from SN 10242 to 18818, GTH-5519 (PN 57.0005

from SN 10242 to 18818, GTH-5519 (PN 57.0005
OPERATOR HANDBOOK
Code 57.0005.9200 - Rev.0 12/2005
Handler with telescopic boom
GTH-5519
From serial n. 10242
To serial n.
18818
English
Edition
CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE
CAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES
TECHNICAL SERVICES
Genie Scandinavia
Phone +46 31 575100
Fax +46 31 579020
Genie Mexico City
Phone +52 55 5666 5242
Fax +52 55 5666 3241
Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544
Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie North America
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
Genie Japan
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Genie Germany
Phone +49 (0)4202 88520
Fax +49 (0)4202 8852-20
Genie Australia Pty Ltd.
Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910
Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754
Genie Holland
Phone +31 183 581 102
Fax +31 183 581 566
Operator Handbook 57.0005.9200 - GTH-5519
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by
any means without prior written permission from TEREXLIFT srl.
In pursuing a policy of constant quality improvement, TEREXLIFT srl reserves the right to make changes at any time and
without undertaking to give prior notice; therefore, also this publication may be subject to modifications.
Some photos or drawings have been used to illustrate a specific function; as a result, they may not refer to the machine
treated in this manual.
© Copyright 2006 TEREXLIFT srl - All rights reserved.
Produced by:
LIST OF THE REVISED PAGES
Revision
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Revised
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Notes
B-7, C-20, D-1, D-3, D-7, D-27
Revised pages
D-12
oil level
Added pages: engine
Issued
by
LIST OF THE REVISED PAGES
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Handler with telescopic boom GTH-5519
INTRODUCTION
■ INTRODUCTION
This handbook provides information for a safe and
proper operation and maintenance of the machine.
Sections are subdivided into chapters and paragraphs
that are numbered progressively.
The quickest way to look for an information is the
reference to the general index or the titles of the single
chapters and paragraphs that represent keys for an
easy consultation.
STRICTLY COMPLY WITH THE INSTRUCTIONS
GIVEN IN THIS HANDBOOK!
READ AND UNDERSTAND THIS HANDBOOK
BEFORE STARTING, USING AND CARRYING
OUT ANY OPERATION WITH AND ON THE
MACHINE.
Take care of this handbook and keep it in an
accessible place within the machine, even
after its reading, so that it will always be
within reach if in doubt.
The handbook is divided into seven sections:
Sect.
Sect.
Sect.
Sect.
Sect.
Sect.
Sect.
A
B
C
D
E
F
G
GENERAL INFORMATION
SAFETY
OPERATING INSTRUCTIONS
MAINTENANCE
TROUBLESHOOTING
OPTIONAL ATTACHMENTS
TABLES AND ENCLOSURES
If you are unsure about anything, please address to
GENIE Assistance Service or to your agent/dealer:
addresses, phone and fax numbers are printed in
the cover and in the title-page of this manual.
Section A contains general concepts that are decisive
for the knowledge of the main parts of the machine.
It also contains all necessary data for a correct
identification of the machine, the technical features of
the machine, etc.
Section B is especially addressed to the personnel,
who shall operate, repair and service the machine, and,
in case of companies with a wide fleet of machines, to
the safety responsible.
It describes the essential compulsory qualities of the
personnel in charge and other important information
for the safety of persons and things.
IMPORTANT
Any difference between the contents of this manual
and the real functional character of the machine
can be attributed to either a machine manufactured
before the issue of this manual or to a manual going
to be updated after some changed effected on the
machine.
Always contact GENIE Assistance Service for any
updated version of this manual and any additional
information.
Section C is mainly addressed to the operators who
operate the machine. This section illustrates all control
devices.
Additionally, it contains the main use instructions -i.e.
engine starting, machine parking, machine storing.
Section D is addressed to the maintenance responsible
and the servicemen.
The section describes the maintenance schedule and
the relevant intervals.
Section E deals with the failure diagnostics.
Section F makes a list of the main interchangeable
attachments that can be coupled to the machine:
dimensions, weight, application field and limits of use.
Section G contains tables and various enclosed
documents like load charts, wiring diagrams, hydraulic
schemes, torque wrench setting table, etc.
Page
1
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INTRODUCTION
■ SYMBOLS
When using the machine, operators could have to face
some situations requiring special care and particular
knowledge.
When these situations involve the safety of operators
or bystanders, the machine efficiency and proper
utilisation, this handbook stresses these specific
instructions by means of SPECIAL SYMBOLS.
There are six special (or safety) symbols in this manual,
always combined with keywords that class the situations
according to their danger degree.
The symbols are always followed by a text explaining
the situation taken into account, the attention to be
paid to such situation, the method and the behaviour to
be adopted. When necessary, it stresses prohibitions
or supplies instructions to prevent dangers.
ATTENTION
Draws the attention to situations that involve the
machine efficiency.
IMPORTANT
Draws the attention to important technical
information or practical advice that allows for a
safer and more efficient use of the machine.
PROTECT THE
ENVIRONMENT
Sometimes, it can be followed by illustrations.
We list below the special (or safety) symbols according
to the relative seriousness of the hazard situation:
Draws the attention to important environmentrelated information.
DANGER
WHEN READING THIS MANUAL, PAY THE
GREATEST ATTENTION TO THESE SPECIAL
SYMBOLS AND THE EXPLANATION OF THE
SITUATIONS THEY EMPHASIZE.
Draws the attention to situations that involve your
own as well as the others’ safety and that can result
in serious or lethal injury.
The manual in electronic format also contains the
following symbol:
ELECTRICAL
DANGER
which enables the user to return to the
table of contents
Draws the attention to situations that involve your
own as well as the others’ safety and that can result
in serious injury or lethal injury.
CAUTION
Draws the attention either to situations that involve
your own as well as the others’ safety and that can
result in minor or moderate injury or to situations
that involve the machine efficiency.
Page
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GENERAL INDEX
GENERAL INDEX
GENERAL INFORMATION
Sect.
A
SAFETY
Sect.
B
OPERATING INSTRUCTIONS
Sect.
C
MAINTENANCE
Sect.
D
TROUBLESHOOTING
Sect.
E
OPTIONAL ATTACHMENTS
Sect.
F
TABLES AND DOCUMENTS ENCLOSED
Sect.
G
Page
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Intentionally blank page
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GENERAL INFORMATION
Section
A
GENERAL INFORMATION
TABLE OF CONTENTS
A-1
A-1.1
A-1.2
A-1.2.1
A-1.3
A-2
A-2.1
A-2.2
A-2.3
A-2.4
A-2.5
A-3
A-3.1
A-3.2
A-3.3
A-3.4
A-3.5
A-4
A-4.1
A-4.2
A-4.3
A-4.4
A-5
A-5.1
A-5.2
A-5.3
A-5.4
A-5.5
A-5.6
A-5.7
A-5.8
A-6
A-7
A-7.1
CONVENTIONAL REFERENCES ................................................................................
Machine position ........................................................................................................
Labels and warning plates applied on the machine ...................................................
Position .......................................................................................................................
Explanation of the different symbols used on the machine .......................................
MACHINE IDENTIFICATION .......................................................................................
Machine model and type ............................................................................................
Manufacturer ..............................................................................................................
Machine identification plates ......................................................................................
Chassis serial number ................................................................................................
Identification plates of the main parts ........................................................................
ALLOWED USE ..........................................................................................................
Allowed use ................................................................................................................
Improper use ..............................................................................................................
Residual hazards ........................................................................................................
Applicable standards ..................................................................................................
Safety devices ............................................................................................................
GENERAL DESCRIPTION ..........................................................................................
List of the main components ......................................................................................
Description of the main components .........................................................................
Optional accessories ..................................................................................................
Kits supplied on request .............................................................................................
TECHNICAL DATA AND PERFORMANCE .................................................................
Main dimensions ........................................................................................................
Restrictions of use ......................................................................................................
Weight ........................................................................................................................
Speed .........................................................................................................................
Payload and reach ......................................................................................................
Forks ...........................................................................................................................
Diesel engine ..............................................................................................................
Electrical system ........................................................................................................
LIFETIME ....................................................................................................................
ITEMS SUPPLIED .......................................................................................................
Literature supplied ......................................................................................................
Page
A-1
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A-2
A-2
A-3
A-3
A-6
A-8
A-8
A-8
A-8
A-9
A-9
A-10
A-10
A-10
A-10
A-11
A-12
A-13
A-13
A-14
A-14
A-14
A-15
A-15
A-15
A-15
A-15
A-16
A-16
A-16
A-16
A-17
A-17
A-17
Handler with telescopic boom GTH-5519
GENERAL INFORMATION
A-1 CONVENTIONAL REFERENCES
■ A-1.1
MACHINE POSITION
Conventionally the machine should be considered
positioned as shown in the figure.
This convention is necessary to make any reference of
this handbook to different machine parts (front, rear,
etc.) clear and unmistakable.
Any exception to this rule will always be specified.
UPPER PART
REAR PART
RIGHT SIDE
FRONT PART
LEFT SIDE
LOWER PART
Page
A-2
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GENERAL INFORMATION
■ A-1.2
LABELS AND WARNING PLATES
APPLIED ON THE MACHINE
This paragraph lists the labels and warning plates
normally applied on standard machines or on special
attachments coupled to the machine.
IMPORTANT
The familiarisation with these labels is never a
waste of time.
Make sure they are easy to read. For this purpose,
clean them or replace those that become
unreadable (either graphic or text).
To clean labels, use of a soft cloth, water and soap.
Never use solvents, petrol, etc.
When a label is applied on a part to be replaced,
make sure that the replaced part is already labelled
as required or apply a new label.
■ A-1.2.1 Position
s.r.l.
Zona industriale - 06019 - Umbertide ( PG ) - Italy
MODEL NUMBER
SERIAL NUMBER
YEAR OF MANUFACTURE
UNLADEN TRUCK MAXIMUM WEIGHT
lb
TRUCK CAPACITY
lb
THIS TRUCK IS COMPLIANT TO PART III OF ASME B56.6-2002 WHERE APPLICABLE
MADE IN ITALY
09.4616.0101
09.4618.0109
09.4618.0109
09.4618.0109
09.4618.0109
09.4618.0109
09.4618.0109
09.4618.0109
Page
A-3
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GENERAL INFORMATION
HYDRAULIC
OIL
09.4616.0051
01234567
Death or Serious Injury can result
from handling of personnel with
this machine.
97673
Never equip machine with any
form of personnel platform or
allow personnel to ride on
attachment.
F
09.4618.0645
97673 A
R
09.4618.0389
09.4618.0643
DANGER
WARNING
Explosion / Burn Hazard
WARNING
Will cause death, burns or blindness
due to ignition of explosive gases or
corrosive acid.
Burn Hazard
Burns may result from
contact with hot surfaces.
Do not touch.
Allow surfaces to cool
before servicing.
Crush Hazard
Explosion / Burn
Hazard
Keep all open flames and sparks away.
Wear personal protective equipment,
including face shield, gloves and long
sleeve shirt.
Moving parts can crush or
cut causing severe injury.
Release of hot pressurized
fluids can cause Burns or
Blindness.
Consult operation and maintenance
manual for jump starting instructions.
Keep all body parts clear of
moving parts during
equipment operation
Allow system to cool and
always open carefully.
97671 A
97664 A
97675 A
97667 A
97667
97671
97675
97664
WARNING
97667
Burn Hazard
09.4618.0205
97667 A
60°
80°
Burns may result from
contact with hot surfaces.
Do not touch.
Allow surfaces to cool
before servicing.
40
0° 20°
°
09.4618.0644
09.4618.0643
WARNING
Crush Hazard
Moving parts can crush or
cut causing severe injury.
Keep all body parts clear of
moving parts during
equipment operation
97664
97664 A
WARNING
09.4618.0010
09.4618.0010
09.4618.0641
VIETATO APRIRE CON MOTORE IN MOTO
DO NOT OPEN WHILE ENGINE IS RUNNING
N'OUVRIR QU'A L'ARRET DU MOTEUR
ÖFFNEN NUR BEI STILLSTEHENDEM MOTOR
ABRIR SOLO CON MOTOR PARADO
PROIBIDO ABRIR COM O MOTOR LIGADO
VERBODEN KOFFERBAK TE OPENEN
WANNEER DE MOTOR DRAAIT
Skin Injection Hazard
Escaping fluid under pressure
can penetrate skin and could
cause death or serious injury.
Keep away from leaks and pin
holes.
Use a piece of cardboard to
search for leaks. Do not use
hands.
82558 A
09.4618.0061
09.4618.0061
82558
WARNING
Crush Hazard
Moving parts can cause Death or
Serious Injury.
P=4,5bar
Keep clear of elevated
components.
P=4,5bar
97668
Support components before
performing service.
Crush Hazard
Moving parts can crush or
cut causing severe injury.
97665
09.4618.0109
Keep all body parts clear of
moving parts during
equipment operation
97664 A
97674 A
97674
97664
(top of chassis) (boom rest)
WARNING
WARNING
Electrical Hazard
Overturning Hazard
Death or serious injury can result
from contacting electric power lines.
Death or Serious Injury can result
from overturning forklift.
Always contact the electric power line
owner. The electric power shall be
disconnected or the power lines
moved or insulated before machine
operations begin.
97676
Power Line Voltage
0 to 50 kV
50 to 200 kV
200 to 350 kV
350 to 500 kV
500 to 750 kV
750 to 1000 kV
• Never exceed published capacity or
extend load beyond load chart band.
• Never lower maximum load before
retracting boom.
• Do not travel on terrain or in areas that
could cause machine to overturn.
Required Clearance
10 ft / 3.03 m
15 ft / 4.60 m
20 ft / 6.10 m
25 ft / 7.62 m
35 ft / 10.67 m
45 ft / 13.72 m
• Always level machine using sway
control before raising boom above
horizontal.
• Carry loads so maximum machine
stability is maintained.
97676 A
97668 A
Always Use
Seat Belt
Death or Serious Injury can
result from failure to wear
seat belt.
This machine is equipped
with a Roll Over Protection
System (ROPS).
Always adjust seat and
fasten seat belt before
starting engine.
97665 A
WARNING
WARNING
97670
Falling Object Hazard
Death or Serious Injury can
result from falling objects.
Crush Hazard
Crush Hazard
An unattended machine can
move or roll.
Set park brake, lower carriage
or attachment to ground before
leaving machine.
Failure to heed could result in
Death or Serious Injury.
Death or Serious Injury can result
from people riding on this
machine other than at the
operator's station.
No passengers are permitted to
ride on this machine or any
attachment.
Read and understand
operator's manual and safety
signs before using or
maintaining machine.
If you do not understand the
information in the manuals,
consult your supervisor, the
owner or the manufacturer.
• Do not operate machine
while people are under or
near elevated boom whether
boom is loaded or unloaded.
• Always remain completely
within the canopy enclosure
while operating machine.
97669 A
97666 A
Only operate this machine from
the operator's station.
97670 A
97672 A
09.4618.0644
97672
97666
97669
97664
WARNING
Emergency
Exit Handle
Crush Hazard
Moving parts can crush or
cut causing severe injury.
Crush Hazard
Moving parts can crush or
cut causing severe injury.
97688 A
Keep all body parts clear of
moving parts during
equipment operation
Keep all body parts clear of
moving parts during
equipment operation
97664 A
97664 A
09.4618.0061
P=4,5bar
Page
97664
97688
WARNING
A-4
Document 57.0005.9200 - 12/2005
09.4618.0061
P=4,5bar
Handler with telescopic boom GTH-5519
GENERAL INFORMATION
Code Description
82558 Fluid at pressure
97664 Risk of crushing hands
97665 Safety belts
97666 Read the user’s manual
97667 Risk of burns and scalds
97668 Risk of overturning
97669 Risk due to falling objects
97670 Risk of crushing
97671 Risk of explosion / burns
97672 Risk of crushing
97673 Prohibition to lift people
97674 Risk of crushing
97675 Risk of explosion / burns
97676 Electrical hazard
97688 Emergency exit handle
09.4616.0051 Hydraulic oil
09.4616.0101 Machine data plate
09.4618.0010 Prohibition to open with the engine running
09.4618.0061 Tyre inflation pressure
09.4618.0109 Sticker with various warnings
09.4618.0205 Boom tilting degree
09.4618.0389 Control lever controls
09.4618.0641 Sticker: "Genie"
09.4618.0643 Sticker: "Genie GTH-5519"
09.4618.0644 Sticker: "GTH-5519"
09.4618.0645 Load chart
Page
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GENERAL INFORMATION
■ A-1.3
EXPLANATION OF THE DIFFERENT
SYMBOLS USED ON THE MACHINE
This paragraph illustrates those symbols that are
normally applied on the main control devices and
instruments of a standard machine, and those that can
be applied on accessories or special attachments.
