PN 57.0008.6200 - Genie Industries

Operator's Manual
Serial number range
GTH - 5519
From: 16381
To: 16382
From: 17548
To: 17565
From: 17822
To: 17825
From: 18154
To: 18168
From: 18556
To: 18586
Part No. 57.0008.6200
Rev B
March 2009
TECHNICAL SERVICES
Genie Scandinavia
Phone +46 31 575100
Fax +46 31 579020
Genie Mexico City
Phone +52 55 5666 5242
Fax +52 55 5666 3241
Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544
Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie North America
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
Genie Japan
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Genie Germany
Phone +49 (0)4202 88520
Fax +49 (0)4202 8852-20
Genie Australia Pty Ltd.
Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910
Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754
Genie Holland
Phone +31 183 581 102
Fax +31 183 581 566
Operator's manual 57.0008.6200 - GTH-5519
No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means without
prior written permission from TEREXLIFT srl.
In pursuing a policy of constant quality improvement, TEREXLIFT srl reserves the right to make changes at any time and
without undertaking to give prior notice; therefore, also this publication may be subject to modifications.
Some photos or drawings have been used to illustrate a specific function; as a result, they may not refer to the machine
treated in this manual.
© Copyright 2007 TEREXLIFT srl - All rights reserved.
Produced by: TEREXLIFT Technical Literature Dept. - Umbertide- Perugia
REVISED PAGE LIST
Revision
N.
Date
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03/2009
Revised
pages
Section A, Section C, Section G
Notes
Revision
Issued
by
Handler with telescopic boom GTH-5519
INTRODUCTION
INTRODUCTION
This manual provides information for a safe and proper
operation and maintenance of the machine.
Section G contains tables and various enclosed
documents like load charts, wiring diagrams, hydraulic
schemes, torque wrench setting table, etc.
Sections are subdivided into chapters and paragraphs
that are numbered progressively.
STRICTLY COMPLY WITH THE
INSTRUCTIONS GIVEN IN THIS HANDBOOK!
READ AND UNDERSTAND THIS HANDBOOK
BEFORE STARTING, USING AND
CARRYING OUT ANY OPERATION WITH
AND ON THE MACHINE.
The quickest way to look for information is the reference
to the general index or the titles of the single chapters
and paragraphs that represent keys for an easy
consultation.
The handbook is divided into seven sections:
Sect. A
GENERAL INFORMATION
Sect. B
SAFETY PRECAUTIONS
Sect. C
OPERATING INSTRUCTIONS
Sect. D
MAINTENANCE
Sect. E
TROUBLESHOOTING
Sect. F
OPTIONAL ATTACHMENTS
Sect. G TABLES AND ENCLOSURES
Take care of this manual and keep it in an
accessible place within the machine, even
after its reading, so that it will always be within
reach if in doubt.
Section A contains general concepts that are decisive
for the knowledge of the main parts of the machine.
It also contains all necessary data for a correct
identification of the machine, the technical features of
the machine, etc.
Section B is especially addressed to the personnel, who
shall operate, repair and service the machine, and, in
case of companies with a wide fleet of machines, to
those responsible for safety.
It describes the essential compulsory qualities of the
personnel in charge and other important information
for the safety of persons and things.
If you are unsure about anything, please address to
GENIE Assistance Service or to your agent/dealer:
addresses, phone and fax numbers are printed in
the cover and in the title-page of this manual.
IMPORTANT
Any difference between the contents of this manual
and the real functional character of the machine
can be attributed to either a machine manufactured
before the issue of this manual or to a manual going
to be updated after some changed effected on the
machine.
Always contact GENIE Assistance Service for any
updated version of this manual and any additional
information.
Section C is mainly addressed to the operators who
operate the machine. This section illustrates all control
devices.
Additionally, it contains the main use instructions -i.e.
engine starting, machine parking, machine storing.
Section D is addressed to those responsible for
maintenance and the servicemen.
The section describes the maintenance schedule and
the relevant intervals.
Section E deals with the failure diagnostics.
Section F makes a list of the main interchangeable
attachments that can be coupled to the machine:
dimensions, weight, application field and limits of use.
Page
1
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SYMBOLS
SYMBOLS
When using the machine, operators could have to face
some situations requiring special care and particular
knowledge.
When these situations involve the safety of operators or
bystanders, the machine efficiency and proper utilisation,
this handbook stresses these specific instructions by
means of SPECIAL SYMBOLS.
There are seven special (or safety) symbols in this
manual, always combined with keywords that class the
situations according to their danger degree.
The symbols are always followed by a text explaining
the situation taken into account, the attention to be paid
to such situation, the method and the behaviour to be
adopted. When necessary, it stresses prohibitions or
supplies instructions to prevent dangers.
CAUTION
Yellow with safety alert symbol: used to indicate
a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
ATTENTION
Yellow without safety alert symbol: used to indicate
a potentially hazardous situation which, if not
avoided, may result in damage to the machine or
the systems.
PROTECT THE
ENVIRONMENT
Green: used to draw the attention to important
information on environment protection.
Sometimes, it can be followed by illustrations.
We list below the special (or safety) symbols according
to the relative degree of a hazard:
IMPORTANT
Green: used to indicate operation and maintenance
information
Safety Alert symbol: when you see this symbol, be
alert to the possibility of personal injury. Strictly obey
all the safety messages accompanying this symbol
to avoid the risk of serious injury or death.
WHEN READING THIS MANUAL, PAY THE
GREATEST ATTENTION TO THESE SPECIAL
SYMBOLS AND THE EXPLANATION OF THE
SITUATIONS THEY EMPHASIZE.
DANGER
Red: used to indicate an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
DANGER
Orange: used to indicate a potentially hazardous
situation which, if not avoided, could result in death
or serious injury.
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GENERAL INDEX
GENERAL INDEX
GENERAL INFORMATION
Sect.
A
SAFETY PRECAUTIONS
Sect.
B
OPERATING INSTRUCTIONS
Sect.
C
MAINTENANCE
Sect.
D
TROUBLESHOOTING
Sect.
E
OPTIONAL ATTACHMENTS
Sect.
F
TABLES AND DOCUMENTS ENCLOSED
Sect.
G
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INTENTIONALLY BLANK PAGE
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GENERAL INFORMATION
Section
A
GENERAL INFORMATION
TABLE OF CONTENTS
A-1
A-1.1
A-1.2
A-1.2.1
A-1.3
A-2
A-2.1
A-2.2
A-2.3
A-2.4
A-2.5
A-3
A-3.1
A-3.2
A-3.3
A-3.4
A-3.5
A-4
A-4.1
A-4.2
A-4.3
A-4.4
A-5
A-6
A-7
A-7.1
CONVENTIONAL REFERENCES ..................................................................................
Machine position ............................................................................................................
Labels and warning plates applied on the machine ........................................................
Position ...........................................................................................................................
Explanation of the different symbols used on the machine .............................................
MACHINE IDENTIFICATION ..........................................................................................
Machine model and type .................................................................................................
Manufacturer ...................................................................................................................
Machine identification plates ...........................................................................................
Chassis serial number ....................................................................................................
Identification plates of the main parts .............................................................................
ALLOWED USE ..............................................................................................................
Allowed use.....................................................................................................................
Improper use ...................................................................................................................
Residual hazards ............................................................................................................
Applicable standards.......................................................................................................
Safety devices.................................................................................................................
GENERAL DESCRIPTION .............................................................................................
List of the main components ...........................................................................................
Description of the main components...............................................................................
Optional accessories.......................................................................................................
Kits supplied on request..................................................................................................
TECHNICAL DATA AND PERFORMANCE.....................................................................
LIFETIME ........................................................................................................................
ITEMS SUPPLIED ..........................................................................................................
Literature supplied ..........................................................................................................
Page
A-1
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A-2
A-2
A-3
A-3
A-6
A-8
A-8
A-8
A-8
A-9
A-9
A-10
A-10
A-10
A-10
A-11
A-12
A-13
A-13
A-14
A-14
A-14
A-15
A-17
A-17
A-17
Handler with telescopic boom GTH-5519
GENERAL INFORMATION
A-1 CONVENTIONAL REFERENCES
A-1.1 MACHINE POSITION
Conventionally the machine should be considered
positioned as shown in the figure.
This convention is necessary to make any reference
of this handbook to different machine parts (front, rear,
etc.) clear and unmistakable.
Any exception to this rule will always be specified.
UPPER PART
REAR PART
RIGHT SIDE
FRONT PART
LEFT SIDE
LOWER PART
Page
A-2
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GENERAL INFORMATION
A-1.2 LABELS AND WARNING PLATES APPLIED
ON THE MACHINE
This paragraph lists the labels and warning plates
normally applied on standard machines or on special
attachments coupled to the machine.
IMPORTANT
The familiarisation with these labels is never a
waste of time.
Make sure they are easy to read. For this purpose,
clean them or replace those that become unreadable
(either graphic or text).
To clean labels, use of a soft cloth, water and soap.
Never use solvents, petrol, etc.
When a label is applied on a part to be replaced,
make sure that the replaced part is already labelled
as required or apply a new label.
A-1.2.1
Position
s.r.l.
Zona industriale - 06019 - Umbertide ( PG ) - Italy
MODEL NUMBER
SERIAL NUMBER
YEAR OF MANUFACTURE
UNLADEN TRUCK MAXIMUM WEIGHT
lb
TRUCK CAPACITY
lb
THIS TRUCK IS COMPLIANT TO PART III OF ASME B56.6-2002 WHERE APPLICABLE
MADE IN ITALY
09.4616.0101
09.4618.0109
09.4618.0109
09.4618.0109
09.4618.0109
09.4618.0109
09.4618.0109
09.4618.0109
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A-3
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GENERAL INFORMATION
HYDRAULIC
OIL
09.4616.0051
01234567
Death or Serious Injury can result
from handling of personnel with
this machine.
97673
Never equip machine with any
form of personnel platform or
allow personnel to ride on
attachment.
F
09.4618.0783
97673 A
R
09.4618.0389
09.4618.0782
CAUTION
09.4618.0643
09.4618.0782
09.4618.0780
INSTRUCTIONS
NOTICE
1
DANGE
R
WARNING
0
Explosion / Burn Hazard
Will cause death, burns or blindness
due to ignition of explosive gases or
corrosive acid.
Burn Hazard
Explosion / Burn
Hazard
Keep all open flames and sparks away.
Wear personal protective equipment,
including face shield, gloves and long
sleeve shirt.
Burns may result from
contact with hot surfaces.
Do not touch.
Allow surfaces to cool
before servicing.
09.4618.1262
Release of hot pressurized
fluids can cause Burns or
Blindness.
Consult operation and maintenance
manual for jump starting instructions.
Allow system to cool and
always open carefully.
97671 A
09.4618.1262
97675 A
97667 A
09.4618.0777
97667
97671
97675
09.4618.0777
WARNING
97667
Burn Hazard
80
Burns may result from
contact with hot surfaces.
Do not touch.
Allow surfaces to cool
before servicing.
60
09.4618.0205
97667 A
0
20
40
WARNING
09.4618.0644
Crush Hazard
Moving parts can crush or
cut causing severe injury.
Keep all body parts clear of
moving parts during
equipment operation
97664 A
09.4618.0643
97664
WARNING
Crush Hazard
Moving parts can crush or
cut causing severe injury.
Keep all body parts clear of
moving parts during
equipment operation
97664
97664 A
WARNING
09.4618.0010
09.4618.0010
09.4618.0641
VIETATO APRIRE CON MOTORE IN MOTO
DO NOT OPEN WHILE ENGINE IS RUNNING
N'OUVRIR QU'A L'ARRET DU MOTEUR
ÖFFNEN NUR BEI STILLSTEHENDEM MOTOR
ABRIR SOLO CON MOTOR PARADO
PROIBIDO ABRIR COM O MOTOR LIGADO
VERBODEN KOFFERBAK TE OPENEN
WANNEER DE MOTOR DRAAIT
Skin Injection Hazard
Escaping fluid under pressure
can penetrate skin and could
cause death or serious injury.
Keep away from leaks and pin
holes.
Use a piece of cardboard to
search for leaks. Do not use
hands.
82558 A
09.4618.0061
09.4618.0061
82558
WARNING
Crush Hazard
Moving parts can cause Death or
Serious Injury
.
P=4,5bar
Keep clear of elevated
components.
P=4,5bar
97668
Support components before
performing service.
Crush Hazard
Moving parts can crush or
cut causing severe injury.
97665
09.4618.0109
Keep all body parts clear of
moving parts during
equipment operation
97664 A
97674 A
97674
97664
(top of chassis) (boom rest)
WA RNING
WA RNING
Electrical Hazard
Overturning Hazard
Death or serious injury can result
from contacting electric power lines.
Death or Serious Injury can result
from overturning forklift.
Always contact the electric power line
owner. The electric power shall be
disconnected or the power lines
moved or insulated before machine
operations begin.
97676
Power Line Voltage
0 to 50 kV
50 to 200 kV
200 to 350 kV
350 to 500 kV
500 to 750 kV
750 to 1000 kV
• Never exceed published capacity or
extend load beyond load chart band.
• Never lower maximum load before
retracting boom.
• Do not travel on terrain or in areas that
could cause machine to overturn.
Required Clearance
10 ft / 3.03 m
15 ft / 4.60 m
20 ft / 6.10 m
25 ft / 7.62 m
35 ft / 10.67 m
45 ft / 13.72 m
• Always level machine using sway
control before raising boom above
horizontal.
• Carry loads so maximum machine
stability is maintained.
97676 A
97668 A
Always Use
Seat Belt
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.
97665 A
WARNING
WA RNING
97670
Falling Object Hazard
Death or Serious Injury can
result from falling objects.
• Do not operate machine
while people are under or
near elevated boom whether
boom is loaded or unloaded.
Crush Hazard
Crush Hazard
An unattended machine can
move or roll.
Set park brake, lower carriage
or attachment to ground before
leaving machine.
Failure to heed could result in
Death or Serious Injury.
Death or Serious Injury can result
from people riding on this
machine other than at the
operator's station.
No passengers are permitted to
ride on this machine or any
attachment.
Read and understand
operator's manual and safety
signs before using or
maintaining machine.
• Always remain completely
within the canopy enclosure
while operating machine.
If you do not understand the
information in the manuals,
consult your supervisor, the
owner or the manufacturer.
97669 A
97666 A
Only operate this machine from
the operator's station.
97670 A
97672 A
09.4618.0776
09.4618.0644
NOTICE
09.4618.0776
97672
97666
97669
97664
WARNING
WARNING
Emergenc
y
Exit Handl
e
Crush Hazard
Moving parts can crush or
cut causing severe injury.
Crush Hazard
Moving parts can crush or
cut causing severe injury.
97688 A
Keep all body parts clear of
moving parts during
equipment operation
Keep all body parts clear of
moving parts during
equipment operation
97664 A
97664 A
09.4618.0061
P=4,5bar
Page
97664
97688
A-4
Document 57.0008.6200 - 03/2009
09.4618.0061
P=4,5bar
Handler with telescopic boom GTH-5519
GENERAL INFORMATION
Code Description
82558 Fluid at pressure
97664 Risk of crushing hands
97665 Safety belts
97666 Read the user’s manual
97667 Risk of burns and scalds
97668 Risk of overturning
97669 Risk due to falling objects
97670 Risk of crushing
97671 Risk of explosion / burns
97672 Risk of crushing
97673 Prohibition to lift people
97674 Risk of crushing
97675 Risk of explosion / burns
97676 Electrical hazard
97688 Emergency exit handle
09.4616.0051 Hydraulic oil
09.4616.0101 Machine data plate
09.4618.0010 Prohibition to open with the engine running
09.4618.0061 Tyre inflation pressure
09.4618.0109 Sticker with various warnings
09.4618.0205 Boom tilting degree
09.4618.0389 Control lever controls
09.4618.0641 Sticker: "Genie"
09.4618.0643 Sticker: "Genie GTH-5519"
09.4618.0644 Sticker: "GTH-5519"
09.4618.0783 Load chart
09.4618.0782
Connect./disconnect. quick coupling
09.4618.0777 Testing ports TP2 - TP3
09.4618.0776
Upper door unlock system
09.4618.1262
Flow reversal button
09.4618.0780
Continuous flow knob sticker
Page
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Handler with telescopic boom GTH-5519
GENERAL INFORMATION
A-1.3 EXPLANATION OF THE DIFFERENT
SYMBOLS USED ON THE MACHINE
This paragraph illustrates those symbols that are
normally applied on the main control devices and
instruments of a standard machine, and those that
can be applied on accessories or special attachments.
They are mainly (ISO) standardised symbols that are
now part of the common life. But we consider useful to
explain them once again.
Symbol
Description
IMPORTANT
Spend the necessary time to become familiar with
these symbols and to learn their meaning.
Symbol
Description
Hazard warning lights
Steering mode switch
Windscreen wiper
Engine oil pressure
Boom up
Windscreen washer
Boom down
Cab ventilation fan
Boom out
Fuel gauge
Boom in
Hydraulic oil temperature
Attachment locked
Position lights
Attachment unlocked
High beam
Turn signals
Fork pitching forward
Parking brake
Fork pitching back
Battery charge
Oil filter clogged
Air filter clogged
Glow plug preheating
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A-6
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GENERAL INFORMATION
Symbol
Description
Symbol
Front (optional) work light
Road/jobsite selector switch
Lifting point
Fuel plug
Engine oil filler
Page
A-7
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Description
Handler with telescopic boom GTH-5519
GENERAL INFORMATION
A-2 MACHINE IDENTIFICATION
IMPORTANT
Check that the operator handbook refers to the
delivered machine.
When asking for information or technical assistance,
always specify model, type and serial number of
the machine.
