Genie GTH-5519 Original Instructions Manual
  1. Manuals
  2. Brands
  3. Genie Manuals
  4. Multi Terrain Loaders
  5. GTH-5519
  6. Original instructions manual

Genie GTH-5519 Original Instructions Manual

Hide thumbs Also See for GTH-5519:
Table of Contents

Advertisement

Quick Links

See also: Service & Repair Manual , Maintenance Manual
Operator's Manual
GTH-5519
Tier 4 Interim
Tier 4 Final
Serial number range
From GTH5516M-4511
To GTH5516M-5337
Original Instructions
Second Edition
First Printing
November 2015
Part No.
57.0009.0619

Advertisement

Table of Contents
loading

Related Manuals for Genie GTH-5519

Summary of Contents for Genie GTH-5519

  • Page 1 Operator’s Manual Serial number range GTH-5519 From GTH5516M-4511 To GTH5516M-5337 Tier 4 Interim Tier 4 Final Original Instructions Second Edition First Printing November 2015 Part No. 57.0009.0619...

  • Page 2: Table Of Contents

    Load Charts ............57 Copyright © 2015 by Terex Corporation Second Edition: First Printing, November 2015 Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “GTH” is a trademark of Terex SouthDakota, Inc.

  • Page 3: Introduction

    This book is an operation and daily maintenance transporting and placing loads with the established manual for the user or operator of a Genie machine. load range charts. Use of this product in any other way is prohibited This manual,along with the AEM Rough Terrain and contrary to its intended use.
  • Page 4 Second Edition - First Printing Introduction Contacting the Manufacturer At times it may be necessary to contact Genie. When you do, be ready to supply the model number and serial number of your machine, along with your name and contact information.
  • Page 5 ENVIRONMENT 5 You read, understand and obey the employer’s safety rules and worksite regulations. 5 You read, understand and obey all applicable governmental regulations. 5 You are properly trained to safely operate the machine. Part No. 57.0009.0619 GTH-5519...
  • Page 6 PROTECT THE safety signs are installed before the machine is put ENVIRONMENT into service. Use mild soap and water to clean safety signs. Do not use solvent based cleaners, which may damage the safety sign material. GTH-5519 Part No. 57.0009.0619...

  • Page 7: Symbol And Hazard Pictorials Definitions

    Burn Hazard hazard No open flame. starting aids cool. Allow engine Work platform use compartment Refer to load charts Explosion/burn No smoking. No Fall hazard access hazard open flame. and manual Keep load low Sway operation Part No. 57.0009.0619 GTH-5519...

  • Page 8: General Safety

    November 2015 Second Edition - First Printing General Safety for Tier 4 Interim GTH-5519 Part No. 57.0009.0619...
  • Page 9 Second Edition - First Printing November 2015 General Safety for Tier 4 Interim Part No. 57.0009.0619 GTH-5519...
  • Page 10 November 2015 Second Edition - First Printing General Safety for Tier 4 Final GTH-5519 Part No. 57.0009.0619...
  • Page 11 Second Edition - First Printing November 2015 General Safety for Tier 4 Final Part No. 57.0009.0619 GTH-5519...

  • Page 12: Work Area Safety

    Do not alter or disable machine components that in any way affect safety and stability. Do not replace items critical to machine stability with items of different weight or specification. Do not replace factory-installed tires with tires of different specification or ply rating. GTH-5519 Part No. 57.0009.0619...
  • Page 13 Do not lift personnel with this machine unless it is equipped with Construction sites and roads will frequently change an approved work platform. slope from place to place, can be hard and soft, and change due to construction activities and weather. Part No. 57.0009.0619 GTH-5519...
  • Page 14 Do not operate the machine in low light conditions. Operators must comply with employer, job site and governmental rules regarding use of personal protective equipment. Do not drive the machine directly up to anyone. GTH-5519 Part No. 57.0009.0619...
  • Page 15 An air leak or hydraulic leak can penetrate and/or burn skin. Be sure all maintenance has been performed as specified in this manual and the appropriate Genie Relieve pressure before service manual. disconnecting hydraulic lines. Keep away from leaks and pin Be sure all decals are in place and legible.
  • Page 16 Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present. Do not spray ether into engines equipped with glow plugs or air intake grid heaters. GTH-5519 Part No. 57.0009.0619...
  • Page 17 For power lines over 1000kV, the minimum clearance distance must be established by the utility owner or operator or by a registered professional engineer who is a qualified person with respect to electrical power transmission and distribution. Part No. 57.0009.0619 GTH-5519...
  • Page 18 Explosion Hazards Keep sparks, flames and lighted tobacco away from batteries. Batteries emit explosive gas. Electrocution Hazard Avoid contact with electrical terminal. GTH-5519 Part No. 57.0009.0619...

