PN 57.0009.0412_111

PN 57.0009.0412_111
Operator’s Manual
Serial number range
GTH-5519
From serial n.: 19388
(Perkins Tier III) To serial n.: 24471
GTH-5519
(Deutz Tier III)
From serial n.: 19006
To serial n.: 25040
With Maintenance
Information
First Edition
Eleventh Printing
Part No. 57.0009.0412
Operator’s Manual
First Edition - Eleventh Printing
Important
Contents
Read, understand and obey these safety rules
and operating instructions before operating the
machine. Only trained and qualified personnel
shall be authorized to operate the machine.
This manual shall be kept with the machine at
all times.
Introduction ..........................................Page 3
Machine Identification ..........................Page 5
Symbols Used On The Machine ..........Page 7
Labels And Plates Applied On The
Machine ...............................................Page 9
Safety Precautions ..............................Page 17
Description Of The Main Components ...Page 25
Controls And Instruments ....................Page 27
Inspections ..........................................Page 41
Operating Instructions .........................Page 45
Transporting The Machine...................Page 57
Maintenance ........................................Page 61
Faults And Troubleshooting.................Page 85
Optional Attachments ..........................Page 89
Specifications ......................................Page 95
Load Charts .........................................Page 99
Diagrams And Schemes ......................Page 107
For any further information, please call
Terexlift.
Contact us:
ZONA INDUSTRIALE I-06019 UMBERTIDE
(PG) - ITALY
Telephone +39 075 941811
Telefax +39 075 9415382
Technical Assistance Service
Telephone: +39 075 9418129
+39 075 9418175
e-mail: [email protected]
Original Instructions
First Edition: Tenth Printing, October 2011
For the electronic version of this manual visit
www.genielift.com/operator_manuals.asp
© Copyright 2006 TEREXLIFT srl - All rights reserved
Produced by:
TEREXLIFT Technical Literature Dept.
Umbertide (PG) Italy
2
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Introduction
Symbols
Safety alert symbol: used to
alert you to potential personal
injury hazards. Obey all safety
messages that follow this
symbol to avoid possible
injury or death
DANGER
Red: indicates a hazardous
situation which, if not avoided,
will result in death or serious
injury.
WARNING Orange: indicates a hazardous
situation which, if not avoided,
could result in death or serious
injury.
CAUTION
NOTICE
PROTECT THE
ENVIRONMENT
Yellow : indicates a hazardous
situation which, if not avoided,
could result in minor or
moderate injury.
Blue: indicates a hazardous
situation which, if not avoided,
could result in property
damage.
Green: used to draw the
attention to important
information on environment
protection.
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4
GTH-5519
Part No. 57.0009.0412
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Operator’s Manual
Machine Identification
Check that the operator handbook refers to the
delivered machine.
MACHINE IDENTIFICATION PLATES
The following data plates are applied on the
machine:
MODEL AND TYPE
Handler with telescopic boom:
Machine data plate
The identification plate contains the main identification
data of the machine like model, serial number and
year of manufacture.
The data plate is applied on the front right side of
the chassis.
models:
GTH-5519
MANUFACTURER
TEREXLIFT srl
Zona Industriale - I-06019 UMBERTIDE (PG) ITALY
Enrolled in the register of companies at the Court of
Perugia under no. 4823
C.C.I.A.A. 102886
Fiscal Code/V.A.T. no. 00249210543
ROPS-FOPS cab type-approval plate
The ROPS - FOPS type-approval plate is located
inside the driving cab above the rear glass.
Fork data plate
Placed on the left side of the fork frame.
This plate shows the identification data of fork such
as model, serial number, year of manufacture, weight,
nominal payload, centre of the load and model of the
machine on which the forks are installed.
APPLICABLE STANDARDS
For the operator’s safety, the following standards were
obeyed during the risk assessment of the handler
fitted with telescopic boom norme:
Directive
Title
ANSI/ITSDF B56.6-2002 part III where applicable.
CSA B335-04 where applicable.
Part No. 57.0009.0412
GTH-5519
5
Operator’s Manual
First Edition - Eleventh Printing
Machine Identification
CHASSIS SERIAL NUMBER
The chassis serial number is punched on the front
left part of the chassis side member.
IDENTIFICATION PLATES OF THE MAIN
PARTS
The plates of the main components, not directly
manufactured by TEREXLIFT srl (for instance,
engines, pumps, etc.), are located where originally
applied by the manufacturers.
Chassis serial number
HOW TO READ
YOUR SERIAL
NUMBER
(The chassis serial number is punched on the front left
part of the chassis side member)
GTH-5519 P 07 17882
MODEL
ENGINE
TYPE
SERIAL
NUMBER
YEAR OF
MANIFACTURER
Machine data plate
(The data plate is applied on the front right side of the chassis)
6
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Symbols Used On The Machine
Fuel level
General alarm
Hydraulic oil filter
clogged
Hydraulic oil filter
Low Hydraulic Oil
Level
Not active
Not active
Rear Wheel Aligned
Parking brake
Battery charge
Turn signals
High beam
Glow Plugs Preheating
High Coolant Temperature
Low beam
Air Filter Restricted
Hour-meter
Hydraulic Oil
Temperature Indicator
Position lights
Windscreen washer
Cab ventilation fan
Position lights
Fog lamp
Hazard warning lights
Continuous Oil Flow
Steering mode
Anchorage points
Fuel cap
Hydraulic oil
Engine oil level
Moving gears
Risk of crushing injury
to the hands
Hot surfaces. Risk of
burns
Part No. 57.0009.0412
Low engine oil
pressure
GTH-5519
7
Operator’s Manual
First Edition - Eleventh Printing
Symbols Used On The Machine
HAZARD PICTORIAL DESCRIPTIONS
Electrocution
Hazard
Maintain required
clearance.
Falling Object
Hazard
No people under
load.
Fall Hazard
No riders.
Overturning
Hazard
Keep load low.
Bodily Injury
Hazard
Always wear seat
belt.
Injection Hazard
Use cardboard to
search for leaks.
Overturning
Hazard
Read the operator's Crush Hazard
manual.
x
8
Keep away from
moving parts.
Operate from
operator's station.
Burn Hazard
Allow system to
cool.
Overturning
Hazard
Keep away from
belts and fans.
No smoking. No
open flame.
Burn Hazard
Allow surfaces to
cool.
Crush Hazard
Lower forks. Set
parking brake.
Bodily injury hazard. Crush Hazard
GTH-5519
Explosion/Burn
Hazard
Support boom
when performing
maintenance.
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Labels And Plates Applied On The Machine
Shading indicates decal is hidden from view, i.e. under covers.
23
21
8
15
16
28
32
31
A
27
19
37
20
11
3
26
3
12
17
1
24
2
4
6
14
30
5
10
9
11
28
25
B
7
22
33 DEUTZ
3
34
27
Part No. 57.0009.0412
32
35
3
31
GTH-5519
13
38
36
33 PERKINS
9
Operator’s Manual
First Edition - Eleventh Printing
Labels And Plates Applied On The Machine
Use the pictures on these pages to verify that all decals are legible and in place.
The following chart shows quantities and description too.
Ref.
Decal
Code
Description
Qt.
SAFETY PIN
STORAGE POSITION
WORKING POSITION
1
09.4618.0791 Safety pin operation
1
09.4618.0791
2
97669C
3
P= 4.5 bar
65 psi
4
Warning - Falling Object Hazard
09.4618.0061 Tyre inflation sticker P= 4.5 bar / 65 psi
1
4
114352B
Overturning Hazard for Cab
1
97665B
Warning - Bodly Injury Hazard
1
97666B
Warning - Improper Operation
1
97667B
Warning - Burn Hazard
2
WARNING
Bodily Injury Hazard
Death or serious injury
can result from failure
to wear seat belt.
5
This machine is
equipped with a Roll
Over Protection System
(ROPS).
Always adjust seat and
fasten seat belt before
starting engine. 97665 B
WARNING
6
Improper operation or
maintenance can result in
serious injury or death.
97666 B
Read and understand
operator's manual and all
safety signs before using
or maintaining machine.
If you do not understand
the information in the
manuals, consult your
supervisor, the owner or
the manufacturer.
WARNING
7
Burn Hazard
Contact with
hot surfaces
can cause
burns.
Do not touch.
Allow surfaces
to cool before
servicing.
97667 B
10
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Labels And Plates Applied On The Machine
Ref.
Decal
Code
Description
Qt.
DANGER
8
Crush Hazard
Death or serious injury could
result from rolling of an
unattended machine.
97670B
Warning - Crush Hazard, Parking Brake
1
97672B
Danger - Crush Hazard, No Riders
1
114356A
Oveturing hazard_use load chars
1
97673B
Danger - Fall Hazard, No Riders
2
97674B
Warning - Crush Hazard, Overhead Parts
1
97675B
Warning - Burn Hazard, Hot Component
1
Set parking brake, lower carriage
or attachment to ground before
leaving machine.
97670 B
DANGER
Crush Hazard
Death or
Serious Injury
can result from
people riding
on this machine
other than at
the operator's
station.
9
x
No
passengers
are permitted
to ride on this
machine or
any
attachment.
97672 B
WARNING
Overturning
Hazard
Death or serious
injury can result
from using this
machine without a
load chart.
10
Never operate the
machine if the
load chart is
missing.
114356 A
DANGER
11
Death or Serious Injury can result
from handling of personnel with this
machine.
97673 B
Never equip machine with any form
of personnel platform or allow
personnel to ride on attachment.
WARNING
12
Crush Hazard
Moving parts can
cause Death or
Serious Injury.
Keep clear of elevated
components.
Support components
before performing
service.
97674 B
WARNING
13
Burn Hazard
Hot fluid under
pressure can scald.
Allow to cool before
opening.
Part No. 57.0009.0412
97675 B
GTH-5519
11
Operator’s Manual
First Edition - Eleventh Printing
Labels And Plates Applied On The Machine
Ref.
Decal
Code
14
15
Description
97676B
Emergency
Exit Handle
97688
Qt.
Danger - Electrocution Hazard
1
Emergency Exit Handle
1
Warning - Injection Hazard
1
97688 A
WARNING
Injection Hazard
Escaping fluid under pressure can
penetrate skin, causing serious injury.
16
82558B
Relieve pressure before disconnecting
hydraulic lines. Keep away from leaks
and pin holes. Use a piece of cardboard
or paper to search for leaks. Do not use
hand.
Fluid injected into skin must be
surgically removed within a few hours
by a doctor familiar with this type of
injury or gangrene will result.
82558 B
17
09.4618.0928 Label - Hydraulic Oil
1
09.4618.0786 Label - Testing ports
1
09.4618.0928
19
TP5
TP4
TP3
TP2
TP1
09.4618.0786
09.4618.0776
20
Label - Upper Door Internal Unlock
System
1
09.4618.0776
NOTICE
21
09.4618.0781 Label - Flow Reversal Button
1
09.4618.0781
CAUTION
22
09.4618.0782
Caution - Connect./disconnect. Quick
Coupling OPTIONAL
1
09.4618.0780
Label - Continuous Flow Knob
(up to s/n: 24128)
1
09.4618.0782
09.4618.0780
23
12
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Labels And Plates Applied On The Machine
Decal
09
Description
09.4618.1634
634
23
Code
.4 6 1 8
.1
Ref.
24
Label - Continuous Flow Knob
(from s/n: 24129)
Qt.
1
09.4618.0819 Label - Lever Controls
1
09.4618.0792 Label - Engine Cover Closing
1
OPTIONAL: Hydraulic Quick Attach
SET “0”
INSTRUCTIONS
1
0
2
PUSH
09.4618.0781
09.4618.0819
25
09.4618.0792
114470
26
27
28
GTH-5519
GTH-5519
29
30
Part No. 57.0009.0412
Cosmetic - GENIE Logo
1
09.4618.0644 Cosmetic - GTH-5519
2
09.4618.0643 Cosmetic - Genie GTH-5519
2
09.4618.0109 Sticker With Various Warnings
1
97668B
Warning - Overturning Hazard
GTH-5519
1
13
Operator’s Manual
First Edition - Eleventh Printing
Labels And Plates Applied On The Machine
Ref.
Decal
Code
Description
Qt.
WARNING
Crush Hazard
Machine
movement can
cause serious
injury or death.
31
114365A
Crush Hazard
2
114367B
Falling Objects
2
28162C
Fan Belt
1
28159C
Diesel
1
28175H
Warning for Engine Cover
1
31788C
Warning - Burn Hazard, Hot Component
1
Stay away from
machine.
114365 A
32
WARNING
33
Bodily injury hazard.
Contact with moving parts
may cause serious injury.
Stay clear of belts and fan
when engine is running.
28162 C
34
28159 024C
35
Compartment access
is restricted.
Contact with
components under
any cover may result
in serious injury.
28175 H
Only trained maintenance personnel
should access compartments. Access
by operator is only advised when
performing Pre-operation Inspection. All
compartments must remain closed and
secured during operation.
DANGER
Explosion / Burn Hazard
Ignition of explosive gases or contact with corrosive
acid will cause death, burns or blindness
36
Keep all open flames and sparks away. Wear
personal protective equipment, including face
shield, gloves and long sleeve shirt.
READ MANUALS
Read all manuals prior to operation.
DO NOT OPERATE equipment if you do not
understand the information in the manuals.
Consult your supervisor, the owner or the
manufacturer.
31788 C
14
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Labels And Plates Applied On The Machine
Ref.
Decal
37
Code
Description
Qt.
09.4618.1025
Label - Upper Door External Unlock
System
1
09.4618.1025
FG1
K02
38
Ref.
FG2
K01
Description
Ref.
09.4618.0949 Label - Fuses and Relays Engine Board
