Genie Agri-625 / Agri-730 Operator's Manual

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Page 1

Operator’s Manual

GTH-2506 AGRI-625

Serial number range

From s/n: 18957 t

o s/n: 20194

From s/n: 19057 to s/n: 20135

With Maintenance

Information

First Edition

ourth Printing

Part No. 57.0009.0413

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Operator’s Manual

First Edition - Fourth Printing

Important

Read, understand and obey these safety rules and operating instructions before operating the machine. Only trained and qualified personnel shall be authorized to operate the machine. This manual shall be kept with the machine at all times.

For any further information, please call Terexlift.

ZONA INDUSTRIALE I-06019 UMBERTIDE (PG) - ITALY Telephone +39 075 941811 - Telefax +39 075 9415382

Technical Assistance Service

Telephone: +39 075 9418129 +39 075 9418171

e-mail: im.service@terexlift.it

Contents

Introduction ..........................................Page 3

Machine Identification ..........................Page 5

Symbols Used On The Machine ..........Page 7

Labels And Plates Applied On The

Machine ...............................................Page 9

Safety Precautions ..............................Page 15

Description Of The Main Components ...Page 23

Controls And Instruments ....................Page 25

Inspections ..........................................Page 41

Operating Instructions .........................Page 45

Transporting The Machine...................Page 59

Maintenance ........................................Page 63

Faults And Troubleshooting.................Page 89

Optional Attachments ..........................Page 93

Specifications ......................................Page 113

Load Charts .........................................Page 115

Diagrams And Schemes ......................Page 121

Warranty ..............................................Page 131

reserved.

Produced by: TEREXLIFT Technical Literature Dept.

Umbertide (PG) Italy

2 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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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

WARNING

CAUTION

NOTICE

PROTECT THE ENVIRONMENT

Red: indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Orange: indicates a hazardous

situation which, if not avoided, could result in death or serious injury.

Yellow : indicates a hazardous

situation which, if not avoided, could result in minor or moderate injury.

Blue: indicates a hazardous situation which, if not avoided, could result in property damage.

Green: used to draw the

attention to important

information on environment

protection.

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Intentionally blank page

4 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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Machine Identification

Check that the operator handbook refers to the delivered machine.

MODEL AND TYPE

Handler with telescopic boom:

models: GTH-2506 / AGRI-625

MANUFACTURER

TEREXLIFT srl

Zona Industriale - I-06019 UMBERTIDE (PG) ITALY

Enrolled in the register of companies at the Court of Perugia under no. 4823

C.C.I.A.A. 102886 Fiscal Code/V.A.T. no. 00249210543

APPLICABLE STANDARDS

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

Directive Title

ISO 3449:1992 Earth-moving machinery - Falling-

object protective structures Laboratory tests and performance requirements.

EN 13510: 2002 Earth-moving machinery - Roll-over

protective structures - Laboratory tests and performance requirements.

ISO 6292:1996 Powered industrial trucks and tractors

- Brake performance and component strength.

EN 13059:2002 Safety of Industrial trucks- Test

methods for measuring vibration

ISO 2867:1994 Earth-moving machinery - Access

systems

EN ISO 6683:2005 Earth-moving machinery - Seat

belts and seat belt anchorages

- Performance requirements and tests

ISO 11112: 1995 Earth-moving machinery -

+ AMD 1: 2001 Operator’s seat - Dimensions and

requirements

98/37/CE Machinery Directive 89/336/CEE Electromagnetic compatibility 2000/14/CE Environment Acoustic Emissions

Standard Title

EN 1459:1988 Harmonised standard. Safety of

industrial trucks - Self- propelled

variable reach trucks.

EN 281:1988 Self-propelled industrial trucks sit-

down rider-controlled. Rules for the

construction and layout of pedals.

EN 1175-2:1998

ISO 2330:1995 Fork-lift trucks - Fork arms - Technical

ISO 3287: 1999 Powered industrial trucks - Symbols

Part No. 57.0009.0413 GTH-2506 - AGRI-625 5

Electrical requirements - General

requirements of internal combustion

engine powered trucks.

characteristics and testing.

for operator controls.

MACHINE IDENTIFICATION PLATES

The following data plates are applied on the machine:

Machine data plate

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

On machines destined for the Italian market, the data plate is installed in the driving cab, on the right, and is well-visible when the door is opened. On the machines destined for foreign markets, the data plate is applied on the front right side of the chassis.

