3P/700-REM 4400 from SN 60980 (PN 57.0303

3P/700-REM 4400 from SN 60980 (PN 57.0303
Operator’s Manual
Serial number range
Work Platform:
3P/700-REM 4400
2P/300 F
From serial n.: 60980
From serial n.: 61310
With Maintenance
Information
First Edition
Second Printing
Part No. 57.0303.5119
Operator’s Manual
First Edition - Second Printing
Important
Contents
Read, understand and obey these safety rules
and operating instructions , as well as those within
the machines operator's manual, before operating
the machine. Only trained and qualified personnel
shall be authorized to operate the machine. This
manual is only a supplement to the machines
operator's manual and both manuals shall be
kept with the machine at all times.
Introduction ..........................................Page 3
Work Platform Identification.................Page 5
Symbols Used On The Work Platform Page 7
Labels And Plates Applied On The
Work Platform ......................................Page 9
Safety Precautions ..............................Page 15
Man-Platforms Description ....................Page 25
Inspections ..........................................Page 31
Operating Instructions .........................Page 35
Maintenance ........................................Page 59
Faults And Troubleshooting.................Page 65
Specifications ......................................Page 69
Stability Test ........................................Page 71
Load Charts .........................................Page 77
Diagrams And Schemes ......................Page 91
Beaufort Wind Scale ............................Page 103
EC Declaration Of Conformity .............Page 105
Warranty ..............................................Page 107
Routine Check Schedule .....................Page 113
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: Second Printing, April 2010
For the electronic version of this manual visit
www.genielift.com/operator_manuals.asp
© Copyright 2010 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.
WARNINGOrange: indicates a hazardous
situation which, if not avoided,
could result in death or serious
injury.
CAUTION Yellow : indicates a hazardous
situation which, if not avoided,
could result in minor or
moderate injury.
NOTICE
Blue: indicates a hazardous
situation which, if not avoided,
could result in property
damage.
PROTECT THE
ENVIRONMENT Green:
used to draw the
attention to important
information on environment
protection.
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Part No. 57.0303.5119
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Operator’s Manual
Work Platform Identification
Check that the operator handbook refers to the
delivered machine.
DESIGNATION
Mobile Elevating Work Platform
MODEL AND TYPE
Electrically controlled work platform complete with
emergency electropump:
3P/700-REM 4400
2P/300 F
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
Directive
Title
2006/42/EC
2004/108/EC
Machinery Directive
Electromagnetic compatibility
Standard
Title
WORK PLATFORM IDENTIFICATION PLATES
The following data plates are applied on the work
platform:
Work platform data plate
The identification plate contains the main identification
data of the work platform like model, serial number
and year of manufacture.
CE MARKING
This work platform fulfils the safety requirements of
the Machinery Directive.The conformity has been
certified and the placing of the CE marking on the
work platform demonstrates compliance with the
regulatory requirements.
The CE marking is placed directly on the identification
plate of the work platform.
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.
EN 280:2001
+ A2:2009
Mobile elevating work platforms Design calculations, stability criteria,
construction - Safety, examinations
and tests
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Work Platform Identification
WORK PLATFORM IDENTIFICATION PLATE
The work platform identification plate is applied in
the rear side of the work platform (see the image
here below).
Model:
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
Model Year: AAAA
Designation:
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
Serial number:
AAAAAAAAAA
Manufacture Year:
AAAA
Mass of Platform (Kg): AAAAAAAAA
Rated Capacity of Platform (Kg): AAAAAAAAA
Country of Manufacture: ITALY
Manufacturer:
Terexlift srl z.i.Buzzacchero
06019 Umbertide, Italy
LEFT SIDE
REAR SIDE
FRONT SIDE
RIGHT SIDE
REAR SIDE
RIGHT SIDE
FRONT SIDE
LEFT SIDE
6
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Operator’s Manual
Symbols Used Work Platforms
Boom Lowering
Boom Raising
Boom Extension
Boom Retraction
Functions Enabling
Switch
Basket Rotation
Engine Start
Emergency Pump
Safety Alert Symbol
Horn
Basket Rotation
(for 2P/300 F)
Functions Enabling
Switch (for 2P/300 F)
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Operator’s Manual
Labels And Plates Applied On The Work Platform
Dashed indicates decal is hidden from view.
3P/700 REM 4400
12
13
10
6
4
9
14
3
4
7
2
1
11
4
A
16
4
11
8
4
14
1
3
4
4
15
9
13
14
4
17
5
15
4
18
15
11
7
17
4
9
16
5
13
4
14
2
13
4
9
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Labels And Labels Applied On The Work Platform
2P/300 F
4
6
3
12
10
7
11
A
8
4
4
16
7
11
19
2
19
11
15
19
11
10
4
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2
16
Part No. 57.0303.5119
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Operator’s Manual
Labels And Labels Applied On The Work Platform
Use the pictures on these pages to verify that all decals are legible and in place.
The following chart shows quantities and description too.
Ref.
Decal
Code
1
09.4618.0790
Description
Keep away from path of
moving work platform
Qt. 3P/700
Qt.
REM 4400 2P/300 F
2
/
Maximum wind allowed
on the work platform
09.4618.0788
12,5 m/sec and Maximum
hand strenght allowed
2
2
09.4618.1344 Fall hazard
2
2
09.4618.1268 Lanyard attachment point
12
4
Maximum payload 700 kg
09.4618.1183 including people on board;
maximum occupants 3
2
/
09.4618.0789 Overturning danger alarm
1
1
Crush hazard, keep away
from moving parts
2
2
09.4618.1269 Read the operator's manual
1
1
09.4618.0790
2
09.4618.0788
3
4
09.4618.1268
09.4618.1344
= 700
5
Kg
09.4618.1183
6
09.4618.0789
7
09.4618.0922
09.4618.0922
8
09.4618.1269
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Labels And Labels Applied On The Work Platform
Ref.
Decal
9
Qt. 3P/700
Qt.
REM 4400 2P/300 F
Code
Description
09.4618.0919
Crush Hazard, keep away
from moving parts
4
/
09.4618.0921
Label - Use limits close to
electric power lines
1
1
Crush Hazard, keep away
from moving parts (only on
09.4618.1185
work platforms coupled to
SR machine models)
3
4
Maximum slope allowed
< 1%
1
1
Maximum payload of the
extensible parts 360 kg
09.4618.1342
including people on board;
maximum occupants 3
4
/
4
/
09.4618.0919
10
09.4618.0921
11
09.4618.1185
12
<1%
09.4618.1330
09.4618.1330
13
360 kg
09.4618.1342
14
09.4618.1343
Lock the extensible parts
using the proper handles
09.4618.1343
15
09.4618.1345 Reflecting decal
3 units
(mt 0,60)
mt 1,70
16
09.4618.1345 Reflecting decal
2 units
(mt 0,90)
2 units
(mt 0,60)
12
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Part No. 57.0303.5119
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Operator’s Manual
Labels And Labels Applied On The Work Platform
Ref.
Decal
Code
Description
Qt. 3P/700
Qt.
REM 4400 2P/300 F
17
Reflecting decal (only on
09.4618.1345 work platforms coupled to
SR machine models)
2 unità
(mt 0,25)
/
18
Crush Hazard, keep away
from moving parts (only on
09.4618.1185
work platforms coupled to
EX & ER machine models)
3
/
Maximum payload 300 kg
09.4618.1363 including people on board;
maximum occupants 2
/
3
Work platform data plate. The
identification plate contains
the main identification data of
the work platform.
1
1
09.4618.1185
19
300 kg
09.4618.1363
Model:
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
Model Year: AAAA
A
Designation:
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMM
Serial number:
AAAAAAAAAA
Manufacture Year:
AAAA
Mass of Platform (Kg):
AAAAAAAAA
Rated Capacity of Platform (Kg): AAAAAAAAA
Country of Manufacture: ITALY
Manufacturer:
Terexlift srl z.i.Buzzacchero
06019 Umbertide, Italy
Part No. 57.0303.5119
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Operator’s Manual
Safety Precautions
DAMAGED WORK PLATFORM HAZARDS
•
•
•
•
•
Do not use a damaged or defective work platform.
Do a thorough pre-operation inspection of the
work platform and test all functions before each
work shift. Tag and remove from service a
damaged or defective work platform.
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 manual is intact,
legible and placed in the special container located
in the work platform.
SAFETY DEVICES
Several safety devices have been fitted to the
work platform. 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 defective device.
For the checking procedures, read chap.
"Maintenance"
MOMENT LIMITING SYSTEM
PERSONAL INJURY HAZARDS
•
•
•
Do not operate the work platfrom in case
of hydraulic oil leak. Hydraulic oil leaks can
penetrate or burn the skin.
Always operate the work platform in a well
ventilated area to avoid carbon monoxide
poisoning.
Do not lower the work platform if the area
underneath is not clear of personnel or
obstructions.
Part No. 57.0303.5119
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.
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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.
Do not operate the work platform unless:
•
•
•
•
•
16
You learn and practice the principles of safe work
platform 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 work platform functions
prior to use.
4. Inspect the work place.
5. Only use the work platform 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 work platform.
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 work platform.
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 work platform.
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 work platform 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
work platform directly or indirectly or make it
unsafe;
• contact TEREXLIFT Assistance Service for
any suggestion and the necessary written
permission.
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Part No. 57.0303.5119
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Operator’s Manual
Safety Precautions
REQUISITES OF THE PERSONNEL IN CHARGE
Requisites of the WORK PLATFORM
OPERATORS
The operators who use the work platform 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, the identification
and hazard warning plates. They shall be skilled and
trained about the work platform use.
Requisites of the SERVICEMEN
The personnel charged with the work platform
maintenance shall be qualified, specialized in the
maintenance of handlers, 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 work platform is not a
complex intervention and can be carried out
by the operator too, provided he has a basic
knowledge of mechanics.
NOTICE
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.
Part No. 57.0303.5119
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Safety Precautions
WORKING CLOTHES
During work, but especially when maintaining or
repairing the work platform, 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.
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 machine dimensions in the different
configurations.
DANGER
The machine with work platform is not electrically
insulated and does not provide protection from
contact with or proximity to electrical power lines.
Always keep the work platform at a minimum safe
distance from them. Electrical hazards!
• Keep away from the machine with work platform
in case of contact with energized power lines.
Personnel on the ground must never touch or
operate the machine with platform 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 MAN-PLATFORM
Under special working conditions, the following
personal protective man-platform should be used:
• Breathing set (or dust mask).
• Ear-protectors or equivalent man-platform.
• 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 work platform during
a storm.
WARNING
Operator have to survey his/her field of vision
when operating the telehandler.
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Safety Precautions
•
The machine shall be parked on a ground
adequate to the maximum admissible payload. If
the subsoil collapses, the machine could tip over.
To avoid any risk of overturning, the following
precautions should be taken:
1. Ask your employer (site manager or manager
assistant) if there may be buried pipes, pits,
old tanks, cellar floor, dung yards, etc. under
the ground onto which the outriggers shall be
lowered.
2. A rough estimate of the ground consistency can
be done using the tables and picture in this page.
3. The resistance of the subsoil is in relation
to the ground type and geomorphological
characteristics.
Table 1 indicates the superficial pressure which
can be admitted under the outriggers of the
machine.
Type of ground,
geomorphological
features
Admissible
superficial pressure
loose, non-compact soil
generally speaking,
not solid;
special precautions
needed
loamy, peaty,pasty soil
rippable, soft ground
non-cohesive, well compact soil, sand, gravel
rippable
soil
kg/cm2
0.2
semi-solid
1.0
0.1
solid
2.0
0.2
hard
4.0
0.4
above
10.0
above
1.0
Table 1
Part No. 57.0303.5119
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/cm2 (800x800mm 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.
N/mm2
2.0
Rocks, concrete, heavy
traffic paved roads
WARNING
The distance (a) from the foot of the overhang
shall be adequate to height (h) of the same
overhang.
If the ground fulfils the required conditions:
a:h=1:1
(values with a grey background in table 1)
In the case of doubts:
a:h=2:1
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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.
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.
•
•
•
•
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.
WARNING
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.
•
•
•
•
•
•
•
•
•
20
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Part No. 57.0303.5119
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Operator’s Manual
Safety Precautions
•
•
•
•
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.
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.
•
•
•
•
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.
It is forbidden to increase the work platform
working envelope or height by means of additional
man-platforms such as ladders.
Part No. 57.0303.5119
•
•
•
•
•
•
•
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
•
•
•
•
•
•
•
•
•
22
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.
•
•
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.
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Safety Precautions
ALLOWED USE
IMPROPER USE
The work platform has been designed and built to
operate as a rotary work platform for coupling with
the telescopic (GTH-EX) or rotary (GTH-SR, GTHER) handlers made by TEREXLIFT.The use of the
work platform allows to lift operators, material and
man-platform to carry out works of various kind. 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 work platform 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 machine or the work platform other
than those of routine maintenance is expressly
forbidden. Any modification of the machine or
the work platform not carried out by TEREXLIFT
or an authorised assistance centre involves the
automatic invalidation of the conformity of the
machine to the Directive 2006/42/EC.
Improper use means a utilisation of the work platform
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 of the most frequent and
hazardous situations of improper use:
Carrying protruding loads on the work
platform;
Not strictly complying with the operation and
maintenance instructions of this handbook;
Working beyond the operation limits of the
work platform;
Working without outriggers;
Working with outriggers resting on unstable
or yielding grounds;
Working on steep slopes or working with a
nonlevelled machine due to an inefficient
action of the outriggers;
Fit mobile guards that may increase the wind
action and jeopardise the stability of the
machine;
Using the work platform for purposes other
than those recommended;
Using telescopic handlers not approved or
not manufactured by TEREXLIFT;
Attach loads to the boom anywhere other
than on the quick coupling frame.
DANGER
Using the aerial work platform to perform
manoeuvres in the air is prohibited if the work
platform is not correctly fastened to the lift.
Always avoid all contact with non-moving
objects (buildings) or moving objects (vehicles,
hoisting man-platform, etc.) to prevent any
damage to the work platform and possible risks
to health and safety.
Part No. 57.0303.5119
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24
MAN-PLATFORM
Part No. 57.0303.5119
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Operator’s Manual
Man-Platforms Description
3P/700 REM 4400 MAIN COMPONENTS
1. Electric cable reel (only for EX and SR)
2. Rotation actuator
3. Control board
4. Correct coupling micro-switches
5. Quick coupling frame
6. Cage
7. Locking handles for work platform extension
8. Entrance gates to get access to the cage
9. Load cells
10. Electronic control unit









