Operator`s Manual - Genie Industries

Operator`s Manual - Genie Industries
Operator’s Manual
Serial number range
FIXED HOOK on
PLATE
From serial n.: 61606
4000mm/900kg JIB
From serial n.: 61902
2000mm/2000kg JIB
From serial n.: 61903
3000kg HOIST
From serial n.: 61958
With Maintenance
Information
First Edition
First Printing
Part No. 57.0303.5159
Operator’s Manual
First Edition - First Printing
Important
Contents
Read, understand and obey these safety rules
and operating instructions before operating the
machine. Only trained and qualified personnel
shall be authorized to operate the machine.
This manual shall be kept with the machine at
all times.
Introduction ..........................................Page
Equipment Identification ......................Page
Labels And Plates Applied...................Page
Safety Precautions ..............................Page
Equipment Description ..........................Page
Inspections ..........................................Page
Operating Instructions .........................Page
Maintenance ........................................Page
Faults And Troubleshooting.................Page
Specifications ......................................Page
Load Charts .........................................Page
Diagrams And Schemes ......................Page
Beaufort Wind Scale ............................Page
Tables of Material ................................Page
EC Declaration of Conformity ..............Page
Routine Check List ..............................Page
For any further information, please call
Terexlift.
Contact us:
ZONA INDUSTRIALE I-06019 UMBERTIDE
(PG) - ITALY
Telephone +39 075 941811
Telefax +39 075 9415382
Technical Assistance Service
Telephone: +39 075 9418129
+39 075 9418175
e-mail: [email protected]
Original Instructions
First Edition: First Printing, May 2011
For the electronic version of this manual visit
www.genielift.com/operator_manuals.asp
Copyright © 2011 TEREXLIFT srl
All rights reserved
Produced by:
TEREXLIFT Technical Literature Dept.
Umbertide (PG) Italy
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Operator’s Manual
Introduction
Symbols
Safety alert symbol: used to
alert you to potential personal
injury hazards. Obey all safety
messages that follow this
symbol to avoid possible
injury or death
DANGER
Red: indicates a hazardous
situation which, if not avoided,
will result in death or serious
injury.
WARNING Orange: indicates a hazardous
situation which, if not avoided,
could result in death or serious
injury.
CAUTION
NOTICE
PROTECT THE
ENVIRONMENT
Yellow : indicates a hazardous
situation which, if not avoided,
could result in minor or
moderate injury.
Blue: indicates a hazardous
situation which, if not avoided,
could result in property
damage.
Green: used to draw the
attention to important
information on environment
protection.
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Operator’s Manual
Equipment Identification
Check that the Operator's Manual refers to the
delivered equipment.
DESIGNATION:
 FIXED HOOK ON PLATE
 JIB
 HOIST
IDENTIFICATION PLATE
The following data plate is applied on the equipment.
The identification plate contains model, designation,
serial number, weight, payload and year of
manufacture, as shown below.
MODEL:
 Fixed Hook on Plate
 4000mm/900kg Hydraulic Jib
 4000mm/900kg Jib
 2000mm/400kg Jib
 2000mm/2000kg Jib
 3000kg Hoist
Model:
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
Model Year: AAAA
Designation:
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
Serial number:
AAAAAAAAAA
Manufacture Year:
AAAA
Unit mass (Kg) :
AAAAAAAAA
Rated capacity: MMMM MMMMMMMMM
Center of gravity from mounting face (mm): AAAAAAAAA
Country of Manufacture: ITALY
Manufacturer:
Terexlift srl z.i.Buzzacchero
06019 Umbertide, Italy
MANUFACTURER:
TEREXLIFT srl
Zona Industriale - I-06019 UMBERTIDE (PG) ITALY
Enrolled in the register of companies at the Court of
Perugia under no. 4823
C.C.I.A.A. 102886
Fiscal Code/V.A.T. no. 00249210543
APPLICABLE STANDARDS
For the operator’s safety, the following standards were
obeyed during the risk assessment of the handler
fitted with telescopic boom norme:
Directive
Title
2006/42/EC
Machinery Directive
Standard
Title
EN 1459:1988/A2:2009 Safety of Industrial trucks Self- propelled variable reach trucks.
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Operator’s Manual
Labels And Plates Applied
Use the pictures on these pages to verify that all labels and plates are legible and in place.
The following chart shows quantities and description too.
Ref.
Decal
Code
1
900 kg
/
2
Description
PLATE_Maximum payload.
ONLY for 4000mm/900kg JIB
09.4618.1346 Entanglement Hazard
Qt.
1
1
09.4618.1346
Model:
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
Model Year: AAAA
Designation:
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
A
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
Serial number:
AAAAAAAAAA
Manufacture Year:
AAAA
Unit mass (Kg) :
AAAAAAAAA
/
IDENTIFICATION PLATE
1
Rated capacity: MMMM MMMMMMMMM
Center of gravity from mounting face (mm): AAAAAAAAA
Country of Manufacture: ITALY
Manufacturer:
Terexlift srl z.i.Buzzacchero
06019 Umbertide, Italy



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Operator’s Manual
Safety Precautions
DAMAGED MACHINE HAZARDS
•
•
•
•
•
SAFETY DEVICES
Do not use a damaged or modified equipment.
Do a thorough pre-operation inspection of the
equipment and test all functions before each work
shift. Tag and remove from service a damaged
or modified equipment.
Make sure that all maintenance jobs have been
carried out as specified in this manual and in the
telehandler's specific manuals.
Make sure that all plates are in place and legible.
Make sure that the operator’s manual is intact,
legible and placed in the special container located
in the machine.
Several safety devices have been fitted to the
telehandler. They must never be tampered with
or removed.
Regularly check the efficiency of such devices.
In case of faults, stop working immediately and
proceed in replacing the modified device.
For the checking procedures, read chap.
"Maintenance" of the telehandler Operator's
Manual.
PERSONAL INJURY HAZARDS
•
•
•
Do not operate the equipment in case of hydraulic
oil or air leak of the telehandler. Air or hydraulic
oil leaks can penetrate or burn the skin.
Always operate the telehandler 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.
Part No. 57.0303.5159
MOMENT LIMITING SYSTEM
The moment limiting system has been developed
to help the operator to maintain the telehandler
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.
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Safety Precautions
GENERAL REMARKS
Not observing the instructions
and safety rules in this manual
may result in death or serious
injury.
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 telehandler.
Do not operate the equipment unless:
•
•
•
•
•
10
You learn and practice the principles of safe work
equipment 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 equipment functions prior
to use.
4. Inspect the work place.
5. Only use the equipment 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 equipment.
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 equipment.
NOTICE
If you recognise hazardous situations, you can
prevent accidents!
DANGER
The instructions given in this handbook are the
ones established by TEREXLIFT. They do not
exclude other safe and most convenient ways for
the telehandler and/or the equipment 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
telehandler and/or the equipment, directly or
indirectly, or make it unsafe;
• contact TEREXLIFT Assistance Service for any
suggestion and the necessary written permission.
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Operator’s Manual
Safety Precautions
REQUISITES OF THE PERSONNEL IN CHARGE
Requisites of the TELEHANDLER OPERATORS
The operators who use the telehandler and/or the
equipment, regularly or occasionally, 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. They shall be
skilled and trained about the telehandler and/or the
equipment use.
NOTICE
Requisites of the SERVICEMEN
The personnel charged with the telehandler and
the equipment maintenance shall be qualified,
specialized in their maintenance, 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.
NOTICE
From a technical point of view, the ordinary
maintenance of the telehandler and/or the
equipment is not a complex intervention and can
be carried out by the operator too, provided he
has a basic knowledge of mechanics.
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.
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Safety Precautions
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.
• Ear-protectors or equivalent equipment.
• Protective helmet.
• Protective gloves.
• Working shoes.
OTHER DANGERS
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 telehandler dimensions in the different
configurations.
DANGER
The telehandler 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!
• Keep away from the machine in case of contact
with energized power lines. Personnel on
the ground must never touch or operate the
telehandler until energized power lines are shut
off.
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
Use only type-approved working clothing in good
condition.
Personal PROTECTIVE EQUIPMENT
Under special working conditions, the following
personal protective equipment should be used:
• Breathing set (or dust mask).
• Goggles or facial masks.
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
DANGER
Do not, at any time, use the machine during a
storm.
WARNING
Operator have to survey his/her field of vision
when operating the telehandler.
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Operator’s Manual
Safety Precautions
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.
•
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.
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.
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.
WARNING
Set the telehandler to working configuration and
level it.
•
•
•
•
•
Ensure you have enough fuel to avoid a sudden
stop of the engine, especially during a crucial
manoeuvre.
Clean instruments, data plates, lights and the cab
windscreen thoroughly.
Check the correct functioning of all the safety
devices installed on the telehandler and/or on
the equipment.
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.
•
•
•
•
•
•
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Safety Precautions
•
•
•
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.
WARNING
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.
•
•
•
14
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.
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.
Before any maintenance or repair work, remove
the attachment.
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.
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Safety Precautions
EXPLOSION OR FIRE hazards
•
•
•
•
•
•
•
•
•
DAMAGED COMPONENT hazards
Do not start the engine if you smell or detect
LPG, gasoline, diesel fuel 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.
Part No. 57.0303.5159
•
•
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.
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.
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Safety Precautions
SUSPENDED LOAD HAZARDS
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
16
A suspended load has a dynamic, and therefore
unpredictable, effect on machine stability, so
extreme caution should always be exercised
when operating with suspended loads.
Only lift the load when the telehandler is on firm
level ground.
Do not operate the machine while people are
under a suspended load.
All movements of the load must be accomplished
at lowest possible speed.
Do not lift loads when wind speeds exceed 20
mph (32 kmh).
Level the telehandler before lifting the load.
Use guide ropes or tag lines by qualified
personnel to help control the load and prevent it
from swinging.
Do not attempt to use the telehandler frameleveling to compensate for a swinging load.
Never drag the load.
Do not try to move fixed or obstructed loads.
Only lift a load vertically; do not pull a load
horizontally as it could cause excessive swinging
of the load.
When visibility is or could be obstructed, the
operator shall use alternative/additional means
to safely transport the load.
Use of additional personnel to direct the operator
in his movements as well as surrounding ground
traffic.
Speed shall be limited by any conditions that
could cause any unexpected movement of the
load, or jeopardize the safe transport of the load.
The boom shall be fully retracted during travel.
Only travel on solid surfaces.
Start, travel, turn and stop slowly to prevent the
load from becoming unstable or swing.
Do not exceed walking speed.
The load shall be transported as low to the ground
as practical.
Do not use any controls for re-positioning the load
when traveling. Come to a gradual and complete
stop before attempting to re-position the load.
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Part No. 57.0303.5159
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Operator’s Manual
Equipment Description
JIB AND HOIST MAIN COMPONENTS
1. Quick couplings (if any)
2. Hook
3. Coupling frame
4. Winch







