handler with telescopic boom gth 55-19 - genieliftmanuals.gogenielift.com/parts and service...
Post on 04-Apr-2020
2 Views
Preview:
TRANSCRIPT
INDEXEnglish
Edition
Handler with telescopic boom
GTH 55-19
(from serial number 10242 to serial number 18818)
WORKSHOP MANUALCode 57.4401.8200 - 2nd Edition 05/2007
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
3
GTH 55-19
WORKSHOP MANUALCode 57.4401.8200 - 2nd Edition 05/2007
Number: ....................................
Consigned to: ................................................................................................................................
INDEX
DECLARATION
I, the undersigned..............................................................................................................................
declare that I have received the Workshop manual for GENIE lifts series GTH 55-19.
Copies consigned: n° ...... on paper
n° ...... on CD-Rom
The undersigned is obliged to use the manual in their workshop, without disclosing the informa-
tion in the same in any way, to unauthorised workshops and third parties in general, and not to
photocopy or reproduce this manual or parts of the same in any way without the prior written
authorisation of TEREXLIFT to do so.
If business relations between the undersigned and GENIE should come to an end, the undersigned
is obliged to return the copies received without charges for GENIE.
Yours sincerely
date ............................
For acceptance
The consignee Company stamp
and signature of the Legal representative
...........................................
Copy to return stamped and signed for acceptance by theLegal representative of the company receiving the copies of the manual.
WORKSHOP MANUALCode 57.4401.8200 - 2nd Edition 05/2007
Number: ....................................
Consigned to: ................................................................................................................................
DECLARATION
I, the undersigned..............................................................................................................................
declare that I have received the Workshop manual for GENIE lifts series GTH 55-19.
Copies consigned: n° ...... on paper
n° ...... on CD-Rom
The undersigned is obliged to use the manual in their workshop, without disclosing the informa-
tion in the same in any way, to unauthorised workshops and third parties in general, and not to
photocopy or reproduce this manual or parts of the same in any way without the prior written
authorisation of TEREXLIFT to do so.
If business relations between the undersigned and GENIE should come to an end, the undersigned
is obliged to return the copies received without charges for GENIE.
Yours sincerely
date ............................
For acceptance
The consignee Company stamp
and signature of the Legal representative
...........................................
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
3
GTH 55-19
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
6
GTH 55-19
Revision Revised IssuedNo. date pages Notes by
1 04-2006 Publicated
2 05-2007 Sect. C Manual revision
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
LIST OF REVISED PAGES
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
7
GTH 55-19
MANUAL CONTENTS
Sect. A GENERAL INFORMATION
Sect. B SAFETY REGULATIONS
Sect. C TECHNICAL OPERATION DATA
Sect. D CHECKS AND ADJUSTMENTS
Sect. E DISMANTLING AND REASSEMBLY
Sect. F TROUBLESHOOTING
Sect. G DANA AXLE ASSEMBLY/DISMANTLING
Sect. H DEUTZ ENGINE MAINTENANCE
Sect. I REPAIR INSTRUCTIONS - REXROTH PUMP
Sect. L REPAIR INSTRUCTIONS - REXROTH MOTOR
CONTENTS
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
8
GTH 55-19
SERIAL NUMBER IDENTIFICATION
Machine denomination Literature valid up to serial number
GTH 55-19 xxxxxx
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
1
GTH 55-19
TECHNICAL OPERATING DATA
Section CTECHNICAL OPERATING DATA
SECTION INDEX
C.01 Principles of hydraulics ...............................................................................
C.02 Hydraulic symbols ............................................................................... page 3
C.03 Hydraulic schemes ...................................................................................... 4
C.04 Electrical symbols ........................................................................................ 5
C.05 Wiring diagrams ........................................................................................... 6
C.06 Cylinder size ................................................................................................. 27
C.07 Control lever ................................................................................................. 32
C.08 Hydraulic main valve .................................................................................... 33
C.09 Pumps and motors ....................................................................................... 34
C.10 Valves ............................................................................................................ 36
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
2
GTH 55-19
TECHNICAL OPERATING DATA
Intentionally blank page
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
3
GTH 55-19
TECHNICAL OPERATING DATA
Emergency controls
ACTUATORS
Pushbutton control
Rotary control
Pedal control
Proximity control
Lever control
Timed control
Mechanical/manual control
Key control
Resistance
RESISTANCES
Resistor
Potentiometer
Variable resistance
Intermittent lamp
SIGNALS
Whistle
Lamp
Buzzer
Siren
Bell
Horn
Horizontal fuse
FUSES AND RELAYS
Relay
Battery
ACCUMULATORS
Thermocouple
Element
Ring
TERMINALS AND GROUNDS
Ground
Terminal
Ground to frame
Knot
Protection ground
Frame ground 2
Coil
COILS
Mechanical coupling coil
Winding
A/C coil
Coil with diode
Winding with diode
Connector
CONNECTORS
Auto-transformer
STATIC APPLICATIONS
Transformer
Motor
DYNAMICAPPLICATIONS
M
G Generator
M3
As_3p_motor
Rectifier
ELECTRONIC PARTS
- +
Light-emitting diode
Diode
Condenser
Manual NC contact
PUSHBUTTONS
Manual NO contact
NC mushroom-headpushbutton
NO mushroom-headpushbutton
NC level
NO level
Pushbutton with NCreturn
Pushbutton with NOreturn
NC tie-rod
NO tie-rod
C.02 HYDRAULIC SYMBOLS
Thermal
CONTACTS
Normally open (NO)
Normally closed (NC)
NO limit switch
NC limit switch
Contactor
Magneto-thermal closure
Thermal closure
Thermal opening
Exchange
NC proximity
NO proximity
NO mechanical
NC mechanical
Selector
Selector2
Magneto-thermal opening
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
4
GTH 55-19
TECHNICAL OPERATING DATA
General hydraulic scheme
C.03
M
X1X2 G MH S
AA
M1X1X2
TG
T1 PS Fa Fa1 Fe
b
MB
a
T2R
B BU
MAFS
CF EF
LS
LS
LR
TP
P1 4 23T
X
Y
A1
X1
X2
X3
X4
B1
B3
A3
B2
A2
A4
B4
T
P
C
Y1
Y2
Y3
Y4
P
T R
Engine
Hydrostatictransmission
pump
Hydrostatictransmission
motor
Flushing valve
Function pumpwith integratedpriority valve
21.7 gpm / 82 L/min
Suctionfilter
Suctionfilter
Heatexchanger
Check valve7 psi / 0.5 bar
Anti cavitationvalves72 psi / 5 bar
Check valve7 psi / 0.5 bar
Check valve7 psi / 0.5 bar
Check valve36 psi / 2.5 bar
Check valve36 psi / 2.5 bar
Thank
Accumulatorcapacity: 0.13 gallons / 0.5 Liters
pre-charge pressure: 725 psi / 50 bar
Boom functionspiloting selector valve
Shuttlevalve
Continous flowselector valve
Load handlingcontrol lever
Load handlingcontrols
main valve
Steeringrotatingactuator
Front axle
Service brakecircuit reservoir
Service brakepedal pump
Pressure reducingvalve
Hydrauliccollector
Parking brakeselector valve
Parking brakecontrol valve
0.02 in0.5 mm
7 psi0.5 bar
Slavecylinder
Boom extendretract cylinder
Boom liftcylinder
Tiltcylinder
4:14350 psi300 bar
11:14350 psi300 bar
4:14350 psi300 bar
4.2:14350 psi300 bar
3915 psi270 bar
4205 psi290 bar
6525 psi450 bar
362 psi25 bar
725 psi50 bar
6525 psi450 bar
6235 psi430 bar
2465 psi170 bar
3262 psi225 bar
406 psi28 bar
Quick couplinghydraulic ports
Forks attachmentquick coupling cylinder
Steering modeselector valve
Front axlesteering cylinder
Rear axlesteering cylinder
TP2
TP4
TP3
TP1
Piloted checkvalve 4:1
1
1
2
2
3
3
A B
CD E FG H
A B
T P
E U
DR
P1
P2
T
A
P
B
Boom functions hydrauliccircuit test port
Hydrostatic transmissionhigh pressure test port
Hydrostatic transmissionboost pressure test port
Hydraulic piloting linetest port
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
5
GTH 55-19
TECHNICAL OPERATING DATA
C.04 ELECTRICAL SYMBOLS
Emergency controls
ACTUATORS
Pushbutton control
Rotary control
Pedal control
Proximity control
Lever control
Timed control
Mechanical/manual control
Key control
Resistance
RESISTANCES
Resistor
Potentiometer
Variable resistance
Intermittent lamp
SIGNALS
Whistle
Lamp
Buzzer
Siren
Bell
Horn
Horizontal fuse
FUSES AND RELAYS
Relay
Battery
ACCUMULATORS
Thermocouple
Element
Ring
TERMINALS AND GROUNDS
Ground
Terminal
Ground to frame
Knot
Protection ground
Frame ground 2
Coil
COILS
Mechanical coupling coil
Winding
A/C coil
Coil with diode
Winding with diode
Connector
CONNECTORS
Auto-transformer
STATIC APPLICATIONS
Transformer
Motor
DYNAMICAPPLICATIONS
M
G Generator
M3
As_3p_motor
Rectifier
ELECTRONIC PARTS
- +
Light-emitting diode
Diode
Condenser
Manual NC contact
PUSHBUTTONS
Manual NO contact
NC mushroom-headpushbutton
NO mushroom-headpushbutton
NC level
NO level
Pushbutton with NCreturn
Pushbutton with NOreturn
NC tie-rod
NO tie-rod
Thermal
CONTACTS
Normally open (NO)
Normally closed (NC)
NO limit switch
NC limit switch
Contactor
Magneto-thermal closure
Thermal closure
Thermal opening
Exchange
NC proximity
NO proximity
NO mechanical
NC mechanical
Selector
Selector2
Magneto-thermal opening
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
6
GTH 55-19
TECHNICAL OPERATING DATA
Wiring diagram - page 1 of 6 (up to serial no. 16979)
C.05.01
+
-
RDø5
0BK
ø50
M
BNø6
BNø6
RDø1
0
BUø4
D+W
B+
BU/R
Dø1
RDø1
0 BUø2
.5
X11
1X2
5015
30
58
2 310P
RDø6
RDø4
19
BNø4
VTø1
.5
30
15
X34
8787A85
BUø1
.5
30
BN/B
Kø1
OG
/GNø
1
86
VTø1
.5
BKø1
27X4
BUø4
BKø1
RDø6
BUø1
.5
30 86
87 85
BNø6
BNø6
50A
WHø
6
50A
RDø6
RDø5
0
8550T
BUø1
BKø1
3086 87
WH/
RDø1
WHø
6
WHø
6VT
/WHø
1.5
L
WHø
6
15X4
BNø2
.5W
H/RD
ø1.5
10A
X27
RD/BKø1
VT/WHø1
X425
18X2 X5
5
10A
RD/B
Kø1
BNø2
.5
7X2
23X4
X216
4
OG
ø1
3FNR
FN
+
PK/B
Kø1.