A-2.1 MACHINE MODEL AND TYPE
Handler with telescopic boom:
❑
model GTH-5519
Zona Industriale - 06019 - Umbertide (PG) - Italy
MODEL NUMBER
SERIAL NUMBER
YEAR OF MANUFACTURE
A-2.2 MANUFACTURER
TEREXLIFT srl
Zona Industriale (Ind. Estate) - I-06019 UMBERTIDE
(PG) - ITALY
Enrolled in the register of companies at the Court of
Perugia under no. 4823
C.C.I.A.A. n° 102886
Fiscal Code/V.A.T. no. 00249210543
UNLADEN TRUCK MAXIMUN WEIGHT
Lb
TRUCK CAPACITY
Lb
THIS TRUCK IS COMPLIANT TO PART III OF ASME B56.6 - 2002 WHERE APPLICABLE
MADE IN ITALY
A-2.3 MACHINE IDENTIFICATION PLATES
Machine data plate.
At the front, on the right side of the chassis.
The identification plate contains the main
identification data of the machine like model, serial
number and year of manufacture.
Page
A-8
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Handler with telescopic boom GTH-5519
GENERAL INFORMATION
T E RE XL I F T
s.r.l.
ZONA INDUSTRIALE - 06019 UMBERTIDE (PG) - ITALY
Tel. +39 (0) 75 94181 Fax +39 (0) 75 9415382
ASSIEME FORCHE-FORKS ASSY
GROUPE FOURCHES-GABELGROUPPE
JUNTO HORQUILLAS
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.
MODELLO - TYPE - DÉSIGNATION
MODELL - MODELO
__._____._____
N° SERIE - SERIAL N°-N° DE SERIE
- SERIEN N°- N° DE BASTIDOR
.............
ANNO DI COSTRUZIONE YEAR OF CONSTRUCTION ANNÉE DE CONSTRUCTION BAUJHAR - AÑO DE CONSTRUCCIÓN
______
MASSA - MASS - MASSE MASSE - MASA
____
CENTRO DI GRAVITÀ - CENTER OF
GRAVITY - CENTRE DE GRAVITÉ SCHWERPUNKT - CENTRO DE GRAVEDAD
PORTATA NOMINALE - PAY LOAD PORTEE NOMINALL - NENN
TRAGFÄHIGKEIT - CARGA NOMINAL
CENTRO DI CARICO - LOAD CENTER CENTRE DE CHARGE - LASTPUNKT CENTRO DE CARGA
___
____
___
MODELLO MACCHINA - MACHINE MODEL DESOGNATION MACHINE - MASCHINEN MODELL
MODELO MÁQUINA
A-2.4 CHASSIS SERIAL NUMBER
The chassis serial number is punched on the front
left part of the chassis side member.
A-2.5 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.
Page
A-9
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Handler with telescopic boom GTH-5519
GENERAL INFORMATION
A-3 ALLOWED USE
A-3.1 ALLOWED USE
The handlers have been designed and manufactured for
lifting, handling and transporting agricultural or industrial
products by means of specific attachments (see section
F) manufactured by TEREXLIFT srl.
Any other use is considered contrary to that established
and, therefore, improper.
The compliance with and the strict respect of the
operation, maintenance and repair conditions, indicated
by the Manufacturer, represent an essential part of the
allowed use.
The handler must be used and serviced only by operators
knowing its characteristics and the safety procedures
in depth.
It is also essential to comply with the safety at work
legislation, the precautions concerning safety and
industrial medicine as well as the local and national
road traffic regulations.
A-3.2 IMPROPER USE
Improper use means a utilisation of the handler following
working criteria that do not comply with the instructions
of this manual, and that, in general, may result in risks
for both operators and bystanders.
DANGER
We list below some of the most frequent and
hazardous situations of improper use:
- Carrying passengers on the machine
- Not strictly complying with the operation and
maintenance instructions of this handbook
- Working beyond the handler working limits
- Working on unstable edges of ditches
- Driving crosswise on slopes or hills
- Working during a storm
- Working on steep slopes
- Using attachments other than those
recommended
- Using attachments not approved or directly
manufactured by Terexlift
- Working in potentially explosive areas
- Working in confined and non-ventilated
environments.
A-3.3 RESIDUAL HAZARDS
Although the machine has been designed and
manufactured according to the latest technology and
all expected hazards have been eliminated, some
operations performed by the machine operator can result
in potentially hazardous situations. Among them:
• Hazards deriving from a too high work or transfer
speed in relation to the load handled or the ground
condition of the jobsite.
• Hazards deriving from work procedures adopted
during the check or replacement of a block valve
(residual pressure - uncontrolled movements).
• Hazards deriving from work procedures adopted
while disassembling parts of the machine -e.g. the
cylinders, without supporting mobile parts suitably
(risk of uncontrolled fall of the mobile part).
• Hazard deriving from an accidental overturning
of the machine in the event the operator has not
fastened the safety belts.
Page
A-10
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Handler with telescopic boom GTH-5519
GENERAL INFORMATION
A-3.4 APPLICABLE STANDARDS
For the operator’s safety, the following standards were
obeyed during the risk assessment of the handler fitted
with telescopic boom:
Standard
Title
ANSI/ASME B56.6-2002 part III where applicable.
Page
A-11
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Handler with telescopic boom GTH-5519
GENERAL INFORMATION
A-3.5 SAFETY DEVICES
•
The machine is equipped with a negative brake on
the front axle which engages automatically when
the engine stops.
When this brake is disengaged, the engine start-up
is inhibited.
•
Block valves fitted to all cylinders:
A Block valve on attachment coupling cylinder
B Block valve on lifting cylinder
C Block valve on balance cylinder
D Block valve on boom extension cylinder
E Block valve on attachment pitching cylinder
Page
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GENERAL INFORMATION
A-4 GENERAL DESCRIPTION
A-4.1 LIST OF THE MAIN COMPONENTS
3
1
-
5
6
7
2
8
1
2
3
4
5
6
7
8
9
10
11
12
4
9
J
K
Forks
Attachment holding frame
2nd boom section
1st boom section
Engine hood
Driving cab
Left rear view mirror
Front axle
Chassis
Left front wheel mud-guard
Left front wheel reduction gear
Left rear wheel reduction gear
Page
A-13
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L
Handler with telescopic boom GTH-5519
GENERAL INFORMATION
A-4.2
DESCRIPTION OF THE MAIN
COMPONENTS
Hydrostatic transmission
This unit consists of parts which drive the machine
shifting, and namely:
- a variable displacement pump connected to the
thermal engine by an elastic joint
- a motor with variable displacement and automatic
adjustment in relation to the wheel torque required,
complete with power divider, directly applied on the
rear axle
- a hydraulic oil filter, placed on the discharge line to
the tank
- a heat exchanger to cool the circuit down.
Motion is transmitted to the rear axle from the power
divider through a Cardan shaft.
Engine
The thermal engine is equipped with a heat exchanger
which uses the engine oil as cooling medium.
Steering axles/(front and rear) differential gears
The differential axles transmit the motion to the wheels.
The locking device acting on the front axle enables the
machine to move also on low grip grounds.
Tyres
The machine is equipped with tyres suitably sized for
the maximum load allowed on the handler.
When worn, they shall be replaced with new ones having
the same dimensions and loading capacity.
Telescopic boom
The machine is equipped with a telescopic boom with
hydraulic-driven extension. The telescopes slides on
interchangeable pads made of wearproof material.
Driving cab
Type-approved driving cab in compliance with standards
ANSI/ASME B56.6-2002.
A-4.3 OPTIONAL ACCESSORIES
The machine can be fitted with a wide range of optional
accessories: please address to Genie sales network.
IMPORTANT
Please check the accessories available for your
machine.
A-4.4 KITS SUPPLIED ON REQUEST
The machine is prepared for the installation of the
following assembly kits:
- Driving cab glasses (including door)
- Heater
- Air conditioning
- Work lights (including courtesy lamp in the cab)
- Beacon
Boom hydraulic circuit
It consists of a gear pump connected to the thermal
engine which, through a special valve, dispenses oil
to the hydraulic drive and a distributor for the following
functions:
- boom lifting/lowering
- telescopic boom extension/retraction
- attachment rotation
- attachment locking
Braking circuit
It consists of an independent circuit: the pedal directly
acts on the brake pump which dispenses oil to the front
axle braking unit with discs in oil bath.
The parking brake, of negative type, acts on the braking
unit of the service brake. This brake is engaged every
time the handler's engine is stopped or pressing down
the light pushbutton located to the right of the driving
place.
Page
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GENERAL INFORMATION
A-5 TECHNICAL DATA AND PERFORMANCE
H
B
A
D
F
E
G
C
I
Measurements
Metric
Imperial
A
Height .................................................................................................
1935 mm
6 ft 4 in
B
Height at steering whell ......................................................................
1250 mm
4 ft 1 in
C
Width ..................................................................................................
1810 mm
5 ft 11 in
D
Inside cab width..................................................................................
750 mm
2 ft 6 in
E
Track...................................................................................................
1500 mm
4 ft 11 in
F
Wheelbase .........................................................................................
2320 mm
7 ft 7 in
G
Length at fork-holder plate .................................................................
3840 mm
12 ft 7 in
H
Ground clearance ...............................................................................
330 mm
1 ft 1 in
I
Overall Length ....................................................................................
5040 mm
6 ft 7 in
Lifting height (max) .............................................................................
5790 mm
19 in
Lifting capacity (max) .........................................................................
2500 kg
5500 lbs
Lift capacity at maximum height .........................................................
2000 kg
4400 lbs
Lift capacity at maximum reach ..........................................................
860 kg
1900 lbs
Forward reach (max) ..........................................................................
3350 mm
11 ft
Reach at maximum height..................................................................
605 mm
2 ft
Fork-holder plate rotation ...................................................................
130°
130°
Weight *** ...........................................................................................
4450 kg
9810 lbs
*Max Load; ** No Load; ***With Fork
Page
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GENERAL INFORMATION
Productivity
Metric
Lifting/lowering speed ** .....................................................................
Extension/retraction speed ** .............................................................
Inside/outside turning radius ..............................................................
Break-out force (with 500lt shovel SAE J732/80) ...............................
Towing capacity al dinamometro */** ..................................................
Travel speed (max).............................................................................
Chassis levelling on both axles ..........................................................
Floating forks ............................................................................ lenght
section
Tyres (DIN 70631) ..............................................................................
Power
Imperial
7/4 s
7/4 s
7/4 s
7/4 s
1750mm / 3000mm 5ft 9in / 9ft 10in
3700 kg
8157 lbs
4230 kg/3100 kg 9325 lbs/6835 lbs
24 km/h
15 mph
2,3°
2,3°
1200 mm
3ft 11in
100 x 40 mm
3,9 in x 1,6 in
12-16.5, 8 holes 12-16.5, 8 holes
Metric
Imperial
Engine
Displacement......................................................................................
Cylinder arrangement .........................................................................
Combustion System ...........................................................................
Max Power Output (@ 2600rpm) .......................................................
Max Torque Output (@ 1600rpm).......................................................
Aspiration ...........................................................................................
Cylinder’s number ..............................................................................
Hydraulic
Hydraulic output/pressure ..................................................................
Perkins 804C-33
3,331 litres
203 in3
Vertical in-line
In-direct injection
47,0 kW
63,0 hp
190 N-m
140 lb-ft
Aspirated
4
4
80 l/min / 270 bar
21 USgal/min / 3916 psi
Tank Capacities
Metric
Imperial
Petrol ..................................................................................................
Engine oil............................................................................................
Hydraulic oil ........................................................................................
60 litres
10 litres
70 litres
16 USgal
2,5 USgal
18,5 USgal
IMPORTANT
This is a device of Class A. In a residential environment, such device can cause radio disturbance. In such
cases, the operator is required to take suitable measures.
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GENERAL INFORMATION
A-7 ITEMS SUPPLIED
A-6 LIFETIME
The lifetime of the machine is 10000 hours provided
all checks, service jobs and overhauls are done at the
times scheduled.
The following items are supplied together with the
machine:
Description
DANGER
After this time, the machine must compulsorily be
inspected and tested by the Manufacturer before
being used again.
IMPORTANT
Five years or 6000 hours after the first placing into
operation of the machine (whichever occurs first),
check the state of the structure paying an extreme
attention to the welded supporting joints and the pins
of both boom and platform (see chap. D-3.20).
Page
- Spanner CH 19
(for fork positioning)
- Allen wrench CH 6
(for fork positioning)
- 12 V lamps
(spare)
GTH-5519
✘
✘
✘
A-7.1 LITERATURE SUPPLIED
The machines comes with the following literature:
- Machine operator’s handbook
- PERKINS engine use and maintenance manual
- Spare parts catalogue
- Warranty and handing over certificate
A-17
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GENERAL INFORMATION
Intentionally blank page
Page
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SAFETY PRECAUTIONS
Section
B
SAFETY PRECAUTIONS
TABLE OF CONTENTS
B-1
B-2
B-2.1
B-2.2
B-2.3
B-2.4
B-3
B-3.1
B-3.2
B-3.3
B-3.4
B-3.5
B-3.6
B-3.7
B-4
GENERAL REMARKS ....................................................................................................
PREREQUISITES OF THE PERSONNEL IN CHARGE.................................................
Requisites of the machine operators ..............................................................................
Requisites of the servicemen ..........................................................................................
Working clothes ..............................................................................................................
Personal protective equipment .......................................................................................
SAFETY PRECAUTIONS ...............................................................................................
Hazards on the jobsite ....................................................................................................
Operation or maintenance hazards.................................................................................
Machine operation hazards.............................................................................................
Damaged component hazards ........................................................................................
Explosion or fire hazards ................................................................................................
Damaged machine hazards ............................................................................................
Personal injury hazards ..................................................................................................
SAFETY DEVICES .........................................................................................................
Page
B-1
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B-2
B-3
B-3
B-3
B-4
B-4
B-4
B-4
B-5
B-7
B-7
B-7
B-8
B-8
B-8
Handler with telescopic boom GTH-5519
SAFETY PRECAUTIONS
DANGER
Not observing the instructions
and safety rules in this manual
may result in death or serious
injury.
B-1 GENERAL REMARKS
Most accidents occurring while working, repairing or
maintaining machines, are caused by not complying
with the basic safety precautions.
Therefore, it is necessary to pay steady attention to
the potential hazards and the effects that may come
of operations carried out on the machine.
IMPORTANT
Do not operate the machine unless:
☛ You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1 Avoid hazardous situations.
Read and understand the safety instructions
before going on to the next chapter.
2 Always perform a pre-operation inspection.
3 Always test the machine functions prior to
use.
4 Inspect the work place.
5 Only use the machine for the intended
application.
☛ 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.
☛ Read, understand and obey the employer’s safety
rules and worksite regulations.
☛ Read, understand and obey the applicable national
regulations.
☛ Only trained personnel informed on the safety rules
can operate the machine.
If you recognise hazardous situations, you can
prevent accidents!
For instance, this handbook makes use of special
safety symbols to stress any potentially hazardous
situation.
DANGER
The instructions given in this handbook are the ones
established by GENIE. They do not exclude other
safe and most convenient ways for the machine
installation, operation and maintenance that take
into account the available spaces and means.
If you decide to follow instructions other than those
given in this manual, you shall absolutely:
• be sure that the operations you are going to carry
out are not explicitly forbidden;
• be sure that the methods are safe, say, in compliance
with the rules and provisions given in this section;
• be sure that the methods cannot damage the
machine directly or indirectly or make it unsafe;
• contact GENIE Assistance Service for any suggestion
and the necessary written permission.
IMPORTANT
If in doubt, it is always better to ask! For this
purpose, contact GENIE: the assistance service is at
your disposal. Addresses, phone and fax numbers
are given in the cover and in the title-page of this
manual.
Page
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SAFETY PRECAUTIONS
B-2 R E Q U I S I T E S O F T H E
PERSONNEL IN CHARGE
B-2.1 R E Q U I S I T E S O F T H E M A C H I N E
OPERATORS
The 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.
B-2.2 R E Q U I S I T E S
OF
THE
SERVICEMEN
The personnel charged with the machine maintenance
shall be qualified, specialised in the maintenance of
earth-moving machines, 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.
IMPORTANT
From a technical point of view, the ordinary
maintenance of the machine is not a complex
intervention and can be carried out by the machine
operator, too, provided he has a basic knowledge
of mechanics.
IMPORTANT
The operator shall have a licence (or a driving
licence) when provided for by the laws enforced in
the country where the machine works. Please, ask
the competent bodies.
Page
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SAFETY PRECAUTIONS
B-2.3 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.
B-3
SAFETY PRECAUTIONS
B-3.1 HAZARDS ON THE JOBSITE
Always take into account the features of the job site
where you are going to work:
• Always examine the working area and compare
it with the machine dimensions in the different
configurations.
DANGER
The machine is not electrically insulated and
does not provide protection from contact with or
proximity to electrical power lines.
Always keep at a minimum safe distance from
the telescopic boom and the lifted load. Electrical
DANGER
DEATH OR INJURY CAN RESULT FROM
CONTACTING ELECTRIC POWER LINES.
ALWAYS CONTACT THE ELECTRIC POWER LINES
OWNER. THE ELECTRIC POWER SHALL BE
DISCONNECTED OR THE POWER LINES MOVED
OR INSULATED BEFORE MACHINE OPERATIONS
BEGIN
POWER LINE VOLTAGE REQUIRED CLEARANCE
IMPORTANT
0
50
200
350
500
750
Use only type-approved working clothing in good
condition.
B-2.4 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.
IMPORTANT
Use only type-approved protective equipment in
good condition.
Page
to
to
to
to
to
to
50
200
350
500
750
1000
kV
kV
kV
kV
kV
kV
10
15
20
25
35
45
ft
ft
ft
ft
ft
ft
3.00
4.60
6.10
7.62
10.67
13.72
m
m
m
m
m
m
hazards!
• Keep away from the machine in case of contact with
energized power lines. Personnel on the ground
must never touch or operate the machine until
energized power lines are shut off.
DANGER
Do not at any time use the machine during a
storm.
B-4
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SAFETY PRECAUTIONS
DANGER
Make sure the machine (wheels and stabilisers)
rests on a firm ground to prevent hazardous
unstable conditions.
