Terex Genie SHOV5DL15B-1001 User manual

Operator’s Manual
Serial number range
Original Instructions
First Edition
Second Printing
Part No. 57.0303.5251
500L Loading Shovel.......from serial n: SHOV5DL15B-1001
800L Loading Shovel.......from serial n: SHOV8DL15B-1001
800L Loading Shovel.....from serial n: SHOV8CDL15B-1001
800L Loading Shovel..... from serial n: SHOV8RDL15B-1001
Brick-Holder Basket.......from serial n: BBSKETDL15B-1001
250L Mixing Bucket..........from serial n: MXBC2515B-1001
500L Mixing Bucket...........from serial n: MXBC515B-1001
500L Man. Conc. Bucket....from s/n: CB5MADL15B-1001
500L Hyd. Conc. Bucket....from s/n: CB5HYDL15B-1001
800L Man. Conc. Bucket....from s/n: CB8MADL15B-1001
800L Hyd. Conc. Bucket....from s/n: CB8HYDL15B-1001

December 2015
2 SHOVEL - BUCKET - BASKET Part No. 57.0303.5251
First Edition - Second Printing
Contents
Introduction..........................................Page 3
Symbol and Hazard Pict.Definition......Page 8
General Safety.....................................Page 9
Work Area Safety.................................Page 10
Safety Precautions............................ Page 11
Legend.................................................Page 13
Attachment Description .......................Page 14
Attachment Application Field...............Page 17
Inspections ..........................................Page 18
Operating Instructions .........................Page 22
Parking and Storage............................Page 31
Tansport and lifting instruction.............Page 32
Maintenance........................................Page 42
Specification ........................................Page 46
Load Charts.........................................Page 52
Diagrams And Schemes......................Page 66
EC Declaration of Conformity..............Page 68
TEREX Global GmbH
Bleicheplatz 2
8200 Schaffhausen
Switzerland
Technical Assistance Service
Telephone: [phone]
[phone]
e-mail: [email protected]
Copyright © 2015 by Terex Corporation
First Edition: Second Printing, December 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 South
Dakota, Inc.

First Edition - Second Printing December 2015
Part No. 57.0303.5251 SHOVEL - BUCKET - BASKET 3
Introduction
About This Manual
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie machine.
This manual should be considered a permanent part
of your machine and should remain with the machine
at all times. If you have any questions, contact Genie.
In this manual, the term "machine" can be referred
to both the attachment or the truck, according to
the context.
This manual shall be used in conjunction with the
user manual of the telehandler.

December 2015
4 SHOVEL - BUCKET - BASKET Part No. 57.0303.5251
First Edition - Second Printing
Introduction
Product Identification
The attachment serial number is located on the
serial label.
• 500L Loading Shovel 59.0201.9019 GT
• 800L Loading Shovel 59.0201.9020 GT
• 800L Loading Shovel 59.0201.9021 GT
• 800L Loading Shovel 59.0201.9022 GT
• Brick-Holder Basket 59.0401.2032 GT
• 250L Mixing Bucket 59.0401.2018 GT
• 500L Mixing Bucket 59.0401.2016 GT
• 500L Man. Concrete Bucket 59.0401.2028 GT
• 500L Hyd. Concrete Bucket 59.0401.2029 GT
• 800L Man. Concrete Bucket 59.0401.2030 GT
• 800L Hyd. Concrete Bucket 59.0401.2031 GT
Intended Use
The Loading Shovels and Mixing Bucket are designed
to move and to mix loose materials. Brick-Holder
Basket is designed to lift and lower loose materials.
Use of this product in any other way is prohibited
and contrary to its intended use.


First Edition - Second Printing December 2015
Part No. 57.0303.5251 SHOVEL - BUCKET - BASKET 5
Introduction
Bulletin Distribution and
Compliance
Safety of product users is of paramount importance
to Genie. Various bulletins are used by Genie
to communicate important safety and product
information to dealers and machine owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most current
owner on record along with their associated dealer,
so it is important to register your machine and keep
your contact information up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
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:
• Accident reporting
• Questions regarding product applications and
safety
• Standardsand regulatorycompliance information
• Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that applies
to your machine.
Please register your machine by visiting us on the
web at www.genielift.co.uk.