51
R
BN/B
Kø1.
5
3X2
BNø2
.5
F13
PKø1
.510
A
7X2
1X3X2
2
BATT
ERY
F05 F04
15
30 2/G10
2/G10
4/C7BU/RDø1
2/A1031
OG/GNø1.53/C9
3/C3
BN/BKø1.5
3/B8
3/C9PKø1.5
5/F2WH/RDø1.5
4/C7
2/C9
SW01
A01
SW02 M01
X17
M02 Y01
X21
K02
SW03
H01
RD/BKø1
RD/BKø1
RD/BKø1
F30 F31 K11R01
A02
X25
PREH
EATI
NGCO
NTRO
LUN
IT M
AXI F
USE
STAR
TER
MO
TOR
ALTE
RNAT
OR
ADDI
TIO
NAL
FUEL
SOLE
NOID
VAL
VE
SYST
EMPR
OTE
CTIO
NFU
SE
STAR
TING
RELA
Y
GLO
W P
LUG
S
PREH
EATI
NGCO
NTRO
L UN
IT
DISC
ONN
ECTI
ON
BATT
ERY
1234567810 9
A
B
C
D
E
F
G
910 8 7 6 5 4 3 2 1
G
F
E
D
C
B
A
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
7
GTH 55-19
TECHNICAL OPERATING DATA
Wiring diagram - page 2 of 6 (up to serial no. 16979)
C.05.02
87A 8785
RD/B
Kø1
86
RDø2
.5
30K01
BKø1
YE/G
Nø2.
5
6X2
10A
YE/B
Kø1.
5YE
/GNø
2.5
F02
GN/
BKø1
.510
AF03
X311
BKø1
YE/BKø1.5
X312
1X6
YE/G
Nø1.
5
BKø1
.5
X662
X3
YEø1BKø1
YEø1.5GN/BKø1.5
X421
10X3
31 3/A10
3/G10
3/G1030
151/G1
1/G1 30
15
311/A1
1/F2RD/BKø1
YE/G
Nø2.
5SW04
YE/GNø1.5
YE/GNø1.5
H02
X11 X11H03
YEø1
.5BK
ø1.5
SW05
1X14
X142
REAR
WO
RK L
IGHT
OPT
IONA
L
FRO
NT W
ORK
LIG
HT S
WIT
CHO
PTIO
NAL
FRO
NTW
ORK
LIG
HTO
PTIO
NAL
REAR
WO
RKLI
GHT
SW
ITCH
OPT
IONA
L
8
1
2
3 6
5
4
78
1
2
3 6
5
4
7
1234567810 9
A
B
C
D
E
F
G
910 8 7 6 5 4 3 2 1
G
F
E
D
C
B
A
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
8
GTH 55-19
TECHNICAL OPERATING DATA
Wiring diagram - page 3 of 6 (up to serial no. 16979)
C.05.03
OG
/BKø
1
30K05
PKø1
.5
8787A
BKø1
RD/G
Nø1
RD/G
Nø1
OG
ø1
86 30
TQ/R
Dø1
RDø1
K033086
OG
/GNø
1.5
PKø1
.5
87A85 87 87A85 87
86
85
BN/B
Kø1.
5RD
/GNø
1
2/A1 31
15
302/G1
2/G1 15
30 4/G10
4/G10
4/A1031
1/F7
PK/BKø1.51/E5
BKø1
1
OG
ø1
212v
RDø1
RD/B
Kø1
X565
X5
RD/BKø11/F2
RD/B
Kø1
GY/
BUø1
X46
12X2
BKø1
RDø1
WH/YEø1
RDø1
78BKø11
4
32
56
OG/YEø1
RD/BKø1
12X4
X36
4/F9
12v2
OG
/YEø
1
1
5X3
5/F1
X411
OG
/BKø
1
13X4
+ -
BN/BKø1.51/E7
4
7
5BUø1BN/GNø1BN/GNø1
6
P
8
1
2
GY/WHø1
BKø1TQ/RDø1
3GY/WHø1
BUø1
BKø1
X27
5ABN
/GNø
1BN
ø2.5
F08
GY/WHø14/C6
JOYSTICK
CX7
X7AB
X7
BNø2
.5BN
/BKø
17.
5A
G9GR
15X2
5/G9
BN/BKø1
SS01
Y02
GY/
BUø1
X18 X18SS02
X10X10
OG/GNø1.5
K04
H04SW06
SW07
SW08
WH/OGø1
F12
Y03 Y04
Y05 HA01
BKø1
BKø1
OG
/BKø
1BK
ø1
X241
2X24
OG/YEø1
X45
17X4
ATTA
CHM
ENT
COUP
LING
/RE
LEAS
ESO
LENO
ID V
ALVE
HYDR
AULI
C ST
OP
AIR
FILT
ERCL
OG
GIN
GSE
NSO
R
SOLE
NOID
VAL
VEFW
D SP
EED
PARK
ING
BRA
KESW
ITCH
PARK
ING
BRA
KESO
LENO
ID V
ALVE
REVE
RSE
SPEE
DSO
LENO
ID V
ALVE
BACK
-UP
HORN
21
12v
21
12v
1234567810 9
A
B
C
D
E
F
G
910 8 7 6 5 4 3 2 1
G
F
E
D
C
B
A
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
9
GTH 55-19
TECHNICAL OPERATING DATA
Wiring diagram - page 4 of 6 (up to serial no. 16979)
C.05.04
+-
00 00 0 0 3
4X5
31 5/A10
5/G10
5/G1030
153/G1
3/G1 30
15
313/A1
7BKø1
5
6OG/YEø1
4
8
2
3
1
BU/RDø1.5
TQ/GNø1
F07
BNø2
.5BU
/RDø
1.5
5A
7X2
BKø1
TQ/G
Nø1
3/C3
J14
J15
J13
J10J11
J4J1
J12
PKø1
RD/B
Kø1
GY/
YEø1
GY/
WHø
1
WH/
BUø1
J5
J6
J2J3J9
J8
J7
YEø1BK
ø1
WH/
GNø
1
BU/R
Dø1
BU/R
Dø1
GY/
RDø1
WH/GNø15/E2
1/F8BU/RDø1
4X4
X2916
X2
X423
P
GY/
RDø1
X27
7.5A
VT/W
Hø1
BNø2
.5
F11
8X3
9X3
S-+
BKø1
YEø1
S+ -
GN/
RDø1
RD/B
Kø1
BKø1
1/F2
RD/BKø1
X214
22X4
BKø1
PKø1
GY/
YEø1
X49
5X2X2
13
GY/WHø1
3/C6
X48
2X5
BKø1
WH/
BUø1
RD/BKø1
3/C8
X51
26X4
RD/G
Nø1
T
GN/
RDø1
GY/
GNø
1
T
X416
11X2
5/E4VT/WHø1
Y06
SW09
P01
OG/YEø1
BU/RDø1.5TQ/GNø1
SS03 SS04SS05
X22X19 X19
SS06
X16
SS07
X20
P02 P03
YEø1
BKø1
BKø1
RD/B
Kø1
GY/
GNø
1
X19
X43
HYDR
AULI
C O
ILTE
MPE
RATU
RESE
NSO
R
ENG
INE
OIL
TEM
PERA
TURE
SENS
OR
ENG
INE
OIL
TEM
PERA
TURE
GAU
GE
VSE
SOLE
NOID
VALV
E SW
ITCH
HYDR
AULI
C O
ILTE
MPE
RATU
REG
AUG
E
FUEL
FLO
AT
ENG
INE
OIL
PRES
SURE
TRAN
SDUC
ER
VSE
SOLE
NOID
VALV
E
NEG
ATIV
E BR
AKE
PRES
SURE
SWIT
CH
21
12v
A
B
C
D
E
F
G
1234567810 9
G
F
E
D
C
B
A
910 8 7 6 5 4 3 2 1
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
10
GTH 55-19
TECHNICAL OPERATING DATA
Wiring diagram - page 5 of 6 (up to serial no. 16979)
C.05.05
4/A1 31
15
304/G1
4/G1 15
30
31
YE/R
Dø1
PK/Y
Eø1
BN/B
Kø1
CA
FE
BKø1
BU/RDø1
B
X24
1X4
BKø1
1
PK/Y
Eø1
212v 12v
2
YE/R
Dø1
1
BKø1
X42
7X3
78BKø1
VTø11
4
32
56
GY/RDø1.5
F06
X27
10A
GY/
RDø1
.5BN
ø2.5
X210
X47
3X3
VTø1
BKø1
7BKø1
5
4
6
8
1
2
3BN/RDø1
WH/BKø1.5
WH/BKø1
M
BN/R
Dø1
BKø1
BNø2
.5W
H/BK
ø1.5
5A
7X2
F10
BKø1
.5BU
/BKø
1.5
M
X27
15A
BU/B
Kø1.
