Genie GTH-2506 Video Game Furniture User manual

OPERATOR HANDBOOK

Cod. 57.0003.5200 - Rev.4A 05/2007

Handler with telescopic boom

GTH-2506

From serial number: 17106

To serial number: 18956

English

Edition

CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE

CAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES

EUROPEAN TECHNICAL SERVICES

GENIE FRANCE

10 Z.A. de la Croix Saint-Mathieu

28320 Gallardon

France

Tel. : 0033 (0)2 37 26 09 99

Fax : 0033 (0)2 37 26 09 98

GENIE SCANDINAVIA

Tagenevägen 72

425 37 Hisings Kärra

Sweden

Tel. : 0046 315 751 00

Fax : 0046 315 790 20

GENIE GERMANY

Finienweg 3

28832 Achim/Bremen

Germany

Tel. : 0049 (0)4202 8852 0

Fax : 0049 (0)4202 8852 20

GENIE IBÉRICA

Gaià 31

Poligono Industrial Plà d’en Coll

08110 Montcada i Reixac

Barcelona

Spain

Tel. : 0034 93 579 5090

Fax : 0034 93 579 5091

GENIE UK

The Maltings

Wharf Road

Grantham

Lincs NG31 6BH

United Kingdom

Tel. : 0044 (0)1476 584333

Fax : 0044 (0)1476 58433

Operator Handbook 57.0003.5200 - GTH-2506

All rights reserved. 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.

Some photos or drawings have been used to illustrate a specific function; as a result, they may not refer to the machine treated in this manual.

© Copyright 2004 TEREXLIFT srl - All rights reserved

Produced by:

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No.

Revision date

1 12/2003

12/2003

12/2003

12/2003

2 05/2004

3 10/2004

10/2004

10/2004

10/2004

LIST OF REVISED PAGES

Revised pages

A-3, C-16, C-20, C-21

D-1, D-8, D-9, D-13, D-16

E-2

G-9

A-3, A-4, A-5, A-6, A-13, A-18, B-1, B-7, C-1,

Notes

Revision

Revision

Revision

Revision

C-8, C-9, C-17, C-22, C-24, C-27, C-28, D-19,

E-3

E-4, E-5

C-23, C-28

Revised pages

Added pages

Revised pages

A-1, A-3, A-5, A-14, C-1, C-15, C-16, C-19, C-20,

C-21, C-22, C-23, D-19, G-10 Revised pages: TCE version

A-7, C-17

D-22, D-23, G-1, G-4, G-5, G-6, G-7, G-8

Added pages: TCE version

Revised pages: wiring diagram

G-9, G-10, G-11, G-12, G-13, G-14, G-15, G-16

C-1, C-7, C-8, C-18

Added pages: wiring diagram

Revised pages: disabling the overload warning system

Issued by

Handler with telescopic boom GTH-2506

INTRODUCTION

■ INTRODUCTION

This handbook provides information for a safe and proper operation and maintenance of the machine.

STRICTLY COMPLY WITH THE INSTRUCTIONS

GIVEN IN THIS HANDBOOK!

READ AND UNDERSTAND THIS HANDBOOK

BEFORE STARTING, USING AND CARRYING

OUT ANY OPERATION WITH AND ON THE

MACHINE.

The handbook is divided into seven sections:

Sect.

A GENERAL INFORMATION

Sect.

B SAFETY

Sect.

C OPERATING INSTRUCTIONS

Sect.

D MAINTENANCE

Sect.

E TROUBLESHOOTING

Sect.

F OPTIONAL ATTACHMENTS

Sect.

G TABLES AND ENCLOSURES

Sections are subdivided into chapters and paragraphs that are numbered progressively.

The quickest way to look for an information is the reference to the general index or the titles of the single chapters and paragraphs that represent keys for an easy consultation.

Take care of this handbook and keep it in an accessible place within the machine, even after its reading, so that it will always be within reach if in doubt.

If you are unsure about anything, please address to

GENIE Assistance Service or to your agent/dealer: addresses, phone and fax numbers are printed in the cover and in the title-page of this manual.

Section A contains general concepts that are decisive for the knowledge of the main parts of the machine.

It also contains all necessary data for a correct identification of the machine, the technical features of the machine, etc.

Section B is especially addressed to the personnel, who shall operate, repair and service the machine, and, in case of companies with a wide fleet of machines, to the safety responsible.

It describes the essential compulsory qualities of the personnel in charge and other important information for the safety of persons and things.

Section C is mainly addressed to the operators who operate the machine. This section illustrates all control devices.

Additionally, it contains the main use instructions -i.e.

engine starting, machine parking, machine storing.

Section D is addressed to the maintenance responsible and the servicemen.

The section describes the maintenance schedule and the relevant intervals.

Section E deals with the failure diagnostics.

Section F makes a list of the main interchangeable attachments that can be coupled to the machine: dimensions, weight, application field and limits of use.

Section G contains tables and various enclosed documents like load charts, wiring diagrams, hydraulic schemes, torque wrench setting table, etc.

IMPORTANT

Any difference between the contents of this manual and the real functional character of the machine can be attributed to either a machine manufactured before the issue of this manual or to a manual going to be updated after some changed effected on the machine.

Always contact Genie Assistance Service for any updated version of this manual and any additional information.

Page 1

Document 57.0003.5200 - 11/2003


INTRODUCTION

■

SYMBOLS

When using the machine, operators could have to face some situations requiring special care and particular knowledge.

When these situations involve the safety of operators or bystanders, the machine efficiency and proper utilisation, this handbook stresses these specific instructions by means of SPECIAL 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:

DANGER

Draws the attention to situations that involve your own as well as the others’ safety and that can result in serious or lethal injury.

ATTENTION

Draws the attention to situations that involve the machine efficiency.

IMPORTANT

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

PROTECT THE

ENVIRONMENT

Draws the attention to important environmentrelated information.

WHEN READING THIS MANUAL, PAY THE

GREATEST ATTENTION TO THESE SPECIAL

SYMBOLS AND THE EXPLANATION OF THE

SITUATIONS THEY EMPHASIZE.

ELECTRICAL

DANGER

Draws the attention to situations that involve your own as well as the others’ safety and that can result in serious injury or lethal injury.

The manual in electronic format also contains the following symbol: which enables the user to return to the table of contents

CAUTION

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.

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GENERAL INDEX

GENERAL INDEX

GENERAL INFORMATION

SAFETY

OPERATING INSTRUCTIONS

MAINTENANCE

TROUBLESHOOTING

OPTIONAL ATTACHMENTS

TABLES AND DOCUMENTS ENCLOSED

Sect.

Sect.

Sect.

Sect.

C

D

A

B

Sect.

E

Sect.

Sect.

F

G

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Intentionally blank page

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Section

A

GENERAL INFORMATION

TABLE OF CONTENTS

A-3.2

A-3.3

A-3.4

A-3.5

A-4

A-4.1

A-4.2

A-4.3

A-5

A-5.1

A-5.2

A-5.3

A-5.4

A-1

A-1.1

A-1.2

A-1.3

A-2

A-2.1

A-2.2

A-2.3

A-2.4

A-2.5

A-2.6

A-3

A-3.1

A-5.5

A-5.6

A-5.7

A-5.8

A-5.9

A-5.10

A-6

A-7

A-7.1

CONVENTIONAL REFERENCES ................................................................................

A-2

Machine position ........................................................................................................

A-2

Labels and warning plates applied on the machine ...................................................

A-3

Explanation of the different symbols used on the machine .......................................

A-8

MACHINE IDENTIFICATION .......................................................................................

A-10

Machine model and type ............................................................................................

A-10

Manufacturer ..............................................................................................................

A-10

Machine identification plates ......................................................................................

A-10

CE mark ......................................................................................................................

A-11

Chassis serial number ................................................................................................

A-11

Identification plates of the main parts ........................................................................

A-11

ALLOWED USE ..........................................................................................................

A-12

Allowed use ................................................................................................................

A-12

Improper use ..............................................................................................................

A-12

Residual hazards ........................................................................................................

A-12

Applicable standards ..................................................................................................

A-13

Safety devices ............................................................................................................

A-14

GENERAL DESCRIPTION ..........................................................................................

A-16

List of the main components ......................................................................................

A-16

Description of the main components .........................................................................

A-17

Optional accessories ..................................................................................................

A-17

TECHNICAL DATA AND PERFORMANCE .................................................................

A-18

Main dimensions ........................................................................................................

A-18

Restrictions of use ......................................................................................................

A-18

Weight ........................................................................................................................

A-18

Speed .........................................................................................................................

A-18

Payload and reach ......................................................................................................

A-19

Forks ...........................................................................................................................

A-19

Diesel engine ..............................................................................................................

A-19

Electrical system ........................................................................................................

A-19

Machine sound levels .................................................................................................

A-19

Vibration levels ...........................................................................................................

A-19

LIFETIME ....................................................................................................................

A-20

ITEMS SUPPLIED .......................................................................................................

A-20

Literature supplied ......................................................................................................

A-20

Page A-1

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A-1 CONVENTIONAL REFERENCES

■ A-1.1

MACHINE POSITION

Conventionally the machine should be considered positioned as shown in the figure.

This convention is necessary to make any reference of this handbook to different machine parts (front, rear, etc.) clear and unmistakable.

Any exception to this rule will always be specified.

UPPER PART

RIGHT SIDE

FRONT PART

LOWER PART

Page A-2

Document 57.0003.5200 - 11/2003

REAR PART

LEFT SIDE



■ A-1.2

LABELS AND WARNING PLATES

APPLIED ON THE MACHINE

This paragraph lists the labels and warning plates normally applied on standard machines or on special attachments coupled to the machine.

IMPORTANT

The familiarisation with these labels is never a waste of time.

Make sure they are easy to read. For this purpose, clean them or replace those that become unreadable (either graphic or text).

To clean labels, use of a soft cloth, water and soap.

Never use solvents, petrol, etc.

When a label is applied on a part to be replaced, make sure that the replaced part is already labelled as required or apply a new label.

Description:

Printed on PVC, it guides the operator through the task of learning the main functions of the handler.

Meaning:

An overview of the operator's handbook concerning:

control lever,

machine starting,

overload warning system

main safety precautions, and including the fork load charts with or without use of the outriggers.

Location: in the cab, fixed to the upright with a magnet.

Not present in the TCE version .

2506

GUIDA RAPIDA PER L’USO

PUSH

PUSH

Y

PUSH

Y

AVVIAMENTO DELLA MACCHINA

• Posizionare il selettore marce ed il cambio meccanico in folle.

• Inserire il freno di stazionamento e controllare che la spia sia accesa.

• Avviare il motore ruotando il commutatore di avviamento in posizione e mantenerlo fino allo spegnimento della spia. Ruotarlo q u i n d i i n p o s i z i o n e p e r l’avviamento del motore. Qualora, d o p o c i r c a 2 0 s e c o n d i , l'avviamento del motore non avesse luogo, rilasciare la chiave ed attendere circa due minuti prima di tentare un nuovo avviamento.

USO DELLE LEVE DI COMANDO

Premere sempre il pulsante di comando intenzionale , prima di eseguire un comando

• Abbassamento/sollevamento del braccio azionare la leva in direzione -

• Brandeggio indietro/avanti dell'attrezzo terminale azionare la leva in direzione -

• Richiamo/sfilo del braccio telescopico premere il pulsante sulla leva ed azionare la leva di comando in direzione

-

• Blocco/sblocco attrezzi premere il pulsante per sbloccarli ed azionare la leva in direzione per bloccare gli attrezzi, in direzione

INDICATORE DI STABILITA’ (ARB)

Durante il lavoro mantenere sotto controllo l’indicatore di stabilità.

Gli 8 LED indicano:

LED verdi 1-2-3-4 Macchina stabile

LED gialli 5-6 M a c c h i n a i n s t a b i l e . S p i a ro s s a

LED rossi 7-8 lampeggiante ed allarme acustico intermittente

Macchina in allarme. Pericolo di ribaltamento. Spia rossa accesa ed allarme acustico continuo. Eseguire il rientro in condizioni di sicurezza.

1 2 3 4 5

6

7

8

ATTENZIONE

E’ vietato utilizzare la macchina e gli accessori senza prima aver letto e compreso le norme di utilizzo e di sicurezza contenute nel manuale di istruzioni.

Il mancato rispetto delle norme di utilizzo e di sicurezza puo’ causare pericolo grave all’operatore e a terzi.

Le istruzioni sono consegnate con la macchina e copie aggiuntive possono essere richieste al rivenditore o direttamente a Terexlift.

L’operatore è responsabile del rispetto delle norme sopra riportate non sollevare carichi se la macchina appoggia su terreno instabile o inclinato.

Non sollevare mai carichi superiori a quelli indicati in tabella.

Non sono ammesse manovre di sollevamento con macchina in movimento.

P r i m a d i a b b a n d o n a r e i l p o s t o d i m a n o v r a :

- abbassare eventuali carichi sospesi

- portare in posizione di riposo gli organi di comando del braccio

- posizionare la leva marcia avanti-indietro in folle, inserire il freno a mano e arrestare il motore.

Norme per l'utilizzo di macchine dotate di stabilizzatori

E’ vietato utilizzare gli stabilizzatori se il carico è già sollevato: gli stabilizzatori servono solamente ad aumentare la stabilità della macchina.

L'uso scorretto degli stabilizzatori può causare il ribaltamento della macchina.

Una apposita spia sul cruscotto indica che gli stabilizzatori sono abbassati: accertarsi che la spia sia accesa.

Prima di sollevare il carico livellare la macchina controllando l'apposito indicatore di livello.

5

4

3

2

1

0 m

-1

4

6

2506

3 2

3340

1

2000 Kg

2500 Kg

0

450

5750

500

Page A-3

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XX

Description: label with yellow background and black inscription showing the “ Guaranteed sound power level ”.

Meaning: it indicates the guaranteed sound power level measured in accordance with the Directive 2000/14/EC

Location: in the cab, on the rear left-side glass.

DANGER

ELECTRIC CABLES AND

POWER LINES

KEEP EVERY PART OF THE MACHINE, LOADS AND

ACCESSORIES AT LEAST 6 METERS FROM

OVERHEAD POWER LINES

Description: label with transparent background “ Use limits close to electric lines ”.

Meaning: it defines the minimum distance to be kept when the machine is used close to aerial electric lines.

Location: in the cab, on the windscreen, to the right of the driving place.

VIETATO APRIRE CON MOTORE IN MOTO

DO NOT OPEN WHILE ENGINE IS RUNNING

N'OUVRIR QU'A L'ARRET DU MOTEUR

ÖFFNEN NUR BEI STILLSTEHENDEM MOTOR

ABRIR SOLO CON MOTOR PARADO

PROIBIDO ABRIR COM O MOTOR LIGADO

VERBODEN KOFFERBAK TE OPENEN WANNEER DE MOTOR DRAAIT.

Description: label on yellow background “ Do not open while engine is running ”.

Meaning: do not open the engine bonnet when engine is running, since this may result in serious injury due to moving parts or hot components.

Location: on the engine bonnet.

Page A-4

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6

5

4

3

2

1

0

-1

4 3

2500 Kg

2

3340

1

450

0

500

5750

Description: label with transparent background "Load chart".

Meaning: it defines the exact working limits of the machine (in terms of payload and reach ) to be strictly respected by the operator when using the machine.

Location: in the cab, inside the quick-guide fixed to the upright with a magnet

In the TCE version the label is applied on the cab glass, to the right of the driving seat.

IMPORTANT

The load charts shown in these pages are supplied as mere example. For the payload limits, see the load charts referring to the specific machine model.

Page A-5

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KEEP OUT OF

WORKING RANGE

Description: label on yellow background with black drawing " Hot surfaces. Risk of burns ".

Description: red/white label “ Keep out of the working range of the machine ”.

Meaning: when the machine is running, entering the working range of the machine is prohibited.

Location: on the telescopic boom, both on the right and on the left.

Meaning:

Applied on those surfaces which during operation can become hot and cause burns.

Location:

In all parts involved such as exhaust silencer, thermal engine, heat exchanger.

Description: label on yellow background with black drawing

Description:

" Unscrew the plug with extreme caution: hot oil. Risk of burns!

".

Description: label with white background “ Keep out of the working range of the machine ”.

Meaning: when the machine is running, entering the working range of the machine is prohibited.

Location: one on the right side in the casing of the engine compartment one on the left side on the fuel tank

Meaning:

Warns the operator of the risk of burns when unscrewing the plug of the compensation tank of the heat exchanger.

Location: on the heat exchanger.

Page A-6

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WARNING

ONLY AUTHORIZED PERSONNEL CAN OPERATE

THIS EQUIPMENT. THE MANUFACTURER/DEALER

TAKE NO RESPONSABILITY FOR DAMAGE OR

INJURY CAUSED BY MISUSE OF THIS EQUIPMENT.

BEFORE OPERATING THE MACHINE ENSURE YOU

HAVE READ AND UNDERSTOOD THE SAFETY

GUIDELINES GIVEN IN THE MACHINE’S MANUAL.

THE INSTRUCTIONS ARE DELIVERED WITH THE

MACHINE; ADDITIONAL COPIES MAY BE

OBTAINED FROM YOUR DEALER OR DIRECTLY

FROM TEREXLIFT.

WARNING

DO NOT RAISE BOOM ON UNSTABLE OR SLOPING

GROUND.

NEVER EXCEED MAXIMUM PERMITTED LOADS

(SEE LOAD CHARTS).

EXERCISE CAUTION WHILE USING THE BOOM IN

A RAISED POSITION.

BEFORE LEAVING THE CAB ENSURE THE

FOLLOWING:

- TRANSMISSION IS NEUTRAL.

- PHAND BRAKE IS ON.

- BRING ANY LOAD TO THE GROUND.

- IGNITION SWITCH IS OFF AND KEY REMOVED.

WARNING

SAFETY GUIDELINES FOR MACHINES EQUIPPED

WITH STABILIZERS

NEVER USE THE STABILIZERS IF THE LOAD IS

ALREADY RAISED; THE STABILIZERS CAN BE USED

ONLY TO INCREASE THE STABILITY OF THE

MACHINE.

MPROPER USE OF THE STABILIZERS CAN CAUSE

INSTABILITY.

ENSURE THAT THE STABILIZER INDICATOR LAMP

IS ON BEFORE USING THE BOOM.

BEFORE RAISING ANY LOAD, LEVEL THE MACHINE

BY MEANS OF THE LEVEL INDICATOR.

Description: label with transparent background “ General application limits ”.

Meaning: it defines the main limits to be strictly obeyed by the operator when using the machine.

Location:

Present only in the TCE version : within the cab, on the windscreen, to the right of the driving place.

Description: label with transparent background explaining the use of the control lever.

Meaning: by means of special symbols, this label explains all pfunctions and motions of the control lever and the pushbuttons.

Location:

Present only in the TCE version : in the cab, on the windscreen, to the right of the driving place.

Page A-7

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■ A-1.3

EXPLANATION OF THE DIFFERENT

SYMBOLS USED ON THE MACHINE

This paragraph illustrates those symbols that are normally applied on the main control devices and instruments of a standard machine, and those that can be applied on accessories or special attachments.

They are mainly (ISO) standardised symbols that are now part of the common life. But we consider useful to explain them once again.

IMPORTANT

Spend the necessary time to become familiar with these symbols and to learn their meaning.

