UM GTH-4013 - GB - Genie Industries

UM GTH-4013 - GB - Genie Industries
Operator's manual
Part N.
57.0007.0200
Rev. 0
01/2006
From serial n. 14518
To serial n. 19104
English
Edition
GTH-4013
CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE
CAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES
TECHNICAL SERVICES
Genie Scandinavia
Phone +46 31 575100
Fax +46 31 579020
Genie Mexico City
Phone +52 55 5666 5242
Fax +52 55 5666 3241
Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544
Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie North America
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
Genie Japan
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Genie Germany
Phone +49 (0)4202 88520
Fax +49 (0)4202 8852-20
Genie Australia Pty Ltd.
Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910
Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754
Genie Holland
Phone +31 183 581 102
Fax +31 183 581 566
Operator's manual 57.0007.0200 - GTH-4013
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 2006 TEREXLIFT srl - All rights reserved.
Produced by: TEREXLIFT Technical Literature Dept. - Studio VEGA - Forlì
REVISED PAGE LIST
Revision
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Handler with telescopic boom GTH-4013
INTRODUCTION
■ INTRODUCTION
Sections are subdivided into chapters and paragraphs
that are numbered progressively.
This manual 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 quickest way to look for 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 manual 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.
The handbook is divided into seven sections:
Sect.
Sect
Sect
Sect.
Sect.
Sect.
Sect.
A
B
C
D
E
F
G
GENERAL INFORMATION
SAFETY PRECAUTIONS
OPERATING INSTRUCTIONS
MAINTENANCE
TROUBLESHOOTING
OPTIONAL ATTACHMENTS
TABLES AND ENCLOSURES
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.
IMPORTANT
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
those responsible for safety.
It describes the essential compulsory qualities of the
personnel in charge and other important information
for the safety of persons and things.
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.
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 those responsible for
maintenance 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.
Page
1
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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 seven 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 degree of a hazard:
CAUTION
Yellow with safety alert symbol: used to indicate a
potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
ATTENTION
Yellow without safety alert symbol: used to indicate
a potentially hazardous situation which, if not
avoided, may result in damage to the machine or
the systems.
PROTECT THE
ENVIRONMENT
Green: used to draw the attention to important
information on environment protection.
IMPORTANT
Green: used to indicate operation and maintenance
information.
Safety Alert symbol: when you see this symbol, be
alert to the possibility of personal injury. Strictly
obey all the safety messages accompanying this
symbol to avoid the risk of serious injury or death.
WHEN READING THIS MANUAL, PAY THE
GREATEST ATTENTION TO THESE SPECIAL
SYMBOLS AND THE EXPLANATION OF THE
SITUATIONS THEY EMPHASIZE.
DANGER
Red: used to indicate an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
The manual in electronic format also contains the
following symbol:
which enables the user to return to the
table of contents
DANGER
Orange: used to indicate a potentially hazardous
situation which, if not avoided, could result in death
or serious injury.
Page
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GENERAL INDEX
GENERAL INDEX
GENERAL INFORMATION
Sect.
A
SAFETY PRECAUTIONS
Sect.
B
OPERATING INSTRUCTIONS
Sect.
C
MAINTENANCE
Sect.
D
TROUBLESHOOTING
Sect.
E
OPTIONAL ATTACHMENTS
Sect.
F
TABLES AND DOCUMENTS ENCLOSED
Sect.
G
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INTENTIONALLY BLANK PAGE
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GENERAL INFORMATION
Section
A
GENERAL INFORMATION
TABLE OF CONTENTS
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-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-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 ................................................................................
Machine position ........................................................................................................
Labels and warning plates applied on the machine ...................................................
Explanation of the different symbols used on the machine .......................................
MACHINE IDENTIFICATION .......................................................................................
Machine model and type ............................................................................................
Manufacturer ..............................................................................................................
Machine identification plates ......................................................................................
CE marking .................................................................................................................
Chassis serial number ................................................................................................
Identification plates of the main parts ........................................................................
ALLOWED USE ..........................................................................................................
Allowed use ................................................................................................................
Improper use ..............................................................................................................
Residual hazards ........................................................................................................
Applicable standards ..................................................................................................
Safety devices ............................................................................................................
GENERAL DESCRIPTION ..........................................................................................
List of the main components ......................................................................................
Description of the main components .........................................................................
Optional accessories ..................................................................................................
TECHNICAL DATA AND PERFORMANCE .................................................................
Main dimensions ........................................................................................................
Limits of use ...............................................................................................................
Weight ........................................................................................................................
Speed .........................................................................................................................
Payload and reach ......................................................................................................
Forks (floating type) ....................................................................................................
Diesel engine ..............................................................................................................
Electrical system ........................................................................................................
Machine sound levels .................................................................................................
Vibration levels ...........................................................................................................
LIFETIME ....................................................................................................................
ITEMS SUPPLIED .......................................................................................................
Literature supplied ......................................................................................................
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A-1
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A-2
A-2
A-3
A-10
A-12
A-12
A-12
A-12
A-13
A-13
A-13
A-14
A-14
A-14
A-14
A-15
A-16
A-20
A-20
A-21
A-21
A-22
A-22
A-22
A-22
A-22
A-23
A-23
A-23
A-23
A-23
A-23
A-24
A-24
A-24
Handler with telescopic boom GTH-4013
GENERAL INFORMATION
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
REAR PART
RIGHT SIDE
FRONT
PART
LEFT SIDE
LOWER PART
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A-2
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GENERAL INFORMATION
■ 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.
09.4618.0661
09.4618.0026
09.4618.0230
09.4618.0030
09.4618.0171
09.4616.0040
09.4618.0022
09.4618.0361
09.4618.0241
09.4618.0547
09.4618.0061
09.4618.0242
09.4618.0212
09.4618.0230
09.4618.0547
09.4618.0061
09.4618.0227
09.4616.0109
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GENERAL INFORMATION
09.4618.0361
09.4618.0663
09.4618.0661
09.4616.0068
09.4618.0361
09.4618.0516
09.4618.0230
09.4618.0230
09.4618.0212
09.4618.0010
09.4618.0547
09.4618.0061
09.4618.0662
09.4618.0230
09.4618.0243
09.4618.0547
09.4618.0061
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A-4
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GENERAL INFORMATION
Decal
Code
Description
09.4618.0022
Keep out of the working range of the machine.
When the machine is running, entering the working
range of the machine is prohibited.
09.4618.0212
Keep out of the working range of the machine.
When the machine is running, entering the working
range of the machine is prohibited.
KEEP OUT OF
WORKING RANGE
Guaranteed sound power level. It indicates the
guaranteed sound power level measured in
accordance with the Directive 2000/14/EC.
XX
09.4618.0516
09.4618.0663
Quick guide.
An overview of the operator's handbook concerning:
- control lever,
- machine starting,
- overload warning system
- main safety precautions.
3
4
The guide also includes the fork load charts with or
without use of the outriggers.
• Load chart for operations without outriggers (or
with outriggers up). 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 without outriggers (or with
retracted outriggers).
• Load chart for operations with outriggers down.
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
with lowered outriggers.
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A-5
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GENERAL INFORMATION
Decal
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.
CHANGE MECHANICAL
GEAR ONLY WHEN THE
MACHINE IS STATIONARY
DANGER
Code
Description
09.4618.0010
Do not open while engine is running.
Do not open the engine bonnet when engine is
running, since this may result in serious injury due to
moving parts or hot components.
09.4618.0030
Do not change mechanical gear when the machine
is running.
09.4618.0026
Use limits close to electric power lines. It defines
the minimum distance to be kept when the machine
works close to aerial power lines.
09.4618.0361
Maximum pressure on the ground. The value
indicates the maximum pressure on the ground of the
outriggers to prevent the machine from sinking into
the ground and avoid instability.
09.4618.0227
Fork pitching. Warning for road circulation which
indicates the need to pitch back and block the forks.
ELECTRIC CABLES AND
POWER LINES
KEEP EVERY PART OF THE MACHINE, LOADS AND
ACCESSORIES AT LEAST 6 METERS FROM
OVERHEAD POWER LINES
P max kg/cm2
XXX
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GENERAL INFORMATION
Decal
Code
Description
09.4618.0230
Warning stickers. Applied near coupling points,
silencer, fan belt, hydraulic oil level, tank, etc.
Anchorage points. Applied near the holes envisaged for
machine lifting.
Fuel cap. Applied near the engine oil cap.
Hydraulic oil. Applied near the hydraulic oil plug or level
indicator.
Engine oil level. Applied near the engine oil dipstick.
Moving gears. Applied near the fan of the heat exchanger.
Unscrew the plug with extreme caution: hot water.
Risk of burns! Warns the operator of the risk of burns
when unscrewing the plug of the compensation tank of the
heat exchanger.
Hot surfaces. Risk of burns. Applied on those surfaces
which during operation can become hot and cause burns.
Risk of crushing injury to the hands. Use extreme
caution when moving the outriggers.
Presence of moving parts. Use extreme caution when
moving the outriggers.
09.4618.0547
(standard)
Tyre inflation sticker.
Placed near the wheels, this label shows the
recommended tyre inflation pressure.
P= 5,5 bar
09.4618.0061
(optional)
P= 4,5 bar
GTH-4013
09.4618.0241
09.4618.0242
09.4618.0243
"GENIE" sticker.
09.4618.0661
"GENIE GTH-4013" sticker.
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GENERAL INFORMATION
Decal
Code
Kg 4000
Description
09.4616.0040
Max capacity. Indicates the maximum capacity of
the machine.
09.4616.0068
Machine data plate. The identification plate contains
the main identification data of the machine.
09.4616.0109
Fork data plate. This plate shows the main data of
the fork installed on the machine.
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
200
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
kg
PESO MAX ASSALE POST. - MAX REAR AXLE WEIGHT - POIDS MAX ESSIEU ARRIERE
ZUL. ACHSLAST HI. N. ST VZO - PESO MAX EJE POSTERIOR
kg
PESO TOTALE - TOTAL WEIGHT - POIDS TOTAL - ZUL. GESAMTGEWICHT N. ST VZO
PESO TOTAL
kg
MATRICOLA MOTORE TERMICO - ENGINE SERIAL N. - N. MOTEUR THERMIQUE
FABRIK NR. DIESEL MOTOR - NO. DE SERIE MOTOR TERMICO
OMOLOGAZIONE
FABBRICATO IN ITALIA - MADE IN ITALY
T E RE XL I F T
s.r.l.
ZONA INDUSTRIALE - 06019 UMBERTIDE (PG) - ITALY
Tel. +39 (0) 75 94181 Fax +39 (0) 75 9415382
ASSIEME FORCHE-FORKS ASSY
GROUPE FOURCHES-GABELGROUPPE
JUNTO HORQUILLAS
MODELLO - TYPE - DÉSIGNATION
MODELL - MODELO
__._____._____
N° SERIE - SERIAL N°-N° DE SERIE
- SERIEN N°- N° DE BASTIDOR
.............
ANNO DI COSTRUZIONE YEAR OF CONSTRUCTION ANNÉE DE CONSTRUCTION BAUJHAR - AÑO DE CONSTRUCCIÓN
______
MASSA - MASS - MASSE MASSE - MASA
____
CENTRO DI GRAVITÀ - CENTER OF
GRAVITY - CENTRE DE GRAVITÉ SCHWERPUNKT - CENTRO DE GRAVEDAD
PORTATA NOMINALE - PAY LOAD PORTEE NOMINALL - NENN
TRAGFÄHIGKEIT - CARGA NOMINAL
CENTRO DI CARICO - LOAD CENTER CENTRE DE CHARGE - LASTPUNKT CENTRO DE CARGA
___
____
___
MODELLO MACCHINA - MACHINE MODEL DESOGNATION MACHINE - MASCHINEN MODELL
MODELO MÁQUINA
ROPS-FOPS cab type-approval plate. This plate
shows the type-approval data of the driving cab
according to ROPS - FOPS regulations.
ATTENTION
09.4618.0171
TO PREVENT DAMAGE OF INTERNAL
Re-sequencing the telescopic boom extension. If,
during normal operation, a change in the boom
extended lengths is noticed, proceed with resequencing as indicated in the operator’s manual.
BOOM HOSES BOOM SECTIONS NEED
TO BE EXTENDED EQUALLY OTHERWISE
RE-SEQUENCING WILL BE REQUIRED.
SEE OPERATORS MANUAL FOR MORE
DETAILS.
09.4618.0171
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GENERAL INFORMATION
Decal
ATTENZIONE!
CAUTION!
Code
Description
09.4618.0514
Caution: accumulator under pressure.
09.4618.0673
Emergency controls. Reminds the operator the
correct procedure for the manual operation of the
main valve in an emergency. It also shows the controls
and the relevant controlled movements of all the
levers of the main valve.
IN ATTESA DA
RECIPIENTE IN PRESSIONE
TEREX
HIGH PRESSURE
ACCUMULATOR
Page
A-9
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GENERAL INFORMATION
■ A-1.3
EXPLANATION OF THE DIFFERENT
SYMBOLS USED ON THE MACHINE
IMPORTANT
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.
Spend the necessary time to become familiar with
these symbols and to learn their meaning.
Symbol
Symbol
Description
Description
Hazard warning lights
Battery charge
Windscreen washer
Attachment pushbutton (if any)
Cab ventilation fan
Steering mode switch
Brake pressure
Diesel engine water temperature
Engine oil pressure
Fuel level
Boom up
Hydraulic oil temperature
Boom down
Position lights
Boom out
High beam
Boom in
Low beam
Attachment locked
Fog lamp
Attachment unlocked
Turn signals
Fork pitching forward
Parking brake
Fork pitching back
Right outrigger down
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GENERAL INFORMATION
Symbol
Symbol
Description
Description
Right outrigger up
Lifting point
Left outrigger down
Emergency pump
Left outrigger up
Sway right
Sway left
Machine sway control
Cab controls
Platform controls
Road setting
Oil filter clogged
Air filter clogged
Speed selector switch
1st speed engaged
2nd speed engaged
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A-11
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GENERAL INFORMATION
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
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
GTH-4013
200
MATRICOLA - SERIAL N. - N. DE SERIE - FZ.-IDENT NR. - NO. DE SERIE
■ 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
PESO MAX ASSALE ANT. - MAX FRONT AXLE WEIGHT - POIDS MAX ESSIEU AVANT
ZUL. ACHSLAST VO. N. ST VZO - PESO MAX EJE ANTERIOR
kg
PESO MAX ASSALE POST. - MAX REAR AXLE WEIGHT - POIDS MAX ESSIEU ARRIERE
ZUL. ACHSLAST HI. N. ST VZO - PESO MAX EJE POSTERIOR
kg
PESO TOTALE - TOTAL WEIGHT - POIDS TOTAL - ZUL. GESAMTGEWICHT N. ST VZO
PESO TOTAL
kg
MATRICOLA MOTORE TERMICO - ENGINE SERIAL N. - N. MOTEUR THERMIQUE
FABRIK NR. DIESEL MOTOR - NO. DE SERIE MOTOR TERMICO
OMOLOGAZIONE
FABBRICATO IN ITALIA - MADE IN ITALY
■ A-2.3 MACHINE IDENTIFICATION PLATES
The following data plates are applied on the machine.
Machine data plate
The identification plate contains the main identification
data of the machine like model, serial number and year
of manufacture.
On machines destined for the Italian market, the data
plate is installed in the driving cab, on the right, and
is well-visible when the door is opened. On the machines
destined for foreign markets, the data plate is applied
on the front right side of the chassis.
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A-12
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GENERAL INFORMATION
Road traffic data plate
The road traffic data plate is installed on the front
right side of the chassis (only on machines destined for
the Italian market).
This plate shows the road traffic related data and the
weights of the specific machine model.
ROPS-FOPS cab type-approval plate
The ROPS - FOPS type-approval plate is located
inside the driving cab above the rear glass.
■ A-2.5 CHASSIS SERIAL NUMBER
The chassis serial number is punched on the front left
part of the chassis side member .
■ 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.
Fork data plate
Placed on the left side of the fork frame.
This plate shows the identification data of fork such as
model, serial number, year of manufacture, weight,
nominal payload, centre of the load and model of the
machine on which the forks are installed.
■ A-2.4
CE MARKING
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 .
DATI OMOLOGAZIONE STRADALE
TIPO
OMOLOGAZIONE
NUMERO DI IDENTIFICAZIONE
MASSA TOTALE AMMISSIBILE (*)
CARICO MAX ASSE ANTERIORE (*)
CARICO MAX ASSE POSTERIORE (*)
(*) In funzione della gommatura
T E RE XL I F T
s.r.l.
da
kg a
kg
da
da
kg a
kg a
kg
kg
MASSA RIMORCHIABILE AMMISSIBILE:
- MASSA NON FRENATA
kg
-
MASSA CON FRENATURA INDIPENDENTE
kg
-
MASSA CON FRENATURA AD INERZIA
kg
-
MASSA CON FRENATURA ASSISTITA
kg
COEFFICIENTE DI ASSORBIMENTO
CORRETTO DEL MOTORE
m-1
ZONA INDUSTRIALE - 06019 UMBERTIDE (PG) - ITALY
Tel. +39 (0) 75 94181 Fax +39 (0) 75 9415382
Zona Industriale, I-06019 Umbertide (PG) - Italy
Tel. +39 (0)75 941811 - Fax +39 (0)75 9415382
ASSIEME FORCHE-FORKS ASSY
GROUPE FOURCHES-GABELGROUPPE
JUNTO HORQUILLAS
MODELLO - TYPE - DÉSIGNATION
MODELL - MODELO
__._____._____
N° SERIE - SERIAL N°-N° DE SERIE
- SERIEN N°- N° DE BASTIDOR
.............
ANNO DI COSTRUZIONE YEAR OF CONSTRUCTION ANNÉE DE CONSTRUCTION BAUJHAR - AÑO DE CONSTRUCCIÓN
______
MASSA - MASS - MASSE MASSE - MASA
____
CENTRO DI GRAVITÀ - CENTER OF
GRAVITY - CENTRE DE GRAVITÉ SCHWERPUNKT - CENTRO DE GRAVEDAD
PORTATA NOMINALE - PAY LOAD PORTEE NOMINALL - NENN
TRAGFÄHIGKEIT - CARGA NOMINAL
CENTRO DI CARICO - LOAD CENTER CENTRE DE CHARGE - LASTPUNKT CENTRO DE CARGA
___
____
___
MODELLO MACCHINA - MACHINE MODEL DESOGNATION MACHINE - MASCHINEN MODELL
MODELO MÁQUINA
Page
A-13
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GENERAL INFORMATION
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
Applying loads in different points of the
attachment holding plate
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-14
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GENERAL INFORMATION
■ A-3.4
APPLICABLE STANDARDS
EN 50081-1: 1997 Electromagnetic compatibility – Generic
requirements on emissions - Part 1
For the operator’s safety, the following standards were
obeyed during the risk assessment of the handler fitted
with telescopic boom:
EN 50082-1: 1997 Electromagnetic compatibility – Generic
requirements on immunity - Part 1
Directive
Title
EN 60204-1:1998 Safety of machinery - Electrical
equipment of machines - Part 1
98/37/CE
89/336/CEE
2000/14/CE
Machinery Directive
Electromagnetic compatibility
Environment Acoustic Emissions
Standard
Title
EN 1459:1988
Harmonised standard. Safety of industrial
trucks - Self- propelled variable reach
trucks.
EN 281:1988
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
Page
A-15
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GENERAL INFORMATION
■ A-3.5
SAFETY DEVICES
• Load limiting device. It consists of a load cell fitted
to the rear axle and a display installed in the driving
place. This device enables the operator to check
the stability variation through a bar with 8 LED's (4
green, 2 yellow and 2 red).
• Limit switch on the outriggers
When the outriggers are lowered to the ground:
- the overload warning system changes the meter
scale
- the man-platform can be used
- the transmission is deactivated
• Emergency stop pushbutton: on the dashboard,
to the right of the steering wheel. Pressing down
this button stops the engine of the machine
Before starting work again, find and rectify the
relevant causes, then reset the button to neutral
position turning it clockwise.
Page
A-16
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GENERAL INFORMATION
• Safety pushbutton on joystick (dead man button).