5BN
ø2.5
BKø1
VT/W
Hø1
M
RDø1
.5BK
ø1
F09
2X6 X6
4
2ARD
ø1.5
RDø4
F01
X63
X26
5X6
YE/R
Dø1.
5
28X4
WH/
RDø1
.5BK
ø1.5
WH/
GNø
1
T
4/C7WH/GNø1
X217
14X4
12v2
WH/
OG
ø1
1
BKø1
X429
AX7
3/F1
3/C1
BN/BKø1
VT/WHø14/C5
1/D3
WH/RDø1.5
Y07 Y08
HA02M03 M04
H05H06
Y09SS08
Y10
X23
SW10
SW12SW11
WH/
OG
ø1
X15
X15 X9
X9
1
2
X13X13 X12X12
1X8
X82
24X4
EXTE
ND/R
ETRA
CTBO
OM
SO
LENO
IDVA
LVE
REAR
WIN
DSCR
EEN
WIP
ER/W
ASHE
RM
OTO
RO
PTIO
NAL
WIN
DSCR
EEN
WIP
ER/W
ASHE
RSW
ITCH
OPT
IONA
L
FRO
NTW
INDS
CREE
NW
IPER
/WAS
HER
MO
TOR
OPT
IONA
L
HORN
ENG
INE
STO
PSO
LENO
ID
STEE
RING
SELE
CTO
R
BEAC
ON
CAB
LIG
HTIN
G
HORN
SW
ITCH
OPT
IONA
LFL
ASHI
NGCO
NNEC
TOR
ENG
INE
OIL
COO
LING
TEM
PERA
TURE
SENS
OR
PARA
LLEL
WHE
EL S
TEER
ING
SOLE
NOID
VAL
VE
FOUR
WHE
ELST
EERI
NGSO
LENO
ID V
ALVE
1234567810 9
A
B
C
D
E
F
G
910 8 7 6 5 4 3 2 1
G
F
E
D
C
B
A
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
11
GTH 55-19
TECHNICAL OPERATING DATA
Wiring diagram - page 6 of 6 (up to serial no. 16979)
C.05.06
Other componentsA##
R##
P##
M##
K##
HA##
H##
F##
Lamp, light
Indicator
Potentiometer
Switces, selector
Solenoid valve
Sensor, microswitches, pressure switches, transducer
Fuse
Clacson or back-up horn
Motor engine or pump
Resistance
DescriptionLabel
Relè
RP##
SW##
SS##
Y##
X## Connectors
LIST OF ABBREVIATION
TurquoiseTQ
PK
WH
GY
VT
Orange
Acronym Colour
Blue
Yellow
Red
Black
COLOUR TABLE
White
Pink
Grey
Violet
Green
Brown
BK
BN
RD
OG
YE
GN
BU
A
B
C
D
E
F
G
1234567810 9
G
F
E
D
C
B
A
910 8 7 6 5 4 3 2 1
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
12
GTH 55-19
TECHNICAL OPERATING DATA
Wiring diagram - page 1 of 6 (from serial no. 16980)
C.05.07
+
-
RDø5
0BK
ø50
M
BNø6
BNø6
RDø1
0
BUø4
D+W
B+
BU/R
Dø1
RDø1
0 BUø2
.5
X11
1X2
5015
30
58
2 310P
RDø6
RDø4
19
BNø4
VTø1
.5
30
15
X34
8787A85
BUø1
.5
30
BN/B
Kø1
OG
/GNø
1
86
VTø1
.5
BKø1
27X4
BUø4
BKø1
RDø6
BUø1
.5
30 86
87 85
BNø6
BNø6
50A
WHø
6
50A
RDø6
RDø5
0
8550T
BUø1
BKø1
3086 87
WH/
RDø1
WHø
6
WHø
6VT
/WHø
1.5
L
WHø
6
15X4
BNø2
.5W
H/RD
ø1.5
10A
X27
RD/BKø1
VT/WHø1
X425
18X2 X5
5
10A
RD/B
Kø1
BNø2
.5
7X2
23X4
X216
4
OG
ø1
3FNR
FN
+
PK/B
Kø1.
51
R
BN/B
Kø1.
5
3X2
BNø2
.5
F13
PKø1
.510
A
7X2
1X3X2
2
BATT
ERY
F05 F04
15
30 2/G10
2/G10
4/C7BU/RDø1
2/A1031
OG/GNø1.53/C9
3/C3
BN/BKø1.5
3/B8
3/C9PKø1.5
5/F2WH/RDø1.5
4/C7
2/C9
SW01
A01
SW02 M01
X17
M02 Y01
X21
K02
SW03
H01
RD/BKø1
RD/BKø1
RD/BKø1
F30 F31 K11R01
A02
X25
PREH
EATI
NGCO
NTRO
LUN
IT M
AXI F
USE
STAR
TER
MO
TOR
ALTE
RNAT
OR
ADDI
TIO
NAL
FUEL
SOLE
NOID
VAL
VE
SYST
EMPR
OTE
CTIO
NFU
SE
STAR
TING
RELA
Y
GLO
W P
LUG
S
PREH
EATI
NGCO
NTRO
L UN
IT
DISC
ONN
ECTI
ON
BATT
ERY
1234567810 9
A
B
C
D
E
F
G
910 8 7 6 5 4 3 2 1
G
F
E
D
C
B
A
8787A85
3086K07
3/F10
3/E8PK
PARK
ING
BRA
KELI
NE P
RESS
URE
SWIT
CH
5/E6WH/BUø1
F12
BNPK
RD/G
N
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
13
GTH 55-19
TECHNICAL OPERATING DATA
Wiring diagram - page 2 of 6 (from serial no. 16980)
C.05.08
87A 8785
RD/B
Kø1
86
RDø2
.5
30K01
BKø1
YE/G
Nø2.
5
6X2
10A
YE/B
Kø1.
5YE
/GNø
2.5
F02
GN/
BKø1
.510
AF03
X311
BKø1
YE/BKø1.5
X312
1X6
YE/G
Nø1.
5
BKø1
.5
X662
X3
YEø1BKø1
YEø1.5GN/BKø1.5
X421
10X3
31 3/A10
3/G10
3/G1030
151/G1
1/G1 30
15
311/A1
1/F2RD/BKø1
YE/G
Nø2.
5SW04
YE/GNø1.5
YE/GNø1.5
H02
X11 X11H03
YEø1
.5BK
ø1.5
SW05
1X14
X142
REAR
WO
RK L
IGHT
OPT
IONA
L
FRO
NT W
ORK
LIG
HT S
WIT
CHO
PTIO
NAL
FRO
NTW
ORK
LIG
HTO
PTIO
NAL
REAR
WO
RKLI
GHT
SW
ITCH
OPT
IONA
L
8
1
2
3 6
5
4
78
1
2
3 6
5
4
7
1234567810 9
A
B
C
D
E
F
G
910 8 7 6 5 4 3 2 1
G
F
E
D
C
B
A
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
14
GTH 55-19
TECHNICAL OPERATING DATA
Wiring diagram - page 3 of 6 (from serial no. 16980)
C.05.09
OG
/BKø
1
30K05
PKø1
.5
8787A
BKø1
PKRD/G
Nø1
OG
ø1
86 30
TQ/R
Dø1
RDø1
K033086
OG
/GNø
1.5
PKø1
.5
87A85 87 87A85 87
86
85
BN/B
Kø1.
5RD
/GNø
1
2/A1 31
15
302/G1
2/G1 15
30 4/G10
4/G10
4/A1031
1/F7
PK/BKø1.51/E5
BKø1
1
OG
ø1
212v
RDø1
RD/B
Kø1
X565
X5
RD/BKø11/F2
RD/B
Kø1
GY/
BUø1
X46
12X2
BKø1
RDø1
WH/YEø1
RDø1
78BKø11
4
32
56
OG/YEø1
RD/BKø1
12X4
X36
4/F9
12v2
OG
/YEø
1
1
5X3
5/F1
X411
OG
/BKø
1
13X4
+ -
BN/BKø1.51/E7
4
7
5BUø1BN/GNø1BN/GNø1
6
P
8
1
2
GY/WHø1
BKø1TQ/RDø1
3GY/WHø1
BUø1
BKø1
X27
5ABN
/GNø
1BN
ø2.5
F08
GY/WHø14/C6
JOYSTICK
CX7
X7AB
X7
BNø2
.5BN
/BKø
17.
