Service Manual Genie GTH 55-19 PDF

SERVICE MANUAL
Code 57.4403.3200 - 2nd Edition 01/2008
Handler with telescopic boom

GTH 55-19
(from serial n. 17548 to serial n. 17565)
English
Edition INDEX
GTH 55-19
2
Intentionally blank page
Document 57.4403.3200 - 2nd Edition 01/2008 INDEX

GTH 55-19

SERVICE MANUAL
Code 57.4403.3200 - 2nd 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
photocopy or reproduce this manual or parts of the same in any way without the prior written
authorisation of GENIE 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 the

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

GTH 55-19
3
SERVICE MANUAL
Code 57.4403.3200 - 2nd 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
photocopy or reproduce this manual or parts of the same in any way without the prior written
authorisation of GENIE 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
........................................... ...........................................

GTH 55-19
4
LIST OF REVISED PAGES
Revision Revised pages Notes Issued by

No. Date
1 06-2007 Publication
2 01-2008 Section 2, 5, 6 Revision
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GTH 55-19
5
GENERAL INDEX
MANUAL CONTENTS
INTRODUCTION
Sect. 1 SAFETY RULES
Sect. 2 TECHNICAL SPECIFICATIONS
Sect. 3 SCHEDULED MAINTENANCE INSPECTIONS
Sect. 4 SCHEDULED MAINTENANCE PROCEDURES
Sect. 5 TROUBLESHOOTING
Sect. 6 SCHEMES
Sect. 7 REPAIR PROCEDURES

GTH 55-19
6
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

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.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However, several
procedures require specialized skills, as well as specific
tools and equipment.
In these instances, we strongly recommend letting service
and repair the machine at an authorized TEREXLIFT
service center.
Technical Publications
No part of this publication may be reproduced, stored in a
retrieval system or transmitted in any form or by any means
without prior written permission from TEREXLIFT srl.
In pursuing a policy of constant quality improvement,
TEREXLIFT srl reserves the right to make changes at any
time and without undertaking to give prior notice; therefore,
also this publication may be subject to modifications.
Contact Us
http://www.terexlift.com
e-mail: [email protected]
http://www.genielift.com
© Copyright 2007 TEREXLIFT srl - All rights reserved.
Document 57.4403.3200 - 1st Edition 06/2007 INDEX

GTH 55-19
INTRODUCTION ii
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-
loop pump for hydrostatic drives, model A4VG56 (2) with
adjustment valve of DA type. The max displacement of this
swashplate pump is 56 cm3/rev. and the max calibration
pressure is 430 bar (6235 psi). This pump is used to
supply hydraulic power under form of pressure and flow
rate which is then used for moving the machine. On the
through-shaft of such drive pump there is a Casappa
open-loop gear pump (with fixed displacement) (3) with
priority valve integrated in the housing. The displacement
of this pump is 27 cm3/rev. Its function is to provide
hydraulic power, under form of pressure and flow rate, to
the steering circuit of the machine (primary branch of the
priority valve) and to the circuit for the telescopic boom
movements (secondary branch of the priority valve).The
assembly of the two pumps involves they have a rotation
velocity equal to the speed of the diesel engine.
The suction line of the open-loop pump (3) is protected
by an immersed filter (8), placed inside the hydraulic fluid
tank (10) whose capacity is 75 litres (20 gallons). Just
upstream of the connection with the suction line, there
is a gate valve with ball valve (9) which lets you cut out
the hydraulic oil tank in order to perform maintenance
interventions on the machine's hydraulic system without
having to drain oil off the tank built in the same circuit. The
filter (34), placed in the line returning to pump (3), purifies
most oil coming from the hydraulic circuit operating the
telescopic boom before this oil returns to the tank. In
addition to purify the oil coming from the main open-loop
circuit of the machine (telescopic boom operating circuit),
this filter can deliver oil at a minimum pressure of 0.5 bar
to the suction line of the drive pump (2).This construction
feature of the filter guarantees important advantages in
terms of absence of cavitation in the transmission suction
line, especially when the machine is started from cold.
The one-way valve (11) set at 2.5 bar (36 psi) protects the
pump housing against high pressures and guarantees a
certain circulation of the drain oil to the hydrostatic motor
reducing, in this way, the temperature. From port “G” of
the drive pump (2) low-pressure oil is taken (25-30 bar)
to feed the anti-cavitation circuit of the automatic fork
levelling system, the pilot circuit of the main valve of
the telescopic boom (16) and the parking brake unlock
circuit. The hydraulic energy produced by the drive pump
(2) is converted into mechanical power by a closed-loop
hydrostatic motor, model Bosch-Rexroth A6VM107 (5)
equipped with adjustment valve of DA1 type and with
flush valve (36) for reducing the max temperatures inside

GTH 55-19
INTRODUCTION iii
the drive circuit. The max displacement of this bent-axis

motor is 107 cm3/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” type with a
displacement of 125 cm3/rev., receives oil from the priority
line of pump (3) in relation to the “load sensing” signal
sent by the hydraulic drive and connected to such pump
with function of pilot signal. In this way, the input flow
to the hydraulic drive is exactly the one needed for the
instantaneous steering functions; any excess flow of the
pump is available for operating the different movements
of the telescopic boom. The steering circuit is protected
against input overpressures by a pressure reducing valve
set at 170 bar (2465 psi). On the two delivery lines to the
steering cylinders there are other two pressure reducing
valves with anti-shock function set at 225 bar (3262 psi).
These two valves are intended to limit possible shocks
on the steering wheel due to overstress caused by the
wheels on the steering cylinders. These pressure reducing
valves are installed in the hydrostatic drive (12) and
cannot be regulated from the outside. The steering circuit
is completed by the front steering cylinder (14), the rear
steering cylinder (15) (these cylinders being integral part
of the front axle (26) and the rear axle (27) respectively)
and by a 4-way/3-position solenoid valve (13) for the
selection of the three different steer modes (rear wheels
straight, co-ordinate front/rear steering and independent
front/rear steering).When the solenoid valve (13) is not
energised, the front steering cylinder is fed by the hydraulic
drive and the rear cylinder is blocked. When one magnet
or the other of the solenoid valve (13) is energised, the
chambers of the cylinders are connected in a different
manner thus causing the desired effect on the steering
mode. The Walvoil hydraulic 4-section main valve (16)
receives oil from the secondary line of pump (3) and feeds
all the movements of the telescopic boom. Each of the
4 sections of the main valve controls a specific function
of the machine (lifting/lowering, attachment holding plate
rotation, boom extension/retraction, attachment locking/
unlocking). In the head there is a pressure relief valve set
at 270 bar (3915 psi) which reduces the max pressure at
the main valve inlet and drains the excess oil. The joystick
(18) is used to reduce the pressures of the main valve
section pilot lines and to move the main sliders of the
main valve in a proportional manner with respect to their
neutral position. Slider 1 of the main valve controls the
lifting cylinder (17) of the telescopic boom. This cylinder
has one single-acting compensation valve with safety
function. Slider 2 of the main valve controls the attachment
holding frame cylinder (19) of the telescopic boom. This
cylinder is equipped with a double-acting compensation
valve serving also as a safety valve. Parallel to this
cylinder, there is the fork levelling compensation cylinder
(20) (also called balancing cylinder) which is equipped

GTH 55-19
INTRODUCTION iv
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). These
valves deliver oil, taken from the low-pressure line of the
transmission pump (2), to the fork levelling compensation
circuit when needed. The two pressure relief valves (7)
set at 290 bar (4205 psi) which protect the automatic fork
levelling circuit during the boom lifting/lowering phases
and in case of overload on the attachment holding frame
(for instance, in the case of use of the bucket) are installed
in the two control lines of cylinder (19) and they are
integral to module 2. Slider 3 of the main valve controls
the extension cylinder (22) of the telescopic boom which
operates the movement of the second boom telescope
and is equipped with a single-acting compensation valve
used as well as safety valve.
Slider 4 of the main valve controls the attachment locking
cylinder (23). This cylinder has a double one-way valve
with hydraulic release and safety function. On the feeding
lines of this cylinder, there are two quick-fit connectors
(24) for the connection of the hydraulic lines to those
optional attachments necessitating hydraulic power for
their operation (ex. hydraulic winch and maintenance jib,
mixing bucket, etc.).
The special hydraulic block (21) has been designed

to group, in a single element, some valves of the low-
pressure circuit fed through port “G” of pump (2), which,
in the previous versions of the machine, were installed
separately. In particular, this block houses the selection
solenoid valve (29) operating the parking brake and the
relevant valve controlling the flow rate of the calibrated
throttle with 0.5mm diameter; the selection solenoid
valves (31) and (35) used to switch the pilot lines coming
from joystick (18) and relevant to the longitudinal axis
of this joystick (forward/backward) which, depending
on the operation of the two pushbuttons installed on the
control lever in the driving place, activate one of the three
sections of the main valve (16), and namely the lift/lower
movement, the attachment holding plate rotation movement
and the attachment lock/unlock movement. The selection
solenoid valve (30), again built in block (21), activates the
attachment lock/unlock line (also used as auxiliary line for
the operation of optional attachments) without any need to
move the joystick (continuous flow). The pressure reducing
valve with screw adjustment (38), when operated together
with solenoid valve (30), allows to adjust the oil flow rate
of the attachment lock/unlock line (auxiliary line) through
the adjustment of the pilot pressure on the line of the
fourth element of the main valve (16). Finally, one of the
hydraulic ports of the block connected to the feeding line of
the parking brake is used for the connection of the safety

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 (37)
to operate the service brake, located inside the front axle
(26). The brake pump can provide a maximum pressure of
80 bar (1160 psi), thus depending on the pressure exerted
on the brake pedal placed inside the driving place.
The pressure switch (4) set at 2.8-6.3 bar (40 - 90 psi),
placed on the pump head, sends an electrical signal
when the service brake is engaged. The oil coming from
the drain line of the main valve operating the telescopic
boom (16) is cooled down by the heat exchanger (32).
This exchanger is divided in two sectors, the former
absorbs heat from the cooling circuit of the diesel engine
and the latter absorbs heat from the hydraulic circuit of
the machine. The oil cooled down by the heat exchanger
is sent back to the special filter (34) and finally drained
into tank (10). A one-way valve (33) calibrated at 8 bar
(116 psi), is installed parallel to the input line of the heat
exchanger and used as safety valve. Its function is to
avoid overpressure conditions of the heat exchanger (as
is the case of a machine starting at low temperatures)
by directly draining any excess oil into the tank.

GTH 55-19
INTRODUCTION vi
GTH 55-19 hydraulic schematic

GTH 55-19 1
SAFETY
Section 1
SAFETY INFORMATION
SECTION INDEX
1.1 Safety rules ...........................................................................................page 2

1.1-1 Personal safety ............................................................................................. 2
1.1-2 Workplace safety .......................................................................................... 3
1.2 General remarks............................................................................................ 4
1.3 Servicemen's requisites .............................................................................. 4
1.3-1 Personal protective equipment ................................................................... 5
1.4 General safety precautions ......................................................................... 5
1.4-1 Working areas . ............................................................................................. 5
1.4-2 Precautions during work ............................................................................. 5

GTH 55-19 1
SAFETY
1.1 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.
There are six special (or safety) symbols in this manual, Draws the attention to important environment-related
always combined with keywords that class the situations information.
according to their danger degree.
The symbols are always followed by a text explaining
the situation taken into account, the attention to be paid Be sure to wear protective eye wear and
to such situation, the method and the behaviour to be other protective clothing if the situation
adopted. When necessary, it stresses prohibitions or warrants it.
supplies instructions to prevent dangers.
Sometimes, it can be followed by illustrations.
Be aware of potential crushing hazards such
We list below the special (or safety) symbols according as moving parts, free swinging or unsecured
to the relative seriousness of the hazard situation: components when lifting or placing loads.
Always wear approved steel-toed shoes.
Draws the attention to situations that involve your

own as well as the others’ safety and that can result
in serious or lethal injury.

Draws the attention either to situations that involve

your own as well as the others’ safety and that can
result in minor or moderate injury or to situations
that involve the machine efficiency.


GTH 55-19 1
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. Keep
work surfaces clean and free of debris that
could get into machine components and
cause damage.
Be sure that your workshop or work area is

properly ventilated and well lit.
Be sure any forklift, overhead crane or other

lifting or supporting device is fully capable of
supporting and stabilizing the weight to be
lifted. Use only chains or straps that are in
good condition and of ample capacity.
Be sure that fasteners intended for one time

use (i.e., cotter pins and self-locking nuts)
are not reused. These components may fail
if they are used a second time.
Be sure to properly dispose of old oil or other

fluids. Use an approved container. Please
be environmentally safe.

GTH 55-19 1
SAFETY
1.2 GENERAL REMARKS 1.3 SERVICEMEN'S REQUISITES
Most accidents occurring while working, servicing or The operators who use the machine regularly or
maintaining operation machines, are caused by not occasionally (e.g. for maintenance or transport) shall
complying with the basic safety precautions. have the following requisites:
Therefore, it is necessary to pay steady attention to
the potential hazards and the effects that may come of health:
operations carried out on the machine. before and during any operation, operators shall never
take alcoholic beverages, medicines or other substances
that may alter their psycho-physical conditions and,
consequently, their working abilities.
If you recognise hazardous situations, you can
physical:
prevent accidents!
good eyesight, acute hearing, good co-ordination and
ability to carry out all required operations in a safe way,
For instance, this handbook makes use of special safety
according to the instructions of this manual.
symbols to highlight potentially hazardous situations.
mental:
ability to understand and apply the rules, regulations and
safety precautions. They shall be careful and sensible
The instructions given in this handbook are the ones for their own as well as for the others’ safety and shall
established by GENIE. They do not exclude other desire to carry out the work correctly and in a responsible
safe and most convenient ways for the machine way.
commissioning, operation and maintenance that take
into account the available spaces and means. emotional:
they shall keep calm and always be able to evaluate their
If you decide to follow instructions other than those given own physical and mental conditions.
in this manual, you must:
• be sure that the operations you are going to carry training:
out are not explicitly forbidden; they shall read and familiarise with this handbook, its
• be sure that the methods are safe and in compliance enclosed graphs and diagrams, the identification and
with the indications given in this section; hazard warning plates. They shall be skilled and trained
• be sure that the methods cannot damage the machine about the machine use.
directly or indirectly or make it unsafe;
• contact GENIE Assistance Service for any suggestion
and the necessary written permission.
It is recommended to take part in at least one technical

training course organised by GENIE Assistance
Do not hesitate to pose questions if you are in Office.
doubt! Contact GENIE: the assistance service is at
your disposal. Addresses, phone and fax numbers
are given in the cover and in the title-page of this
manual.
Ordinary and extraordinary maintenance of the
machineare quite complex from a technical point
of view and should be performed by an authoirsed
service centre.

GTH 55-19 1
SAFETY
1.3-1 PERSONAL PROTECTIVE EQUIPMENT 1.4 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.
sleeves nor objects that can get stuck in moving parts The following list contains safety rules which must
of the machine absolutely be obeyed to prevent accidents and
• Protective helmet when working under or in the injuries.
vicinity of suspended load
• Protective gloves 1.4-1 WORKING AREA
• Working shoes
• Make sure the area all around the machine is safe.
• Breathing set (or dust mask) Always be aware of potential risks.
• Ear-protectors or equivalent equipment • During work, keep the working area in order. Never
leave objects scattered: they could hinder the
• Goggles or facial screen. machine movements and represent a danger for
personnel.
1.4-2 PRECAUTIONS DURING WORK

Use only type-approved protective equipment
in good condition. • Do not walk or stop under raised loads or machine
parts supported by hydraulic cylinders or ropes
only.
• Keep the machine handholds and access steps
always clean from oil, grease or dirt to prevent falls
or slips.
• When entering/leaving the cab or other raised parts,
always face the machine; never turn the back.
• When carrying out operations at hazardous heights
(over 3 meters from the ground), always use type-
approved safety belts or fall preventing devices.
• Do not enter/leave the machine when it is running.
• Before servicing the engine, let its parts cool down.
• Do not leave the driving place when the machine is
running.
• Neither stop nor carry out interventions under or
between the machine wheels when engine is running.
When maintenance in this area is needed, stop the
engine, engage the parking brake and chock the
wheels to prevent accidental movements.
• Do not carry out maintenance or repair works without
a sufficient lighting.
• When using the machine lights, the beam should be
oriented in order not to blind the personnel at work.
• Before applying voltage to electric cables or
components, ensure they are properly connected
and efficient.
• Do not carry out interventions on electric components
with voltage over 48V.

GTH 55-19 1
SAFETY
• Do not connect wet plugs or sockets.