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Operator’s Manual

Machine Identification

First Edition - Fourth Printing

Road traffic data plate

The road traffic data plate is installed on the front right side of the chassis (only on machines destined for the Italian market). This plate shows the road traffic related data and the weights of the specific machine model.

ROPS-FOPS cab type-approval plate

The ROPS - FOPS type-approval plate is located inside the driving cab above the rear glass.

Fork data plate

Placed on the left side of the fork frame. This plate shows the identification data of fork such

as model, serial number, year of manufacture, weight, nominal payload, centre of the load and model of the machine on which the forks are installed.

HOW TO READ YOUR SERIAL NUMBER

CE MARKING

This machine fulfils the safety requirements of the Machinery Directive.The conformity has been certified and the placing of the CE marking on the machine demonstrates compliance with the regulatory requirements. The CE marking is placed directly on the identification plate of the machine.

CHASSIS SERIAL NUMBER

The chassis serial number is punched on the front left part of the chassis side member.

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.

Chassis serial number

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

GTH-2506 P 07 17882

MODEL

ENGINE

TYPE

YEAR OF

MANIFACTURER

Machine data plate

(On machines destined for the Italian market, the machine data plate is installed in the driving cab, on the right, and is well-visible when the door is opened. On the machines destined for foreign markets, the data plate is applied on the front right side of the chassis)

6 GTH-2506 - AGRI-625 Part No. 57.0009.0413

SERIAL

NUMBER

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First Edition - Fourth Printing Operator’s Manual

Symbols Used On The Machine

Fuel Level

General Alarm

Low Engine Oil

Pressure

Hydraulic Oil Filter

Clogged

Not Active

Hydraulic Oil Filter

Not Active Glow Plugs Preheating High Coolant Tempe-

Low Hydraulic Oil

Level

Rear Wheel Aligned Air Filter Restricted Hour-meter

Parking Brake Battery Charge

Turn Signals High Beam

Low Beam

rature

Hydraulic Oil

Position Lights

Temperature Indicator

09.4618.0916

Steering Mode Cab Ventilation Fan Lift Point

Continuous Oil Flow Auxiliary Hydraulic

Air Condition

Line

Transfer Mode Hazard Warning Lights

09.4618.0917

09.4618.0928

Fuel Cap Hydraulic Oil

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Operator’s Manual

Symbols Used On The Machine

HAZARD PICTORIAL DESCRIPTIONS

First Edition - Fourth Printing

Electrocution Hazard

No riders.

Read the operator's manual.

Crush Hazard

Maintain required clearance.

Burn Hazard

Support boom when performing maintenance.

Keep away from moving parts.

Falling Object Hazard

Allow system to cool.

Crush Hazard

No people under load.

Explosion/Burn Hazard

Burn Hazard

Keep clear of moving parts.

Fall Hazard

No smoking. No open flame.

Allow surfaces to cool.

Allow compartment access

8 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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Labels And Plates Applied On The Machine

Shading indicates decal is hidden from view, i.e. under covers.

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Labels And Plates Applied On The Machine

Use the pictures on these pages to verify that all decals are legible and in place.

Use the pictures on these pages to verify that all decals are legible and in place. The following chart shows quantities and description too.

The following chart shows quantities and description too.

Ref. Decal Code Description Qt.

SAFETY PIN

WORKING POSITION

1 09.4618.0791 Safety pin operation 1

STORAGE POSITION

09.4618.0791

2 09.4618.0784

P= 4.5 bar 65 psi

09.4618.0061

The capacity of the truck and attachment combination shall be complied with.

Tyre inflation sticker P= 4.5 bar / 65 psi 4

4 09.4618.0918 Falling Object Hazard 3

09.4618.0918

5 09.4618.0919 Crush Hazard 4

09.4618.0919

6 09.4618.0257 Guaranteed sound power level 1

106

7 09.4618.0920 Compartment Access 1

8 09.4616.0102 Max Capacity 1

Kg 2500

09.4618.0920

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Labels And Plates Applied On The Machine

Ref. Decal Code Description Qt.

TP4

9 09.4618.0786 Label - Testing ports 1

TP5

TP3

NOTICE

10 09.4618.0776

09.4618.0776

QUICK GUIDE FOR THE USE

2506

Machine stable. Machine unstable. The red LED flashes and buzzer sounds intermittently. Hazardous overload. Risk of overturning. The red LED is constantly lit and the buzzer sounds continuously. Retract the load within safety limits.