Symbol Description

Hazard warning lights

Windscreen wiper

Windscreen washer

Cab ventilation fan

Fuel gauge


Steering mode switch

Engine oil pressure

Boom up

Boom down

Boom out

Boom in

Hydraulic oil temperature

Attachment locked

Position lights

High beam

Turn signals

Parking brake

Battery charge

Attachment unlocked

Fork pitching forward

Fork pitching back

Oil filter clogged

Attachment pushbutton

Air filter clogged

Glow plug preheating

Page A-8

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Front (optional) work light


Road/jobsite selector switch

Lifting point

Fuel plug

Engine oil filler

Engine oil dipstick

Page A-9

Document 57.0003.5200 - 10/2004



A-2 MACHINE IDENTIFICATION

IMPORTANT

Check that the operator handbook refers to the delivered machine.

When asking for information or technical assistance, always specify model, type and serial number of the machine.

■

A-2.1

MACHINE MODEL AND TYPE

Handler with telescopic boom:

❑ model GTH-2506

Fig. A 8

■ A-2.2

MANUFACTURER

TEREXLIFT srl

Zona Industriale (Ind. Estate) - I-06019 UMBERTIDE

(PG) - ITALY

Enrolled in the register of companies at the Court of

Perugia under no. 4823

C.C.I.A.A. n ° 102886

Fiscal Code/V.A.T. no. 00249210543

TEREXLIFT srl - ZONA INDUSTRIALE - 06019 UMBERTIDE (PG) - ITALY

Tel. (075) 941.811 Fax (075) 941.53.82 Telex 66106 ITALMA I

MODELLO - MODEL - MODELE - TYP - MODELO

ANNO DI COSTRUZIONE - YEAR OF MANUFACTURE - ANNEE DE FABRICATION

BAUJAHR - AÑO DE FABRICACIÓN

MATRICOLA - SERIAL N. - N. DE SERIE - FZ.-IDENT NR. - NO. DE SERIE

PESO MAX ASSALE ANT. - MAX FRONT AXLE WEIGHT - POIDS MAX ESSIEU AVANT

ZUL. ACHSLAST VO. N. ST VZO - PESO MAX EJE ANTERIOR

PESO MAX ASSALE POST. - MAX REAR AXLE WEIGHT - POIDS MAX ESSIEU ARRIERE

ZUL. ACHSLAST HI. N. ST VZO - PESO MAX EJE POSTERIOR

PESO TOTALE - TOTAL WEIGHT - POIDS TOTAL - ZUL. GESAMTGEWICHT N. ST VZO

PESO TOTAL

MATRICOLA MOTORE TERMICO - ENGINE SERIAL N. - N. MOTEUR THERMIQUE

FABRIK NR. DIESEL MOTOR - NO. DE SERIE MOTOR TERMICO

OMOLOGAZIONE

200

FABBRICATO IN ITALIA - MADE IN ITALY kg kg

Fig. A 9

■ A-2.3

MACHINE IDENTIFICATION PLATES

Three identification plates are applied on the machine.

They are:

Machine data plate.

Placed on the driving seat base in a well visible position when opening the cab door ( Fig. A8 ) or instead of the road traffic data plate ( Fig. A10 ) on machines destined for foreign markets.

The identification plate ( Fig. A9 ) contains the main identification data of the machine like model, serial number and year of manufacture.

ROPS-FOPS cab type-approval plate.

Placed on the driving seat base in a well visible position when opening the cab door ( Fig. A8 ).

Fig. A10

Page A-10

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Road traffic data plate.

Placed on the front right side of the chassis (only for machines destined for the Italian market). This plate contains the road traffic related data and the weights of the specific machine model ( Fig. A11) .

DATI OMOLOGAZIONE STRADALE

TIPO

OMOLOGAZIONE

NUMERO DI IDENTIFICAZIONE

MASSA TOTALE AMMISSIBILE (*)

CARICO MAX ASSE ANTERIORE (*)

CARICO MAX ASSE POSTERIORE (*)

(*) In funzione della gommatura

MASSA RIMORCHIABILE AMMISSIBILE:

MASSA NON FRENATA

MASSA CON FRENATURA INDIPENDENTE

MASSA CON FRENATURA AD INERZIA

MASSA CON FRENATURA ASSISTITA

COEFFICIENTE DI ASSORBIMENTO

CORRETTO DEL MOTORE da kg a kg da kg a kg da kg a kg kg kg kg kg m

-1

Zona Industriale, I-06019 Umbertide (PG) - Italy

Tel. +39 (0)75 941811 - Fax +39 (0)75 9415382

Fig. A11

■ A-2.4

CE MARK

This machine fulfils the safety requirements of the

Machinery Directive.The conformity has been certified and the placing of the CE marking on the machine demonstrates compliance with the regulatory requirements.

The CE marking is placed directly on the identification plate of the machine. ( Fig. A8 and A9 ).

■ A-2.5

CHASSIS SERIAL NUMBER

The chassis serial number is punched on the front left part of the chassis side member ( Fig. A10 ).

■ A-2.6

IDENTIFICATION PLATES OF THE MAIN

PARTS

The plates of the main components, not directly manufactured by TEREXLIFT srl (for instance, engines, pumps, etc.), are located where originally applied by the manufacturers.

Fig. A 8

TEREXLIFT srl - ZONA INDUSTRIALE - 06019 UMBERTIDE (PG) - ITALY

Tel. (075) 941.811 Fax (075) 941.53.82 Telex 66106 ITALMA I

MODELLO - MODEL - MODELE - TYP - MODELO

ANNO DI COSTRUZIONE - YEAR OF MANUFACTURE - ANNEE DE FABRICATION

BAUJAHR - AÑO DE FABRICACIÓN

MATRICOLA - SERIAL N. - N. DE SERIE - FZ.-IDENT NR. - NO. DE SERIE

PESO MAX ASSALE ANT. - MAX FRONT AXLE WEIGHT - POIDS MAX ESSIEU AVANT

ZUL. ACHSLAST VO. N. ST VZO - PESO MAX EJE ANTERIOR

PESO MAX ASSALE POST. - MAX REAR AXLE WEIGHT - POIDS MAX ESSIEU ARRIERE

ZUL. ACHSLAST HI. N. ST VZO - PESO MAX EJE POSTERIOR

PESO TOTALE - TOTAL WEIGHT - POIDS TOTAL - ZUL. GESAMTGEWICHT N. ST VZO

PESO TOTAL

MATRICOLA MOTORE TERMICO - ENGINE SERIAL N. - N. MOTEUR THERMIQUE

FABRIK NR. DIESEL MOTOR - NO. DE SERIE MOTOR TERMICO

OMOLOGAZIONE

200 kg kg

FABBRICATO IN ITALIA - MADE IN ITALY

Fig. A 9

Fig. A10

Page A-11

Document 57.0003.5200 - 10/2004



A-3 ALLOWED USE

■ A-3.1

ALLOWED USE

The handlers have been designed and manufactured for lifting, handling and transporting agricultural or industrial products by means of specific attachments

(see section F ) manufactured by TEREXLIFT srl.

Any other use is considered contrary to that established and, therefore, improper.

The compliance with and the strict respect of the operation, maintenance and repair conditions, indicated by the Manufacturer, represent an essential part of the allowed use.

The handler must be used and serviced only by operators knowing its characteristics and the safety procedures in depth.

It is also essential to comply with the safety at work legislation, the precautions concerning safety and industrial medicine as well as the local and national road traffic regulations.

IMPORTANT

Effecting changes or carrying out interventions on the machine other than those of routine maintenance is expressly forbidden. Any modification of the machine not carried out by

GENIE or an authorised assistance centre involves the automatic invalidation of the conformity of the machine to the Directive 98/37/EC.

■ A-3.2

IMPROPER USE

Improper use means a utilisation of the handler following working criteria that do not comply with the instructions of this manual, and that, in general, may result in risks for both operators and bystanders.

DANGER

We list below some of the most frequent and hazardous situations of improper use:

Carrying passengers on the machine

Not strictly complying with the operation and maintenance instructions of this handbook

Working beyond the handler working limits

Working on unstable edges of ditches

Driving crosswise on slopes or hills

Working during a storm

Working on steep slopes

Using attachments other than those recommended

Using attachments not approved or directly manufactured by Terexlift

Working in potentially explosive areas

Working in confined and non-ventilated environments.

■ A-3.3

RESIDUAL HAZARDS

Although the machine has been designed and manufactured according to the latest technology and all expected hazards have been eliminated, some operations performed by the machine operator can result in potentially hazardous situations. Among them:

• Hazards deriving from a too high work or transfer speed in relation to the load handled or the ground condition of the jobsite.

• Hazards deriving from work procedures adopted during the check or replacement of a block valve

(residual pressure - uncontrolled movements).

• Hazards deriving from work procedures adopted while disassembling parts of the machine -e.g. the cylinders, without supporting mobile parts suitably

(risk of uncontrolled fall of the mobile part).

• Hazard deriving from an accidental overturning of the machine in the event the operator has not fastened the safety belts.

Page A-12

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■ A-3.4

APPLICABLE STANDARDS

For the operator’s safety, the following standards were obeyed during the risk assessment of the handler fitted with telescopic boom:

Directive Title

98/37/CE

89/336/CEE

2000/14/CE

Machinery Directive

Electromagnetic compatibility

Environment Acoustic Emissions

Standard Title

EN 1459:1988

EN 281:1988

Harmonised standard. Safety of industrial trucks - Self- propelled variable reach trucks.

Self-propelled industrial trucks sit- down rider-controlled. Rules for the construction and layout of pedals.

EN 1175-2:1998 Electrical requirements - General requirements of internal combustion engine powered trucks prEN ISO 13564:1996 Test method for measuring visibility from self-propelled trucks.

ISO 2330:1995 Fork-lift trucks - Fork arms - Technical characteristics and testing.

ISO/DIS 3287 Powered industrial trucks. Pictorial signs.

Control symbols.

ISO 3449:1992 Earth-moving machinery - Falling-object protective structures - Laboratory tests and performance requirements.

EN 13510: 2002 Earth-moving machinery - Roll-over protective structures - Laboratory tests and performance requirements.

ISO 3776:1989 Tractors for agriculture - Seat belt anchorages.

ISO 3795:1989 Road vehicles, tractors and machinery for agriculture and forestry -

Determination of burning behaviour of interior materials.

ISO 5053:1987 Powered industrial trucks - Terminology.

ISO 6292:1996 Powered industrial trucks and tractors - Brake performance and component strength.

EN 13059:2002 Safety of industrial trucks - Test methods for measuring vibration

EN 50081-1: 1997 Electromagnetic compatibility – Generic requirements on emissions - Part 1

EN 50082-1: 1997 Electromagnetic compatibility – Generic requirements on immunity - Part 1

EN 60204-1:1998 Safety of machinery - Electrical equipment of machines - Part 1

Page A-13

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■ A-3.5 SAFETY DEVICES

• Load limiting device. A load cell is fitted to the rear axle. The cab display with 8 LED’s (4 green, 2 yellow and 2 red) lets you estimate the variation of stability of the machine.

• Emergency stop pushbutton: when pressed down, it stops the engine and blocks the movements of the machine.

Before starting work again, find and rectify the causes which compelled to an emergency stop, then reset the button to neutral position pressing it down while turning clockwise.

• Safety pushbutton on joystick (dead man button) .

(Not present in the TCE version)

This button must be pressed and held down while executing a function with the control lever. If the button is released, the movement in progress will be blocked.

• Presence micro-switch in the driving seat

(only in the TCE version)

Located inside the seat cushion, it prevents any machine starting if the operator is not correctly seated in the driving seat.

Page A-14

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• Block valves fitted to all cylinders:

A Block valve on attachment coupling cylinder

B Block valve on lifting cylinder

C Block valve on balance cylinder

D Block valve on boom extension cylinder

E Block valve on attachment pitching cylinder

Page A-15

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A-4 GENERAL DESCRIPTION

■ A-4.1

LIST OF THE MAIN COMPONENTS

1 - Forks

2 - Attachment holding frame

3 - 2 nd boom section

4 - 1 st boom section

5 - Engine hood

6 - Driving cab according to ROPS-FOPS provisions

7 - Left rear view mirror

8 - Beacon

9 - Front axle

10 - Chassis

11 - Left front wheel mud-guard

12 - Left front wheel reduction gear

13 - Access door

14 - Left rear wheel reduction gear

Page A-16

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■ A-4.2

DESCRIPTION OF THE MAIN COMPONENTS

Hydrostatic transmission

This unit consists of parts which drive the machine shifting, and namely:

a variable displacement pump connected to the thermal engine by an elastic joint

a motor with variable displacement and automatic adjustment in relation to the wheel torque required, complete with power divider, directly applied on the rear axle

a hydraulic oil filter, placed on the discharge line to the tank

a heat exchanger to cool the circuit down.

Motion is transmitted to the rear axle from the power divider through a Cardan shaft.

Engine

The thermal engine is equipped with a heat exchanger which uses the engine oil as cooling medium.

Steering axles/(front and rear) differential gears

The differential axles transmit the motion to the wheels.

The locking device acting on the front axle enables the machine to move also on low grip grounds.

Tyres

The machine is equipped with tyres suitably sized for the maximum load allowed on the handler.

When worn, they shall be replaced with new ones having the same dimensions and loading capacity.

Overload warning system

The overload warning system installed on the vehicle enables the operator to work in safety conditions. A display with 6 LED's hows the stability variation. When th the 6 red LED comes on, the machine movements are blocked, except for the boom retraction under safe conditions.

Boom hydraulic circuit

It consists of a gear pump connected to the thermal engine which, through a special valve, dispenses oil to the hydraulic drive and a distributor for the following functions:

boom lifting/lowering

telescopic boom extension/retraction

attachment rotation

attachment locking

Braking circuit

It consists of an independent circuit: the pedal directly acts on the brake pump which dispenses oil to the front axle braking unit with discs in oil bath.

The parking brake, of negative type, acts on the braking unit of the service brake. This brake is engaged every time the handler's engine is stopped or pressing down the light pushbutton located to the right of the driving place.

Telescopic boom

The machine is equipped with a telescopic boom with hydraulic-driven extension. The telescopes slides on interchangeable pads made of wearproof material.

Driving cab

Type-approved driving cab in compliance with standards ISO 3449 and EN 13510 (ROPS and FOPS).

■ A-4.3

OPTIONAL ACCESSORIES

The machine can be fitted with a wide range of optional accessories: please address to Genie sales network.

IMPORTANT

Please check the accessories available for your machine.

Page A-17

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A-5 TECHNICAL DATA AND PERFORMANCE

D

F

G

H

■

A-5.1

MAIN DIMENSIONS

A Overall height

B Height to the steering wheel

C Overall width

D Cab width

E Track

F Wheel-base

G Length to the front tyres

H Length to the attachment holding plate

I Ground clearance

• Internal steering radius

• External steering radius

■

A-5.2 RESTRICTIONS OF USE

• Angle of approach

• Departure angle

• Ambient temperature

■

A-5.3 WEIGHT

• Weight in working order

■

A-5.4 SPEED

Travel speed

Max. slope with full load

Page A-18

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E

C

° C kg km/h mm mm mm mm mm mm mm mm mm mm mm

GTH-2506

1920

1230

1800

860

1500

2280

3310

3720

360

1730

3400

90 °

70 °

-20 ° /+40 °

4470

23

60%



■ A-5.5

PAYLOAD AND REACH

Max lifting height

Reach at max height

Max reach forward

Attachment holding plate rotation

Maximum payload

Payload at max height

Payload at max reach

■ A-5.6

FORKS

Dimensions

Weight

Fork holding frame - class

■

A-5.7

DIESEL ENGINE

Make

Model/Type

Features: mm kg

Fixed type

1200x100x35

45+45

FEM II A mm mm mm kg kg kg

GTH-2506

5750

450

3340

135 °

2500

1250

800

Floating type

1200x100x40

52+52

FEM II A mm cc kW

Aspirated version

DEUTZ AG

F4M 2011

Diesel

4 cylinders in line

4 strokes direct injection

94 x 112

3108

46,5

Bore x Stroke

Total displacement

Power at 2600 rpm (ISO 3046 IFN)

■

A-5.8

ELECTRICAL SYSTEM

Voltage

Battery

V

Ah

12

100

■

A-5.9

MACHINE SOUND LEVELS

Guaranteed sound power level

(in accordance with the Directive 2000/14/CE)

Measured sound pressure level

(in accordance with the Directive 98/37/CE)

■ A-5.10

VIBRATION LEVELS

Mean assessed vibration level transmitted to arms

Mean assessed vibration level transmitted to body

Values calculated in accordance with standard prEN13059 dB dB

Lwa =

Lpa =

m/s 2 m/s 2

103

< 2.5

< 0.5

IMPORTANT

This is a device of Class A. In a residential environment, such device can cause radio disturbance. In such cases, the operator is required to take suitable measures.

Page A-19

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A-6 LIFETIME

The lifetime of the machine is 10 000 hours provided all checks, service jobs and overhauls are done at the times scheduled.

DANGER

After this time, the machine must compulsorily be inspected and tested by the Manufacturer before being used again.

A-7 ITEMS SUPPLIED

Following items are supplied together with the machine:

Description

- Spanner CH 19

(for fork positioning)

- Allen wrench CH 6

(for fork positioning)

- 12 V lamps

(spare)

GTH-2506

✘

✘

✘

■

A-7.1

LITERATURE SUPPLIED

The machines comes with the following literature:

Machine operator's handbook

DEUTZ engine use and maintenance manual

Page A-20

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SAFETY

Section

B

SAFETY


B-1

B-2

B-2.1

B-2.2

B-2.3

B-2.4

B-3

B-3.1

B-3.2

B-3.3

B-4

B-5

GENERAL REMARKS .................................................................................................

B-2

PREREQUISITES OF THE PERSONNEL IN CHARGE ...............................................

B-2

Requisites of the machine operators .........................................................................

B-2

Requisites of the servicemen .....................................................................................

B-3

Working clothes ..........................................................................................................

B-3

Personal protective equipment ..................................................................................

B-3

SAFETY PRECAUTIONS ............................................................................................

B-4

Job site .......................................................................................................................

B-4

Getting ready to work .................................................................................................

B-5

During work or maintenance ......................................................................................

B-5

SAFETY DEVICES ......................................................................................................

B-7

LOAD LIMITING SYSTEM ..........................................................................................

B-7

Page B-1

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SAFETY

B-1 GENERAL REMARKS

Most accidents occurring while working, repairing 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.

IMPORTANT

If you recognise hazardous situations, you can prevent accidents!

For instance, this handbook makes use of special safety symbols to stress any potentially hazardous situation.

CAUTION

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 installation, 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 shall absolutely:

• be sure that the operations you are going to carry out are not explicitly forbidden;

• be sure that the methods are safe, say, in compliance with the rules and provisions 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.

B-2 REQUISITES OF THE

PERSONNEL IN CHARGE

■

B-2.1

REQUISITES OF THE MACHINE

OPERATORS

The operators who use the machine regularly or occasionally (i.e. for transport reasons) shall have the following prerequisites: 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 enforced 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 identification and hazard warning plates. They shall be skilled and trained about the machine use.

IMPORTANT

The operator shall have a licence (or a driving licence) when provided for by the laws enforced in the country where the machine works. Please, ask the competent bodies. In Italy the operator must be at least 18 year old.

IMPORTANT

If in doubt, it is always better to ask! For this purpose, 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.