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Equipment Description
HOIST GENERAL DESCRIPTION
JIB GENERAL DESCRIPTION
This attachment is used to handle payloads which
are suspended by a rope system.
It mainly consists of a steel truss beams welded
structure which is provided with two lateral flanges
having mechanical slots (on the upper area) and
holes (in the lower area) to be coupled with the GTH
telehandlers standard interface. These two lateral
flanges are connected together (by welding) through
a central steel plate which is then welded to the truss
beams structure.
The truss beam welded structure is shaped to have,
in its lower end, four supporting feet sustaining the
attachment when it is on the ground and not linked
to the telehandler.
The hydraulic hoist is installed on the front surface
of the central steel plate. The hoist is hydraulically
powered through the auxiliary line provided at the
end of the telescopic boom. The hydraulic connection
between this line and the hoist is provided through
two hydraulic quick coupling adapters. This hoist
is equipped with a mechanical drum where a steel
rope is winded.
The end of the steel rope is linked directly or through
a steel pulley (depending on the model of the
attachment) to a certified hook, capable to lift the
payload.
The hook is certified to handle the payload defined
for this attachment (its structural strength meets
or exceeds the maximum payload defined for the
complete attachment).
A special hydraulic switch is installed close to the
hook area with the aim to signal when the hook is
completely lifted up.
When the hook is completely lifted up no hydraulic
pressure is provided to the hoist so avoiding any not
necessary overload on the jib structural components.
18
This attachment is used to handle payloads which
is suspended by a rope system.
It mainly consists of a steel truss beams welded
structure which is provided with two lateral flanges
having mechanical slots (on the upper area) and
holes (in the lower area) to be coupled with the GTH
telehandlers standard interface.
These two lateral flanges are connected together (by
welding) through a central steel plate which is then
welded to the truss beams structure.
The truss beam welded structure is shaped to
have, in its forward end, a mechanical link for the
connection to a certified steel hook.
The hook is certified to handle the payload defined
for this attachment (its structural strength meets
or exceeds the maximum payload defined for the
complete attachment).
The hydraulic version of this attachment is provided
with an hydraulic hoist installed inside the truss
beam structure immediately ahead of the central
steel plate.
The hoist is hydraulically powered through the
auxiliary line provided at the end of the telescopic
boom.
The hydraulic connection between this line and
the hoist is provided through two hydraulic quick
coupling adapters.
This hoist is equipped with a mechanical drum where
a steel rope is winded.
The end of the steel rope is linked to the certified
hook, placed at the end of the truss beams structure.
The rope is guided, between the hoist drum and the
hook, by steel pulleys installed inside the truss beam
structure and at the end of the truss beams structure.
At the end of this structure a special hydraulic switch
is installed with the aim to signal when the hook is
completely lifted up.
When the hook is completely lifted up no hydraulic
pressure is provided to the hoist so avoiding any not
necessary overload on the jib structural components.
HOOK - JIB - HOIST
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Equipment Description
HOOK MAIN COMPONENTS
1. Hook
2. Coupling frame

HOOK GENERAL DESCRIPTION
This attachment is used to handle payloads which
is suspended by a rope system.
It mainly consists of a steel welded structure which is
provided with two lateral flanges having mechanical
slots (on the upper area) and holes (in the lower
area) to be coupled with the GTH telehandlers
standard interface.
The welded structure is shaped to have, in its central
part, a structural beam protruded forward and having
at the front end a mechanical link for the connection
to a certified steel hook.
The hook is certified to handle the payload defined
for this attachment (its structural strength meets
or exceeds the maximum payload defined for the
complete attachment).

Part No. 57.0303.5159
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Equipment Description
ALLOWED USE
IMPROPER USE
The hoist and the jib are designed to vertically raise
and lower loads by winding and unwinding the cable
around the drum.
Any other use is considered contrary to what
established and, therefore, improper.
The compliance with and the strict respect of the
use, maintenance and repair instructions of the
Manufacturer represent an essential part of the
allowed use.
The use, maintenance and repair of the equipment
shall be carried out by skilled personnel having the
necessary knowledge of its special features and the
safety precautions to be taken.
It is also essential to comply with the national safety
at work legislation, the provisions concerning the
safety and health of workers at work, and the road
traffic regulations.
NOTICE
Effecting changes or carrying out interventions
on the telehandler and/or on the equipment
other than those of routine maintenance is
expressly forbidden. Any modification of the
telehandler and/or of the equipment not carried
out by TEREXLIFT or an authorised assistance
centre involves the automatic invalidation of the
conformity of the machine.
20
Improper use means any utilisation of the equipment
following working criteria which do not comply with
the instructions of this manual, and which, in general,
may result in risks for both operator and bystanders .
DANGER
We list below some improper use of the jibs/
hoists. Others may exist.
Not strictly complying with the operation and
maintenance instructions of this handbook
and of the telehandler handobook;
Never use the jibs/hoists to lift and/or
transport people;
Working beyond the operation limits of the
euipment;
Working or resting the machine on unstable
or yielding grounds;
Working on steep slopes or working with a
nonlevelled telehandler;
Fit mobile guards that may increase the wind
action and jeopardise the stability of the
machine;
Using telescopic handlers not approved
or not manufactured by TEREXLIFT in
combination with these attachments;
Attach loads to the boom anywhere other
than on the quick coupling frame.
HOOK - JIB - HOIST
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Equipment Description
EQUIPMENT APPLICATION FIELD
The following table represents the application field of equipment installed on Terexlift telehandlers
2500kg Fixed 5000kg Fixed
Hook on Plate Hook on Plate
GTH-2506
4000mm /
900kg
Hydraulic or
Mechanical
Jib

