Handler with telescopic boom GTH 55-19

1 WORKSHOP MANUAL. Code - 1st Edition 04/2006. Handler with telescopic boom GTH 55-19 (da matr. xxxxxx). English Edition INDEX. GTH 55-19 . 2. Intentionally blank page Document - 1st Edition 04/2006 INDEX. GTH 55-19 . 3. WORKSHOP MANUAL. Code - 1st Edition 04/2006. Number: .. Consigned to: .. DECLARATION. I, the declare that I have received the Workshop 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 photocopy or reproduce this manual or parts of the same in any way without the prior written authorisation of TEREXLIFT to do so.

2 If business relations between the undersigned and GENIE should come to an end, the undersigned is obliged to return the copies received without charges for GENIE. Yours sincerely date .. For acceptance The consignee Company stamp and signature of the Legal representative .. Copy to return stamped and signed for acceptance by the Legal representative of the company receiving the copies of the manual. Document - 1st Edition 04/2006 INDEX. GTH 55-19 . 3. WORKSHOP MANUAL. Code - 1st Edition 04/2006. Number: .. Consigned to: .. DECLARATION. I, the declare that I have received the Workshop 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 photocopy or reproduce this manual or parts of the same in any way without the prior written authorisation of TEREXLIFT to do so.

3 If business relations between the undersigned and GENIE should come to an end, the undersigned is obliged to return the copies received without charges for GENIE. Yours sincerely date .. For acceptance The consignee Company stamp and signature of the Legal representative .. Document - 1st Edition 04/2006 INDEX. GTH 55-19 . LIST OF REVISED PAGES 6. Revision Revised Issued No. date pages Notes by 1 04-2006 Publicated 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. Document - 1st Edition 04/2006 INDEX. GTH 55-19 . CONTENTS 7. MANUAL CONTENTS. Sect. A GENERAL INFORMATION. Sect. B SAFETY REGULATIONS. Sect. C TECHNICAL OPERATION DATA. Sect. D CHECKS AND ADJUSTMENTS.

4 Sect. E DISMANTLING AND REASSEMBLY. Sect. F TROUBLESHOOTING. Sect. G DANA AXLE ASSEMBLY/DISMANTLING. Sect. H DEUTZ ENGINE MAINTENANCE. Sect. I REPAIR INSTRUCTIONS - REXROTH PUMP. Sect. L REPAIR INSTRUCTIONS - REXROTH MOTOR. Document - 1st Edition 04/2006 INDEX. GTH 55-19 . SERIAL NUMBER IDENTIFICATION 8. Machine denomination Literature valid up to serial number GTH 55-19 xxxxxx Document - 1st Edition 04/2006 INDEX. GTH 55-19 C. TECHNICAL OPERATING DATA 1. Section C. TECHNICAL OPERATING DATA. SECTION INDEX. Principles of hydraulics .. Hydraulic symbols .. page 3. Hydraulic schemes .. 4. Electrical symbols .. 5. Wiring diagrams .. 6. Cylinder size .. 21. Control lever .. 26. Hydraulic main valve .. 27. Pumps and motors.

5 28. Valves .. 30. Document - 1st Edition 04/2006 INDEX. GTH 55-19 C. TECHNICAL OPERATING DATA 2. Intentionally blank page Document - 1st Edition 04/2006 INDEX. GTH 55-19 C. TECHNICAL OPERATING DATA 3. HYDRAULIC SYMBOLS. ACTUATORS ACCUMULATORS DYNAMIC CONTACTS. APPLICATIONS. Emergency controls Battery Thermal M Motor Pushbutton control Thermocouple Normally open (NO). Rotary control Element Normally closed (NC). G Generator TERMINALS AND GROUNDS. Pedal control NO limit switch Ring Proximity control NC limit switch Ground M As_3p_motor 3. Lever control Contactor Terminal ELECTRONIC PARTS. Timed control Magneto-thermal closure Ground to frame - +. Rectifier Mechanical/manual control Magneto-thermal opening Knot Key control Thermal closure Protection ground Light-emitting diode Thermal opening RESISTANCES Diode Frame ground 2.