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.
• 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
Page
A-17
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GENERAL INFORMATION
E
F
G
H
Block valve on attachment pitching cylinder
Block valve on the outrigger cylinder
Block valve on the rear axle block cylinder
Block valve on machine sway cylinders
Page
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GENERAL INFORMATION
• Limit switches and safety switches:
L Limit switch fitted to the left side of the boom
that, through a jack fixed to the chassis, blocks
the rear axle when the boom inclination is above
40°.
M Limit switch fitted to the right side of the boom
that blocks the outriggers and the sway function
(axle oscillation) when the boom is raised more
than 2 metres above the ground.
N Switch on the parking brake which prevents
forward/reverse gear shifting, as well as any
other movements of the machine if the brake is
engaged.
Page
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GENERAL INFORMATION
A-4 GENERAL DESCRIPTION
■ A-4.1
LIST OF THE MAIN COMPONENTS
10
1
2
5
3
6
7
8
1
2
3
5
6
7
8
9
10
11
12
13
14
15
-
9
11
3rd boom section
2nd boom section
1st boom section
Rear view mirror, left side
Chassis
Forks
Attachment holding frame
Left sway cylinder
Driving cab according to ROPS-FOPS provisions
Front axle
Fuel tank
Access step
Hydraulic oil tank
Rear axle
Page
A-20
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13
14
15
Handler with telescopic boom GTH-4013
GENERAL INFORMATION
■ A-4.2
DESCRIPTION OF THE MAIN
COMPONENTS
Chassis
Made of high tensile steel to improve robustness and
durability, it is equipped, at the front, with two
independent outriggers. A hydraulic cylinder between
chassis and rear axle allows compensating side slopes
up to ± 6°.
Hydrostatic transmission unit
Closed circuit hydrostatic transmission with continuous
speed adjustment, mainly consisting of:
- a variable displacement pump connected to the
thermal engine by an elastic joint
- a variable displacement motor connected to the
power divider-gearbox.
- a hydraulic oil filter, placed on the injection line from
the tank
- a water/oil heat exchanger to cool the circuit down.
This transmission with permanent 4 wheel drive
improves the traction force, thus resulting in an
increased climbing ability on slopes up to 60% at a
max speed of 35 km/h.
Power divider/Two-speed gearbox
The power divider/mechanical gearbox has two speeds
that can be selected by pressing the relevant button in
the driving cab, a work speed and a travel speed.
Speeds can only be selected when the machine stands
still. From the gearbox, through two Cardan shafts,
motion is transmitted to the front and rear axles fitted
with differentials.
Axles
Equipped with an automatic differential lock acting on
the rear axle which lets the machine move also on low
grip grounds. The front axle is the steer type; the rear
axle is the steer/oscillating type. When the high speed
is engaged, only the front wheels are allowed to steer.
Brake circuit
The brake system is the multidisc type in oil bath, with
self-adjustment, built in the front and rear axle and
acting on every wheel. The pedal directly acts on the
brake pump which delivers oil to the blocking cylinders
through a line with a pressure accumulator.
Steering
Servo-assisted steering system with extremely reduced
turning radius and three steering modes (T-WAY).
Page
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 machine is equipped with a system controlling the
longitudinal stability which enables the operator to work
under absolute safety conditions. A bar with green,
yellow and red LED's indicates the percentage of
applied load with respect to the maximum payload of
the machine. When the second red LED comes on,
the machine movements are blocked, except for boom
retraction, and an audible alarm starts sounding to alert
to the risk.
Telescopic boom
In order to improve visibility, the boom is placed under
the visual angle of the operator. Made of high tensile
steel, it consists of two telescopic sections sliding on
long-life pads, easily accessible for maintenance. The
attachment holding plate with a 138° inclination is
equipped with a hydraulic coupling system that can
be operated from the driving place.
Boom hydraulic circuit
It consists of a gear pump connected to the thermal
engine which, through a valve, distributes oil to the
hydraulic drive and an electro-proportional main valve
for the following functions:
- telescopic boom movements
- attachment rotation
- machine swaying
- attachment locking
- outrigger operation.
Driving cab
Large and comfortable cab mounted on vibration-proof
supports to improve the driver's comfort. Adjustable
seat with air-suspension and built-in armrest. Userfriendly dashboard. Multipurpose joystick with electroproportional control and ergonomic handle. The cab
comes complete with connections for the A/C system
and the CD player-radio set. Cab complies 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.
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GENERAL INFORMATION
A-5 TECHNICAL DATA AND PERFORMANCE
D
A
B
I
E
F
C
G
J
H
■ A-5.1
MAIN DIMENSIONS
A
B
C
D
E
F
G
H
I
J
•
•
Overall height ............................................................................................................ mm
Height to the steering wheel ..................................................................................... mm
Overall width ............................................................................................................. mm
Cab width .................................................................................................................. mm
Track ......................................................................................................................... mm
Wheel-base ............................................................................................................... mm
Length to the front tyres ........................................................................................... mm
Length to the attachment holding plate .................................................................... mm
Ground clearance ..................................................................................................... mm
Max width with extended outriggers ........................................................................ mm
Internal steering radius ............................................................................................. mm
External steering radius ............................................................................................ mm
GTH-4013
2425
1600
2330
910
1920
2950
4830
6100
430
2890
1140
3790
■
•
•
•
A-5.2 LIMITS OF USE
Angle of approach ...........................................................................................................
Departure angle ..............................................................................................................
Min/max ambient temperature.................................................................................... °C
38°
46°
-20°/+40°
■ A-5.3
WEIGHT
• Weight in working order .............................................................................................. kg
9820
■ A-5.4
SPEED
- Working speed (*) .................................................................................................... km/h
- Travel speed (*) ........................................................................................................ km/h
- Max. slope with full load ............................................................................................. %
(*) = either forward or reverse motion.
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60
Handler with telescopic boom GTH-4013
GENERAL INFORMATION
■ A-5.5
PAYLOAD AND REACH
- Max lifting height:
with outriggers .......................................................................................................... mm
without outriggers ..................................................................................................... mm
- Reach at max height without outriggers ................................................................... mm
- Max reach forward with outriggers ........................................................................... mm
- Attachment holding plate rotation ..................................................................................
- Maximum payload with outriggers ............................................................................. kg
- Payload at max height with outriggers ....................................................................... kg
- Payload at max reach with outriggers ........................................................................ kg
GTH-4013
13000
12810
650
9020
138°
4000
3000
1250
■
-
A-5.6
FORKS (FLOATING TYPE)
Dimensions ............................................................................................................... mm
Weight ..................................................................................................................... kg
Fork holding frame - class ..............................................................................................
■
-
A-5.7
DIESEL ENGINE
Make
........................................................................................................ CUMMINS
Model/Type .....................................................................................................................
Features: .........................................................................................................................
-
Bore x Stroke ............................................................................................................ mm
Total displacement ...................................................................................................... cc
Power at 2200 rpm .................................................................................................... kW
4B 4,5T
Diesel
4 cylinders in line
4 strokes
direct injection
102 x 120
4500
74
■ A-5.8
ELECTRICAL SYSTEM
- Voltage ....................................................................................................................... V
- Battery ..................................................................................................................... Ah
12
120
1200x120x50
70
FEM III
Turbo version
■ A-5.9
MACHINE SOUND LEVELS
- Guaranteed sound power level
(in accordance with the Directive 2000/14/CE) ................................................................. dB
- Measured sound pressure level
(in accordance with the Directive 98/37/CE) .................................................................... dB
Lwa = .....
■ A-5.10 VIBRATION LEVELS
- Mean assessed vibration level transmitted to arms ................................................ m/s2
- Mean assessed vibration level transmitted to body ................................................ m/s2
Values calculated in accordance with standard prEN13059
< 2.5
< 0.5
Lpa = .....
IMPORTANT
This is a Class A device. In a residential environment, such device can cause radio disturbance. In such
cases, the operator is required to take suitable measures.
Page
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GENERAL INFORMATION
A-7 ITEMS SUPPLIED
A-6 LIFETIME
The lifetime of the machine is 10000 hours provided
all checks, service jobs and overhauls are done at the
times scheduled.
This lifetime should be halved if the handler is used
with an aerial man-platform.
DANGER
After this time, the machine must compulsorily be
inspected and tested by the Manufacturer before
being used again.
Following items are supplied together with the
machine:
Description
GTH-4013
- Spanner CH 19
(for fork positioning)
- Allen wrench CH 6
(for fork positioning)
- 12 V lamps
(spare)
✘
✘
✘
IMPORTANT
Five years or 6000 hours after the first placing into
operation of the machine (whichever occurs first),
check the state of the structure paying an extreme
attention to the welded supporting joints and the
pins of both boom and platform (see chap. D-3.18).
Page
■ A-7.1
LITERATURE SUPPLIED
The machines comes with the following literature:
-
Machine operator's handbook
Engine use and maintenance manual
Spare parts catalogue
Warranty and handing over certificate
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SAFETY PRECAUTIONS
Section
B
SAFETY PRECAUTIONS
TABLE OF CONTENTS
B-1
GENERAL REMARKS .................................................................................................
B-2
B-2
PREREQUISITES OF THE PERSONNEL IN CHARGE ...............................................
B-3
B-2.1
Requisites of the machine operators .........................................................................
B-3
B-2.2
Requisites of the servicemen .....................................................................................
B-3
B-2.3
Working clothes ..........................................................................................................
B-4
B-2.4
Personal protective equipment ..................................................................................
B-4
B-3
SAFETY PRECAUTIONS ............................................................................................
B-4
B-3.1
Hazards on the jobsite ...............................................................................................
B-4
B-3.2
Operation or maintenance hazards ............................................................................
B-5
B-3.3
Machine operation hazards ........................................................................................
B-7
B-3.4
Damaged component hazards ...................................................................................
B-7
B-3.5
Explosion or fire hazards ............................................................................................
B-7
B-3.6
Damaged machine hazards ........................................................................................
B-8
B-3.7
Personal injury hazards ..............................................................................................
B-8
B-4
SAFETY DEVICES ......................................................................................................
B-8
B-5
MOMENT LIMITING SYSTEM ....................................................................................
B-8
Page
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SAFETY PRECAUTIONS
DANGER
Not observing the instructions
and safety rules in this manual
may result in death or serious
injury.
B-1 GENERAL REMARKS
Most accidents occurring while working, repairing or
maintaining 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
Do not operate the machine unless:
☛ You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1 Avoid hazardous situations.
Read and understand the safety instructions
before going on to the next chapter.
2 Always perform a pre-operation inspection.
3 Always test the machine functions prior to
use.
4 Inspect the work place.
5 Only use the machine for the intended
application.
☛ Read, understand and obey the manufacturer’s
instructions and the safety rules, the safety and
operator’s manuals, and the decals applied on the
machine.
☛ Read, understand and obey the employer’s safety
rules and worksite regulations
☛ Read, understand and obey the applicable national
regulations.
☛ Only trained personnel informed on the safety rules
can operate the machine.
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.
DANGER
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.
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
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SAFETY PRECAUTIONS
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 be familiar with this handbook, its
enclosed graphs and diagrams, the identification and
hazard warning plates. They shall be skilled and trained
about the machine use.
■ 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 be familiar with this handbook, its
enclosed graphs and diagrams, the identification and
warning plates. They shall be skilled and trained about
the machine functioning.
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.
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.
Page
B-3
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SAFETY PRECAUTIONS
■ 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 not wear clothes with large
sleeves or objects that can get stuck in moving
parts of the machine.
• Protective helmet.
• Protective gloves.
• Working shoes.
B-3 SAFETY PRECAUTIONS
■ B-3.1 HAZARDS ON THE JOBSITE
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.
DANGER
The machine is not electrically insulated and does
not provide protection from contact with or
proximity to electrical power lines.
Always keep at a minimum safe distance from the
telescopic boom and the lifted load. Electrical
hazards!
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
50
200
350
500
750
IMPORTANT
to
to
to
to
to
to
50
200
350
500
750
1000
kV
kV
kV
kV
kV
kV
10
15
20
25
35
45
ft
ft
ft
ft
ft
ft
3.00
4.60
6.10
7.62
10.67
13.72
m
m
m
m
m
m
Use only type-approved working clothing in good
condition.
•
■ 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.
Keep away from the machine in case of contact
with energized power lines. Personnel on the
ground must never touch or operate the machine
until energized power lines are shut off.
DANGER
Do not at any time use the machine during a storm.
IMPORTANT
Use only type-approved protective equipment in
good condition.
Page
B-4
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SAFETY PRECAUTIONS
■ B-3.2
DANGER
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).
•
•
•
•
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.
In presence of trenches, lower the outriggers at a
safe distance from the trench edge.
OPERATION OR MAINTENANCE
HAZARDS
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).
DANGER
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.
•
•
•
•
•
A
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!
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.
B
A≥B
Page
B-5
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SAFETY PRECAUTIONS
•
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
approved fall restraint or fall arrest devices.
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.
•
•
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.
Avoid the use of tools in bad condition or use in an
improper way i.e. pliers instead of adjustable
wrenches, etc.
Applying loads in different points of the attachment
holding plate is forbidden.
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.
•
•
•
•
•
•
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-6
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SAFETY PRECAUTIONS
•
•
•
•
•
•
•
•
Do not empty catalytic mufflers or other vessels
containing burning materials without taking the
necessary precautions.
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 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
any means.
After work, never leave the machine under
potentially dangerous conditions.
■ B-3.3
MACHINE OPERATION HAZARDS
Absolutely avoid the following work situations:
• Do not handle loads beyond the maximum
capacity of the machine
• Do not raise or extend the boom if the machine is
not on a firm, level surface.
• Do not operate the machine in strong wind. Do
not increase the surface area of the machine or
forked load exposed to the wind. Increasing the
area exposed to the wind will decrease machine
stability.
• Use extreme caution and slow speeds when the
machine is driven across uneven or unstable
grounds, slippery surfaces or near trenches or
drop-offs.
• Limit travel speed according to ground conditions,
slopes, presence of personnel or other factors
which may cause collision.
• Do not place or attach overhanging loads to any
part of the machine.
Page
■ B-3.4 DAMAGED COMPONENT HAZARDS
• Do not use battery chargers or batteries with a
voltage above 12V to start the engine.
• Do not use the machine as a ground for welding.
■ B-3.5 EXPLOSION OR FIRE HAZARDS
• Do not start the engine if you smell or detect LPG,
gasoline, diesel fule or other explosive substances.
• Do not refuel the machine with the engine running.
• Refuel the machine and charge the battery only in
a well ventilated area away from sparks, naked
flames and lighted cigarettes.
• Do not operate the machine in dangerous
environments or in places with flammable or
explosive gases or materials.
• Do not inject ether in engines equipped with glow
plugs.
• Do not leave fuel cans or bottles in unsuitable
places.
• Neither smoke nor use open flames in areas subject
to fire dangers and in presence of fuel, oil or
batteries.
• Carefully handle all flammable or dangerous
substances.
• Do not tamper with fire-extinguishers or pressure
accumulators: explosion hazard!
B-7
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SAFETY PRECAUTIONS
■ B-3.6
DAMAGED MACHINE HAZARDS
• Do not use a damaged or defective machine.
• Do a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Tag and remove from service a damaged or
defective machine.
• Make sure that all maintenance jobs have been
carried out as specified in this manual and the
appropriate service manual.
• Make sure that all decals are in place and legible.
• Make sure that the operator’s, safety and
responsibilities manuals are intact, legible and
placed in the special container located in the
machine.
■ B-3.7
PERSONAL INJURY HAZARDS
• Do not operate the machine in case of hydraulic
oil or air leak. Air or hydraulic oil leaks can penetrate or burn the skin.
• Always operate the machine in a well ventilated
area to avoid carbon monoxide poisoning.
• Do not lower the boom if the area underneath is
not clear of personnel or obstructions.
Page
■ 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-3.17.
■ B-5 MOMENT LIMITING SYSTEM
The moment limiting system has been developed to
help the operator to maintain the machine longitudinal
stability. Audible and visual messages are provided
when the limits of longitudinal stability are being
approached.
However this device cannot replace the experience of
the operator. It is up to the user to adopt the necessary
safety measures to work within the rated limits of the
machine.
B-8
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OPERATING INSTRUCTIONS
Section
C
OPERATING INSTRUCTIONS
TABLE OF CONTENTS
C-1
C-2
C-2.1
C-2.1.1
C-2.2
C-2.3
C-2.4
C-2.5
C-2.6
C-3
C-3.1
C-3.2
C-3.2.1
C-3.2.2
C-3.2.3
C-3.2.4
C-3.2.5
C-3.2.6
C-3.2.7
C-3.2.8
C-3.2.9
C-3.3
C-3.3.1
C-3.3.2
C-3.4
C-3.4.1
C-3.4.2
C-3.4.3
C-3.4.4
C-3.4.5
C-3.4.6
C-3.4.7
C-3.5
C-3.6
C-3.7
PRE-OPERATION INSPECTION ............ C-2
ENTERING THE MACHINE .................... C-4
Entering the cab ..................................... C-4
Emergency exit-way ............................... C-4
Adjusting the seat .................................. C-5
Fastening the seat belts ......................... C-5
Adjusting the steering column ................ C-6
Adjusting the rear view mirrors .............. C-6
Switching on the cab interior lamp ........ C-6
DRIVING PLACE ..................................... C-7
Controls and instruments ....................... C-7
Engine controls and instruments ........... C-9
Ignition switch ........................................ C-9
Forward/reverse gear switch .................. C-9
Turn signals - windscreen wiper lights - horn switch ............................... C-10
Brakes .................................................. C-11
Accelerator control ............................... C-11
Gearbox controls .................................. C-12
Steering mode selection ...................... C-12
Cab/road/platform changeover switch .. C-12
Auxiliary drive controls ......................... C-13
Instruments and warning lights ............ C-14
Instruments .......................................... C-14
Warning lights ...................................... C-15
Control lever ......................................... C-16
Function selection ................................ C-17
Emergency stop ................................... C-18
Disabling the overload warning system . C-18
Lifting/lowering the boom .................... C-19
Extending/retracting the boom ............ C-20
Pitching the attachment holding frame
forward/back ........................................ C-21
Quick-coupling the attachments .......... C-22
Machine sway control .......................... C-23
Outrigger control .................................. C-24
Manual controls .................................... C-25
Page
C-4
C-4.1
C-4.1.1
C-4.2
C-4.3
C-4.4
C-4.5
C-4.6
C-4.7
C-5
C-5.1
C-5.2
C-5.2.1
C-5.2.2
C-5.2.2
C-5.3
C-5.3.1
C-5.3.2
C-5.4
C-6
C-6.1
C-6.1.1
C-6.1.2
C-6.2
C-6.3
C-6.4
C-6.5
C-6.5.1
C-6.5.2
C-6.6
C-6.6.1
C-6.6.2
C-6.7
C-6.7.1
SETUP .................................................. C-26
Before starting the engine .................... C-26
Checks at the machine start-up ........... C-26
Starting the engine ............................... C-26
Jump-starting the engine ..................... C-27
Low temperature starting ..................... C-28
Starting the machine ............................ C-29
Use of the man-platform ...................... C-29
Stopping and parking the machine ...... C-30
USING THE HANDLER ......................... C-30
Using the load charts ........................... C-31
Load limiter........................................... C-32
Description of the controls ................... C-32
Operation ............................................. C-32
Alarm codes and resetting ................... C-33
Handling loads ..................................... C-34
Adjusting the forks ............................... C-34
Working phases ................................... C-35
Changing the optional attachment ....... C-36
TRANSPORTING THE MACHINE ........ C-38
Moving a disabled machine ................. C-38
Setting the gear lever in neutral ........... C-38
Dismantling the Cardan shaft ............... C-39
Road or site transfer ............................. C-40
Lifting the machine ............................... C-41
Transporting the machine on other
vehicles ................................................ C-41
Parking and storage ............................. C-42
Short inactivity ...................................... C-42
Machine storage................................... C-42
Cleaning and washing the machine ..... C-43
Cleaning instructions ............................ C-43
Washing instructions ............................ C-43
Machine disposal ................................. C-43
Disposal of batteries ............................ C-43
C-1
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OPERATING INSTRUCTIONS
Fundamentals
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.
