Handler with telescopic boom GTH 55-19 - Manuals - Geniemanuals.gogenielift.com/Parts And Service Manuals/data/Service... · INDEX English Edition Handler with telescopic boom GTH

INDEXEnglish

Edition

Handler with telescopic boom

GTH 55-19 (da matr. xxxxxx)

WORKSHOP MANUALCode 57.4401.8200 - 1st Edition 04/2006

Document 57.4401.8200 - 1st Edition 04/2006 INDEX

2

GTH 55-19

Intentionally blank page


3

GTH 55-19


Number: ....................................

Consigned to: ................................................................................................................................

INDEX

DECLARATION

I, the undersigned..............................................................................................................................

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.

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 theLegal representative of the company receiving the copies of the manual.


Number: ....................................

Consigned to: ................................................................................................................................

DECLARATION

I, the undersigned..............................................................................................................................

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.

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

...........................................


3

GTH 55-19


6

GTH 55-19

Revision Revised IssuedNo. 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

LIST OF REVISED PAGES


7

GTH 55-19

MANUAL CONTENTS

Sect. A GENERAL INFORMATION

Sect. B SAFETY REGULATIONS

Sect. C TECHNICAL OPERATION DATA

Sect. D CHECKS AND ADJUSTMENTS

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

CONTENTS


8

GTH 55-19

SERIAL NUMBER IDENTIFICATION

Machine denomination Literature valid up to serial number

GTH 55-19 xxxxxx


C

1

GTH 55-19

TECHNICAL OPERATING DATA

Section CTECHNICAL OPERATING DATA

SECTION INDEX

C.01 Principles of hydraulics ...............................................................................

C.02 Hydraulic symbols ............................................................................... page 3

C.03 Hydraulic schemes ...................................................................................... 4

C.04 Electrical symbols ........................................................................................ 5

C.05 Wiring diagrams ........................................................................................... 6

C.06 Cylinder size ................................................................................................. 21

C.07 Control lever ................................................................................................. 26

C.08 Hydraulic main valve .................................................................................... 27

C.09 Pumps and motors ....................................................................................... 28

C.10 Valves ............................................................................................................ 30


C

2

GTH 55-19




C

3

GTH 55-19


Emergency controls

ACTUATORS

Pushbutton control

Rotary control

Pedal control

Proximity control

Lever control

Timed control

Mechanical/manual control

Key control

Resistance

RESISTANCES

Resistor

Potentiometer

Variable resistance

Intermittent lamp

SIGNALS

Whistle

Lamp

Buzzer

Siren

Bell

Horn

Horizontal fuse

FUSES AND RELAYS

Relay

Battery

ACCUMULATORS

Thermocouple

Element

Ring

TERMINALS AND GROUNDS

Ground

Terminal

Ground to frame

Knot

Protection ground

Frame ground 2

Coil

COILS

Mechanical coupling coil

Winding

A/C coil

Coil with diode

Winding with diode

Connector

CONNECTORS

Auto-transformer

STATIC APPLICATIONS

Transformer

Motor

DYNAMICAPPLICATIONS

M

G Generator

M3

As_3p_motor

Rectifier

ELECTRONIC PARTS

- +

Light-emitting diode

Diode

Condenser

Manual NC contact

PUSHBUTTONS

Manual NO contact

NC mushroom-headpushbutton

NO mushroom-headpushbutton

NC level

NO level

Pushbutton with NCreturn

Pushbutton with NOreturn

NC tie-rod

NO tie-rod

C.02 HYDRAULIC SYMBOLS

Thermal

CONTACTS

Normally open (NO)

Normally closed (NC)

NO limit switch

NC limit switch

Contactor

Magneto-thermal closure

Thermal closure

Thermal opening

Exchange

NC proximity

NO proximity

NO mechanical

NC mechanical

Selector

Selector2

Magneto-thermal opening

Operation: Table:


C

4

GTH 55-19


General hydraulic scheme

C.03

M

X1X2 G MH S

AA

M1X1X2

TG

T1 PS Fa Fa1 Fe

b

MB

a

T2R

B BU

MAFS

CF EF

LS

LS

LR

TP

P1 4 23T

X

Y

A1

X1

X2

X3

X4

B1

B3

A3

B2

A2

A4

B4

T

P

C

Y1

Y2

Y3

Y4

P

T R

Engine

Hydrostatictransmission

pump

Hydrostatictransmission

motor

Flushing valve

Function pumpwith integratedpriority valve

21.7 gpm / 82 L/min

Suctionfilter

Suctionfilter

Heatexchanger

Check valve7 psi / 0.5 bar

Anti cavitationvalves72 psi / 5 bar





Thank

Accumulatorcapacity: 0.13 gallons / 0.5 Liters

pre-charge pressure: 725 psi / 50 bar

Boom functionspiloting selector valve

Shuttlevalve

Continous flowselector valve

Load handlingcontrol lever

Load handlingcontrols

main valve

Steeringrotatingactuator

Front axle

Service brakecircuit reservoir

Service brakepedal pump

Pressure reducingvalve

Hydrauliccollector

Parking brakeselector valve

Parking brakecontrol valve

0.02 in0.5 mm

7 psi0.5 bar

Slavecylinder

Boom extendretract cylinder

Boom liftcylinder

Tiltcylinder

4:14350 psi300 bar

11:14350 psi300 bar

4:14350 psi300 bar

4.2:14350 psi300 bar

3915 psi270 bar

4205 psi290 bar

6525 psi450 bar

362 psi25 bar

725 psi50 bar

6525 psi450 bar

6235 psi430 bar

2465 psi170 bar

3262 psi225 bar

406 psi28 bar

Quick couplinghydraulic ports

Forks attachmentquick coupling cylinder

Steering modeselector valve

Front axlesteering cylinder

Rear axlesteering cylinder

TP2

TP4

TP3

TP1

Piloted checkvalve 4:1

1

1

2

2

3

3

A B

CD E FG H

A B

T P

E U

DR

P1

P2

T

A

P

B

Boom functions hydrauliccircuit test port

Hydrostatic transmissionhigh pressure test port

Hydrostatic transmissionboost pressure test port

Hydraulic piloting linetest port


C

5

GTH 55-19


C.04 ELECTRICAL SYMBOLS

Emergency controls

ACTUATORS

Pushbutton control

Rotary control

Pedal control

Proximity control

Lever control

Timed control

Mechanical/manual control

Key control

Resistance

RESISTANCES

Resistor

Potentiometer

Variable resistance

Intermittent lamp

SIGNALS

Whistle

Lamp

Buzzer

Siren

Bell

Horn

Horizontal fuse

FUSES AND RELAYS

Relay

Battery

ACCUMULATORS

Thermocouple

Element

Ring

TERMINALS AND GROUNDS

Ground

Terminal

Ground to frame

Knot

Protection ground

Frame ground 2

Coil

COILS

Mechanical coupling coil

Winding

A/C coil

Coil with diode

Winding with diode

Connector

CONNECTORS

Auto-transformer

STATIC APPLICATIONS

Transformer

Motor

DYNAMICAPPLICATIONS

M

G Generator

M3

As_3p_motor

Rectifier

ELECTRONIC PARTS

- +

Light-emitting diode

Diode

Condenser

Manual NC contact

PUSHBUTTONS

Manual NO contact

NC mushroom-headpushbutton

NO mushroom-headpushbutton

NC level

NO level

Pushbutton with NCreturn

Pushbutton with NOreturn

NC tie-rod

NO tie-rod

Thermal

CONTACTS

Normally open (NO)

Normally closed (NC)

NO limit switch

NC limit switch

Contactor

Magneto-thermal closure

Thermal closure

Thermal opening

Exchange

NC proximity

NO proximity

NO mechanical

NC mechanical

Selector

Selector2

Magneto-thermal opening

Operation: Table:


C

6

GTH 55-19


Wiring diagram - page 1 of 6

C.05.01

+

-

RDø5

0BK

ø50

M

BNø6

BNø6

RDø1

0

BUø4

D+W

B+

BU/R

Dø1

RDø1

0 BUø2

.5

X11

1X2

5015

30

58

2 310P

RDø6

RDø4

19

BNø4

VTø1

.5

30

15

X34

8787A85

BUø1

.5

30

BN/B

Kø1

OG

/GNø

1

86

VTø1

.5

BKø1

27X4

BUø4

BKø1

RDø6

BUø1

.5

30 86

87 85

BNø6

BNø6

50A

WHø

6

50A

RDø6

RDø5

0

8550T

BUø1

BKø1

3086 87

WH/

RDø1

WHø

6

WHø

6VT

/WHø

1.5

L

WHø

6

15X4

BNø2

.5W

H/RD

ø1.5

10A

X27

RD/BKø1

VT/WHø1

X425

18X2 X5

5

10A

RD/B

Kø1

BNø2

.5

7X2

23X4

X216

4

OG

ø1

3FNR

FN

+

PK/B

Kø1.