2000mm /
2000kg
Jib
3000 kg Hoist

GTH-3007



GTH-4013SX
GTH-4017SX




GTH-4013EX
GTH-4017EX




GTH-4016SR
GTH-4018SR




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Intentionally blank page
22
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Part No. 57.0303.5159
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Operator’s Manual
Inspections
Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
Make sure:
You learn and practice the principles of safe
machine operation contained in this operator's
manual and in the telehandler one.
1. Avoid hazardous situations.
2. Always perform a pre-operation
inspection.
Know and understand the pre-operation
inspection before going on to the next
section.
3. Always perform function tests prior to use.
4. Inspect the workplace.
5. Only use the telehandler and the equipment
as they were intended.
The pre-operation inspection is a visual inspection
performed by the operator prior to each work shift.
The inspection is designed to discover if anything
is apparently wrong with a telehandler and/or with
an equipment before the operator performs the
function tests.
The pre-operation inspection also serves to
determine if routine maintenance procedures are
required. Only routine maintenance items specified
in this manual may be performed by the operator.
If damage or any unauthorized variation from
factory delivered condition is discovered, the
telehandler and/or the equipment must be tagged
and removed from service.
Repairs to the telehandler and/or the equipment
may only be made by a qualified service
technician, according to the manufacturer's
specifications. After repairs are completed, the
operator must perform a pre-operation inspection
again before going on to the function tests.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer's specifications.
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Operator’s Manual
First Edition - First Printing
Inspections
PRE-OPERATION INSPECTION
NOTICE
For the Maintenance and the Pre-operation
Inspection of the telehandler, refer to the specific
Operator's Manual presents placed inside the
cabin.
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.
For the equipment:
• Make sure the operator’s manuals are intact,
legible and placed inside the telehandler.
• Make sure all decals are present and legible. See
“Labels And Plates Applied” chapter.
• Check for hydraulic oil leaks and proper oil level.
Top up if necessary. See “Maintenance” chapter.
Check the following components or zones for
damage, missing or wrongly fitted parts or nonauthorised modifications:
• electrical components and electrical cables
• hydraulic hoses and fittings
• fuel and hydraulic oil tanks
• nuts, bolts and other fasteners
Check the entire structure for:
• cracks on welds or structural components
• dents or damage to the structure
WARNING
If even one single item is damaged or modified,
do not start work. Stop the machine and repair
the fault.
24
HOOK - JIB - HOIST
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Inspections
FUNCTION TESTS FUNDAMENTALS
The function tests are designed to discover
any malfunctions before the machine is put into
service. The operator must follow the step-bystep instructions to test all machine functions. A
malfunctioning machine must never be used. If
malfunctions are discovered, the machine must
be tagged and removed from service. Repairs
to the machine may only be made by a qualified
service technician, according to the manufacturer's
specifications. After repairs are completed, the
operator must perform a pre-operation inspection
and function tests again before putting the
machine into service.
Make sure:
TESTS
About the telehandler:
1. Select a test area that is firm, level and free of
obstruction.
2. Enter the operator's compartment and sit on the
seat.
3. Fasten the seat belt.
4. Adjust all the mirrors.
5. Be sure the parking brake is on and the
transmission control is in neutral.
6. Start the engine.
You learn and practice the principles of safe
machine operation contained in this operator's
manual and in the telehandler one.
1. Avoid hazardous situations.
2. Always perform a pre-operation
inspection.
Know and understand the pre-operation
inspection before going on to the next
section.
3. Always perform function tests prior to use.
Perform all the tests provided for the
telehandler and listed in the machine
Operator's Manual.
Test the Control Lever
4. Inspect the workplace.
7. Using the control lever, momentarily raise and
lower the rope.
5. Only use the telehandler and the equipment
as they were intended.
 Result: All functions should operate smoothly.
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Operator’s Manual
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Inspections
WORKPLACE INSPECTION
The workplace inspection helps the operator
determine if the workplace is suitable for safe machine
operation. It should be performed by the operator
prior to moving the machine to the workplace.
It is the operator's responsibility to read and remember
the workplace hazards, then watch for and avoid them
while moving, setting up and operating the machine
Be aware of and avoid the following hazardous
situations:
•
drop-offs or holes
•
bumps, floor obstructions or debris
•
sloped surfaces
•
unstable or slippery surfaces
•
overhead obstructions and high voltage
conductors
•
hazardous locations
•
inadequate surface support to withstand all
load forces imposed by the machine
•
wind and weather conditions
•
the presence of unauthorized personnel
•
other possible unsafe conditions
26
HOOK - JIB - HOIST
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Operating Instructions
This section provides the operator and the ground
staff a practical guide for the gradual learning of
the use of the telehandler fitted with either a hook,
jib or hoist.
Both operator and ground staff shall have all the
necessary requisites and shall become familiar
with both telehandler and equipment before starting
using them.
This familiarisation ensures a proper use during work.
WARNING
For a safe use of the telehandler with equipment,
before elevating any load, always know the weight
of the loads going to be handled.
WARNING
Before using the telehandler, 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.
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Operator’s Manual
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Operating Instructions
CHANGING THE EQUIPMENT
Version with MECHANICAL LOCKING
Version with HYDRAULIC LOCKING
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).
• Pull out pin 1 locking the attachment after
removing the safety split-pin 2 at its end.
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
and connect the hydraulic locking pipes of the
attachments to couplings 3.



•
•
•
•
•
•
•
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 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.
Refit pin 1 fixing it with its safety split-pin 2.
Re-couple the connectors of the attachment (if
any).
WARNING
After substitution, visually check the attachment
is correctly coupled to the boom, before operating
the machine. A wrongly coupled attachment may
result in death or serious injury.
28
•
•
•
•
•
•
•
•
•
Rest the attachment flat on the ground.
Remove the safety pin 2 placed at its end.
Free the attachment operating the control of the
attachment locking/unlocking cylinder
Pitch the attachment holding frame forward and
lower the boom to release the attachment upper
lock.
Move back with the machine and drive to the new
attachment to be coupled.
Hold the frame pitched forward and hook the
upper lock of the new attachment.
Retract and raise the attachment some
centimetres. It will centre automatically on the
quick coupling frame.
Operate the attachment locking lever and
secure the attachment in place with safety pin 2
previously removed.
Re-couple the connectors of the attachment.
HOOK - JIB - HOIST
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Operating Instructions
CONNECTING THE EQUIPMENT
n Hydraulic connection (if any)
To use the hoists or the hydraulic jib, these shall be
connected hydraulically as follows:
• after mounting the equipment as described
above, disconnect the hydraulic hoselines of
the attachment locking/release cylinder from
quick couplings 3,
• store the removed hoselines in rest position,
• connect the hydraulic hoselines of the winch to
the quick couplings 3.

This hydraulic connection allows winding/unwinding
the rope on/from the winch. The operation is
performed with the controls usually used for locking
and releasing the attachments, as described in the
relative paragraphes.
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Operator’s Manual
First Edition - First Printing
Operating Instructions
STABILITY CONTROL SYSTEM
All the telehandlers are equipped with an automatic
stability control system which warns the operator
of the variation of stability of the machine and
blocks any manoeuvre before the same reaches a
critical condition. A display inside the cabin shows
the stability status of the machine and the relative
equipment.
LLMI/ LLMC HAZARDS
The LLMI/LLMC will only function to the design
specification:
• when the truck is static;
• when the truck is on consolidated, stable and
level ground;
• when the truck is performing loading or placing
functions;
• when the LLMI/LLMC is activated (not
overridden);
The LLMI will only warn the operator in the event of
inadequate stability in the longitudinal plane in the
forward direction.
The LLMI/LLMC is not intended for warning of the
risk of overturning in the case of:
• a sudden overload;
• travelling with the load in the elevated position;
• travelling on rough terrain or on grounds with
obstacles and holes;
• travelling across a slope or turning on a slope;
• driving in bends too fast or too sharp;
Adjustments affecting the setting of the LLMI/LLMC
shall be performed only by authorised personnel.
The system changes according with the telehandler
and can easly be recognized depending on the
display fitted into the cabin:
MODEL N°1