It is the operator responsibility to perform a preoperation inspection and routine maintenance.
Pre-operation inspection means a visual inspection
performed by the operator prior to each work shift.
The inspection has to be carried out on the machine
to detect possible faults before the operator starts
testing the machine functions.
The pre-operation inspection also helps understand
if some routine maintenance procedures are required.
The operator can only perform the routine
maintenance procedures envisaged in this manual.
See the list on the next page and check each single
component.
If the machine is damaged or a non-authorized
modification has been done, the machine must be
tagged and removed from service.
Repairs must be carried out by qualified technical
personnel according to the manufacturer’s
specifications. After any repair, the operator should
repeat the pre-operation inspection before testing the
machine functions.
■ C-1 PRE-OPERATION INSPECTION
Scheduled maintenance procedures must be
performed by qualified technical personnel according
to the technical specifications of the manufacturer and
the requirements envisaged in the responsibilities
manual.
Do not operate the machine, unless:
☛ You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1 Avoid hazardous situations.
Read and understand the safety rules before
going on to the next chapter.
2 Always perform a pre-operation inspection.
Read and understand the safety rules before
going on to the next chapter.
3 Always test the machine functions prior to use.
4 Inspect the work place.
5 Only use the machine for the intended
application.
Page
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OPERATING INSTRUCTIONS
Pre-operation inspection
☛ Make sure the operator’s manuals are intact, legible
and placed inside the machine.
☛ Make sure all decals are present and legible. See
“Decals” chapter.
☛ Check for engine oil leaks and proper oil level. Top
up if necessary. See “Maintenance” chapter.
☛ Check for axle oil leaks and proper oil level. Top
up if necessary. See “Maintenance” chapter.
☛ Check for hydraulic oil leaks and proper oil level.
Top up if necessary. See “Maintenance” chapter.
☛ Check for engine coolant leaks and proper coolant
level. Add coolant if necessary. See “Maintenance”
chapter.
☛ Check for battery fluid leaks and proper fluid level.
Add distilled water if necessary. See “Maintenance”
chapter.
Check the following components or zones for damage,
missing or wrongly fitted parts or non-authorised
modifications:
• electrical components, wiring and electrical
cables
• hydraulic hoses, fittings, cylinders and main
valves
• fuel and hydraulic oil tanks
• drive pump and motor and transmission axles
• steering system
• braking system
• boom telescopes sliding pads
• clean glasses, lights and rear view mirrors
• engine and relevant components
• limit switches and horn
• lights
• moment limiter
• joystick pushbutton
• emergency stop button
• machine ignition control
• emergency pump (if any)
• nuts, bolts and other fasteners.
• protective bar or access gate to the platform (if
any)
Page
Check the entire machine for:
• cracks on welds or structural components
• dents or damage to the machine.
☛ Make sure that all structural and other critical
components are present and the relevant fasteners
and pins are fitted and properly tightened
☛ After inspection, check that all the compartment
covers are in place and latched.
DANGER
If even one single item is damaged or defective,
do not start work. Stop the machine and repair the
fault.
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.
ATTENTION
If the machine shall be used in a marine or
equivalent environment, protect it against salt
deposits with an adequate treatment against
saltiness to prevent rust formation.
C-3
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OPERATING INSTRUCTIONS
■ C-2 ENTERING THE MACHINE
■ C-2.1 ENTERING THE CAB
DANGER
�
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 1 and open the door.
�
�
�
Door closing from inside:
• Pull the door with force: it locks automatically.
Door opening from inside:
• Lower 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.
■ C-2.1.1 Leaving the cab in an emergency
In an emergency, use the rear window of the cab as
safety exit-way.
This window has special locking handles with plastic
pins 5 easy to pull out when you need to fully open the
glass.
To unlock the door latched in open position:
• Press button 4 to unlock the door from the catch
• Once released, re-close the upper section of the
door by means of handle 3.
ATTENTION
�
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.
Page
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OPERATING INSTRUCTIONS
■ C-2.2 ADJUSTING THE SEAT
Position the seat so you can comfotarbly reach all the
controls. The handler seat is fitted with devices which
let you adjust the seat springing, height and distance
from the controls, the backrest angle and the armrest
height.
•
Adjusting the seat distance from the controls
To slide the seat forward or back, rotate lever A
and push the seat to the desired direction. Then
release the bar and make sure that the seat locks
in position.
•
Adjusting seat height and springing
Free the lever of knob B and turn clockwise or
counter-clockwise until reaching the desired
springing. Once you'are correctly seated in the seat
check that the yellow indicator C is in the green
field.
•
Adjusting the backrest angle
Operate lever D, press your back firmly against the
backrest and put the backrest at the angle you
wish, then release the lever.
•
Adjusting the armrest height
Raise armrest E and turn wheel F to put the armrest
at the height you want.
■ C-2.3
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.
DANGER
•
•
The seat is for one person only.
Don't adjust the seat when the machine is
moving.
FASTENING THE SEAT BELTS
3
2
Page
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1
Handler with telescopic boom GTH-4013
OPERATING INSTRUCTIONS
■ C-2.4
ADJUSTING THE STEERING COLUMN
Both steering column and dashboard can be set to a
different angle.
To adjust the steering wheel angle, unlock lever 1 and
pull or push the steering wheel to the required position,
then re-lock lever 1.
DANGER
■ C-2.5
ADJUSTING THE REAR VIEW MIRRORS
The machine is fitted with two rear view mirrors:
•
Rear view mirror 55 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.
•
Rear view mirror 56 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.
Before driving the machine, ensure the steering
wheel is perfectly clamped.
56
55
■ C-2.6
SWITCHING ON THE CAB INTERIOR
LAMP
The ceiling light fixture is fixed to the rear top strut of
the cab. The relevant lamp is switched on/off by switch
A.
Page
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OPERATING INSTRUCTIONS
C-3 DRIVING PLACE
■ C-3.1
CONTROLS AND INSTRUMENTS
1 Fresh air flap
2 Left outrigger switch
3 Right outrigger switch
4 Locking lever - steering column angle adjustment
5 Switch: turn signals - windscreen washer - horn
6 Steering selector switch
7 Light indicators and warning lights
8 Fuel gauge
9 Turn signals
10 Revs counter / Hourmeter
11 Display
12 Water temperature indicator
13 Mechanical gearbox switch
14 Hazard warning lights switch
15 Fog lamp switch
16 Air conditioning fan switch
17 Emergency pump switch (only with man-platform)
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Road lights switch
Hydraulic oil temperature indicator
Ignition switch
Emergency stop pushbutton
Load limiter disabling key
Brake pedal
Gas pedal
Multipurpose control lever
Manual accelerator
Parking brake
Fuse and relay box
Cab heater control cock
Adjustable seat
Forward/reverse gear selector switch
Sway control (right/left)
Cab/road/platform switch
Load moment indicator
Windscreen water reservoir
Storage pocket
Inclinometer
☞
See on next page
Page
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OPERATING INSTRUCTIONS
34
1
2
3
4
5
6
7
8
9
10
9
11
12
10
15
20
RPM x 100
5
25
0
30
13
14
15
32
16
33
17
P
18
31
19
23
K2
3
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
F12
F15
F21
F27
F5
F11
F14
F20
F26
F4
F10
F13
F19
F25
F3
F9
F18
F24
F17
F23
F16
F22
F8
F1
F7
INT
21
K
K
K
F2
20
K
INT
K
F6
24
22
29
30
37
25
28
27
26
1
35
36
Page
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OPERATING INSTRUCTIONS
C-3.2
■ C-3.2.2
ENGINE CONTROLS AND
INSTRUMENTS
Forward/reverse gear selector switch
Three-position switch with lock in neutral position:
■ C-3.2.1 Ignition switch
Five-position switch:
No circuit under voltage, key can be removed
and engine is stopped
0
Neutral position; no gear engaged
1
Shift lever to pos. 1 to select the forward gear
2
Shift lever to pos. 2 to select the reverse gear
IMPORTANT
Circuits under voltage, presetting for the engine
starting. Board controls and instruments are on.
Thermal starter for cold climates. Rotate the key
in this position and wait until the warning light
7.2 signalling the glow plugs preheating goes
off; then rotate it to stroke end and start the
engine
The engine can be started only if selector 31 is to
the neutral "0" position.
Engine starting; when released, key springs back
to pos. I automatically.
of the ignition key to switch the controls
P Position
from cab to platform.
31
1
P
0
2
Page
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OPERATING INSTRUCTIONS
■ 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:
To switch the handler lights, lever can be set to three
different positions along its vertical axis:
0
low beam ON, stable condition
1
high beam ON, stable condition
2
high beam used for intermittent signalling; when
released, the lever springs back to position 0.
I
I0 J I
I
I0 J I
■ Windscreen washer function:
Push the second stage of the lever along its axis to
direct a jet of water onto the cab windscreen.
I
I0 J I
■ Turn signals function:
Set lever to pos. 1 to indicate a turn leftwards or to
pos. 2 to indicate a turn rightwards.
I
I0 J I
■ Windscreen wiper function:
To operate the windscreen wiper, rotate the lever tip to
one of the four positions:
I
Wiper OFF
0
Wiper OFF
J
Low speed
I
High speed
I
I0 J I
I
I0 J I
Page
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OPERATING INSTRUCTIONS
■ C-3.2.4
■ C-3.2.5
Brakes
Accelerator control
23
Service brake pedal
Gradually step on the brake pedal to decelerate and
stop the machine. The pedal operates on the axle
shafts of both axles.
24
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,
27
Parking brake
To engage the parking brake, pull the lever upward
while holding the locking button pressed down.
Release the button when reaching the required braking
tension. It operates on the axle shafts of the front axle
and, when engaged, it cuts both forward and reverse
gear off.
26
Gas lever
By pulling the lever up, the engine rpm increases
gradually.
To reduce the rpm, set the lever down.
DANGER
Never use the parking brake to slow down the
machine, unless in an emergency. It may reduce
the brake efficiency.
24
23
K2
3
K
INT
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
F6
F12
F15
F21
F27
F5
F11
F14
F20
F26
F4
F10
F13
F19
F25
F3
F9
F18
F24
F17
F23
F16
F22
F2
F8
F1
F7
INT
26
27
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OPERATING INSTRUCTIONS
■ C-3.2.6
■ C-3.2.7
Speed controls
13 Mechanical gearbox pushbutton
Used to engage the 1st or 2nd gear.
Push the button to select the required
speed.
Each pressure corresponds to the
selection of a new speed.
Steering mode selection
6 Steering mode switch
Three-position switch for the selection
0
1
2 of the steering mode:
1 Crab steering
0 Two-wheel steering
2 Four-wheel steering
■ C-3.2.8 Cab/road/platform switch
33 Switch
Three-position switch:
ATTENTION
Do not change gear when the machine is running.
1
0
2
IMPORTANT
1 Rotate the switch to position 1 to
select the job-site setting and operate the handler by the cab controls
2 Rotate the selector switch to
position 0 to select the road setting
When a gear is not correctly put, the warning light
7.14 comes on (see C-3.3.2).
3 Rotate the switch to position 2 to
remove the ignition switch key and
operate the handler by the platform
controls. The green light indicator
lights up.
10
15
20
RPM x 100
Page
C-12
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5
25
0
30
P
Handler with telescopic boom GTH-4013
OPERATING INSTRUCTIONS
■ C-3.2.9
18
Auxiliary drive controls
Three-position switch placed on the right
side of the dashboard:
0 Lights OFF
1 Position lights ON (the switch indicator
lights up partially)
2 Low beam ON (the switch indicator fully
lights up).
They are located on the dashboard, to the right.
14
Hazard warning lights switch
Fitted with on-off position, it switches on
the turn signals simultaneously
15
Fog lamp switch
Road lights switch
29 Cab heater control cock
Two-position switch:
0 Fog lamp OFF
1 Fog lamp ON (the switch indicator lights
up).
16
Air conditioning fan switch
Three-position switch:
0 OFF
1 Low speed
2 High speed
17
Emergency pump switch
(only with man-platform)
Two-position switch:
0 OFF
1 Hold pressed down to turn on the electric
pump ad operate the controls.
Located on the left side of the driving seat base.
• Turn the cock clockwise to switch off heated air.
• Turn the cock clockwise to switch on the cab
heater.
• Adjust the flow of heated air in the cab operating
the A/C fan switch 16.
ATTENTION
Check the operation of the emergency pump every
week as it could get damaged if it is not used.
29
15
18
16
14
17
P
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29
Handler with telescopic boom GTH-4013
OPERATING INSTRUCTIONS
C-3.3 INSTRUMENTS AND WARNING
LIGHTS
■ C-3.3.1
8
10
11
12
Engine coolant temperature indicator
This indicates the engine coolant temperature.
If the red warning light 7.15 comes on (temperature above 100 °C), stop the engine and
find and rectify the problem (radiator dirty,
low engine coolant level, etc.).
19
Hydraulic oil temperature indicator
This indicates the temperature of the
hydraulic oil in the tank.
If the red warning light on the instrument
comes on, stop the machine and find and
rectify the problem (filters restricted, pump
damaged, valves blocked, etc.)).
Instruments
Fuel gauge
This indicates the fuel level in the tank. When
the indicator reaches the red zone, there are
roughly 15 litres in the tank and the warning
light 7.1 comes on.
Revs counter
It shows the engine rpm.
Display
The display has two text lines.
• The first shows the revs counter (total
operating time of the machine).
• The second line displays the travel speed of
the machine in km/h.
10
8
10
15
12
20
RPM x 100
5
25
0
30
11
P
19
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OPERATING INSTRUCTIONS
■ C-3.3.2
Warning lights (ref. 7)
7.1
Warning light - fuel reserve
This light comes on to alert to a low fuel level in
the tank.
7.2
Warning light - glow plugs preheating
This light indicates the pre-heating of the engine
glow plugs. Before starting the engine wait for
this light to go off.
If the light fails to go off, a glow plug could be
broken.
7.9
Warning light - electronic gearbox
malfunction
This light comes on to alert to a failure of the
electronic gearbox. Contact GENIE Service
Centre or your dealer.
7.10 Warning light - water in fuel
This light comes on to alert to the presence of
water in fuel.
7.3
Warning light - low battery charge
Signals a low charge by the alternator.
7.11 Warning light - low hydraulic oil level
This light comes on to alert to a low level of the
hydraulic oil for a correct functioning. Replenish
and eliminate the oil leak.
7.4
Warning light - low engine oil pressure
This red light comes on to warn that the pressure
in the engine lubrication system is not enough
for a proper operation.
Stop the engine and find and rectify the problem.
7.12 Warning light - high beam
Blue warning light that signals when high beam
is ON.
7.5
Warning light - parking brake engaged
When ON, this light indicates that the parking
brake is engaged.
7.6
Warning light - low brake pressure
It lights when the pressure of the braking circuit
is too low for a correct functioning.
7.7
Warning light - hydraulic oil filter clogged
When this lamp sets to on, immediately change
the oil filter on the return line to the tank.
7.8
Warning light - air filters restricted
When this lamp come on, proceed with cleaning
or changing the air filter cartridge (see
"Maintenance" section).
7.1
7.2
7.3
7.4
7.5
7.6
7.13 Warning light - position lights
Green warning light that signals when position
lights are ON.
7.14 General alarm warning light
This light comes on to alert to a failure of the
machine. The light also comes on when the
mechanical gear is not put. Contact GENIE
Service Centre.
7.15 Warning light - high coolant temperature
This light comes on to alert to a too high temperature of the cooling medium.
5
25
0
30
7.7
7.8
Page
7.9
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7.10
7.11
7.14
7.15
7.12
7.13
Handler with telescopic boom GTH-4013
OPERATING INSTRUCTIONS
C-3.4 CONTROL LEVER
The handlers are equipped with a multipurpose electroproportional lever that allows operating all machine
movements.
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.
Pressing buttons or , you move the boom
telescopes out and in and you lock/unlock the
attachment fitted to the machine.
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
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.
DANGER
The control lever shall be operated only when
correctly seated in the driving place.
DANGER
Before operating the control lever, make sure that
nobody is within the working range of the machine.
Page
C-16
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OPERATING INSTRUCTIONS
■ C-3.4.1
Function selection
After pressing the intentional control pushbutton ,
the lever is enabled to carry out the following motions:
•
Boom lowering/lifting
shift the control lever to or .
For any further information see paragraph C-3.4.4
•
Attachment frame forward/back pitching
shift the control lever to or .
For any further information see paragraph C-3.4.6
•
Telescope retraction/extension
press button to or without shifting the
control lever
For any further information see paragraph C-3.4.5
•
Attachment coupling/release
press button and shift the control lever to or For any further information see paragraph C-3.4.7
Page
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OPERATING INSTRUCTIONS
■ C-3.4.2
■ C-3.4.3 Disabling the overload warning system
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 engine, reset the button by
rotating clockwise.
CAUTION
The key switch nder cap 22 is used to deactivate the
load limiter.
DANGER
WORKING WITH THE OVERLOAD WARNING
SYSTEM CUT OUT CAN RESULT IN A MACHINE
OVERTURNING AND IN SERIOUS INJURY.
IMPORTANT
Before restarting the machine, find and rectify the
faults that caused the emergency.
The load limiting system disconnect key is active
only in the jobsite mode.
When the machine is in the “Platform” mode, the
limiting system cannot be deactivated.
IMPORTANT
The moment limiter disconnect key should be kept
by the site manager or the person responsible for
the jobsite safety.
22
21
Page
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OPERATING INSTRUCTIONS
■ C-3.4.4 Lifting/lowering the boom
DANGER
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 •
Smoothly shift the lever to position to lift the
boom or to position to lower it.
Page
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OPERATING INSTRUCTIONS
■ C-3.4.5
Extending/retracting the boom
DANGER
Before operating the boom, make sure that nobody
is within the working range of the machine.
To extend or retract the telescopic elements of the
boom:
•
Set the control lever to central position and press
button •
Press button to to move out the boom
telescope; press the same button to to move
in the boom telescope.
IMPORTANT
Do not operate the control lever. Boom is moved in
and out by simply pressing buttons or .
Page
C-20
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OPERATING INSTRUCTIONS
■ C-3.4.6
Pitching the attachment holding frame
forward/back
DANGER
Before operating the boom, make sure that nobody
is within the working range of the machine.
To tilt forward/back the attachment holding frame:
•
Set the control lever to central position and press
button •
Smoothly shift the lever to position to pitch
the holding frame forward
•
Smoothly shift the lever to position to pitch
the holding frame back
Page
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OPERATING INSTRUCTIONS
■ C-3.4.7
Quick-coupling the attachments
DANGER
Before operating the boom, make sure that nobody
is within the working range of the machine.
To lock the attachments:
•
Shift the control lever to central position and press
button •
Press button •
Shift the control lever to position to lock the
attachment
Shift the control lever to position to release
the attachment
•
Page
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OPERATING INSTRUCTIONS
C-3.5 MACHINE SWAY CONTROL
DANGER
IMPORTANT
Do not operate the sway control, when boom is
raised beyond the horizontal position.
Check that the machine is level on inclinometer 37.
The water level must be right in the middle of the
instrument.
To sway the machine:
•
Press button 32 and hold it down until the
coòplete execution of the function selected:
select X to raise the right-hand side of the
machine
select Y to lower the right-hand side of the
machine.
IMPORTANT
In an alarm condition (red stability LED indicator
ON) or when the boom is raised beyond the
horizontal position, the function-key 32 is not
enabled.
IMPORTANT
Do not operate the control lever. The sway control
is activated by simply pressing button .
Page
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OPERATING INSTRUCTIONS
C-3.6 OUTRIGGER CONTROL
IMPORTANT
DANGER
Before lowering the outriggers, make sure that
nobody is within the working range of the machine.
In an alarm condition (red stability LED indicator
ON) or when the boom is raised beyond the
horizontal position, the function-keys 2 and 3 are
not enabled.