  • Page 19: Legend

    4. Left rear view mirror 13. Brake pedal 5. Boom angle indicator 14. Accelerator pedal 6. Boom 15. Transmission control lever 7. Cab 16. Right rear view mirror 8. Hydraulic oil level gauge 17. Operators manual storage 9. Engine Part No. 57.0009.0619 GTH-5519...

  • Page 20: Controls

    November 2015 Second Edition - First Printing Controls 26 10 BRAKE GTH-5519 Part No. 57.0009.0619...
  • Page 21 & boom working lights on. Push the bottom automatically. of the switch to turn the cab, boom and rear working lights on. Push the top of the rocker Instrument panel switch to turn them off. Part No. 57.0009.0619 GTH-5519...
  • Page 22 21 Cab heater fan switch (if equipped) Push the switch to turn the cab heater fan on: first position for low speed and second position for high speed. Release the switch to turn the cab heater fan off. GTH-5519 Part No. 57.0009.0619...
  • Page 23 10. Engine air filter restricted indicator light 22. Brake pressure low indicator light 11. Engine Alert indicator light 23. High beam indicator light 12. Engine Critical Fault indicator light 24. Battery voltage low indicator light 13. Not active Part No. 57.0009.0619 GTH-5519...
  • Page 24 Discontinue use of the machine and service. 11 Engine Alert indicator light This light flashes to warn of a problem with the engine. To identify the problem, see the two sections “Engine Lamp Logic” GTH-5519 Part No. 57.0009.0619...

  • Page 25: Inspections

    Scheduled maintenance inspections shall be PROTECT THE performed by qualified service technicians, according ENVIRONMENT to the manufacturer’s specifications and the requirements listed in the responsibilities manual. Part No. 57.0009.0619 GTH-5519...
  • Page 26 ‰ Electrical components, wiring and electrical cables ‰ Hydraulic hoses, fittings, cylinders and manifolds ‰ Fuel and hydraulic tanks ‰ Drive motors and drive hubs ‰ Boom wear pads ‰ Tires and wheels ‰ Mirrors ‰ Engine and related components GTH-5519 Part No. 57.0009.0619...
  • Page 27 Know and understand the pre-operation inspection before going on to the next section. CAUTION 3. Always perform function tests prior to use. 4. Inspect the workplace. 5. Only use the machine as it was intended. NOTICE PROTECT THE ENVIRONMENT Part No. 57.0009.0619 GTH-5519...
  • Page 28 13 Push the bottom of the parking brake switch to turn it on. 14 Insert the key in the ignition switch. 15 Turn the key to start the engine. ~ Result: The engine should not start. GTH-5519 Part No. 57.0009.0619...
  • Page 29 36 With the foot on the service brake, slowly release ~ Result: The front wheels and the rear wheels the service brake. should turn in the same direction as the steering ~ Result: The machine should not move. wheel. Part No. 57.0009.0619 GTH-5519...
  • Page 30 39 Put the transmission control lever in forward. Slowly let up on the brake pedal. ~ Result: The drive function should not operate. Test the Lights (if equipped) 40 Verify that all lights are functional. GTH-5519 Part No. 57.0009.0619...
  • Page 31 It should be performed by the operator prior to moving the machine to the workplace. It is the operator’s responsibility to read and remember the workplace hazards, then watch for and avoid them while moving, setting up and operating the machine. Part No. 57.0009.0619 GTH-5519...
  • Page 32 System 82558 Warning – Skin Injection Hazard 09.4618.1742 Label - Emergency Exit Handles 97667 Warning – Burn Hazard 1258639 Cosmetic - Genie Low Relief Danger/Warning – 2 Decal 214418 Combination Label - Load Chart, Standard 09.4618.1738 Carriage 215267 Label – Product Registration Label - Load Chart 60 And 66 Inch Warning –...
  • Page 33 237598 214418 1258639 237598 28175 97667 09.4618.0644 09.4618.1622 09.4618.1688 09.4618.1742 load chart set 09.4618.1025 09.4618.0776 82558 09.4618.0644 237598 09.4618.0643 215267 82366 214418 214418 09.4618.1690 215268 09.4618.1691 Shading indicates decal is hidden from view, i.e. under covers Part No. 57.0009.0619 GTH-5519...
  • Page 34 Warning – Burn Hazard 09.4618.1742 Label - Emergency Exit Handles Danger/Warning – 2 Decal 214418 Combination 1258639 Cosmetic - Genie Low Relief 215267 Label – Product Registration 09.4618.1738 Label - Load Chart, Standard Carriage Label - Load Chart 60 And 66 Inch 215268 Warning –...
  • Page 35 237598 214418 09.4618.0644 1258639 237598 28175 97667 09.4618.1622 09.4618.1688 09.4618.1742 load chart set 09.4618.1025 09.4618.0776 82558 09.4618.0644 237598 09.4618.0643 215267 82366 214418 214418 09.4618.1690 215268 09.4618.1691 Shading indicates decal is hidden from view, i.e. under covers Part No. 57.0009.0619 GTH-5519...