51

R

BN/B

Kø1.

5

3X2

BNø2

.5

F13

PKø1

.510

A

7X2

1X3X2

2

BATT

ERY

F05 F04

15

30 2/G10

2/G10

4/C7BU/RDø1

2/A1031

OG/GNø1.53/C9

3/C3

BN/BKø1.5

3/B8

3/C9PKø1.5

5/F2WH/RDø1.5

4/C7

2/C9

SW01

A01

SW02 M01

X17

M02 Y01

X21

K02

SW03

H01

RD/BKø1

RD/BKø1

RD/BKø1

F30 F31 K11R01

A02

X25

PREH

EATI

NGCO

NTRO

LUN

IT M

AXI F

USE

STAR

TER

MO

TOR

ALTE

RNAT

OR

ADDI

TIO

NAL

FUEL

SOLE

NOID

VAL

VE

SYST

EMPR

OTE

CTIO

NFU

SE

STAR

TING

RELA

Y

GLO

W P

LUG

S

PREH

EATI

NGCO

NTRO

L UN

IT

DISC

ONN

ECTI

ON

BATT

ERY

1234567810 9

A

B

C

D

E

F

G

910 8 7 6 5 4 3 2 1

G

F

E

D

C

B

A

Operation: Table:


C

7

GTH 55-19



C.05.02

87A 8785

RD/B

Kø1

86

RDø2

.5

30K01

BKø1

YE/G

Nø2.

5

6X2

10A

YE/B

Kø1.

5YE

/GNø

2.5

F02

GN/

BKø1

.510

AF03

X311

BKø1

YE/BKø1.5

X312

1X6

YE/G

Nø1.

5

BKø1

.5

X662

X3

YEø1BKø1

YEø1.5GN/BKø1.5

X421

10X3

31 3/A10

3/G10

3/G1030

151/G1

1/G1 30

15

311/A1

1/F2RD/BKø1

YE/G

Nø2.

5SW04

YE/GNø1.5

YE/GNø1.5

H02

X11 X11H03

YEø1

.5BK

ø1.5

SW05

1X14

X142

REAR

WO

RK L

IGHT

OPT

IONA

L

FRO

NT W

ORK

LIG

HT S

WIT

CHO

PTIO

NAL

FRO

NTW

ORK

LIG

HTO

PTIO

NAL

REAR

WO

RKLI

GHT

SW

ITCH

OPT

IONA

L

8

1

2

3 6

5

4

78

1

2

3 6

5

4

7

1234567810 9

A

B

C

D

E

F

G

910 8 7 6 5 4 3 2 1

G

F

E

D

C

B

A

Operation: Table:


C

8

GTH 55-19



C.05.03

OG

/BKø

1

30K05

PKø1

.5

8787A

BKø1

RD/G

Nø1

RD/G

Nø1

OG

ø1

86 30

TQ/R

Dø1

RDø1

K033086

OG

/GNø

1.5

PKø1

.5

87A85 87 87A85 87

86

85

BN/B

Kø1.

5RD

/GNø

1

2/A1 31

15

302/G1

2/G1 15

30 4/G10

4/G10

4/A1031

1/F7

PK/BKø1.51/E5

BKø1

1

OG

ø1

212v

RDø1

RD/B

Kø1

X565

X5

RD/BKø11/F2

RD/B

Kø1

GY/

BUø1

X46

12X2

BKø1

RDø1

WH/YEø1

RDø1

78BKø11

4

32

56

OG/YEø1

RD/BKø1

12X4

X36

4/F9

12v2

OG

/YEø

1

1

5X3

5/F1

X411

OG

/BKø

1

13X4

+ -

BN/BKø1.51/E7

4

7

5BUø1BN/GNø1BN/GNø1

6

P

8

1

2

GY/WHø1

BKø1TQ/RDø1

3GY/WHø1

BUø1

BKø1

X27

5ABN

/GNø

1BN

ø2.5

F08

GY/WHø14/C6

JOYSTICK

CX7

X7AB

X7

BNø2

.5BN

/BKø

17.

5A

G9GR

15X2

5/G9

BN/BKø1

SS01

Y02

GY/

BUø1

X18 X18SS02

X10X10

OG/GNø1.5

K04

H04SW06

SW07

SW08

WH/OGø1

F12

Y03 Y04

Y05 HA01

BKø1

BKø1

OG

/BKø

1BK

ø1

X241

2X24

OG/YEø1

X45

17X4

ATTA

CHM

ENT

COUP

LING

/RE

LEAS

ESO

LENO

ID V

ALVE

HYDR

AULI

C ST

OP

AIR

FILT

ERCL

OG

GIN

GSE

NSO

R

SOLE

NOID

VAL

VEFW

D SP

EED

PARK

ING

BRA

KESW

ITCH

PARK

ING

BRA

KESO

LENO

ID V

ALVE

REVE

RSE

SPEE

DSO

LENO

ID V

ALVE

BACK

-UP

HORN

21

12v

21

12v

1234567810 9

A

B

C

D

E

F

G

910 8 7 6 5 4 3 2 1

G

F

E

D

C

B

A

Operation: Table:


C

9

GTH 55-19



C.05.04

+-

00 00 0 0 3

4X5

31 5/A10

5/G10

5/G1030

153/G1

3/G1 30

15

313/A1

7BKø1

5

6OG/YEø1

4

8

2

3

1

BU/RDø1.5

TQ/GNø1

F07

BNø2

.5BU

/RDø

1.5

5A

7X2

BKø1

TQ/G

Nø1

3/C3

J14

J15

J13

J10J11

J4J1

J12

PKø1

RD/B

Kø1

GY/

YEø1

GY/

WHø

1

WH/

BUø1

J5

J6

J2J3J9

J8

J7

YEø1BK

ø1

WH/

GNø

1

BU/R

Dø1

BU/R

Dø1

GY/

RDø1

WH/GNø15/E2

1/F8BU/RDø1

4X4

X2916

X2

X423

P

GY/

RDø1

X27

7.5A

VT/W

Hø1

BNø2

.5

F11

8X3

9X3

S-+

BKø1

YEø1

S+ -

GN/

RDø1

RD/B

Kø1

BKø1

1/F2

RD/BKø1

X214

22X4

BKø1

PKø1

GY/

YEø1

X49

5X2X2

13

GY/WHø1

3/C6

X48

2X5

BKø1

WH/

BUø1

RD/BKø1

3/C8

X51

26X4

RD/G

Nø1

T

GN/

RDø1

GY/

GNø

1

T

X416

11X2

5/E4VT/WHø1

Y06

SW09

P01

OG/YEø1

BU/RDø1.5TQ/GNø1

SS03 SS04SS05

X22X19 X19

SS06

X16

SS07

X20

P02 P03

YEø1

BKø1

BKø1

RD/B

Kø1

GY/

GNø

1

X19

X43

HYDR

AULI

C O

ILTE

MPE

RATU

RESE

NSO

R

ENG

INE

OIL

TEM

PERA

TURE

SENS

OR

ENG

INE

OIL

TEM

PERA

TURE

GAU

GE

VSE

SOLE

NOID

VALV

E SW

ITCH

HYDR

AULI

C O

ILTE

MPE

RATU

REG

AUG

E

FUEL

FLO

AT

ENG

INE

OIL

PRES

SURE

TRAN

SDUC

ER

VSE

SOLE

NOID

VALV

E

NEG

ATIV

E BR

AKE

PRES

SURE

SWIT

CH

21

12v

A

B

C

D

E

F

G

1234567810 9

G

F

E

D

C

B

A

910 8 7 6 5 4 3 2 1

Operation: Table:


C

10

GTH 55-19



C.05.05

4/A1 31

15

304/G1

4/G1 15

30

31

YE/R

Dø1

PK/Y

Eø1

BN/B

Kø1

CA

FE

BKø1

BU/RDø1

B

X24

1X4

BKø1

1

PK/Y

Eø1

212v 12v

2

YE/R

Dø1

1

BKø1

X42

7X3

78BKø1

VTø11

4

32

56

GY/RDø1.5

F06

X27

10A

GY/

RDø1

.5BN

ø2.5

X210

X47

3X3

VTø1

BKø1

7BKø1

5

4

6

8

1

2

3BN/RDø1

WH/BKø1.5

WH/BKø1

M

BN/R

Dø1

BKø1

BNø2

.5W

H/BK

ø1.5

5A

7X2

F10

BKø1

.5BU

/BKø

1.5

M

X27

15A

BU/B

Kø1.

5BN

ø2.5

BKø1

VT/W

Hø1

M

RDø1

.5BK

ø1

F09

2X6 X6

4

2ARD

ø1.5

RDø4

F01

X63

X26

5X6

YE/R

Dø1.

5

28X4

WH/

RDø1

.5BK

ø1.5

WH/

GNø

1

T

4/C7WH/GNø1

X217

14X4

12v2

WH/

OG

ø1

1

BKø1

X429

AX7

3/F1

3/C1

BN/BKø1

VT/WHø14/C5

1/D3

WH/RDø1.5

Y07 Y08

HA02M03 M04

H05H06

Y09SS08

Y10

X23

SW10

SW12SW11

WH/

OG

ø1

X15

X15 X9

X9

1

2

X13X13 X12X12

1X8

X82

24X4

EXTE

ND/R

ETRA

CTBO

OM

SO

LENO

IDVA

LVE

REAR

WIN

DSCR

EEN

WIP

ER/W

ASHE

RM

OTO

RO

PTIO

NAL

WIN

DSCR

EEN

WIP

ER/W

ASHE

RSW

ITCH

OPT

IONA

L

FRO

NTW

INDS

CREE

NW

IPER

/WAS

HER

MO

TOR

OPT

IONA

L

HORN

ENG

INE

STO

PSO

LENO

ID

STEE

RING

SELE

CTO

R

BEAC

ON

CAB

LIG

HTIN

G

HORN

SW

ITCH

OPT

IONA

LFL

ASHI

NGCO

NNEC

TOR

ENG

INE

OIL

COO

LING

TEM

PERA

TURE

SENS

OR

PARA

LLEL

WHE

EL S

TEER

ING

SOLE

NOID

VAL

VE

FOUR

WHE

ELST

EERI

NGSO

LENO

ID V

ALVE

1234567810 9

A

B

C

D

E

F

G

910 8 7 6 5 4 3 2 1

G

F

E

D

C

B

A

Operation: Table:


C

11

GTH 55-19



C.05.06

Other componentsA##

R##

P##

M##

K##

HA##

H##

F##

Lamp, light

Indicator

Potentiometer

Switces, selector

Solenoid valve

Sensor, microswitches, pressure switches, transducer

Fuse

Clacson or back-up horn

Motor engine or pump

Resistance

DescriptionLabel

Relè

RP##

SW##

SS##

Y##

X## Connectors

LIST OF ABBREVIATION

TurquoiseTQ

PK

WH

GY

VT

Orange

Acronym Colour

Blue

Yellow

Red

Black

COLOUR TABLE

White

Pink

Grey

Violet

Green

Brown

BK

BN

RD

OG

YE

GN

BU

A

B

C

D

E

F

G

1234567810 9

G

F

E

D

C

B

A

910 8 7 6 5 4 3 2 1

Operation: Table:


C

12

GTH 55-19


Legend wiring diagram

C.05.07

SW12 F75

K11 1 B5

B33Y04

B64SS04

SW10SW11 5

5F5E9

SW03 1 F5

G9

G2G1

F6F3

F10B10

B4

433322

11

SW09SW08SW07SW06SW05SW04

SW01SW02

R01 1

3SS02SS03

SS05

SS07SS08

Y01Y02

4

45

13

B7B7

B2

B7C10

SS06

F6

SS01 3 B9

4 B5B34B2

B53

B2

Y03

B2B8B10B10

A01

Y10

B311 C10

5 B1

A02

55543

Y06Y07Y08Y09

Y05K1

K5K4K3K2

21333

F24P03

M03

B91B81

5 B5

M01M02

P01F44

4 G7

B45

P02

M04

E6D9D4D3

HA02

D9

5 B6

B22 B5

F21

D51F13D1

D3

H02

B1

B3B4F8

B5B6

3

5532

1

HA01

H06H05H04H03

H01

F31F30 1

5F1F2F3

F4

F5F6F7F8F9F10

F11

F12

22

1

154355

4

3

D3D8D8

D3

D8D8

D4D4

D5

D6

DescriptionLabel PositionPage Label Description Page Position

ADDITIONAL FUEL SOLENOID VALVE

DISCONNECTION BATTERY

JOYSTICK

REVERSE SPEED

ENGINE START ENABLING COMMAND WITH SPEED LEVER IN NEUTERFORWARD SPEEDFORWARD/REVERS SPEED ENABLING COMMAND

FRONT/REAR WORK LIGHTS OPTIONAL

ENGINE OIL TEMPERATURE SENSOR

ENGINE OIL PRESSURE TRANSDUCER

HYDRAULIC OIL TEMPERATURE SENSOR

AIR FILTER CLOGGING SENSOR

HORN PARKING BRAKE SOLENOID VALVE

FUEL FLOAT

BACK-UP HORN

WHEEL STEERING SOLENOID VALVEWHEEL STEERING SOLENOID VALVE

SOLENOID VALVE-FWD SPEED

EXTEND/RETRACT BOOM SOLENOID VALVE

ATTACHMENT COUPLING/RELEASE SOLENOID VALVE

BEACONCAB LIGHTING

REAR WINDSCREEN WIPER/WASHER MOTOR OPTIONALFRONT WINDSCREEN WIPER/WASHER MOTOR OPTIONAL

PARKING BRAKE SWITCH

HORN SWITCH

FRONT WORK LIGHT SWITCH OPTIONALREAR WORK LIGHT SWITCH OPTIONAL

ENGINE OIL TEMPERATURE GAUGEHYDRAULIC OIL TEMPERATURE GAUGEWARNING LIGHTS-FUEL GAUGE

FRONT WINDSCREEN WIPER/WASHER SWITCH OPTIONAL

VSE SOLENOID SWITCH

HYDRAULIC STOP

IGNITION KEY SWITCH

STEERING SELECTOR

CHANGEOVER-OVER SWITCH

ATTACHMENT COUPLING/RELEASE SWITCH

NEGATIVE BRAKE PRESSURE SWITCH

REVERSE SPEED SOLENOID VALVE

GLOW PLUGS

PREHEATING CONTROL UNIT

VSE SOLENOID VALVE

SYSTEM PROTECTION FUSEPREHEATING CONTROL UNIT MAXIFUSE

ENGINE STOP SOLENOID

ENGINE OIL COOLING TEMPERATURE SENSOR

12V BATTERYSTARTER MOTORALTERNATOR

RELAY K3/RELAY K5 POWER SUPPLY

INTERIOR LAMP POWER SUPPLYFRONTWORK LIGHT SWITCH POWER SUPPLYREAR WORK LIGHT SWITCH POWER SUPPLY

GLOWE LIGHT INSTRUMENT, AIR FILTER SOILED WARNING LIGHT, VSE SWITCH LIGHTPOWER SUPPLY: ENGINE STOP SOLENOID, PREHEATING CONTROL UNITHORN SWITCH POWER SUPPLY