December 2015
6 SHOVEL - BUCKET - BASKET Part No. 57.0303.5251
First Edition - Second Printing
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
attachment operation contained in this operator’s
manual.
1.Avoid hazardous situations.
Know and understand the safety rules
before going on to the next section.
2. Always perform a pre-operation inspection.
3. Always perform function tests prior to use.
4. Only use the machine as it was intended.
You read, understand and obey the manufacturer’s
instructions and the safety rules, the safety and
operator’s manuals, and the decals applied on
the machine.
You read, understand and obey the employer’s
safety rules and work-site regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

First Edition - Second Printing December 2015
Part No. 57.0303.5251 SHOVEL - BUCKET - BASKET 7
Introduction
Hazard Classification
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
Indicates a hazardous situation
which, if not avoided, will result
in death or serious injury.
WARNING
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
CAUTION
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
NOTICE
Indicates a property damage
message.
Standards
The following standards and/or regulations apply to
this machine:
Directive
2006/42/EC Machinery Directive
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.

December 2015
8 SHOVEL - BUCKET - BASKET Part No. 57.0303.5251
First Edition - Second Printing
Symbol and Hazard Pictorials Definitions
Falling object
Hazard
Close the gate Falling Hazard Fix brick holder with
Chain to Forks plate
Read the
operator's
manual
Crush Hazard Keep clear of
moving parts
No ride Brick
Holder
Basket

First Edition - Second Printing December 2015
Part No. 57.0303.5251 SHOVEL - BUCKET - BASKET 9
09.4618.0922
09.4618.1355 09.4618.1354 09.4618.1352
09.4618.1353
General Safety
800 Kg
09.4618.1353 09.4618.1352
09.4618.1354
140
mm
09.4618.1355
09.4618.0922

December 2015
10 SHOVEL - BUCKET - BASKET Part No. 57.0303.5251
First Edition - Second Printing
Work Area Safety
For work area safety, refer to the same section in
the telehandler operator's manual.

First Edition - Second Printing December 2015
Part No. 57.0303.5251 SHOVEL - BUCKET - BASKET 11
Safety Precautions
Requirements for Machine
Operators
Operators who use the machine regularly or
occasionally (i.e. for transport reasons) shall have
the following prerequisites:
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 enforced 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 be familiar with this handbook,
its enclosed graphs and diagrams, the identification
and hazard warning plates. They shall be skilled and
trained about the machine use.
The operator shall have a licence (or a driving
licence) when provided for by the laws enforced in
the country where the machine is operated.Please,
ask the competent bodies. In Italy the operator must
be at least 18 year old.
Requirements for Service
Personnel
Personnel in charge of the machine maintenance
shall be qualified, specialised in the maintenance
of telehandlers, and shall have the following
prerequisites:
physical:
good eyesight, acute hearing, good co-ordination
and ability to carry out all required maintenance
operations in a safe way, according to this manual.
mental:
ability to understand and apply the enforced 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.
training:
they shall read and be familiar with this handbook,
its enclosed graphs and diagrams, the identification
and warning plates. They shall be skilled and trained
about the machine functioning.
From a technical point of view, routine maintenance
of the machine is not a complex procedure and can
be carried out by the machine operator too, provided
he has a basic knowledge of mechanics.

December 2015
12 SHOVEL - BUCKET - BASKET Part No. 57.0303.5251
First Edition - Second Printing
Safety Precautions
Working clothes
During work, but especially when maintaining or
repairing the machine, operators must wear suitable
protective clothing:
• Overalls or any other comfortable garments.
Operators should not wear clothes with large
sleeves or objects that can get stuck in moving
parts of the machine.
• Protective helmet.
• Protective gloves.
• Working shoes.
Use only approved safety workwear in good
condition.
Personal protective equipment
Under special working conditions, the following
personal protective equipment should be used:
• Breathing set (or dust mask).
• Ear-protectors or equivalent equipment.
• Goggles or facial masks.

