Terex Genie GTH 55-19 Service Manual
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Terex Genie GTH 55-19 Service Manual

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SERVICE MANUAL
Code 57.4403.3200 - 2
Edition 01/2008
nd
Handler with telescopic boom
GTH 55-19
(from serial n. 17548 to serial n. 17565)
(from serial n. 17822 to serial n. 17825)
(from serial n. 18154 to serial n. 18168)
(from serial n. 18556 to serial n. 18586)
English
INDEX
Edition

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  • Page 1 SERVICE MANUAL Code 57.4403.3200 - 2 Edition 01/2008 Handler with telescopic boom GTH 55-19 (from serial n. 17548 to serial n. 17565) (from serial n. 17822 to serial n. 17825) (from serial n. 18154 to serial n. 18168) (from serial n. 18556 to serial n. 18586) English INDEX Edition...
  • Page 2 GTH 55-19 Intentionally blank page Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 3 GTH 55-19 SERVICE MANUAL Code 57.4403.3200 - 2 Edition 01/2008 Number: ........Consigned to: ..........................DECLARATION I, the undersigned.......................... declare that I have received the Service manual for GENIE lifts series GTH 55-19. Copies consigned: n° ..on paper n° ..on CD-Rom The undersigned is obliged to use the manual in their workshop, without disclosing the informa- tion in the same in any way, to unauthorised workshops and third parties in general, and not to...
  • Page 5 GTH 55-19 SERVICE MANUAL Code 57.4403.3200 - 2 Edition 01/2008 Number: ........Consigned to: ..........................DECLARATION I, the undersigned.......................... declare that I have received the Service manual for GENIE lifts series GTH 55-19. Copies consigned: n° ..on paper n° ..on CD-Rom The undersigned is obliged to use the manual in their workshop, without disclosing the informa- tion in the same in any way, to unauthorised workshops and third parties in general, and not to...
  • Page 6 GTH 55-19 LIST OF REVISED PAGES Revision Revised pages Notes Issued by Date 06-2007 Publication 01-2008 Section 2, 5, 6 Revision Document 57.4403.3200 - 2 Edition 01/2008 INDEX INDEX...
  • Page 7 GTH 55-19 GENERAL INDEX MANUAL CONTENTS INTRODUCTION Sect. 1 SAFETY RULES Sect. 2 TECHNICAL SPECIFICATIONS Sect.  SCHEDULED MAINTENANCE INSPECTIONS Sect. 4 SCHEDULED MAINTENANCE PROCEDURES Sect. 5 TROUBLESHOOTING Sect. 6 SCHEMES Sect. 7 REPAIR PROCEDURES Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 8 GTH 55-19 SERIAL NUMBER IDENTIFICATION Machine denomination Literature valid up to serial number from 17548 to 17565, from 17822 to 17825, GTH 55-19 from 18154 to 18168, from 18556 to 18586 Document 57.4403.3200 - 2 Edition 01/2008 INDEX INDEX...
  • Page 9 GTH 55-19 INTRODUCTION INTRODUCTION Important Read, understand and obey the safety rules and operating instructions in the GTH 55-19 Operator's Handbook before attempting any maintenance or repair procedure. This manual provides the machine owner and user with detailed information on the scheduled maintenance. It also provided qualified service technicians with infromation on troubleshooting and repair procedures.
  • Page 10 GTH 55-19 INTRODUCTION DESCRIPTION OF THE MACHINE OPERATION The mechanical energy source of this machine is a Perkins diesel engine (1), model 804C-33 Tier 2, which supplies 47.1 kW at 2600 rev/min (63 HP) with a max torque of 198 Nm (146 lb-ft) at 1600 rev/min. On the flywheel side of the engine, and connected to the same by a Technodrive coupler complete with elastic joint and with a 1-to-1 ratio, there is Bosch-Rexroth closed-...
  • Page 11 GTH 55-19 INTRODUCTION the drive circuit. The max displacement of this bent-axis motor is 107 cm /rev. The motor is directly flanged to the front steering axle (26). The mechanical torque produced by the drive motor is transmitted to the rear axle (27) through a Cardan shaft. The hydraulic drive (12) of “load sensing”...
  • Page 12 GTH 55-19 INTRODUCTION with a special double-acting compensation valve. Inside this valve, the one-way valves are mounted in reversed manner with respect to the normal position to avoid the pressurisation of the cylinder when the rotation control of the attachment holding frame is activated. Again inside this valve, there are other two one-way valves, set at 5 bar (72 psi), serving as anti-cavitation check valves (6).
  • Page 13 GTH 55-19 INTRODUCTION pressure switch (28). This pressure switch prevents the machine from moving when the pressure of the parking brake line is too low to guarantee the complete release of this brake. The circuit of the service brake is operated by a SAFIM 27-20 pump (25) which takes hydraulic oil from tank (7) to operate the service brake, located inside the front axle (26).
  • Page 14 GTH 55-19 INTRODUCTION GTH 55-19 hydraulic schematic Document 57.4403.3200 - 1 Edition 06/2007 INDEX...

  • Page 15: Table Of Contents

    GTH 55-19 SAFETY Section 1 SAFETY INFORMATION SECTION INDEX Safety rules ..................page 1.1-1 Personal safety .................... 1.1-2 Workplace safety ..................General remarks ................... Servicemen's requisites ................1.-1 Personal protective equipment ..............General safety precautions ................ 1.4-1 Working areas ....................1.4-2 Precautions during work ................

  • Page 16: Safety Rules

    GTH 55-19 SAFETY SAFETY RULES 1.1-1 Personal Safety Draws the attention to important technical information or practical advice that allows for a safer and more In this manual, any important information is preceded by efficient use of the machine. a SPECIAL SYMBOL. All operators who work or service the machine must know the exact meaning of these safety symbols.

  • Page 17: Workplace Safety

    GTH 55-19 SAFETY 1.1-2 Workplace Safety Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use.

  • Page 18: General Remarks

    GTH 55-19 SAFETY SERVICEMEN'S REQUISITES GENERAL REMARKS The operators who use the machine regularly or Most accidents occurring while working, servicing or occasionally (e.g. for maintenance or transport) shall maintaining operation machines, are caused by not have the following requisites: complying with the basic safety precautions.

