Terex Genie GTH-5519 Operator's Manual
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Terex Genie GTH-5519 Operator's Manual

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Operator's Manual
GTH-5519
Tier 4 Interim
Tier 4 Final
Serial number range
From GTH55M-7009
Original Instructions
Fourth Edition
Third Printing
April 2019
Part No.
57.0009.0619GT

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Summary of Contents for Terex Genie GTH-5519

  • Page 1 Operator’s Manual Serial number range GTH-5519 From GTH55M-7009 Tier 4 Interim Tier 4 Final Original Instructions Fourth Edition Third Printing April 2019 Part No. 57.0009.0619GT...

  • Page 2: Table Of Contents

    Copyright © 2019 by Terex Corporation Fourth Edition: Third Printing, April 2019 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. GTH-5519 Part No.

  • Page 3: Introduction

    Fourth Edition - Third Printing April 2019 Introduction About This Manual Intended Use Genie appreciates your choice of our machine for A variable reach rough terrain forklift truck is defined your application. Our number one priority is user as a wheeled type truck with a pivoting boom, which safety, which is best achieved by our joint efforts.
  • Page 4 April 2019 Fourth Edition - Third 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. At minimum, Genie should be contacted for: •...
  • Page 5 Fourth Edition - Third Printing April 2019 Introduction Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury. Do Not Operate Unless:  You learn and practice the principles of safe machine operation contained in this operator’s manual.
  • Page 6 April 2019 Fourth Edition - Third Printing Introduction Hazard Classification Standards Safety alert symbol - used to Many aspects of rough terrain forklift operation and alert you to potential personal testing are discussed in standards published by injury hazards. Obey all safety the American National Standards Institute and the messages that follow this Industrial Truck Standards Development Foundation.

  • Page 7: Symbol And Hazard Pictorials Definitions

    Fourth Edition - Third Printing April 2019 Symbol and Hazard Pictorials Definitions Maintain required Injection hazard Electrocution Crush hazard. No people under Read the operator's clearance. hazard load manual. Use a piece of Maintain required cardboard or paper Always wear seat Tip-over hazard Tip-over hazard Crush hazard.

  • Page 8: General Safety

    April 2019 Fourth Edition - Third Printing General Safety for Tier 4 Interim GTH-5519 Part No. 57.0009.0619GT...
  • Page 9 Fourth Edition - Third Printing April 2019 General Safety for Tier 4 Interim Part No. 57.0009.0619GT GTH-5519...
  • Page 10 April 2019 Fourth Edition - Third Printing General Safety for Tier 4 Final GTH-5519 Part No. 57.0009.0619GT...
  • Page 11 Fourth Edition - Third Printing April 2019 General Safety for Tier 4 Final Part No. 57.0009.0619GT GTH-5519...

  • Page 12: Work Area Safety

    April 2019 Fourth Edition - Third Printing Work Area Safety Overturning Hazards Do not raise the boom unless the Using the load chart, confirm that machine is level. The machine level the load is within the rated capacity indicator should be at zero degrees. of the machine.
  • Page 13 Fourth Edition - Third Printing April 2019 Work Area Safety Traveling on Slopes Hazards Operators should be properly trained and use their best judgment and experience to take the When driving, keep the boom at necessary precautions to prevent a tip-over. or below horizontal and keep the load close to the ground.
  • Page 14 April 2019 Fourth Edition - Third Printing Work Area Safety Collision Hazards Falling Object Hazards Keep people, equipment and Operate the machine at speeds that will keep the material out of the work area. load under control. Start and stop movements Do not operate the machine smoothly.
  • Page 15 Fourth Edition - Third Printing April 2019 Work Area Safety Damaged Machine Hazards Bodily Injury Hazards Do not use a damaged or malfunctioning machine. Always adjust the seat and fasten the seat belt before starting the Conduct a thorough pre-operation inspection of the engine.
  • Page 16 April 2019 Fourth Edition - Third Printing Work Area Safety Component Damage Hazards Burn Hazards Do not use any battery or charger greater than 12V Allow hot surfaces to cool before to jump-start the engine. touching or servicing. Do not use the machine as a ground for welding. Crush Hazards Explosion and Fire Hazards Keep clear of moving parts during machine operation.
  • Page 17 Fourth Edition - Third Printing April 2019 Work Area Safety Electrocution Hazards Do not use the machine as a ground for welding. This machine is not electrically insulated and will not provide protection from contact with or Always contact the electrical power line owner. The proximity to electrical current.
  • Page 18 April 2019 Fourth Edition - Third Printing Work Area Safety Battery Safety Employer's Responsibilities Burn Hazards Employers are responsible for providing a safe work environment and for complying with local and Batteries contain acid. national governmental regulations. Always wear protective clothing and eye wear when working with batteries.