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Man-Platforms Description
3P/700 REM 4400 GENERAL DESCRIPTION
The work platform is an attachment that can be
installed in Genie GTH telehandlers range. It
consists of an extensible structure designed for
carrying persons and tools not exceeding the rated
capacity, rotating respect to the fixed part of the work
platform that shall be coupled to the telehandlers
boom articulation.
The work platform ranges from -90° to + 90° respect
to the central position, and the rotation is possible
by means of an hydraulic rotary actuator that is
activated by the platform controls.
In order to activate the controls positioned on the
work platform is mandatory to connect it to the boom
articulation and verify that the boom articulation
pins are engaged to the fixed part of the platform;
furthermore is mandatory to connect electrically and
hydraulically the platform to the devices available
on the telehandlers boom.
The operators are allowed to extend/retract the
extensible parts of the platform between multiple
positions that can be chosen in order to facilitate
the activities in the jobsite.
By means of the platform controls, the boom
movements are allowed within the platform work
area if the load does not exceed the rated load or
the allowed load that can be variable along the work
area, in these cases just the safety manoeuvres are
allowed (boom lift and retract). When the platform
reach a stability limit position an audible alarm
together with a visible led warn the operators, refer
to the following instructions for explanations.
If the rated load is exceeded, the platform is blocked
until the overload is removed, an audible alarm
together with a visible led warn the operators, refer
to the following instructions for explanations.
26
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Man-Platforms Description
2P/300 F MAIN COMPONENTS
1. Electric cable reel (it is present only in the work
platform to be coupled with the EX and SR type
of machines)
2. Control board
3. Correct coupling micro-switches
4. Quick coupling frame
5. Cage
6. Entrance gates to get access to the cage
7. Overload micro-switches
8. Electronic control unit (only for ER and SR)








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Man-Platforms Description
2P/300 F GENERAL DESCRIPTION
The work platform is an attachment that can be
installed in Genie GTH telehandlers range. It
consists of a basket type steel structure designed
for carrying persons and tools (the payload) and
having a payload not exceeding the rated capacity
of the machine. This attachment can be coupled
with the telehandlers boom articulation and is not
provided with additional movements except those
available from the machine (boom up/down, boom
telescoping in/out, turret slewing when applicable).
In order to activate the controls positioned on the
work platform is mandatory to connect it to the boom
articulation and verify that the boom articulation
pins are engaged to the fixed part of the platform;
furthermore is mandatory to connect electrically
the platform to the relevant socket available on the
telehandlers boom.
The operators are allowed to access the internal area
of the platform through a specific access gate which
is normally kept in its closed position by gravity.
By means of the platform controls, the boom
movements are allowed within the platform work
area if the load does not exceed the rated load or
the allowed load that can be variable along the work
area, in these cases just the safety manoeuvres are
allowed (boom lift and retract). When the platform
reach a stability limit position an audible alarm
together with a visible led warn the operators, refer
to the following instructions for explanations.
If the rated load is exceeded, the platform is blocked
until the overload is removed, an audible alarm
together with a visible led warn the operators, refer
to the following instructions for explanations.
28
MAN-PLATFORM
Part No. 57.0303.5119
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Operator’s Manual
Man-Platforms Description
MAN-PLATFORMS APPLICATION FIELD
The following table represents the application field of man-platform installed on Terexlift telehandlers
GTH-4013EX
2P/300 F
3P/700 REM 4400