  • Page 19: Personal Protective Equipment

    GTH 55-19 SAFETY 1.-1 PERSONAL PROTECTIVE EQUIPMENT SAFETY PRECAUTIONS During work, but especially when maintaining or repairing the machine, operators must wear suitable protective clothing and equipment: • Overalls or any other comfortable garments. Read and understand the following safety instructions Operators should wear neither clothes with large before servicing the machine.
  • Page 20 GTH 55-19 SAFETY • Do not connect wet plugs or sockets. • Signs and stickers shall never be removed, hidden or become unreadable. Treatment and disposal of used oils is subject to • Except for maintenance purposes, do not remove federal, national and local laws and regulations.
  • Page 21 GTH 55-19 TECHNICAL SPECIFICATIONS Section 2 TECHNICAL SPECIFICATIONS SECTION INDEX Main dimensions .................page Tyres ......................Limit of use ....................Weight ......................Speed ......................Payload and reach ..................2.7 Forks (floating type) ..................Diesel engine ....................Electrical system ..................2.0 Machine sound levels ................. 2. Vibration levels ....................
  • Page 22 GTH 55-19 TECHNICAL SPECIFICATIONS MAIN DIMENSIONS GTH 55-9 Height 6' - 4" Height at steering whell 4' - 1" Width 5' - 11" Inside cab width 2' - 6" Track 4' - 11" Wheelbase 7' - 7" Length at fork-holder plate 12' - 7"...
  • Page 23 GTH 55-19 TECHNICAL SPECIFICATIONS LIMIT OF USE GTH 55-9 • Angle of approach (machine front side) ° • Departure angle (machine rear side) ° • Ambient temperature °C WEIGHT TELELIFT 352 400 GTH 55-9 • Weight with fork 9810 SPEED GTH 55-9 •...
  • Page 24 GTH 55-19 TECHNICAL SPECIFICATIONS 2.7 FORKS (floating type) GTH 55-9 • Dimensions 47.2" x 3,9" x 1,6" • Weight 9270 TELELIFT 352 400 DIESEL ENGINE GTH 55-9 • Make PERKINS • Model/Type 804C-33 • Displacement • Cylinder arrangement Vertical in-line • Combustion System In-direct injection •...
  • Page 25 GTH 55-19 TECHNICAL SPECIFICATIONS 2. VIBRATION LEVELS GTH 55-9 • Mean assessed vibration level transmitted to arms < 2.5 • Mean assessed vibration level transmitted to body < 0.5 Values calculated in accordance with standard prEN13059 This is a Class A device. In a residential environ- ment, such device can cause radio disturbance.
  • Page 26 GTH 55-19 TECHNICAL SPECIFICATIONS 2.3 TIGHTENING TORQUES Thread Pitch Wrench measure Tightening torques diameter Material class 10.9 10.9 12.9 12.9 10.9 12.9 10.9 12.9 10.9 12.9 Normal Galvanized Normal Galvanized Normal Galvanized 5931/32 5933÷36 5923÷30 10,3 10,6 14,8 13,3 17,8 16,0 1,25 25,1...
  • Page 27 GTH 55-19 TECHNICAL SPECIFICATIONS Thread Pitch Standard nuts Low nuts diameter 13,0 1,25 23,0 32,0 14,0 20,0 25,0 35,0 16,0 22,0 46,0 64,0 29,0 40,0 1,25 49,0 68,0 31,0 42,0 1,75 80,0 110,0 50,0 69,0 1,25 88,0 125,0 55,0 78,0 125,0 180,0 78,0...
  • Page 28 GTH 55-19 TECHNICAL SPECIFICATIONS 2.4 DRILL DIAMETERS FOR THREADS Thread DRILL DIAMETER DRILL BIT x pitch LIMITS DIAMETER M 4 x 0,7 3,42 3,24 3,30 x 0,5 3,60 3,46 3,50 M 5 x 0,8 4,33 4,13 4,20 x 0,5 4,60 4,46 4,50 M 6 x 1...
  • Page 29 GTH 55-19 TECHNICAL SPECIFICATIONS 2.5 STANDARD TIGHTENING TORQUES FOR FITTING SEALS 60° CONICAL SEALS F RONT O-LOK (Parker) SEALS ■ ■ Thread TIGHTENING Thread TIGHTENING diameter TORQUES (0+10%) diameter TORQUES (0+10%) 60° CONICAL FRONT O-LOK SEALS (Parker) SEALS inc. inc. G 1/8" 9/16"-18 G 1/4"...
  • Page 30 GTH 55-19 TECHNICAL SPECIFICATIONS SEALS WITH GRIP-RING FITTING ASSEMBLY ■ ■ Thread TIGHTENING Thread TIGHTENING diameter TORQUE diameter TORQUES (0+10%) (0+10%) SEALS JOINTS WITH Fitting Pipe ø GRIP-RING inc. Series inc. G 1/8" M10x1 G 1/8" M10x1 G 1/8" M10x1 M12x1.5 G 1/8"...
  • Page 31 GTH 55-19 TECHNICAL SPECIFICATIONS 2.6 LOCKING MATERIAL THREAD LOCKERS Product APPLICATION Characteristics Locking Resistance Temp. °C Thread speed Loctite 290 Thread locking to 150° M 12 Rapid Medium Loctite 222 Thread locking to 150° M 20 Moderate Loctite 243 Thread locking to 150°...
  • Page 32 1500 1000 GTH 55-19 TECHNICAL SPECIFICATIONS 30° 60° 90° 120° 150° • Attach the load to the natural seat of the hook. 2.7 HOISTING INSTRUCTIONS Attaching a load to an end can cause the load to fall down during raising and result in serious injury. All parts weighing more than 25 kg MUST COMPULSORILY be handled with suitable hoisting means.
  • Page 33 GTH 55-19 TECHNICAL SPECIFICATIONS 2.8 ADVICE TO RENEW FLEXIBLE HOSES Before disconnecting or refitting a flexible hose, carefully clean the area all around. Blow some compressed air to remove any impurity. For an easier renewal of the hoses, whose run is not clearly visible, proceed as follows: Before disconnecting a hydraulic pipe, place containers of suitable size underneath to prevent...
  • Page 34 GTH 55-19 TECHNICAL SPECIFICATIONS 2.9 LISTS OF RECOMMENDED SPARE PARTS Code Description Q.ty 07.0700.0023 Oil filter cartridge (inside the tank) 09.4604.0004 Hydraulic oil filter 07.0700.0037 Primary engine air filter element 07.0700.0036 Safety engine air filter element 07.0723.0149 Cab air filter 07.4501.0139 Fuel filter 07.4501.0138 Engine oil filter 07.0705.0093 Solenoid 07.0705.0096 Solenoid 07.0705.0099 Solenoid 07.0728.0007 Solenoid 07.0709.0417 Seals kit 07.0701.0200 Seals kit 07.4529.0112...
  • Page 35 GTH 55-19 TECHNICAL SPECIFICATIONS Code Description Q.ty 09.4618.0644 Sticker: GTH-5519 32x5 (white) 97664 Sticker: Risk of crushing-English 09.4618.0641 Sticker: Genie 50x14 (white) 09.4618.0061 Sticker: Tyre inflation pressure (4.5 Bar) 09.4618.0010 Sticker: Prohibition to open with the engine running 97673 Sticker: Prohibition to lift people-English 09.4618.0782 Sticker: Connect./disconnect.
  • Page 36 GTH 55-19 TECHNICAL SPECIFICATIONS Code Description Q.ty 51.0804.9000 Boom shim 04.4210.0019 Quick coupling: F 1/2” Faster Art. 2FFI12GASF 04.4210.0018 Quick coupling: M 1/2” Faster Art. FFI12GASM 04.4239.0005 Block valve 04.4239.0005 Block valve 04.4239.0052 Block valve 04.4240.0052 Solenoid valve 56.0006.0002 Relay: 12v 20/30A 04.0605.0612 Flex hose 04.0605.0615...
  • Page 37 GTH 55-19 TECHNICAL SPECIFICATIONS 2.20 MACHINE PAINT COLOUR GENIE machines BLU GENIE GRIGIO GENIE NERO RAL 9500 Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 38 GTH 55-19 TECHNICAL SPECIFICATIONS 2.2 CHECKING THE CYLINDER MOVEMENT TIMES The check of the movement times of the cylinders To check the engine speed, the area easy to reach is shall be done with the hydraulic oil at a temperature the shaft of the CASAPPA pump.
  • Page 39 GTH 55-19 TECHNICAL SPECIFICATIONS 2.22 HYDRAULIC SETTINGS • Increase the pressure of valve A of the main valve to 300 bar moving the lifting cylinder to end of stroke (fully out). PRELIMINARY OPERATIONS • With the engine running at maximum speed, tilt the forks to one direction by means of the joystick Check that the engine idle is set at 950 rpm and that and act on one of the two valves B until reaching a...
  • Page 40 GTH 55-19 TECHNICAL SPECIFICATIONS S E T T I N G T H E H Y D R O M AT I K P U M P STARTING THE CALIBRATION HYDROSTATIC TRANSMISSION • Set the forward-neutral-reverse selector to the Do the calibration of the hydrostatic transmission with forward or reverse position.
  • Page 41 GTH 55-19 TECHNICAL SPECIFICATIONS CALIBRATION OF THE MAXIMUM PRESSURE 4. CALIBRATING THE POWER STEERING Do this operation with extreme caution. The proper • Fit a coupling complete with mini-socket Z in the functioning of pump and transmission depends on this position shown in annex 2.
  • Page 42 GTH 55-19 TECHNICAL SPECIFICATIONS HYDRAULIC SYSTEM - MAIN VALVE annex 1 Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 43 GTH 55-19 TECHNICAL SPECIFICATIONS POWER STEERING SYSTEM annex 2 Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 44 GTH 55-19 TECHNICAL SPECIFICATIONS Intentionally blank page Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 45 GTH 55-19 SCHEDULED MAINTENANCE INSPECTIONS Section  SCHEDULED MAINTENANCE INSPECTIONS SECTION INDEX Introduction ...................page About this section ..................Maintenance table ..................Maintenance inspection report ..............Document 57.4403.3200 - 1 Edition 06/2007 INDEX...
  • Page 46 GTH 55-19 SCHEDULED MAINTENANCE INSPECTIONS INTRODUCTION • Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. • Scheduled maintenance must be carried out at the intervals indicated in the MAINTENANCE REPORT. Failure to properly complete each inspection when required may cause death, serious injury or substantial machine damage.