  • Page 19: Legend

    Fourth Edition - Third Printing April 2019 Legend 1. Left/right level indicator 13. Brake pedal 2. Steering wheel 14. Accelerator pedal 3. Control handle 15. Transmission control lever 4. Left rear view mirror 16. Right rear view mirror 5. Boom angle indicator 17.

  • Page 20: Controls

    April 2019 Fourth Edition - Third Printing Controls 26 10 *NOTE: The horn button 2 is positioned at the end of the transmission control lever up to machine serial number GTH55M-10886. The horn button 2 is positioned at the centre of the steering wheel from machine serial number GTH55M-10887 and GTH55M-10851, GTH55M-10854, GTH55M-10860, GTH55M-10862, GTH55M-10863, GTH55M-10864, GTH55M-10866, GTH55M-10867, GTH55M-10869, from GTH55M-10872 to GTH55M-10882, and GTH55M-10884,GTH55M-10885.
  • Page 21 Fourth Edition - Third Printing April 2019 Controls Steering wheel Control handle Turn the steering wheel to the right to turn the Pull the control handle back and the boom will front wheels to the right. Turn the steering wheel raise.
  • Page 22 April 2019 Fourth Edition - Third Printing Controls 17 Hazard warning lights switch (if equipped) 22 Seat adjustment Push the switch to turn the hazard warning 23 Continuous oil flow potentiometer lights on. Release the switch to turn the hazard Turn the potentiometer clockwise to increase the warning lights off.
  • Page 23 Fourth Edition - Third Printing April 2019 Controls °c 1230 engine rpm 000000.0 Instrument Panel 14. Not active 1. Low engine oil pressure indicator light 15. Engine coolant temperature gauge with 2. Parking brake engaged indicator light high coolant temperatur indicator light 3.
  • Page 24 April 2019 Fourth Edition - Third Printing Controls 1 Low engine oil pressure indicator light 12 Engine Critical Fault indicator light When illuminated this light indicates that the engine This light comes on to warn of a problem with the oil pressure is too low which can lead to machine engine.

  • Page 25: Inspections

    Fourth Edition - Third Printing April 2019 Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection Do Not Operate Unless: performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator ...
  • Page 26 April 2019 Fourth Edition - Third Printing Inspections Pre-operation Inspection  Limit switches  Be sure that the operator’s, safety and responsibilities manuals are complete, legible  Lights, alarms and beacons (if equipped) and in the storage container located in the cabin. ...
  • Page 27 Fourth Edition - Third Printing April 2019 Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 28 April 2019 Fourth Edition - Third Printing Inspections Function Tests Test the Control Handle 16 Start the machine with the parking brake on Select a test area that is firm, level and free of and the transmission control lever set to neutral obstruction.
  • Page 29 Fourth Edition - Third Printing April 2019 Inspections Test the Steering Test the Transmission and Brakes 21 Rotate the steer selector to the right side to select 29 Be sure the boom is fully lowered and retracted. four-wheel steer. 30 Step on the brake pedal. Push the top of the 22 Check the steering operation by turning the parking brake switch to turn it off.
  • Page 30 April 2019 Fourth Edition - Third Printing Inspections Test the Drive 43 Release the parking brake and slowly let up on the brake pedal and slowly approach the object. 37 Step on the brake pedal. Stop the machine before it reaches the object. 38 Push the bottom of the parking brake switch.
  • Page 31 Fourth Edition - Third Printing April 2019 Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions or debris Do Not Operate Unless:  sloped surfaces  You learn and practice the principles of safe ...
  • Page 32 Label - Load Chart 60 And 66 Inch Danger – Explosion/Burn Hazard, 09.4618.0801 237971 Bucket Fueling Label - Load Chart Scrap Grapple 09.4618.0643 Cosmetic - Genie GTH-5519 09.4618.0802 Bucket 09.4618.0644 Cosmetic - GTH-5519 Label - Load Chart 60 Inch Forks Danger/Warning – 7 Decal 09.4618.0803 - Optional 48 Inch Forks - 48 Inch 09.4618.1622...
  • Page 33 Fourth Edition - Third Printing April 2019 Inspections 09.4618.0643 237601 237605 97667 97602 237971 97667 28159 237598 214418 1258639 237598 09.4618.2048 1263543 97667 09.4618.0644 09.4618.1622 09.4618.1688 09.4618.1742 load chart set 09.4618.0776 1280819 09.4618.1025 1280820 82558 09.4618.1999 09.4618.0644 237598 09.4618.0643 215267 82366 214418 214418...
  • Page 34 Fueling 09.4618.0801 Bucket 826345 Label – Ultra Low Sulfur Fuel Only Label - Load Chart Scrap Grapple 09.4618.0643 Cosmetic - Genie GTH-5519 09.4618.0802 Bucket 09.4618.0644 Cosmetic - GTH-5519 Label - Load Chart 60 Inch Forks 09.4618.0803 - Optional 48 Inch Forks - 48 Inch Danger/Warning –...
  • Page 35 Fourth Edition - Third Printing April 2019 Inspections 09.4618.0643 237601 237605 97602 237971 97667 826345 28159 97667 237598 214418 09.4618.0644 1258639 237598 09.4618.2048 1263543 97667 09.4618.1622 09.4618.1688 09.4618.1742 load chart set 09.4618.0776 1280819 09.4618.1025 1280820 82558 09.4618.1999 09.4618.0644 237598 09.4618.0643 215267 82366 214418...