They are mainly (ISO) standardised symbols that are
now part of the common life. But we consider useful to
explain them once again.
Symbol
Description
IMPORTANT
Spend the necessary time to become familiar with
these symbols and to learn their meaning.
Symbol
Description
Steering mode switch
Hazard warning lights
Engine oil pressure
Windscreen wiper
Boom up
Windscreen washer
Boom down
Cab ventilation fan
Boom out
Fuel gauge
Boom in
Hydraulic oil temperature
Attachment locked
Position lights
Attachment unlocked
High beam
Turn signals
Fork pitching forward
Parking brake
Fork pitching back
Battery charge
Oil filter clogged
Air filter clogged
Glow plug preheating
Page
A-6
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GENERAL INFORMATION
Symbol
Symbol
Description
Front (optional) work light
Road/jobsite selector switch
Lifting point
Fuel plug
Engine oil filler
Page
A-7
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Description
Handler with telescopic boom GTH-5519
GENERAL INFORMATION
A-2 MACHINE IDENTIFICATION
IMPORTANT
Check that the operator handbook refers to the
delivered machine.
When asking for information or technical
assistance, always specify model, type and serial
number of the machine.
■ A-2.1 MACHINE MODEL AND TYPE
Handler with telescopic boom:
❑
model GTH-5519
■ A-2.2 MANUFACTURER
TEREXLIFT srl
Zona Industriale (Ind. Estate) - I-06019 UMBERTIDE
(PG) - ITALY
Enrolled in the register of companies at the Court of
Perugia under no. 4823
C.C.I.A.A. n° 102886
Fiscal Code/V.A.T. no. 00249210543
Zona Industriale - 06019 - Umbertide (PG) - Italy
MODEL NUMBER
SERIAL NUMBER
YEAR OF MANUFACTURE
UNLADEN TRUCK MAXIMUN WEIGHT
Lb
TRUCK CAPACITY
Lb
THIS TRUCK IS COMPLIANT TO PART III OF ASME B56.6 - 2002 WHERE APPLICABLE
MADE IN ITALY
■ A-2.3 MACHINE IDENTIFICATION PLATES
Machine data plate.
At the front, on the right side of the chassis.
The identification plate contains the main
identification data of the machine like model, serial
number and year of manufacture.
Page
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GENERAL INFORMATION
■ A-2.4 CHASSIS SERIAL NUMBER
The chassis serial number is punched on the front
left part of the chassis side member.
■ A-2.5
IDENTIFICATION PLATES OF THE MAIN
PARTS
The plates of the main components, not directly
manufactured by TEREXLIFT srl (for instance, engines,
pumps, etc.), are located where originally applied by
the manufacturers.
Page
A-9
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GENERAL INFORMATION
A-3 ALLOWED USE
■ A-3.1 ALLOWED USE
The handlers have been designed and manufactured
for lifting, handling and transporting agricultural or
industrial products by means of specific attachments
(see section F) manufactured by TEREXLIFT srl.
Any other use is considered contrary to that established
and, therefore, improper.
The compliance with and the strict respect of the
operation, maintenance and repair conditions, indicated
by the Manufacturer, represent an essential part of the
allowed use.
The handler must be used and serviced only by
operators knowing its characteristics and the safety
procedures in depth.
It is also essential to comply with the safety at work
legislation, the precautions concerning safety and
industrial medicine as well as the local and national
road traffic regulations.
ATTENTION
Effecting changes or carrying out interventions on
the machine other than those of routine
maintenance is expressly forbidden. Any
modification of the machine not carried out by
GENIE or an authorised assistance centre involves
the automatic invalidation of the conformity of the
machine to the Directive 98/37/EC.
■ A-3.2 IMPROPER USE
Improper use means a utilisation of the handler
following working criteria that do not comply with the
instructions of this manual, and that, in general, may
result in risks for both operators and bystanders.
DANGER
We list below some of the most frequent and
hazardous situations of improper use:
Carrying passengers on the machine
Not strictly complying with the operation and
maintenance instructions of this handbook
Working beyond the handler working limits
Working on unstable edges of ditches
Driving crosswise on slopes or hills
Working during a storm
Working on steep slopes
Using attachments other than those
recommended
Using attachments not approved or directly
manufactured by Terexlift
Working in potentially explosive areas
Working in confined and non-ventilated
environments.
■ A-3.3 RESIDUAL HAZARDS
Although the machine has been designed and
manufactured according to the latest technology and
all expected hazards have been eliminated, some
operations performed by the machine operator can
result in potentially hazardous situations. Among them:
• Hazards deriving from a too high work or transfer
speed in relation to the load handled or the ground
condition of the jobsite.
• Hazards deriving from work procedures adopted
during the check or replacement of a block valve
(residual pressure - uncontrolled movements).
• Hazards deriving from work procedures adopted
while disassembling parts of the machine -e.g. the
cylinders, without supporting mobile parts suitably
(risk of uncontrolled fall of the mobile part).
• Hazard deriving from an accidental overturning of
the machine in the event the operator has not
fastened the safety belts.
Page
A-10
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GENERAL INFORMATION
■ A-3.4
APPLICABLE STANDARDS
EN 50081-1: 1997 Electromagnetic compatibility – Generic
requirements on emissions - Part 1
For the operator’s safety, the following standards were
obeyed during the risk assessment of the handler fitted
with telescopic boom:
EN 50082-1: 1997 Electromagnetic compatibility – Generic
requirements on immunity - Part 1
Directive
Title
EN 60204-1:1998 Safety of machinery - Electrical
equipment of machines - Part 1
98/37/CE
89/336/CEE
2000/14/CE
Machinery Directive
Electromagnetic compatibility
Environment Acoustic Emissions
Standard
Title
EN 1459:1988
Harmonised standard. Safety of industrial
trucks - Self- propelled variable reach
trucks.
EN 281:1988
Self-propelled industrial trucks sit- down
rider-controlled. Rules for the
construction and layout of pedals.
EN 1175-2:1998
Electrical requirements - General
requirements of internal combustion
engine powered trucks
ANSI/ASME B56.6-2002 part III where applicable.
prEN ISO 13564:1996 Test method for measuring visibility from
self-propelled trucks.
ISO 2330:1995
Fork-lift trucks - Fork arms - Technical
characteristics and testing.
ISO/DIS 3287
Powered industrial trucks. Pictorial signs.
Control symbols.
ISO 3449:1992
Earth-moving machinery - Falling-object
protective structures - Laboratory tests
and performance requirements.
EN 13510: 2002
Earth-moving machinery - Roll-over
protective structures - Laboratory tests
and performance requirements.
ISO 3776:1989
Tractors for agriculture - Seat belt
anchorages.
ISO 3795:1989
Road vehicles, tractors and machinery
for agriculture and forestry Determination of burning behaviour of
interior materials.
ISO 5053:1987
Powered industrial trucks - Terminology.
ISO 6292:1996
Powered industrial trucks and
tractors - Brake performance and
component strength.
EN 13059:2002
Safety of industrial trucks - Test methods
for measuring vibration
Page
A-11
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GENERAL INFORMATION
■ A-3.5
SAFETY DEVICES
• The machine is equipped with a negative brake on
the front axle which engages automatically when
the engine stops.
When this brake is disengaged, the engine startup is inhibited.
• Block valves fitted to all cylinders:
A Block valve on attachment coupling cylinder
B Block valve on lifting cylinder
C Block valve on balance cylinder
D Block valve on boom extension cylinder
E Block valve on attachment pitching cylinder
Page
A-12
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GENERAL INFORMATION
A-4 GENERAL DESCRIPTION
■ A-4.1
LIST OF THE MAIN COMPONENTS
�
�
-
�
�
�
�
�
1
2
3
4
5
6
7
8
9
10
11
12
�
�
쐅
쐈
Forks
Attachment holding frame
2nd boom section
1st boom section
Engine hood
Driving cab
Left rear view mirror
Front axle
Chassis
Left front wheel mud-guard
Left front wheel reduction gear
Left rear wheel reduction gear
Page
A-13
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쐉
Handler with telescopic boom GTH-5519
GENERAL INFORMATION
■ A-4.2
DESCRIPTION OF THE MAIN COMPONENTS
Hydrostatic transmission
This unit consists of parts which drive the machine
shifting, and namely:
- a variable displacement pump connected to the
thermal engine by an elastic joint
- a motor with variable displacement and automatic
adjustment in relation to the wheel torque required,
complete with power divider, directly applied on
the rear axle
- a hydraulic oil filter, placed on the discharge line to
the tank
- a heat exchanger to cool the circuit down.
Motion is transmitted to the rear axle from the power
divider through a Cardan shaft.
Engine
The thermal engine is equipped with a heat exchanger
which uses the engine oil as cooling medium.
Steering axles/(front and rear) differential gears
The differential axles transmit the motion to the wheels.
The locking device acting on the front axle enables
the machine to move also on low grip grounds.
Tyres
The machine is equipped with tyres suitably sized for
the maximum load allowed on the handler.
When worn, they shall be replaced with new ones
having the same dimensions and loading capacity.
Boom hydraulic circuit
It consists of a gear pump connected to the thermal
engine which, through a special valve, dispenses oil
to the hydraulic drive and a distributor for the following
functions:
- boom lifting/lowering
- telescopic boom extension/retraction
- attachment rotation
- attachment locking
Telescopic boom
The machine is equipped with a telescopic boom with
hydraulic-driven extension. The telescopes slides on
interchangeable pads made of wearproof material.
Driving cab
Type-approved driving cab in compliance with
standards ANSI/ASME B56.6-2002.
■ A-4.3
OPTIONAL ACCESSORIES
The machine can be fitted with a wide range of optional
accessories: please address to Genie sales network.
IMPORTANT
Please check the accessories available for your
machine.
■ A-4.4
The machine is prepared for the installation of the
following assembly kits:
- Driving cab glasses (including door)
- Heater
- Air conditioning
- Work lights (including courtesy lamp in the cab)
- Beacon
Braking circuit
It consists of an independent circuit: the pedal directly
acts on the brake pump which dispenses oil to the
front axle braking unit with discs in oil bath.
The parking brake, of negative type, acts on the braking
unit of the service brake. This brake is engaged every
time the handler's engine is stopped or pressing down
the light pushbutton located to the right of the driving
place.
Page
KITS SUPPLIED ON REQUEST
A-14
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GENERAL INFORMATION
A-5 TECHNICAL DATA AND PERFORMANCE
I
B
A
D
F
E
G
C
H
■ A-5.1
A
B
C
D
E
F
G
H
I
•
•
MAIN DIMENSIONS
Overall height
Height to the steering wheel
Overall width
Cab width
Track
Wheel-base
Length to the front tyres
Length to the attachment holding plate
Ground clearance
Internal steering radius
External steering radius
■ A-5.2 RESTRICTIONS OF USE
•
Angle of approach
•
Departure angle
•
Ambient temperature
■ A-5.3 WEIGHT
•
Weight in working order (with forks)
■ A-5.4 SPEED
Travel speed
Max. slope with full load
Page
A-15
Document 57.0005.9200 - 12/2005
ft
ft
ft
ft
ft
ft
ft
ft
ft
ft
ft
GTH-5519
6' - 3.60"
4' - 0.50"
5' - 10.92"
2' - 9.84"
4' - 10.92"
7' - 5.76"
10' - 10.32"
12' - 2.40"
1' - 2.16"
5' - 8.16"
11' - 1.80"
°C
90°
70°
-20°/+40°
lb
9855
mph
15
60%
Handler with telescopic boom GTH-5519
GENERAL INFORMATION
■ A-5.5
PAYLOAD AND REACH
GTH-5519
-
Max lifting height
Reach at max height
Max reach forward
Attachment holding plate rotation
Maximum payload
Payload at max height
Payload at max reach
ft
ft
ft
lb
lb
lb
■ A-5.6
FORKS Floating type
Dimensions
Weight
ft 3'-11.28" x 0'-3.86" x 0'-1.56"
lb
114 + 114
■ A-5.7
DIESEL ENGINE
Make
Model/Type
Features:
-
18' - 10.32"
1' - 5.76"
10' - 11.52"
135°
5500
2600
1700
Aspirated version
DEUTZ AG
F4M 2011
Diesel
4 cylinders in line
4 strokes
direct injection
in
3.7" x 4.41"
cu in
189.65
kW
46,5
Bore x Stroke
Total displacement
Power at 2600 rpm (ISO 3046 IFN)
■ A-5.8
ELECTRICAL SYSTEM
Voltage
Battery
V
Ah
12
100
IMPORTANT
This is a device of Class A. In a residential environment, such device can cause radio disturbance. In such
cases, the operator is required to take suitable measures.
Page
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GENERAL INFORMATION
A-7 ITEMS SUPPLIED
A-6 LIFETIME
The lifetime of the machine is 10 000 hours provided
all checks, service jobs and overhauls are done at the
times scheduled.
The following items are supplied together with the
machine:
Description
DANGER
After this time, the machine must compulsorily be
inspected and tested by the Manufacturer before
being used again.
GTH-5519
- Spanner CH 19
(for fork positioning)
- Allen wrench CH 6
(for fork positioning)
- 12 V lamps
(spare)
■ A-7.1
✘
✘
✘
LITERATURE SUPPLIED
The machines comes with the following literature:
- Machine operator's handbook
- DEUTZ engine use and maintenance manual
Page
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GENERAL INFORMATION
Intentionally blank page
Page
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SAFETY
Section
B
SAFETY
TABLE OF CONTENTS
B-1
GENERAL REMARKS .................................................................................................
B-2
B-2
PREREQUISITES OF THE PERSONNEL IN CHARGE ...............................................
B-2
B-2.1
Requisites of the machine operators .........................................................................
B-2
B-2.2
Requisites of the servicemen .....................................................................................
B-3
B-2.3
Working clothes ..........................................................................................................
B-3
B-2.4
Personal protective equipment ..................................................................................
B-3
B-3
SAFETY PRECAUTIONS ............................................................................................
B-4
B-3.1
Job site .......................................................................................................................
B-4
B-3.2
Getting ready to work .................................................................................................
B-5
B-3.3
During work or maintenance ......................................................................................
B-5
B-4
SAFETY DEVICES ......................................................................................................
B-7
Page
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SAFETY
B-1 GENERAL REMARKS
B-2
Most accidents occurring while working, repairing or
maintaining operation machines, are caused by not
complying with the basic safety precautions.
Therefore, it is necessary to pay steady attention to
the potential hazards and the effects that may come
of operations carried out on the machine.
IMPORTANT
If you recognise hazardous situations, you can
prevent accidents!
For instance, this handbook makes use of special
safety symbols to stress any potentially hazardous
situation.
CAUTION
The instructions given in this handbook are the
ones established by GENIE. They do not exclude
other safe and most convenient ways for the
machine installation, operation and maintenance
that take into account the available spaces and
means.
If you decide to follow instructions other than those
given in this manual, you shall absolutely:
• be sure that the operations you are going to carry
out are not explicitly forbidden;
• be sure that the methods are safe, say, in
compliance with the rules and provisions given in
this section;
• be sure that the methods cannot damage the
machine directly or indirectly or make it unsafe;
• contact GENIE Assistance Service for any
suggestion and the necessary written permission.
■ B-2.1
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 psycho-physical
conditions and, consequently, their working abilities.
physical:
good eyesight, acute hearing, good co-ordination and
ability to carry out all required operations in a safe way,
according to the instructions of this manual.
mental:
ability to understand and apply the enforced rules,
regulations and safety precautions. They shall be
careful and sensible for their own as well as for the
others’ safety and shall desire to carry out the work
correctly and in a responsible way.
emotional:
they shall keep calm and always be able to evaluate
their own physical and mental conditions.
training:
they shall read and familiarise with this handbook, its
enclosed graphs and diagrams, the identification and
hazard warning plates. They shall be skilled and trained
about the machine use.