  • Page 47 GTH 55-19 SCHEDULED MAINTENANCE INSPECTIONS ABOUT THIS SECTION Intervention times Maintenance interventions have been divided into 7 different groups in relation to the time at which they must be carried out, say daily, weekly, monthly, every 6 months, yearly, every 2 years and at 5 years (afterwards every 2 years).
  • Page 48 GTH 55-19 SCHEDULED MAINTENANCE INSPECTIONS MAINTENANCE TABLE TABLE A During the first 10 working hours: Check the oil level within reduction gears, power divider and differential gears. Check the tightening of the wheel bolts. Check the tightening of all bolts and nuts. Check the couplings for oil leaks.
  • Page 49 GTH 55-19 SCHEDULED MAINTENANCE INSPECTIONS TABLE B Within the first 50 working hours: Change the engine oil. Every 50 working hours or weekly: 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.
  • Page 50 GTH 55-19 SCHEDULED MAINTENANCE INSPECTIONS TABLE D Every 500 working hours or every six months: 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.
  • Page 51 GTH 55-19 SCHEDULED MAINTENANCE INSPECTIONS MAINTENANCE INSPECTION REPORT Table A Y N R Table C Y N R During the first 10 working hours: Model Every 250 working hours: A-1 Oil level within reduction gears, C-1 Engine oil and relevant filter. Serial number power divider and differential C-2 Oil level in the differential gears...
  • Page 52 GTH 55-19 SCHEDULED MAINTENANCE INSPECTIONS Table F Y N R Model Every 2000 working hours: Change the engine coolant Serial number Table G Y N R Date At 6000 working hours: Hour meter Checking the state of the structure Machine owner Inspected by Inspector signature Inspector title...
  • Page 53 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES Section 4 SCHEDULED MAINTENANCE PROCEDURES SECTION INDEX Introduction ...................page About this section ..................TABLE A procedures ..................TABLE B procedures ..................TABLE C procedures ..................TABLE D procedures ..................TABLE E procedures ..................TABLE F procedures ..................TABLE G procedures ...................
  • Page 54 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES INTRODUCTION • Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. • Scheduled maintenance must be carried out at the intervals indicated in the MAINTENANCE REPORT. Failure to properly complete each inspection when required may cause death, serious injury or substantial machine damage.
  • Page 55 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES ABOUT THIS SECTION This section describes the maintenance interventions to be carried out on the machine according to the indications of the maintenance inspection report (see chapter 3). Safety symbols: Draws the attention to situations that involve your own as well as the others’...
  • Page 56 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES TABLE A PROCEDURES A-1 C H E C K T H E O I L L E V E L W I T H I N REDUCTION GEARS, POWER DIVIDER AND DIFFERENTIAL GEARS To check the oil level within the wheel reduction To check the oil level in the front and rear differential gears: gears:...
  • Page 57 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES To check the oil level in the power divider: Stop the machine on a level ground and engage the parking brake. Clean the plug A all around, then remove it and check if oil is level with the hole. If necessary, add new oil through hole A until it is level.
  • Page 58 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES A-2 CHECK THE TIGHTENING OF THE WHEEL BOLTS If you have to check the tightening of the wheel bolts or replace a wheel, proceed as follows: Raise the machine using a hydraulic jack. Remove the wheel rolling it on the ground. Line up the wheel with the axle and fit the 8 nuts.
  • Page 59 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES A- CHECK THE TIGHTENING OF ALL BOLTS A-4 CHECK THE COUPLINGS FOR OIL AND NUTS LEAKS Before starting your daily work, proceed with a random Before starting your work, do a walk-around inspection check of the bolts. and check for oil leaks.
  • Page 60 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES A-5 INSPECT THE OPERATOR MANUAL A-6 INSPECT THE DECALS AND PLACARDS Maintaining the operator manual in good condition is Maintaining all of safety and instructional decals and essential to safe machine operation. placards in good condition is mandatory for safe machi- ne operation.
  • Page 61 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES A-7 CHECK THE ENGINE OIL LEVEL To check the engine oil level: • Park the machine on a flat ground, stop the engine and check the parking brake is engaged. • Remove dipstick A and check if oil reaches the max mark B.
  • Page 62 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES A-8 CLEAN THE AIR SUCTION FILTER Clean the engine air filter every 10 hours: Stop the engine and engage the parking brake. Unlatch the fasteners A and remove cover B. Pull out the filter cartridge C. Clean the filter bowl.
  • Page 63 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES A-9 CHECK AND CLEAN THE RADIATOR When using a steam-washer, always wear protective clothes. Hot steam may cause serious injury. Open the radiator panel. Check the fins of radiator for sediments. If necessary, prepare a compressed air nozzle (max. 2 bar) or a nozzle distributing water under pressure or steam.
  • Page 64 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES A-10 CHECK THE HYDRAULIC OIL LEVEL IN THE TANK 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 B fitted into the tank.
  • Page 65 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES A-11 CHECK THE GREASING OF THE BOOM SECTION PADS 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. At regular intervals, check that the telescopes are well greased in correspondence of the sliding pads.
  • Page 66 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES A-12 GREASE THE FORKS Before use grease, thoroughly clean the intervention zone 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.
  • Page 67 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES A-1 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 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.
  • Page 68 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES A-14 CHECK THE EFFICIENCY OF THE LIGHTING ELECTRIC SYSTEM If the LIGHTS KIT is installed, check every day that the electrical system powering the lights of the machine is in efficient working order. When switched on, lamps get hot. Before touching Use the assistance of a second technician to check that a lamp with your fingers, let it cool down.
  • Page 69 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES A-15 CHECK THE EFFICIENCY OF BRAKING • Connect the flexible hose of the compressor to the mini-socket TP4 placed inside the engine SYSTEM AND PARKING BRAKE compartment. For any intervention on the braking system (adjustment and/or substitution of the brake discs) address to the GENIE Technical Service Centre or the nearest GENIE authorised workshop.
  • Page 70 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES • Check that air flows out of valve B. As soon as oil TO BLEED THE CIRCUIT OF THE PARKING BRAKE, DO THE FOLLOWING: without air bubbles starts flowing out of this valve, close the same. •...
  • Page 71 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES 2 4 6 8 10 8 6 A-16 CHECK THE EFFICIENCY OF THE STEERING SELECTION SYSTEM 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 72 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES A-17 CHECK THE EFFICIENCY OF THE FORK A-18 MAKE SURE THE SAFETY DEVICES BALANCING SYSTEM INSTALLED ARE IN EFFICIENT WORKING ORDER Attempt to start the engine with the forward or reverse gear put. Test the system without any load on the machine’s The engine must not start.
  • Page 73 When necessary, add clean water or an antifreeze mixture through cap B. 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...
  • Page 74 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES TABLE B PROCEDURES B-1 CHANGE THE ENGINE OIL AND RENEW THE FUEL FILTER B-2 CHECK THE TENSION OF THE ALTERNATOR BELT For the engine maintenance, please refer to the specific Operator handbook (code SLBU 7853-00) supplied with the machine.
  • Page 75 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES B- CHECK THE TYRE INFLATION 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. OKAY WRONG For the tyre inflation or substitution, please refer to the table below: STANDARD GTH 55-19...