• Signs and stickers shall never be removed, hidden
or become unreadable.
• Except for maintenance purposes, do not remove Treatment and disposal of used oils is subject to
safety devices, covers, guards,. Should their removal federal, national and local laws and regulations.
be necessary, stop the engine, remove them with Collect and deliver these wastes to authorised
the greatest care and always remember to refit them centres.
before starting the engine and using the machine
again. • Use the assistance of a second person to handle
• Aleays stop the engine and disconnect the batteries loads weighing 30 to 50 kg.
before maintenance or service. • For loads over 50 kg, the use of special hoisting
• Do not lubricate, clean or adjust moving parts. equipment in good condition and equipped as per
• Do not carry out operations manually when specific enforced regulations is mandatory.
tools are provided for this purpose.
• Absolutely avoid to use tools in bad conditions or in
an improper way.
• Before carrying out operations on hydraulic lines
under pressure (hydraulic oil, compressed air) and/or
before disconnecting hydraulic components, ensure
the relevant line has been previously depressurised
and does not contain any hot fluid.
Any intervention on the hydraulic or pneumatic

circuit must be carried out by authorised personnel.
Before any operation on lines under pressure, release
any residual pressure from the circuit.
Do not use your fingers to check for pressure leaks.
Fine jets of air, oil or fuel can injure you.
• Neither smoke nor use open flames if there is a risk

of fire or close to fuel, oil or batteries.
• Do not leave fuel cans or bottles in unsuitable
places.
• Do not empty catalytic mufflers or other vessels
containing burning materials without taking the
necessary precautions.
• Carefully handle all flammable or dangerous
substances.
• After any maintenance or repair work, make sure
that no tool, cloth or other object has been left within
compartments with moving parts or in which suction
and cooling air circulates.
• Never give orders to several people at a ime. Instructions
and signs must be given by one person only.
• Always pay the due attention to the instructions given
by the foreman.
• Never distract the operator during working phases
or crucial manoeuvres.
• Do not call an operator suddenly, if unnecessary.
• Do not frighten an operator or throw objects by no
means.
• After work, never leave the machine under potentially
dangerous conditions.

GTH 55-19 2
TECHNICAL SPECIFICATIONS
Section 2
SECTION INDEX
2.1 Main dimensions ..................................................................................page 2

2.2 Tyres .............................................................................................................. 3
2.3 Limit of use ................................................................................................... 3
2.4 Weight ........................................................................................................... 3
2.5 Speed . ........................................................................................................... 3
2.6 Payload and reach . ...................................................................................... 3
2.7 Forks (floating type) ..................................................................................... 4
2.8 Diesel engine ................................................................................................ 4
2.9 Electrical system .......................................................................................... 4
2.10 Machine sound levels .................................................................................. 4
2.11 Vibration levels ............................................................................................. 5
2.12 Refuelling ...................................................................................................... 5
2.13 Tightening torques ....................................................................................... 6
2.14 Drill diameters for threads . ......................................................................... 8
2.15 Standard tightening torques for fitting seals ............................................ 9
2.16 Locking material ........................................................................................... 11
2.17 Hoisting instructions ................................................................................... 12
2.18 Advice to renew flexible hoses ................................................................... 13
2.19 Lists of recommended spare parts . ........................................................... 14
2.20 Machine paint colour ................................................................................... 17
2.21 Checking the cylinder movement times . ................................................... 18
2.22 Hydraulic settings ........................................................................................ 19

GTH 55-19 2
2.1 MAIN DIMENSIONS

D
B
H
F
E
G
C
GTH 55-19
A Height ft 6' - 4"
B Height at steering whell ft 4' - 1"
C Width ft 5' - 11"
D Inside cab width ft 2' - 6"
E Track ft 4' - 11"
F Wheelbase ft 7' - 7"
G Length at fork-holder plate ft 12' - 7"
H Ground clearance ft 1' - 1"
I Overall length ft 6' - 7"
• Internal steering radius ft 5' - 9"
• External steering radius ft 11'
• Chassis levelling on both axles ° 2,3
2.2 TYRES
GTH 55-19
Standard
- Dimensions 12-16.5
- Load index 10 pr
- Rim 9.75 x 16.5
- Wheel disc 8 holes DIN 70361
- Pressure bar 4.5
- Pressure Psi 65

GTH 55-19 2
2.3 LIMIT OF USE
GTH 55-19
• Angle of approach (machine front side) ° 90
• Departure angle (machine rear side) ° 60
• Ambient temperature °C -
2.4 WEIGHT
TELELIFT 3512 4010
GTH 55-19
• Weight with fork lb 9810
2.5 SPEED
GTH 55-19
• Travel speed (max) mph 15
• Max. slope with full load % 70
• Traction to the dynamometer (max load) lb 9325
• Traction to the dynamometer (no load) lb 6835
TELELIFT 3512 4010
2.6 PAYLOAD AND REACH
GTH 55-19
• Max lifting height ft 19'
• Max forward reach ft 11'
• Reach at maximum height ft 2'
• Fork-holder plate rotation ° 130
• Max lifting capacity lb 5500
• Lift capacity at maximum height lb 4400
• Lift capacity at maximum reach lb 1900
• Break-out force (with 500lt shovel SAE J732/80) lb 8157

GTH 55-19 2
2.7 FORKS (floating type)
GTH 55-19
• Dimensions in 47.2" x 3,9" x 1,6"
• Weight lb 9270
TELELIFT 3512 4010

2.8 DIESEL ENGINE
3 5 1 2
GTH 55-19
• Make PERKINS
• Model/Type 804C-33
• Displacement in 3
203
• Cylinder arrangement Vertical in-line
• Combustion System In-direct injection
• Max Power Output (@ 2600rpm) hp 63,0
• Max Torque Output (@ 1600rpm) lb-ft 140
• Rated Power (@ 2600rpm) 116 ft-lb / 58 hp
• Aspiration Aspirated
• Cylinder’s number 4
TELELIFT 3512 4010

2.9 ELECTRICAL SYSTEM
GTH 55-19
• Voltage V 12
• Battery Ah 100
TELELIFT 3512 4010

2.10 MACHINE SOUND LEVELS
- Not applicable

GTH 55-19 2
2.11 VIBRATION LEVELS
GTH 55-19
• Mean assessed vibration level transmitted to arms m/s2 < 2.5
• Mean assessed vibration level transmitted to body m/s2 < 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. In
such cases, the operator is required to take suitable
measures.
2.12 REFUELLING
GTH 55-19
• Diesel engine l 11 + 3.5
• Fuel tank l 60
• Hydraulic oil tank l 62
• Front differential gear with reduction gear l 6
• Rear differential gear l 5
• Front wheel reduction gears l 1.5 + 1.5
• Rear wheel reduction gears l 0.7 + 0.7
• Brake oil tank l 0.1
Products:
Engine oil: SHELL RIMULA SAE 15W-40 (API CH-4/ CG-4/ CF-4/CF, ACEA E3, MB 228.3)
Power divider-Differential gears-Reduction gears: FUCHS TITAN GEAR LS 85 W-90 (API GL-5 LS / GL-5)
Hydraulic system and brakes: SHELL TELLUS T 46 (DENISON HF-1 DIN 51524 part. 2 e 3)

GTH 55-19 2
2.13 TIGHTENING TORQUES
Thread Pitch Wrench measure Tightening torques

diameter mm Material class
S SS S SSS S 4.8
4.8
S4.8 8.8
8.8 S 10.9
8.84.8 10.9
10.9 8.8 12.9
12.9
12.9
4.8 10.9 8.8 12.910.9 12.9
UNI UNI UNI Normal Galvanized Normal Galvanized Normal Galvanized
mm mm 5931/32 5933÷36 5923÷30 Nm Nm Nm Nm Nm Nm
4 0,7 7 3 2,5 2 3,2 2,8 4,4 3,9 5,3 4,8
5 0,8 8 4 3 2,5 6,1 5,5 8,7 7,8 10,3 9,3
6 1 10 5 4 3 10,6 9,5 14,8 13,3 17,8 16,0
8 1,25 13 6 5 4 25,1 22,5 35,4 31,8 42,5 30,2
1 13 6 5 4 26,5 23,8 37,3 33,5 44,7 40,3
10 1,5 17 8 6 5 51,1 46,0 71,9 64,7 86,3 77,6
1,25 17 8 6 5 53,4 48,1 75,1 67,5 90,2 81,1
12 1,75 19 10 8 6 86,5 77,8 121,4 109,2 145,9 131,3
1,25 19 10 8 6 92,4 83,2 129,5 116,6 156,1 140,5
14 2 22 12 10 6 137,7 123,9 193,8 174,4 232,6 209,3
1,5 22 12 10 6 145,9 131,3 206,1 185,5 246,9 222,0
16 2 24 14 10 8 209,1 188,2 293,8 264,4 353,0 317,7
1,5 24 14 10 8 218,3 196,5 308,1 277,3 369,3 332,4
18 2,5 27 14 12 8 288,7 259,8 406,1 365,5 487,7 436,9
1,5 27 14 12 8 314,2 282,8 442,8 398,5 530,6 477,5
20 2,5 30 17 12 10 408,1 367,3 573,4 516,1 687,7 618,9
1,5 30 17 12 10 439,7 395,8 619,3 557,4 742,8 662,5
22 2,5 32 17 - 12 542,3 488,5 763,2 686,9 915,3 823,7
1,5 32 17 - 12 582,6 524,3 819,3 737,4 983,6 885,3
24 3 36 19 - 12 705,1 634,5 990,8 891,7 1193,3 1074,4
2 36 19 - 12 745,3 671,3 1051,0 945,9 1255,1 1129,5
27 3 41 19 - - 1036,0 927,5 1448,9 1304,0 1734,6 1561,2
2 41 19 - - 1091,8 982,6 1530,6 1377,5 1836,7 1653,0
30 3,5 46 22 - - 1307,9 1258,1 1989,3 1772,4 2357,1 2121,4
2 46 22 - - 1510,2 1359,1 2122,4 1910,2 2540,8 2286,7
33 3,5 50 24 - - 2000,0 1800,0 2800,0 2520,0 3400,0 3060,0
2 50 24 - - 1610,0 1450,0 2300,0 2070,0 2690,0 2420,0
36 4 55 27 - - 2600,0 2340,0 3700,0 3330,0 4300,0 3870,0
3 55 27 - - 2800,0 2520,0 3900,0 3510,0 4600,0 4140,0
39 4 60 27 - - 3400,0 3060,0 4800,0 4320,0 5600,0 5040,0
3 60 27 - - 3600,0 3240,0 5100,0 4590,0 5900,0 5310,0

GTH 55-19 2
Thread Pitch Standard nuts Low nuts

diameter
5S 5S
8G 8G 5S 5S
8G 8G
Nm Nm Nm Nm
4 0,7 5,5 3,5
5 0,8 5,5 3,5
6 1 9,5 13,0 6,0 8,0
8 1,25 23,0 32,0 14,0 20,0
1 25,0 35,0 16,0 22,0
10 1,5 46,0 64,0 29,0 40,0
1,25 49,0 68,0 31,0 42,0
12 1,75 80,0 110,0 50,0 69,0
1,25 88,0 125,0 55,0 78,0
14 2 125,0 180,0 78,0 110,0
1,5 140,0 195,0 88,0 120,0
16 2 195,0 275,0 120,0 170,0
1,5 210,0 295,0 130,0 185,0
18 2,5 270,0 390,0 170,0 245,0
1,5 305,0 425,0 190,0 265,0
20 2,5 305,0 540,0 190,0 340,0
1,5 425,0 600,0 260,0 375,0
22 2,5 510,0 720,0 320,0 450,0
1,5 570,0 800,0 360,0 500,0
24 3 660,0 930,0 410,0 580,0
2 720,0 1000,0 450,0 630,0
27 3 980,0 1400,0 610,0 880,0
2 1050,0 1500,0 660,0 940,0
30 3,5 1350,0 1850,0 850,0 1160,0
2 1450,0 2050,0 910,0 1280,0
33 3,5 1650,0 2310,0 1050,0 1470,0
2 1980,0 2770,0 1270,0 1780,0
36 4 2120,0 2970,0 1360,0 1900,0
3 2550,0 3570,0 1630,0 2280,0
39 4 2730,0 3820,0 1750,0 2450,0
3 3250,0 4550,0 2080,0 2910,0

GTH 55-19 2
2.14 DRILL DIAMETERS FOR THREADS
Thread DRILL DIAMETER DRILL BIT

x pitch LIMITS DIAMETER
max min
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 5,15 4,92 5,00
x 0,75 5,38 5,19 5,20
M 8 x 1,25 6,91 6,65 6,80
x 1 7,15 6,92 7,00
M 10 x 1,5 8,87 8,38 8,50
x 1,25 9,38 9,19 9,20
M 12 x 1,75 10,44 10,10 10,20
x 1,5 10,68 10,38 10,50
M 14 x 2 12,21 11,83 12,00
x 1,5 12,68 12,38 12,50
M 16 x 2 14,21 13,84 14,00
x 1,5 14,68 14,38 14,50
M 18 x 2,5 15,74 15,29 15,50
x 1,5 16,68 16,38 16,50
M 20 x 2,5 17,74 17,29 17,50
x 1,5 18,68 18,38 18,50
M 22 x 2,5 19,74 19,29 19,50
x 1,5 20,68 20,38 20,50
M 24 x 3 21,25 20,75 21,00
x 2 22,21 21,83 22,00
M 27 x 3 24,25 23,75 24,00
x 2 25,21 24,83 25,00
M 30 x 3,5 26,77 26,21 26,50
x 3 27,25 26,75 27,00
M 33 x 3,5 27,77 29,21 29,50
x 2 31,21 30,83 31,00
M 36 x 4 32,27 31,65 32,00
x 3 33,25 32,75 33,00
M 39 x 4 35,27 34,67 35,00
x 3 36,25 35,75 36,00

GTH 55-19 2
2.15 STANDARD TIGHTENING TORQUES FOR

FITTING SEALS
■ 60° CONICAL SEALS ■ FRONT 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. mm Nm inc. mm Nm
G 1/8" 15 9/16"-18 25
G 1/4" M 10 x 1 20 11/16"-16 40
9/16"-18 25 13/16"-16 55
11/16"-16 40 1"-14 80
13/16"-16 55 1.3/16"-12 115
3/4"-16 62 1.7/16"-12 130
1"-14 80 1.11/16"-12 190
7/8"-14 80 2"-12 245
1.1/16"-12 110
1.3/16"-12 115
1.5/16"-12 160
1.7/16"-12 130
1.11/16"-12 190 ■ 37° COUNTER-SUNK CONICAL SEALS (JIC)
1.5/8"-12 225
Thread TIGHTENING
1.7/8"-12 270
diameter TORQUES (0+10%)
2"-12 245
37° CONICAL
2.1/4"-12 360
SEALS (JIC)
inc. mm Nm
7/16"-20 M10x1 15
1/2"-20 M12x1.5 20
9/16"-18 M14x1.5 28
M16x1.5 62
3/4"-16 M18x1.5 62
7/8"-14 M22x1.5 80
1.1/16"-12 M27x2 110
1.3/16"-12 141
1.5/16"-12 M33x2 160
1.5/8"-12 M42x2 225
1.7/8"-12 M48x2 270
2.1/4"-12 M10x1 360

GTH 55-19 2
TECHNICAL SPECIFICATIONS 10
■ SEALS WITH GRIP-RING ■ FITTING ASSEMBLY
Thread TIGHTENING Thread TIGHTENING

diameter TORQUE diameter TORQUES (0+10%)
(0+10%)
SEALS JOINTS
WITH A B
Fitting Pipe ø GRIP-RING
inc. mm Series mm Nm inc. mm Nm Nm
G 1/8" M10x1 LL 4 10 G 1/8" M10x1 25 12
G 1/8" M10x1 LL 6 10 M12x1.5 30 18
G 1/8" M10x1 L 6 25 G 1/4" 40 18
G 1/4" M12x1.5 L 8 50 M14x1.5 50 20
G 1/4" M14x1.5 L 10 50 M16x1.5 60 35
G 1/8" M20x1.5 L 12 130 M18x1.5 80 50
G 1/8" M20x1.5 L 15 190 G 3/8" 95 40
G 1/8" M20x1.5 L 18 245 M20x1.5 140 60
G 1/8" M20x1.5 L 22 130 G 1/2" M22x1.5 140 75
G 1/8" M20x1.5 L 28 190 M26x1.5 220 85
G 1/8" M20x1.5 L 35 245 G 3/4" 250 110
G 1/8" M20x1.5 L 42 245 M27x2 250 100
G 1/4" M12x1.5 S 6 50 G 1" 400 190
G 1/4" M14x1.5 S 8 50 M33x2 400 150
G 3/8" M16x1.5 S 10 80 G 1.1/4" 600 240
G 3/8" M18x1.5 S 12 80 M42x2 600 260
G 1/2" M22x1.5 S 16 105 G 1.1/2" 800 300
G 3/4" M27x2 S 20 220 M48x2 800 350
G 1" M33x2 S 25 370
G 1.1/4" M42x2 S 30 500
G 1.1/2" M48x2 S 38 600
A B
A Male face
Mechanical seal or copper washer
B Male face
Soft seal with O-ring