  • Page 36: Operating Instructions

    That means every new operator should perform a pre-operation inspection, function tests, and a workplace inspection before using the machine. NOTICE Additionally, everyone working on or near the product also needs to be familiar with the applicable safety precautions. PROTECT THE ENVIRONMENT GTH-5519 Part No. 57.0009.0619...
  • Page 37 In extreme cold conditions, 0°F / -18°C and below, 09.4618.1742 machines should be equipped with optional cold start kits. Attempting to start the engine when temperatures are below 0°F / -18°C may require the use of a booster battery. Part No. 57.0009.0619 GTH-5519...
  • Page 38 To drive in reverse, move the transmission control lever toward you and move it down: the back-up alarm sounds and the rear working light turns on (if equipped). To return to neutral, move the transmission control lever to the center position. GTH-5519 Part No. 57.0009.0619...
  • Page 39 Obtain a larger machine capable of handling the load within specifications. Placing the load Travel to the desired work site and carefully stop the machine. Put the transmission in neutral. Apply the parking brake. Part No. 57.0009.0619 GTH-5519...
  • Page 40 Gradually move the controller to lower and extend the boom into final position. Lower the load until the weight is completely off the forks. Do not apply a downward force with the forks. GTH-5519 Part No. 57.0009.0619...
  • Page 41 Second Edition - First Printing November 2015 Operating Instructions Controller movements 143 mm OPTIONAL 09.4618.1688 Control handle only Control handle only with Control handle only with yellow thumb red thumb switch (B) switch (A) Part No. 57.0009.0619 GTH-5519...
  • Page 42 9 Refit mechanical locking pin fixing it with its safety together with the dashboard Lock/Unlock split-pin. Enabling Switch. 10 Re-couple the connectors of the attachment (if 11. Re-couple the connectors of the attachment (if any). any). GTH-5519 Part No. 57.0009.0619...
  • Page 43 Connect one end of the second jumper cable to the negative (-) post of the booster battery. Make the final cable connection to the engine block or the furthest ground point away from the battery. Start the engine. Part No. 57.0009.0619 GTH-5519...
  • Page 44 Operators should be properly trained and use their best judgment and experience to take the necessary precautions to prevent tip over. Operators must assess the jobsite variables and avoid exceeding the machine’s (or operator’s) capabilities for terrain and conditions. GTH-5519 Part No. 57.0009.0619...

  • Page 45: Transport And Lifting Instructions

    US Department of Transportation regulations, other localized regulations, and their company policy. 5 Genie customers needing to containerize any lift or Genie product should source a qualified freight forwarder with expertise in preparing, CAUTION loading and securing construction and lifting equipment for international shipment.
  • Page 46 Prior to loading, level the telehandler and retract the boom. Adjust the rigging to prevent damage to the chains. Use a spotter to load and unload the telehandler. Keep the boom as low as possible when loading and unloading. Set the parking brake. GTH-5519 Part No. 57.0009.0619...
  • Page 47 5 Be sure the crane capacity, loading surfaces and straps or lines are sufficient to withstand the machine weight. See the serial label for the machine weight. CAUTION NOTICE PROTECT THE 30 in / ENVIRONMENT 0.77 m 60 in / 1.52 m Part No. 57.0009.0619 GTH-5519...