GTH-4017EX

GTH-4514EX

GTH-4016SR


GTH-4018SR


GTH-6025 ER


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30
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Part No. 57.0303.5119
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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 manplatform 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 man-platform 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 man-platform must be
tagged and removed from service.
Repairs to the telehandler and/or the manplatform 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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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.
For the man-platform:
• 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
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.
CHECKS PRIOR TO USE
•
•
•
•
Check the efficiency of the overload warning
system
Check the efficiency of the emergency stop
pushbutton
Check the efficiency of the micro-switches on
the work platform attaching point
Check the efficiency of the control enabling
pushbutton
For the checks to be done, see the section
"Maintenance"
WARNING
If even one single item is damaged or defective,
do not start work. Stop the machine and repair
the fault.
32
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second 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.
Perform all the tests provided for the
telehandler and listed in the machine
Operator's Manual.
3. Always perform function tests prior to use.
4. Inspect the workplace.
5. Only use the telehandler and the manplatform as they were intended.
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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
34
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Operating Instructions
INTRODUCTION
This section provides the operator and the ground
operator a practical guide for the gradual learning of
the use of the machine fitted with work platform. Both
operators shall have all the necessary requisites
and shall become familiar with both handler and
man-platform before starting using them. This
familiarization ensures not only a proper use during
work, but also a prompt and timely intervention of
the ground staff when sudden manoeuvres to protect
the operator on the work platform and the machine
integrity are required.
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
no part of the machine operates at less than 6
meters from the power lines.
DANGER
Overloading the work platform is always
forbidden. The number of people and the
maximum admissible load are indicated in the
identification plate of the work platform and in
the section "Specifications" of this manual.
Part No. 57.0303.5119
DANGER
Never use the telehandler combined with work
platform if the machine has not been stabilized.
For EX type telehandlers, lower the outriggers
completely on flat ground and visually level the
flatbed of the work platform. For SR, ER type,
lower the outriggers, even independently of
one another, until the spirit level on the turret
is central and then visually level the flatbed of
the platform. The maximum slope allowed for
the use of the work platform-machine system
is about 1%.
NOTICE
During the use of the work platform, one person
must be charged with supervising the operators
on the work platform from the ground to intervene
and lower the work platform to the ground in an
emergency - for the correct emergency procedure
see the section "Operating instructions" of this
manual (paragraph "Lowering the work platform
in emergency")
For the controls operated from the driving place
of the handler, please refer to the operator’s
handbook of the handler.
During the transfer of the machine coupled
wit the work platform on public roads, always
respect the highway code for the country of use.
The use of the the work platform combined with
a telehandler is allowed at temperatures ranging
between -20°C and +40°C
MAN-PLATFORM
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Operator’s Manual
First Edition - Second Printing
Operating Instructions
COUPLING THE WORK PLATFORM TO THE
HANDLER
To couple the work platform to the handler, proceed
as follows:
•
disconnect any mounted attachment and store
it in a safe place.
•
Approach the quick coupling frame to the work
platform and ensure the frame is rotated forward
(see fig. 4).
•
Hook the upper lock of the work platform (fig.
4, position A)
•
Retract and lift the work platform some centimetres.
The work platform will centre on the quick
coupling frame automatically.
•
•
Open cover B protecting the current socket on
the boom and plug in the work platform power
cable plug E (see fig. 7 for EX and SR models,
fig. 6 for ER model).
Secure the work platform power cable with the
proper bracket in position F (only for EX and SR
models, see fig. 7).
Fig. 5
Fig. 4
•
•
•
36
Operate the joystick for locking the work
platform definitively (see par. “Changing
the attachments” in the machine operator’s
manual).
Unhook the pipes of the attachment lock cylinder
from the fitting in position C and connect them
to the fittings in position D (see fig. 5 for EX and
SR model, see fig. 6 for ER model)
Hook up the work platform pipes to the fittings
in position C ( see fig. 5 for EX and SR models,
see fig. 6 for ER model)
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Operating Instructions
DANGER
Fig. 6
E
D
C
Using the work platform for aerial manoeuvres
if the platform is correctly coupled but the pin
is not driven in or if the locking pin is driven in
but the power cable is not correctly connected
is expressly forbidden. It is forbidden to use the
machine if the work platform is coupled, and a
person is in the platform, but the handler controls
are still activated.
NOTICE
The bypass key of the load limiter of the handler
is only activated when the "Road-PlatformJobsite" selector in the handler cab (see the
image here below) is turned to "Jobsite" (position
A). When this selector is turned to "Platform"
(position B) the bypass key is not active and the
load limiter cannot be disabled.
Fig. 7
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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.
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
10
9
5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
6
7
8
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
Operation
When power is turned on, light 4 comes on. The
display 2 remains off and the monitoring system runs
a self-test before displaying number 0 on display 2.
At this time, the system is activated.
During operation, the led-bar 3 lights up gradually
depending on the variation of stability.
Green LED’s: during normal operation when the
percentage of overturning moment is
between 0 and 89, these LED’s are ON.
The machine is stable.
Yellow LED’s: they light up when the machine
tends to overturn and the percentage of
overturning moment with respect to the
threshold value is between 90 and 100.
The system enters the pre-alarm mode,
light 10 flashes and the buzzer sounds
with an intermittent sound.
Red LED’s: risk of overturning: the percentage of
overturning moment is above 100 with
respect to the threshold value.
The machine enters the alarm mode: light
10 is lit, the buzzer sounds continuously
and any dangerous manoeuvre is blocked.
The operator can only retract the load
within safety limits.
Alarm codes and resetting
The limiter has diagnostic facilities to aid in the
identification of failures of the transducers, breakages
of the cables or defects of the electronic system.
When a failure is signalled, the limiter enters the safety
mode blocking any dangerous manoeuvres. Lights
5, 8 and 10 start flashing, the buzzer start sounding
and an error message is shown on the display.
The meaning of the error messages is shown in
Section “Faults and Troubleshooting” of each
telehandler Operator's Manual.
DANGER
Before using the machine, make sure that the first
green LED of the overload warning system is ON.
38
MAN-PLATFORM
Part No. 57.0303.5119
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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.





1.
2.
3.
4.
5.
Test button
Stability indicator with LED-bar
Green light - power OK
Not used
Buzzer cut off
TEST BUTTON, pushing this button all leds and
buzzer are tested: LEDS flash and buzzer sounds
for three times.
BUZZER CUT OFF, pushing this button buzzer is
cut off for 10 seconds.
Operation
When power is turned on, light 3 comes 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
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
extraction slows 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 defects of the electronic system.
When a failure is signalled, the limiter enters the
safety mode blocking any dangerous manoeuvres:
LED L6 starts flashing in conjuction with another
LED which represents the 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.
L4
L3
L2
L1
Part No. 57.0303.5119
LED Bar
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First Edition - Second Printing
Operating Instructions
MODEL N°3
ESC
55%
+
-
1
2
3
FORKS
OUTRIGGERS LATERAL
MAX LOAD ........................ 50.3t
RAISED LOAD ................... 10.2t
ANGLE ............................... 12.3°
EXTENSION...................... 12.3m
RADIUS.............................. 7m
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
40
ENTER
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
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
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Operating Instructions
DANGER
55%
FORKS
OUTRIGGERS LATERAL
MAX LOAD ........................ 50.3t
RAISED LOAD ................... 10.2t
ANGLE ............................... 12.3°
EXTENSION...................... 12.3m
RADIUS.............................. 7m
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.
fig. A
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).
LANGUAGE
EXTENSION SENSOR
•
•
•
•
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.
Press the two buttons PLUS (+) and MINUS
(-) simultaneously to access to the Diagnostic
Screen Pages. These pages can only be
consulted. Use the ARROWS to pass from one
page to another.
ANGLE SENSOR
CLOCK
CLOCK
ITALIANO
ENGLISH

15:25:42
10/01/09
FRANÇAIS
ESPAÑOL
LANGUAGE
EXTENSION SENSOR
LANGUAGE
EXTENSION SENSOR
ANGLE SENSOR
CLOCK
CLOCK
MIN1 20MIN2
20
MAX1 1000 MAX2 1000
N1 915
MAN-PLATFORM
ANGLE SENSOR
EXIT
Part No. 57.0303.5119
LANGUAGE
EXTENSION SENSOR
ANGLE SENSOR

N2 913

ZERO1 511
ZERO2 511
N1 552
N2 551
EXIT
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Operator’s Manual
First Edition - Second Printing
Operating Instructions
MODEL N°4
ENTER
1
2
3
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 buzzer emits an intermittent sound.
Red LED ON
Alarm condition. The raised load exceeds the
maximum allowed load, the buzzer emits a
continuous sound 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 four
areas:
LT area: operating modes
1 Front operation with stabilizers
2 Side operation with stabilizers
3 Front operation without stabilizers
4 Side operation without stabilizers
Display area and control keys
Display B Indicates the weight raised for the
system calibration
C Indicates the max. load that can be
raised
D Indicates the distance of the load from
the slewring axis
E Indicates the operating mode (1-2-3-4)
F Indicates the attachment used (F-P-WJ-R)
Keys INDEX To change the operating mode I
(E in the display).
ENTER To confirm.
I area:
To set the buzzer off.
Buzzer is reset automatically to on
in an alarm or pre-alarm condition.
attachments
F Pallet fork
P Platform
W Winch
J Extension jib
R Robot
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
42
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Operating Instructions
WARNING
The automatic recognition system of some
attachments is a mere help for the operator who
must, in any case, verify that the attachment on
the display is the one actually in use.
Operation
At the machine starting, the overload warning system
runs an automatic check.
After about 10 seconds, the date and the machine
model are displayed followed by the first page showing
the last attachment used or the new attachment with
electrical recognition.
Once the automatic diagnosis is completed, the
machine is ready for use.
If the attachment used is of “mechanical” type, proceed
with the manual search and selection. Press INDEX
until the letter corresponding to the used attachment
is displayed in the F window.
Press ENTER to confirm.
The machine is ready to use.
DANGER
Before using the machine, make sure that the first
green LED is ON, and that the operating mode
shown in window and the attachment shown
in window are those actually used.
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 instable conditions may also be caused by
an abrupt operation of the control lever during
the load handling. If, during work, several LED’s
switch on simultaneously, operate the levers
more smoothly.
Part No. 57.0303.5119
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43
Operator’s Manual
First Edition - Second Printing
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.
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

44
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Operating Instructions
SWITCHING THE CONTROLS FROM THE
HANDLER TO THE WORK PLATFORM
•
Move with the handler to the working site,
lower the outriggers to the ground and level the
machine checking its position on the water level
on the cab dashboard and engage the parking
brake.
•
Level the flatbed of the work platform;
•
Run the engine just over idle operating the gas
pedal.
•
Connect the power cable of the work platform
to the handler.
•
Set the Road/Jobsite/Platform selector to
"Platform" (position B); the green light indicator
b lights up signalling that the controls have been
switched to the work platform.
•
Enter the work platform and proceed as
explained below:
Insert the key of the Road/Site/Platform selector
into switch 1 and turn the key to position 1 (see
the following image) to enable the work platform
controls.
Push the button 3 in the following image to start
the engine.
On the antioverload display that is inside the
cab select the function "Work Platform" and
confirm it selecting "enter" (only for SR machine
models, on the EX and ER models is confirmed
automatically).
•
•
•
3P/700 REM 4400 & 2P/300 F (when coupled
with ER and SR models)
b
0
1