If the ground is not firm enough, position some
supporting planks under the stabilisers or the
wheels. These plates must grant a specific
pressure of 1.2 to 1.5 kg/cm2 (500x500mm plates
are sufficient).
•
•
•
Look for the best route to the job site.
When the machine is running, nobody can enter its
working range.
While working, keep the working area in order.
Never leave objects scattered: they could hinder
the machine movements and represent a danger
for personnel.
B-3.2 O P E R AT I O N O R M A I N T E N A N C E
HAZARDS
Before any operation, following precautions should be
taken:
• First of all, make sure that the maintenance
interventions have been carried out with care
according to the established schedule (see section
D - Maintenance).
DANGER
Set the machine to working configuration and sway
it. Use the special inclinometer to the right of the
driving place to check that the machine is level
before operating it.
•
•
•
•
•
Ensure you have enough fuel to avoid a sudden
stop of the engine, especially during a crucial
manoeuvre.
Clean instruments, data plates, lights and the cab
windscreen thoroughly.
Check the correct functioning of all the safety
devices installed on the machine and in the job
site.
In case of troubles or difficulties, inform the
foreman at once. Never start working under unsafe
conditions.
Do not carry out any repair work in a makeshift way
to start working!
During work, and especially maintenance, always pay
the greatest attention:
• Do not walk or stop under raised loads or machine
parts supported by hydraulic cylinders or ropes
only.
• Keep the machine handholds and access steps
always clean from oil, grease or dirt to prevent falls
or slips.
Page
B-5
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SAFETY PRECAUTIONS
•
When entering/leaving the cab or other raised parts,
always face the machine; never turn the back.
•
•
•
•
•
•
•
•
•
When carrying out operations at hazardous heights
(over 1.5 meters from the ground), always use
approved fall restraint or fall arrest devices.
Do not enter/leave the machine while it is running.
Do not leave the driving place when the machine is
running.
Neither stop nor carry out interventions under
or between the machine wheels when engine is
running. When maintenance in this area is required,
stop the engine.
•
•
Except for maintenance purposes, do not remove
safety devices, shields, protection cases, etc.
Should their removal be necessary, stop the engine,
remove them with the greatest care and always
remember to refit them before starting the engine
and using the machine again.
Before any maintenance or repair work, stop the
engine and disconnect the batteries.
Do not lubricate, clean or adjust moving parts.
Do not carry out operations manually when specific
tools are provided for this purpose.
Avoid the use of tools in bad condition or use in
an improper way i.e. pliers instead of adjustable
wrenches, etc.
Applying loads in different points of the attachment
holding plate is forbidden.
Before carrying out operations on hydraulic
lines under pressure or disconnecting hydraulic
components, ensure the relevant line has been
previously depressurised and does not contain any
hot fluid.
DANGER
Any intervention on the hydraulic circuit must be
carried out by authorised personnel.
The hydraulic circuit of this machine is fitted with
pressure accumulators. You and others could be
seriously injured if accumulators are not completely
depressurised.
For this purpose, shut the engine down and step
on the brake pedal 8÷10 times.
•
•
•
•
•
•
Do not carry out maintenance or repair works without
a sufficient lighting.
When using the machine lights, the beam should
be oriented in order not to blind the personnel at
work.
Before applying voltage to electric cables or
components, check their connection and proper
functioning.
Do not carry out interventions on electric components
with voltage over 48V.
Do not connect wet plugs or sockets.
Plates and hazard warning stickers shall never be
removed, hidden or become unreadable.
Page
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SAFETY PRECAUTIONS
•
•
•
•
•
•
•
•
Do not empty catalytic mufflers or other vessels
containing burning materials without taking the
necessary precautions.
After any maintenance or repair work, make sure
that no tool, cloth or other object has been left within
machine compartments, fitted with moving parts, or
where suction and cooling air circulates.
When working, do not give instructions or signs to
several people at the same time. Instructions and
signs must be given by one person only.
Always pay due attention to the instructions given
by the foreman.
Never distract the operator during working phases
or crucial manoeuvres.
Do not call an operator suddenly, if unnecessary.
Do not frighten an operator or throw objects by any
means.
After work, never leave the machine under potentially
dangerous conditions.
B-3.3 MACHINE OPERATION HAZARDS
Absolutely avoid the following work situations:
• Do not handle loads beyond the maximum capacity
of the machine.
• Do not raise or extend the boom if the machine is
not on a firm, level surface.
• Do not operate the machine in strong wind. Do
not increase the surface area of the machine or
forked load exposed to the wind. Increasing the
area exposed to the wind will decrease machine
stability.
• Use extreme caution and slow speeds when the
machine is driven across uneven or unstable
grounds, slippery surfaces or near trenches or dropoffs.
• Limit travel speed according to ground conditions,
slopes, presence of personnel or other factors which
may cause collision.
• Do not place or attach overhanging loads to any part
of the machine.
Page
B-3.4 DAMAGED COMPONENT HAZARDS
•
Do not use battery chargers or batteries with a
voltage above 12V to start the engine.
Do not use the machine as a ground for welding.
•
B-3.5 EXPLOSION OR FIRE HAZARDS
•
•
•
•
•
•
•
•
•
Do not start the engine if you smell or detect
LPG, gasoline, diesel fule or other explosive
substances.
Do not refuel the machine with the engine
running.
Refuel the machine and charge the battery only in a
well ventilated area away from sparks, naked flames
and lighted cigarettes.
Do not operate the machine in dangerous
environments or in places with flammable or
explosive gases or materials.
Do not inject ether in engines equipped with glow
plugs.
Do not leave fuel cans or bottles in unsuitable
places.
Neither smoke nor use open flames in areas
subject to fire dangers and in presence of fuel, oil
or batteries.
Carefully handle all flammable or dangerous
substances.
Do not tamper with fire-extinguishers or pressure
accumulators: explosion hazard!
B-7
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SAFETY PRECAUTIONS
B-3.6 DAMAGED MACHINE HAZARDS
•
•
•
•
•
B-4 SAFETY DEVICES
Do not use a damaged or defective machine.
Do a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Tag and remove from service a damaged or
defective machine.
Make sure that all maintenance jobs have been
carried out as specified in this manual and the
appropriate service manual.
Make sure that all decals are in place and legible.
Make sure that the operator ’s, safety and
responsibilities manuals are intact, legible and
placed in the special container located in the
machine.
DANGER
Several safety devices have been fitted to the
machine. They must never be tampered with or
removed (see chap. A-3.5).
Regularly check the efficiency of such devices (see
check card, chap. G-5).
In case of faults, stop working immediately and
proceed in replacing the defective device.
For the checking procedures, read chap. D-3.16.
B-3.7 PERSONAL INJURY HAZARDS
•
•
•
Do not operate the machine in case of hydraulic oil
or air leak. Air or hydraulic oil leaks can penetrate
or burn the skin.
Always operate the machine in a well ventilated area
to avoid carbon monoxide poisoning.
Do not lower the boom if the area underneath is not
clear of personnel or obstructions.
Page
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OPERATING INSTRUCTIONS
Section
C
OPERATING INSTRUCTIONS
TABLE OF CONTENTS
C-1
PRE-OPERATION INSPECTION ................C-2
C-4
SETUP.......................................................C-21
C-2
ENTERING THE MACHINE ........................C-4
C-4.1
Before starting the engine .........................C-21
C-2.1
Entering the cab (only with cabin
closed or glass kit installed).........................C-4
C-4.1.1 Checks at the machine start-up .................C-21
C-2.1.1 Emergency exit-way (only with cabin
closed or glass kit installed).........................C-5
C-2.2
Adjusting the seat ........................................C-6
C-2.3
Fastening the seat belts .............................C-6
C-2.4
Adjusting the steering column .....................C-7
C-2.5
Adjusting the rear view mirrors ....................C-7
C-2.6
Switching on the cab interior lamp...............C-7
C-3
DRIVING PLACE ........................................C-8
C-3.1
Controls and instruments.............................C-8
C-3.2
Engine controls and instruments ..............C-10
C-3.2.1 Ignition switch ...........................................C-10
C-3.2.2 Forward/reverse gear switch ....................C-10
C-3.2.3 Brakes ...................................................... C-11
C-3.2.4 Accelerator control .................................... C-11
C-3.2.5 Pushbutton enabling the attachment
coupling/release ........................................C-12
C-3.2.6 Steering mode selection ...........................C-12
C-3.2.7 Continuous oil flow ...................................C-12
C-3.2.8 Auxiliary drive controls...............................C-13
C-3.3
Instruments and light indicators ................C-13
C-3.3.1 Instruments ..............................................C-13
C-3.3.2 Light indicators .........................................C-14
C-3.4
Control lever .............................................C-15
C-3.4.1 Function selection .....................................C-16
C-3.4.2 Lifting/lowering the boom...........................C-17
C-4.2
Starting the engine ....................................C-21
C-4.3
Jump-starting the engine ...........................C-22
C-4.4
Low temperature starting ...........................C-23
C-4.5
Disconnecting the battery ..........................C-23
C-4.6
Starting the machine..................................C-23
C-4.7
Stopping and parking the machine ............C-24
C-5
USING THE HANDLER ...........................C-24
C-5.1
Using the load charts .................................C-25
C-5.2
Handling loads ...........................................C-26
C-5.2.1 Adjusting the floating forks ........................C-26
C-5.2.2 Working phases .........................................C-27
C-5.3
Changing the attachment ..........................C-28
C-6
TRANSPORTING THE MACHINE ............C-29
C-6.1
Moving a disabled machine .......................C-29
C-6.2
Road or site transfer ..................................C-29
C-6.3
Lifting the machine ....................................C-30
C-6.4
Transporting the machine on other
vehicles......................................................C-30
C-6.5
Parking and storage ..................................C-31
C-6.5.1 Short inactivity ...........................................C-31
C-6.5.2 Machine storage ........................................C-31
C-6.6
Cleaning and washing the machine...........C-32
C-6.6.1 Cleaning instructions .................................C-32
C-6.6.2 Washing instructions..................................C-32
C-6.7
Machine disposal .......................................C-32
C-3.4.3 Pitching the attachment holding frame
forwards/backwards...................................C-18
C-3.4.4 Extending/retracting the telescope ...........C-19
C-3.4.5 Quick-coupling the attachments ...............C-20
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OPERATING INSTRUCTIONS
Fundamentals
INTRODUCTION
This section provides the operator a practical guide for
the gradual learning of the machine use.
The operator should get into the driving cab and carry
out the preliminary adjustments, then memorise the
position of the different controls and instruments.
The familiarisation with the controls ensures not only a
correct use during the working phases, but also a prompt
and timely intervention of the operator, when he shall
carry out sudden manoeuvres to safeguard his safety
and the machine integrity.
It is necessary to learn how to use and foresee the
machine reactions. Learn how to operate the machine
controls in a safe and open place, without obstacles
and anybody standing around. Do not ram the controls.
Operate them slowly to understand their effect on the
machine.
It is the operator responsibility to perform a pre-operation
inspection and routine maintenance.
Pre-operation inspection means a visual inspection
performed by the operator prior to each work shift.
The inspection has to be carried out on the machine to
detect possible faults before the operator starts testing
the machine functions.
The pre-operation inspection also helps understand if
some routine maintenance procedures are required.
The operator can only perform the routine maintenance
procedures envisaged in this manual.
See the list on the next page and check each single
component.
If the machine is damaged or a non-authorized
modification has been done, the machine must be
tagged and removed from service.
Repairs must be carried out by qualified technical
personnel according to the manufacturer’s specifications.
After any repair, the operator should repeat the preoperation inspection before testing the machine
functions.
C-1 PRE-OPERATION INSPECTION
Scheduled maintenance procedures must be performed
by qualified technical personnel according to the technical
specifications of the manufacturer and the requirements
envisaged in the responsibilities manual.
Do not operate the machine,
unless:
☛ You learn and practice the principles of safe machine
operation contained in this operator’s manual.
1 Avoid hazardous situations.
Read and understand the safety rules before
going on to the next chapter.
2 Always perform a pre-operation inspection.
Read and understand the safety rules before
going on to the next chapter.
3 Always test the machine functions prior to use.
4 Inspect the work place.
5 Only use the machine for the intended
application.
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OPERATING INSTRUCTIONS
Pre-operation inspection
☛ Make sure the operator’s manuals are intact, legible
and placed inside the machine.
☛ Make sure all decals are present and legible. See
“Decals” chapter.
☛ Check for engine oil leaks and proper oil level. Top
up if necessary. See “Maintenance” chapter.
☛ Check for axle oil leaks and proper oil level. Top up
if necessary. See “Maintenance” chapter.
☛ Check for hydraulic oil leaks and proper oil level. Top
up if necessary. See “Maintenance” chapter.
☛ Check for engine coolant leaks and proper coolant
level. Add coolant if necessary. See “Maintenance”
chapter.
☛ Check for battery fluid leaks and proper fluid level.
Add distilled water if necessary. See “Maintenance”
chapter.
Check the following components or zones for damage,
missing or wrongly fitted parts or non-authorised
modifications:
• electrical components, wiring and electrical
cables
• hydraulic hoses, fittings, cylinders and
distributors
• fuel and hydraulic oil tanks
• drive pump and motor and transmission axles
• steering system
• braking system
• boom telescopes sliding pads
• clean glasses, lights and rear view mirrors
• engine and relevant components
• limit switches and horn
• lights
• machine ignition control
• nuts, bolts and other fasteners.
Page
Check the entire machine for:
• cracks on welds or structural components
• dents or damage to the machine.
☛ Make sure that all structural and other critical
components are present and the relevant fasteners
and pins are fitted and properly tightened
☛ After inspection, check that all the compartment
covers are in place and latched.
DANGER
If even one single item is damaged or defective,
do not start work. Stop the machine and repair the
fault.
Checking the tyres
☛ Check the correct inflation of the tyres; see par. “Tyre
inflation” in the Maintenance section
☛ Make sure that the tyre plies are not cut or worn.
DANGER
A tyre burst may result in serious injury; never use
the machine if tyres are worn, wrongly inflated or
damaged.
ATTENTION
If the machine shall be used in a marine or equivalent
environment, protect it against salt deposits with
an adequate treatment against saltiness to prevent
rust formation.
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OPERATING INSTRUCTIONS
ATTENTION
C-2 ENTERING THE MACHINE
C-2.1 ENTERING THE CAB
(ONLY WITH CABIN CLOSED OR GLASS
KIT INSTALLED)
DANGER
The upper section of the door must be secured to
the rear part of the driving cab or latched to the
lower section of the same door.
Always make sure that your hands and shoe soles
are clean and dry before getting into the driving
cab. Always face the machine when entering and
leaving it and hold to the suitable handles.
The handler cab is equipped with an access door on
the left-hand side.
Door opening from outside:
• Insert the key and release lock 1.
• Press the pushbutton and open the door.
➋
➊
➌
Door closing from inside:
• Pull the door with force: it locks automatically.
Door opening from inside:
• Lift lever 2 and release the lock to open the door
completely.
• Rotate handle 3 to open the upper section of the
door and lock it against the special catch.
➍
To unlock the door latched in open position:
• Press button 4 to unlock the door from the catch,
close and latch the door to the lower section using
handle 3.
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OPERATING INSTRUCTIONS
C-2.1.1
Leaving the cab in an emergency (ONLY
WITH CABIN CLOSED OR GLASS KIT
INSTALLED)
In an emergency, the operator can use he front or the
rear window as safety exit-ways.
The rear window has handles for partially opening the
glass. Such handles are locked in position by some
wing nuts 5 which, if driven out, allow opening the glass
completely.
The front window has two handles 6 which, if turned,
enable the operator to pass through.
➎
➏
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OPERATING INSTRUCTIONS
C-2.2 ADJUSTING THE SEAT
A correct adjustment of the seat ensures the operator
a safe and comfortable driving. The handler seat is
fitted with devices which allow for the adjustment of
the springing, the height and the distance from the
controls.
•
•
•
➌
➋
➊
Seat distance from the controls
The seat is equipped with an adjusting device to
slide the same seat forward or back with respect to
the steering column.
To adjust the seat, pull lever 1 outwards and push the
seat to the desired direction. Then release the lever
and make sure that the seat locks in position.
In some seats height can be adjusted to three
different positions. Lift the seat until you hear the
click signalling that the seat is locked in position.
To lower the seat, raise to end of stroke to release
the mechanism, then release the seat: it will return
to the bottom position.
Springing adjustment (optional)
Rotate lever 2 clockwise or anticlockwise according
to the springing degree required. Rotate clockwise/
anticlockwise to increase/reduce the seat springing.
To reverse this control, pull out and rotate the lever
knob by 180°.
Height adjustment (optional)
Turn knob 3 clockwise to lift the seat; turn it counterclockwise to lower the seat.
➊
C-2.3 FASTENING THE SEAT BELTS
Sit correctly in the driving seat; then:
• The safety belts are equipped with reel retractor. To
fasten the belt, pull tab 1 and push it into buckle 2.
• To release the belt, push button 3 and remove the
tab from the buckle.
• Make sure that the buckle is correctly located at the
hip point and not on the stomach.
• Operate the end adjusters to reach the length you
wish and make sure the buckle is always in the
middle.
➌
➋
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OPERATING INSTRUCTIONS
C-2.4 ADJUSTING THE STEERING COLUMN
Both steering column and dashboard can be set to a
different angle. For this purpose:
• Loosen lever 1 and adjust as required, then retighten lever 1.
DANGER
Before driving the machine, ensure the steering
wheel is perfectly clamped.
C-2.5 ADJUSTING THE REAR VIEW MIRRORS
The machine is fitted with two rear view mirrors:
• The right rear view mirror is located on a special
supporting bracket in advanced position and allows
checking the area behind the machine, on the righthand side. To adjust its position, manually rotate the
joint it is fitted with.
• The left rear view mirror is placed on the left upper
post of the windscreen and allows checking the
area behind the machine, on the left- hand side. To
adjust its position, manually rotate the joint it is fitted
with.
