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Terex Genie GTH-5519 User Manual

Terex Genie GTH-5519
113 pages
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Operator’s Manual
First Edition
Eleventh Printing
Part No. 57.0009.0412
Serial number range
With Maint
enance
Information
GTH-5519 (Perkins Tier III)
GTH-5519 (Deutz Tier III)
From serial n.: 19006
To serial n.: 25040
From serial n.: 19388
To serial n.: 24471
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Terex Genie GTH-5519 Specifications

General IconGeneral
ModelGTH-5519
Maximum Lift Height19 ft (5.79 m)
Engine Power74 hp (55 kW)
Tire Size12 x 16.5
Maximum Lift Capacity5, 500 lbs
Ground Clearance14 in (356 mm)

Summary

Operator's Manual Overview

Serial Number Range Identification

Identifies the serial number range for the operator's manual.

Introduction to Machine Operation

Safety Symbols Explanations

Explains safety alert symbols used in the manual and on the machine.

Machine Identification Details

Machine Identification Plates

Describes the locations and purpose of various data plates on the machine.

Machine Identification Continued

Chassis Serial Number Location

Details the location of the chassis serial number on the machine.

Symbols Used On The Machine

Instrument and Indicator Symbols

Explains various instrument and indicator symbols on the machine.

Hazard Pictorial Descriptions

Explains various hazard pictorial symbols and their meanings.

Labels And Plates Applied On The Machine

Decal Locations Diagram

Diagram showing the location of various decals on the machine.

Specific Decal Details (Refs 1-7)

Details specific decals, their codes, descriptions, and quantities.

Specific Decal Details (Refs 8-13)

Details specific decals, their codes, descriptions, and quantities.

Specific Decal Details (Refs 14-23)

Details specific decals, their codes, descriptions, and quantities.

Specific Decal Details (Refs 23-30)

Details specific decals, their codes, descriptions, and quantities.

Specific Decal Details (Refs 31-36)

Details specific decals, their codes, descriptions, and quantities.

Specific Decal Details (Refs 37, 38, A, B)

Details specific decals, their codes, descriptions, and quantities.

Safety Precautions

Damaged Machine Hazards

Precautions regarding the use of damaged or defective machines.

Personal Injury Hazards

Hazards that can cause personal injury, like fluid leaks.

Safety Devices Importance

Importance of safety devices and not tampering with them.

General Safety Remarks

General advice on avoiding accidents by following safety precautions.

Conditions Required Before Operation

Conditions that must be met before operating the machine.

Operator Prerequisites

Prerequisites for machine operators regarding health, training, and mental state.

Servicemen Prerequisites

Prerequisites for maintenance personnel regarding skills and training.

Working Clothes and PPE Requirements

Guidelines on appropriate working clothes and personal protective equipment.

Jobsite Hazards: Electrical and Storm

Hazards on the jobsite, especially electrical hazards and storm conditions.

Operation and Maintenance Hazards

Precautions to be taken before operation or maintenance.

Safe Entry and Exit Procedures

Safety measures for entering and leaving the machine safely.

Prohibited Actions During Maintenance

Warnings against lubricating, cleaning, or adjusting moving parts.

Hydraulic Circuit Safety Interventions

Warning about hydraulic circuit interventions by authorized personnel only.

Machine Operation Hazards to Avoid

Work situations to absolutely avoid, such as exceeding capacity or operating in strong wind.

Explosion and Fire Hazard Prevention

Precautions to prevent explosion or fire, especially related to fuels.

Damaged Component Hazard Precautions

Precautions when using damaged components like batteries or for welding.

Personal Injury Hazards (Leaks, Ventilation)

Hazards related to hydraulic oil leaks and operating in poorly ventilated areas.

Description Of The Main Components

Component Identification Diagram

Diagram and list identifying major components of the machine.

Controls And Instruments

Dashboard Controls Overview

Identification and function of controls and instruments on the dashboard.