Page B-2

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SAFETY

■ B-2.2

REQUISITES OF THE SERVICEMEN

The personnel charged with the machine maintenance shall be qualified, specialised in the maintenance of earth-moving machines, and shall have the following prerequisites: physical: good eyesight, acute hearing, good co-ordination and ability to carry out all required maintenance operations in a safe way, according to this manual.

mental: ability to understand and apply the enforced 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 training: they shall read and familiarise with this handbook, its enclosed graphs and diagrams, the identification and warning plates. They shall be skilled and trained about the machine functioning.

■ B-2.4

PERSONAL PROTECTIVE EQUIPMENT

Under special working conditions, the following personal protective equipment should be used:

• Breathing set (or dust mask).

• Ear-protectors or equivalent equipment.

• Goggles or facial masks.

IMPORTANT

Use only type-approved protective equipment in good condition.

IMPORTANT

From a technical point of view, the ordinary maintenance of the machine is not a complex intervention and can be carried out by the machine operator, too, provided he has a basic knowledge of mechanics.

■ B-2.3

WORKING CLOTHES

During work, but especially when maintaining or repairing the machine, operators must wear suitable protective clothing:

• 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.

• Protective gloves.

• Working shoes.

IMPORTANT

Use only type-approved working clothing in good condition.

Page B-3

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SAFETY

B-3 SAFETY PRECAUTIONS

■ B-3.1

JOB SITE

Always take into account the features of the job site where you are going to work:

• Always examine the working area and compare it with the machine dimensions in the different configurations.

• Look for the best route to the job site.

• When the machine is running, nobody can enter its working range.

• While working, keep the working area in order.

Never leave objects scattered: they could hinder the machine movements and represent a danger for personnel.

ELECTRICAL

DANGER

Pay the greatest attention to overhead electric lines.

Always keep at a minimum safe distance from the telescopic boom and the lifted load. Electrical hazards!

DANGER

Do not at any time use the machine during a storm.

DANGER

DEATH OR INJURY CAN RESULT FROM

CONTACTING ELECTRIC POWER LINES.

ALWAYS CONTACT THE ELECTRIC POWER LINES

OWNER. THE ELECTRIC POWER SHALL BE

DISCONNECTED OR THE POWER LINES MOVED

OR INSULATED BEFORE MACHINE OPERATIONS

BEGIN

POWER LINE VOLTAGE REQUIRED CLEARANCE

0 a 50 kV 10 ft 3.00 m

50 a 200 kV 15 ft 4.60 m

200 a

350 a

350 kV

500 kV

500 a 750 kV

750 a 1000 kV

20 ft

25 ft

35 ft

45 ft

6.10 m

7.62 m

10.67 m

13.72 m

CAUTION

Make sure the machine (wheels and stabilisers) rests on a firm ground to prevent hazardous unstable conditions.

If the ground is not firm enough, position some supporting planks under the stabilisers or the wheels. These plates must grant a specific pressure of 1.2 to 1.5 kg/cm 2 (500x500mm plates are sufficient).

Page B-4

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SAFETY

■ B-3.2

GETTING READY TO WORK

Before any operation, following precautions should be taken:

• First of all, make sure that the maintenance interventions have been carried out with care according to the established schedule (see section

D - Maintenance ).

• 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 1.5 meters from the ground), always use type-approved safety belts or fall preventing devices.

CAUTION

Set the machine to working configuration and sway it. Use the special inclinometer to the right of the driving place to check that the machine is level before operating it.

• Ensure you have enough fuel to avoid a sudden stop of the engine, especially during a crucial manoeuvre.

• Clean instruments, data plates, lights and the cab windscreen thoroughly.

• Check the correct functioning of all the safety devices installed on the machine and in the job site.

• In case of troubles or difficulties, inform the foreman at once. Never start working under unsafe conditions.

• Do not carry out any repair work in a makeshift way to start working!

• Do not enter/leave the machine while it is running.

• 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 required, stop the engine.

■ B-3.3

DURING WORK OR MAINTENANCE

During work, and especially maintenance, always pay the greatest attention:

• 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.

• 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, check their connection and proper functioning.

• Do not carry out interventions on electric components with voltage over 48V .

• Do not connect wet plugs or sockets.

• Plates and hazard warning stickers shall never be removed, hidden or become unreadable.

Page B-5

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SAFETY

• Except for maintenance purposes, do not remove safety devices, shields, protection cases, etc.

Should their removal be necessary, stop the engine, remove them with the greatest care and always remember to refit them before starting the engine and using the machine again.

• Before any maintenance or repair work, stop the engine and disconnect the batteries.

• Do not lubricate, clean or adjust moving parts.

• Do not carry out operations manually when specific tools are provided for this purpose.

• Absolutely avoid to use tools in bad conditions or in an improper way i.e. pliers instead of adjustable wrenches, etc.

• Before carrying out operations on hydraulic lines under pressure or disconnecting hydraulic components, ensure the relevant line has been previously depressurised and does not contain any hot fluid.

DANGER

Any intervention on the hydraulic circuit must be carried out by authorised personnel.

The hydraulic circuit of this machine is fitted with pressure accumulators. You and others could be seriously injured if accumulators are not completely depressurised.

For this purpose, shut the engine down and step on the brake pedal 8

÷

10 times.

• Neither smoke nor use open flames in areas subject to fire dangers and in presence of fuel, oil or batteries.

Page B-6

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SAFETY

• 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.

B-4 SAFETY DEVICES

DANGER

Several safety devices have been fitted to the machine. They must never be tampered with or removed (see chap. A-3.5) .

Regularly check the efficiency of such devices (see check card, chap. G-5) .

In case of faults, stop working immediately and proceed in replacing the defective device.

For the checking procedures, read chap. D-3.15

.

• Do not tamper with fire-extinguishers or pressure accumulators: explosion hazard!

• After any maintenance or repair work, make sure that no tool, cloth or other object has been left within machine compartments, fitted with moving parts, or where suction and cooling air circulates.

• When working, do not give instructions or signs to several people at the same time. 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.

■

B-3.5 LOAD LIMITING SYSTEM

The load limiting system has been developed to help use the machine in safety conditions and alerting with visual and sound messages when the machine is nearing a danger zone.

However this device cannot replace the experience of the Operator. It is up to the user to adopt the necessary safety measures to work in safety conditions.

Page B-7

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SAFETY


Page B-8

Document 57.0003.5200 - 11/2003



Section

C

OPERATING INSTRUCTIONS


C-1 BEFORE ENTERING THE MACHINE .... C-2

C-2 ENTERING THE MACHINE ................... C-3

C-2.1

Entering the cab ................................... C-3

C-2.1

.

1 Emergency exit-way ............................. C-4

C-2.2

Adjusting the seat ................................. C-5

C-2.3

Fastening the seat belts ....................... C-5

C-2.4

Adjusting the steering column .............. C-6

C-2.5

Adjusting the rear view mirrors ............. C-6

C-2.6

Switching on the cab interior lamp ....... C-6

C-3 DRIVING PLACE ................................... C-7

C-3.1

Controls and instruments ..................... C-7

C-3.2

Engine controls and instruments .......... C-9

C-3.2.1

Ignition switch ....................................... C-9

C-3.2.2

Forward/reverse gear switch ................ C-9

C-3.2.3

Turn signals - windscreen wiper lights - horn switch ............................. C-10

C-3.2.4

Brakes ................................................. C-11

C-3.2.5

Accelerator control ............................. C-11

C-3.2.6

Pushbutton enabling the attachment coupling/release ................................. C-12

C-3.2.7

Steering mode selection ..................... C-12

C-3.2.8

Road/Jobsite switch ........................... C-12

C-3.2.9

Auxiliary drive controls ....................... C-13

C-3.3

Instruments and light indicators ......... C-14

C-3.3.1

Instruments ......................................... C-14

C-3.3.2

Light indicators ................................... C-14

C-3.4

Control lever ....................................... C-15

C-3.4.1

Function selection .............................. C-16

C-3.4.1.1

Function selection (TCE version) ......... C-17

C-3.4.2

Emergency stop .................................. C-18

C-3.4.2.1

Disabling the overload warning system .. C-18

C-3.4.3

Lifting/lowering the boom ................... C-19

C-3.4.4

Pitching the attachment holding frame forward/back ...................................... C-20

C-3.4.5

Extending/retracting the boom ........... C-21

C-3.4.6

Quick-coupling the attachments ........ C-22

C-4 SETUP ................................................ C-23

C-4.1

Before starting the engine .................. C-23

C-4.1.1

Checks at the machine start-up ......... C-23

C-4.2

Starting the engine ............................. C-23

C-4.3

Jump-starting the engine .................... C-24

C-4.4

Low temperature starting ................... C-25

C-4.5

Disconnecting the battery ................... C-25

C-4.6

Starting the machine ........................... C-25

C-4.7

Stopping and parking the machine .... C-26

C-5 USING THE HANDLER ....................... C-26

C-5.1

Using the load charts .......................... C-27

C-5.2

Load limiter ......................................... C-28

C-5.2.1

Description of the controls ................. C-28

C-5.2.2

Operation ............................................ C-28

C-5.2.3

Alarm codes and resetting .................. C-29

C-5.3

Handling loads .................................... C-30

C-5.3.1

Adjusting the forks .............................. C-30

C-5.3.2

Working phases .................................. C-31

C-5.4

Changing the attachment ................... C-32

C-6 TRANSPORTING THE MACHINE ....... C-33

C-6.1

Moving a disabled machine ................ C-33

C-6.1.1

Unlocking the negative brake ............. C-33

C-6.2

Road or site transfer ........................... C-34

C-6.3

Lifting the machine ............................. C-35

C-6.4

Transporting the machine on other vehicles ............................................... C-35

C-6.5

Parking and storage ........................... C-36

C-6.5.1

Short inactivity .................................... C-36

C-6.5.2

Machine storage ................................. C-36

C-6.6

Cleaning and washing the machine .... C-37

C-6.6.1

Cleaning instructions .......................... C-37

C-6.6.2

Washing instructions .......................... C-37

C-6.7

Machine disposal ................................ C-37

C-6.7.1

Disposal of batteries ........................... C-37

Page C-1

Document 57.0003.5200 - 10/2004



INTRODUCTION

This section provides the operator a practical guide for the gradual learning of the machine use.

The operator should get into the driving cab and carry out the preliminary adjustments, then memorise the position of the different controls and instruments.

The familiarisation with the controls ensures not only a correct use during the working phases, but also a prompt and timely intervention of the operator, when he shall carry out sudden manoeuvres to safeguard his safety and the machine integrity.

It is necessary to learn how to use and foresee the machine reactions. Learn how to operate the machine controls in a safe and open place, without obstacles and anybody standing around. Do not ram the controls.

Operate them slowly to understand their effect on the machine.

C-1 BEFORE ENTERING THE

MACHINE

Checks and cleaning

• Clean glasses, lights and rear view mirrors.

• Check that pins, joints and bolts are well tightened in position.

• Check for oil, fuel or coolant leaks.

Checking the tyres

• Check the correct inflation of the tyres; see par.

“ Tyre inflation ” in the Maintenance section.

• Make sure that the tyre plies are not cut or worn.

DANGER

A tyre burst may result in serious injury; never use the machine if tyres are worn, wrongly inflated or damaged.

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C-2 ENTERING THE MACHINE

■ C-2.1 ENTERING THE CAB

CAUTION

Always make sure that your hands and shoe soles are clean and dry before getting into the driving cab. Always face the machine when entering and leaving it and hold to the suitable handles.

The handler cab is equipped with an access door on the left-hand side.

Door opening from outside:

• Insert the key and release lock 1 .

• Press the pushbutton and open the door.

CAUTION

The upper section of the door must be secured to the rear part of the driving cab or latched to the lower section of the same door.

Door closing from inside:

• Pull the door with force: it locks automatically.

Door opening from inside:

• Lift lever 2 and release the lock to open the door completely.

• Rotate handle 3 to open the upper section of the door and lock it against the special catch.

To unlock the door latched in open position:

• Press button 4 to unlock the door from the catch, close and latch the door to the lower section using handle 3 .

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■ C-2.1.1

Leaving the cab in an emergency

In an emergency, the operator can use he front or the rear window as safety exit-ways.

The rear window has handles for partially opening the glass. Such handles are locked in position by some wing nuts 5 which, if driven out, allow opening the glass completely.

The front window has two handles 6 which, if turned, enable the operator to pass through.

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■ C-2.2 ADJUSTING THE SEAT

A correct adjustment of the seat ensures the operator a safe and comfortable driving. The handler seat is fitted with devices which allow for the adjustment of the springing, the height and the distance from the controls.

• Seat distance from the controls

The seat is equipped with an adjusting device to slide the same seat forward or back with respect to the steering column.

To adjust the seat, pull lever 1 outwards and push the seat to the desired direction. Then release the lever and make sure that the seat locks in position.

• Springing adjustment

Rotate lever 2 clockwise or anticlockwise according to the springing degree required. Rotate clockwise/ anticlockwise to increase/reduce the seat springing. To reverse this control, pull out and rotate the lever knob by 180 ° .

• Height adjustment

Turn knob 3 clockwise to lift the seat; turn it counter-clockwise to lower the seat.

In some seats height can be adjusted to three different positions. Lift the seat until you hear the click signalling that the seat is locked in position.

To lower the seat, raise to end of stroke to release the mechanism, then release the seat: it will return to the bottom position.

■ C-2.3

FASTENING THE SEAT BELTS

Sit correctly in the driving seat; then:

• The safety belts are equipped with reel retractor.

To fasten the belt, pull tab 1 and push it into buckle

2 .

• To release the belt, push button 3 and remove the tab from the buckle.

• Make sure that the buckle is correctly located at the hip point and not on the stomach.

• Operate the end adjusters to reach the length you wish and make sure the buckle is always in the middle.

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■ C-2.4

ADJUSTING THE STEERING COLUMN

Both steering column and dashboard can be set to a different angle. For this purpose:

• Loosen lever 1 and adjust as required, then retighten lever 1 .

DANGER

Before driving the machine, ensure the steering wheel is perfectly clamped.

■ C-2.5

ADJUSTING THE REAR VIEW MIRRORS

The machine is fitted with two rear view mirrors:

• The right rear view mirror is located on a special supporting bracket in advanced position and allows checking the area behind the machine, on the righthand side. To adjust its position, manually rotate the joint it is fitted with.

• The left rear view mirror is placed on the left upper post of the windscreen and allows checking the area behind the machine, on the left- hand side.

To adjust its position, manually rotate the joint it is fitted with.

■ C-2.6 SWITCHING ON THE CAB LIGHTS

The ceiling light fixture of the cab has an internal lamp and a courtesy lamp.

To switch on the cab interior lights:

• Switch 4 in pos. A

• Switch 4 in pos. B

• Switch 4 in pos. C cab interior lights OFF cab interior lights ON.

courtesy lamp ON

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C-3 DRIVING PLACE

■ C-3.1 CONTROLS AND INSTRUMENTS

1 Dashboard

2 Water level

3 Brake oil tank

4 Ignition switch

5 Turn signals - windscreen wiper - horn switch

6 Fuse compartment

7 Forward/reverse speed selection lever

8 Brake pedal

9 Steering column locking lever

10 Hazard lights switch

11 Steering selection switch

12 Road light switch

13 Gas pedal

14 Overload warning system display

15 Fresh air flap

16 Emergency stop button

17 Pushbutton enabling the attachment coupling/release

18 Control lever

19 Negative brake on/off switch

20 Road/Jobsite switch

21 Cab heater cock

22 Optional attachment switch with built-in green lamp (if any)

23 Air conditioning fan switch

24 Storage tray

25 Windscreen water reservoir

26 Seat

27 Storage pocket

28 Warning light - glow plugs preheating

29 Warning light - air filter clogged

30 Load limiter disabling key

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6

7

9

8



28 1 2

10 8 6

4 2 0 2 4 6 8 10

3 4 5

40

80

120

° C

N

F

R

0 1 2 3 4 5 6 7

40

80

120

° C

10 17 11 12 13

26

14

15

16

A C

18

30

19

20

21

23

22

24

25

27

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C-3.2

ENGINE CONTROLS AND

INSTRUMENTS

■

C-3.2.1

Ignition switch

Three-position switch:

No circuit under voltage, key can be removed and engine is stopped

Circuits under voltage, presetting for the engine starting. Board controls and instruments are on.

The warning light 28 signalling the glow plugs preheating comes on. Wait until the light goes off before starting the engine.

Engine starting; when released, key springs back to pos. automatically.

■

C-3.2.2

Forward/reverse gear selector switch

Three-position switch with lock in neutral position:

N

F

Neutral position; no gear engaged

Shift lever to pos. F to select the forward gear

R Shift lever to pos. R to select the reverse gear

40

80

120

° C

N

F

R

40

80

120

° C

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■

C-3.2.3 Turn signals - Windscreen wiper - Horn

- Lights

■

Horn function :

When sliding the lever along its axis, horn switches on, independently from other pre-set functions.

■

Lights function :

The lever operates the light switching and shall be used in conjuntion with pushbutton 12.

■

Windscreen washer function :

Push the second stage of the lever along its axis to direct a jet of water onto the cab windscreen.

■

Windscreen wiper function :

To operate the windscreen wiper, rotate the lever tip to one of the three positions:

Wiper OFF

Low speed

High speed

12 Road lights switch

1

2

3

Three-position switch placed on the dashboard on the right-hand side over the ignition switch.

Pushbutton in pos. 1 :

• Lever in position or : Lights OFF

Pushbutton in pos. 2 (the warning light 61 comes on):

• Lever in position or : Position lights ON

Pushbutton in pos. 3 :

• Lever in position : high beam ON (the warning lights 60 and 61 come on)

• Lever in position : low beam ON (the warning light

61 comes on)

• Lever in position : high beam intermittent signalling

(releasing the lever, it springs back to position )

■

Turn signals function :

Set lever to pos. to indicate a turn leftwards or to pos. to indicate a turn rightwards.

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■

C-3.2.4

Brakes

8 Service brake pedal

Gradually step on the brake pedal to decelerate and stop the machine. The pedal operates on the front axle.

Fully depressing the brake pedal causes a reset of the displacement of the power drive pump making the brake action more powerful.

■

C-3.2.5

Accelerator control

13 Gas pedal

Its pressure controls the engine rpm and, coupled to the gearbox, the machine speed. It is fitted with an adjustable stop in the lower part

19 Parking brake

The parking brake of negative type engages automatically when the engine is stopped.

When the handler’s engine is restarted, pressing the pushbutton switch 19 unlocks the parking brake.

To stop the handler without shutting down the engine, press the pushbutton switch 19 to engage the parking brake and push it once again to disengage the brake.

Every pressure of the pushbutton switches the warning light on and off. When the red warning light is on, the parking brake is engaged.

CAUTION

Never use the parking brake to slow down the machine, unless in an emergency. It may reduce the brake efficiency.

8

40

80

120

° C

N

F

R

0 1 2 3 4 5 6 7

40

80

120

° C

13

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■

C-3.2.6 Pushbutton enabling the attachment coupling/release

17 Selection button

Pushbutton with two stable positions.

Pressing this button activates the attachment coupling and release. The built-in button light switches on.

■ C-3.2.7

Steering mode selection

11 Steering mode switch

Three-position switch for the selection of the steering mode:

■

C-3.2.8

Road/Jobsite switch

20 Selection button

Button with two stable positions:

1 Press to select the road setting. The high speed can be engaged, the boom control is disabled and only the two-wheel steering is enabled. The built-in button light switches on.

2 Press the button again to select the work setting and enable the boom control and the four-wheel steering. The built-in button light switches off.