➌
➋
➊
C-2.6 SWITCHING ON THE CAB LIGHTS
The ceiling light fixture of the cab has an internal lamp
and a courtesy lamp.
To switch on the cab interior lights:
• Switch 4 in pos. A
cab interior lights OFF
• Switch 4 in pos. B
cab interior lights ON.
• Switch 4 in pos. C
courtesy lamp ON
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OPERATING INSTRUCTIONS
C-3 DRIVING PLACE
C-3.1 CONTROLS AND INSTRUMENTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Dashboard
Water level
Brake oil tank
Ignition switch
Fresh air flap
Warning light - glow plugs preheating
Warning light - air filter clogged
Fuse compartment
Forward/reverse speed selection lever
Steering column locking lever
Brake pedal
Pushbutton enabling the attachment coupling/release
Steering selection switch
Horn pushbutton
Gas pedal
Warning light - engine filter soiled
Control lever
Negative brake on/off switch
Continuous oil flow potentiometer
Flow reversal button
21 Air conditioning fan switch (only with cabin
closed)
22 Windscreen washer pushbutton (only with cabin
closed)
23 Storage tray
24 Storage pocket
25 Seat
IMPORTANT
The warning lights, controls and instruments not
indicated in this list or in the drawings on the
following pages are part of the optional assembly
kits. When looking for one of such devices, please
refer to the pages of the specific assembly kit at
the end of this manual or to the specific installation
instructions.
☞
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OPERATING INSTRUCTIONS
1
2
16
2 0 2 4 6 8
10 8 6 4
10
3
4
5
6
7
8
01234567
9
F
N
10
R
11
12
13 14
15
17
25
18
21
22
19
20
23
24
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OPERATING INSTRUCTIONS
C-3.2 E N G I N E
CONTROLS
INSTRUMENTS
C-3.2.1 Ignition switch
AND
C-3.2.2
Forward/reverse gear selector switch
Three-position switch with lock in neutral position:
Three-position switch:
No circuit under voltage, key can be removed
and engine is stopped
Circuits under voltage, presetting for the engine
starting. Board controls and instruments are
on.
The warning light 6 signalling the glow plugs
preheating comes on. Wait until the light goes
off before starting the engine.
N
Neutral position; no gear engaged
F
Shift lever to pos. F to select the forward gear
R
Shift lever to pos. R to select the reverse gear
ATTENTION
Once the reverse gear is engaged, a sound allarm
will be activated
Engine starting; when released, key springs back
to pos. I automatically.
80
40
80
40
120
°C
01234567
F
N
R
➒
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OPERATING INSTRUCTIONS
C-3.2.3
Brakes
C-3.2.4
11 Service brake pedal
Gradually step on the brake pedal to decelerate and stop
the machine. The pedal operates on the front axle.
Fully depressing the brake pedal causes a reset of the
displacement of the power drive pump and makes the
braking action more powerful.
Accelerator control
15 Gas pedal
Its pressure controls the engine rpm and, coupled to
the gearbox, the machine speed. It is fitted with an
adjustable stop in the lower part
18 Parking brake
The parking brake of negative type engages
automatically when the engine is stopped.
When the handler’s engine is restarted, pressing the
pushbutton switch 18 unlocks the parking brake.
To stop the handler without shutting down the engine,
press the pushbutton switch 18 to engage the parking
brake and push it once again to disengage the brake.
Every pressure of the pushbutton switches the warning
light on and off. When the red warning light is on, the
parking brake is engaged.
ATTENTION
Never use the parking brake to slow down the
machine, unless in an emergency. It may reduce
the brake efficiency.
18
01234567
F
N
R
11
15
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OPERATING INSTRUCTIONS
C-3.2.5
12
Pushbutton enabling the attachment
coupling/release
C-3.2.7
20
Flow reversal button
Selection button
1
Two-position button with return to the neutral
point. Press this button every time you wish to
couple/release an attachment. Hold the button
pressed down until the movement has been
completed.
C-3.2.6
0
0 No oil flow.
13 Steering mode switch
Three-position switch for the selection of the steering
mode:
Crab steering
0
Two-wheel steering
2
Four-wheel steering
Pushbutton with orange glass cap, with two
stable positions. Press this button to switch the
hydraulic circuit feeding the attachments with
auxiliary lines.
1 Continuous oil flow delivery to the used
attachment.
Steering mode selection
1
Continuous oil flow
19
Continuous oil flow potentiometer
By turning the potentiometer clockwise,
the flow rate in the circuit feeding
the attachments’ movement lines is
increased.
IMPORTANT
Clock wise, rottation of the steering
wheel steers the truck to the operator's
right
F
N
R
12
13
20
19
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OPERATING INSTRUCTIONS
C-3.2.8
14
Auxiliary drive controls
C-3.3 I N S T R U M E N T S
INDICATORS
C-3.3.1 Instruments
Horn pushbutton
Pushbutton with green glass
Press this button to operate the horn.
22
AND
LIGHT
54
Engine coolant temperature indicator
Signals the engine coolant temperature.
(engine oil)
53
Fuel gauge
Signals the fuel level within the tank.
Windscreen washer button
By holding this button pressed down, a jet of
water is sprayed on the windscreen and the
rear window.
23
Air conditioning fan switch (only with cabin
closed)
Three-position switch:
0 OFF
1 Low speed
2 High speed
01234567
52
Hour-meter
Signals the total operating hours of the
machine.
51
Hydraulic oil temperature indicator
Signals the temperature of the hydraulic
oil within the reservoir.
60 61 62 63 64 65 66 67 68
21
01234567
22
51
14
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OPERATING INSTRUCTIONS
C-3.3.2
60
Light indicators
Indicator light - high beam
Blue indicator light that signals when high
beam is ON.
This indicator is active only when the lights
kit is installed.
61
Indicator light - position lights
Green indicator light that signals when
position lights are ON.
This indicator is active only when the lights
kit is installed.
63
Indicator light - engine air filter restricted
When this lamp come on, proceed with
cleaning or changing the air filter cartridge
(see “Maintenance” section).
6
Indicator light - glow plugs preheating
Green light indicators which signal the
preheating phase of the engine glow plugs.
Before starting the engine wait for these lights
to go off.
7
Indicator light - air filter soiled
Orange light indicator which signals when
the air intake filter of the engine is getting
soiled.
Clean or replace
the filtering
c a r t r i d g e
6
immediately.
7
64
Indicator light - low battery charge
Signals a low charge by the alternator.
65
Indicator light - low engine oil pressure
It lights when the engine oil pressure is too
low.
66
Indicator light - parking brake engaged
When ON, this light indicates that the parking
brake is engaged.
67
Indicator light - negative brake
accumulator
Not activated.
F
N
R
60 61 62 63 64 65 66 67 68
68
Indicator light - turn signals
Green indicator light that signals when turn
signals are ON.
This indicator is active only when the lights
kit is installed.
01234567
51
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OPERATING INSTRUCTIONS
C-3.4 CONTROL LEVER
Handlers are equipped with a hydraulically driven servocontrolled lever.
The lever has two pushbuttons: one for coupling/
releasing the attachments and the other for pitching
the attachment frame forwards/backwards .
Shifting the lever to one of the four directions (right/left,
forwards/backwards) moves the boom up and down
and the telescope out and in.
IMPORTANT
Seize the control lever correctly and move it
gently.
The motion speed of the actuators depends on
the lever position: a small motion results in a slow
motion of the actuators; vice versa, a full range
motion of the lever corresponds to the max. speed
of the actuator.
DANGER
The control lever shall be operated only when
correctly seated in the driving place.
DANGER
Before operating the control lever, make sure
that nobody is within the working range of the
machine.
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OPERATING INSTRUCTIONS
C-3.4.1 Function selection
The lever is enabled to carry out the following
motions:
•
Boom lowering/lifting
shift the control lever to or •
Boom extraction/retraction
shift the control lever to or •
Attachment back/forward tilting
press button and shift the control lever to or
•
Attachment coupling/release
press button together with the dashboard enabling
button and shift the lever to or Page
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OPERATING INSTRUCTIONS
C-3.4.2
Lifting/lowering the boom
DANGER
Before operating the boom, make sure that nobody
is within the working range of the machine.
To lift or lower the boom:
• Smoothly shift the lever to position to lift the boom
or to position to lower it.
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OPERATING INSTRUCTIONS
C-3.4.3
Pitching the attachment holding frame
forwards/backwards
DANGER
Before operating the boom, make sure that nobody
is within the working range of the machine.
To tilt the attachment holding frame forwards/
backwards:
• Press button and shift the lever to position to tilt the frame forwards or to position to tilt it
backwards.
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OPERATING INSTRUCTIONS
C-3.4.4
Extending/retracting the telescope
DANGER
Before operating the boom, make sure that nobody
is within the working range of the machine.
To extend or retract the boom telescope:
• Smoothly shift the lever to position to extend the
boom or to position to retract it.
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OPERATING INSTRUCTIONS
C-3.4.5
Quick-coupling the attachments
DANGER
Before operating the boom, make sure that nobody
is within the working range of the machine.
To lock the attachments:
• Press button together with the dashboard
enabling button (12) and shift the lever to position
to unlock the attachment or to position to lock
the attachment.
F
N
R
12
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OPERATING INSTRUCTIONS
C-4 SETUP
C-4.1 BEFORE STARTING THE ENGINE
•
•
•
•
•
•
•
•
•
To ensure safe conditions to the operators and
the bystanders, and a longer life to your machine,
perform a walk-around inspection before starting
the engine.
Remove any dirt or rubbish from the cab interior,
and especially from pedals and control levers.
Remove oil, grease and mud from pedals and control
levers.
Make sure that your hands and shoe soles are clean
and dry.
Check the seat belts can be fastened properly.
Check that lights, indicators, side/tail lights, hazard
indicator lights, wipers and horn are in working
order.
Adjust the driving seat so that you can reach all
control levers comfortably and fully depress the
brake pedal without moving your back from the
driving seat.
Adjust the rear view mirrors to give you a good view
close behind the machine when you are correctly
seated.
Check the parking brake is engaged.
C-4.1.1 Checks at the machine start-up
Check the efficiency of the safety devices as described
in chap. D-3.16, namely:
• machine start control.
C-4.2 STARTING THE ENGINE
For the low temperature starting, see paragraph C4.4.
• Engage the parking brake.
•
•
•
•
•
Put the forward/reverse speed selection lever to
neutral.
Step on the gas pedal.
To start the engine, turn the
ignition switch to position
II. Release the switch
when the engine starts. If
the engine does not start
within 20 seconds, release
the key and wait at least 2
minutes before attempting
again.
After the start-up, let the engine run at idle for some
seconds before engaging a gear; this allows for
a gradual warm up of the engine oil and a better
lubrication.
In case of engine jump-starting, remove the booster
cables (see following chapter).
ATTENTION
If the light indicators do not switch off/on when
engine is running, immediately stop the machine
and find and rectify the fault.
IMPORTANT
Engine cannot be started if the parking brake is
not engaged.
DANGER
After the start-up, when leaving the driving place,
the engine continues to run. DO NOT LEAVE THE
DRIVING PLACE BEFORE HAVING SHUT THE
ENGINE DOWN, LOWERED THE BOOM TO THE
GROUND AND ENGAGED THE PARKING BRAKE.
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OPERATING INSTRUCTIONS
C-4.3 JUMP-STARTING THE ENGINE
ATTENTION
Do not start the engine using a quick charge booster
to avoid any damage to the electronic boards.
B
DANGER
A
When jump-starting the engine through the battery
of another machine, make sure that the two vehicles
cannot collide to prevent formation of sparks.
Batteries give off a flammable gas and sparks may
burn it and cause an explosion
Do not smoke when checking the electrolyte
level.
Keep any metal object like buckles, watch straps,
etc. clear of the battery positive (+) terminal. These
elements can short between the terminal and nearby
metal work and the operator can get burned.
The booster supply must have the same rated
voltage and output of the battery installed on the
handler.
To jump-start the engine:
• Turn any users off by the special control levers.
• Put the gear lever to neutral and engage the parking
brake.
• Ensure the machine battery A is connected to the
frame earth, the terminals are well tightened and
the electrolyte level is regular.
• Connect the two batteries as shown in the figure.
Connect first the positive terminals of the two
batteries, then the negative terminal of the booster
supply B to the machine frame earth.
• If the booster supply is installed on a second vehicle,
make sure that the latter does not touch the handler.
To avoid damage to the electronic instruments
of the machine, the engine of the machine
where the booster supply is installed, must be
stopped.
• Turn the ignition key and start the handler, then
follow the procedure explained in chapter C-4.2
“Starting the engine”.
Page
•
Disconnect the cables. Remove first the negative
terminal from the frame earth, then from the booster
supply. Disconnect the positive terminal from the
machine battery, then from the booster supply.
DANGER
Use only a 12V battery; other devices like battery
chargers, etc. may cause an explosion of the battery
or result in damage to the electrical system.
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OPERATING INSTRUCTIONS
C-4.4 LOW TEMPERATURE STARTING
In case of cold starting, use an oil with a SAE viscosity
adequate to the ambient temperature.
Please refer to the engine use and maintenance
manual.
The machine is supplied with oil SAE 15W/40.
C-4.5 DISCONNECTING THE BATTERY
Before any maintenance or repair work, and especially
before welding any components on the machine, remove
the cables at the battery.
ATTENTION
Before disconnecting the battery, set all switches
within the cab to OFF.
To disconnect the battery, disconnect the negative
(-) lead from the frame earth first. To connect the
battery, connect the positive (+) lead first.
C-4.6 STARTING THE MACHINE
When the engine reaches the running temperature,
ensure all parts are in transfer position and the gearbox
lever is in neutral. Then, proceed as follows:
• Select the required steering mode.
• Select the required gear (forward or reverse).
• Release the parking brake pressing button 18 (the
warning light on the pushbutton must be off).
• Slowly step on the gas pedal to start moving off.
To start the engine from cold, proceed as follows:
• Engage the parking brake.
• Turn the ignition switch to position I and wait until the
warning light 6 signalling the glow plugs preheating
goes off. Step down on the gas pedal and start the
engine turning the ignition switch to II. Release as
soon as the engine starts.
• Let the engine run at idle for a few seconds before
putting a gear; this allows for a gradual warm up of
the engine oil and a better lubrication.
• In case of engine jump-starting, remove the booster
ables (see chapter C-4.3).
Page
DANGER
Do not operate the forward/reverse gear lever
when the machine is running. The machine would
reverse the running direction abruptly and you could
seriously be injured.
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OPERATING INSTRUCTIONS
C-4.7 S T O P P I N G A N D PA R K I N G T H E
MACHINE
When possible, stop the machine on a dry, level and
solid ground. Then:
• Bring the machine to a smooth stop by easing up the
gas pedal and stepping down on the brake pedal.
• Set the forward/back speed lever to neutral
position.
• Engage the parking brake pressing button 18 (the
warning light on the pushbutton must be on).
• Release the service brake pedal.
• Rest the attachment coupled to the boom flat on the
ground.
• Rotate the ignition key to “0” and remove the key.
• Leave the driving cab and lock the cab door.
• Disconnect the battery (see chapter C-4.5).
DANGER
Always face the machine when getting off the driving
cab; make sure that your hands and shoe soles are
clean and dry, and hold to the handholds to prevent
falls or slips.
DANGER
Always engage the parking brake after stopping the
machine to prevent possible accidental motions of
the vehicle.
C-5 USING THE HANDLER
This chapter describes some techniques and provides
instructions for a safe use of the machine fitted with
standard forks. Before using different attachments,
thoroughly read the chapter “Optional attachments".
DANGER
Before using the machine, inspect the job site and
check for possible hazardous conditions. Make
sure that there are no holes, moving banks or
debris that may cause you to lose the control of
the machine.
DANGER
Pay the greatest attention when working close to
electric lines. Check their position and ensure that
no part of the machine operates at less than 6 meters
from the power lines.
DANGER
For a safe use of the machine, always check the
weight of the loads going to be handled.
Always refer to the load charts applied in the cab.
ATTENTION
Leaving a battery connected can result in shorts
and, as a consequence, in a fire.
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OPERATING INSTRUCTIONS
C-5.1 USING THE LOAD CHARTS
On the cab windscreen, there are the load charts that
indicate the operator how far a load can be extended.
The load chart indicates the payload limits of the machine
under safe conditions.
To operate under safe conditions, always refer to these
charts.
The extension level of the boom can be checked with
the help of the letters A (A, B, C) painted on the same
boom and compared with the load chart, while the actual
degrees of inclination of the boom are shown by the
angle indicator B.
20 ft
70° E
D
60°
IMPORTANT
C
50°
B
15 ft
A
The load charts illustrated in this manual are given
only as a mere example. To define the payload
limits, refer to the load charts applied in the cab of
your machine.
10 ft
30°
3000 lbs
D
4400 lbs
E
B
A
0°
0 ft
The load charts applied on the cab windscreen
refer to a stationary machine standing on a solid
and level ground.
Raise the load some centimetres and check its
stability before raising it completely.
1900 lbs
DANGER
10°
2000 lbs
20°
5 ft
Page
55
00
lb
s
40°
15 ft
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10 ft
C
5 ft
0 ft
Handler with telescopic boom GTH-5519
OPERATING INSTRUCTIONS
C-5.2 HANDLING LOADS
C-5.2.1 Adjusting the floating forks
Forks shall be spaced to suit the load going to be
handled. For this purpose:
• Loosen the nut of the locking screws.
• Raise the forks and slide them on the pivot until
correct spacing.
• Lock the screws re-tightening the nut.
DANGER
•
•
•
•
•
Page
The centre of gravity of the load must always be
halfway between the forks.
Ensure you exactly know the weight of the load
before handling it.
When extending the boom, do not exceed the
payload limit.
Refer to the payload limits given in the load
chart applied in the cab or in the quick user’s
guide.
Space the forks as wide as possible to suit the
load being handled.