1.
2.
3.
4.
5.
Used only for calibration
Stability indicator with LED-bar
Green light - power OK
Used for calibration. On machine models
provided with outriggers it lights up when
the outriggers are lowered.
Used only for calibration
Operation
When power is turned on, light 3, the led bar 2 and
button 4 and 5 come on.
The monitoring system runs a self-test.
During operation, the LED-bar 2 lights up gradually
depending on the variation of stability.
L6
L5
L4
L3
L2
L1
30
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LED Bar
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Operating Instructions
MODEL N°2
Green LED’s (L1 and L2): during normal operation
when the percentage of overturning moment is
between 0 and 89, these LED’s are ON. The machine
is stable.
Orange LED’s (L3 and L4): 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 99.
The system enters the pre-alarm mode: the buzzer
sounds with an intermittent sound and the boom
extension, lowering and forks forwards tilting
movements slow down.
Red LED’s (L5 and L6): risk of overturning! The
percentage of overturning moment is above 100 with
respect to the threshold value.
The machine enters the alarm mode: the buzzer
sounds continuously and any dangerous manoeuvre
is blocked: boom up, boom down, boom out, forks
frame forwards. The operator can only retract the
load within safety limits.
Alarm codes and resetting
The limiter has diagnostic facilities to aid in the
identification of failures of the transducers, breakages
of the cables or damages of the electronic system.
When a failure is signalled, the limiter enters the
safety mode blocking any dangerous manoeuvres:
LED L6 starts flashing representing an alarm code.
The meaning of these alarm codes is shown in section
“Faults and Troubleshooting”.
DANGER
Before using the machine, make sure that the first
green LED of the overload warning system is ON.
ESC
55%
+
-
1
2
3
FORKS
OUTRIGGERS LATERAL
MAX LOAD ........................ 50.3t
RAISED LOAD ................... 10.2t
ANGLE ............................... 12.3°
EXTENSION...................... 12.3m
RADIUS.............................. 7m
ENTER
Green LED ON
Stability condition. The raised load does not
exceed 90% of maximum allowed load of the
chart in that defined working position.
Yellow LED ON
Pre-alarm condition. The raised load exceeds
90% of maximum allowed load, but it is still inferior
to it: the boom movements are slow down and
the acoustic alarm emits short bips.
Red LED ON
Alarm condition. The raised load exceeds the
maximum allowed load, the acoustic alarm emits
long bips and the machine motions are stopped,
but for those allowing to return the load within
safety limits.
The display of the limiting device is divided into
three areas:
LED’s area: Three LED’s warn of the variation of
the working condition:
1 green LED - machine stable
2 yellow LED - machine in pre-alarm
3 red LED - machine in alarm
Control Keys
ESC To go back to the previous screen
page
ENTER To confirm and open the screen
page linked
ARROWS To scroll the lines up or down
PLUS (+) Additional selection button
MINUS (-) Additional selection button
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Operator’s Manual
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Operating Instructions
•
55%
FORKS
OUTRIGGERS LATERAL
MAX LOAD ........................ 50.3t
RAISED LOAD ................... 10.2t
ANGLE ............................... 12.3°
EXTENSION...................... 12.3m
RADIUS.............................. 7m
(-) simultaneously to access to the Diagnostic
Screen Pages. These pages can only be
consulted. Use the ARROWS to pass from one
page to another.
fig. A
Display, which is divided into 8 lines_ fig.A
1. Load percentage strip
2. Indicates the attachment used
3. Indicates the operating mode
4. Indicates the max. load that can be raised
5. Indicates the weight raised for the system
calibration
6. Indicates the boom angle
7. Indicates the boom extension (it’ll be = 0
meters once the boom is fully retracted)
8. Indicates the distance of the load from the
slewring axis and, in case of necessity, it
displays the related warning message
Operation
• At the machine starting, the overload warning
system runs an automatic check and the software
datas are displayed.
• Within 3/4 seconds, the list of attachments
allowed is displayed: using the arrows, the
operator has to select the right attchment and
then press ENTER to confirm.
• Once the attachment has been selected, the
display shows the Standard Screen Page (fig.A).
•
•
32
Press the two buttons PLUS (+) and MINUS
From this screen page, pushing PLUS (+) for
some seconds, the operator can open the UPPER
LEVEL (B) where other four sub-menus are
displayed: one of these, LANGUAGE (C) can
be modified while the other three, CLOCK (D),
EXTENTION SENSOR (E) and ANGLE SENSOR
(F), can only be consulted.
Pressing ESC, go back to the Standard Screen
Page.
LANGUAGE
LANGUAGE
EXTENSION SENSOR
EXTENSION SENSOR
ANGLE SENSOR
ANGLE SENSOR
CLOCK
CLOCK

ITALIANO
ENGLISH

15:25:42
10/01/09
FRANÇAIS
ESPAÑOL
LANGUAGE
EXTENSION SENSOR
LANGUAGE
EXTENSION SENSOR
ANGLE SENSOR
ANGLE SENSOR
CLOCK
CLOCK
MIN1 20MIN2
20
MAX1 1000 MAX2 1000
N1 915
N2 913
EXIT

ZERO1 511
ZERO2 511
N1 552
N2 551
EXIT
DANGER
Before using the machine, make sure that the
green LED is ON, and that the operating mode
shown in line 3 and the attachment shown in line
2 are those actually used.
HOOK - JIB - HOIST
Part No. 57.0303.5159
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Operator’s Manual
Operating Instructions
USING THE LOAD CHARTS
The load charts 1 indicates the maximum permissible
load in relation to the boom extension and the type of
attachment used. 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 (pos.3), while the actual degrees
of inclination of the boom are shown by the angle
indicator 2.
All the load charts are placed into a dedicated holder
installed in the cabin.
The tag 4 located at the top of each load chart,
indicates the type of attachment used.
WARNING
The load charts applied on the cab 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.
DANGER
A suspended load has a dynamic, and therefore
an unpredictable effect on machine stability,
operate with caution.
The load chart illustrated in this chapter is given
only as a mere example. To define the payload
limits, refer to the load charts applied within the
cab of your machine.

GTH-4017 SX

A
EXAMPLE
B
C

D
E
09.4618.0937

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Operator’s Manual
First Edition - First Printing
Operating Instructions
SLINGING LOAD
EVALUATING THE LOAD
The operator should take all practicable steps to
establish the weight and the position of its centre of
gravity of any load. A drawing may be available giving
the weight or it may be calculable within reasonable
limits of accuracy. The following gives guidance as
to the various ways of obtaining this information.
WARNING
Verify that the load to be lifted respects the max
payload of the equipment and of the telehandler.
Refer to the relative Load Chart.
WEIGHT
1. Look to see if the weight is marked on the load.
If it is, check to ensure that it is the weight of all
parts of the load;
2. Check the weight stated on any documentation.
3. Look at the drawing of the load. If the weight
is marked, check as in (1) above to ensure it
includes all parts of the load.
4. Estimate the weight of the load by using tables
of material weights, as, for example, the ones
shown in the "Tables of Material" section.
CENTRE OF GRAVITY
The “centre of gravity” (CoG) is a point which, if the
load could be suspended from the hook, the load
would be in perfect balance.
The hook needs to be directly over the centre of
gravity, for the load to be stable, as shown in fig.A.
Fig.A
34
Lifting a load with the centre of gravity offset will
cause the load to shift until a balance is restored.
If there is the slightest doubt of the stability of a load,
it should be slowly lifted just clear of the ground. If
the load tilts, the sling should be refixed in a more
stable position.
LOAD SECURITY
Before lifting it is essential to ensure that, when
clear of the ground, the load will adopt the intended
attitude and remain securely attached to the lifting
appliance without overloading any of the lifting gear.
This means that the load must be both balanced and
stable.
BALANCE
In the majority of lifts it will be intended that the
load will remain level when clear of the ground. To
achieve this it is first necessary to position the hook
of the lifting appliance vertically above the centre of
gravity of the load.
The legs of the sling(s) should be distributed as
evenly as is practicable according to the lifting points
available. The angle which the individual leg makes
with the vertical, affects the proportion of the load
which will be imposed upon it and all legs should
therefore be, so far as is practicable, at a similar
angle to provide equal loading.
If the load tilts on lifting, the load in the sling legs will
become unequal. This effect is especially significant
at small included angles between sling legs.
With rigid loads when three or more legs are
employed, consideration should be given to how
many of the legs will bear the weight as it may be
found that only two or three will take the majority
with the remaining legs providing a relatively small
‘balancing force’ only. If this is the case, larger capacity
tackle will be required.
STABILITY
In this context, stability means ‘resistance to toppling’.
An object with a narrow base and a high centre of
gravity will need less force to topple it than one with
a wide base and a low centre of gravity.
As the height of the centre of gravity increases relative
HOOK - JIB - HOIST
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Operating Instructions
to the width of the base, a point will be reached where
the object will fall over unless it is supported by external
means. At this point the object is regarded as being
unstable and the greater the support required the
more unstable it is.
A similar situation exists with a suspended load.
Forces which try to topple the load will inevitably
be present (e.g. wind, acceleration, braking). It is
essential, therefore, when slinging a load, to ensure
that it is sufficiently stable to resist these toppling
forces.
A load will be inherently stable if the lifting tackle is
attached ABOVE the centre of gravity and properly
positioned around it.
HARNESSING ACCESSORIES
A good packing between sling and load is fondamental.
Operate as follow:
• Check the load: dimensions, weight and units
• Select the right sling for each job using the
manufacturers' tables
• Inspect each item of lifting equipment before
and after lifts
• Protect slings from damage by sharp edges with
corner saddles, padding, or wooden blocks
•
•
•
When lifting long loads, particularly in confined
spaces, slingers should attach a rope or ‘tag line’
to one or both ends of the load so that rotational
movement may be controlled.
Hook unused sling legs to the sling ring.
WARNING
•
•
•
•
•
•
•
•
•
•
•
Avoid impact loading: do not jerk the load
when lifting or lowering the sling. This
increases the actual stress on the sling.
Do not exceed the capacities of slings
Do not twist or tie knots in slings or use bolts,
nails or pieces of wire to shorten slings.
Do not splice together broken slings.
Do not carry a load by inserting the point of
the hook into a link of the chain.
Do not leave unused slings, accessories, or
blocking lying on the floor. Hang on racks or
store in a proper place.
Do not use a sling to drag a load.
Do not shorten a chain with knots or by
twisting other than by means of an integral
chain clutch.
Do not use homemade chains or strings.
Do not heat treat or weld chain links: the
lifting capacity will be reduced drastically.
Do not expose chain links to chemicals
without the manufacturers approval.
Hooks are designed to support the load in the
bowl A. Users should ensure that the hook of a
sling engages freely in the lifting point so that
the weight of the load is supported in the bowl
of the hook.
Wedging or forcing the hook tip B into the
lifting points results in the hook being
stressed in a manner for which it was not
designed which may easily lead to hook
deformation and premature failure.
Protect your hands and fingers: when slack
is being taken out of a sling, keep them from
between the sling and load so they will not
be trapped and crushed. Step away before
the lift is made.
Part No. 57.0303.5159
WARNING
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Operator’s Manual
First Edition - First Printing
Operating Instructions
CONTROLS
n GTH-2506 and GTH-3007 controls
DANGER
Before operating the winch, make sure that
nobody is within its working range.
To lower/recover the winch rope:
•
set the control lever to central position,
•
press button ,
•
shift the control lever to position to lower
the rope,
shift the control lever to position to recover
the rope.
•
WARNING
As the raising and lowering speed of the
winch is determined by the flow of the oil, it
is recommended to move the control lever
gently when you perform raising and lowering
manoeuvers so as to avoid violent joilts of the
load which would provoke strains on all the
structural elements and could result in the
machine becoming unstable.
1
36
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Part No. 57.0303.5159
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Operator’s Manual
Operating Instructions
n GTH-4013SX and GTH-4017SX controls
DANGER
Before operating the winch, make sure that
nobody is within its working range.
To lower/recover the winch rope:
•
set the lever to central position,
•
•
shift the lever to position to lower the rope,
shift the lever to position to recover the rope.
WARNING
As the raising and lowering speed of the
winch is determined by the flow of the oil, it
is recommended to move the control lever
gently when you perform raising and lowering
manoeuvers so as to avoid violent joilts of the
load which would provoke strains on all the
structural elements and could result in the
machine becoming unstable.
Part No. 57.0303.5159
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Operator’s Manual
First Edition - First Printing
Operating Instructions
n GTH-4013EX, GTH-4017EX controls
DANGER
Before operating the winch, make sure that
nobody is within its working range.
To lower/recover the winch rope:
• Set the control lever to central position,
• Press button ,
• Shift the control lever to position to lower
the rope,
• Shift the control lever to position to recover
the rope.
WARNING
As the raising and lowering speed of the
winch is determined by the flow of the oil, it
is recommended to move the control lever
gently when you perform raising and lowering
manoeuvers so as to avoid violent joilts of the
load which would provoke strains on all the
structural elements and could result in the
machine becoming unstable.
1
38
HOOK - JIB - HOIST
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Operating Instructions
n GTH-4016SR and GTH-4018SR controls
DANGER
Before operating the winch, make sure that
nobody is within its working range.
To lower/recover the winch rope:
WITH LEFT JOYSTICK (Optional Configuration)
• Set the control lever to central position and
press switch .
• Smoothly shift the lever to position to lower
the rope.
• Shift the lever to position to recover the rope.
WITH RIGHT JOYSTICK (Standard
Configuration)
• Set the control lever to central position and press
switch .
• Press button and hold it pressed until the end
of the motion.
• Smoothly shift the lever to position to lower
the rope.
• Shift the lever to position to recover the rope.
As the raising and lowering speed of the
winch is determined by the flow of the oil, it
is recommended to move the control lever
gently when you perform raising and lowering
manoeuvers so as to avoid violent joilts of the
load which would provoke strains on all the
structural elements and could result in the
machine becoming unstable.
OPTIONAL CONFIGURATION
Part No. 57.0303.5159
WARNING
HOOK - JIB - HOIST
STANDARD CONFIGURATION
39
Operator’s Manual
First Edition - First Printing
Operating Instructions
OPERATION
FIXED HOOK ON PLATE
2000 KG EXTENSION JIB