5A
G9GR
15X2
5/G9
BN/BKø1
SS01
Y02
GY/
BUø1
X18 X18SS02
X10X10
OG/GNø1.5
K04
H04SW06
SW07
SW08
WH/OGø1
F12
Y03 Y04
Y05 HA01
BKø1
BKø1
OG
/BKø
1BK
ø1
X241
2X24
OG/YEø1
X45
17X4
ATTA
CHM
ENT
COUP
LING
/RE
LEAS
ESO
LENO
ID V
ALVE
HYDR
AULI
C ST
OP
AIR
FILT
ERCL
OG
GIN
GSE
NSO
R
SOLE
NOID
VAL
VEFW
D SP
EED
PARK
ING
BRA
KESW
ITCH
PARK
ING
BRA
KESO
LENO
ID V
ALVE
REVE
RSE
SPEE
DSO
LENO
ID V
ALVE
BACK
-UP
HORN
21
12v
21
12v
1234567810 9
A
B
C
D
E
F
G
910 8 7 6 5 4 3 2 1
G
F
E
D
C
B
A
1/E3RD/GNø1
1/D4
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
15
GTH 55-19
TECHNICAL OPERATING DATA
Wiring diagram - page 4 of 6 (from serial no. 16980)
C.05.10
+-
00 00 0 0 3
4X5
31 5/A10
5/G10
5/G1030
153/G1
3/G1 30
15
313/A1
7BKø1
5
6OG/YEø1
4
8
2
3
1
BU/RDø1.5
TQ/GNø1
F07
BNø2
.5BU
/RDø
1.5
5A
7X2
BKø1
TQ/G
Nø1
3/C3
J14
J15
J13
J10J11
J4J1
J12
PKø1
RD/B
Kø1
GY/
YEø1
GY/
WHø
1
WH/
BUø1
J5
J6
J2J3J9
J8
J7
YEø1BK
ø1
WH/
GNø
1
BU/R
Dø1
BU/R
Dø1
GY/
RDø1
WH/GNø15/E2
1/F8BU/RDø1
4X4
X2916
X2
X423
P
GY/
RDø1
X27
7.5A
VT/W
Hø1
BNø2
.5
F11
8X3
9X3
S-+
BKø1
YEø1
S+ -
GN/
RDø1
RD/B
Kø1
BKø1
1/F2
RD/BKø1
X214
22X4
BKø1
PKø1
GY/
YEø1
X49
5X2X2
13
GY/WHø1
3/C6
X48
2X5
BKø1
WH/
BUø1
RD/BKø1
3/C8
X51
26X4
RD/G
Nø1
T
GN/
RDø1
GY/
GNø
1
T
X416
11X2
5/E4VT/WHø1
Y06
SW09
P01
OG/YEø1
BU/RDø1.5TQ/GNø1
SS03 SS04SS05
X22X19 X19
SS06
X16
SS07
X20
P02 P03
YEø1
BKø1
BKø1
RD/B
Kø1
GY/
GNø
1
X19
X43
HYDR
AULI
C O
ILTE
MPE
RATU
RESE
NSO
R
ENG
INE
OIL
TEM
PERA
TURE
SENS
OR
ENG
INE
OIL
TEM
PERA
TURE
GAU
GE
VSE
SOLE
NOID
VALV
E SW
ITCH
HYDR
AULI
C O
ILTE
MPE
RATU
REG
AUG
E
FUEL
FLO
AT
ENG
INE
OIL
PRES
SURE
TRAN
SDUC
ER
VSE
SOLE
NOID
VALV
E
NEG
ATIV
E BR
AKE
PRES
SURE
SWIT
CH
21
12v
A
B
C
D
E
F
G
1234567810 9
G
F
E
D
C
B
A
910 8 7 6 5 4 3 2 1
1/C1
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
16
GTH 55-19
TECHNICAL OPERATING DATA
Wiring diagram - page 5 of 6 (from serial no. 16980)
C.05.11
4/A1 31
15
304/G1
4/G1 15
30
31
YE/R
Dø1
PK/Y
Eø1
BN/B
Kø1
CA
FE
BKø1
BU/RDø1
B
X24
1X4
BKø1
1
PK/Y
Eø1
212v 12v
2
YE/R
Dø1
1
BKø1
X42
7X3
78BKø1
VTø11
4
32
56
GY/RDø1.5
F06
X27
10A
GY/
RDø1
.5BN
ø2.5
X210
X47
3X3
VTø1
BKø1
7BKø1
5
4
6
8
1
2
3BN/RDø1
WH/BKø1.5
WH/BKø1
M
BN/R
Dø1
BKø1
BNø2
.5W
H/BK
ø1.5
5A
7X2
F10
BKø1
.5BU
/BKø
1.5
M
X27
15A
BU/B
Kø1.
5BN
ø2.5
BKø1
VT/W
Hø1
M
RDø1
.5BK
ø1
F09
2X6 X6
4
2ARD
ø1.5
RDø4
F01
X63
X26
5X6
YE/R
Dø1.
5
28X4
WH/
RDø1
.5BK
ø1.5
WH/
GNø
1
T
4/C7WH/GNø1
X217
14X4
12v2
WH/
OG
ø1
1
BKø1
X429
AX7
3/F1
3/C1
BN/BKø1
VT/WHø14/C5
1/D3
WH/RDø1.5
Y07 Y08
HA02M03 M04
H05H06
Y09SS08
Y10
X23
SW10
SW12SW11
WH/
OG
ø1
X15
X15 X9
X9
1
2
X13X13 X12X12
1X8
X82
24X4
EXTE
ND/R
ETRA
CTBO
OM
SO
LENO
IDVA
LVE
REAR
WIN
DSCR
EEN
WIP
ER/W
ASHE
RM
OTO
RO
PTIO
NAL
WIN
DSCR
EEN
WIP
ER/W
ASHE
RSW
ITCH
OPT
IONA
L
FRO
NTW
INDS
CREE
NW
IPER
/WAS
HER
MO
TOR
OPT
IONA
L
HORN
ENG
INE
STO
PSO
LENO
ID
STEE
RING
SELE
CTO
R
BEAC
ON
CAB
LIG
HTIN
G
HORN
SW
ITCH
OPT
IONA
LFL
ASHI
NGCO
NNEC
TOR
ENG
INE
OIL
COO
LING
TEM
PERA
TURE
SENS
OR
PARA
LLEL
WHE
EL S
TEER
ING
SOLE
NOID
VAL
VE
FOUR
WHE
ELST
EERI
NGSO
LENO
ID V
ALVE
1234567810 9
A
B
C
D
E
F
G
910 8 7 6 5 4 3 2 1
G
F
E
D
C
B
A
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
17
GTH 55-19
TECHNICAL OPERATING DATA
Wiring diagram - page 6 of 6 (from serial no. 16980)
C.05.12
Other componentsA##
R##
P##
M##
K##
HA##
H##
F##
Lamp, light
Indicator
Potentiometer
Switces, selector
Solenoid valve
Sensor, microswitches, pressure switches, transducer
Fuse
Clacson or back-up horn
Motor engine or pump
Resistance
DescriptionLabel
Relè
RP##
SW##
SS##
Y##
X## Connectors
LIST OF ABBREVIATION
TurquoiseTQ
PK
WH
GY
VT
Orange
Acronym Colour
Blue
Yellow
Red
Black
COLOUR TABLE
White
Pink
Grey
Violet
Green
Brown
BK
BN
RD
OG
YE
GN
BU
A
B
C
D
E
F
G
1234567810 9
G
F
E
D
C
B
A
910 8 7 6 5 4 3 2 1
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
18
GTH 55-19
TECHNICAL OPERATING DATA
Legend wiring diagram
C.05.13
SW12 F75
K11 1 B5
B33Y04
B64SS04
SW10SW11 5
5F5E9
SW03 1 F5
G9
G2G1
F6F3
F10B10
B4
433322
11
SW09SW08SW07SW06SW05SW04
SW01SW02
R01 1
3SS02SS03
SS05
SS07SS08
Y01Y02
4
45
13
B7B7
B2
B7C10
SS06
F6
SS01 3 B9
4 B5B34B2
B53
B2
Y03
B2B8B10B10
A01
Y10
B311 C10
5 B1
A02
55543
Y06Y07Y08Y09
Y05K1
K5K4K3K2
21333
F24P03
M03
B91B81
5 B5
M01M02
P01F44
4 G7
B45
P02
M04
E6D9D4D3
HA02
D9
5 B6
B22 B5
F21
D51F13D1
D3
H02
B1
B3B4F8
B5B6
3
5532
1
HA01
H06H05H04H03
H01
F31F30 1
5F1F2F3
F4
F5F6F7F8F9F10
F11
F12
22
1
154355
4
3
D3D8D8
D3
D8D8
D4D4
D5
D6
DescriptionLabel PositionPage Label Description Page Position