  • Page 76 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES B-4 CHECK THE TIGHTENING OF THE WHEEL NUTS If you have to check the tightening of the wheel bolts or replace a wheel, proceed as follows: Raise the machine using a hydraulic jack Remove the wheel rolling it on the ground. Line up the wheel with the axle and fit the 8 nuts.
  • Page 77 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES B-5 CHECK THE TIGHTENING OF THE CARDAN SHAFT SCREWS Check every week that the screws of the Cardan shaft A are tight. For the correct tightening torques, please refer to par. 2.13 in section 2 “Technical Specifications”. Document 57.4403.3200 - 1 Edition 06/2007 INDEX...
  • Page 78 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES TABLE C PROCEDURES C-2 C H E C K T H E O I L L E V E L I N T H E DIFFERENTIAL GEARS AND POWER C-1 CHANGE THE ENGINE OIL AND RELEVANT DIVIDER FILTER To check the oil level in the front and rear differential...
  • Page 79 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES To check the oil level in the power divider: C- CHECK THE OIL LEVEL IN THE FOUR WHEEL REDUCTION GEARS Stop the machine on a level ground and engage the parking brake. To check the oil level within the wheel reduction Clean the plug A all around, then remove it and check gears: if oil is level with the hole.
  • Page 80 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES C-4 CHECK AND CLEAN THE ENGINE AIR FILTER To clean the engine air filter : Stop the engine and engage the parking brake. Unlatch the fasteners A and remove cover B. Pull out the filter cartridge C. Clean the filter bowl.
  • Page 81 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES C-5 C H E C K T H E C L A M P I N G O F T H E C A B L E H E A D S TO T H E B AT T E RY TERMINALS Check the cable clips are well secured to the battery terminals.
  • Page 82 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES C-6 CHECK THE AIR SUCTION HOSE BETWEEN ENGINE AND FILTER Check the state of all the rubber sleeves A of the air suction line between engine and filter every month. If you use the machine continuously for several days, check these sleeves, as well as the hose clamps more frequently.
  • Page 83 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES C-7 CHECK THE CYLINDER CHROMIUM- PLATED RODS Visually check the cylinder rods for scoring every month. For this operation, fully extend all of the cylinders and check that their rods are intact. Document 57.4403.3200 - 1 Edition 06/2007 INDEX...
  • Page 84 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES CHECK THE HYDRAULIC LINES C-9 CHECK THE ELECTRIC CABLES Every month, do a random check of the oil-dynamic Every month, do a random check of the electrical ca- hoses to be sure they are not worn. In particular, we bles to be sure they are not damaged.
  • Page 85 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES C-10 CHECK THE WEAR OF 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 not supplied by GENIE.
  • Page 86 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES C-11 ADJUST THE PLAY OF 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.
  • Page 87 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES C-12 GREASE THE SLIDING PARTS OF THE BOOM SECTIONS Check every month that the telescopes are well greased in correspondence of the sliding pads. If necessary, scrape off the old grease and brush new grease. We recommend using: - INTERFLON grease FIN GREASE LS 2 code 640772...
  • Page 88 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES C-1 CHECK THE LEVEL OF THE BATTERY ELECTROLYTE 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 Risk of explosion or shorts. During the recharge, cell levels are correct.
  • Page 89 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES C-14 CHECK THE EFFICIENCY OF THE BLOCK VALVES 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 (3500 kg roughly) onto the boom.
  • Page 90 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES Do the check of the valves taking all the possible precautionary measures: Wear safety glasses Wear safety gloves Wear safety shoes Wear suitable working clothes Use guards against leaks of oil at high pressure Do the check in a free space with barriers all around to keep non-authorised people away Ensure that the part to be checked is in safe condition and that the action generated does...
  • Page 91 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES TABLE D PROCEDURES D-2 CHECK THE TIGHTENING OF THE ENGINE FIXING SCREWS D-1 VISUALLY CHECK THE SMOKE QUANTITY E VA C U AT E D F R O M T H E E N G I N E Every 6 months, check that the screws fixing the engine EXHAUST to the machine chassis are tight.
  • Page 92 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES D- CHECK THE TIGHTENING OF THE CAB D-4 CHECK THE BACKLASH BETWEEN PINS FIXING SCREWS AND BUSHINGS IN ALL JOINTS Every 6 months, check that the screws fixing the cab to Every 6 months, check the machine randomly to be sure the machine chassis are tight.
  • Page 93 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES D-5 CHANGE THE HYDRAULIC OIL FILTER 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 94 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES D-6 CHANGE THE HYDRAULIC OIL FILTER IN THE TANK To change the hydraulic oil filter cartridge of the service circuits, proceed as follows: Stop the machine on a level ground and engage the parking brake. Remove the inspection hatch A and unscrew the oil filter fitted inside the tank.
  • Page 95 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES D-7 HAVE THE HYDRAULIC SYSTEM CHECKED BY A SKILLED TECHNICIAN Every 6 months, we recommend have the efficiency of the hydraulic system checked by a skilled technician. In case of need, please contact the GENIE Service Centre.
  • Page 96 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES D-8 CHANGE THE MAIN CARTRIDGE OF THE ENGINE AIR FILTER Changing the external element: Stop the engine and engage the parking brake. Unlatch the fasteners A and remove cover B. Pull out the filter cartridge C. Clean the filter bowl.
  • Page 97 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES D-9 CLEAN THE CAB AIR FILTER If the machine comes with a closed cab, clean the air filter in the cab every six months. Replace the cartridge if the filtering cloth is damaged. Cleaning and changing the cartridge: Shut the engine down and engage the parking brake.
  • Page 98 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES TABLE E PROCEDURES E-1 CHANGE THE SAFETY ELEMENT OF ENGINE AIR FILTER To change the safety element: Stop the engine and engage the parking brake. Unlatch the fasteners A and remove cover B. Pull out the filter cartridge C. Loosen wing nut and remove the inner element D.
  • Page 99 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES E-2 CHANGE THE OIL WITHIN POWER DIVIDER AND DIFFERENTIAL GEARS To change the oil level in the front and rear differential To change the oil level in the power divider: gears: Stop the machine on a level ground and engage the Stop the machine on a level ground and engage the parking brake.
  • Page 100 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES E- CHANGE THE OIL IN THE FOUR WHEEL REDUCTION GEARS To change the oil in the wheel reduction gears: Stop the machine on a level ground and ensure the parking brake is engaged and plug A is oriented along the vertical axis.
  • Page 101 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES E-4 CHANGE THE HYDRAULIC OIL To change the hydraulic oil: Stop the machine on a level ground and make sure the parking brake is engaged. Release the pressure from the hydraulic circuit. Place a container of suitable size under the drain plug, placed in the lower part of the reservoir, and collect any oil leaks.
  • Page 102 (50% water-antifreeze) through cap A. This proportion will provide protection up to -38°C. 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...
  • Page 103 GTH 55-19 SCHEDULED MAINTENANCE PROCEDURES TABLE G PROCEDURES G-1 C H E C K I N G T H E S TAT E O F T H E STRUCTURE Five years after the first placing into operation of the machine or after 6000 hours (whichever occurs first), check the state of the structure paying attention to the welded supporting joints and the boom pins.
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  • Page 105 GTH 55-19 TROUBLESHOOTING Section 5 TROUBLESHOOTING SECTION INDEX Introduction ...................page About this section ..................Problems-Causes-Solutions................ 5.3. Hydraulic faults..................... 5.3.2 Electrical faults ..................... Document 57.4403.3200 - 2 Edition 01/2008 INDEX...

