom to horizontal position with the telescope slightly extended to work on the cylinder connecting pin rod side 2 With a 0 51 on wrench remove the screw fixing the pin drop shaped head 3 Knock out and extract the pin using a plug of soft material aluminium copper wood etc 4 Remove the rear guard to gain access to the rear part of the boom 5 Place a container of suitable size under the hydraulic piping before disconnecting 49 PROTECT THE ENVIRONMENT Used oils must be handled and disposed of according to local regulations Address to legally authorised centres 6 With a 1 06 in wrench disconnect the two hydraulic hoses from the blocking valve then plug the disconnected connectors to prevent dust and impurities from entering the circuit _ Ge _ Document 57 0009 0415 GTH 5519 GTH 5519 S 21 Section 7 Repair Procedures February 2009 TABLE 006 Operation Cylinder disassembly Boom extension cylinder 7 Loosen and remove
24. A 8 Clean the air suction filter 9 A 9 Check and clean the radiator 10 A 10 Check the hydraulic oil level in the tank 11 A 11 Check the greasing of the boom section pads 12 A 12 Grease the forks 13 A 13 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 14 A 14 Check the efficiency of the lighting electric system 15 A 15 Check the efficiency of braking system and parking brake 16 A 16 Check the efficiency of the steering selection system 18 A 17 Check efficiency of the fork balancing system 19 A 18 Make sure the safety devices installed are in efficient working order 19 A 19 Check the engine coolant level 20 4 4 Table B procedures 21 B 1 Check the machine is in efficient working order 21 B 2 Check the tension of the alternator belt 21 B 3 Check the tyre inflation 22 B 4 Check the tightening of the wheel nuts 23 B 5 Check the tightening of the cardan shaft screws 24 4 5 Table C procedures 25 C 1 Change the engine oil and relevant filter 25 C 2 Check the oil level in the differential gears and power divider 26 C 3 Check the oil level in the four wheel reduction gears 27 C 4 Check and clean the engine air filter 27 C 5 Check the clamping of the cableheads to the battery terminals 28 C 6 Check the air suction hose between engine and filter 28 C 7 Check the cylinder chromium plated rods 29 C 8 Check the hydraulic lines 29 C 9 Check the electric cables 30 C
25. Removing the engine from the machine Table 003 Reassembling the engine on the machine GTH5519 GTH 5519 5 18 Sling the engine using a two leg chain with hook to be coupled to the front lug and the rear supporting bracket of the battery 19 Raise the engine with caution and ensure no parts are still connected 20 Remove the engine from the machine rest it on a wooden pallet and hold it in position with some plugs Reassembling the engine Toreassemble the engine repeatthe steps above in reversed order considering the precautions below 1 Handle the engine with extreme caution to prevent it from crashing against the machine Document 57 0009 0415 GTH 5519 GTH 5519 S 15 Section 7 Repair Procedures February 2009 TABLE 003 Operation Reassembling the engine on the machine Table 003 GTH5519 GTH 5519 S Intentionally blank page GTH 5519 GTH 5519 S Document 57 0009 0415 16 February 2009 Section 7 Reapair Procedures TABLE 004 Operation Hydrostatic pump disassembly Table 004 GTH5519 GTH 5519 S Bridge crane or swing hoist payload Standard tools 2000 Ibs Operation 7 PROTECT THE ENVIRONMENT Before disconnecting the hydraulic piping place containers of suitable size underneath to prevent oil spillage Carefully clean the area around the piping to be disconnected plug all disconnected parts with caps rags or adhesive tape to prevent dust or impurities from en
26. SERVICE BRAKE PRESSURE Connect a 3626 psi manometer to the mini socket TP5 Step down on the brake pump pedal The working pressure is about 1160 psi and is given by the force exerted on the pedal Document 57 0009 0415 GTH 5519 GTH 5519 S 13 February 2009 Section 2 Technical Specifications TECHNICAL SPECIFICATION annex 1 POWER STEERING SYSTEM 2 n A 27 EU 2223 ve pi enie G GTH 5519 GTH 5519 S Document 57 0009 0415 14 February 2009 Section 3 Maintenance Inspections Maintenance Inspections 3 1 INTRODUCTION Maintenance inspections shall be completed person trained and qualified on the maintenance of this machine e Scheduled maintenance must be carried out at the intervals indicated in the MAINTENANCE REPORT Failure to properly complete each inspection when required may cause death serious injury or substantial machine damage Immediately tag and remove from service a damaged or malfunctioning machine Repairany machine damage or malfunction before operating machine Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 1 Section 3 Maintenance Inspections February 2009 MAINTENANCE INSPECTIONS 3 2 ABOUT THIS SECTION Intervention times Maintenance interventions have been divided into 7 different groups in relation to the time at which they must be carried out say daily weekly
27. monthly every 6 months yearly every 2 years and at 5 years afterwards every 2 years For ease of use the service intervals have been grouped in different tables as explained below Inspection Table Daily A Weekly Monthly Six month A B C D Yearly A B C D E Every 2 years A B C D E F At 5 years afterwards every 2 years G Maintenance table The maintenance table contains general information on the type of intervention to be carried out at a certain interval For the explanation of the maintenance jobs to be done please refer to chapter 4 Maintenance Procedures Maintenance inspection report The maintenance report summarises all ofthe interventions to be carried at a given interval and lets the maintenance technician note the result of the check or intervention carried out This card can be photocopied to be used at the different service intervals and to keep a trace of all interventions carried out 2 GTH 5519 GTH 5519 S Genie Document 57 0009 0415 2009 Section 3 Maintenance Inspections CREE MAINTENANCE INSPECTIONS 3 3 MAINTENANCE TABLE TABLE A During the first 10 working hours A 1 Check the oil level within reduction gears power divider and differential gears A 2 Check the tightening of the wheel bolts A 3 Check the tightening of all bolts and nuts 4 Check the couplings for oil leaks Every 10 wor
28. of the valve Testthe efficiency of the braking system Once the circuit has been bled make sure the brake circuit is in efficient working order CHECKING THE BRAKE OIL LEVEL The oil within the braking circuit must be at about 0 0218723 yd from the tank plug E Geni Document 57 0009 0415 GTH 5519 GTH 5519 S 17 Section 4 Maintenance Procedures February 2009 TABLE A A 16 CHECK THE EFFICIENCY OF THE STEERING SELECTION SYSTEM 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 follow the procedure below 1 2 10 Move to a solid and level ground Set the steering selection switch A to four wheel steer pos 2 Rotate the steering up to its stop either to the right or to the left Setthe steering selection switch to two wheel steer pos 0 Rotate the steering up to its stop turn in the same direction as above Reset the steering selection switch to four wheel steer pos 2 Rotate the steering to the side opposite to point 3 So that the rear axle reaches its stop Reset the steering selection switch to two wheel steer pos 0 Rotate the steering to the same side as in
29. 10 Check the wear of the sliding pads of the boom sections 31 C 11 Adjust the play of the sliding pads of the boom sections 32 C 12 Grease the sliding parts of the boom sections 33 C 13 Check the level of the battery electrolyte 34 C 14 Check the efficiency of the block valves 35 xvi GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 r J e TABLE OF CONTENTS 4 6 Table D procedures 37 D 1 Visually check the smoke quantity evacuated from the engine exhaust 37 D 2 Check the tightening of the engine fixing screws 37 D 3 Checkthe tightening of the cab fixing screws 38 D 4 Check the backlash between pins and bushings in all joints 38 D 5 Change the hydraulic oil filter 39 D 6 Change the hydraulic oil filter in the tank 40 D 7 Have the hydraulic system checked by a skilled technician 41 D 8 Change the main cartridge of the engine air filter 42 D 9 Clean the cab air filter 43 D 10 Change engine oil oil filter and fuel filter 44 4 7 Table E procedures 45 E 1 Change the safety element of engine air filter 45 E 2 Change the oil in power divider and differential gears 46 E 3 Change the oil in the four wheel reduction gears 47 E 4 Change the hydraulic oil 48 4 8 Table F procedures 49 F 1 Change the engine coolant 49 4 9 Table G procedures 50 G 1 The machine structure 50 Section 5 Rev Problems Causes Solutions 1 5 1 Introduction 1 5 2 About this secti
30. 25 B V15 5 lt 3 12 20 18 6 16 1 5 23 X27 X27 Xn xn 2 5 5 Xs Y amp 5 5 lt ps Ds x p m m xa m Y52 a Y QY 2 X51 X52 x x x2 xn xa 31 31 25 e e 4 Se lt e Si X 5 ow Ow ES lt lt Sw gr KS O ge SA ks So Sas Sr 9 E 59 559 9 94 AOT 9 9 Se PE 5 5 S 99 Pes 5 9 lt 9 e C lt v v enie A TEREX COMPANY 8 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 6 Schemes REV SCHEMES 1 e 3 4 5 ROAD LIGHTS SELECTOR LEVER WINDSCREEN WINDSCREEN ROAD LIGHTS SWITCH STOP LIGHT WIPER MOTOR WASHER PUMP PRESSURE SWITCH 25 H 35 m 1 1 xut T 58 V EN 47 55
31. 9 With a 0 67 in hexagonal wrench remove the pad fixing screws 10 With a screwdriver pry off the worn pads Fit new pads after applying a few drops of Loctite 495 on the threads Tighten the pad fixing screws to 22 25 To renew the pads of the telescope proceed as follows 11 Removeall pads from the fixed section to extend the telescope see instructions above 12 Fully extend the boom then lower the nose to the ground and place a stand underneath the telescope near the fixed section 13 Remove the pin from the extension cylinder rod side see table GTH5519 GTH5519 S 006 Move back with the machine slowly to extend about 0 2187227 yd of the telescope out of the fixed section LB Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 29 Section 7 Repair Procedures February 2009 TABLE 009 Operation Renewing the slide pads of the telescopic boom 14 Check the internal measure of the fixed section and the external measure of the telescope to verify if some shims are necessary considering that the final tolerance must range from 0 039 in to 0 059 in 15 With a 0 23 in hexagonal wrench remove the worn pads Fit new pads after applying a few drops of Loctite 495 on the threads Tighten the pad fixing screws to 22 25 15 Clean and grease the internal and external walls of the boom sections in the sliding points of the pads To this end use INTERFLON FIN GREASE LS2 16 Retract the telescope i
32. W e Interior lamp 12V SV 8 5 8 5W e License plate lights 12V BA 15s 5W e Back up lamps 12V BA 15s 21W Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 15 Section 4 Maintenance Procedures February 2009 TABLE A A 15 CHECK THE EFFICIENCY OF BRAKING SYSTEM AND PARKING BRAKE For any intervention on the braking system adjustment and or substitution of the brake discs address to the GENIE Technical Service Centre or the nearest GENIE authorised workshop 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 A and B to eliminate any air from the circuit Thefirst valveis usedto purgethe service brake circuit B the second valve is used to purge the negative parking brake circuit A 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 DO THE FOLLOWING Make sure that compressor F contains a sufficient quantity of oil so you can proceed with the circuit bleeding Connect the flexible hose of the compressor to the mini socket TP5 placed inside the engine compartment Connect the compressor to an air source and pressurise the system Unscrew to help air flow out of the braking circuit G
33. a 2 5 5 a 4 1 5 i R 4 5 dj 8 PREHEATING d wl FG 262 STARTER Ed GLOW mc ER soa soa RELAY g RELAY S 2 4 ele esis 1 2 1 1 xm xoa 35 86 K H 5 7 FR gt 3 YB Yh 69 BIA T 2 31 ry 2 gt 21 5 FH L SM SNe ES xe 59 4 x S so es S N MS s S D JS MERE COMPANY 6 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 6 Schemes REV SCHEMES 1 e 3 4 EMERGENCY LIGHTS FORWARD REVERSE LEVER T 11 13 1 1 As x59 x59 Ad lt y 558 1 5 X58 M s 5 5 b M 4 75 1 6 5 2 xm X21 X21 ox 3 L 2M qq LU am a NES 51 2 81 11 qe 5
34. at 40 90 psi placed on the pump head sends an electrical signal when the service brake is engaged The oil coming from the drain line of the main valve operating the telescopic boom 16 is cooled down by the heat exchanger 32 This exchanger is divided in two sectors the former absorbs heat from the cooling circuit of the diesel engine and the latter absorbs heat from the hydraulic circuit of the machine The oil cooled down by the heat exchanger is sent back to the special filter 34 and finally drained into tank 10 A one way valve 33 calibrated at 116 psi is installed parallel to the input line of the heat exchanger and used as safety valve Its function is to avoid overpressure conditions of the heat exchanger as is the case of a machine starting at low temperatures by directly draining any excess oil into the tank Document 57 0009 0415 Description DESCRIPTION GTH 55 19 GTH 55 19 S TIER 3 hydraulic schematic February 2009 oz 1 isd OLY 338 einssaid 15009 ainssaid Bunjoe1o oneisoup H 81 00 9G 3ueureoe dsip uoissiusuej onejsop H seujuonong Bunojid pue Bursues peo 188 6299 ainssaid ou 5 pue enssed Y
35. change the mud guards 0 30 change the steering wheel 0 30 replace the complete solenoid valve block 2 00 Document 57 0009 0415 GTH 5519 GTH 5519 S 3 Section 7 Repair Procedures February 2009 ______________________________________________________________________________________________ Intentionally blank page 4 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Procedures TABLE 001 Operation Cylinder disassembly Table 001 GTH5519 GTH 5519 S Boom raising cylinder Bridge crane payload 20000 Ibs Standard tools Textile bridles or chains with hooks Adjustable stands Operation 1 Release the attachment 2 Anchor the attachment holding frame to the hooks of the slinging chain 3 Raise the boom to max height the hinging pin of the cylinder rod must be over the driving cabin operating alternately the bridge crane and the hydraulic boom raising control of the machine 4 Stop raising when the slinging chains are slightly under tension 5 Place a container of suitable size under the hydraulic piping before disconnecting PROTECT THE 2 Used oils must be handled disposed of according to local regulations Address to legally authorised centres 6 With a 0 94 incwrench disconnect two hydraulic hoses from the blocking valve then plug the disconnected connectors to prevent dust and impurities from entering the circ
36. cylinder to end of stroke and do not let the engine run at max speed for more than 5 seconds PHOTO 2 Geni Document 57 0009 0415 GTH 5519 GTH 5519 S 11 Section 2 Technical Specifications February 2009 TECHNICAL SPECIFICATION 3 SETTING THE HYDROMATIK PUMP HYDROSTATIC TRANSMISSION Do the calibration of the hydrostatic transmission with the hydraulic oil at 140 F Connect 0 868 psi manometer to the mini socket TP3 to read the boost pressure value see photo 1 e Connect a 0 8688 psi manometer to the mini socket TP2 to read the high pressure value see photo 1 STARTING THE CALIBRATION Set the forward neutral reverse selector to the forward position Run the engine at 1200 rpm Check the value on the tachometer Adjust shutter D by means ofthe register until reading a value of 724 psi on the high pressure manometer TP2 Keep to one side of the machine during this operation Hold the selector to neutral position and make sure the maximum speed of the engine does not exceed 2600 rpm Deutz engine or 2500 rpm Perkins engine The engine must run at a idle speed of 950 rpm Otherwise adjust the minimum speed e Read the boost pressure on manometer and ensure it is about 362 435 psi with the engine running at idle speed The boost pressure has not a fixed value but varies from pump to pump Hold the machine blocked by disconnecting the power plug of the solenoid v