•
•
Remove the key from selector (it shall be used
to access to the work platform control board).
Stop the engine.
NOTICE

2P/300 F (when coupled with EX models)
OFF
Before switching the controls from the handler to
the work platform, set the control switch on the
dashboard to position P for EX and SR machine
models, to position I for ER model.
ON


START
DANGER
P
The operator on the ground shall never leave the
handler cab unattended and must always be in
contact with the operator on the work platform.
Part No. 57.0303.5119
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Operator’s Manual
First Edition - Second Printing
Operating Instructions
STEPPING INTO THE WORK PLATFORM
To enter the work platform, lift the entrance gates B
located on the two sides of the cage (see the image
here below). Be sure that both the entrance gates
are properly closed before operating.
EXTENDING THE WORK PLATFORM for
3P/700 REM 4400
The work platform has an extending flatbed; to
extend the flatbed, proceed as follows:
•
lower the work platform to the ground, stop the
diesel engine and engage the parking brake;
•
lift the handles A (there are two for each
extending side of the work platform) and push
them towards outside;
•
extend the mobile part (from the interior side to
the outer side) until reaching the special safety
lock, then lower the handles A to secure it.
46
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Operating Instructions
USE OF THE SAFETY BELT
DANGER
- Occupants must wear a safety belt or harness
in accordance with governmental regulations.
Attach the lanyard to the proper anchorages
provided in the work platform.
- Do not sit, stand or climb on the work platform
guard rails. Maintain a firm footing on the work
platform at all times.
- Do not climb down from the work platform
when raised.
- Keep the work platform floor clear of debris.
- Close the work platform entrance gates before
operating.
- Do not enter or exit the platform unless the
machine is in the stowed position and the work
platform is at ground level.
Part No. 57.0303.5119
NOTICE
Use only type-approved and CE-marked safety
belts in good conditions. For the use of safety
belts, please refer to the manual supplied by
the manufacturer.
MAN-PLATFORM
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Operator’s Manual
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Operating Instructions
CONTROL PLACE ON THE WORK PLATFORMS
3P/700 REM 4400 & 2P/300 F (when coupled
with ER and SR models)

0




1





11
2P/300 F (when coupled with EX models)

OFF

ON
12


START

48



MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Operating Instructions
1. Key-switch enabling the controls:
(use the key of the Road/Jobsite/Platform selector previously
removed from the handler)
•
•
turn the key to position 0 to deactivate the
controls, the machine engine will switch off.
turn the key to position 1 to activate the controls.
2. Emergency pump button:
the pressure of this button activates the electric
pump used for emergency manoeuvres. When
the button is released, the pump is deactivated.
3. Engine start button:
press this button to start the telehandler engine.
4. Boom lifting/lowering lever:
•
press the function enabling switch 6 and holding
it down move the control lever up, the boom will
raise.
• press the function enabling switch 6 and holding
it down move the control lever down, the boom
will lower.
5. Boom extension/retraction lever:
•
press the function enabling switch 6 and holding
it down move the control lever down, the boom
will extend.
•
Press the function enabling switch 6 and holding
it down move the control lever up, the boom will
retract.
6. Function enabling switch:
this button must be pressed and hold down
during the operation of the control levers. If the
button is released, the given command is not
performed or interrupted. If this button is pressed
for more than 3 seconds without operate any
control you should release and press it again
before operating the control otherwise it is not
performed.
7. Alarm LED:
the red LED lit associated with a sound alarm
indicates the presence of an error in the work
platform-machine system. Refer to table with the
list of the functional errors in the section "Faults
and Troubleshooting" of this manual to identify
the error.To make the diagnostics of any possible
existing error press at the same time the function
Part No. 57.0303.5119
enabling switchs 6 and 11 and hold them down
for about 3 seconds.
8. Basket rotation lever:
• press the button 11 and holding it down move
the control lever toward left, the work platform
will rotate to the left.
• press the button 11 and holding it down move
the control lever toward right, the work platform
will rotate to the right.
• press the function enabling switch 6 and holding
it down move the control lever toward left, the
machine turret will rotate to the left (only for SR
and ER machine models).
• press the function enabling switch 6 and holding
it down move the control lever toward right, the
machine turret will rotate to the right (only for SR
and ER machine models).
9. Horn button:
push the horn button and the horn will sound,
release it and the horn will stop.
10. Emergency stop pushbutton:
when pressed down the machine engine switch
off and all the movements of the work platform
are stopped. Before starting work again, find
and rectify the causes which compelled to an
emergency stop, then reset the button to neutral
position pressing it down while turning clockwise.
11. Pushbutton to enable the work platform
rotation (ONLY for 3P/700 REM 4400):
this pushbutton has to be pressed and hold
down for the whole duration of the control. If it
is released the action stops.
12. Basket rotation selector:
NOT ACTIVE.
NOTICE
The emergency pump is driven by an electric
motor. It is advisable to let it run for about 30
seconds, then stop it for about 2 minutes to allow
the motor to cool down.
MAN-PLATFORM
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Operator’s Manual
First Edition - Second Printing
Operating Instructions
LOWERING THE WORK PLATFORM IN
EMERGENCY
CASE A):
•
Press the emergency stop pushbutton 10 on the
work platform control board.
•
Only in the ER machine model, pull the
emergency stop pushbutton 10 to disconnect it.
•
Press the emergency pump button 2 and the
dead man button 6 together and holding them
down move the proper control lever to perform
the required movement.
There are two possible types of emergency descent
to bring the work platform back down to the ground:
A) the operator is able to use the controls on board
the work platform but the engine stopped previously
will not restart.
B) the operator is unable to work the controls on the
work platform.

0
1
3P/700 REM 4400 &
2P/300 F
(when coupled with ER
and SR models)