ADDITIONAL FUEL SOLENOID VALVE
DISCONNECTION BATTERY
JOYSTICK
REVERSE SPEED
ENGINE START ENABLING COMMAND WITH SPEED LEVER IN NEUTERFORWARD SPEEDFORWARD/REVERS SPEED ENABLING COMMAND
FRONT/REAR WORK LIGHTS OPTIONAL
ENGINE OIL TEMPERATURE SENSOR
ENGINE OIL PRESSURE TRANSDUCER
HYDRAULIC OIL TEMPERATURE SENSOR
AIR FILTER CLOGGING SENSOR
HORN PARKING BRAKE SOLENOID VALVE
FUEL FLOAT
BACK-UP HORN
WHEEL STEERING SOLENOID VALVEWHEEL STEERING SOLENOID VALVE
SOLENOID VALVE-FWD SPEED
EXTEND/RETRACT BOOM SOLENOID VALVE
ATTACHMENT COUPLING/RELEASE SOLENOID VALVE
BEACONCAB LIGHTING
REAR WINDSCREEN WIPER/WASHER MOTOR OPTIONALFRONT WINDSCREEN WIPER/WASHER MOTOR OPTIONAL
PARKING BRAKE SWITCH
HORN SWITCH
FRONT WORK LIGHT SWITCH OPTIONALREAR WORK LIGHT SWITCH OPTIONAL
ENGINE OIL TEMPERATURE GAUGEHYDRAULIC OIL TEMPERATURE GAUGEWARNING LIGHTS-FUEL GAUGE
FRONT WINDSCREEN WIPER/WASHER SWITCH OPTIONAL
VSE SOLENOID SWITCH
HYDRAULIC STOP
IGNITION KEY SWITCH
STEERING SELECTOR
CHANGEOVER-OVER SWITCH
ATTACHMENT COUPLING/RELEASE SWITCH
NEGATIVE BRAKE PRESSURE SWITCH
REVERSE SPEED SOLENOID VALVE
GLOW PLUGS
PREHEATING CONTROL UNIT
VSE SOLENOID VALVE
SYSTEM PROTECTION FUSEPREHEATING CONTROL UNIT MAXIFUSE
ENGINE STOP SOLENOID
ENGINE OIL COOLING TEMPERATURE SENSOR
12V BATTERYSTARTER MOTORALTERNATOR
RELAY K3/RELAY K5 POWER SUPPLY
INTERIOR LAMP POWER SUPPLYFRONTWORK LIGHT SWITCH POWER SUPPLYREAR WORK LIGHT SWITCH POWER SUPPLY
GLOWE LIGHT INSTRUMENT, AIR FILTER SOILED WARNING LIGHT, VSE SWITCH LIGHTPOWER SUPPLY: ENGINE STOP SOLENOID, PREHEATING CONTROL UNITHORN SWITCH POWER SUPPLY
PARKING BRAKE SWITCH POWER SUPPLY, PARKING BRAKE SOLENOID VALVE POWER SUPPLYREAR WINDSCREEN WIPER/WASHER MOTOR POWER SUPPLYWINDSCREEN WIPER/WASHER SWITCH POWER SUPPLY
ENGINE OIL TEMPERATURE GAUGESTEERING SELECTOR POWER SUPPLY, JOISTICK
K1 RELAY EXCITATION, HYDRAULIC STOP, FUEL GAUGE INSTRUMENT POWER SUPPLY,
BEACON POWER SUPPLY, LIGHTING: FUEL GAUGE WARNING LIGHT, HYDRAULIC OIL TEMPERATURE GAUGE
ATTACHMENT COUPLING/RELEASE SOLENOID VALVE POWER SUPPLY
PREHEATING GLOW PLUGS WARNING LIGHTFRONT WORK LIGHT OPTIONALREAR WORK LIGHT OPTIONALAIR FILTER SOILED WARNING LIGHT
STARTING RELAY
A
B
C
D
E
F
G
1234567810 9
G
F
E
D
C
B
A
910 8 7 6 5 4 3 2 1
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
19
GTH 55-19
TECHNICAL OPERATING DATA
B6
14
44145
B9B3
B2B7
B2B7
X25
X18
X13X12
X05
X03X02
X14
X11X10X09X08X07X06
X04
X01 ENGINE CONNECTOR 4 WAYS
X16X17
X19
X21X22X23X24
X20
X15
CAB CONNECTOR 18 WAYSCAB CONNECTOR 12 WAYSENGINE CONNECTOR 29 WAYSCAB CONNECTOR 6 WAYSCAB CONNECTOR 6 WAYS
FRONT WINDSCREEN CONNECTOR 2 WAYSJOYSTICK CONNECTOR 3 WAYS
REAR WINDSCREEN CONNECTOR 2 WAYSHYDRAULIC STOP CONNECTOR 2 WAYSWORK LIGHT CONNECTOR 2 WAYSCAB LIGHTING CONNECTOR 2 WAYSBEACON CONNECTOR 2 WAYSBEACON CONNECTOR 2 WAYSKLAXON CONNECTOR 2 WAYSHYDRAULIC OIL TEMPERATURE CONNECTOR 1 WAYSTARTER MOTOR CONNECTOR 1 WAYAIR FILTER CLOGGING CONNECTOR 2 WAYSFUEL LEVEL CONNECTOR 3 WAYSENGINE OIL TEMPERATURE CONNECTOR 1 WAYADDITIONAL FUEL CONNECTOR 1 WAYENGINE OIL PRESSURE CONNECTOR 1 WAYHIGH TEMPERATURTE CONNECTOR 1 WAYBACK-UP HORN CONNECTOR 2 WAYSGLOW PLUGS CONNECTOR 1 WAY
Label Description Page Position Label Description Page Position
1234567810 9
A
B
C
D
E
F
G
910 8 7 6 5 4 3 2 1
G
F
E
D
C
B
A
Legend wiring diagram
C.05.14
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
20
GTH 55-19
TECHNICAL OPERATING DATA
FUSES AND RELAYS
7.5A
K10
15A
10A
5A
K5
K9
K8
K4
K3
K7
K6
K2
K1
19 5
24
5A
5A28
27
7,5A
7,5A
5A
26
25
5A
15A
5A23
22
10A
10A20
21
10
2A
5A
7,5A
7,5A
5A
14
13
12
11
5A
15A
5A
10A
10A
9
8
6
7
10A
5A
10A18
17
2A15
1610A
10A
5A
4
3
1
2
5A
1234567810 9
A
B
C
D
E
F
G
910 8 7 6 5 4 3 2 1
G
F
E
D
C
B
A
Fuse and relays
C.05.15
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
21
GTH 55-19
TECHNICAL OPERATING DATA
Connectors
C.05.16
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
22
GTH 55-19
TECHNICAL OPERATING DATA
GROUND
FUEL FLOAT SS04
GLOW PLUGS R01WH/GNø11GLOW PLUGSCONNECTOR
X25
GROUND
BACK-UP HORN HA01
HIGH TEMPERATURE SENSOR SS08
ENGINE OIL PRESSURE SENSOR SS03
ADDITIONAL FUEL Y01
ENGINE OIL TEMP. SENSOR SS07
FUEL FLOAT SS04
GROUND
AIR FILTER CLOGGING SENSOR SS01
STARTER TEMPERATURE M01
HYDR. OIL TEMP.SENSOR SS06
GROUND
+12 V KLAXON HA02
CONNECTOR 2 WAYSBACK-UP HORN
HIGH TEMP.CONNECTOR
CONNECTOROIL PRESS.
ADDITIONAL FUELCONNECTOR
CONNECTORSTART. TEMP.
CONNECTOROIL TEMP. SENS.
CONNECTOROIL TEMP. SENS.
CONNECTOR 3 WAYSFUEL FOLAT
CONNECT. 2 WAYSAIR FILT. CLOG. SENS.