To operate the outriggers:
IMPORTANT
Right outrigger
•
Press button 3 and hold it down to enable the
motion of the right outrigger:
Do not operate the control lever. The outriggers
are moved in and out by simply pressing buttons
or .
select Y to lower the outrigger
select X to raise the outrigger
Left outrigger
•
Press button 2 and hold it down to enable the
motion of the left outrigger:
select Y to lower the outrigger
select X to raise the outrigger
Page
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OPERATING INSTRUCTIONS
C-3.7 MANUAL CONTROLS
In case of a malfunction of the control lever, it is
possible to use the emergency manual controls of the
main valve.
The main valve has four control levers that operate the
following functions:
Lever In position Boom down
In position Boom up
Lever In position Fork holding frame pitched backwards
In position Fork holding frame pitched forwards
Lever In position Boom telescope in
In position Boom telescope out
Lever In position Attachment unlocked
In position Attachment locked
1
IMPORTANT
The manual controls can be used only if the
machine is running or it is equipped with the
emergency pump.
Z
In order to operate the emergency pump with the
manual controls, follow the instructions below:
•
Open the rear cover to reach the main valve.
•
Fit the control levers (supplied) to the elements of
the main valve.
•
Activate the emergency pump by holding button Z
pressed down. If the button is released, the pump
stops.
•
Shift the lever of the main valve to the position
corresponding to the movement you wish to obtain.
DANGER
• When operating the emergency controls in
manual mode, the load limiting device is disabled.
DANGER
For the use of the emergency controls, observe the
following sequence:
Lever in Boom fully retracted
Lever in Boom lowered
Page
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2
3
4
Handler with telescopic boom GTH-4013
OPERATING INSTRUCTIONS
■ C-4 SETUP
■ C-4.2
■ 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-4.1.1 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 above the Terex logo comes on. The
display remains off while the system runs a self-test.
After that, the display shows 1 or 0 depending on the
attachment selected (1 = platform; 0 = forks or any
other attachment).
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-3.17, namely:
• overload warning system
• joystick pushbutton
• emergency pushbutton
• machine start control
• emergency pump
Page
STARTING THE ENGINE
•
Put the mechanical gear lever to neutral.
•
Step on the gas pedal.
•
To start the engine, rotate the ignition switch to
position
, and release 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 engine starting,
slow down the rpm and
wait 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
connecting cables (see following chapter).
P
CAUTION
If the light indicators do not switch off/on when
engine is running, immediately stop the machine
and find and rectify the fault.
IMPORTANT
Engine cannot be started if the speed switch is not
in the neutral position.
DANGER
Once it has been started, the engine continues to
run even if you leave the driving place. DO NOT
LEAVE THE DRIVING PLACE BEFORE HAVING
SHUT THE ENGINE DOWN, LOWERED THE BOOM
TO THE GROUND, TURNED THE SPEED SWITCH
TO THE NEUTRAL POSITION AND ENGAGED THE
PARKING BRAKE.
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OPERATING INSTRUCTIONS
■ C-4.3
JUMP-STARTING THE ENGINE
ATTENTION
Do not start the engine using a quick charge
booster to avoid any damage to the electronic
boards.
B
A
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.
To avoid damage to the electronic instruments
of the machine, the engine of the machine where
the booster supply is installed, must be stopped.
• Turn the ignition key and start the handler, then
follow the procedure explained in chapter C-4.2
“Starting the engine”.
Page
• 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.
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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OPERATING INSTRUCTIONS
■ 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 engine use and maintenance manual.
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.
•
and wait
Turn the ignition switch to position
until the warning light 7.2 signalling the glow plugs
preheating goes off. Step down on the gas pedal
and start the engine turning the ignition switch to
position
. 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.
Page
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OPERATING INSTRUCTIONS
■ C-4.5
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 a gear suiting the job you are going to carry
out and the conditions of the job site.
Select the required steering mode.
Select the required gear (forward or reverse).
Release the parking brake.
Slowly step on the gas pedal to start moving off.
■ C-4.6
USE OF THE MAN-PLATFORM
For the use of the man-platform, proceed as follows:
1
Couple the man-platform to the attachment holding
frame.
2
Sway the machine; check the operation on the
water level in the cab.
3
Level the platform floor.
IMPORTANT
The platform floor cannot be levelled once the
controls have been switched from the driving cabin
to the platform. Before starting using the platform,
make sure the floor is level.
DANGER
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.
4
Turn the cab/road/platform switch to platform
position (the green indicator comes on).
5
The display of the load limiter shows n. 1 to warn
that the man-platform is installed.
Stop the engine, turn the ignition switch to P
position and engage the parking brake.
6
7
Remove the key from the cab/road/platform switch
to use it for the platform controls.
8
Open the protection cover of the power socket on
the boom and plug in the platform plug.
9
Enter the man-platform and insert the key,
previously removed, in the controls switch.
IMPORTANT
If the platform controls remain disabled once the
key has been inserted, check the correct position
of the sensors of the attachment coupling pin (see
relevant manual) and the efficiency of the
outriggers' limit switches (see D-3.17).
IMPORTANT
For the use and maintenance of the man-platform,
read the specific manual - code 57.0302.9200.
Page
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OPERATING INSTRUCTIONS
■ 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 and ensure its indicator
light switches 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.
Disconnect the power cables of the battery.
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".
DANGER
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.
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.
DANGER
DANGER
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.
Always engage the parking brake after stopping
the machine to prevent possible accidental motions
of the vehicle.
ATTENTION
Leaving a battery connected can result in shorts
and, as a consequence, in a fire.
Page
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OPERATING INSTRUCTIONS
■ C-5.1 USING THE LOAD CHARTS
The charts indicating the maximum permissible load
in relation to the boom extension and the type of
attachment used are installed on the cab windscreen
and/or illustrated in the quick guide.
Chart A must be used when working with outriggers,
whilst chart B shows the payload limits when operating
without outriggers.
To operate under safe conditions, always refer to these
charts.
The extension level of the boom can be checked with
the help of the letters (A, B, C, D, E) painted on the
same boom and compared with the load chart, while
the actual degrees of inclination of the boom are
shown by the angle indicator .
DANGER
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.
DANGER
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.
70°
A
8
12810
kg
1
0°
10 9
0
8
7
6
5
4
3
2
1
0
LOAD CENTRE = 600 mm
1250 kg
2
1
0
3
10°
2
13000
7
6
6270
0°
10 9
8
5
4
3
2
1
1980
2040
9080
9020
Page
kg
20°
4
6200
0
6
5
1500 kg
1000 kg
500 kg
10°
0
0
40
3500 kg
0
40
20°
4
A
30°
3000 kg
35
6
B
40°
7
00
30°
7
9
kg
30
8
C
10
B
2500 kg
40°
9
50°
C
2000 kg
10
D
11
200
0k
25
g
00
kg
00
kg
50°
E
60°
12
D
11
3
E
60°
12
70°
13
1500 kg
13
5
B
14
14
250 kg
A
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0
LOAD CENTRE = 600 mm
Handler with telescopic boom GTH-4013
OPERATING INSTRUCTIONS
■ 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.
1
2
3
■ C-5.2.1 Description of the controls
1
2
3
4
5
6
7
8
9
10
Calibration selection button
Display
Stability indicator with LED-bar
Green light – power OK
Yellow light – calibration mode
Calibration confirmation button
Not used
Red light – outrigger position
Buzzer ON/OFF pushbutton
Red light –overload pre-alarm / alarm
4
10
9
5
The digit on display 2 shows the selected attachment.
The user can choose among:
Red LED’s:
0: Generic
1: Platform
■ 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 the digit corresponding to the
used attachment on display 2. At this time, the system
is activated.
6
7
8
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 overload warning system
During operation, the led-bar 3 lights up gradually
depending on the variation of stability.
Boom extension
without outriggers
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.
Overload warning
system in alarm
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.
Boom retraction
Alarm ceases
Lowering of the outriggers
or reduction of the load to
be handled
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OPERATING INSTRUCTIONS
■ C-5.2.3 Alarm codes and resetting
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.
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”.
10
5
Page
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OPERATING INSTRUCTIONS
■ C-5.3
HANDLING LOADS
DANGER
■ C-5.3.1 Adjusting the forks
Forks shall be spaced to suit the load going to be
handled. For this purpose:
•
The centre of gravity of the load must always
be halfway between the forks.
•
Lift the clamping lever of the forks.
•
•
Slide the forks to the desired position, then re-lock
the lever.
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.
Page
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OPERATING INSTRUCTIONS
■ 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.
•
When the forks are clear of the load, set them to
transfer position.
•
Release the parking brake and start a new working
cycle.
DANGER
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.
Do not move off when the load is raised 20÷30 cm
above the ground. Risk of machine overturning or
load fall.
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.
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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OPERATING INSTRUCTIONS
■ C-5.4
CHANGING THE ATTACHMENT
DANGER
ATTENTION
Use only attachments directly manufactured or
recommended by Terexlift and detailed in the
“Optional attachments” section.
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.
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.
Page
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OPERATING INSTRUCTIONS
•
Operate the control lever to lock the attachment.
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.
Page
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OPERATING INSTRUCTIONS
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 parking brake.
Tow the machine for short distances and at a low
speed only.
Use a rigid drawbar.
Select the two-wheel steer.
Put the transmission selection lever to neutral.
Put the gearbox lever to neutral (see chap. C6.1.1)
Raise the front wheels of the machine and remove
the Cardan shaft of the transmission (see chap. C6.1.2).
When possible, start the engine and use the
hydraulic drive and the braking system.
■ C-6.1.1
Setting the gear lever in neutral
CAUTION
Do not tow the machine without setting the
mechanical gear lever to neutral position.
To set the gear lever to neutral:
• Disconnect the cylinder feeding pipes and and plug them.
•
Pry the cursor of the gear lever to neutral
position.
•
Plug holes and of the cylinder.
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OPERATING INSTRUCTIONS
■ C-6.1.2 Dismantling the Cardan shaft
Before towing a disabled machine, dismatle the two
(front and rear) Cardan shafts loosening the screws
that fix them to the axle and the reduction gear as
shown in the picture.
Page
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OPERATING INSTRUCTIONS
■ C-6.2 ROAD OR SITE TRANSFER
Only for the Italian market
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.
•
Sway the machine.
•
Lock the machine as indicated in the Registration Card (only
for the Italian market):
Lock the boom sections, the lifting cylinder, the attachment
rotation cylinder, the outriggers (see photo).
Lock the rear wheel steering using the special pins (if any).
Cover the teeth of the conventional
forks with the special guard;
or withdraw the
floating forks.
•
•
ATTENTION
With the floating forks pitched
back, do not move the fork
pitching cylinder as the machine
could suffer from damage.
•
•
•
•
•
•
Retract boom and attachment to transfer position.
Set the ROAD-CAB-PLATFORM switch to “ROAD".
Make sure that lights, horn and turn signals are in working
order.
Engage a high speed.
Do not change mechanical gear when the machine is running.
The transfer speed of the vehicle will depend on the engine
rpm and the position of the control lever.
IMPORTANT
Public road circulation is allowed only for transferring an
unloaded machine.
Do not use the machine to tow trailers.
Page
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OPERATING INSTRUCTIONS
■ 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).
Page
■ 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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OPERATING INSTRUCTIONS
■ 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.
■ 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
Take all precautions to prevent damage to those persons
who will approach the machine while stationary:
•
Carefully dry all machine parts by blowing some
compressed air.
•
Park the machine so that it does not hinder other
operations.
•
Lubricate the machine thoroughly.
•
•
Lower the boom fitted with attachment on the
ground.
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.
ATTENTION
•
Start the engine for about 10 minutes at least once
a month.
Leaving a battery connected can result in shorts
and, as a consequence, in a fire.
•
When weather is particularly cold, empty the
radiator.
•
Disengage the transmission and put the parking
brake.
•
Remove the key from the ignition switch and lock
the cab door.
•
Disconnect the power cables of the battery.
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.
Page
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OPERATING INSTRUCTIONS
■ C-6.6 CLEANING AND WASHING THE
■ C-6.7
MACHINE DISPOSAL
MACHINE
PROTECT THE
ENVIRONMENT
■ 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
ATTENTION
Do not use water at high pressure for washing the
machine and especially the main valve, the solenoid
valves and electrical parts.
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.
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.
ATTENTION
If the machine shall be used in a marine or
equivalent environment, protect it against salt
deposits with an adequate treatment against
saltiness to prevent rust formation.
Page
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OPERATING INSTRUCTIONS
INTENTIONALLY BLANK PAGE
Page
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MAINTENANCE
Section
D
MAINTENANCE
TABLE OF CONTENTS
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-3.6
D-3.7
D-3.8
D-3.9
D-3.10
D-3.11
D-3.12
D-3.13
D-3.14
D-3.15
D-3.16
D-3.17
D-3.18
D-4
D-4.1
D-4.2
D-4.3
D-5
D-5.1
D-5.2
D-5.2.1
D-5.2.2
D-5.2.3
D-5.2.4
D-5.2.5
LUBRICANTS - HEALTH AND SAFETY PRECAUTIONS .............................. D-2
ORDINARY MAINTENANCE ......................................................................... D-4
Oil change schedule ...................................................................................... D-5
MAINTENANCE INTERVENTIONS ................................................................ D-6
Access to the engine compartment .............................................................. D-7
Greasing ........................................................................................................ D-8
Tyres and wheels .......................................................................................... D-9
Brakes ........................................................................................................... D-9
Engine air filter ............................................................................................. D-10
Cab air filter ................................................................................................. D-11
Engine cooling system ................................................................................ D-12
Checking the oil level in the tank ................................................................ D-13
Changing the hydraulic oil ........................................................................... D-14
Changing the oil filter cartridge ................................................................... D-15
Oil level in the differential gears .................................................................. D-16
Oil level in the (front/rear) wheel reduction gears ........................................ D-16
Oil level in the gearbox ................................................................................ D-17
Shafting alignment ...................................................................................... D-18
Adjusting the sliding pads of the boom sections ........................................ D-19
Re-sequencing the telescopic boom .......................................................... D-20
Checking the safety devices ....................................................................... D-21
Checking the state of the structure ............................................................. D-26
ELECTRICAL SYSTEM ................................................................................ D-27
Battery ......................................................................................................... D-27
Fuses and relays ......................................................................................... D-28
12V DC lamps ............................................................................................. D-30
REFUELLING ............................................................................................... D-31
Refuelling ..................................................................................................... D-31
Product specifications ................................................................................ D-31
Engine oil ..................................................................................................... D-31
Lubrication oils and relevant filtering elements ........................................... D-31
Fuel .............................................................................................................. D-32
Grease ......................................................................................................... D-32
Engine coolant ............................................................................................ D-32
Page
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MAINTENANCE
INTRODUCTION
A thorough and regular maintenance keeps the
machine in a safe and efficient working condition.
Observe and obey:
☛ The operator can only perform the routine
maintenance operations envisaged in this manual.
☛ Scheduled maintenance procedures shall be
completed by qualified technical personnel
according to the manufacturer’s specifications.
Maintenance symbol legend:
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.
IMPORTANT
The following symbols are used in this manual to help
you understand better the instructions provided. When
one or more symbols appear at the beginning of a
maintenance procedure, they indicate the following:
Indicates that tools are required to
perform the procedure.
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.
Indicates that new parts are required to
perform the procedure.
Indicates that a cold engine is required
to perform the procedure.
SERVICE INTERVAL
Running-in _________________________________
Ordinary ___________________________________
Indicates the time interval for the
maintenance jobs expressed in working
hours.
Page
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MAINTENANCE
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.
Page
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MAINTENANCE
D-2 ORDINARY 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.
10 Check the efficiency of the lighting electric system
11 Check the efficiency of braking system and parking
brake
12 Check the efficiency of the steering selection
system
13 Check the efficiency of the fork balancing system.
14 Make sure the safety devices installed are in
efficient working order - see procedure in chap.
D-3.17.
Every 50 working hours or weekly
Jobs to be done in addition to those above
1
2
3
4
5
During the first 10 working hours
1
2
3
4
Check the oil level within reduction gears, power
divider and differential gears
Regularly check the tightening of the wheel bolts
Check the tightening of all bolts and nuts
Check the couplings for oil leaks
Within the first 50 working hours
1
6
Every 250 working hours or monthly
Jobs to be done in addition to those above
1
2
3
Change the engine oil and renew the fuel filter
4
Within the first 100 working hours
1
Change the oil of the differential casing, the wheel
reducer and the gearbox
5
6
Every 10 working hours or daily
1
2
3
4
5
6
7
8
9
Check the engine oil level
Clean the air suction filter
Check the engine coolant level
Clean the radiator, if necessary
Check the hydraulic oil level in the tank
Check the greasing of the boom section pads
Grease the attachment holding frame
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
Check the efficiency of the overload warning system
7
8
9
10
11
12
13
Page
Check the tension of the alternator belt
Check the tyre inflation
Check the tightening of the wheel nuts
Check the tightening of the Cardan shaft screws
Check the operation of the emergency pump (if it
is installed).
Clean the radiator fins
Change the engine oil and relevant filter
Check the oil level in the front and rear differential
gears
Check the oil level in the four wheel reduction
gears
Check the main filtering element of the engine air
filter. Replace, if necessary
Check the clamping of the cableheads to the
battery terminals
Check the air suction hose between engine and
filter
Check the cylinder chromium-plated rods
Check the hydraulic lines are not worn because of
rubbing against the frame or other mechanical
components
Check the electric cables do not rub against the
frame or other mechanical components
▲ Check the wear of the sliding pads of the boom
sections
▲ Adjust the play of the sliding pads of the boom
sections
Remove any grease from the boom, then regrease the sliding parts of the boom sections
Check the level of the battery electrolyte
D-4
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MAINTENANCE
Every 3 working months
Every 2000 working hours or every two years
1
Jobs to be done in addition to those above
Check the efficiency of the block valves - see
chap. D-3.17
Every 500 working hours or every six months
1
Change the engine coolant
Jobs to be done in addition to those above.
Every 6000 hours or 5 years and, subsequently,
every 2 years
1
Jobs to be done in addition to those above
2
3
4
5
6
7
8
9
Visually check the smoke quantity evacuated from
the engine exhaust
Check the tightening of the engine fixing screws
Check the tightening of the cab fixing screws
Check the backlash between pins and bushings
in all joints
Change the hydraulic oil filter in the tank
Have the hydraulic system checked by a skilled
technician
Change the main cartridge of the engine air filter
Renew the cartridge of the engine oil filter and the
fuel filter
Change the oil of the front and rear differential
casings
1
Check that the structure is intact paying a special
attention to the welded supporting joints and the
boom pins (see chap. D-3.18).
Every 1000 working hours or yearly
Jobs to be done in addition to those above
1
2
3
4
Change the safety element of engine air filter
Change the oil of the gearbox
Change the oil in the four wheel reduction gears
Change the hydraulic oil
■ D-2.1
OIL CHANGE SCHEDULE
Intervento
Engine
Axles and
power
divider
ore di
lavoro*
intervalli di
tempo*
Oil level check
10
daily
First change
50
-
Subsequent changes
250
monthly
MB228.3)
Oil level check
250
monthly
TRACTORENAULT THFI 208 LF SAE 80W
-
-
API GL4 / FORD M2C 86B
1000
yearly
MASSEY FERGUSON M 1135
10
daily
SHELL TELLUS T 46
-
-
1000
yearly
First change
Subsequent changes
Hydraulic
oil
Oil level check
First change
Subsequent changes
* whichever occurs first
Page
D-5
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Tipo olio
SHELL RIMULA 15W-40
(API CH-4/CG-4/CF-4/CF; ACEA E3;
DENISON HF-1, DIN 51524 part 2 & 3
Handler with telescopic boom GTH-4013
MAINTENANCE
D-3 MAINTENANCE INTERVENTIONS
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.
ATTENTION
The qualified staff charged with the maintenance
of the hydraulic circuit must clean all areas around
with care before any intervention.
DANGER
When raising a component for maintenance
purposes, secure it in a safe way before any
maintenance intervention.
PROTECT THE
ENVIRONMENT
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
DANGER
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.
For this purpose, shut the engine down and step
on the brake pedal 8÷10 times.
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 main valve in both working directions
(alternately) to depressurise the hydraulic circuit.
Page
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MAINTENANCE
■ D-3.1
ACCESS
TO
COMPARTMENT
THE
ENGINE
For any operation within the engine compartment,
open the protection bonnet.