37. from both containers of suitable size underneath to prevent sides oil spillage tie a cord to one end of the hose remove the hose pulling the cord until it comes out completely untie the cord and tie it to the new hose Plug all disconnected parts to prevent dust or pull the cord from the other side to refit the hose impurities from entering the circuit They can cause until reaching the connecting point to the line serious damage 4 DANGER Before disconnecting the hydraulic pipe check that there is no residual pressure In case eliminate the pressure operating the control levers with the engine stopped In any case disconnect the hydraulic pipe with extreme caution and always wear suitable personal protection equipment e g goggles gloves facial screen etc Wrap up the end of the pipe to be disconnected with some rags and slowly loosen the pipe connector so that air comes out as slow as possible Useful advice for mounting flexible hoses YES NO YES YES Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 7 Section 2 Technical Specifications TECHNICAL SPECIFICATION 2 17 LISTS OF RECOMMENDED SPARE PARTS Code 07 0700 0023 09 4604 0004 07 0700 0037 07 0700 0036 07 4501 0068 07 4501 0067 07 4501 0139 07 4501 0138 07 0705 0093 07 0705 0096 07 0705 0099 07 0728 0007 07 0709 0417 07 0701 0200 07 4529 0112 07 4529 0027 635965 07 0705 0081 640096 63999
38. that the telescopes are well greased in correspondence of the sliding pads If necessary scrape off the old grease and apply a thin film of new grease Use only INTERFLON grease FIN GREASE LS 2 code 640772 Avoid mixing greases of different type or features and do not use greases of lower quality Document 57 0009 0415 GTH 5519 GTH 5519 S 33 Section 4 Maintenance Procedures February 2009 TABLE C C 13 CHECK THE LEVEL OF THE BATTERY ELECTROLYTE Check the electrolyte level every 250 working hours if necessary add distilled water Ensure the fluid is 0 19 0 23 inc above the plates and the cell levels are correct 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 4 DANGER 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 4 DANGER Before disconnecting the battery set all switches within the cab to OFF disconnectthe battery disconnect the negative lead from the frame earth first To connect the battery connect the positive lead first Recharge the battery far from the machine in a well vent
39. the engine and engage the parking brake Unlatch the fasteners A and remove cover B Pull out the filter cartridge C Clean the filter bowl Dry clean the cartridge at max 87 psi 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 B and lock in place with fasteners A If the warning light air filter restriction the driving place comes on replace the two filter elements C and D Stop the engine and engage the parking brake Unlatch the fasteners and remove cover B Pull out the filter elements C and D Check the filter element for cracks by introducing lamp inside Install the new filter elements C and D Close cover B and lock in place with fasteners A TABLE A Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 9 Section 4 Maintenance Procedures February 2009 TABLE A A 9 4 DANGER When using a steam washer always wear protective clothes Hot steam may cause serious injury CHECK AND CLEAN THE RADIATOR Stop the engine and engage the parking brake reach radiator C open the engine cover Check the fins of radiator C for sediments If necessary prepare a compressed air nozzle max 29 psi or a nozzle distributing water under pressure or steam Cleaning using compress
40. to a torque 221 Ibfeft Checkthe tightening of wheels one hour after the job They might get loose until they do not stay correct On new machines and when a wheel has been di sassembled or replaced check the nut torque of the wheels every 2 hours until they stay correct Always use tyres having the dimensions indicated in the vehicle registration card STANDARD GTH 5519 5519 S Dimensions front and rear 12 16 5 Load index 10 pr Rim 9 75x16 5 Wheel disc 8 holes DIN 70361 Pressure Psi 65 Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 23 February 2009 Section 4 Maintenance Procedures TABLE B 5 CHECKTHETIGHTENING OF THECARDAN SHAFT SCREWS Check every week that the screws of the Cardan shaft A are tight please refer to par Technical Specifications For the correct tightening torques 2 13 in section 2 enie G GTH 5519 GTH 5519 S Document 57 0009 0415 24 February 2009 Section 4 Maintenance Procedures Drr JH dcc J N geil TABLE C 4 5 TABLE C PROCEDURES Remove dipstick D engine level check Fill the engine through the hole of plug B see 1 ENGINE OIL AND RELEVANT technical specifications table 2 13 Check the oil is level with the hole Operate the starting motor and let the engine run for a
41. 0 379 380 515 320 433 16 220 298 300 406 310 420 420 569 350 4744 9 320 433 430 583 450 60 60 827 50 691 14 350 474 470 637 500 678 670 908 560 759 8 480 650 640 867 680 922 910 1233 770 1044 12 530 718 710 962 750 1016 990 1342 840 1139 7 590 800 790 1071 970 1315 1290 1749 100 1477 12 670 908 890 1206 1080 1464 1440 1952 120 1654 _7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074 12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620 12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067 METRIC FASTENER TORQUE CHART Size Class 8 8 Class 10 9 Class 12 9 DRY DRY DRY 3 3 i ik Eh le N O gt Po gt D oI a 05 D gt OO N coc m 4 Y lt oo c no NI o PO O1 rp B 5 B B A A OP Co OTN lt wo oO o A A NIB PO BID
42. 0415 GTH 5519 GTH 5519 S Description February 2009 DESCRIPTION 18 is used to reduce the pressures of the main valve section pilot lines and to move the main sliders of the main valve in a proportional manner with respect to their neutral position Slider 1 of the main valve controls the lifting cylinder 17 of the telescopic boom This cylinder has one single acting compensation valve with safety function Slider 2 ofthe main valve controls the attachment holding frame cylinder 19 of the telescopic boom This cylinder is equipped with a double acting compensation valve serving also as a safety valve Parallel to this cylinder there is the fork levelling compensation cylinder 20 also called balancing cylinder which is equipped with a special double acting compensation valve Inside this valve the one way valves are mounted in reversed manner with respect to the normal position to avoid the pressurisation of the cylinder when the rotation control of the attachment holding frame is activated Again inside this valve there are other two one way valves set at 72 psi serving as anti cavitation check valves 6 These valves deliver oil taken from the low pressure line of the transmission pump 2 tothe fork levelling compensation circuit when needed The two pressure relief valves 7 setat 4205 psi which protect the automatic fork levelling circuit during the boom lifting lowering phases and in case of overload on the attac
43. 14 35 5 Plug in Connector Spotlights work boom F19 10A FUSE Windscreen washer motor 43 37 5 Plug in Connector Rear left road light F20 10A FUSE ECO Multipurpose Instruments 12 X39 Plug in Connector Back up horn F102 20A FUSE Fan 12 Plug in Connector 5 In Out relay card FGI 50A FUSE Maxi fuse electric system power 11 XLA Plug in Connector Trasmission reverse mode solenoid valve FG2 40A FUSE Maxi fuse glow plugs 14 X41 Plug in Connector Windscreen cabin roof 61 Battery 14 X42 Plug in Connector Windscreen rear cabin G9 Alternator 11 X40 1 Plug in Connector Fuel level gauge Relay hig beam 12 X403 Plug in Connector Fuel level gauge K2 Relay low beam 575 Plug in Connector Rear right road light Relay horn X46 Plug in Connector Rear wheels aligned sensor Kh Relay optional 53 X49 Plug in Connector Parking brake solenoid valve K5 Relay securuty low pressure switch parking brake 22 5 Plug in Connector 21 way In Out relay card K6 Relay trasmission reverse mode 23 X51 Plug in Connector Four wheels steering solenoid valve KT Relay trasmission forward mode 22 X52 Plug in Connector Crab steering solenoid valve Relay starter enabling switch 11 53 Plug in Connector Front right road light K9 Timer 22 X54 Plug in Connector Front left road light K01 Preheating glow plugs 14 X51 Plug in Connector Road light switch K02 Relay start engine 13 x58 Plug in Connector Forward reverse switch
44. 3 639992 07 0705 0085 07 0705 0082 07 0700 0028 07 0738 0003 53 3001 5400 53 3001 5500 53 3001 6200 53 3001 6300 07 0701 0007 07 0701 0209 56 0016 0090 56 0016 0089 07 0704 0118 07 0704 0117 07 0704 0119 07 0703 0080 07 0703 0148 634973 07 0703 0071 07 0703 0060 56 0021 0078 07 0723 0042 09 0803 0400 09 0803 0401 07 0723 0486 09 4670 0004 07 0723 0446 Description Hydraulic oil filter inside the tank Hydraulic oil filter Engine air primary filter Engine air secondary filter Fuel filter Deutz Engine oil filter Deutz Fuel filter Perkins Engine oil filte Pekins Negative brake electrovalve solenoid Lock unlock attachment fork dumping electrovalve solenoid Boom hydraulic line continous oil electrovalve solenoid Steering electrovalve solenoids Axals cylinders seals kit Transmission pump seals kit Service pump seals kit Break pedal seals kit Fork movement cylinder seals kit Lifting cylinder valve seals kit Lifting cylinder seals kit Extension cylinder seals kit Fork balance cylinder seals kit Fork movement cylinder valve seals kit Fork balance cylinder valve seals kit Hydraulic oil return filter restriction indicator Cardan spider Perkins engine cooler collector Perkins engine cooler collector Deutz engine cooler collector Deutz engine cooler collector Transmission pump electrovalve coil Transmission pump electrovalve Speed switch Diesel engine ignition switch Red cap Push button S 4 c
45. 39 Section 4 Maintenance Procedures February 2009 TABLE D 0 6 CHANGE THE HYDRAULIC OIL FILTER IN THE TANK To change the hydraulic oil filter cartridge of the service circuits proceed as follows Stop machine on a level ground and engage the parking brake Remove the inspection hatch A and unscrew the oil filter B fitted inside the tank Checkthetankisclean then fita new filtering element and refit the inspection hatch Check the oil level within the tank Add new oil if necessary 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 Flow rate 1 STR 100 1 Filtering 60 code 09 4604 0004 PROTECT THE 42 Handling and disposing of used oils may be ruled local or national regulations Address to authorised waste centres When changing the oil drain it when it is still hot and the polluting substances are in suspension 40 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures s qu sc ss eger TABLE D D 7 HAVETHEHYDRAULIC SYSTEMCHECKED BY A SKILLED TECHNICIAN Every six months we recommend having the system checked to be sure it is in efficient working order In particular we recommend checking the max pressure of the main valve
46. 5 19 GTH 55 19 S oz Ayoedeo yue s u yue seul uopong Bunojid pue ainssaid pue ensse1d MOT SUONOUN seujeinsseid ___ uoissiusue eunssed 1 540102 LINDY isd 911 4eq 8 ainssaid _ yoayo 125 1 yoinus 51 3104456 ainsseid 13004 oneisoip H HW _ 81 22 98 3ueuieoe dsip onejsoJp H Sseid jasaiq Burusn 4 81 90 JO 3ueureoejdsip 9nejsoJp H uy suogoury woog 358 ainsseud ufu 1 dL uossiusuen W isd ensseJd x9euo L isd 8 pazunssaid YIM 1eyy
47. 55 a 8 15 3 5 3 4 z 515 a T 1 1 aan MDs 6 A ws x x Pol x x x x 13 4 9l F10 F12 WA 5A 10 02 01 m mL all nn fis PN 30 1 A 15 15 L 5 s LAL Iss K9 6 KITE K6777 13 13 lt RELAY CARD 8 7 81 gt M Ter 15 9 15 M EM gi B R15 15 ZNI 15 e 15 NI 2 FAN E COMPRESSOR 4 1 747 2 5 RELAY RELAY 26 1 31 30 oxn s o m xm m 100 101 3 N A ui P E a a 5 3 4 3 1 1 1 003 105 50 851 B45 41 pus SN PR PRA PA 7 B40 ICOMPRESSOR B46 M106 M196 4 Vins Vins 4 15 31 Gt a 3 31 S Se SS Sea lt lt 9 S 56 lt o ST SS ew E See SE se X lt Y SEF 5 S 594 SU S ROS lt 3S lt S gs QS S de 9 A TEREX COMPANY Document 57 0009 0415 GTH 5519 GTH 5519 S 7 Section 6 Schemes February 2009 SCHEMES REV A Page 3 5
48. 6 Payload and reach 2 27 Forks floating type 3 2 8 Diesel engine 3 2 9 Hydraulic system 3 2 10 Electrical system 3 2 11 Machine sound levels 4 2 12 Vibration levels 4 2 13 Refilling 4 2 14 Tightening torques 5 2 15 Hoisting instructions 6 2 16 Advice to renew flexible hoses 7 2 17 Lists of recommended spare parts 8 2 18 Machine paint colour 9 2 19 Checking the cylinder movement times 10 2 20 Hydraulic settings 11 1 Preliminary operations 11 2 Calibrating the boom main valve 11 2 1 Calibrating the main valve pressure control valve 11 3 Setting the hydromatik pump hydrostatic transmission 12 3 1 Calibration of the maximum pressure 13 4 Calibrating the power steering 13 5 Negative brake pressure 13 6 Service brake pressure 13 Document 57 0009 0415 GTH 5519 GTH 5519 S XV February 2009 TABLE OF CONTENTS Section 3 Rev Maintenance Inspections 1 3 1 Introduction 1 3 2 About this section 2 3 3 Maintenance table 3 3 4 Maintenance inspection report 6 Section 4 Rev Maintenance Procedures 1 4 1 Introduction 1 4 2 About this section 2 4 3 Table A procedures 3 A 1 Check the oil level within reduction gears power divider and differential gears 3 A 2 Check the tightening of the wheel bolts and the tyre pressure 5 A 3 Check the tightening of all bolts and nuts 6 A 4 Check the couplings for oil leaks 6 5 Inspect the Operator s manual 7 6 Inspect the decals and plates 7 A 7 Check the engine oil level 8
49. 9 5 Bridge crane payload 2000 Ibs Textile bridles or chains with hooks screws fixing the lower cover of the engine A TEREX COMPANY Document 57 0009 0415 GTH 5519 GTH 5519 S 11 Section 7 Repair Procedures February 2009 TABLE 003 Operation Removing the engine from the machine Table 003 GTH5519 GTH 5519 S 8 Remove the lower cover 9 With a screwdriver disconnect the fuel feeding and return piping held in position by the special hose clamps 10 Disconnect the throttle control cable removing the locking clip loosen the cable register with a 0 67 in wrench to pull out the cable 12 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Procedures TABLE 003 Operation Removing the engine from the machine Table 003 GTH5519 GTH 5519 S 11 Close the oil tank cocks 12 Disconnect the flexible hose of the silencer loosening the clamps with a 0 51 in wrench 13 Remove the manifold with a 0 67 in wrench 14 Disconnect all the electrical wires connected to the engine and namely oil pressure bulb electrical stop water temperature bulb the three alternator connections starter motor ground between chassis and engine the two coils of the transmission pump solenoid valve 15 Disconnect the radiator remove the clamps fixing the sleeves to the radiator Document 57 0009 0415 GTH 5519 GTH 5519 S 13 Section 7 Repair Procedures February 2009 TAB
50. BETWEEN PINS AND BUSHINGS IN ALL JOINTS Every 6 months check the machine randomly to be sure the backlash between pins and relevant bushings on the joints is not too high If you have to change some parts please refer to the spare parts catalogue enclosed with the technical literature of the machine Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures TABLE D D 5 CHANGE THE HYDRAULIC OIL FILTER To change the hydraulic oil filter element proceed as follows 1 Stop the machine on a level ground and engage the parking brake 2 Place a container of suitable size under the filter to collect any oil leaks 3 Remove the filter 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 PROTECT THE 7 ENVIRONMENT Handling and disposing of used oils may be ruled by local or national regulations Address to authorised waste centres 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 Flow rate 1 MPS 150 Filtering 10 u code 09 4604 0001 When changing the drain it when it is still hot and the polluting substances are in suspension Document 57 0009 0415 GTH 5519 GTH 5519 S
51. CTION The tables on the following pages should be used to find and rectify problems that can occur when using the machine Prepare adequate tools and especially a voltmeter and a pressure gauge to carry out the checks explained on next pages Theinitials ofthe electrical and hydraulic parts indicated in the following tables are given to help you find such parts on the schemes and diagrams in chapter 6 The tables should be read as follows once you have identified the problem search this problem in the problem column analysethe possible causes explained inthe causes column proceed with the check or replacement according to the instructions provided in the solutions column check that the machine runs well if the problem cannot be eliminated check again all indications in the causes column and proceed accordingly For any further information contact the GENIE Service Centre 2 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 5 Problems Causes Solutions E PROBLEMS CAUSES SOLUTIONS 5 3 PROBLEMS CAUSES SOLUTIONS 5 3 1 Hydraulic faults Problem Cause Solution The machine does not move neither forwards nor in reverse Low pressure of the drive pump DA valve damaged Hydraulic oil filter restricted Re calibrate the pump see sec 2 Check the operation and replace the valve if necessary Change the oil filter The boom does not move Low press