IMPORTANT
The operator shall have a licence (or a driving
licence) when provided for by the laws enforced in
the country where the machine works. Please, ask
the competent bodies. In Italy the operator must
be at least 18 year old.
IMPORTANT
If in doubt, it is always better to ask! For this
purpose, contact GENIE: the assistance service is
at your disposal. Addresses, phone and fax numbers
are given in the cover and in the title-page of this
manual.
Page
REQUISITES
OF
THE
PERSONNEL IN CHARGE
B-2
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SAFETY
■ B-2.2 REQUISITES OF THE SERVICEMEN
The personnel charged with the machine maintenance
shall be qualified, specialised in the maintenance of
earth-moving machines, and shall have the following
prerequisites:
physical:
good eyesight, acute hearing, good co-ordination and
ability to carry out all required maintenance operations
in a safe way, according to this manual.
mental:
ability to understand and apply the enforced rules,
regulations and safety precautions. They shall be
careful and sensible for their own as well as for the
others’ safety and shall desire to carry out the work
correctly and in a responsible way
training:
they shall read and familiarise with this handbook, its
enclosed graphs and diagrams, the identification and
warning plates. They shall be skilled and trained about
the machine functioning.
■ B-2.4 PERSONAL PROTECTIVE EQUIPMENT
Under special working conditions, the following
personal protective equipment should be used:
• Breathing set (or dust mask).
• Ear-protectors or equivalent equipment.
• Goggles or facial masks.
IMPORTANT
Use only type-approved protective equipment in
good condition.
IMPORTANT
From a technical point of view, the ordinary
maintenance of the machine is not a complex
intervention and can be carried out by the machine
operator, too, provided he has a basic knowledge
of mechanics.
■ B-2.3 WORKING CLOTHES
During work, but especially when maintaining or
repairing the machine, operators must wear suitable
protective clothing:
• Overalls or any other comfortable garments.
Operators should wear neither clothes with large
sleeves nor objects that can get stuck in moving
parts of the machine.
• Protective helmet.
• Protective gloves.
• Working shoes.
IMPORTANT
Use only type-approved working clothing in good
condition.
Page
B-3
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SAFETY
•
•
B-3 SAFETY PRECAUTIONS
■ B-3.1 JOB SITE
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.
ELECTRICAL
DANGER
•
Look for the best route to the job site.
When the machine is running, nobody can enter
its working range.
While working, keep the working area in order.
Never leave objects scattered: they could hinder
the machine movements and represent a danger
for personnel.
DANGER
Do not at any time use the machine during a storm.
Pay the greatest attention to overhead electric
lines.
Always keep at a minimum safe distance from the
telescopic boom and the lifted load. Electrical
hazards!
DANGER
DEATH OR INJURY CAN RESULT FROM
CONTACTING ELECTRIC POWER LINES.
ALWAYS CONTACT THE ELECTRIC POWER LINES
OWNER. THE ELECTRIC POWER SHALL BE
DISCONNECTED OR THE POWER LINES MOVED
OR INSULATED BEFORE MACHINE OPERATIONS
BEGIN
POWER LINE VOLTAGE REQUIRED CLEARANCE
0
50
200
350
500
750
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
CAUTION
Make sure the machine (wheels and stabilisers)
rests on a firm ground to prevent hazardous
unstable conditions.
If the ground is not firm enough, position some
supporting planks under the stabilisers or the
wheels. These plates must grant a specific pressure
of 1.2 to 1.5 kg/cm 2 (500x500mm plates are
sufficient).
Page
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SAFETY
■ B-3.2 GETTING READY TO WORK
Before any operation, following precautions should be
taken:
• First of all, make sure that the maintenance
interventions have been carried out with care
according to the established schedule (see section
D - Maintenance).
•
•
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
type-approved safety belts or fall preventing
devices.
CAUTION
Set the machine to working configuration and sway
it checking the special water level in the driving
cab, at the top on the strut.
• 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!
■ B-3.3 DURING WORK OR MAINTENANCE
During work, and especially maintenance, always pay
the greatest attention:
• Do not walk or stop under raised loads or machine
parts supported by hydraulic cylinders or ropes
only.
• Keep the machine handholds and access steps
always clean from oil, grease or dirt to prevent falls
or slips.
•
•
•
•
•
•
•
•
•
Page
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.
Do not connect wet plugs or sockets.
Plates and hazard warning stickers shall never be
removed, hidden or become unreadable.
B-5
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SAFETY
•
•
•
•
•
•
Except for maintenance purposes, do not remove
safety devices, shields, protection cases, etc.
Should their removal be necessary, stop the engine,
remove them with the greatest care and always
remember to refit them before starting the engine
and using the machine again.
Before any maintenance or repair work, stop the
engine and disconnect the batteries.
Do not lubricate, clean or adjust moving parts.
Do not carry out operations manually when specific
tools are provided for this purpose.
Absolutely avoid to use tools in bad conditions or
in an improper way i.e. pliers instead of adjustable
wrenches, etc.
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.
Page
DANGER
Any intervention on the hydraulic circuit must be
carried out by authorised personnel.
The hydraulic circuit of this machine is fitted with
pressure accumulators. You and others could be
seriously injured if accumulators are not completely
depressurised.
For this purpose, shut the engine down and step
on the brake pedal 8÷10 times.
•
Neither smoke nor use open flames in areas subject
to fire dangers and in presence of fuel, oil or
batteries.
B-6
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SAFETY
•
•
•
Do not leave fuel cans or bottles in unsuitable
places.
Do not empty catalytic mufflers or other vessels
containing burning materials without taking the
necessary precautions.
Carefully handle all flammable or dangerous
substances.
B-4 SAFETY DEVICES
DANGER
Several safety devices have been fitted to the
machine. They must never be tampered with or
removed (see chap. A-3.5).
Regularly check the efficiency of such devices (see
check card, chap. G-5).
In case of faults, stop working immediately and
proceed in replacing the defective device.
For the checking procedures, read chap. D-3.14
•
•
•
•
•
•
•
•
Do not tamper with fire-extinguishers or pressure
accumulators: explosion hazard!
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 the 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 no
means.
After work, never leave the machine under
potentially dangerous conditions.
Page
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SAFETY
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Page
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OPERATING INSTRUCTIONS
Section
C
OPERATING INSTRUCTIONS
TABLE OF CONTENTS
C-1
BEFORE ENTERING THE MACHINE .... C-2
C-3.4.5 Quick-coupling the attachments ........ C-19
C-2
ENTERING THE MACHINE ................... C-3
C-4
SETUP ................................................ C-20
Entering the cab (only with cabin
closed or glass kit installed) ................. C-3
C-2.1.1 Emergency exit-way (only with cabin
closed or glass kit installed) ................. C-4
C-4.1
Before starting the engine .................. C-20
C-2.2
Adjusting the seat ................................. C-5
C-2.3
Fastening the seat belts ....................... C-5
C-2.4
Adjusting the steering column .............. C-6
C-2.5
Adjusting the rear view mirrors ............. C-6
C-2.6
Switching on the cab interior lamp ....... C-6
C-3
DRIVING PLACE ................................... C-7
C-3.1
Controls and instruments ..................... C-7
C-3.2
Engine controls and instruments .......... C-9
C-5.2.1 Adjusting the floating forks ................. C-25
C-3.2.1 Ignition switch ....................................... C-9
C-5.2.2 Working phases .................................. C-26
C-3.2.2 Forward/reverse gear switch ................ C-9
C-5.3
Changing the attachment ................... C-27
C-3.2.3 Brakes ................................................. C-10
C-6
TRANSPORTING THE MACHINE ....... C-28
C-3.2.4 Accelerator control ............................. C-10
C-6.1
Moving a disabled machine ................ C-28
C-3.2.5 Pushbutton enabling the attachment
C-6.1.1 Unlocking the negative brake ............. C-28
C-2.1
C-4.1.1 Checks at the machine start-up ......... C-20
C-4.2
Starting the engine ............................. C-20
C-4.3
Jump-starting the engine .................... C-21
C-4.4
Low temperature starting ................... C-22
C-4.5
Disconnecting the battery ................... C-22
C-4.6
Starting the machine ........................... C-22
C-4.7
Stopping and parking the machine .... C-23
C-5
USING THE HANDLER ....................... C-23
C-5.1
Using the load charts .......................... C-25
C-5.2
Handling loads .................................... C-25
coupling/release ................................. C-11
C-6.2
Road or site transfer ........................... C-28
C-3.2.6 Steering mode selection ..................... C-11
C-6.3
Lifting the machine ............................. C-29
C-3.2.7 Road/Jobsite switch ........................... C-11
C-6.4
Transporting the machine on other
C-3.2.8 Auxiliary drive controls ....................... C-12
C-3.3
Instruments and light indicators ......... C-12
vehicles ............................................... C-29
C-6.5
Parking and storage ........................... C-30
C-3.3.1 Instruments ......................................... C-12
C-6.5.1 Short inactivity .................................... C-30
C-3.3.2 Light indicators ................................... C-13
C-6.5.2 Machine storage ................................. C-30
C-3.4
C-6.6
Control lever ....................................... C-14
Cleaning and washing the machine .... C-31
C-3.4.1 Function selection .............................. C-14
C-6.6.1 Cleaning instructions .......................... C-31
C-3.4.2 Lifting/lowering the boom ................... C-16
C-6.6.2 Washing instructions .......................... C-31
C-3.4.3 Pitching the attachment holding frame
C-6.7
forwards/backwards ........................... C-17
Machine disposal ................................ C-31
C-6.7.1 Disposal of batteries ........................... C-31
C-3.4.4 Extending/retracting the telescope .... C-18
Page
C-1
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OPERATING INSTRUCTIONS
C-1
INTRODUCTION
This section provides the operator a practical guide
for the gradual learning of the machine use.
The operator should get into the driving cab and carry
out the preliminary adjustments, then memorise the
position of the different controls and instruments.
The familiarisation with the controls ensures not only a
correct use during the working phases, but also a
prompt and timely intervention of the operator, when
he shall carry out sudden manoeuvres to safeguard
his safety and the machine integrity.
It is necessary to learn how to use and foresee the
machine reactions. Learn how to operate the machine
controls in a safe and open place, without obstacles
and anybody standing around. Do not ram the controls.
Operate them slowly to understand their effect on the
machine.
Page
BEFORE ENTERING THE
MACHINE
Checks and cleaning
• Clean glasses, lights and rear view mirrors.
• Check that pins, joints and bolts are well tightened
in position.
• Check for oil, fuel or coolant leaks.
Checking the tyres
• Check the correct inflation of the tyres; see par.
“Tyre inflation” in the Maintenance section.
• Make sure that the tyre plies are not cut or worn.
DANGER
A tyre burst may result in serious injury; never use
the machine if tyres are worn, wrongly inflated or
damaged.
C-2
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OPERATING INSTRUCTIONS
C-2 ENTERING THE MACHINE
■ C-2.1
ENTERING THE CAB
(ONLY WITH CABIN CLOSED OR
GLASS KIT INSTALLED)
CAUTION
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.
Always make sure that your hands and shoe soles
are clean and dry before getting into the driving
cab. Always face the machine when entering and
leaving it and hold to the suitable handles.
The handler cab is equipped with an access door on
the left-hand side.
Door opening from outside:
• Insert the key and release lock 1.
• Press the pushbutton and open the door.
�
�
�
Door closing from inside:
• Pull the door with force: it locks automatically.
Door opening from inside:
• Lift lever 2 and release the lock to open the door
completely.
• Rotate handle 3 to open the upper section of the
door and lock it against the special catch.
�
To unlock the door latched in open position:
• Press button 4 to unlock the door from the catch,
close and latch the door to the lower section using
handle 3.
Page
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OPERATING INSTRUCTIONS
■ C-2.1.1
Leaving the cab in an emergency
(ONLY WITH CABIN CLOSED OR
GLASS KIT INSTALLED)
In an emergency, the operator can use he front or the
rear window as safety exit-ways.
The rear window has handles for partially opening the
glass. Such handles are locked in position by some
wing nuts 5 which, if driven out, allow opening the glass
completely.
The front window has two handles 6 which, if turned,
enable the operator to pass through.
�
�
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OPERATING INSTRUCTIONS
■ C-2.2 ADJUSTING THE SEAT
A correct adjustment of the seat ensures the operator
a safe and comfortable driving. The handler seat is
fitted with devices which allow for the adjustment of
the springing, the height and the distance from the
controls.
•
�
�
�
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.
■ C-2.3
FASTENING THE SEAT BELTS
Sit correctly in the driving seat; then:
•
The safety belts are equipped with reel retractor.
To fasten the belt, pull tab 1 and push it into buckle
2.
•
To release the belt, push button 3 and remove the
tab from the buckle.
•
Make sure that the buckle is correctly located at
the hip point and not on the stomach.
•
Operate the end adjusters to reach the length you
wish and make sure the buckle is always in the
middle.
�
�
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OPERATING INSTRUCTIONS
■ C-2.4
ADJUSTING THE STEERING COLUMN
Both steering column and dashboard can be set to a
different angle. For this purpose:
•
Loosen lever 1 and adjust as required, then retighten lever 1.
DANGER
Before driving the machine, ensure the steering
wheel is perfectly clamped.
■ C-2.5
ADJUSTING THE REAR VIEW MIRRORS
The machine is fitted with two rear view mirrors:
• The right rear view mirror is located on a special
supporting bracket in advanced position and allows
checking the area behind the machine, on the righthand side. To adjust its position, manually rotate
the joint it is fitted with.
• The left rear view mirror is placed on the left upper
post of the windscreen and allows checking the
area behind the machine, on the left- hand side.
To adjust its position, manually rotate the joint it is
fitted with.
�
�
�
■ C-2.6
SWITCHING ON THE CAB LIGHTS
The ceiling light fixture of the cab has an internal lamp
and a courtesy lamp.
To switch on the cab interior lights:
• Switch 4 in pos. A
cab interior lights OFF
• Switch 4 in pos. B
cab interior lights ON.
• Switch 4 in pos. C
courtesy lamp ON
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OPERATING INSTRUCTIONS
C-3 DRIVING PLACE
■ C-3.1 CONTROLS AND INSTRUMENTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Dashboard
Water level
Brake oil tank
Ignition switch
Fresh air flap
Warning light - glow plugs preheating
Warning light - air filter clogged
Fuse compartment
Forward/reverse speed selection lever
Steering column locking lever
Brake pedal
Pushbutton enabling the attachment coupling/
release
Steering selection switch
Horn pushbutton
Gas pedal
Seat
Control lever
Negative brake on/off switch
Continuous flow selector
Storage tray
Storage pocket
Windscreen washer pushbutton (only with cabin
closed)
Air conditioning fan switch (only with cabin closed)
Cab heater cock (only with cabin closed)
IMPORTANT
The warning lights, controls and instruments not
indicated in this list or in the drawings on the
following pages are part of the optional assembly
kits. When looking for one of such devices, please
refer to the pages of the specific assembly kit at
the end of this manual or to the specific installation
instructions.
Page
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OPERATING INSTRUCTIONS
1
2
3
2 0 2 4 6 8
10 8 6 4
10
4
5
6
7
8
01234567
9
F
N
10
R
11
12
13 14
15
17
16
19
23
22
A
C
24
18
20
21
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OPERATING INSTRUCTIONS
C-3.2
■ C-3.2.2
ENGINE CONTROLS AND
INSTRUMENTS
Forward/reverse gear selector switch
Three-position switch with lock in neutral position:
■ C-3.2.1 Ignition switch
Three-position switch:
No circuit under voltage, key can be removed
and engine is stopped
N
Neutral position; no gear engaged
F
Shift lever to pos. F to select the forward gear
R
Shift lever to pos. R to select the reverse gear
Circuits under voltage, presetting for the engine
starting. Board controls and instruments are on.
The warning light 6 signalling the glow plugs
preheating comes on. Wait until the light goes
off before starting the engine.