•
•
•
•
•

Couple the hook and hold it in position by means
of the attachment locking system (mechanical
or hydraulic).
Set the attachment supports in working position
1, using the dedicated pins A.
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.
To remove the attachment, set the supports
in resting position 2, then carefully tilt the
attachment forward, lower the boom resting the
attachment on the ground and retract the boom.
•
•
•
•
Couple the jib and hold it in position by means
of the attachment locking system (mechanical
or hydraulic).
Set the attachment supports in working position
1.
To change the working height, operate the
lever according to the “Quick-Coupling The
Attachments” function.
To remove the attachment, set the supports
in resting position 2, then carefully tilt the
attachment forward, lower the boom resting the
attachment on the ground and retract the boom.
•
CAUTION
The fixed hook has been designed to support
the load declared beside. 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.
40
HOOK - JIB - HOIST
Part No. 57.0303.5159
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Operator’s Manual
Operating Instructions
900 KG MECHANICAL EXTENSION JIB
900 KG HYDRAULIC EXTENSION JIB



•

Couple the jib and hold it in position by means
of the attachment locking system (mechanical
or hydraulic).
• Set the attachment supports in working position
1, using the dedicated pins A.
• Lift the attachment support 3 locking it in working
position by means of the dedicated pin B.
• 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.
• To remove the attachment, set the supports in
resting position 2, lower the attachment support
3 locking it in resting position by means of the
dedicated pin B, carefully tilt the attachment
forward, lower the boom resting the attachment
on the ground, then retract the boom.
Once the attachment quick connectors have been
disconnected from the boom connectors, take care
to reconnect them to the proper rest connectors that
are present on the jib, in order to prevent impurities
from entering the circuit. Carefully protect the rest
connectors with the proper plugs when they are not
used.
Part No. 57.0303.5159

•
•
•
•
•
•

Couple the jib and hold it in position by means
of the attachment locking system (mechanical
or hydraulic).
Set the attachment supports in working position
1, using the dedicated pins A.
Lift the attachment support 3 locking it in working
position by means of the dedicated pin B.
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.
To remove the attachment, set the supports in
resting position 2, lower the attachment support
3 locking it in resting position by means of the
dedicated pin B, carefully tilt the attachment
forward, lower the boom resting the attachment
on the ground, then retract the boom
HOOK - JIB - HOIST
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Operator’s Manual
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Operating Instructions
3000 KG HYDRAULIC HOIST


•
Couple the hoist and hold it in position by means
of the attachment locking system (mechanical
or hydraulic).
• Set the attachment supports in working position
1, using the dedicated pins A.
• To change the working height, operate the
lever according to the “Quick-Coupling The
Attachments” function.
• To remove the attachment, set the supports
in resting position 2, then carefully tilt the
attachment forward, lower the boom resting the
attachment on the ground and retract the boom.
Once the attachment quick connectors have been
disconnected from the boom connectors, take care
to reconnect them to the proper rest connectors
that are present on the hoist, in order to prevent
impurities from entering the circuit. Carefully protect
the rest connectors with the proper plugs when they
are not used.
42
HOOK - JIB - HOIST
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Operating Instructions
TRANSPORTING A SUSPENDED LOAD
Once the load is attached, operate as follow:
• raise the load and check if it is correctly
suspended: the wire shall be tightened and
shall not be in slack-condition when the load
movement begins;
• completly retract the boom;
• raise it again to the transport height of 300-500mm
from the ground;
• make sure a load is high enough to clear all
objects before starting to move;
• identify any risks present on the route to be
travelled;
• avoid excessively undulating ground when
travelling;
• consider that when transporting load permissible
gradients are 10% downhill, 15% uphill, 5% side;
• consider effects of the wind on load: wind speed
should not exceed 10m/s or number 5 of the
Beaufort Scale, as explain in the "Beaufort Wind
Scale" section;
• initiate movements of the load with the lowest
available speed;
• travel at walking speed (1,5 km/h).
•
•
•
•
•
•
LOAD LANDING
Before a load is lifted, a place should be prepared
where it is to be put down. The nature of the load
will determine the type of preparation necessary but
most loads should be lowered onto timber battens.
The sling may then be easily withdrawn. The load
should never be landed directly on to the chain.
DANGER
Do not allow suspended loads to oscillate.
Do not drag loads when they are hooked up.
Do not ride on hooks or loads.
Do not allow workers to walk or work under
a load.
Do not leave suspended loads unattended.
Warn all people out of the load area before
starting the lift.
WARNING
When visibility is or could be obstructed, the
operator shall use alternative/additional means
to safely transport the load: use of additional
personnel to direct the operator in his movements
as well as surrounding ground traffic.
Part No. 57.0303.5159
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Operating Instructions
STOPPING and STORING the EQUIPMENT
and the TELEHANDLER
NOTICE
Lay the equipment on a dry and level ground.
To release the attachment from the telehandler:
• Approach the place where you will release the
equipment.
• Lower the equipment on the ground.
• Stop the engine of the telehandler
• Disconnect the hydraulic pipes of the equipment
from the boom fittings.
• Restart the engine.
• Operate the joystick to release the equipment
from the quick coupling plate.
• Tilt the coupling plate forward and lower the
boom to release the upper lock of the equipment.
• Move back with the telehandler.
The equipment itself can be handled by means
of the telehandler to which it is coupled or by
means of machines equipped with forks that have
a suitable rated capacity.
NOTICE
When the equipment is parked, check the state of
the wire rope. This must be tensioned, correctly
wound on the winch drum and not be twisted to
avoid frays and breakage.
44
HOOK - JIB - HOIST
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Operating Instructions
n Moving the Equipment
CAUTION
•
HOIST, insert the forks into the dedicated lug 3
When the equipment shall be moved, use
only means having a suitable capacity. The
characteristic data are detailed in the relevant
chapter of this manual and on the identification
plate.
According to the equipment, proceed as follow for
moving:
• 900kg JIB, insert the forks into the four
dedicated lugs 1