GTH 55-19 2
2.16 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 Low
Loctite 243 Thread locking to 150° M 20 Rapid Medium
Loctite 262 Thread locking to 150° M 20 Moderate High
Loctite 270 Thread locking to 150° M 20 Moderate Very high
Loctite 277 Thread locking to 150° M 36 Slow High
Loctite 272 Thread locking to 200° M 36 Slow High
THREAD SEALANT For hermetic sealing. Not suitable for thermoplastic materials
Product APPLICATION Characteristics Locking Disassembly

max Thread speed difficulty
°C max type
Loctite 511 Fitting sealant 150° M80 Con./Cyl. Rapid Low
Loctite 542 Fitting sealant 150° M36 Con./Cyl. Rapid Moderate
Loctite 545 Fitting sealant 150° M36 Con./Con. Moderate Low
Loctite 565 Fitting sealant 150° M80 Con./Cyl. Instantaneous Low
Loctite 572 Fitting sealant 150° M80 Con./Cyl. Moderate Low
Loctite 577 Fitting sealant 150° M80 Con./Cyl. Rapid Moderate
GASKETS Total sealing in 24-72 hours
Product APPLICATION Characteristics Formation Resistance

max Play time to fluids
°C max mm
Loctite 518 Formed-in-place gasket 150° 0,5 Moderate Excellent
Loctite 573 Formed-in-place gasket 150° 0,2 Slow Excellent
Loctite 574 Formed-in-place gasket 150° 0,5 Rapid Excellent
Loctite 5999 Formed-in-place gasket 200° 6,0 Instantaneous Excellent
Loctite 5900 Formed-in-place gasket 200° 6,0 Instantaneous Excellent
Loctite 5920 Formed-in-place gasket 250° M 36 Slow Good

1500 kg
1000
GTH 55-19
500
2
30° 60° 90° 120° 150° a

2.17 HOISTING INSTRUCTIONS • Attach the load to the natural seat of the hook.
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.
In the Disassembly and Assembly section there is a
clear indication of the weight of the part to handle,
while chapter A.12 contains a summary table with
the weight of the single components.
P P P P P
Before removing parts of the machine, make sure that:
• all fixing bolts have been removed 00% 88% 79% 7% 4%
• all hydraulic and electrical parts have been
disconnected
• the part to be removed is not blocked. • Do not attach a heavy load to ropes forming a wide
suspension angle. The total capacity of the ropes
STRANDED ROPES reduces proportionally to the angle as shown in the
• Use ropes or other hoisting accessories suitable to following chart.
the weight of the part to be handled. For ropes, refer
to the following table:
STRANDED ROPES kg
Rope diameter Max admissible load 2000 a
mm kg
10 1000 1500 kg
11.2 1400
1000
12.5 1600
14 2200 500
16 2800
18 3600 30° 60° 90° 120° 150° a
20 4400
22.4 5600
30 10000
40 18000
50 28000
60 40000
The value of the admissible load has been considered

as equal to 1/6 the rope breaking load.
P P P P P
00% 88% 79% 7% 4%

GTH 55-19 2
2.18 ADVICE TO RENEW FLEXIBLE HOSES 1 Before disconnecting or refitting a flexible hose,
carefully clean the area all around.
2 Blow some compressed air to remove any impurity.
3 For an easier renewal of the hoses, whose run is not
Before disconnecting a hydraulic pipe, place clearly visible, proceed as follows:
containers of suitable size underneath to prevent - disconnect the hose to be replaced from both
oil spillage. sides
- tie a cord to one end of the hose
- remove the hose pulling the cord until it comes out
completely
Plug all disconnected parts to prevent dust or
- untie the cord and tie it to the new hose
impurities from entering the circuit. They can cause
serious damage. - pull the cord from the other side to refit the hose
until reaching the connecting point to the line.
Before disconnecting the hydraulic pipe, check that

there is no residual pressure. In case, eliminate the
pressure operating the control levers with the engine
stopped.
In any case, disconnect the hydraulic pipe with
extreme caution and always wear suitable personal
protection equipment -e.g. goggles, gloves, facial
screen, etc.
Wrap up the end of the pipe to be disconnected with
some rags and slowly loosen the pipe connector so
that air comes out as slow as possible.
Useful advice for mounting flexible hoses:
NO
YES
NO YES
NO
YES
NO
NO
YES
YES

GTH 55-19 2
2.19 LISTS OF RECOMMENDED SPARE PARTS
Code Description Q.ty

07.0700.0023 Oil filter cartridge (inside the tank) 1
09.4604.0004 Hydraulic oil filter 1
07.0700.0037 Primary engine air filter element 1
07.0700.0036 Safety engine air filter element 1
07.0723.0149 Cab air filter 1
07.4501.0139 Fuel filter 1
07.4501.0138 Engine oil filter 1
07.0705.0093 Solenoid 1
07.0705.0096 Solenoid 1
07.0705.0099 Solenoid 1
07.0728.0007 Solenoid 2
07.0709.0417 Seals kit 2
07.0701.0200 Seals kit 1
07.4529.0112 Seals kit 1
07.0701.0210 Seals kit 1
07.4529.0027 Seals kit 1
639395 Seals kit 1
07.0705.0081 Seals kit 1
640096 Seals kit 1
639993 Seals kit 1
635965 Seals kit 1
07.0705.0085 Seals kit 1
639992 Seals kit 1
07.0705.0082 Seals kit 1
07.0700.0028 Restriction indicator 1
07.0738.0003 Star wheel 1
53.3001.5400 Manifold 1
53.3001.5500 Manifold 1
07.0701.0007 Coil 2
07.0701.0209 Solenoid valve 2
07.0703.0479 Speed switch 1
07.0703.0472 Ignition switch 1
07.0704.0118 Red cap 2
07.0704.0117 Pushbutton 2
07.0704.0119 Yellow cap 2
04.4239.0004 Valve on balance cylinder 1
07.0703.0081 2A fuse 2
07.0703.0080 5A fuse 2
634972 7.5A fuse 2
07.0703.0148 10A fuse 2
634973 15A fuse 2
634975 20A fuse 2
07.0703.0060 50A fuse 1
07.4501.0059 Relay 1
57.0008.6100 Operator’s manual (ITA) 1
57.0008.6200 Operator’s manual (GB) 1
57.0409.9000 Spare parts catalogue (ITA) 1
57.0410.0000 Spare parts catalogue (GB) 1

GTH 55-19 2

09.4618.0644 Sticker: GTH-5519 32x5 (white) 1
97664 Sticker: Risk of crushing-English 1
09.4618.0641 Sticker: Genie 50x14 (white) 1
09.4618.0061 Sticker: Tyre inflation pressure (4.5 Bar) 1
09.4618.0010 Sticker: Prohibition to open with the engine running 1
97673 Sticker: Prohibition to lift people-English 2
09.4618.0782 Sticker: Connect./disconnect. quick coupling 1
09.4618.0643 Sticker: Genie GTH-5519 130x15 (white) 1
09.4618.0777 Sticker: Testing ports Tp2, Tp3 1
97675 Sticker: Risk of explosion-English 1
97671 Sticker: Risk of explosion-English 1
97665 Sticker: Safety belts-English 1
97668 Sticker: Risk of overturning-English 1
97676 Sticker: Electrical hazard-English 1
97666 Sticker: Read the user’s manual-English 1
97669 Sticker: Risk due to falling objects-English 1
09.4618.0205 Sticker: Boom tilting degree 1
97688 Sticker: Emergency exit handle-English 1
82558 Sticker: Fluid at pressure-English 1
09.4618.0776 Sticker: Upper door unlock system 1
09.4616.0051 Decal: Hydraulic oil 1
09.4618.0783 Decal: Load chart 1
09.4618.0389 Decal: Control lever controls 1
09.4618.0780 Decal: Continuous flow knob 1
09.4618.0781 Decal: Flow reversal button 1
09.4618.0109 Sticker with various warnings 1
09.4616.0101 Machine data plate 1
09.4618.0778 Sticker: Testing ports Tp1 1
09.4618.0779 Sticker: Testing ports Tp4 1
56.0013.0001 Fuel gauge 1
07.0723.0042 Mirror 1
09.0803.0228 Left mud-guard 1
09.0803.0229 Right mud-guard 1
09.4645.0030 Cable 1
09.4670.0004 Vibration-proof support 1
07.0723.0446 Wiper blade 1
07.0723.0037 Wiper blade 1
07.0723.0024 Mirror 1
07.0703.0088 Switch 1
07.0703.0476 Switch 1
641065 Switch 1
54.0702.0013 Sliding guide 2
51.0809.3900 Boom shim 2

GTH 55-19 2

51.0804.9000 Boom shim 4
04.4210.0019 Quick coupling: F 1/2” Faster Art. 2FFI12GASF 2
04.4210.0018 Quick coupling: M 1/2” Faster Art. FFI12GASM 2
04.4239.0005 Block valve 1
04.4239.0005 Block valve 1
04.4239.0052 Block valve 1
04.4240.0052 Solenoid valve 1
56.0006.0002 Relay: 12v 20/30A 2
04.0605.0612 Flex hose 1
04.0605.0615 Flex hose 1
04.0605.0613 Flex hose 1
04.0605.0614 Flex hose 1
52.1100.7500 Carter 1
09.4604.0047 Hydraulic oil filter 1
09.4604.0052 Air filter complete 1
05.4309.0001 Brake pump 1
07.0704.0133 Joystick 1
07.0704.0042 Valve 1
04.4239.0002 Block valve 1
07.0722.0023 Valve 1
04.4237.0010 Complete servo-control 1
04.4239.0051 Block valve 1

GTH 55-19 2
2.20 MACHINE PAINT COLOUR
GENIE machines
BLU GENIE
GRIGIO GENIE
NERO RAL 9500

GTH 55-19 2
2.21 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.
of 60°. Min engine speed = 950 rpm
Max engine speed = 2600 rpm
BOOM LIFTING/LOWERING
Lift
GTH 55-19 Time (s)
up down
Max engine speed 7” 4”
Min. engine speed 18” 11”
Lower
BOOM EXTENSION/RETRACTION Extend Retract

GTH 55-19 Time (s)
out in
ATTACHMENT DUMPING
GTH 55-19 Time (s)

Roll-back
dumping roll-back
Dump

GTH 55-19 2
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
1. PRELIMINARY OPERATIONS (fully out).
• With the engine running at maximum speed, tilt
Check that the engine idle is set at 950 rpm and that the forks to one direction by means of the joystick
the engine maximum speed is set at 2600 rpm. and act on one of the two valves B until reaching a
pressure of 290 bar. Adjust the second valve B by
Warm up the hydraulic oil to 60°C by keeping one of the pitching the forks back.
elements of the boom main valve to full stroke under • When both fork inclination valves have been
pressure. calibrated, reset the pressure control valve to 270
To reach this temperature in a faster way, cover the oil bar (3915 psi) by adjusting the adjustment screw A.
core of the radiator with a carton in the case of a water-
oil combined cooler, or the oil radiator if the machine is
equipped with a separate oil radiator.
For safety reasons, do not hold the cylinder to end

2. CALIBRATING THE BOOM MAIN VALVE of stroke and do not let the engine run at max speed
for more than 5 seconds.
Open the engine bonnet, find the mini-socket ref. 9 (see
picture below) and fit a 0-400 bar pressure gauge (0-
5972 psi) to this socket.
9 B
B
A
2.1 CALIBRATING THE MAIN VALVE PRESSURE

CONTROL VALVE
Remove the central protective cover of the machine and,

with a 13mm wrench, loosen the locknut of the pressure
relief valve A of the main valve (see annex 1).
With the engine running at max speed, move the boom
fully up and to end of stroke by operating joystick 1, and
set valve A to 270 bar (3915 psi).
For the inspection of the safety valves B, proceed as
follows:
• Connect a 0-400 bar (0-5972 psi) manometer to the
mini-socket ref. 9.

GTH 55-19 2
3. 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.
the hydraulic oil at 60°C. • Run the engine at 1200 rpm. Check the value on the
• Connect a 0-60 bar (868 psi) manometer A to the tachometer.
mini-socket ref. 4 to read the boost pressure value
• Adjust shutter D by means of the register until reading
(see annex 1).
a value of 50 bar (724 psi) on the high-pressure
• Connect a 0-600 bar (0-8688 psi) manometer B manometer B.
to the mini-socket ref. 5 to read the high-pressure
value.
B
200
300 400
500 D
00 600
0
A
30 40
20
5
50
0
60
0
4 4
5
Do not fit the manometer to the application point
corresponding to the reverse speed. This operation
is extremely dangerous for the serviceman who is
D
calibrating the transmission.
• Hold the selector to neutral position and make sure

the maximum speed of the engine does not exceed
2600 rpm. The engine must run at a idle speed of
950 rpm. Otherwise, adjust the minimum speed.
• Read the boost pressure on manometer A and
ensure it is about 30 bar with the engine running at
idle speed.
The boost pressure has not a fixed value but varies
from pump to pump.
• Hold the machine blocked by disconnecting the
power plug of the solenoid valve controlling the
parking brake.

GTH 55-19 2
3.1 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.
calibration.
• Fit a 0-250 bar pressure gauge (0-3620 psi) to the
mini-socket Z.
• Set the forward-neutral-reverse selector to the
• Select the front axle steering mode.
forward position.
• Move the steering cylinder to stroke end and make
• Run the engine at maximum speed and check the
sure the value of the power steering A is 170 bar
high-pressure value on the manometer B. If this
(2465 psi). If the value is less, tighten valve X; if the
value is less than 430 bar (6235 psi), increase the
value is greater, loosen the valve.
pressure to 430 bar (6235 psi) by means of the
pressure cut-off valve E. Note: To gain access to valve X, remove the
protection cap (see annex 2).
• Remove the manometers and do an attempt.
300 400
B
200
E
500
100 600
0
30 40
20
50
10
60
0

GTH 55-19 2
HYDRAULIC SYSTEM - MAIN VALVE annex 1

GTH 55-19 2
POWER STEERING SYSTEM annex 2

GTH 55-19 2

GTH 55-19 3
SCHEDULED MAINTENANCE INSPECTIONS
Section 3
SCHEDULED MAINTENANCE
INSPECTIONS
SECTION INDEX
3.1 Introduction............................................................................................page 2
3.2 About this section......................................................................................... 3
3.3 Maintenance table......................................................................................... 4
3.4 Maintenance inspection report.................................................................... 7

GTH 55-19 3
3.1 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.
• Immediately tag and remove from service a
damaged or malfunctioning machine.
• Repair any machine damage or malfunction before
operating machine.

GTH 55-19 3
3.2 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).
For ease of use, the service intervals have been grouped
in different tables, as explained below:
Inspection Table
Daily A
Weekly A+B
Monthly A+B+C
Six month A+B+C+D
Yearly A+B+C+D+E
Every 2 years A+B+C+D+E+F
At 5 years (afterwards every 2 years) G
Maintenance table
The maintenance table contains general information
on the type of intervention to be carried out at a certain
interval.
For the explanation of the maintenance jobs to be done,
please refer to chapter 4 "Maintenance Procedures".
Maintenance inspection report

The maintenance report summarises all of the interventions
to be carried at a given interval and lets the maintenance
technician note the result of the check or intervention
carried out.
This card can be photocopied to be used at the different
service intervals and to keep a trace of all interventions
carried out.

GTH 55-19 3
3.3 MAINTENANCE TABLE
TABLE A
During the first 10 working hours:
A-1 Check the oil level within reduction gears, power divider and differential gears.
A-2 Check the tightening of the wheel bolts.
A-3 Check the tightening of all bolts and nuts.
A-4 Check the couplings for oil leaks.
Every 10 working hours or daily:
A-5 Inspect the Operator Manual.
A-6 Inspect the decals and placards.
A-7 Check the engine oil level
A-8 Clean the air suction filter.
A-9 Check and clean the radiator.
A-10 Check the hydraulic oil level in the tank.
A-11 Check the greasing of the boom section pads.
A-12 Grease the forks.
A-13 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.
A-14 Check the efficiency of the lighting electric system.
A-15 Check the efficiency of braking system and parking brake.
A-16 Check the efficiency of the steering selection system.
A-17 Check the efficiency of the fork balancing system.
A-18 Make sure the safety devices installed are in efficient working order.
A-19 Check the engine coolant level.