Engine starting; when released, key springs
back to pos. I automatically.
80
40
80
120
40
°C
01234567
F
N
R
�
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OPERATING INSTRUCTIONS
■ C-3.2.3
11
■ C-3.2.4
Brakes
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
Accelerator control
15
Gas pedal
Its pressure controls the engine rpm and, coupled to
the gearbox, the machine speed. It is fitted with an
adjustable stop in the lower part
Parking brake
The parking brake of negative type engages
automatically when the engine is stopped.
When the handler’s engine is restarted, pressing the
pushbutton switch 18 unlocks the parking brake.
To stop the handler without shutting down the engine,
press the pushbutton switch 18 to engage the parking
brake and push it once again to disengage the brake.
Every pressure of the pushbutton switches the warning
light on and off. When the red warning light is on, the
parking brake is engaged.
CAUTION
Never use the parking brake to slow down the
machine, unless in an emergency. It may reduce
the brake efficiency.
01234567
F
N
A
R
18
11
15
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C
Handler with telescopic boom GTH-5519
OPERATING INSTRUCTIONS
■ C-3.2.5 Pushbutton enabling the attachment
coupling/release
12
Selection button
Two-position button with return to the neutral
point. Press this button every time you wish to
couple/release an attachment. Hold the button
pressed down until the movement has been
completed.
■ C-3.2.6
13
■ C-3.2.7
19
Continuous flow selector
Selection button
Button with two stable positions:
1 Pressing this selector delivers a
continuous flow of oil to the attachment
in use. The built-in light switches on.
2 Pressing this selector again lets the circuit
returns to normal mode: oil is delivered
to the attachment only when the control
lever is operated. The built-in light
switches off.
Steering mode selection
Steering mode switch
Three-position switch for the selection of the
steering mode:
1
Crab steering
0
Two-wheel steering
2
Four-wheel steering
F
N
R
12
13
19
A
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C
Handler with telescopic boom GTH-5519
OPERATING INSTRUCTIONS
■ C-3.2.8
14
22
23
Auxiliary drive controls
C-3.3 INSTRUMENTS AND LIGHT
INDICATORS
■ C-3.3.1
Horn pushbutton
Pushbutton with green glass
Press this button to operate the horn.
Windscreen washer button
When pushed, it sprays a jet of detergent
solution on the windscreen and makes the
wiper functioning easier.
Air conditioning fan switch (only with cabin
closed)
Three-position switch:
0 OFF
1 Low speed
2 High speed
Cab heater control cock (only with cabin
closed)
To the right of the driving seat.
• Turn the heated air regulator 24 counter-clockwise
so the air heating fluid starts circulating.
The amount of heated air will be proportional to the
opening of the relevant regulator.
• Adjust the heated air operating switch 23 to select
one of the three available speeds.
• Open the air flaps and adjust their position to direct
the air as you want.
• Turn the heated air regulator clockwise to switch
off heated air.
Instruments
54
Engine coolant temperature indicator
Signals the engine coolant temperature.
(engine oil)
53
Fuel gauge
Signals the fuel level within the tank.
01234567
52
Hour-meter
Signals the total operating hours of the
machine.
51
Hydraulic oil temperature indicator
Signals the temperature of the hydraulic
oil within the reservoir.
24
60 61 62 63 64 65 66 67 68
23
22
14
A
01234567
C
51
24
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Handler with telescopic boom GTH-5519
OPERATING INSTRUCTIONS
■ C-3.3.2
60
61
Light indicators
Indicator light - high beam
Blue indicator light that signals when high
beam is ON.
This indicator is active only when the lights
kit is installed.
6
Indicator light - glow plugs preheating
Green light indicators which signal the
preheating phase of the engine glow plugs.
Before starting the engine wait for these lights
to go off.
7
Indicator light - air filter soiled
Orange light indicator which signals when the
air intake filter of the engine is getting soiled.
Clean or replace
the
filtering
c a r t r i d g e
6
immediately.
Indicator light - position lights
Green indicator light that signals when
position lights are ON.
This indicator is active only when the lights
kit is installed.
7
F
N
R
63
Indicator light - air filter soiled
Not activated.
64
Indicator light - low battery charge
Signals a low charge by the alternator.
65
Indicator light - low engine oil pressure
It lights when the engine oil pressure is too
low.
66
Indicator light - parking brake engaged
When ON, this light indicates that the parking
brake is engaged.
67
Indicator light
accumulator
Not activated.
68
Indicator light - turn signals
Green indicator light that signals when turn
signals are ON.
This indicator is active only when the lights
kit is installed.
-
negative
brake
60 61 62 63 64 65 66 67 68
01234567
51
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OPERATING INSTRUCTIONS
C-3.4 CONTROL LEVER
Handlers are equipped with a hydraulically driven
servo-controlled lever.
The lever has two pushbuttons: one for coupling/
releasing the attachments and the other for pitching
the attachment frame forwards/backwards .
Shifting the lever to one of the four directions (right/
left, forwards/backwards) moves the boom up and
down and the telescope out and in.
IMPORTANT
Seize the control lever correctly and move it gently.
The motion speed of the actuators depends on the
lever position: a small motion results in a slow
motion of the actuators; vice versa, a full range
motion of the lever corresponds to the max. speed
of the actuator.
CAUTION
The control lever shall be operated only when
correctly seated in the driving place.
CAUTION
Before operating the control lever, make sure that
nobody is within the working range of the machine.
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OPERATING INSTRUCTIONS
■ C-3.4.1
Function selection
The lever is enabled to carry out the following motions:
•
Boom lowering/lifting
shift the control lever to or •
Boom extraction/retraction
shift the control lever to or •
Attachment back/forward tilting
press button and shift the control lever to or •
Attachment coupling/release
press button together with the dashboard
enabling button and shift the lever to or Page
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OPERATING INSTRUCTIONS
■ C-3.4.2 Lifting/lowering the boom
CAUTION
Before operating the boom, make sure that nobody
is within the working range of the machine.
To lift or lower the boom:
•
Smoothly shift the lever to position to lift the
boom or to position to lower it.
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OPERATING INSTRUCTIONS
■ C-3.4.3
Pitching the attachment holding frame
forwards/backwards
CAUTION
Before operating the boom, make sure that nobody
is within the working range of the machine.
To tilt the attachment holding frame forwards/
backwards:
•
Press button and shift the lever to position to tilt the frame forwards or to position to tilt it
backwards.
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OPERATING INSTRUCTIONS
■ C-3.4.4
Extending/retracting the telescope
CAUTION
Before operating the boom, make sure that nobody
is within the working range of the machine.
To extend or retract the boom telescope:
•
Smoothly shift the lever to position to extend
the boom or to position to retract it.
Page
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OPERATING INSTRUCTIONS
■ C-3.4.5
Quick-coupling the attachments
CAUTION
Before operating the boom, make sure that nobody
is within the working range of the machine.
To lock the attachments:
•
Press button together with the dashboard
enabling button (12) and shift the lever to position
to unlock the attachment or to position to
lock the attachment.
F
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OPERATING INSTRUCTIONS
■ C-4.2
C-4 SETUP
STARTING THE ENGINE
For the low temperature starting, see paragraph C-4.4.
■ C-4.1
•
BEFORE STARTING THE ENGINE
To ensure safe conditions to the operators and the
bystanders, and a longer life to your machine,
perform a walk-around inspection before starting
the engine.
•
Remove any dirt or rubbish from the cab interior,
and especially from pedals and control levers.
•
Remove oil, grease and mud from pedals and
control levers.
•
Make sure that your hands and shoe soles are clean
and dry.
•
Check the seat belts can be fastened properly.
•
Check that lights, indicators, side/tail lights, hazard
indicator lights, wipers and horn are in working
order.
•
Adjust the driving seat so that you can reach all
control levers comfortably and fully depress the
brake pedal without moving your back from the
driving seat.
•
Adjust the rear view mirrors to give you a good
view close behind the machine when you are
correctly seated.
•
Check the parking brake is engaged.
•
Engage the parking brake.
•
Put the forward/reverse speed selection lever to
neutral.
•
Step on the gas pedal.
•
To start the engine, turn the ignition switch to
position II. Release the switch when the engine
starts. If the engine does not start within 20
seconds, release the key and wait at least 2 minutes
before attempting again.
•
After the start-up, let
the engine run at idle
for some seconds
before engaging a
gear; this allows for a
gradual warm up of the
engine oil and a better
lubrication.
•
In case of engine jump-starting, remove the booster
cables (see following chapter).
ATTENTION
If the light indicators do not switch off/on when
engine is running, immediately stop the machine
and find and rectify the fault.
■ C-4.1.1 Checks at the machine start-up
Check the efficiency of the safety devices as described
in chap. D-3.15, namely:
• machine start control.
IMPORTANT
Engine cannot be started if the parking brake is not
engaged.
DANGER
After the start-up, when leaving the driving place,
the engine continues to run. DO NOT LEAVE THE
DRIVING PLACE BEFORE HAVING SHUT THE
ENGINE DOWN, LOWERED THE BOOM TO THE
GROUND AND ENGAGED THE PARKING BRAKE.
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OPERATING INSTRUCTIONS
■ C-4.3
JUMP-STARTING THE ENGINE
ATTENTION
B
Do not start the engine using a quick charge
booster to avoid any damage to the electronic
boards.
A
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.
•
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; then start the vehicle and reach an rpm
corresponding to 1/4 of full throttle.
•
Turn the ignition key and start the handler, then
follow the procedure explained in chapter C-4.2
“Starting the engine”.
Page
Disconnect the cables. Remove first the negative
terminal from the frame earth, then from the booster
supply. Disconnect the positive terminal from the
machine battery, then from the booster supply.
DANGER
Use only a 12V battery; other devices like battery
chargers, etc. may cause an explosion of the battery
or result in damage to the electrical system.
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OPERATING INSTRUCTIONS
■ C-4.4
■ C-4.5
LOW TEMPERATURE STARTING
In case of cold starting, use an oil with a SAE viscosity
adequate to the ambient temperature.
Please refer to the DEUTZ engine use and maintenance
manual.
The machine is supplied with oil SAE 15W/40.
DISCONNECTING THE BATTERY
Before any maintenance or repair work, and especially
before welding any components on the machine,
remove the cables at the battery.
CAUTION
Before disconnecting the battery, set all switches
within the cab to OFF.
To disconnect the battery, disconnect the negative
(-) lead from the frame earth first. To connect the
battery, connect the positive (+) lead first.
■ C-4.6
STARTING THE MACHINE
When the engine reaches the running temperature,
ensure all parts are in transfer position and the gearbox
lever is in neutral. Then, proceed as follows:
•
•
•
To start the engine from cold, proceed as follows:
•
Engage the parking brake.
•
Turn the ignition switch to position I and wait until
the warning light 6 signalling the glow plugs
preheating goes off. Step down on the gas pedal
and start the engine turning the ignition switch to II.
Release as soon as the engine starts.
•
Let the engine run at idle for a few seconds before
putting a gear; this allows for a gradual warm up of
the engine oil and a better lubrication.
•
In case of engine jump-starting, remove the booster
ables (see chapter C-4.3).
Page
•
Select the required steering mode.
Select the required gear (forward or reverse).
Release the parking brake pressing button 18 (the
warning light on the pushbutton must be off).
Slowly step on the gas pedal to start moving off.
CAUTION
Do not operate the forward/reverse gear lever when
the machine is running. The machine would reverse
the running direction abruptly and you could
seriously be injured.
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OPERATING INSTRUCTIONS
■ C-4.7
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 pressing button 18 (the
warning light on the pushbutton must be on).
•
Release the service brake pedal.
•
Rest the attachment coupled to the boom flat on
the ground.
•
Rotate the ignition key to “0” and remove the key.
•
Leave the driving cab and lock the cab door.
•
Disconnect the battery (see chapter C-4.5).
C-5 USING THE HANDLER
This chapter describes some techniques and provides
instructions for a safe use of the machine fitted with
standard forks. Before using different attachments,
thoroughly read the chapter “Optional attachments".
CAUTION
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.
ELECTRICAL
DANGER
Pay the greatest attention when working close to
electric lines. Check their position and ensure that
no part of the machine operates at less than 6
meters from the power lines.
DANGER
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.
CAUTION
For a safe use of the machine, always check the
weight of the loads going to be handled.
Always refer to the load charts applied in the cab.
DANGER
Always engage the parking brake after stopping
the machine to prevent possible accidental motions
of the vehicle.
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OPERATING INSTRUCTIONS
■ C-5.1 USING THE LOAD CHARTS
CAUTION
On the cab windscreen, there are the load charts that
indicate the operator how far a load can be extended.
The load chart indicates the payload limits of the
machine under safe conditions.
To operate under safe conditions, always refer to these
charts.
The 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.
CAUTION
The load charts illustrated in this manual are given
only as a mere example. To define the payload
limits, refer to the load charts applied in the cab of
your machine.
GTH- 5519 CAPACITY CHART
20
70 deg
E
60 deg
D
C
50 deg
15
B
A
40 deg
30 deg
5500 lb
10
ft
1700 lb
10 deg
4000 lb
5
2600 lb
2000 lb
20 deg
0 deg
0
-3 deg
E
D
C
B
A
5
15
10
5
0
Forward reach, ft
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OPERATING INSTRUCTIONS
■ C-5.2 HANDLING LOADS
CAUTION
■ C-5.2.1 Adjusting the floating forks
Forks shall be spaced to suit the load going to be
handled. For this purpose:
•
The centre of gravity of the load must always
be halfway between the forks.
•
•
•
Ensure you exactly know the weight of the load
before handling it.
•
When extending the boom, do not exceed the
payload limit.
•
Refer to the payload limits given in the load
chart applied in the cab or in the quick user’s
guide.
•
Space the forks as wide as possible to suit the
load being handled.
•
Loosen the nut of the locking screws.
Raise the forks and slide them on the pivot until
correct spacing.
Lock the screws re-tightening the nut.
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OPERATING INSTRUCTIONS
■ C-5.2.2 Working phases
When forks are correctly spaced, the handler is ready
to use.
Work can be subdivided into three different phases:
loading, transfer and unloading.
•
Release the parking brake and start a new working
cycle.
CAUTION
Loading phase
•
Approach the load to the handled perpendicularly
and check that the machine is level on the
inclinometer.
•
Insert the forks under the load and raise the load
some centimetres.
•
Pitch the forks backwards and check the machine
stability before handling a load.
Do not move off when the load is raised 20÷30 cm
above the ground. Risk of machine overturning or
load fall.
Transfer phase
•
Do not start or brake abruptly.
•
Drive to the unloading point cautiously and keep
the load 20÷30 cm from the ground.
•
Suit the machine speed to the ground conditions to
avoid dangerous jumps, side skids of the vehicle
and possible load falls.
•
When driving on slopes or ramps, hold the load
uphill.
DANGER
Do not drive on slopes sideways; this wrong
manoeuvre is one of the main reasons for accidents
due to vehicle overturning.
Unloading phase
•
Drive to the unloading point with straight wheels
and bring the machine to a smooth stop leaving
enough space to operate the boom.
•
Put the parking brake and set the transmission to
neutral.
•
Position the load some centimetres above the
desired position and set the forks level.
•
Lower the load and make sure it is level.
•
Carefully withdraw the forks by operating the boom
retraction control and, if necessary, raise or lower
the boom as forks come out.
•
When the forks are clear of the load, set them to
transfer position.
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OPERATING INSTRUCTIONS
■ C-5.3
CHANGING THE ATTACHMENT
CAUTION
ATTENTION
Use only attachments directly manufactured or
recommended by Terexlift and detailed in the
“Optional attachments” section.
After substitution, visually check the attachment is
correctly coupled to the boom, before operating
the machine. A wrongly coupled attachment may
result in damage to persons or things.
To change an attachment, operate as follows:
•
Drive to the place where you will release the
mounted attachment (when possible, a solid and
sheltered site).
•
Disconnect the quick connectors of the
attachment (if any), and connect the hydraulic
locking pipes of the attachments to couplings A.
•
Rest the attachment flat on the ground.
•
Pitch the attachment holding frame forward and
lower the boom to release the attachment upper
lock.
•
Move back with the machine (or with the boom)
and drive to the new attachment to be coupled.