USING THE JOYSTICK

• Boom lowering/lifting: shift the lever to 

• Attachment frame forward/back pitching: shift the lever to 

• Telescope retraction/extension: shift button  to 

• Attachment coupling/release: press button  and shift

the control lever to 

WARNING

Do not use the machine and its attachments before having read and understood the use and safety instructions of this manual. Not obeying the use and safety instructions can result in serious or lethal injury. The instructions are delivered with the machine; additional copies may be obtained from your dealer or directly from Terexlift. The operator is responsible for obeying the aforesaid instructions. Do not raise boom on unstable or sloping ground. Never exceed maximum permitted loads (see load charts). Lifting manoeuvres with the machine in operation are forbidden. Before leaving the control place:

- lower any suspended load to the ground

- set the controls of the boom to neutral position

- set the speed lever to neutral position, engage the parking brake and stop the engine.

STARTING THE MACHINE

• Put the gear switch and the mechanical gear lever to neutral.

• Engage the parking brake and ensure its light

indicator switches on.

• To start the engine, rotate the ignition switch to poristion and hold it in position. The turn the switch to position and start the engine.

• If the engine does not start within

20 seconds, release the key and wait at least 2 minutes before

11 09.4618.0794

attempting again.

OVERLOAD WARNING SYSTEM (ARB)

During work, steadly check the display of the overload warning system. The 8 LED indicator show:

Green LED 1-2-3-4 Yellow LED 5-6

Red LED 7-8

12 09.4618.0921

TP1TP2

09.4618.0786

Label - Upper Door Internal Unlock System

Optional

Quick guide and Control lever decal for GTH-2506

09.4618.0794

Label - Use limits close to electric power lines

09.4618.0921



13 09.4618.0792 Label - Engine Cover Closing 1







09.4618.0792

14 09.4618.0922 Crush Hazard 6

09.4618.0922

15 16 17

09.4618.0240

09.4618.0241

09.4618.0242

Cosmetic - GENIE Logo in WHITE

1 1 1

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Labels And Plates Applied On The Machine

Ref. Decal Code Description Qt.

18 19

GTH-2506

AGRI-625

09.4618.0390

09.4618.0930

09.4618.0737

09.4618.0932

Cosmetic - Genie GTH-2506

Cosmetic - Genie AGRI-625

20 09.4618.0923 Burn Hazard 2

09.4618.0923

21 09.4618.0924 Burn/Explosion Hazard 1

09.4618.0924

22 09.4618.0925 Crush Hazard 1

09.4618.0925

23 09.4618.0926 No Riders 1

09.4618.0926

2 1

24 09.4618.0927 Burn Hazard 1

09.4618.0927

25 09.4618.0916 Lift Point 4

09.4618.0916

26 09.4618.0917 Diesel Fuel Cap 1

09.4618.0917

27 09.4618.0928 Hydraulic Oil 2

09.4618.0928

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Labels And Plates Applied On The Machine

Ref. Decal Code Description Qt.

FG1 FG2

Name Description

K02 Starter Enabling Switch K01 Glow Plugs Preheating

09.4618.1001

09.4618.0949

GTH-2506

K02

28 09.4618.0949 Label - Engine Fuses & Relays Board 1

Name Description

FG1 Main Fuse FG2 Glow Plugs

K01

29 09.4618.1001 Label - Maintenance Collar 1

NOTICE

30 09.4618.1025

09.4618.1025

Label - Upper Door External Unlock System

31 09.4618.0986 Crush Hazard 1

09.4618.0986

GTH-2506

Name Description

F01 Warning F02 High Beam F03 Low Beam F04 Horn

F 10 F 20 F 09 F 19 F 08 F 18

F 17

32 09.4618.0947 Label - Cabin Fuses & Relays Board 1

F 07

F 16

F 06 F 05

F 15

F 04

F 14

F 03

F 13

F 02

F 12

F 01

F 11

F05 Road/Jobsite

R-Front & L-Rear

F06

Position Lights L-Front & R-Rear

F07

Position Lights

F08 Power Supply OPT

Hydraulic Circuit

F09 2 F10 ARB Instrument F11 Heating F12 Gear Selector F13 Work Light F14 Rear Axle Sensor F15 Flashing Beacon F16 Stop Light

Hazard Warning

F17

Light F18 Emergency Stop F19 Wiper F20 Instrument Panel

09.4618.0947

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Labels And Plates Applied On The Machine

Ref. Decal Code Description Qt.