GTH 55-19 3
TABLE B
Within the first 50 working hours:
B-1 Change the engine oil.
Every 50 working hours or weekly:
B-2 Check the tension of the alternator belt.
B-3 Check the tyre inflation.
B-4 Check the tightening of the wheel nuts.
B-5 Check the tightening of the cardan shaft screws.
TABLE C
Every 250 working hours or monthly:
C-1 Change the engine oil and relevant filter.
C-2 Check the oil level in the front and rear differential gears and the power divider.
C-3 Check the oil level in the four wheel reduction gears.
C-4 Check the cartridge of the engine air filter. Replace, if necessary.
C-5 Check the clamping of the cableheads to the battery terminals.
C-6 Check the air suction hose between engine and filter.
C-7 Check the cylinder chromium-plated rods.
C-8 Check the hydraulic lines are not worn because of rubbing against the frame or other mechanical
components.
C-9 Check the electric cables do not rub against the frame or other mechanical components.
C-10 Check the wear of the sliding pads of the boom sections.
C-11 Adjust the play of the sliding pads of the boom sections.
C-12 Remove any grease from the boom, then re-grease the sliding parts of the boom sections.
C-13 Check the level of the battery electrolyte.
C-14 Check the efficiency of the block valves.

GTH 55-19 3
TABLE D
Every 500 working hours or every six months:
D-1 Visually check the smoke quantity evacuated from the engine exhaust.
D-2 Check the tightening of the engine fixing screws.
D-3 Check the tightening of the cab fixing screws.
D-4 Check the backlash between pins and bushings in all joints.
D-5 Change the cartridge of the hydraulic oil filter.
D-6 Change the cartridge of the hydraulic oil filter in the tank.
D-7 Have the hydraulic system checked by a skilled technician.
D-8 Change the cartridge of the engine air filter.
D-9 Clean or replace, if nececessary, the air filter in the cab.
TABLE E
Every 1000 working hours or yearly:

E-1 Change the inner element of engine air filter.
E-2 Change the oil in the front and rear differential units and in the power divider.
E-3 Change the oil in the four wheel reduction gears.
E-4 Change the hydraulic oil.
TABLE F
Every 2000 working hours or every 2 years:

F-1 Change the engine coolant.
TABLE F
At 6000 hours or 5 years and, subsequently, every 2 years:

G-1 Checking the state of the structure.

GTH 55-19 3
3.4 MAINTENANCE INSPECTION REPORT
Table A Y N R Table C Y N R
Model During the first 10 working hours:
Every 250 working hours:
A-1 Oil level within reduction gears,
Serial number C-1 Engine oil and relevant filter.
power divider and differential
C-2 Oil level in the differential gears
gears.
Date and reducer.
A-2 Tightening of the wheel bolts.
C-3 Oil level in the four reduction
A-3 Tightening of all bolts and nuts.
Hour meter gears.
A-4 Check the couplings for oil
C-4 Cartridge of the engine air filter.
leaks.
Machine owner C-5 Clamping of the cableheads to
Every 10 working hours: the battery terminals.
Inspected by A-5 Operator Manual. C-6 Air suction hose between engine
A-6 Decals and placards. and filter.
Inspector signature A-7 Engine oil level. C-7 Cylinder chromium-plated rods.
A-8 Air suction filter. C-8 Check the hydraulic lines.
Inspector title A-9 Radiator. C-9 Check the electric cables.
A-10 Hydraulic oil level in the tank. C-10 Wear of the sliding pads of the
Inspector company A-11 Greasing of the boom section boom sections.
pads. C-11 Play of the sliding pads of the
Instructions: A-12 Grase the forks. boom sections.
A-13 Grease all joints of the boom, the C-12 Sliding parts of the boom sections.
- Make copies of this page to use for each
rear axle shaft joint, the transmission C-13 Level of the battery electrolyte.
inspection.
shafts, the front and rear axles and C-14 Efficiency of the block valves.
- Select the appropriate checklist(s) for the any equipment of the machine.
type of inspection to be performed. A-14 Efficiency of the lighting electric
Table D Y N R
Every 10 hours: A system.
A-15 Efficiency of braking system and Every 500 working hours:
Every 50 hours: A+B parking brake. D-1 Smoke from engine exhaust.
A-16 Efficiency of the steering selec- D-2 Tightening of the engine fixing
Every 250 hours: A+B+C
tion system. screws.
Every 500 hours: A+B+C+D A-17 Efficiency of the fork balancing D-3 Tightening of the cab fixing screws.
system. D-4 Backlash between pins and
Every 1000 hours: A+B+C+D+E
A-18 Safety devices. bushings in all joints.
Every 2000 hours: A+B+C+D+E+F D-5 Hydraulic oil filter of the
At 6000 hours: G transmission.
Table B Y N R D-6 Hydraulic oil filter in the tank.
- Place a check in the appropriate box Within the first 50 working hours: D-7 Efficiency of hydraulic system.
after each inspection procedure is B-1 Change the engine oil. D-8 Cartridge of the engine air filter.
completed. D-9 Air filter in the cab.
Every 50 working hours:
- Use the maintenance tables in this sec-
tion and the step-by-step procedures in B-2 Tension of the alternator belt.
Table E Y N R
section 4 to learn how to perform these B-3 Check the tyre inflation.
B-4 Tightening of the wheel nuts. Every 1000 working hours:
inspection. E-1 Oil of the differential casing and
B-5 Tightening of the cardan shaft
- If any inspection receives an "N", tag screws. the power divider.
and remove the machine from service, E-2 Oil in the four wheel reduction
repair and re-inspect it. After repair, gears.
place a check in the "R" box. E-3 Change the hydraulic oil.
Legend:
Y = yes, acceptable
N = no, remove from service
R = repaired.

GTH 55-19 3
Table F Y N R
Model Every 2000 working hours:
F-1 Change the engine coolant
Serial number
Date Table G Y N R
At 6000 working hours:
Hour meter G-1 Checking the state of the
structure
Machine owner
Inspected by
Inspector signature
Inspector title
Inspector company
Instructions:
- Make copies of this page to use for each
inspection.
- Select the appropriate checklist(s) for the
type of inspection to be performed.
Every 10 hours: A
Every 50 hours: A+B
Every 250 hours: A+B+C
Every 500 hours: A+B+C+D
Every 1000 hours: A+B+C+D+E
Every 2000 hours: A+B+C+D+E+F
At 6000 hours: G
- Place a check in the appropriate box
after each inspection procedure is
completed.
- Use the maintenance tables in this sec-
tion and the step-by-step procedures in
section 4 to learn how to perform these
inspection.
- If any inspection receives an "N", tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the "R" box.
Legend:
Y = yes, acceptable
N = no, remove from service
R = repaired.

GTH 55-19 4
SCHEDULED MAINTENANCE PROCEDURES
Section 4
SCHEDULED MAINTENANCE
PROCEDURES
SECTION INDEX
4.3 TABLE A procedures..................................................................................... 4
4.4 TABLE B procedures..................................................................................... 22
4.5 TABLE C procedures..................................................................................... 26
4.6 TABLE D procedures..................................................................................... 39
4.7 TABLE E procedures..................................................................................... 46
4.8 TABLE F procedures..................................................................................... 50
4.9 TABLE G procedures.................................................................................... 51

GTH 55-19 4
4.1 INTRODUCTION

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.
• Immediately tag and remove from service a
damaged or malfunctioning machine.
• Repair any machine damage or malfunction before
operating machine.
• Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
- machine parked on a flat level surface;
- boom in the stowed position;
- key switch in the OFF position with the key
removed.

GTH 55-19 4
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 important technical information

or practical advice that allows for a safer and more
efficient use of the machine.
Draws the attention to important environment-related

information.

GTH 55-19 4
4.3 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:
- Stop the machine on a level ground and ensure the - Stop the machine on a level ground and engage the
parking brake is engaged and plug A finds on the parking brake.
horizontal axis.
- Loosen level plug A and check if oil is level with the
- Clean the plug all around, then remove it and check hole.
if oil is level with the hole.
- If necessary, add new oil through the hole of the level
- If necessary, add new oil through hole A until it is
plug until it comes out.
level.
- Refit the plug. - Refit and tighten plug A.
Place a container of suitable size under the plug. Place a container of suitable size under the plug.

A

GTH 55-19 4
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
level.
- Refit the plug.
Place a container of suitable size under the plug.

GTH 55-19 4
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.
- Tighten the nuts following the alternate sequence
shown in the picture with a pneumatic screwdriving
machine.
- Lower the machine to the ground.
Re-tighten all nuts to a torque 300 Nm.
Check the tightening of wheels one hour after the job.

They might get loose until they do not stay correct.
1
6
4
On new machines, and when a wheel has been di-
sassembled or replaced, check the nut torque of the

wheels every 2 hours until they stay correct.
7
8
2
Always use tyres having the dimensions indicated 5

in the vehicle registration card.
Standard
GTH 55-19
Dimensions (front and rear) 12-16.5
Load index 10 pr
Rim 9.75x16.5
Wheel disc 8 holes DIN 70361
Pressure bar/Psi 4.5/65

GTH 55-19 4
A-3 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.
For the correct tightening torques, please refer to par. If you find them, rectify before starting using the
2.13 in section 2 “Technical Specifications”. machine.

GTH 55-19 4
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. Decals alert operators and personnel to
Manual are included with each machine and should be
the many possible hazards associated with using this
stored in the cab. An illegible or missing manual will not
machine.
provide safety and operational information necessary for
a safe operating condition. An illegible decal will fair to alert personnel of a procedure or
hazard and could result in unsafe operating conditions.
In particular:
- refer to the “labels and warning plates applied on the
- check to be sure the storage container is in good
machine” section in the Operator Manual and use the
condition.
decal list and illustrations to determine that all decals
- check to make sure that the operator manual are and placards are in place.
present, complete and in the storage container in
- inspect all decals for legibility and damage. Replace
the cab.
any damaged or illegible decal immediately.
- examine the pages of each manual to be sure that
they are legible and in good condition.
- always return the manual to the storage container
after use. Contact GENIE Service Centre if replacement decals
are needed.
Contact GENIE Service Centre if replacement manuals

are needed.

GTH 55-19 4
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. D
• Remove dipstick  and check if oil reaches the max
mark .
• Remove dipstick  once again and check if oil reaches

the max mark .
 • Refit the plug.
MAX
MIN 
• If oil is below this mark, remove plug  and pour new

oil into the engine using the special appliance .

GTH 55-19 4
SCHEDULED MAINTENANCE PROCEDURES 10
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.
A
- Dry clean the cartridge (at max. 6 bar pressure) and
direct the air jet from inside to outside.
B
- Check the filter element for cracks by introducing a
lamp inside.
- Refit the cartridge and make sure it is properly
positioned.
- Close cover B and lock in place with fasteners A.
C
As soon as the warning lamp on the cab dashboard
switches on, replace the outer element.

GTH 55-19 4
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.
Cleaning using compressed air

- Direct a jet of compressed air toward radiator paying
attention not to damage its fins.
- Remove any loose particles of dirt with some
water.
Cleaning using water under pressure or steam

- Spray radiator with a cold commercial detergent and
wait for at least 10 minutes to allow the detergent to
react.
- Wash radiator using a jet of water or steam.
The core fouling depends on the dust of the outside

environment and the presence of oil and fuel leaks
in the motor area. It is therefore advisable to remove
oil and fuel leaks immediately in case of very dusty
environments.

GTH 55-19 4
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. A
Check the hydraulic oil level (visually) through the special

level B fitted into the tank.
When necessary, add new oil through filler A.
Check the oil level with the machine in the travel

position, tha is boom lowered and telescopes fully
in.
The handling and disposing of used oils can be

ruled by local or national regulations. Address to
authorised centres.

GTH 55-19 4
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.
If necessary, scrape off the old grease and brush new
grease. We recommend using:
- INTERFLON grease FIN GREASE LS 2
Avoid mixing greases of different type or features

and do not use greases of lower quality.

GTH 55-19 4
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.
Smear pin A with grease to help the forks slide on it.

Recommended grease:
- AGIP graphitized grease type GR NG 3

GTH 55-19 4
A-13 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.
Remove any old grease with a degreaser from the
telescopes before smearing them with new grease.
Regularly grease the machine to grant it efficient

conditions and a long life.
By means of a pump, inject grease into the special
greasers.
As the fresh grease comes out, stop the operation.
The greasing points are shown in the following figures:
- the symbol represents the points to be greased

by a pump
- the symbol represents the points to be greased

by a brush

GTH 55-19 4
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.
the front lights (position lights, low and high beams and
turn signals) and the rear lights (position lights, stop/tail
lights and turn signals) are in excellent state of repair.
Also check beacon located on the cab roof.
Never touch the bulb of halogen lamps (mount type
If one lamp or more must be replaced, use the table H3) with your fingers: this may damage the lamp
below as a reference. (use of a clean cloth or a paper tissue). If you touch
it accidentally, thoroughly clean with a paper tissue
and some ethyl alcohol.
Use Voltage Mount type Power

• Front low/high beam 12 V P45t 45/40 W
• Front position lights 12 V BA 9s 3W
• Side/tail turn signals 12 V BA 15s 21 W
• Stop lights and rear position lights 12 V BAY 15d 21/5 W
• Beacon - Work lights (OPTIONAL) 12 V H3 55 W
• Dashboard indicators and cab lighting 12 V W 2x4,6d 1,2 W
• Interior lamp 12 V SV 8,5-8 5W
• License plate lights 12 V BA 15s 5W
• Back-up lamps 12 V BA 15s 21W

GTH 55-19 4
A-15 CHECK THE EFFICIENCY OF BRAKING • Connect the flexible hose of the compressor to
SYSTEM AND PARKING BRAKE the mini-socket TP4 placed inside the engine
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.
4
TP
The malfunctioning of the braking system may depend
on the presence of air in the hydraulic circuit.
The braking system is equipped with two purge valves A
and B to eliminate any air from the circuit. The first valve
is used to purge the service brake circuit (B); the second
valve is used to purge the negative parking brake circuit
(A). Both valves can be easily reached through the slot
located on the front part of the chassis.
• Connect the compressor to an air source and

pressurise the system.
• Unscrew valve B to help air flow out of the braking
A B circuit.
• Open the cap of the feeding tank D.
TO BLEED THE CIRCUIT OF THE SERVICE BRAKE,

DO THE FOLLOWING:
• Make sure that compressor F contains a sufficient
quantity of oil so you can proceed with the circuit
bleeding.
• Open the tap of the compressor F which has been
previously connected to mini-socket TP4.
4
TP

GTH 55-19 4
• Check that air flows out of valve B. As soon as oil TO BLEED THE CIRCUIT OF THE PARKING BRAKE,
without air bubbles starts flowing out of this valve, DO THE FOLLOWING:
close the same. • Start the diesel engine.
• Check that the fluid in tank E reaches the recommended • Press pushbutton C to unlock the parking brake.
level. • Slowly unscrew valve A and close the same as soon
as oil mixed with air starts flowing out.
• Repeat until oil without air bubbles starts flowing out
of the valve.
E • Test the efficiency of the braking system.
Oil level C
• Close the tap of the compressor.

• Disconnect the hose from mini-socket TP4.
• Test the efficiency of the braking system.
In order to bleed the service brake circuit WITHOUT

A COMPRESSOR (for this operation, two service
technicians are needed – one in the driving place and
the other near the drain valve B): Once the circuit has been bled, make sure the brake
circuit is in efficient working order.
1 Fill tank D with oil.
2 With the machine stopped, step down on the brake
pedal 5-6 times.
3 Hold the pedal pressed down and slowly unscrew
valve B. Close the valve as soon as oil mixed with
air starts flowing out.
4 Ease up the brake pedal.
Checking the brake oil level
5 Repeat steps 2, 3 and 4 until oil without air bubbles
The oil within the braking circuit must be at about 2 cm
starts flowing out of the valve.
from the tank plug E.
6 Test the efficiency of the braking system.
Oil level

GTH 55-19 4
2 0 2 4 6 8
10 8 6 4 10
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.
To fix this problem, rather than checking the alignment 01234567
visually, follow the procedure below:

1 Move to a solid and level ground.
F
2 Set the steering selection switch A to “four-wheel N
R
steer” (pos. 2). 
3 Rotate the steering up to its stop (either to the right
 
or to the left).
4 Set the steering selection switch to “two-wheel steer”
(pos. 0).
A
5 Rotate the steering up to its stop (turn in the same
direction as above).
6 Reset the steering selection switch to “four-wheel
steer” (pos. 2).
7 Rotate the steering (to the side opposite to point 3)
so that the rear axle reaches its stop
8 Reset the steering selection switch to “two-wheel
steer” (pos. 0)   
9 Rotate the steering (to the same side as in point 7)
so that the front axle reaches its stop
10 Reset the steering selection switch to “four-wheel
steer” (pos. 2)
Now the wheels should be re-aligned.

GTH 55-19 4
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

Test the system without any load on the machine’s gear put.
forks. The engine must not start. If the engine starts, contact
the GENIE Technical Service.
Repeat the operation putting first one gear, then the
To check the efficiency of the fork balancing system, obey other.
the instructions below:
- Drive the machine to a flat, smooth ground.
- Move the retracted boom fully down and align the
forks with the ground.
- Start lifting the boom and check that the forks remain
parallel to the ground.
If the forks do not remain parallel to the ground,

consult section 5 “Problems - Causes - Solutions”.