The bonnet is equipped with pneumatic shock
absorbers which unburdens and hold the bonnet in
raised position. To open the bonnet:
• Shut the engine down and put the parking brake.
• Turn the key to unlock and open the bonnet.
DANGER
Take all precautions when approaching the engine
compartment. Some parts of the engine may be
very hot.
Always use protective gloves.
Page
D-7
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MAINTENANCE
■ D-3.2
GREASING
ATTENTION
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.
Use only PTFE INTERFLON FIN GREASE LS 2 to
lubricate the sliding parts of the telescopic section.
Observe the following schedule:
• After the first 50 operating hours (1 week)
• After the first 250 operating hours (1 month)
• Every 1000 operating hours (6 months)
Remove any old grease from the boom and smear
the sliding area of the blocks with a thin coat of
grease.
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
Page
D-8
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MAINTENANCE
■ D-3.3
■ D-3.4 BRAKES
TYRES AND WHEELS
•
DANGER
For any intervention on the braking system
(adjustment and/or substitution of the brake discs)
address to the GENIE Technical Assistance Service
or the nearest GENIE authorised workshop.
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.
RIGHT WAY
OKAY
WRONG
WRONG WAY
For the tyre inflation or substitution, please refer to the
table below:
GTH-4013
STANDARD OPTIONAL
Dimensions (front and rear) 405/70-20
405/70-24
P.R. (or load index)
14 pr
14 pr
Rim
13x20
13x24
Wheel disc
8 holes DIN 70361
Pressure
bar/Psi
5.5/80
4.5/65
SERVICE INTERVAL
Running-in _________ Within the first 10 hours
Ordinary __________________ Every 250 hours
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.
IMPORTANT
Always use tyres having the dimensions indicated
in the vehicle registration card.
Page
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MAINTENANCE
■ D-3.5
ENGINE AIR FILTER
Clean the engine air filter and replace the elements,
when necessary.
1 Cleaning and changing the external element:
- Stop the engine and engage the parking brake.
- Open the four latches A.
- Remove the protection cap B.
- Extract the external cartridge C.
- Clean the filter bowl.
- Beat the cartridge against a piece of wood surface
to eliminate any dust.
- Dry clean the cartridge (max. pressure: 6 bar).
- Check for cracks in the filtering element.
- Before refitting the cleaned cartridge or a new
one, smear its seal with a thin coat of grease; fit
the cartridge and make sure it is properly
positioned.
- Refit cap B.
ATTENTION
As soon as the warning lamp 7.8 on the cab
dashboard switches on, replace the outer element.
Never wash the cartridge with water or solvents.
2
Changing the internal element:
- See step 1 for removing the outer element
- Extract the internal cartridge D.
- Clean the filter bowl.
- Smear the seal with grease, then mount the new
element and make sure it is correctly positioned.
- Refit the main filter and the cap as described in
point 1.
ATTENTION
The inner element should be replaced every two
times the outer element is replaced.
Never wash the cartridge with water or solvents.
SERVICE INTERVAL
Running-in ____________________________ None
Cleaning ___________________ Every 10 hours
Outer element change ______ Every 500 hours
Inner element change _____ Every 1000 hours
Page
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MAINTENANCE
■ D-3.6
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 filter A out of the housing accessible from the
outside of the cab.
- Clean the filter bowl.
- Clean the filter cartridge by beating it against a
piece of wood. Replace the cartridge if damaged.
ATTENTION
Paper filters must never be cleaned using
compressed air or washed with water and/or
solvents.
Page
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MAINTENANCE
■ D-3.7 ENGINE COOLING SYSTEM
DANGER
When the coolant is hot, the cooling system is
under pressure. With warm engine, loosen the
radiator plug slowly and carefully, without removing
it, to drain the pressure. Use protection gloves and
keep your face at a safe distance.
•
Every week, before starting working (when the
coolant is cold), check the coolant level which shall
be kept at 2 centimetres from plug .
•
When necessary, add clean water or an antifreeze
mixture through cap .
•
Change the antifreeze mixture every two years.
To drain the antifreeze:
- Let the engine cool down
- Unscrew the plug at the bottom of the radiator
or disconnect the rubber hose, if no plug is
present. Allow the coolant to flow out into a
special container.
- Refit the hose and pour new antifreeze (50%
water-antifreeze). This proportion will provide
protection up to -38°C.
•
Daily clean the radiator grille using a brush with
hard bristles or compressed air at a max pressure
of 6 bar.
SERVICE INTERVAL
Running-in ____________________________ None
Ordinary ____________________ Every 50 hours
On delivery, the machine is filled with a cooling mixture
consisting of 50% water and 50% anti-freeze.
TEREX PRO COOL
Protection against boiling / freezing
Product
Freezing
Boiling
%
point
point
33
-17 °C
123 °C
40
-24 °C
126 °C
50
-36 °C
128 °C
70
-67 °C
135 °C
Page
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MAINTENANCE
■ D-3.8 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.
Visually check the hydraulic oil level through level located on the reservoir and visible through the slot on
the right side of the chassis.
When necessary, add new oil through filler .
SERVICE INTERVAL
Running-in _________ Within the first 10 hours
Ordinary ____________________ Every 50 hours
PROTECT THE
ENVIRONMENT
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres
Page
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MAINTENANCE
■ D-3.9
CHANGING THE HYDRAULIC OIL
To change the hydraulic oil, 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 D5.2.2 until it is level with .
SERVICE INTERVAL
Running-in ____________________________ None
Ordinary ________________ Every 1000 hours
Page
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MAINTENANCE
■ D-3.10 CHANGING THE OIL FILTER CARTRIDGE
To change the hydraulic oil filter element, proceed as follows:
1 Stop the machine on a level ground and engage the parking
brake.
2 Place a container of suitable size under the filter to collect
any oil leaks.
3 Remove the filter cover to get access to the filter element.
4 Change the filter element, then, before fitting a new one,
thoroughly clean and grease both seat and gasket.
5 Refit and tighten the filter cover.
ATTENTION
Hydraulic oil filter canisters cannot be cleaned or washed
and refitted.
They must be replaced with new ones of the type
recommended by the manufacturer (see par. D-5.2.2).
PROTECT THE
ENVIRONMENT
The handling and disposing of used oils may be ruled by
local or national regulations. Address to authorised centres.
SERVICE INTERVAL
Running-in ____________________________ None
Ordinary __________________ Every 500 hours
Page
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MAINTENANCE
■ D-3.11 OIL LEVEL IN THE DIFFERENTIAL GEARS
■ D-3.12
To check the oil level in the front and rear differential
gears:
To check the oil level within the wheel reduction 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, top-up through hole until oil comes
out from hole .
•
•
•
Refit and tighten plugs and .
•
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.
•
To change the oil:
OIL LEVEL IN THE (front/rear) WHEEL
REDUCTION GEARS
To change the oil:
•
Place a container of suitable size under drain plug
.
•
•
Loosen the drain plug, the level plug and the filler
and allow oil to flow out from the reduction gear.
•
•
Refit and tighten drain plug .
•
•
Add new oil through the filler until it is level with hole
.
•
•
Refit and tighten plugs and .
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 .
Refit and tighten plug .
•
•
SERVICE INTERVAL
Running-in _________ Within the first 10 hours
Ordinary __________________ Every 250 hours
SERVICE INTERVAL
Running-in _________ Within the first 10 hours
Ordinary __________________ Every 250 hours
Page
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MAINTENANCE
■ D-3.13 OIL LEVEL IN THE GEARBOX
To check the oil level within the gearbox:
•
•
•
•
•
Stop the machine on a level ground and make sure
the parking brake is engaged.
Clean level plug A all around.
Remove the plug and check if oil is level with the
hole.
When necessary, add new oil through plug A until
it is level with the hole.
Refit and tighten the plug.
To change the oil:
•
•
•
•
•
•
Place a container of suitable size under the drain
plug.
Remove the level plug A and the filler.
Remove the drain plug B and empty the gearbox.
Refit and tighten the drain plug B.
Add new oil through the filler until it is level with hole
A.
Refit and tighten filler/level plug A.
SERVICE INTERVAL
Running-in _________ Within the first 10 hours
Ordinary __________________ Every 250 hours
Page
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MAINTENANCE
■ D-3.14 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.
10
15
20
RPM x 100
5
25
0
30
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 6 to “four-wheel
steer” (pos. 2)
P
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
1
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.
SERVICE INTERVAL
Running-in ____________________________ None
Ordinary ___________________ When necessary
Page
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0
2
Handler with telescopic boom GTH-4013
MAINTENANCE
■ D-3.15 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
Max. wearing thickness
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.
SERVICE INTERVAL
Minimum 1 mm
Running-in ____________________________ None
Ordinary ___________________ When necessary
Page
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MAINTENANCE
D-3.16
RE-SEQUENCING THE
TELESCOPIC BOOM
If, during normal operation, a change in the boom
extended lengths of 6 inches or more is noticed when
the boom is retracted, proceed as follows:
1
Fully retract the telescope cylinder and hold the
system over relief (approx. 15 seconds); the boom
sections should become equal.
If after performing this procedure the boom still remains
out of sequence, proceed with the steps below.
2
Move the boom to the zero position, fully retract
the boom and hold the retract system over relief
for approx. 20 seconds.
3
Raise the boom to approx. 60° and operate the
retract function over relief for approx. 20 seconds.
4
Lower the fully retracted boom to the lowest angle
possible without striking the ground and hold the
retract system over relief for approx. 20 seconds.
If, despite these procedures, the boom does not return
in sequence, raise the boom to approx. 60°, fully extend
and retract it to full stroke and hold the system over
relief (approx. 20 seconds) in each direction.
By following these procedures the boom re-sequencing
should be correct.
SERVICE INTERVAL
Running-in ____________________________ None
Ordinary ___________________ When necessary
Page
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MAINTENANCE
■ D-3.17 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 joystick pushbutton (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 the
GENIE Technical Service
10
■ Checking the emergency stop pushbutton
5
(at every use)
8
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.
Page
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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 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.
• To check the efficiency of the block valves of the outriggers,
lower them to the ground and unload the weight of the tyres
without raising them. Loosen the cylinder hoses to check
the efficiency of the valve.
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.
Attachment coupling cylinder
Lifting cylinder
Balance cylinder
Extension cylinder
Attachment pitching cylinder
Page
Outrigger cylinder
D-22
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MAINTENANCE
DANGER
Do the check of the valves taking all the possible
precautionary measures:
- Wear safety glasses
- Wear safety gloves
- Wear safety shoes
- Wear suitable working clothes
- Use guards against leaks of oil at high pressure
- Do the check in a free space with barriers all
around to keep non-authorised people away
- Ensure that the part to be checked is in safe
condition and that the action generated does
not result in an uncontrolled movement of the
machine.
Rear axle block cylinder
TO REMOVE THE BLOCK VALVES OR THE
CYLINDERS
- Lower the boom to the ground in a firm way
since the removal of the block valve or the
cylinder can cause an uncontrolled downmovement.
- After refitting the valve or the cylinder, replenish
the circuit and eliminate any air before starting
working. To eliminate the air from the circuit,
move the involved cylinders to end-of-stroke in
the two directions (opening/closing. To eliminate
the air from the fork balance cylinder, move the
boom up and down and tilt the fork plate
forwards/back.
Machine sway cylinders
Page
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MAINTENANCE
■ Checking the limit switches of the outriggers (at
every use)
To check the limit switches of the outriggers:
• Lower the outriggers to the ground and attempt to
engage a gear.
If the gear can be engaged, contact the GENIE
Technical Assistance Service.
Proceed on one outrigger at a time.
• With the outriggers up, light A on the load limiter
panel must be off; with the outriggers down to the
ground, the same light must be on. Should it not be
the case, contact the GENIE Technical Service.
DANGER
If a limit switch is faulty or a lever is deformed,
immediately replace the part.
A
■ 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 operation of the emergency pump
(weekly)
If the machine is equipped with an emergency pump,
check it is in efficient working order every week.
17
This pump is not used regularly and, as a result, it could
get damaged and be out of order in case of need.
To check that the pump is in efficient order, stop the
engine, press the on-off button for some seconds and
check that the pump works regularly.
Page
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MAINTENANCE
■ Checking the limit switches (at every use)
Limit switch L on the boom
• Raise and tilt the boom more than 40° and check if
the axle is blocked.
Should this not be the case, contact the GENIE
Technical Assistance Service.
Limit switch M on the boom
• Raise the boom beyond the horizontal and ensure
the sway control and the outrigger conttrol are
blocked.
Should this not be the case, contact the GENIE
Technical Assistance Service.
■ Checking the microswitch O on the parking
brake (at every use)
To check the efficiency of the microswitch on the
parking brake, proceed as follows:
• sit on the driving place, put the parking brake and
attempt to move with the machine. The machine
must stand still. Shoudl this not be the case, adjust
the distance of the brake microswitch or replace it.
Page
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MAINTENANCE
■ D-3.18
CHECKING THE STATE OF THE
STRUCTURE
Five years or 6000 hours after the first placing into
operation of the machine (whichever occurs first),
check the state of the structure paying an extreme attention to the welded supporting joints and the pins of
both boom and platform (if present).
DANGER
After the first 5 years, repeat this check every 2
years.
Page
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MAINTENANCE
D-4 ELECTRICAL SYSTEM
•
Before disconnecting the battery, set all
switches within the cab to OFF.
DANGER
•
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.
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
Any intervention on the electrical system unless
performed by authorized personnel, is expressly
forbidden.
Risk of explosion or shorts. During the recharge,
an explosive mixture with release of hydrogen gas
forms.
D-4.1 BATTERY
•
•
•
•
•
DANGER
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.
ATTENTION
Do not add sulphuric acid; add only distilled water.
DANGER
•
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.
Page
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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.
■
Fuses
Ref.
Circuit
Amp.
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
EMERGENCY LIGHT
HEATING
STOP LIGHTS MICRO-SWITCH
REAR WINDSCREEN WIPER
WORK MODE SELECTOR
LOW BEAM
RIGHT POSITION LIGHTS SWITCH
INSTRUMENTS LIGHTING
INDICATOR LIGHTS POWER SUPPLY
LIGHTS SWITCH
BEACON
WORK LIGHTS
FUSE
DRIVE SWITCH
HIGH BEAM
EMERGENCY
LIGHTS AND FLASHING
OUTRIGGERS
WORK MODE SELECTOR
PLATFORM EMERGENCY BUTTON
HORN
PLATFORM FUNCTION
CAB LIGHTS
EMERGENCY BUTTON
3B6 CONTROL UNIT
OUTRIGGERS
OPTIONAL
10
15
5
7.5
10
15
3
3
7.5
7.5
7.5
10
10
10
10
15
10
10
10
10
15
15
10
10
10
10
10
K23
K18
K8
K16
K15
K5
K17
K7
K1
K11
K22
K6
K10
K9
K12
K20
K21
K2
K4
K3
K13
K14
F6
F12
F15
F21
F27
F5
F11
F14
F20
F26
F4
F10
F13
F19
F25
F3
F9
F18
F24
F2
F8
F17
F23
F1
F7
F16
F22
J3
Page
K19
K24
D-28
Document 57.0007.0200 - 01/2006
RELE’
K22
J2
J1
Handler with telescopic boom GTH-4013
MAINTENANCE
■
Engine compartment fuses and relays
Ref.
FM1
FM2
K01
Circuit
MAXI FUSE 1
MAXI FUSE 2
RELAY - START-UP
K01
Amp.
50
70
FM2
FM1
■
Fuse box relays
Ref.
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K11
K12
K13
K14
K15
K16
K17
K18
K19
K20
K21
K22
K23
K24
K36
Circuit
RELAY - HIGH BEAM
RELAY - LOW BEAM
RELAY - HORN
RELAY - WORK LIGHTS
RELAY - 1ST-2ND MECHANICAL SPEED
RELAY - OPTIONAL
RELAY - FORWARD SPEED
RELAY - REVERSE SPEED
RELAY - TRANSMISSION DISCONNECTED
RELAY - TRANSMISSION DISCONNECTED
RELAY - START-UP ENABLING COMMAND
RELAY - ELECTROSTOP
RELAY - EMERGENCY PUMP
RELAY - OUTRIGGERS
RELAY - IN/OUT MOV.
RELAY - UP/DOWN MOV.
RELAY - TURRET ROTATION
RELAY - OPTIONAL
RELAY - FORK COUPLING
RELAY - PLATFORM OVERLOAD WARNING
SYSTEM ON
RELAY - POWER SUPPLY FROM PLATFORM
PLATFORM INTERMITTENCE
FLASHING FUNCTION
TIMER
RELAY - AUX CIRCUIT MAIN LINE
K36
ATTENTION
•
•
•
•
•
Page
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.
D-29
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MAINTENANCE
■
D-4.3 12V DC LAMPS
Use
•
•
•
•
•
•
•
•
•
Voltage
Mount type
Front low/high beam ............................................................ 12 V ....................... P45t
Front position lights ............................................................. 12 V ..................... BA 9s
Side/tail turn signals ............................................................ 12 V ................... BA 15s
Stop lights and rear position lights ...................................... 12 V ................. BAY 15d
Beacon - Work lights (OPTIONAL) ....................................... 12 V .......................... H3
Dashboard indicators and cab lighting ................................ 12 V ................ W 2x4,6d
Interior lamp ......................................................................... 12 V ................. SV 8.5-8
License plate lights .............................................................. 12 V ................... BA 15s
Back-up lamps ..................................................................... 12 V ................... BA 15s
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-30
Document 57.0007.0200 - 01/2006
Power
................. 45/40 W
........................ 3 W
...................... 21 W
................... 21/5 W
...................... 55 W
..................... 1.2 W
........................ 5 W
........................ 5 W
....................... 21W
Handler with telescopic boom GTH-4013
MAINTENANCE
D-5 REFUELLING
■ D-5.1
REFUELLING
Part
Diesel engine
Engine cooling system
Fuel tank
Hydraulic system tank
Gearbox
Differential gears
Wheel reduction gears
Capacity
(litres)
12
15
150
135
1.5
8.7
0.75
Product
Engine oil
Water+antifreeze
Diesel fuel
Hydraulic oil
Oil
Oil
Oil
Product
specifications
see par.
D-5.2.1
D-5.2.5
D-5.2.3
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 SAE 15W-40
(API CH-4 / CG-4 / CF-4 / CF, ACEA E3, MB 228.3)
■ 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 TRACTORENAULT
THFI 208 LF SAE 80W
API GL4 / FORD M2C 86B
Massey Ferguson M 1135
Hydraulic system and brakes
DENISON HF-1 DIN 51524 part 2 & 3
SHELL TELLUS T 46
ATTENTION
Never mix different oils: this may result in troubles and component breaks.
Oils for hydraulic system:
Arctic climates:
Temperatures below -10°C
Mild climates:
Temperatures from -15°C to + 45°C
Tropical climates: Temperatures above + 30°C
Use SHELL Tellus T22
Use SHELL Tellus T46
Use SHELL Tellus T68
Filtering elements:
Filter
Flow rate l/1'
Filtering
Coupling
Oil filter
150
10 μ
1" 1/4 BSP
Page
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Handler with telescopic boom GTH-4013
MAINTENANCE
■ D-5.2.3 Fuel
■ D-5.2.5 Engine coolant
Refuel through cap A. Use only Diesel fuel with less
than 0.5% sulphur content, according to the
specifications of the diesel engine operation handbook.
It is advisable to use an antifreeze mixture (50% water50% antifreeze). At the delivery, the machine is refilled
with:
ATTENTION
TEREX PRO COOL by VALVOLINE
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.
The use of this product guarantees protection to the
circuit for 3 years or 7000 hours without having to add
any dry coolant additive.
TEREX PRO COOL
Protection against boiling / freezing
Product
Freezing
Boiling
%
point
point
33
-17 °C
123 °C
40
-24 °C
126 °C
50
-36 °C
128 °C
70
-67 °C
135 °C
ATTENTION
Use an antifreeze mixture in the proportions
recommended by the manufacturer in relation to
the ambient temperature of the jobsite.