1
09.4618.0205 Boom tilting degree
1
Machine data plate. The identification plate
09.4616.0101 contains the main identificaion data of the
machine.
1
Description
Glow Plugs Preheating
FG1
Main Fuse
Starter Enabling Switch
FG2
Glow Plugs Fuse
09.4618.0949
80
K01
K02
60
A
40
20
0
TE E FT srl - ON N T
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T
MO E O - MO E - MO E E - T P - MO E O
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NNO
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PE O M
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M
PE O M
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. H T H . N. T O - PE O M E E PO TE O
PE O TOT E - TOT
PE O TOT
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TOT -
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M T O MOTO E TE M O - ENG NE E
N. - N. MOTE
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N . E E MOTO - NO. E E E MOTO TE M O
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N. - N. E E E - F .- ENT N . - NO. E E E
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Part No. 57.0009.0412
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Intentionally blank page
16
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Safety Precautions
SAFETY DEVICES
DAMAGED MACHINE HAZARDS
•
•
•
•
•
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 manual is legible
and placed in the special container located in the
machine.
Several safety devices have been fitted to the
machine. They must never be tampered with or
removed.
Regularly check the efficiency of such devices.
In case of faults, stop working immediately and
proceed in replacing the defective device.
For the checking procedures, read chap.
"Maintenance"
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.
Part No. 57.0009.0412
GTH-5519
17
Operator’s Manual
First Edition - Eleventh Printing
Safety Precautions
Not observing the instructions
and safety rules in this manual
may result in death or serious
injury.
Do not operate the machine unless:
•
•
•
•
•
18
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. A l w a y s p e r f o r m a p r e - o p e r a t i o n
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.
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.
NOTICE
If you recognise hazardous situations, you can
prevent accidents!
DANGER
The instructions given in this handbook are the
ones established by TEREXLIFT. 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 TEREXLIFT Assistance Service for
any suggestion and the necessary written
permission.
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Safety Precautions
REQUISITES OF THE PERSONNEL IN CHARGE
Requisites of the MACHINE 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 psychophysical 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.
Requisites of the SERVICEMEN
The personnel charged with the machine maintenance
shall be qualified, specialised in the maintenance
of telehandlers, and shall have the following
prerequisites:
physical:
good eyesight, acute hearing, good co-ordination
and ability to carry out all required maintenance
operations in a safe way, according to this manual.
mental:
ability to understand and apply the enforced rules,
regulations and safety precautions. They shall be
careful and sensible for their own as well as for the
others’ safety and shall desire to carry out the work
correctly and in a responsible way.
training:
they shall read and be familiar with this handbook,
its enclosed graphs and diagrams, the identification
and warning plates. They shall be skilled and trained
about the machine functioning.
NOTICE
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.
NOTICE
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. In Italy the operator
must be at least 18 year old.
Part No. 57.0009.0412
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19
Operator’s Manual
First Edition - Eleventh Printing
Safety Precautions
OTHER DANGERS
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.
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
hazards!
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
0
50
200
350
500
750
Use only type-approved working clothing in good
condition.
Personal PROTECTIVE EQUIPMENT
Under special working conditions, the following
personal protective equipment should be used:
• Breathing set (or dust mask).
• Ear-protectors or equivalent equipment.
• Goggles or facial masks.
•
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
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.
20
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Safety Precautions
OPERATION or MAINTENANCE 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.
•
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.
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.
WARNING
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.
•
•
•
•
•
•
•
•
•
•
Part No. 57.0009.0412
Do not connect wet plugs or sockets.
Plates and hazard warning stickers shall never
be removed, hidden or become unreadable.
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.
GTH-5519
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Operator’s Manual
First Edition - Eleventh Printing
Safety Precautions
•
•
•
•
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.
WARNING
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.
•
•
•
22
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.
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.
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
drop-offs.
• 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.
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Safety Precautions
EXPLOSION OR FIRE hazards
•
•
•
•
•
•
•
•
•
DAMAGED COMPONENT hazards
Do not start the engine if you smell or detect
LPG, gasoline, diesel fuel 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.
Part No. 57.0009.0412
•
•
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.
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.
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24
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Part No. 57.0009.0412
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Operator’s Manual
Description Of The Main Components
4
3
2
10
1
5
7
6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
8
9
Forks
2nd boom section
1st boom section
Engine hood
Driving cab
Front axle
Chassis
Left front wheel mud-guard
Left front wheel reduction gear
Left rear wheel reduction gear
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26
GTH-5519
Part No. 57.0009.0412
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Operator’s Manual
Controls And Instruments
1
8
10
5
6
GT
H-
25
06
16
09.4
618
.083
4
11
PROPOSTA G RAFIC A
STRUMENTO ECO
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15
BRAKE OIL
4
2
13
3
12
9
09.4618.0780
7
14
1.
2.
3.
4.
5.
6.
7.
8.
Fresh Air Flap
Forward/reverse Gear Selector Lever
Steering Colum Angle Adjustment
Turn Signals - Windscreen Washer - Horn
Ignition Switch
Load Charts Holder
Continuous Oil Flow Potentiometer
Hazard Warning Lights Switch
Part No. 57.0009.0412
9.
10.
11.
12.
13.
14.
15.
16.
GTH-5519
Multipurpose Control Lever
Gas Pedal
Instruments Dashboard
Cab Heater Control Knob
Fuses And Relays Board
Windscreen water reservoir
Service Brake Pedal
Service Brake Oil Tank
27
Operator’s Manual
First Edition - Eleventh Printing
Controls And Instruments
Forward/reverse gear selector switch
Three-position switch with lock in neutral position:
Ignition switch
Three-position switch:
0
Neutral position; no gear engaged
0
No circuit under voltage, key can be removed
and engine is stopped
1
1
Circuits under voltage, presetting for the engine starting. Board controls and instruments
are on.
Shift lever to pos. 1 to select the forward
gear
2
Shift lever to pos. 2 to select the reverse
gear
2
Engine starting; when released, key springs
back to pos.1 automatically.
1
0
0
1
2
2
Horn function:
When sliding the lever along its axis, horn switches
on, independently from other pre-set functions.
28
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Part No. 57.0009.0412
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Operator’s Manual
Controls And Instruments
Turn signals - Lights (OPTIONAL)
(only with closed cabin)
Turn signals function:
Set lever to pos. 1 to indicate a turn leftwards or to
pos. 2 to indicate a turn rightwards.
When starting the engine the lights of all the
pushbuttons turn automatically on!
Only the switching-on of the orange warning light
sets on the top of the pushbutton will indicate
the activation of the function.
I
)0J)
17
Road lights switch (OPTIONAL)
Three-position switch placed on the right side of the
dashboard:
0 Lights OFF
1 Position lights ON (the orange lights
turn on)
Lights function:
To switch the handler lights, lever can be set to three
different positions along its horizontal axis:
0
low beam ON, stable condition
1
high beam ON, stable condition
2
high beam used for intermittent signalling;
when released, the lever springs back to
position 0.
2 Low beam ON (the orange lights turn
on)
17
I
)0J)
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Controls And Instruments
Accelerator control
Brakes
15 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.
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.
When starting the engine the light of the pushbutton
turns automatically on! When the orange light at the
top of the pushbutton and the dashboard warning
light are on, the parking brake is engaged.
10
Gas Pedal
Its pressure controls the engine rpm and the machine
speed. It is fitted with an adjustable stop in the lower
part.
When starting the engine the lights of all the
pushbuttons turn automatically on!
Only the switching-on of the orange warning light
sets on the top of the pushbutton will indicate
the activation of the function.
CAUTION
Never use the parking brake to slow down the
machine, unless in an emergency. It may reduce
the brake efficiency.
PROPOSTA GR
STRUMENTO ECO
30/10/07
15
18
10
BRAKE OIL
30
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Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Controls And Instruments
Steering mode selection
20 Steering Mode Switch
Three-position switch for the selection of the steering
mode:
0
1
2
1 Four-wheel steering
0
Two-wheel steering
2
Crab steering
G
TH
-2
50
6
20
18
.08
34
PROPOSTA G RAFIC A
STRUMENTO ECO
30/10/07
Continuous Oil Flow
09
.46
Before activate the Continuous Oil Flow function,
make sure the connectors of the attachment are
coupled.
22
Flow Reversal Button
Pushbutton with orange glass cap, with three stable
positions. Press this button to switch the hydraulic
circuit feeding the attachments with auxiliary lines to
one or another direction.
22
1 Continuous oil flow delivery to the used
attachment.
0 Joystick flow control (refer to the
function selection section of this manual
for Joystick Flow Control instructions,
page 34).
2 Continuous oil flow return to the used
attachment.
7
7
09.4618.0780
Continuous Oil Flow Potentiometer
By turning the potentiometer clockwise, the flow rate
in the circuit feeding the attachments’
movement lines is increased.
09.4618.0780
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Controls And Instruments
Auxiliary drive controls
8 Hazard Warning Lights Switch (OPTIONAL)
Fitted with on-off position, it switches on the turn
signals simultaneously. When the
hazard warning light is lit, the relevant
switch and the turn signals light start
flashing.
23 Cab Heater Fan Switch (OPTIONAL)
Three-position switch:
28 Windscreen Washer Switch (OPTIONAL)
Two-position switch:
0 Washer OFF
1 Jet of water on the cab windscreen
29 Work Lights Switch (OPTIONAL)
Three-position switch:
0 Fan OFF
0 Lights OFF
1 Low speed
1 Boom light ON
2 High speed
27 A/C Switch (OPTIONAL)
Two-position switch:
0 A/C OFF
2 Cab and Boom ligths ON
12 Cab Heater Control Knob (OPTIONAL)
Located at the
bottom of the driving
seat base, it adjusts
the flow of heated air
in the cab.
1 A/C ON
12
09
.46
18
.08
34
PROPOSTA GRAFIC A
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BRAKE OIL
29
23
8
27
28
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Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Controls And Instruments
Instruments
25
Engine coolant temperature indicator
This indicates the engine coolant temperature. If the
finger is in the red zone and the warning light comes
on, you must stop the machine and find and rectify
the problem.
26
Hydraulic oil temperature indicator
This indicates the temperature of the hydraulic
oil in the tank. If the temperature rises above the
permissible value or the red warning light comes
on, you must stop the machine and find and rectify
the problem.
19
19
Hour-meter
Signals the total operating hours of the machine. Use
the hour-meter to gauge the routine maintenance
jobs.
26
25
PROPOSTA G RAFIC A
STRUMENTO ECO
30/10/07
24
24
Fuel gauge
This indicates the fuel level in the tank.
