Terex Genie GTH-5519 Operator's Manual
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Terex Genie GTH-5519 Operator's Manual

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Operator's Manual
GTH-5519
GTH-5519
Serial number range
From serial n.: 19388
To serial n.: 24471
(Perkins Tier III)
From serial n.: 19006
(Deutz Tier III)
To serial n.: 25040
With Maintenance
Information
First Edition
Eleventh Printing
Part No.
57.0009.0412

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Summary of Contents for Terex Genie GTH-5519

  • Page 1 Operator’s Manual Serial number range From serial n.: 19388 GTH-5519 To serial n.: 24471 (Perkins Tier III) From serial n.: 19006 GTH-5519 (Deutz Tier III) To serial n.: 25040 With Maintenance Information First Edition Eleventh Printing Part No. 57.0009.0412...

  • Page 2: Table Of Contents

    Telephone +39 075 941811 Telefax +39 075 9415382 Technical Assistance Service Telephone: +39 075 9418129 +39 075 9418175 e-mail: UMB.Service@terex.com Original Instructions First Edition: Tenth Printing, October 2011 For the electronic version of this manual visit www.genielift.com/operator_manuals.asp © Copyright 2006...

  • Page 3: Introduction

    First Edition - Eleventh Printing Operator’s Manual Introduction Symbols Safety alert symbol: used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death DANGER Red: indicates a hazardous situation which, if not avoided, will result in death or serious injury.
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  • Page 5: Machine Identification

    First Edition - Eleventh Printing Operator’s Manual Machine Identification Check that the operator handbook refers to the MACHINE IDENTIFICATION PLATES delivered machine. The following data plates are applied on the machine: MODEL AND TYPE Machine data plate Handler with telescopic boom: The identification plate contains the main identification data of the machine like model, serial number and GTH-5519...
  • Page 6 Operator’s Manual First Edition - Eleventh Printing Machine Identification CHASSIS SERIAL NUMBER The chassis serial number is punched on the front left part of the chassis side member. IDENTIFICATION PLATES OF THE MAIN PARTS The plates of the main components, not directly manufactured by TEREXLIFT srl (for instance, engines, pumps, etc.), are located where originally applied by the manufacturers.

  • Page 7: Symbols Used On The Machine

    First Edition - Eleventh Printing Operator’s Manual Symbols Used On The Machine General alarm Fuel level Low engine oil Parking brake Battery charge pressure L o w H y d r a u l i c O i l Hydraulic oil filter Hydraulic oil filter Turn signals High beam...
  • Page 8 Operator’s Manual First Edition - Eleventh Printing Symbols Used On The Machine HAZARD PICTORIAL DESCRIPTIONS Electrocution Falling Object Maintain required No people under Fall Hazard Hazard Hazard clearance. load. Always wear seat Bodily Injury Keep load low. No riders. Overturning belt.

  • Page 9: Labels And Plates Applied On The Machine

    First Edition - Eleventh Printing Operator’s Manual Labels And Plates Applied On The Machine Shading indicates decal is hidden from view, i.e. under covers. DEUTZ PERKINS Part No. 57.0009.0412 GTH-5519...
  • Page 10 Operator’s Manual First Edition - Eleventh Printing Labels And Plates Applied On The Machine Use the pictures on these pages to verify that all decals are legible and in place. The following chart shows quantities and description too. Ref. Decal Code Description SAFETY PIN...
  • Page 11 First Edition - Eleventh Printing Operator’s Manual Labels And Plates Applied On The Machine Ref. Decal Code Description DANGER 97670B Warning - Crush Hazard, Parking Brake Crush Hazard Death or serious injury could result from rolling of an unattended machine. Set parking brake, lower carriage or attachment to ground before leaving machine.
  • Page 12 Operator’s Manual First Edition - Eleventh Printing Labels And Plates Applied On The Machine Ref. Decal Code Description 97676B Danger - Electrocution Hazard Emergency 97688 Emergency Exit Handle Exit Handle 97688 A WARNING Injection Hazard Escaping fluid under pressure can penetrate skin, causing serious injury.
  • Page 13 PUSH 09.4618.0781 09.4618.0819 09.4618.0792 Label - Engine Cover Closing 09.4618.0792 114470 Cosmetic - GENIE Logo GTH-5519 09.4618.0644 Cosmetic - GTH-5519 GTH-5519 09.4618.0643 Cosmetic - Genie GTH-5519 09.4618.0109 Sticker With Various Warnings 97668B Warning - Overturning Hazard Part No. 57.0009.0412 GTH-5519...
  • Page 14 Operator’s Manual First Edition - Eleventh Printing Labels And Plates Applied On The Machine Ref. Decal Code Description WARNING Crush Hazard Machine movement can cause serious 114365A injury or death. Crush Hazard Stay away from machine. 114365 A 114367B Falling Objects WARNING 28162C Fan Belt...
  • Page 15 First Edition - Eleventh Printing Operator’s Manual Labels And Plates Applied On The Machine Ref. Decal Code Description Label - Upper Door External Unlock 09.4618.1025 System 09.4618.1025 09.4618.0949 Label - Fuses and Relays Engine Board Ref. Description Ref. Description Glow Plugs Preheating Main Fuse Starter Enabling Switch Glow Plugs Fuse...
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  • Page 17: Safety Precautions