•

•
HOOK, run two slings through the frame holes
as shown in the draft below
2000kg JIB, insert the forks into the two
dedicated lugs 2

Part No. 57.0303.5159
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Operator’s Manual
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Operating Instructions
n Parking for Short Periods
Always park the telehandler in a safe way after a
working day, a shift and at night.
Take all precautions to prevent damage to those
persons who will approach the machine while
stationary:
• Park the machine so that it does not hinder other
operations.
• Put the parking brake.
• Remove the key from the ignition switch and
lock the cab door.
Parking for Long Periods
In case of extended inactivity of the telehandler and/
or the equipment, follow the above precautions and
additionally:
• Wash the machine thoroughly. For a better
cleaning, remove grills and protection casings.
CAUTION
Do not use gasoline, solvents or other flammable
products for cleaning purposes. Use only
authorized, non-flammable and harmless
solvents. Wear safety goggles and a protection
mask when you use compressed air. In case of
washing, do not direct the jet of water towards
electrical parts.
•
•
•
•
•
46
Carefully dry all machine parts by blowing some
compressed air.
Lubricate the machine thoroughly.
Do a walk-around inspection and replace any
worn or damaged part.
Re-paint any worn or damaged part.
Store the machine in a sheltered and wellventilated place.
WARNING
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 re-starting the machine and
the equipment, carry out an extraordinary
maintenance and carefully check all mechanical,
hydraulic and electrical components.
DISPOSAL
PROTECT THE
ENVIRONMENT
At the end of the telehandler and/or the equipment
life, call in a specialised firm to dispose of it in
compliance with the local or national regulations.
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.
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.
HOOK - JIB - HOIST
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Maintenance
INTRODUCTION
Observe and obey:
*
*
A thorough and regular maintenance keeps the
machine in a safe and efficient working condition.
For this reason, it is advisable to wash, grease and
service the machine properly, especially after having
worked under particular conditions (muddy or dusty
environments, heavy operations, etc.).
Always ensure all machine components are in good
condition. Check for oil leaks or loosening of guards,
and make sure that the safety devices are efficient.
In case of damages, find and rectify them before
using the machine again.
Not respecting the ordinary maintenance schedule
of this manual automatically voids TEREXLIFT
warranty.
The operator can only perform
the routine maintenance
operations in this manual.
Scheduled maintenance
procedures shall be completed
by qualified technical personnel
according to the manufacturer’s
specifications.
Maintenance symbol legend:
The following symbol is used in this manual to
Indicates the time interval for the maintenance
jobs expressed in working hours.
SERVICE INTERVAL
Running-in ____________________________
Ordinary ______________________________
Part No. 57.0303.5159
NOTICE
Effecting changes or carrying out interventions
on the telehndler or the equipment other than
those of routine maintenance is expressly
forbidden. Any modification not carried out
by TEREXLIFT or an authorized assistance
centre involves the automatic invalidation of
the conformity of the machine to the Directive
2006/42/EC
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Operator’s Manual
First Edition - First Printing
Maintenance
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 specialized firms for disposal.
Oil leaks
In case of accidental oil leaks, cover with sand
or type-approved 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.
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 or the equipment 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
damage detected during the maintenance is promptly
rectified before using the machine.
At every use
1. Check the efficiency of the safety systems
installed, as described into the dedicated
paragraph "Safety Devices".
2. Ensure all bolts and nuts are properly tightened
3. Check the couplings for oil leaks
4. Check the hydraulic system
5. Check the electrical connection
6. Check the wear of the rope
7. Check the hook
8. Check the safety devices
9. Make a visual check of the structure, paying
particular attention to signs of corrosion and
structural welds.
Every 10 working hours
1. Grease all moving parts.
Fire
In case of fire, use carbon dioxide, dry chemical or
foam extinguishers. Do not use water.
48
HOOK - JIB - HOIST
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Maintenance
MAINTENANCE INTERVENTIONS
WARNING
All maintenance interventions must be carried
out with engine stopped, parking brake engaged,
equipment flat on the ground and gear lever in
neutral.
WARNING
Any intervention on the hydraulic circuit must
be carried out by skilled personnel.
The hydraulic circuit of the telehandler 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.
WARNING
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.
Part No. 57.0303.5159
CAUTION
High pressure lines must be replaced by qualified
personnel only.
Any foreign matters entering the closed circuit
may result in a sudden deterioration of the
transmission.
CAUTION
The qualified staff charged with the maintenance
of the hydraulic circuit must clean all areas around
with care before any intervention.
PROTECT THE
ENVIRONMENT
The handling and disposing of used oils can be
ruled by local or national regulations. Address
to authorised centres.
NOTICE
During maintenance or repair works, and while
welding, turn off the disconnected battery
switch, located into the engine compartment.
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Operator’s Manual
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Maintenance
CHECKING THE ROPE FOR WEAR
CHEKING THE HOOK
DANGER
Every time you use the hook, check the hook tip A
is in good condition.
Working intentionally with worn and/or damaged
ropes can be highly dangerous. Immediately
replace the worn and/or damaged rope.
TEREXLIFT disclaims any responsibility for
damage to persons and/or property arising from
the non-compliance with this precaution.
Check the ropes daily and find and rectify any possible
fault. Ropes must be replaced when the following
signs of deterioration are found:
• when the total diameter of the rope gets reduced
by 10% with respect to the original diameter,
even in a single point;
• when the rope shows dents, twists or permanent
bends caused by damages or sharp edges;
• when a strand is completely broken or when it
has suffered from such damages that its useful
section is reduced by 40% in some points;
• when the central section of the rope (core) comes
out even in a single point;
• when, even though the rope is under tension,
one or more strands are slacken or protrude
out of the rope;
•
in case of clear damages caused by heat (torch,
electric arc, etc.)..
Model
4000mm/900kg
Jib
3000 kg Hoist
Ø Rope
Length
8 mm
37 m
12 mm
70 m
SERVICE INTERVAL
Running-in __________________________ None
Ordinary ________________________Every Use
SERVICE INTERVAL
Running-in __________________________ None
Ordinary ________________________Every Use
50
HOOK - JIB - HOIST
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Maintenance
CHECKING THE SAFETY DEVICES
Checking the MOMENT LIMITING SYSTEM of
the TELEHANDLER
(at every use)
At the telehandler start-up, the moment limiting
system runs an automatic check. In the case of
troubles, the red led will come on and the buzzer will
sound to warn of the error. The telehandler will enter
the alarm mode and no operation will be allowed.
To check the system manually, proceed as follows:
• Set the telehandler on wheels.
• Load a weight of 1000 kg.
• Raise the boom about 30 cm above the ground.
• Extend the telescope and check if the system
enters the alarm mode once reached the distance
indicated in the load charts for the attachment
fitted to the machine.
• If the system does not enter the alarm mode,
contact the TEREXLIFT Technical Service.
Checking the FLUID POWERED LOCKING
VALVE of the WINCH
(at every use)
This device stops the load moving, obstructs motoring
over, blocks tubes in the event of their breaking.
To check its efficiency:
• lift a weight
• move the control lever to recover the rope
• set the lever to neutral position: the weight has
to stop. If not, contact the TEREXLIFT Technical
Service.
Checking the LIMIT SWITCHES of the WINCH
(at every use)
This device must maintain the range of the movement
of the load between the pre-fixed limits.
To check its efficiency:
• lift a weight
• smoothly move the control lever to recover the
rope: the weight should stop once reached the
fixed limits. If not, stop recovering the rope and
contact the TEREXLIFT Technical Service.
Checking the HOIST LIMITING MECHANISM
of the WINCH
(at every use)
This device must prevent the winch from hoisting
weights which are greater than its maximum limit.
To check its efficiency:
• lift a weight higher then the euipment payload
• move the control lever to recover the rope: the
winch should stop at soon as the weight is hoisted
from the ground. If not, contact the TEREXLIFT
Technical Service.
Go to the section "Routine Check Schedule"
to note down the results of the safety devices
daily check.
SERVICE INTERVAL
Checking the PARKING BRAKE of the WINCH
(at every use)
This device stops the drum when loads are suspended.
To check its efficiency:
• lift a weight
• move the control lever to lower the rope
• set the lever to neutral position: the weight has
to stop. If not, contact the TEREXLIFT Technical
Service.
Part No. 57.0303.5159
Running-in __________________________ None
Ordinary ________________________Every Use
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Operator’s Manual
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Maintenance
GREASING
CAUTION
Before injecting grease into the greasers,
thoroughly clean them to avoid that mud, dust
or other matters can mix with the lubricant and
reduce or annihilate the lubrication effect.
Remove any old grease with a degreaser from
the telescopes before smearing them with new
grease.
Regularly grease the machine to grant it efficient
conditions and a long life. By means of a pump,
inject grease into the special greasers. As the fresh
grease comes out, stop the operation.
For the rope lubrication, use the assistance of a
second operator to stop the machine in an emergency;
smear the rope with grease while unwinding it at the
minimum permitted speed.
52
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
HOOK - JIB - HOIST
10 hours
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Faults And Troubleshooting
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, but call in a skilled technician.
PROBLEM
THE OVERLOAD
WARNING SYSTEM IS IN
ALARM
NOISE IN THE
HYDRAULIC CIRCUIT
WARNING
The equipment is an accessory coupled to a
telehandler. A modified telehandler may affect
the proper functioning of the equipment. For this
reason, it is recommended to read the telehandler
manual for all faults which are not listed below.
CAUSES
•
The attachment has been
overloaded
•
Presence of air in the circuit
SOLUTIONS
•
Remove any excess load. Take note of
the limits of the use of the telehandler
with the equipment is coupled to.
•
Purge the circuit
•
Operate the hoist with gradually
increasing loads until it turns regularly
and the noise disappears
NOISE DURING HOISTING
•
ACCOMPANIED BY
JERKY ROTATION
Insufficient circulation of oil in
the circuit
WITH THE DISTRIBUTOR
SET IN THE CENTER THE
LOAD TENDS TO GO
DOWN
•
Brake spring are broken
•
Replace springs
•
Insufficient pressure in the
hydraulic circuit
Damaged motor
•
Make sure the maximum-load valve on
the control distributor is set correctly
Check the drainage of the motor: if the
oil flow exceeds 1l/min , replace the
motor
THE HOIST CANNOT LIFT
THE LOAD
•
•
NOTICE
In case of faults not listed in this chapter, address to the TEREXLIFT Technical Assistance, your
nearest authorised workshop or dealer.
Part No. 57.0303.5159
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54
HOOK - JIB - HOIST
Part No. 57.0303.5159
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Operator’s Manual
Specifications
FIXED HOOK ON PLATE
• code 59.0700.9004 for GTH-2506
FIXED HOOK ON PLATE
• code 59.0700.9002 for GTH-3007, GTH-4013SX,
GTH-4017SX, GTH-4013EX, GTH-4017EX, GTH4016SR, GTH-4018SR