52. D 4 Check the backlash between pins and bushings in all joints D 5 Replace the hydraulic oil filter cartridge of the drive pump return suction line D 6 Change the cartridge of the hydraulic oil filter in the tank D 7 Have the hydraulic system checked by a skilled technician D 8 Change the cartridge of the engine air filter D 9 Clean or replace if nececessary the air filter in the cab D 10 Change the engine oil and replace oil filter and fuel filter every 500 hours or one year TABLEE Every 1000 working hours or yearly E 1 Change the internal element of engine air filter E 2 Change the oil in front and rear differential boxes and power divider E 3 Change the oil in the four wheel reduction gears E 4 Change the hydraulic oil Every 2000 working hours or every 2 years F 1 Change the engine coolant TABLE G At 6000 hours or 5 years and subsequently every 2 years G 1 Checking the state of the structure Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 5 Section 3 Maintenance Inspections MAINTENANCE INSPECTIONS 3 4 MAINTENANCE INSPECTION REPORT During the first 10 working hours 1 Oillevel within reduction gears po Serial number wer divider and differential gears A 2 Tightening of the wheel bolts Date A 3 Tightening of all bolts and n
53. EADS TO THE BATTERY TERMINALS Check the cable clips are well secured to the battery terminals To tighten the clips always use a box wrench never pliers 4 DANGER 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 C 6 CHECKTHEAIRSUCTIONHOSE BETWEEN ENGINE AND FILTER Check the state of all the rubber sleeves A of the air suction line between engine and filter every month If youuse the machine continuously for several days check these sleeves as well as the hose clamps more frequently 28 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures C 7 CHECK THE CYLINDER CHROMIUM PLATED RODS Visually check the cylinder rods A for scoring every month For this operation fully extend all of the cylinders and check that their rods are intact In case of problems replace the cylinder TABLE C C 8 CHECK THE HYDRAULIC LINES Every month do a random check of the oil dynamic hoses to be sure they are not worn In particular we recommend checking the hoses located near moving mechanical parts as they could rub against such parts and get damaged Replace any worn hoses immediately before using the machine again Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 29 S
54. ENTIAL GEARS AND POWER DIVIDER To check the oil level in the wheel flow dividers Stop the machine on a level ground and ensure the parking brake is engaged and plug A finds on the horizontal axis Clean the plug all around then remove it with a 0 47 hex head wrench and check if oil is level with the hole necessary add new oil through hole A until it is level Refitthe plug 49 PROTECT THE ENVIRONMENT 4 Place a container of suitable size under the plug To check the oil level in the front and rear differential gears Stop the machine on a level ground and engage the parking brake Using a 0 39inc hex head wrench unscrew plug A 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 A PROTECT THE 42 Place a container of suitable size under the plug To check the oil level in the power divider Stopthe machine on a level ground and engage the parking brake Using a 0 39 hex head wrench unscrew plug A and check if oil is level with the hole f necessary add new oil through hole A until it is level the plug PROTECT THE 7 ENVIRONMENT Place a container of suitable size under the plug 26 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009
55. February 2009 TABLE C C 11 ADJUSTTHEPLAY OF THESLIDINGPADS 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 Adjusting the pads Removeorloosenthe screws fixing the padsin relation to type of shims used with or without slots Fit the necessary amount of shims If the residual thickness of the pad is insufficient or near the maximum wearing limit renew the pad Tighten the 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 22 Screws M14 Ipfeft 36 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 of the plastic layer with respect to the iron bush fixing the block is equal or inferior to 0 039 inc Max wearing thickness Minimum 0 039 inc 32 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures sd oec TABLE C C 12 GREASE THE SLIDING PARTS OF THE BOOM SECTIONS Check every month
56. GTH 5519 5 Before disconnecting any flexible hoses label them for an easier reassembly Operation 1 Disconnect the delivery and return pipes with a 1 41 in wrench 2 Disconnect all users with 0 94 in wrench 3 Disconnect all pilot systems with a 0 67 in wrench 4 Remove the 3 fixing screws with two 0 51 in wrenches screw lock nut 26 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Procedures TABLE 009 Operation Renewing the slide pads of the telescopic table 009 boom GTH5519 GTH 5519 S P Standard tools ADJUSTING THE PLAY WITH SHIMS If the play between the boom sections is too great 0 078 in or more proceed in shimming the guide pads of the boom sections Usually the guide pads subject to premature wear are bottom pads of the fixed section top pads of the telescope Proceed as follows 1 Lower the boom to the ground and ensure the telescope is fully retracted 2 With a thickness gauge check the play of all pads After adjustment the minimum play in the narrowest point must be 0 019 0 039 7 87 3 Measure the thickness of the slide pads The 2 36 TA value of the bottom pads of the fixed section and of the top pads of the telescope must be at least 0 51 in For the remaining pads the minimum Thickn 0 039 0 078 in if needed 2 36 1 18 thickness must never be less than 0 35 in 4 fthethickness reaches the m
57. Genie A TEREX COMPANY Serial number range GTH 5519 ew 5519 Part 57 0009 0415 February 2009 Service Manual February 2009 EEE M s Ms Msnm Qe Intentionally blank page 2 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Introduction Introduction Important Read understand and obey the safety rules and operating instructions in the GTH 55 19 Operator s Manual part n 57 0009 0412 before attempting any maintenance or repair procedure This manual provides the machine owner and user with detailed information on the scheduled maintenance It also provided qualified service technicians with infromation on troubleshooting and repair procedures Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills as well as specific tools and equipment In these instances we strongly recommend letting service and repair the machine at an authorized TEREXLIFT Service center Technical Publications No part of this publication may be reproduced stored retrieval system ortransmitted in any form orby any means without prior written permission from TEREXLIFT srl In pursuing a policy of constant quality improvement TEREXLIFT srl reservesthe rightto make changes atany time and without undertakin
58. H 5519 GTH 5519 S Section 6 Schemes February 2009 SCHEMES REV A Page 5 5 1 2 3 4 5 AIR CONDITION SWITCH CABIN FAN SWITCH HEATING FAN WORK LIGHT WORK FLASHING CABIN SWITCH SPOTLIGHT BEACON INTERIOR T LIGHT 45 gt 45 e t 2 ES PES d 5 gt 4 119 4 57 Yo n SJA st L3 E 5 2 3 E2 3 4 4 4 9 2 x 21 1 1 1 10 2 3 X5 XT Ur xs X6 X6 is X6 X6 X6 25 gt 45 5 e 1 1 5 ds Ay ay Ay 1 x xB popolol2o 0002020 777 F3 FAS 25A PAU 10 Ki 415 15 15 RELAY CARD re 10 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 6 Schemes REV A SCHEMES 6 4 1 Wiring diagrams Component description 1 e 3 4 5 PART LEGEND Item Description S
59. LE 003 Operation Removing the engine from the machine Table 003 GTH5519 GTH 5519 S 16 Disconnect the hydraulic pipes of the radiator 9 PROTECT THE ENVIRONMENT Before disconnecting the hydraulic piping place containers of suitable size underneath to prevent oil spillage Plug all disconnected parts to prevent dust and impurities from entering the circuit They can cause serious damage disconnect the two drain lines of the hydraulic pump with a 1 41 in wrench disconnect the suction line of the hydraulic pump with a 1 96 in wrench disconnect the low pressure line duct with a 0 74 in wrench disconnect the four flanges which connect the drive pump to the drive motor with a 0 31 in Allen wrench disconnect the suction line of the service pump with a 0 31 in Allen wrench ref A disconnect the delivery line ducts of the hydraulic drive and the main valve with a 1 41 in wrench and a 0 94 in wrench disconnect the load sensing signal line from the hydraulic drive with a 0 67 in wrench Once all operations have been performed make sure that all the electrical wires and the hydraulic lines are disconnected from the motor m n 17 Remove the four screws two on the front and two at the back of the vibration damping brackets with a 0 86 in wrench 14 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Procedures TABLE 003 Operation
60. NISON HF 1 DIN 51524 part 2 e 3 4 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 2 Technical Specifications 214 TIGHTENING TORQUES TECHNICAL SPECIFICATION Document 57 0009 0415 5 8 3 4 7 8 1 14 15 SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength DRY LUBED in Ibs Nm in ibs Nm in ibs Nm ya 20 80 9 too 10 124 140 130 147 __28 90 101 120 135 120 135 160 18 140 15 8 bum ue ft lbs Nm ft ibs Nm ft lbs ft lbs ft lbs sie 18 B vo 7 2 te 339 2 284 24 14 19 19 257 20 271 27 366 _ 24 325 16 29 332 31 2 33 47 4 596 38 55 24 26 352 35 474 37 501 49 664 43 583 746 14 37 501 49 64 50 678 70 947 61 827 _ 20 41 555 55 745 60 813 80 1084 68 921 12 L 13 5 773 75 1016 80 1084 110 149 93 16 _ 20 64 867 85 15 90 122 120 162 105 142 9 46 12 80 1084 110 149 120 162 150 203 130 176 18 90 122 120 162 130 16 170 230 140 189 114 110 149 150 203 160 217 210 284 10 24 18 130 176 170 230 180 244 240 325 200 271 _ 10 200 21 270 366 28
61. ORKS Before injecting fresh grease thoroughly clean the intervention zone to avoid that mud dust or other matters can mix with the lubricant and reduce or annihilate the lubrication effect Smear pin A with grease to help the forks slide on it Recommended grease graphitized grease tipo GR NG Document 57 0009 0415 GTH 5519 GTH 5519 S 13 Section 4 Maintenance Procedures February 2009 TABLE A A 13 GREASE ALL JOINTS OF THE BOOM THE REAR AXLE SHAFT JOINT THE TRANSMISSION SHAFTS THEFRONT AND REAR AXLES AND ANY EQUIPMENT OF THE MACHINE 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 i thesymbol represents the points to be greased by a pump the symbol EN represents the points to be greased by a brush
62. SAFETY PRECAUTIONS During work but especially when maintaining or repairing the machine operators must wear suitable protective clothing and equipment e Overalls or any other comfortable garments Operators should wear neither clothes with large sleeves nor objects that can get stuck in moving parts of the machine Protective helmet when working under or in the vicinity of suspended load Protective gloves Working shoes Breathing set or dust mask Ear protectors or equivalent equipment Goggles or facial screen Use only type approved protective equipment in good condition 4 DANGER Read and understand the following safety instructions before servicing the machine The following list contains safety rules which must absolutely be obeyed to prevent accidents and injuries 1 4 1 WORKING AREA sure the area all around the machine is safe Always be aware of potential risks e During work keep the working area in order Never leave objects scattered they could hinder the machine movements and represent a danger for personnel 1 4 2 PRECAUTIONS DURING WORK Do not walk or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only e Keep the machine handholds and access steps always clean from oil grease or dirt to prevent falls or slips e When entering leaving the cab or other raised parts always face the machine never turn the back e When carrying out oper
63. TH 5519 6 4 Fix the cylinder with a textile bridle connected to the bridge crane to support its weight 5 Place a container of suitable size under the hydraulic piping before disconnecting 49 PROTECT THE LM ENVIRONMENT Used oils must be handled and disposed of according to local regulations Address to legally authorised centres 6 With a 0 94 in wrench disconnect two hydraulic hoses from the blocking valve then plug the disconnected connectors to prevent dust and impurities from entering the circuit 7 Drive out the lower pin 8 Unscrew and extract the screw fixing the pin with two 0 51 in wrenches 9 Knock out the pin using a plug of soft material aluminium copper wood etc and extract it through the hole on the frame 10 Remove the cylinder from the machine using the bridge crane 10 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Procedures Operation Removing the engine from the machine Table 003 Operation 1 Open the engine cover 2 Secure the cover with a belt or hold it raised by hand so it cannot move 3 Using two 0 51 in wrenches remove the two screws of the spring 4 Again with two 0 51 in wrenches loosen the three screws that secure the cover to the frame 5 Remove the upper cover 6 Disconnect the two battery leads and remove the battery using a 0 51 in wrench 7 With two 0 67 in wrenches remove the six TABLE 003 GTH5519 GTH 551
64. ace a check in the R box Legend Y yes acceptable remove from service R repaired Genie Every 1000 working hours E 1 Inner element of engine air filter E 2 Oil of the differential casing and the power divider E 3 Oil in the four wheel reduction gears E 4 Hydraulic oil 6 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 3 Maintenance Inspections Imc ccc cct cati MAINTENANCE INSPECTIONS Model Every 2000 working hours F 1 Changethe engi lant Serial number Change the engine coolan Date _________________________ At6000 working hours Hour meter 6 1 Checking the state of the structure Machine owner Inspected by Inspector signature Inspector title Inspector company Instructions Make copies of this page to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Every 10 hours A Every 50 hours A B Every 250 hours A B C Every 500 hours A B C D Every 1000 hours A B C D E Every 2000 hours At 6000 hours G Place a check in the appropriate box after each inspection procedure is completed Use the maintenance tables in this sec tion and the step by step procedures in section 4 to learn how to perform these inspection f any inspection receives an tag and remov
65. achine regularly or occasionally e g for maintenance or transport shall have the following requisites 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 rules regulations and safety precautions They shall be careful and sensible for their own as well as for the others safety and shall desire to carry out the work correctly and in a responsible Way emotional they shall keep calm and always be able to evaluate their own physical and mental conditions training they shall read and familiarise with this handbook its enclosed graphs and diagrams the identification and hazard warning plates They shall be skilled and trained about the machine use Itisrecommendedto take part atleastone technical training course organised by GENIE Assistance Office Ordinary and extraordinary maintenance of the machineare quite complex from a technical point of view and should be performed by an authoirsed service centre Document 57 0009 0415 2009 Section 1 Safety Rules SAFETY RULES 1 3 1 PERSONAL PROTECTIVE EQUIPMENT 1 4 GENERAL