    First Edition - Eleventh Printing Operator’s Manual Safety Precautions SAFETY DEVICES DAMAGED MACHINE HAZARDS • Do not use a damaged or defective machine. • Do a thorough pre-operation inspection of the machine and test all functions before each work shift. Tag and remove from service a damaged or defective machine.
  • Page 18 Operator’s Manual First Edition - Eleventh Printing Safety Precautions GENERAL REMARKS Not observing the instructions and safety rules in this manual Most accidents occurring while working, repairing or may result in death or serious maintaining machines, are caused by not complying injury.
  • Page 19 First Edition - Eleventh Printing Operator’s Manual Safety Precautions REQUISITES OF THE PERSONNEL IN CHARGE Requisites of the SERVICEMEN Requisites of the MACHINE OPERATORS The personnel charged with the machine maintenance The operators who use the machine regularly or shall be qualified, specialised in the maintenance occasionally (i.e.
  • Page 20 Operator’s Manual First Edition - Eleventh Printing Safety Precautions OTHER DANGERS Hazards on the JOBSITE WORKING CLOTHES Always take into account the features of the job site During work, but especially when maintaining or where you are going to work: repairing the machine, operators must wear suitable protective clothing: •...
  • Page 21 First Edition - Eleventh Printing Operator’s Manual Safety Precautions OPERATION or MAINTENANCE hazards • When entering/leaving the cab or other raised parts, always face the machine; never turn the Before any operation, following precautions should back. be taken: • First of all, make sure that the maintenance interventions have been carried out with care according to the established schedule.
  • Page 22 Operator’s Manual First Edition - Eleventh Printing Safety Precautions • Do not lubricate, clean or adjust moving parts. • When working, do not give instructions or signs to several people at the same time. Instructions • Do not carry out operations manually when specific tools are provided for this purpose.
  • Page 23 First Edition - Eleventh Printing Operator’s Manual Safety Precautions EXPLOSION OR FIRE hazards DAMAGED COMPONENT hazards • Do not start the engine if you smell or detect • Do not use battery chargers or batteries with a LPG, gasoline, diesel fuel or other explosive voltage above 12V to start the engine.
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  • Page 25: Description Of The Main Components

    First Edition - Eleventh Printing Operator’s Manual Description Of The Main Components 1. Forks 2. 2 boom section 3. 1 boom section 4. Engine hood 5. Driving cab 6. Front axle 7. Chassis 8. Left front wheel mud-guard 9. Left front wheel reduction gear 10.
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  • Page 27: Controls And Instruments