CONNEC. 2 WAYSKLAXON
GROUND
+12 V LIGHT H03
+12 V BEACON H05
+12 V CAB LIGHTING H06
GROUND
GROUND
+12 V LIGHT H02
HYDRAULIC STOP SIGNAL
+12 V WINDSCREEN M03
GROUND
BEACON
CONNEC. 2 WAYSCAB LIGHTING
CONNEC. 2 WAYSWORK LIGHT
CONNECTOR 2 WAYSHYDRAULIC STOP
CONNECTOR 2 WAYSFRONT WINDSCREEN
CONNECTOR 3 WAYSJOYSTICK
+12 V JOYSTICK
JOYSTICK SIDE 2
JOYSTICK SIDE 1
SIGNAL PER P02 FROM SS06
+12 V BRAKE PRESS. LIGHT P01 J14
+12 V J1 OF P01
+12 V H01, ECCIT. K01, SS02, H04
+12 V LIGHT SW07
WORK LIGHT OPTIONAL H02
BEACON H05
CAB LIGHTING H06
GROUND
CAB CONNECTOR 6 WAYS
BKø1
BKø1
RD/BKø1
RD/BKø1
X23 WH/GNø11
1 GY/RDø1X22
X21 BUø2.51
1 GY/GNø1X20
X19PKø1
GY/YEø1
2
1
1
2
GY/BUø1
BKø1X18
X17 BUø41
1 GN/RDø1X16
X15
21
X14 YEø1.5
BKø1.52
11 2
1
2 BKø1
WH/VTø1X13 2
1
1
2X12RDø1.5
BKø12
1
1
2 BKø1.5
YE/GNø1.5X11 2
1
X10 RD/BKø1
RDø12
1
X09 1
2 BKø1.5
BU/BKø1.51 2
X08
C
B A
YE/GNø1.5
WH/VTø1
RDø1.5
BKø1
6
5
4
3
2
1
X066
5
1
4
2
3
DE
UT
SC
H
1
2
3
4
5
6
RD/BKø1
N. C.
WH/BUø1
GN/RDø1
6
5
1
4
2
3
DE
UT
SC
H
Pin
BN/BKø1
WH/GNø1
WH/OGø1
BN/RDø1
BKø12
1
A
B
C
X05
X07
X24
4 BKø1
BKø1
OG/BKø1
BKø1
VTø1
Pin
2
1
2
1
ConnectorColour
DescriptionFuse Line
ConnectorColour
Fuse LineDescription
Engine Line Engine Line
GROUND
GROUNDCAB CONNECTOR 6 WAYS
+12 V WINDSCREEN M04
GROUNDREAR WINDSCREENCONNECTOR 2 WAYS
HYDRAULIC STOP SIGNAL
GROUNDCONNEC. 2 WAYS
BEACONCONNEC. 2 WAYS
2
1
A
B
C
D
E
F
G
1234567810 9
G
F
E
D
C
B
A
910 8 7 6 5 4 3 2 1
Connectors
C.05.16
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
23
GTH 55-19
TECHNICAL OPERATING DATA
Position of the electrical components on the machine
C.05.17
X13
X14
H05H06
X12
X23 SS08
X20 X22
A01
SW02
100
SS07 SS03
M02
Y09
Y01
H03
Y06
X24
HA01
X21
A02
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
24
GTH 55-19
TECHNICAL OPERATING DATA
Position of the electrical components on the machine
C.05.17
X18
SS01
X25X17
M01
SS06
X16
R01
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
25
GTH 55-19
TECHNICAL OPERATING DATA
Position of the electrical components on the machine
C.05.17
X07
X01
X02
X03
X04
X05
SS02
X10
X06 X08
X09
SW01
SW03
X11
H02
M03
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
26
GTH 55-19
TECHNICAL OPERATING DATA
Position of the electrical components on the machine
C.05.17
X19
Y04
Y10
SS05
Y03
Y07
Y08SS04
HA02
X15
Y02Y05
P03
P01
P02
SW06 SW09 SW08
SW12 SW10 H01
P03P03P03
H04
SW11
SW07Y06
SW05 SW04
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
27
GTH 55-19
TECHNICAL OPERATING DATA
Boom raising cylinder
C.06.01
ø 55 STROKE 708
CLOSED 1187 - OPEN 1967
80 ø 55
ø 1
10
ø 7
0
Pressure
BRSOR
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
28
GTH 55-19
TECHNICAL OPERATING DATA
Boom extension cylinder
C.06.02
Spacer 375 Stroke 2135
CLOSED 2785 - OPEN 4920
ø 30
60
ø 30
Pressure
BRSOR
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
29
GTH 55-19
TECHNICAL OPERATING DATA
Balance cylinder
C.06.03
CLOSED 665 - OPEN 1045
STROKE 380
Pressure
BRSOR
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
30
GTH 55-19
TECHNICAL OPERATING DATA
Fork movement cylinder
C.06.04
STROKE 325
CLOSED 626 - OPEN 951
ø 1
20
ø 6
0
Pressure
BRSOR
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
31
GTH 55-19
TECHNICAL OPERATING DATA
Attachment locking cylinder
C.06.05
CLOSED 555/OPEN 739
FEEDING DISTANCE BETWEEN CENTRES 404
495
92C
H 2
7
ø 3/8"
ø 3
0
M20
x1.5
ø 5
0
BRSOR
Pre
ssu
re
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
32
GTH 55-19
TECHNICAL OPERATING DATA
Hand-lever
C.07
A
A A
T
A A
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
33
GTH 55-19
TECHNICAL OPERATING DATA
Hydraulic main valve
C.08
W
W
W
VA1
T
G 1/2”
ø 8,5
n° 3 fori
VB1
G 1/4”VA2 VA3 VA4
VB2 VB3 VB4
G 3/4”
P
DATA
Nominal flow
Nominal pressure
Max back-pressure to drain T
Fluid temperature range
80 l/min
315 bar
15 - 75 mm2/s
-40|B a +60|BC
3 cm3/minMax internal leakage A(B)->T @ 100 bar:
Viscosity
Working elements
Slider diameter 18 mm
Monobloc actuator with paralleled circuit
Ambient temperature
12 mm2/s
400 mm2/s
4
working range
minimum
maximum
19/16 - ISO 4406Admissible contamination degree
-20|B a +80|BC
25 bar
Max pressure on V 50 bar
A1 A2 A3 A4
B1 B2 B3 B4
W
P
Q=80 l/min
290 bar 290 bar
270 bar
A1 B1
HYDRAULIC SCHEME
T
A2 B2 A3 B3 A4 B4VA1
VB1 VB2
VA2 VA3
VB3 VB4
VA4
OPERATING CONDITIONS(mineral oil - viscosity 46 mm2/s @ 40|BC)
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
34
GTH 55-19
TECHNICAL OPERATING DATA
Hydraulic pump
C.09.01
PUMP TECHNICAL DATA
- Rotation direction ............................................................................ .........Counterclockwise- Displacement .................................................................................................34.555 cm3/rev- Inlet pressure range for pump.......................................................... .....................0.7 - 3 bar- Max continuous pressure ............................................................P1 .........................260 bar- Max intermittent pressure............................................................P2 .........................280 bar- Max peak pressure ......................................................................P3 .........................300 bar- Speed....................................................................................min P1 ...................350 min^-1
max P1 .................3000 min^-1- Gaskets ............................................................................................ ..............................NBR- Working temperature........................................................................ .................-25°C +80°C- Viscosity range .........................................................recommended ........12 to 100 mm^2/s
admissible..........max 750 mm^2/s- Contamination class ...................................................ΔP > 200 bar .................8 - Nas 1638
βx = 75-10 μm.....19/17/14 - ISO 4406ΔP < 200 bar ...............10 - Nas 1638
βx = 75-25 μm.....21/19/16 - ISO 4406
140 Nm
70 Nm
50 Nm
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
35
GTH 55-19
TECHNICAL OPERATING DATA
Brake pump
C.09.02
A BRAKE PUMPB BRAKE OIL SUMPC FRONT AXLE
B
A
C
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
36
GTH 55-19
TECHNICAL OPERATING DATA
Boom raising and extension cylinder blocking valve
C.10.01
FITTINGS V1-V2: G 1/2”C1-C2: ø12
V2
C2 C1
V1
V1V2
V1
C1
C2
V1
SEZ. A-A
V2
V2
V2 V1
C2 C1
AA
TECHNICAL DATA
• Max working pressure = 350 bar• Piloting ratio = 4:1• Weight = 2.5 kg• Valve setting = 1.3 times higher than
the load induced pressure• Steel manifold
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
37
GTH 55-19
TECHNICAL OPERATING DATA
Balance cylinder blocking valve
C.10.02
INSTALLATION SCHEME
C1 C2
V1 V2
MATERIAL
Manifold: Steel
TECHNICAL DATA
Max flow = see diagramMax pressure = 350 BarSetting = 100 - 350 barStandard setting (Q=5 l/min) = 300 barValve setting = 1.3 times higher thanthe load induced pressurePiloting ratio = 11:1Weight = 2 kg
FITTINGS
C1-C2 = G 1/2”V1-V2 = ø 8,5
0
4
8
12
16
20
24
0 10 20 30 40 50 60
FLOW - Q (l/min)
PR
ES
SU
RE
- Δ
p (
bar)
C1 C2
V2V1
O.ring 31,42x2,62
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
38
GTH 55-19
TECHNICAL OPERATING DATA
Fork movement cylinder blocking valve
C.10.03
MATERIAL
Manifold: Steel
TECHNICAL DATA
Max flow = see diagramMax pressure = 350 BarSetting = 100 - 350 barStandard setting (Q=5 l/min) = 300 barValve setting = 1.3 times higher thanthe load induced pressurePiloting ratio = 4,2:1Weight = 2 kg
FITTINGS
C1-C2 = G 1/2”V1-V2 = ø 8,5
INSTALLATION SCHEME
C1 C2
V1 V2
O.ring 31,42x2,62
V1
C2C1
V2
0
4
8
12
16
20
24
0 10 20 30 40 50 60
FLOW - Q (l/min)
PR
ES
SU
RE
- Δ
p (
bar)
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
39
GTH 55-19
TECHNICAL OPERATING DATA
Attachment cylinder blocking valve
C.10.04
C2
V2
C1
V1
V1 V2
C2C1
TECHNICAL DATA
• Max working pressure = 350 bar• Opening pressure = 3 bar• Max flow = 15 l/min• Piloting ratio = 4:1• Weight = 0.7 kg
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
40
GTH 55-19
TECHNICAL OPERATING DATA
Pressure reducing valve
C.10.05
INSTALLATION SCHEME
MATERIAL
Body: Aluminium 702 State T6Internal parts: case-hardened and tempered steel
TECHNICAL DATA
Max flow = 20 l/minMax pressure = 210 BarSetting = 5 - 50 bar(test setting 40 bar with 5 l/min)Piloting ratio = 1:7Fluid: 20-200 cSt mineral oilAmbient temperature = 0 +40 °CGaskets : BUNA N
BLOW-BYBlow-by in Dr: 20 cc/min at a pressure of 150 bar withoil with 46 cSt viscosity
FITTINGS
U - E - Dr = G 3\8”
Cylindrical fitting tightening torque 0 60 Nm (do notuse conical fittings)
RECOMMENDED CONTAMINATIONLEVEL - ISO 4406
FILTRATION - OIL CONTAMINATION
TYPE OF SYSTEMTYPE OF VALVE
- High performance systems 16/13- Systems with working pressures from 210 to 350 bar- Systems with proportional controls- Systems with high frequency cycles
- Systems with working pressures up to 210 bar 18/14- Spool valves- Valves with calibrated orifice
- Systems with low working pressures 19/15- Piloting systems- Systems with low frequency cycles
E
U Dr
7 Nm
13
Dr
E U
Q
Operation: Table:
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
41
GTH 55-19
TECHNICAL OPERATING DATA
DHI solenoid valve
C.10.06
A B
P Ta b
A B
P T
Installation position
Coupling surface condition
Ambient temperature
Fluid
Recommended viscosity 15÷100 mm2/s at 40 °C (ISO VG 15÷100)
Fluid contamination class
Fluid temperature
Pressure limits
Maximum flow
Utilisation factor
Voltage and power frequency
Threshold tolerance
MAIN CHARACTERISTICS OF THE DHI SOLENOID VALVES
Any
Surface texture index , flatness ratio 0.01/100 (ISO 1101)0,4
-20 °C to +70 °C
Hydraulic oil as per DIN 51524
ISO 19/16, obtained through 25 μm and ß25≥ 75 line filters (recommended)
T ≤ 80 °C, if T ≤ 60 °C choose PE seals
P, A, B ports: 350 bar – T port: 120 bar
60 l/min for DI
100%
12 DC
±10%
A B
Port
Spool type
P-A
4 D D D D A
Q/Δp CHARTS
Tests done with fluid viscosity of 43 mm2/s at 40 °C
P-B A-T B-T P-T
Flow [l/min]
Inle
t p
ress
ure
[b
ar]
Spools 4 with electrical connectors = T
M
S
T
X
Y
V
10 20 30 40 50 60 70 8000
50
100
150
200
250
300
350
400
59 5966
Weight: 1,8 kg28
,5
79,5
46
45
= =
Flow [l/min]
D
B
A
C
21
17,5
14
10,5
7
3,5
0
Lo
ad lo
ss Δ
p [
bar
]
0 10 20 30 40 50 60
Document 57.4401.8200 - 2nd Edition 05/2007 INDEX
C
42
GTH 55-19
TECHNICAL OPERATING DATA
Intentionally blank page
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
D
1
GTH 55-19
CHECKS AND ADJUSTMENTS
Section DCHECKS AND ADJUSTMENTS
SECTION INDEX
D.01 Speed check ........................................................................................ page 2
D.02 Checking the max. current of the solenoid coils ......................................