Operator Station Controls Overview

Identification of controls and instruments in the operator station.

Ignition Switch Operation Details

Details the three-position ignition switch and its functions.

Gear Selector and Horn Functionality

Explains gear selection and horn operation.

Turn Signals and Optional Lights Operation

Operation of turn signals and optional lights.

Optional Road Lights Switch Function

Operation of the optional road lights switch.

Brake System Operation Details

Explanation of the service brake pedal and parking brake.

Accelerator Pedal Functionality

Description of the gas pedal and its function.

Steering Mode Selection Guide

How to select steering modes using the switch.

Continuous Oil Flow and Flow Reversal

Using continuous oil flow and flow reversal functions.

Auxiliary Drive Controls Overview

Controls for hazard lights, heater fan, A/C, washer, and work lights.

Cab Heater Control Knob Function

Adjustment of heated air flow in the cab.

Machine Indicators and Gauges Explained

Explanation of engine coolant, oil temp, fuel gauge, and hour-meter.

Warning Lights Explanations

Detailed explanation of various warning lights on the dashboard.

Control Lever Operation Guide

Operation of the servo-controlled lever and its pushbuttons.

Control Lever Function Selection Guide

How to select functions like boom lifting, extension, and tilting.

Lifting and Lowering the Boom Operation

Step-by-step guide to lifting and lowering the boom.

Extending and Retracting the Boom Operation

Instructions for extending and retracting the boom.

Pitching the Attachment Frame Operation

How to tilt the attachment frame forward or backward.

Hydraulic Quick Coupling/Release Procedure

Procedure for coupling and releasing attachments.

Inspections Procedures

Pre-operation Inspection Fundamentals

Importance and purpose of pre-operation inspection by the operator.

Pre-Operation Inspection Checklist Details

Detailed checklist for pre-operation inspection of machine parts.

Tyre Inspection Procedures

Procedures for checking tyre inflation, wear, and condition.

Function Tests Procedure Guide

Step-by-step guide for testing all machine functions before use.

Control Lever and Steering Tests

Testing control lever functions and steering operations.

Transmission and Brake Tests

Procedures for testing the transmission and brakes.

Workplace Inspection Importance

Importance and procedure for inspecting the workplace before operation.

Operating Instructions

Introduction to Safe Machine Operation

Introduction to operating techniques and safety for standard forks.

Entering the Machine Cab Procedures

Procedures for entering the machine cab, including door operation.

Emergency Cab Exit Procedures

Using windows as emergency exits from the cab.

Adjusting the Operator Seat Details

Instructions for adjusting seat distance, springing, and height.

Seat Belt Fastening Instructions

How to properly fasten and use the seat belts.

Steering Column Angle Adjustment Guide

How to adjust the steering column angle and ensure it is clamped.

Rear View Mirror Adjustment Guide

Procedures for adjusting the right and left rear view mirrors.

Engine Starting Procedure

Step-by-step guide for starting the engine.

Jump-Starting the Engine Safety

Safety precautions and procedure for jump-starting the engine.

Low Temperature Starting Procedure

Using appropriate oil and procedure for cold starting.

Battery Connection for Jump-Start

Detailed procedure for connecting batteries for jump-starting.

Starting the Machine After Engine Start

Steps to start the machine once the engine is running.

Stopping and Parking the Machine Safely

Procedures for safely stopping and parking the machine.

Using Load Charts for Safe Lifting

How to use load charts to determine safe lifting capacities.

Handling Loads Safely Guidelines

Procedures for adjusting forks and handling loads safely.

Adjusting Forks (FEM and Floating)

How to adjust FEM forks and floating forks.

Working Phases Overview

Breakdown of work into loading, transfer, and unloading phases.

Loading Phase Procedures

Steps for approaching, inserting, and retracting the load.

Transfer Phase Safety Practices

Safe driving practices for transferring loads.

Unloading Phase Procedures

Procedures for unloading loads safely.