OFF

ON
2P/300 F
(when coupled with
EX models)
START

50

MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Operating Instructions
CASE B):
EX MODELS:
If the operator on the work platform cannot operate
the emergency controls installed in the work platform,
the ground assistant shall execute the emergency
manoeuvre to lower the work platform to the ground.
•
Press the emergency pushbutton that is inside
the cab, the machine engine will switch off.
•
Open the compartment where is located the
main valve.
•
Press the emergency pump button Z that is
located close to the main valve and holding it
down move the lever to lower the machine boom
and bring the work platform back to the ground.
If the emergency pump button is released the
pump action stops.
The main valve has some control levers that operate
the following functions:
1
2
Part No. 57.0303.5119
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Operator’s Manual
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Operating Instructions
SR MODELS
GTH 6025 ER
Lever 1
Lever 2
Lever 3
A
Boom up
B
Boom down
A
Boom extention
B
Boom retraction
A
Turret clockwise rotation
B
Turret counter-clockwise rot.
Lever 1
Lever 2
Lever 3
A
Turret clockwise rotation
B
Turret counter-clockwise rot.
A
Boom extention
B
Boom retraction
A
Boom lowering
B
Boom raising
Z
X
Y
Z Y
Z
Z
X
B
B
A
A
52
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Operating Instructions
•
•
NOTICE
The load limiter will not intervene when
using the emergency controls in manual
mode.
Use the emergency controls only to take the
machine back in a safety condition.
DANGER
If it is not possible to lower the work platform in
emergency due to the main valve failure, please
contact Terexlift Service Department.
DANGER
When using the emergency controls, always
follow the sequence here below with care:
EX machines:
Lever 2 In A
Lever 1 In A
Total boom retraction
Boom lowering
SR machines:
Lever 2 In B
Lever 1 In B
Total boom retraction
Boom lowering
GTH 6025 ER:
Lever 2 In B
Lever 3 In A
Total boom retraction
Boom lowering
NOTICE
Use the manual controls of the handler only if a
real hazard exists.
Part No. 57.0303.5119
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Operating Instructions
CORRECT WORK PROCEDURE
Step1: couple the work platform to the telehandler
Step 2: fix the work platform using the work platform
attachment quick coupling cylinder
Step 3: place the machine on a level surface with
the outriggers completely lowered and extended
Step 4: release the piston blocking turret rotation
(ER series only)
Step 5: engage the parking brake
Step 6: set the forward/reverse lever to neutral
position
Step 13: connect and fix the power plug on the
connector that is on the boom
Step 14: check the work platform load as described
in the section "Maintenance" in the paragraph
"checking the work platform load cells"
Step 15: start the machine engine from the work
platform
Step 16: on the antioverload display that is inside the
cab select the function "Work platform" and confirm
it selecting "enter" (only for SR models)
Step 17: This procedure has to be executed every
time you use the work platform after using other
attachments on the machine.
Now you are ready to work with the work platform.
Step 7: set the road/jobsite/platform switch to
platform
Step 8: turn the ignition switch to position P for EX
and SR machine models, to position I for ER models
Step 9: remove the key from the road/jobsite/platform
selector (it shall be used to operate the work platform
controls)
Step 10: release the piston blocking turret rotation
(SR series only)
Step 11:using the proper cotter pin block the
attachment quick coupling cylinder
Step 12: connect the hydraulic pipes of the work
platform to the boom fitting
54
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Operating Instructions
USE PRECAUTIONS
•
•
•
•
•
•
STOPPING AND STORING THE EQUIPMENT
DANGER
The second and unique copy of the key of the
Road/Site/Platform selector shall be kept by
the jobsite manager or the person charged
with the workplace safety.
This key shall be used only for lowering
the work platform to the ground in an
emergency.
Do not at any time use the work platform for
purposes other than those for which it was
specifically intended -e.g. as a crane.
Enter/leave the work platform only when it
is lowered to the ground.
The loading of a rotating work platform can
only be done with the work platform in the
central position.
Do not at any time use man-platform or
accessory parts to increase the working
or lifting height of the work platform (e.g.
ladders fitted to the basket, etc.).
It is forbidden to move the work platform
from side to side of the working area while
the operators are on board.
NOTICE
NOTICE
Lay the work platform on a dry and level ground.
To release the work platform from the handler:
•
Approach the place where you will release the
work platform.
•
Lower the work platform on the ground.
•
Stop the engine of the handler and remove
the key from the work platform control board
(selector I/0).
•
Leave the work platform.
•
Disconnect the hydraulic pipes of the work
platform from the boom fittings in position C
and connect the pipes of the attachment lock
cylinder in their place after having removed
them from the boom fittings in position D (see
image 9).
•
Remove the work platform power cable plug
from the boom socket and close the cover to
protect the socket against dirt and rain.
•
Enter the handler cab and insert the key
you removed from the work platform into the
Road/Site/Platform selector and turn it to
“Jobsite”(position A); the green light indicator
b will switch off.
In case of situations or working conditions other
than those described in this manual, contact the
manufacturer to get the necessary permission
and any useful advice.
WARNING
b
The work platforms dealt with in this manual
are not equipped with safety devices protecting
the operators aboard from objects falling from
above.
Part No. 57.0303.5119
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Operator’s Manual
First Edition - Second Printing
Operating Instructions
•
Move the ignition switch on the machine
dashboard from position P to position I for EX
and SR series, from position I to position 0 for
ER series (see the image below).
PARKING FOR LONG PERIODS
If the lift and work platform need to be parked for long
periods of disuse we recommend that you:
•
•
•
P
•
•
•
On the antioverload display that is inside the
cab select the function "Forks" and confirm it
selecting "enter" (only for SR models)
NOTICE
Now, controls can be operated from the handler
cabin only.
D
C
•
•
Wash the work platform with care.
Do not direct the water to the electric components.
After washing, dry all parts thoroughly with a jet
of air.
Grease all parts of the work platform.
Carry out a general inspection and replace any
worn or damaged parts.
Repaint any damaged or worn parts.
Place the work platform in a covered, well
ventilated area.
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 work platform,
carry out an extraordinary maintenance and
carefully check all mechanical, hydraulic and
electrical components.
9
•
•
•
•
56
Restart the engine.
Operate the joystick to release the work platform
from the quick coupling plate.
Tilt the coupling plate forward and lower the
boom to release the upper lock of the work
platform.
Move back with the machine.
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Operating Instructions
WORK PLATFORM TRANSPORT
WORK PLATFORM HANDLING
The work platform 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.
In the second case proceed as follows:
1. retract the extensible part of the work platform
and lock it with the proper handles A ( ONLY for
3P/700 REM 4400);
2. approach the work platform;
3. insert the forks in the proper guides B.
The work platform is in the transport position when
the relevant controls are disabled and cannot be
used. In this condition, only the cab controls are
activated.
WARNING
Before moving with the work platform coupled
to the handler, make sure it is correctly coupled
to the attachment coupling frame.
MACHINE DISPOSAL
PROTECT THE
ENVIRONMENT
At the end of the machine life, call in a specialised
firm to dispose of it in compliance with the local
or national regulations.
BATTERY DISPOSAL
Part No. 57.0303.5119
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.
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Intentionally blank page
58
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Maintenance
Observe and obey:
*
*
INTRODUCTION
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.
A thorough and regular maintenance keeps the
machine in a safe and efficient working condition.
For this reason, it is advisable to wash, grease and
service the machine properly, especially after having
worked under particular conditions (muddy or dusty
environments, heavy operations, etc.).
Always ensure all machine components are in good
condition. Check for oil leaks or loosening of guards,
and make sure that the safety devices are efficient.
In case of defects, find and rectify them before using
the machine again.
Not respecting the ordinary maintenance schedule
of this manual automatically voids TEREXLIFT
warranty.
SERVICE INTERVAL
Running-in ____________________________
Ordinary ______________________________
Part No. 57.0303.5119
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Operator’s Manual
First Edition - Second 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.
Fire
In case of fire, use carbon dioxide, dry chemical or
foam extinguishers. Do not use water.
60
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 work platform 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.
NOTICE
Effecting changes or carrying out interventions
on the machine or the work platform other
than those of routine maintenance is expressly
forbidden. Any modification of the machine or
the work platform 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
At every use of the work platform
1
2
3
Check the efficiency of the safety systems
installed (see the section "Safety Devices" in
this manual).
Remove any material from the grilled floor to
avoid blocks of the extending parts of the work
platform.
Make a visual check of the structure, paying
particular attention to signs of corrosion and
structural welds.
During the first 10 operating hours
1
2
Check if there are oil leaks.
Check the tightening of all bolts and nuts.
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Maintenance
MAINTENANCE INTERVENTIONS
Every 50 operating hours or weekly
1
2
3
Do a visual check on the structure paying
special attention to signs of corrosion, welds
and those parts supporting the load.
Check the mechanical, hydraulic and electrical
systems as indicated in the handler’s manual.
Grease all moving parts.
NOTICE
The intervals and the duration of the periodic
checks and tests can be subject to local or
national regulations.
Do the necessary checks before using the work