•
Hold the frame pitched forward and hook the
upper lock of the new attachment.
•
Retract and raise the attachment some
centimetres. It will centre automatically on the
quick coupling frame.
•
Operate the control lever to lock the attachment.
Page
C-27
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OPERATING INSTRUCTIONS
•
Couple the connectors of the attachment, if any,
to the quick couplings of the frame.
DANGER
After the substitution of an attachment or after any
coupling operation, visually check the attachment.
A wrongly coupled attachment may result in damage
to persons or things.
■ C-6.1.1 Unlocking the negative brake
To unlock the negative brake of a faulty machine,
proceed as follows:
• Loosen the two opposite screws located on the
front axle in order to remove the washers.
• Remove the horseshoe-shaped washers located
under the two screws.
• Re-tighten screws turning alternately the front
screw and the rear screw 1/2 turn to unlock the
brake.
To relock the nagetive brake, loosen the screws turning alternately the front screw and the rear screw
1/2 turn, refit the horseshoe washers and re-tighten
screws .
C-6 TRANSPORTING THE MACHINE
■ C-6.1 MOVING A DISABLED MACHINE
Tow the machine only when no alternative is possible,
since this operation may result in serious damage to
the transmission. When possible, repair the machine
on site.
When the machine shall absolutely be towed:
•
•
•
•
•
•
•
Unlock the negative brake (see chap. C-6.1.1)
Tow the machine for short distances and at a low
speed only.
Use a rigid drawbar.
Select the two-wheel steer.
Set the gearbox lever to neutral.
When possible, start the engine and use the
hydraulic drive and the braking system.
Raise the front wheels of the machine and remove
the Cardan shaft of the transmission.
■ C-6.2 ROAD OR SITE TRANSFER
When travelling on public roads, strictly obey the local
or national road traffic regulations.
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OPERATING INSTRUCTIONS
■ C-6.3
LIFTING THE MACHINE
When the machine shall be lifted, use only means
having a suitable capacity. The characteristic data are
detailed in the relevant chapter of this manual and on
the identification plate.
For the machine lifting, anchor the chains to the special
lugs on the machine (marked with the decal below).
Page
■ C-6.4
TRANSPORTING THE MACHINE ON
OTHER VEHICLES
To transport the machine on another vehicle, follow the
steps below:
•
Put chocks at the machine wheels.
•
Ensure ramps are correctly positioned.
•
Retract the boom to transfer position.
•
Carefully drive the machine onto the transporting
vehicle.
•
Put the parking brake and rest the attachment flat
on the vehicle platform.
•
Ensure the overall dimensions do not exceed the
allowed limits.
•
Shut the engine down and close the driving cab of
the machine.
•
Secure the machine to the vehicle platform by
wheel-chocks.
•
Anchor the machine to the transporting vehicle with
suitable chains.
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OPERATING INSTRUCTIONS
■ C-6.5
PARKING AND STORAGE
■ C-6.5.1 Short inactivity
Always park the machine in a safe way after a working
day, a shift and at night.
■ C-6.5.2 Machine storage
In case of extended inactivity of the machine, follow
the above precautions. Additionally:
•
Wash the machine thoroughly. For a better
cleaning, remove grills and protection casings
Take all precautions to prevent damage to those persons
who will approach the machine while stationary:
•
Carefully dry all machine parts by blowing some
compressed air.
•
Park the machine so that it does not hinder other
operations.
•
Lubricate the machine thoroughly.
•
•
Lower the boom fitted with attachment on the
ground.
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.
•
Remove the key from the ignition switch. Leave
the driving cab and lock the cab door.
•
Disconnect the battery (see chapter C-4.5).
IMPORTANT
Always remember that the ordinary maintenance
must be carried out even during the machine
inactivity. Pay particular attention to the fluid levels
and to those parts subject to ageing. Before restarting the machine, carry out an extraordinary
maintenance and carefully check all mechanical,
hydraulic and electrical components.
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OPERATING INSTRUCTIONS
■ C-6.6 CLEANING AND WASHING THE
■ C-6.7
MACHINE DISPOSAL
MACHINE
■ C-6.6.1 Cleaning instructions
Clean the machine in accordance with the following
instructions:
•
Remove any oil or grease traces with a dry solvent
or a volatile mineral alcohol
•
Before assembling a new part, remove any
protection product (rust-preventer, grease, wax
etc.).
•
Remove any trace of rust from metal parts with
some emery cloth before smearing the part with a
protection product (rust-preventer, paint, oil etc.).
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.
■ C-6.7.1 Battery disposal
PROTECT THE
ENVIRONMENT
■ C-6.6.2 Washing instructions
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.
Page
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.
In Italy, used or discarded batteries have been
classified as “Toxic wastes” in accordance with
Presidential decree n. 397 of 09/09/1988 and Law n.
475 O.G. n. 18 of 09/11/1988 because they contain
lead and sulphuric acid. Their disposal through
recycling must be done only through companies
authorised and belonging to the “Consorzio
Obbligatorio Batterie Esauste e dei rifiuti piombosi”
(Cobat) which collect and dispose of used lead-acid
batteries throughout the national territory.
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.
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OPERATING INSTRUCTIONS
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MAINTENANCE
Section
D
MAINTENANCE
TABLE OF CONTENTS
D-1
D-2
D-2.1
D-3
D-3.1
D-3.2
D-3.3
D-3.4
D-3.5
D-3.5.1
D-3.6
D-3.7
D-3.8
D-3.9
D-3.10
D-3.10.1
D-3.10.2
D-3.11
D-3.11.1
D-3.11.2
D-3.12
D-3.13
D-3.14
D-3.15
D-4
D-4.1
D-4.2
D-5
D-5.1
D-5.2
D-5.2.1
D-5.2.2
D-5.2.3
D-5.2.4
LUBRICANTS - HEALTH AND SAFETY PRECAUTIONS .............................. D-2
ROUTINE MAINTENANCE ............................................................................ D-3
Oil change schedule ...................................................................................... D-4
MAINTENANCE JOBS .................................................................................. D-5
Disconnecting the battery ............................................................................. D-5
Access to the engine and tanks compartments ........................................... D-6
Greasing ........................................................................................................ D-7
Tyres and wheels .......................................................................................... D-8
Brakes ........................................................................................................... D-9
Checking the brake oil level .......................................................................... D-9
Engine air filter ............................................................................................. D-10
Cab air filter (only with cabin closed or glass kit installed) ......................... D-11
Engine cooling circuit .................................................................................. D-11
Checking the oil level in the tank ................................................................ D-12
Changing the oil filter canisters on the intake line ...................................... D-13
Transmission oil filter .................................................................................. D-13
Auxiliary circuits oil filter .............................................................................. D-14
Oil level in the differential gears and the rducer .......................................... D-15
Front and rear differential gears .................................................................. D-15
Reducer ....................................................................................................... D-15
Oil level in the (front/rear) wheel reduction gears ........................................ D-16
Shafting alignment ...................................................................................... D-17
Adjusting the sliding pads of the boom sections ........................................ D-18
Checking the safety devices ....................................................................... D-19
ELECTRICAL SYSTEM ................................................................................ D-21
Battery ......................................................................................................... D-21
Fuses and relays ......................................................................................... D-22
REFUELLING ............................................................................................... D-24
Refuelling ..................................................................................................... D-24
Product specifications ................................................................................ D-24
Engine oil ..................................................................................................... D-24
Lubrication oils and relevant filtering elements ........................................... D-24
Fuel .............................................................................................................. D-25
Grease ......................................................................................................... D-25
Page
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MAINTENANCE
D-1
INTRODUCTION
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.).
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.
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.
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.
The maintenance interventions are based on the
machine working hours. Regularly check the hourmeter and keep it in good condition to define the
maintenance intervals correctly.
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.
Not respecting the ordinary maintenance schedule of
this manual automatically voids GENIE warranty.
IMPORTANT
Oil leaks
In case of accidental oil leaks, cover with sand or typeapproved granulate. Then scrape off and dispose of it
as chemical waste.
First aid
Eyes
For the engine maintenance, please refer to the
specific Operator handbook supplied with the
machine.
Intake
Skin
: In case of accidental contact with the
eyes, wash with fresh water. If the
irritation persists, seek medical advice.
: In case of oil intake, do not induce
vomiting, but seek medical advice.
: In case of a prolonged contact, wash
with soap and water
Fire
In case of fire, use carbon dioxide, dry chemical or
foam extinguishers. Do not use water.
Page
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MAINTENANCE
Every 50 working hours or weekly
D-2 ROUTINE MAINTENANCE
Jobs to be done in addition to those above
A wrong or neglected maintenance can result in
possible risks for both operator and bystanders. Make
sure maintenance and lubrication are carried out
according to the manufacturer’s instructions to keep
the machine safe and efficient.
The maintenance interventions are based on the
machine working hours. Regularly check the hourmeter and keep it in good conditions to define the
maintenance intervals correctly. Make sure any defect
detected during the maintenance is promptly rectified
before using the machine.
1
2
3
4
Every 250 working hours or monthly
Jobs to be done in addition to those above
1
2
3
ATTENTION
4
All " ▲ " marked operations must be carried out by
a skilled technician.
1
2
3
4
Check the oil level within reduction gears, power
divider and differential gears
Regularly check the tightening of the wheel bolts
Check the tightening of all bolts and nuts
Check the couplings for oil leaks
Within the first 50 working hours
1
5
6
During the first 10 working hours
7
8
9
10
Change the oil for the first time
11
Every 10 working hours or daily
1
2
3
4
5
6
7
Check the engine oil level
Clean the air suction filter
Clean the radiator, if necessary
Check the hydraulic oil level in the tank
Check the greasing of the boom section pads
Grease the attachment holding frame
Grease all joints of the boom, the rear axle shaft
joint, the transmission shafts, the front and rear
axles and any equipment of the machine
8 Check the efficiency of the lighting electric system
9 Check the efficiency of braking system and parking
brake
10 Check the efficiency of the steering selection
system
11 Check the efficiency of the fork balancing system.
12 Make sure the safety devices installed are in efficient
working order - see procedure in chap. D-3.14.
Page
Check the tension of the alternator belt
Check the tyre inflation
Check the tightening of the wheel nuts
Check the tightening of the Cardan shaft screws
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
1
Check the efficiency of the block valves - see
chap. D-3.14.
Every 500 working hours or every six months
Jobs to be done in addition to those above.
1
2
3
4
5
6
Visually check the smoke quantity evacuated from
the engine exhaust
Check the tightening of the engine fixing screws
Check the tightening of the cab fixing screws
Check the backlash between pins and bushings
in all joints
Change the hydraulic oil filter of the transmission
Change the hydraulic oil filter in the tank
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MAINTENANCE
7
8
9
Have the hydraulic system checked by a skilled
technician
Change the main cartridge of the engine air filter
Clean or replace, if nececessary, the air filter in the
cab
Every 1000 working hours or yearly
Jobs to be done in addition to those above
1
2
3
Change the oil in the front and rear differential units
and in the power divider
Change the oil in the four wheel reduction gears
Change the hydraulic oil
■ D-2.1
OIL CHANGE SCHEDULE
Job
Engine
Axles and
power
divider
Hydraulic
oil
operating
hours*
service
interval*
Oil level check
10
daily
First change
50
-
Subsequent changes
250
monthly
Oil level check
250
monthly
-
-
Subsequent changes
1000
yearly
Oil level check
250
monthly
Subsequent changes
1000
yearly
First change
* whichever occurs first
Page
D-4
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Oil type
SHELL RIMULA 15W-40
FUCHS TITAN GEAR LS 85 W-90
API GL-5 LS / GL-5
SHELL TELLUS T 46
DENISON HF-1, DIN 51524 part 3 Cat. HV
Handler with telescopic boom GTH-5519
MAINTENANCE
D-3 MAINTENANCE JOBS
ATTENTION
DANGER
All maintenance interventions must be carried out
with engine stopped, parking brake engaged,
working attachments flat on the ground and gear
lever in neutral.
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.
ATTENTION
CAUTION
The qualified staff charged with the maintenance
of the hydraulic circuit must clean all areas around
with care before any intervention.
When raising a component for maintenance
purposes, secure it in a safe way before any
maintenance intervention.
CAUTION
Any intervention on the hydraulic circuit must be
carried out by skilled personnel.
The hydraulic circuit of this machine is fitted with
pressure accumulators. You and others could be
seriously injured if accumulators are not completely
depressurised.
To depressurise the accumators, just steer the
machine wheels some times with engine shut down
until noticing a gradual binding of the handwheel.
PROTECT THE
ENVIRONMENT
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
■ D-3.1
DISCONNECTING THE BATTERY
Before any maintenance or repair work, and especially
before welding any components on the machine,
remove the cables at the battery.
CAUTION
CAUTION
Before any operation on hydraulic lines or
components, make sure there is no residual
pressure. For this purpose, stop the engine, engage
the parking brake and operate the control levers of
the distributors in both working directions
(alternately) to depressurise the hydraulic circuit.
Page
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.
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MAINTENANCE
■ D-3.2
ACCESS TO THE ENGINE AND
TANKS COMPARTMENTS
■
Engine compartment
For any operation within the engine compartment,
open the protection bonnet.
Hood is equipped with lock & key and a supporting rod
that holds it in position.
From the engine compartment, you get access to:
• Thermal engine
• Engine air filter • Hydraulic oil tank plug
• Radiator fluid compensation cup
• Battery
To get access to the engine compartment:
•
•
•
•
Shut the engine down and put the parking brake.
Unlock the bonnet lock Lift the bonnet using the special handle until it
latches in the gas spring.
To close the bonnet: press on the green locking
device on the gas spring and lower the bonnet.
DANGER
Take all precautions when approaching
the engine compartment. Some parts of
the engine may be very hot. Always use
protective gloves.
■
Diesel fuel tank compartment
To gain access to the fuel tank, open the rear cover of
the machine as follows:
• Shut the engine down and put the parking brake.
• Fully raise the cover by means of the special
handle.
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MAINTENANCE
■ D-3.3
GREASING
ATTENTION
Before injecting grease into the greasers, thoroughly
clean them to avoid that mud, dust or other matters
can mix with the lubricant and reduce or annihilate
the lubrication effect.
Remove any old grease with a degreaser from the
telescopes before smearing them with new grease.
Regularly grease the machine to grant it efficient
conditions and a long life.
By means of a pump, inject grease into the special
greasers.
As the fresh grease comes out, stop the operation.
The greasing points are shown in the following figures:
-
the symbol
represents the points to be greased
by a pump
-
the symbol
represents the points to be
greased by a brush.
SERVICE INTERVAL
Running-in ____________________________ None
Ordinary ____________________ Every 10 hours
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MAINTENANCE
■ D-3.4
TYRES AND WHEELS
DANGER
Over-inflated or overheated tyres can burst. Do not
flame-cut or weld the wheel rims. For any repair
work, call in a qualified technician.
YES
NO
WRONG WAY
RIGHT WAY
For the tyre inflation or substitution, please refer to the
table below:
GTH-5519
Dimensions
12-16.5 EM14
Load index
pr 10
Rim
9.75x16
Wheel disc
Pressure
8 holes DIN 70361
bar
Psi
4.5
65
On new machines, and when a wheel has been
disassembled or replaced, check the nut torque of the
wheels every 2 hours until they stay correct.
ATTENTION
Always use tyres having the dimensions indicated
in the vehicle registration card.
SERVICE INTERVAL
Running-in _________ Within the first 10 hours
Ordinary __________________ Every 250 hours
Page
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MAINTENANCE
D-3.5 BRAKES
•
For any intervention on the braking system
(adjustment and/or substitution of the brake discs)
call in a specialised technician.
The malfunctioning of the braking system may depend
on the presence of air within the hydraulic circuit.
The braking system has two bleeding valves: valve for the service brake circuit and valve for the negative
parking brake circuit.
To bleed the circuit of the service brake:
• Make sure that the oil is level within the feeding tank
.
• Step on the brake pedal repeatedly.
• Slowly unscrew valve and re-close it as soon as
oil mixed with air bubbles comes out.
• Repeat the operation until bubble-free oil comes
out.
• Bleed from both sides of the machine.