If the fuel level is low (reserve), the relevant warning
light comes on.
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Operator’s Manual
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Controls And Instruments
Warning lights (ref. 11)
11.1 Warning light - low battery charge
Signals a low charge by the alternator.
11.2 Warning light - low engine oil pressure
It lights when the engine oil pressure is too low
11.3 Warning light - air filter restricted
When this lamp come on, proceed with cleaning or
changing the air filter cartridge.
11.4 Warning light - low brake pressure
It lights when the pressure of the brake circuit is too
low for a correct functioning.
11.5 Warning light - parking brake engaged
When ON, this light indicates that the parking brake
is engaged.
11.6 Warning light - high coolant temperature
This red light comes on to alert to a too high
temperature of the cooling medium.Stop the engine
and find and rectify the problem.
11.7 Warning light - high beam
Blue warning light that signals when high beam is
ON.
11.8
Warning light - hydraulic oil filter clogged
When this lamp sets to on, immediately change the
oil filter on the return line to the tank.
11.10
11.4
11.5
11.13
11.15
11.15
11.6
PROPOSTA G RAFIC A
STRUMENTO ECO
30/10/07
11.11
11.9 Warning light - low hydraulic oil level
This light comes on to alert to a low level of the
hydraulic oil for a correct functioning. Replenish and
eliminate the oil leak.
11.10 General alarm warning light
This red light comes on to warn of a problem of the
machine. Contact the TEREXLIFT Service Centre.
11.11 Warning light - low fuel level
If the fuel level is low (reserve), the relevant warning
light comes on.
11.12 OPTIONAL Warning light - rear wheel
aligned
When ON, this light indicates that the rear wheel
are aligned.
11.13 Warning light - glow plugs preheating
This amber light indicates the pre-heating of the
engine glow plugs. Before starting the engine wait
for this light to go off. If the light fails to go off, a glow
plug could be broken. The machine can be started
normally without pre-heating up to a temperature
of -12°C.
11.14 Warning light - low beam
Green warning light that signals when low beam is
ON.
11.15 Not active
11.1
34
11.2
11.8
11.9
11.12
11.3
GTH-5519
11.14
11.7
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Controls And Instruments
CONTROL LEVER
Handlers are equipped with a hydraulically driven
servo-controlled lever.
The lever has two pushbuttons: one for coupling/
releasing the attachments 3 and the other for pitching
the attachment frame forwards/backwards 2.
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.
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.
The control lever shall be operated only when
correctly seated in the driving place.
Before operating the control lever, make sure
that nobody is within the working range of the
machine.
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Controls And Instruments
Function selection
The lever is enabled to carry out the following
motions:
•
Boom lowering/lifting
shift the control lever to A or B
•
Boom extraction/retraction
shift the control lever to C or D
•
Attachment back/forward tilting
press button 2 and shift the control lever to A or
B
•
Hydraulic Quick Coupling/Release
OPTIONAL
I. set the Flow Reversal Button to “0” (central
position)
II. press button 3 together with the dashboard
enabling button and shift the lever to A or B
OPTIONAL: Hydraulic Quick Attach
SET “0”
INSTRUCTIONS
1
0
2
PUSH
09.4618.0781
09.4618.0819
36
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Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Controls And Instruments
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 B to lift the
boom or to position A to lower it.
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Operator’s Manual
First Edition - Eleventh Printing
Controls And Instruments
Extending/retracting the boom
DANGER
Before operating the boom, make sure that nobody
is within the working range of the machine.
To extend or retract the telescopic elements of the
boom:
• Smoothly shift the lever to position D to extend
the boom or to position C to retract it.
38
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Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Controls And Instruments
Pitching the attachment holding frame
forward/back
DANGER
Before operating the boom, make sure that nobody
is within the working range of the machine.
To tilt forward/back the attachment holding frame:
• Press button 2 and shift the lever to position A
to tilt the frame forwards or to position B to tilt it
backwards.
Part No. 57.0009.0412
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Operator’s Manual
First Edition - Eleventh Printing
Controls And Instruments
Hydraulic Quick Coupling/Release
OPTIONAL
DANGER
Before operating the boom, make sure that nobody
is within the working range of the machine.
To coupling or release the attachment:
•
•
set the Flow Reversal Button to “0” (central
position)
press button 3 together with the dashboard
enabling button and smoothly shift the lever to
position A to coupling or to position B to release
it.
09.4618.0819
SET “0”
INSTRUCTIONS
1
0
2
PUSH
09.4618.0781
40
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Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Inspections
Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
Make sure:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1
Avoid hazardous situations.
2
Always perform a pre-operation
inspection.
The pre-operation inspection is a visual inspection
performed by the operator prior to each work shift.
The inspection is designed to discover if anything
is apparently wrong with a machine before the
operator performs the function tests.
The pre-operation inspection also serves to
determine if routine maintenance procedures are
required. Only routine maintenance items specified
in this manual may be performed by the operator.
Know and understand the pre-operation
inspection before going on to the next
section.
Refer to the list on the next page and check each
of the items.
3
Always perform function tests prior to use.
4
Inspect the workplace.
5
Only use the machine as it was intended.
If damage or any unauthorized variation from
factory delivered condition is discovered, the
machine must be tagged and removed from
service.
Repairs to the machine may only be made by
a qualified service technician, according to the
manufacturer's specifications. After repairs are
completed, the operator must perform a
pre-operation inspection again before going on to
the function tests.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer's specifications.
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Operator’s Manual
First Edition - Eleventh Printing
Inspections
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
“Labels and plates applied on the machine”
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 nonauthorised modifications:
• electrical components, wiring and electrical
cables
• hydraulic hoses, fittings, cylinders and main
valves
• 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
Check the entire machine for:
• cracks on welds or structural components
• dents or damage to the machine
42
*
*
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.
WARNING
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.
WARNING
A tyre burst may result in serious injury; never
use the machine if tyres are worn, wrongly
inflated or damaged.
CAUTION
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.
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Inspections
FUNCTION TESTS
CAUTION
The function tests are designed to discover
any malfunctions before the machine is put into
service. The operator must follow the step-by-step
instructions to test all machine functions.
A malfunctioning machine must never be used. If
malfunctions are discovered, the machine must
be tagged and removed from service. Repairs
to the machine may only be made by a qualified
service technician, according to the manufacturer's
specifications.
After repairs are completed, the operator must
perform a pre-operation inspection and function
tests again before putting the machine into
service.
Test the Control Lever
7 Using the control lever, momentarily raise the
boom, extend the boom, retract the boom and
lower the boom.
Result: All functions should operate smoothly.
8 Using the control lever and the yellow button,
momentarily tilt the forks up and tilt the forks
down.
Result: The function should operate smoothly.
Test the Steering
9 Push the right side of the steer selector switch
to select four-wheel steer.
10 Check the steering operation by turning the
steering wheel approximately ¼ turn in each
direction.
Result: The front wheels should turn in the
same direction as the steering wheel. The rear
wheels should turn in the opposite direction.
TESTS
11 Straighten the wheels.
1 Select a test area that is firm, level and free
of obstruction. Be sure there is no load on the
forks or attachment.
12 Push the steer selector switch to the middle
position to select two-wheel steer.
2 Enter the operator's compartment and sit on the
seat.
13 Check the steering operation by turning the
steering wheel approximately ¼ turn in each
direction.
3 Fasten the seat belt.
Result: The front wheels should turn in the
same direction as the steering wheel. The rear
wheels should not turn.
4 Adjust the interior rear view mirror and the
exterior right hand mirror, if required.
14 Straighten the wheels.
5 Be sure the parking brake is on and the
transmission control is in neutral.
6 Start the engine. See Starting the Engine in the
Operating Instructions section.
15 Push the left side of the steer selector switch to
select crab steer.
16 Check the steering operation by turning the
steering wheel approximately ¼ turn in each
direction.
Result: The front wheels and rear wheels
should turn in the same direction as the
steering wheel.
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Inspections
WORKPLACE INSPECTION
Test the Transmission and Brakes
WARNING
17 Be sure the boom is fully lowered and retracted.
18 Step on the service brake pedal.
19 Move the transmission control lever to forward.
Slowly let up on the service brake pedal. As
soon as the machine starts to move, push the
service brake pedal.
Result: The machine should move forward,
then come to an abrupt stop.
20 Move the transmission control lever to reverse.
Slowly let up on the service brake pedal. As
soon as the machine starts to move, push the
service brake pedal.
Result: The machine should move in reverse,
then come to an abrupt stop. The back-up
alarm should sound when the transmission
control lever is in reverse.
The workplace inspection helps the operator
determine if the workplace is suitable for safe
machine operation. It should be performed by
the operator prior to moving the machine to the
workplace.
It is the operator's responsibility to read and
remember the workplace hazards, then watch
for and avoid them while moving, setting up and
operating the machine
Be aware of and avoid the following hazardous
situations:
•
drop-offs or holes
21 Move the transmission control lever to neutral.
•
bumps, floor obstructions or debris
22 Push the top of the parking brake switch.
•
sloped surfaces
•
unstable or slippery surfaces
•
overhead obstructions and high voltage
conductors
•
hazardous locations
•
24 Push the bottom of the parking brake switch.
The parking brake is off when the indicator light
is off.
inadequate surface support to withstand all
load forces imposed by the machine
•
wind and weather conditions
•
the presence of unauthorized personnel
Test Auxilliary Hydraulics (if equipped with
swing carriage)
•
other possible unsafe conditions
Result: The red parking brake indicator light
should come on, indicating the parking brake is
on.
23 Move the transmission control lever forward,
then in reverse.
Result: The machine should not move.
25 Using the auxiliary hydraulics switch,
momentarily rotate the carriage to the right and
to the left.
Result: The function should operate smoothly.
Test the Road Lights (optional)
26 Verify that all lights are functional.
44
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Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Operating Instructions
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”.
WARNING
For a safe use of the machine, always check the
weight of the loads going to be handled.
WARNING
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.
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Operator’s Manual
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Operating Instructions
ENTERING THE MACHINE
(only for closed cabin)
To unlock the door latched in open position:
ENTERING THE CAB
WARNING
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.
•
Press button 4to unlock
the door from the catch
•
Once released, re-close
the upper section of the
door by means of handle
3.