■ D-5.2.4 Grease
For the machine greasing, use:
• Lithium-based
Vanguard LIKO
grease, type EP2
When greasing by pump
• Graphitized AGIP
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
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Handler with telescopic boom GTH-4013
FAULTS AND TROUBLESHOOTING
Section
E
FAULTS AND
TROUBLESHOOTING
TABLE OF CONTENTS
E-1
FAULTS AND TROUBLESHOOTING .............................................................. E-2
E-1.1
Fault - Cause - Solution ................................................................................. E-2
Page
E-1
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Handler with telescopic boom GTH-4013
FAULTS AND TROUBLESHOOTING
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 that 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
PROBLEM
THE DASHBOARD DOES NOT TURN
ON
CAUSES
• Battery disconnected
• Battery down
• Fuse in the engine compartment box
blown (F2G)
THE ENGINE DOES NOT START
The starter does not run
THE ENGINE DOES NOT START
The starter runs, but the engine
does not start
• Connect the battery using the
relevant switch
• Check the battery condition
• Check the main fuse in the engine
compartment and replace if
necessary
• Forward/reverse gear selector not in
neutral position
• Battery down
• Battery cut-out switch ON
• Emergency button ON
• Set the switch to 0
• Engine start fuse blown (F5G)
• Check the engine starting fuse
located in the box in the engine
compartment and replace if
necessary.
• Refuel.
• Change the filter. See engine
operator handbook
• Refuel, then refer to engine operator
handbook
• No fuel
• Fuel filter clogged
• Fuel hose empty (fuel used up)
THE MACHINE DOES NOT MOVE
FORWARD/BACK
SOLUTIONS
• Changeover switch in neutral
• Mechanical gear not engaged
• Parking brake engaged
• Fuse F14 blown
• Outrigger micro-switches ON
Page
E-2
Document 57.0007.0200 - 01/2006
• Recharge or replace the battery
• Disconnect the battery
• Reset the button
• Set the gear switch to correct
position
• Engage the gear
• Disengage
• Check the 10A fuse F14 and replace
if necessary.
• Check that the mechanical limit
stops are in the rest position
Handler with telescopic boom GTH-4013
FAULTS AND TROUBLESHOOTING
PROBLEM
NO SELECTION OF THE STEERING
MODE
CAUSES
SOLUTIONS
• "CAB/ROAD/PLATFORM" switch
set to “ROAD”
• "CAB/ROAD/PLATFORM" selector
damaged
• Fuse F13 blown
• Select “CAB”
• Alarm of the overload warning system
• Retract or raise the boom within safe
limits
If the alarm condition persists,
retract the boom operating the
cutout key of the overload warning
system and address to the nearest
authorised workshop
THE OVERLOAD WARNING
SYSTEM DOES NOT WORK
• Fuse F25 blown
• Check the 10A fuse F25 and replace
if necessary
BOOM DOES NOT MOVE
• Fuse F24 blown
• Check the 10A fuse F24 and replace
if necessary
• Select “CAB”
• If theproblem persists, turn the
"CAB/ROAD/PLATFORM" selector
to "ROAD" and then again to "CAB"
without shutting down the engine.
This will reset the electronic control
unit.
NO BOOM LOWERING AND
EXTENSION, NO HOLDING FRAME
PITCHING
ALARM OF THE OVERLOAD
WARNING SYSTEM
(red LED ON)
• "CAB/ROAD/PLATFORM" switch
set to “ROAD”
NO CHANGE BETWEEN 1st AND 2nd
MECHANICAL GEAR AND VICE
VERSA
• Fuse F14 blown
• Relay K5
• Mechanical gearbox control unit
K24
• Pushbutton (ref. 13 . C-12)
• Check the selactor - reconnect or
replace
• Check the 10A fuse F13 and replace
if necessary.
• Check fuse F14 and replace if
necessary
• Check the relay
• Check the control unit
• Check the pushbutton
• Coil Y8 - Y9
• Check the coil
THE LOAD LIMITING SYSTEM DOES
NOT CHANGE WORK SCALE
• Outriggers limit switches inefficient
• Check the efficiency of the outrigger
limit switches or replace if
necessary.
THE LOAD LIMITING SYSTEM IS
BLOCKED
(red LED’s lit)
• Low stability
• 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.
Page
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Handler with telescopic boom GTH-4013
FAULTS AND TROUBLESHOOTING
PROBLEM
CAUSES
SOLUTIONS
CHECKING THE MICRO-SWITCHES
WHEN THE DLE 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
THE DLE LOAD LIMITING SYSTEM
IS IN ALARM
• Fuse blown (F25 - 10 A)
• Check and replace fuse, if
necessary
• System failure
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.
Page
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Handler with telescopic boom GTH-4013
FAULTS AND TROUBLESHOOTING
PROBLEM
CAUSES
SOLUTIONS
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 re-calibrate the machine.
A Data error in RAM
• Stop and restart the machine. If the
error message is still shown,
address to the GENIE service
centre.
B Outrigger incongruence
• 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.
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.
IMPORTANT
In case of faults not listed in this chapter, address to the GENIE Technical Assistance, your nearest
authorised workshop or dealer.
Page
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FAULTS AND TROUBLESHOOTING
Notes ...........................................................
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Page
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Handler with telescopic boom GTH-4013
OPTIONAL ATTACHMENTS
Section
F
OPTIONAL ATTACHMENTS
TABLE OF CONTENTS
F-1.1
Shovel ...................................................................................................
F-3
F-1.2
Concrete skip ........................................................................................
F-4
F-1.3
Mixing bucket ........................................................................................
F-5
F-1.4
Fixed hook on plate ...............................................................................
F-6
F-1.5
Hydraulic winch .....................................................................................
F-7
F-1.6
Extension jib ..........................................................................................
F-7
F-1.7
Forks with hydraulic side-shift ..............................................................
F-8
F-1.8
Man-platform .........................................................................................
F-9
Page
F-1
Document 57.0007.0200 - 01/2006
Handler with telescopic boom GTH-4013
OPTIONAL ATTACHMENTS
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 movements
like, for instance, the pole and pipe planter, a flow
selecting valve shall be installed on the machine or
the attachment. This valve will be operated by the
relevant switch in the cab.
Page
F-2
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Handler with telescopic boom GTH-4013
OPTIONAL ATTACHMENTS
■ F-1.1
Application
Quick-coupling fitted attachment for moving soil, sand,
debris, cereals, etc.
SHOVEL
Capacity
GTH-4013
Code
Litres 800 59.0202.2000
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
Litres
800
Width
mm
2250
Length
mm
1000
Height
mm
940
Weight
kg
380
SAE capacity
m3
0,8
ATTENTION
Attachment suitable for moving loose material. Do
not use for digging operations.
Page
F-3
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Handler with telescopic boom GTH-4013
OPTIONAL ATTACHMENTS
■ F-1.2
Application
Attachment coupled to the standard forks of the
handler and fixed by means of the special chains with
shackle provided.
CONCRETE SKIP
Code
Man. unloading
Hydr. unloading
litres 500
59.0400.0000
59.0400.1000
litres 800
59.0400.2000
59.0400.3000
Safety
Strictly obey the general safety precautions given in
section B “Safety”.
Operation
Fork the skip bearing in mind the side where the
product will be unloaded.
Secure the skip to the forks using the chains provided.
To unload the concrete, manually operate the gate
opening lever if the skip opening is done by hand.
If the skip is equipped with hydraulic cylinder for the
gate opening, 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 skip for damage before using it.
Wash 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.
Check the chains after every use and replace them if
worn or damaged.
Technical data
Litres
500
800
Width
mm
1200
1200
Length
mm
1200
1200
Height
mm
1270
1520
Weight
kg
220
260
SAE capacity
m3
0,5
0,8
Page
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Handler with telescopic boom GTH-4013
OPTIONAL ATTACHMENTS
■ F-1.3
Application
Quick-coupling fitted attachment for mixing and
distributing concrete.
MIXING BUCKET
Capacity
GTH-4013
Code
Litres 500 59.0401.0000
Safety
Strictly obey the general safety precautions given in
section B “SAFETY”.
Operation
To load/unload the material, operate the rotation lever
of the attachment holding plate.
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 F2).
Maintenance
DANGER
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.
Technical data
Width (A)
Length (B)
Height (C)
Dead weight
All up weight
Output capacity
Total capacity
Output level from shaft centre (D)
Litres
mm
mm
mm
kg
kg
litres
litres
mm
500
1850
1080
1120
780
2000
500
785
140
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.
Rest position
D
C
A
Page
F-5
Document 57.0007.0200 - 01/2006
B
Handler with telescopic boom GTH-4013
OPTIONAL ATTACHMENTS
■ F-1.4
Application
Quick-coupling fitted attachment for lifting loads by
means of special slings.
FIXED HOOK ON PLATE
Payload
GTH-4013
Code
kg 4000 59.0700.4000
Safety
Strictly obey the general safety precautions given in
section B “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.
Technical data
Width
Length
Height
Weight
mm
mm
mm
kg
970
620
600
132
IMPORTANT
The fixed hook has been designed to support a load
of 5400 kg. The max payload corresponds to the
nominal capacity rating of the handler on which it is
installed and is indicated on the load charts supplied
with the equipment.
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-6
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Handler with telescopic boom GTH-4013
OPTIONAL ATTACHMENTS
■ F-1.5
■ F-1.6
HYDRAULIC WINCH
Payload
GTH-4013
EXTENSION JIB
Code
mechanical
hydraulic
Code
kg 3000 59.0901.4000
GTH-4013
Technical data
Payload
Width
Length
Height
Weight
59.0802.0000
59.0801.9000
Technical data
kg
mm
mm
mm
kg
3000
960
880
1650
280
Length
Width
Height
Weight
Payload
mm
mm
mm
kg
kg
4000
970
600
360
900
For the use of this attachment, read the specific
manual supplied - code: 57.0300.9200
For the use of this attachment, read the specific
manual supplied - code: 57.0300.9200
IMPORTANT
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.
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
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Handler with telescopic boom GTH-4013
OPTIONAL ATTACHMENTS
■ F-1.7
FORKS WITH HYDRAULIC SIDE-SHIFT
Payload
GTH-4013
Application
Quick-coupling fitted attachment for handling
palletised loads.
Code
kg 4000 59.0601.2000
Safety
Strictly obey the general safety precautions given in
section B “SAFETY”.
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.
Technical data
Payload kg
Width
Length
Height (with protection)
Weight
Stroke
Fork attachments
4000
mm
mm
mm
kg
mm
1400
1600
1140
180
± 100
FEM 3
Page
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Handler with telescopic boom GTH-4013
OPTIONAL ATTACHMENTS
■ F-1.8
MAN-PLATFORM
Application and codes
Platform model
GTH-4013
2P-300F
2P-500 REM 4400
59.1108.1000
59.1108.0000
For the use of this attachment, read the specific
manual supplied - code: 57.0302.9200
Page
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Handler with telescopic boom GTH-4013
OPTIONAL ATTACHMENTS
INTENTIONALLY BLANK PAGE
Page
F-10
Document 57.0007.0200 - 01/2006
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
Section
G
TABLES AND
DOCUMENTS ENCLOSED
TABLE OF CONTENTS
G-1
TORQUE WRENCH SETTING ...............................................................
G-2
G-2.1
Load Chart with forks - GTH-4013 with outriggers ...............................
G-3
G-2.2
Load Chart with forks - GTH-4013 on wheels ......................................
G-4
G-3.1.1
Load limiting system wiring diagram - Layout ......................................
G-5
G-3.1.2
Load limiting system wiring diagram - External connections ...............
G-6
G-3.2
Wiring diagram ......................................................................................
G-7
G-3.2.1
Sheet 1 of 9 ...........................................................................................
G-7
G-3.2.2
Sheet 2 of 9 ...........................................................................................
G-8
G-3.2.3
Sheet 3 of 9 ...........................................................................................
G-9
G-3.2.4
Sheet 4 of 9 ...........................................................................................
G-10
G-3.2.5
Sheet 5 of 9 ...........................................................................................
G-11
G-3.2.6
Sheet 6 of 9 ...........................................................................................
G-12
G-3.2.7
Sheet 7 of 9 ...........................................................................................
G-13
G-3.2.8
Sheet 8 of 9 ...........................................................................................
G-14
G-3.2.9
Sheet 9 of 9 ...........................................................................................
G-15
G-3.2.9.1
Sheet 9a of 9 .........................................................................................
G-16
G-3.2.10
Wiring diagram - Components description ...........................................
G-17
G-4
HYDRAULIC SCHEME - GTH-4013 ......................................................
G-21
G-5
ROUTINE CHECK SCHEDULE-SAFETY DEVICES ...............................
G-23
Page
G-1
Document 57.0007.0200 - 01/2006
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-1 TORQUE WRENCH SETTINGS
Dxp
Pre-loading (N)
Torque wrench setting (Nm)
4.8
8.8
10.9
12.9
4.8
8.8
10.9
12.9
M 4 x 0,7
1970
3930
5530
6640
1,5
3,1
4,3
5,2
M 5 x 0,8
3180
6360
8950
10700
3
6
8,5
10,1
M6x1
4500
9000
12700
15200
5,2
10,4
14,6
17,5
M 8 x 1,25
8200
16400
23100
27700
12,3
24,6
34,7
41,6
M8x1
8780
17600
24700
29600
13
26
36,6
43,9
M 10 x 1,5
13000
26000
36500
43900
25,1
50,1
70,5
84,6
M 10 x 1,25
13700
27400
38500
46300
26,2
52,4
73,6
88,4
M 12 x 1,75
18900
37800
53000
63700
42,4
84,8
119
143
M 12 x 1,25
20600
41300
58000
69600
45,3
90,6
127
153
M 14 x 2
25800
51500
72500
86900
67,4
135
190
228
M 14 x 1,5
28000
56000
78800
94500
71,7
143
202
242
M 16 x 2
35200
70300
98900
119000
102
205
288
346
M 16 x 1.5
37400
74800
105000
126000
107
214
302
362
M 18 x 2,5
43000
86000
121000
145000
142
283
398
478
M 18 x 1,5
48400
96800
136000
163000
154
308
434
520
M 20 x 2,5
54900
110000
154000
185000
200
400
562
674
M 20 x 1,5
60900
122000
171000
206000
216
431
607
728
M 22 x 2,5
67900
136000
191000
229000
266
532
748
897
M 22 x 1,5
74600
149000
210000
252000
286
571
803
964
M 24 x 3
79100
158000
222000
267000
345
691
971
1170
M 24 x 2
86000
172000
242000
290000
365
731
1030
1230
M 27 x 3
103000
206000
289000
347000
505
1010
1420
1700
M 27 x 2
111000
222000
312000
375000
534
1070
1500
1800
M 30 x 3,5
126000
251000
353000
424000
686
1370
1930
2310
M 30 x 2
139000
278000
391000
469000
738
1480
2080
2490
IMPORTANT
Sensor maximum driving torque: 15 Nm.
Page
G-2
Document 57.0007.0200 - 01/2006
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-2.1
LOAD CHART WITH FORKS - GTH-4013 WITH OUTRIGGERS
14
70°
13
E
60°
12
D
11
50°
C
10
9
B
40°
8
A
7
0
30°
kg
0
40
13000
6
2
1
0
6
3500 kg
7
3000 kg
10°
2500 kg
3
1250 kg
4
2000 kg
20°
1500 kg
5
6270
0°
10 9
8
5
4
3
2
1
0
1980
9020
Page
G-3
Document 57.0007.0200 - 01/2006
LOAD CENTRE = 600 mm
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-2.2
LOAD CHART WITH FORKS - GTH-4013 ON WHEELS
14
70°
13
60°
12
g
D
200
0k
50°
kg
25
40°
A
35
00
30°
7
kg
30
8
6
0
1500 kg
1000 kg
500 kg
250 kg
10°
12810
kg
0
40
20°
4
3
B
00
9
C
00
10
kg
11
5
E
6200
2
1
0
0°
10 9
8
7
6
5
4
3
2
1
0
2040
9080
Page
G-4
Document 57.0007.0200 - 01/2006
LOAD CENTRE = 600 mm
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
X3B
X4B
X4A
Description
Control panel
Extensometric sensor - double bridge
Connecting cable
1
2
3
X1
3
Ref
1
X3A
X2
2
Imput Output
Signals
G-3.1.1 LOAD LIMITING SYSTEM WIRING DIAGRAM - Layout
Page
G-5
Document 57.0007.0200 - 01/2006
Document 57.0007.0200 - 01/2006
Page
G-6
-VB
+VB
1
+VB
-VB
CUTOFF
OUTRIGGERS
BASKET (NC)
SPARE
COLOUR
YELLOW
PINK
RED
WHITE (-VB)
BROWN
WHITE
GREEN
X2
-VB
+VB
14
BLUE (OUT3)
8
15
RED (OUT4)
7
18
GREY (INP3)
6
21
20
19
PINK (INP2)
SIGNAL
5
8
YELLOW (INP1)
X2
4
3
(+VPFIN)
R9
3
7
(KB)
OUTRIGGERS
YELLOW (INP0)
1
2
3
4
5
6
7
8
2
2
BASKET
BROWN (+VB)
1
22
6
7
8
9
17
5
11
SHLD
BLUE (-IN1)
10
4
13
RED (+IN2)
YELLOW (+OUT1)
GREEN (-OUT1)
RED (+IN1)
X3B
3
4
YELLOW (+OUT2)
2
5
GREEN (-OUT2)
9
1
12
BLUE (-IN2)
X3A
6
SHLD
23 16
SHLD
BLACK (-REF1)
BLUE (-IN1)
YELLOW (+OUT1)
GREEN (-OUT1)
RED (+IN1)
WHITE (+REF1)
SHLD
BLACK (-REF2)
BLUE (-IN2)
GREEN (-OUT2)
YELLOW (+OUT2)
RED (+IN2)
WHITE (+REF2)
10 X4B
X4A
X1
DESCRIPTION
CODE
MV 282089-1
SUPER SEAL MALE
X4B
LOAD CELL
MV 282089-1
MV 282107-1
SUPER SEAL FEMALE
SUPER SEAL FEMALE
X3B
X4A
MV 282107-1
DEUTSCH CONNECTOR
SUPER SEAL MALE
MV 770680-1
X2
AMP CONNECTOR 23 C.
FEMALE
X3A
X1
CONN.
NR.
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-3.1.2 LOAD LIMITING SYSTEM WIRING DIAGRAM - External connections
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-3.2 WIRING DIAGRAM
G-3.2.1 Sheet 1 of 9
SHIFT-ON-FLY
OPTIONAL
0 1 2
3
4
15
C/N1
10
S1
58
P
2
M6
R1.5
1
19
50a
15/54
20
RPM x 100
5
25
0
3
S11
5
30
kmi
30
trip
R6
R6
kmi/h
P1
9.1
7.2
23
R1.5
M6
C/N1
R6
J3
+30
9
1
2
X8
X8
X1
22
X1
23
X1
L1
X1
21
X1
A1
X1
19
S1
X1
18
H/R1
X1
17
32
X29
X17
X1
16
Z/N1
X1
15
G/N1
X1
14
V1
X1
12
Z-N1
X1
11
N1
X1
9
C-L1
X1
8
S0.5
X1
7
H-L1
X1
6
A-G1
5
A/V1
4
B-R1
X1
G1
H1
C/N1
H-R1.5
X1
H-N1
X1
3
R/N1
2
L-G1
1
X21
J2 F22
+15
15A
4
3.1
S1
K11
86 87a
85
87
A1
Z/N1
G/N1
Z-N1
V1
R/N1
L1
B-R1
L-G1
5.1
4.1
4.1
4.1
4.1
6.1
5.1
6.1
7.1
G1
4.1
R10
2.1
L-G1
2.1
M1.5
2.1
31
2.1
30
RELAY
CARD
8
X17
R6
R10
C1
2.1
M1.5
C1
2.1
A
9
7
X30
X29
X29
8
31
X21
X29
13
10
1
4
5
6
X29
X29
X29
X29
X29
X29
C1
B
X30
K01
87a
85
30
H-L1
H-N1
A-G1
A/V1
M1.5
50A
C-L1
L4
FM2
R10
50A
R4
N1
FM1
87
H1
R6
R10
86
2
R70
G1
M6
M730
M
50
12Vcc
1
XG4 XG4
R16
l
X1Y
G4 30
3
D+
G
Y1
W
B14
B11
p
B6
B2
p
p
B5
U
t
31
N70
STARTER
ALTERNATOR
SOLENOID VAKVE
ENGINE STOP
Page
HYDRAULIC
OIL FILTER
RESTRICTED
HYDRAULIC
OIL LEVEL
G-7
Document 57.0007.0200 - 01/2006
AIR FILTER
CLOGGED
N1
N1
N1
N1
N1
N1
SB1
ENGINE ENGINE
OIL
WATER
PRESSURE TEMP.