ROPS-FOPS cab type-approval plate.

A 09.4616.0100

TEREXLIFT srl - ZONA INDUSTRIALE - 06019 UMBERTIDE (PG) - ITALY Tel. (075) 941.811 Fax (075) 941.53.82 Telex 66106 ITALMA I

MODELLO - MODEL - MODELE - TYP - MODELO

ANNO DI COSTRUZIONE - YEAR OF MANUFACTURE - ANNEE DE FABRICATION BAUJAHR - AÑO DE FABRICACIÓN

B 09.4616.0112

C 09.4616.0109

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

PESO MAX ASSALE ANT. - MAX FRONT AXLE WEIGHT - POIDS MAX ESSIEU AVANT ZUL. ACHSLAST VO. N. ST VZO - PESO MAX EJE ANTERIOR

PESO MAX ASSALE POST. - MAX REAR AXLE WEIGHT - POIDS MAX ESSIEU ARRIERE ZUL. ACHSLAST HI. N. ST VZO - PESO MAX EJE POSTERIOR

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

MATRICOLA MOTORE TERMICO - ENGINE SERIAL N. - N. MOTEUR THERMIQUE FABRIK NR. DIESEL MOTOR - NO. DE SERIE MOTOR TERMICO

OMOLOGAZIONE

FABBRICATO IN ITALIA - MADE IN ITALY

ASSIEME FORCHE-FORKS ASSY GROUPE FOURCHES-GABELGROUPPE JUNTO HORQUILLAS

MODELLO - TYPE - DƒSIGNATION MODELL - MODELO

N¡ SERIE - SERIAL N¡-N¡ DE SERIE

- SERIEN N¡- N¡ DE BASTIDOR

ANNO DI COSTRUZIONE YEAR OF CONSTRUCTION ANNƒE DE CONSTRUCTION BAUJHAR - A„O DE CONSTRUCCIîN

MASSA - MASS - MASSE MASSE - MASA

CENTRO DI GRAVITË - CENTER OF GRAVITY - CENTRE DE GRAVITƒ SCHWERPUNKT - CENTRO DE GRAVEDAD

PORTATA NOMINALE - PAY LOAD PORTEE NOMINALL - NENN TRAGF€HIGKEIT - CARGA NOMINAL

CENTRO DI CARICO - LOAD CENTER CENTRE DE CHARGE - LASTPUNKT CENTRO DE CARGA

MODELLO MACCHINA - MACHINE MODEL DESOGNATION MACHINE - MASCHINEN MODELL MODELO MçQUINA

200

kgkg kg kg

This plate shows the type-approval data of the driving cab according to ROPS - FOPS regulations.

Machine data plate. The identification plate contains the main identification data of the machine.

Fork data plate. This plate shows the main

data of the fork installed on the machine.

D 09.0803.0357 Boom tilting degree 1

14 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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First Edition - Fourth Printing Operator’s Manual

Safety Precautions

DAMAGED MACHINE HAZARDS

• Do not use a damaged or defective machine.

• Do a thorough pre-operation inspection of the machine and test all functions before each work shift. Tag and remove from service a damaged or defective machine.

• Make sure that all maintenance jobs have been carried out as specified in this manual and the appropriate service manual.

• Make sure that all decals are in place and legible.

• Make sure that the operator’s is intact, legible and placed in the special container located in the machine.

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.

SAFETY DEVICES

Several safety devices have been fitted to the machine. 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

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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Operator’s Manual

Safety Precautions

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GENERAL REMARKS

Not observing the instructions and safety rules in this manual may result in death or serious injury.

Do not operate the machine unless:

• You learn and practice the principles of safe

machine operation contained in this operator’s manual.

1. Avoid hazardous situations. Read and understand the safety instructions before going on to the next chapter.

2. Always perform a pre-operation inspection.

3. Always test the machine functions prior to use.

4. Inspect the work place.

5. Only use the machine for the intended application.

• Read, understand and obey the manufacturer’s

instructions and the safety rules, the safety and operator’s manuals, and the decals applied on the machine.

• Read, understand and obey the employer’s safety rules and worksite regulations.

• Read, understand and obey the applicable national regulations.

• Only trained personnel informed on the safety rules can operate the machine.