PARKING BRAKE SWITCH POWER SUPPLY, PARKING BRAKE SOLENOID VALVE POWER SUPPLYREAR WINDSCREEN WIPER/WASHER MOTOR POWER SUPPLYWINDSCREEN WIPER/WASHER SWITCH POWER SUPPLY

ENGINE OIL TEMPERATURE GAUGESTEERING SELECTOR POWER SUPPLY, JOISTICK

K1 RELAY EXCITATION, HYDRAULIC STOP, FUEL GAUGE INSTRUMENT POWER SUPPLY,

BEACON POWER SUPPLY, LIGHTING: FUEL GAUGE WARNING LIGHT, HYDRAULIC OIL TEMPERATURE GAUGE

ATTACHMENT COUPLING/RELEASE SOLENOID VALVE POWER SUPPLY

PREHEATING GLOW PLUGS WARNING LIGHTFRONT WORK LIGHT OPTIONALREAR WORK LIGHT OPTIONALAIR FILTER SOILED WARNING LIGHT

STARTING RELAY

A

B

C

D

E

F

G

1234567810 9

G

F

E

D

C

B

A

910 8 7 6 5 4 3 2 1

Operation: Table:


C

13

GTH 55-19


B6

14

44145

B9B3

B2B7

B2B7

X25

X18

X13X12

X05

X03X02

X14

X11X10X09X08X07X06

X04

X01 ENGINE CONNECTOR 4 WAYS

X16X17

X19

X21X22X23X24

X20

X15

CAB CONNECTOR 18 WAYSCAB CONNECTOR 12 WAYSENGINE CONNECTOR 29 WAYSCAB CONNECTOR 6 WAYSCAB CONNECTOR 6 WAYS

FRONT WINDSCREEN CONNECTOR 2 WAYSJOYSTICK CONNECTOR 3 WAYS

REAR WINDSCREEN CONNECTOR 2 WAYSHYDRAULIC STOP CONNECTOR 2 WAYSWORK LIGHT CONNECTOR 2 WAYSCAB LIGHTING CONNECTOR 2 WAYSBEACON CONNECTOR 2 WAYSBEACON CONNECTOR 2 WAYSKLAXON CONNECTOR 2 WAYSHYDRAULIC OIL TEMPERATURE CONNECTOR 1 WAYSTARTER MOTOR CONNECTOR 1 WAYAIR FILTER CLOGGING CONNECTOR 2 WAYSFUEL LEVEL CONNECTOR 3 WAYSENGINE OIL TEMPERATURE CONNECTOR 1 WAYADDITIONAL FUEL CONNECTOR 1 WAYENGINE OIL PRESSURE CONNECTOR 1 WAYHIGH TEMPERATURTE CONNECTOR 1 WAYBACK-UP HORN CONNECTOR 2 WAYSGLOW PLUGS CONNECTOR 1 WAY

Label Description Page Position Label Description Page Position

1234567810 9

A

B

C

D

E

F

G

910 8 7 6 5 4 3 2 1

G

F

E

D

C

B

A

Legend wiring diagram

C.05.07

Operation: Table:


C

14

GTH 55-19


FUSES AND RELAYS

7.5A

K10

15A

10A

5A

K5

K9

K8

K4

K3

K7

K6

K2

K1

19 5

24

5A

5A28

27

7,5A

7,5A

5A

26

25

5A

15A

5A23

22

10A

10A20

21

10

2A

5A

7,5A

7,5A

5A

14

13

12

11

5A

15A

5A

10A

10A

9

8

6

7

10A

5A

10A18

17

2A15

1610A

10A

5A

4

3

1

2

5A

1234567810 9

A

B

C

D

E

F

G

910 8 7 6 5 4 3 2 1

G

F

E

D

C

B

A

Fuse and relays

C.05.08

Operation: Table:


C

15

GTH 55-19


+12 V S. V. FOURWHEEL STEER. FROM SW10 TO Y08

PREHEATING LIGHT FROM K02 TO A02

HYDR. OIL TEMP. SENSOR SS06 A P02

+12 V START MOTOR DEUTZ FROM K02 TO A02

OPTIONAL

+12 V EXTEND/RETRACT S.V. FROM SW08 TO Y10

ENGINE STOP SOLENOID FROM F05 TO Y09

RECHARGE BATTERY SIGNAL M02 TO P01

+12 V GLOW PLUGS FROM F02 TO A02

FUEL FLOAT SS04 TO P01

+12 V REAR WORK LIGHT SW05 TO H03

S.V. PARKING BRAKE SW03 TO Y03

ENGINE OIL TEMP. SENSOR SS07 TO P03

HIGH TEMP. ENG. SENSOR FROM SS09 TO P01

+12 V BACK-UP HORN FROM K05 TO HA01

ENGINE CONNECTOR 29 WAYS

+12 V S. V. PARALLEL STEER. FROM SW10 TO YO7

ENGINE OIL PRESSURE LIGHT FROM SS03 TO P01

+12 V FRONT SPEED FROM K03 TO Y02

AIR FILTERCLOGGING SENSOR SS01 TO H04

NEGATIVE BRAKE PRESSURE SWITCH SS05 TO P01

FUEL FLOAT SSO4 TO P01

+12 V S.V. VSE FROM SW09 TO Y06

+12 V KLAXON FROM HA02 TO SW12

+12 V REAR SPEED FROM K05 TO Y05

S.V. RELEASE ATTACH. FROM Y04 TO SW07 AND SW09

+12 V PER X06 PIN 1 FROM SW04 TO H02

+12 V PER SW04 FROM F02

FROM SW10 TO Y08

CAB CONNECTOR 12 WAYS

+12 V FROM SW12 TO HA02 (KLAXON)