1 Crab steering

0 Two-wheel steering

2 Four-wheel steering

DANGER

Before switching on the ROAD function, align the rear wheels of the machine.

N

F

R

17 11

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A C

20



■

C-3.2.9

Auxiliary drive controls

Beacon

When the machine is started up, the beacon activates automatically.

22 Optional attachment pushbutton (if any)

Pushbutton with orange glass.

The pressure of this button causes the switching of the hydraulic circuit for the movement of the attachments equipped with auxiliary lines.

10 Hazard warning lights switch

Fitted with on-off position, it switches on the turn signals simultaneously

12 Road lights switch

This switch is located above the ignition switch and is used in conjunction with lever

5 ( see C-3.2.3

).

23 Air conditioning fan switch

Three-position switch:

0 OFF

1 Low speed

2 High speed

21 Cab heater control cock

To the right of the driving seat.

• Rotate clockwise for fresh air

• Rotate anticlockwise for warm air

• Adjust the flow of warm air within the cab by the air conditioning fan switch 23 .

40

80

120

° C

N

F

R

0 1 2 3 4 5 6 7

40

80

120

° C

5

10 12

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21

A C

23



C-3.3 INSTRUMENTS AND LIGHT

INDICATORS

■ C-3.3.1

Instruments

54 Engine coolant temperature indicator

Signals the engine coolant temperature.

40

80

120

° C

66

67

53 Fuel gauge

Signals the fuel level within the tank.

68

0 1 2 3 4 5 6 7

52 Hour-meter

Signals the total operating hours of the machine.

28

51

40

80

120

° C

Hydraulic oil temperature indicator

Signals the temperature of the hydraulic oil within the reservoir.

29

■

C-3.3.2

Light indicators

60

61

Indicator light - high beam

Blue indicator light that signals when high beam is ON.

Indicator light - position lights

Green indicator light that signals when position lights are ON.

63 Indicator light - air filter soiled

Not activated.

Indicator light - parking brake engaged

When ON, this light indicates that the parking brake is engaged.

Indicator light - negative brake accumulator

This light indicates that the accumulator of the negative brake is getting discharged.

Indicator light - turn signals

Green indicator light that signals when turn signals are ON.

Indicator light - glow plugs preheating

Green light indicators which signal the preheating phase of the engine glow plugs.

Before starting the engine wait for these lights to go off.

Indicator light - air filter soiled

Orange light indicator which signals when the air intake filter of the engine is getting soiled.

Clean or replace the filtering c a r t r i d g e immediately.

28

29

40

80

120

° C

N

F

R

60 61 62 63 64 65 66 67 68

64

65

Indicator light - low battery charge

Signals a low charge by the alternator.

Indicator light - low engine oil pressure

It lights when the engine oil pressure is too low.

40

80

120

° C

0 1 2 3 4 5 6 7

40

80

120

° C

51 52 54

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C-3.4 CONTROL LEVER

Handlers are equipped with an hydraulically driven servo-controlled lever.

The lever is equipped with two buttons for locking/ releasing the attachments and for extending/ retracting the telescopic boom .

When shifted to one of the four directions (right/left, forward/back), it controls the boom lifting/lowering and the forward/back pitching of the attachment frame.

It is also equipped with an intentional control button

that must be pressed and held in position until the movement is completed.

If the button is not pressed down, the lever, though operated, does not perform any function.

IMPORTANT

In the TCE version, the intentional control pushbutton is not installed.

For the functions of the control lever in the TCE version, please refer to par. C-3.4.1.1

.

IMPORTANT

Seize the control lever correctly and move it gently.

The motion speed of the actuators depends on the lever position: a small motion results in a slow motion of the actuators; vice versa, a full range motion of the lever corresponds to the max. speed of the actuator.

CAUTION

The control lever shall be operated only when correctly seated in the driving place.

CAUTION

Before operating the control lever, make sure that nobody is within the working range of the machine.

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OPERATING INSTRUCTIONS

C-3.4.1 Function selection

IMPORTANT


.

After pressing the intentional control pushbutton 4, the lever is enabled to carry out the following motions:

• Boom lowering/lifting shift the control lever to A or B

• Attachment back/forward tilting press button 2 and shift the control lever to C or

D

• Boom extraction/retraction shift the control lever to C or D

• Attachment coupling/release press button 3 together with the dashboard enabling button ( 17 ) and shift the lever to C or D

DANGER

When pressing the intentional control button 4 and the lever is not correctly set to central position, the control of the selected actuator is operated immediately.

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C-3.4.1.1 Function selection

For TCE version

The lever is enabled to carry out the following motions:

• Boom lifting/lowering

Smoothly shift the lever to position B to lift the boom or to position A to lower it.

• Boom extraction/retraction

Smoothly shift the lever to position D to extend the boom or to position C to retract it.

• Attachment forward/back tilting

Press button 2 and shift the lever to position D to tilt the frame forward or to position C to tilt it back.

• Attachment coupling/release

Press button 3 together with the dashboard enabling button ( 17 ) and shift the lever to position D to unlock the attachment or to position C to lock the attachment.

DANGER

Before operating the boom, make sure that no persons or animals are within the working range of the machine. Should that be the case, wait until the intruders leave the working range before operating the handler.

17

N

F

R

0 1 2 3 4

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C-3.4.2 Emergency stop

The operated functions can be stopped at any time by pressing the emergency stop button (21) .

By pressing this button, the engine of the machine is shut down.

Before restarting the machine, it is necessary to reset the pushbutton by rotating clockwise.

C-3.4.2.1 Disabling the load limiting system

The key-switch 30 lets you disable the load limiter.

DANGER

WORKING WITH THE LOAD LIMITER CUT OUT

CAN RESULT IN A MACHINE OVERTURNING AND

IN SERIOUS INJURY.

USE THIS OPTION ONLY IN CASE OF NEED AND

DON'T FORGET TO REACTIVATE THE LOAD LIMI-

TER AFTER THE EMERGENCY.

CAUTION

Before restarting the machine, find and rectify the faults that caused the emergency.

4 6 8 10

40

80

120

° C

21

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C-3.4.3 Lifting/lowering the boom

CAUTION

Before operating the boom, make sure that nobody is within the working range of the machine.

To lift or lower the boom:

• Set the control lever to central position and press button 4

• Smoothly shift the lever to position B to lift the boom or to position A to lower it.

IMPORTANT


.

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■ C-3.4.4 Extending/retracting the boom

CAUTION


• Set the control lever to central position and press button 4

• Smoothly shift the lever to position D to extend or to position C to retract the boom.

IMPORTANT


.

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■ C-3.4.5 Pitching the attachment holding frame forward/back

CAUTION


• Set the control lever to central position and press button

• Press button and shift the lever to position to extend the boom or to position to retract it.

IMPORTANT


.

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■

C-3.4.6

Quick-coupling the attachments

CAUTION


To lock the attachments:

• Shift the control lever to central position and press button

• Press button together with the dashboard enabling button ( 17 ) and shift the lever to position to unlock the attachment or to position to lock the attachment.

IMPORTANT


.

N

F

R

0 1 2 3 4

17

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C-4 SETUP

■ C-4.1

BEFORE STARTING THE ENGINE

• To ensure safe conditions to the operators and the bystanders, and a longer life to your machine, perform a walk-around inspection before starting the engine.

• Remove any dirt or rubbish from the cab interior, and especially from pedals and control levers.

• Remove oil, grease and mud from pedals and control levers.

• Make sure that your hands and shoe soles are clean and dry.

• Check the seat belts can be fastened properly.

• Check that lights, indicators, side/tail lights, hazard indicator lights, wipers and horn are in working order.

• Adjust the driving seat so that you can reach all control levers comfortably and fully depress the brake pedal without moving your back from the driving seat.

• Adjust the rear view mirrors to give you a good view close behind the machine when you are correctly seated.

• Check the parking brake is engaged.

■ C-4.2

STARTING THE ENGINE

For the low temperature starting, see paragraph C-4.4.

• Put the mechanical gear lever to neutral.

• Step on the gas pedal.

• To start the engine, turn the ignition switch to position . Release the switch when the engine starts. If the engine does not start within 20 seconds, release the key and wait at least 2 minutes before attempting again.

• After the start-up, let the engine run at idle for some seconds before engaging a gear; this allows for a gradual warm up of the engine oil and a better lubrication.

• In case of engine jump-starting, remove the booster cables (see following chapter).

ATTENTION

If the light indicators do not switch off/on when engine is running, immediately stop the machine and find and rectify the fault.

■

C-4.1.1

Checks at the machine start-up

When power is turned on, the load limiting system activates automatically. If the power supplied is correct, the green light 4 above the Terex logo comes on. The display remains off while the system runs a self-test.

After that, the system is activated and 0 appears on the display.

If during the check phase, the load limiting system finds a fault, it enters the safety mode automatically blocking any dangerous manoeuvres and an error message starts flashing on the display. For any further information, refer to chap. C-5.2

.

Also check the efficiency of the safety devices as described in chap. D-3.15

, namely:

• overload warning system

• joystick pushbutton (not present in the TCE version)

• seat micro-switch (only in the TCE version)

• parking brake proximity switch

• emergency pushbutton

• machine start control

IMPORTANT

Engine cannot be started if the speed switch is not in the neutral position and the operator is not correctly seated in the driving seat.

DANGER

After the start-up, when leaving the driving place, the engine continues to run. DO NOT LEAVE THE

DRIVING PLACE BEFORE HAVING SHUT THE

ENGINE DOWN, LOWERED THE BOOM TO THE

GROUND AND ENGAGED THE PARKING BRAKE.

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■ C-4.3



JUMP-STARTING THE ENGINE

DANGER

When jump-starting the engine through the battery of another machine, make sure that the two vehicles cannot collide to prevent formation of sparks.

Batteries give off a flammable gas and sparks may burn it and cause an explosion

Do not smoke when checking the electrolyte level.

Keep any metal object like buckles, watch straps, etc. clear of the battery positive (+) terminal. These elements can short between the terminal and nearby metal work and the operator can get burned.

The booster supply must have the same rated voltage and output of the battery installed on the handler.

To jump-start the engine:

• Turn any users off by the special control levers.

• Put the gear lever to neutral and engage the parking brake.

• Ensure the machine battery A is connected to the frame earth, the terminals are well tightened and the electrolyte level is regular.

• Connect the two batteries as shown in the figure.

Connect first the positive terminals of the two batteries, then the negative terminal of the booster supply B to the machine frame earth.

• If the booster supply is installed on a second vehicle, make sure that the latter does not touch the handler; then start the vehicle and reach an rpm corresponding to 1/4 of full throttle.

• Turn the ignition key and start the handler, then follow the procedure explained in chapter C-4.2

“Starting the engine”.

• Disconnect the cables. Remove first the negative terminal from the frame earth, then from the booster supply. Disconnect the positive terminal from the machine battery, then from the booster supply.

A

B

DANGER

Use only a 12V battery; other devices like battery chargers, etc. may cause an explosion of the battery or result in damage to the electrical system.

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■ C-4.4

LOW TEMPERATURE STARTING

In case of cold starting, use an oil with a SAE viscosity adequate to the ambient temperature.

Please refer to the DEUTZ engine use and maintenance manual.

■ C-4.5

DISCONNECTING THE BATTERY

During maintenance or repair works, and while welding, turn off the battery main switch , located behind the rear right wheel compartment.

The machine is supplied with oil SAE 15W/40.

To start the engine from cold, proceed as follows:

• Put the mechanical gear lever to neutral.

• Turn the ignition switch to position and wait until the warning light 28 signalling the glow plugs preheating goes off. Step down on the gas pedal and start the engine turning the ignition switch to

.

Release as soon as the engine starts.

• Let the engine run at idle for a few seconds before putting a gear; this allows for a gradual warm up of the engine oil and a better lubrication.

• In case of engine jump-starting, remove the booster ables (see chapter C-4.3).

■

C-4.6

STARTING THE MACHINE

When the engine reaches the running temperature, ensure all parts are in transfer position and the gearbox lever is in neutral. Then, proceed as follows:

• Select the required steering mode.

• Select the required gear (forward or reverse).

• Release the parking brake pressing button 19 (the warning light on the pushbutton must be off).

• Slowly step on the gas pedal to start moving off.

CAUTION

Do not operate the forward/reverse gear lever when the machine is running. The machine would reverse the running direction abruptly and you could seriously be injured.

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■ C-4.7

STOPPING AND PARKING THE

MACHINE

When possible, stop the machine on a dry, level and solid ground. Then:

• Bring the machine to a smooth stop by easing up the gas pedal and stepping down on the brake pedal.

• Set the forward/back speed lever to neutral position.

• Engage the parking brake pressing button 19 (the warning light on the pushbutton must be on).

• Release the service brake pedal.

• Rest the attachment coupled to the boom flat on the ground.

• Rotate the ignition key to “ 0 ” and remove the key.

• Leave the driving cab and lock the cab door.

• Set the battery cut-out switch to OFF position.

C-5 USING THE HANDLER

This chapter describes some techniques and provides instructions for a safe use of the machine fitted with standard forks. Before using different attachments, thoroughly read the chapter “Optional attachments".

CAUTION

Before using the machine, inspect the job site and check for possible hazardous conditions. Make sure that there are no holes, moving banks or debris that may cause you to lose the control of the machine.

ELECTRICAL

DANGER

Pay the greatest attention when working close to electric lines. Check their position and ensure that no part of the machine operates at less than 6 meters from the power lines.

DANGER

Always face the machine when getting off the driving cab; make sure that your hands and shoe soles are clean and dry, and hold to the handholds to prevent falls or slips.

CAUTION

For a safe use of the machine, always check the weight of the loads going to be handled.

Always refer to the load charts applied on the cab windscreen or to the quick guide with the fork capacity ratings.

DANGER

Always engage the parking brake after stopping the machine to prevent possible accidental motions of the vehicle.

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■ C-5.1 USING THE LOAD CHARTS

The charts indicating the maximum permissible load in relation to the boom extension are installed on the cab windscreen and/or illustrated in the quick guide.

The load chart indicates the payload limits of the machine under safe conditions.

To operate under safe conditions, always refer to these charts.

CAUTION

The load charts applied on the cab windscreen refer to a stationary machine standing on a solid and level ground.

Raise the load some centimetres and check its stability before raising it completely.

CAUTION

The load charts illustrated in this manual are given only as a mere example. To define the payload limits, refer to the load charts applied within the cab of your machine.

450

6



5750

5

500

4

3

2500 Kg

2

1

0

-1

4 3 2

3340

1 0

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■

C-5.2 LOAD LIMITER

On the front top strut of the cab, there is limiter 34 which warns the operator of the variation of stability of the machine and blocks any manoeuvre before the same reaches a critical condition.

■

C-5.2.1 Description of the controls

1 Calibration selection button

2 Display

3 Stability indicator with LED-bar

4 Green light – power OK

5 Yellow light – calibration mode

6 Calibration confirmation button

7 Not used

8 Yellow light – outrigger position

9 Buzzer ON/OFF pushbutton

10 Red light –overload pre-alarm / alarm

The digit on display 2 shows the selected attachment or the alarm code.

■

C-5.2.2 Operation

When power is turned on, light 4 comes on. The display

2 remains off and the monitoring system runs a selftest before displaying digit 0 to warn that the system is activated.

During operation, the led-bar 3 lights up gradually depending on the variation of stability.

Green LED’s : during normal operation when the percentage of overturning moment is between 0 and 89, these LED’s are ON.

The machine is stable.

Yellow LED’s : they light up when the machine tends to overturn and the percentage of overturning moment with respect to the threshold value is between 90 and 100.

The system enters the pre-alarm mode, light 10 flashes and the buzzer sounds with an intermittent sound.

4

1

5 6

2

7

3

Boom extension

Overload warning system in alarm

8

10

9

Red LED’s : risk of overturning: the percentage of overturning moment is above 100 with respect to the threshold value.

The machine enters the alarm mode : light 10 is lit, the buzzer sounds continuously and any dangerous manoeuvre is blocked. The operator can only retract the load within safety limits.

Example of use of the stability indicator

Boom retraction

Alarm ceases

Reduction of the load to be handled

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DANGER

Before using the machine, make sure that the first green LED of the overload warning system is ON.

The overload warning system must not be used to check the load going to be lifted: it has only been designed to signal possible unbalances of the machine along its motion axis.

Such unbalances may also be caused by an abrupt operation of the levers during the load handling. If, during work, several indicators light up, operate the levers more smoothly.

■

C-5.2.3 Alarm codes and resetting

The limiter has diagnostic facilities to aid in the identification of failures of the transducers, breakages of the cables or defects of the electronic system.

When a failure is signalled, the limiter enters the safety mode blocking any dangerous manoeuvres. Lights 5 ,

8 and 10 start flashing, the buzzer start sounding and an error message is shown on the display.

The meaning of the error messages is shown in Section

E “ Faults and Troubleshooting”

8

10

5

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■

C-5.3 HANDLING LOADS

■ C-5.3.1 Adjusting the forks

Forks shall be spaced to suit the load going to be handled. For this purpose:

• Lift the clamping lever of the forks.

• Slide the forks to the desired position, then re-lock the lever.

CAUTION

• The centre of gravity of the load must always be halfway between the forks.

• Ensure you exactly know the weight of the load before handling it.

• When extending the boom, do not exceed the payload limit.

• Refer to the payload limits given in the load chart applied on the cab windscreen or in the quick user’s guide.

• Space the forks as wide as possible to suit the load being handled.

In the case of floating forks:

• Loosen the nut of the locking screws.

• Raise the forks and slide them on the pivot until correct spacing.

• Lock the screws re-tightening the nut.

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■ C-5.3.2 Working phases

When forks are correctly spaced, the handler is ready to use.

Work can be subdivided into three different phases: loading, transfer and unloading.

Loading phase

• Approach the load to the handled perpendicularly and check that the machine is level on the inclinometer.

• Insert the forks under the load and raise the load some centimetres.

• Pitch the forks back and make sure that the overload warning system LEDs are in limits.

Transfer phase

• Do not start or brake abruptly.

• Drive to the unloading point cautiously and keep the load 20 ÷ 30 cm from the ground.

• Suit the machine speed to the ground conditions to avoid dangerous jumps, side skids of the vehicle and possible load falls.

• When driving on slopes or ramps, hold the load uphill.

• When the forks are clear of the load, set them to transfer position.

• Release the parking brake and start a new working cycle.

CAUTION

Do not move off when the load is raised 20

÷

30 cm above the ground. Risk of machine overturning or load fall.

DANGER

Do not drive on slopes sideways; this wrong manoeuvre is one of the main reasons for accidents due to vehicle overturning.

Unloading phase

• Drive to the unloading point with straight wheels and bring the machine to a smooth stop leaving enough space to operate the boom.

• Put the parking brake and set the transmission to neutral.

• Position the load some centimetres above the desired position and set the forks level.

• Lower the load and make sure it is level.

• Carefully withdraw the forks by operating the boom retraction control and, if necessary, raise or lower the boom as forks come out.

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■ C-5.4

CHANGING THE ATTACHMENT

ATTENTION

Use only attachments directly manufactured or recommended by Terexlift and detailed in the

“Optional attachments” section.

To change an attachment, operate as follows:

• Drive to the place where you will release the mounted attachment (when possible, a solid and sheltered site).

• Disconnect the quick connectors of the attachment (if any), and connect the hydraulic locking pipes of the attachments to couplings A .

• Rest the attachment flat on the ground.