To bleed the circuit of the negative parking brake:
• Press the parking brake button . As soon as the
light indicator on the button goes off, start bleeding
through valve until air-free oil comes out.
A
D-3.5.1 Checking the brake oil level
The oil within the braking circuit must be at about 2 cm
from the tank plug .
Level
Page
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C
Handler with telescopic boom GTH-5519
MAINTENANCE
■ D-3.6
ENGINE AIR FILTER
Clean the engine air filter every 10 hours; replace the
filtering element, if necessary.
1 Cleaning and changing the external element:
- Stop the engine and engage the parking brake.
- Unscrew wingnut A and remove cover B.
- Unscrew wingnut C and remove the outer
element D.
- Clean the filter bowl.
- Clean the cartridge by beating it some times on
the ground paying attention not to damage the
filtering element.
Do not dry-clean the filtering element.
- Check for cracks in the filtering element by
introducing a lamp inside.
- Smear the seal with grease, then refit the element.
- Tighten wingnut C, close cover B and tighten
with wingnut A.
ATTENTION
As soon as the warning lamp on the cab dashboard
switches on, replace the outer element.
SERVICE INTERVAL
Running-in ___________________________ None
Cleaning ___________________ Every 10 hours
Filtering element substitution _ Every 500 hours
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MAINTENANCE
■ D-3.7
CAB AIR FILTER (ONLY WITH CABIN
CLOSED OR GLASS KIT INSTALLED)
Every six months clean the air filter in the cab. Replace
the cartridge if the filtering cloth is damged.
1 Cleaning and changing the cartridge:
- Shut the engine down and engage the parking
brake.
- Pull out the filter A located to the left of the driving
place.
- Clean the filter bowl.
- Clean the filter cartridge and replace in case of
damage.
ATTENTION
Do not, at any times, dry-clean the filters. Use some
water and/or solvent.
■ D-3.8
ENGINE COOLING CIRCUIT
The cooling radiator is lubricated with the engine oil
and does not need any maintenance.
Page
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MAINTENANCE
■ D-3.9
CHECKING THE OIL LEVEL IN THE
TANK
DANGER
Fine jets of hydraulic oil under pressure can
penetrate the skin. Do not use your fingers, but a
piece of cardboard to detect oil leaks.
Check the hydraulic oil level (visually) through the
special level fitted into the tank.
When necessary, add new oil through filler .
CAUTION
Check the oil level with handler set to transfer position
(lowered boom and retracted telescopic element).
SERVICE INTERVAL
Running-in _________ Within the first 10 hours
Ordinary ____________________ Every 50 hours
If oil must be changed, proceed as follows:
1 Stop the machine on a level ground and make sure
the parking brake is engaged.
2 Release the pressure from the hydraulic circuit.
3 Place a container of suitable size under the drain
plug, placed in the lower part of the reservoir, and
collect any oil leaks.
4 Remove the drain plug and allow oil to flow out into
the container.
5 Remove the inspection cover of tank .
6 Carefully wash the tank with Diesel oil and blow a
jet of compressed air.
7 Refit the drain plug and the inspection cover.
8 Add new oil by making sure that it matches the
recommended type indicated in paragraph D-5.2.2.
until it is level with .
PROTECT THE
ENVIRONMENT
SERVICE INTERVAL
Running-in ____________________________ None
Ordinary ________________ Every 1000 hours
Page
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
D-12
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MAINTENANCE
■ D-3.10
CHANGING THE OIL FILTER
CANISTERS ON THE INTAKE LINE
■ D-3.10.1 Transmission oil filter
Every 50 hours, check the clogging degree of the
filtering element using the vacuometer .
The indexed scale of the vacuometer is divided into 3
areas:
1 - Green area: Normal condition
2 - Yellow area: Replace the filter as soon as
possible
3 - Red area:
Shut the engine down to prevent
damage to the hydraulic system.
Change the filter and/or check for
the fault reasons.
IMPORTANT
40
30
50
15
20
20
10
60
25
5
Hydraulic oil filter cartridges cannot be cleaned or
washed and refitted.
They must be replaced with new ones of the type
recommended by the manufacturer (see par. D5.2.2).
10
30
70
76
in Hg
cm Hg
PROTECT THE
ENVIRONMENT
0
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
To change the hydraulic oil filter element on the suction
line, 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, then close cock .
3 Remove the filtering element using a wrench.
4 Change the filtering element, then, before fitting a
new one, thoroughly clean and grease both seat
and gasket.
5 Hand-tighten and re-open cock .
IMPORTANT
When changing the oil, drain it when it is still hot
and the polluting substances are in suspension.
SERVICE INTERVAL
Running-in ____________________________ None
Ordinary __________________ Every 500 hours
When the dashboard indicator switches on
Page
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MAINTENANCE
■ D-3.10.2 Auxiliary circuits oil filter
To change the hydraulic oil filter cartridge of the service
circuits, proceed as follows:
1
Stop the machine on a level ground and engage the
parking brake.
2
Remove the inspection hatch and unscrew the
oil filter fitted inside the tank.
3
Check the tank is clean, then fit a new filtering
element and refit the inspection hatch.
4
Check the oil level within the tank. Add new oil, if
necessary.
SERVICE INTERVAL
Running-in ____________________________ None
Ordinary __________________ Every 500 hours
Page
D-14
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Handler with telescopic boom GTH-5519
MAINTENANCE
D-3.11 OIL LEVEL IN THE DIFFERENTIAL
GEARS AND THE REDUCER
■ D-3.11.1 Front and differential gears
To check the oil level in the front and rear differential
gears:
•
Stop the machine on a level ground and engage the
parking brake.
•
Loosen level plug and check if oil is level with the
hole.
•
If necessary, add new oil through the hole of the
level plug until it comes out.
•
Refit and tighten plug .
For the oil change:
•
Place a container of suitable size under drain plug
.
•
Loosen the drain plug and the level plug and
allow oil to flow out from the differential gears.
•
Refit and tighten drain plug .
•
Add new oil through plug until it is level with the
hole.
•
Refit and tighten level/filler plug.
SERVICE INTERVAL
Running-in _________ Within the first 10 hours
Ordinary __________________ Every 250 hours
■ D-3.11.2 Reducer
To check the oil level in the reducer
•
Stop the machine on a level ground and engage the
parking brake.
•
Loosen level plug and check if oil is level with the
hole.
•
If necessary, add new oil through the hole of the
level plug until it comes out.
•
Refit and tighten plug .
For the oil change:
•
Place a container of suitable size under drain plug
.
•
Loosen the drain plug and the level plug and
allow oil to flow out from the reduction gear.
•
Refit and tighten drain plug .
•
Add new oil through plug until it is level with the
hole.
•
Refit and tighten plug .
SERVICE INTERVAL
Running-in _________ Within the first 10 hours
Ordinary __________________ Every 250 hours
Page
D-15
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MAINTENANCE
■ D-3.12
OIL LEVEL IN THE (front/rear) WHEEL
REDUCTION GEARS
PROTECT THE
ENVIRONMENT
To check the oil level within the wheel reduction gears:
•
Stop the machine on a level ground and ensure the
parking brake is engaged and plug finds on the
horizontal axis.
• Clean the plug all around, then remove it and check
if oil is level with the hole.
• If necessary, add new oil through hole until it is
level.
• Refit the plug.
For the oil change:
• Stop the machine and ensure the plug is oriented
along the vertical axis.
• Place a container of suitable size under the reduction
gear plug.
• Unscrew plug and drain any oil from the reduction
gear.
• Rotate the wheel by 90° until the plug finds again
on the horizontal axis.
• Add new oil through hole .
• Refit and tighten plug .
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
IMPORTANT
When changing the oil, drain it when it is still hot
and the polluting substances are in suspension.
SERVICE INTERVAL
Running-in _________ Within the first 10 hours
Ordinary __________________ Every 250 hours
Page
D-16
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MAINTENANCE
D-3.13 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.
01234567
F
To fix this problem, rather than checking the alignment
visually, follow the procedure below:
N
R
�
1) Move to a solid and level ground
�
�
2) Set the steering selection switch 13 to “four-wheel
steer” (pos. 2)
3) Rotate the steering up to its stop (either to the right
or to the left)
4) Set the steering selection switch to “two-wheel
steer” (pos. 0)
5) Rotate the steering up to its stop (turn in the same
direction as above)
�
6) Reset the steering selection switch to “four-wheel
steer” (pos. 2)
7) Rotate the steering (to the side opposite to point 3)
so that the rear axle reaches its stop
8) Reset the steering selection switch to “two-wheel
steer” (pos. 0)
9) Rotate the steering (to the same side as in point 7)
so that the front axle reaches its stop
10) Reset the steering selection switch to “four-wheel
steer” (pos. 2)
Now the wheels should be re-aligned.
SERVICE INTERVAL
Running-in ____________________________ None
Ordinary ___________________ When necessary
Page
D-17
Document 57.0005.9200 - 12/2005
�
�
Handler with telescopic boom GTH-5519
MAINTENANCE
■ D-3.14 ADJUSTING THE SLIDING PADS OF
THE BOOM SECTIONS
Any boom section is fitted with adjustable pads located
on the four sides of the profile. These pads are secured
to both fixed and mobile part of every section.
All pads can be adjusted by the special shims supplied
by GENIE upon demand.
Adjusting the pads:
•
Remove or loosen the screws fixing the pads in
relation to type of shims used (with or without
slots).
•
Fit the necessary amount of shims.
•
If the residual thickness of the pad is insufficient or
near the maximum wearing limit, renew the pad.
•
Tighten the screws fixing the pads at the
recommended torque (see below). Use a
dynamometric wrench.
Tightening torques of the pad screws in relation to
the screw diameter
Screws M10
Nm 30
Screws M14
Nm 50
Tightening torques higher than those recommended
can cause the break of the pad or of the locking
threaded bush.
ATTENTION
Pads must compulsorily be replaced if the residual
thickness of the plastic layer with respect to the
iron bush fixing the block is equal or inferior to 1
mm.
Max. wearing thickness
SERVICE INTERVAL
Minimum 1 mm
Running-in ____________________________ None
Ordinary ___________________ When necessary
Page
D-18
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Handler with telescopic boom GTH-5519
MAINTENANCE
■ D-3.15 CHECKING THE SAFETY DEVICES
■ Checking the block valves (every 3 months).
Attachment coupling cylinder
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 (2400 kg
roughly) onto the boom.
• Raise the load some centimetres above the ground
(max 10 cm). To check the valve on the telescope
extension cylinder move the boom to maximum
height and extend it some centimetres.
• Loosen the oil hoses to the cylinder of which you
are checking the valve with caution.
During the check, the oil will flow out of the hoses and
the load shall remain blocked in position. Should that
not be the case, the valve must be replaced. Contact
GENIE Technical Service.
DANGER
-
Wear safety glasses
Wear safety gloves
Wear safety shoes
Wear suitable working clothes
Use guards against leaks of oil at high pressure
Do the check in a free space with barriers all
around to keep non-authorised people away
During the check proceed with extreme caution.
Ensure that the part to be checked is in safe
condition and that the action generated does
not result in an uncontrolled movement of the
machine
Lifting cylinder
Extension cylinder
Balance cylinder
Attachment pitching cylinder
Page
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MAINTENANCE
■ Checking the machine start control
(at every use)
Attempt to start the engine with the forward or reverse
gear put.
The engine must not start. If the engine starts, contact
the GENIE Technical Service.
Repeat the operation putting first one gear, then the
other.
Page
D-20
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MAINTENANCE
D-4 ELECTRICAL SYSTEM
DANGER
All maintenance interventions must be carried out
with engine stopped, parking brake engaged,
working attachments on the ground and gearbox
lever in neutral.
DANGER
When raising a component for maintenance
purposes, secure it in a safe way before carrying
out any maintenance.
•
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.
D-4.1 BATTERY
•
Check the electrolyte level every 250 working
hours; if necessary, add distilled water.
•
Ensure the fluid is 5÷6 mm above the plates and the
cell levels are correct.
•
Check the cable clips are well secured to the
battery terminals. To tighten the clips, always use
a box wrench, never pliers.
•
Protect the terminals smearing them with pure
vaseline.
•
Remove the battery and store it in a dry place,
when the machine is not used for a long time.
DANGER
Risk of explosion or shorts. During the recharge,
an explosive mixture with release of hydrogen gas
forms.
DANGER
Do not add sulphuric acid; add only distilled water.
DANGER
•
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.
Page
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Handler with telescopic boom GTH-5519
MAINTENANCE
D-4.2 FUSES AND RELAYS
The electrical system is protected by fuses placed in
the driving cab, on the left. Before replacing a blown
fuse with a new one having the same amperage, find
out and rectify the fault.
■
Ref.
Circuit
F26
F27
F28
F29
Not used
Not used
Not used
Spare fuses
Amp.
7.5
5
5
Fuses
Ref.
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
Circuit
Amp.
Interior lamp power supply
2
Frontwork light switch power supply
10
Rear work light switch power supply
10
E1 relay pickup, E2 relay pickup, E3 relay pickup,
Relay E6 power supply, hydraulic stop,
warning lights-fuel gauge instrument, air filter
soiled warning light, preheating warning light,
engine oil cooling temperature indicator light,
engine oil temperature indicator
5
Power supply: engine stop solenoid,
preheating control unit
10
Horn switch power supply
10
Vse solenoid valve switch power supply
5
Parking brake switch power supply
5
Windscreen wiper/washer motor power supply
15
Windscreen wiper/washer switch power supply
5
Power supply: beacon, lighting: warning lights,
fuel gauge, engine oil temperature indicator,
engine oil cooling temperature indicator
7.5
Power supply: steering selector
7.5
Relay E3/Relay E5 power supply
5
Not used
5
Not used
2
Not used
10
Not used
10
Not used
5
Not used
10
Not used
10
Not used
5
Not used
5
Not used
15
Not used
5
Not used
7.5
Page
F14
F28
F13
F27
F12
F26
F11
F25
F10
F24
F9
F23
F8
F22
F7
F21
F6
F20
F5
F19
F4
F18
F3
F17
F2
F16
F1
F15
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F29
F29
F29
F29
INT
E5
E4
E3
E2
E1
E6
Handler with telescopic boom GTH-5519
MAINTENANCE
■
Engine compartment fuses and relays
E11 F30 F31 E12
Ref.
Circuit
F30
Timer fuse
70
F31
Start-up and main board
fuse
50
E11
Glow plugs timer relay
E12
Start relay
■
Amp
Fuse box relays
Ref.
Circuit
E1
Front/rear work lights
E2
Engine start with parking brake engaged
E3
Relay E4 enabling command
E4
Forward speed enabling command
E5
Reverse speed
E6
Stop
ATTENTION
•
•
•
•
•
Do not use fuses having a higher amperage
than that recommended, since they can
damage the electric system seriously.
If the fuse blows after a short time, look for the
fault source by checking the electric system.
Always keep some spare fuses for an
emergency.
Never try to repair or short blown fuses.
Make sure the contacts of fuses and fusesockets ensure a good electric connection and
are not oxidised.
Page
F14
F28
F13
F27
F12
F26
F11
F25
F10
F24
F9
F23
F8
F22
F7
F21
F6
F20
F5
F19
F4
F18
F3
F17
F2
F16
F1
F15
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F29
F29
F29
F29
INT
E5
E4
E3
E2
E1
E6
Handler with telescopic boom GTH-5519
MAINTENANCE
D-5 REFUELLING
■ D-5.1
REFUELLING
Part
Diesel engine
Fuel tank
Hydraulic system tank
Front differential gear with reduction gear
Rear differential gear
Front wheel reduction gears
Rear wheel reduction gears
Brake oil tank
Product
Engine oil
Diesel fuel
Hydraulic oil
Oil
Oil
Oil
Oil
Hydraulic oil
Capacity
(litres)
11 + 3.5
60
120
6
5
1.5 + 1.5
0.7 + 0.7
0.1
Product
specifications
see par.
D-5.2.1
D-5.2.3
D-5.2.2
D-5.2.2
D-5.2.2
D-5.2.2
D-5.2.2
D-5.2.2
■ D-5.2 PRODUCT SPECIFICATIONS
■ D-5.2.1 Engine oil
Use the oil recommended by the Diesel engine Manufacturer (see the relevant handbook delivered with the
machine).