GTH 55-19 4
A-19 CHECK THE ENGINE COOLANT LEVEL
When the coolant is hot, the cooling system is under

pressure. With warm engine, loosen the radiator plug
slowly and carefully, without removing it, to drain the
pressure. Use protection gloves and keep your face
at a safe distance. A
• Every week, before starting working (with the coo-

lant cold), check the coolant level through the glass
cap of plug A.
• 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 Boiling
point point B
33 -17 °C 123 °C
40 -24 °C 126 °C
50 -36 °C 128 °C
70 -67 °C 135 °C

GTH 55-19 4
4.4 TABLE B PROCEDURES
B-1 CHANGE THE ENGINE OIL AND RENEW

THE FUEL FILTER
B-2 CHECKTHETENSIONOFTHEALTERNATOR
BELT
For the engine maintenance, please refer to the

specific Operator handbook (code SLBU 7853-00)
supplied with the machine.

GTH 55-19 4
B-3 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
Load index 10 pr
Rim 9.75x16.5
On new machines, and when a wheel has been

disassembled or replaced, check the nut torque of the
Always use tyres having the dimensions indicated


GTH 55-19 4
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.
- Tighten the nuts following the alternate sequence
shown in the picture with a pneumatic screwdriving
machine.
- Lower the machine to the ground.
Re-tighten all nuts to a torque 300 Nm.
Check the tightening of wheels one hour after the job.

They might get loose until they do not stay correct.
1
6
4
On new machines, and when a wheel has been di-
sassembled or replaced, check the nut torque of the

7
8
2
Always use tyres having the dimensions indicated 5

Standard
GTH 55-19
Load index 10 pr
Rim 9.75x16.5

GTH 55-19 4
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”.

GTH 55-19 4
4.5 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
gears:
For the engine maintenance, please refer to the parking brake.
specific Operator handbook (code SLBU 7853-00)
supplied with the machine. - Loosen level plug A and check if oil is level with the
hole.
- If necessary, add new oil through the hole of the level
plug until it comes out.
- Refit and tighten plug A.

GTH 55-19 4
To check the oil level in the power divider: C-3 CHECK THE OIL LEVEL IN THE FOUR
- Stop the machine on a level ground and engage the WHEEL REDUCTION GEARS
parking brake.
- Clean the plug A all around, then remove it and check To check the oil level within the wheel reduction
if oil is level with the hole. gears:
- If necessary, add new oil through hole A until it is - Stop the machine on a level ground and ensure the
level. parking brake is engaged and plug A finds on the
- Refit the plug. horizontal axis.
- Clean the plug all around, then remove it and check
Place a container of suitable size under the plug. level.
- Refit the plug.

GTH 55-19 4
C-4 CHECK AND CLEAN THE ENGINE AIR

FILTER
To clean the engine air filter :

- Clean the filter bowl. A
- Dry clean the cartridge (at max. 6 bar pressure) and
B
direct the air jet from inside to outside.
- Check the filter element for cracks by introducing a
lamp inside.
- Refit the cartridge and make sure it is properly posi-
tioned.
C

GTH 55-19 4
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. To tighten the clips, always use a box wrench,
never pliers.
- Keep out of items which can produce sparks, of

naked flames or lit cigarettes.
- Do not rest metal objects onto the battery. This
can result in a dangerous short especially during
a recharge.

GTH 55-19 4
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.

GTH 55-19 4
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.

GTH 55-19 4
C-8 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. In particular, we
recommend checking the hoses located near moving recommend checking the cables located near moving
mechanical parts as they could rub against such parts mechanical parts as they could rub against such parts
and get damaged. and get damaged.
Replace any worn hoses immediately before using Replace any worn cables immediately before using
the machine again. the machine again.

GTH 55-19 4
C-10 CHECK THE WEAR OF THE SLIDING PADS

OF THE BOOM SECTIONS

All pads can be adjusted by the special shims not
supplied by GENIE.
Pads must compulsorily be replaced if the residual

thickness of the plastic layer with respect to the iron
bush fixing the block is equal or inferior to 1 mm.
Max. wearing thickness
Minimum 1 mm

GTH 55-19 4
C-11 ADJUST THE PLAY OF THE SLIDING PADS

OF THE BOOM SECTIONS

All pads can be adjusted by the special shims.
Adjusting the pads:
- Remove or loosen the screws fixing the pads in re-
lation to type of shims used (with or without slots).
- Fit the necessary amount of shims.
- If the residual thickness of the pad is insufficient or
near the maximum wearing limit, renew the pad.
- Tighten the screws fixing the pads at the recommended
torque (see below). Use a dynamometric wrench.
Tightening torques of the pad screws in relation to

the screw diameter
Screws M10 Nm 30
Screws M14 Nm 50
Tightening torques higher than those recommended
can cause the break of the pad or of the locking
threaded bush.
Pads must compulsorily be replaced if the residual

thickness of the plastic layer with respect to the iron
bush fixing the block is equal or inferior to 1 mm.
Max. wearing thickness
Minimum 1 mm

GTH 55-19 4
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
Avoid mixing greases of different type or features

and do not use greases of lower quality.

GTH 55-19 4
C-13 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.
an explosive mixture with release of hydrogen gas
- Protect the terminals smearing them with pure forms.
vaseline.
- Remove the battery and store it in a dry place, when
the machine is not used for a long time.
Do not add sulphuric acid; add only distilled water.
Battery electrolyte contains sulphuric acid. It can

burn you if it touches your skin and eyes. Always
wear goggles and protective gloves, and handle the
battery with caution to prevent spillage. Keep metal
objects (watch straps, rings, necklaces) clear of the
battery leads, since they can short the terminals and
burn you.
- Before disconnecting the battery, set all switches

within the cab to OFF.
- To disconnect the battery, disconnect the negative
(-) lead from the frame earth first.
- To connect the battery, connect the positive (+)
lead first.
- Recharge the battery far from the machine, in a
well-ventilated place.
- Keep out of items which can produce sparks, of
naked flames or lit cigarettes.
- Do not rest metal objects onto the battery. This
can result in a dangerous short especially during
a recharge.
- Because the electrolyte is highly corrosive, it
must never come in contact with the frame of
the handler or electric/electronic parts. If the
electrolyte comes in contact with these parts,
contact the nearest authorised assistance
centre.

GTH 55-19 4
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.
- Raise the load some centimetres above the ground
(max 10 cm). To check the valve on the telescope
extension cylinder move the boom to maximum height
and extend it some centimetres. Attachment pitching cylinder
- Loosen the oil hoses to the cylinder of which you are
checking the valve with caution.
- To check the efficiency of the block valves of the Attachment coupling cylinder
outriggers, lower them to the ground and unload the
weight on the tyres. Loosen the cylinder hoses to
check the efficiency of the valve.
During the check, the load shall remain blocked in po-

sition.
Should that not be the case, the valve must be replaced.
Contact GENIE Technical Service.
Lifting cylinder
Extension cylinder

GTH 55-19 4
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 Balance cylinder
not result in an uncontrolled movement of the
machine.
TO REMOVE THE BLOCK VALVES OR THE

CYLINDERS
- Lower the boom to the ground in a firm way since
the removal of the block valve or the cylinder can
cause an uncontrolled down-movement.
- After refitting the valve or the cylinder, replenish
the circuit and eliminate any air before starting
working. To eliminate the air from the circuit, move
the involved cylinders to end-of-stroke in the two
directions (opening/closing. To eliminate the air
from the fork balance cylinder, move the boom up
and down and tilt the fork plate forwards/back.

GTH 55-19 4
4.6 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.
For this operation, use a torque wrench and tighten the
To check the quantity of smoke evacuated from the engine screws to a torque of 124 Nm.
exhaust, proceed as follows:
- Start the engine of the machine.
- Wait for a few minutes so the engine can warm up
correctly.
- Visually check that the amount of smoke coming
out of the exhaust is normal; repeat the check while
accelerating the engine.
Do this check outdoors or use an adequate smoke

extraction system.
In case of excess smoke, strictly obey the instruc-

tions provided in the relevant Use and maintenance
manual enclosed with the technical literature of the
machine.

GTH 55-19 4
D-3 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. the backlash between pins and relevant bushings on the
For this operation, use a torque wrench and tighten the joints is not too high.
screws to a torque of 188 Nm.
If you have to change some parts, please refer to the

spare parts catalogue enclosed with the technical
literature of the machine.

GTH 55-19 4
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.
3 Remove the filter cover  per accedere alla cartuccia
A.
4 Change the filter element, then, before fitting a new
one, thoroughly clean and grease both seat and
gasket.
5 Refit and tighten the filter cover.
A
The handling and disposing of used oils may be
authorised centres.
Hydraulic oil filter canisters cannot be cleaned or

washed and refitted.
They must be replaced with new ones of the type
recommended by the manufacturer:
Flow rate l/1’ = MPS 150
Filtering = 10 �
code = 09.4604.0001
When changing the oil, drain it when it is still hot and

the polluting substances are in suspension.

GTH 55-19 4
D-6 CHANGE THE HYDRAULIC OIL FILTER IN

THE TANK
To change the hydraulic oil filter cartridge of the service

circuits, proceed as follows:
parking brake.
- Remove the inspection hatch A and unscrew the oil
filter fitted inside the tank.
- Check the tank is clean, then fit a new filtering element
and refit the inspection hatch.
- Check the oil level within the tank. Add new oil, if
necessary.
Hydraulic oil filter canisters cannot be cleaned or

washed and refitted.
They must be replaced with new ones of the type
recommended by the manufacturer:
Flow rate l/1’ = STR 100/1
Filtering = 60 �
code = 09.4604.0004
The handling and disposing of used oils may be

authorised centres.
When changing the oil, drain it when it is still hot and

the polluting substances are in suspension.

GTH 55-19 4
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.

GTH 55-19 4
D-8 CHANGE THE MAIN CARTRIDGE OF THE

ENGINE AIR FILTER
Changing the external element:

- Clean the filter bowl. A
- Mount the new cartridge D and make sure it is cor-
B
rectly positioned.


GTH 55-19 4
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.
- Pull out the filter A located to the left of the driving
place.
- Clean the filter bowl.
- Clean the filter cartridge and replace in case of A
damage.
Paper filters must never be cleaned using compressed

air or washed with water and/or solvents.

GTH 55-19 4
4.7 TABLE E PROCEDURES
E-1 CHANGE THE SAFETY ELEMENT OF

ENGINE AIR FILTER
To change the safety element:

- Loosen wing nut and remove the inner element D. A
- Clean the filter bowl. B
- Mount the new safety element and make sure it is
correctly positioned.
- Tighten wingnut.
- Refit the outer element C.
C
The inner element should be replaced every second
time the outer element is replaced.

GTH 55-19 4
E-2 CHANGE THE OIL WITHIN POWER DIVIDER

AND DIFFERENTIAL GEARS
To change the oil level in the power divider: To change the oil level in the front and rear differential
gears:
parking brake. - Stop the machine on a level ground and engage the
parking brake.

- Remove the level plug A and the filler.
- Loosen the drain plug B and the level plug A and
- Remove the drain plug B and allow oil to flow out
allow oil to flow out from the differential gears.
from the power divider.
- Refit and tighten drain plug B.
- Refit and tighten the drain plug B .
- Add new oil through plug A until it is level with the
- Add new oil through the filler until it is level with hole
hole.
A.
- Refit and tighten filler/level plug.
Recommended oil:
Recommended oil:
- FUCHS TITAN GEAR LS 85 W-90 API GL-5 LS / GL-
5
5

B
B

GTH 55-19 4
E-3 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.
- Unscrew plug A and drain any oil from the reduction

gear.
- Rotate the wheel by 90° until the plug finds again on
the horizontal axis.
- Add new oil through hole A.
Recommended oil:
5

GTH 55-19 4
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. A
- Place a container of suitable size under the drain
plug, placed in the lower part of the reservoir, and
collect any oil leaks.
- Remove the drain plug and allow oil to flow out into
the container.
- Remove the inspection cover C of tank.
- Carefully wash the tank with Diesel oil and blow a jet
of compressed air.
- Refit the drain plug and the inspection cover C.
- Add new oil through hole B, by making sure that it
matches the recommended type indicated until it is
level with A.
Recommended oil:
- SHELL TELLUS T22 (Temperatures below -10° C)
- SHELL TELLUS T46 (Temperatures from -15° C to
+45° C)
- SHELL TELLUS T68 (Temperatures above +30° C)
The handling and disposing of used oils can be

authorised centres.

GTH 55-19 4
4.8 TABLE F PROCEDURES
F-1 CHANGE THE ENGINE COOLANT
When the coolant is hot, the cooling system is under

pressure. With warm engine, loosen the radiator plug A
slowly and carefully, without removing it, to drain the
pressure. Use protection gloves and keep your face
at a safe distance.
To drain the antifreeze:

- Let the engine cool down.
- Unscrew the plug B at the bottom of the radiator or
disconnect the rubber hose, if no plug is present. Allow
the coolant to flow out into a special container.
- Refit the plug or the hose and pour new antifreeze
(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 Boiling
point point
33 -17 °C 123 °C B
40 -24 °C 126 °C
50 -36 °C 128 °C
70 -67 °C 135 °C

GTH 55-19 4
4.9 TABLE G PROCEDURES
G-1 C hecking the state of the

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.
After the first 5 years, repeat this check every 2

years.

GTH 55-19 4

GTH 55-19 5
TROUBLESHOOTING
Section 5
TROUBLESHOOTING
SECTION INDEX
5.3 Problems-Causes-Solutions........................................................................ 4
5.3.1 Hydraulic faults............................................................................................. 4
5.3.2 Electrical faults.............................................................................................. 9

GTH 55-19 5
TROUBLESHOOTING
5.1 INTRODUCTION
Perform all troubleshooting on a firm level

surface.
of this machine.
• Immediately tag and remove from service a Two person will be required to safely perform
damaged or malfunctioning machine. some troubleshooting procedures.
• Repair any damage or malfunction before operating
machine.
• Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
- machine parked on a flat level surface;
- boom in the stowed position;
- key switch in the OFF position with the key
removed.
Before troubleshooting:
• Read, understand and obey the safety rules and
operating instructions printed in the Operator
Manual of the machine.
• Be sure that all necessary tools are available and
ready for use.
• Read each appropriate flow chart thoroughly.
• Pay special attention to the following warnings:

Crushing hazard. When testing or replacing any
hydraulic component, always support the structure
and secure it from movement.
Electrocution hazard. Contact with electrically

charged circuits may result in death or serious
injry. Remove all rings, watches and other
jewerly.
Spraying hydraulic oil can penetrate and burn

skin; loosen hydraulic connections very slowly
to allow the oil pressure to dissipate gradually.
Do not allow oil to squirt or spray.

GTH 55-19 5
TROUBLESHOOTING
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.
The initials of the electrical and hydraulic parts indicated in

the following tables are given to help you find such parts
on the schemes and diagrams in chapter 6.
The tables should be read as follows:

- once you have identified the problem, search this
problem in the "problem" column;
- analyse the possible causes explained in the "causes"
column;
- proceed with the check or replacement according to
the instructions provided in the "solutions" column;
- check that the machine runs well;
- if the problem cannot be eliminated, check again
all indications in the "causes" column and proceed
accordingly.
For any further information, contact the GENIE

Service Centre.