platform.
Every 5 years
5 years after the machine (handler and aerial
work platform) has been placed into service, it is
necessary to inspect the structure, paying special
attention to the welds on the load-bearing joints and
the pins on the telescopic boom and work platform.
WARNING
For maintenance interventions, only use
manufacturer’s recommended spare parts you
can find indicated on the relatives SPARE
PARTS CATALOGUE
•
3P/700 REM 4400, code 57.0701.9003;
• 2P/300 F, code 57.0701.9004
WARNING
Before using the work platform:
•
ensure all bolts and nuts are properly
tightened
•
check the couplings for oil leaks
•
check the hydraulic system
•
check the electric system.
DANGER
All maintenance interventions shall be carried
out with working implements on the ground.
When, for maintenance purposes, a component
shall be lifted, secure it in a safe and stable way,
before carrying out any operation.
Any intervention on the hydraulic circuit must
compulsorily be carried out by skilled personnel.
PROTECT THE
ENVIRONMENT
The handling and disposing of used oils can be
ruled by local or national regulations. Address
to authorised centres.
Part No. 57.0303.5119
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Maintenance
GREASING
CAUTION
Weekly grease the points shown in figures here
below:
Before injecting grease into the greasers,
thoroughly clean them to avoid that mud, dust
or other matters can mix with the lubricant and
reduce or annihilate the lubrication effect.
Remove any old grease with a degreaser from
the telescopes before smearing them with new
grease.
Regularly grease the machine to grant it efficient
conditions and a long life.
By means of a pump, inject grease into the special
greasers.
As the fresh grease comes out, stop the operation.
The greasing points are shown in the following figures:
-
represents the points to be
the symbol
greased by a pump
-
represents the points to be
the symbol
greased by a brush.
CAUTION
For the machine greasing, use SHELL lithiumbased grease, type SUPER GREASE EP when
greasing by pump and AGIP graphitised grease,
type GR NG 3, when greasing by brush.
WARNING
Never mix different greases or oils: this may
result in troubles and component breaks.
SERVICE INTERVAL
Running-in __________________________ None
Ordinary __________________ Every
62
MAN-PLATFORM
40 hours
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Maintenance
CHEKING THE SAFETY DEVICES
Checking the attachment locking MICROSWITCHES
Checking the work platform LOAD CELLS for
3P/700 REM 4400 and OVERLOAD MICROSWITCHES for 2P/300 F
(at every use)
The function of this devices is to detect the load that
is on the work platform
Load a known weight on to the work platform
corresponding to the maximum admissible load
plus 20%;
Ensure the system alarm warns of the overload
state and all the movements of the work platform
are blocked until the 20% weight in excess is
removed.
Checking the STABILITY CONTROL SYSTEM
(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 control lever ENABLING PUSH
BUTTON
(at every use)
This pushbutton has to be pressed and hold down
for the whole duration of the control. If the button is
released, the action stops. It is used to avoid any
accidental movement.
To check its efficiency
• attempt a movement without pressing this button
down: the movement must be disabled. Should
that not be the case, contact the TEREXLIFT
Technical Service.
Part No. 57.0303.5119
(at every use)
They are placed on the work platform attach to test its
correct connection to the handler on both sides (the
locking pin that fix the work platform to the handler
has to be completely inserted).
To check their efficiency
• attempt to move the work platform without
coupling it to the handler:it shall remain blocked;
should this not be the case, check the microswitches for damage and replace if necessary.
Checking the EMERGENCY PUMP BUTTON
(at every use)
the pressure of this button activates the electric
pump used for emergency manoeuvres. When the
button is released, the pump is deactivated.
To check its efficiency:
• after pressing down the emergency stop
pushbutton, press down the emergency pump
button and holding it down check that the
required control is operated by the joystick.
Checking the EMERGENCY STOP
PUSHBUTTON
(at every use)
When pressed down the machine engine switch
off and all the movements of the work platform are
stopped. Before starting work again, find and rectify
the causes which compelled to an emergency stop,
then reset the button to neutral position pressing it
down while turning clockwise.
To check its efficiency:
• press it down during a movement: the pressure
of the pushbutton shall cause the movement to
stop and the engine to switch off.
Checking the blocking valve on the work
PLATFORM ROTATION ACTUATOR for
3P/700 REM 4400 (at every use)
To check the efficiency of a valve, proceed as
follows:
• position the work platform some centimetres
above the ground with the boom fully withdrawn
• Push the work platform by hand and attempt to
rotate it with the assistance of a second person.
The work platform must not move. Should that
not be the case, change the valve.
MAN-PLATFORM
63
Operator’s Manual
First Edition - Second Printing
Maintenance
DANGER
Take all the necessary precautions while
checking the efficiency of the valve:
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-authorized people away
During the check proceed with extreme
caution.
DANGER
Always use the lock ring of the lift cylinder (see
picture below), when carrying out maintenance
on the work platform or, in general, any operation in the area under the boom:
I. Lift and extend the boom
II. Unscrew the two screws on the frame (pos.
A) to release the ring
III. Put the ring on the lift cylinder rod (pos. B)
IV.
Lock the ring by tightening the screws
provided on the ring.
NOTICE
Also check the blocking valves of the handler
to which the work platform is coupled as per
Operator 's Handbook instructions.
Checking the outrigger micro-switches
(at every use of the work platform)
To check the efficiency of the outrigger microswitches, proceed as follows:
lower the outriggers leaving one of them raised.
Couple the work platform to the handler and
plug in the special power plug on the boom.
Switch the Road/Jobsite/Work platform switch
to Platform.
Operate the platform controls and ensure they
do not move.
NOTICE
It is forbidden to pass or stop in the area beneath
the work platform if the lock ring has not been
installed on the lift cylinder.
If the micro-switch is faulty or the lever is
deformed, immediately replace the defective
part.
64
NOTICE
Go to the section "Routine Check Schedule"
to note down the results of the safety devices
daily check.
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second 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 on the machine, but call in a skilled
technician.
PROBLEM
WARNING
The work platform is an man-platform coupled
to an handler. A defective handler may affect the
proper functioning of the work platform. For this
reason, it is recommended to read the handler
manual for all faults which are not listed below.
CAUSES
SOLUTIONS
• Work platform power cable is not • Connect the power cable to the handler
boom
connected to the handler
THE WORK
PLATFORM
CONTROLS DO NOT
FUNCTION
• Road/Jobsite/Platform selector is
set to "Jobsite" or "Road" control
• Set the switch to "Platform" control
• Switching procedure from handler to • Switch again the controls from the handler
platform incorrect
to the platform
THE OVERLOAD
WARNING SYSTEM IS
IN ALARM
THE OVERLOAD
WARNING SYSTEM
IS IN ALARM EVEN
IF THE EMBARKED
LOAD IS LESS
THAN THE MAX
ADMISSIBLE
• Overload of the work platform
• Remove any load in excess from the work
platform. Take note of the payload limits of
the machine to which the work platform is
coupled
• One of more load cells can be
defective
• Replace the defective load cell
NOTICE
In case of faults not listed in this chapter, address to the TEREXLIFT Technical Assistance, your
nearest authorised workshop or dealer.
Part No. 57.0303.5119
MAN-PLATFORM
65
Operator’s Manual
First Edition - Second Printing
Faults And Troubleshooting
FUNCTIONAL ALARMS LIST
ALARM
CODE
LED
ACOUSTIC
SIGNAL
SERIES EX
SERIES ER
SERIES SR
INITIAL CHECK UP
1
FIXED LIT UP
3 sec
SYNCHRONOUS
WITH LED
X
X
X
ACTIVATION
OF THE
VISUALIZATION
MODALITY OF THE
WORK PLATFORM
ALARMS
2
FIXED LIT UP
3 sec
NOT ACTIVATED
X
X
X
WORK PLATFORM
NOT SAFELY
CONNECTION
4
FIXED LIT UP
BLINKING
100ms-TYPE 4
X
X
X
WORK PLATFORM
NOT ENABLED
(JOBSITE/WORK
PLATFORM
SELECTOR)
5
FIXED LIT UP
BLINKING
250ms-TYPE 3
EMERGENCY STOP
ACTIVATED
6
FIXED LIT UP
BLINKING
500ms-TYPE 2
X
X
X
SYSTEM ERROR
ACTIVATED
7
FLASHING
250ms-TYPE 3
ACTIVATED
BLINKING - 1 sec
EVERY 5secTYPE 5
X
X
X
WORK PLATFORM
OVERLOAD ALARM
8
FLASHING
500ms-TYPE 2
SYNCHRONOUS
WITH LED
X
X
X
TELEHANDLER
OVERLOAD ALARM
9
FLASHING
1sec-TYPE 1
SYNCHRONOUS
WITH LED
X
OUTRIGGERS
ALARM
10
FIXED LIT UP
SYNCHRONOUS
WITH LED
X
TELEHANDLER
OVERLOAD ALARM
11
FLASHING
1sec-TYPE 1
MANAGED BY
SYNCHRONOUS
THE
WITH LED
TELEHANDLER
MANAGED BY
THE
TELEHANDLER
OUTRIGGERS
ALARM
11
FIXED LIT UP
MANAGED BY
SYNCHRONOUS
THE
WITH LED
TELEHANDLER
MANAGED BY
THE
TELEHANDLER
On the ER machine models it is possible to visualize
the error code directly on the antioverload display
that is inside the cab. Select ENTER from the main
screen to activate the diagnostics mode. By means
of the keys + and - it is possible to scroll the pages
to and fro; select the P14: Clio page, after few
minutes you will visualize the screen showed here
below where you will find the error code written
inside the red circle.
66
MAN-PLATFORM
X
CA
CB
.
.
8
8
8408
0
0
0
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Faults And Troubleshooting
FASTENER TORQUE CHARTE
SAE FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
SIZE
Grade 5
THREAD
LUBED
DRY
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
DRY
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
80
90
9
10.1
100
120
11.3
13.5
110
120
12.4
13.5
140
160
15.8
18
130
140
14.7
15.8
LUBED
5/16
LUBED
in- lbs
20
28
1/4
A574 High Strength
Black Oxide Bolts
LUBED
Grade 8
DRY
LUBED
DRY
LUBED
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
METRIC FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
Class 4.6
Size
(m m )
5
6
7
LUBED
DRY
LUBED
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
DRY
in- lbs
Nm
in-lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
f t - lbs
Nm
f t -lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
ft - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
Part No. 57.0303.5119
MAN-PLATFORM
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First Edition - Second Printing
Intentionally blank page
68
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Specifications
3P/700 REM 4400
code 59.1111.6001 for GTH 4013EX, GTH
4514EX, GTH 4017 EX
code 59.1111.6002 for GTH 4016SR, GTH
4018SR
•
•
•
3P/700 REM 4400
code 59.1111.6003 for GTH 6025ER