66. als and plates in good condition is mandatory for safe machine operation Decals alert operators and personneltothe many possible hazards associated with using this machine Anillegible decal willfairto alert personnel of a procedure or hazard and could result in unsafe operating conditions refer to the labels and warning plates applied on the machine section in the Operator Manual and use the decal list and illustrations to determine that all decals and placards are in place inspect all decals for legibility and damage Replace any damaged or illegible decal immediately Contact GENIE Service Centre if replacement decals are needed Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 7 Section 4 Maintenance Procedures February 2009 TABLE A A 7 CHECK THE ENGINE OIL LEVEL To check the engine oil level e Park the machine on flat ground stop the engine and check the parking brake is engaged e Remove dipstick A and check if oil reaches the max mark B e Remove dipstick A once again and check if oil reaches the max mark B Refit the plug e If oil is below this mark remove plug C and pour new oil into the engine using the special appliance D 8 5519 551 9 5 Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures A 8 CLEAN THE AIR SUCTION FILTER Clean the engine air filter every 10 hours Stop
67. alve controlling the parking brake Genie 12 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 2 Technical Specifications 3 1 CALIBRATION OF THE MAXIMUM PRESSURE Do this operation with extreme caution The proper functioning of pump and transmission depends on this calibration Set the forward neutral reverse selector to the forward position Run the engine at maximum speed and check the high pressure value on the manometer TP2 If this value is less than 6235 psi increase the pressure to 6235 psi by means of the pressure cut off valve E e Remove the manometers and test the machine Genie 4 TECHNICAL SPECIFICATION CALIBRATING THE POWER STEERING Fit a coupling complete with mini socket Z in the position shown in annex 1 Fit a 0 3620 psi pressure gauge to the mini socket 7 Select the front axle steering mode Move the steering cylinder to stroke end and make sure the value of the power steering A is 2465 psi If the value is less tighten valve X if the value is greater loosen the valve Note To gain access to valve X remove the protection cap see annex 1 NEGATIVE BRAKE PRESSURE Connect a 0 868 psi manometer to the mini socket Start the engine and unlock the brake by operating the relevant button S in the driving place The pressure gauge shall display a value of 362 psi approx given by the supercharge of the drive pump
68. ap Yellow cap 5A fuse 10A fuse 15A fuse 25A fuse 50A big fuse Timer relay Mirror Left mud guard Right mud guard Accelerator cable Thermal engine antivibrant element Cab roof wiper blade Genie February 2009 Q ty es tt COD ND ND PO ND PD YD ND BSB BH SB SB Be 2 2 2 26 24 4 se oe oe os GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 2 Technical Specifications Code 07 0723 0037 56 0017 0037 56 0017 0044 56 0017 0048 56 0017 0035 56 0017 0049 54 0702 0013 54 0702 0000 54 0702 0001 54 0702 0002 54 0702 0005 04 4210 0019 04 4210 0018 07 0704 0133 07 0704 0042 07 0703 0319 07 0703 0175 07 0703 0305 07 0703 0304 07 0703 0306 Description Frontal window wiper blade Lights cab fan switch Brake road jobsite work light switch Air conditioning continous oil switch Switch 3 steering ways switch Pad Pad Pad Pad Pad Quick coupling female 1 2 Faster Art 2FFI12GASF Quick coupling male 1 2 Faster Art FFI12GASM Handle joystick Distributor pressure control valve Rear stop and position lights Rear turn signal lamp 3 W front lamp 40 50 W front lamp 21 W front lamp 2 18 MACHINE PAINT COLOUR GENIE machines BLUE GENIE GREY GENIE BLACK RAL 9500 Document 57 0009 0415 GTH 5519 GTH 5519 S TECHNICAL SPECIFICATION Q ty
69. ations at hazardous heights over 3 meters from the ground always use type approved safety belts or fall preventing devices Donotenter leave the machine when it is running e Before servicing the engine let its parts cool down not leave the driving place when the machine is running e Neither stop nor carry out interventions under or between the machine wheels when engine is running When maintenance in this area is needed stop the engine engage the parking brake and chock the wheels to prevent accidental movements Donotcarry 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 ensure they are properly connected and efficient Donotcarry out interventions on electric components with voltage over 48V Genie TEREX COMPANY 5 Document 57 0009 0415 GTH 5519 GTH 5519 S xiii Section 1 Safety Rules February 2009 SAFETY RULES e Do not connect wet plugs or sockets e Signs and stickers shall never be removed hidden or become unreadable e Except for maintenance purposes do not remove safety devices covers guards Should their removal be necessary stop the engine remove them with the greatest care and always remember to refit them before starting the engine and using the machine again e Aleays stop the eng
70. e Repairany damage or malfunction before operating machine Unless otherwise specified perform each procedure with the machine in the following configuration machine parked a flat level surface boom the stowed position key switch in the OFF position with the key removed Before troubleshooting Read understand and obey the safety rules and operating instructions printed in the Operator Manual of the machine Besure that all necessary tools are available and ready for use Read each appropriate flow chart thoroughly Pay special attention to the following warnings 4A DANGER Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement Electrocution hazard Contact with electrically charged circuits may result in death or serious injry Remove all rings watches and other jewerly Genie A TEREX COMPANY Spraying hydraulic oil can penetrate and burn skin loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Perform all troubleshooting on a firm level surface Two person will be required to safely perform some troubleshooting procedures Document 57 0009 0415 GTH 5519 GTH 5519 S 1 Section 5 Problems Causes Solutions February 2009 Emm MM R EE PROBLEMS CAUSES SOLUTIONS 5 2 ABOUT THIS SE
71. e cleaned using compressed air or washed with water and or solvents Document 57 0009 0415 GTH 5519 GTH 5519 S 43 Section 4 Maintenance Procedures February 2009 TABLE D D 10 CHANGE ENGINE OIL OIL FILTER AND FUEL FILTER EVERY 500 HOURS OR EVERY YEAR WHICHEVER OCCURS FIRST Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin Drain the while the is warm This allows waste particles that are suspended in the oil to drain As the oil cools the waste particles will settle to the bottom of the crankcase and cannot be drained through hole A Park the machine on a level surface Unscrew plug B engine filling plug Place a collecting tray under plug A and with an appropriate wrench unscrew this plug and allow the oil to drain into the tray If the engine has two drain plugs allow the oil to drain off from both Once oil has been drained clean plug A with care and refit it If necessary replace the plug gasket Unscrew filter C with an appropriate tool Remove it from its seat Check the filter surface and the filter housing base are clean Apply a thin film of clean engine oil to the seal of the filter Install the filter by hand Remove dipstick D engine level check Fill the engine through the hole of plug B see technical specifications table 2 13 Check the oi
72. e down Seals rod and liner of the fork tilting cylinder worn out Leakage in the cylinder block valve Dismantle the cylinder and check and replace any defective parts Check the leakage remove the valve and rectify or replace The fork tilting is not efficient The seals of the fork levelling cylinder are damaged Leakage in the cylinder block valve Line from main valve to block valve defective Safety valves of the main valve maladjusted or damaged Fit a new kit of seals and check the tightness of the cylinder Check the valve operation if necessary clean or change the valve Check the hydraulic line carefully and replace any defective pipelines Check the efficiency of the safety valve fitted to the ports of the main valve If necessary proceed with the clibration or replacement The boom extension is not efficient The seals of the internal boom extension cylinder are damaged Cylinder rod damaged Leakage in the cylinder block valve Hydraulic line defective Main valve damaged Fit a new kit of seals and check the tightness of the cylinder Check the rod condition Check the valve operation if necessary clean or replace the valve Check the hydraulic line carefully and replace any defective pipelines Check the efficiency of the main valve and replace if necessary Document 57 0009 0415 GTH 5519 GTH 5519 S Section 5 Problems Causes Solutions
73. e the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 7 Section 3 Maintenance Inspections February 2009 Intentionally blank page 8 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures 4 1 INTRODUCTION Document 57 0009 0415 Maintenance inspections shall be completed by person trained and qualified on the maintenance of this machine Scheduled maintenance must be carried out at the intervals indicated in the MAINTENANCE REPORT Failure to properly complete each inspection when required may cause death serious injury or substantial machine damage Immediately tag and remove from service a damaged or malfunctioning machine Repairany machine damage or malfunction before operating machine Unless otherwise specified perform each procedure with the machine in the following configuration machine parked on a flat level surface boom in the stowed position key switch in the OFF position with the key removed GTH 5519 GTH 5519 S 1 Maintenance Procedures Section 4 Maintenance Procedures February 2009 MAINTENANCE PROCEDURES 42 ABOUT THIS SECTION This section describes the maintenance interventions to becarried outonthe machine accordingto the indica
74. eck the efficiency or replace Check the efficiency or replace Reconnect or replace the wiring Check the efficiency or replace No steer selection Fuse F9 blown Steer selector damaged Coils of the steer selection solenoid valve damaged Broken or damaged wiring Change the fuse Check the efficiency or replace the Switch if necessary Check the coils replace if necessary Reconnect or replace the wiring Hydraulic oil thermometer defective Indicator damaged Temperature sensor defective Broken or damaged wiring Change the part Check or replace the sensor Reconnect or replace the wiring The parking brake lamp does not come on Dashboard instrument damaged Broken or damaged wiring Change Reconnect or replace the wiring The fuel gauge does not work Dashboard instrument damaged Fuel sensor defective Broken or damaged wiring Change Check and replace the sensor if necessary Reconnect or replace the wiring Document 57 0009 0415 GTH 5519 GTH 5519 S Section 5 Problems Causes Solutions ssl PROBLEMS CAUSES SOLUTIONS February 2009 Problem Cause Solution The engine coolant thermometer does not work Indicator defective Temperature sensor defective Broken or damaged wiring Change the part Check and replace the sensor if necessary Reconnect or replace the wiring High hydraulic oil temperature The joystick d
75. ection 4 Maintenance Procedures February 2009 TABLE C C 9 CHECK THE ELECTRIC CABLES Every month do a random check of the electrical cables to be sure they are not damaged In particular we recommend checking the cables located near moving mechanical parts as they could rub against such parts and get damaged Replace any worn cables immediately before using the machine again Tav 605040 pos 1 30 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures H P N cQ ge TABLE C C 10 CHECK THE WEAR OF 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 Pads must compulsorily be replaced if the residual thickness of the plastic layer with respect to the iron bush fixing the block is equal or inferior to 0 039 wearing thickness Minimum 0 039 inc Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 31 Section 4 Maintenance Procedures
76. ective Check the pump operation and bleed the system if necessary Check the operation of the brake disks of the front axle When the engine is stopped the lifting cylinder does not support the boom Block valves damaged or dirty Cylinder seal defective Check the efficiency of the valves replace if necessary Replace the seal When the engine is stopped the cylinder does not support the forks Block valves damaged or dirty Cylinder seal defective Check the efficiency of the valves replace if necessary Replace the seal When the engine is stopped and the boom is high the extension cylinder moves in When the load is lifted the fork cannot be levelled Block valves damaged or dirty Cylinder seal defective Seals of the levelling cylinder worn out Shockproof valves of the main valve dirty or maladjusted One way valves of the levelling cylinder dirty or damaged Check the efficiency of the valves replace if necessary Replace the seal Dismantle the cylinder and replace the seals Remove the valves dry clean or replace if damaged and re calibrate Remove the valves dry clean or replace if damaged and replace in their seats GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 5 Problems Causes Solutions P M MM 1 PROBLEMS CAUSES SOLUTIONS Problem Cause Solution When the max load is applied forks mov
77. ed air Direct a jet of compressed air toward radiator C paying attention not to damage its fins Remove any loose particles of dirt with some wa ter Cleaning using water under pressure or steam Spray radiator C with a cold commercial detergent and wait for at least 10 minutes to allow the detergent to react Wash radiator C using a jet of water or steam The core fouling depends on the dust of the outside environment and the presence of oil and fuel leaks in the motor area It is therefore advisable to remove oil and fuel leaks immediately in case of very dusty environments 10 GTH 5519 GTH 5519 S DEUTZ MODEL PERKINS MODEL Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures TABLE A A 10 CHECK THE HYDRAULIC OIL LEVEL IN THE TANK 4 DANGER Fine jets of hydraulic oil under pressure can penetrate the skin Do not use your fingers but a piece of cardboard to detect oil leaks Stop the machine on a level ground and make sure the parking brake is engaged Make sure the boom of the machine is fully retracted and lowered Check the hydraulic oil level visually through the special level B fitted into the tank When necessary add new oil through filler A Check the oil level with the machine in the travel position tha is boom lowered and telescopes fully in 49 PROTECT THE we ENVIRONMENT Handling and d
78. emes February 2009 SCHEMES 11 16 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 6 Schemes SCHEMES Legend of the hydraulic components Description radiator Quick fit couplings for attachment lock unlock control 17 Boom lifting lowering cylinder c lt gt Drvingcad 0 Document 57 0009 0415 GTH 5519 GTH 5519 S 17 Section 6 Schemes February 2009 eee Intentionally blank page 18 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Procedures LLL Repair Procedures 7 1 TIME SCHEDULE Job Operators Expected needed time h 1 30 1 00 1 00 1 00 1 00 1 00 1 00 2 30 change the ignition key change the speed switch change the light and horn switch change the joystick change the fork locking releasing pushbutton change the fork locking releasing red pushbuttons change the brake pump change the boom lifting cylinder change the boom lifting cylinder kit complete overhaul 1 30 change the block valve of the boom lifting cylinder 0 30 change the cylinder inside the boom 2 30 change the extension cylinder kit inside the boom 1 30 change the block valve of the extension cylinder inside the boom change the fork pitching cylinder change the fork pitching cylinder kit change the valve of the fork pitching cylinder change the attachment locking cylinder change the attachment locking cylinder kit change the block val
79. ench and check if oil is level with the hole f necessary add new oil through hole A until it is level Refit the plug 9 PROTECT THE Ge ENVIRONMENT Place a container of suitable size under the plug TABLE A To check the oil level in the front and rear differential gears Stop the machine on a level ground and engage the parking brake Loosen level plug A with a 0 39inc hex head wrench and check if oil is level with the hole Ifnecessary add new oil through the hole of the level plug until it comes out Refit and tighten plug A PROTECT THE ENVIRONMENT Place a container of suitable size under the plug Geni enie Document 57 0009 0415 GTH 5519 GTH 5519 S 3 Section 4 Maintenance Procedures February 2009 pr H i TABLE A To check the oil level in the power divider Stop the machine a level ground and engage the parking brake Clean plug A all around then remove it with a 0 47inc hex head wrench and check if oil is level with the hole f necessary add new oil through hole A until it is level Refit the plug 49 PROTECT THE ENVIRONMENT Place a container