GTH 55-19 5
TROUBLESHOOTING
5.3 Problems-Causes-Solutions
5.3.1 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
The boom does not move Low pressure Set the max pressure of the main
valve to 270 bar
Hydraulic pump damaged Replace the pump
Load sensing valve defective Check the efficiency of the valve;

replace if necessary
The valve of the main valve leaks Dismantle the valve, check and
eliminate any foreign matters
Joystick damaged Check the efficiency of the joystick;

Wrong wheel shafting Leakage in the steering cylinders Check and replace the seals if
necessary
Leakage in the steer selection Check the efficiency of the solenoid

solenoid valve valve
The steering wheel is hard (low Low pressure Check the pressure; in case, reset
force in the cylinders) (170 bar)
Priority valve damaged Check the efficiency of the valve;

Low booster supply Pump damaged Change the pump
Motor damaged Change the motor
The machine drive is not Hydraulic oil filter restricted Clean the oil filter
enough
Low hydraulic oil level Replenish the tank up to the
recommended level

GTH 55-19 5
TROUBLESHOOTING
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 Check the operation of the brake

disks of the front axle
When the engine is stopped, the Block valves damaged or dirty Check the efficiency of the valves;
lifting cylinder does not support replace if necessary
the boom
Cylinder seal defective Replace the seal
When the engine is stopped, the Block valves damaged or dirty Check the efficiency of the valves;
cylinder does not support the replace if necessary
forks
When the engine is stopped and Block valves damaged or dirty Check the efficiency of the valves;
the boom is high, the extension replace if necessary
cylinder moves in
When the load is lifted, the fork Seals of the levelling cylinder worn Dismantle the cylinder and replace
cannot be levelled out the seals
Shockproof valves of the main valve Remove the valves, dry-clean

dirty or maladjusted or replace if damaged, and re-
calibrate
One-way valves of the levelling Remove the valves, dry-clean or

cylinder dirty or damaged replace if damaged, and replace in
their seats

GTH 55-19 5
TROUBLESHOOTING
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; remove the
valve and rectify or replace
Low pressure in the hydraulic circuit Re-calibrate the main valve
The fork tilting is not efficient The seals of the fork levelling cylinder Fit a new kit of seals and check the
are damaged tightness of the cylinder
Leakage in the cylinder block valve Check the valve operation; if

necessary, clean or change the
valve
Line from main valve to block valve Check the hydraulic line carefully and
defective replace any defective pipelines
Safety valves of the main valve Check the efficiency of the safety
maladjusted or damaged valve fitted to the ports of the main
valve. If necessary, proceed with the
clibration or replacement
The boom extension is not The seals of the internal boom Fit a new kit of seals and check the
efficient extension cylinder are damaged tightness of the cylinder
Cylinder rod damaged Check the rod condition

necessary, clean or replace the
valve
Hydraulic line defective Check the hydraulic line carefully and

replace any defective pipelines
Main valve damaged Check the efficiency of the main

valve and replace if necessary

GTH 55-19 5
TROUBLESHOOTING
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

necessary, clean or replace the
valve
During the down-movement, the Leakage in the cylinder block valve Check the valve operation; if
boom jerks necessary, clean or replace the
valve
Operating the joystick no function Joystick damaged Check the joystick efficiency; replace
is activated if necessary
Valve of the main valve damaged Check the efficiency of the valve;
The steering wheel is slow and Couplings damaged Replace the couplings
noisy
Hydraulic drive damaged Replace the hydraulic drive
Differential noisy and high No oil Check the oil level and refill. If
temperature on the body trouble cannot be rectified, dismantle
the unit
Bearings damaged Replace the bearings
The boom is hard to move in Sliding blocks worn out Check all the front bottom pads and
when it is fully extended in the the rear top pads for wear; clean
horizontal position the sliding guides of the boom
thoroughly and lubricate with the
special “INTERFLON FIN GREASE
LS 2” grease
When moving out the second Sliding blocks worn out Check the play and replace any
telescope, the boom tends to worn parts or place shims
move right and left
When moving out the second Grease is insufficient or inadequate Check that the grease smeared
telescope, the boom tends to on the boom is INTERFLON FIN
jump GREASE LS2; smear the boom
againwith grease

GTH 55-19 5
TROUBLESHOOTING
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.
If the overfeeding pressure drops
down, replace the pump and clean
the pump-motor couplings

GTH 55-19 5
TROUBLESHOOTING
5.3.2 Electrical faults
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
Engine does not start, starter 50A fuse blown Change the fuse
does not run
Dashboard damaged Check the dashboard and replace
if necessary
K01 relay damaged Change the relay
Speed switch ruined Check or replace the speed switch
70A engine start relay damaged Change the relay

(K11)
Starter defective Change the starter

Engine does not start - starter No fuel Refuel

runs but engine does not start
Fuel filter clogged Clean or replace the filter
Fuel ducts empty Eliminate any air
Start aid solenoid damaged Check the efficiency and replace if

necessary
Engine stop solenoid damaged Check the efficiency and replace if

necessary
The machine does not move Speed switch damaged Check the efficiency or replace the
forward/back switch if necessary
Fuse F23 broken Change the fuse
Relays K02-K03-K05 damaged Change the relays

GTH 55-19 5
TROUBLESHOOTING 10
Forward/reverse speed solenoid Check the efficiency or replace

valves damaged
Service brake micro-switch Check the efficiency or replace

damaged
Parking brake switch Check the efficiency or replace
Negative brake pressure switch Check the efficiency or replace
No steer selection Fuse F20 blown Change the fuse
Steer selector damaged Check the efficiency or replace the

switch if necessary
Coils of the steer selection solenoid Check the coils; replace if

valve damaged necessary
Hydraulic oil thermometer Indicator damaged Change the part

defective
Temperature sensor defective Check or replace the sensor
The parking brake lamp does not Dashboard instrument damaged Change
come on
The fuel gauge does not work Dashboard instrument damaged Change
Fuel sensor defective Check and replace the sensor if

necessary

GTH 55-19 5
TROUBLESHOOTING 11
The engine coolant thermometer Indicator defective Change the part

does not work
Temperature sensor defective Check and replace the sensor if
necessary
High hydraulic oil temperature Hydraulic oil bulb damaged Check or replace the bulb if
necessary
Indicator defective Change the part
Radiador clogged Check the radiator and eliminate any

impurities from the fins
The joystick does not operate the Fuse F20 blown Change the fuse
boom extension/retraction
Road-jobsite-platform selector Check and replace the selector if
damaged necessary
Yellow button on control lever Check the efficiency of the yellow

pushbutton
Main valve selection valve Check the efficiency of the solenoids

and replace if they are damaged
The joystick does not operate the Fuse F20 blown Change the fuse
attachment locking/unlocking
Red button on control lever Check the efficiency of the red
pushbutton
Main valve selection valve Check the efficiency of the electrical

coils and replace if they are
damaged
Mouvement selection button Check the efficiency or replace

GTH 55-19 5
TROUBLESHOOTING 12

GTH 55-19 6
SCHEMES
Section 6
SCHEMES
SECTION INDEX
6.1 Hydraulic symbols ...............................................................................page 2

6.2 Hydraulic schemes . ..................................................................................... 5
6.2.1 GTH 55-19 . .................................................................................................... 5
6.3 Electrical symbols ........................................................................................ 7
6.4 Wiring diagrams ........................................................................................... 9
6.4.1 Wiring diagrams - Component description . .............................................. 17
6.4.2 Fuses and relays .......................................................................................... 19
6.5 Position of the electrical and hydraulical components on the machine 20
6.5.1 Hydraulical components . ............................................................................ 20

GTH 55-19 6
SCHEMES
6.1 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 M Control with electric Pressure relief valve
directions of flow motor with direct control
Reversible fixed motor with Direct pressure control Pressure relief valve
two directions of flow with hydraulic control
PUMP
Fixed displacement pump Indirect (piloted) pressure Pressure reducing
with one direction of flow control valve
Fixed displacement pump Control with electromagnet Sequence valve

with two directions of flow and piloted distributor
PIPES AND CONNECTIONS Adjustable throttle

Variable displacement pump
with one direction of flow valve
Induction and return pipe
Two-way flow
Variable displacement pump regulator
with flow regulator
Piloting pipe
CYLINDERS Cut-out cock
Single-acting cylinder POWER SOURCES
Blow-by pipe
M Electric motor
Single-acting cylinder
with spring return Flexible hose Thermal engine
OTHER EQUIPMENT
Double-acting cylinder
Connecting point Accumulator
Double-acting cylinder
with bilateral rod Pipe cross Water tank
without connection
Telescopic cylinder
Compressor
Breather
COMMANDS AND CONTROLS
Shaft rotating in one direction Closed pressure fitting Filter
Pressure fitting with

Shaft rotating in two directions connected pipe Cooler
Quick fitting
Hand-operated control Pressure gauge
Quick fitting with check
Hand-operated control valves
with pushbutton Thermometer
DISTRIBUTION - SETTING
ELEMENTS
Hand-operated control
with lever Non-return valve Flowmeter
Hand-operated control
with pedal Pressure switch
Calibrated non-return valve
Mechanical control
with pushbutton
Unlockable non-return Drain to tank
Mechanical control valve indication
with spring

GTH 55-19 6
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
of transient connection during
passage phase
Electro-hydraulic single-acting
servo valve

GTH 55-19 6
SCHEMES

GTH 55-19 6
SCHEMES
6.2 Hydraulic scheme

6.2.1 GTH 55-19

GTH 55-19 6
SCHEMES

GTH 55-19 6
SCHEMES
6.3 ELECTRICAL SYMBOLS

ACTUATORS ACCUMULATORS DYNAMIC
APPLICATIONS
Emergency controls Battery
M Motor
Pushbutton control Thermocouple
Rotary control Element

G Generator
TERMINALS AND GROUNDS
Pedal control
Ring
Proximity control
Ground M As_3p_motor
3
Lever control
Terminal
ELECTRONIC PARTS
Timed control
Ground to frame - +
Rectifier
Mechanical/manual control
Knot
Key control
Protection ground Light-emitting diode
RESISTANCES Diode
Frame ground 2
Resistance
COILS Condenser
Resistor
Coil
PUSHBUTTONS
Potentiometer
Mechanical coupling coil Manual NC contact
Variable resistance
Winding
Manual NO contact
SIGNALS
A/C coil
Intermittent lamp
NC mushroom-head
pushbutton
Whistle
Coil with diode NO mushroom-head
pushbutton
Lamp
NC level
Buzzer Winding with diode
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

GTH 55-19 6
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

12V BATTERY
6.4
DISCONNECTION
BATTERY
STARTER
MOTOR
WIRING DIAGRAMS
Document 57.4403.3200 - 2nd Edition 01/2008

ALTERNATOR
FUEL ENRICHER
SCHEMES
GTH 55-19
INDEX
PREHEATING

6
CONTROL UNIT
MAXIFUSE
SYSTEM
PROTECTION
FUSE
CHANGE OVER
SWITCH
RELAY
STARTING
PARKING BRAKE
LINE PRESSURE
SWITCH
PREHEATING
CONTROL UNIT
GLOW PLUGS
OIL FILTER
CLOGGING
WARNING LIGHT
AIR FILTER
PREHEATING
GLOW PLUGS
AIR FILTER
CLOGGING
SENSOR
FORWARD SPEED
SOLENOID VALVE

SERVICE BRAKE
SENSOR
SCHEMES
GTH 55-19
PARKING
BRAKE SWITCH
INDEX
FAST SPEED
SOLENOID VALVE
6
10
BUZZER
REAR LIGHT
REVERSE SPEED
SOLENOID VALVE
GTH 55-19 6
SCHEMES 11
30 30
2/G1 4/G10
15 15
2/G1 4/G10
9/C4
5/C5
4F5
SW05
1
WH/RDø1.5
WH/RDø1.5
BNø1
SW04 BN/WHø1 3
2 RDø1
1 2 4
WH/BKø1 6
5 BU/RDø1 5/C5
2 1
0
WH/BKø1
BUø1.5
BUø1.5
8 7
BKø1 BU/RDø1
1/F6 1/D4 X2 X5 X5 X5 X2
4 2 4 3 4
WH/RDø1.5
BN/WHø1
BNø1
49
C
F22 F17
10A
15
C2
A
WH/BKø1
G
C3
49A 31
WH/TQø1
BNø2.5
A03
BNø2.5
4/G8
X8 X5
14 1
BKø1.5
WH/TQø1
5/B5
TQ/BKø1
TQø1
6/F5
WH/RDø1.5
A04 A05
Y07
BKø1.5
31 31
1/A1 4/A10
SOLENOID VALVE
MUSHROOM-HEAD
INTERMITTENCE
LIGHT INDICATOR
EMERGENCY
FENGINE STOP
PUSHBUTTON
INDICATOR
EMERGENCY
SWITCH
DIODE
DIODE
3/A1
3/G10
3/G10
15
30
F7
GYø1.5 7.5A GY/BKø1
8
F6
X10
GYø1.5 GYø1.5 7.5A GYø1
5/C8
BKø1
HEAD LIGHT TQø1

5
INDICATOR LIGHT
H08
YEø1
X9
RIGHT
GYø1 GYø1
GNø1 GNø1 10A GNø1.5
7
9
X9
F8
X10
6/C8
3/D1
GNø1.5
F9
5/B8
8
X9
GN/BKø1 GN/BKø1 10A GNø1.5
TQ/BKø1
SCHEMES
GTH 55-19
GY/BKø1 GY/BKø1
6
HEAD LIGHT
X9
H07
INDICATOR LIGHT YE/BKø1
LEFT
TQ/BKø1 TQ/BKø1
5
5
X7
X6
BKø1
INDEX
BKø1
TQ/BKø1
6
12
REAR AND
H06
STOP LIGHTS YEø1
LEFT
RDø1
3/G1
2/C8
YEø1
REAR
H05
NUMBER-PLATE BKø1
RDø1
TQø1
LIGHT
RDø1
4
X9
REAR AND
H04
YE/BKø1
STOP LIGHTS
RIGHT TQø1 TQø1
2
2
X7
X6
3
X9
BKø1
YE/BKø1
YEø1
2
X9
F4
YEø1 YEø1 5A YEø1.5 YEø1.5

1
1
X9
X10
F5
YE/BKø1 5A YEø1.5
6
X10
5
X10
YE/BKø1
6/D8
YEø1
YE/BKø1
YE/BKø1
7/F9
5/E1
6/C7
6/G1
31
15
30
5/A10
5/G10
5/G10
GTH 55-19 6
SCHEMES 13
30 30
4/G10 6/G10
15 15
4/G10 6/G10
1
RDø1.5 3
2 YEø1.5
TQ/BKø1
4
GY/RDø1.5
GN/BKø1.5
X4 X10 X5
BN/RDø1
6 7 TQø1 7 BNø1.5 6
VTø1
5 GN/BKø1.5
0
4 1 8 7 12 2 9 10
56 30 H 53C 53b 53 L R
1
8 7
VTø1
123 2 1 0 L 0 R BKø1 YE/BKø1 6/F1
GN/BKø1.5
56b 56a 31b L
X8 X2 5 3 6 11
11 4 SW06 SW07 4/F1
GNø1.5
GYø1.5
BN/RDø1
VTø1
F10 F18 F11
10A
15A
15A
VTø1
BNø2.5
BN/RDø1
4/C9 GYø1.5
WH/BKø1
3/G5
3/F1
BKø1
VTø1
M M
M03 M04
HA02 3/C1
4/F7 GNø1
BKø1
BKø1
31 31
4/A1 6/A10
WASHER MOTOR
WIPER MOTOR
WIND-SCREEN
WIND-SCREEN
WIND-SCREEN
SWITCHES
INDICATOR
HORN
LIGHTS
LIGHTS
WIPER
WIPER

5/G10
5/G10
5/A1
31
15
30
DASHBOARD
LIGHT BKø1
INDICATOR
SS03
WATER
TEMPERATURE WH/GNø1 WH/GNø1 WH/GNø1
13
X8
X7
T
SENSOR
1/F2
RD/BKø1

RD/BKø1
4/C8
1/F8
4/B2
GNø1
8/G10
BU/RDø1
YE/BKø1
2/C7
P01
4/D1
J6
J5
YEø1
GY/WHø1
J7
SS04
BU/RDø1
J8
ENGINE OIL
SCHEMES
GTH 55-19
PRESSURE GY/RDø1 GY/RDø1 GY/RDø1

J9
8
8
T
X6
X7
TRANSDUCER
J3
BU/RDø1
J2
YEø1
4
-
J1
X10
+
RD/BKø1
J4
0 0 0 0 0 0 3
GY/YEø1 GY/YEø1 GY/YEø1
9
7
X6
X7
J10
FUEL FLOAT BKø1 GY/WHø1

J11
GNø1 GNø1
8
SS08
X5
J12
YE/BKø1
J13
INDEX
PKø1 PKø1
1
J15
J14
10
X6
X7
6
14
BUø1
SS05
WH/BUø1 WH/BUø1 WH/BUø1
3/C6
1
3
WH/TQø1
X13
X14
BKø1
NEGATIVE BRAKE
PRESSURE
SWITCH
1/F1
P02
RD/BKø1
RD/BKø1 YEø1
HYDRAULIC OIL
+ -
TEMPERATURE
GAUGE BKø1
S
RD/GNø1 RD/GNø1 BKø1

11
15
X6
X7
SS06
T
HYDRAULIC OIL
TEMPERATURE GN/RDø1
SENSOR
P03
RD/BKø1 YE/BKø1
+ -
ENGINE WATER
TEMPERATURE BKø1
S
GAUGE
GY/GNø1 GY/GNø1
7
9
BKø1
T
X6
X7
WATER
GY/GNø1
TEMPERATURE
SENSOR
SS07
5/F1
4/B1
31
15
30
YE/BKø1
YE/BKø1
7/A10
7/G10
7/G10
GTH 55-19 6
SCHEMES 15
30 30
6/G10 8/G10
15 15
6/G10 8/G10
BN/BKø1
8/F7
X5
10
BN/BKø1 BN/BKø1
SW09
YE/BKø1
8 7
YE/BKø1 BKø1
4/C1 3
2 WH/BKø1.5 A06 A07
OG/GNø1
1
YE/RDø1
BN/BKø1
PK/YEø1
6
5 BU/RDø1.5
PKø2.5
4
OG/GNø1
X2 B A C
4
X7 X7
3 SW08 6
E F
BU/RDø1
BKø1
YE/RDø1
PK/YEø1
OG/BUø1.5
F19 F20
15A
7.5A
BNø2.5
BNø2.5
X6 X6
X2 4 6
4
YE/RDø1
PK/YEø1
WH/BKø1.5
BU/RDø1.5
BKø1.5
M 12v 12v
M06 1
2 Y08 Y09
1
2
BKø1
BKø1
31 31
6/A1 8/A10
AIR VENTILATOR
AIR VENTILATOR
SOLENOID VALVE
SOLENOID VALVE
SELECTOR
STEERING
STEERING
STEERING
SWITCH
MOTOR
WHEEL
WHEEL
WARM