+12 V REAR WORK LIGHTFROM SW05 TO H03

+12 V LIGHT P02 AND P03

+12 V PER J02 OF P01

SWITCH SW07

+12 V PER SW07

+12 V PER K2

+12 V PER SW05

FROM SW03 F TO K02 AND K03

PREHEATING LIGHT H01 FROM A02

FROM SENSOR SS08 TO J6 OF P01

ALTERNATOR AND BATTERY LIGHT J03-J08 OF P01

+12 V STEERING SELECTOR

FUEL LEVEL J04 OF P01

PARKING BRAKE LIGHT J10 OF P01

+12 V FROM KEY SWITCH

GROUND

LIGHT ENGINE OIL PRESSURE J09 OF P01

+12 V PER SW12

FROM ENGINE OIL TEMPER.SENSOR TO P03

LIGHT FILTER FROM CLOGGING SENSOR SS1

+12 V TO K1

FROM SW10 TO Y07


+12 V PER DEVIO SW03

SW03 POSITION R TO K2 AND K5

GROUND

GROUND

+12 V FROM F31

ENGINE CONNECTOR 4 WAYS

DASHBOARD LIGHT INDICATOR

BUø1.5

VT/WHø1

YE/RDø1.5

YEø1

GY/GNø1

29 WH/OGø1

28

19

20

21

22

23

24

25

27

26 GN/RDø1

YE/RDø1.5

VT/WHø1.5

WH/RDø1.5

BU/RDø1

GY/YEø1

YEø1.5

N. C.

N. C.

X04

28

29

30

18

17

27

16

31

7

6

15

26

198

2

1

14

5

11

10

412

25

21

3

9

20

22

2413

23

12

11

10

1

2

3

4

5

6

7

9

8

10 3

49

8 5

12

11

1

7

2

6

DE

UT

SC

H

Pin

WH/YEø1

YE/GNø1.5

YE/BKø1.5

YEø1.5

YEø1

YE/RDø1

OG/YEø1

OG/GNø1.5

GN/BKø1.5

VTø1

VTø1.5

PK/YEø1

YE/RDø1

TQ/GNø1

GY/RDø1

OGø1

GY/BUø1

VTø1

PKø1

WH/BUø18

9

7

6

5

4

3

2

1

X03

10

11

12

13

14

15

16

18

17 BUø1

N. C.

GY/GNø1

WH/RDø1

WH/GNø1

OG/BKø1

OG/YEø1

OG/BKø1

N. C.

GY/RDø1.5

GY/GNø1

GY/WHø1

GY/YEø1

BN/BKø1

BU/RDø1

VT/WHø1.5

WH/GNø117

18

16

15

14

13

12

11

10

X02

X01

P01

18

17

16

1514 13

12

11

10

98

76

5

4 3

12

43

12

Connector

4

3

2

1

1

2

3

4

5

6

7

9

8 BKø2.5

GY/RDø1

BNø4

RDø4

PKø1

PK/YEø1

PK/BKø1.5

BN/BKø1.5

RDø6

RDø6

BKø2.5

BKø4

N.C.

GY/YEø1

BU/RDø1

YEø1

RD/BKø1

WH/GNø1

N. C.

BU/RDø1

GY/RDø1

GY/WHø1

N. C.

N. C.

WH/BUø1

PKø1

BKø1

Fuse Line

Colour

J5

J13

J14

J12

J11

J10

J9

J8

J7

J6

Pin Description

J1

J2

J3

J4

+12 V FROM F04

LIGHT DASHBOARD FROM F11

FUEL LEVEL FROM SS04

GROUND

HIGH TEMPERATURE FROM SS08

ENGINE OIL PRESSURE FROM SS03

PARKING BRAKE FROM SW06

LIGHT LOW LEVEL FUEL FROM SS04

BRAKE PRESSURE FROM SS05

LIGHT BATTERY + SIGNAL COUNTER FROM M02

DescriptionColour

Fuse LineEngine LineConnector

LIGHT BATTERY + SIGNAL COUNTER FROM M02

+12 V FROM F31

LIGHT LOW LEVEL FUEL J13 OF P01

Engine Line

1234567810 9

A

B

C

D

E

F

G

910 8 7 6 5 4 3 2 1

G

F

E

D

C

B

A

+-

00 00 0 0 3

J14

J15

J13

J10J11

J4J1

J12

J5

J6

J2J3J9

J8

J7

Connectors

C.05.09

Operation: Table:


C

16

GTH 55-19


GROUND

FUEL FLOAT SS04

GLOW PLUGS R01WH/GNø11GLOW PLUGSCONNECTOR

X25

GROUND

BACK-UP HORN HA01

HIGH TEMPERATURE SENSOR SS08

ENGINE OIL PRESSURE SENSOR SS03

ADDITIONAL FUEL Y01

ENGINE OIL TEMP. SENSOR SS07

FUEL FLOAT SS04

GROUND

AIR FILTER CLOGGING SENSOR SS01

STARTER TEMPERATURE M01

HYDR. OIL TEMP.SENSOR SS06

GROUND

+12 V KLAXON HA02

CONNECTOR 2 WAYSBACK-UP HORN

HIGH TEMP.CONNECTOR

CONNECTOROIL PRESS.

ADDITIONAL FUELCONNECTOR

CONNECTORSTART. TEMP.

CONNECTOROIL TEMP. SENS.

CONNECTOROIL TEMP. SENS.

CONNECTOR 3 WAYSFUEL FOLAT

CONNECT. 2 WAYSAIR FILT. CLOG. SENS.

CONNEC. 2 WAYSKLAXON

GROUND

+12 V LIGHT H03

+12 V BEACON H05

+12 V CAB LIGHTING H06

GROUND

GROUND

+12 V LIGHT H02

HYDRAULIC STOP SIGNAL

+12 V WINDSCREEN M03

GROUND

BEACON

CONNEC. 2 WAYSCAB LIGHTING

CONNEC. 2 WAYSWORK LIGHT

CONNECTOR 2 WAYSHYDRAULIC STOP

CONNECTOR 2 WAYSFRONT WINDSCREEN

CONNECTOR 3 WAYSJOYSTICK

+12 V JOYSTICK

JOYSTICK SIDE 2

JOYSTICK SIDE 1

SIGNAL PER P02 FROM SS06

+12 V BRAKE PRESS. LIGHT P01 J14

+12 V J1 OF P01

+12 V H01, ECCIT. K01, SS02, H04

+12 V LIGHT SW07

WORK LIGHT OPTIONAL H02

BEACON H05

CAB LIGHTING H06

GROUND


BKø1

BKø1

RD/BKø1

RD/BKø1

X23 WH/GNø11

1 GY/RDø1X22

X21 BUø2.51

1 GY/GNø1X20

X19PKø1

GY/YEø1

2

1

1

2

GY/BUø1

BKø1X18

X17 BUø41

1 GN/RDø1X16

X15

21

X14 YEø1.5

BKø1.52

11 2

1

2 BKø1

WH/VTø1X13 2

1

1

2X12RDø1.5

BKø12

1

1

2 BKø1.5

YE/GNø1.5X11 2

1

X10 RD/BKø1

RDø12

1

X09 1

2 BKø1.5

BU/BKø1.51 2

X08

C

B A

YE/GNø1.5

WH/VTø1

RDø1.5

BKø1

6

5

4

3

2

1

X066

5

1

4

2

3

DE

UT

SC

H

1

2

3

4

5

6

RD/BKø1

N. C.

WH/BUø1

GN/RDø1

6

5

1

4

2

3

DE

UT

SC

H

Pin

BN/BKø1

WH/GNø1

WH/OGø1

BN/RDø1

BKø12

1

A

B

C

X05

X07

X24

4 BKø1

BKø1

OG/BKø1

BKø1

VTø1

Pin

2

1

2

1

ConnectorColour

DescriptionFuse Line

ConnectorColour

Fuse LineDescription

Engine Line Engine Line

GROUND

GROUNDCAB CONNECTOR 6 WAYS

+12 V WINDSCREEN M04

GROUNDREAR WINDSCREENCONNECTOR 2 WAYS

HYDRAULIC STOP SIGNAL

GROUNDCONNEC. 2 WAYS

BEACONCONNEC. 2 WAYS

2

1

A

B

C

D

E

F

G

1234567810 9

G

F

E

D

C

B

A

910 8 7 6 5 4 3 2 1

Connectors

C.05.09

Operation: Table:


C

17

GTH 55-19


Position of the electrical components on the machine

C.05.10

X13

X14

H05H06

X12

X23 SS08

X20 X22

A01

SW02

100

SS07 SS03

M02

Y09

Y01

H03

Y06

X24

HA01

X21

A02

Operation: Table:


C

18

GTH 55-19



C.05.10

X18

SS01

X25X17

M01

SS06

X16

R01

Operation: Table:


C

19

GTH 55-19



C.05.10

X07

X01

X02

X03

X04

X05

SS02

X10

X06 X08

X09

SW01

SW03

X11

H02

M03

Operation: Table:


C

20

GTH 55-19



C.05.10

X19

Y04

Y10

SS05

Y03

Y07

Y08SS04

HA02

X15

Y02Y05

P03

P01

P02

SW06 SW09 SW08

SW12 SW10 H01

P03P03P03

H04

SW11

SW07Y06

SW05 SW04

Operation: Table:


C

21

GTH 55-19


Boom raising cylinder

C.06.01

ø 55 STROKE 708

CLOSED 1187 - OPEN 1967

80 ø 55

ø 1

10

ø 7

0

Pressure

BRSOR

Operation: Table:


C

22

GTH 55-19


Boom extension cylinder

C.06.02

Spacer 375 Stroke 2135


ø 30

60

ø 30

Pressure

BRSOR

Operation: Table:


C

23

GTH 55-19


Balance cylinder

C.06.03


STROKE 380

Pressure

BRSOR

Operation: Table:


C

24

GTH 55-19


Fork movement cylinder

C.06.04

STROKE 325


ø 1

20

ø 6

0

Pressure

BRSOR

Operation: Table:


C

25

GTH 55-19


Attachment locking cylinder

C.06.05

CLOSED 555/OPEN 739

FEEDING DISTANCE BETWEEN CENTRES 404

495

92C

H 2

7

ø 3/8"

ø 3

0

M20

x1.5

ø 5

0

BRSOR

Pre

ssu

re

Operation: Table:


C

26

GTH 55-19


Hand-lever

C.07

A

A A

T

A A

Operation: Table:


C

27

GTH 55-19


Hydraulic main valve

C.08

W

W

W

VA1

T

G 1/2”

ø 8,5

n° 3 fori

VB1

G 1/4”VA2 VA3 VA4

VB2 VB3 VB4

G 3/4”

P

DATA

Nominal flow

Nominal pressure

Max back-pressure to drain T

Fluid temperature range

80 l/min

315 bar

15 - 75 mm2/s

-40|B a +60|BC

3 cm3/minMax internal leakage A(B)->T @ 100 bar:

Viscosity

Working elements

Slider diameter 18 mm

Monobloc actuator with paralleled circuit

Ambient temperature

12 mm2/s

400 mm2/s

4

working range

minimum

maximum

19/16 - ISO 4406Admissible contamination degree

-20|B a +80|BC

25 bar

Max pressure on V 50 bar

A1 A2 A3 A4

B1 B2 B3 B4

W

P

Q=80 l/min

290 bar 290 bar

270 bar

A1 B1

HYDRAULIC SCHEME

T

A2 B2 A3 B3 A4 B4VA1

VB1 VB2

VA2 VA3

VB3 VB4

VA4

OPERATING CONDITIONS(mineral oil - viscosity 46 mm2/s @ 40|BC)

Operation: Table:


C

28

GTH 55-19


Hydraulic pump

C.09.01

PUMP TECHNICAL DATA

- Rotation direction ............................................................................ .........Counterclockwise- Displacement .................................................................................................34.555 cm3/rev- Inlet pressure range for pump.......................................................... .....................0.7 - 3 bar- Max continuous pressure ............................................................P1 .........................260 bar- Max intermittent pressure............................................................P2 .........................280 bar- Max peak pressure ......................................................................P3 .........................300 bar- Speed....................................................................................min P1 ...................350 min^-1

max P1 .................3000 min^-1- Gaskets ............................................................................................ ..............................NBR- Working temperature........................................................................ .................-25°C +80°C- Viscosity range .........................................................recommended ........12 to 100 mm^2/s

admissible..........max 750 mm^2/s- Contamination class ...................................................ΔP > 200 bar .................8 - Nas 1638

βx = 75-10 μm.....19/17/14 - ISO 4406ΔP < 200 bar ...............10 - Nas 1638

βx = 75-25 μm.....21/19/16 - ISO 4406

140 Nm

70 Nm

50 Nm

Operation: Table:


C

29

GTH 55-19


Brake pump

C.09.02

A BRAKE PUMPB BRAKE OIL SUMPC FRONT AXLE

B

A

C

Operation: Table:


C

30

GTH 55-19


Boom raising and extension cylinder blocking valve

C.10.01

FITTINGS V1-V2: G 1/2”C1-C2: ø12

V2

C2 C1

V1

V1V2

V1

C1

C2

V1

SEZ. A-A

V2

V2

V2 V1

C2 C1

AA

TECHNICAL DATA

• Max working pressure = 350 bar• Piloting ratio = 4:1• Weight = 2.5 kg• Valve setting = 1.3 times higher than

the load induced pressure• Steel manifold

Operation: Table:


C

31

GTH 55-19


Balance cylinder blocking valve

C.10.02

INSTALLATION SCHEME

C1 C2

V1 V2

MATERIAL

Manifold: Steel

TECHNICAL DATA

Max flow = see diagramMax pressure = 350 BarSetting = 100 - 350 barStandard setting (Q=5 l/min) = 300 barValve setting = 1.3 times higher thanthe load induced pressurePiloting ratio = 11:1Weight = 2 kg

FITTINGS

C1-C2 = G 1/2”V1-V2 = ø 8,5

0

4

8

12

16

20

24

0 10 20 30 40 50 60

FLOW - Q (l/min)

PR

ES

SU

RE

- Δ

p (

bar)

C1 C2

V2V1

O.ring 31,42x2,62

Operation: Table:


C

32

GTH 55-19


Fork movement cylinder blocking valve

C.10.03

MATERIAL

Manifold: Steel

TECHNICAL DATA

Max flow = see diagramMax pressure = 350 BarSetting = 100 - 350 barStandard setting (Q=5 l/min) = 300 barValve setting = 1.3 times higher thanthe load induced pressurePiloting ratio = 4,2:1Weight = 2 kg

FITTINGS

C1-C2 = G 1/2”V1-V2 = ø 8,5

INSTALLATION SCHEME

C1 C2

V1 V2

O.ring 31,42x2,62

V1

C2C1

V2

0

4

8

12

16

20

24

0 10 20 30 40 50 60

FLOW - Q (l/min)

PR

ES

SU

RE

- Δ

p (

bar)

Operation: Table:


C

33

GTH 55-19


Attachment cylinder blocking valve

C.10.04

C2

V2

C1

V1

V1 V2

C2C1

TECHNICAL DATA

• Max working pressure = 350 bar• Opening pressure = 3 bar• Max flow = 15 l/min• Piloting ratio = 4:1• Weight = 0.7 kg

Operation: Table:


C

34

GTH 55-19


Pressure reducing valve

C.10.05

INSTALLATION SCHEME

MATERIAL

Body: Aluminium 702 State T6Internal parts: case-hardened and tempered steel

TECHNICAL DATA

Max flow = 20 l/minMax pressure = 210 BarSetting = 5 - 50 bar(test setting 40 bar with 5 l/min)Piloting ratio = 1:7Fluid: 20-200 cSt mineral oilAmbient temperature = 0 +40 °CGaskets : BUNA N

BLOW-BYBlow-by in Dr: 20 cc/min at a pressure of 150 bar withoil with 46 cSt viscosity

FITTINGS

U - E - Dr = G 3\8”

Cylindrical fitting tightening torque 0 60 Nm (do notuse conical fittings)

RECOMMENDED CONTAMINATIONLEVEL - ISO 4406

FILTRATION - OIL CONTAMINATION

TYPE OF SYSTEMTYPE OF VALVE

- High performance systems 16/13- Systems with working pressures from 210 to 350 bar- Systems with proportional controls- Systems with high frequency cycles

- Systems with working pressures up to 210 bar 18/14- Spool valves- Valves with calibrated orifice

- Systems with low working pressures 19/15- Piloting systems- Systems with low frequency cycles

E

U Dr

7 Nm

13

Dr

E U

Q

Operation: Table:


C

35

GTH 55-19


DHI solenoid valve

C.10.06

A B

P Ta b

A B

P T

Installation position

Coupling surface condition

Ambient temperature

Fluid

Recommended viscosity 15÷100 mm2/s at 40 °C (ISO VG 15÷100)

Fluid contamination class

Fluid temperature

Pressure limits

Maximum flow

Utilisation factor

Voltage and power frequency

Threshold tolerance

MAIN CHARACTERISTICS OF THE DHI SOLENOID VALVES

Any

Surface texture index , flatness ratio 0.01/100 (ISO 1101)0,4

-20 °C to +70 °C

Hydraulic oil as per DIN 51524

ISO 19/16, obtained through 25 μm and ß25≥ 75 line filters (recommended)

T ≤ 80 °C, if T ≤ 60 °C choose PE seals

P, A, B ports: 350 bar – T port: 120 bar

60 l/min for DI

100%

12 DC

±10%

A B

Port

Spool type

P-A

4 D D D D A

Q/Δp CHARTS

Tests done with fluid viscosity of 43 mm2/s at 40 °C

P-B A-T B-T P-T

Flow [l/min]

Inle

t p

ress

ure

[b

ar]

Spools 4 with electrical connectors = T

M

S

T

X

Y

V

10 20 30 40 50 60 70 8000

50

100

150

200

250

300

350

400

59 5966

Weight: 1,8 kg28

,5

79,5

46

45

= =

Flow [l/min]

D

B

A

C

21

17,5

14

10,5

7

3,5

0

Lo

ad lo

ss Δ

p [

bar

]

0 10 20 30 40 50 60


C

36

GTH 55-19




D

1

GTH 55-19

CHECKS AND ADJUSTMENTS

Section DCHECKS AND ADJUSTMENTS

SECTION INDEX

D.01 Speed check ........................................................................................ page 2

D.02 Checking the max. current of the solenoid coils ......................................

