Terex Genie GTH-5519 User manual

Operator’s Manual
First Edition
Eleventh Printing
Part No. 57.0009.0412
Serial number range
With Maintenance
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

Operator’s Manual
2 GTH-5519 Part No. 57.0009.0412
First Edition - Eleventh Printing
Important
Read, understand and obey these safety rules
and operating instructions before operating the
machine. Only trained and qualified personnel
shall be authorized to operate the machine.
This manual shall be kept with the machine at
all times.
For any further information, please call
Terexlift.
Contents
Introduction..........................................Page 3
Machine Identification..........................Page 5
Symbols Used On The Machine..........Page 7
Labels And Plates Applied On The
Machine...............................................Page 9
Safety Precautions ..............................Page 17
Description Of The Main Components...Page 25
Controls And Instruments....................Page 27
Inspections ..........................................Page 41
Operating Instructions .........................Page 45
Transporting The Machine...................Page 57
Maintenance........................................Page 61
Faults And Troubleshooting.................Page 85
Optional Attachments ..........................Page 89
Specifications ......................................Page 95
Load Charts.........................................Page 99
Diagrams And Schemes......................Page 107
Contact us:
ZONA INDUSTRIALE I-06019 UMBERTIDE
(PG) - ITALY
Telephone [phone]
Telefax [phone]
Technical Assistance Service
Telephone: [phone]
[phone]
e-mail: [email protected]
Original Instructions
First Edition: Tenth Printing, October 2011
For the electronic version of this manual visit
www.genielift.com/operator_manuals.asp
©Copyright 2006 TEREXLIFT srl - All rights reserved
Produced by:
TEREXLIFT Technical Literature Dept.
Umbertide (PG) Italy

Operator’s ManualFirst Edition - Eleventh Printing
Part No. 57.0009.0412 GTH-5519 3
Introduction
Symbols
Safety alert symbol: used to
alert you to potential personal
injury hazards. Obey all safety
messages that follow this
symbol to avoid possible
injury or death
DANGER
Red: indicates a hazardous
situation which, if not avoided,
will result in death or serious
injury.
WARNING
Orange: indicates a hazardous
situation which, if not avoided,
could result in death or serious
injury.
CAUTION
Yellow : indicates a hazardous
situation which, if not avoided,
could result in minor or
moderate injury.
NOTICE
Blue: indicates a hazardous
situation which, if not avoided,
could result in property
damage.
PROTECT THE
ENVIRONMENT
Green: used to draw the
attention to important
information on environment
protection.

Operator’s Manual
4 GTH-5519 Part No. 57.0009.0412
First Edition - Eleventh Printing
Intentionally blank page

Operator’s ManualFirst Edition - Eleventh Printing
Part No. 57.0009.0412 GTH-5519 5
Machine Identification
Check that the operator handbook refers to the
delivered machine.
MODEL AND TYPE
Handler with telescopic boom:
models: GTH-5519
MANUFACTURER
TEREXLIFT srl
Zona Industriale - I-06019 UMBERTIDE (PG) -
ITALY
Enrolled in the register of companies at the Court of
Perugia under no. 4823
C.C.I.A.A. 102886
Fiscal Code/V.A.T. no. 00249210543
APPLICABLE STANDARDS
For the operator’s safety, the following standards were
obeyed during the risk assessment of the handler
fitted with telescopic boom norme:
Directive Title
ANSI/ITSDF B56.6-2002 part III where applicable.
CSA B335-04 where applicable.
MACHINE IDENTIFICATION PLATES
The following data plates are applied on the
machine:
Machine data plate
The identification plate contains the main identification
data of the machine like model, serial number and
year of manufacture.
The data plate is applied on the front right side of
the chassis.
ROPS-FOPS cab type-approval plate
The ROPS - FOPS type-approval plate is located
inside the driving cab above the rear glass.
Fork data plate
Placed on the left side of the fork frame.
This plate shows the identification data of fork such
as model, serial number, year of manufacture, weight,
nominal payload, centre of the load and model of the
machine on which the forks are installed.