  • Page 36: Operating Instructions

    April 2019 Fourth Edition - Third Printing Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety and responsibilities manuals. Do Not Operate Unless: A variable reach rough terrain forklift truck is defined as a wheeled type truck designated...
  • Page 37 Fourth Edition - Third Printing April 2019 Operating Instructions Parking Brake Steer Select Use the parking brake switch to apply the parking Always position all wheels in line with the machine brake before raising the boom or leaving the before switching the steering mode. machine.
  • Page 38 April 2019 Fourth Edition - Third Printing Operating Instructions Transmission Control Use the transmission control lever to control the direction of machine travel. Step on the service brake pedal before putting the transmission into gear. To drive forward, move the transmission control lever toward you and move it up.
  • Page 39 Fourth Edition - Third Printing April 2019 Operating Instructions Transporting a Load Raising and Placing a Load Center the load on the forks. Position the load so The load chart in the cab shows the operating that it is completely against the back of the fork limits of a properly maintained and operated frame.
  • Page 40 April 2019 Fourth Edition - Third Printing Operating Instructions Gradually move the controller to raise and Gradually move the controller to raise and extend the boom to the required height. retract the boom. This will bring the forks out of the load. When the forks are clear of the load and the structure, the boom can be lowered and retracted.
  • Page 41 Fourth Edition - Third Printing April 2019 Operating Instructions Controller movements 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. 57.0009.0619GT GTH-5519...
  • Page 42 April 2019 Fourth Edition - Third Printing Operating Instructions Quick Attach Instructions Version with hydraulic locking (optional) 1. Drive to the place where you will release the Version with mechanical locking mounted attachment (when possible, a solid 1 Drive to the place where you will release the and sheltered site).
  • Page 43 Fourth Edition - Third Printing April 2019 Operating Instructions Engine Condition Indicator Jump Starting the Machine If the Engine Alert indicator light and/or the Engine Jump starting at the battery or battery replacement Critical Fault indicator light switch on, contact is required when the battery is discharged to the service personnel.
  • Page 44 April 2019 Fourth Edition - Third Printing Operating Instructions Driving on a slope Rear Proximity Alarm When the machine is loaded, always travel with The system is designed to supplement other safety the load uphill. When the machine is unloaded, practices and systems such as signal person and travel with the forks or attachment downhill.
  • Page 45 Fourth Edition - Third Printing April 2019 Operating Instructions Moving a disabled machine Clear the area of any personnel before remove Tow the machine only when no alternative is possible, the locking from each of the four tires and tow the since this operation may result in serious damage to vehicle to a suitable location.

  • Page 46: Transport And Lifting Instructions

    April 2019 Fourth Edition - Third Printing Transport and Lifting Instructions  Before loading for transport, make sure the deck, ramps and machine tires are free of mud, snow and ice. Failure to do so could cause the machine to slide. ...
  • Page 47 Fourth Edition - Third Printing April 2019 Transport and Lifting Instructions Securing to Truck or Trailer for Transit Securing the Chassis Turn the key switch to the off position and remove Use chains of ample load capacity. the key before transporting. Use a minimum of 4 chains.
  • Page 48 April 2019 Fourth Edition - Third Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Determine the center of gravity of your machine using the picture on this page. Remove all loose items on the machine. Observe and Obey: Attach the rigging only to the designated lifting points on the machine.