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 1
and open the door.

Leaving the cab in an emergency
Door closing from inside:
Pull the door with force: it locks automatically.
Door opening from inside:
• Push lever 2 to open the
door completely.
• Rotate handle 3 to open
the upper section of the
door and lock it against the
special catch.
OP
EN
In an emergency, the operator can use the 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 which, if driven out, allow opening
the glass completely.
The front window has one, 5, handle which, if turned,
enables the operator to pass through.


CAUTION

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.
46
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Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Operating Instructions
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.
•
•
•
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.
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
counter-clockwise to lower the seat.
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.
•
•

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.
DANGER
3
The seat is for one person only.
Don’t adjust the seat when the machine is
moving.
Part No. 57.0009.0412
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
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1
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Operating Instructions
STEERING COLUMN ANGLE ADJUSTMENT
Both steering column and dashboard can be set to
a different angle.
To adjust the steering wheel angle, unlock lever 3
and pull or push the steering wheel to the required
position, then re-lock lever 3.
WARNING
Before driving the machine, ensure the steering
wheel is perfectly clamped.
ADJUSTING THE REAR VIEW MIRRORS
The machine is fitted with two rear view mirrors:
• The right rear view mirror 2 is located on a special
supporting bracket in advanced position and
allows checking the area behind the machine,
on the right-hand side. To adjust its position,
manually rotate the joint it is fitted with.
• The left rear view mirror 3 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.
3
➌
➋
RAKE OIL
48
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Part No. 57.0009.0412
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Operator’s Manual
Operating Instructions
STARTING THE ENGINE
For the low temperature starting, see paragraph
“Low Temperature Starting”.
• Engage the parking brake.
•
•
•
•
•
Put the forward/reverse speed selection lever to
neutral.
Step on the gas pedal.
To start the engine, turn the
0 1
ignition switch to position 2.
Release the switch when
2
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 paragraph).
CAUTION
If the light indicators do not switch off/on when
engine is running, immediately stop the machine
and find and rectify the fault.
Engine cannot be started if the speed switch is
not in the neutral position.
JUMP-STARTING THE ENGINE
CAUTION
Do not start the engine using a quick charge
booster to avoid any damage to the electronic
boards.
DANGER
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.
WARNING
Once it has been started, the engine continues to
run even if you leave the driving place. DO NOT
LEAVE THE DRIVING PLACE BEFORE HAVING
SHUT THE ENGINE DOWN, LOWERED THE BOOM
TO THE GROUND, TURNED THE SPEED SWITCH
TO THE NEUTRAL POSITION AND ENGAGED
THE PARKING BRAKE.
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Operating Instructions
•
•
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.
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.
•
•
Turn the ignition key and start the handler.
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.
50
To start the engine from cold, proceed as follows:
• Set the forward/back speed lever to neutral
position.
• Turn the ignition switch to the glow plugs
preheating position and wait until the relevant
warning light 11.13 goes off. Step down on the
gas pedal and start the engine by turning the
ignition switch. Release the switch as soon as
the engine fires.
• 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.
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Operating Instructions
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.
• Slowly step on the gas pedal to start moving
off.
WARNING
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.
STOPPING AND PARKING THE 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 and ensure its indicator
light switches 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.
WARNING
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.
WARNING
Always engage the parking brake after stopping
the machine to prevent possible accidental
motions of the vehicle.
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Operating Instructions
USING THE LOAD CHARTS
The load charts 1 indicates the maximum permissible
load in relation to the boom extension and the type of
attachment used. 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, B, C, D, E) painted
on the same boom (pos.3), while the actual degrees
of inclination of the boom are shown by the angle
indicator 2.
All the load charts are placed into a dedicated holder
installed in the right side of the cabin, on the top of
the dashbord. The tag 4 located at the top of each
load chart represents the type of attachment used.
WARNING
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.
WARNING
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 within the
cab of your machine.
B
C

D

E
GTH 5519
20 ft

70°
E
D
C
B
A
60°
50°
15 ft
5500 lbs
30°
4400 lbs
2000 lbs
10 ft
3000 lbs
40°

5 ft
10°
0 ft
1900 lbs
20°
0°
B A
E D C
10 ft
Forward reach, ft
52
5 ft
0 ft
09.4618.0812
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Operating Instructions
HANDLING LOADS
Adjusting the forks
With FEM forks (optional)
Forks shall be spaced to suit the load going to be
handled. For this purpose:
• Lift the clamping lever of the forks.
• Slide the forks to the desired position, then re-lock
the lever.
With floating forks
In the case of floating forks:
• Loosen the nut
of the locking
screws.
• Raise the forks
and slide them
on the pivot
until correct
spacing.
• Lock the
screws retightening the
nut.
Part No. 57.0009.0412
•
•
•
•
•
DANGER
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 on the cab windscreen 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
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 back to retract the load.
•
•
•
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.
Transfer phase
• Do not start or brake abruptly.
• Drive to the unloading point cautiously and keep
the load 8÷12 in 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.
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Part No. 57.0009.0412
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Operator’s Manual
Operating Instructions
CHANGING THE ATTACHMENT
CAUTION
Use only attachments directly manufactured or
recommended by Terexlift and detailed in the
“Optional attachments” section.
WARNING
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.
Version with MECHANICAL LOCKING
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).
• Pull out pin 1 locking the attachment after
removing the safety split-pin 2 at its end.