80. enie 16 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures Open the cap of the feeding tank D Open the tap of the compressor F which has been previously connected to mini socket TP5 Check that air flows out of valve B As soon as oil without air bubbles starts flowing out of this valve close the same e Check thatthe fluid in tank E reaches the recommended level Close the tap of the compressor Disconnect the hose from mini socket TP5 Test the efficiency of the braking system In order to bleed the service brake circuit WITHOUT A COMPRESSOR for this operation two service technicians are needed one the driving place and the other near the drain valve B 1 Fill tank D with oil 2 With the machine stopped step down on the brake pedal 5 6 times 3 Hold the pedal pressed down and slowly unscrew valve B Close the valve as soon as oil mixed with air starts flowing out 4 Ease up the brake pedal 5 Repeat steps 2 3 and 4 until oil without air bubbles starts flowing out of the valve 6 Testthe efficiency of the braking system TABLE A TO BLEED THE CIRCUIT OF THE PARKING BRAKE DO THE FOLLOWING Start the diesel engine Press pushbutton C to unlock the parking brake Slowly unscrew valve A and close the same as soon as oil mixed with air starts flowing out Repeat until oil without air bubbles starts flowing out
81. enoid valve 15 FI 10A FUSE Warning light 21 X13 p Plug in Connector Air conditioning compressor 23 F2 15A FUSE High beam 42 13 5 Plug in Connector conditioning compressor 23 15A FUSE Low beam 42 xu Plug in Connector 2 way Power from battery 1 Fi 15A Horn X15 Plug in Connector 15 way Power to engine F5 10A FUSE Road jobsite switch 33 181 Plug in Connector Stop light pressure switch 45 F6 5A FUSE Position light front right and rear left 4 4 X18 2 Plug in Connector Stop light pressure switch 45 F7 5A FUSE Position light front left and rear right 4 4 196 Plug in Connector conditioning fan motor 22 F8 10A FUSE Optional 11 2 Plug in Connector 21 way In Out relay card 22 F9 10A FUSE Steering mode units 32 X20 Plug in Connector Joystick F10 5A FUSE Optional 23 X21 Plug in Connector 2 way In Out relay card 25A FUSE Heater fan switch 53 X22 Plug in Connector Windscreen washer motor F12 10A FUSE Forward reverse switch 24 25 Plug in Connector ECO Multipurpose Instruments FB 15A FUSE Spotlights work 53 X26 Plug in Connector 12 way In Out relay card Fis 10 FUSE Rear wheels aligned sensor 3 2 X27 Plug in Connector 31 way In Out relay card F15 10A FUSE Flashing beacon light 54 X2d Plug in Connector 3 way Diode 16 10A FUSE Stop light 45 x3 Plug in Connector 17 way Relay card F17 10A FUSE Road light m X34 Plug in Connector Stop engine F18 10A FUSE Optional
82. eto thermal opening 7 Thermal closure J A Thermal opening Exchange lt NC proximity gt NO proximity gt NO mechanical NC mechanical Selector bi Selector2 Document 57 0009 0415 GTH 5519 GTH 5519 S 5 Section 6 Schemes February 2009 SCHEMES 6 4 WIRING DIAGRAMS REV A Page 1 5 1 2 3 4 9 GAUGES CLUSTER ei ENGINE IGNITION KEY 21 7 5 F102 20A e as ee te a vod ad sd debeo ebd 2b a a oda 11 C 21 E 21 31 ZM 2i HN ES 1 6i 11 GLi 8 ti 5 5 41 8 2 1 1 3 20 x x x2 30 15 D 12 F20 TA 21 mL v 03 04 05 15 Le a 7 E 23 15 15 0 F8 4 23 10 F18 RELAY CARD 6 9 1 10 X3 x X3 2 B RI5 oy 2 5 5 g 5 Py m t 1 1 6 0 2 15 n 3 1 3 5 X15 X15 X15 xt X103 xt kw Yu Y p
83. f the cylinder using two 0 74 in wrenches Genie 000 Document 57 0009 0415 GTH 5519 GTH 5519 S 7 Section 7 Repair Procedures February 2009 ea TABLE 001 Operation Cylinder disassembly Table 001 Boom raising cylinder GTH5519 GTH 5519 S 18 Knock out the pin using a plug of soft material aluminium copper wood etc and extract it through the hole on the frame 19 Lower the boom onto the adjustable stand to remove the slinging chains 20 Sling the cylinder with a textile bridle and remove it the machine using the bridge crane To reassemble the cylinder repeat the steps above in reversed order Remember to set the circuit under pressure before releasing the bridge crane 8 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Procedures TABLE 002 Operation Cylinder disassembly Table 002 GTH5519 GTH 5519 S Fork balance cylinder Bridge crane payload 2000 Ibs Standard tools Textile bridles or chains with hooks Adjustable stands Operation 1 Release the attachment 2 Remove the screw fixing the rod pin with two 0 51 in wrenches 3 Knock out and extract the pin using a plug of soft material aluminium copper wood etc Document 57 0009 0415 GTH 5519 GTH 5519 S 9 Section 7 Repair procedures February 2009 M TABLE 002 Operation Cylinder disassembly Table 002 Fork balance cylinder GTH5519 G
84. few seconds Startthe engine andletit run AT IDLE and LOADLESS Hot oil and hot components can cause personal for some 2 minutes injury Do not allow hot oil or hot components to Stop the engine wait for a few minutes and then B check that oil level reaches the MAX mark on the Drain the crankcase while the oil is warm This dipstick D allows waste particles that are suspended in the oil to drain As the oil cools the waste particles will settle to the bottom of the crankcase and cannot be drained through hole A Park the machine on a level surface For the engine maintenance please refer to the Unscrew plug B engine filling plug specific Operator handbook code SLBU 7853 00 supplied with the machine Place a collecting tray under plug A and with an appropriate wrench unscrew this plug and allow the oil to drain into the tray If the engine has two drain plugs allow the oil to drain off from both Once oil has been drained clean plug A with care and refit it If necessary replace the plug gasket Unscrew filter C with an appropriate tool Remove it from its seat Check the filter surface and the filter housing base are clean Apply a thin film of clean engine oil to the seal of the filter Install the filter by hand Document 57 0009 0415 GTH 5519 GTH 5519 S 25 Section 4 Maintenance Procedures February 2009 TABLE C C 2 CHECKTHEOILLEVELINTHEDIFFER
85. flow Variable displacement pump with one direction of flow Variable displacement pump with flow regulator CYLINDERS Single acting cylinder Single acting cylinder with spring return Double acting cylinder Double acting cylinder with bilateral rod Telescopic cylinder COMMANDS AND CONTROLS Shaft rotating in one direction Shaft rotating in two directions Hand operated contro Hand operated contro with pushbutton Hand operated contro with lever Hand operated contro with pedal Mechanical control with pushbutton Mechanical control with spring Document 57 0009 0415 Mechanical control with roller Electro magnetic control with winding solendoid Control with electric motor Direct pressure control Indirect piloted pressure control Control with electromagnet and piloted distributor 9 PIPES AND CONNECTIONS Induction and return pipe Piloting pipe Blow by pipe Flexible hose Connecting point Pipe cross without connection Breather Closed pressure fitting Pressure fitting with connected pipe Quick fitting Quick fitting with check valves DISTRIBUTION SETTING ELEMENTS Non return valve Calibrated non return valve Unlockable non return valve a A TEREX COMPANY GTH 5519 GTH 5519 S a
86. g to give prior notice therefore also this publication may be subject to modifications Contact Us http www terexlift com e mail info terexlift it http www genielift com Copyright 2007 TEREXLIFT srl All rights reserved First Edition First Printing February 2008 Genie Document 57 0009 0415 GTH 5519 GTH 5519 S For going to Table of Contents click on Genie symbol Machine Identification February 2009 MACHINE IDENTIFICATION Machine Identification CHASSIS SERIAL NUMBER The chassis serial number is punched at the front of the chassis on the right side 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 HOW TO READ THE MACHINE SERIAL NUMBER a N REX iir s r l Zona Industriale 06019 Umbertide PG Italy MODEL NUMBER SERIAL NUMBER YEAR OF MANUFACTURE UNLADEN TRUCK MAXIMUN WEIGHT Lb TRUCK CAPACITY Lb THIS TRUCK IS COMPLIANT PART Ill OF ASME B56 6 2002 WHERE APPLICABLE MADE IN ITALY S 7 MACHINE DATA PLATE Chassis serial number The chassis serial number is punched at the front of the chassis on the right side GTH 5519 P 07 17882 SERIAL NUMBER ENGINE TYPE YEAR OF MANIFACTURER Machine data
87. ge the fuse Check the dashboard and replace if necessary Reconnect or replace the wiring Engine does not start starter does not run 50A fuse blown Dashboard damaged K02 relay damaged Speed switch ruined K8 engine start relay damaged Starter defective Change the fuse Check the dashboard and replace if necessary Change the relay Check or replace the speed switch Change the relay Change the starter Engine does not start starter runs but engine does not start No fuel Fuel filter clogged Fuel ducts empty Start aid solenoid damaged Engine stop solenoid damaged Broken or damaged wiring Refuel Clean or replace the filter Eliminate any air Check the efficiency and replace if necessary Check the efficiency and replace if necessary Reconnect or replace the wiring The machine does not move forward back Speed switch damaged Fuse F12 broken Relays K05 K07 K08 damaged Check the efficiency or replace the Switch if necessary Change the fuse Change the relays Genie GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 5 Problems Causes Solutions M a PROBLEMS CAUSES SOLUTIONS Problem Cause Solution Forward reverse speed solenoid valves damaged Service brake micro switch damaged Broken or damaged wiring Negative brake pressure switch Ch
88. ght of the part to be handled For ropes refer to the following table STRANDED ROPES Rope diameter Max admissible load mm lbs 10 2204 11 2 3086 12 5 3527 14 4850 16 6172 18 7936 20 9700 22 4 12345 30 22046 40 39683 50 61729 60 88184 The value of the admissible load has been considered as equal to 1 6 the rope breaking load 6 GTH 5519 GTH 5519 S Attach the load to the natural seat of the hook Attaching a load to an end can cause the load to fall down during raising and result in serious injury 79 100 88 71 41 Do not attach a heavy load to ropes forming wide suspension angle The total capacity of the ropes reduces proportionally to the angle as shown in the following chart 65 409 3306 2204 1102 4 30 60 90 120 150 Document 57 0009 0415 2009 Section 2 Technical Specifications TECHNICAL SPECIFICATION 217 ADVICE TO RENEW FLEXIBLE HOSES 1 Before disconnecting or refitting a flexible hose carefully clean the area all around 7 2 Blow some compressed air to remove any impurity E NT 3 Foran easier renewal of the hoses whose run is not clearly visible proceed as follows Before disconnecting a hydraulic pipe place disconnect the hose to be replaced
89. h Item Description Sh B6 Air filter clogged switch 13 XB Power air condition compressor plug 23 B35 Engine oil pressure transducer 12 X61 Steering unit plug 31 839 Back Up horn 4 4 Yh Transmission reverse mode solenoid valve 18 B40 Fuel level gauge 21 Y12 Transmission forward mode solenoid valve 15 Bai Hydraulic oil temperature switch 25 va Additional fuel solenoid valve 12 45 Parking brake low pressure switch 24 Engine stop solenoid 14 B46 Rear wheels aligned sensor 25 Y37 Fork Up Down solenoid valve 3 2 50 Hydraulic oil temperature switch 23 Y42 Attachement lock unlock solenoid valve 3 2 851 Hydraulic oil filter clogged switch 23 Y53 Continuous flow solenoid valve B 855 Buzzer 44 Y54 Continuous flow solenoid valve 33 B10A Coolant thermistor 12 Y49 Parking brake solenoid valve 34 E1 Work spotlight 54 Y51 Four wheels steering solenoid valve 34 E2 Flashing beacon 54 Ys2 Crub steering solenoid valve 31 Cabin light 54 x1 Plug in Connector 11 way Relay card 5 Work spotligth 45 X10A Plug in Connector Coolant thermistor 12 7 Rear left road light 43 x103 Plug in Connector 3 way Air conditionig motor 14 E38 License plate light 45 X106 Plug in Connector Air conditionig fan motor 2 2 E42 Rear right road light m x Plug in Connector Heating fan 53 E53 Front right road light 4 2 X12 Plug in Connector Windscreen washer pump 4 E54 Front left road light 4 2 12 Plug in Connector Trasmission forward mode sol
90. hment holding frame for instance in the case of use of the bucket are installed in the two control lines of cylinder 19 and they are integral to module 2 Slider 3 of the main valve controls the extension cylinder 22 of the telescopic boom which operates the movement of the second boom telescope and is equipped with a single acting compensation valve used as well as safety valve Slider 4 of the main valve controls the attachment locking cylinder 23 This cylinder has a double one way valve with hydraulic release and safety function On the feeding lines of this cylinder there are two quick fit connectors 24 for the connection of the hydraulic lines to those optional attachments necessitating hydraulic power for their operation ex hydraulic winch and maintenance jib mixing bucket etc The special hydraulic block 21 has been designed to group inasingle element some valves of the low pressure circuit fed through of pump 2 which in the previous versions ofthe machine were installed separately In particular this block houses the selection solenoid valve 29 operating the parking brake and the relevant valve controlling the flow rate of the calibrated throttle with 0 02in diameter the selection solenoid valves 31 and 35 used to switch the pilot lines coming from joystick 18 and relevant to the longitudinal axis of this joystick forward backward which depending on the operation of the two pushbut
91. hose run is not clearly visible proceed as follows remove the bracket A which secures the hoses to the second boom telescope disconnect the hose to be replaced from both sides attach a cord to the side of the hose which reaches the boom tip disconnect the hose from the rear side of the boom remove the hose pulling the cord until it comes out completely disconnect the cord and reconnect the same to the end of the new flexible hose making sure the hose has been previously plugged to prevent dirt from entering the circuit proceed in reverse order and re assemble the hose Section 7 Repair Procedures February 2009 TABLE 010 Operation Renewing the flexible hoses inside the boom TH5519 GTH 5519 S Useful advice for mounting flexible hoses 32 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Procedures TABLE 011 Operation Cylinder disassembly Table 011 GTH5519 GTH 5519 5 Attachment rotation cylinder Bridge crane payload 2000 Ibs Standard tools Textile bridles or chains with hooks Adjustable stands Operation 1 Remove the attachment 2 Remove the screw fixing the pin rod side with two 0 67 in wrenches 3 Knock out and extract the pin using a plug of soft material aluminium copper wood etc 4 Openentirely the cylinder by the hydraulic drive and then stop the machine 5 Place a container of suitable size under the hyd
92. ilated 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 dangerous short especially during a recharge Because the electrolyte 15 highly corrosive itmust nevercome in contact with the frame of the handler orelectric electronic parts If the electrolyte comes in contact with these parts contact the nearest authorised assistance centre Genie 4 DANGER Risk of explosion or shorts During the recharge an explosive mixture with release of hydrogen gas forms 4 DANGER Do not add sulphuric acid add only distilled water GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures C 14 CHECK THE EFFICIENCY OF THE BLOCK VALVES 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 0 1093613 yd 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 During the check the load shall remain blocked in position Should that not be the case the valve must be replaced Contact GENIE Technical Se