    First Edition - Eleventh Printing Operator’s Manual Controls And Instruments BRAKE OIL 09.4618.0780 1. Fresh Air Flap 9. Multipurpose Control Lever 2. Forward/reverse Gear Selector Lever 10. Gas Pedal 3. Steering Colum Angle Adjustment 11. Instruments Dashboard 4. Turn Signals - Windscreen Washer - Horn 12.
  • Page 28 Operator’s Manual First Edition - Eleventh Printing Controls And Instruments Forward/reverse gear selector switch Ignition switch Three-position switch with lock in neutral position: Three-position switch: Neutral position; no gear engaged No circuit under voltage, key can be removed Shift lever to pos. 1 to select the forward and engine is stopped gear Circuits under voltage, presetting for the en-...
  • Page 29 First Edition - Eleventh Printing Operator’s Manual Controls And Instruments Turn signals - Lights (OPTIONAL) (only with closed cabin) Turn signals function: Set lever to pos. 1 to indicate a turn leftwards or to pos. 2 to indicate a turn rightwards. When starting the engine the lights of all the pushbuttons turn automatically on! Only the switching-on of the orange warning light...
  • Page 30 Operator’s Manual First Edition - Eleventh Printing Controls And Instruments Accelerator control Brakes Service Brake Pedal Gas Pedal Gradually step on the brake pedal to decelerate Its pressure controls the engine rpm and the machine and stop the machine. The pedal operates on the speed.
  • Page 31 First Edition - Eleventh Printing Operator’s Manual Controls And Instruments Steering mode selection Steering Mode Switch Three-position switch for the selection of the steering mode: Four-wheel steering Two-wheel steering Crab steering 8 .0 Continuous Oil Flow Before activate the Continuous Oil Flow function, make sure the connectors of the attachment are coupled.
  • Page 32 Operator’s Manual First Edition - Eleventh Printing Controls And Instruments Auxiliary drive controls 28 Windscreen Washer Switch (OPTIONAL) Two-position switch: 8 Hazard Warning Lights Switch (OPTIONAL) Fitted with on-off position, it switches on the turn 0 Washer OFF signals simultaneously. When the hazard warning light is lit, the relevant 1 Jet of water on the cab windscreen switch and the turn signals light start...
  • Page 33 First Edition - Eleventh Printing Operator’s Manual Controls And Instruments Instruments Fuel gauge Engine coolant temperature indicator This indicates the fuel level in the tank. This indicates the engine coolant temperature. If the If the fuel level is low (reserve), the relevant warning finger is in the red zone and the warning light comes light comes on.
  • Page 34 Operator’s Manual First Edition - Eleventh Printing Controls And Instruments Warning lights (ref. 11) 11.9 Warning light - low hydraulic oil level 11.1 Warning light - low battery charge This light comes on to alert to a low level of the Signals a low charge by the alternator.
  • Page 35 First Edition - Eleventh Printing Operator’s Manual Controls And Instruments CONTROL LEVER Handlers are equipped with a hydraulically driven servo-controlled lever. The lever has two pushbuttons: one for coupling/ releasing the attachments 3 and the other for pitching the attachment frame forwards/backwards 2. Shifting the lever to one of the four directions (right/ left, forwards/backwards) moves the boom up and down and the telescope out and in.
  • Page 36 Operator’s Manual First Edition - Eleventh Printing Controls And Instruments Function selection The lever is enabled to carry out the following motions: • Boom lowering/lifting shift the control lever to A or B • Boom extraction/retraction shift the control lever to C or D •...
  • Page 37 First Edition - Eleventh Printing Operator’s Manual Controls And Instruments Lifting/lowering the boom DANGER Before operating the boom, make sure that nobody is within the working range of the machine. To lift or lower the boom: • Smoothly shift the lever to position B to lift the boom or to position A to lower it.
  • Page 38 Operator’s Manual First Edition - Eleventh Printing Controls And Instruments Extending/retracting the boom DANGER Before operating the boom, make sure that nobody is within the working range of the machine. To extend or retract the telescopic elements of the boom: •...
  • Page 39 First Edition - Eleventh Printing Operator’s Manual Controls And Instruments Pitching the attachment holding frame forward/back DANGER Before operating the boom, make sure that nobody is within the working range of the machine. To tilt forward/back the attachment holding frame: •...
  • Page 40 Operator’s Manual First Edition - Eleventh Printing Controls And Instruments H y d r a u l i c Q u i c k C o u p l i n g / R e l e a s e OPTIONAL DANGER Before operating the boom, make sure that nobody...