7/A1
7/G10
7/G10
31
15
30
3
WH/YEø1
X15

Y10
2
1
ATTACHEMNT BKø1
2
2
WH/YEø1 WH/YEø1
RELEASE
X8
X16
12v
SOLENOID VALVE
CONTINUOUS
OIL
SCHEMES
GTH 55-19
Y11
2
1
0
7/G8
ATTACHEMNT
2
1
BN/BKø1
BKø1
3
2
WH/OGø1 WH/OGø1
COUPLING
X8
X15
SOLENOID VALVE
12v
1
X15
INDEX
Y12
JOYSTICK
SW14
FORk
2
1
BKø1
9
4
BU/YEø1 BU/YEø1
6
16
ROTATION
X8
X15
SOLENOID VALVE
12v
HA03
F21
10
5
4
VT/WHø1 VT/WHø1.5 BNø2.5

X3
X2
A
M
BKø1
BEACON
H09
4
3
YE/GNø1.5 YE/GNø1.5 YE/GNø1.5

X3
X10
BKø1
WORK LIGHT
2
X10
WORK LIGHT
SWITCH
(OPTIONAL)
YE/BKø1.5
BKø1
5
2
SW12
1
0
6
4
3
7
1
YE/GNø1.5
YE/GNø1.5
15
30
31
9/A10
9/G10
9/G10
GTH 55-19 6
SCHEMES 17
6.4.1 Wiring diagram - Component description
Ref. Description Sheet Ref. Description Sheet

F1 5 A FUSE K06 GEAR ENGAGEMENT FROM PARKING BRAKE LINE
F2 10 A FUSE LOW PRESSURE BULB 1
F3 10 A FUSE K11 START RELAY 1
F4 5 A FUSE
F5 10 A FUSE M01 STARTER MOTOR 1
F6 10 A FUSE M02 ALTERNATOR 1
F7 5 A FUSE M03 WINDSCREEN WIPER MOTOR 5
F8 5 A FUSE M04 WINDSCREEN WIPER/WASHER MOTOR 5
F9 15 A FUSE M06 FAN MOTOR 7
F10 5 A FUSE
F11 7,5 A FUSE P01 WARNING LIGHTS - FUEL GAUGE INSTRUMENT 5
F12 7,5 A FUSE P02 ENGINE OIL TEMPERATURE INDICATOR 5
F13 5 A FUSE P03 ENGINE OIL COOLING TEMPERATURE INDICATOR 5
F14 2 A FUSE
F15 2 A FUSE R01 GLOW PLUGS 1
F16 20 A FUSE
F17 10 A FUSE SW01 IGNITION KEY 1
F18 5 A FUSE SW02 PARKING BRAKE SWITCH 2
F19 20 A FUSE SW03 CHANGE OVER SWITCH 1
F20 10 A FUSE SW04 MUSHROOM-HEAD BUTTON 3
F21 15 A FUSE SW05 HAZARD WARNING LIGHT / TURN SIGNALS SWITCH 3
F22 5 A FUSE SW06 LIGHT SWITCH-TURN SIGNALS-WINDSCREEN
F23 15 A FUSE WIPER/WASHER 5
F24 5 A FUSE SW07 LIGHTS SELECTION SWITCH 5
F25 7,5 A FUSE SW08 STEERING SELECTOR 7
F26 7,5 A FUSE SW09 HEATING FAN SWITCH 7
F27 5 A FUSE
F28 5 A FUSE SW11 CONTINUOUS OIL SWITCH 8
F29 SPARE FUSES (15A - 10A - 7,5A - 5A) SW12 OPTIONAL WORK LIGHT SWITCH 8
F30 PREHEATING CONTROL UNIT MAXIFUSE SW13 BATTERY CUTOFF 1
F31 SYSTEM PROTECTION FUSE SW14 JOYSTICK 8

H01 WARNING LIGHTS: AIR FILTER SOILED, SS01 SERVICE BRAKE SENSOR 2
PREHEATING GLOW PLUGS WARNING LIGHT 1 SS02 AIR FILTER CLOGGING SENSOR 1
H03 BACK-UP LAMPS 2 SS03 WATER TEMPERATURRE SENSOR 6
H04 REAR RIGHT-HAND LIGHT 4 SS04 ENGINE OIL PRESSURE SENSOR 6
H05 LICENSE PLATE LAMP 4 SS05 NEGATIVE BRAKE PRESSURE SWITCH 6
H06 REAR LEFT-HAND LIGHT 4 SS06 HYDRAULIC OIL TEMPERATURE SENSOR 6
H07 FRONT LIGHT LAMP - LEFT TURN SIGNAL 4 SS07 WATER TEMPERATURE SENSOR 6
H08 FRONT LIGHT LAMP - RIGHT TURN SIGNAL 4 SS08 FUEL FLOAT 6
H09 WORK LIGHT 8
Y01 FUEL ENRICHER SOLENOID 1
HA01 BACK-UP HORN 2 Y02 SOLENOID VALVE - FWD SPEED 2
HA02 HORN 5 Y03 SOLENOID VALVE - PARKING BRAKE 2
HA03 BEACON 8 Y04 SOLENOID VALVE - REVERSE SPEED 2
Y07 ENGINE STOP SOLENOID 3
K01 OPTIONAL WORK LIGHT Y08 WHEEL STEERING SOLENOID VALVE 7
K02 STARTING ENABLING COMMAND 1 Y09 WHEEL STEERING SOLENOID VALVE 7
K03 FORWARD SPEED ENABLING COMMAND 2 Y10 SOLENOID VALVE - ATTACHMENT RELEASE 8
K04 INHIBITION WITH SERVICE BRAKE ENGAGED 2 Y11 SOLENOID VALVE - ATTACHMENT COUPLING 8
K05 REVERSE SPEED ENABLING COMMAND 2 Y12 SOLENOID VALVE - FORK ROTATION 8


GTH 55-19 6
SCHEMES 18
Ref. Description Sheet

A01 12V BATTERY 1
A02 PREHEATING CONTROL UNIT 1
A03 TURN SIGNALS FLASHING 3
A04 DIODE 3
A05 DIODE 3
A06 DIODE 7
A07 DIODE 7

X01 4-WAY CONNECTOR - ENGINE FUSES LINE
X02 4-WAY CONNECTOR - STEERING COLUMN
X03 6-WAY CONNECTOR - CAB
X06 12-WAY CONNECTOR - ENGINE
X15 4-WAY CONNECTOR - JOYSTICK

GTH 55-19 6
SCHEMES 19
6.4.2 Fuses and relays
FUSES
Ref. Circuit Amp.
F1 FUSE 5 29
7.5A
F2 FUSE 10 14
2A
28
5A
29
10A
F3 FUSE 10 13
5A
27
5A
29
5A
F4 FUSE 5 12
7,5A
26
7,5A 29
15A
F5 FUSE 10 11
7,5A
25
7,5A
F6 FUSE 10 5A 5A
K5 K10
10 24
F7 FUSE 5 9
15A
23
15A
F8 FUSE 5 5A 5A K4 K9
8 22
F9 FUSE 15 5A 15A
7 21
F10 FUSE 5 10A 10A
F11 FUSE 7,5 6 20 K3 K8
10A 20A
F12 FUSE 7,5 5 19
5A 5A
F13 FUSE 5 4 18
K2 K7
10A 10A
F14 FUSE 2 3 17
F15 FUSE 2 2
10A
16
20A
F16 FUSE 20 1
5A
15
2A K1 K6
F17 FUSE 10
F18 FUSE 5
F19 FUSE 20
F20 FUSE 10
F21 FUSE 15
F22 FUSE 5
F23 FUSE 15
F24 FUSE 5
F25 FUSE 7,5
F26 FUSE 7,5
F27 FUSE 5
F28 FUSE 5
F29 SPARE FUSES
F30 PREHEATING CONTROL UNIT MAXIFUSE
F31 SYSTEM PROTECTION FUSE
K12 F30 F31 K11
RELAYS
Ref. Circuit
K01 OPTIONAL WORK LIGHT
K02 STARTING ENABLING COMMAND
K03 FORWARD SPEED ENABLING COMMAND
K04 INHIBITION WITH SERVICE BRAKE
ENGAGED
K05 REVERSE SPEED ENABLING COMMAND
K06 GEAR ENGAGEMENT FROM PARKING BRAKE
LINE LOW PRESSURE BULB
K11 START RELAY
K12 PRE-HEATING RELAY

GTH 55-19 6
SCHEMES 20
6.5 POSITION OF THE ELECTRICAL AND HYDRAULICAL COMPONENTS ON THE MACHINE
6.5.1 Hydraulical components
17
7
20
10
16

GTH 55-19 6
SCHEMES 21
13
21
22
24
25

GTH 55-19 6
SCHEMES 22
18
12
14
23
15
19
11

GTH 55-19 6
SCHEMES 23
Legend of the hydraulic components
Pos. Description
1 Diesel engine
2 Drive pump
3 Service pump
4 Hydraulic oil return filter
5 Drive motor
6 One-way valves
7 Combined engine fluid/hydraulic oil
radiator
8 Service pump suction filter
9 Front axle
10 Hydraulic oil tank
11 Rear axle
12 Hydraulic steering
13 Steering selection solenoid valve
14 Brake pump
15 Quick-fit couplings for attachment lock/
unlock control
16 Main valve
17 Boom lifting/lowering cylinder
18 Joystick
19 Fork tilting cylinder
20 Fork levelling cylinder
21 Main valve control block
22 Boom extension/retraction cylinder
23 Attachment coupling cylinder
24 Fuel tank
25 Load cell

GTH 55-19 6
SCHEMES 24

GTH 55-19 7
REPAIR PROCEDURES
Section 7
REPAIR PROCEDURES
SECTION INDEX
7.1 Time schedule ......................................................................................page 2

7.2 Repair procedures......................................................................................... 5
001 - Cylinder disassembly - Boom raising cylinder................................. 5
002 - Cylinder disassembly - Fork balance cylinder.................................. 9
003 - Cylinder disassembly - Attachment locking cylinder
+ DFE valve (if any)....................................................................................... 11
004 - Removing the engine from the machine............................................ 15
005 - Hydrostatic pump disassembly.......................................................... 21
006 - Disassembling the hydraulic motor................................................... 23
007 - Cylinder disassembly - Boom extension cylinder............................ 25
008 - Water-oil cooler disassembly.............................................................. 27
009 - Main valve disassembly...................................................................... 29
010 - Renewing the slide pads of the telescopic boom............................. 31
011 - Renewing the flexible hoses inside the boom................................... 35
012 - Cylinder disassembly - Attachment rotation cylinder...................... 37

GTH 55-19 7
REPAIR PROCEDURES
7.1 TIME SCHEDULE
Job Operators Expected

needed time (h)
change the ignition key 1 1,00

change the gear switch lever 1 0,15
change the speed switch 1 0,15
change the joystick 1 1,00
change the fork locking/releasing pushbutton 1 0,20
change the fork locking/releasing red pushbuttons 1 0,20
change the brake pump 1 0,30
change the boom lifting cylinder 1 2,15
change the boom lifting cylinder kit
(complete overhaul) 1 1,30
change the block valve of the boom lifting cylinder 1 0,30
change the cylinder inside the boom 1 2,30
change the extension cylinder kit inside the boom 1 1,30
change the block valve of the extension cylinder
inside the boom 1 0,30
change the fork pitching cylinder 1 1,30
change the fork pitching cylinder kit 1 1,30
change the valve of the fork pitching cylinder 1 0,30
change the attachment locking cylinder 1 1,00
change the attachment locking cylinder kit 1 1,15
change the block valve of the attachment locking cylinder 1 0,30
change the fork compensation cylinder 1 2,00
change the fork compensation cylinder kit 1 1,30
change the valve of the fork compensation cylinder 1 0,45
check the one-way valves of the fork compensation
cylinder 1 0,20
change the boom internal line for the boom extension 1 1,30
change the boom internal line for the fork pitching 2 2,00
change the boom internal line for the fork locking 2 2,00
change the boom slide pads 1 2,30
check the transmission pump pressures 2 0,30 each
check the pressure of the main actuator operating the boom
movements 2 0,30 each
check the pressure of brake pump and hydrostatic steering unit 1 0,30
check the pressure of pressure relief valves and safety valves 1 1,30
change the drive pump 1 2,00

GTH 55-19 7
REPAIR PROCEDURES

needed time (h)
change the drive motor 1 2,00

change motor, pump, transmission piping + tests 1 5,00
change the actuator control pump 1 2,00
change and calibrate the actuator 1 2,30
change the DFE valve 1 0,30
change relays and fuses 1 0,10
change the windscreen wiper motor (closed cab version) 1 1,00
change a solenoid valve 1 0,30
change the gas pedal complete with cord 1 1,00
change the manual throttle complete with cord 1 0,30
change the front axle shaft 1 2,30
change the rear axle shaft 1 2,00
change 1 cardan joint 1 1,00
change the cardan joints 1 2,00
change the axle shaft hub 1 1,30
change the boom assy 2 4,00 each
change the boom anchoring pin 2 1,00 each
change the attachment locking cylinder pins 1 0,30
change a cab pushbutton 1 0,30
change and test the actuator pressure relief valve or the sliders 1 0,30
change and test the actuator safety valve 1 0,30
change the one-way valve 1 0,20
change the maxi-fuses and search for troubles 1 1,00
bleed the brake circuit 2 0,15 each
disassemble and reassemble a wheel 1 1,00
disassemble the Deutz engine 2 2,30
dismantle the hydraulic oil tank 1 3,00
dismantle the fuel tank 1 2,00
change the oil-water cooler 1 2,00
change the fork pivot pin support 1 2,00
change the engine bonnet 1 1,00
change the canister of the air filter 1 0,10
check the seals of the steering cylinder 2 1,00
change the return filter of the hydraulic oil tank 1 0,30
change the hydrostatic steering unit 1 2,00
change the battery 1 0,20
change the exhaust pipe 1 0,30
change the mud-guard supports 1 0,30

GTH 55-19 7
REPAIR PROCEDURES

needed time (h)
change the mud-guards 1 0,20

change the steering wheel 1 0,20
replace the complete solenoid valve block 1 2,00

GTH 55-19 7
REPAIR PROCEDURES
Operation: Cylinder disassembly Table:

76
Boom raising cylinder
GTH5519-001
Hrs. Min.
Bridge crane, payload 5000 kg (20000 lb) Standard tools 2 15

Textile bridles or chains with hooks Adjustable stands
Operation:
1 Release the attachment 2
2 Anchor the attachment holding frame to the
hooks of the slinging chain
3 Raise the boom to max. height (the hinging pin of

the cylinder rod must be over the driving cabin)
operating alternately the bridge crane and the
hydraulic boom raising control of the machine
4 Stop raising when the slinging chains are slightly

under tension
5 Place a container of suitable size under the

hydraulic piping before disconnecting
Used oils must be handled and disposed of

according to local regulations. Address to
legally authorised centres.
6 With a 27 mm wrench, disconnect two hydraulic

hoses from the blocking valve, then plug the 6
disconnected connectors to prevent dust and
impurities from entering the circuit

GTH 55-19 7
REPAIR PROCEDURES


GTH5519-001
7 To move the boom using the up/down controls
of the bridge crane, previously disconnect the 8
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.)
10 Fix the balance cylinder to the cabin with a sling

and esnure it does not hinder the movement of
the boom
11 Secure the raising cylinder to the cabin with a

sling
9
11
10

GTH 55-19 7
REPAIR PROCEDURES


GTH5519-001
12 Remove the screw which fixes the rod pin to the
boom using two 19 mm wrenches 12

13
14 Put two wooden plugs, each 100mm high, on
the oil cylinder to support the raising cylinder
15 Lower the boom until the cylinder rests on the

supporting plugs previously positioned
16 Untie the sling fixing the cylinder to the boom,

then raise the boom with the bridge crane to go
on working
17 Remove the screw which fixes the bottom-side

pin of the cylinder using two 19 mm wrenches
17

GTH 55-19 7
REPAIR PROCEDURES


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
To reassemble the cylinder, repeat the steps 18

above in reversed order.
Remember to set the circuit under pressure
before releasing the bridge crane.
18