•
•
•
•
•
•
•
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 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.
Refit pin 1 fixing it with its safety split-pin 2.
Re-couple the connectors of the attachment (if
any).
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Operating Instructions
SET “0”
INSTRUCTIONS
1
0
PUSH
2
Version with HYDRAULIC LOCKING
(OPTIONAL)
09.4618.0781
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) from the couplings 3.
09.4618.0819
•
•
•
•
•

•
•
•
•
56
Free the attachment pressing joystick button 3
together with the dashboard enabling button and
smoothly shift the lever to position B.
Pitch the attachment holding frame forward and
lower the boom to release the attachment upper
lock.
Move back with the machine 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.
Coupling the attachment pressing joystick button
3 together with the dashboard enabling button
and smoothly shift the lever to position A.
Re-couple the connectors of the attachment (if
any).
Rest the attachment flat on the ground.
Set the Flow Reversal Button to "0" (central
position), as shown in the following draft .
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Transporting The Machine
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:
• Unlock the parking brake.
• Tow the machine for short distances and at a low
speed only (less than 3 mi/h).
• Use a rigid drawbar.
• Select the two-wheel steer.
• Set the forward/back speed lever to neutral
position.
• Raise the front wheels of the machine.
• When possible, start the engine and use the
hydraulic drive and the braking system.
ROAD OR SITE TRANSFER
When travelling on public roads, strictly obey the
local or national road traffic regulations.
Besides, take into account the following general
precautions:
•
•
Align the rear wheels.
Cover the teeth of the conventional forks with the
special guard; or withdraw the floating forks.
NOTICE
With the floating
forks pitched back,
do not move the fork
pitching cylinder as
the machine could
suffer from damage.
•
•
Retract boom and attachment to transfer
position.
The transfer speed of the vehicle will depend on
the engine rpm and the position of the control
lever.
NOTICE
Public road circulation is allowed only for
transferring an unloaded machine.
Do not use the machine to tow trailers.
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Transporting The Machine
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).
TRANSPORTING THE MACHINE ON OTHER
VEHICLES
To transport the machine on another vehicle, follow
the steps below:
• 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
wheel-chocks.
• Anchor the machine to the transporter's platform
by fixing the chains to the special eyebolts A on
the chassis.
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Operator’s Manual
Transporting The Machine
PARKING AND STORAGE
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.
• Disengage the transmission and put the parking
brake.
• Remove the key from the ignition switch and lock
the cab door.
CAUTION
Leaving a battery connected can result in shorts
and, as a consequence, in a fire.
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 wellventilated place.
• Start the engine for about 10 minutes at least
once a month.
• When weather is particularly cold, empty the
radiator.
NOTICE
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
re-starting the machine, carry out an extraordinary
maintenance and carefully check all mechanical,
hydraulic and electrical components.
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Transporting The Machine
CLEANING AND WASHING THE MACHINE
MACHINE DISPOSAL
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.).
CAUTION
Do not use water at high pressure for washing
the machine and especially the main valve, the
solenoid valves and electrical 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.
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.
Battery disposal
PROTECT THE
ENVIRONMENT
Used lead-acid batteries cannot be disposed
of as normal industrial solid wastes. Because
of the presence of harmful substances, they
must be collected, eliminated and/or recycled in
accordance with the laws of the UE.
Used batteries must be kept in a dry and confined
place. Make sure the battery is dry and the cell
plugs are tight. Place a sign on the battery to
warn of not using it. If before disposal the battery
is left in the open air, it will be necessary to dry,
smear the box and the elements with a coat of
grease and tighten the plugs. Do not rest the
battery on the ground; it is always advisable to
rest it on a pallet and cover it. The disposal of
batteries shall be as rapid as possible.
CAUTION
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.
60
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Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Maintenance
INTRODUCTION
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:
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.
A thorough and regular maintenance keeps the
machine in a safe and efficient working condition.
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.
Not respecting the ordinary maintenance schedule
of this manual automatically voids TEREXLIFT
warranty.
NOTICE
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
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.
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.
Oil leaks
In case of accidental oil leaks, cover with sand or
type-approved granulate. Then scrape off and dispose
of it as chemical waste.
62
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Part No. 57.0009.0412
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Operator’s Manual
Maintenance
ORDINARY MAINTENANCE
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.
CAUTION
All "" marked operations must be carried out
by a skilled technician.
During the first 10 working hours
1. Check the oil level within reduction gears, power
divider and differential gears
2. Regularly check the tightening of the wheel
bolts
3. Check the tightening of all bolts and nuts
4. Check the couplings for oil leaks
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.
Part No. 57.0009.0412
Every 50 working hours or weekly
Jobs to be done in addition to those above
1.
2.
3.
4.
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.
Every 250 working hours or monthly
Jobs to be done in addition to those above
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
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 regrease the sliding parts of the boom sections.
Check the level of the battery electrolyte.
Every 3 working months
Jobs to be done in addition to those above
1. Check the efficiency of the block valves.
GTH-5519
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Operator’s Manual
First Edition - Eleventh Printing
Maintenance
Every 500 working hours or every six
months
Every 500 working hours or yearly
Jobs to be done in addition to those above
1. Change the engine oil and renew the fuel filter.
1. Visually check the smoke quantity evacuated
from the engine exhaust.
2. Check the tightening of the engine fixing
screws.
3. Check the tightening of the cab fixing screws.
4. Check the backlash between pins and bushings
in all joints.
5. Change the hydraulic oil filter in the tank.
6. Have the hydraulic system checked by a skilled
technician.
7. Change the main cartridge of the engine air
filter.
8. C h a n g e t h e h y d r a u l i c o i l f i l t e r o f t h e
transmission
9. Clean or replace, if necessary, the air filter in
the cab.
Jobs to be done in addition to those above
Every 1000 working hours or yearly
Jobs to be done in addition to those above
1. Change the oil in the front and rear differential
units and in the power divider
2. Change the oil in the four wheel reduction
gears.
3. Change the hydraulic oil.
OIL CHANGE SCHEDULE
Operating
hours *
Service
interval *
Oil level check
10
daily
First change
500
-
Subsequent changes
500
yearly
Oil level check
250
monthly
Job
Engine
Axles and
power
divider
Hydraulic
oil
First change
Subsequent changes
Oil level check
First change
Subsequent changes
-
-
1000
yearly
10
daily
-
-
1000
yearly
Oil type
SHELL RIMULA 15W-40
(API CH-4/CG-4/CF-4/CF;
ACEA E3; MB228.3)
FUCHS TITAN GEAR LS 85
W-90
API GL-5 LS / GL-5
SHELL TELLUS T 46
DENISON HF-1, DIN 51524
part 2 & 3
* whichever occurs first.
64
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Maintenance
MAINTENANCE INTERVENTIONS
WARNING
All maintenance interventions must be carried
out with engine stopped, parking brake engaged,
working attachments flat on the ground and gear
lever in neutral.
WARNING
When raising a component for maintenance
purposes, secure it in a safe way before any
maintenance intervention.
WARNING
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.
For this purpose, shut the engine down and step
on the brake pedal 8÷10 times.
CAUTION
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.
CAUTION
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.
WARNING
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 main valve in both working
directions (alternately) to depressurise the
hydraulic circuit.
Part No. 57.0009.0412
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Operator’s Manual
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Maintenance
ACCESS TO THE 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 A
• Engine air filter B
• Radiator fluid compensation cup C
• Battery D
DANGER
Take all precautions when
approaching the engine compartment.
Some parts of the engine may be very
hot. Always use protective gloves.
To get access to the engine compartment:
• Shut the engine down and put the parking
brake.
• Unlock and raise the hatch with handle.
Perkins version
Deutz version


 







66
GTH-5519

Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Maintenance
ENGINE AIR FILTER
CAUTION
The inner element should be replaced every two
times the outer element is replaced.
Never wash the cartridge with water or
solvents.





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 A and remove cover B
- Pull out the filter cartridge C.
- 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 B and lock in place with fasteners
A.
CAUTION

As soon as the warning lamp 11.3 on the cab
dashboard switches on, replace the outer
element.
Never wash the cartridge with water or
solvents.
2
Changing the internal element
- See step 1 for removing the outer element.
- Extract the internal cartridge D.
- 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.
SERVICE INTERVAL
Running-in _____________________________ None
Cleaning _____________________ Every 10 hours
Outer element change __________ Every 500 hours
Inner element change ________ Every 1000 hours
Part No. 57.0009.0412
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Maintenance
ENGINE COOLING SYSTEM

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.
•
Deutz
version


Weekly check the coolant level through the level
window C, before starting working (when fluid is
cold).
When necessary, add clean water or an antifreeze
mixture through cap A.
Change the antifreeze mixture every two years.
To drain the antifreeze:
- Let the engine cool down
- Unscrew the plug B 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 -37°F.
Daily clean the radiator grille using a brush with
hard bristles or compressed air at a max pressure
of 6 bar.
•
•
•

Perkins
version

Both
versions


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 %
SERVICE INTERVAL
Running-in __________________________ None
Ordinary __________________ Every
68
33
40
50
70
Freezing point
1.5°F
-11°F
-33°F
-88°F
Boiling point
253°F
259°F
262°F
275°F
50 hours
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Maintenance
CHANGING THE HYDRAULIC OIL
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.
Visually check the hydraulic oil level through level A
located on the reservoir and visible through the slot
on the right side of the chassis.
When necessary, add new oil through filler B.
SERVICE INTERVAL
To change the hydraulic oil, 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 C.
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 until it is level with A.
Running-in _________ Within the first 10 hours
Ordinary __________________ Every
50 hours
PROTECT THE
ENVIRONMENT
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
SERVICE INTERVAL
Running-in __________________________ None
Ordinary ________________Every