  • Page 41: Inspections

    First Edition - Eleventh Printing Operator’s Manual Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection Make sure: performed by the operator prior to each work shift. The inspection is designed to discover if anything You learn and practice the principles of safe is apparently wrong with a machine before the...
  • Page 42 Operator’s Manual First Edition - Eleventh Printing Inspections PRE-OPERATION INSPECTION • Make sure the operator’s manuals are intact, * Make sure that all structural and other critical legible and placed inside the machine. components are present and the relevant • Make sure all decals are present and legible.
  • Page 43 First Edition - Eleventh Printing Operator’s Manual Inspections FUNCTION TESTS CAUTION Test the Control Lever 7 Using the control lever, momentarily raise the boom, extend the boom, retract the boom and The function tests are designed to discover lower the boom. any malfunctions before the machine is put into service.
  • Page 44 Operator’s Manual First Edition - Eleventh Printing Inspections WORKPLACE INSPECTION Test the Transmission and Brakes WARNING 17 Be sure the boom is fully lowered and retracted. 18 Step on the service brake pedal. 19 Move the transmission control lever to forward. The workplace inspection helps the operator Slowly let up on the service brake pedal.

  • Page 45: Operating Instructions

    First Edition - Eleventh Printing Operator’s Manual Operating Instructions WARNING 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 For a safe use of the machine, always check the attachments”.
  • Page 46 Operator’s Manual First Edition - Eleventh Printing Operating Instructions ENTERING THE MACHINE (only for closed cabin) To unlock the door latched in open position: ENTERING THE CAB WARNING  • Press button 4 to unlock   the door from the catch Always make sure that your hands and shoe soles •...
  • Page 47 First Edition - Eleventh Printing Operator’s Manual Operating Instructions ADJUSTING THE SEAT A correct adjustment of the seat ensures the operator a safe and comfortable driving. The handler seat is fitted with devices which allow for the adjustment of the springing, the height and the distance from the controls.
  • Page 48 Operator’s Manual First Edition - Eleventh Printing Operating Instructions ADJUSTING THE REAR VIEW MIRRORS STEERING COLUMN ANGLE ADJUSTMENT The machine is fitted with two rear view mirrors: Both steering column and dashboard can be set to • The right rear view mirror 2 is located on a special a different angle.
  • Page 49 First Edition - Eleventh Printing Operator’s Manual Operating Instructions STARTING THE ENGINE JUMP-STARTING THE ENGINE For the low temperature starting, see paragraph CAUTION “Low Temperature Starting”. • Engage the parking brake. • Put the forward/reverse speed selection lever to neutral. Do not start the engine using a quick charge booster to avoid any damage to the electronic •...
  • Page 50 Operator’s Manual First Edition - Eleventh Printing Operating Instructions LOW TEMPERATURE STARTING • Connect the two batteries as shown in the In case of cold starting, use an oil with a SAE viscosity figure. Connect first the positive terminals of the adequate to the ambient temperature.
  • Page 51 First Edition - Eleventh Printing Operator’s Manual Operating Instructions STARTING THE MACHINE STOPPING AND PARKING THE MACHINE When the engine reaches the running temperature, When possible, stop the machine on a dry, level and ensure all parts are in transfer position and the gearbox solid ground.
  • Page 52 Operator’s Manual First Edition - Eleventh Printing Operating Instructions USING THE LOAD CHARTS WARNING The load charts 1 indicates the maximum permissible load in relation to the boom extension and the type of attachment used. To operate under safe conditions, always refer to these charts.
  • Page 53 First Edition - Eleventh Printing Operator’s Manual Operating Instructions HANDLING LOADS DANGER Adjusting the forks With FEM forks (optional) Forks shall be spaced to suit the load going to be handled. For this purpose: • Lift the clamping lever of the forks. •...
  • Page 54 Operator’s Manual First Edition - Eleventh Printing Operating Instructions WORKING PHASES When forks are correctly spaced, the handler is • Carefully withdraw the forks by operating the ready to use. boom retraction control and, if necessary, raise Work can be subdivided into three different phases: or lower the boom as forks come out.
  • Page 55 First Edition - Eleventh Printing Operator’s Manual Operating Instructions WARNING CHANGING THE ATTACHMENT CAUTION Use only attachments directly manufactured or After substitution, visually check the attachment recommended by Terexlift and detailed in the is correctly coupled to the boom, before operating “Optional attachments”...
  • Page 56 Operator’s Manual First Edition - Eleventh Printing Operating Instructions SET “0” INSTRUCTIONS PUSH Version with HYDRAULIC LOCKING 09.4618.0781 (OPTIONAL) 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).