  • Page 106: Introduction

    GTH 55-19 TROUBLESHOOTING INTRODUCTION Perform all troubleshooting on a firm level surface. • Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. Two person will be required to safely perform • Immediately tag and remove from service a some troubleshooting procedures.

  • Page 107: About This Section

    GTH 55-19 TROUBLESHOOTING ABOUT THIS SECTION The tables on the following pages should be used to find and rectify problems that can occur when using the machine. Prepare adequate tools, and especially a voltmeter and a pressure gauge to carry out the checks explained on next pages.

  • Page 108: Problems-Causes-Solutions

    GTH 55-19 TROUBLESHOOTING PROBLEmS-CAUSES-SOLUTIONS 5.3. Hydraulic faults Problem Cause Solution The machine does not move Low pressure of the drive pump Re-calibrate the pump (see sec. 2) neither forwards nor in reverse DA valve damaged Check the operation and replace the valve if necessary Hydraulic oil filter restricted Change the oil filter...
  • Page 109 GTH 55-19 TROUBLESHOOTING Problem Cause Solution The oil in the tank is contaminated Drain the oil, clean tank and pipes, empty the pumps and add new oil By stepping down on the pedal, Brake pump damaged Check the pump operation and the machine does not brake bleed the system if necessary Front axle brakes defective...
  • Page 110 GTH 55-19 TROUBLESHOOTING Problem Cause Solution When the max load is applied, Seals, rod and liner of the fork tilting Dismantle the cylinder and check forks move down cylinder worn out and replace any defective parts Leakage in the cylinder block valve Check the leakage;...
  • Page 111 GTH 55-19 TROUBLESHOOTING Problem Cause Solution The boom lifting is not not The seals of the lifting cylinder are Fit a new kit of seals and check the efficient damaged tightness of the cylinder Cylinder rod damaged Check the rod condition Leakage in the cylinder block valve Check the valve operation;...
  • Page 112 GTH 55-19 TROUBLESHOOTING Problem Cause Solution Foreign matters on the sliding blocks Check and eliminate any foreign and the relevant surfaces of the matters boom Low traction Drive pump defective Check the pressure values of the drive pump and re-calibrate if necessary.

  • Page 113: 5.3.2 Electrical Faults

    GTH 55-19 TROUBLESHOOTING 5.3.2 Electrical faults Problem Cause Solution No power to dashboard Battery switch off Turn on the switch Battery down Check the battery efficiency; replace if necessary 50A fuse blown Change the fuse Dashboard damaged Check the dashboard and replace if necessary Broken or damaged wiring Reconnect or replace the wiring...
  • Page 114 GTH 55-19 TROUBLESHOOTING Problem Cause Solution Forward/reverse speed solenoid Check the efficiency or replace valves damaged S e r v i c e b r a k e m i c r o - s w i t c h Check the efficiency or replace damaged Parking brake switch...
  • Page 115 GTH 55-19 TROUBLESHOOTING Problem Cause Solution The engine coolant thermometer Indicator defective Change the part does not work Temperature sensor defective Check and replace the sensor if necessary Broken or damaged wiring Reconnect or replace the wiring High hydraulic oil temperature Hydraulic oil bulb damaged Check or replace the bulb if necessary...
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  • Page 117 GTH 55-19 SCHEMES Section 6 SCHEMES SECTION INDEX Hydraulic symbols ................page Hydraulic schemes ..................6.2. GTH 55-9 ..................... Electrical symbols ..................Wiring diagrams ..................6.4. Wiring diagrams - Component description ..........6.4.2 Fuses and relays ..................Position of the electrical and hydraulical components on the machine 6.5. Hydraulical components ................

  • Page 118: Hydraulic Symbols

    GTH 55-19 SCHEMES HYDRAULIC SYMBOLS MOTORS Fixed motor with one Mechanical control Combined non-return direction of flow with roller and throttle valve Fixed motor with two Electro-magnetic control Switching valve directions of flow with winding (solendoid) Variable motor with two Control with electric Pressure relief valve directions of flow...
  • Page 119 GTH 55-19 SCHEMES DISTRIBUTION - SETTING ELEMENTS Two-position and two-way distributor, with manual lever control and spring return Three-way and two-position distributor, with hydraulic control Two-position, three-way distributor, with electro-magnetic control and spring return Distributor with mechanical control and span proportional to the action of the same control Two-position, three-way distributor, with representation...
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  • Page 121: Hydraulic Schemes

    GTH 55-19 SCHEMES 6.2 HydrauliC SCHEME 6.2.1 GTH -19 Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
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  • Page 123: Electrical Symbols

    GTH 55-19 SCHEMES ELECTRICAL SYMBOLS ACTUATORS ACCUMULATORS DYNAMIC APPLICATIONS Emergency controls Battery Motor Pushbutton control Thermocouple Rotary control Element Generator TERMINALS AND GROUNDS Pedal control Ring Proximity control Ground As_3p_motor Lever control Terminal ELECTRONIC PARTS Timed control Ground to frame Rectifier Mechanical/manual control Knot...
  • Page 124 GTH 55-19 SCHEMES CONTACTS Thermal Normally open (NO) Normally closed (NC) NO limit switch NC limit switch Contactor Magneto-thermal closure Magneto-thermal opening Thermal closure Thermal opening Exchange NC proximity NO proximity NO mechanical NC mechanical Selector Selector2 Document 57.4403.3200 - 2 Edition 01/2008 INDEX...