• Pitch the attachment holding frame forward and lower the boom to release the attachment upper lock.

• Move back with the machine (or with the boom) and drive to the new attachment to be coupled.

• Hold the frame pitched forward and hook the upper lock of the new attachment.

• Retract and raise the attachment some centimetres. It will centre automatically on the quick coupling frame.

• Operate the control lever to lock the attachment.

CAUTION

After substitution, visually check the attachment is correctly coupled to the boom, before operating the machine. A wrongly coupled attachment may result in damage to persons or things.

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• Couple the connectors of the attachment, if any, to the quick couplings of the frame.

DANGER

After the substitution of an attachment or after any coupling operation, visually check the attachment.

A wrongly coupled attachment may result in damage to persons or things.

C-6 TRANSPORTING THE MACHINE

■ C-6.1 MOVING A DISABLED MACHINE

Tow the machine only when no alternative is possible, since this operation may result in serious damage to the transmission. When possible, repair the machine on site.

When the machine shall absolutely be towed:

• Unlock the negative brake (see chap. C-6.1.1)

• Tow the machine for short distances and at a low speed only.

• Use a rigid drawbar.

• Select the two-wheel steer.

• Set the gearbox lever to neutral.

• When possible, start the engine and use the hydraulic drive and the braking system.

• Raise the front wheels of the machine and remove the Cardan shaft of the transmission.

■ C-6.1.1

Unlocking the negative brake

To unlock the negative brake of a faulty machine, proceed as follows:

• Loosen the two opposite screws located on the front axle in order to remove the washers.

• Remove the horseshoe-shaped washers located under the two screws.

• Re-tighten screws turning alternately the front screw and the rear screw 1/2 turn to unlock the brake.

To relock the nagetive brake, loosen the screws turning alternately the front screw and the rear screw

1/2 turn, refit the horseshoe washers and re-tighten screws .

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■ C-6.2 ROAD OR SITE TRANSFER

When travelling on public roads, strictly obey the local or national road traffic regulations.

Besides, take into account the following general precautions:

• Align the rear wheels.

• Select the two-wheel steer.

• Set the ROAD-JOBSITE switch 20 to “ROAD” (the light on the pushbutton comes on).

• Lock the machine as indicated in the Registration

Card:

Lock the boom sections, the lifting cylinder, and the attachment rotation cylinder (see photo).

• Cover the teeth of the conventional forks with the special guard; or withdraw the floating forks.

• Retract boom and attachment to transfer position.

• Make sure that lights, horn and turn signals are in working order.

• Start the machine (the beacon will switch on automatically).

• Select the forward or reverse speed.

• The transfer speed of the vehicle will depend on the engine rpm .

CAUTION

Public road circulation is allowed only for transferring an unloaded machine.

Do not use the GTH-2506 for towing purposes.

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■ C-6.3

LIFTING THE MACHINE

When the machine shall be lifted, use only means having a suitable capacity. The characteristic data are detailed in the relevant chapter of this manual and on the identification plate.

For the machine lifting, anchor the chains to the special lugs on the machine (marked with the decal below).

■ C-6.4

TRANSPORTING THE MACHINE ON

OTHER VEHICLES

To transport the machine on another vehicle, follow the steps below:

• Put chocks at the machine wheels.

• Ensure ramps are correctly positioned.

• Retract the boom to transfer position.

• Carefully drive the machine onto the transporting vehicle.

• Put the parking brake and rest the attachment flat on the vehicle platform.

• Ensure the overall dimensions do not exceed the allowed limits.

• Shut the engine down and close the driving cab of the machine.

• Secure the machine to the vehicle platform by wheel-chocks.

• Anchor the machine to the transporting vehicle with suitable chains.

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■

C-6.5

PARKING AND STORAGE

■ C-6.5.1

Short inactivity

Always park the machine in a safe way after a working day, a shift and at night.

Take all precautions to prevent damage to those persons who will approach the machine while stationary:

• Park the machine so that it does not hinder other operations.

• Lower the boom fitted with attachment on the ground.

• Remove the key from the ignition switch and lock the cab door.

• Disconnect the battery by the appropriate switch

(“Battery cut-out switch”).

■ C-6.5.2

Machine storage

In case of extended inactivity of the machine, follow the above precautions. Additionally:

• Wash the machine thoroughly. For a better cleaning, remove grills and protection casings

• Carefully dry all machine parts by blowing some compressed air.

• Lubricate the machine thoroughly.

• Do a walk-around inspection and replace any worn or damaged part.

• Re-paint any worn or damaged part.

• Remove the battery, smear its terminals with vaseline and store it in a dry place. Battery can be used for other purposes. Otherwise, periodically check its charge level.

• Refuel the tank to prevent internal oxidation.

• Store the machine in a sheltered and wellventilated place.

• Start the engine for about 10 minutes at least once a month.

• When weather is particularly cold, empty the radiator.

IMPORTANT

Always remember that the ordinary maintenance must be carried out even during the machine inactivity. Pay particular attention to the fluid levels and to those parts subject to ageing. Before restarting the machine, carry out an extraordinary maintenance and carefully check all mechanical, hydraulic and electrical components.

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■

C-6.6

CLEANING AND WASHING THE

MACHINE

■

C-6.6.1 Cleaning instructions

Clean the machine in accordance with the following instructions:

• Remove any oil or grease traces with a dry solvent or a volatile mineral alcohol

• Before assembling a new part, remove any protection product (rust-preventer, grease, wax etc.).

• Remove any trace of rust from metal parts with some emery cloth before smearing the part with a protection product (rust-preventer, paint, oil etc.).

■

C-6.6.2 Washing instructions

External washing

Before washing the machine, check that the engine is shut down and the doors and windows are closed.

Do not, at any times, use fuel to clean the machine. Use water or some steam. In cold climates, dry the locks after washing or smear them with an antifreeze.

Before using the machine again, check its conditions.

Internal washing

Wash the machine interior with some water and a sponge. Do not use water at high pressure. After washing, dry with a clean cloth.

Washing the engine

Before washing the engine, protect the air intake filter to prevent water from entering the circuit.

■

C-6.7

MACHINE DISPOSAL

PROTECT THE

ENVIRONMENT

At the end of the machine life, call in a specialised firm to dispose of it in compliance with the local or national regulations.

■

C-6.7.1

BATTERY DISPOSAL

PROTECT THE

ENVIRONMENT

Used lead-acid batteries cannot be disposed of as normal industrial solid wastes. Because of the presence of harmful substances, they must be collected, eliminated and/or recycled in accordance with the laws of the UE.

In Italy, used or discarded batteries have been classified as “Toxic wastes” in accordance with

Presidential decree n. 397 of 09/09/1988 and Law n.

475 O.G. n. 18 of 09/11/1988 because they contain lead and sulphuric acid. Their disposal through recycling must be done only through companies authorised and belonging to the “Consorzio

Obbligatorio Batterie Esauste e dei rifiuti piombosi”

(Cobat) which collect and dispose of used lead-acid batteries throughout the national territory.

Used batteries must be kept in a dry and confined place. Make sure the battery is dry and the cell plugs are tight. Place a sign on the battery to warn of not using it. If before disposal the battery is left in the open air, it will be necessary to dry, smear the box and the elements with a coat of grease and tighten the plugs. Do not rest the battery on the ground; it is always advisable to rest it on a pallet and cover it. The disposal of batteries shall be as rapid as possible.

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MAINTENANCE

Section

D

MAINTENANCE


D-3.10.1

D-3.10.2

D-3.11

D-3.11.1

D-3.11.2

D-3.12

D-3.13

D-3.14

D-3.15

D-4

D-4.1

D-4.2

D-4.3

D-5

D-1

D-2

D-2.1

D-3

D-3.1

D-3.2

D-3.3

D-3.4

D-3.5

D-3.5.1

D-3.6

D-3.7

D-3.8

D-3.9

D-3.10

D-5.1

D-5.2

D-5.2.1

D-5.2.2

D-5.2.3

D-5.2.4

LUBRICANTS - HEALTH AND SAFETY PRECAUTIONS .............................. D-2

ROUTINE MAINTENANCE ............................................................................ D-3

Oil change schedule ...................................................................................... D-4

MAINTENANCE JOBS .................................................................................. D-5

Disconnecting the battery ............................................................................. D-5

Access to the engine and tanks compartments ........................................... D-6

Greasing ........................................................................................................ D-7

Tyres and wheels .......................................................................................... D-8

Brakes ........................................................................................................... D-9

Checking the brake oil level .......................................................................... D-9

Engine air filter ............................................................................................. D-10

Cab air filter ................................................................................................. D-11

Engine cooling circuit .................................................................................. D-11

Checking the oil level in the tank ................................................................ D-12

Changing the oil filter canisters on the intake line ...................................... D-13

Transmission oil filter .................................................................................. D-13

Auxiliary circuits oil filter .............................................................................. D-14

Oil level in the differential gears and the rducer .......................................... D-15

Front and rear differential gears .................................................................. D-15

Reducer ....................................................................................................... D-15

Oil level in the (front/rear) wheel reduction gears ........................................ D-16

Shafting alignment ...................................................................................... D-17

Adjusting the sliding pads of the boom sections ........................................ D-18

Checking the safety devices ....................................................................... D-19

ELECTRICAL SYSTEM ................................................................................ D-21

Battery ......................................................................................................... D-21

Fuses and relays ......................................................................................... D-22

12V DC lamps ............................................................................................. D-24

REFUELLING ............................................................................................... D-25

Refuelling ..................................................................................................... D-25

Product specifications ................................................................................ D-25

Engine oil ..................................................................................................... D-25

Lubrication oils and relevant filtering elements ........................................... D-25

Fuel .............................................................................................................. D-26

Grease ......................................................................................................... D-26

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MAINTENANCE

INTRODUCTION

A thorough and regular maintenance keeps the machine in a safe and efficient working condition.

For this reason, it is advisable to wash, grease and service the machine properly, especially after having worked under particular conditions (muddy or dusty environments, heavy operations, etc.).

Always ensure all machine components are in good condition. Check for oil leaks or loosening of guards, and make sure that the safety devices are efficient. In case of defects, find and rectify them before using the machine again.

The maintenance interventions are based on the machine working hours. Regularly check the hourmeter and keep it in good condition to define the maintenance intervals correctly.

Not respecting the ordinary maintenance schedule of this manual automatically voids GENIE warranty.

IMPORTANT

For the engine maintenance, please refer to the specific Operator handbook supplied with the machine .

D-1 LUBRICANTS - HEALTH AND

SAFETY PRECAUTIONS

Health

A prolonged skin contact with oil can cause irritation.

Use rubber gloves and protective goggles. After handling oil, carefully wash your hands with soap and water.

Storage

Always keep lubricants in a closed place, out of the children’s reach. Never store lubricants on the open air and without a label indicating their contents.

Disposal

New or exhausted oil is always polluting! Never drain oil on the ground. Store new oil in a suitable warehouse.

Pour exhausted oil into cans and deliver them to specialised firms for disposal.

Oil leaks

In case of accidental oil leaks, cover with sand or typeapproved granulate. Then scrape off and dispose of it as chemical waste.

First aid

Eyes

Intake

Skin

: In case of accidental contact with the eyes, wash with fresh water. If the irritation persists, seek medical advice.

: In case of oil intake, do not induce vomiting, but seek medical advice.

: In case of a prolonged contact, wash with soap and water

Fire

In case of fire, use carbon dioxide, dry chemical or foam extinguishers. Do not use water.

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MAINTENANCE

D-2 ROUTINE MAINTENANCE

A wrong or neglected maintenance can result in possible risks for both operator and bystanders. Make sure maintenance and lubrication are carried out according to the manufacturer’s instructions to keep the machine safe and efficient.

The maintenance interventions are based on the machine working hours. Regularly check the hourmeter and keep it in good conditions to define the maintenance intervals correctly. Make sure any defect detected during the maintenance is promptly rectified before using the machine.

ATTENTION

All " ▲ " marked operations must be carried out by a skilled technician.

During the first 10 working hours

1 Check the oil level within reduction gears, power divider and differential gears

2 Regularly check the tightening of the wheel bolts

3 Check the tightening of all bolts and nuts

4 Check the couplings for oil leaks

Within the first 50 working hours

1 Change the oil for the first time

Every 10 working hours or daily

1 Check the engine oil level

2 Clean the air suction filter

3 Clean the radiator, if necessary

4 Check the hydraulic oil level in the tank

5 Check the greasing of the boom section pads

6 Grease the attachment holding frame

7 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

8 Check the efficiency of the lighting electric system

9 Check the efficiency of braking system and parking brake

10 Check the efficiency of the steering selection system

11 Check the efficiency of the fork balancing system.

12 Make sure the safety devices installed are in efficient working order - see procedure in chap. D-3.15

.

Every 50 working hours or weekly

Jobs to be done in addition to those above

1 Check the tension of the alternator belt

2 Check the tyre inflation

3 Check the tightening of the wheel nuts

4 Check the tightening of the Cardan shaft screws

Every 250 working hours or monthly


1 Change the engine oil and relevant filter

2 Check the oil level in the front and rear differential gears and the reducer

3 Check the oil level in the four wheel reduction gears

4 Check the condition of the canister of the engine air filter; renew the canister if necessary

5 Check the clamping of the cableheads to the battery terminals

6 Check the air suction hose between engine and filter

7 Check the cylinder chromium-plated rods

8 Check the hydraulic lines are not worn because of rubbing against the frame or other mechanical components

9 Check the electric cables do not rub against the frame or other mechanical components

10 ▲ Check the wear of the sliding pads of the boom sections

11 ▲ Adjust the play of the sliding pads of the boom sections

12 Remove any grease from the boom, then regrease the sliding parts of the boom sections

13 Check the level of the battery electrolyte

Every 3 working months

1 Check the efficiency of the block valves - see chap. D-3.15.

Every 500 working hours or every six months

Jobs to be done in addition to those above.

1 Visually check the smoke quantity evacuated from the engine exhaust

2 Check the tightening of the engine fixing screws

3 Check the tightening of the cab fixing screws

4 Check the backlash between pins and bushings in all joints

5 Change the hydraulic oil filter of the transmission

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MAINTENANCE

6 Change the hydraulic oil filter in the tank

7 Have the hydraulic system checked by a skilled technician

8 Change the main cartridge of the engine air filter

9 Clean or replace, if nececessary, the air filter in the cab

Every 1000 working hours or yearly


1 Change the oil in the front and rear differential units and in the power divider

2 Change the oil in the four wheel reduction gears

3 Change the hydraulic oil

■

D-2.1

OIL CHANGE SCHEDULE

Engine

Axles and power divider

Hydraulic oil

Job

Oil level check

First change

Subsequent changes

Oil level check

First change

Subsequent changes

Oil level check

Subsequent changes operating hours*

10

50

250

250

-

1000

250

1000 service interval* daily

monthly monthly

yearly monthly yearly

Oil type

SHELL RIMULA 15W-40

FUCHS TITAN GEAR LS 85 W-90

API GL-5 LS / GL-5

SHELL TELLUS T 46

DENISON HF-1, DIN 51524 part 3 Cat. HV

* whichever occurs first

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MAINTENANCE

D-3 MAINTENANCE JOBS

DANGER

All maintenance interventions must be carried out with engine stopped, parking brake engaged, working attachments flat on the ground and gear lever in neutral.

ATTENTION

High pressure lines must be replaced by qualified personnel only.

Any foreign matters entering the closed circuit may result in a sudden deterioration of the transmission.

CAUTION

When raising a component for maintenance purposes, secure it in a safe way before any maintenance intervention.

CAUTION

Any intervention on the hydraulic circuit must be carried out by skilled personnel.

The hydraulic circuit of this machine is fitted with pressure accumulators. You and others could be seriously injured if accumulators are not completely depressurised.

To depressurise the accumators, just steer the machine wheels some times with engine shut down until noticing a gradual binding of the handwheel.

ATTENTION

The qualified staff charged with the maintenance of the hydraulic circuit must clean all areas around with care before any intervention.

PROTECT THE

ENVIRONMENT

The handling and disposing of used oils can be ruled by local or national regulations. Address to authorised centres.

CAUTION

Before any operation on hydraulic lines or components, make sure there is no residual pressure. For this purpose, stop the engine, engage the parking brake and operate the control levers of the distributors in both working directions

(alternately) to depressurise the hydraulic circuit.

■

D-3.1

DISCONNECTING THE BATTERY

During maintenance or repair works, and while welding, turn off the battery main switch, located behind the rear right wheel compartment ( C-4.5, p. C-25 ).

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MAINTENANCE

■

D-3.2

ACCESS TO THE ENGINE AND

TANKS COMPARTMENTS

■

Engine compartment

For any operation within the engine compartment, open the protection bonnet.

Hood is equipped with lock & key and a supporting rod that holds it in position.

From the engine compartment, you get access to:

• Thermal engine

• Engine air filter

• Hydraulic oil tank plug

• Radiator fluid compensation cup

• Battery

To get access to the engine compartment:

• Shut the engine down and put the parking brake.

• Unlock the bonnet lock

• Lift the bonnet using the special handle until it latches in the gas spring.

• To close the bonnet: press on the green locking device on the gas spring and lower the bonnet.

DANGER

Take all precautions when approaching the engine compartment. Some parts of the engine may be very hot. Always use protective gloves.

■

Diesel fuel tank compartment

To gain access to the fuel tank, open the rear cover of the machine as follows:

• Shut the engine down and put the parking brake.

• Fully raise the cover by means of the special handle.

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MAINTENANCE

■

D-3.3

GREASING

ATTENTION

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.

SERVICE INTERVAL

Running-in ____________________________ None

Ordinary ____________________ Every

10 hours

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MAINTENANCE

■

D-3.4

TYRES AND WHEELS

DANGER

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.

YES

RIGHT WAY

NO

WRONG WAY

For the tyre inflation or substitution, please refer to the table below:

Dimensions

Load index

Rim

Wheel disc

Pressure bar

Psi

GTH-2506

12-16.5 EM14 pr 10

9.75x16

8 holes DIN 70361

4.5

65

On new machines, and when a wheel has been disassembled or replaced, check the nut torque of the wheels every 2 hours until they stay correct.

ATTENTION

Always use tyres having the dimensions indicated in the vehicle registration card.


Running-in _________ Within the first

10 hours

Ordinary __________________ Every

250 hours

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MAINTENANCE

D-3.5 BRAKES

• For any intervention on the braking system

(adjustment and/or substitution of the brake discs) call in a specialised technician.

The malfunctioning of the braking system may depend on the presence of air within the hydraulic circuit.

The braking system has two bleeding valves: valve for the service brake circuit and valve for the negative parking brake circuit.

To bleed the circuit of the service brake:

• Make sure that the oil is level within the feeding tank

.

• Step on the brake pedal repeatedly.

• Slowly unscrew valve and re-close it as soon as oil mixed with air bubbles comes out.

• Repeat the operation until bubble-free oil comes out.

• Bleed from both sides of the machine.

To bleed the circuit of the negative parking brake:

• Press the parking brake button . As soon as the light indicator on the button goes off, start bleeding through valve until air-free oil comes out.

A C

D-3.5.1 Checking the brake oil level

The oil within the braking circuit must be at about 2 cm from the tank plug .

Level

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MAINTENANCE

■

D-3.6

ENGINE AIR FILTER

Clean the engine air filter every 10 hours; replace the filtering element, if necessary.

1 Cleaning and changing the external element:

- Stop the engine and engage the parking brake.