First Edition - Second Printing December 2015
Part No. 57.0303.5251 SHOVEL - BUCKET - BASKET 13
Legend
Shovel, Bucket, Brick-Holder Basket main components
A. Fork Slots
B. Coupling Frame
C. Quick coupling (if any)




December 2015
14 SHOVEL - BUCKET - BASKET Part No. 57.0303.5251
First Edition - Second Printing
Attachment Description
Brick Holder Basket
This attachment is designed to handle bricks pallets,
and other materials and to place them where are
necessary in the construction working sites.
It consists of a main basket made by welded steel
square shaped tubes and steel grids preventing any
debris exceeding small sizes that can accidentally
drop from the basket when this is operated at height.
A door is hinged on the right side of the basket
to make it easier to load and unload the pallets/
materials on/from the basket.
The door can be secured in the closed position by
a dedicated latch. The overall basket is installed
on a bottom structure having two rectangular
hollow shaped steel tubes working as slots for the
telehandlers forks.
The longitudinal movement of the basket, when
engaged with the forks, is controlled by a chain and
a shackle which must be secured before using the
basket to handle materials.
This equipment is coupled to the telehandler
through the forks slots A

Shovel
The shovel consists of a welded concave shaped
steel structure designed to move and load loose
material such as soil, sand debris, inert material.
The main components of this structure are the front
blade, which works as the leading edge of the shovel
“cutting” the material volume and separating the part
which is gathered by the shovel itself, the central
concave shell, which provides the volume for the
material to be gathered, and the side walls, which
laterally close the useful volume of the shovel.
On the rear area of the shovel, there are two
shaped plates welded to its main structure and
designed to be coupled with the GTH telehandlers
standard attachment interface. Considering the
typical limitation in the maximum rotation of the
attachment articulation, the design of the shovel
and its mechanical interface with the attachments
articulation is optimized to provide the best
compromise in terms of material loading and
unloading capabilities.
This equipment is coupled to the telehandler
through the coupling frame B


First Edition - Second Printing December 2015
Part No. 57.0303.5251 SHOVEL - BUCKET - BASKET 15
Attachment Description
Mixing Bucket
This bucket is designed to produce limited volumes
of concrete by mixing its main components (cement,
aggregates, sand and water) and to discharge such
volumes (when the concrete is ready). It mainly
consists of a welded concave shaped steel structure
designed to gather from ground aggregates, cement
and sand, before the concrete mixing phase is
started, and then to mix these components with water
in order to produce concrete. The main components
of this welded structure are the front blade, which
works as the leading edge of the bucket “cutting”
the material volume and separating the part which
is gathered by the bucket itself, the central concave
shell, which provides the volume for the material to
be gathered and mixed, and the side walls, which
laterally close the useful volume of the bucket. To
mix the concrete components, a mixing blade made
by welded and shaped plates, is provided and
installed longitudinally to the main axis of the bucket.
This blade rotates on bearings installed on the side
walls of the bucket and is powered by a hydraulic
motor and a gear box which are located externally
of the right side wall of the bucket.
The concrete, after the mixing phase, can be
discharged through a dedicated door located on
the bottom of the bucket and activated through
a mechanism and a hydraulic cylinder. The
mixing blade and the concrete discharge door
are hydraulically powered through the hydraulic
auxiliary line available on the top of the boom. These
two functions are controlled by a dedicated radio
remote control device which can be operated also
by operators working outside of the machine cabin.
Before the concrete mixing phase is started, the top
of the bucket must be closed by a dedicated door,
made by a steel grid and hinged on the top of the
rear wall of the bucket, with the aim of protection
against moving parts. The steel grid allows the
operator to check when the concrete is ready for
discharge. On the rear area of the bucket, there are
two shaped plates welded to its main structure and
designed to be coupled with the GTH telehandlers
standard attachments interface.
This equipment is coupled to the telehandler
through the coupling frame B