GTH 55-19 7
REPAIR PROCEDURES

26
Fork balance cylinder
GTH5519-002
Hrs. Min.
Bridge crane, payload 500 kg (2000 lb) Standard tools 2 -


1
Operation:
1 Release the attachment 2
2 Remove the screw fixing the rod pin with two 13
mm wrenches

3

GTH 55-19 7
REPAIR PROCEDURES 10

Fork balance cylinder

GTH5519-002
4 Fix the cylinder with a textile bridle connected
to the bridge crane to support its weight

Used oils must be handled and disposed of ac-

cording to local regulations. Address to legally
authorised centres.
4

impurities from entering the circuit
7 Drive out the lower pin
8 Unscrew and extract the screw fixing the pin with

two 13 mm wrenches
9 Knock out the pin using a plug of soft material

(aluminium, copper, wood, etc.) and extract it 9
through the hole on the frame
10 Remove the cylinder from the machine using

the bridge crane

GTH 55-19 7

12
Attachment locking cylinder + DFE valve
GTH5519-003
(if any) Hrs. Min.

Textile bridles or chains with hooks

1
Operation:
1 Release the attachment
2 With a 13mm wrench, remove the protective

cover of the attachment lock/unlock cylinder 2
3 Disconnect the flexible hoses connected to the

DFE valve (if present; usually it is used when 3
the attachment needs an additional hydraulic
line) from the quick connectors on the telescopic
section of the boom

GTH 55-19 7
Attachment locking cylinder

GTH5519-003
4 With a 17 mm wrench, disconnect the flexible
hoses from the attachment locking cylinder 4
5 With a 17 mm wrench, loosen the four screws

fixing the cylinder without removing them
5

GTH 55-19 7

GTH5519-003
6 With a 2.5 mm hexagonal wrench, remove the
grub-screw fixing the terminal pin on both sides 6
of the cylinder (if present)
7 With two 27 mm wrenches, loosen and pull out

the terminal pins from their housings 7
8 Remove the four screws, previously loosened,
to set the cylinder free
9 Seize and remove the cylinder
10 If necessary, position the cylinder on the bench

and disconnect the pipes

GTH 55-19 7
Operation: Cylinder reassembly Table:

GTH5519-003
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. Clean
and use the amount indicated in the bottle
2 Lock the four fixing screws of the cylinder to the

holding frame with the terminal pins completely
driven into their housing but free to rotate
(correct alignment of the pins with the holes)
3 Block the grub-screws of the terminal pins with

Loctite 245

GTH 55-19 7
Operation: Removing the engine from the machine Table:

340
GTH5519-004
Hrs. Min.


2
Operation:
1 Open the engine cover 3
2 Secure the cover with a belt or hold it raised by
hand so it cannot move
3 Using two 13mm wrenches, remove the two

screws of the spring
4 Again with two 13mm wrenches, loosen the three

screws that secure the cover to the frame
4
5 Remove the upper cover
6 Disconnect the two battery leads and remove

the battery
7 With two 17mm wrenches, remove the six

screws fixing the lower cover of the engine
8 7

GTH 55-19 7
GTH5519-004
8 Remove the lower cover
9 With a screwdriver, disconnect the fuel feeding
and return piping held in position by the special
9
hose-clamps
10 Disconnect the throttle control cable removing 10

the locking clip; loosen the cable register with a
17 mm wrench to pull out the cable
11 Close the oil tank cocks

11

GTH 55-19 7

GTH5519-004
12 Disconnect the flexible hose of the silencer
loosening the clamps with a 13 mm wrench
12
13 Remove the manifold with a 17 mm wrench
14 Disconnect all the electrical wires connected to

the engine, and namely:
❑ oil pressure bulb,
❑ electrical stop,
❑ water temperature bulb,
❑ the three alternator connections,
❑ starter motor,
❑ ground between chassis and engine,
❑ the two coils of the transmission pump
solenoid valve.
15 Disconnect the radiator:

a) remove the clamps fixing the sleeves to the
radiator
b) remove the three screws that hold the fan
protective grille in place
15a 15b

GTH 55-19 7
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. They can
cause serious damage.
❑ disconnect the two drain lines of the

hydraulic pump with a 36mm wrench
❑ disconnect the suction line of the hydraulic
pump with a 50mm wrench
❑ disconnect the “low pressure line” duct with
16
a 19mm wrench
❑ disconnect the four flanges which connect
A
the drive pump to the drive motor with a
8mm Allen wrench
❑ disconnect the suction line of the service
pump with a 8mm Allen wrench (ref. A),
❑ disconnect the delivery line ducts of the
hydraulic drive and the main valve with a
36mm wrench and a 24mm wrench
❑ disconnect the load sensing signal line from
the hydraulic drive with a 17mm wrench.
Once all operations have been performed make sure

that all the electrical wires and the hydraulic lines are 17
disconnected from the motor.
17 Remove the four screws (two on the front and

two at the back) of the vibration supports with a
22 mm wrench

GTH 55-19 7

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
18
19 Raise the engine with caution and ensure no

parts are still connected
20 Remove the engine from the machine, rest it on

a wooden pallet and hold it in position with some
plugs
Reassembling the engine:
To reassemble the engine, repeat the steps above

in reversed order considering the precautions
below.
1 Handle the engine with extreme caution to

prevent it from crashing against the machine

GTH 55-19 7
Operation: Reassembling the engine on the machine Table:
GTH5519-004
Page left intentionally blank

GTH 55-19 7
Operation: Hydrostatic pump disassembly Table:

40
GTH5519-005
Hrs. Min.
Bridge crane or swing hoist, payload 500 Standard tools 2 -

kg (2000 lb)
Operation:
1

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
impurities from entering the circuit. They can
cause serious damage.
2
1 Using two 17mm wrenches, remove the six
screws that fix the engine lower cover
2 Remove the lower cover
3 Close the oil tank cocks

3

GTH 55-19 7

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
5 Disconnect the hydraulic piping:

❑ disconnect the two drain lines of the
hydraulic pump with a 36mm wrench
❑ disconnect the suction line of the hydraulic
pump with a 50mm wrench
❑ disconnect the “low pressure line” duct with
a 19mm wrench
❑ disconnect the four flanges which connect
the drive pump to the drive motor with a
8mm Allen wrench
❑ disconnect the suction line of the service
pump with a 8mm Allen wrench
❑ disconnect the delivery line ducts of the
hydraulic drive and the main valve with a
36mm wrench and a 24mm wrench
❑ disconnect the load sensing signal line from
the hydraulic drive with a 17mm wrench.
Once all operations have been performed, make

sure that all electrical wires and hydraulic lines are
disconnected from the motor.
6 Disconnect the service pump from the drive

pump by driving out bolts A with a 19mm
6
spanner. Place the pump on to a bench and plug
all the outlets.
7
7 Remove the fixing screws B of the drive pump
with a 14mm hex-head wrench and then secure A
the pump to the bridge crane with a textile sling
and pull it out of the motor. Place the pump on
to a bench and plug all the outlets. B

GTH 55-19 7
Operation: Disassembling the hydraulic motor Table:

44
GTH5519-006
Hrs. Min.
Bridge crane or swing hoist, payload 500 Standard tools 2 -

kg (2000 lb)
Operation:

oil spillage.

connectors, clothes or adhesive tape to prevent
dust or impurities from entering the circuit. They
can cause serious damage.
1 Remove the central covers A-B of the machine

by driving out all the bolts with two 13mm
wrenches
B
2 Using a 36mm wrench and a 17mm wrench,
disconnect the hoses
3 Disconnect the two delivery hoses with a 19 mm

wrench
A

GTH 55-19 7

Operation: Disassembling the hydraulic motor Table:
GTH5519-006
4 Remove the four locking screws of the motor
with a 24mm wrench 4
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

GTH 55-19 7

92
Boom extension cylinder
GTH5519-007
Hrs. Min.


1
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 2
4 Remove the rear guard to gain access to the

rear part of the boom


6 With a 27 mm wrench, disconnect the two

hydraulic hoses from the blocking valve, then 6
plug the disconnected connectors to prevent
dust and impurities from entering the circuit.

GTH 55-19 7
Boom extension cylinder

GTH5519-007
7 Loosen and remove the screw fixing the cylinder
pin (bottom side) with two 13 mm wrenches 7

soft material (aluminium, copper, wood, etc.) 8
9 Pull out the cylinder from the boom section and
sling it with the textile bridles connected to the
bridge crane

GTH 55-19 7
Operation: Water-oil cooler disassembly Table:

24
GTH5519-008
Hrs. Min.
Standard tools 2 -
Operation:

oil spillage.

1 Empty the cooler opening the special cock

2-3
2 Disconnect the two inlet and outlet hoses from
the cooler with a 36 mm wrench
3 Disconnect the water pipes from/to the engine

loosening the hose-clamps with a screwdriver

GTH 55-19 7

Operation: Water-oil cooler disassembly Table:
GTH5519-008
4 Remove the two screws of the vibration supports
with a 22 mm wrench
4
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

GTH 55-19 7
Operation: Main valve disassembly Table:

27
GTH5519-009
Hrs. Min.
Standard tools 2 30

oil spillage.

Before disconnecting the hydraulic piping,

ensure the line is not under pressure. Release the
pressure if necessary by operating the control
levers with the engine stopped.
In any case, disconnect the hydraulic piping
with extreme caution and always wear suitable
personal protection equipment -e.g. goggles,
gloves, facial screen, etc.
Wrap up the end of the pipe to be disconnected
with some rags and slowly loosen the pipe
connector so that air comes out as slow as
possible.

GTH 55-19 7

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
3 Disconnect all pilot systems with a 19 mm
wrench
4 Remove the 3 fixing screws with two 13 mm
wrenches (screw + lock nut)

GTH 55-19 7
Operation: Renewing the slide pads of the telescopic Table:

-
boom
GTH5519-010
Hrs. Min.
Standard tools 1 30
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.
Usually, the guide pads subject to premature wear
are:
• bottom pads of the fixed section
• top pads of the telescope
Proceed as follows:
1 Lower the boom to the ground and ensure the

telescope is fully retracted
2 With a thickness gauge, check the play of all

pads.
After adjustment, the minimum play in the
narrowest point must be: 0,5÷1 mm
200
3 Measure the thickness of the slide pads. The 60 40
value of the bottom pads of the fixed section and
of the top pads of the telescope must be at least
Thickn. 1÷2 mm
13 mm. For the remaining pads, the minimum
if needed
thickness must never be less than 9 mm
60
30
4 If the thickness reaches the minimum value,

renew the pads before adjusting the residual 16
play with some shims
5 Remove the fixing screws from the pads and

position as many shims as necessary to reach 100
the normal thickness value 70 15
25
10
12,5

GTH 55-19 7

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. 20 mm
Sp. 15 mm
Sp. 15 mm
Sp. 20 mm
New pad thickness: 15 mm
Max wearing thickness: 6 mm
Torque:
30÷35 Nm
Minimum thickness: 9 mm

GTH 55-19 7
GTH5519-010
RENEWING THE PADS
9
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. Hold it in horizontal position
for removing the top pads
9 With a 17mm hexagonal wrench, remove the

pad fixing screws
10 With a screwdriver, pry off the worn pads. Fit

new pads after applying a few drops of Loctite
495 on the threads
10
Tighten the pad fixing screws to 30÷35 Nm.
To renew the pads of the telescope, proceed as

follows:
11 Remove all pads from the fixed section to extend

the telescope - see instructions above
12 Fully extend the boom, then lower the nose to

the ground and place a stand underneath the
telescope near the fixed section
13 Remove the pin from the extension cylinder (rod

side) - see table GTH5519-013.
Move back with the machine slowly to extend
about 20 cm of the telescope out of the fixed
section

GTH 55-19 7

GTH5519-010
14 Check the internal measure of the fixed section
and the external measure of the telescope to 15
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. Fit new pads after applying a few
drops of Loctite 495 on the threads
Tighten the pad fixing screws to 30÷35 Nm.
15 Clean and grease the internal and external walls

of the boom sections in the sliding points of the
pads. To this end, use
INTERFLON FIN GREASE LS2
16 Retract the telescope into the fixed section and

refit the pin of the extension cylinder
17 With a thickness gauge, ensure the play

between the boom sections is correct in both
positions -i.e. with the boom fully extended and
fully retracted.

GTH 55-19 7
Operation: Renewing the flexible hoses inside Table:

-
the boom
GTH5519-011
Hrs. Min.
Standard tools 2 -
How to renew flexible hoses:

1 Before disconnecting or refitting a flexible hose,
carefully clean the area all around.
containers of suitable size underneath to prevent 2 Blow some compressed air to remove any
oil spillage. impurity.
3 For an easier renewal of the hoses, whose run
is not clearly visible, proceed as follows:
- disconnect the hose to be replaced from both
Plug all disconnected parts to prevent dust or sides
impurities from entering the circuit. They can - tie a cord to one end of the hose
cause serious damage. - remove the hose pulling the cord until it comes
out completely
- untie the cord and tie it to the new hose
Before disconnecting the hydraulic piping, - pull the cord from the other side to refit the
ensure there is no pressure in the line. In case, hose until reaching the connecting point to
release the pressure by operating the control the line.
levers with the engine stopped.
In any case, disconnect the hydraulic piping
with extreme caution and always wear suitable
personal protection equipment -e.g. goggles,
gloves, facial screen, etc.
Wrap up the end of the pipe to be disconnected
with some rags and slowly loosen the pipe
connector so that air comes out as slow as
possible.

GTH 55-19 7

Operation: Renewing the flexible hoses inside the boom Table:
GTH5519-011
Useful advice for mounting flexible hoses:

GTH 55-19 7

36
Attachment rotation cylinder
GTH5519-012
Hrs. Min.


1
Operation:
1 Remove the attachment 2
2 Remove the screw fixing the pin (rod side) with
two 17 mm wrenches


hydraulic piping before disconnecting the
same
6 Using a 13mm wrench, remove the protection

cover from the valve of the attachment rotation 6
cylinder


GTH 55-19 7
Attachment rotation cylinder

GTH5519-012
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
9 Remove the screw fixing the cylinder pin (bottom

side) with two 17 mm wrenches
9

11 Secure the cylinder to the bridge crane with a
textile bridle, then slightly raise the boom to set
the cylinder free
12 Remove the cylinder using the bridge crane

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SERVICE MANUAL

Code 57.4403.3200 - 2nd Edition 01/2008

Handler with telescopic boom

Intentionally blank page

Document 57.4403.3200 - 2nd Edition 01/2008 INDEX

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

The consignee Company stamp

Copy to return stamped and signed for acceptance by the

Document 57.4403.3200 - 2nd Edition 01/2008 INDEX

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

The consignee Company stamp

Document 57.4403.3200 - 2nd Edition 01/2008 INDEX

Revision Revised pages Notes Issued by

Document 57.4403.3200 - 2nd Edition 01/2008 INDEX

Sect. 1 SAFETY RULES

Sect. 2 TECHNICAL SPECIFICATIONS

Sect. 3 SCHEDULED MAINTENANCE INSPECTIONS

Sect. 4 SCHEDULED MAINTENANCE PROCEDURES

Sect. 7 REPAIR PROCEDURES

Document 57.4403.3200 - 2nd Edition 01/2008 INDEX

Machine denomination Literature valid up to serial number

from 17548 to 17565, from 17822 to 17825,

Document 57.4403.3200 - 2nd Edition 01/2008 INDEX

© Copyright 2007 TEREXLIFT srl - All rights reserved.

Document 57.4403.3200 - 1st Edition 06/2007 INDEX

DESCRIPTION OF THE MACHINE OPERATION

The mechanical energy source of this machine is a Perkins

Document 57.4403.3200 - 1st Edition 06/2007 INDEX

the drive circuit. The max displacement of this bent-axis

Document 57.4403.3200 - 1st Edition 06/2007 INDEX

with a special double-acting compensation valve. Inside

The special hydraulic block (21) has been designed

Document 57.4403.3200 - 1st Edition 06/2007 INDEX

pressure switch (28). This pressure switch prevents the

The circuit of the service brake is operated by a SAFIM

Document 57.4403.3200 - 1st Edition 06/2007 INDEX

GTH 55-19 hydraulic schematic

Document 57.4403.3200 - 1st Edition 06/2007 INDEX

1.1 Safety rules ...........................................................................................page 2

Document 57.4403.3200 - 1st Edition 06/2007 INDEX

1.1 SAFETY RULES

1.1-1 Personal Safety Draws the attention to important technical information

Draws the attention to situations that involve your

Draws the attention to situations that involve your

Draws the attention either to situations that involve

Draws the attention either to situations that involve

Document 57.4403.3200 - 1st Edition 06/2007 INDEX

1.1-2 Workplace Safety

Be sure to keep sparks, flames and

Be sure that all tools and working areas are

Be sure that your workshop or work area is

Be sure any forklift, overhead crane or other

Be sure that fasteners intended for one time

Be sure to properly dispose of old oil or other

Document 57.4403.3200 - 1st Edition 06/2007 INDEX

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