  • Page 57: Transporting The Machine

    First Edition - Eleventh Printing Operator’s Manual Transporting The Machine MOVING A DISABLED MACHINE ROAD OR SITE TRANSFER Tow the machine only when no alternative is possible, When travelling on public roads, strictly obey the since this operation may result in serious damage to local or national road traffi...
  • Page 58 Operator’s Manual First Edition - Eleventh Printing Transporting The Machine LIFTING THE MACHINE TRANSPORTING THE MACHINE ON OTHER VEHICLES When the machine shall be lifted, use only means To transport the machine on another vehicle, follow having a suitable capacity. The characteristic data the steps below: are detailed in the relevant chapter of this manual and on the identification plate.
  • Page 59 First Edition - Eleventh Printing Operator’s Manual Transporting The Machine PARKING AND STORAGE Machine storage Short inactivity In case of extended inactivity of the machine, follow Always park the machine in a safe way after a working the above precautions. Additionally: day, a shift and at night.
  • Page 60 Operator’s Manual First Edition - Eleventh Printing Transporting The Machine CLEANING AND WASHING THE MACHINE MACHINE DISPOSAL PROTECT THE Clean the machine in accordance with the following instructions: ENVIRONMENT • Remove any oil or grease traces with a dry solvent or a volatile mineral alcohol At the end of the machine life, call in a specialised •...