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-3.2.2 Sheet 2 of 9
SHIFT-ON-FLY
OPTIONAL
1
3
C1
4
5
B-R1
4.1
B-R1
1.2
2
K36
1
S54
S13
1
0
9
5
S171
86
l
1.5
R10
X36
L-G1
N1
L-N1
C1
30
-
X36
1.2
87
85
10
12
X6
13
X6
N1
3.1
G-M1
7.1
C-R1
7.1
L-G1
9.1
31
3.1
N-Z1
L-G1
5
X20
C1
4
X20
L-N1
C-R1
B/R1
A/G1
G-M1
N1
6
5
4
2
9
X6
X6
X6
X4
X4
F20
10A
+15
K12
K13
85
87
86 87a
30
85
87
30
AUX CIRCUIT
RELAY
J1
M10
86 87a
RELAY
CARD
14
M1
M1.5
X6
M1
1.5
M1.5
1.5
L-G1
1.5
31
L-G1
11
X6
9.1
Page
G-8
Document 57.0007.0200 - 01/2006
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-3.2.3 Sheet 3 of 9
SHIFT-ON-FLY
OPTIONAL
1
2
F
3
4
R
1
F
S14
+
3
1
2
4
X12
X12
X12
X12
9
5
10
N1
S-G1
4.1
7.1
M-V1
4.1
31
4.1
B-N1
G-R1
C-R1
N1
C-R1
N1
G-V1
2.5
1
0
R
N1
SX12
5
14
15
X19
X19
16
X19
B/N1
S-G1
C-R1
H-V1
V/N1
2
12
5
17
4
1
8
X16
X16
X16
X17
X16
X16
X16
4
86 87a
30
85
87
86 87a
30
85
K10
K9
87
86 87a
30
53M
85
87
K24
K6
K8
86 87a
31
53S
K7
T
15
1.2
G-R1
C-R1
85
87
K5
86 87a
30
85
87
86 87a
30
85
87
30
F14
10A
RELAY
CARD
+15
6
7
X16
X16
B/N1
B/N1
A-B1
V-N1
C-R1
13
X16
M-B1
10
X16
M-V1
3
X16
M-V1
9
X16
M-V1
11
X16
3
27
30
X29
X21
X21
12
17
X29
X21
M-V1
1
2
2
XY9
N1
N1
2.5
H3A
X3A
N1
2
X3A
N1
Y9
XY8
31
SOLENOID VALVE
FORWARD SPEED
19
X21
1
XY9
N1
Y8
36
X21
M-V1
M-V1
V-N1
1
XY8
35
X21
C-R1
2
X29
SOLENOID VALVE
REVERSE SPEED
BACK-UP
HORN
Page
G-9
Document 57.0007.0200 - 01/2006
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-3.2.4 Sheet 4 of 9
SHIFT-ON-FLY
OPTIONAL
3
4
B-R1
B-R1
B-R1
P75
6.1
B-N1.5
10
9
B-N1.5
B1.5
N1
8
H-L1
S308
6
2
N1
3
B-N1.5
1
0 1 2
9
G1.5
10
G1.5
8
2
H-G1.5
H-G1
H/N1
N1
6
3
S80
N1
6
X75
1
0 1 2
9
B-G1
5
X75
B-R1
4
X75
H/N1
N1
3
X75
G1
2
X75
N1
N1
N1
5.1
H-G1
5.1
H-B1
V-B1
5.1
5.1
Z1
5.1
H-G1.5
5.1
V1
8
11
11
X20
X19
X20
X20
X19
7
8
X20
X19
B-R1.5
H-G1.5
H/N1
V1
V-B1
X19
19
H-G1.5
X20
10
B1.5
X20
Z1
X19
G1
G1
10
B-G1
6
G1.5
17
H-B1
3
H/N1
1.5
1
X75
10
5
B-R1.5
1
0
S78
1.5
B-R1
H-G1.5
1
3.5
5
B-R1
B-R1
2.5
2
B-R1
1
B-R1
G1
11
X5
15
16
13
3
10
7
3
14
2
X17
X17
X17
X6
X17
X17
X17
X17
X5
K2
86 87a
85
87
K1
F6
86 87a
15A
30
87
85
F15
K4
F19
10A
K3
86 87a
10A
30
85
87
86 87a
30
85
F21
87
10
F12
15A
3
X9
F10
10A
7.5A
X8
F17
10A
30
+15
+30
F7
F8
3A
F3
3A
AUX CIRCUIT
RELAY
5A
8
X5
2
9
12
11
3
2
1
22
23
29
5
X21
X22
X22
X22
X22
X22
X22
X21
X21
X21
X22
16
17
X26
S-N1
G/N1
Z1.5
39
X21
15
X26
28
X26 X21
14
X26
1
1
1
X301
FRONT
LEFT
LIGHT
FRONT
RIGHT
LIGHT
5.1
X340
4
X340
N1
N1.5
2
X340
N1.5
2
X301
N1.5
2
X303
N1.5
1
XE2
N1
1
XE9
N1.5
HIDRAULIC
OIL
TEMPERATURE
31
3
X340
E340
31
E301
31
FUEL
GAUGE
5.1
5.1
5.1
5.1
B-N1.5
E303
X303
S16
B-N1.5
H23
R1.5
R1.5
6
XE2
Z1.5
R1
M-N1.5
R1
A1
5
XE2
R
3
XE2
N1
1
2
XE2
57
L
59c
31
R
E2
E6
59c
5
M-V1
G-N1
6
XE9
E9
L1
A1
L1
A1
L1
R1
G1
A1
S-N1
5
XE9
XE24
N1.5
N1.5
3
XE9
N1
1
XE25
N1
4
2
XE9
57
3
XE24 XE24 XE24
31
L
2
E24 XE24
58
5
56a
4
58
56a
56b
3
XE25 XE25 XE25 XE25
31
t
E25
56b
2
B13
N1
G1
V1.5
L1
V1.5
G-N1
H-N1
Z/N1
Z-N1
H1.5
M-V1
B15
3.5
M-N1
26
X21
B-N1.5
1
X17
R1.5
2
X17
R1.5
6
X17
G1
4
X9
G1
5
X5
H1.5
3.5
1
X5
G/N1
Z-N1
5
X17
H1.5
1.5
12
X17
V1.5
G/N1
7
X5
V1.5
Z/N1
1.5
4
X17
H1.5
1.5
11
X17
G/N1
10
X5
B-N1.5
RELAY
CARD
REAR
LEFT
LIGHT
LICENCE
PLATE
LIGHT
Page
REAR
RIGHT
LIGHT
STOP LIGHT
MICRO-SWITCH
G-10
Document 57.0007.0200 - 01/2006
HORN
REAR LEFT REAR RIGHT
WORK
WORK
LIGHT
LIGHT
REAR
WORK LIGHTS
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-3.2.5 Sheet 5 of 9
SHIFT-ON-FLY
OPTIONAL
1
2
3
4
5
SX11
53b 53a
49
M13
31
J
HORN
0
M306
I
I
53
WIPER
53a
M
M
53b
31b
1 0
2
8
5
4
6
3
10
Sx
S87
31
2
X306
H-G1.5
V-B1
H-B1
H-G1
Z1
N1
L1
L1
A1
7
H-G1
1
X306
L1
2
X13
A1
4
X13
A-R1
1
X13
R1
6
X13
N1
3
X13
A-N1
9
X11
A-B1
10
X11
L-N1
6
X11
L1
8
X11
A1
2
X11
H1
11
X11
A/B1
13
X11
A/N1
7
X11
Z1
1
X11
A-N1
5
X11
A-B1
3
X11
L/N1
12
X11
H-B1
4
1
N1
N1
5
3
20
21
2
1
X26
X20
X19
X19
X20
X20
RN1
9a
N1
6.1
31
6.1
L1
A1
A1
1
8
8
X9
X9
X7
F1
13
12
X8
X9
F16
10A
15A
+15
AUX CIRCUIT
RELAY
4
X9
F27
10A
A/R1
1.5
1.5
H
L
R-G1
4.5
4.5
4.5
4.5
4.5
4.5
56a
X11
V-B1
H-G1.5
56b
H-G1
30 54s 54d 31b
56
Dx
+30
K23
+
CL
31
P
27
6.1
-
A1
L1
RELAY
CARD
21
L1
4.5
L1
4.5
A1
4.5
A1
4.5
31
20
A1
X21
N1.5
4.5
4
X22
X21
L1
L1
X22
A1
8
A1
Page
G-11
Document 57.0007.0200 - 01/2006
N1
L1
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-3.2.6 Sheet 6 of 9
SHIFT-ON-FLY
OPTIONAL
1
2
3
4
5
E304
M300
M
E302
1
M
0
S4
4
N1
C1.5
A-R1.5
B-R1
C1.5
A-R1.5
A-R1.5
N1
R1
N1.5
L-R1
3
M305
1
X305 X305
G-V1.5
N1.5
B-R1
B-R1
M
9
X300
X305
8
13
14
X26
X20
X20
B-R1
5.5
9
2
7
X9
X9
X9
11
X9
C1.5
N1
N1.5
6
X26
R1
7
X26
L-R1
1
X19
G-V1.5
4.5
B-R1
B-R1
B-R1
10
B-R1
1.5
S82
5
3
N1
B-R1
N1
1
II I 0
9
1
X300
5.5
10
5
M1.5
2
1
M1.5
H4
B-R1.5
H3
N1
H2
N1
N1
H1
N1
N1
N1
12
12
13
1
X20
X26
X26
X26
12
X19
M1.5
6
5
5
3
X9
X9
X8
X9
27
F9
F4 F11
7.5A
7.5A
7.5A
F23
F2
10A
15A
+30
AUX CIRCUIT
RELAY
RELAY
CARD
R/N1
A-R1
7.1
31
7.1
A-R1
1.5
11
X29
A-R1
B-R1.5
18
X21
R/N1
38
X21
M3
M
B17
3.5
C-R1
5.5
31
SENSOR
BRAKE FAILURE
SENSOR
SPEED ALARM
A/C SISTEM
Page
G-12
Document 57.0007.0200 - 01/2006
N1.5
N1.5
N1.5
N1.5
C-R1
N1
N1
PONTE
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-3.2.7 Sheet 7 of 9
SHIFT-ON-FLY
OPTIONAL
1
3
5
A/N1
8.1
7
8
X25
X25
C1
H/N1
9.1
B-G1
9.1
B-N1
9.1
G-M1
H-R1.5
9.1
9.1
G-M1
H/N1
6
X25
G-M1
5
X25
H9
H/N1
4
X25
S31
H/N1
3
X25
Z-N1.5
2
X25
R-N1
1
X25
B1
B-G1
L-G1
4
X61
S30
1 0 2
A/R1
3
B-N1
2
R-N1
1
X61
S34 S33 S32
B-G1
C1
S10
8.1
C-R1
M-N1
PLAT. SCALE CHANGE
GROUND
p
OVERLOAD SIGNAL
S6b
p
POWER SUPPLY
S6a
V1.5
3B6 OVERLOAD
WARNING SYSTEM
A25
H/N1
C-R1
C1
H-R1.5
1.2
B-N1
S-G1
4
X26
H-R1
L-G1
3
X26
G-M1
1.5
3.5
2
X26
R-N1
2.5
4
G-M1
OUTRIGGER DOWN
2.5
2
A/R1
A-N1
6
2
6
2
4
12
5
7
6
C7
B4
A7
X4
X6
X5
X7
X7
X7
X7
X7
X7
XJ1
XJ1
XJ1
53
9.2
+15
K18
K22
F18
85
87
87A
F13 F25
10A
30
+30
K19
86 87a
86
10A
87
85
86 87a
30
85
87
TECNORD
CONTROL
UNIT
30
10A
+30
+15
+30
RELAY
CARD
11
13
A3
X7
X7
XJ1
A-N1
9.1
Z-M1
8.1
31
8.1
Z-M1
3
X7
A-G1
A/R1
9
X7
A-R1
7
10
16
6
1
6
X22
X22
X21
X22
X21
X21
37
M-G1
M-G1
X21
4
A-N1
1
2
4
A
X1.2 X1.2 X1.2
B
B10
4
S-B1
31
MICRO-SWITCH
RIGHT
OUTRIGGER
LOW BOOM
SENSOR
HIGH BOOM
SENSOR
REAR AXLE
SENSOR
Page
G-13
Document 57.0007.0200 - 01/2006
N1
X28A
S-L1
MICRO-SWITCH
LEFT
OUTRIGGER
C
X10B X10B X10B
B1.2
N1
X28A
2
M-G1
A-G1
M-G1
1
X1.1 X1.1 X1.1
B1.1
3
X29A
1
X28A
N1
4
X28A
N1
N1
6.5
2
S28
N1
3
X29A
1
X29A
M-G1
N1
X29A
B-G1
A-R1
A/R1
2
S29
M-G1
Z-M1
M-G1
6.5
10
X7
A-N1
3
X5
G-M1
9
X5
B-G1
4
X5
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-3.2.8 Sheet 8 of 9
SHIFT-ON-FLY
OPTIONAL
1
7.5
2
3
4
5
Z-M1
X90
4
9
1
10
0
B
C
D
F
S22
A
1
1 0 2
2
S2
E
7
3
M-N1
V1.5
7.5
A/N1
8
DIAGNOSTIC
INTERFACE
9
4
10
1
2
3
4
X90
X90
X90
X90
M-N1
7
15
5
7
8
1
1
X6
X6
X4
X4
X4
X7
X6
F26
K14
86 87a
10A
85
F5
87
10A
10
X6
A4
B6
A6
C6
A5
A8
B8
B8
XJ1
XJ1
XJ1
XJ1
XJ1
XJ1
XJ1
XJ2
+15
9.1
L-N1.5
9.4
TECNORD
CONTROL UNIT
10A
30
+30
L1
B5
XJ1
F24
M-N1.5
G1
H-R1
C-R1
M-N1.5
A/N1
L-N1.5
M-N1.5
7.3
2
M-N1
3
S3
8
M-N1
2
V1.5
7
Z-M1
10
A-B1
C-N1
M/B1
1
1 0 2
H-R1
4
9
C-N1
8
L/R1
3
2
M-N1
S1
7
M-N1
1
1 0 2
+15
RELAY
CARD
A3
A4
A1
A2
A5
A6
XJ2
XJ2
XJ2
XJ2
XJ2
XJ2
Y14
2
Y15
2
X13A
S/N1
Y11
2
X14
S/N1
1
1
X11A
X10A
Y10
2
X15
2
X11A
X10A
31
N1
1
X15
N1
1
X14
Y13
2
A/B1
Z/B1
V/B1
1
X13A
C/N1
21
X29
X12A
N1
A/B1
20
X29
N1
2
Z/B1
19
X29
1
X18A
V/B1
18
X29
Y12
N1
N1
7.5
17
X29
N1
2
16
X29
X12A
Y18
X19A
4
X21
N1
1
X18A
N1
Y19
3
X21
M/N1
H-R1
C-N1
1
X19A
C/N1
4
X4
M/N1
17
X6
N1
8
X6
H-R1
16
X6
C-N1
9
X6
31
SOLENOID VALVE
CRAB STEER
SOLENOID VALVE
FOUR-WHEEL
STEER
SOLENOID VALVE SOLENOID VALVE
RIGHT OUTRIGGER
RIGHT
DOWN
OUTRIGGER UP
Page
SOLENOID VALVE SOLENOID VALVE
LEFT OUTRIGGER LEFT OUTRIGGER
DOWN
UP
G-14
Document 57.0007.0200 - 01/2006
SOLENOID VALVE
LEFT SWAY
SOLENOID VALVE
RIGHT SWAY
9.1
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-3.2.9 Sheet 9 of 9
SHIFT-ON-FLY
OPTIONAL
1
2
3
SX10
4
X28
MANIPULATOR
A
B
C
D
E
F
PLATFORM
G
H
j
3
4
5
6
7
8
9
10
11
12
15
16
13
14
M1
L-N1.5
C/N1
L-G1
V-B1
BR1
G-M1
H/N1
X28
H-R1.5
9a
2
1
X10
2.5
2.2
1.2
5
L-G1
M1
C/N1
V-B1
H/N1
H-R1.5
G-M1
H/N1
L-N1.5
8.5
5
3
10
X18
X18
X18
K16
86 87a
87
85
K17
86 87a
30
85
87
30
85
Z1
S-G1
C/B1
N-Z1
A/G1
V-B1
G-V1
H/L1
V-Z1
B1
G/R1
L-B1
3
B3
B1
C1
C5
A2
A1
C3
B2
C2
C4
C2
B2
C5
B7
C8
X4
XJ1
XJ1
XJ1
XJ1
XJ1
XJ1
XJ1
XJ2
XJ2
XJ1
XJ1
XJ1
XJ2
XJ1
XJ1
K20
K21
86 87a
1
X4
53
7.2
K15
A-N1
B-G1
H/N1
B-G1
B-N1
B-N1
7.5
7.5
L-N1
7.5
7.5
7.5
87
86 87a
30
87
85
86 87a
30
87
85
TECNORD
CONTROL UNIT
30
RELAY
CARD
11
6
2
4
1
9
13
12
A7
B5
C8
B1
C3
C1
A8
X18
X18
X18
X18
X18
X18
X18
X18
XJ2
XJ2
XJ2
XJ2
XJ2
XJ2
XJ2
H-L1
A-N1
R-V1
Z/N1
B-G1
V/N1
V/N1
C-L1
L/G1
M-N1.5
V-Z1
25
9
12
13
11
40
X21
X21
X21
X21
X21
X21
Z-V1
R-V1
5
X21
L-G1
8
X21
B-G1.5
7
X21
M-N1
10
X21
C-L1
8.5
M-N1.5
7.5
V/N1
7
X18
L-R1
8
X18
V/N1
V/N1
3
1
3
1
3
A
C
1
1
1
X6A
X4A
X4A
X5A
X5A
X7A
X7A
X8A
X30A
X31
Y31
2
X31
SOLENOID VALVE
FORK IN/OUT
MOIVEMENT
SOLENOID VALVE
UP/DOWN
MOIVEMENT
SOLENOID VALVE
FORK ROTATION
SOLENOID VALVE
ATACHMENT
LOCKED/UNLOCKED
Page
MAIN
SOLENOID VALVE
G-15
Document 57.0007.0200 - 01/2006
SHOCK-ABSORBER
BLOCK
SOLENOID VALVE
N1
2
X30A
N1
2
X8A
N1
B
X7A
N1
2
X5A
N1
2
X4A
N1
2
X6A
SHOCK-ABSORBER
BLOCK
SOLENOID VALVE
N1
Y30
N1.5
Y08
N1
Y7
N1
Y5
N1.5
Y4
N1
N1.5
31
Z-N1
1
X6A
Y6
8.5
M-N1
M-N1
M-N1
M-N1
31
/./
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-3.2.9.1 Sheet 9a of 9
SHIFT-ON-FLY
OPTIONAL
BR1
LB1
Z1
85
30
A1
G1
1
2
LB1
GM1
G1
BR1
Z1
RG1
S1
G1
G1
G1
G1
N1
AV1
GM1
AV1
V1
Z1
2
deustch
X402
1
GV1
B1
X402
G1
X402
X402
GV1
1
6
X402
M1
8
9
B1
4
X402 2
X402
1
deustch
A
GV
REVS SENSOR
L1
B
L1
2nd SPEED
SOLENOID VALVE
M
5
X413
V1
C
A
LG1
1st SPEED
SOLENOID VALVE
X416
X414
X402
7
X402
HYDRAULIC MOTOR
SOLENOID VALVE
SEAT
MICRO-SWITCH
X401
2 SPEED
MICRO-SWITCH
G1
2nd SPEED SOLENOID VALVE
DIAGNOSTIC
+12V
GROUND
1st SPEED SOLENOID VALVE
ERROR LAMP
REVS SENSOR GND
REVS SENSOR SIGNAL
1st SPEED MICRO SIGNAL
HYDRAULIC MOTOR
SOLENOID VALVE
+12V
RELAY IN
DIAGNOSTIC
LG1
st
1 SPEED
MICRO-SWITCH
X410
X411
G1
2nd SPEED MICRO SIGNAL
RELAY IN
X412
L1
nd
G1
GROUND
10
Z1
31
G1
Page
G-16
Document 57.0007.0200 - 01/2006
48
50
51
MN1 LN1
BR1
RG1
L1
REXROTH
CONTROL UNIT
1A
30
ERROR LAMP
11
2nd SPEED
LIGHT
87
15
7,5A
86 87a
17
G1
F404
+12V
27
85
F405
87
N1
28
86 87a
S1
29
M1
X403
X415
X400
V1
30
RN1
32
LB1
33
RN1
BR1
37
X334
X334
41
1
1
B/R1
9
S1
RN1
42
5.5
RN1
52
VN1
D
C
H
REXROTH DIAGNOSTIC
X409
A
B
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-3.2.10 Wiring diagram - Components description
Ref.