  • Page 125: Wiring Diagrams

    GTH 55-19 SCHEMES 6.4 WIRING DIAGRAMS Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 126 GTH 55-19 SCHEMES Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 127 GTH 55-19 SCHEMES 2/G1 4/G10 2/G1 4/G10 9/C4 5/C5 SW05 BNø1 BN/WHø1 SW04 RDø1 WH/BKø1 BU/RDø1 5/C5 BKø1 BU/RDø1 1/F6 1/D4 4/G8 5/B5 6/F5 1/A1 4/A10 Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 128 GTH 55-19 SCHEMES 3/G10 5/G10 3/G10 5/G10 TQ/BKø1 3/D1 TQø1 5/E1 3/G1 GNø1.5 5/B8 2/C8 RDø1 YEø1 6/C7 6/C8 YE/BKø1 YE/BKø1 7/F9 5/C8 YE/BKø1 6/G1 YE/BKø1 6/D8 3/A1 5/A10 Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 129 GTH 55-19 SCHEMES 4/G10 6/G10 4/G10 6/G10 RDø1.5 YEø1.5 TQ/BKø1 BNø1.5 TQø1 GN/BKø1.5 BKø1 YE/BKø1 1 2 3 6/F1 SW06 SW07 4/F1 GYø1.5 4/C9 3/G5 3/F1 HA02 3/C1 GNø1 4/F7 4/A1 6/A10 Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 130 GTH 55-19 SCHEMES 5/G10 7/G10 5/G10 7/G10 YE/BKø1 4/B1 WH/TQø1 3/C6 YE/BKø1 BUø1 5/F1 RD/BKø1 8/G10 BU/RDø1 1/F8 RD/BKø1 RD/BKø1 1/F2 1/F1 GY/WHø1 2/C7 YE/BKø1 4/B2 YEø1 4/D1 GNø1 4/C8 SS07 SS06 SS04 SS08 SS05 SS03 5/A1 7/A10 Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 131 GTH 55-19 SCHEMES 6/G10 8/G10 6/G10 8/G10 BN/BKø1 8/F7 BN/BKø1 BN/BKø1 SW09 YE/BKø1 YE/BKø1 BKø1 4/C1 WH/BKø1.5 OG/GNø1 BU/RDø1.5 PKø2.5 OG/GNø1 SW08 BU/RDø1 6/A1 8/A10 Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 132 GTH 55-19 SCHEMES 7/G10 9/G10 7/G10 9/G10 BN/BKø1 7/G8 YE/BKø1.5 YE/GNø1.5 SW14 BKø1 YE/GNø1.5 SW12 HA03 7/A1 9/A10 Document 57.4403.3200 - 2 Edition 01/2008 INDEX...

  • Page 133: Wiring Diagrams - Component Description

    GTH 55-19 SCHEMES 6.4.1 W iring diagram - Component description Ref. Description Sheet Ref. Description Sheet K06 GEAR ENGAGEMENT FROM PARKING BRAKE LINE 5 A FUSE LOW PRESSURE BULB 10 A FUSE K11 START RELAY 10 A FUSE 5 A FUSE M01 STARTER MOTOR 10 A FUSE M02 ALTERNATOR 10 A FUSE M03 WINDSCREEN WIPER MOTOR 5 A FUSE M04 WINDSCREEN WIPER/WASHER MOTOR 5 A FUSE M06 FAN MOTOR 15 A FUSE F10 5 A FUSE P01 WARNING LIGHTS - FUEL GAUGE INSTRUMENT F11 7,5 A FUSE P02 ENGINE OIL TEMPERATURE INDICATOR 5...
  • Page 134 GTH 55-19 SCHEMES Ref. Description Sheet 12V BATTERY PREHEATING CONTROL UNIT TURN SIGNALS FLASHING DIODE DIODE DIODE DIODE 4-WAY CONNECTOR - ENGINE FUSES LINE 4-WAY CONNECTOR - STEERING COLUMN 6-WAY CONNECTOR - CAB 6-WAY CONNECTOR - STEERING COLUMN 12-WAY CONNECTOR - STEERING COLUMN 12-WAY CONNECTOR - ENGINE 15-WAY CONNECTOR - STEERING COLUMN 15-WAY CONNECTOR - ENGINE...

  • Page 135: Fuses And Relays

    GTH 55-19 SCHEMES 6.4.2 Fuses and relays FUSES Ref. Circuit Amp. FUSE 7.5A FUSE FUSE 10 FUSE 7,5A 7,5A FUSE 7,5A 7,5A FUSE FUSE FUSE FUSE F10 FUSE F11 FUSE 7,5 F12 FUSE F13 FUSE F14 FUSE F15 FUSE F16 FUSE F17 FUSE F18 FUSE F19 FUSE F20 FUSE...

  • Page 136: Position Of The Electrical And Hydraulical Components On The Machine

    GTH 55-19 SCHEMES POSITION OF THE ELECTRICAL AND HYDRAULICAL COMPONENTS ON THE MACHINE 6.5. Hydraulical components Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 137 GTH 55-19 SCHEMES Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 138 GTH 55-19 SCHEMES Document 57.4403.3200 - 2 Edition 01/2008 INDEX...
  • Page 139 GTH 55-19 SCHEMES Legend of the hydraulic components Pos. Description Diesel engine Drive pump Service pump Hydraulic oil return filter Drive motor One-way valves Combined engine fluid/hydraulic oil radiator Service pump suction filter Front axle Hydraulic oil tank Rear axle Hydraulic steering Steering selection solenoid valve Brake pump...
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  • Page 141 GTH 55-19 REPAIR PROCEDURES Section 7 REPAIR PROCEDURES SECTION INDEX Time schedule ..................page Repair procedures ..................001 - Cylinder disassembly - Boom raising cylinder ........ 002 - Cylinder disassembly - Fork balance cylinder ......... 00 - Cylinder disassembly - Attachment locking cylinder + DFE valve (if any) ..................

  • Page 142: Repair Procedures

    GTH 55-19 REPAIR PROCEDURES TIME SCHEDULE Job Operators Expected needed time (h) change the ignition key 1,00 change the gear switch lever 0,15 change the speed switch 0,15 change the joystick 1,00 change the fork locking/releasing pushbutton 0,20 change the fork locking/releasing red pushbuttons 0,20 change the brake pump 0,30...