  • Page 61: Maintenance

    First Edition - Eleventh Printing Operator’s Manual Maintenance Observe and obey: INTRODUCTION The operator can only perform t h e r o u t i n e m a i n t e n a n c e A thorough and regular maintenance keeps the operations envisaged in this machine in a safe and efficient working condition.
  • Page 62 Operator’s Manual First Edition - Eleventh Printing Maintenance LUBRICANTS - HEALTH AND SAFETY PRECAUTIONS Health First aid A prolonged skin contact with oil can cause irritation. Eyes : In case of accidental contact with Use rubber gloves and protective goggles. After the eyes, wash with fresh water.
  • Page 63 First Edition - Eleventh Printing Operator’s Manual Maintenance ORDINARY MAINTENANCE Every 50 working hours or weekly A wrong or neglected maintenance can result in Jobs to be done in addition to those above possible risks for both operator and bystanders. Make sure maintenance and lubrication are carried 1.
  • Page 64 Operator’s Manual First Edition - Eleventh Printing Maintenance Every 500 working hours or every six Every 500 working hours or yearly months Jobs to be done in addition to those above Jobs to be done in addition to those above 1.
  • Page 65 First Edition - Eleventh Printing Operator’s Manual Maintenance MAINTENANCE INTERVENTIONS CAUTION WARNING High pressure lines must be replaced by qualifi ed personnel only. All maintenance interventions must be carried Any foreign matters entering the closed circuit out with engine stopped, parking brake engaged, may result in a sudden deterioration of the working attachments fl...
  • Page 66 Operator’s Manual First Edition - Eleventh Printing Maintenance ACCESS TO THE ENGINE COMPARTMENT DANGER 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. T a k e a l l p r e c a u t i o n s w h e n From the engine compartment, you get access to: approaching the engine compartment.
  • Page 67 First Edition - Eleventh Printing Operator’s Manual Maintenance ENGINE AIR FILTER CAUTION Clean the engine air filter and replace the elements, when necessary. The inner element should be replaced every two times the outer element is replaced. Cleaning and changing the outer element: Never wash the cartridge with water or - Shut the engine down and engage the parking solvents.
  • Page 68  of 6 bar. On delivery, the machine is filled with a cooling mixture consisting of 50% water and 50% anti-freeze. TEREX PRO COOL Protection against boiling / freezing Product % Freezing point Boiling point 1.5°F...
  • Page 69 First Edition - Eleventh Printing Operator’s Manual Maintenance CHANGING THE HYDRAULIC OIL CHECKING THE OIL LEVEL IN THE TANK DANGER To change the hydraulic oil, proceed as follows: 1 Stop the machine on a level ground and make Fine jets of hydraulic oil under pressure can sure the parking brake is engaged.
  • Page 70 Operator’s Manual First Edition - Eleventh Printing Maintenance CHANGING THE OIL FILTER CARTRIDGE To change the hydraulic oil filter element, proceed as follows: 1 Stop the machine on a level ground and engage the parking brake. 2 Place a container of suitable size under the filter to collect any oil leaks.
  • Page 71 First Edition - Eleventh Printing Operator’s Manual Maintenance CAB AIR FILTER (ONLY FOR CLOSED CABIN) Every six months clean the air filter in the cab. Replace the cartridge if the filtering cloth is damged. Cleaning and changing the cartridge: - Shut the engine down and engage the parking brake.
  • Page 72 Operator’s Manual First Edition - Eleventh Printing Maintenance OIL LEVEL IN THE (front/rear) WHEEL OIL LEVEL IN THE DIFFERENTIAL GEARS REDUCTION 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.
  • Page 73 First Edition - Eleventh Printing Operator’s Manual Maintenance OIL LEVEL IN THE POWER DIVIDER GEARBOX To check the oil level in the power diver gearbox:  Filling plug • Stop the machine on a level ground and make  Drain plug sure the parking brake is engaged.
  • Page 74 Operator’s Manual First Edition - Eleventh Printing Maintenance GREASING CAUTION CAUTION Before injecting grease into the greasers, Use only PTFE INTERFLON FIN GREASE LS 2 thoroughly clean them to avoid that mud, dust to lubricate the sliding parts of the telescopic or other matters can mix with the lubricant and section.
  • Page 75 First Edition - Eleventh Printing Operator’s Manual Maintenance TYRES AND WHEELS Always use tyres having the dimensions indicated in the vehicle registration card. SERVICE INTERVAL Over-infl ated tyres can burst. Running-in _________ Within the first hours Ordinary _________________ Every hours Overheated can burst.
  • Page 76 Operator’s Manual First Edition - Eleventh Printing Maintenance SHAFTING ALIGNMENT During operation, the alignment of the front and rear axles of the machine can be subject to variations. This can depend on an oil blow-by from the steering control circuit, or on a steering of both axles when front and rear wheels are not perfectly aligned.
  • Page 77 First Edition - Eleventh Printing Operator’s Manual Maintenance ADJUSTING THE SLIDING PADS OF THE BOOM SECTIONS  Any boom section is fitted with adjustable pads  located on the four sides of the profile. These pads are secured to both fixed and mobile part of every section.
  • Page 78 Operator’s Manual First Edition - Eleventh Printing Maintenance BLOCK VALVES fitted to all CYLINDERS To remove the block valves or the cylinders All machine’s cylinders are equipped with block Lower the boom to the ground in a firm way since valves: the removal of the block valve or the cylinder can cause an uncontrolled down-movement.
  • Page 79 First Edition - Eleventh Printing Operator’s Manual Maintenance C H E C K I N G T H E S T A T E T H E STRUCTURE Checking the MACHINE START CONTROL (at every use) Five years or 6000 hours after the fi rst placing into Attempt to start the engine with the forward or reverse operation of the machine (whichever occurs fi...
  • Page 80 Operator’s Manual First Edition - Eleventh Printing Maintenance ELECTRICAL SYSTEM WARNING WARNING All maintenance interventions must be carried Battery electrolyte contains sulphuric acid. It • out with engine stopped, parking brake engaged, can burn you if it touches your skin and eyes. working attachments on the ground and gearbox Always wear goggles and protective gloves, lever in neutral.
  • Page 81 First Edition - Eleventh Printing Operator’s Manual Maintenance FUSES AND RELAYS The electrical system is protected by fuses placed in the driving cab, on the left. Before replacing a blown fuse with a new one having the same amperage, find out and rectify the fault.
  • Page 82 Operator’s Manual First Edition - Eleventh Printing Maintenance Engine compartment fuses and relays CAUTION (Deutz Version) • 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.
  • Page 83 First Edition - Eleventh Printing Operator’s Manual Maintenance REFUELLING Deutz Perkins Part Product Capacity (USgal) Capacity (USgal) Diesel engine Engine oil Engine cooling system Water+antifreeze Fuel tank Diesel fuel 15.6 15.6 Hydraulic system tank Hydraulic oil Front differential gear with reduction gear 1 + 0.2 1 + 0.2 Rear differential...
  • Page 84  water-50% antifreeze). At the delivery, the machine is refilled with: TEREX PRO COOL by VALVOLINE The use of this product guarantees protection to the circuit for 3 years or 7000 hours without having to add any dry coolant additive.