TECHNICAL DATA




Length
2110 mm
Height
1850 mm
Width
2520 mm
Width
4610 mm
TECHNICAL DATA




Length
2110 mm
Height
1600 mm
Width
2520 mm
Width
4610 mm
Max. Payload
700 Kg
Max. Payload
700 Kg
Operator on board:
3 Max
Operator on board:
3 Max
Rotation:
90°+90°
Rotation:
90°+90°
Extension:
from 2520 to 4700
Extension:
from 2520 to 4700
Weight:
920 Kg
Weight:
880 Kg
Part No. 57.0303.5119
MAN-PLATFORM
69
Operator’s Manual
First Edition - Second Printing
Specifications
2P/300 F
code 59.1111.6010 for GTH 4013EX, GTH
4514EX, GTH 4017 EX
code 59.1111.6005 for GTH 4016SR, GTH
4018SR
•
•
•
2P/300 F
code 59.1111.6000 for GTH 6025 ER






TECHNICAL DATA
 Length
 Height
 Width
1490 mm
TECHNICAL DATA
1520 mm
2300 mm
 Length
 Height
 Width
Max. Payload
300 Kg
Max. Payload
300 Kg
Operator on board:
2 Max
Operator on board:
2 Max
Rotation:
No
Rotation:
No
Extension:
No
Extension:
No
Weight:
400 Kg
Weight:
320 Kg
70
1710 mm
MAN-PLATFORM
1340 mm
2190 mm
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Stability Test
GTH 6025 ER + 3P/700-REM 4400 STABILITY TEST
Test n. 1.1.1
:
Work area with 700 kg. payload - Front
Telehandler configuration
:
Turret aligned with the under-carriage
Tilt table angle
:
4.5°
Telescopic boom angle (*)
:
11.4°
Telescopic boom length (**)
:
17.63 m
Nominal payload
:
700 kg
Test load
:
1240 kg
(*) Absolute (i.e. with respect to the horizon)
(**)From boom hinge to articulation hinge, parallel to telescopic line
Test n. 1.1.2
:
Work area with 300 kg. payload - Front
Telehandler configuration
:
Turret aligned with the under-carriage
Tilt table angle
:
4.5°
Telescopic boom angle (*)
:
6.2°
Telescopic boom length (**)
:
19.25 m
Nominal payload
:
300 kg
Test load
:
740 kg
(*) Absolute (i.e. with respect to the horizon)
(**)From boom hinge to articulation hinge, parallel to telescopic line
Test n. 1.1.3
:
Work area with 120 kg. payload - Front
Telehandler configuration
:
Turret aligned with the under-carriage
Tilt table angle
:
4.5°
Telescopic boom angle (*)
:
6.2°
Telescopic boom length (**)
:
19.80 m
Nominal payload
:
120 kg
Test load
:
490 kg
(*) Absolute (i.e. with respect to the horizon)
(**)From boom hinge to articulation hinge, parallel to telescopic line
Part No. 57.0303.5119
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71
Operator’s Manual
First Edition - Second Printing
Stability Test
Test n. 1.1.4
:
Work area with 700 kg. payload - Side
Telehandler configuration
:
Turret perpendicular to the under-carriage
Tilt table angle
:
4.5°
Telescopic boom angle (*)
:
6.2°
Telescopic boom length (**)
:
15.18 m
Nominal payload
:
700 kg
Test load
:
1240 kg
(*) Absolute (i.e. with respect to the horizon)
(**)From boom hinge to articulation hinge, parallel to telescopic line
Test n. 1.1.5
:
Work area with 300 kg. payload - Side
Telehandler configuration
:
Turret perpendicular to the under-carriage
Tilt table angle
:
4.5°
Telescopic boom angle (*)
:
6.2°
Telescopic boom length (**)
:
16.81 m
Nominal payload
:
300 kg
Test load
:
840 kg
(*) Absolute (i.e. with respect to the horizon)
(**)From boom hinge to articulation hinge, parallel to telescopic line
Test n. 1.1.6
:
Work area with 120 kg. payload - Side
Telehandler configuration
:
Turret perpendicular to the under-carriage
Tilt table angle
:
4.5°
Telescopic boom angle (*)
:
6.2°
Telescopic boom length (**)
:
17.63 m
Nominal payload
:
120 kg
Test load
:
540 kg
(*) Absolute (i.e. with respect to the horizon)
(**)From boom hinge to articulation hinge, parallel to telescopic line
72
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Stability Test
Test n. 2.1
:
Telehandler configuration
:
Turret aligned with the under-carriage
Tilt table angle
:
0.5° max.
Payload
:
700 kg
Telescopic boom angle (*)
1:
5.3°
Telescoping has stopped at (**):
1:
17.6 m
"
2:
31.2°
"
2:
18.45 m
"
3:
57.2°
"
3:
22.5 m
"
4:
78°
"
4:
23.36 m
(*) Absolute (i.e. with respect to the horizon)
(**)From boom hinge to articulation hinge, parallel to telescopic line
Test n. 2.2
:
Telehandler configuration
:
Turret perpendicular to the under-carriage
Tilt table angle
:
0.5° max.
Payload
:
700 kg
Telescopic boom angle (*)
1:
5.3°
Telescoping has stopped at (**):
1:
14.4 m
"
2:
26°
"
2:
15.2 m
"
3:
42°
"
3:
16.8 m
"
4:
62°
"
4:
20.1 m
(*) Absolute (i.e. with respect to the horizon)
(**)From boom hinge to articulation hinge, parallel to telescopic line
Test n. 2.3
:
Telehandler configuration
:
Turret aligned with the under-carriage
Tilt table angle
:
0.5° max.
Payload
:
300 kg
Telescopic boom angle (*)
1:
10.4°
Telescoping has stopped at (**):
1:
19.3 m
"
2:
36.4°
"
2:
20.9 m
"
3:
52°
"
3:
23.4 m
"
4:
73°
"
4:
23.4 m
(*) Absolute (i.e. with respect to the horizon)
(**)From boom hinge to articulation hinge, parallel to telescopic line
Part No. 57.0303.5119
MAN-PLATFORM
73
Operator’s Manual
First Edition - Second Printing
Stability Test
Test n. 2.4
:
Telehandler configuration
:
Turret perpendicular to the under-carriage
Tilt table angle
:
0.5° max.
Payload
:
300 kg
Telescopic boom angle (*)
1:
5.3°
Telescoping has stopped at (**):
1:
16 m
"
2:
36.4°
"
2:
18.5 m
"
3:
52°
"
3:
20.1 m
"
4:
73°
"
4:
23.4 m
(*) Absolute (i.e. with respect to the horizon)
(**)From boom hinge to articulation hinge, parallel to telescopic line
Test n. 2.5
:
Telehandler configuration
:
Turret aligned to the under-carriage
Tilt table angle
:
0.5° max.
Payload
:
120 kg
Telescopic boom angle (*)
1:
5.3°
Telescoping has stopped at (**):
1:
19.3 m
"
2:
26°
"
2:
20.1 m
"
3:
47°
"
3:
23.4 m
"
4:
74°
"
4:
23.4 m
(*) Absolute (i.e. with respect to the horizon)
(**)From boom hinge to articulation hinge, parallel to telescopic line
Test n. 2.6
:
Telehandler configuration
:
Turret perpendicular to the under-carriage
Tilt table angle
:
0.5° max.
Payload
:
120 kg
Telescopic boom angle (*)
1:
5.3°
Telescoping has stopped at (**):
1:
17.6 m
"
2:
21°
"
2:
17.6 m
"
3:
42°
"
3:
20.1 m
"
4:
74°
"
4:
23.4 m
(*) Absolute (i.e. with respect to the horizon)
(**)From boom hinge to articulation hinge, parallel to telescopic line
74
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Stability Test
Test n. 3.1
:
Load sensing system (ref. EN 280, pt. 5.4.1.2)
Tilt table angle
:
0.5° max.
Movements allowed?
YES
Test load
:
da 700 a 735 kg
Test load
:
>735 kg
NO
X
X
NOTICE
To verify the vibration level transmitted to the
operator refer to the operator's manual of the
telehandler associated to the work platform.
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Load Charts
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15
57.2900.0225
rev. A
70°
14
E
60°
13
12
D
50°
C
11
40°
10
B
A
9
14.16 m
30°
8
7
20°
6
300 kg
5
4
10°
3
2
0°
1
0
-1
10
9
8
7
6
5
4
3
2
1
0
9.01 m
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Load Charts
2P/300 F COUPLED TO GTH 4017 EX
19
57.2900.0151
rev. A
80,2°
18
70°
17
E
60°
16
15
D
50°
14
C
13
40°
12
B
10
A
30°
9
8
7
17.82 m
11
20°
4
10°
300 kg
5
120 kg
6
3
2
1
0
14 13 12 11 10
9
8
7
6
5
4
3
2
1
0
12.53 m
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16
57.2900.0159
rev. A
77,3°
15
70°
14
E
60°
13
D
50°
12
C
11
B
40°
10
A
14.88 m
9
30°
8
7
6 20°
4
300 kg
5
10°
3
2
1
0
-1
10
9
8
7
6
5
4
3
2
1
0
9.58 m
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Load Charts
2P/300 F COUPLED TO GTH 4016 SR
57.2900.0414 rev. A
18
75°
17
70°
E
16
60°
15
D
14
50°
C
13
12
B
40°
11
A
10
16.97 m
30°
9
8
20°
300 kg
7
5
10°
4
0 kg
6
3
2
1
0°
-3.7°
0
-1
15 14 13 12 11 10
9
8
7 6 5
12.40 m
4
3
2
1
0
13.72 m
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20
57.2900.0417 rev. A
19
70°
75°
18
E
60°
17
16
D
50°
15
C
14
40°
13
B
12
30°
A
19.05 m
11
10
9
20°
300 kg
8
7
6
5
10°
0 kg
4
3
2
0°
1 -2.6°
0
-1
17 16 15 14 13 12 11 10
9
8
7
6
5
4
3
2
1
0
15.29 m
15.90 m
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27
57.2900.0415 rev. 0
78°
26
70°
25
E
24
60°
23
22
D
21
50°
20
19
C
18
40°
17
B
16
15
26.15 m
30°
14
A
13
12
11
20°
10
9
8
7
0 kg
5
4
300 kg
10°
120 kg
6
3
2
0°
1
0
-1
-5.5°
-2
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10
9
8
7
6
5
4
3
2
1
0
19.16 m
20.8 m
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27
57.2900.0416 rev. 0
78°
26
70°
25
E
24
60°
23
22
21
D
50°
20
19
C
18
40°
17
B
16
15
30°
A
26.15 m
14
13
12
11
20°
10
9
8
7
0 kg
5
4
300 kg
10°
120 kg
6
3
2
0°
1
0
-1
-5.5°
-2
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10
9
8
7
6
5
4
3
2
1
0
17.53 m
18.7 m
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Diagrams And Schemes
WIRING DIAGRAM 3P/700 REM 4400 COUPLED WITH GTH 4016 SR AND GTH 4018 SR
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GTH 4017 EX
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GTH 4017 EX
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Diagrams And Schemes
3P/700 REM 4400 WORK PLATFORM HYDRAULIC DIAGRAM
Hydraulic actuator
P1
P2
Flow regulator valve
Flow regulator valve
Manplatform support
B
A
Electrovalve
T
P
Boom-machine connecting line
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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,
against the wind. Swaying of skyscrapers
Moderate
13.9 - 17.1
may be felt, especially by people on upper
gale, Near
gale
floors.
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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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
Warranty
LIMITED PRODUCT WARRANTY
Genie Industries (“Seller”) warrants its new manplatform manufactured and sold worldwide, to be
free, under normal use and service, of any defects
in manufacture or materials for the following time
periods, commencing on the date on which such
man-platform is invoiced to the original purchaser
or the date on which such man-platform is first put
into service, whichever occurs first:
• with respect to structural elements: 5 years;
• with respect to electrical componentry: 2 years
• with respect to hydraulic componentry (except
as provided below): 2 years
• with respect to o-rings, seals, hoses and
brakes: 1 year
provided that:
1. Seller receives written notice of the defect
within fourteen (14) days of its discovery and Buyer
establishes that
i. the man-platform has been maintained and
operated within the limits of rated and normal
usage
ii. the defect did not result in any manner from
the intentional or negligent action or inaction by
Buyer, its agents or employees
2. a new machine registration certificate has been
completed, signed and delivered to Seller within
fourteen (14) days of the man-platform’s “in-service”
date.
If requested by Seller, Buyer must return the
defective man-platform to Seller’s manufacturing
facility, or other location designated by Seller,
for inspection, and if Buyer cannot establish that
conditions (1) (i) and