93. ine and disconnect the batteries before maintenance or service e Do not lubricate clean or adjust moving parts e Do not carry out operations manually when specific tools are provided for this purpose e Absolutely avoid to use tools in bad conditions or in an improper way e Before carrying out operations on hydraulic lines under pressure hydraulic oil compressed air and or before disconnecting hydraulic components ensure the relevant line has been previously depressurised and does not contain any hot fluid 4 DANGER Any intervention on the hydraulic or pneumatic circuit must be carried out by authorised personnel Before any operation on lines under pressure release any residual pressure from the circuit Do not use your fingers to check for pressure leaks Fine jets of air oil or fuel can injure you Neither smoke nor use open flames if there is a risk of fire or close to fuel oil or batteries e not leave fuel cans or bottles in unsuitable places not empty catalytic mufflers or other vessels containing burning materials without taking the necessary precautions e Carefully handle all flammable or dangerous substances e After any maintenance or repair work make sure that no tool cloth or other object has been left within compartments with moving parts or in which suction and cooling air circulates e Never give orders to several people at a ime Instructions and signs must be given by one pers
94. inimum value re new the pads before adjusting the residual play 0 62 with some shims 5 Remove the fixing screws from the pads and position as many shims as necessary to reach 3 93 the normal thickness value 2 75 0 59 0 98 0 49 ___________________________ Document 57 0009 0415 GTH 5519 GTH 5519 S 27 Section 7 Repair Procedures February 2009 TABLE 009 Operation Renewing the slide pads of the telescopic boom TH5519 GTH 5519 S 6 Refit the fixing screws torque 22 25 Ibf ft after pouring some Loctite 495 on their threads 7 After shimming fully extend the boom carefully clean the sliding rails of the pads then smear with a thin coat of grease INTERFLON FIN GREASE LS2 Thickness 0 78 in New pad thickness 0 59 in Max wearing thickness 0 23 in Torque 22225 Ibf ft AA A Minimum thickness 0 35 GTH 5519 GTH 5519 S Document 57 0009 0415 28 February 2009 Section 7 Repair Procedures TABLE 009 Operation Renewing the slide pads of the telescopic boom Table 009 GTH5519 GTH 5519 S RENEWING THE PADS To renew the pads of the fixed section proceed as follows 8 Stopthe machine extend the telescope and lower the nose to the ground for an easier removal of the bottom pads Hold it in horizontal position for removing the top pads
95. isposing of used oils might be ruled by local or national regulations Address to authorised waste centres Genie ees eee Document 57 0009 0415 GTH 5519 GTH 5519 S 11 Section 4 Maintenance Procedures February 2009 TABLE A A 11 CHECK THE GREASING OF THE BOOM SECTION PADS 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 At regular intervals check that the sliding pads of the telescopes are well greased red strip on the picture Using a brush apply a thin coat of fresh grease If necessary scrape off the old grease and smear the telescope with fresh grease INTERFLON grease FIN GREASE LS 2 Use only greases of the recommend type avoid mixing greases with different characteristics and never use greases of a lower quality Before injecting fresh grease into the greasing nipples 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 12 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures e a TABLE A A 12 GREASE THE F
96. king hours or daily A 5 Make sure the Operator s Manual is inside the machine A 6 Check that all safety decals and plates on the machine are in seat and legible A 7 Check the engine oil level A 8 Clean the air suction filter A 9 Check and clean the radiator A 10 Check the hydraulic oil level in the tank A 11 Check the greasing of the boom section pads 12 Grease the forks A 13 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 A 14 Check the efficiency of the lighting electric system A 15 Check the efficiency of braking system and parking brake A 16 Check the efficiency of the steering selection system 17 Check the efficiency of the fork balancing system 18 Make sure the safety devices installed in efficient working order 19 Check the engine coolant level Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 3 Section 3 Maintenance Inspections February 2009 MAINTENANCE INSPECTIONS TABLE B Within the first 50 working hours B 1 Check the machine is in efficient working order Every 50 working hours or weekly B 2 Check the tension of the alternator belt B 3 Check the tyre inflation B 4 Check the tightening of the wheel nuts B 5 Check the tightening of the cardan shaft screws Every 250 working hours or mon
97. l is level with the hole Operate the starting motor and let the engine run for a few seconds Startthe engine andletitrun AT IDLE and LOADLESS for some 2 minutes Stop the engine wait for a few minutes and then check that oil level reaches the MAX mark on the dipstick D For the engine maintenance please refer to the specific Operator handbook code SLBU 7853 00 supplied with the machine Park the machine on a level surface and stop the engine Place a collecting tray underneath to catch any escaping fuel Clean the fuel filter outside Open the drain valve E and allow the fuel to drain into the collecting tray Remove the filter bowl from the mounting base Free the filter element and clean all its parts thoroughly Install a new filter element by hand Bleed the fuel system Start the engine and let it run at idle for a few minutes i Sa or 5 E LE S E BR 44 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures TABLE E 4 7 TABLE E PROCEDURES E 1 CHANGE THE SAFETY ELEMENT OF ENGINE AIR FILTER To change the safety element Stop the engine and engage the parking brake Unlatch the fasteners A and remove cover B Pull out the filter cartridge C Loosen wing nut and remove the inner element D Clean the filter bowl Mount the new safety element and make
98. nd fuses change the windscreen wiper motor closed cab version change a solenoid valve change the gas pedal complete with cord change the manual throttle complete with cord change the front axle shaft change the rear axle shaft change a cardan joint change the axle shaft hub change the boom assy change the boom anchoring pin change the attachment locking cylinder pins change a cab pushbutton change and test the actuator pressure relief valve or the sliders change and test the actuator safety valve change the one way valve change the maxi fuses and search for troubles bleed the brake circuit disassemble and reassemble a wheel disassemble thermal engine dismantle the hydraulic oil tank dismantle the fuel tank change the oil water cooler change the fork pivot pin support change the engine bonnet change the canister of the air filter check the seals of the steering cylinder change the return filter of the hydraulic oil tank change the hydrostatic steering unit change the battery change the exhaust pipe change the mud guard supports lt lt lij 2 GTH 5519 GTH 5519 S Document 57 0009 0415 2009 Section 7 Repair Procedures REPAIR PROCEDURES Job Operators Expected needed time h
99. nto the fixed section and refit the pin of the extension cylinder 17 With a thickness gauge ensure the play between the boom sections is correct in both positions i e with the boom fully extended and fully retracted 30 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Procedures Operation Renewing the flexible hoses inside the boom How to renew flexible hoses 9 PROTECT THE 47 ENVIRONMENT Before disconnecting the hydraulic piping place containers of suitable size underneath to prevent oil spillage Plug all disconnected parts to prevent dust or impurities from entering the circuit They can cause serious damage Before disconnecting the hydraulic piping ensure there is no pressure in the line In case release the pressure by operating the control levers with the engine stopped In any case disconnect the hydraulic piping with extreme caution and always wear suitable personal protection equipment e g goggles gloves facial screen etc Wrap up the end of the pipe to be disconnected with some rags and slowly loosen the pipe connector so that air comes out as slow as possible GTH 5519 GTH 5519 S 81 Document 57 0009 0415 TABLE 010 Table O10 GTH5519 GTH 5519 5 Before disconnecting or refitting a flexible hose carefully clean the area all around Blow some compressed air to remove any impurity For an easier renewal of the hoses w
100. ny oil leaks Remove the drain plug D and allow oil to flow out into the container Remove the inspection cover C of tank Carefully wash the tank with Diesel oil and blow a jet of compressed air Refitthe drain plug and the inspection cover C Add new oil through hole B by making sure that it matches the recommended type indicated until it is level with A Recommended oil SHELL TELLUS T22 Temperatures below 14 F SHELL TELLUS T46 Temperatures from 5 F to 1 13 F SHELL TELLUS T68 Temperatures above 86 49 PROTECT THE we ENVIRONMENT Handling and disposing of used oils might be ruled by local or national regulations Address to author ised waste centres 48 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures TABLE F 4 8 TABLE F PROCEDURES DEUTZ MODEL F 1 CHANGE THE ENGINE COOLANT 4 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 safe distance To drain the antifreeze Let the engine cool down Relieve the internal pressure from the circuit by loosening plug A Remove plug A Place collecting tray under the drain tap or under plug B Open thedraintap or
101. o limit possible shocks on the steering wheel due to overstress caused by the wheels on the steering cylinders These pressure reducing valves are installed in the hydrostatic drive 12 and cannot be regulated from the outside The steering circuit is completed by the front steering cylinder 14 the rear steering cylinder 15 these cylinders being integral part of the front axle 26 and the rear axle 27 respectively and by a 4 way 3 position solenoid valve 13 for the selection of the three different steer modes rear wheels straight co ordinate front rear steering and independentfront rear steering Whenthe solenoid valve 13 is not energised the front steering cylinder is fed by the hydraulic drive and the rear cylinder is blocked When one magnet or the other of the solenoid valve 13 is energised the chambers ofthe cylinders are connected in adifferent mannerthus causingthe desired effect on the steering mode The Walvoil hydraulic 4 section main valve 16 receives oil from the secondary line of pump 3 and feeds all the movements of the telescopic boom Each of the4 sections ofthe main valve controls a specific function of the machine lifting lowering attachment holding plate rotation boom extension retraction attachment locking unlocking In the head there is a pressure relief valve set at 3915 psi which reduces the max pressure at the main valve inlet and drains the excess oil The joystick Genie Document 57 0009
102. oes not operate the boom extension retraction The joystick does not operate the attachment locking unlocking Hydraulic oil bulb damaged Indicator defective Radiador clogged Fuse F5 blown Road jobsite platform selector damaged Main valve selection valve Broken or damaged wiring Fuse F20 blown Red button on control lever Main valve selection valve Mouvement selection button Check or replace the bulb if necessary Change the part Check the radiator and eliminate any impurities from the fins Change the fuse Check and replace the selector if necessary Checkthe efficiency of the solenoids and replace if they are damaged Reconnect or replace the wiring Change the fuse Check the efficiency of the red pushbutton Check the efficiency of the electrical coils and replace if they are damaged Check the efficiency or replace 10 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 6 Schemes 6 1 HYDRAULIC SYMBOLS ipe T gt MOTORS Fixed motor with one direction of flow Fixed motor with two directions of flow Variable motor with two directions of flow Reversible fixed motor with two directions of flow PUMP Fixed displacement pump with one direction of flow Fixed displacement pump with two directions of
103. of suitable size under the plug 4 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures A 2 CHECKTHETIGHTENING OF THE WHEEL BOLTS AND THE TYRE PRESSURE If you have to check the tightening of the wheel bolts or replace a wheel proceed as follows Raise the machine using a hydraulic jack Remove the wheel rolling it on the ground Line up the wheel with the axle and fit the 8 nuts Tighten the nuts following the alternate sequence shown in the picture with a pneumatic screwdriving machine Lower the machine to the ground Re tighten all nuts to a torque 221 IbPft Checkthetightening of wheels one hour after the job They might get loose until they do not stay correct On new machines and when a wheel has been di sassembled or replaced check the nut torque of the wheels every 2 hours until they stay correct Always use tyres having the dimensions indicated in the vehicle registration card GTH 5519 GTH 5519 S 5 STANDARD GTH 5519 GTH 5519 S Dimensions front and rear 12 16 5 Load index 10 pr Rim 9 75x16 5 Wheel disc 8 holes DIN 70361 Pressure Psi 65 Document 57 0009 0415 TABLE A Remove nut A from the tyre Connect the hose of the pressure gauge Read the pressure on the pressure gauge If the pressure is not the one recommended adjust to the value indicated on the table to
104. on only e Always pay the due attention to the instructions given by the foreman e Never distract the operator during working phases or crucial manoeuvres e Do not call an operator suddenly if unnecessary Do not frighten an operator or throw objects by no means xiv GTH 5519 GTH 5519 S e After work never leave the machine under potentially dangerous conditions PROTECT THE 42 Treatment and disposal of used oils is subject to federal national and local laws and regulations Collect and deliver these wastes to authorised centres e Use the assistance of a second person to handle loads weighing 66 to 110 Ib e For loads over 110 Ib the use of special hoisting equipment in good condition and equipped as per enforced regulations is mandatory Document 57 0009 0415 February 2009 E Table of Contents Introduction iii Important iii Machine Identification iv Description V Description of the machine operation V GTH 55 19 GTH 55 19 S TIER 3 hydraulic schematic vii Section 1 Rev Safety Rules ix 11 Safety rules X 1 1 1 Personal Safety X 1 1 2 Workplace Safety xi 1 2 General remarks xii 1 3 Servicemen s requisites xii 1 3 1 Personal Protective equipment xiii 1 4 General safety precautions xiii 1 4 1 Working area xiii 1 4 2 Precautions during work xiii Section 2 Rev Technical Specification 1 21 Main dimensions 1 2 2 Tyres 1 2 3 Limit of use 2 2 4 Weight 2 2 5 Speed 2 2
105. on 2 5 3 Problems Causes Solutions 3 5 3 1 Hydraulic faults 3 5 3 2 Electrical faults 8 Section 6 Rev Schemes 1 6 1 Hydraulic symbols 1 6 2 Hydraulic schemes 3 6 2 1 GTH 55 19 GTH 55 19 S 3 6 3 Electrical symbols 4 A 6 4 Wiring diagrams 6 A 6 4 1 Wiring diagrams Component description 11 A 6 4 2 Fuses and relays 12 6 5 Position of the electrical and hydraulical components on the machine 13 6 5 1 Hydraulical components 13 Section 7 Rev Repair Procedures 1 7 1 Time schedule 1 001 Cylinder disassembly Boom raising cylinder 5 002 Cylinder disassembly Fork balance cylinder 9 003 Removing the engine from the machine 11 004 Hydrostatic pump disassembly 17 005 Disassembling the hydraulic motor 19 006 Oylinder disassembly Boom extension cylinder 21 007 Water oil cooler disassembly 23 008 Main valve disassembly 25 009 Renewing the slide pads of the telescopic boom 27 010 Renewing the flexible hoses inside the boom 31 011 Cylinder disassembly Attachment rotation cylinder 33 Document 57 0009 0415 GTH 5519 GTH 5519 S xvii February 2009 lt Intentionally blank page xviii GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 2 Technical Specifications Technical Specification 2 1 MAIN DIMENSIONS GTH 5519 GTH 5519 S m