- Unscrew wingnut A and remove cover B .

- Unscrew wingnut C and remove the outer element D .

- Clean the filter bowl.

- Clean the cartridge by beating it some times on the ground paying attention not to damage the filtering element.

Do not dry-clean the filtering element.

- Check for cracks in the filtering element by introducing a lamp inside.

- Smear the seal with grease, then refit the element.

- Tighten wingnut C , close cover B and tighten with wingnut A .

ATTENTION

As soon as the warning lamp on the cab dashboard switches on, replace the outer element.


Running-in ___________________________ None

Cleaning ___________________ Every

10 hours

Filtering element substitution _ Every

500

hours

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MAINTENANCE

■

D-3.7

CAB AIR FILTER

Every six months clean the air filter in the cab. Replace the cartridge if the filtering cloth is damged.

1 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.

- Do not dry-clean the filtering cartridge.

ATTENTION

Do not, at any times, dry-clean the filters. Use some water and/or solvent.

■

D-3.8

ENGINE COOLING CIRCUIT

The cooling radiator is lubricated with the engine oil and does not need any maintenance.

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MAINTENANCE

■

D-3.9

CHECKING THE OIL LEVEL IN THE

TANK

DANGER

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.

Check the hydraulic oil level (visually) through the special level fitted into the tank.

When necessary, add new oil through filler .

CAUTION

Check the oil level with handler set to transfer position

(lowered boom and retracted telescopic element).



10 hours

Ordinary ____________________ Every

50 hours

If oil must be changed, proceed as follows:

1 Stop the machine on a level ground and make sure the parking brake is engaged.

2 Release the pressure from the hydraulic circuit.

3 Place a container of suitable size under the drain plug, placed in the lower part of the reservoir, and collect any oil leaks.

4 Remove the drain plug and allow oil to flow out into the container.

5 Remove the inspection cover of tank .

6 Carefully wash the tank with Diesel oil and blow a jet of compressed air.

7 Refit the drain plug and the inspection cover.

8 Add new oil by making sure that it matches the recommended type indicated in paragraph D-5.2.2.

until it is level with .


Running-in ____________________________ None

Ordinary ________________ Every

1000 hours

PROTECT THE

ENVIRONMENT


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MAINTENANCE

■

D-3.10

CHANGING THE OIL FILTER

CANISTERS ON THE INTAKE LINE

■ D-3.10.1 Transmission oil filter

Every 50 hours, check the clogging degree of the filtering element using the vacuometer .

The indexed scale of the vacuometer is divided into 3 areas:

1 - Green area: Normal condition

2 - Yellow area: Replace the filter as soon as possible

3 - Red area: Shut the engine down to prevent damage to the hydraulic system.

Change the filter and/or check for the fault reasons.

40

30

50

15

20

60

25

70

76

30 in Hg cm Hg

10

5

0

20

10

IMPORTANT

Hydraulic oil filter cartridges cannot be cleaned or washed and refitted.

They must be replaced with new ones of the type recommended by the manufacturer ( see par. D-

5.2.2

).

PROTECT THE

ENVIRONMENT


To change the hydraulic oil filter element on the suction line, 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, then close cock .

3 Remove the filtering element using a wrench.

4 Change the filtering element, then, before fitting a new one, thoroughly clean and grease both seat and gasket.

5 Hand-tighten and re-open cock .

IMPORTANT

When changing the oil, drain it when it is still hot and the polluting substances are in suspension.


Running-in ____________________________ None

Ordinary __________________ Every

500 hours

When the dashboard indicator switches on

Page D-13

Document 57.0003.5200 - 12/2003


MAINTENANCE

■ D-3.10.2 Auxiliary circuits oil filter

To change the hydraulic oil filter cartridge of the service circuits, proceed as follows:

1 Stop the machine on a level ground and engage the parking brake.

2 Remove the inspection hatch and unscrew the oil filter fitted inside the tank.

3 Check the tank is clean, then fit a new filtering element and refit the inspection hatch.

4 Check the oil level within the tank. Add new oil, if necessary.


Running-in ____________________________ None

Ordinary __________________ Every

500 hours

Page D-14

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MAINTENANCE

D-3.11 OIL LEVEL IN THE DIFFERENTIAL

GEARS AND THE REDUCER

■

D-3.11.1 Front and differential gears

To check the oil level in the front and rear differential gears:

• Stop the machine on a level ground and engage the parking brake.

• Loosen level plug 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 .

For the oil change:

• Place a container of suitable size under drain plug

.

• Loosen the drain plug and the level plug and allow oil to flow out from the differential gears.

• Refit and tighten drain plug .

• Add new oil through plug until it is level with the hole.

• Refit and tighten level/filler plug.

■

D-3.11.2 Reducer

To check the oil level in the reducer

• Stop the machine on a level ground and engage the parking brake.

• Loosen level plug 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.


For the oil change:

• Place a container of suitable size under drain plug

.

• Loosen the drain plug and the level plug and allow oil to flow out from the reduction gear.

• Refit and tighten drain plug .

• Add new oil through plug until it is level with the hole.




10 hours

Ordinary __________________ Every

250 hours



10 hours

Ordinary __________________ Every

250 hours

Page D-15

Document 57.0003.5200 - 11/2003


MAINTENANCE

■

D-3.12

OIL LEVEL IN THE (front/rear) WHEEL

REDUCTION GEARS

To check the oil level within the wheel reduction gears:

• Stop the machine on a level ground and ensure the parking brake is engaged and plug finds on the horizontal axis.

• Clean the plug all around, then remove it and check if oil is level with the hole.

• If necessary, add new oil through hole until it is level.

• Refit the plug.

For the oil change:

• Stop the machine and ensure the plug is oriented along the vertical axis.

• Place a container of suitable size under the reduction gear plug.

• Unscrew plug 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 .


PROTECT THE

ENVIRONMENT


IMPORTANT

When changing the oil, drain it when it is still hot and the polluting substances are in suspension.



10 hours

Ordinary __________________ Every

250 hours

Page D-16

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MAINTENANCE

D-3.13 SHAFTING ALIGNMENT

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 visually, follow the procedure below:

1) Move to a solid and level ground

2) Set the steering selection switch 11 to “ four-wheel 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 )

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.

�

40

80

120

° C

N

F

R

0 1 2 3 4 5 6 7

�

� �

�

40

80

120

° C

�


Running-in ____________________________ None

Ordinary ___________________ When necessary

Page D-17

Document 57.0003.5200 - 11/2003


MAINTENANCE

■

D-3.14

ADJUSTING THE SLIDING PADS OF

THE BOOM SECTIONS

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.

All pads can be adjusted by the special shims supplied by GENIE upon demand.

Adjusting the pads :

• Remove or loosen the screws fixing the pads in relation 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.

ATTENTION

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


Running-in ____________________________ None

Ordinary ___________________ When necessary

Page D-18

Document 57.0003.5200 - 11/2003

Minimum 1 mm


MAINTENANCE

■

D-3.15

CHECKING THE SAFETY DEVICES

■

Checking the load limiting system

(at every use)

When power is turned on, the DLE load limiting system runs a self-test. In the case of troubles, LED’s 5 , 8 and

10 start flashing, the buzzer sounds, an error code is shown on the display and the machine enters the alarm mode and cannot be operated.

The meaning of the error messages is shown in Section

E “ Faults and Troubleshooting” .

To do a manual check, it will be enough to load a weight exceeding the maximum permitted with the boom fully out and attempt to lift it. The system shall enter in alarm; should that not be the case, contact GENIE Technical

Service.

■

Checking the emergency stop pushbutton

(at every use)

To check the efficiency of this pushbutton, simply press it down during a movement. The pressure of the pushbutton shall cause the movement to stop and the engine to shut down. Should that not be the case, contact GENIE Technical Service.

5 8

10

■ Checking the machine start control

(at every use)

Attempt to start the engine with the forward or reverse gear put.

The engine must not start. If the engine starts, contact the GENIE Technical Service.

Repeat the operation putting first one gear, then the other.

■

Checking the seat micro-switch (only in the TCE version)

(at every use)

To check if the seat micro-switch is in efficient working order, simply attempt to start the machine without being seated. The machine must remain stopped.

Should that not be the case, contact GENIE Technical

Service.

■

Checking the joystick pushbutton (not present in the TCE version)

(at every use)

To check if the pushbutton on the control lever is in efficient working order, it will be enough to attempt to operate the lever without pressing this button.

In this condition, the lever shall not operate any movement. Should that not be the case, contact GENIE

Technical Service.

Page D-19

Document 57.0003.5200 - 10/2004


MAINTENANCE

■

Checking the block valves (every 3 months) .

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 (2000 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.

• Loosen the oil hoses to the cylinder of which you are checking the valve with caution.

During the check, the oil will flow out of the hoses and the load shall remain blocked in position. Should that not be the case, the valve must be replaced. Contact

GENIE Technical Service.

DANGER

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

During the check proceed with extreme caution.

Ensure that the part to be checked is in safe condition and that the action generated does not result in an uncontrolled movement of the machine

Page D-20

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MAINTENANCE

D-4 ELECTRICAL SYSTEM

DANGER

DANGER

All maintenance interventions must be carried out with engine stopped, parking brake engaged, working attachments on the ground and gearbox lever in neutral.

DANGER

When raising a component for maintenance purposes, secure it in a safe way before carrying out any maintenance.

DANGER

Before any operation on hydraulic lines or components, make sure there is no residual pressure. For this purpose, stop the engine, engage the parking brake and operate the control levers of the distributors (in both working directions alternately) to release the pressure from the hydraulic circuit.

• 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.

D-4.1 BATTERY

• 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 cell levels are correct.

• Check the cable clips are well secured to the battery terminals. To tighten the clips, always use a box wrench, never pliers.

• Protect the terminals smearing them with pure vaseline.

• Remove the battery and store it in a dry place, when the machine is not used for a long time.

DANGER

Risk of explosion or shorts. During the recharge, an explosive mixture with release of hydrogen gas forms.

DANGER

Do not add sulphuric acid; add only distilled water.

Page D-21

Document 57.0003.5200 - 11/2003


MAINTENANCE

D-4.2 FUSES AND RELAYS

The electrical system is protected by fuses placed in the driving cab, on the left. Before replacing a blown fuse with a new one having the same amperage, find out and rectify the fault.

Ref.

Circuit

F24 Relay K06 power supply

F25 Parking brake switch power supply

F26 Optional

F27 Optional

F28 Optional

F29 Spare fuses

■ Fuses

Ref.

Circuit

F1 Power supply: interior lamp, emergency switch, turn signals +30

F2 Power supply: K04 relay

F3 Optional

F4 Front right/rear left position lights, license plate lights, position lights indicator, engine oil temperature indicator

F5 Front left/rear right position lights, fuel gauge-hourmeter-warning lamps lighting, engine oil cooling temperature indicator light, fan switch, lights selection switch

F6 Right low beam

F7 Left low beam

F8 Right high beam

Amp

5

F9 Left high beam, High beam warning lamp

F10 Horn

F11 Windscreen washer kit

F12 Optional

F13 Optional

F14 Optional

F15 Preheating control unit power supply

F16 Power supply: hydraulic stop, fuel gaugehourmeter-warning lamps indicator, engine oil cooling temperature indicator, engine oil temperature indicator

K04 relay pickup, air filter warning light, preheating warning light, road safety switch

F17 Power supply: hazard warning light and turn signals switch +15

F18 Power supply: light switch - windscreen washer switch, windscreen washer motor

F19 Heating system fan power supply

5

15

15

15

F20 Road safety switch power supply

F21 Power supply: beacon

7,5

10

F22 Engine stop mushroom-head button power supply 10

F23 Relay K02/Relay K05 power supply 7,5

10

15

10

5

7,5

7,5

10

5

-

-

-

.

15

7,5

15

F25

F24

F23

F22

F21

F20

F19

F28

F27

F26

F18

F17

F16

F15

F11

F10

F9

F6

F5

F8

F7

F14

F13

F12

F4

F3

F2

F1

F29

F29

F29

F29

K05

K04

K03

K02

K01

INT

K06

Amp .

5

10

-

-

-

Page D-22

Document 57.0003.5200 - 10/2004


MAINTENANCE

■ Engine compartment fuses and relays

Ref.

Circuit

F30 Preheating control unit maxifuse

F31 System protection fuse

K11 Start relay

A02 Preheating control unit

Amp .

50

50

A02 F30 F31 K11

■

Fuse box relays

Ref.

Circuit

K01 Starting enabling command

K02 Forward speed enabling command

K03 Inhibition with brake pedal stepped down

K04 Overload warning system control unit enabling command

K05 Reverse speed enabling command

K06 Overload warning system solenoid valve enabling command

ATTENTION

• Do not use fuses having a higher amperage than that recommended, since they can damage the electric system seriously.

• If the fuse blows after a short time, look for the fault source by checking the electric system.

• Always keep some spare fuses for an emergency.

• Never try to repair or short blown fuses.

• Make sure the contacts of fuses and fusesockets ensure a good electric connection and are not oxidised.

F11

F10

F9

F8

F7

F6

F5

F14

F13

F12

F4

F3

F2

F1

F25

F24

F23

F22

F21

F20

F19

F28

F27

F26

F18

F17

F16

F15

F29

F29

F29

F29

K05

K04

K03

K02

K01

INT

K06

Page D-23

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MAINTENANCE

■ D-4.3 12V DC LAMPS

Use Voltage Mount type Power

• Front low/high beam ............................................................ 12 V ....................... P45t ................. 45/40 W

• Front position lights ............................................................. 12 V ..................... BA 9s ........................ 3 W

• 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 ........................ 5 W

• License plate lights .............................................................. 12 V ................... BA 15s ........................ 5 W

• Back-up lamps ..................................................................... 12 V ................... BA 15s ....................... 21W

CAUTION

When switched on, lamps get hot. Before touching a lamp with your fingers, let it cool down.

IMPORTANT

Never touch the bulb of halogen lamps (mount type

H3) with your fingers: this may damage the lamp

(use of a clean cloth or a paper tissue). If you touch it accidentally, thoroughly clean with a paper tissue and some ethyl alcohol.

Page D-24

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MAINTENANCE

D-5 REFUELLING

■

D-5.1

REFUELLING

Part

Diesel engine

Fuel tank

Product

Engine oil

Diesel fuel

Hydraulic system tank Hydraulic oil

Front differential gear with reduction gear Oil

Front differential gear

Front wheel reduction gears

Oil

Oil

Rear wheel reduction gears

Brake oil tank

Oil

Hydraulic oil

Capacity

(litres)

11 + 3.5

60

120

6

5

1.5 + 1.5

0.7 + 0.7

0.1

Product specifications see par.

D-5.2.1

D-5.2.3

D-5.2.2

D-5.2.2

D-5.2.2

D-5.2.2

D-5.2.2

D-5.2.2

■

D-5.2 PRODUCT SPECIFICATIONS

■

D-5.2.1 Engine oil

Use the oil recommended by the Diesel engine Manufacturer (see the relevant handbook delivered with the machine).

At the delivery, the machine is refilled with:

SHELL RIMULA 15W-40

■

D-5.2.2

Lubrication oils and relevant filtering elements

Refill the machine with following lubricants:

Use Product Definition

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 3 Cat. HV

ATTENTION

Never mix different oils: this may result in troubles and component breaks.

■

Filtering elements:

Filter

Transmission oil filter

Auxiliary circuit oil filter (inside the tank)

Flow l/1'

MPS 150

STR 100/1

Filtering

10 µ

60 µ

Code

09.4604.0001

09.4604.0004

Page D-25

Document 57.0003.5200 - 11/2003


MAINTENANCE

■

D-5.2.3

Fuel

Use only Diesel fuel with less than 0.5% sulphur content, according to the specifications of the diesel engine operation handbook.

ATTENTION

In cold climates (temperature under -20

°

C) use only

“Arctic” type Diesel fuel, or oil-diesel fuel, or oildiesel fuel mixtures. The composition of the latter can vary in relation to the ambient temperature up to max. 80% oil.

■

D-5.2.4

Grease

For the machine greasing, use:

• L i t h i u m - b a s e d

Vanguard LIKO grease, type EP2

When greasing by pump

• Graphitized SHELL grease, type GR NG 3

When greasing by brush

• INTERFLON FIN

GREASE LS 2

For the telescopic boom sliding blocks

ATTENTION

Avoid mixing greases of different type or features and do not use greases of lower quality.

Page D-26

Document 57.0003.5200 - 11/2003


FAULTS AND TROUBLESHOOTING

Section

E

FAULTS AND

TROUBLESHOOTING


E-1

E-1.1

FAULTS AND TROUBLESHOOTING .............................................................. E-2

Fault - Cause - Solution ................................................................................. E-2

Page E-1

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E-1 FAULTS AND TROUBLESHOOTING

This chapter represents a practical guide for the operator for fixing the most common failures and, at the same time, detecting those interventions which must be carried out by qualified technical engineers.

If you are unsure about anything, do not carry out operations on the machine, but call in a skilled technician.

DANGER

Any repair work, maintenance or troubleshooting must be carried out with machine stopped, boom in rest position or laid on the ground, parking brake engaged and ignition key removed.

E-1.1 Fault - Cause - Solution

DASHBOARD DOES NOT SWITCH

ON

• The 50A fuse F31 supplying power to the dashboard is blown (engine compartment)

• Battery disconnected

• Replace the fuse

• Battery down

• Battery cut-out switch OFF

• Connect the battery using the relevant switch

• Check the battery

• Switch it on

ENGINE DOES NOT START

Starter does not run

ENGINE DOES NOT START

Starter runs, but engine does not start

• Parking brake not engaged

• Battery down

• Battery cut-out switch OFF

• Engage the parking brake and ensure the relevant indicator on the dashboard switches on

• Recharge or replace the battery

• Switch it on

• Fuse F15 blown

• No fuel

• Diesel fuel filter clogged

• Diesel fuel hose empty (fuel used up)

• Solenoid valve - engine stop

• Check the fuse

• Refuel

• See DEUTZ engine operator manual

• Refuel, then refer to DEUTZ engine operator manual

• Check the solenoid valve; replace, if necessary

MACHINE DOES NOT MOVE

THE MACHINE DRIVE IS NOT

ENOUGH

• Speed selector switch in neutral

• Parking brake engaged

• Fuse F23 blown

• Hydraulic oil filter clogged

• Set the speed selector switch correctly

• Disengage

• Check the fuse; replace, if necessary

• Replace the filter

NO SELECTION OF THE

STEERING MODE

“ROAD” FUNCTION ON, EVEN

WHEN SELECTING THE

“JOBSITE” FUNCTION

• Fuse F20 controlling the steering selection blown

• “ROAD/JOBSITE” switch set to

“ROAD”

• No “ROAD/JOBSITE” selection

• Sostituire il fusibile

• Set to "JOBSITE"

• Check and replace fuse necessary

F20 , if

Page E-2

Document 57.0003.5200 - 12/2003



NO BOOM LOWERING AND

EXTENSION, NO HOLDING FRAME

TILTING

• Fuse blown

• Emergency button ON

• Replace fuses F2

• Reset the button and/or F24

THE HYDRAULIC OIL

THERMOMETER DOES NOT WORK

• This is normal, when the outside temperature is low and/or the machine is used for short periods, since the hydraulic oil cannot warm up over

40 ÷ 50 ° C

THE PARKING BRAKE LIGHT

DOES NOT LIGHT UP

• Fuse blown • Check and replace fuse F2 , if necessary

BOOM DOES NOT MOVE • Fuse blown

• “ROAD/JOBSITE” switch set to

“ROAD”

• Emergency button ON

• Check and replace fuse F22 , if necessary

• Set to “CAB”

• Reset the button

THE LOAD LIMITING SYSTEM DOES

NOT CHANGE WORK SCALE

THE LOAD LIMITING SYSTEM IS

BLOCKED

(red LED’s lit)

• Outriggers limit switches inefficient

• Low stability

• Check the efficiency of the outrigger limit switches or replace if necessary.