  • Page 85: Faults And Troubleshooting

    First Edition - Eleventh Printing Operator’s Manual Faults And Troubleshooting FAULTS AND TROUBLESHOOTING WARNING This chapter represents a practical guide for the operator for fixing the most common failures and, at the same time, detecting those interventions that must be carried out by qualified technical engineers. Any repair work, maintenance or troubleshooting If you are unsure about anything, do not carry out must be carried out with machine stopped, boom...
  • Page 86 Operator’s Manual First Edition - Eleventh Printing Faults And Troubleshooting PROBLEM CAUSES SOLUTIONS This is normal, when the outside THE HYDRAULIC OIL temperature is low and/or the THERMOMETER DOES machine is used for short periods, NOT WORK since the hydraulic oil cannot warm up over 104÷122°F THE PARKING BRAKE LIGHT DOES NOT LIGHT...
  • Page 87 First Edition - Eleventh Printing Operator’s Manual Faults And Troubleshooting TORQUE WRENCH SETTINGS METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class 4.6 Class 8.8 Class 10.9 Class 12.9 Size 10.9 12.9...
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  • Page 89: Optional Attachments

    First Edition - Eleventh Printing Operator’s Manual Optional Attachments INTRODUCTION This section provides information on the optional interchangeable attachments, especially manufac- tured for the handlers. Use only genuine attachments, described in this section, after having read their features thoroughly and understood their use. To install and remove the attachments, follow the instructions supplied in the “Operating Instructions”...
  • Page 90 Operator’s Manual First Edition - Eleventh Printing Optional Attachments SIDE TILT FORK CARRIAGE Safety Strictly obey the general safety precautions given in section “Safety”. When using the tilt feature keep the load as level as possible, using extreme caution when driving off of a slope to reposition the forks, to prevent the load from sliding off of the forks or pallet.
  • Page 91 First Edition - Eleventh Printing Operator’s Manual Optional Attachments • Always space the forks correctly for the load. Loads can fall off incorrectly spaced forks. Make sure the forks are completely under the load before lifting. • Never stack loads on uneven ground. Loads stacked on uneven ground can topple.
  • Page 92 Operator’s Manual First Edition - Eleventh Printing Optional Attachments SCRAP GRAPPLE Safety Strictly obey the general safety precautions given in section “Safety”. • Never heap load heavy material where the combined weight of the bucket and the material could exceed the rated capacity of the loader. •...
  • Page 93 First Edition - Eleventh Printing Operator’s Manual Optional Attachments Installation 1. Install hydraulic hoses and couplers onto the 90° elbows on the valve (If not already installed). 2. See paragraph “CHANGING THE ATTACHMENT” in the “Operating Instructions” section for fitting the bucket.
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  • Page 95: Specifications

    First Edition - Eleventh Printing Operator’s Manual Specifications MEASUREMENTS Height ..................6ft 4in Height at steering whell .............. 4ft 1in Width ..................5ft 11in Inside cab width ................2ft 6in Track ................... 4ft 11in Wheelbase .................. 7ft 7in Length at fork-holder plate ............12ft 7in Ground clearance ...............
  • Page 96 Operator’s Manual First Edition - Eleventh Printing Specifications POWER Engine ............Deutz Perkins Model ............D2011 L04 804D.33 Displacement ..........220 in 210 in Cylinder arrangement ........Vertical in line Vertical in line Combustion System ........In-direct injection In-direct injection Max Power Output ........
  • Page 97 First Edition - Eleventh Printing Operator’s Manual Specifications CENTER OF GRAVITY GTH-5519 Part No. 57.0009.0412 GTH-5519...
  • Page 98 Operator’s Manual First Edition - Eleventh Printing Intentionally blank page GTH-5519 Part No. 57.0009.0412...