1000 hours



Part No. 57.0009.0412
GTH-5519
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Operator’s Manual
First Edition - Eleventh Printing
Maintenance
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 to get access to the filter
element 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.
CAUTION
The hydraulic oil filter cartridge shall be replaced
as soon as the clogging indicator light on the
control board comes on (see par. Controls and
instruments).
CAUTION


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.
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
70
500 hours
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Maintenance
CAB AIR FILTER (ONLY FOR CLOSED
CABIN)
Every six months clean the air filter in the cab. Replace
the cartridge if the filtering cloth is damged.
Cleaning and changing the cartridge:
- Shut the engine down and engage the parking
brake.
- Pull filter A out of the housing accessible from
the inside of the cab.
- Clean the filter bowl.
- Clean the filter cartridge by beating it against
a piece of wood. Replace the cartridge if
damaged.
CAUTION
Paper filters must never be cleaned using
compressed air or washed with water and/or
solvents.
Part No. 57.0009.0412

1

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Maintenance
OIL LEVEL IN THE (front/rear) WHEEL
REDUCTION GEARS
OIL LEVEL IN THE 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, top-up through hole
comes out from hole .
•
Refit and tighten plugs  and .
 until oil
To change the oil:
• Place a container of suitable size under drain
plug .
•
Loosen the drain plug, the level plug  and the
filler  and allow oil to flow out from the reduction
gear.
•
•
Refit and tighten drain plug .
Add new oil through the filler until it is level with
hole .
•
Refit and tighten plugs  and .
Filling plug
Drain plug
Level plug
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.
To change the oil:
• 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.
SERVICE INTERVAL
SERVICE INTERVAL
Running-in _________ Within the first 10 hours
Ordinary _________________ Every
72
250 hours
Running-in _________ Within the first 10 hours
Ordinary _________________ Every
GTH-5519
250 hours
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Maintenance
OIL LEVEL IN THE POWER DIVIDER
GEARBOX
To check the oil level in the power diver gearbox:
• Stop the machine on a level ground and make
sure the parking brake is engaged.
•
•
Clean level plug  all around.
Remove the plug and check if oil is level with the
hole.
•
When necessary, add new oil through plug
until it is level with the hole.
Refit and tighten the plug.
•
Filling plug
Drain plug

To change the oil:
• Place a container of suitable size under the drain
plug.
•
Remove the plug .
•
Remove the drain plug  and empty the power
divider gearbox.
•
Refit and tighten the drain plug .
•
Pour in new oil through the filler  placed at
the top of the reduction gear of the power divider.
Stop when oil is level with hole .
•
Refit and tighten plug .
SERVICE INTERVAL
Running-in _________ Within the first 10 hours
Ordinary _________________ Every
Part No. 57.0009.0412
250 hours
GTH-5519
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Operator’s Manual
First Edition - Eleventh Printing
Maintenance
GREASING
CAUTION
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:
-
represents the points to be
the symbol
greased by a pump
-
the symbol
represents the points to be
greased by a brush.
CAUTION
Use only PTFE INTERFLON FIN GREASE LS 2
to lubricate the sliding parts of the telescopic
section. Observe the following schedule:
• After the first 50 operating hours (1 week)
• After the first 250 operating hours (1 month)
• Every 1000 operating hours (6 months)
Remove any old grease from the boom and
smear the sliding area of the blocks with a thin
coat of grease.
SERVICE INTERVAL
Running-in __________________________ None
Ordinary __________________ Every
74
10 hours
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Maintenance
TYRES AND WHEELS
Always use tyres having the dimensions indicated
in the vehicle registration card.
SERVICE INTERVAL
Over-inflated tyres can burst.
Running-in _________ Within the first 10 hours
Ordinary _________________ Every
250 hours
Overheated can burst. Do not weld the wheel
rims. For any repair work, call in a qualified
technician.
RI
OKAY
BRAKES
For any intervention on the braking system (adjustment
and/or substitution of the brake discs) address to the
TEREXLIFT Technical Assistance Service or the
nearest TEREXLIFT authorised workshop.
RON
WRONG
For the tyre inflation or substitution, please refer to
the table below:
GTH 5519
Dimensions (front and
rear)
P.R. (or load index)
Rim
Wheel disc
Pressure
bar/Psi
12-16.5
10 pr
9.75x16.5
8 holes DIN
70361
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.
Torque: 295 lbs/ft.
Part No. 57.0009.0412
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Operator’s Manual
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Maintenance
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:
1) Move to a solid and level ground
PROPOSTA G RAFIC A
STRUMENTO ECO
30/10/07
27
2) Set the steering selection switch 27 to “fourwheel steer” (pos. 1)
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 “fourwheel steer" (pos. 1)
7) Rotate the steering (to the side opposite to point
3) so that the rear axle reaches its stop
1
0
2
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 “fourwheel steer" (pos. 1)
Now the wheels should be re-aligned.
SERVICE INTERVAL
Running-in __________________________ None
Ordinary __________________ When necessary
76
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Maintenance
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 TEREXLIFT 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
ldf-ft 22
Screws M14





ldf-ft 37
Tightening torques higher than those recommended can cause the break of the pad or of the
locking threaded bush.
Max. wearing thickness
CAUTION
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.
Minimum 0.04 in
SERVICE INTERVAL
Running-in __________________________ None
Ordinary __________________ When necessary
Part No. 57.0009.0412
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First Edition - Eleventh Printing
Maintenance
BLOCK VALVES fitted to all CYLINDERS
All machine’s cylinders are equipped with block
valves:
Compensation cylinder
Lifting cylinder
Telescopic boom extension cylinder
Attachment swinging cylinder
•
•
•
•
To remove the block valves or the cylinders
- Lower the boom to the ground in a firm way since
the removal of the block valve or the cylinder can
cause an uncontrolled down-movement.
- After refitting the valve or the cylinder, replenish
the circuit and eliminate any air before starting
working. To eliminate the air from the circuit,
move the involved cylinders to end-of-stroke in
the two directions (opening/closing. To eliminate
the air from the fork balance cylinder, move the
boom up and down and tilt the fork plate forwards/
back.
WARNING
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 4 in). 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.
• To check the efficiency of the block valves of the
outriggers, lower them to the ground and unload
the weight of the tyres without raising them.
Loosen the cylinder hoses to check the efficiency
of the valve.
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 TEREXLIFT Technical Service.
78
Do the check of the valves taking all the possible
precautionary measures:
- 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
- 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.
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
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 TEREXLIFT Technical Service.
Repeat the operation putting first one gear, then
the other.
CHECKING THE
STRUCTURE
S TAT E
OF
THE
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 (if present).
WARNING
After the first 5 years, repeat this check every
2 years.
Part No. 57.0009.0412
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Operator’s Manual
First Edition - Eleventh Printing
Maintenance
ELECTRICAL SYSTEM
WARNING
WARNING
All maintenance interventions must be carried
out with engine stopped, parking brake engaged,
working attachments on the ground and gearbox
lever in neutral.
WARNING
When raising a component for maintenance
purposes, secure it in a safe way before carrying
out any maintenance.
WARNING
Any intervention on the electrical system unless
performed by authorized personnel, is expressly
forbidden.
•
•
•
•
•
•
•
BATTERY
•
•
•
•
•
Check the electrolyte level every 250 working
hours; if necessary, add distilled water.
Ensure the fluid is about 0.2 in 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.
WARNING
Risk of explosion or shorts. During the recharge,
an explosive mixture with release of hydrogen
gas forms.
CAUTION
Do not add sulphuric acid; add only distilled
water.
80
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Maintenance
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.
Cabin Fuses
REF.
DESCRIPTION
AMP.
F01
WARNING
10
F02
HIGH BEAM
15
F03
LOW BEAM
15
F04
HORN
15
F05
CONTINUOUS FLOW
10
F06
R-FRONT & L-REAR
POSITION LIGHTS
5
F07
L-FRONT & R-REAR
POSITION LIGHTS
5
F08
POWER SUPPLY OPT
10
F09
STEERING MODE
10
F10
LOCK/UNLOCK
ATTACHMENT
5
F11
HEATING
F12
F 10
F 20
F 09
F 19
F 08
F 18
F 07
F 17
F 06
F 16
F 05
F 15
F 04
F 14
F 03
F 13
25
F 02
F 12
GEAR SELECTOR
10
F 01
F 11
F13
WORK LIGHT
15
F14
WINDSCREEN WASHER
10
F15
FLASHING BEACON
10
F16
STOP LIGHT
10
F17
ROAD LIGHTS
10
F18
EMERGENCY STOP
10
F19
WIPER
10
F20
INSTRUMENT PANEL
10
Part No. 57.0009.0412
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First Edition - Eleventh Printing
Maintenance
Engine compartment fuses and relays
(Deutz Version)
CAUTION
•
FG1
K02
•
FG2
K01
•
REF
DESCRIPTION
AMP
FG1
MAIN FUSE
50
FG2
GLOW PLUGS FUSE
40
K01
GLOW PLUGS PREHEATING
K02
ENGINE STARTER
82
•
•
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.
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Maintenance
REFUELLING
Part
Product
Diesel engine
Deutz
Perkins
Capacity (USgal)
Capacity (USgal)
Engine oil
2.6
2
Water+antifreeze
3.4
3.4
Diesel fuel
15.6
15.6
Hydraulic oil
17
17
Front differential gear with reduction gear
Oil
1 + 0.2
1 + 0.2
Rear differential
Oil
1
1
Front wheel reduction gears
Oil
0.4
0.4
Rear wheel reduction gears
Oil
0.4
0.4
Engine cooling system
Fuel tank
Hydraulic system tank
PRODUCT SPECIFICATIONS
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 SAE 15W-40
(API CH-4 / CG-4 / CF-4 / CF, ACEA E3, MB 228.3)
Lubrication oils and relevant filtering elements
Refill the machine with following lubricants:
Use
Power divider-Differential gearsReduction gears
Hydraulic system and brakes
Product
Definition
TRACTORENAULT
THFI 208 LF SAE 80W
API GL4 / FORD M2C 86B
Massey Ferguson M1135
SHELL TELLUS T46
DENISON HF-1
DIN51524 part 2 & 3
CAUTION
Never mix different oils: this may result in troubles and component breaks.
Oils for hydraulic system:
Arctic climates:
Temperatures below 14°F
Mild climates:
Temperatures from 5°F to 113°F
Tropical climates: Temperatures above 86°F
Part No. 57.0009.0412
GTH-5519
Use SHELL Tellus T22
Use SHELL Tellus T46
Use SHELL Tellus T68
83
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Maintenance
Fuel
Refuel through cover A. Use only Diesel fuel
with less than 0.5% sulphur content, according to
the specifications of the diesel engine operation
handbook.
CAUTION
Grease
For the machine greasing, use:
Lithium-based
Vanguard LIKO
grease, type EP2
When greasing by
pump.
Graphitized AGIP
grease, type GR NG 3
When greasing by
brush.
INTERFLON FIN
GREASE LS 2
On the telescopic
boom
In cold climates (temperature under -4°F) use
only “Arctic” type Diesel fuel, or oil-diesel fuel,
or oil-diesel fuel mixtures. The composition of
the latter can vary in relation to the ambient
temperature up to max. 80% oil.
CAUTION
Avoid mixing greases of different type or features
and do not use greases of lower quality.