• Retract the load within safety limits.

If the error message is still shown, move the boom to rest condition operating the overload warning system cutout key and contact your nearest authorised service centre.

CHECKING THE MICRO-SWITCHES

WHEN THE ARB IS IN ALARM, THE

BOOM IN/OUT MOVEMENTS, THE

OUTRIGGER UP-MOVEMENT AND

THE MACHINE SWAY FUNCTION

REMAIN ACTIVATED

• Check that the connectors are correctly plugged in the actuator

• If the connectors are plugged in correctly, contact the GENIE

Technical Assistance

CHECKING THE MICRO-SWITCHES

WITH THE BOOM RAISED 2

METRES ABOVE THE GROUND THE

OUTRIGGER UP-MOVEMENT AND

THE MACHINE SWAY FUNCTION

REMAIN ACTIVATED

• Check that the connectors are correctly plugged in the actuator

• If the connectors are plugged in correctly, contact the GENIE

Technical Assistance

Page E-3

Document 57.0003.5200 - 05/2004



THE DLE LOAD LIMITING SYSTEM

IS IN ALARM

• Fuse blown ( F25 - 10 A )

• System failure

• Check and replace fuse, if necessary

ERROR MESSAGES OF THE DLE

LOAD LIMITING SYSTEM SHOWN

ON THE DISPLAY

1 E2PROM error • Stop and restart the machine to

RESET the system. If the error message is still shown, address to the GENIE service centre to recalibrate the machine.

2 The value read from CELL 1 is higher than max permissible

• Check the wiring between control panel and load cell

• Check that the load cell is fixed correctly

• Check the connecting cable or the connectors is/are not shorted

• If the error message is still shown, address to the GENIE service centre and let the load cell be checked.

3 The value read from CELL 2 is higher than max permissible

• Check the wiring between control panel and load cell

• Check that the load cell is fixed correctly

• Check the connecting cable or the connectors is/are not shorted

• If the error message is still shown, address to the GENIE service centre and let the load cell be checked.

4 Block relay error during operation • Check the efficiency of relay and wiring

• Stop and restart the machine and check the outputs. If the error message is still shown, address to the GENIE service centre to replace the DLE unit.

5-6-7-8 Block relay error when power is turned on

• Check the efficiency of relay and wiring

• Stop and restart the machine and run a new test. If the error message is still shown, address to the GENIE service centre to replace the DLE unit.

9 CELL 1 and CELL 2 reading incongruence. The values read from the two cells are different.

• Check that the cells are intact and fixed correctly. If the error message is still shown, address to the GENIE service centre to replace the load cell or recalibrate the machine.

Page E-4

Document 57.0003.5200 - 05/2004



A Data error in RAM

B Outrigger incongruence

C Error in A.D.C. reading check

• Stop and restart the machine. If the error message is still shown, address to the GENIE service centre.

• An input is not read. Check the wiring, the power cord and the connector of the DLE unit. If the error message is still shown, address to the GENIE service centre.

• Stop and restart the machine. If the error message is still shown, address to the GENIE service centre.

ATTENTION

In case of faults not listed in this chapter, address to the GENIE Technical Assistance, your nearest authorised workshop or dealer.

Page E-5

Document 57.0003.5200 - 05/2004



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Page E-6

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Section

F

OPTIONAL ATTACHMENTS


F-1.1

F-1.2

F-1.3

F-1.4

F-1.5

F-1.6

F-1.7

Shovel ...................................................................................................

Cereal shovel .........................................................................................

Fixed hook on plate ...............................................................................

Mixing bucket ........................................................................................

Extension jib ..........................................................................................

Forks with hydraulic side-shift ..............................................................

Fork with jaw .........................................................................................

F-3

F-4

F-5

F-6

F-7

F-8

F-9

Page F-1

Document 57.0003.5200 - 11/2003



INTRODUCTION

This section provides information on the optional interchangeable attachments, especially manufactured for the handlers.

Use only genuine attachments, described in this section, after having read their features thoroughly and understood their use.

To install and remove the attachments, follow the instructions supplied in the OPERATION section, par.

C-5.4.

DANGER

When replacing interchangeable attachments, keep any person clear of the working area.

DANGER

Mounting optional attachments, and especially the extension jib, can change the centre of gravity of the machine. Before handling a load, check its weight and compare it with the values on the load charts. The weight of the used attachment must always be deducted from the rated payload .

■

Procedure to connect hydraulic lines:

• Couple the new attachment and lock it hydraulically.

• Disconnect the quick couplings of the attachment locking cylinder and connect them to the false connectors to prevent them from getting dirty.

• Connect the feeding hoses of the new attachment to the quick couplings previously set free.

When the new attachment has two hydraulic motions like, for instance, the pole and pipe planter, a flow selecting valve shall be installed on the machine or the attachment and operated from the cab by means of switch 22 .

Page F-2

Document 57.0003.5200 - 11/2003

■

F-1.1

SHOVEL

Code

Litres 500



GTH-2506

59.0200.0000

Application

Quick-coupling fitted attachment for moving soil, sand, debris, cereals, etc.

Safety

Strictly obey the general safety precautions given in section B “SAFETY”.

Operation

ATTENTION

When using a shovel, load the material only when the boom is completely retracted and push against the heap with straight wheels.

To load/unload the material, operate the rotation lever of the attachment holding plate.

Maintenance

Visually check the shovel for damage before using it.

Technical data

Capacity

A Width

B Length

H Height

Weight litres mm mm mm kg

500

1850

760

700

290

ATTENTION

Attachment suitable for moving loose material. Do not use for digging operations.

Page F-3

Document 57.0003.5200 - 11/2003



■

F-1.2

CEREAL SHOVEL

Code

Litres 800

GTH-2506

59.0200.1000

Application

Quick coupling attachment for loading cereals or inert materials, etc.

Safety


Operation

ATTENTION

When using a shovel, load the material only when the boom is completely retracted and push against the heap with straight wheels.


Maintenance

Visually check the shovel for damage before using it.


Capacity

A Width

B Length

H Height

Weight litres mm mm mm kg

800

1850

800

1150

350

ATTENTION

Attachment suitable for moving loose material. Do not use for digging operations.

Page F-4

Document 57.0003.5200 - 11/2003



■

F-1.3

FIXED HOOK ON PLATE

Payload

2500 kg

Code GTH-2506

59.0700.0000

Application

Quick-coupling fitted attachment for lifting loads by means of special slings.

Safety


Do not oscillate the load.

Do not drag hooked loads.

Lift the load before extending the boom.

Operation

Fork the hook and hold it in position by means of the locking cylinder.

All loads must be bridled with special textile slings or chains in compliance with all pertinent regulations.

To handle the load, raise and rotate the telescopic boom of the handler.

Maintenance

Visually check the hook for damage before using it.

Check the safety catch is in good working order.


Payload

Width

Length

Height

Weight kg 2500 mm mm mm kg

920

615

500

120

IMPORTANT

Make sure this attachment can be used in the destination country of the machine. In Italy, this attachment must be enrolled at ISPESL and submitted to yearly test.

Application must be submitted directly by the user.

Page F-5

Document 57.0003.5200 - 11/2003

■

F-1.4

MIXING BUCKET

Code

Litres 250

GTH-2506

59.0400.9000


Width

Length

Height

Weight

SAE capacity



Litres mm mm mm kg m 3

250

....

...

...

...

...

Application

Quick-coupling fitted attachment for mixing and distributing concrete.

Safety


Operation


To start the mixing auger, operate the attachment locking lever after connecting the feeding lines of the new attachment to the quick couplings (see page F-2).

Maintenance

CAUTION

Before any maintenance, rest the bucket on the ground, stop the machine, remove the starter key and lock the cab door to prevent anybody from gaining access to the control panel.

Visually check the bucket for damage before using it.

Wash thoroughly with water after use or in case of prolonged inactivity to prevent the mix or residues from hardening.

Check for oil leaks from hoses and connectors.

Carefully protect the quick connectors once disconnected to prevent impurities from entering the circuit.

Page F-6

Document 57.0003.5200 - 11/2003

■

F-1.5

Code

400 kg

EXTENSION JIB



GTH-2506

59.0800.0000

Application

Quick-coupling fitted attachment for maintenance interventions at high working heights.

Safety


Never lift wrongly slung loads.

Avoid abrupt acceleration or deceleration.

Avoid load oscillations, and especially do not move the load from the vertical pull line.

Do not pull crosswise and do not tow.

Operation

To change the working height, operate the rotation lever of the attachment holding plate.

Maintenance

Visually check the jib for damage before using it.

Check the safety catch is in good working order.

Daily grease the joints using the greasing gun.

Characteristics

Payload

A Length

B Width

H Height

Weight kg mm mm mm kg

400

2100

920

630

115

IMPORTANT

Make sure this attachment can be used in the destination country of the machine. In Italy, this attachment must be enrolled at ISPESL and submitted to yearly test.

Application must be submitted directly by the user.

Page F-7

Document 57.0003.5200 - 11/2003



■

F-1.6

FORKS WITH HYDRAULIC SIDE-SHIFT

Application

Quick-coupling fitted attachment for handling palletised loads with possibility of shifting the load to the side by ± 100 mm.

Safety


• Do not load loose materials

• Do not move superposed pallets

Operation

To adjust the tilting, operate the rotation lever of the attachment holding plate.

To side-shift, operate the attachment locking lever after connecting the feeding lines of the new attachment to the quick couplings (see page F-2).

Maintenance

Visually check the attachment for damage before using it.

Check for hydraulic oil leaks.

Daily grease the joints using a greasing gun, and smear the sliding guides with graphitized grease.

Machine

Code

GTH-2506

59.0600.0000


Payload kg

Width

Length

Height (with protection)

Weight

Stroke

Fork attachments

2600 mm 1240 mm 1600 mm 1000 kg 180 mm ± 100

FEM 2

Page F-8

Document 57.0003.5200 - 11/2003

■

F-1.7

FORK WITH JAW

Machine

Fork with jaw



GTH-2506

59.1300.1000

Application

Interchangeable quick-coupling attachment for loading and handling manure, shrubs and other loose agricultural products.

Safety


Operation

To adjust the fork tilting, operate the rotation lever of the holding plate.

For loading operations, act on the locking lever after connecting the feeding lines of the new attachment to the quick couplings (see page F-2).

Maintenance

Visually check for damage before using the fork. Check for hydraulic oil leaks. Daily grease the joints using a greasing pump, and the sliding profiles with graphitized grease.

Characteristics

Width

Length

Height

Weight

Teeth mm mm mm kg

1980

900

800

315

9+13

Page F-9

Document 57.0003.5200 - 11/2003




Page F-10

Document 57.0003.5200 - 11/2003



Section

G

TABLES AND

DOCUMENTS ENCLOSED


G-1

G-2.1

G-2.2

G-3.1

G-3.2.1

G-3.2.2

G-3.2.3

TORQUE WRENCH SETTING ...............................................................

Load Chart with forks ............................................................................

Load Chart with forks ............................................................................

Wiring diagram - Fuses and relays ........................................................

Wiring diagram 1/9 ................................................................................

Wiring diagram 2/9 ................................................................................

Wiring diagram 3/9 ................................................................................

G-3.2.4

G-3.2.5

G-3.2.6

G-3.2.7

Wiring diagram 4/9 ................................................................................

G-10

Wiring diagram 5/9 ................................................................................

G-11

Wiring diagram 6/9 ................................................................................

G-12

Wiring diagram 7/9 ................................................................................

G-13

G-3.2.8

Wiring diagram 8/9 ................................................................................

G-14

G-3.2.9.1

Wiring diagram 9/9 (valid up to serial no. 10739) ..................................

G-15

G-3.2.9.2

Wiring diagram 9/9 (valid from serial no. 10740) ...................................

G-16

G-3.3

General wiring diagram (description) ....................................................

G-17

G-4.1

G-5

Hydraulic scheme ..................................................................................

G-18

Routine check schedule-Safety devices ...............................................

G-20

G-2

G-3

G-4

G-5

G-7

G-8

G-9

Page G-1

Document 57.0003.5200 - 10/2004



G-1 TORQUE WRENCH SETTINGS

D x p

M 20 x 1,5

M 22 x 2,5

M 22 x 1,5

M 24 x 3

M 24 x 2

M 27 x 3

M 27 x 2

M 30 x 3,5

M 30 x 2

M 4 x 0,7

M 5 x 0,8

M 6 x 1

M 8 x 1,25

M 8 x 1

M 10 x 1,5

M 10 x 1,25

M 12 x 1,75

M 12 x 1,25

M 14 x 2

M 14 x 1,5

M 16 x 2

M 16 x 1.5

M 18 x 2,5

M 18 x 1,5

M 20 x 2,5

Pre-loading (N)

18900

20600

25800

28000

35200

37400

43000

48400

4.8

1970

3180

4500

8200

8780

13000

13700

8.8

3930

6360

9000

16400

17600

26000

27400

37800

41300

51500

56000

10.9

5530

8950

12700

23100

24700

36500

38500

53000

58000

72500

78800

12.9

6640

10700

15200

27700

29600

43900

46300

63700

69600

86900

94500

70300 98900 119000

74800 105000 126000

86000 121000 145000

96800 136000 163000

54900 110000 154000 185000

60900 122000 171000 206000

67900 136000 191000 229000

74600 149000 210000 252000

79100 158000 222000 267000

86000 172000 242000 290000

103000 206000 289000 347000

111000 222000 312000 375000

126000 251000 353000 424000

139000 278000 391000 469000

102

107

142

154

42,4

45,3

67,4

71,7

12,3

13

25,1

26,2

4.8

1,5

3

5,2

345

365

505

534

200

216

266

286

686

738

Torque wrench setting (Nm)

205

214

283

308

84,8

90,6

135

143

24,6

26

50,1

52,4

8.8

3,1

6

10,4

691

731

1010

1070

400

431

532

571

1370

1480

288

302

398

434

119

127

190

202

34,7

36,6

70,5

73,6

10.9

4,3

8,5

14,6

971

1030

1420

1500

562

607

748

803

1930

2080

346

362

478

520

143

153

228

242

41,6

43,9

84,6

88,4

12.9

5,2

10,1

17,5

1170

1230

1700

1800

674

728

897

964

2310

2490

IMPORTANT

Sensor maximum driving torque: 15 Nm.

Page G-2

Document 57.0003.5200 - 11/2003

2

1

0

-1

4



G-2.1

LOAD CHART WITH FORKS - GTH-2506

GTH-2506

From serial no. xxxxx

To serial no.

15272

450

6

5750

5

500

4

3

2500 Kg

3 2

3340

1

0

Page G-3

Document 57.0003.5200 - 11/2003

1

0

-1

4



G-2.2

LOAD CHART WITH FORKS - GTH-2506

GTH-2506

From serial no. 15273

To serial no.

xxxxx

450

6

5750

5

500

4

3

2000 K g

2500 Kg

2

3 2

3340

1 0

Page G-4

Document 57.0003.5200 - 11/2003



G-3.1 WIRING DIAGRAM - FUSES AND RELAYS

Ref.

Circuit Amp .

F1 Power supply: interior lamp, emergency switch, turn signals +30

F2 Power supply: K04 relay

F3 Optional

F4 Front right/rear left position lights, license plate lights, position lights indicator, engine oil temperature indicator

F5 Front left/rear right position lights, fuel gauge-hourmeter-warning lamps lighting, engine oil cooling temperature indicator light, fan switch, lights selection switch

F6 Right low beam

F7 Left low beam

F8 Right high beam

F9 Left high beam, High beam warning lamp

F10 Horn

F11 Windscreen washer kit

F12 Optional

F13 Optional

F14 Optional

F15 Preheating control unit power supply

5

F16 Power supply: hydraulic stop, fuel gaugehourmeter-warning lamps indicator, engine oil cooling temperature indicator, engine oil temperature indicator

K04 relay pickup, air filter warning light, preheating warning light, road safety switch

F17 Power supply: hazard warning light and turn signals switch +15

F18 Power supply: light switch - windscreen washer switch, windscreen washer motor

5

15

15

F19 Heating system fan power supply

F20 Road safety switch power supply

15

7,5

F21 Power supply: beacon 10

F22 Engine stop mushroom-head button power supply 10

F23

F24

F25

F26

F27

F28

Relay K02/Relay K05 power supply

Relay K06 power supply

Parking brake switch power supply

Optional

Optional

Optional

F29 Spare fuses

7,5

5

10

-

-

-

10

15

10

5

7,5

7,5

10

5

-

-

-

15

7,5

15

F21

F20

F19

F18

F17

F16

F15

F24

F23

F22

F28

F27

F26

F25

F7

F6

F5

F4

F3

F2

F1

F10

F9

F8

F14

F13

F12

F11

F29

F29

F29

F29

K05

K04

K03

K02

K01

Ref.

Circuit

F30 Preheating control unit maxifuse

F31 System protection fuse

K11 Start relay

A02 Preheating control unit

A02 F30

INT

K06

Amp .

50

50

F31 K11

RELAYS

Ref.