  • Page 99: Load Charts

    First Edition - Eleventh Printing Operator’s Manual Load Charts GTH 5519 UNIVERSAL ATTACHMENT ADAPTER GTH 5519 09.4618.0804 Part No. 57.0009.0412 GTH-5519...
  • Page 100 Operator’s Manual First Edition - Eleventh Printing Load Charts GTH 5519 FLOATING FORKS GTH 5519 09.4618.0812 GTH-5519 Part No. 57.0009.0412...
  • Page 101 First Edition - Eleventh Printing Operator’s Manual Load Charts GTH 5519 SCRAP GRAPPLE BUCKET GTH 5519 09.4618.0802 Part No. 57.0009.0412 GTH-5519...
  • Page 102 Operator’s Manual First Edition - Eleventh Printing Load Charts GTH 5519 TRUSS BOOM GTH 5519 09.4618.0806 GTH-5519 Part No. 57.0009.0412...
  • Page 103 First Edition - Eleventh Printing Operator’s Manual Load Charts GTH 5519 60 INCH FORKS - OPTIONAL 48 INCH FORKS - 48 INCH CUBING TINES GTH 5519 60 INCH FORKS OPT. 48 INCH ITA FORKS 48 INCH CUBING TINES 09.4618.0803 Part No. 57.0009.0412 GTH-5519...
  • Page 104 Operator’s Manual First Edition - Eleventh Printing Load Charts GTH 5519 60 INCH OR 66 INCH BUCKET GTH 5519 60 INCH BUCKET 66 INCH BUCKET 09.4618.0801 GTH-5519 Part No. 57.0009.0412...
  • Page 105 First Edition - Eleventh Printing Operator’s Manual Load Charts GTH 5519 ROTATING OR SIDE SHIFT FORK CARRIAGE - STANDARD FORK TINES GTH 5519 ROTATING OR SIDE SHIFT FORK CARRIAGE STANDARD FORK TINES 09.4618.0805 Part No. 57.0009.0412 GTH-5519...
  • Page 106 Operator’s Manual First Edition - Eleventh Printing Load Charts GTH 5519 SIDE SHIFT FORK CARRIAGE - 60” FORK TINES GTH 5519 SIDE SHIFT FORK CARRIAGE 60” FORK TINES 09.4618.1680 GTH-5519 Part No. 57.0009.0412...

  • Page 107: Diagrams And Schemes

    First Edition - Eleventh Printing Operator’s Manual Diagrams And Schemes GTH 5519 WIRING DIAGRAM 1/5 (Rev.G, P/N: 57.1800.5109) Part No. 57.0009.0412 GTH-5519...
  • Page 108 Operator’s Manual First Edition - Eleventh Printing Diagrams And Schemes GTH 5519 WIRING DIAGRAM 2/5 (Rev.G, P/N: 57.1800.5109) GTH-5519 Part No. 57.0009.0412...
  • Page 109 First Edition - Eleventh Printing Operator’s Manual Diagrams And Schemes GTH 5519 WIRING DIAGRAM 3/5 (Rev.G, P/N: 57.1800.5109) Part No. 57.0009.0412 GTH-5519...
  • Page 110 Operator’s Manual First Edition - Eleventh Printing Diagrams And Schemes GTH 5519 WIRING DIAGRAM 4/5 (Rev.G, P/N: 57.1800.5109) GTH-5519 Part No. 57.0009.0412...
  • Page 111 First Edition - Eleventh Printing Operator’s Manual Diagrams And Schemes GTH 5519 WIRING DIAGRAM 5/5 (Rev.G, P/N: 57.1800.5109) Part No. 57.0009.0412 GTH-5519...
  • Page 112 Operator’s Manual First Edition - Eleventh Printing Diagrams And Schemes GTH 5519 HYDRAULIC DIAGRAM (Rev.C, P/N: 57.2201.3000) GTH-5519 Part No. 57.0009.0412...

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