Engine coolant
It is advisable to use an antifreeze mixture (50%
water-50% antifreeze). At the delivery, the machine
is refilled with:
TEREX PRO COOL by VALVOLINE
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 %
33
40
50
70
Freezing point
1.5°F
-11°F
-33°F
-88°F
Boiling point
253°F
259°F
262°F
275°F
NOTICE
Use an antifreeze mixture in the proportions
recommended by the manufacturer in relation to
the ambient temperature of the jobsite.
84
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Operator’s Manual
Faults And Troubleshooting
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 that 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.
PROBLEM
THE DASHBOARD
DOES NOT TURN ON
THE STARTER DOES
NOT RUN
THE STARTER RUNS,
BUT THE ENGINE
DOES NOT START
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.
CAUSES
SOLUTIONS
• The 50A fuse F61 supplying power • Replace the fuse
to the dashboard is blown (engine
compartment)
• Battery down
• Check the battery
• Forward/reverse gear selector
• Set the lever on neutral position
• Battery down
• Recharge or replace the battery
•
•
•
•
•
•
•
•
Fuses F8 and F12 blown
No fuel
Diesel fuel filter clogged
Diesel fuel hose empty (fuel used up)
• Solenoid valve - engine stop
THE MACHINE
DOES NOT MOVE
FORWARD/BACK
WARNING
Check the fuses
Refuel
See engine operator manual
Refuel, then refer to engine operator
manual
• Check the solenoid valve; replace, if necessary
• Speed selector switch in neutral
• Set the speed selector switch correctly
• Parking brake engaged
• Fuse F12 blown
• Disengage
• Check the fuse; replace, if necessary
NO SELECTION
OF THE STEERING
MODE
• Fuse F9 controlling the steering • Replace the fuse
selection blown
• Steering mode selector
• Check the selector; replace if necessary
THE MACHINE DRIVE IS
NOT ENOUGH
• Hydraulic oil filter clogged
Part No. 57.0009.0412
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• Replace the filter
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Faults And Troubleshooting
PROBLEM
THE HYDRAULIC OIL
THERMOMETER DOES
NOT WORK
CAUSES
SOLUTIONS
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 104÷122°F
THE PARKING BRAKE
LIGHT DOES NOT LIGHT • Fuse F12 blown
UP
• Replace fuse
BOOM DOES NOT
MOVE
• Check and replace fuse, if necessary
• Fuse F5 blown
NOTICE
In case of faults not listed in this chapter, address to the TEREXLIFT Technical Assistance, your nearest
authorised workshop or dealer.
86
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Operator’s Manual
Faults And Troubleshooting
TORQUE WRENCH SETTINGS
METRIC FASTENER TORQUE CHART
This chart is to be used as a guide only unless noted elsewhere in this manual
Class 4.6
Size
(m m )
5
6
7
LUBED
DRY
LUBED
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
DRY
in- lbs
Nm
in-lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
f t - lbs
Nm
f t -lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
ft - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
NOTICE
Sensor maximum driving torque: 11 lbs/ft.
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Operator’s Manual
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 “Operating Instructions”
section.
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.
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Optional Attachments
SIDE TILT FORK CARRIAGE
Safety
Strictly obey the general safety precautions given
in section “Safety”.
When using the tilt feature keep the load as level as
possible, using extreme caution when driving off of
a slope to reposition the forks, to prevent the load
from sliding off of the forks or pallet.
NOTE: If the carriage tilts or drifts due to oil leakage
within the cylinder assembly, discontinue use until
the problem has been corrected.
When using the shift feature to pick up a load,
be sure to return the forks and load to the center
position as soon as possible. Do NOT travel with
loaded forks shifted to the side.
TECHNICAL DATA
Capacity
6000 lbs
Width (without forks)
15.98 in
Length
51.48 in
Height (with protection)
41.25 in
Weight
Tilt Rotation
638 lbs
10° left and right
Application
Quick-coupling fitted attachment for handling
palletised loads with possibility of rotation tilting by
± 10°.
90
Operating The Telehandler
Avoid steep hillside operation, which could cause
the telehandler to overturn.
Consult the other sections of this machine
operator’s for maximum incline allowable.
When operating on a slope, keep the load low, and
proceed with extreme caution.
Do not drive ACROSS a steep slope - drive straight
up and down.
With LOADED forks - drive with the forks and load
facing uphill.
With EMPTY forks - drive with the forks facing
downhill.
Working With The Attachment
• Never use the attachment for a work platform or
personnel carrier.
• Specified lift capacities must not be exceeded,
otherwise machine stability will not be sufficient.
Always observe lift capacity limits listed in machine
specifications or on load charts furnished with the
telehandler.
• Always check locking pins before operating any
attachment.
• Never lift, move, or swing loaded forks over
anyone.
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Optional Attachments
• Always space the forks correctly for the load.
Loads can fall off incorrectly spaced forks. Make
sure the forks are completely under the load before
lifting.
• Never stack loads on uneven ground. Loads
stacked on uneven ground can topple.
• Never lift a load with one fork. A load lifted with
one fork can slip off and cause injury.
• Secure loads properly. Unsecured loads can fall
unexpectedly.
• Do not handle round bales with fork lift tines.
• Don’t obstruct your vision when traveling or
working. Carry the forks low for
maximum stability and visibility.
Maintenance & Service
DAILY
• Check all bolts and nuts for tightness.
• Replace any missing bolts or nuts with approved
replacement parts.
• Check hydraulic system for hydraulic oil leaks.
• Visually inspect the machine for worn parts or
cracked welds, and repair as necessary.
EVERY 40 HOURS
Lubrication is an important part of maintenance. It is
recommended that all grease fittings be lubricated
after the intitial 8 hours of operation, and then after
every 40 hours of use.
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Optional Attachments
SCRAP GRAPPLE
Safety
TECHNICAL DATA
Heaped Capacity
0.83 yd3
Overall Grappl Width
78.00 in
Overall Grapple Depth
28.00 in
Grapple Height (Closed)
51.00 in
Grapple Hook Opening
42.80 in
Weight
1096 lbs
92
Strictly obey the general safety precautions given
in section “Safety”.
• Never heap load heavy material where the
combined weight of the bucket and the material
could exceed the rated capacity of the loader.
• When using the grapple bucket, be sure that the
load does not stick out too far in front of the bucket
and be sure that the weight of the load is not too
heavy. A light load sticking out too far can have the
same tipping effect of the loader as a heavy load
carried in close.
• Never operate the grapple forks when people are
nearby and could be injured by the hydraulic action
of the grapple.
• Do NOT obstruct your vision when traveling or
working. Carry the bucket LOW for maximum
stability and visibility while traveling.
• Operate at speeds slow enough so that you have
complete control at all times. Travel slowly over
rough or slippery ground and on hillsides.
• Stay in gear when traveling downhill. Do not
shift into neutral. Maintain engine RPM to provide
steering and braking functions. Use the same gear
range for traveling down a grade as you would for
traveling up the grade.
• Avoid steep slopes or unstable surfaces. If
you must drive on a slope, keep the load low
and proceed with extreme caution. Do not drive
ACROSS a steep slope under any circumstances.
Drive straight up and down the slope.
• Avoid turning on an incline, if at all possible. If it is
necessary, use extreme caution and make the turn
wide and SLOW with the bucket carried low.
GTH-5519
Part No. 57.0009.0412
First Edition - Eleventh Printing
Operator’s Manual
Optional Attachments
Installation
1. Install hydraulic hoses and couplers onto
the 90° elbows on the valve (If not already installed).
2. See paragraph “CHANGING THE ATTACHMENT”
in the “Operating Instructions” section for fitting
the bucket.
3. Connect the bucket hydraulic couplers to the
machine auxiliary hydraulics. Route hoses in such
a fashion as to prevent chafing and pinching.
4. Start engine and slowly cycle grapple cylinders
several times to purge system of air and check
for proper hydraulic connection, hose routing and
hose length.
5. Inspect for proper assembly and check for
leaks by operating the telehandler and opening and
closing the grapple forks.
Detaching Bucket From Telehandler
1. On firm level ground, close grapple.
2. Lower boom arms completely down on loader
frame until level bucket is about two inches off the
ground.
3. Turn off engine. Move control lever back and
forth several times to relieve pressure in line,
then disconnect quick couplers between bucket
and machine auxiliary hydraulic oil lines.
NOTE: Connect hydraulic couplers together to
prevent contaminants from entering the bucket
hydraulic system.
4.
See
paragraph
“CHANGING
THE
ATTACHMENT” in the “Operating Instructions”
section for detaching (removing) an attachment.
NOTE: Frequent lubrication of grease fittings
on the end of all pivot pins (with a multi-purpose
grease) will greatly increase life of product.
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Specifications
H
B
A
D
F
E
G
C
I
MEASUREMENTS
A
Height .........................................................................................
B
Height at steering whell ..............................................................
C
Width ..........................................................................................