106. oom main valve to full stroke under pressure To reach this temperature in a faster way cover the oil core of the radiator with a carton in the case of a water oil combined cooler or the oil radiator if the machine is equipped with a separate oil radiator 2 CALIBRATING THE BOOM MAIN VALVE Go to the front of the machine find the mini socket TP1 see photo 1 which is located on the internal wall of the chassis on the left and fit the 0 5972 psi pressure gauge PHOTO 1 21 CALIBRATING THE MAIN VALVE PRESSURE CONTROL VALVE Remove the central protective covers of the machine and using a 0 51inc wrench loosen the locknut of the pressure relief valve A of the main valve see photo 2 With the engine running at max speed move the boom fully up and to end of stroke by operating joystick and set valve A to 3915 psi For the inspection of the safety valves B proceed as follows Increase the pressure of valve A of the main valve to 4351 psi moving the lifting cylinder to end of stroke TECHNICAL SPECIFICATION With the engine running at maximum speed tilt the forks to one direction by means of the joystick and act on one of the two valves B until reaching a pressure of 4206 psi Adjust the second valve B by pitching the forks back When both fork inclination valves have been calibrated reset the pressure control valve to 3915 psi by adjusting the adjustment screw A For safety reasons do not hold the
107. pads for wear clean the sliding guides of the boom thoroughly and lubricate with the special INTERFLON FIN GREASE LS 2 grease Check the play and replace any worn parts or place shims GTH 5519 GTH 5519 S When moving out the second Grease is insufficient or Check that the grease smeared telescope the boom tends to inadequate on the boom is INTERFLON FIN jump GREASE LS2 smear the boom againwith grease Genie Document 57 0009 0415 February 2009 Section 5 Problems Causes Solutions PROBLEMS CAUSES SOLUTIONS Problem Cause Solution Foreign matters on the sliding blocks and the relevant surfaces of the boom Check and eliminate any foreign matters Low traction Drive pump defective Check the pressure values of the drive pump and re calibrate if necessary If the overfeeding pressure drops down replace the pump and clean the pump motor couplings Document 57 0009 0415 GTH 5519 GTH 5519 S Section 5 Problems Causes Solutions A W w AA PROBLEMS CAUSES SOLUTIONS 5 3 2 Electrical faults February 2009 Problem Cause Solution No power to dashboard Battery switch off Battery down 50A fuse blown F61 Dashboard damaged Broken or damaged wiring Turn on the switch Check the battery efficiency replace if necessary Chan
108. plate iv 5519 GTH 5519 S Document 57 0009 0415 February 2009 Description DESCRIPTION OF THE MACHINE OPERATION The mechanical energy source of this machine is a diesel engine 1 which can be of two differenttypes A Perkins engine model 804D 33 Tier 3 with a power of 47 1 kW at 2500 rev min 63 HP and a maximum torque of 147 lb ft at 1600 rev min or a Deutz engine model 02011 104 Tier 3 with a power 50 kW at 2600 rev min 68 HP and a maximum torque of 155 Ib ft at 1700 rev min On the flywheel side of the engine and connected to the same by aTechnodrive coupler complete with elastic joint and with a 1 to 1 ratio there is Bosch Rexroth closed loop pump for hydrostatic drives model A4VG56 2 with adjustment valve of DA type The max displacement of this swashplate pump is 0 0000732 yd3 rev and the max calibration pressure is 6235 psi This pump is used to supply hydraulic power under form of pressure and flow rate which is then used for moving the machine On the through shaft of such drive pump there is a Casappa open loop gear pump with fixed displacement 3 with priority valve integrated in the housing The displacement of this pump is 0 0000353 Its function is to provide hydraulic power under form of pressure and flow rate to the steering circuit of the machine primary branch of the priority valve and to the circuit for the telescopic boom movements secondary branch of the priority val
109. point 7 so that the front axle reaches its stop Reset the steering selection switch to four wheel steer pos 2 Now the wheels should be re aligned 18 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures A 17 CHECK THE EFFICIENCY OF THE FORK BALANCING SYSTEM Test the system without any load on the machine s forks To check the efficiency of the fork balancing system obey the instructions below Drive the machine to a flat smooth ground Move the retracted boom fully down and align the forks with the ground Start lifting the boom and check that the forks remain parallel to the ground If the forks do not remain parallel to the ground consult section 5 Problems Causes Solutions TABLE A A 18 MAKE SURE THE SAFETY DEVICES INSTALLED ARE IN EFFICIENT WORKING ORDER 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 Document 57 0009 0415 GTH 5519 GTH 5519 S 19 Section 4 Maintenance Procedures February 2009 TABLE A A 19 CHECK THE ENGINE COOLANT LEVEL 4 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 press
110. pump on to a bench and plug all the outlets 7 Remove the fixing screws B of the drive pump with a 0 55 in hex head wrench and then secure the pump to the bridge crane with a textile sling and pull it out of the motor Place the pump on to a bench and plug all the outlets TEREX COMPANY 18 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Procedures TABLE 005 Operation Disassembling the hydraulic motor Table 005 GTH5519 5519 5 Bridge crane or swing hoist payload Standard tools 2000 Ibs Operation 9 PROTECT THE Ge ENVIRONMENT Before disconnecting the hydraulic piping place containers of suitable size underneath to prevent oil spillage Carefully clean the area around the piping to be disconnected plug all disconnected parts with connectors clothes or adhesive tape to prevent dustor impurities from entering the circuit They can cause serious damage 1 Remove the central covers of the machine by driving out all the bolts with two 0 51 in wrenches N Using a 1 41 in wrench and a 0 67 in wrench disconnect the hoses Disconnect the two delivery hoses with a 0 74 in wrench LB 0 Document 57 0009 0415 GTH 5519 GTH 5519 S 19 Section 7 Repair Procedures February 2009 TABLE 005 Operation Disassembling the hydraulic motor Table 005 GTH5519 GTH 5519 5 4 Remove the four locking screws of the motor with a 0 94 in wrench
111. raulic piping before disconnecting the same 6 Using a 0 51 in wrench remove the protection cover from the valve of the attachment rotation cylinder 9 PROTECT THE ENVIRONMENT Used oils must be handled and disposed of according to local regulations Address to legally authorised centres _ _ Document 57 0009 0415 GTH 5519 GTH 5519 5 33 Section 7 Repair Procedures February 2009 TABLE O11 Operation Cylinder disassembly Attachment rotation cylinder With a 0 94 in wrench disconnect two hydraulic hoses from the blocking valve then plug the disconnected connectors to prevent dust and impurities from entering the circuit 8 Place a wooden plug under the cylinder rod then lower the boom using the hydraulic controls as far as the rod rests on the wooden plug 9 Remove the screw fixing the cylinder pin bottom side with two 0 67 in wrenches 10 Knock out and extract the pin using a plug of soft material aluminium copper wood etc 11 Secure the cylinder to the bridge crane with a textile bridle then slightly raise the boom to set the cylinder free 12 Remove the cylinder using the bridge crane 3 34 GTH 5519 GTH 5519 S Document 57 0009 0415
112. re 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 seriousness of the hazard situation Draws the attention to situations that involve your own as well as the others safety and that can result in serious or lethal injury Draws the attention to situations that involve your own as well as the others safety and that can result in serious or lethal injury Draws the attention either to situations that involve your own as well as the others safety and that can result in minor or moderate injury or to situations that involve the machine efficiency Draws the attention either to situations that involve your own as well as the others safety and that can result in minor or moderate injury or to situations that involve the machine efficiency X GTH 5519 GTH 5519 S NOTICE Drawstheattention to importanttechnical information or practical advice that allows for a safer and more efficient use of the machine PROTECT THE ENVIRONMENT Draws the attention to importantenvironment related information e jl Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be a
113. remove the drain plug B located at the bottom of the radiator and allow the fluid to drain into the container the fluid has been drained close the drain tap or refit plug B and pour new antifreeze 50 water antifreeze through cap A This proportion will provide protection up to 38 C On delivery the machine is filled with a cooling mixture consisting of 50 water and 50 anti freeze TEREX PRO COOL Protection against boiling freezing Product Freezing Boiling point point 253 4 F 12 F 2588F Document 57 0009 0415 GTH 5519 GTH 5519 S 49 Section 4 Maintenance Procedures February 2009 pr M s i TABLE G 4 9 TABLE G PROCEDURES G 1 CHECK THE MACHINE 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 pins After the first 5 years repeat this check every 2 years 50 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 5 Problems Causes Solutions Problems Causes Solutions 5 1 INTRODUCTION Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Immediately tag and remove from service a damaged or malfunctioning machine
114. rvice 49 PROTECT THE ENVIRONMENT Place a container of suitable size under the plug TABLE C Telescopic boom extension cylinder d Attachment coupling cylinder Fork pitching cylinder Fork levelling cylinder Document 57 0009 0415 GTH 5519 GTH 5519 S 35 Section 4 Maintenance Procedures February 2009 TABLE C 4 DANGER Do the check of the valves taking all the possible precautionary measures Wear safety glasses Wear safety gloves Wear safety shoes Wear suitable working clothes Use guards against leaks of oil at high pressure Do the check in a free space with barriers all around to keep non authorised people away 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 TO REMOVE THE BLOCK VALVES OR THE CYLINDERS Lower the boom to the ground in a firm way since the removal of the block valve or the cylinder can cause an uncontrolled down movement After refitting the valve or the cylinder replenish the circuit and eliminate any air before starting working To eliminate the air from the circuit move the involved cylinders to end of stroke in the two directions opening closing To eliminate the air from the fork balance cylinder move the boom up and down and tilt the fork plate forwards back Telescopic boom lifting cylinder 36
115. servicing or maintaining operation machines are caused by not complying with the basic safety precautions Therefore it is necessary to pay steady attention to the potential hazards and the effects that may come of operations carried out on the machine If you recognise hazardous situations you can prevent accidents For instance this handbook makes use of special safety symbols to highlight potentially hazardous situations NOTICE 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 commissioning 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 must sure that the operations you are going to carry out are not explicitly forbidden be sure that the methods are safe and in compliance with the indications given in this section be sure that the methods cannot damage the machine directly or indirectly or make it unsafe e contact GENIE Assistance Service for any suggestion and the necessary written permission Do not hesitate to pose questions if you are in doubt Contact GENIE the assistance service is at your disposal Addresses phone and fax numbers are given in the cover and in the title page of this manual xii GTH 5519 GTH 5519 S 1 3 SERVICEMEN S REQUISITES The operators who use the m
116. si to feed the anti cavitation circuit of the automatic fork levelling system the pilot circuit of the main valve of the telescopic boom 16 and the parking brake unlock circuit The hydraulic energy produced by the drive pump 2 is converted into mechanical power by a closed loop hydrostatic motor model Bosch Rexroth A6VM107 5 equipped with adjustment valve of DA1 type and with flush valve 36 for reducing the max temperatures inside the drive circuit The max displacement of this bent axis motor is 0 00014 yd rev The motor is directly flanged to the front steering axle 26 The mechanical torque produced by the drive motor is transmitted to the rear axle 27 through a Cardan shaft The hydraulic drive 12 of load sensing type with a displacement of 0 0001635 yd3 rev receives oil from the priority line of pump 3 in relation to the load sensing signal sent by the hydraulic drive and connected to such pump with function of pilot signal In this way the input flow to the hydraulic drive is exactly the one needed for the instantaneous steering functions any excess flow of the pump is available for operating the different movements of the telescopic boom The Steering circuit is protected against input overpressures by a pressure reducing valve set at 2465 psi On the two delivery lines to the steering cylinders there are other two pressure reducing valves with anti shock function set at 3262 psi These two valves are intended t
117. sure it is correctly positioned Tighten wingnut Refit the outer element C Close cover B and lock in place with fasteners A The inner element should be replaced every second time the outer element is replaced Document 57 0009 0415 GTH 5519 GTH 5519 S 45 Section 4 Maintenance Procedures February 2009 TABLE E E 2 CHANGETHEOILIN POWER DIVIDER AND DIFFERENTIAL GEARS To change the oil level in the power divider Stop the machine on a level ground and engage the parking brake 7 ENVIRONMENT Place a container of suitable size under the plug PROTECT THE Remove the level plug A and the filler Remove the drain plug B and allow oil to flow out from the power divider Refit and tighten the drain plug B Add new oil through the filler until it is level with hole A Refit and tighten filler level plug Recommended oil FUCHS TITAN GEAR LS 85 W 90 GL 5 LS GL 5 46 GTH 5519 GTH 5519 S To change the oil level in the front and rear differential gears Stop the machine on a level ground and engage the parking brake 9 PROTECT THE ENVIRONMENT Place a container of suitable size under the plug Loosen the drain plug B and the level plug A and allow oil to flow out from the differential gears Refit and tighten drain plug B new oil through plug A until it is level with the hole
118. tering the circuit They can cause serious damage Using two 0 67 in wrenches remove the six screws that fix the engine lower cover Remove the lower cover N Close the oil tank cocks Document 57 0009 0415 GTH 5519 GTH 551 9 S 17 Section 7 Repair Procedures February 2009 TABLE 004 Operation Hydrostatic pump disassembly 4 With a screwdriver remove the two electrical connections of the solenoid valve which controls the machine forward reverse movements 5 Disconnect the hydraulic piping disconnect the two drain lines of the hydraulic pump with a 1 41 in wrench disconnect the suction line of the hydraulic pump with a 1 96 in wrench disconnect the low pressure line duct with a 0 74 in wrench disconnect the four flanges which connect the drive pump to the drive motor with a 0 31 in Allen wrench disconnect the suction line of the service 8 Proceed in reverse order to re assemble the pump with a 0 31 in Allen wrench hydrostatic pump disconnect the delivery line ducts of the hydraulic drive and the main valve with a 1 41 in wrench and a 0 94 in wrench disconnect the load sensing signal line from the hydraulic drive with a 0 67 in wrench Once all operations have been performed make sure that all electrical wires and hydraulic lines are disconnected from the motor 6 Disconnect the service pump from the drive pump by driving out bolts A with a 0 74 in spanner Place the
119. the screw fixing the cylinder pin bottom side with two 0 51 in wrenches 8 Knock out and extract the pin using a plug of soft material aluminium copper wood etc 9 Pull out the cylinder from the boom section and sling it with the textile bridles connected to the bridge crane 22 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Porcedures TABLE 007 Operation Water oil cooler disassembly Table 007 GTH5519 5519 5 Standard tools Operation 7 PROTECT THE Ge ENVIRONMENT Before disconnecting the hydraulic piping place containers of suitable size underneath to prevent oil spillage Carefully clean the area around the piping to be disconnected plug all disconnected parts with connectors clothes or adhesive tape to prevent dust or impurities from entering the circuit They can cause serious damage Empty the cooler opening the special cock N Disconnect the two inlet and outlet hoses from the cooler with a 1 41 in wrench Disconnect water pipes from to the engine loosening the hose clamps with a screwdriver TEREX COMPANY Document 57 0009 0415 GTH 5519 GTH 5519 S 23 Section 7 Repair Procedures February 2009 TABLE 007 Operation Water oil cooler disassembly 4 Remove the two screws of the vibration supports with a 0 86 in wrench 5 Remove the two screws which fix the radiator to the guard wall using a 0 51 in wrench