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OPERATING INSTRUCTIONS
C-5.2.2 Working phases
When forks are correctly spaced, the handler is ready
to use.
Work can be subdivided into three different phases:
loading, transfer and unloading.
Loading phase
• Approach the load to the handled perpendicularly
and check that the machine is level on the
inclinometer.
• Insert the forks under the load and raise the load
some centimetres.
• Pitch the forks backwards and check the machine
stability before handling a load.
DANGER
Do not move off when the load is raised 20÷30 cm
above the ground. Risk of machine overturning or
load fall.
Transfer phase
• Do not start or brake abruptly.
• Drive to the unloading point cautiously and keep the
load 20÷30 cm from the ground.
• Suit the machine speed to the ground conditions to
avoid dangerous jumps, side skids of the vehicle
and possible load falls.
• When driving on slopes or ramps, hold the load
uphill.
DANGER
Do not drive on slopes sideways; this wrong
manoeuvre is one of the main reasons for accidents
due to vehicle overturning.
Unloading phase
• Drive to the unloading point with straight wheels and
bring the machine to a smooth stop leaving enough
space to operate the boom.
• Put the parking brake and set the transmission to
neutral.
• Position the load some centimetres above the
desired position and set the forks level.
• Lower the load and make sure it is level.
• Carefully withdraw the forks by operating the boom
retraction control and, if necessary, raise or lower
the boom as forks come out.
• When the forks are clear of the load, set them to
transfer position.
• Release the parking brake and start a new working
cycle.
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OPERATING INSTRUCTIONS
C-5.3 CHANGING THE ATTACHMENT
DANGER
DANGER
Use only attachments directly manufactured or
recommended by Terexlift and detailed in the
“Optional attachments” section.
After substitution, visually check the attachment
is correctly coupled to the boom, before operating
the machine. A wrongly coupled attachment may
result in damage to persons or things.
To change an attachment, operate as follows:
•
Drive to the place where you will release the
mounted attachment (when possible, a solid and
sheltered site).
•
Disconnect the quick connectors of the attachment
(if any), and connect the hydraulic locking pipes of
the attachments to couplings A.
•
Rest the attachment flat on the ground.
•
Pitch the attachment holding frame forward and
lower the boom to release the attachment upper
lock.
•
Move back with the machine (or with the boom) and
drive to the new attachment to be coupled.
•
Hold the frame pitched forward and hook the upper
lock of the new attachment.
•
Retract and raise the attachment some centimetres.
It will centre automatically on the quick coupling
frame.
Operate the control lever to lock the attachment.
•
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OPERATING INSTRUCTIONS
•
Couple the connectors of the attachment, if any, to
the quick couplings of the frame.
DANGER
After the substitution of an attachment or after any
coupling operation, visually check the attachment. A
wrongly coupled attachment may result in damage
to persons or things.
C-6 T R A N S P O R T I N G
MACHINE
THE
C-6.1 MOVING A DISABLED MACHINE
Tow the machine only when no alternative is possible,
since this operation may result in serious damage to
the transmission. When possible, repair the machine
on site.
When the machine shall absolutely be towed:
• Tow the machine for short distances and at a low
speed only.
• Use a rigid drawbar.
• Select the two-wheel steer.
• Set the gearbox lever to neutral.
• When possible, start the engine and use the
hydraulic drive and the braking system.
• Raise the front wheels of the machine and remove
the Cardan shaft of the transmission.
C-6.2 ROAD OR SITE TRANSFER
When travelling on public roads, strictly obey the local
or national road traffic regulations.
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OPERATING INSTRUCTIONS
C-6.3 LIFTING THE MACHINE
When the machine shall be lifted, use only means
having a suitable capacity. The characteristic data are
detailed in the relevant chapter of this manual and on
the identification plate.
For the machine lifting, anchor the chains to the special
lugs on the machine (marked with the decal below).
Page
C-6.4 TRANSPORTING THE MACHINE ON
OTHER VEHICLES
To transport the machine on another vehicle, follow
the steps below:
• Put chocks at the machine wheels.
• Ensure ramps are correctly positioned.
• Retract the boom to transfer position.
• Carefully drive the machine onto the transporting
vehicle.
• Put the parking brake and rest the attachment flat
on the vehicle platform.
• Ensure the overall dimensions do not exceed the
allowed limits.
• Shut the engine down and close the driving cab of
the machine.
• Secure the machine to the vehicle platform by wheelchocks.
• Anchor the machine to the transporting vehicle with
suitable chains.
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OPERATING INSTRUCTIONS
C-6.5 PARKING AND STORAGE
C-6.5.1 Short inactivity
Always park the machine in a safe way after a working
day, a shift and at night.
Take all precautions to prevent damage to those persons
who will approach the machine while stationary:
• Park the machine so that it does not hinder other
operations.
• Lower the boom fitted with attachment on the
ground.
• Remove the key from the ignition switch. Leave the
driving cab and lock the cab door.
• Disconnect the battery (see chapter C-4.5).
ATTENTION
Leaving a battery connected can result in shorts
and, as a consequence, in a fire.
C-6.5.2 Machine storage
In case of extended inactivity of the machine, follow the
above precautions. Additionally:
• Wash the machine thoroughly. For a better cleaning,
remove grills and protection casings
• Carefully dry all machine parts by blowing some
compressed air.
• Lubricate the machine thoroughly.
• Do a walk-around inspection and replace any worn
or damaged part.
• Re-paint any worn or damaged part.
• Remove the battery, smear its terminals with
vaseline and store it in a dry place. Battery can be
used for other purposes. Otherwise, periodically
check its charge level.
• Refuel the tank to prevent internal oxidation.
• Store the machine in a sheltered and well-ventilated
place.
• Start the engine for about 10 minutes at least once
a month.
ATTENTION
Always remember that the ordinary maintenance
must be carried out even during the machine
inactivity. Pay particular attention to the fluid levels
and to those parts subject to ageing. Before restarting the machine, carry out an extraordinary
maintenance and carefully check all mechanical,
hydraulic and electrical components.
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OPERATING INSTRUCTIONS
C-6.6 C L E A N I N G A N D WA S H I N G T H E
MACHINE
C-6.6.1 Cleaning instructions
Clean the machine in accordance with the following
instructions:
• Remove any oil or grease traces with a dry solvent
or a volatile mineral alcohol
• Before assembling a new part, remove any protection
product (rust-preventer, grease, wax etc.)
• Remove any trace of rust from metal parts with
some emery cloth before smearing the part with a
protection product (rust-preventer, paint, oil etc.).
C-6.6.2
C-6.7 MACHINE DISPOSAL
PROTECT THE
ENVIRONMENT
At the end of the machine life, call in a specialised
firm to dispose of it in compliance with the local or
national regulations.
Washing instructions
ATTENTION
Never use water at pressure for washing components
of the machine such as main valve, solenoid valves,
electric and electronic parts.
External washing
Before washing the machine, check that the engine is
shut down and the doors and windows are closed.
Do not, at any times, use fuel to clean the machine. Use
water or some steam. In cold climates, dry the locks
after washing or smear them with an antifreeze.
Before using the machine again, check its conditions.
Internal washing
Wash the machine interior with some water and a
sponge. Do not use water at high pressure. After
washing, dry with a clean cloth.
Washing the engine
Before washing the engine, protect the air intake filter
to prevent water from entering the circuit.
ATTENTION
If the machine shall be used in a marine or equivalent
environment, protect it against salt deposits with
an adequate treatment against saltiness to prevent
rust formation.
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MAINTENANCE
Section
D
MAINTENANCE
TABLE OF CONTENTS
D-1
LUBRICANTS - HEALTH AND SAFETY
PRECAUTIONS ..........................................D-3
D-2
ROUTINE MAINTENANCE .........................D-4
D-2.1 Oil change schedule ....................................D-5
D-3
MAINTENANCE JOBS ...............................D-6
D-3.1 Disconnecting the battery ............................D-6
D-3.2 Access to the engine and tanks
compartments ..............................................D-7
D-3.3 Greasing ......................................................D-8
D-3.4 Tyres and wheels.........................................D-9
D-3.5 Check the efficiency of braking system and
parking brake ............................................D-10
D-3.5.1 Checking the brake oil level....................... D-11
D-3.6 Engine air filter...........................................D-12
D-3.7 Cab air filter (only with cabin closed or
glass kit installed) ......................................D-13
D-3.8 Engine cooling circuit ................................D-14
D-3.9 Engine oil level ..........................................D-15
D-3.10 Checking the oil level in the tank ...............D-16
D-3.11 Changing the oil filter cartridge ...............D-17
D-3.11.1 Auxiliary circuits oil filter ............................D-18
D-3.12 Oil level in the differential gears
and the rducer ...........................................D-19
D-3.12.1 Front and rear differential gears ................D-19
D-3.12.2 Reducer .....................................................D-19
D-3.13 Oil level in the (front/rear) wheel reduction
gears .........................................................D-20
D-3.14 Shafting alignment .....................................D-21
D-3.15 Adjusting the sliding pads of the boom
sections .....................................................D-22
D-3.16 Checking the safety devices ......................D-23
Page
D-3.17
D-4
D-4.1
D-4.2
D-5
D-5.1
D-5.2
D-5.2.1
D-5.2.2
Checking the state of the structure .........D-24
ELECTRICAL SYSTEM ............................D-25
Battery .......................................................D-25
Fuses and relays .......................................D-26
REFUELLING ..........................................D-28
Refuelling...................................................D-28
Product specifications................................D-28
Engine oil ..................................................D-28
Lubrication oils and relevant filtering
elements ....................................................D-28
D-5.2.3 Fuel............................................................D-29
D-5.2.4 Grease .......................................................D-29
D-5.2.5 Engine coolant..........................................D-29
D-1
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MAINTENANCE
INTRODUCTION
A thorough and regular maintenance keeps the machine
in a safe and efficient working condition.
Observe and obey:
☛ The operator can only perform the routine maintenance operations envisaged in this manual.
☛ Scheduled maintenance procedures shall be completed by qualified technical personnel according
to the manufacturer’s specifications.
Maintenance symbol legend:
IMPORTANT
The following symbols are used in this manual
to help you understand better the instructions
provided. When one or more symbols appear at
the beginning of a maintenance procedure, they
indicate the following:
Indicates that tools are required to
perform the procedure.
For this reason, it is advisable to wash, grease and
service the machine properly, especially after having
worked under particular conditions (muddy or dusty
environments, heavy operations, etc.).
Always ensure all machine components are in good
condition. Check for oil leaks or loosening of guards,
and make sure that the safety devices are efficient. In
case of defects, find and rectify them before using the
machine again.
The maintenance interventions are based on the
machine working hours. Regularly check the hour-meter
and keep it in good condition to define the maintenance
intervals correctly.
Not respecting the ordinary maintenance schedule of
this manual automatically voids GENIE warranty.
IMPORTANT
For the engine maintenance, please refer to the
specific Operator handbook supplied with the
machine.
Indicates that new parts are required to
perform the procedure.
Indicates that a cold engine is required to
perform the procedure.
SERVICE INTERVAL
Running-in _____________________________
Ordinary _______________________________
Indicates the time interval for the
maintenance jobs expressed in working
hours.
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MAINTENANCE
D-1 LUBRICANTS - HEALTH AND
SAFETY PRECAUTIONS
Health
A prolonged skin contact with oil can cause irritation. Use
rubber gloves and protective goggles. After handling oil,
carefully wash your hands with soap and water.
Storage
Always keep lubricants in a closed place, out of the
children’s reach. Never store lubricants on the open air
and without a label indicating their contents.
Disposal
New or exhausted oil is always polluting! Never drain oil
on the ground. Store new oil in a suitable warehouse. Pour
exhausted oil into cans and deliver them to specialised
firms for disposal.
Oil leaks
In case of accidental oil leaks, cover with sand or typeapproved granulate. Then scrape off and dispose of it
as chemical waste.
First aid
Eyes:
Intake:
Skin:
In case of accidental contact with the eyes,
wash with fresh water. If the irritation
persists, seek medical advice.
In case of oil intake, do not induce
vomiting, but seek medical advice.
In case of a prolonged contact, wash
with soap and water.
Fire
In case of fire, use carbon dioxide, dry chemical or foam
extinguishers. Do not use water.
Page
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MAINTENANCE
Every 50 working hours or weekly
D-2 ROUTINE MAINTENANCE
Jobs to be done in addition to those above
A wrong or neglected maintenance can result in possible
risks for both operator and bystanders. Make sure
maintenance and lubrication are carried out according
to the manufacturer’s instructions to keep the machine
safe and efficient.
The maintenance interventions are based on the
machine working hours. Regularly check the hourmeter and keep it in good conditions to define the
maintenance intervals correctly. Make sure any defect
detected during the maintenance is promptly rectified
before using the machine.
1
2
3
4
Every 250 working hours or monthly
Jobs to be done in addition to those above
1
2
ATTENTION
3
All "▲" marked operations must be carried out by
a skilled technician.
4
5
During the first 10 working hours
1
2
3
4
Check the oil level within reduction gears, power
divider and differential gears
Regularly check the tightening of the wheel bolts
Check the tightening of all bolts and nuts
Check the couplings for oil leaks
1
6
7
8
9
Within the first 50 working hours
Change the oil for the first time
10
Every 10 working hours or daily
1
2
3
4
5
6
7
Check the engine oil level
Clean the air suction filter
Clean the radiator, if necessary
Check the hydraulic oil level in the tank
Check the greasing of the boom section pads
Grease the attachment holding frame
Grease all joints of the boom, the rear axle shaft
joint, the transmission shafts, the front and rear
axles and any equipment of the machine
8 Check the efficiency of the lighting electric system
9 Check the efficiency of braking system and parking
brake
10 Check the efficiency of the steering selection system
11 Check the efficiency of the fork balancing system.
12 Make sure the safety devices installed are in efficient
working order - see procedure in chap. D-3.16.
Page
Check the tension of the alternator belt
Check the tyre inflation
Check the tightening of the wheel nuts
Check the tightening of the Cardan shaft screws
11
12
13
Change the engine oil and relevant filter
Check the oil level in the front and rear differential
gears and the reducer
Check the oil level in the four wheel reduction
gears
Check the condition of the canister of the engine
air filter; renew the canister if necessary
Check the clamping of the cableheads to the battery
terminals
Check the air suction hose between engine and
filter
Check the cylinder chromium-plated rods
Check the hydraulic lines are not worn because
of rubbing against the frame or other mechanical
components
Check the electric cables do not rub against the
frame or other mechanical components
▲ Check the wear of the sliding pads of the boom
sections
▲ Adjust the play of the sliding pads of the boom
sections
Remove any grease from the boom, then re-grease
the sliding parts of the boom sections
Check the level of the battery electrolyte
Every 3 working months
1
Check the efficiency of the block valves - see chap.
D-3.16.
Every 500 working hours or every six months
Jobs to be done in addition to those above.
1
2
3
4
5
6
Visually check the smoke quantity evacuated from
the engine exhaust
Check the tightening of the engine fixing screws
Check the tightening of the cab fixing screws
Check the backlash between pins and bushings in
all joints
Change the hydraulic oil filter of the transmission
Change the hydraulic oil filter in the tank
D-4
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MAINTENANCE
7
8
9
Have the hydraulic system checked by a skilled
technician
Change the main cartridge of the engine air filter
Clean or replace, if nececessary, the air filter in the
cab
Every 1000 working hours or yearly
Jobs to be done in addition to those above
1
2
3
Change the oil in the front and rear differential units
and in the power divider
Change the oil in the four wheel reduction gears
Change the hydraulic oil
D-2.1 OIL CHANGE SCHEDULE
Job
Engine
Axles and
power
divider
Hydraulic
oil
operating
hours*
service
interval*
Oil level check
10
daily
First change
50
-
Subsequent changes
250
monthly
Oil level check
250
monthly
-
-
Subsequent changes
1000
yearly
Oil level check
250
monthly
Subsequent changes
1000
yearly
First change
* whichever occurs first
Page
D-5
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Oil type
SHELL RIMULA 15W-40
FUCHS TITAN GEAR LS 85 W-90
API GL-5 LS / GL-5
SHELL TELLUS T 46
DENISON HF-1, DIN 51524 part 3 Cat. HV
Handler with telescopic boom GTH-5519
MAINTENANCE
D-3 MAINTENANCE JOBS
ATTENTION
DANGER
All maintenance interventions must be carried
out with engine stopped, parking brake engaged,
working attachments flat on the ground and gear
lever in neutral.
DANGER
When raising a component for maintenance
purposes, secure it in a safe way before any
maintenance intervention.
DANGER
Any intervention on the hydraulic circuit must be
carried out by skilled personnel.
The hydraulic circuit of this machine is fitted with
pressure accumulators. You and others could be
seriously injured if accumulators are not completely
depressurised.
To depressurise the accumators, just steer the
machine wheels some times with engine shut down
until noticing a gradual binding of the handwheel.
The qualified staff charged with the maintenance
of the hydraulic circuit must clean all areas around
with care before any intervention.
PROTECT THE
ENVIRONMENT
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
D-3.1 DISCONNECTING THE BATTERY
Before any maintenance or repair work, and especially
before welding any components on the machine, remove
the cables at the battery.
DANGER
Before disconnecting the battery, set all switches
within the cab to OFF.
To disconnect the battery, disconnect the negative
(-) lead from the frame earth first. To connect the
battery, connect the positive (+) lead first.
DANGER
Before any operation on hydraulic lines or
components, make sure there is no residual
pressure. For this purpose, stop the engine, engage
the parking brake and operate the control levers
of the distributors in both working directions
(alternately) to depressurise the hydraulic circuit.
ATTENTION
High pressure lines must be replaced by qualified
personnel only.
Any foreign matters entering the closed circuit
may result in a sudden deterioration of the
transmission.
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MAINTENANCE
D-3.2 ACCESS TO THE ENGINE AND TANKS
COMPARTMENTS
Engine compartment
For any operation within the engine compartment, open
the protection bonnet.