6 Resistance Exchange COILS Condenser Resistor Coil NC proximity PUSHBUTTONS. Potentiometer Mechanical coupling coil Manual NC contact NO proximity Variable resistance Winding Manual NO contact NO mechanical SIGNALS. A/C coil Intermittent lamp NC mushroom-head pushbutton NC mechanical Whistle Coil with diode NO mushroom-head pushbutton Selector Lamp NC level Buzzer Winding with diode Selector2. NO level Siren CONNECTORS. Connector Pushbutton with NC. Bell return STATIC APPLICATIONS. Pushbutton with NO. Horn return Auto-transformer FUSES AND RELAYS NC tie-rod Transformer Horizontal fuse NO tie-rod Relay Document - 1st Edition 04/2006 INDEX. GTH 55-19 C. TECHNICAL OPERATING DATA 4. Operation: General hydraulic scheme Table: Hydraulic piloting line test port TP2.

7 Service brake Pressure reducing Parking brake circuit reservoir valve T P selector valve DR 3 2. Service brake Load handling pedal pump 406 psi A B T R 28 bar control lever X. E U 1 Continous flow Shuttle selector valve in 7 psi valve mm Hydraulic bar Check valve collector 7 psi / bar 3 1. Front axle Parking brake 2. control valve P2 A B. :1. 4350 psi Forks attachment P1 300 bar quick coupling cylinder Y. Quick coupling G HCDEF. hydraulic ports 1 4 T P 3 2 boom functions Rear axle piloting selector valve steering cylinder B A. Tilt cylinder T P. Steering mode selector valve Piloted check valve 4:1. C. Slave Front axle cylinder steering cylinder 4:1. 4350 psi 300 bar 3262 psi B4. R 225 bar L. A4. 11:1. 4350 psi X4 Y4. Steering B3.

8 Rotating 300 bar actuator A3. Anti cavitation boom lift valves boom extend X3. 72 psi / 5 bar retract cylinder 4205 psi Y3. cylinder 290 bar B2. 4:1 A2 P. 4350 psi LS 300 bar X2 Y2. B1. A1. P 2465 psi T. 170 bar Accumulator X1 Y1. capacity: gallons / Liters pre-charge pressure: 725 psi / 50 bar T. P. Load handling boom functions hydraulic 3915 psi controls circuit test port TP 270 bar main valve 1. Hydrostatic transmission high pressure test port Flushing valve b a TP3. Hydrostatic R T1 T2 PS Fa Fa1 Fe MB transmission Check valve motor 36 psi / bar 6525 psi 725 psi B U B X2 X1 M1. 450 bar 50 bar Engine Function pump CF EF. with integrated LS. priority valve gpm / 82 L/min M 362 psi 25 bar 6525 psi 450 bar 6235 psi Hydrostatic 430 bar A T.

9 Transmission A G. pump G MH S FS MA. X2 X1. Suction Check valve 7 psi / bar Check valve Suction filter 36 psi / bar Thank filter Check valve 7 psi / bar TP4 Heat Hydrostatic transmission exchanger boost pressure test port Document - 1st Edition 04/2006 INDEX. GTH 55-19 C. TECHNICAL OPERATING DATA 5. ELECTRICAL SYMBOLS. ACTUATORS ACCUMULATORS DYNAMIC CONTACTS. APPLICATIONS. Emergency controls Battery Thermal M Motor Pushbutton control Thermocouple Normally open (NO). Rotary control Element Normally closed (NC). G Generator TERMINALS AND GROUNDS. Pedal control NO limit switch Ring Proximity control NC limit switch Ground M As_3p_motor 3. Lever control Contactor Terminal ELECTRONIC PARTS. Timed control Magneto-thermal closure Ground to frame - +.

10 Rectifier Mechanical/manual control Magneto-thermal opening Knot Key control Thermal closure Protection ground Light-emitting diode Thermal opening RESISTANCES Diode Frame ground 2. Resistance Exchange COILS Condenser Resistor Coil NC proximity PUSHBUTTONS. Potentiometer Mechanical coupling coil Manual NC contact NO proximity Variable resistance Winding Manual NO contact NO mechanical SIGNALS. A/C coil Intermittent lamp NC mushroom-head pushbutton NC mechanical Whistle Coil with diode NO mushroom-head pushbutton Selector Lamp NC level Buzzer Winding with diode Selector2. NO level Siren CONNECTORS. Connector Pushbutton with NC. Bell return STATIC APPLICATIONS. Pushbutton with NO. Horn return Auto-transformer FUSES AND RELAYS NC tie-rod Transformer Horizontal fuse NO tie-rod Relay Document - 1st Edition 04/2006 INDEX.