D.03 Checking and calibrating the circuit pressure .......................................... 4

D.04 Checking the engine oil level ...................................................................... 11

Procedure: Table:


D

2

GTH 55-19


Checking the movement times of cylinders

D.01

The check of the movement times of the cylindersshall be done with the hydraulic oil at a temperatureof 60°.

To check the engine speed, the area easy to reach isthe shaft of the CASAPPA pump.Min engine speed = 950 rpmMax engine speed = 2700 rpm

BOOM LIFTING/LOWERING

Time (s) up down

Max engine speed 7” 4”

Min. engine speed 18” 11”

BOOM EXTENSION/RETRACTION

Time (s) out in

Max engine speed 7” 4”

Min. engine speed 19” 10”

Lifting

Lowering

ExtensionRetraction

Procedure: Table:


D

3

GTH 55-19


ATTACHMENT DUMPING

Time (s) dumping roll-back

T. Max 3” 4”T. Min 10” 12”

D.01Checking the movement times of cylinders

The maximum speed that can be attained on a levelground is 24 km/h in both forward and reverse speed.

Roll-back

Dumping

Procedure: Table:


D

4

GTH 55-19


Checking and calibrating the circuit pressure

D.03

1. PRELIMINARY OPERATIONS

Warm up the hydraulic oil to 80°C by keeping one of theelements of the boom main valve to full stroke underpressure.To reach this temperature in a faster way, cover the oilcore of the radiator with a carton in the case of a water-oil combined cooler, or the oil radiator if the machine isequipped with a separate oil radiator.

2. SETTING THE BOOM MAIN VALVE

Find the mini-socket for the pressure gauge ref. 2 onthe Walvoil main valve (see annex 1).

2.1 SETTING THE MAIN VALVE PRESSURECONTROL VALVE

Connect a 0-400 bar manometer to the mini-socket ref.2. Fully raise the boom to stroke end by means of joystickref. 1.Calibrate valve A (see annex 2) to 270 bar with the Dieselengine at full speed.To calibrate the safety valves B (see annex 2), proceedas follows:

• Connect a 0-400 bar manometer to the mini-socketref. 2.

• Increase the pressure of valve A of the main valve to290 bar moving the raising cylinder to stroke end (fullyout).

• With the engine running at maximum speed, pitchthe forks forward by means of the joystick and act onone of the two valves B until reaching a pressure of280 bar.

• Proceed in adjusting the second valve B (280 bar) bypitching the forks back.

• When both fork inclination safety valves have beencalibrated, reset the pressure control valve to 270 barby adjusting the register A.

3. SETTING THE PRESSURE RELIEFVALVE

• Fit a fitting with mini-socket ref. 3 in the positionshown in annex 1.

• Connect a 0-60 bar manometer to the mini-socketref. 3 (see annex 1), with the engine running atminimum speed moving any of the elements of themain valve to stroke end, then set valve E (see annex1) to 28 bar.

• Remove the manometer from the mini-socket and re-tighten the protection cap.

4. SETTING THE HYDROMATIK PUMPHYDROSTATIC TRANSMISSION

Do the calibration of the hydrostatic transmission withthe hydraulic oil at 80°C.

• Connect a 0-60 bar manometer A to the mini-socketref. 4 to read the boost pressure value.

• Connect a 0-600 bar manometer B to the mini-socketref. 5 to read the high-pressure value.

0 600

300200

100500

400

0 60

3020

1050

40

5

4

A

B

Procedure: Table:


D

5

GTH 55-19



D.03

Do not fit the manometer to the application pointcorresponding to the reverse speed. This operationis extremely dangerous for the serviceman who iscalibrating the transmission.

• Hold the selector to neutral position and make surethe maximum speed of the engine does not exceed2800 rpm. The engine must run at a idle speed of950 rpm. Otherwise, adjust the minimum speed.

• Read the boost pressure on manometer A and ensureit is about 26/28 bar with the engine running at idlespeed.The boost pressure has not a fixed value but variesfrom pump to pump.

• Remove coil ref. 5 from solenoid valve ref. 6 (seeannex 3) so the machine remains braked.

STARTING THE CALIBRATION

• Set the forward-neutral-reverse selector to theforward or backward position.

• Run the engine at 1200 rpm. Check the value on thetachometer.

• Adjust shutter D by means of the register until readinga value of 50 bar on the high-pressure manometer B.

4.1 CALIBRATION OF THE MAXIMUM PRESSURE

Do this operation with extreme caution. The properfunctioning of pump and transmission depends on thiscalibration.

• Set the forward-neutral-reverse selector to theforward position.

• Run the engine at maximum speed and check thehigh-pressure value. If this value is less than 420 bar,increase the pressure to 430 bar by means of thepressure cut-off valve E.

• Remove the manometers and do an attempt.

D

0 600

300200

100500

400

0 60

3020

1050

40

E

B

Procedure: Table:


D

6

GTH 55-19



4.2 CALIBRATION OF THE MECHANICAL ZERO

The calibration of the mechanical zero G is required ifthe machine is set to neutral position with the forward-reverse speed lever.

• Set the forward-neutral-reverse selector to neutralposition.

• With the engine running at idle speed, adjust themechanical zero screw by rotating it until the high-pressure manometer reads the same value measuredby the boost pressure manometer.

0 60

3020

1050

40

0 60

3020

1050

40

G

D.03

5. SETTING THE POWER STEERING

• Fit a fitting with mini-socket Z in the position shownin annex 4.

• Connect a 0-250 bar manometer to the mini-socketZ.

• Select the front axle steering mode.

• Move the steering cylinder to stroke end and makesure the value of the power steering A is 170 bar. Ifthe value is less, tighten valve X; if the value is greater,loosen the valve.

Note: To gain access to valve X, remove theprotection cap (see annex 4).

5.1 CHECKING THE NEGATIVE BRAKE PRESSURE

Fit a 0-60bar pressure gauge to mini-socket ref. W (seeannex 3) to check the pressure acting on the parkingbrake of the front axle.The brake is unlocked when the pressure value is 25 to28 bar.

Procedure: Table:


D

7

GTH 55-19



D.03

Annex 1

TP2

T

B

12

E

3

Procedure: Table:


D

8

GTH 55-19



D.03

Annex 2

A

B

Procedure: Table:


D

9

GTH 55-19



D.03

Annex 3

AP

B

T

5

6

W

Procedure: Table:


D

10

GTH 55-19



D.03

Annex 4

A

Z

X

Procedure: Table:


D

11

GTH 55-19


Checking the engine oil level

D.04To 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.

• If oil is below this mark, remove plug C and pour newoil into the engine using the special appliance D.

• Remove dipstick A once again and check if oilreaches the max mark B.

• Refit the plug.

If one of the connecting pipes of radiator E breaks:• Stop the machine immediately, if possible on a flat

ground; stop the engine and check the parking brakeis engaged.