  • Page 49: Maintenance

    Fourth Edition - Third Printing April 2019 Maintenance Diesel Fuel Requirements Satisfactory engine performance is dependent on the use of a good quality fuel. The use of a good quality fuel will give the following result: long engine life and acceptable exhaust emissions Observe and Obey: levels.
  • Page 50 April 2019 Fourth Edition - Third Printing Maintenance Check the Engine Oil Level Check the Hydraulic Oil Level Maintaining the proper engine oil level is essential Maintaining the hydraulic oil at the proper level is to good engine performance and service life. essential to machine operation.
  • Page 51 Fourth Edition - Third Printing April 2019 Maintenance Check the Engine Coolant Level - Check the Tire Pressure Liquid Cooled Models Tip-over hazard. An over-inflated tire can explode which may compromise machine Maintaining the engine coolant at the proper level stability and cause the machine to tip over.
  • Page 52 April 2019 Fourth Edition - Third Printing Maintenance Check the Battery Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Proper battery condition is essential to good this machine according to the procedures found in machine performance and operational safety.

  • Page 53: Attachments

    Fourth Edition - Third Printing April 2019 Attachments Overturning Hazards Suspended Load Hazards Work Area Safety Do not lift a suspended load without the proper and legible load capacity chart for the attachment/ General Safety telehandler combination you are using. Do not permit Do not lift a suspended load without first the load to swing...
  • Page 54 April 2019 Fourth Edition - Third Printing Attachments Collision Hazards Identify the proper lifting points of the load, taking into consideration the center of gravity and load Be sure that the load is clear of any adjacent stability. obstacles before lifting. Do not attempt to use the telehandler frame- When visibility is or could be obstructed, near leveling to compensate for a swinging load or to...
  • Page 55 Fourth Edition - Third Printing April 2019 Attachments Lifting a Suspended Load Traveling Verify that the landing point is level and can safely Be sure that the path of travel is level and capable support the load. of supporting the telehandler with its load. Properly secure the attachment to the telehandler Keep the boom, and load, as low as practical while maintaining visibility in the direction of travel.
  • Page 56 April 2019 Fourth Edition - Third Printing Attachments Placing the Load Signal Person (from 1926.1419) Ask a signal person to assist with placing the Per OSHA CFR 1926.1419, a signal person is load if visibility will be obstructed at the point of required when: operation.
  • Page 57 Fourth Edition - Third Printing April 2019 Attachments STOP. With arm EMERGENCY STOP. With both arms extended HOIST. With upper RAISE BOOM. With extended horizontally to horizontally to the side, palms down, arms are arm extended to the arm extended the side, palm down, swung back and forth.
  • Page 58 April 2019 Fourth Edition - Third Printing Attachments Suspended Load Hazards Rigger Requirements (from OSHA CFR 1926.404) When employees are engaged in hooking, unhooking, or guiding the load, or in the initial connection of a load to a component or structure and are within the fall zone, all of the following criteria must be met: The materials being hoisted must be rigged to...

  • Page 59: Specifications

    Fourth Edition - Third Printing April 2019 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 2,36 m Ground clearance, center 1 ft 1 in...
  • Page 60 April 2019 Fourth Edition - Third Printing Specifications Rear proximity Sensor Range Approximate detection range. Minimum rear proximity sensor detection height is 2 ft / 0.6 m. GTH-5519 Part No. 57.0009.0619GT...

  • Page 61: Load Charts

    Fourth Edition - Third Printing April 2019 Load Charts Load Capacity Field Calculations To calculate the new reduced load capacity at a load center greater than the standard 24 in / 61 cm load center, multiply the zone capacity from Always center the load on the forks.
  • Page 62 April 2019 Fourth Edition - Third Printing Load Charts GTH-5519, Standard Carriage 10 ft 5 ft 0 ft 3.05 m 1.52 m 20 ft 6.10 m 15 ft 4.57 m 10 ft 3.05 m 5 ft 1.52 m 0 ft 10 ft 5 ft 0 ft...
  • Page 63 Fourth Edition - Third Printing April 2019 Load Charts GTH-5519, Scrap Grapple Bucket GTH-5519, 60 inch Forks - optional 48 inch Forks - 48 inch cubing Tines OPT. 48 48 INC Part No. 57.0009.0619GT GTH-5519...
  • Page 64 April 2019 Fourth Edition - Third Printing Load Charts GTH-5519, Universal Attachment Adapter 09.4618 GTH-5519, Rotating Or Side Shift Fork Carriage - Standard Fork Tines ROTATING OR SIDE SHIFT F STANDA 09 46 GTH-5519 Part No. 57.0009.0619GT...
  • Page 65 Fourth Edition - Third Printing April 2019 Load Charts GTH-5519, Truss Boom 09 461 GTH-5519, Side Shift Fork Carriage - 60” Fork Tines SIDE SHIF 09 4 Part No. 57.0009.0619GT GTH-5519...
  • Page 66 April 2019 Fourth Edition - Third Printing Load Charts GTH-5519, Shackle GTH-5519 09.4618.1867 GTH-5519 Part No. 57.0009.0619GT...
  • Page 67 California Proposition 65 WARNING Operating, servicing and maintaining this equipment, passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.

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