  • Page 143: Repair Procedures

    GTH 55-19 REPAIR PROCEDURES Job Operators Expected needed time (h) change the drive motor 2,00 change motor, pump, transmission piping + tests 5,00 change the actuator control pump 2,00 change and calibrate the actuator 2,30 change the DFE valve 0,30 change relays and fuses 0,10 change the windscreen wiper motor (closed cab version)
  • Page 144 GTH 55-19 REPAIR PROCEDURES Job Operators Expected needed time (h) change the mud-guards 0,20 change the steering wheel 0,20 replace the complete solenoid valve block 2,00 Document 57.4403.3200 - 1 Edition 06/2007 INDEX...
  • Page 145 GTH 55-19 REPAIR PROCEDURES Cylinder disassembly Operation: Table: Boom raising cylinder GTH5519-001 Hrs. Min. Bridge crane, payload 5000 kg (20000 lb) Standard tools Textile bridles or chains with hooks Adjustable stands Operation: 1 Release the attachment 2 Anchor the attachment holding frame to the hooks of the slinging chain  Raise the boom to max.
  • Page 146 GTH 55-19 REPAIR PROCEDURES Operation: Cylinder disassembly Table: Boom raising cylinder GTH5519-001 7 To move the boom using the up/down controls of the bridge crane, previously disconnect the rod of the fork balance cylinder 8 Remove the screw fixing the pin with two 17 mm wrenches 9 Knock out and extract the pin using a plug of soft material (aluminium, copper, wood, etc.)
  • Page 147 GTH 55-19 REPAIR PROCEDURES Operation: Cylinder disassembly Table: Boom raising cylinder GTH5519-001 12 Remove the screw which fixes the rod pin to the boom using two 19 mm wrenches 1 Knock out and extract the pin using a plug of soft material (aluminium, copper, wood, etc.) 14 Put two wooden plugs, each 100mm high, on the oil cylinder to support the raising cylinder...
  • Page 148 GTH 55-19 REPAIR PROCEDURES Operation: Cylinder disassembly Table: Boom raising cylinder GTH5519-001 18 Knock out the pin using a plug of soft material (aluminium, copper, wood, etc.) and extract it through the hole on the frame 19 Lower the boom onto the adjustable stand to remove the slinging chains 20 Sling the cylinder with a textile bridle and remove it from the machine using the bridge crane...

  • Page 149: Cylinder Disassembly - Fork Balance Cylinder

    GTH 55-19 REPAIR PROCEDURES Cylinder disassembly Operation: Table: Fork balance cylinder GTH5519-002 Hrs. Min. Bridge crane, payload 500 kg (2000 lb) Standard tools Adjustable stands Textile bridles or chains with hooks Operation: 1 Release the attachment 2 Remove the screw fixing the rod pin with two 13 mm wrenches  Knock out and extract the pin using a plug of soft material (aluminium, copper, wood, etc.)
  • Page 150 GTH 55-19 REPAIR PROCEDURES Operation: Cylinder disassembly Table: Fork balance cylinder GTH5519-002 4 Fix the cylinder with a textile bridle connected to the bridge crane to support its weight 5 Place a container of suitable size under the hydraulic piping before disconnecting Used oils must be handled and disposed of ac- cording to local regulations.

  • Page 151: Dfe Valve (If Any)

    GTH 55-19 REPAIR PROCEDURES Cylinder disassembly Operation: Table: Attachment locking cylinder + DFE valve GTH5519-00 Hrs. Min. (if any) Bridge crane, payload 500 kg (2000 lb) Standard tools Textile bridles or chains with hooks Operation: 1 Release the attachment 2 With a 13mm wrench, remove the protective cover of the attachment lock/unlock cylinder  Disconnect the flexible hoses connected to the DFE valve (if present;...
  • Page 152 GTH 55-19 REPAIR PROCEDURES Operation: Cylinder disassembly Table: Attachment locking cylinder GTH5519-00 4 With a 17 mm wrench, disconnect the flexible hoses from the attachment locking cylinder 5 With a 17 mm wrench, loosen the four screws fixing the cylinder without removing them Document 57.4403.3200 - 1 Edition 06/2007 INDEX...
  • Page 153 GTH 55-19 REPAIR PROCEDURES Operation: Cylinder disassembly Table: Attachment locking cylinder GTH5519-00 6 With a 2.5 mm hexagonal wrench, remove the grub-screw fixing the terminal pin on both sides of the cylinder (if present) 7 With two 27 mm wrenches, loosen and pull out the terminal pins from their housings 8 Remove the four screws, previously loosened, to set the cylinder free...
  • Page 154 GTH 55-19 REPAIR PROCEDURES Operation: Cylinder reassembly Table: Attachment locking cylinder GTH5519-00 Reassembling the cylinder: To reassemble the cylinder, repeat the steps above in reversed order considering the precautions below. 1 Block the terminal pins on the cylinder rods after smearing the threads with Loctite 245.

  • Page 155: Removing The Engine From The Machine

    GTH 55-19 REPAIR PROCEDURES Removing the engine from the machine Operation: Table: GTH5519-004 Hrs. Min. Bridge crane, payload 500 kg (2000 lb) Standard tools Textile bridles or chains with hooks Operation: 1 Open the engine cover 2 Secure the cover with a belt or hold it raised by hand so it cannot move  Using two 13mm wrenches, remove the two screws of the spring...
  • Page 156 GTH 55-19 REPAIR PROCEDURES Operation: Removing the engine from the machine Table: GTH5519-004 8 Remove the lower cover 9 With a screwdriver, disconnect the fuel feeding and return piping held in position by the special hose-clamps 10 Disconnect the throttle control cable removing the locking clip;...
  • Page 157 GTH 55-19 REPAIR PROCEDURES Operation: Removing the engine from the machine Table: GTH5519-004 12 Disconnect the flexible hose of the silencer loosening the clamps with a 13 mm wrench 1 Remove the manifold with a 17 mm wrench 14 Disconnect all the electrical wires connected to the engine, and namely: oil pressure bulb, ❑...
  • Page 158 GTH 55-19 REPAIR PROCEDURES Operation: Removing the engine from the machine Table: GTH5519-004 16 Disconnect the hydraulic piping: Before disconnecting the hydraulic piping, place containers of suitable size underneath to prevent oil spillage. Plug all disconnected parts to prevent dust and impurities from entering the circuit.
  • Page 159 GTH 55-19 REPAIR PROCEDURES Operation: Removing the engine from the machine Table: Reassembling the engine on the machine GTH5519-004 18 Sling the engine using a two-leg chain with hook to be coupled to the front lug and the rear supporting bracket of the battery 19 Raise the engine with caution and ensure no parts are still connected 20 Remove the engine from the machine, rest it on...
  • Page 160 GTH 55-19 REPAIR PROCEDURES Operation: Reassembling the engine on the machine Table: GTH5519-004 Page left intentionally blank Document 57.4403.3200 - 1 Edition 06/2007 INDEX...