Operator’s Manual
6 GTH-5519 Part No. 57.0009.0412
First Edition - Eleventh Printing
Machine Identification
CHASSIS SERIAL NUMBER
The chassis serial number is punched on the front
left part of the chassis side member.
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
YOUR SERIAL
NUMBER
Chassis serial number
(The chassis serial number is punched on the front left
part of the chassis side member)
Machine data plate
(The data plate is applied on the front right side of the chassis)
GTH-5519 P 07 17882
MODEL
ENGINE
TYPE
YEAR OF
MANIFACTURER
SERIAL
NUMBER

Operator’s ManualFirst Edition - Eleventh Printing
Part No. 57.0009.0412 GTH-5519 7
Symbols Used On The Machine
Fuel level General alarm Low engine oil
pressure
Parking brake Battery charge
Hydraulic oil filter
clogged
Hydraulic oil filter Low Hydraulic Oil
Level Turn signals High beam
Not active Not active Glow Plugs Preheating High Coolant Tempe-
rature
Low beam
Rear Wheel Aligned Air Filter Restricted Hour-meter Hydraulic Oil
Temperature Indicator
Position lights
Windscreen washer Cab ventilation fan Position lights Fog lamp Hazard warning lights
Continuous Oil Flow Steering mode Anchorage points Fuel cap Hydraulic oil
Engine oil level Moving gears Risk of crushing injury
to the hands Hot surfaces. Risk of
burns

Operator’s Manual
8 GTH-5519 Part No. 57.0009.0412
First Edition - Eleventh Printing
Symbols Used On The Machine
HAZARD PICTORIAL DESCRIPTIONS
Bodily Injury
Hazard
Always wear seat
belt.
Crush Hazard Support boom
when performing
maintenance.
No riders.
Fall Hazard
Maintain required
clearance.
Electrocution
Hazard
No people under
load.
Falling Object
Hazard
Injection Hazard Use cardboard to
search for leaks.
Crush Hazard
Read the operator's
manual.
Keep away from
moving parts.
Burn Hazard
Burn Hazard
Explosion/Burn
Hazard
Lower forks. Set
parking brake.
No smoking. No
open flame.
Allow system to
cool.
Allow surfaces to
cool.
Overturning
Hazard
Crush Hazard
Overturning
Hazard
Overturning
Hazard
Keep load low.
Operate from
operator's station.
x
Bodily injury hazard.
Keep away from
belts and fans.

Operator’s ManualFirst Edition - Eleventh Printing
Part No. 57.0009.0412 GTH-5519 9
Labels And Plates Applied On The Machine
12
3
3
26
27
16
31
32
1
17
20
37
11
28
19
A
8
15
21
23
Shading indicates decal is hidden from view, i.e. under covers.
7
25 28 B
2
4
5
10
11
9
6
14
30
24
3
3
31
22
32
34
35
36
38
13
27
33
33
PERKINS
DEUTZ

Operator’s Manual
10 GTH-5519 Part No. 57.0009.0412
First Edition - Eleventh Printing
Labels And Plates Applied On The Machine
Ref. Decal Code Description Qt.
109.4618.0791 Safety pin operation 1
297669C Warning - Falling Object Hazard 1
309.4618.0061 Tyre inflation sticker P= 4.5 bar / 65 psi 4
4114352B Overturning Hazard for Cab 1
597665B Warning - Bodly Injury Hazard 1
697666B Warning - Improper Operation 1
797667B Warning - Burn Hazard 2
WORKING POSITION STORAGE POSITION
SAFETY PIN
09.4618.0791
P= 4.5 bar
65 psi
Use the pictures on these pages to verify that all decals are legible and in place.
The following chart shows quantities and description too.
97665 B
WARNING
Bodily Injury Hazard
Death or serious injury
can result from failure
to wear seat belt.
This machine is
equipped with a Roll
Over Protection System
(ROPS).
Always adjust seat and
fasten seat belt before
starting engine.
97666 B
Read and understand
operator's manual and all
safety signs before using
or maintaining machine.
If you do not understand
the information in the
manuals, consult your
supervisor, the owner or
themanufacturer.
WARNING
Improper operation or
maintenance can result in
serious injury or death.
97667 B
Burn Hazard
Contact with
hotsurfaces
can cause
burns.
Do not touch.
Allow surfaces
to cool before
servicing.
WARNING