Circuit

K01 Starting enabling command

K02 Forward speed enabling command

K03 Inhibition with brake pedal stepped down

K04 Overload warning system control unit enabling command

K05 Reverse speed enabling command

K06 Overload warning system solenoid valve enabling command

Page G-5

Document 57.0003.5200 - 10/2004




Page G-6

Document 57.0003.5200 - 10/2004



G-3.2.1 WIRING DIAGRAM 1/9

30

15

X7

11

SW01

P 0 1 2 3

58 15 19 50

30

X2

2

X8

6

BU/RDø1

6/E8

X4

4

X5

9

OG/GNø1.5

2/C10

BN/BKø1.5

2/C4

X7

12

X2

1

SW03

R N F

3

R N

4

F

+

1

PKø1.5

2/C10 X5

11

X2

4

X8

14

SW04

1 2

2 1

K01

85 87A 87

86 30

F23 F22

F15

X2

4

X2

4

X7

4

VT/WHø1

RD/BKø1

GY/BUø1

RD/BKø1

RD/BKø1

6/E9

X10

11

X10

12 RD/BKø1

6/E4

RD/BKø1

2/C9

H01

X2

4

30

15

2/G10

2/G10

X7

13

F16

C

M05

X1

2

X6

12

X8

12

X8

4

X9

9

X6

10

A01

-

SW13

M

M01

X17

B+

W

D+

M02

X21

Y01

Y07

F30 F31 K11

30 86

87 85

86 87 30 L T 50 85

A02

R01

SS02

31

2/A10

Page G-7

Document 57.0003.5200 - 10/2004

1/G1

1/G1


30

15

P

GY/WHø1

TQ/RDø1

BKø1

GY/WHø1

2

3

8

1

SW02

5

6

7

4

BN/GNø1

BN/GNø1

BUø1

K02

85 87A 87

86 30

K03

85 87A 87

86 30

OG/GNø1.5

1/F7

PKø1.5

1/E5

X8

5

RD/BKø1

1/E2

RDø1 4/F5

9/C7

X4

5

GY/WHø1

6/D7

X8

15

1

2

12v

Y02

1

2

12v

Y03

SS01

1/A1

31

F25

X2

4

K05

85 87A 87

86 30

1/E7

BN/BKø1.5



X6

3

X5

6

OG/BKø1

X8

8

30

15

3/G10

3/G10

HA01

-

+

OG/BKø1

BKø1

H03

OG/BKø1

BKø1

1

2

12v

Y04

31

3/A10

Page G-8

Document 57.0003.5200 - 10/2004



2/G1

2/G1


30

15

X5

1

49

C

C2

C3

A03

G

49A 31

6/F5

X5

2

X5

4

5/C5

BN/WHø1

WH/BKø1

BKø1

2

5

8

SW05

0

1

7

1

3

4

6

BNø1

RDø1

BU/RDø1

BU/RDø1

9/C4

X5

3

F17

X2

4

A04 A05

4/G8

5/B5

30

15

4/G10

4/G10

4F5

5/C5

1/A1

31 31

4/A10

Page G-9

Document 57.0003.5200 - 10/2004


3/G10

3/G10

30

15

X9

5

3/D1

TQ/BKø1

X10

9

GNø1.5

5/B8

X7

5

X9

6

X6

5

F7 F6 F8 F9

X10

8

5/C8

X9

7

6/C8

X9

8

3/A1

H08 H07

X10

1



30

15

5/G10

5/G10

5/E1 3/G1 TQø1

2/C8 RDø1

X7

2

X9

4

X6

2

F4 F5

H06 H05 H04

X9

3

YE/BKø1

X9

2

X9

1

YEø1

YE/BKø1

6/C7

7/F9

X10

5

YE/BKø1

X10

6

YE/BKø1 6/D8

6/G1

31

5/A10

Page G-10

Document 57.0003.5200 - 10/2004




4/G10

4/G10

30

15

X8

11

X4

6

X10

7

X2

4

4

56 30

1

1 2 3

56b

5

56a

3

8

H

7

53C

12

53b

2 1 0

2

53

BUø1.5

L 0 R

9

L

10

R

TQø1

TQ/BKø1

31b

6 11

L

SW06

TQ/WHø1.5

F10 F18

X4

1

X4

2

X5

7

F11

30

15

6/G10

6/G10

RDø1.5

BNø1.5

2

5

BKø1

8

0

1

7

1

3

4

6

YEø1.5

GN/BKø1.5

YE/BKø1

SW07 4/F1

6/F1

4/C9 GYø1.5

4/A1

31

HA02

4/F7 GNø1

Page G-11

Document 57.0003.5200 - 10/2004

X4

3

GY/RDø1.5

3/G5

M

M03

3/F1

3/C1

M04

M

31

6/A10

5/G10

5/G10


30

15

X7

1

RD/BKø1

1/F2

RD/BKø1

8/G10

P01

+

J5

J6

J7

J8

0 0 0 0 0 0 3

J9

J3

J2

J1

J4

J10

J11

J12

J13

J15

J14 BUø1

WH/TQø1

3/C6

X13

3

BU/RDø1

1/F8

GY/WHø1

2/C7

YE/BKø1

4/B2

X7

8

X10

4

X7

7

X5

8

X7

10

X14

1

4/C8

GNø1

4/D1

YEø1

X8

13

X6

8

X6

9

X6

1

P02

+ S

RD/BKø1

1/F1

X7

15

X6

11

SS03

T

SS04

T

SS08 SS05

SS06

T



P03

30

15

7/G10

7/G10

YE/BKø1

4/B1

YE/BKø1

5/F1

+ S

X7

9

X6

7

T SS07

5/A1

31 31

7/A10

Page G-12

Document 57.0003.5200 - 10/2004




6/G10

6/G10

30

15

X2

4

YE/BKø1

4/C1

BN/BKø1

8/F7

BN/BKø1

SW09

YE/BKø1

OG/GNø1

8

2

PKø2.5

5

SW10

OGø1.5

BN/BKø1

OG/BUø1.5

OGø1.5

2

3

8

1

1

6

7

3

4

BKø1

WH/BKø1.5

BU/RDø1.5

OG/GNø1

5

6

7

4

BKø1

OG/BUø1.5

PK/BUø1

9/D9

X5

10

BN/BKø1

A06

X7

3

BU/RDø1

B

E

A C

F

SW08

A07

X7

6

8/G10

8/G10

F19 F20

X2

4

M06

M

X6

4

1

2

12v

Y08

X6

6

Y09

1

2

12v

6/A1

31 31

8/A10

Page G-13

Document 57.0003.5200 - 10/2004


7/G10

7/G10

30

15

6/E8

RD/BKø1

2

WH/YEø1

5

BKø1

8

0

1

7

1

3

4

6

RD/BKø1

WH/YEø1

RD/BKø1

X16

1 SW11

7/A1

31

X15

3

X16

2

X8

2

BN/BKø1

7/G8

X15

2

X8

3

X15

1

SW14

X15

4

X8

9

Y10 1

2

12v

Y11 1

2

12v

Y12 1

2

12v

X2

4

X10

3

F21

X3

5

HA03

M

H09

X3

4



30

15

9/G10

9/G10

X10

2

YE/BKø1.5

2

5

BKø1

8

0

1

7

1

3

4

6

YE/GNø1.5

YE/GNø1.5

SW12

31

9/A10

Page G-14

Document 57.0003.5200 - 10/2004



G-3.2.9.1 WIRING DIAGRAM 9/9 (valid up to serial no. 10739)

8/G10

8/G10

30

15

X17 1 2

DISLPAY COBO PER

ANTIRIBALTAMENTO

1 2 3 4 5 6 7 8 9 10 11 12 X12 1 2 X11

8/A1

31

SS09

X8

1

X8

7

7/E6

30

15

2/C7

RD/BKø1

X2

3

K04

85 87A 87

86 30

F2 F1 F3

X8

10

X2

4

K06

85 87A 87

86 30

F24

H02

RDø1

BKø1

X3

6

X10

10

RDø1

3/G4

1

2

12v

Y05

1

2

12v

Y06

31

Page G-15

Document 57.0003.5200 - 10/2004

G-3.2.9.2 WIRING DIAGRAM 9/9 (valid from serial no. 10740)

8/G10

8/G10

30

15

DISLPAY 3B6 PER

ANTIRIBALTAMENTO

1 2 7 18 19 16 9 10 17 11 X12 1 2 X11

8/A1

31

X18

1 2 3 4

7/E6

1 2 3 4

X8

SS09

2/C7

RD/BKø1



30

15

X2

3

K04

85 87A 87

86 30

F2 F1 F3

X8

10

X2

4

K06

85 87A 87

86 30

F24

H02

RDø1

BKø1

X3

6

X10

10

RDø1

3/G4

1

2

12v

Y05

1

2

12v

Y06

31

Page G-16

Document 57.0003.5200 - 10/2004



G-3.3 GENERAL WIRING DIAGRAM

(description)

Ref Description Sheet

F1 POWER SUPPLY: INTERIOR LAMP,

EMERGENCY SWITCH,

TURN SIGNALS +30

F2 POWER SUPPLY: K04 RELAY

F3 OPTIONAL

F4 FRONT RIGHT/REAR LEFT POSITION

LIGHTS, LICENSE PLATE LIGHTS,

POSITION LIGHTS INDICATOR,

ENGINE OIL TEMPERATURE INDICATOR

F5 FRONT LEFT/REAR RIGHT POSITION

LIGHTS, FUEL GAUGE-HOURMETER-

WARNING LAMP ILLUMINATION,

ENGINE OIL COOLING TEMPERATURE

INDICATOR LIGHT, FAN SWITCH,

LIGHTS SELECTION SWITCH

F6 RIGHT LOW BEAM

F7 LEFT LOW BEAM

F8 RIGHT HIGH BEAM

F9 LEFT HIGH BEAM, HIGH BEAM

WARNING LAMP

F10 HORN

F11 WINDSCREEN WASHER KIT

F12 OPTIONAL

F13 OPTIONAL

F14 OPTIONAL

F15 PREHEATING CONTROL UNIT

POWER SUPPLY

F16 POWER SUPPLY: HYDRAULIC STOP, FUEL

GAUGE-HOURMETER-WARNING LAMPS

INDICATOR, ENGINE OIL COOLING

TEMPERATURE INDICATOR, ENGINE OIL

TEMPERATURE INDICATOR, K04 RELAY

PICKUP, AIR FILTER WARNING LIGHT,

PREHEATING WARNING LIGHT,

ROAD SAFETY SWITCH

F17 POWER SUPPLY: HAZARD WARNING

LIGHT AND TURN SIGNALS SWITCH +15

F18 POWER SUPPLY: LIGHT SWITCH -

WINDSCREEN WASHER SWITCH,

WINDSCREEN WASHER MOTOR

F19 HEATING SYSTEM FAN POWER SUPPLY

F20 ROAD SAFETY SWITCH POWER SUPPLY

4

1

1

3

4

4

4

4

4

5

5

5

7

7

9

9

9


F21 POWER SUPPLY: BEACON 8

F22 ENGINE STOP MUSHROOM-HEAD

BUTTON POWER SUPPLY

F23 POWER SUPPLY: RELAY K02, K05

F24 RELAY K06 POWER SUPPLY

F25 PARKING BRAKE SWITCH

POWER SUPPLY 2

F26 OPTIONAL

F27 OPTIONAL

F28 OPTIONAL

F30 PREHEATING CONTROL UNIT MAXIFUSE 1

F31 SYSTEM PROTECTION FUSE 1

1

1

2

H01 WARNING LIGHTS: AIR FILTER SOILED,

PREHEATING GLOW PLUGS

WARNING LIGHT

H02 CAB LIGHTING

H03 BACK-UP LAMPS

H04 REAR RIGHT-HAND LIGHT

H05 LICENSE PLATE LAMP

H06 REAR LEFT-HAND LIGHT

H07 FRONT LIGHT LAMP - LEFT TURN

SIGNAL

H08 FRONT LIGHT LAMP - RIGHT TURN

SIGNAL

H09 WORK LIGHT

4

4

8

1

4

4

9

2

4

HA01 BACK-UP HORN

HA02 HORN

HA03 BEACON

K01 STARTING ENABLING COMMAND 1

K02 FORWARD SPEED ENABLING COMMAND 2

K03 INHIBITION WITH BRAKE PEDAL

STEPPED DOWN

K04 OVERLOAD WARNING SYSTEM

CONTROL UNIT ENABLING COMMAND

2

9

K05 REVERSE SPEED ENABLING COMMAND 2

K06 OVERLOAD WARNING SYSTEM

SOLENOID VALVE ENABLING COMMAND 9

K11 START RELAY 1

2

5

8

Page G-17

Document 57.0003.5200 - 10/2004

Ref Description

M01 STARTER MOTOR

M02 ALTERNATOR

M03 WINDSCREEN WIPER/WASHER MOTOR

M04 WINDSCREEN WIPER/WASHER MOTOR

M05 COMPRESSED AIR COMPRESSOR

M06 FAN MOTOR

Sheet

1

5

1

1

5

7

P01 WARNING LIGHTS-FUEL GAUGE

INSTRUMENT

P02 ENGINE OIL TEMPERATURE

TRANSDUCER

P03 ENGINE OIL COOLING TEMPERATURE

INDICATOR

R01 GLOW PLUGS

6

6

6

1

SW01 IGNITION KEY

SW02 PARKING BRAKE SWITCH

SW03 CHANGEOVER-OVER SWITCH

SW04 MUSHROOM-HEAD BUTTON

SW05 HAZARD WARNING LIGHT / TURN

SIGNALS SWITCH

SW06 LIGHT SWITCH-TURN SIGNALS-

WINDSCREEN WIPER/WASHER

SW07 LIGHTS SELECTION SWITCH

SW08 STEERING SELECTOR

SW09 HEATING FAN SWITCH

SW10 ROAD SAFETY SWITCH

SW11 ROAD SAFETY SWITCH

SW12 OPTIONAL WORK LIGHT SWITCH

SW13 BATTERY CUTOFF

SW14 JOYSTICK

SS01 HYDRAULIC STOP

SS02 AIR FILTER CLOGGING SENSOR

SS03 WATER TEMPERATURRE SENSOR

SS04 ENGINE OIL PRESSURE TRANSDUCER

SS05 NEGATIVE BRAKE PRESSURE SWITCH

SS06 HYDRAULIC OIL TEMPERATURE

TRANSDUCER

SS07 WATER TEMPERATURRE SENSOR

1

1

1

2

3

8

1

7

8

8

7

7

5

5

2

1

6

6

6

6

6

Ref Description

SS08 FUEL FLOAT

SS09 LOADING CELL

Sheet

6

9

Y01 SOLENOID VALVE - STARTER

Y02 SOLENOID VALVE - FWD SPEED

Y03 SOLENOID VALVE - PARKING BRAKE

Y04 SOLENOID VALVE - REVERSE SPEED

Y05 SOLENOID VALVE - OVERLOAD WARNING

SYSTEM

Y06 SOLENOID VALVE - OVERLOAD WARNING

SYSTEM

Y07 ENGINE STOP SOLENOID

Y08 WHEEL STEERING SOLENOID VALVE

Y09 WHEEL STEERING SOLENOID VALVE

Y10 SOLENOID VALVE - ATTACHMENT

COUPLING-RELEASE

Y11 SOLENOID VALVE - DEADMAN

Y12 SOLENOID VALVE - BOOM EXTENSION

2

2

1

2

9

7

7

9

1

8

8

8

A01 12V BATTERY

A02 PREHEATING CONTROL UNIT

A03 TURN SIGNALS FLASHING

A04 DIODE

A05 DIODE

A06 DIODE

A07 DIODE

X01 4-WAY CONNECTOR - ENGINE FUSES LINE

X02 4-WAY CONNECTOR - STEERING COLUMN

X03 6-WAY CONNECTOR - CAB



X06 12-WAY CONNECTOR - ENGINE





X11 2-WAY CONNECTOR - OVERLOAD

WARNING SYSTEM CONTROL UNIT 9

X12 CONNECTOR - OVERLOAD WARNING

SYSTEM CONTROL UNIT 9

3

3

1

1

3

7

7




X15 4-WAY CONNECTOR - JOYSTICK



WARNING SYSTEM CONTROL UNIT

CALIBRATION


WARNING SYSTEM CONTROL UNIT

9

9

VT

GY

WH

PK

TQ

COLOUR TABLE

Acronym Colour

BK

BN

RD

OG

YE

GN

BU

Black

Brown

Red

Orange

Yellow

Green

Blue

Purple

Grey

White

Pink

Light blue

LIST OF ABBREVIATIONS

Label

F##

Description

Fuses

H##

HA##

K##

M##

P##

R##

RP##

SW##

SS##

Lamps, lights, warning lights

Clacson or back-up horn

Relays

Motor or pump

Indicators

Resistance

Potentiometers

Y##

X##

A##

Switches, selectors

Sensors, micro-switches, pressure switches, transducers

Solenoid valves

Connectors

Other components



Page G-18

Document 57.0003.5200 - 10/2004



G-4.1 HYDRAULIC SCHEME Drw. 57.2201.1300 rev. A

Hydraulic piloting line test port

TP

2

Ev5

A

T P

B

Parking/emergency brake selector valve

4 ways / 2 positions

T R

Service brake circuit reservoir

Pressure reducing valve setting pressure: 28 bar

Service brake pedal pump max operating pressure: 80 bar

E

DR

U

Front axle

Parking/emergency brake control valve orifice dia.: 0.5 mm cracking pressure:

0.5 bar

P2

P1

B A

T P

Service brake pressure switch activating pressure:

2,8-6,3 bar

Emergency brake minimum pressure pressure switch activating pressure:

60 bar

Forks tilt cylinder

Rear axle steering cylinder

Ev3

Steering mode selector valve


Ev4

Forks levelling slave cylinder

Front axle steering cylinder

Steering rotating actuator displacement: 125 cc/ rev.

R

Anti-shock valves cracking pressure:

225 bar

Accumulator capacity:

L

0.5 liters precharge pressure:

50 bar

Anticavitation valves cracking pressure

5 bar

Boom lift cylinder

Double overcenter/safety valve piloting ratio: 4.2/1 cracking pressure: 350 bar

Piloting lines hydraulic collectors

Double overcenter/safety valve piloting ratio: 4.2/1 cracking pressure: 350 bar

Forks attachment quick coupling cylinder

Quick coupling hydraulic ports

3 ways / 2 positions selector valve lockout telescoping out

Hydraulically piloted double check valve piloting ratio: 4/1

Single overcenter/safety valve piloting ratio: 4.2/1 cracking pressure: 350 bar

Boom telescoping cylinder

3 2

1 Ev9

P

Max relief valve cracking pressure:

170 bar

T

L

S

Single overcenter/safety valve piloting ratio: 4.2:1 cracking pressure: 300 bar

Boom functions hydraulic circuit test port

TP

1

Boom functions control lever

1 4

B

4

A

4

X

4

B

3

A

3

280 bar

X

3

B

2

A

2

X

2

B

1

A

1

X

1

T

P

T

130 bar

280 bar

260 bar

Check valve cracking pressure

0.5 bar

M

L

X

1

1.3

AH M sp TP

4

M t

Hydrostatic transmission boost pressure test port

0.7 0.7


0.5 bar

T

Z

Y

Ev1

Ev2

2 bar

Boom functions pump with integrated priority valve displacement 27 cc/rev

Diesel engine

M

Shutoff valve

Hydrostatic transmissionpump max displacement 55 cc/rev

Suction screen

0.9

0.9

445 bar

445 bar

19 bar

6.4

32 bar

A M p

S

L

U

P

B M s

C

X

P 3 2

Y

Y

4

Y

3

Y

2

Ev10

Y

1

TP

3

Hydrostatic transmission high pressure test port

U

A

Hydrostatic transmission motor max displacement 105 cc / rev

M

1

A

X

260 bar

14 bar max min

T

B

Ev11

B L X

3 2

1

Ev6

Ev8

Boom functions main valve

(4 sections)

A B

G H C D E F Ev7

Boom functions piloting selector valve



2.5 bar

Oil tank capacity 70 liters

3 ways / 2 positions selector valve lockout boom down

T

HYDRAULIC CIRCUIT

COLORS LEGENDA

Boom/steering pump pressure lines

Hydrostatic transmission high pressure lines

Boom / steering functions lines

Low pressure and transmission charge pressure lines

Hydrostatic transmission and boom functions valve piloting lines

Boom / steering and transmission pumps suction lines

Tank lines

Heat exchanger

Shutoff valve

Page G-19

Document 57.0003.5200 - 10/2004

G-5 ROUTINE CHECK SCHEDULE - SAFETY DEVICES

COMPONENT

Date

Result/Notes

Positive Negative Signature



Table key explanation:

Block valve 1

Block valve 2

Block valve 3

Block valve 4

Block valve 5

Block valve 6

Block valve 7

Block valve 8

Block valve 9

Block valve on lifting cylinder

Block valve on fork balance cylinder

Block valve on telescope extension cylinder

Block valve on attachment moving cylinder

Block valve on attachment locking cylinder

Micro 1

Micro 2

Micro 3

Micro 4

Micro 5

SAR + Display

EMERGENCY

Joystick button

Presence micro-switch in driving seat (only in the TCE version)

Overload warning system - Electronic card and display

Emergency stop pushbutton

Dead man pushbutton on control lever (not present in the TCE version)

Page G-20

Document 57.0003.5200 - 10/2004

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