Changing Attachments (Mechanical Locking)

Procedure for changing attachments using mechanical locking.

Changing Attachments (Hydraulic Locking)

Procedure for changing attachments using hydraulic locking.

Transporting The Machine

Road and Site Transfer Precautions

Precautions for travelling on public roads and general transfer.

Moving a Disabled Machine Procedures

Procedures and precautions for towing a disabled machine.

Lifting the Machine Safely

Safe procedures and means for lifting the machine.

Transporting Machine on Other Vehicles

Steps for safely transporting the machine on another vehicle.

Parking and Storage for Short Inactivity

Procedures for parking and storing the machine for short inactivity.

Machine Storage for Extended Inactivity

Additional precautions for extended machine inactivity and storage.

Cleaning and Washing the Machine Guide

Instructions for cleaning and washing the machine.

Machine and Battery Disposal Guidelines

Environmental considerations for machine and battery disposal.

Maintenance Procedures

Operator's Role in Routine Maintenance

Operator's role in routine maintenance and need for qualified personnel.

Maintenance Symbol Legend

Explanation of symbols used to indicate maintenance requirements.

Service Interval Guidelines

Indicates time intervals for maintenance jobs like running-in and ordinary service.

Lubricant Health and Safety Precautions

Health, storage, disposal, and leak precautions for lubricants.

Ordinary Maintenance Overview

General principles of ordinary maintenance and defect rectification.

First 10 Working Hours Maintenance

Specific checks to be performed during the first 10 working hours.

Daily/10 Working Hours Maintenance

Daily or every 10 working hours maintenance checks.

Weekly/50 Working Hours Maintenance

Weekly or every 50 working hours maintenance checks.

Monthly/250 Working Hours Maintenance

Monthly or every 250 working hours maintenance checks.

3 Working Months Maintenance

Maintenance checks to be performed every 3 working months.

500 Working Hours / Six Months Maintenance

Maintenance checks every 500 hours or six months.

500 Working Hours / Yearly Maintenance

Yearly or every 500 working hours maintenance.

1000 Working Hours / Yearly Maintenance

Yearly or every 1000 working hours maintenance.

Oil Change Schedule Details

Schedule for changing engine, axles, power divider, and hydraulic oil.

General Maintenance Intervention Safety Warnings

General safety warnings for all maintenance interventions.

Accessing the Engine Compartment

Procedures for accessing the engine compartment and its components.

Engine Air Filter Maintenance Procedure

Procedures for cleaning and changing the engine air filter elements.

Engine Cooling System Maintenance

Procedures for checking and maintaining the engine cooling system.

Checking Hydraulic Oil Level

How to check and add hydraulic oil level.

Changing Hydraulic Oil Procedure

Procedure for changing the hydraulic oil in the tank.

Changing Hydraulic Oil Filter Cartridge

Procedure for changing the hydraulic oil filter cartridge.

Cab Air Filter Maintenance

Procedure for cleaning and changing the cab air filter.

Differential Gear Oil Level Management

How to check and change oil levels in differential gears.

Wheel Reduction Gear Oil Level Management

How to check and change oil levels in wheel reduction gears.

Power Divider Gearbox Oil Level Management

How to check and change oil level in the power divider gearbox.

Greasing Procedures and Schedule

Procedures and schedule for greasing the machine.

Tyres and Wheels Maintenance

Information on tyre inflation, substitution, and wheel nut torque.

Brake System Maintenance Details

Information on brake system interventions and authorized workshops.

Shafting Alignment Procedure

Procedure to re-align the front and rear axles of the machine.

Adjusting Boom Section Sliding Pads

How to adjust and replace sliding pads on boom sections.

Block Valves on Cylinders Checks

Checking the efficiency of block valves and their removal.

Machine Start Control Check Procedure

Procedure to check the machine start control for safety.

Structural State Checking Procedure

Periodic inspection of the machine structure, joints, and pins.

Electrical System Safety Precautions

General safety warnings for electrical system maintenance.

