Terex Genie GTH-5519 User manual

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

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GTH 55-19
2
Intentionally blank page

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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.

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

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INDEX
GTH 55-19
LIST OF REVISED PAGES
4
Revision Revised pages Notes Issued by
No. Date
1 06-2007 Publication
2 01-2008 Section 2, 5, 6 Revision
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Document 57.4403.3200 - 2nd Edition 01/2008 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
GENERAL INDEX
5

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GTH 55-19
SERIAL NUMBER IDENTIFICATION
6
Machine denomination Literature valid up to serial number
GTH 55-19 from 17548 to 17565, from 17822 to 17825,
from 18154 to 18168, from 18556 to 18586

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INTRODUCTION
i
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 qualied 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 specic
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 modications.
Contact Us
http://www.terexlift.com
e-mail: [email protected]
http://www.genielift.com
© Copyright 2007 TEREXLIFT srl - All rights reserved.

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INTRODUCTION
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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 ywheel 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 DAtype.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 ow
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 xed 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 ow 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 lter (8), placed inside the hydraulic uid
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
lter (34), placed in the line returning to pump (3), puries
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 lter 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 lter 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
ush valve (36) for reducing the max temperatures inside

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the drive circuit. The max displacement of this bent-axis
motor is 107 cm3/rev.
The motor is directly anged 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 ow
to the hydraulic drive is exactly the one needed for the
instantaneous steering functions; any excess ow 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 specic 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

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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-t 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 ow 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,theattachmentholdingplaterotationmovement
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 ow). The pressure reducing
valve with screw adjustment (38), when operated together
with solenoid valve (30), allows to adjust the oil ow 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

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INTRODUCTION
v
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 lter (34) and nally 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.

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INTRODUCTION
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GTH 55-19 hydraulic schematic

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GTH 55-19
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

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1.1 SAFETY RULES
1.1-1 Personal Safety
In this manual, any important information is preceded by
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,
always combined with keywords that class the situations
according to their danger degree.
The symbols are always followed by a text explaining
the situation taken into account, the attention to be paid
to such situation, the method and the behaviour to be
adopted. When necessary, it stresses prohibitions or
supplies instructions to prevent dangers.
Sometimes, it can be followed by illustrations.
We list below the special (or safety) symbols according
to the relative seriousness of the hazard situation:
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 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 efciency.
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 efciency.
Drawstheattentionto important technicalinformation
or practical advice that allows for a safer and more
efcient use of the machine.
Draws the attention to important environment-related
information.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards such
as moving parts, free swinging or unsecured
components when lifting or placing loads.
Always wear approved steel-toed shoes.

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GTH 55-19
SAFETY
1.1-2 Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from ammable and
combustible materials like battery gases
and engine fuels. Always have an approved
re 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
uids. Use an approved container. Please
be environmentally safe.

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SAFETY
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1.2 GENERAL REMARKS
Most accidents occurring while working, servicing or
maintaining operation machines, are caused by not
complying with the basic safety precautions.
Therefore, it is necessary to pay steady attention to
the potential hazards and the effects that may come of
operations carried out on the machine.
If you recognise hazardous situations, you can
prevent accidents!
For instance, this handbook makes use of special safety
symbols to highlight potentially hazardous situations.
The instructions given in this handbook are the ones
established by GENIE. They do not exclude other
safe and most convenient ways for the machine
commissioning, operation and maintenance that take
into account the available spaces and means.
If you decide to follow instructions other than those given
in this manual, you must:
• be sure that the operations you are going to carry
out are not explicitly forbidden;
• be sure that the methods are safe and in compliance
with the indications given in this section;
• be sure that the methods cannot damage the machine
directly or indirectly or make it unsafe;
• contact GENIE Assistance Service for any suggestion
and the necessary written permission.
Do not hesitate to pose questions if you are in
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.
1.3 SERVICEMEN'S REQUISITES
The operators who use the machine regularly or
occasionally (e.g. for maintenance or transport) shall
have the following requisites:
health:
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.
physical:
good eyesight, acute hearing, good co-ordination and
ability to carry out all required operations in a safe way,
according to the instructions of this manual.
mental:
ability to understand and apply the rules, regulations and
safety precautions. They shall be careful and sensible
for their own as well as for the others’ safety and shall
desire to carry out the work correctly and in a responsible
way.
emotional:
they shall keep calm and always be able to evaluate their
own physical and mental conditions.
training:
they shall read and familiarise with this handbook, its
enclosed graphs and diagrams, the identication and
hazard warning plates. They shall be skilled and trained
about the machine use.
It is recommended to take part in at least one technical
training course organised by GENIE Assistance
Ofce.
Ordinary and extraordinary maintenance of the
machineare quite complex from a technical point
of view and should be performed by an authoirsed
service centre.

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SAFETY
1.3-1 PERSONAL PROTECTIVE EQUIPMENT
During work, but especially when maintaining or repairing
the machine, operators must wear suitable protective
clothing and equipment:
• Overalls or any other comfortable garments.
Operators should wear neither clothes with large
sleeves nor objects that can get stuck in moving parts
of the machine
• Protective helmet when working under or in the
vicinity of suspended load
• Protective gloves
• Working shoes
• Breathing set (or dust mask)
• Ear-protectors or equivalent equipment
• Goggles or facial screen.
Use only type-approved protective equipment
in good condition.
1.4 SAFETY PRECAUTIONS
Read and understand the following safety instructions
before servicing the machine.
The following list contains safety rules which must
absolutely be obeyed to prevent accidents and
injuries.
1.4-1 WORKING AREA
• Make sure the area all around the machine is safe.
Always be aware of potential risks.
• During work, keep the working area in order. Never
leave objects scattered: they could hinder the
machine movements and represent a danger for
personnel.
1.4-2 PRECAUTIONS DURING WORK
• 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 sufcient 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 efcient.
• Do not carry out interventions on electric components
with voltage over 48V.

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• 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
safety devices, covers, guards,. Should their removal
be necessary, stop the engine, remove them with
the greatest care and always remember to ret them
before starting the engine and using the machine
again.
• Aleays stop the engine and disconnect the batteries
before maintenance or service.
• Do not lubricate, clean or adjust moving parts.
• Do not carry out operations manually when specic
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 uid.
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 ngers to check for pressure leaks.
Fine jets of air, oil or fuel can injure you.
• Neither smoke nor use open ames if there is a risk
of re or close to fuel, oil or batteries.
• Do not leave fuel cans or bottles in unsuitable
places.
• Do not empty catalytic mufers 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.
Treatment and disposal of used oils is subject to
federal, national and local laws and regulations.
Collect and deliver these wastes to authorised
centres.
• Use the assistance of a second person to handle
loads weighing 30 to 50 kg.
• For loads over 50 kg, the use of special hoisting
equipment in good condition and equipped as per
enforced regulations is mandatory.