120. the side Section 4 Maintenance Procedures February 2009 TABLE A A 3 CHECK THE TIGHTENING OF ALL BOLTS AND NUTS Before starting your daily work proceed with a random check of the bolts For the correct tightening torques please refer to par 2 14 in section 2 Technical Specifications Genie A 4 CHECK THE COUPLINGS FOR OIL LEAKS Before starting your work do a walk around inspection and check for oil leaks If you find them rectify before starting using the machine 6 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures 5 INSPECT THE OPERATOR S MANUAL Maintaining the operator s manual in good condition is essential to safe machine operation Manual are included with each machine and should be stored in the cab An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In particular check to be sure the storage container is in good condition check to make sure that the operator manual are present complete and in the storage container in the cab examine the pages of each manual to be sure that they are legible and in good condition always return the manual to the storage container after use Contact GENIE Service Centre if replacement manuals are needed TABLE A A 6 INSPECT THE DECALS AND PLATES Maintaining all of safety and instructional dec
121. thly C 1 Change the engine oil and replace the oil filter after the first 250 working hours 2 Check the oil level in front and rear differential gears and power divider C 3 Check the oil level in the four wheel reduction gears 4 Check the cartridge of the engine air filter Replace if necessary C 5 Check the clamping of the cableheads to the battery terminals C 6 Check the air suction hose between engine and filter Replace if necessary 7 Check the cylinder chromium plated rods C 8 Check the hydraulic lines are not worn because of rubbing against the frame or other mechanical components C 9 Check the electric cables do not rub against the frame or other mechanical components C 10 Check the wear of the sliding pads of the boom sections C 11 Adjust the play of the sliding pads of the boom sections C 12 Remove any grease from the boom then re grease the sliding parts of the boom sections C 13 Check the level of the battery electrolyte C 14 Check the efficiency of the block valves GTH 5519 GTH 5519 S Document 57 0009 0415 A 2009 Section 3 Maintenance Inspections MAINTENANCE INSPECTIONS TABLED Every 500 working hours or every six months D 1 Visually check the smoke quantity evacuated from the engine exhaust D 2 Check the tightening of the engine fixing screws D 3 Check the tightening of the cab fixing screws
122. tions of the maintenance inspection report see chapter 3 Safety symbols gt Draws the attention to situations that involve your own as well as the others safety and that can result in serious or lethal injury Draws the attention to situations that involve your own as well as the others safety and that can result in serious or lethal injury Draws the attention either to situations that involve your own as well as the others safety and that can result in minor or moderate injury or to situations that involve the machine efficiency Draws the attention either to situations that involve your own as well as the others safety and that can result in minor or moderate injury or to situations that involve the machine efficiency Drawstheattentionto importanttechnical information or practical advice that allows for a safer and more efficient use of the machine 4 PROTECT THE 6 20 ENVIRONMENT Draws the attention to important environment related information 2 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures 4 3 TABLE A PROCEDURES 1 CHECK THE OIL LEVEL WITHIN REDUCTION GEARS POWER DIVIDER AND DIFFERENTIAL GEARS To check the oil level within the wheel reduction gears Stop the machine on a level ground and ensure the parking brake is engaged and plug A finds on the horizontal axis Clean the plug all around then remove it with a 0 47inc hex head wr
123. tons installed on the control lever in the driving place activate one of the three sections of the main valve 16 and namely the lift l ower movement the attachment holding plate rotation movement and the attachment lock vi GTH 5519 GTH 5519 S unlock movement The selection solenoid valve 30 again built in block 21 activates the attachment lock unlock line also used as auxiliary line for the operation of optional attachments withoutany needto move the joystick continuous flow The pressure reducing valve with screw adjustment 38 when operated together with solenoid valve 30 allows to adjustthe oil flow rate ofthe attachment lock unlock line auxiliary line through the adjustment of the pilot pressure on the line of the fourth element of the main valve 16 Finally one of the hydraulic ports of the block connected to the feeding line of the parking brake is used for the connection of the safety pressure switch 28 This pressure switch prevents the machine from moving when the pressure of the parking brake line is too low to guarantee the complete release of this brake The circuit of the service brake is operated by a SAFIM 27 20 pump 25 which takes hydraulic oil from tank 37 to operate the service brake located inside the front axle 26 The brake pump can provide a maximum pressure of 1160 thus depending on the pressure exerted on the brake pedal placed inside the driving place The pressure switch 4 set
124. uit Genie Document 57 0009 0415 GTH 5519 GTH 5519 S 5 Section 7 Repair Procedures February 2009 TABLE 001 Operation Cylinder disassembly Table 001 Boom raising cylinder GTH5519 GTH 5519 S 7 move the boom using the up down controls of the bridge crane previously disconnect the rod of the fork balance cylinder 8 Remove the screw fixing the pin with two 0 51 in wrenches 9 Knock out and extract the pin using a plug of soft material aluminium copper wood etc 10 Fix the balance cylinder to the cabin with a sling and esnure it does not hinder the movement of the boom 11 Secure the raising cylinder to the cabin with a sling 6 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 7 Repair Procedures ee ay TABLE 001 Operation Cylinder disassembly Table 00 1 Boom raising cylinder GTH5519 GTH 5519 S 12 Remove the screw which fixes the rod pin to the boom using two 0 74 in wrenches 13 Knock out and extract the pin using a plug of soft material aluminium copper wood etc 14 Puttwo wooden plugs each 3 93 in high on the oil cylinder to support the raising cylinder 15 Lower the boom until the cylinder rests on the supporting plugs previously positioned 16 Untie the sling fixing the cylinder to the boom then raise the boom with the bridge crane to go on working 17 Remove the screw which fixes the bottom side pin o
125. ure Hydraulic pump damaged Load sensing valve defective The valve of the main valve leaks Joystick damaged Set the max pressure of the main valve to 3915 psi Replace the pump Check the efficiency of the valve replace if necessary Dismantle the valve check and eliminate any foreign matters Check the efficiency of the joystick replace if necessary Wrong wheel shafting The steering wheel is hard low force in the cylinders Leakage in the steering cylinders Leakage in the steer selection solenoid valve Low pressure Priority valve damaged Check and replace the seals if necessary Check the efficiency of the solenoid valve Check the pressure in case reset 2465 psi Check the efficiency of the valve replace if necessary Low drive pump supercharge Pump damaged Motor damaged Change the pump Change the motor The machine drive is not enough Hydraulic oil filter restricted Low hydraulic oil level Clean the oil filter Replenish the tank up to the recommended level Document 57 0009 0415 GTH 5519 GTH 5519 S Section 5 Problems Causes Solutions a PROBLEMS CAUSES SOLUTIONS February 2009 Problem Cause Solution The oil in the tank is contaminated Drain the oil clean tank and pipes empty the pumps and add new oil By stepping down on the pedal the machine does not brake Brake pump damaged Front axle brakes def
126. ure Use protection gloves and keep your face at a safe distance DEUTZ ENGINE e Every week before starting working with the coo lant cold check the coolant level through the glass cap of plug A When necessary add clean water or an antifreeze mixture through cap B On delivery the machine is filled with a cooling mixture consisting of 50 water and 50 anti freeze PERKINS ENGINE TEREX PRO COOL Protection against boiling freezing Product Freezing Boiling point point 2 DEUTZ ENGINE PERKINS ENGINE Sud eres 20 GTH 5519 GTH 5519 S Document 57 0009 0415 February 2009 Section 4 Maintenance Procedures 4 4 TABLE B PROCEDURES B 1 CHECK THE MACHINE IS IN EFFICIENT WORKING ORDER Doa walk around inspection and check the machine is in efficient working order Check for fluid leaks Make sure that all hydraulic and electrical components are in efficient working order For the engine maintenance please refer to the specific Operator handbook code SLBU 7853 00 supplied with the machine TABLE B B 2 CHECKTHETENSIONOFTHEALTERNATOR BELT Visually check belt A for damages or cracks this belt doesn t need to be tensioned as the system is equipped with an automatic tensioning device For the engine maintenance please refer to the specific Operator handbook code SLBU 7853 00 supplied with the machine
127. uts A 4 Check the couplings for oil leaks Hour meter Every 10 working hours Machine owner A 5 Operator Manual A 6 Decals and placards Inspected by A 7 Engine oil level A 8 Air suction filter Inspector signature A 9 Radiator A 10 Hydraulic oil level in the tank Inspector title 1 Greasingofthe boom section pads A 12 Grase the forks Inspector company 777 3 Grease all joints of the boom the rearaxleshaftjoint the transmission Instructions shafts the front and rear axles and Make copies of this page to use for each any equipment of the machine _ inspection A 14 Six ofthe lighting electric System Selectthe appropriate checklist s forthe 115 Eficency dang systemand type of inspection to be performed parking brake Every 10 hours A A 16 Efficiency of the steering selec tion system Every 50 hours A B A 17 Efficiency of the fork balancing Every 250 hours A B C system A 18 Safety devices Every 500 hours A B C D A 19 Engine coolant level Every 1000 hours A B C D E Every 2000 hours A B C D E F At 6000 hours G Within the first 50 working hours B 1 efficienc Place a check in the appropriate box after each inspection procedure is Every 50 working hours completed B 2 Tension of the alternator belt February 2009 ee Every 250 working hours C 1 Engine oil and relevant filter C 2 Oil level in the differential gears and reducer
128. uv Bujana o4 wal eT nal 20 GZ Joyenioe Buneyo1 Buueais Buueejs 1 l I suonisod skem 10 29 96 Buueejs Buueejs l y uod sdy enie G A TEREX COMPANY GTH 5519 GTH 5519 S February 2009 6 2 6 2 1 2010 snounuoo Mexny OUT suonounj woog 5 54 10 1959 91155919 BuneAnoe L5 9 yams eunsseid eyeJq aS isd 062 ensse1d BuneAnoe eJnsseud eunsseid yesq upped snouguoo JANO Document 57 0009 0415 Mechanical manual control Key control RESISTANCES Knot Protection ground Light emitting diode Diode Section 6 Schemes February 2009 SCHEMES 6 3 ELECTRICAL SYMBOLS ACTUATORS ACCUMULATORS DYNAMIC ae APPLICATIONS Emergency controls 4 Battery Motor Pushbutton control gt Thermocouple Rotary control
129. ve The assembly of the two pumps involves they have a rotation velocity equal to the speed of the diesel engine The suction line of the pump 3 is protected by an immersed filter 8 placed inside the hydraulic fluid tank 10 whose capacity is 75 litres 20 gallons Just upstream ofthe connection with the suction line there is a gate valve with ball valve 9 which lets you cut out the hydraulic oil tank order to perform maintenance interventions on the machine s hydraulic system without having to drain oil off the tank built in the same circuit The filter 34 placed in the line returning to pump 3 purifies most oil coming from the hydraulic circuit operating the telescopic boom before this oil returns to the tank In addition to purify the oil coming from the main open loop circuit of the machine telescopic boom operating circuit this filter can deliver oil ata minimum pressure of 7 25 psi to the suction line of the drive pump 2 This construction feature of the filter guarantees important advantages in terms of absence of cavitation in the transmission suction line especially when the machine is started from cold The one way valve 11 set at 36 psi protects the pump housing against high pressures and guarantees a certain circulation of the drain oil to the hydrostatic motor reducing in this way the temperature From port of the drive pump 2 low pressure oil is taken 362 345 Description p
130. ve of the attachment locking cylinder change the fork compensation cylinder change the fork compensation cylinder kit change the valve of the fork compensation cylinder check the one way valves of the fork compensation cylinder 1 00 change the boom internal line for the boom extension 1 00 change the boom internal line for the fork pitching 2 00 change the boom internal line for the fork locking 2 00 change the boom slide pads 2 30 check the transmission pump pressures 0 30 each check the pressure of the main actuator operating the boom movements 0 30 each check the pressure of brake pump and hydrostatic steering unit 1 00 change the drive pump 2 30 1 00 2 00 1 30 0 30 1 00 1 30 0 30 2 00 1 30 1 00 Document 57 0009 0415 GTH 5519 GTH 5519 S 1 Section 7 Repair Procedures February 2009 LIE EI ccc ae REPAIR PROCEDURES Job Operators Expected needed time h 2 00 5 00 2 00 2 30 1 00 0 30 1 30 0 30 1 00 0 30 2 30 2 30 1 00 1 30 4 00 each 1 00 each 0 30 0 30 0 30 0 30 0 30 1 00 0 30 each 1 00 2 30 each 3 00 2 00 2 00 2 00 1 00 0 30 1 00 each 0 30 2 00 0 30 0 30 0 30 change the drive motor change motor pump transmission piping tests change the actuator control pump change and calibrate the actuator change the DFE valve change relays a
131. ware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Document 57 0009 0415 2009 Section 1 Safety Rules SAFETY RULES 1 1 2 Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are x properly maintained and ready foruse Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure that your workshop or work area is H properly ventilated and well lit lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity i Be sure any forklift overhead crane or other Be sure that fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components fail if they are used a second time Be sure to properly dispose of old oil or other 4 fluids Use an approved container Please be environmentally safe Genie Document 57 0009 0415 GTH 5519 GTH 5519 S xi Section 1 Safety Rules February 2009 SAFETY RULES 12 GENERAL REMARKS Most accidents occurring while working
132. wif 1 1 L vii GTH 5519 GTH 5519 S Document 57 0009 0415 Description February 2009 E DESCRIPTION Intentionally blank page viii GTH 5519 GTH 5519 S Document 57 0009 0415 2009 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the Operator s Manual are also safety hazards when maintenace and repair procedures are performed Do Not Perform Maintenace Unless You are trained and qualified to perform maintenace on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Document 57 0009 0415 GTH 5519 GTH 5519 S ix Section 1 Safety Rules February 2009 SAFETY RULES 1 1 SAFETY RULES 1 1 1 Personal Safety In this manual any important information is preceded by a SPECIAL SYMBOL All operators who work or service the machine must know the exact meaning of these safety symbols There are six special or safety symbols in this manual always combined with keywords that class the situations according to their danger degree The symbols a

PN 57.0009.0415

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