TECHNICAL DATA
TECHNICAL DATA
Width
1335 mm
Height in resting position
1110 mm
Length
830 mm
Height in working position
910 mm
Width
1335 mm
Height in resting position
1110 mm
Length
Height in working position
830 mm
1070 mm
Weight
120 kg
Weight
160 kg
Payload
2500 kg
Payload
5000 kg
CoG
150 mm
CoG
180 mm
Part No. 57.0303.5159
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Operator’s Manual
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Specifications
4000MM/900KG HYDR. JIB
• code 59.0802.3009 for GTH-3007, GTH-4013SX,
4000MM/900KG MECH. JIB
• code 59.0802.3008 for GTH-3007, GTH-4013SX,
GTH-4017SX, GTH-4013EX, GTH-4017EX, GTH4016SR, GTH-4018SR
GTH-4017SX, GTH-4013EX, GTH-4017EX, GTH4016SR, GTH-4018SR








TECHNICAL DATA




Width
1190 mm
Height in resting position
1220 mm
Length
4485 mm
Height in working position
1610 mm




Width
1190 mm
Height in resting position
1220 mm
Length
4450 mm
Height in working position
980 mm
Weight
320 kg
Weight
245 kg
Payload
900 kg
Payload
900 kg
CoG
56
TECHNICAL DATA
1400 mm
CoG
HOOK - JIB - HOIST
1340 mm
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Specifications
2000MM/2000KG JIB
• code 59.0802.3007 for GTH-2506, GTH-3007, GTH-
3000kg HOIST
• code 59.0901.9002 for GTH-4013SX, GTH-4017SX,
4013SX, GTH-4017SX, GTH-4013EX, GTH-4017EX,
GTH-4016SR, GTH-4018SR
GTH-4013EX, GTH-4017EX, GTH-4016SR, GTH4018SR








TECHNICAL DATA




TECHNICAL DATA
Width
1335 mm
Height in resting position
1080 mm
Length
2290 mm
Height in working position
800 mm