D
Inside cab width ..........................................................................
E
Track ...........................................................................................
F
Wheelbase ..................................................................................
G
Length at fork-holder plate ..........................................................
H
Ground clearance .......................................................................
I
Overall Length ............................................................................
Lifting height (max) ..................................................................................
Lifting capacity(max) ................................................................................
Lift capacity at maximum height ..............................................................
Lift capacity at maximum reach ...............................................................
Forward reach (max) ...............................................................................
Reach at maximum height .......................................................................
Fork-holder plate rotation ........................................................................
Weight*** .................................................................................................
6ft 4in
4ft 1in
5ft 11in
2ft 6in
4ft 11in
7ft 7in
12ft 7in
1ft 1in
16ft 7in
19ft
5500lbs
4400lbs
1900lbs
11ft
2ft
130°
9810lbs
PRODUCTIVITY
Lifting/lowering speed** ...........................................................................
Extension/retraction speed** ...................................................................
Inside/outside turning radius ....................................................................
Break-out force (with 500lt shovel SAE J732/80) ...................................
Towing capacity at dynamometer*/** .......................................................
Travel speed (max) ..................................................................................
Chassis levelling on both axles ...............................................................
Floating forks ...........................................................................................
Tyres(DIN 70631) ....................................................................................
7s/4s
7s/4s
5ft 9in/9ft 10in
8157 lbs
9325lbs/6835lbs
15 mph
2.3°
L 3ft 11in section3,9in x 1,6in
12-16.5, 8 holes wheel disk
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Specifications
POWER
Engine ...........................................................
Model ............................................................
Displacement ................................................
Cylinder arrangement ....................................
Combustion System ......................................
Max Power Output ........................................
Max Torque Output ........................................
Rated Power .................................................
Aspiration .......................................................
Cylinder’s number .........................................
Alternator rating ...........................................
Battery CCA rating .......................................
Hydraulic
Hydraulic output/pressure ..............................
Deutz
D2011 L04
220 in3
Vertical in line
In-direct injection
68 hp (@2600 rpm)
155 lb-ft (@1700 rpm)
136 ft-lb/68hp (@2600rpm)
Naturally aspirated
4
95 A
720 A
Perkins
804D.33
210 in
Vertical in line
In-direct injection
63 hp (@2500 rpm)
147 lb-ft (@1600 rpm)
132 ft-lb/63hp (@2500rpm)
Naturally aspirated
4
95 A
720 A
18.5 USgal/min / 4061 psi
17.8 USgal/min / 4061 psi
FLOOR LOADING SPECIFICATIONS
Occupied Floor Area ....................................................................................
Occupied Floor Pressure .............................................................................
Max. Tire Load .............................................................................................
Max Axle Load .............................................................................................
Tire Contact Pressure ..................................................................................
45,21 ft2
20,2 psi
8918 lbs
17835 lbs
44,96 psi
*Max Load; ** No Load; ***With Fork
96
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Operator’s Manual
Specifications
Part No. 57.0009.0412
GTH-5519
4460 kg
MASS = 9830 lb
CENTER OF GRAVITY GTH-5519
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Load Charts
GTH 5519 UNIVERSAL ATTACHMENT ADAPTER
GTH 5519
09.4618.0804
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Load Charts
GTH 5519 FLOATING FORKS
GTH 5519
09.4618.0812
100
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Operator’s Manual
Load Charts
GTH 5519 SCRAP GRAPPLE BUCKET
GTH 5519
09.4618.0802
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Load Charts
GTH 5519 TRUSS BOOM
GTH 5519
09.4618.0806
102
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Operator’s Manual
Load Charts
GTH 5519 60 INCH FORKS - OPTIONAL 48 INCH FORKS - 48 INCH CUBING TINES
GTH 5519
60 INCH FORKS
OPT. 48 INCH ITA FORKS
48 INCH CUBING TINES
09.4618.0803
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Load Charts
GTH 5519 60 INCH OR 66 INCH BUCKET
GTH 5519
60 INCH BUCKET
66 INCH BUCKET
09.4618.0801
104
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Operator’s Manual
Load Charts
GTH 5519 ROTATING OR SIDE SHIFT FORK CARRIAGE - STANDARD FORK TINES
GTH 5519
ROTATING OR SIDE SHIFT FORK CARRIAGE
STANDARD FORK TINES
09.4618.0805
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Load Charts
GTH 5519 SIDE SHIFT FORK CARRIAGE - 60” FORK TINES
GTH 5519
2800 lbs / 1270 kg
2300 lbs / 1043 kg
1800 lbs / 816 kg
1400 lbs / 635 kg
45
00
lbs
/2
04
1k
g
SIDE SHIFT FORK CARRIAGE
60” FORK TINES
09.4618.1680
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Operator’s Manual
Diagrams And Schemes
GTH 5519 WIRING DIAGRAM 1/5 (Rev.G, P/N: 57.1800.5109)
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Diagrams And Schemes
GTH 5519 WIRING DIAGRAM 2/5 (Rev.G, P/N: 57.1800.5109)
108
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Operator’s Manual
Diagrams And Schemes
GTH 5519 WIRING DIAGRAM 3/5 (Rev.G, P/N: 57.1800.5109)
Part No. 57.0009.0412
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Diagrams And Schemes
GTH 5519 WIRING DIAGRAM 4/5 (Rev.G, P/N: 57.1800.5109)
110
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Diagrams And Schemes
GTH 5519 WIRING DIAGRAM 5/5 (Rev.G, P/N: 57.1800.5109)
Part No. 57.0009.0412
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111
112
GTH-5519
A
T
L
LS
Ev4
M
R T1 T2
Ev1
X1
Cracking pressure
450 bar
(6525 psi)
Cracking pressure
450 bar
(6525 psi)
Ev2
Boom lift cylinder
MH
Cracking press.
430 bar (6235 psi)
TP3
Hydrostatic transmission
boost pressure test port
G
Cracking press.
25 bar
(362 psi)
PS Fa Fa1
MB
TP2
S FS
Fe
Hydrostatic transmission
high pressure test port
MA
A
B
CF
EF
2
LS
U
T
P
T
X1
A1
X2
B1
X3
B2
A2
X4
B3
A3
A4
B4
1
X
270 bar
(3915 psi)
A
X2
G
T
X1
Hydrostatic transmission motor
max displacement: 107 cc / rev
B
4
Y
C
F
M2
M1
P1
Boom functions
main valve
(4 sections)
T1 T T2
1 mm (0,04 in.)
Ev6
Parking brake
minimum pressure
pressure switch
activating pressure:
20 bar (290 psi)
P P2 P3
Check valve
cracking pressure
8 bar (116 psi)
Y1
Y2
Y3
Y4
0,5 mm (0,02 in.)
Ev5
Parking brake
selector valve
F1
Flushing valve
290 bar (4205 psi)
290 bar (4205 psi)
P
Boom functions pump
with integrated priority valve
displacement: 27 cc/rev
max flow rate 18.5 GPM
Boom functions hydraulic
circuit test port
3
Boom functions
control lever
Shutoff valve
Suction screen
TP1
Boom telescoping cylinder
Single overcenter/safety valve
piloting ratio: 4.2/1
cracking pressure: 350 bar
(5075 psi)
Hydraulically piloted
double check valve
piloting ratio: 4/1
Quick coupling
hydraulic ports
Forks attachment
quick coupling cylinder
Double overcenter/safety valve
piloting ratio: 4.2/1
cracking pressure: 350 bar
(5075 psi)
Single overcenter/safety valve
piloting ratio: 4.2:1
cracking pressure: 350 bar
(5075 psi)
Double overcenter/safety valve
piloting ratio: 4.2/1
cracking pressure: 350 bar
(5075 psi)
Anticavitation valves
cracking pressure
5 bar (72 psi)
Forks tilt cylinder
Service brake
pedal pump
max operating
pressure: 80 bar
(1160 psi)
Service brake
circuit reservoir
Forks levelling
slave cylinder
Check valve
cracking pressure
2.5 bar (36 psi)
Max relief valve
cracking
pressure:
170 bar
(2465 psi)
Anti-shock
valves
cracking
pressure:
225 bar
(3262 psi)
P
R
Front axle
Diesel engine
P
R
T
B
P1
P2
T
Hydrostatic transmission
X2
pump max displacement: 56 cc / rev
Steering rotating actuator
displacement: 125 cc / rev.
Front axle
steering cylinder
Steering mode
selector valve
4 ways / 3 positions
Ev3
Rear axle
steering cylinder
Service brake
circuit test port
TP4
Service brake
pressure switch
activating pressure:
2,8-6,3 bar
(40-90 psi)
Ev7
2
C1
B2
Return filter
with suction line
pressurized at 0,5 bar
(8 psi)
Heat exchanger
C2 B1
Ev8
Forks tilt function
enabling valve
Quick connect/disconnect
attachment enabling valve
Oil tank capacity
75 liters (20 gallons)
Tank lines
Suction lines
Load sensing and piloting lines
Low pressure and transmission
charge pressure lines
Functions driving lines
Hydrostatic transmission
high pressure lines
Open circuits high pressure lines
HYDRAULIC CIRCUIT
COLORS LEGENDA
Ax1 Ax2 1
Auxiliary continous flow
selector valve
Auxiliary continous flow
metering valve
Operator’s Manual
First Edition - Eleventh Printing
Diagrams And Schemes
GTH 5519 HYDRAULIC DIAGRAM (Rev.C, P/N: 57.2201.3000)
Part No. 57.0009.0412
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