  • Page 48: Maintenance

    Indicates that new parts will be required to perform this procedure. Indicates that a cold engine will be required to perform this procedure. Moving a disabled machine For towing procedure, please refer to the Service Manual Section 4, Repair Procedures. GTH-5519 Part No. 57.0009.0619...
  • Page 49 ~ Result: The hydraulic oil level should be Deutz 2.9 Tier 4 Final halfway in the sight gauge. Oil type SHELL RIMULA R4 L 15W-40 Add oil as needed. Do not overfill. Hydraulic oil specifications Hydraulic Oil type CHEVRON RANDO HD EQUIVALENT Part No. 57.0009.0619 GTH-5519...
  • Page 50 Add air as needed. Tire pressure 65 psi 4.5 bar Check Mirrors Maintaining the indirect visual aids is essential to workplace visibility. 1. Visually inspect all mirrors to ensure they are working properly and clean and free from debris. GTH-5519 Part No. 57.0009.0619...
  • Page 51 Be sure that the battery hold-down brackets are in place and secure. Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and cables. Part No. 57.0009.0619 GTH-5519...

  • Page 52: Attachments

    Only lift a load vertically; do not pull a load horizontally as it could cause excessive swinging of the load. The weight of all rigging (slings, shackles etc.) must be included as part of the load. GTH-5519 Part No. 57.0009.0619...
  • Page 53 Do not operate the machine while people are Fall Hazards under the load or in the fall zone. Do not lift or suspend personnel. Do not suspend loads using slings or chains from the forks or fork carriage. Avoid lifting double tiered loads. Part No. 57.0009.0619 GTH-5519...
  • Page 54 Be sure that all boom and attachment movements are performed as slow as practical to avoid swinging of the load. GTH-5519 Part No. 57.0009.0619...
  • Page 55 When using hand signals, follow the requirements removed. set forth in OSHA CFR 1926.1419-1926.1422. The hand signal chart below may be used in place of the Standard Method in Appendix A of Subpart CC of Part OSHA CFR 1926. Part No. 57.0009.0619 GTH-5519...
  • Page 56 GTH-5519 Part No. 57.0009.0619...
  • Page 57 The materials being hoisted must be rigged to prevent unintentional displacement. Hooks with self-closing latches or their equivalent must be used. Exception: “J” hooks are permitted to be used for setting wooden trusses. The materials must be rigged by a qualified rigger. Part No. 57.0009.0619 GTH-5519...

  • Page 58: Specifications

    November 2015 Second Edition - First Printing Specifications GTH-5519 Height, stowed 6 ft 4 in 1,92 m Length, stowed, without 12 ft 2 in 3,70 m forks Width, standard tires 5 ft 11 in 1,81 m Wheelbase 7 ft 9 in...

  • Page 59: Load Charts

    10 ft 3.05 m 5 ft 1.52 m 0 ft 10 ft 5 ft 0 ft 3.05 m 1.52 m GTH-5519, 60 and 66 inch Bucket 09.4618.1738 GTH 5519 60 INCH BUCKET 66 INCH BUCKET 09.4618.0801 Part No. 57.0009.0619 GTH-5519...
  • Page 60 Second Edition - First Printing Load Charts GTH-5519, Scrap Grapple Bucket GTH 5519 09.4618.0802 GTH-5519, 60 inch Forks - optional 48 inch Forks - 48 inch cubing Tines GTH 5519 60 INCH FORKS OPT. 48 INCH ITA FORKS 48 INCH CUBING TINES 09.4618.0803...
  • Page 61 Second Edition - First Printing November 2015 Load Charts GTH-5519, Universal Attachment Adapter GTH 5519 09.4618.0804 GTH-5519, Rotating Or Side Shift Fork Carriage - Standard Fork Tines GTH 5519 ROTATING OR SIDE SHIFT FORK CARRIAGE STANDARD FORK TINES 09.4618.0805 Part No.
  • Page 62 November 2015 Second Edition - First Printing Load Charts GTH-5519, Truss Boom GTH 5519 09.4618.0806 GTH-5519, Side Shift Fork Carriage - 60” Fork Tines GTH 5519 SIDE SHIFT FORK CARRIAGE 60” FORK TINES 09.4618.1680 GTH-5519 Part No. 57.0009.0619...
  • Page 63 Second Edition - First Printing November 2015 Load Charts GTH-5519, Shackle GTH-5519 09.4618.1867 Part No. 57.0009.0619 GTH-5519...
  • Page 64 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. www.genielift.com...

Table of Contents