At the delivery, the machine is refilled with:
SHELL RIMULA 15W-40
■ D-5.2.2 Lubrication oils and relevant filtering elements
Refill the machine with following lubricants:
Use
Product
Definition
Power divider-Differential gears-Reduction gears FUCHS TITAN GEAR LS 85 W-90 API GL-5 LS / GL-5
Hydraulic system and brakes
SHELL TELLUS T 46
DENISON HF-1 DIN 51524 part 3 Cat. HV
ATTENTION
Never mix different oils: this may result in troubles and component breaks.
■ Filtering elements:
Filter
Flow l/1'
Filtering
Code
Transmission oil filter
Auxiliary circuit oil filter (inside the tank)
MPS 150
STR 100/1
10 µ
60 µ
09.4604.0001
09.4604.0004
Page
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Handler with telescopic boom GTH-5519
MAINTENANCE
■ D-5.2.3 Fuel
Use only Diesel fuel with less than 0.5% sulphur
content, according to the specifications of the diesel
engine operation handbook.
ATTENTION
In cold climates (temperature under -20°C) use only
“Arctic” type Diesel fuel, or oil-diesel fuel, or oildiesel fuel mixtures. The composition of the latter
can vary in relation to the ambient temperature up
to max. 80% oil.
■ D-5.2.4 Grease
For the machine greasing, use:
• Lithium-based
Vanguard LIKO grease,
type EP2
When greasing by pump
• Graphitized SHELL
grease, type GR NG 3
When greasing by brush
• INTERFLON FIN
GREASE LS 2
For the telescopic boom
sliding blocks
ATTENTION
Avoid mixing greases of different type or features
and do not use greases of lower quality.
Page
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MAINTENANCE
Intentionally blank page
Page
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Handler with telescopic boom GTH-5519
FAULTS AND TROUBLESHOOTING
Section
E
FAULTS AND
TROUBLESHOOTING
TABLE OF CONTENTS
E-1
FAULTS AND TROUBLESHOOTING .............................................................. E-2
E-1.1
Fault - Cause - Solution ................................................................................. E-2
Page
E-1
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FAULTS AND TROUBLESHOOTING
E-1
FAULTS AND TROUBLESHOOTING
This chapter represents a practical guide for the
operator for fixing the most common failures and, at
the same time, detecting those interventions which
must be carried out by qualified technical engineers.
If you are unsure about anything, do not carry out
operations on the machine, but call in a skilled
technician.
DANGER
Any repair work, maintenance or troubleshooting
must be carried out with machine stopped, boom
in rest position or laid on the ground, parking brake
engaged and ignition key removed.
E-1.1 Fault - Cause - Solution
DASHBOARD DOES NOT SWITCH
ON
• The 50A fuse F31 supplying power
to the dashboard is blown (engine
compartment)
• Battery disconnected
• Battery down
• Battery cut-out switch OFF
ENGINE DOES NOT START
Starter does not run
ENGINE DOES NOT START
Starter runs, but engine does not
start
• Parking brake not engaged
• Connect the battery using the
relevant switch
• Check the battery
• Switch it on
• Battery down
• Battery cut-out switch OFF
• Engage the parking brake and
ensure the relevant indicator on the
dashboard switches on
• Recharge or replace the battery
• Switch it on
•
•
•
•
•
•
•
•
Fuse F15 blown
No fuel
Diesel fuel filter clogged
Diesel fuel hose empty (fuel used up)
• Solenoid valve - engine stop
MACHINE DOES NOT MOVE
• Replace the fuse
• Speed selector switch in neutral
• Parking brake engaged
• Fuse F3 blown
Check the fuse
Refuel
See DEUTZ engine operator manual
Refuel, then refer to DEUTZ engine
operator manual
• Check the solenoid valve; replace,
if necessary
• Set the speed selector switch
correctly
• Disengage
• Check the fuse; replace, if
necessary
THE MACHINE DRIVE IS NOT
ENOUGH
• Hydraulic oil filter clogged
• Replace the filter
NO SELECTION OF THE STEERING
MODE
• Fuse F20 controlling the steering
selection blown
• “ROAD/JOBSITE” switch set to
“ROAD”
• Sostituire il fusibile
• No “ROAD/JOBSITE” selection
• Check and replace fuse F20, if
necessary
“ROAD” FUNCTION ON, EVEN
WHEN SELECTING THE “JOBSITE”
FUNCTION
Page
E-2
Document 57.0005.9200 - 12/2005
• Set to "JOBSITE"
Handler with telescopic boom GTH-5519
FAULTS AND TROUBLESHOOTING
NO BOOM LOWERING AND
EXTENSION, NO HOLDING FRAME
TILTING
• Fuse blown
• Replace fuses F2 and/or F24
THE HYDRAULIC OIL
THERMOMETER DOES NOT WORK
• This is normal, when the outside
temperature is low and/or the
machine is used for short periods,
since the hydraulic oil cannot warm
up over 40÷50°C
THE PARKING BRAKE LIGHT DOES
NOT LIGHT UP
• Fuse blown
• Replace fuse F15
BOOM DOES NOT MOVE
• Fuse blown
• Check and replace fuse F22, if
necessary
• Set to “JOBSITE”
• “ROAD/JOBSITE” switch set to
“ROAD”
• Emergency button ON
• Reset the button
ATTENTION
In case of faults not listed in this chapter, address to the GENIE Technical Assistance, your nearest
authorised workshop or dealer.
Page
E-3
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FAULTS AND TROUBLESHOOTING
NOTES .........................................................
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Page
E-4
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OPTIONAL ATTACHMENTS
Section
F
OPTIONAL ATTACHMENTS
TABLE OF CONTENTS
F-1.1
Shovel ...................................................................................................
F-3
F-1.2
Cereal shovel .........................................................................................
F-4
F-1.3
Fixed hook on plate ...............................................................................
F-5
F-1.4
Extension jib ..........................................................................................
F-6
F-1.5
Forks with hydraulic side-shift ..............................................................
F-7
Page
F-1
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Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
INTRODUCTION
This section provides information on the optional
interchangeable attachments, especially manufactured
for the handlers.
Use only genuine attachments, described in this
section, after having read their features thoroughly and
understood their use.
To install and remove the attachments, follow the
instructions supplied in the OPERATION section, par.
C-5.4.


DANGER
When replacing interchangeable attachments, keep
any person clear of the working area.
DANGER
Mounting optional attachments, and especially the
extension jib, can change the centre of gravity of
the machine. Before handling a load, check its
weight and compare it with the values on the load
charts. The weight of the used attachment must
always be deducted from the rated payload.
Page
F-2
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Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
■ F-1.1
Application
Quick-coupling fitted attachment for moving soil, sand,
debris, cereals, etc.
SHOVEL
Code
GTH-5519
Litres 500
Safety
Strictly obey the general safety precautions given in
section B “SAFETY”.
59.0200.0000
Operation
ATTENTION
When using a shovel, load the material only when
the boom is completely retracted and push against
the heap with straight wheels.
To load/unload the material, operate the rotation lever
of the attachment holding plate.
Maintenance
Visually check the shovel for damage before using it.
Technical data
Capacity
litres
500
A
Width
mm
1850
B
Length
mm
760
H
Height
mm
700
-
Weight
kg
290
ATTENTION
Attachment suitable for moving loose material. Do
not use for digging operations.
Page
F-3
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OPTIONAL ATTACHMENTS
■ F-1.2
Application
Quick coupling attachment for loading cereals or inert
materials, etc.
CEREAL SHOVEL
Code
GTH-5519
Litres 800
Safety
Strictly obey the general safety precautions given in
section B “SAFETY”.
59.0200.1000
Operation
ATTENTION
When using a shovel, load the material only when
the boom is completely retracted and push against
the heap with straight wheels.
To load/unload the material, operate the rotation lever
of the attachment holding plate.
Maintenance
Visually check the shovel for damage before using it.
Technical data
Capacity
litres
800
A
Width
mm
1850
B
Length
mm
800
H
Height
mm
1150
-
Weight
kg
350
ATTENTION
Attachment suitable for moving loose material. Do
not use for digging operations.
Page
F-4
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Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
■ F-1.3
Application
Quick-coupling fitted attachment for lifting loads by
means of special slings.
FIXED HOOK ON PLATE
Payload
Code
2500 kg
59.0700.0000
Safety
Strictly obey the general safety precautions given in
section B “SAFETY”.
Do not oscillate the load.
Do not drag hooked loads.
Lift the load before extending the boom.
Operation
Fork the hook and hold it in position by means of the
locking cylinder.
All loads must be bridled with special textile slings or
chains in compliance with all pertinent regulations.
To handle the load, raise and rotate the telescopic
boom of the handler.
Maintenance
Visually check the hook for damage before using it.
Check the safety catch is in good working order.
Technical data
Payload
kg
2500
Width
mm
970
Length
mm
620
Height
mm
600
Weight
kg
105
IMPORTANT
The fixed hook has been designed to support a load
of 2500 kg. The max payload corresponds to the
nominal capacity rating of the handler on which it is
installed and is indicated on the load charts supplied
with the equipment.
IMPORTANT
Make sure this attachment can be used in the
destination country of the machine. In Italy, this
attachment must be enrolled at ISPESL and
submitted to yearly test.
Application must be submitted directly by the user.
Page
F-5
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Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
■ F-1.4
Application
Quick-coupling fitted attachment for maintenance
interventions at high working heights.
EXTENSION JIB
Code
Safety
Strictly obey the general safety precautions given in
section B “SAFETY”.
Never lift wrongly slung loads.
Avoid abrupt acceleration or deceleration.
Avoid load oscillations, and especially do not move
the load from the vertical pull line.
Do not pull crosswise and do not tow.
GTH-5519
400 kg
59.0800.0000
Operation
To change the working height, operate the rotation lever
of the attachment holding plate.
Maintenance
Visually check the jib for damage before using it.
Check the safety catch is in good working order.
Daily grease the joints using the greasing gun.
Characteristics
-
Payload
kg
400
A
Length
mm
2100
B Width
mm
920
H Height
mm
630
kg
115
-
Weight
IMPORTANT
Make sure this attachment can be used in the
destination country of the machine. In Italy, this
attachment must be enrolled at ISPESL and
submitted to yearly test.
Application must be submitted directly by the user.
Page
F-6
Document 57.0005.9200 - 12/2005
Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
■ F-1.5
FORKS WITH HYDRAULIC SIDE-SHIFT
Application
Quick-coupling fitted attachment for handling
palletised loads with possibility of shifting the load to
the side by ± 100 mm.
Safety
Strictly obey the general safety precautions given in
section B “SAFETY”.
• Do not load loose materials
• Do not move superposed pallets
Operation
To adjust the tilting, operate the rotation lever of the
attachment holding plate.
To side-shift, operate the attachment locking lever after
connecting the feeding lines of the new attachment to
the quick couplings (see page F-2).
Maintenance
Visually check the attachment for damage before using it.
Check for hydraulic oil leaks.
Daily grease the joints using a greasing gun, and smear
the sliding guides with graphitized grease.
Machine
Code
GTH-5519
59.0600.0000
Technical data
Payload kg
Width
Length
Height (with protection)
Weight
Stroke
Fork attachments
2600
mm
mm
mm
kg
mm
1240
1600
1000
180
± 100
FEM 2
Page
F-7
Document 57.0005.9200 - 12/2005
Handler with telescopic boom GTH-5519
OPTIONAL ATTACHMENTS
Intentionally blank page
Page
F-8
Document 57.0005.9200 - 12/2005
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
Section
G
TABLES AND
DOCUMENTS ENCLOSED
TABLE OF CONTENTS
G-1
TORQUE WRENCH SETTING ...............................................................
G-2
G-2.1
Load Chart with forks (up to serial no. 14976) ......................................
G-3
G-2.2
Load Chart with forks (from serial no. 14977) .......................................
G-4
G-3.1
Wiring diagram - Fuses and relays ........................................................
G-5
G-3.2
Wiring diagram - fuses system ..............................................................
G-7
G-3.3
Wiring diagram - dashboard system .....................................................
G-8
G-3.4
Wiring diagram - chassis system ..........................................................
G-9
G-3.5
General wiring diagram (description) ....................................................
G-10
G-4.1
Hydraulic scheme ..................................................................................
G-11
G-5
Routine check schedule-Safety devices ...............................................
G-12
Page
G-1
Document 57.0005.9200 - 12/2005
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-1 TORQUE WRENCH SETTINGS
Dxp
Pre-loading (N)
Torque wrench setting (Nm)
4.8
8.8
10.9
12.9
4.8
8.8
10.9
12.9
M 4 x 0,7
1970
3930
5530
6640
1,5
3,1
4,3
5,2
M 5 x 0,8
3180
6360
8950
10700
3
6
8,5
10,1
M6x1
4500
9000
12700
15200
5,2
10,4
14,6
17,5
M 8 x 1,25
8200
16400
23100
27700
12,3
24,6
34,7
41,6
M8x1
8780
17600
24700
29600
13
26
36,6
43,9
M 10 x 1,5
13000
26000
36500
43900
25,1
50,1
70,5
84,6
M 10 x 1,25
13700
27400
38500
46300
26,2
52,4
73,6
88,4
M 12 x 1,75
18900
37800
53000
63700
42,4
84,8
119
143
M 12 x 1,25
20600
41300
58000
69600
45,3
90,6
127
153
M 14 x 2
25800
51500
72500
86900
67,4
135
190
228
M 14 x 1,5
28000
56000
78800
94500
71,7
143
202
242
M 16 x 2
35200
70300
98900
119000
102
205
288
346
M 16 x 1.5
37400
74800
105000
126000
107
214
302
362
M 18 x 2,5
43000
86000
121000
145000
142
283
398
478
M 18 x 1,5
48400
96800
136000
163000
154
308
434
520
M 20 x 2,5
54900
110000
154000
185000
200
400
562
674
M 20 x 1,5
60900
122000
171000
206000
216
431
607
728
M 22 x 2,5
67900
136000
191000
229000
266
532
748
897
M 22 x 1,5
74600
149000
210000
252000
286
571
803
964
M 24 x 3
79100
158000
222000
267000
345
691
971
1170
M 24 x 2
86000
172000
242000
290000
365
731
1030
1230
M 27 x 3
103000
206000
289000
347000
505
1010
1420
1700
M 27 x 2
111000
222000
312000
375000
534
1070
1500
1800
M 30 x 3,5
126000
251000
353000
424000
686
1370
1930
2310
M 30 x 2
139000
278000
391000
469000
738
1480
2080
2490
IMPORTANT
Sensor maximum driving torque: 15 Nm.
Page
G-2
Document 57.0005.9200 - 12/2005
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-2.1
LOAD CHART WITH FORKS - GTH-5519
GTH-5519
From serial no. xxxxx
To serial no.
14976
20
70 deg
E
60 deg
D
C
50 deg
15
B
A
40 deg
30 deg
5500 lb
10
ft
1700 lb
10 deg
4000 lb
5
2600 lb
2000 lb
20 deg
0 deg
0
-3 deg
E
D
C
B
A
5
15
10
5
0
Forward reach, ft
Page
G-3
Document 57.0005.9200 - 12/2005
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-2.2
LOAD CHART WITH FORKS - GTH-5519
20
GTH-5519
From serial no. 14977
To serial no.
xxxxx
70 deg
E
60 deg
D
C
50 deg
15
B
A
40 deg
5500 lb
30 deg
10
C
B
ft
1700 lb
10 deg
4400 lb
5
2600 lb
2000 lb
20 deg
0 deg
0
-3 deg E
D
A
5
15
10
5
0
Forward reach, ft
Page
G-4
Document 57.0005.9200 - 12/2005
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-3.1 WIRING DIAGRAM - FUSES AND RELAYS
FUSES
Ref.
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
Circuit
Amp.