Hood is equipped with lock & key and a supporting rod
that holds it in position.
From the engine compartment, you get access to:
• Thermal engine
• Engine air filter • Hydraulic oil tank plug
• Radiator fluid compensation cup
• Battery
To get access to the engine compartment:
• Shut the engine down and put the parking brake.
• Unlock and raise the hatch with handle . The
gas springs will help the operation.
DANGER
Take all precautions when approaching
the engine compartment. Some parts of
the engine may be very hot. Always use
protective gloves.
Diesel fuel tank compartment
To gain access to the fuel tank, open the rear cover of
the machine as follows:
• Shut the engine down and put the parking brake.
• Fully raise the cover by means of the special
handle.
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MAINTENANCE
D-3.3 GREASING
ATTENTION
Before injecting grease into the greasers, thoroughly
clean them to avoid that mud, dust or other matters
can mix with the lubricant and reduce or annihilate
the lubrication effect.
Remove any old grease with a degreaser from
the telescopes before smearing them with new
grease.
Regularly grease the machine to grant it efficient
conditions and a long life.
By means of a pump, inject grease into the special
greasers.
As the fresh grease comes out, stop the operation.
The greasing points are shown in the following
figures:
-
the symbol
by a pump
represents the points to be greased
-
the symbol
by a brush.
represents the points to be greased
SERVICE INTERVAL
Running-in _________________________ None
Ordinary _________________ Every 10 hours
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MAINTENANCE
D-3.4 TYRES AND WHEELS
DANGER
Over-inflated or overheated tyres can burst. Do not
flame-cut or weld the wheel rims. For any repair
work, call in a qualified technician.
YES
NO
WRONG WAY
RIGHT WAY
For the tyre inflation or substitution, please refer to the
table below:
GTH-5519
Dimensions
12-16.5
Load index
pr 10
Rim
9.75x16.5
Wheel disc
Pressure
8 fori DIN 70361
bar
Psi
4.5
65
On new machines, and when a wheel has been
disassembled or replaced, check the nut torque of the
wheels every 2 hours until they stay correct.
IMPORTANT
Always use tyres having the dimensions indicated
in the vehicle registration card.
SERVICE INTERVAL
Running-in ________ Within the first 10 hours
Ordinary ________________ Every 250 hours
Page
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MAINTENANCE
D-3.5 CHECK THE EFFICIENCY OF BRAKING
SYSTEM AND PARKING BRAKE
•
ATTENTION
Connect the flexible hose of the compressor to
the mini-socket TP4 placed inside the engine
compartment.
The malfunctioning of the braking system may depend
on the presence of air in the hydraulic circuit.
The braking system is equipped with two purge valves
and to eliminate any air from the circuit. The first
valve is used to purge the service brake circuit (); the
second valve is used to purge the negative parking brake
circuit (). Both valves can be easily reached through
the slot located on the front part of the chassis.
TP
4
For any intervention on the braking system
(adjustment and/or substitution of the brake discs)
call in a specialised technician.
• Connect the compressor to an air source and
pressurise the system
• Unscrew valve to help air flow out of the braking
circuit.
• Open the cap of the feeding tank To bleed the circuit of the service brake, proceed
as follows:
• Make sure that compressor contains sufficient
quantity of oil so you can proceed with the circuit
bleeding.
•
Open the tap of the compressor which has been
previously connected to mini-socket TP4.
TP4
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MAINTENANCE
•
•
Check the air flows out of valve . As soon as oil
without air bubbles starts flowing out of this valve,
close the same.
Check that the fluid in tank reaches the
recommended level.
TO BLEED THE CIRCUIT OF THE PARKING BRAKE,
DO THE FOLLOWING:
• Start the diesel engine
• Press pushbutton to unlock the parking brake.
• Slowly unscrew valve and close the same as soon
as oil mixed with air bubbles starts flowing out.
• Repeat until oil without air bubbles starts flowing
out of the valve.
• Test the efficiency of the braking system.
Oil level
•
•
•
Close the tap of the compressor.
Disconnect the hose from mini-socket TP4
Test the efficiency of the braking system.
CAUTION
In order to bleed the service brake circuit WITHOUT
A COMPRESSOR (for this operation, two service
technicians are needed - one in the driving place and
the other near the drain valve ):
1. Fill tank with oil
2. With the machine stopped, step down on the brake
pedal 5-6 time.
3. Hold the pedal pressed down and slowly unscrew
valve . Close the valve as soon as oil mixed with
air starts flowing out.
4. Ease up the brake pedal.
5. Repeat steps 2, 3 and 4 until oil without air bubbles
starts flowing out of the valve.
6. Test the efficiency of the braking system.
Once the circuit has been bled, make sure the brake
circuit is in efficient working order.
D-3.5.1 Checking the brake oil level
The oil within the braking circuit must be at about 2 cm
from the tank plug .
Oil level
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MAINTENANCE
D-3.6 ENGINE AIR FILTER
Clean the engine air filter and replace the elements,
when necessary.
1 Cleaning and changing the outer element:
- Shut the engine down and engage the parking
brake.
- Unlatch the fasteners and remove cover .
- Pull out the filter cartridge .
- Clean the filter bowl.
- Dry clean the cartridge (at max. 6 bar pressure)
and direct the air jet from inside to outside.
- Check the filter element for cracks by introducing
a lamp inside.
- Refit the cartridge and make sure it is properly
positioned.
- Close cover and lock in place with fasteners
.
ATTENTION
As soon as the warning lamp 63 on the cab dashboard
switches on, replace the outer element.
2
Changing the inner element:
- See step 1 for removing the outer element.
- Extract the internal cartridge .
- Clean the filter bowl.
- Mount the new element and make sure it is correctly
positioned.
- Fit the main filter and the cap as described in
point 1.
ATTENTION
The inner element should be replaced every two
times the outer element is replaced.
ATTENTION
Never wash the cartridge with water or solvents.
SERVICE INTERVAL
Running-in _________________________ None
Cleaning _________________ Every 10 hours
Filtering element substitution Every
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MAINTENANCE
D-3.7 CAB AIR FILTER (only with cabin closed
or glass kit installed)
Every six months clean the air filter in the cab. Replace
the cartridge if the filtering cloth is damged.
1 Cleaning and changing the cartridge:
- Shut the engine down and engage the parking
brake.
- Pull out the filter A located to the left of the driving
place.
- Clean the filter bowl.
- Clean the filter cartridge and replace in case of
damage.
ATTENTION
Paper filters must never be cleaned using
compressed air or washed with water and/or
solvents.
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MAINTENANCE
D-3.8 ENGINE COOLING CIRCUIT
DANGER
When the coolant is hot, the cooling system is under
pressure. With warm engine, loosen the radiator
plug slowly and carefully, without removing it, to
drain the pressure. Use protection gloves and keep
your face at a safe distance.
•
•
•
•
Every week, before starting working (with the coolant
cold), check the coolant level through the glass cap
of plug .
When necessary, add clean water or an antifreeze
mixture through cap .
Change the antifreeze mixture every two years.
To drain the antifreeze:
- Let the engine cool down
- Unscrew the plug at the bottom of the radiator
or disconnect the rubber hose, if no plug is present. Allow the coolant to flow out into a special
container.
- Refit the hose and pour new antifreeze (50%
water-antifreeze). This proportion will provide
protection up to -38°C.
Daily clean the radiator grille using a brush with hard
bristles or compressed air at a max pressure of 6
bar.
On delivery, the machine is filled with a cooling mixture
consisting of 50% water and 50% anti-freeze.
TEREX PRO COOL
Protection against boiling / freezing
Product
%
33
40
50
70
Freezing
point
-17 °C
-24 °C
-36 °C
-67 °C
Boiling
point
123 °C
126 °C
128 °C
135 °C
SERVICE INTERVAL
Running-in _________________________ None
Ordinary _________________ Every
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MAINTENANCE
D-3.9 ENGINE OIL LEVEL
To check the engine oil level:
• Park the machine on a flat ground, stop the engine
and check the parking brake is engaged.
• Remove dipstick and check if oil reaches the max
mark .
•
•
MAX
MIN
•
If oil is below this mark, remove plug and pour
new oil into the engine using the special appliance
.
Remove dipstick once again and check if oil
reaches the max mark .
Refit the plug.
If one of the connecting pipes of radiator breaks:
• Stop the machine immediately, if possible on a flat
ground; stop the engine and check the parking brake
is engaged.
• Change the damaged pipe.
• Remove dipstick and check if oil reaches the max
mark .
• If oil is below this mark, remove plug and pour
new oil into the engine using the special appliance
.
• Restart the machine and let oil circulate in the engine
and the radiator.
• Stop the machine and check again the oil level. If
necessary, add new oil step by step until reaching
the max level by starting and stopping the engine
at every step.
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MAINTENANCE
D-3.10 CHECKING THE OIL LEVEL IN THE
TANK
DANGER
Fine jets of hydraulic oil under pressure can
penetrate the skin. Do not use your fingers, but a
piece of cardboard to detect oil leaks.
Check the hydraulic oil level (visually) through the special
level fitted into the tank.
When necessary, add new oil through filler .
ATTENTION
Check the oil level with handler set to transfer
position (lowered boom and retracted telescopic
element).
SERVICE INTERVAL
Running-in ________ Within the first 10 hours
Ordinary _________________ Every 50 hours
If oil must be changed, proceed as follows:
1 Stop the machine on a level ground and make sure
the parking brake is engaged.
2 Release the pressure from the hydraulic circuit.
3 Place a container of suitable size under the drain
plug, placed in the lower part of the reservoir, and
collect any oil leaks.
4 Remove the drain plug and allow oil to flow out into
the container.
5 Remove the inspection cover of tank .
6 Carefully wash the tank with Diesel oil and blow a
jet of compressed air.
7 Refit the drain plug and the inspection cover.
8 Add new oil by making sure that it matches the
recommended type indicated in paragraph D-5.2.2.
until it is level with .
SERVICE INTERVAL
Running-in _________________________ None
PROTECT THE
ENVIRONMENT
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
Ordinary _______________ Every 1000 hours
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MAINTENANCE
D-3.11 CHANGING THE OIL FILTER CARTRIDGE
To change the hydraulic oil filter element, proceed as
follows:
1 Stop the machine on a level ground and engage the
parking brake.
2 Place a container of suitable size under the filter to
collect any oil leaks.
3 Remove the filter cover B per accedere alla cartuccia
A.
4 Change the filter element, then, before fitting a new
one, thoroughly clean and grease both seat and
gasket.
5 Refit and tighten the filter cover.
ATTENTION
Hydraulic oil filter canisters cannot be cleaned or
washed and refitted.
They must be replaced with new ones of the type
recommended by the manufacturer (see par. D5.2.2).
PROTECT THE
ENVIRONMENT
The handling and disposing of used oils may be
ruled by local or national regulations. Address to
authorised centres
SERVICE INTERVAL
Running-in _________________________ None
Ordinary ________________ Every 500 hours
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MAINTENANCE
D-3.11.1 Auxiliary circuits oil filter
To change the hydraulic oil filter cartridge of the service
circuits, proceed as follows:
1 Stop the machine on a level ground and engage the
parking brake.
2 Remove the inspection hatch and unscrew the
oil filter fitted inside the tank.
3 Check the tank is clean, then fit a new filtering
element and refit the inspection hatch.
4 Check the oil level within the tank. Add new oil, if
necessary.
SERVICE INTERVAL
Running-in _________________________ None
Ordinary ________________ Every 500 hours
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MAINTENANCE
D-3.12
OIL LEVEL IN THE DIFFERENTIAL
GEARS AND THE REDUCER
D-3.12.1 Front and differential gears
To check the oil level in the front and rear differential
gears:
• Stop the machine on a level ground and engage the
parking brake.
• Loosen level plug and check if oil is level with the
hole.
• If necessary, add new oil through the hole of the
level plug until it comes out.
• Refit and tighten plug .
For the oil change:
• Place a container of suitable size under drain plug
.
• Loosen the drain plug and the level plug and allow
oil to flow out from the differential gears.
• Refit and tighten drain plug .
• Add new oil through plug until it is level with the
hole.
• Refit and tighten level/filler plug.
SERVICE INTERVAL
Running-in ________ Within the first 10 hours
Ordinary ________________ Every 250 hours
D-3.12.2 Reducer
To check the oil level in the reducer
• Stop the machine on a level ground and engage the
parking brake.
• Loosen level plug and check if oil is level with the
hole.
• If necessary, add new oil through the hole of the
level plug until it comes out.
• Refit and tighten plug .
For the oil change:
• Place a container of suitable size under drain plug
.
• Loosen the drain plug and the level plug and
allow oil to flow out from the reduction gear.
• Refit and tighten drain plug .
• Add new oil through plug until it is level with the
hole.
• Refit and tighten plug .
SERVICE INTERVAL
Running-in ________ Within the first 10 hours
Ordinary ________________ Every 250 hours
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MAINTENANCE
D-3.13 OIL LEVEL IN THE (FRONT/REAR) WHEEL
REDUCTION GEARS
To check the oil level within the wheel reduction
gears:
• Stop the machine on a level ground and ensure the
parking brake is engaged and plug finds on the
horizontal axis.
• Clean the plug all around, then remove it and check
if oil is level with the hole.
• If necessary, add new oil through hole until it is
level.
• Refit the plug.
For the oil change:
• Stop the machine and ensure the plug is oriented
along the vertical axis.
• Place a container of suitable size under the reduction
gear plug.
• Unscrew plug and drain any oil from the reduction
gear.
• Rotate the wheel by 90° until the plug finds again
on the horizontal axis.
• Add new oil through hole .
• Refit and tighten plug .
PROTECT THE
ENVIRONMENT
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
IMPORTANT
When changing the oil, drain it when it is still hot
and the polluting substances are in suspension.
SERVICE INTERVAL
Running-in ________ Within the first 10 hours
Ordinary ________________ Every 250 hours
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MAINTENANCE
D-3.14 SHAFTING ALIGNMENT
During operation, the alignment of the front and rear
axles of the machine can be subject to variations. This
can depend on an oil blow-by from the steering control
circuit, or on a steering of both axles when front and
rear wheels are not perfectly aligned.
To fix this problem, rather than checking the alignment
visually, follow the procedure below:
01234567
F
N
1) Move to a solid and level ground
R
➊
2) Set the steering selection switch 13 to “four-wheel
steer” (pos. 2)
⓪
➋
3) Rotate the steering up to its stop (either to the right
or to the left)
4) Set the steering selection switch to “two-wheel
steer” (pos. 0)
5) Rotate the steering up to its stop (turn in the same
direction as above)
6) Reset the steering selection switch to “four-wheel
steer” (pos. 2)
1
7) Rotate the steering (to the side opposite to point 3)
so that the rear axle reaches its stop
8) Reset the steering selection switch to “two-wheel
steer” (pos. 0)
9) Rotate the steering (to the same side as in point 7)
so that the front axle reaches its stop
10) Reset the steering selection switch to “four-wheel
steer” (pos. 2)
Now the wheels should be re-aligned.
SERVICE INTERVAL
Running-in _________________________ None
Ordinary _________________ When necessary
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MAINTENANCE
D-3.15
ADJUSTING THE SLIDING PADS OF
THE BOOM SECTIONS
Any boom section is fitted with adjustable pads located
on the four sides of the profile. These pads are secured
to both fixed and mobile part of every section.
All pads can be adjusted by the special shims supplied
by GENIE upon demand.
Adjusting the pads:
•
•
•
•
Remove or loosen the screws fixing the pads in
relation to type of shims used (with or without
slots).
Fit the necessary amount of shims.
If the residual thickness of the pad is insufficient or
near the maximum wearing limit, renew the pad.
Tighten the screws fixing the pads at the recommended
torque (see below). Use a dynamometric wrench.
Tightening torques of the pad screws in relation to
the screw diameter
Screws M10
Nm 30
Screws M14
Nm 50
Tightening torques higher than those recommended
can cause the break of the pad or of the locking
threaded bush.
ATTENTION
Pads must compulsorily be replaced if the residual
thickness of the plastic layer with respect to the iron
bush fixing the block is equal or inferior to 1 mm.
Max. wearing thickness
Minimum 1 mm
SERVICE INTERVAL
Running-in _________________________ None
Ordinary _________________ When necessary
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MAINTENANCE
D-3.16 CHECKING THE SAFETY DEVICES
Checking the block valves (every 3 months).
The piloted blocking valves allow to held the load in
position in case of burst of a flexible hose.
To check the efficiency of a valve, proceed as
follows:
• Load a weight near the maximum payload onto the
boom.
• Raise the load some centimetres above the ground
(max 10 cm). To check the valve on the telescope
extension cylinder move the boom to maximum
height and extend it some centimetres.
• Loosen the oil hoses to the cylinder of which you
are checking the valve with caution.
Attachment coupling cylinder
During the check, the oil will flow out of the hoses and
the load shall remain blocked in position. Should that
not be the case, the valve must be replaced. Contact
GENIE Technical Service.
DANGER
-
Wear safety glasses
Wear safety gloves
Wear safety shoes
Wear suitable working clothes
Use guards against leaks of oil at high
pressure
Do the check in a free space with barriers all
around to keep non-authorised people away
During the check proceed with extreme
caution.
Ensure that the part to be checked is in safe
condition and that the action generated does
not result in an uncontrolled movement of the
machine
Lifting cylinder
Extension cylinder
Balance cylinder
Attachment pitching cylinder
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MAINTENANCE
Checking the machine start control
(at every use)
Attempt to start the engine with the forward or reverse
gear put.
The engine must not start. If the engine starts, contact
the GENIE Technical Service.
Repeat the operation putting first one gear, then the
other.
D-3.17 C H E C K I N G T H E S TAT E O F T H E
STRUCTURE
Five years after the first placing into operation of the
machine or after 6000 hours (whichever occurs first),
check the state of the structure paying attention to the
welded supporting joints and the boom pins.
DANGER
After the first 5 years, repeat this check every 2
years.