  • Page 161: Hydrostatic Pump Disassembly

    GTH 55-19 REPAIR PROCEDURES Hydrostatic pump disassembly Operation: Table: GTH5519-005 Hrs. Min. Bridge crane or swing hoist, payload 500 Standard tools kg (2000 lb) Operation: Before disconnecting the hydraulic piping, place containers of suitable size underneath to prevent oil spillage. Carefully clean the area around the piping to be disconnected, plug all disconnected parts with caps, rags or adhesive tape to prevent dust or...
  • Page 162 GTH 55-19 REPAIR PROCEDURES Operation: Hydrostatic pump disassembly Table: GTH5519-005 4 With a screwdriver, remove the two electrical connections of the solenoid valve which controls the machine forward/reverse movements 5 Disconnect the hydraulic piping: disconnect the two drain lines of the ❑...

  • Page 163: Disassembling The Hydraulic Motor

    GTH 55-19 REPAIR PROCEDURES Disassembling the hydraulic motor Operation: Table: GTH5519-006 Hrs. Min. Bridge crane or swing hoist, payload 500 Standard tools kg (2000 lb) Operation: Before disconnecting the hydraulic piping, place containers of suitable size underneath to prevent oil spillage. Carefully clean the area around the piping to be disconnected, plug all disconnected parts with connectors, clothes or adhesive tape to prevent...
  • Page 164 GTH 55-19 REPAIR PROCEDURES Operation: Disassembling the hydraulic motor Table: GTH5519-006 4 Remove the four locking screws of the motor with a 24mm wrench 5 Pull out the motor from the power divider fitted to the front axle 6 Protect the engine compartment to prevent the entrance of impurities Document 57.4403.3200 - 1 Edition 06/2007...

  • Page 165: Cylinder Disassembly - Boom Extension Cylinder

    GTH 55-19 REPAIR PROCEDURES Cylinder disassembly Operation: Table: Boom extension cylinder GTH5519-007 Hrs. Min. Bridge crane, payload 500 kg (2000 lb) Standard tools Textile bridles or chains with hooks Operation: 1 Set the boom to horizontal position with the telescope slightly extended to work on the cylinder connecting pin (rod side) 2 With a 13 mm wrench, remove the screw fixing the pin drop-shaped head...
  • Page 166 GTH 55-19 REPAIR PROCEDURES Operation: Cylinder disassembly Table: Boom extension cylinder GTH5519-007 7 Loosen and remove the screw fixing the cylinder pin (bottom side) with two 13 mm wrenches 8 Knock out and extract the pin using a plug of soft material (aluminium, copper, wood, etc.) 9 Pull out the cylinder from the boom section and sling it with the textile bridles connected to the bridge crane...

  • Page 167: Water-Oil Cooler Disassembly

    GTH 55-19 REPAIR PROCEDURES Water-oil cooler disassembly Operation: Table: GTH5519-008 Hrs. Min. Standard tools Operation: Before disconnecting the hydraulic piping, place containers of suitable size underneath to prevent oil spillage. Carefully clean the area around the piping to be disconnected, plug all disconnected parts with connectors, clothes or adhesive tape to prevent dust or impurities from entering the circuit.
  • Page 168 GTH 55-19 REPAIR PROCEDURES Operation: Water-oil cooler disassembly Table: GTH5519-008 4 Remove the two screws of the vibration supports with a 22 mm wrench 5 Secure the cooler with a textile bridle connected to the swing hoist 6 Hoist with caution by tilting the cooler forward to prevent damage to the fixed fan of the engine VIEW OF THE MACHINE FROM THE BOTTOM...

  • Page 169: Main Valve Disassembly

    GTH 55-19 REPAIR PROCEDURES Main valve disassembly Operation: Table: GTH5519-009 Hrs. Min. Standard tools Before disconnecting the hydraulic piping, place containers of suitable size underneath to prevent oil spillage. Carefully clean the area around the piping to be disconnected, plug all disconnected parts with connectors, clothes or adhesive tape to prevent dust or impurities from entering the circuit.
  • Page 170 GTH 55-19 REPAIR PROCEDURES Operation: Main valve disassembly Table: GTH5519-009 Before disconnecting any flexible hoses, label them for an easier reassembly. Operation: 1 Disconnect the delivery and return pipes with a 32 mm wrench 2 Disconnect all users with a 27 mm wrench  Disconnect all pilot systems with a 19 mm wrench 4 Remove the 3 fixing screws with two 13 mm...
  • Page 171 GTH 55-19 REPAIR PROCEDURES Renewing the slide pads of the telescopic Operation: Table: boom GTH5519-010 Hrs. Min. Standard tools ADJUSTING THE PLAY WITH SHIMS If the play between the boom sections is too great (2 mm or more), proceed in shimming the guide pads of the boom sections.

  • Page 172: Renewing The Slide Pads Of The Telescopic Boom

    GTH 55-19 REPAIR PROCEDURES Operation: Renewing the slide pads of the telescopic boom Table: GTH5519-010 6 Refit the fixing screws (torque: 30÷35 Nm) after pouring some Loctite 495 on their threads 7 After shimming, fully extend the boom, carefully clean the sliding rails of the pads, then smear with a thin coat of grease: INTERFLON FIN GREASE LS2 Sp.
  • Page 173 GTH 55-19 REPAIR PROCEDURES Operation: Renewing the slide pads of the telescopic boom Table: GTH5519-010 RENEWING THE PADS To renew the pads of the fixed section, proceed as follows: 8 Stop the machine, extend the telescope and lower the nose to the ground for an easier removal of the bottom pads.
  • Page 174 GTH 55-19 REPAIR PROCEDURES Operation: Renewing the slide pads of the telescopic boom Table: GTH5519-010 14 Check the internal measure of the fixed section and the external measure of the telescope to verify if some shims are necessary considering that the final tolerance must range from + 1,0 mm to + 1,5 mm 15 With a 6 mm hexagonal wrench, remove the worn pads.

  • Page 175: Renewing The Flexible Hoses Inside The Boom

    GTH 55-19 REPAIR PROCEDURES Renewing the flexible hoses inside Operation: Table: the boom GTH5519-011 Hrs. Min. Standard tools How to renew flexible hoses: 1 Before disconnecting or refitting a flexible hose, carefully clean the area all around. Before disconnecting the hydraulic piping, place 2 Blow some compressed air to remove any containers of suitable size underneath to prevent impurity.
  • Page 176 GTH 55-19 REPAIR PROCEDURES Operation: Renewing the flexible hoses inside the boom Table: GTH5519-011 Useful advice for mounting flexible hoses: Document 57.4403.3200 - 1 Edition 06/2007 INDEX...
  • Page 177 GTH 55-19 REPAIR PROCEDURES Cylinder disassembly Operation: Table: Attachment rotation cylinder GTH5519-012 Hrs. Min. Bridge crane, payload 500 kg (2000 lb) Standard tools Adjustable stands Textile bridles or chains with hooks Operation: 1 Remove the attachment 2 Remove the screw fixing the pin (rod side) with two 17 mm wrenches  Knock out and extract the pin using a plug of soft material (aluminium, copper, wood, etc.)
  • Page 178 GTH 55-19 REPAIR PROCEDURES Operation: Cylinder disassembly Table: Attachment rotation cylinder GTH5519-012 7 With a 24 mm wrench, disconnect two hydraulic hoses from the blocking valve, then plug the disconnected connectors to prevent dust and impurities from entering the circuit. 8 Place a wooden plug under the cylinder rod, then lower the boom using the hydraulic controls as far as the rod rests on the wooden plug...

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