Battery Maintenance and Safety Guidelines

Precautions for checking electrolyte, terminals, and handling the battery.

Fuses and Relays Information

Information on electrical system fuses and relays, and replacement.

Engine Compartment Fuses and Relays (Deutz)

Details of fuses and relays in the engine compartment for Deutz version.

Refueling Specifications and Lubricants

Specifications for fuel, engine oil, and lubrication oils.

Fuel Handling and Cold Climate Use

Fuel type and cold climate fuel recommendations.

Grease Application and Types

Types of grease to use for machine greasing and their application.

Engine Coolant Recommendations

Recommendations for antifreeze mixtures and coolant protection.

Faults And Troubleshooting

Dashboard Not Turning On Troubleshooting

Troubleshooting steps for a non-functional dashboard.

Starter Not Running Troubleshooting

Troubleshooting steps for a starter that does not run.

Engine Start Failure Troubleshooting

Troubleshooting steps for when the starter works but the engine doesn't start.

Machine Movement Troubleshooting

Troubleshooting steps for the machine not moving or having insufficient drive.

Steering Mode Selection Troubleshooting

Troubleshooting steps for issues with steering mode selection.

Hydraulic Oil Thermometer Troubleshooting

Troubleshooting for a non-functional hydraulic oil thermometer.

Parking Brake Light Troubleshooting

Troubleshooting steps for the parking brake light not illuminating.

Boom Movement Troubleshooting

Troubleshooting steps for the boom not moving.

Torque Wrench Settings Chart

Chart providing torque wrench settings for metric fasteners.

Optional Attachments Information

Introduction to Optional Attachments

Introduction to optional attachments and safety precautions for their use.

Side Tilt Fork Carriage Details

Technical data, application, and safety for the side tilt fork carriage.

Operating Telehandler with Attachments

Safe operating practices specific to using the telehandler with attachments.

Working Safely with Attachments Guidelines

General safety rules and precautions for working with attachments.

Attachment Maintenance & Service Schedule

Daily and every 40 hours maintenance and service for attachments.

Scrap Grapple Attachment Information

Technical data, safety, and operating instructions for the scrap grapple.

Attachment Installation Procedures

Instructions for installing hydraulic hoses and couplers for attachments.

Detaching Bucket from Telehandler

Procedures for detaching a bucket from the telehandler.

Machine Specifications

Machine Measurements Table

Table listing various physical measurements of the machine.

Machine Productivity Specifications

Table listing productivity specifications like speed and lift capacity.

Engine and Hydraulic Power Specifications

Engine and hydraulic power specs for Deutz and Perkins engines.

Floor Loading Specifications

Specifications related to floor loading, area, and pressure.

Center of Gravity Information

Diagram showing the center of gravity for the GTH-5519 model.

Load Charts Guide

Universal Attachment Adapter Load Chart

Load chart for the universal attachment adapter.

Floating Forks Load Chart

Load chart for the floating forks attachment.

Scrap Grapple Bucket Load Chart

Load chart for the scrap grapple bucket attachment.

Truss Boom Load Chart

Load chart for the truss boom attachment.

Forks and Tines Load Chart

Load chart for various fork and tine configurations.

Bucket Load Chart (60/66 Inch)

Load chart for 60-inch or 66-inch bucket attachments.

Fork Carriage Load Chart (Standard Tines)

Load chart for fork carriage with standard tines.

Fork Carriage Load Chart (60" Tines)

Load chart for fork carriage with 60-inch tines.

Diagrams And Schemes

Wiring Diagram 1/5

The first part of the machine's wiring diagram.

Wiring Diagram 2/5

The second part of the machine's wiring diagram.

Wiring Diagram 3/5

The third part of the machine's wiring diagram.

Wiring Diagram 4/5

The fourth part of the machine's wiring diagram.

Wiring Diagram 5/5

The fifth part of the machine's wiring diagram.

Hydraulic Diagram

The hydraulic diagram for the machine.

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