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MAINTENANCE
D-4 ELECTRICAL SYSTEM
DANGER
DANGER
•
All maintenance interventions must be carried
out with engine stopped, parking brake engaged,
working attachments on the ground and gearbox
lever in neutral.
DANGER
•
•
When raising a component for maintenance
purposes, secure it in a safe way before carrying
out any maintenance.
•
•
DANGER
•
Any intervention on the electrical system unless
performed by authorized personnel, is expressly
forbidden.
•
•
D-4.1
•
•
•
•
•
BATTERY
Check the electrolyte level every 250 working hours;
if necessary, add distilled water.
Ensure the fluid is 5÷6 mm above the plates and the
cell levels are correct.
Check the cable clips are well secured to the battery
terminals. To tighten the clips, always use a box
wrench, never pliers.
Protect the terminals smearing them with pure
vaseline.
Remove the battery and store it in a dry place, when
the machine is not used for a long time.
Battery electrolyte contains sulphuric acid. It can
burn you if it touches your skin and eyes. Always
wear goggles and protective gloves, and handle
the battery with caution to prevent spillage. Keep
metal objects (watch straps, rings, necklaces)
clear of the battery leads, since they can short
the terminals and burn you.
Before disconnecting the battery, set all switches
within the cab to OFF.
To disconnect the battery, disconnect the
negative (-) lead from the frame earth first.
To connect the battery, connect the positive (+)
lead first.
Recharge the battery far from the machine, in a
well-ventilated place.
Keep out of items which can produce sparks, of
naked flames or lit cigarettes.
Do not rest metal objects onto the battery. This
can result in a dangerous short especially during
a recharge.
Because the electrolyte is highly corrosive, it
must never come in contact with the frame of
the handler or electric/electronic parts. If the
electrolyte comes in contact with these parts,
contact the nearest authorised assistance
centre.
DANGER
Risk of explosion or shorts. During the recharge,
an explosive mixture with release of hydrogen gas
forms.
ATTENTION
Do not add sulphuric acid; add only distilled
water.
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MAINTENANCE
D-4.2 FUSES AND RELAYS
The electrical system is protected by fuses placed in
the driving cab, on the left. Before replacing a blown
fuse with a new one having the same amperage, find
out and rectify the fault.
ATTENTION
•
•
•
Fuses
Ref.
Circuit
Amp.
•
•
Do not use fuses having a higher amperage than
that recommended, since they can damage the
electric system seriously.
If the fuse blows after a short time, look for the
fault source by checking the electric system.
Always keep some spare fuses for an
emergency.
Never try to repair or short blown fuses.
Make sure the contacts of fuses and fusesockets ensure a good electric connection and
are not oxidised.
PAGE IN PREPARATION
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MAINTENANCE
Engine compartment fuses and relays
Ref.
Circuit
xxx xxx xxx xxx
Amp
Fuse box relays
Ref.
Circuit
PAGE IN PREPARATION
ATTENTION
•
•
•
•
•
Do not use fuses having a higher amperage than
that recommended, since they can damage the
electric system seriously.
If the fuse blows after a short time, look for the
fault source by checking the electric system.
Always keep some spare fuses for an
emergency.
Never try to repair or short blown fuses.
Make sure the contacts of fuses and fusesockets ensure a good electric connection and
are not oxidised.
Page
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MAINTENANCE
D-5 REFUELLING
D-5.1 REFUELLING
Part
Diesel engine
Fuel tank
Hydraulic system tank
Front differential gear with reduction gear
Rear differential gear
Front wheel reduction gears
Rear wheel reduction gears
Brake oil tank
Product
Engine oil
Diesel fuel
Hydraulic oil
Oil
Oil
Oil
Oil
Hydraulic oil
Capacity
(litres)
11 + 3.5
60
62
6
5
1.5 + 1.5
0.7 + 0.7
0.1
Product
specifications
see par.
D-5.2.1
D-5.2.3
D-5.2.2
D-5.2.2
D-5.2.2
D-5.2.2
D-5.2.2
D-5.2.2
D-5.2 PRODUCT SPECIFICATIONS
D-5.2.1 Engine oil
Use the oil recommended by the Diesel engine Manufacturer (see the relevant handbook delivered with the
machine).
At the delivery, the machine is refilled with:
SHELL RIMULA 15W-40
D-5.2.2 Lubrication oils and relevant filtering elements
Refill the machine with following lubricants:
Use
Product
Definition
Power divider-Differential gears-Reduction gears FUCHS TITAN GEAR LS 85 W-90 API GL-5 LS / GL-5
Hydraulic system and brakes
SHELL TELLUS T 46
DENISON HF-1 DIN 51524 part 3 Cat. HV
ATTENTION
Never mix different oils: this may result in troubles and component breaks.
Filtering elements:
Filter
Transmission oil filter
Auxiliary circuit oil filter (inside the tank)
Flow l/1'
MPS 150
STR 100/1
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Filtering
10 
60 
Code
09.4604.0001
09.4604.0004
Handler with telescopic boom GTH-5519
MAINTENANCE
D-5.2.3 Fuel
Use only Diesel fuel with less than 0.5% sulphur content,
according to the specifications of the diesel engine
operation handbook.
ATTENTION
D-5.2.5 Engine coolant
It is advisable to use an antifreeze mixture (50% water50% antifreeze). At the delivery, the machine is refilled
with:
TEREX PRO COOL by VALVOLINE
In cold climates (temperature under -20°C) use only
“Arctic” type Diesel fuel, or oil-diesel fuel, or oildiesel fuel mixtures. The composition of the latter
can vary in relation to the ambient temperature up
to max. 80% oil.
The use of this product guarantees protection to the
circuit for 3 years or 7000 hours without having to add
any dry coolant additive.
TEREX PRO COOL
Protection against boiling / freezing
Product
Freezing
Boiling
%
point
point
33
-17 °C
123 °C
40
-24 °C
126 °C
50
-36 °C
128 °C
70
-67 °C
135 °C
D-5.2.4 Grease
For the machine greasing, use:
• Lithium-based Vanguard
LIKO grease, type
EP2
When greasing by pump
• Graphitized SHELL
grease, type GR NG 3
When greasing by brush
• INTERFLON FIN
GREASE LS 2
For the telescopic boom
sliding blocks
ATTENTION
Use an antifreeze mixture in the proportions
recommended by the manufacturer in relation to
the ambient temperature of the jobsite.
ATTENTION
Avoid mixing greases of different type or features
and do not use greases of lower quality.
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MAINTENANCE
INTENTIONALLY BLANK PAGE
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FAULTS AND TROUBLESHOOTING
Section
E
FAULTS AND
TROUBLESHOOTING
TABLE OF CONTENTS
E-1
E-1.1
FAULTS AND TROUBLESHOOTING .............................................................................
Fault - Cause - Solution ..................................................................................................
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FAULTS AND TROUBLESHOOTING
E-1
FAULTS AND TROUBLESHOOTING
This chapter represents a practical guide for the operator
for fixing the most common failures and, at the same
time, detecting those interventions which must be carried
out by qualified technical engineers.
If you are unsure about anything, do not carry out
operations on the machine, but call in a skilled
technician.
E-1.1
DANGER
Any repair work, maintenance or troubleshooting
must be carried out with machine stopped, boom
in rest position or laid on the ground, parking brake
engaged and ignition key removed.
FAULT - CAUSE - SOLUTION
DASHBOARD DOES NOT SWITCH
ON
• The 50A fuse F31 supplying power
to the dashboard is blown (engine
compartment)
• Battery disconnected
• Battery down
• Battery cut-out switch OFF
ENGINE DOES NOT START
Starter does not run
ENGINE DOES NOT START
Starter runs, but engine does not
start
• Connect the battery using the
relevant switch
• Check the battery
• Switch it on
• Battery down
• Battery cut-out switch OFF
• Engage the parking brake and
ensure the relevant indicator on the
dashboard switches on
• Recharge or replace the battery
• Switch it on
•
•
•
•
•
•
•
•
• Parking brake not engaged
Fuse F15 blown
No fuel
Diesel fuel filter clogged
Diesel fuel hose empty (fuel used
up)
• Solenoid valve - engine stop
MACHINE DOES NOT MOVE
• Replace the fuse
• Speed selector switch in neutral
• Parking brake engaged
• Fuse F3 blown
Check the fuse
Refuel
See engine operator manual
Refuel, then refer to engine operator
manual
• Check the solenoid valve; replace,
if necessary
• Set the speed selector switch
correctly
• Disengage
• Check the fuse; replace, if
necessary
THE MACHINE DRIVE IS NOT
ENOUGH
• Hydraulic oil filter clogged
• Replace the filter
NO SELECTION OF THE STEERING
MODE
• Fuse F20 controlling the steering
selection blown
• Replace the fuse
“ROAD” FUNCTION ON, EVEN
WHEN SELECTING THE “JOBSITE”
FUNCTION
• No “ROAD/JOBSITE” selection
• Check and replace fuse F20, if
necessary
Page
E-2
Document 57.0008.6200 - 05/2007
Handler with telescopic boom GTH-5519
FAULTS AND TROUBLESHOOTING
NO BOOM LOWERING AND
EXTENSION, NO HOLDING FRAME
TILTING
• Fuse blown
• Replace fuses F2 and/or F24
THE HYDRAULIC OIL
THERMOMETER DOES NOT WORK
• This is normal, when the outside
temperature is low and/or the machine
is used for short periods, since the
hydraulic oil cannot warm up over
40÷50°C
THE PARKING BRAKE LIGHT DOES
NOT LIGHT UP
• Fuse blown
• Replace fuse F15
BOOM DOES NOT MOVE
• Fuse blown
• Check and replace fuse F22, if
necessary
• Emergency button ON
• Reset the button
IMPORTANT
In case of faults not listed in this chapter, address to the GENIE Technical Assistance, your nearest
authorised workshop or dealer.
Page
E-3
Document 57.0008.6200 - 05/2007
Handler with telescopic boom GTH-5519
FAULTS AND TROUBLESHOOTING
NOTES .........................................................
......................................................................
......................................................................
......................................................................
......................................................................
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......................................................................
......................................................................
......................................................................
......................................................................
......................................................................
......................................................................
......................................................................
......................................................................
......................................................................
......................................................................
......................................................................
Page
E-4
Document 57.0008.6200 - 05/2007
Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
Section
F
OPTIONAL ATTACHMENTS
TABLE OF CONTENTS
F-1.1
F-1.2
F-1.3
F-1.4
F-1.5
Shovel .............................................................................................................................
Cereal shovel ..................................................................................................................
Fixed hook on plate.........................................................................................................
Extension jib....................................................................................................................
Forks with hydraulic side-shift .........................................................................................
Page
F-1
Document 57.0008.6200 - 05/2007
F-3
F-4
F-5
F-6
F-7
Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
INTRODUCTION
This section provides information on the optional interchangeable attachments, especially manufactured
for the handlers.
Use only genuine attachments, described in this
section, after having read their features thoroughly and
understood their use.
To install and remove the attachments, follow the
instructions supplied in the OPERATION section,
par. C-5.3.


DANGER
When replacing interchangeable attachments, keep
any person clear of the working area.
DANGER
Mounting optional attachments, and especially the
extension jib, can change the centre of gravity of the
machine. Before handling a load, check its weight
and compare it with the values on the load charts.
The weight of the used attachment must always be
deducted from the rated payload.
Page
F-2
Document 57.0008.6200 - 05/2007
Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
F-1.1
SHOVEL
Code
Application
Quick-coupling fitted attachment for moving soil, sand,
debris, cereals, etc.
GTH-5519
Litres 500
Safety
Strictly obey the general safety precautions given in
section B “SAFETY”.
59.0200.0000
Operation
ATTENTION
When using a shovel, load the material only when
the boom is completely retracted and push against
the heap with straight wheels.
To load/unload the material, operate the rotation lever
of the attachment holding plate.
Maintenance
Visually check the shovel for damage before using it.
Technical data
Capacity
litres
500
A
Width
mm
1850
B
Length
mm
760
H
Height
mm
700
-
Weight
kg
290
ATTENTION
Attachment suitable for moving loose material. Do
not use for digging operations.
Page
F-3
Document 57.0008.6200 - 05/2007
Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
F-1.2
CEREAL SHOVEL
Code
Application
Quick coupling attachment for loading cereals or inert
materials, etc.
GTH-5519
Litres 800
Safety
Strictly obey the general safety precautions given in
section B “SAFETY”.
59.0200.1000
Operation
ATTENTION
When using a shovel, load the material only when
the boom is completely retracted and push against
the heap with straight wheels.
To load/unload the material, operate the rotation lever
of the attachment holding plate.
Maintenance
Visually check the shovel for damage before using it.
Technical data
Capacity
litres
800
A
Width
mm
1850
B
Length
mm
800
H
Height
mm
1150
-
Weight
kg
350
ATTENTION
Attachment suitable for moving loose material. Do
not use for digging operations.
Page
F-4
Document 57.0008.6200 - 05/2007
Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
F-1.3
FIXED HOOK ON PLATE
Application
Quick-coupling fitted attachment for lifting loads by
means of special slings.
Payload
Code
2500 kg
59.0700.0000
Safety
Strictly obey the general safety precautions given in
section B “SAFETY”.
Do not oscillate the load.
Do not drag hooked loads.
Lift the load before extending the boom.
Operation
Fork the hook and hold it in position by means of the
locking cylinder.
All loads must be bridled with special textile slings or
chains in compliance with all pertinent regulations.
To handle the load, raise and rotate the telescopic boom
of the handler.
Maintenance
Visually check the hook for damage before using it.
Check the safety catch is in good working order.
Technical data
Payload
kg
2500
Width
mm
970
Length
mm
620
Height
mm
600
Weight
kg
105
IMPORTANT
The fixed hook has been designed to support a
load of 2500 kg. The max payload corresponds to
the nominal capacity rating of the handler on which
it is installed and is indicated on the load charts
supplied with the equipment.
Page
F-5
Document 57.0008.6200 - 05/2007
Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
F-1.4
EXTENSION JIB
Code
400 kg
Application
Quick-coupling fitted attachment for maintenance
interventions at high working heights.
Safety
Strictly obey the general safety precautions given in
section B “SAFETY”.
Never lift wrongly slung loads.
Avoid abrupt acceleration or deceleration.
Avoid load oscillations, and especially do not move the
load from the vertical pull line.
Do not pull crosswise and do not tow.
GTH-5519
59.0800.0000
Operation
To change the working height, operate the rotation lever
of the attachment holding plate.
Maintenance
Visually check the jib for damage before using it.
Check the safety catch is in good working order.
Daily grease the joints using the greasing gun.
Characteristics
-
kg
400
A Length
mm
2100
B Width
mm
920
H Height
mm
630
kg
115
-
Payload
Weight
Page
F-6
Document 57.0008.6200 - 05/2007
Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
F-1.5
FORKS WITH HYDRAULIC SIDE-SHIFT
Application
Quick-coupling fitted attachment for handling palletised
loads with possibility of shifting the load to the side by
± 100 mm.
Safety
Strictly obey the general safety precautions given in
section B “SAFETY”.
• Do not load loose materials
• Do not move superposed pallets
Operation
To adjust the tilting, operate the rotation lever of the
attachment holding plate.
To side-shift, operate the attachment locking lever after
connecting the feeding lines of the new attachment to
the quick couplings (see page F-2).
Machine
Code
Maintenance
Visually check the attachment for damage before using
it.
Check for hydraulic oil leaks.
Daily grease the joints using a greasing gun, and smear
the sliding guides with graphitized grease.
GTH-5519
59.0600.0000
Technical data
Payload kg
Width
Length
Height (with protection)
Weight
Stroke
Fork attachments
2600
mm
mm
mm
kg
mm
1240
1600
1000
180
± 100
FEM 2
Page
F-7
Document 57.0008.6200 - 05/2007
Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
Intentionally blank page
Page
F-8
Document 57.0008.6200 - 05/2007
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
Section
G
TABLES AND
DOCUMENTS ENCLOSED
TABLE OF CONTENTS
G-1
G-2.1
G-3.1
G-3.1.1
G-4.1
G-5
TORQUE WRENCH SETTING .......................................................................................
G-2
Load Chart with forks ...................................................................................................... G-3
Wiring diagram ................................................................................................................
G-4
Wiring diagram - Components description ...................................................................... G-12
Hydraulic scheme ........................................................................................................... G-15
ROUTINE CHECK SCHEDULE-SAFETY DEVICES ...................................................... G-17
Page
G-1
Document 57.0008.6200 - 03/2009
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-1 TORQUE WRENCH SETTINGS
Dxp
Pre-loading (N)
Torque wrench setting (Nm)
4.8
8.8
10.9
12.9
4.8
8.8
10.9
12.9
M 4 x 0,7
1970
3930
5530
6640
1,5
3,1
4,3
5,2
M 5 x 0,8
3180
6360
8950
10700
3
6
8,5
10,1
M6x1
4500
9000
12700
15200
5,2
10,4
14,6
17,5
M 8 x 1,25
8200
16400
23100
27700
12,3
24,6
34,7
41,6
M8x1
8780
17600
24700
29600
13
26
36,6
43,9
M 10 x 1,5
13000
26000
36500
43900
25,1
50,1
70,5
84,6
M 10 x 1,25
13700
27400
38500
46300
26,2
52,4
73,6
88,4
M 12 x 1,75
18900
37800
53000
63700
42,4
84,8
119
143
M 12 x 1,25
20600
41300
58000
69600
45,3
90,6
127
153
M 14 x 2
25800
51500
72500
86900
67,4
135
190
228
M 14 x 1,5
28000
56000
78800
94500
71,7
143
202
242
M 16 x 2
35200
70300
98900
119000
102
205
288
346
M 16 x 1.5
37400
74800
105000
126000
107
214
302
362
M 18 x 2,5
43000
86000
121000
145000
142
283
398
478
M 18 x 1,5
48400
96800
136000
163000
154
308
434
520
M 20 x 2,5
54900
110000
154000
185000
200
400
562
674
M 20 x 1,5
60900
122000
171000
206000
216
431
607
728
M 22 x 2,5
67900
136000
191000
229000
266
532
748
897
M 22 x 1,5
74600
149000
210000
252000
286
571
803
964
M 24 x 3
79100
158000
222000
267000
345
691
971
1170
M 24 x 2
86000
172000
242000
290000
365
731
1030
1230
M 27 x 3
103000
206000
289000
347000
505
1010
1420
1700
M 27 x 2
111000
222000
312000
375000
534
1070
1500
1800
M 30 x 3,5
126000
251000
353000
424000
686
1370
1930
2310
M 30 x 2
139000
278000
391000
469000
738
1480
2080
2490
IMPORTANT
Sensor maximum driving torque: 15 Nm.