Width
1335 mm
Height in resting position
1260 mm
Length
Height in working position
830 mm
1840 mm
Weight
255 kg
Weight
350 kg
Payload
2000 kg
Payload
3000 kg
CoG
490 mm
CoG
260 mm
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58
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Part No. 57.0303.5159
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Operator’s Manual
Load Charts
FIXED HOOK ON PLATE COUPLED TO GTH-2506
6
57.2900.0204
rev. 0
70°
E
D
C
B
A
60°
5
50°
4
10°
1
5.78 m
2500 kg
900 kg
20°
2
1000 kg
30°
3
1500 kg
2000 kg
40°
0°
0
4
3
2
1
0
2.90 m
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6
50°
5
40°
4
30°
20°
2
1
0
10°
1100 kg
1500 kg
2000 kg
3
E
D
C
B
A
6.89 m
67°
60°
57.2900.0315 rev. 0
25
00
kg
30
00
kg
7
0°
-2.9°
-1
4
60
3
2
1
3.59 m
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0
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Load Charts
FIXED HOOK ON PLATE COUPLED TO GTH-4013 SX & GTH-4013 EX
13
57.2900.0219
rev. A
68.8°
12
E
60°
11
D
50°
10
C
9
40°
B
8
3000 kg
30°
6
5
1000 kg
500 kg
10°
2
250 kg
3
2000 kg
20°
4
12.69 m
A
7
1
0°
0
-1
-4.18°
10
9
8
7
6
5
4
3
2
1
0
8.62 m
13
57.2900.0220
71.6°
70°
rev. A
12
E
60°
D
11
50°
10
C
9
B
40°
8
12.92 m
A
7
30°
10°
2
3000 kg
1250 kg
3
2500 kg
20°
4
2000 kg
5
1500 kg
6
1
0°
0
-1
-1.43°
10
9
8
7
6
5
4
3
2
1
0
8.57 m
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Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Load Charts
FIXED HOOK ON PLATE COUPLED TO GTH-4016 SR
57.2900.0322 rev. A
17
16
16
70°
15
75°
E
60°
C
11
40°
50°
C
12
11
B
40°
B
10
20°
3000 kg
5
4
10°
900 kg
3
2
1
0°
0°
0
-3.7°
-1
-3.7°
-1
9
8
7
6
5
4
3
2
1
0
14 13 12 11 10
9
8
16
70°
75°
E
15
60°
14
40°
B
1
B
30°
8
750 kg
10°
1000 kg
20°
0 kg
4
A
25
00
7
5
3
2
1
0°
0
-3.7°
14 13 12 11 10
1
20 500
00
k
kg g
kg
9
6
3000 kg
2000 kg
1000 kg
500 kg
350 kg
1500 kg
20°
kg
0
-1
40°
500 kg
00
40
7
15.79 m
30°
8
75°
E
C
300 kg
A
2
0
D
10
10°
1
50°
11
10
3
2
12
C
5
3
60°
13
50°
9
4
70°
14
12
4
5
15
D
11
6
57.2900.0325 rev. A
57.2900.0324 rev. A
16
13
7
12.91 m
12.91 m
15.79 m
14 13 12 11 10
6
kg
20°
750 kg
2000 kg
1500 kg
1000 kg
10°
2
00
40
7
6
5
3
8
15.94 m
kg
30°
3000 kg
00
40
7
A
9
2000 kg
8
15.94 m
30°
1500 kg
A
9
1000 kg
10
0
D
13
50°
12
1
75°
E
60°
14
D
13
4
70°
15
14
6
57.2900.0323 rev. A
600 kg
17
0°
-3.7°
-1
9
8
7
6
5
4
3
2
1
0
14 13 12 11 10
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8
7
6
5
4
3
2
1
0
12.91 m
12.91 m
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Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Load Charts
4000mm/900kg HYDRAULIC and MECHANICAL JIB COUPLED TO GTH-3007
57.2900.0316 rev. 0
8
67°
7
60°
6
50°
5
E
D
C
B
A
4
6.93 m
40°
2
10°
1
450 kg
20°
750 kg
3
500 kg
30°
6
5
900 kg
0°
-2.9°
0
-1
8
7
4
3
2
1
0
7.18 m
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Load Charts
4000mm/900kg HYDRAULIC and MECHANICAL JIB COUPLED TO GTH-4013 SX & GTH-4013 EX
17
57.2900.0221 rev. A
16
15
14
13
68.8°
12
E
60°
11
D
50°
10
40°
8
B
A
7
2
10°
1
0
-1
200 kg
3
900 kg
20°
600 kg
5
300 kg
30°
6
4
16.24 m
C
9
0°
-4.18°
-2
13 12 11 10
9
8
7
6
5
4
3
2
1
0
12.17 m
17
57.2900.0222 rev. A
16
15
14
13
70°
71.6°
12
E
60°
11
D
50°
10
C
B
40°
8
16.55 m
9
A
7
30°
6
5
3
2
10°
900 kg
20°
800 kg
4
1
0 0°
-1 -1.43°
13 12 11 10
9
8
7
6
5
4
3
2
1
0
12.11 m
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Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Load Charts
4000mm/900kg HYDRAULIC and MECHANICAL JIB COUPLED TO GTH-4017 SX & GTH-4017 EX
Part No. 57.0303.5159
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68
HOOK - JIB - HOIST
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Load Charts
4000mm/900kg HYDRAULIC and MECHANICAL JIB COUPLED TO GTH-4018 SR
Part No. 57.0303.5159
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First Edition - First Printing
Load Charts
2000mm/2000kg JIB COUPLED TO GTH-2506
57.2900.0206
rev. A
70°
E
D
C
B
A
60°
5
50°
4
10°
1250 kg
0°
0
5
70
550 kg
20°
2
1
650 kg
30°
3
850 kg
40°
5.78 m
6
4
3
2
4.51 m
1
HOOK - JIB - HOIST
0
Part No. 57.0303.5159
First Edition - First Printing
Operator’s Manual
Load Charts
2000mm/2000kg JIB COUPLED TO GTH-3007
57.2900.0317 rev. 0
67°
60°
7
50°
5
4
20
00
kg
40°
30°
3
7.13 m
6
E
D
C
B
A
10°
1
1000 kg
2
750 kg
20°
1500 kg
8
0°
-2.9°
0
-1
6
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5
4
3
2
5.17 m
1
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0
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2000mm/2000kg JIB COUPLED TO GTH-4013 SX & GTH-4013 EX
16
57.2900.0441
rev. 0
15
14
13
68.9°
E
60°
12
D
11
50°
C
10
40°
B
8
A
7
30°
14.84 m
9
5
2000 kg
1500 kg
6
150 kg
3 10°
2
1000 kg
20°
4
250 kg
5
500 kg
6
1
0
0°
-1 -4.18°
11 10 9
8
7
10.28 m
4
3
2
1
0
16
57.2900.0442
rev. 0
15
14
70°
13
60°
12
11
71.6°
E
D
50°
10
C
40°
B
8
A
30°
7
6
10°
1500 kg
3
2000 kg
20°
4
1150 kg
5
2
1
0
0°
-1.43°
-1
11 10
9
8
7
6
5
4
3
2
1
0
10.21 m
72
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15.07 m
9
First Edition - First Printing
Operator’s Manual
Load Charts
2000mm/2000kg JIB COUPLED TO GTH-4017 SX & GTH-4017 EX
Part No. 57.0303.5159
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Load Charts
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Load Charts
2000mm/2000kg JIB COUPLED TO GTH-4018 SR
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57.2900.0223
rev. A
70°
12
71.6°
E
60°
11
D
50°
10
C
9
B
40°
8
A
7
30°
6
12.39 m
13
3000 kg
2500 kg
2000 kg
3
1500 kg
20°
4
1000 kg
5
2 10°
1
-1
0°
9
-1.43°
8 7
6
5
4
8.45 m
3
2
1
0
13
57.2900.0224
rev. A
68.8°
12
E
60°
11
10
D
50°
C
9
40°
8
B
A
7
6
3000 kg
30°
5
2000 kg
10°
1000 kg
2
500 kg
3
250 kg
20°
4
1
0
0°
-1
-4.18°
10
9
8
7
6
5
4
3
2
1
0
8.49 m
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12.16 m
0
First Edition - First Printing
Operator’s Manual
Load Charts
3000 kg HOIST COUPLED TO GTH-4017 SX & GTH-4017 EX
Part No. 57.0303.5159
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Diagrams and Schemes
HOIST HYDRAULIC DIAGRAM
(Rev.0, P/N: 57.2500.0001)
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Diagrams and Schemes
JIB HYDRAULIC DIAGRAM
(Rev.0, P/N: 57.2500.0000)
82
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Operator’s Manual
Beaufort Wind Scale
Beaufort
Number
0
1
2
3
4
5
6
7
8
9
10
11
12
Wind Speed
Land Condition
m/s
Calm
< 0.3.
Calm. Smoke rises vertically.
Light air
0.3 - 1.5
Wind motion visible in smoke.
Light breeze
1.6 - 3.4
Wind felt on exposed skin. Leaves rustle.
Gentle
3.5 - 5.4
Leaves and smaller twigs in constant motion.
breeze
Moderate
Dust and loose paper raised. Small branches
5.5 - 7.9
breeze
begin to move.
Branches of a moderate size move. Small
Fresh breeze 8.0 - 10.7
trees begin to sway.
Large branches in motion. Whistling heard in
Strong
10.8 - 13.8 overhead wires. Umbrella use becomes diffibreeze
cult. Empty plastic garbage cans tip over.
Whole trees in motion. Effort needed to walk
High wind,
Moderate
against the wind. Swaying of skyscrapers
13.9 - 17.1
may be felt, especially by people on upper
gale, Near
floors.
gale
Some twigs broken from trees. Cars veer on
Gale, fresh
17.2 - 20.7
road. Progress on foot is seriously impeded.
gale
Some branches break off trees, and some
small trees blow over. Construction/temporaStrong gale
20.8 - 24.4
ry signs and barricades blow over. Damage
to circus tents and canopies.
Trees are broken off or uprooted, saplings
Storme,
bent and deformed. Poorly attached asphalt
24.5 - 28.4
whole gale
shingles and shingles in poor condition peel
off roofs.
Widespread damage to vegetation. Many roofing surfaces are damaged; asphalt tiles that
Violent storm 28.5 - 32.6
have curled up and/or fractured due to age
may break away completely.
Very widespread damage to vegetation.
Hurricane
Some windows may break; mobile homes
32.7 >
force
and poorly constructed sheds and barns are
damaged. Debris may be hurled about.
Description
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Operator’s Manual
Tables of Material
MATERIAL WEIGHTS
Material
Aluminium
Brass
Brick
Coal
Copper
Concrete
Iron-steel
Lead
Oil
Paper
Water
Wood
Weight in kg per m3
2700
8500
2100
1450
8800
2400
7700
11200
800
1120
1000
800
VOLUMES OF COMMON SHAPES
Pyramid
¼xLxWxH
Solid Cylinder
πr2 x L
Thick Walled Pipe
π(r12 - r22) x L
Rectangular Solid
LxWxH
Sphere
4π x R3
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Operator’s Manual
EC Declaration of Conformity
EC DECLARATION OF CONFORMITY FULL TEXT
Manufacturer and person authorized to compile the technical file TEREXLIFT s.r.l. Zona Industriale
Buzzacchero 06019 Umbertide (PG) Italia
Hereby declares that the machinery described below
Designation: Mobile Elevating Work Platform (MEWP)
Function: Lifting persons and goods
Model XXXXX
Serial Number XXXXX
complies with the relevant provisions of the machinery directive 2006/42/EC enclosure IV
complies with the model which has obtained an "EC" type certificate, n° XXXXXXXXX, Issued by the
following notified body XXXXX
Also complies with the following European Standards, National Standards and technical provisions:
EN 280/A2:2009
EXAMPLE OF LAYOUT
EXAMPLE
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Operator’s Manual
Routine Check Schedule
SAFETY DEVICES DAILY CHECKING
DATE__________________________
COMPONENT
RESULT
Telehandler LMI Unit
Control
 positive
 negative
Winch Fluid Powered
Locking Valve
 positive
 negative
Winch Parking Brake
 positive
 negative
Winch Limit Switches
 positive
 negative
Winch Hoist Limiting
Mechanism
 positive
 negative
Hook Tip
 positive
 negative
Part No. 57.0303.5159
NOTE
HOOK - JIB - HOIST
SIGNATURE
89
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