• Change the damaged pipe.• Remove dipstick A and check if oil reaches the max

mark B.• If oil is below this mark, remove plug C and pour new

oil into the engine using the special appliance D.• Restart the machine and let oil circulate in the engine

and the radiator.• Stop the machine and check again the oil level. If

necessary, add new oil step by step until reaching themax level by starting and stopping the engine atevery step.

A

B

min

max

C

D

E

E


D

12

GTH 55-19




F

1

GTH 55-19

TROUBLESHOOTING

Section FTROUBLESHOOTING

SECTION INDEX

Hydraulic faults ................................................................................... page 2

Electrical faults ............................................................................................. 5


F

2

GTH 55-19

TROUBLESHOOTING

Trouble Cause Solution

Any service, maintenance or troubleshooting must be carried out with the machine stopped, the boom inrest position lowered to the ground, and the transportation locking devices fitted.

Use the wiring diagrams enclosed for finding solenoid valves (EV), fuses (F), relays (E) or other electricalcomponents in an easier way - see chapter C - Technical data of this manual.

The boom does not move

Wrong wheel shafting

The steering wheel is hard(low force in the cylinders)

• Low pressure

• Hydraulic pump damaged• Load sensing valve defective

• Leakage on the control blockvalve

• Pressure reducing valvemaladjusted

• Joystick damaged

• Leakage in the steeringcylinders

• Leakage in the steer selectionsolenoid valve

• Low pressure

• Priority valve damaged

• Set the max pressure of thecontrol block to 270 bar (seesec. D)

• Replace the pump• Check the efficiency of the

valve; replace if necessary• Dismantle the valve, check

and eliminate any foreignmatters

• Check the efficiency andreset the correct pressure (28bar) if necessary

• Check the efficiency of thejoystick; replace if necessary

• Check and replace the sealsif necessary (see sec. G)

• Check the efficiency of thesolenoid valve

• Check the pressure; in case,reset (170 bar)

• Check the efficiency of thevalve; replace if necessary


F

3

GTH 55-19

TROUBLESHOOTING


When the engine is stopped,the lifting cylinder does notsupport the boom

When the engine is stopped,the cylinder does not supportthe forks

When the engine is stoppedand the boom is high, theextension cylinder moves in

When the load is lifted, thefork cannot be levelled

When the max load is applied,forks move down

Operating the joystick nofunction is activated

The steering wheel is slowand noisy

Differential noisy and hightemperature on the body

• Block valves damaged or dirty

• Cylinder seal defective





• Seals of the levelling cylinderworn out

• Shockproof valves of thecontrol block dirty ormaladjusted

• One-way valves of thelevelling cylinder dirty ordamaged

• Seals, rod and liner of the forktilting cylinder worn out

• Leakage in the cylinder blockvalve

• Low pressure in the hydrauliccircuit

• Joystick damaged

• Control block valve damaged

• Pressure reducing valvedamaged

• Couplings damaged• Hydraulic drive damaged

• No oil

• Bearings damaged

• Check the efficiency of thevalves; replace if necessary

• Replace the seal





• Dismantle the cylinder andreplace the seals

• Remove the valves, dry-clean or replace if damaged,and re-calibrate (see sec. D)

• Remove the valves, dry-clean or replace if damaged,and replace in their seats

• Dismantle the cylinder andcheck and replace anydefective parts

• Check the leakage; removethe valve and rectify orreplace

• Re-calibrate the controlblock (see sec. D)

• Check the joystick efficiency;replace if necessary

• Check the efficiency of thevalve; replace if necessary

• Check the calibration valueof the valve; replace the val-ve if necessary

• Replace the couplings• Replace the hydraulic drive

• Check the oil level and refill.If trouble cannot be rectified,dismantle the unit (see sec.G)

• Replace the bearings (seesec. G)


F

4

GTH 55-19

TROUBLESHOOTING


• Check the play and replaceany worn parts or placeshims

• Check that the greasesmeared on the boom isINTERFLON FIN GREASELS2; smear the boomagainwith grease

• Check and eliminate anyforeign matters

• Check the pressure values ofthe drive pump (see sec. D)and re-calibrate if necessary.If the overfeeding pressuredrops down, replace thepump and clean the pump-motor couplings

• Sliding blocks worn out

• Grease is insufficient orinadequate

• Foreign matters on the slidingblocks and the relevantsurfaces of the boom

• Drive pump defective

When moving out the secondtelescope, the boom tends tomove right and left

When moving out the secondtelescope, the boom tends tojump

Low traction


F

5

GTH 55-19

TROUBLESHOOTING


No power to dashboard

Engine does not start, starterdoes not run

Engine does not start - starterruns but engine does not start

The machine does not moveforward/back

• Battery switch off• Battery down

• 50A fuse blown• Dashboard damaged

• Broken or damaged wiring

• 50A fuse blown• Dashboard damaged

• K2 relay damaged• Speed switch ruined

• 70A engine start relaydamaged

• Starter defective

• No fuel• Fuel filter clogged• Fuel ducts empty• Start aid solenoid damaged

• Engine stop solenoid


• Speed switch damaged

• 10A fuse F13 broken• Relays K3-K4-K5 damaged• Forward/reverse speed

solenoid valves damaged• Parking brake micro-switch

damaged• Parking brake switch


• Turn on the switch• Check the battery efficiency;

replace if necessary• Change the fuse• Check the dashboard and

replace if necessary• Reconnect or replace the

wiring

• Replace the fuse• Check the dashboard and

replace if necessary• Change the relay• Check or replace the speed

switch• Change the relay

• Change the starter

• Refuel• Clean or replace the filter• Eliminate any air• Check the efficiency and

replace if necessary• Check the efficiency and

replace if necessary• Reconnect or replace the

wiring

• Check the efficiency orreplace the switch ifnecessary

• Change the fuse• Change the relays• Check the efficiency or

replace• Check the efficiency or

replace• Check the efficiency or

replace• Reconnect or replace the

wiring


F

6

GTH 55-19

TROUBLESHOOTING


No steer selection

Hydraulic oil thermometerdefective

The parking brake lamp doesnot come on

The fuel gauge does not work

The engine coolantthermometer does not work

High hydraulic oiltemperature

• 7.5A fuse F12 blown• Steer selector damaged• Coils of the steer selection

solenoid valve damaged• Broken or damaged wiring

• 7.5A fuse F11 blown• Indicator damaged• Temperature sensor defective• Broken or damaged wiring

• 10A fuse F4 blown• Dashboard instrument

damaged• Broken or damaged wiring

• 10A fuse F4 blown• Dashboard instrument

damaged• Fuel sensor defective


• 7.5A fuse F11 blown• Indicator defective• Temperature sensor defective


• Hydraulic oil bulb damaged

• Indicator defective• Radiador clogged

• Change the fuse• Check or replace the selector• Check the coils; replace if

necessary• Reconnect or replace the

wiring

• Change the fuse• Change the part• Check or replace the sensor• Reconnect or replace the

wiring

• Change the fuse• Change

• Reconnect or replace thewiring

• Change the fuse• Change

• Check and replace thesensor if necessary


• Change the fuse• Change the part• Check and replace the

sensor if necessary• Reconnect or replace the

wiring

• Check or replace the bulb ifnecessary

• Change the part• Check the radiator and elimi-

nate any impurities from thefins


F

7

GTH 55-19

TROUBLESHOOTING


The joystick does not pitch theforks

The joystick does not lock/release the attachment

• 7.5A fuse F12 blown• Control block selection valve


• 7.5A fuse F12 blown• Control block selection valve


• Operating pushbuttondamaged

• Change the fuse• Check the efficiency of the

electrical coils; replace thecoils if damaged


• Change the fuse• Check the efficiency of the

electrical coils; replace thecoils if damaged


• Check or replace the fuse


F

8

GTH 55-19

TROUBLESHOOTING


Documents

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