Page
G-2
Document 57.0008.6200 - 03/2009
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-2.1 LOAD CHART WITH FORKS - GTH-5519
20 ft
70° E
D
60°
C
50°
B
15 ft
A
10 ft
55
00
lb
s
40°
4400 lbs
10°
3000 lbs
5 ft
2000 lbs
20°
1900 lbs
30°
B
A
0°
0 ft
E
15 ft
10 ft
D
C
0 ft
5 ft
Page
G-3
Document 57.0008.6200 - 03/2009
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-3.1 WIRING DIAGRAM
1/8
12V BATTERY
DISCONNECTION
BATTERY
STARTER
MOTOR
ALTERNATOR
FUEL ENRICHER
PREHEATING
CONTROL UNIT
MAXIFUSE
SYSTEM
PROTECTION
FUSE
CHANGE OVER
SWITCH
RELAY
STARTING
PARKING BRAKE
LINE PRESSURE
SWITCH
PREHEATING
CONTROL UNIT
GLOW PLUGS
OIL FILTER
CLOGGING
WARNING LIGHT
AIR FILTER
PREHEATING
GLOW PLUGS
AIR FILTER
CLOGGING
SENSOR
Page
G-4
Document 57.0008.6200 - 03/2009
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
2/8
FORWARD SPEED
SOLENOID VALVE
SERVICE BRAKE
SENSOR
PARKING
BRAKE SWITCH
FAST SPEED
SOLENOID VALVE
BUZZER
REAR LIGHT
REVERSE SPEED
SOLENOID VALVE
Page
G-5
Document 57.0008.6200 - 03/2009
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
3/8
2/G1
2/G1
1/A1
31
30
15
30
BK¿1.5
15
SOLENOID VALVE
FENGINE STOP
WH/RD¿1.5
X8
14
1/F6
Y07
BU¿1.5
WH/RD¿1.5
1
1
2
SW04
2
1/D4
EMERGENCY
MUSHROOM-HEAD
PUSHBUTTON
WH/RD¿1.5
BU¿1.5
F22
10A
BN¿2.5
WH/RD¿1.5
X2
4
WH/TQø1
WH/TQø1
1
X5
C
BN/WHø1
X5
2
49
49A
BKø1.5
C2
C3
A03
6/F5
INTERMITTENCE
LIGHT INDICATOR
31
G
WH/BKø1
WH/BKø1
X2
5/C5
4
5
8
2
X5
BN/WHø1
3
WH/BKø1
X5
BKø1
4
SW05
EMERGENCY
INDICATOR
SWITCH
1
BNø1
RDø1
9/C4
TQ/BKø1
3
DIODE
BU/RDø1
TQø1
4
BU/RDø1
A04
DIODE
6
7
BNø1
F17
15
A
0
1
BNø2.5
4F5
4/G8
5/B5
5/C5
A05
31
G-6
Document 57.0008.6200 - 03/2009
4/G10
4/G10
4/A10
Page
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
4/8
3/G10
3/G10
3/A1
15
30
15
30
F7
7.5A
GYø1.5
7.5A
GYø1
10A
GNø1.5
GY/BKø1
F6
X10
8
GYø1.5
GYø1.5
5/C8
BKø1
TQø1
5
YEø1
X9
H08
HEAD LIGHT
INDICATOR LIGHT
RIGHT
GYø1
GYø1
GNø1
GNø1
X10
9
F8
7
X9
3/D1
GNø1.5
6/C8
5/B8
F9
TQ/BKø1
X9
8
10A
GN/BKø1
GN/BKø1
GNø1.5
GY/BKø1
GY/BKø1
YE/BKø1
X9
6
H07
HEAD LIGHT
INDICATOR LIGHT
LEFT
TQ/BKø1
TQ/BKø1
4
X9
X7
X6
5
5
BKø1
BKø1
TQ/BKø1
H06
REAR AND
STOP LIGHTS
LEFT
YEø1
RDø1
3/G1
2/C8
YEø1
H05
BKø1
LIGHT
TQø1
RDø1
REAR
NUMBER-PLATE
RDø1
H04
REAR AND
STOP LIGHTS
RIGHT
YE/BKø1
TQø1
TQø1
X7
2
X6
2
X9
3
BKø1
YE/BKø1
YEø1
F4
X9
2
YEø1
YEø1
5A
YEø1.5
YEø1.5
X10
1
X9
1
F5
YE/BKø1
5A
YEø1.5
6
X10
X10
5
YE/BKø1
6/C7
5/E1
YEø1
7/F9
6/G1
YE/BKø1
YE/BKø1
6/D8
31
G-7
Document 57.0008.6200 - 03/2009
5/G10
5/G10
5/A10
Page
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
4/G10
4/G10
4/A1
31
15
30
15
30
BKø1
HA02
HORN
VTø1
VTø1
11
X8
4
X2
F10
VTø1
15A
VTø1
X10
7
GYø1.5
15A
X4
6
4/C9
GNø1
F18
4/F7
BNø2.5
GN/BKø1.5
123
56b
5
GYø1.5
4
56
56a
3
GN/BKø1.5
GNø1.5
1
30
LIGHTS
INDICATOR
WIND-SCREEN
WIPER
GY/RDø1.5
8
H
VTø1
12
53b
2 1 0
SW06
7
53C
BN/RDø1
2
53
31b
6
L 0 R
3/G5
9
R
10
L
L
11
WH/BKø1
TQø1
3/F1
BKø1
M
WIND-SCREEN
WIPER
WASHER MOTOR
M03
BKø1
TQ/BKø1
3/C1
WIND-SCREEN
WIPER MOTOR
F11
M
BN/RDø1
10A
BN/RDø1
7
X5
M04
RDø1.5
BNø1.5
BKø1
2
5
8
SW07
LIGHTS
SWITCHES
0
1
1
3
4
6
7
YEø1.5
GN/BKø1.5
YE/BKø1
4/F1
31
6/F1
G-8
Document 57.0008.6200 - 03/2009
6/G10
6/G10
6/A10
Page
5/8
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
6/8
5/G10
5/G10
5/A1
15
30
15
30
31
DASHBOARD
LIGHT
INDICATOR
BKø1
SS03
WH/GNø1
T
X7
WH/GNø1
1
13
WH/GNø1
X8
WATER
TEMPERATURE
SENSOR
RD/BKø1
1/F2
RD/BKø1
8/G10
P01
GY/WHø1
2/C7
+
J4
J10
GY/WHø1
J11
GNø1
J12
X5
8
J13
YE/BKø1
X7
10
1
J15
GY/YEø1
PKø1
X6
J5
0 0 0 0 0 0 3
RD/BKø1
J1
X7
7
X6
SS08
J14
J7
J9
J2
X10
4
YEø1
GNø1
PKø1
J3
X7
BU/RDø1
GY/YEø1
9
BKø1
J8
GY/RDø1
8
X6
8
T
GY/YEø1
J6
YEø1
4/D1
BU/RDø1
GY/RDø1
GY/RDø1
FUEL FLOAT
BU/RDø1
1/F8
YE/BKø1
4/B2
GNø1
4/C8
SS04
ENGINE OIL
PRESSURE
TRANSDUCER
BUø1
SS05
WH/BUø1
WH/BUø1
X13
3
X14
1
BKø1
WH/TQø1
3/C6
WH/BUø1
NEGATIVE BRAKE
PRESSURE
SWITCH
P02
RD/BKø1
1/F1
YEø1
+ -
RD/BKø1
HYDRAULIC OIL
TEMPERATURE
GAUGE
BKø1
S
X7
15
X6
11
SS06
RD/GNø1
BKø1
RD/GNø1
T
HYDRAULIC OIL
TEMPERATURE
SENSOR
GN/RDø1
P03
YE/BKø1
+ -
RD/BKø1
ENGINE WATER
TEMPERATURE
GAUGE
BKø1
GY/GNø1
S
X7
GY/GNø1
9
X6
7
T
WATER
TEMPERATURE
SENSOR
BKø1
GY/GNø1
SS07
YE/BKø1
4/B1
YE/BKø1
5/F1
31
G-9
Document 57.0008.6200 - 03/2009
7/G10
7/G10
7/A10
Page
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
6/G10
6/G10
6/A1
7/8
31
30
30
BN/BKø1
8
2
5
7
3
1
6
4
BKø1
WH/BKø1.5
BU/RDø1.5
OG/GNø1
F20
OG/BUø1.5
X2
4
15
SW09
YE/BKø1
OG/GNø1
PKø2.5
BN/BKø1
8/F7
7.5A
YE/BKø1
BNø2.5
4/C1
15A
15
X2
4
F19
BNø2.5
M06
X5
10
BU/RDø1.5
M
BKø1.5
WH/BKø1.5
AIR VENTILATOR
MOTOR
BN/BKø1
WARM
AIR VENTILATOR
SWITCH
X7
3
PK/YEø1
X6
PK/YEø1
4
BKø1
1
2
WHEEL
STEERING
SOLENOID VALVE
12v
A06
Y08
BU/RDø1
B
E
A
BN/BKø1
C
BKø1
YE/RDø1
F
STEERING
SELECTOR
PK/YEø1
SW08
A07
Y09
X7
6
YE/RDø1
X6
YE/RDø1
6
BKø1
1
2
WHEEL
STEERING
SOLENOID VALVE
12v
31
G-10
Document 57.0008.6200 - 03/2009
8/G10
8/G10
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Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
8/8
7/G10
7/G10
7/A1
31
15
30
15
30
X15
3
WH/YEø1
Y10
8
0
1
1
3
6
7
4
X15
CONTINUOUS
OIL
2
2
5
X16
WH/OGø1
12v
WH/YEø1
2
X8
WH/YEø1
2
BKø1
1
2
ATTACHEMNT
RELEASE
SOLENOID VALVE
Y11
12v
12v
X15
BU/YEø1
4
X8
9
BU/YEø1
1
2
BKø1
X15
1
SW14
Y12
JOYSTICK
FORk
ROTATION
SOLENOID VALVE
BN/BKø1
7/G8
X8
WH/OGø1
3
BKø1
1
2
ATTACHEMNT
COUPLING
SOLENOID VALVE
F21
HA03
BNø2.5
4
10
A
X2
5
VT/WHø1.5
X3
VT/WHø1
M
BKø1
BEACON
H09
3
YE/GNø1.5
YE/GNø1.5
X10
4
X3
YE/GNø1.5
BKø1
WORK LIGHT
X10
2
YE/BKø1.5
BKø1
WORK LIGHT
SWITCH
(OPTIONAL)
2
5
8
SW12
0
1
1
3
4
6
7
YE/GNø1.5
YE/GNø1.5
31
G-11
Document 57.0008.6200 - 03/2009
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Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-3.1.1
Ref
Wiring diagram - Components description
Description
Sheet
2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31
10 A FUSE
10 A FUSE
5 A FUSE
10 A FUSE
10 A FUSE
5 A FUSE
5 A FUSE
15 A FUSE
5 A FUSE
7,5 A FUSE
7,5 A FUSE
5 A FUSE
2 A FUSE
2 A FUSE
20 A FUSE
10 A FUSE
5 A FUSE
20 A FUSE
10 A FUSE
15 A FUSE
5 A FUSE
15 A FUSE
5 A FUSE
7,5 A FUSE
7,5 A FUSE
5 A FUSE
5 A FUSE
SPARE FUSES (15A - 10A - 7,5A - 5A)
PREHEATING CONTROL UNIT MAXIFUSE
SYSTEM PROTECTION FUSE
H01
WARNING LIGHTS: AIR FILTER SOILED,
PREHEATING GLOW PLUGS WARNING LIGHT
BACK-UP LAMPS
REAR RIGHT-HAND LIGHT
LICENSE PLATE LAMP
REAR LEFT-HAND LIGHT
FRONT LIGHT LAMP - LEFT TURN SIGNAL
FRONT LIGHT LAMP - RIGHT TURN SIGNAL
WORK LIGHT
Ref
K06
Description
Sheet
K11
GEAR ENGAGEMENT FROM PARKING BRAKE LINE
LOW PRESSURE BULB
START RELAY
1
1
M01
M02
M03
M04
M06
STARTER MOTOR
ALTERNATOR
WINDSCREEN WIPER MOTOR
WINDSCREEN WIPER/WASHER MOTOR
FAN MOTOR
1
1
5
5
7
P01
P02
P03
WARNING LIGHTS - FUEL GAUGE INSTRUMENT
ENGINE OIL TEMPERATURE INDICATOR
ENGINE OIL COOLING TEMPERATURE INDICATOR
5
5
5
R01
GLOW PLUGS
1
SW01
SW02
SW03
SW04
SW05
SW06
IGNITION KEY
1
PARKING BRAKE SWITCH
2
CHANGE OVER SWITCH
1
MUSHROOM-HEAD BUTTON
3
HAZARD WARNING LIGHT / TURN SIGNALS SWITCH 3
LIGHT SWITCH-TURN SIGNALS-WINDSCREEN WIPER/
WASHER
5
SW07 LIGHTS SELECTION SWITCH
5
SW08 STEERING SELECTOR
7
SW09 HEATING FAN SWITCH
7
SW11
SW12
SW13
SW14
CONTINUOUS OIL SWITCH
OPTIONAL WORK LIGHT SWITCH
BATTERY CUTOFF
JOYSTICK
8
8
1
8
1
2
4
4
4
4
4
8
SS01
SS02
SS03
SS04
SS05
SS06
SS07
SS08
SERVICE BRAKE SENSOR
AIR FILTER CLOGGING SENSOR
WATER TEMPERATURRE SENSOR
ENGINE OIL PRESSURE SENSOR
NEGATIVE BRAKE PRESSURE SWITCH
HYDRAULIC OIL TEMPERATURE SENSOR
WATER TEMPERATURE SENSOR
FUEL FLOAT
2
1
6
6
6
6
6
6
HA01 BACK-UP HORN
HA02 HORN
HA03 BEACON
2
5
8
K01
K02
K03
K04
K05
1
2
2
2
Y01
Y02
Y03
Y04
Y07
Y08
Y09
Y10
Y11
FUEL ENRICHER SOLENOID
SOLENOID VALVE - FWD SPEED
SOLENOID VALVE - PARKING BRAKE
SOLENOID VALVE - REVERSE SPEED
ENGINE STOP SOLENOID
WHEEL STEERING SOLENOID VALVE
WHEEL STEERING SOLENOID VALVE
SOLENOID VALVE - ATTACHMENT RELEASE
SOLENOID VALVE - ATTACHMENT COUPLING
1
2
2
2
3
7
7
8
8
H03
H04
H05
H06
H07
H08
H09
OPTIONAL WORK LIGHT
STARTING ENABLING COMMAND
FORWARD SPEED ENABLING COMMAND
INHIBITION WITH SERVICE BRAKE ENGAGED
REVERSE SPEED ENABLING COMMAND
Page
G-12
Document 57.0008.6200 - 03/2009
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
Ref
Description
Sheet
Y12
SOLENOID VALVE - FORK ROTATION
8
A01
A02
A03
A04
A05
A06
A07
12V BATTERY
PREHEATING CONTROL UNIT
TURN SIGNALS FLASHING
DIODE
DIODE
DIODE
DIODE
1
1
3
3
3
7
7
X01
X02
X03
X04
X05
X06
X07
X08
X09
X10
X15
X16
4-WAY CONNECTOR - ENGINE FUSES LINE
4-WAY CONNECTOR - STEERING COLUMN
6-WAY CONNECTOR - CAB
6-WAY CONNECTOR - STEERING COLUMN
12-WAY CONNECTOR - STEERING COLUMN
12-WAY CONNECTOR - ENGINE
15-WAY CONNECTOR - STEERING COLUMN
15-WAY CONNECTOR - ENGINE
9-WAY CONNECTOR - ENGINE
12-WAY CONNECTOR - STEERING COLUMN
4-WAY CONNECTOR - JOYSTICK
2-WAY CONNECTOR - STEERING COLUMN
Page
Ref
Description
G-13
Document 57.0008.6200 - 03/2009
Sheet
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
INTENTIONALLY BLANK PAGE
Page
G-14
Document 57.0008.6200 - 03/2009
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-4.1 HYDRAULIC SCHEME
(Drw. 57.2201.3000 - rev. B)
Page
G-15
Document 57.0008.6200 - 03/2009
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
INTENTIONALLY BLANK PAGE
Page
G-16
Document 57.0008.6200 - 03/2009
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-5 ROUTINE CHECK SCHEDULE - SAFETY DEVICES
Block.Valve 9
Block.Valve 8
Block.Valve 7
Block.Valve 6
Block.Valve 5
Block.Valve 4
Block.Valve 3
Block.Valve 2
Date
Block.Valve 1
COMPONENT
Result/Notes
Positive
Page G-17
Document 57.0008.6200 - 03/2009
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Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
Table key explanation:
Block valve 1
Block valve on lifting cylinder
Block valve 2
Block valve on fork balance cylinder
Block valve 3
Block valve on telescope extension cylinder
Block valve 4
Block valve on attachment moving cylinder
Block valve 5
Block valve on attachment locking cylinder
Block valve 6
Block valve 7
Block valve 8
Block valve 9
Page G-18
Document 57.0008.6200 - 03/2009