Interior lamp power supply
2
Frontwork light switch power supply
10
Rear work light switch power supply
10
E1 relay pickup, E2 relay pickup, E3 relay pickup,
Relay E6 power supply, hydraulic stop,
warning lights-fuel gauge instrument, air filter
soiled warning light, preheating warning light,
engine oil cooling temperature indicator light,
engine oil temperature indicator
5
Power supply: engine stop solenoid,
preheating control unit
10
Horn switch power supply
10
Vse solenoid valve switch power supply
5
Parking brake switch power supply
5
Windscreen wiper/washer motor power supply
15
Windscreen wiper/washer switch power supply
5
Power supply: beacon, lighting: warning lights,
fuel gauge, engine oil temperature indicator,
engine oil cooling temperature indicator
7.5
Power supply: steering selector
7.5
Relay E3/Relay E5 power supply
5
Not used
5
Not used
2
Not used
10
Not used
10
Not used
5
Not used
10
Not used
10
Not used
5
Not used
5
Not used
15
Not used
5
Not used
7.5
Not used
7.5
Not used
5
Not used
5
Spare fuses
Engine compartment fuses
F30
F31
Timer fuse
Start-up and main board fuse
50
50
Page
F14
F28
F13
F27
F12
F26
F11
F25
F10
F24
F9
F23
F8
F22
F7
F21
F6
F20
F5
F19
F4
F18
F3
F17
F2
F16
F1
F15
F29
F29
F29
F29
INT
E5
E4
E3
E2
E1
E6
E11 F30 F31 E12
RELAYS
Ref.
Circuit
E1
Front/rear work lights
E2
Engine start with parking brake engaged
E3
Relay E4 enabling command
E4
Forward speed enabling command
E5
Reverse speed
E6
E11
E12
Stop
Glow plugs timer relay
Start relay
G-5
Document 57.0005.9200 - 12/2005
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
Intentionally blank page
Page
G-6
Document 57.0005.9200 - 12/2005
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-3.2 WIRING DIAGRAM - FUSES SYSTEM
17
16
E4
E5
E6
E7
85
87A 87
86
30
E8
85
87A 87
86
30
E9
85
87A 87
86
30
E10
1
2
3
4
5
6
7
8
9 10
5A
30
7.5A
87A 87
86
5A
85
15A
30
5A
87A 87
86
5A
85
10A
30
10A
87A 87
86
5A
85
10A
30
2A
87A 87
86
19
11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28
Rø1.5
GNø1.5
ENø1.5
RNø1
BRø1.5
DRø1.5
FRø1.5
MEø1
FNø1.5
BNø1.5
VBø1
MNø1
Cø1.5
85
RNø1
E3
Rø1
30
Cø1.5
87A 87
86
MNø1.5
85
BEø1.5
E2
REø1
6
30
Cø1.5
3
Nø1
FRø1.5
AGø1
87A 87
86
RNø1
5
85
Fø1.5
4
2
E1
RNø1
7
1
30
Rø2.5
FRø1.5
HEø1
8
87A 87
86
RNø1
HEø1
85
10A
18
7.5A
Rø4
GEø2.5
GEø2.5
Mø2.5
Mø2.5
Mø2.5
Mø2.5
Mø2.5
Mø2.5
Mø2.5
Mø2.5
Mø2.5
Mø4
Nø1
REø1
Nø1
CNø1.5
VNø1
6
DBø1
BEø1.5
3
MEø1
MEø1
Fø1
Vø1.5
5
DBø1
4
2
Nø1
7
1
GEø2.5
RNø1
Rø1
Nø1
DBø1
8
ANø1
P
DBø1
19
14
1
2
REø1
BFø1
3
4
5
6
RNø1
RNø1
RNø1
15
Rø6
MNø1.5
CNø1.5
CGø1
Cø1
Rø4
Mø4
Nø2.5
DRø1
DRø1.5
DEø1
DFø1
DBø1
DGø1
MNø1
FRø1
BEø1
VBø1.5
32
1
Rø6
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Nø2.5
Nø4
CGø1
GRø1
HEø1
DRø1
Aø1
DFø1
Vø1
BFø1
Cø1
HEø1
ANø1
AGø1
ANø1
BEø1
BRø1
DEø1
Fø1
BNø1
BNø1.5
MRø1
18
8
7
1
4
2
5
3
6
19
20
21
22
23
24
25
26
27
28
29
GEø1.5
VBø1
Rø1.5
Nø1
Nø1
Nø1.5
31
1
1
2
2
3
3
4
4
5
5
6
6
7
8
9
10
11
12
13
14
15
16
17
18
Nø1
M
COLOUR LEGEND
22
FGø1
MNø1
Nø1
28
Page
G-7
Document 57.0005.9200 - 12/2005
6
12 11 10
9
8
7
6
5
4
3
2
1
27
26
M
25
Nø1
VNø1
Rø1.5
Nø1
VBø1
Nø1
GEø1.5
GNø1.5
Gø1.5
Gø1
Gø1
GRø1
AGø1
BGø1
Vø1.5
Vø1
ENø1.5
Aø1
29
Nø1.5
GEø1.5
BAø1
BGø1
MNø1
GRø1.5
C
6
GROUND SYMBOL
FNø1.5
30
B
5
M
Nø1.5
A
4
Nø1
GEø1.5
VBø1
Rø1.5
Nø1
Nø1
Nø1.5
24
3
3
21
MRø1
31
2
2
20
FGø1
Gø1.5
DGø1
FRø1
BRø1.5
VBø1.5
REø1
Fø1.5
GRø1.5
BAø1
30
1
1
23
A ORANGE
B WHITE
C PINK
D GREY
E GREEN
F BLUE
G YELLOW
H LIGHT BLUE
M BROWN
N BLACK
R RED
V PURPLE
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-3.3 WIRING DIAGRAM - DASHBOARD SYSTEM
1
-
+
4
J5
2
J7
Nø1
AGø1
3
RNø1
J12
7
2
1
5
RNø1
ENø1.5
Gø1.5
BGø1
7
1
4
2
5
3
6
RNø1
J1
J4
J10
RNø1
Cø1
BFø1
Gø1
RNø1
DGø1
DBø1
FRø1
DRø1
FRø1
S
+ -
S
Nø1
DEø1
J2
RNø1
J3
+ -
Aø1
ENø1.5
Vø1
Vø1.5
BGø1
AGø1
GRø1
Gø1
Gø1
Gø1.5
GNø1.5
GEø1.5
15
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
2
5
6
2
3
4
5
6
7
8
9
10
11
12
6
3
RNF
R
N
4
F
+
1
8
Nø1
GNø1.5
GEø1.5
ERø1
BFø1
8
7
1
4
2
5
3
GEø1.5
6
7
3
4
1
Aø1
3
MNø1.5
2
Rø6
MNø1.5
CNø1.5
CGø1
Cø1
Rø4
Mø4
Nø2.5
DRø1
DRø1.5
DEø1
DFø1
DBø1
DGø1
MNø1
FRø1
BEø1
VBø1
CNø1.5
1
Gø1
5
4
6
8
J11
Nø1
ERø1
J9
8
3
J13
0 0 0 0 0 0 3
J8
Nø1
BEø1
Nø1
Nø1
J14
Gø1
J6
Nø1
Gø1
J15
RNø1
RNø1
RNø1
14
GROUND SYMBOL
MNø1
GRø1
Mø4
Vø1.5
CGø1
9
A
C
Nø1
DRø1.5
COLOUR LEGEND
8
7
2
1
3
58
13
19
B
50
P0 1 23
5
10
E
Vø1
4
6
F
FRø1
Nø1
Rø6
Rø4
30
VBø1
RNø1
DFø1
RNø1
11
15
12
Page
G-8
Document 57.0005.9200 - 12/2005
A ORANGE
B WHITE
C PINK
D GREY
E GREEN
F BLUE
G YELLOW
H LIGHT BLUE
M BROWN
N BLACK
R RED
V PURPLE
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-3.4 WIRING DIAGRAM - CHASSIS SYSTEM
2
1
12v
Nø1
42
+ 12v
43
44
ANø1
Nø1
A
DGø1
Cø1
Nø1
41
CGø1
A
2
1
GRø1
12v
T
DRø1
B
P
Nø1
T
ERø1
12v
40
DEø1
35
GRø1.5
2
1
Aø1
A
BAø1
AGø1
12v
2
1
39
Nø1
34
C
2
1
38
DFø1
Nø1
33
Nø1
Nø1
37
36
32
Rø6
1
2
Nø2.5
Nø4
3
4
CGø1
GRø1
HEø1
DRø1
Aø1
DFø1
Vø1
BFø1
Cø1
HEø1
ANø1
AGø1
ANø1
BEø1
BRø1
DEø1
Fø1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
45
Gø1.5
Nø1.5
18
19
20
22
23
24
25
26
27
28
29
BRø1.5
Gø1.5
DGø1
FRø1
BRø1.5
VBø1.5
REø1
Fø1.5
GRø1.5
BAø1
21
49
30
50
50A
GROUND SYMBOL
50A
55
Fø4
58
Nø1
Bø6
Fø2.5
31
Rø6
Nø1.5
31
51
Page
G-9
Document 57.0005.9200 - 12/2005
60
59
30
L
T
+
50 85
BEø1
FRø1
Rø10
W
M
B+
D+
48
57
56
54
53
52
Vø1
Nø1
12v
47
46
T
86 87
Rø50
Mø6
Mø6
Rø10
Fø4
Rø50
Nø50
Fø1
Nø1
12v
BRø1
Bø6
Bø6
VBø1
1
2
Bø6
ANø1
Nø1
61
12v
Nø1
HEø1
Nø1
BFø1
Nø1
1
2
COLOUR LEGEND
Fø1
1
2
Rø6
Fø1.5
86 30
Mø6
Mø6
85 87
A ORANGE
B WHITE
C PINK
D GREY
E GREEN
F BLUE
G YELLOW
H LIGHT BLUE
M BROWN
N BLACK
R RED
V PURPLE
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-3.5 GENERAL WIRING DIAGRAM (description)
Ref. Description
Ref. Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
WARNING LIGHTS-FUEL GAUGE
ENGINE OIL TEMPERATURE TRANSDUCER
ENGINE OIL COOLING TEMPERATURE
INDICATOR
MOVEMENT STOP SWITCH
REAR WORK LIGHT SWITCH
12-WAY CONNECTOR - STEERING COLUMN
LINE CONNECTION TO CAB LINE
FRONT WORK LIGHT SWITCH
CHANGEOVER-OVER SWITCH
HORN SWITCH
STEERING SELECTOR
IGNITION KEY SWITCH
PREHEATING GLOW PLUGS WARNING
LIGHT
AIR FILTER SOILED WARNING LIGHT
6-WAY CONNECTOR - STEERING COLUMN
LINE CONNECTION TO CAB LINE
18-WAY CONNECTOR - STEERING COLUMN
LINE CONNECTION TO CAB LINE
HYDRAULIC STOP
PARKING BRAKE SWITCH
VSE SOLENOID VALVE CONTROL
FUSES AND RELAYS BOX
WINDSCREEN WIPER/WASHER SWITCH
FRONT WINDSCREEN WIPER/WASHER
MOTOR
REAR WINDSCREEN WIPER/WASHER
MOTOR
SEAT SWITCH
6-WAY CONNECTOR - FUSES LINE
CONNECTION TO CAB LINE
CAB LIGHTING
BEACON
WORK LIGHT
OPTIONAL FLASHING CONNECTOR
JOYSTICK CONNECTOR
OPTIONAL 3-WAY CONNECTOR
31-WAY CONNECTOR - FUSES LINE
CONNECTION TO ENGINE LINE
4-WAY CONNECTOR - FUSES LINE
CONNECTION TO ENGINE LINE
SOLENOID VALVE - ATTACHMENT RELEASE
SOLENOID VALVE - ATTACHMENT COUPLING
SOLENOID VALVE - FWD SPEED
COMPRESSED AIR COMPRESSOR
Page
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
HYDRAULIC OIL TEMPERATURE SENSOR
AIR FILTER CLOGGING SENSOR
ENGINE OIL PRESSURE TRANSDUCER
OIL TEMPERATURE INDICATOR SENSOR
WHEEL STEERING SOLENOID VALVE
WHEEL STEERING SOLENOID VALVE
BACK-UP HORN
FUEL FLOAT
WORK LIGHT
HORN
HIGH SPEED SOLENOID VALVE
ENGINE OIL COOLING TEMPERATURE
SENSOR
ENGINE STOP SOLENOID
PREHEATING CONTROL UNIT MAXIFUSE
SYSTEM PROTECTION FUSE
ALTERNATOR
STARTER MOTOR
12V BATTERY
STARTING RELAY
PREHEATING CONTROL UNIT
GLOW PLUGS
ENGINE STOP SOLENOID VALVE
SOLENOID VALVE - REVERSE SPEED
VSE SOLENOID VALVE
NEGATIVE BRAKE PRESSURE SWITCH
G-10
Document 57.0005.9200 - 12/2005
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-4.1 HYDRAULIC SCHEME
Hydraulic piloting line
test port
TP2
A
T
B
Pressure reducing
valve
Service brake
circuit reservoir
Parking brake
selector valve
T P
R
7 psi
0.5 bar
2
X
1
Continous flow
selector valve
Shuttle
valve
Hydraulic
collector
Check valve
7 psi / 0.5 bar
Front axle
Parking brake
control valve
Load handling
control lever
406 psi
28 bar
U
E
0.02 in
0.5 mm
3
DR
Service brake
pedal pump
3
1
2
P2
A
4.2:1
4350 psi
300 bar
P1
Y
Quick coupling
hydraulic ports
G HCDEF
1
Rear axle
steering cylinder
B
A
T
P
4
T
P
3
Boom functions
piloting selector valve
2
Tilt
cylinder
Steering mode
selector valve
Piloted check
valve 4:1
Slave
cylinder
Front axle
steering cylinder
R
3262 psi
225 bar
C
4:1
4350 psi
300 bar
B4
L
A4
11:1
4350 psi
300 bar
Steering
rotating
actuator
2465 psi
170 bar
Y4
A3
Boom extend
retract cylinder
4205 psi
290 bar
4:1
4350 psi
300 bar
LS
P
X4
B3
Anti cavitation
valves
72 psi / 5 bar
Boom lift
cylinder
X3
B2
A2
Y3
P
X2
B1
Y2
A1
T
Accumulator
X1
capacity: 0.13 gallons / 0.5 Liters
pre-charge pressure: 725 psi / 50 bar
T
Y1
P
Boom functions hydraulic
circuit test port TP
3915 psi
270 bar
1
Load handling
controls
main valve
Hydrostatic transmission
high pressure test port
b
Flushing valve
TP3
a
R T1 T2
PS Fa Fa1
Fe
Hydrostatic
transmission
motor
MB
Check valve
36 psi / 2.5 bar
6525 psi
450 bar
725 psi
50 bar
B
U
B
X2
X1
M1
Engine
Function pump
with integrated
priority valve
21.7 gpm / 82 L/min
CF
EF
LS
M
362 psi
25 bar
6525 psi
450 bar
Hydrostatic
transmission
pump
Suction
filter
6235 psi
430 bar
X2
X1
G
TP4
Hydrostatic transmission
boost pressure test port
Page
G-11
Document 57.0005.9200 - 12/2005
A
MH
Suction
filter
Check valve
7 psi / 0.5 bar
B
Forks attachment
quick coupling cylinder
S FS
A
G
T
MA
Check valve
7 psi / 0.5 bar
Heat
exchanger
Check valve
36 psi / 2.5 bar
Thank
Handler with telescopic boom GTH-5519
TABLES AND DOCUMENTS ENCLOSED
G-5 ROUTINE CHECK SCHEDULE - SAFETY DEVICES
Table key explanation:
Block.Valve 9
Block.Valve 8
Block.Valve 7
Block.Valve 6
Block.Valve 5
Block.Valve 4
Block.Valve 3
Block.Valve 2
Date
Block.Valve 1
COMPONENT
Result/Notes
Positive
Block valve 1
Block valve on lifting cylinder
Block valve 2
Block valve on fork balance cylinder
Block valve 3
Block valve on telescope extension cylinder
Block valve 4
Block valve on attachment moving cylinder
Block valve 5
Block valve on attachment locking cylinder
Negative Signature
❑
❑
Block valve 6
❑
❑
Block valve 7
❑
❑
Block valve 8
❑
❑
Block valve 9
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
Page
G-12
Document 57.0005.9200 - 12/2005
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