D.03 Checking and calibrating the circuit pressure .......................................... 4
D.04 Checking the engine oil level ...................................................................... 11
Procedure: Table:
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
D
2
GTH 55-19
CHECKS AND ADJUSTMENTS
Checking the movement times of cylinders
D.01
The check of the movement times of the cylindersshall be done with the hydraulic oil at a temperatureof 60°.
To check the engine speed, the area easy to reach isthe shaft of the CASAPPA pump.Min engine speed = 950 rpmMax engine speed = 2700 rpm
BOOM LIFTING/LOWERING
Time (s) up down
Max engine speed 7” 4”
Min. engine speed 18” 11”
BOOM EXTENSION/RETRACTION
Time (s) out in
Max engine speed 7” 4”
Min. engine speed 19” 10”
Lifting
Lowering
ExtensionRetraction
Procedure: Table:
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
D
3
GTH 55-19
CHECKS AND ADJUSTMENTS
ATTACHMENT DUMPING
Time (s) dumping roll-back
T. Max 3” 4”T. Min 10” 12”
D.01Checking the movement times of cylinders
The maximum speed that can be attained on a levelground is 24 km/h in both forward and reverse speed.
Roll-back
Dumping
Procedure: Table:
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
D
4
GTH 55-19
CHECKS AND ADJUSTMENTS
Checking and calibrating the circuit pressure
D.03
1. PRELIMINARY OPERATIONS
Warm up the hydraulic oil to 80°C by keeping one of theelements of the boom main valve to full stroke underpressure.To reach this temperature in a faster way, cover the oilcore of the radiator with a carton in the case of a water-oil combined cooler, or the oil radiator if the machine isequipped with a separate oil radiator.
2. SETTING THE BOOM MAIN VALVE
Find the mini-socket for the pressure gauge ref. 2 onthe Walvoil main valve (see annex 1).
2.1 SETTING THE MAIN VALVE PRESSURECONTROL VALVE
Connect a 0-400 bar manometer to the mini-socket ref.2. Fully raise the boom to stroke end by means of joystickref. 1.Calibrate valve A (see annex 2) to 270 bar with the Dieselengine at full speed.To calibrate the safety valves B (see annex 2), proceedas follows:
• Connect a 0-400 bar manometer to the mini-socketref. 2.
• Increase the pressure of valve A of the main valve to290 bar moving the raising cylinder to stroke end (fullyout).
• With the engine running at maximum speed, pitchthe forks forward by means of the joystick and act onone of the two valves B until reaching a pressure of280 bar.
• Proceed in adjusting the second valve B (280 bar) bypitching the forks back.
• When both fork inclination safety valves have beencalibrated, reset the pressure control valve to 270 barby adjusting the register A.
3. SETTING THE PRESSURE RELIEFVALVE
• Fit a fitting with mini-socket ref. 3 in the positionshown in annex 1.
• Connect a 0-60 bar manometer to the mini-socketref. 3 (see annex 1), with the engine running atminimum speed moving any of the elements of themain valve to stroke end, then set valve E (see annex1) to 28 bar.
• Remove the manometer from the mini-socket and re-tighten the protection cap.
4. SETTING THE HYDROMATIK PUMPHYDROSTATIC TRANSMISSION
Do the calibration of the hydrostatic transmission withthe hydraulic oil at 80°C.
• Connect a 0-60 bar manometer A to the mini-socketref. 4 to read the boost pressure value.
• Connect a 0-600 bar manometer B to the mini-socketref. 5 to read the high-pressure value.
0 600
300200
100500
400
0 60
3020
1050
40
5
4
A
B
Procedure: Table:
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
D
5
GTH 55-19
CHECKS AND ADJUSTMENTS
Checking and calibrating the circuit pressure
D.03
Do not fit the manometer to the application pointcorresponding to the reverse speed. This operationis extremely dangerous for the serviceman who iscalibrating the transmission.
• Hold the selector to neutral position and make surethe maximum speed of the engine does not exceed2800 rpm. The engine must run at a idle speed of950 rpm. Otherwise, adjust the minimum speed.
• Read the boost pressure on manometer A and ensureit is about 26/28 bar with the engine running at idlespeed.The boost pressure has not a fixed value but variesfrom pump to pump.
• Remove coil ref. 5 from solenoid valve ref. 6 (seeannex 3) so the machine remains braked.
STARTING THE CALIBRATION
• Set the forward-neutral-reverse selector to theforward or backward position.
• Run the engine at 1200 rpm. Check the value on thetachometer.
• Adjust shutter D by means of the register until readinga value of 50 bar on the high-pressure manometer B.
4.1 CALIBRATION OF THE MAXIMUM PRESSURE
Do this operation with extreme caution. The properfunctioning of pump and transmission depends on thiscalibration.
• Set the forward-neutral-reverse selector to theforward position.
• Run the engine at maximum speed and check thehigh-pressure value. If this value is less than 420 bar,increase the pressure to 430 bar by means of thepressure cut-off valve E.
• Remove the manometers and do an attempt.
D
0 600
300200
100500
400
0 60
3020
1050
40
E
B
Procedure: Table:
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
D
6
GTH 55-19
CHECKS AND ADJUSTMENTS
Checking and calibrating the circuit pressure
4.2 CALIBRATION OF THE MECHANICAL ZERO
The calibration of the mechanical zero G is required ifthe machine is set to neutral position with the forward-reverse speed lever.
• Set the forward-neutral-reverse selector to neutralposition.
• With the engine running at idle speed, adjust themechanical zero screw by rotating it until the high-pressure manometer reads the same value measuredby the boost pressure manometer.
0 60
3020
1050
40
0 60
3020
1050
40
G
D.03
5. SETTING THE POWER STEERING
• Fit a fitting with mini-socket Z in the position shownin annex 4.
• Connect a 0-250 bar manometer to the mini-socketZ.
• Select the front axle steering mode.
• Move the steering cylinder to stroke end and makesure the value of the power steering A is 170 bar. Ifthe value is less, tighten valve X; if the value is greater,loosen the valve.
Note: To gain access to valve X, remove theprotection cap (see annex 4).
5.1 CHECKING THE NEGATIVE BRAKE PRESSURE
Fit a 0-60bar pressure gauge to mini-socket ref. W (seeannex 3) to check the pressure acting on the parkingbrake of the front axle.The brake is unlocked when the pressure value is 25 to28 bar.
Procedure: Table:
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
D
7
GTH 55-19
CHECKS AND ADJUSTMENTS
Checking and calibrating the circuit pressure
D.03
Annex 1
TP2
T
B
12
E
3
Procedure: Table:
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
D
8
GTH 55-19
CHECKS AND ADJUSTMENTS
Checking and calibrating the circuit pressure
D.03
Annex 2
A
B
Procedure: Table:
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
D
9
GTH 55-19
CHECKS AND ADJUSTMENTS
Checking and calibrating the circuit pressure
D.03
Annex 3
AP
B
T
5
6
W
Procedure: Table:
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
D
10
GTH 55-19
CHECKS AND ADJUSTMENTS
Checking and calibrating the circuit pressure
D.03
Annex 4
A
Z
X
Procedure: Table:
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
D
11
GTH 55-19
CHECKS AND ADJUSTMENTS
Checking the engine oil level
D.04To check the engine oil level:• Park the machine on a flat ground, stop the engine
and check the parking brake is engaged.• Remove dipstick A and check if oil reaches the max
mark B.