Description
A25
B1.1
B1.2
B2
B5
B6
B10
B11
B13
3B6 OVERLOAD WARNING SYSTEM
LOW BOOM SENSOR
HIGH BOOM SENSOR
ENGINE OIL PRESSURE
THERMOMETER - ENGINE WATER
AIR FILTER RESTRICTION PRESSURE SWITCH
REAR AXLE SENSOR
HYDRAULIC OIL LEVEL
THERMOMETER - HIGH HYDRAULIC OIL
TEMPERATURE
HYDRAULIC OIL FILTER RESTRICTION
FUEL LEVEL SENSOR
BRAKE FAILURE SENSOR
RPM SENSOR
SPEED ALARM SENSOR
REAR RIGHT LIGHT
LICENCE PLATE LIGHT
REAR LEFT LIGHT
FRONT RIGHT LIGHT
FRONT LEFT LIGHT
REAR RIGHT WORK LIGHT
CAB INTERIOR LIGHTS
REAR LEFT WORK LIGHT
BEACON
REAR WORK LIGHTS
10A FUSE - EMERGENCY LIGHT
15A FUSE - HEATING
5A FUSE - STOP LIGHTS MICRO-SWITCH
7.5A FUSE - REAR WINDSCREEN WIPER
10A FUSE - WORK MODE SELECTOR
15A FUSE - LOW BEAM
3A FUSE - RIGHT POSITION LIGHTS SWITCH
3A FUSE - INSTRUMENTS LIGHTING
7.5A FUSE - INDICATOR LIGHTS POWER
SUPPLY
7.5A FUSE - LIGHTS SWITCH
7.5A FUSE - BEACON
10A FUSE - WORK LIGHTS
10A FUSE
10A FUSE - DRIVE SWITCH
10A FUSE - HIGH BEAM
15A FUSE - EMERGENCY
10A FUSE - LIGHTS AND FLASHING
10A FUSE - OUTRIGGERS
10A FUSE - WORK MODE SELECTOR
10A FUSE - PLATFORM EMERGENCY BUTTON
15A FUSE - HORN
15A FUSE - PLATFORM FUNCTION
10A FUSE - CAB LIGHTS
FUSE - EMERGENCY BUTTON
B14
B15
B17
B35
B36
E2
E6
E9
E24
E25
E301
E302
E303
E304
E340
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
Sheet
7
7
7
1
1
1
7
1
4
1
4
6
3
6
4
4
4
4
4
4
6
4
6
4
5
6
4
6
8
4
4
4
6
4
6
4
7
3
4
5
4
7
4
2
4
1
6
8
Page
Ref.
Description
F25
F26
F27
FM1
FM2
G1
G4
H1
H2
H3
H3A
H4
H9
H23
K01
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K11
K12
K13
K14
K15
K16
K17
K18
K19
K20
Sheet
10A FUSE - 3B6 CONTROL UNIT
10A FUSE - OUTRIGGERS
FUSE - OPTIONAL
MAXI FUSE 1
MAXI FUSE 2
BATTERY
ALTERNATOR
S1 SWITCH INDICATOR LIGHT
S2 SWITCH INDICATOR LIGHT
S3 SWITCH INDICATOR LIGHT
BACK-UP HORN
S4 SWITCH INDICATOR LIGHT
LIGHT INDICATOR - BASKET ENABLED
HORN
RELAY - START-UP
RELAY - HIGH BEAM
RELAY - LOW BEAM
RELAY - HORN
RELAY - WORK LIGHTS
RELAY - 1ST-2ND MECHANICAL SPEED
RELAY - OPTIONAL
RELAY - FORWARD SPEED
RELAY - REVERSE SPEED
RELAY - TRANSMISSION DISCONNECTED
RELAY - TRANSMISSION DISCONNECTED
RELAY - START-UP ENABLING COMMAND
RELAY - ELECTROSTOP
RELAY - EMERGENCY PUMP
RELAY - OUTRIGGERS
RELAY - IN/OUT MOV.
RELAY - UP/DOWN MOV.
RELAY - TURRET ROTATION
RELAY - OPTIONAL
RELAY - FORK COUPLING
RELAY - PLATFORM OVERLOAD
WARNING SYSTEM ON
K21 RELAY - POWER SUPPLY FROM PLATFORM
K22 PLATFORM INTERMITTENCE
K23 FLASHING FUNCTION
K24 TIMER
K36 RELAY - AUX CIRCUIT MAIN LINE
M3
A/C SYSTEM MOTOR
M7
STARTING MOTOR
M13 FRONT WIPER MOTOR
M300 REAR WIPER MOTOR
M305 HEATER
M306 WINDSCREEN WASHER MOTOR
P1
INSTRUMENT
P75 HYDRAULIC OIL TEMPERATURE INSTRUMENT
S1
SWITCH - LH FRONT OUTRIGGER
G-17
Document 57.0007.0200 - 01/2006
7
8
5
1
1
1
1
6
6
6
3
6
7
4
1
4
4
4
4
3
3
3
3
3
3
1
2
2
8
9
9
9
7
7
9
9
7
5
3
2
6
1
5
6
6
5
1
4
8
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
Ref.
Description
S2
S3
S4
S6a
S6b
S10
S11
S13
S14
S16
S22
S28
S29
S30
S31
SWITCH - RH FRONT OUTRIGGER
SWAY FUNCTION SWITCH
SWITCH - A/C SYSTEM
PARKING BRAKE PRESSURE SWITCH
PARKING BRAKE PRESSURE SWITCH
ARB SIGNAL FORCING
START-UP PANEL
EMERGENCY BUTTON
SWITCH - SPEED CHANGE
STOP LIGHT MICRO-SWITCH
STEERING SELECTOR
MICRO-SWITCH - RIGHT OUTRIGGER
MICRO-SWITCH - LEFT OUTRIGGER
PLATFORM FUNCTION INPUT
EMERGENCY MUSHROOM-HEAD
PUSHBUTTON
STEER SELECTOR POWER SUPPLY
JOBSITE ENABLING SIGNAL
3B6 PLATFORM SCALE DISABLING CMD
EMERGENCY STOP BUTTON +50
FOG LIGHT SWITCH
POSITION LIGHTS SWITCH
HEATER SWITCH
WARNING SWITCH
EMERGENCY PUMP SWITCH
WORK LIGHTS SWITCH
BATTERY CUTOFF
MANIPULATOR
LIGHT SWITCH
SPEED SELECTOR
PLATFORM
DIAGNOSTIC INTERFACE
MAIN SOLENOID VALVE
SOLENOID VALVE - ENGINE STOP
SOLENOID VALVE - UP/DOWN MOV.
SOLENOID VALVE - FORK ROTATION
SOLENOID VALVE - FORK IN/OUT MOV.
SOLENOID VALVE - ATTACHMENT
LOCKED-UNLOCKED
SOLENOID VALVE - FORWARD SPEED
SOLENOID VALVE - REVERSE SPEED
SOLENOID VALVE - RIGHT SWAY
SOLENOID VALVE - LEFT SWAY
SOLENOID VALVE - RIGHT OUTRIGGER DOWN
SOLENOID VALVE - RIGHT OUTRIGGER UP
SOLENOID VALVE - LEFT OUTRIGGER DOWN
SOLENOID VALVE - LEFT OUTRIGGER UP
SOLENOID VALVE - FOUR-WHEEL STEER
SOLENOID VALVE - CRAB STEER
SHOCK-ABSORBER BLOCK SOLENOID VALVE
SHOCK-ABSORBER BLOCK SOLENOID VALVE
SOLENOID VALVE - 1st SPEED
S32
S33
S34
S54
S78
S80
S82
S87
S171
S308
SB1
SX10
SX11
SX12
X28
X90
Y08
Y1
Y4
Y5
Y6
Y7
Y8
Y9
Y10
Y11
Y12
Y13
Y14
Y15
Y18
Y19
Y30
Y31
Y33
Sheet
8
8
6
7
7
7
1
2
3
4
8
7
7
7
7
7
7
7
2
4
4
6
5
2
4
1
9
5
3
9
8
9
1
9
9
9
9
3
3
8
8
8
8
8
8
8
8
9
9
3
Page
Ref.
Description
Y34
X1
X1.1
X1.2
X1Y
X3A
X4
X4A
X5
X5A
X6
X6A
X7
X7A
X8
X8A
X9
X10
X10A
X10B
X11
X11A
X12
X12A
X13
X13A
X14
X15
X16
X17
X18
X18A
X19
X19A
X20
X21
X22
X25
X26
X28
X28A
X29
X29A
X30
X30A
X31
X33
X34
X35
X36
X61
X75
SOLENOID VALVE - 2nd SPEED
40-WAY DEUTSCH CONNECTOR - TYPE B
3-WAY DEUTSCH CONNECTOR
3-WAY DEUTSCH CONNECTOR
2-WAY 90° CONNECTOR
2-WAY CONNECTOR
9-WAY MARK CONNECTOR
3-WAY CONNECTOR
11-WAY MARK CONNECTOR
3-WAY CONNECTOR
17-WAY MARK CONNECTOR
3-WAY CONNECTOR
13-WAY MARK CONNECTOR
5-WAY MARK CONNECTOR
3-WAY CONNECTOR
2-WAY CONNECTOR
13-WAY MARK CONNECTOR
9-WAY MATE’N’LOCK CONNECTOR
2-WAY CONNECTOR
3-WAY DEUTSCH CONNECTOR
13-WAY MARK CONNECTOR
2-WAY CONNECTOR
5-WAY MARK CONNECTOR
2-WAY CONNECTOR
6-WAY CONNECTOR
2-WAY CONNECTOR
2-WAY CONNECTOR
2-WAY CONNECTOR
13-WAY MARK CONNECTOR
17-WAY MARK CONNECTOR
13-WAY MARK CONNECTOR
2-WAY CONNECTOR
21-WAY MARK CONNECTOR
2-WAY CONNECTOR
17-WAY MARK CONNECTOR
40-WAY DEUTSCH CONNECTOR - TYPE B
12-WAY DEUTSCH CONNECTOR
12-WAY DEUTSCH CONNECTOR
17-WAY MARK CONNECTOR
24-WAY DEUTSCH CONNECTOR
4-WAY DEUTSCH CONNECTOR
24-WAY DEUTSCH CONNECTOR
4-WAY DEUTSCH CONNECTOR
2-WAY CONNECTOR
2-WAY CONNECTOR
2-WAY CONNECTOR
2-WAY CONNECTOR
2-WAY CONNECTOR
3-WAY DEUTSCH CONNECTOR
2-WAY 90° CONNECTOR
3-WAY DEUTSCH CONNECTOR
6-WAY CONNECTOR
G-18
Document 57.0007.0200 - 01/2006
Sheet
3
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
Ref.
Description
X90
X300
X301
X303
X305
X306
X340
XE2
XE24
XE25
XE9
XG4
XJ1
XJ2
XY8
XY9
4-WAY DEUTSCH CONNECTOR
2-WAY CONNECTOR
6-WAY DEUTSCH CONNECTOR
6-WAY DEUTSCH CONNECTOR
4-WAY CONNECTOR
2-WAY 90° CONNECTOR
6-WAY DEUTSCH CONNECTOR
6-WAY DEUTSCH CONNECTOR
6-WAY DEUTSCH CONNECTOR
6-WAY DEUTSCH CONNECTOR
6-WAY DEUTSCH CONNECTOR
4-WAY CONNECTOR
24-WAY FCI SICMA-2 CONNECTOR
24-WAY FCI SICMA-2 CONNECTOR
2-WAY CONNECTOR
2-WAY CONNECTOR
Sheet
WIRE COLOURS
A
B
C
G
H
L
M
N
R
S
V
Z
LIGHT BLUE
WHITE
ORANGE
YELLOW
GREY
BLUE
BROWN
BLACK
RED
PINK
GREEN
PURPLE
REMARK: Two-colour wires are indicated through a
combination of the aforesaid initials as follows:
G/V = YELLOW/GREEN (crosswise colouring)
G-V = YELLOW-GREEN (lengthswise colouring)
Page
G-19
Document 57.0007.0200 - 01/2006
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
INTENTIONALLY BLANK PAGE
Page
G-20
Document 57.0007.0200 - 01/2006
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
G-4 HYDRAULIC SCHEME - GTH-4013 (Drw. 57.2201.2200 - rev. B)
capacity:
Pressure
0.5 Litri
switch
precharge
pressure activating
pressure
50 bar
2-10 bar
Pressure
switch
activating
pressure
70 bar
F R
R2 R1
Quick coupling
hydraulic ports
N’
Double overcenter safety valve
piloting ratio: 4.2 /1
cracking pressure: 350 bar
Double overcenter safety valve
piloting ratio: 4.2 /1
cracking pressure: 350 bar
Stabilizers/chassis levelling
main valve
Double overcenter safety valve
piloting ratio: 4.2 /1
cracking pressure: 350 bar
B3
Chassis levelling cylinders
A3
Right stabilizer cylinder
Left stabilizer cylinder
Ev11
1
0
1
0
1
0
B2
T1’
Ev12
A2
Ev10
A1
B
T2’
150 bar
Hydraulically piloted
double check valve
Forks attachment
quick coupling cylinder piloting ratio: 4 /1
Double overcenter safety valve
piloting ratio: 4 /1
cracking pressure: 350 bar
Front axle
Rear axle
T2
2
Ev9
B1
T1
P
2
2
Ev7
Ev8
Auxiliaries functions
Tp4 hydraulic circuit test port
T
P
210 bar
Third section boom
telescoping cylinder
N
Hydraulically powered
service/emergency brakes
pedal pump
Forks tilt cylinder
T1
Tp Pp
A
B
A
Rear axle
steering cylinder
T P
Front axle
steering cylinder
R
Anti-shock
valves
cracking
pressure
200 bar
B
Single overcenter safety valve
piloting ratio: 4/1
cracking pressure: 350 bar
Ev4
Ev3
Steering modes
selector valve
4 ways / 3 positions
Forks levelling
slave cylinder
2
2
B
Rear axle pivoting
lockout valve
2 ways / 2 positions
0
1
Pv3
2
B
0
1
E
L
Pv2
Ev15
Ev14
Anticavitation valve
cracking pressure
5 bar
capacity:
0.5 Litri
precharge
pressure
40 bar
Rear axle pivoting
lockout cylinder
LS
Second section boom
telescoping cylinder
Double overcenter safety valve
piloting ratio: 4/1
cracking pressure: 350 bar
290 bar
290 bar
2
B
0
1
T
Ev13
P
270 bar
Check valve
cracking pressure:
0.5 bar (option)
T
Boom functions hydraulic
circuit test port
RPM
Pp
M
Emergency electrical
motor driven pump set
3.2 cc/rev (option)
Hydrostatic transmission
Tp2
high pressure test port
T1 T2
Tp
Tp1
Check valve
cracking pressure:
0.5 bar (option)
Ev2
P
MPR
Check valve
cracking pressure:
8 bar (option)
Boom lift cylinder
R
G1
LS
FLT
Single overcenter safety valve
piloting ratio: 4/1
cracking pressure: 350 bar
Ev1
Tank lines
E
Pv1
T
Check valve
cracking pressure:
2.5 bar
Auxiliary gear pump
brakes/stabilizers /chassis levelling
displacement: 20 cc/rev
Hydrostatic transmission
high pressure lines
Boom / steering, brakes, stabilizers
and chassis levelling functions lines
Low pressure and transmission
charge pressure lines
Hydrostatic transmission and
boom functions valve piloting lines
Boom / steering, auxiliary and
transmission pumps suction lines
E
200 bar
A
Steering rotating actuator
displacement: 315 cc /rev
Max relief valve
cracking
pressure
140 bar
Boom / steering, brakes, stabilizers,
chassis levelling pump pressure lines
A
A
P
HYDRAULIC CIRCUIT
COLORS LEGENDA
1
Pv4
Boom functions
main valve
Double overcenter safety valve
piloting ratio: 7.6 /1
cracking pressure: 350 bar
0
PS
Fa
Fa1
Fe
Heat exchanger
MB
T
450 bar
P
B
Ev6
Ev5
U
B
X2
X1
M1
B A
M
Mechanical gear speed
selector valve
4 ways/3 positions
450 bar
430 bar
25 bar
A
Diesel engine
Mechanical gear speed
selector actuator
Boom functions pump
with integrated priority valve
displacement: 43 cc/rev
T2
X2
Hydrostatic transmission pump
max displacement: 71 cc/rev
G
X1
Hydrostatic transmission Tp3
boost pressure test port
Suction screen
Page
G-21
Document 57.0007.0200 - 01/2006
MH
S FS
MA
A
G
Mechanical gear (2 speeds)
Suction screen
Check valve
cracking pressure:
8 bar
T
Flushing valve
Hydrostatic transmission motor
max displacement: 80 cc/rev
Return filter
with suction line
pressurized at 0,5 bar
Oil tank
capacity
130 liters
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
INTENTIONALLY BLANK PAGE
Page
G-22
Document 57.0007.0200 - 01/2006
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
Table key explanation:
Page
G-23
Document 57.0007.0200 - 01/2006
EMERGENCY
ARB + Display
Limit switch 5
Limit switch 4
Limit switch 3
Limit switch 2
Limit switch 1
Block.Valve 9
Block.Valve 8
Block.Valve 7
Block.Valve 6
Block.Valve 5
Block.Valve 4
Block.Valve 3
Block.Valve 2
Date
Block.Valve 1
COMPONENT
Joystick button
G-5 ROUTINE CHECK SCHEDULE - SAFETY DEVICES
Result/Notes
Positive
Negative Signature
Block valve 1
Block valve on lifting cylinder
Block valve 2
Block valve on fork balance cylinder
Block valve 3
Block valve on telescope extension cylinder
Block valve 4
Block valve on attachment moving cylinder
Block valve 5
Block valve on attachment locking cylinder
❑
❑
Block valve 6
Block valve on front right outrigger cylinder
❑
❑
Block valve 7
Block valve on front left outrigger cylinder
❑
❑
Block valve 8
Block valve on machine sway cylinder
❑
❑
Block valve 9
Block valve on rear axle locking cylinder
❑
❑
❑
❑
Limit switch 1
Limit switch - front right outrigger
❑
❑
Limit switch 2
Limit switch - front left outrigger
❑
❑
Limit switch 3
Limit switch on parking brake
❑
❑
❑
❑
Limit switch 4
Limit switch on boom (left side)
❑
❑
Limit switch 5
Limit switch on boom (right side)
❑
❑
❑
❑
❑
❑
❑
❑
ARB + Display
Solenoid valve - overload warning system - Electronic card and display
❑
❑
EMERGENCY
Emergency stop pushbutton
❑
❑
Joystick button
Dead man pushbutton on control lever
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
Handler with telescopic boom GTH-4013
TABLES AND DOCUMENTS ENCLOSED
INTENTIONALLY BLANK PAGE
Page
G-24
Document 57.0007.0200 - 01/2006
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