December 2015
16 SHOVEL - BUCKET - BASKET Part No. 57.0303.5251
First Edition - Second Printing
Attachment Description
Concrete Bucket
The bucket mainly consists of a welded pyramid
shaped steel structure designed to handle limited
volumes of concrete from one place to another place
inside the typical construction working sites and to
discharge such volumes of concrete.
This pyramidal structure is open on the top to allow
the concrete to be easily loaded and has a section
regularly reducing towards the bottom to facilitate
the discharge of the concrete.
This discharge operation is allowed by a dedicated
steel door, located on the bottom of the bucket which
can be activated by a mechanical lever manually
moved by the operator or, according to the models
selected, by a mechanical articulation which is
hydraulically operated through the hydraulic auxiliary
line available on the top of the boom.
The overall bucket and door mechanism is installed
on a bottom structure having four rectangular
hollow shaped steel tubes working as slots for the
telehandlers forks.
The longitudinal movement of the bucket, when
engaged with the forks, is controlled by a chain and
a shackle which must be secured before using the
bucket to handle materials.
This equipment is coupled to the telehandler
through the forks slots A


First Edition - Second Printing December 2015
Part No. 57.0303.5251 SHOVEL - BUCKET - BASKET 17
The following table represents the application field of attachment installed on Genie telehandlers
Attachment Application Field
GTH-2506 GTH-4014 GTH-4018 GTH-4016R GTH-4018R GTH-5021R
500 L Loading
Shovel 
800 L Loading
Shovel 
Brick-Holder
Basket 
250 L Mixing
Bucket 
500 L Mixing
Bucket  
500 L Manual
Concrete
Bucket

500 L
Hydraulic
Concrete
Bucket

800 L Manual
Concrete
Bucket
 
800 L
Hydraulic
Concrete
Bucket
 

December 2015
18 SHOVEL - BUCKET - BASKET Part No. 57.0303.5251
First Edition - Second Printing
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
performed by the operator prior to each work shift.
The inspection is designed to discover if anything
is apparently wrong with a telehandler and/or with
an equipment before the operator performs the
function tests.
The pre-operation inspection also serves to
determine if routine maintenance procedures are
required. Only routine maintenance items specified
in this manual may be performed by the operator.
If damage or any unauthorized variation from
factory delivered condition is discovered, the
telehandler and/or the equipment must be tagged
and removed from service.
Repairs to the telehandler and/or the equipment
may only be made by a qualified service
technician, according to the manufacturer's
specifications. After repairs are completed, the
operator must perform a pre-operation inspection
again before going on to the function tests.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer's specifications.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s
manual and in the telehandler one.
1.Avoid hazardous situations.
2. Always perform a pre-operation inspection.
Know and understand the pre-operation
inspection before going on to the next
section.
3. Always perform function tests prior to use.
4. Only use the machine as it was intended.

First Edition - Second Printing December 2015
Part No. 57.0303.5251 SHOVEL - BUCKET - BASKET 19
Inspections
Pre-operation Inspection
Make sure the operator's manuals are intact,
legible and placed inside the telehandler.
Be sure that all decals are legible and in
place.
Check for Hydraulic oil leaks.
Checking the following components or areas for
damage, improperly installed or missing parts and
unauthorized modifications:
Hydraulic hoses and fittings
Nuts, bolts and other fastners
Check the entire structure for:
Cracks on welds or structural components
Dents or damage to the structure
Excessive rust, corrosion or oxidation

December 2015
20 SHOVEL - BUCKET - BASKET Part No. 57.0303.5251
First Edition - Second Printing
Inspections
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s
manual and in the telehandler one.
1.Avoid hazardous situations.
2.Always perform a pre-operation inspection.
3. Always perform function tests prior to use.
Know and understand the function tests
before going on to the next section.
4. Only use the machine as it was intended.
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
malfunctions are discovered, the machine must
be tagged and removed from service. Repairs
to the machine may only be made by a qualified
service technician, according to the manufacturer’s
specifications.
After repairs are completed, the operator must perform
a pre-operation inspection and function tests again
before putting the machine into service.