• If oil is below this mark, remove plug C and pour newoil into the engine using the special appliance D.
• Remove dipstick A once again and check if oilreaches the max mark B.
• Refit the plug.
If one of the connecting pipes of radiator E breaks:• Stop the machine immediately, if possible on a flat
ground; stop the engine and check the parking brakeis engaged.
• Change the damaged pipe.• Remove dipstick A and check if oil reaches the max
mark B.• If oil is below this mark, remove plug C and pour new
oil into the engine using the special appliance D.• Restart the machine and let oil circulate in the engine
and the radiator.• Stop the machine and check again the oil level. If
necessary, add new oil step by step until reaching themax level by starting and stopping the engine atevery step.
A
B
min
max
C
D
E
E
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
D
12
GTH 55-19
CHECKS AND ADJUSTMENTS
Intentionally blank page
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
F
1
GTH 55-19
TROUBLESHOOTING
Section FTROUBLESHOOTING
SECTION INDEX
Hydraulic faults ................................................................................... page 2
Electrical faults ............................................................................................. 5
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
F
2
GTH 55-19
TROUBLESHOOTING
Trouble Cause Solution
Any service, maintenance or troubleshooting must be carried out with the machine stopped, the boom inrest position lowered to the ground, and the transportation locking devices fitted.
Use the wiring diagrams enclosed for finding solenoid valves (EV), fuses (F), relays (E) or other electricalcomponents in an easier way - see chapter C - Technical data of this manual.
The boom does not move
Wrong wheel shafting
The steering wheel is hard(low force in the cylinders)
• Low pressure
• Hydraulic pump damaged• Load sensing valve defective
• Leakage on the control blockvalve
• Pressure reducing valvemaladjusted
• Joystick damaged
• Leakage in the steeringcylinders
• Leakage in the steer selectionsolenoid valve
• Low pressure
• Priority valve damaged
• Set the max pressure of thecontrol block to 270 bar (seesec. D)
• Replace the pump• Check the efficiency of the
valve; replace if necessary• Dismantle the valve, check
and eliminate any foreignmatters
• Check the efficiency andreset the correct pressure (28bar) if necessary
• Check the efficiency of thejoystick; replace if necessary
• Check and replace the sealsif necessary (see sec. G)
• Check the efficiency of thesolenoid valve
• Check the pressure; in case,reset (170 bar)
• Check the efficiency of thevalve; replace if necessary
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
F
3
GTH 55-19
TROUBLESHOOTING
Trouble Cause Solution
When the engine is stopped,the lifting cylinder does notsupport the boom
When the engine is stopped,the cylinder does not supportthe forks
When the engine is stoppedand the boom is high, theextension cylinder moves in
When the load is lifted, thefork cannot be levelled
When the max load is applied,forks move down
Operating the joystick nofunction is activated
The steering wheel is slowand noisy
Differential noisy and hightemperature on the body
• Block valves damaged or dirty
• Cylinder seal defective
• Block valves damaged or dirty
• Cylinder seal defective
• Block valves damaged or dirty
• Cylinder seal defective
• Seals of the levelling cylinderworn out
• Shockproof valves of thecontrol block dirty ormaladjusted
• One-way valves of thelevelling cylinder dirty ordamaged
• Seals, rod and liner of the forktilting cylinder worn out
• Leakage in the cylinder blockvalve
• Low pressure in the hydrauliccircuit
• Joystick damaged
• Control block valve damaged
• Pressure reducing valvedamaged
• Couplings damaged• Hydraulic drive damaged
• No oil
• Bearings damaged
• Check the efficiency of thevalves; replace if necessary
• Replace the seal
• Check the efficiency of thevalves; replace if necessary
• Replace the seal
• Check the efficiency of thevalves; replace if necessary
• Replace the seal
• Dismantle the cylinder andreplace the seals
• Remove the valves, dry-clean or replace if damaged,and re-calibrate (see sec. D)
• Remove the valves, dry-clean or replace if damaged,and replace in their seats
• Dismantle the cylinder andcheck and replace anydefective parts
• Check the leakage; removethe valve and rectify orreplace
• Re-calibrate the controlblock (see sec. D)
• Check the joystick efficiency;replace if necessary
• Check the efficiency of thevalve; replace if necessary
• Check the calibration valueof the valve; replace the val-ve if necessary
• Replace the couplings• Replace the hydraulic drive
• Check the oil level and refill.If trouble cannot be rectified,dismantle the unit (see sec.G)
• Replace the bearings (seesec. G)
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
F
4
GTH 55-19
TROUBLESHOOTING
Trouble Cause Solution
• Check the play and replaceany worn parts or placeshims
• Check that the greasesmeared on the boom isINTERFLON FIN GREASELS2; smear the boomagainwith grease
• Check and eliminate anyforeign matters
• Check the pressure values ofthe drive pump (see sec. D)and re-calibrate if necessary.If the overfeeding pressuredrops down, replace thepump and clean the pump-motor couplings
• Sliding blocks worn out
• Grease is insufficient orinadequate
• Foreign matters on the slidingblocks and the relevantsurfaces of the boom
• Drive pump defective
When moving out the secondtelescope, the boom tends tomove right and left
When moving out the secondtelescope, the boom tends tojump
Low traction
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
F
5
GTH 55-19
TROUBLESHOOTING
Trouble Cause Solution
No power to dashboard
Engine does not start, starterdoes not run
Engine does not start - starterruns but engine does not start
The machine does not moveforward/back
• Battery switch off• Battery down
• 50A fuse blown• Dashboard damaged
• Broken or damaged wiring
• 50A fuse blown• Dashboard damaged
• K2 relay damaged• Speed switch ruined
• 70A engine start relaydamaged
• Starter defective
• No fuel• Fuel filter clogged• Fuel ducts empty• Start aid solenoid damaged
• Engine stop solenoid
• Broken or damaged wiring
• Speed switch damaged
• 10A fuse F13 broken• Relays K3-K4-K5 damaged• Forward/reverse speed
solenoid valves damaged• Parking brake micro-switch
damaged• Parking brake switch
• Broken or damaged wiring
• Turn on the switch• Check the battery efficiency;
replace if necessary• Change the fuse• Check the dashboard and
replace if necessary• Reconnect or replace the
wiring
• Replace the fuse• Check the dashboard and
replace if necessary• Change the relay• Check or replace the speed
switch• Change the relay
• Change the starter
• Refuel• Clean or replace the filter• Eliminate any air• Check the efficiency and
replace if necessary• Check the efficiency and
replace if necessary• Reconnect or replace the
wiring
• Check the efficiency orreplace the switch ifnecessary
• Change the fuse• Change the relays• Check the efficiency or
replace• Check the efficiency or
replace• Check the efficiency or
replace• Reconnect or replace the
wiring
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
F
6
GTH 55-19
TROUBLESHOOTING
Trouble Cause Solution
No steer selection
Hydraulic oil thermometerdefective
The parking brake lamp doesnot come on
The fuel gauge does not work
The engine coolantthermometer does not work
High hydraulic oiltemperature
• 7.5A fuse F12 blown• Steer selector damaged• Coils of the steer selection
solenoid valve damaged• Broken or damaged wiring
• 7.5A fuse F11 blown• Indicator damaged• Temperature sensor defective• Broken or damaged wiring
• 10A fuse F4 blown• Dashboard instrument
damaged• Broken or damaged wiring
• 10A fuse F4 blown• Dashboard instrument
damaged• Fuel sensor defective
• Broken or damaged wiring
• 7.5A fuse F11 blown• Indicator defective• Temperature sensor defective
• Broken or damaged wiring
• Hydraulic oil bulb damaged
• Indicator defective• Radiador clogged
• Change the fuse• Check or replace the selector• Check the coils; replace if
necessary• Reconnect or replace the
wiring
• Change the fuse• Change the part• Check or replace the sensor• Reconnect or replace the
wiring
• Change the fuse• Change
• Reconnect or replace thewiring
• Change the fuse• Change
• Check and replace thesensor if necessary
• Reconnect or replace thewiring
• Change the fuse• Change the part• Check and replace the
sensor if necessary• Reconnect or replace the
wiring
• Check or replace the bulb ifnecessary
• Change the part• Check the radiator and elimi-
nate any impurities from thefins
Document 57.4401.8200 - 1st Edition 04/2006 INDEX
F
7
GTH 55-19
TROUBLESHOOTING
Trouble Cause Solution
The joystick does not pitch theforks
The joystick does not lock/release the attachment
• 7.5A fuse F12 blown• Control block selection valve
• Broken or damaged wiring
• 7.5A fuse F12 blown• Control block selection valve
• Broken or damaged wiring
• Operating pushbuttondamaged
• Change the fuse• Check the efficiency of the
electrical coils; replace thecoils if damaged
• Reconnect or replace thewiring
• Change the fuse• Check the efficiency of the
electrical coils; replace thecoils if damaged
• Reconnect or replace thewiring
• Check or replace the fuse
top related