(1) (ii) above have been met, then this warranty shall
not cover the alleged defect.
Delivery inspection certificates are required to be
completed, signed and delivered to Seller within one
hundred twenty (120) days of the man-platform’s
“in-service” date and on file with Seller’s service
department for warranty validation and processing.
Seller’s obligation and liability under this warranty is
Part No. 57.0303.5119
expressly limited to, at Seller’s sole option, repairing
or replacing, with new or remanufactured parts
or components, any part, which appears to Seller
upon inspection to have been defective in material
or workmanship.
Such parts shall be provided at no cost to the owner,
FOB Seller’s parts facility. Freight charges are not
covered. If requested by Seller, components or parts
for which a warranty claim is made shall be returned
to Seller at a location designated by Seller. All return
freight charges are the responsibility of the buyer.
All components and parts replaced under this limited
product warranty become the property of Seller.
This warranty shall be null and void if parts (including
wear parts) other than genuine OEM Seller parts are
used in the man-platform.
Accessories, assemblies and components included in
the Seller man-platform, which are not manufactured
by Seller, are subject to the warranty of their
respective manufacturers.
Normal maintenance, adjustments, or maintenance/
wear parts, including without limitation, glass,
clutch and brake linings, filters, wire rope and paint,
are not covered by this warranty and are the sole
maintenance responsibility of Buyer.
Seller makes no other warranty, express or
implied, and makes no warranty of merchantability
or fitness for any particular purpose.
No employee or representative is authorized to
modify this warranty unless such modification is
made in writing and signed by an authorized officer
of Seller
Seller’s obligation under this warranty shall not
include duty, taxes, environmental fees, including
without limitation, disposal or handling of tires,
batteries, petrochemical items, or any other charges
whatsoever, or any liability for direct, indirect,
incidental, or consequential damages.
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Warranty
Improper maintenance, improper use, abuse,
improper storage, operation beyond rated capacity,
operation after discovery of defective or worn parts,
accident, sabotage or alteration or repair of the manplatform by persons not authorized by Seller shall
render this warranty null and void. Seller reserves
the right to inspect the installation of the product
and review maintenance procedures to determine
if the failure was due to improper maintenance,
improper use, abuse, improper storage, operation
beyond rated capacity, operation after discovery of
defective or worn parts, or alteration or repair of the
man-platform by persons not authorized by Seller.
NO TRANSFERABILITY OF WARRANTY: This
warranty is limited to the original end-user and is
not assignable or otherwise transferable without
the written agreement of Seller.
108
ITEMS NOT COVERED BY SELLER WARRANTY
The following items are not covered under the seller
warranty (the following list is not Exhaustive):
1. Lamps, lenses, filters, consumable items, utility
trailer decks, shop supplies.
2. Items sold by any individual, corporation,
partnership or any other organization or legal
Entity that is not an authorized seller distributor.
3. Inbound freight for replacement components
or outbound freight for any part requested as a
warranty return.
4. Components which are not manufactured by
seller are not covered by seller’s warranty. Such
components are covered only by the warranty,
if any, that is provided by the Manufacturer
of such components. Such components
may include, but are not limited to, Engines,
batteries, tires, customer-supplied products,
transmissions, generators/gensets, Axles.
5. Replacement of Assemblies: seller has the
option to repair or replace any defective part or
assembly. It is seller’s policy to refuse claims for
the replacement of a complete assembly that is
field repairable by the replacement or repair of
defective part(s) within the assembly.
6. Normal Operational Maintenance Services
and Wear Parts: maintenance services and
wear parts are excluded from warranty claims.
Maintenance services and wear parts not
covered include, but are not limited to, such
items as: seals, gaskets, hoses, glass, clutch
and brake linings, wire rope, exterior coatings,
proper tightening of bolts, nuts and fittings,
adding or replacing of fluids, breathers, belts,
nozzles, adjustments of any kind, services
supplies such as lubricants, inspections,
diagnostic time, travel time.
7. Transportation Cost and/ or Damage:
any damage caused by carrier handling is
a transportation claim and should be filed
immediately with the respective carrier.
8. Deterioration: repairs, work required or
parts exposed as the result of age, storage,
weathering, lack of use, demonstration use, or
use for transportation of corrosive chemicals.
MAN-PLATFORM
Part No. 57.0303.5119
First Edition - Second Printing
Operator’s Manual
Warranty
9.
Secondary Failures: should the owner or
operator continue to operate a machine after
It has been noted that a failure has occurred,
seller will not be responsible under the warranty
for resultant damage to other parts due to that
continued operation.
10. Workmanship of Others: seller does not
accept responsibility for improper installation or
labor costs or costs of any kind from personnel
other than personnel authorized by seller.
11. Stop and Go Warranty: seller does not
recognize “stop and go” warranties.
12. Incidental or Consequential Damage:
SELLER SHALL NOT BE LIABLE FOR
ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES OF ANY KIND, INCLUDING, BUT
NOT LIMITED TO, LOST PROFITS, LOSS OF
PRODUCTION, INCREASED OVERHEAD,
LOSS OF BUSINESS OPPORTUNITY,
DELAYS IN PRODUCTION, COSTS OF
REPLACEMENT COMPONENTS AND
INCREASED COSTS OF OPERATION THAT
MAY ARISE FROM THE BREACH OF THIS
WARRANTY. Customer’s sole remedy shall
be limited to (at seller’s sole option) repair or
replacement of the defective part.
THIS WARRANTY IS EXPRESSLY IN LIEU OF AND
EXCLUDES ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED (INCLUDING THE WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE) AND ALL OTHER
OBLIGATIONS OR LIABILITY ON SELLER’S
PART. THERE ARE NO WARRANTIES THAT
EXTEND BEYOND THE LIMITED WARRANTY
CONTAINED HEREIN.
Seller neither assumes nor authorizes any other
person to assume for seller any other liability in
connection with the sale of seller’s man-platform.
This warranty shall not apply to any of seller’s manplatform or any part thereof which has been subject
to misuse, alteration, abuse, negligence, accident,
acts of god or sabotage.
Part No. 57.0303.5119
No action by any party shall operate to extend or
revive this limited warranty without the prior written
consent of seller. In the event that any provision of
this warranty is held unenforceable for any reason,
the remaining provisions shall remain in full force
and effect.
IN THE EVENT OF ANY BREACH OF THE
WARRANTY BY SELLER, SELLER’S LIABILITY
SHALL BE LIMITED EXCLUSIVELY TO THE
REMEDIES (AT SELLER’S SOLE OPTION) OF
REPAIR OR REPLACEMENT OF ANY DEFECTIVE
EQUIPMENT COVERED BY THE WARRANTY. IN
NO EVENT SHALL SELLER, OR ANY SUBSIDIARY
OR DIVISION THEREOF BE LIABLE FOR
INCIDENTAL, INDIRECT, CONSEQUENTIAL OR
OTHER DAMAGES OR LOSSES RESULTING
FROM A BREACH OF WARRANTY INCLUDING,
WITHOUT LIMITATION, LABOR COSTS, LOSS
OF USE OF OTHER EQUIPMENT, THIRD PARTY
REPAIRS, LOST PROFITS, LOST TIME, TOWING
OR HAULING OF EQUIPMENT, RENTAL COSTS,
PERSONAL INJURY, EMOTIONAL OR MENTAL
DISTRESS, IMPROPER PERFORMANCE OR
WORK, PENALTIES OF ANY KIND, LOSS OF
SERVICE OF PERSONNEL, OR FAILURE OF
EQUIPMENT TO COMPLY WITH ANY FEDERAL,
STATE OR LOCAL LAWS.
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Part No. 57.0303.5119
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Operator’s Manual
Warranty is subject to delivery according to the
regulation and the submission of this certificate
to TEREXLIFT s.r.l.
WARRANTY - HANDING OVER CERTIFICATE
Model
Serial Number
Delivery date
___________________
___________________
___________________
Dealer’s stamp and signature
We hereby acknowledge that we received the machine in perfect condition,
as well as the Operator’s Manual.
DATAS OF THE OWNER:
Telephone:_______________________ Telefax: ______________________
Note
___________________________
___________________________
___________________________
___________________________
___________________________
___________________________
___________________________
Signature: ____________________________________________________
Client’s Copy
Name: _______________________________________________________
City: ____________________________ Address: _____________________
Postal Code: _____________________ Country: ______________________
Warranty is subject to delivery according to the
regulation and the submission of this certificate
to TEREXLIFT s.r.l.
WARRANTY - HANDING OVER CERTIFICATE
Model
Serial Number
Delivery date
___________________
___________________
___________________
Dealer’s stamp and signature
We hereby acknowledge that we received the machine in perfect condition,
as well as the Operator’s Manual.
DATAS OF THE OWNER:
Telephone:_______________________ Telefax: ______________________
Note
___________________________
___________________________
___________________________
___________________________
___________________________
___________________________
___________________________
Signature: ____________________________________________________
TEREXLIFT Copy
Name: _______________________________________________________
City: ____________________________ Address: _____________________
Postal Code: _____________________ Country: ______________________
Part No. 57.0303.5119
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Routine Check Schedule
SAFETY DEVICES DAILY CHECKING
DATE: _________________________
COMPONENT
RESULT
NOTE
Load Cells or
Overload Switches
 positive
 negative
LMI Unit Control
 positive
 negative
Emergency Pump
Button
 positive
 negative
Emergency Stop
Pushbutton
 positive
 negative
Presence
micro-switches
 positive
 negative
Enabling Pushbutton
 positive
 negative
Pushbutton to enable
the Work Platform
Rotation
for 3P/700 REM 4400
 positive
 negative
Rotation Actuator
Blocking Valve
for 3P/700 REM 4400
 positive
 negative
Part No. 57.0303.5119
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SIGNATURE
113
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