Most accidents occurring while working, repairing or maintaining machines, are caused by not complying with the basic safety precautions. Therefore, it is necessary to pay steady attention to the potential hazards and the effects that may come of operations carried out on the machine.

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 machine installation, operation and maintenance that take into account the available spaces and means.

If you decide to follow instructions other than those given in this manual, you shall absolutely:

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

• be sure that the methods are safe, say, in compliance with the rules and provisions given in this section;

• be sure that the methods cannot damage the machine directly or indirectly or make it unsafe;

• contact TEREXLIFT Assistance Service for any suggestion and the necessary written permission.

16 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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Safety Precautions

REQUISITES OF THE PERSONNEL IN CHARGE

Requisites of the MACHINE OPERATORS The operators who use the machine regularly or occasionally (i.e. for transport reasons) shall have the following prerequisites:

health:

before and during any operation, operators shall never take alcoholic beverages, medicines or other substances that may alter their psychophysical conditions and, consequently, their working abilities.

physical:

good eyesight, acute hearing, good co-ordination and ability to carry out all required operations in a safe way, according to the instructions of this manual.

mental:

ability to understand and apply the enforced rules, regulations and safety precautions. They shall be careful and sensible for their own as well as for the others’ safety and shall desire to carry out the work correctly and in a responsible way.

emotional:

they shall keep calm and always be able to evaluate their own physical and mental conditions.

training:

they shall read and be familiar with this handbook, its enclosed graphs and diagrams, the identification and hazard warning plates. They shall be skilled and trained about the machine use.

Requisites of the SERVICEMEN The personnel charged with the machine maintenance shall be qualified, specialised in the maintenance of telehandlers, 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 machine is not a complex intervention and can be carried out by the machine 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.

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Operator’s Manual

Safety Precautions

First Edition - Fourth Printing

OTHER DANGERS

WORKING CLOTHES

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

• Overalls or any other comfortable garments. Operators should not wear clothes with large sleeves or objects that can get stuck in moving parts of the machine.

• Protective helmet.

• Protective gloves.

• Working shoes.

Use only type-approved working clothing in good condition.

Personal PROTECTIVE EQUIPMENT

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

• Breathing set (or dust mask).

• Ear-protectors or equivalent equipment.

• Goggles or facial masks.

Hazards on the JOBSITE

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

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

DANGER

The machine is not electrically insulated and does not provide protection from contact with or proximity to electrical power lines. Always keep at a minimum safe distance from the telescopic boom and the lifted load. Electrical hazards!

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 to 50kV 10ft 3.00m

50 to 200 kV 15 ft 4.60 m 200 to 350 kV 20 ft 6.10 m 350 to 500 kV 25 ft 7.62 m 500 to 750 kV 35 ft 10.67 m 750 to 1000 kV 45 ft 13.72 m

• Keep away from the machine in case of contact with energized power lines. Personnel on the ground must never touch or operate the machine until energized power lines are shut off.

DANGER

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

18 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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First Edition - Fourth Printing Operator’s Manual

Safety Precautions

OPERATION or MAINTENANCE hazards

Before any operation, following precautions should be taken:

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

WARNING

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

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

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

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

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

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

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.

• When entering/leaving the cab or other raised parts, always face the machine; never turn the back.

• When carrying out operations at hazardous heights (over 1.5 meters from the ground), always use approved fall restraint or fall arrest devices.

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

• Do not leave the driving place when the machine is running.

• Neither stop nor carry out interventions under or between the machine wheels when engine is running. When maintenance in this area is required, stop the engine.

• Do not carry out maintenance or repair works without a sufficient lighting.

• When using the machine lights, the beam should be oriented in order not to blind the personnel at work.

• Before applying voltage to electric cables or components, check their connection and proper functioning.

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

• Do not connect wet plugs or sockets.

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

• Except for maintenance purposes, do not remove safety devices, shields, protection cases, etc. Should their removal be necessary, stop the engine, remove them with the greatest care and always remember to refit them before starting the engine and using the machine again.

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

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Operator’s Manual

Safety Precautions

First Edition - Fourth Printing

• 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.

• 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.

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.

20 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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First Edition - Fourth Printing Operator’s Manual

Safety Precautions

EXPLOSION OR FIRE 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.

DAMAGED COMPONENT hazards

• Do not use battery chargers or batteries with a voltage above 12V to start the engine.

• Do not use the machine as a ground for welding.

PERSONAL INJURY hazards

• Do not operate the machine in case of hydraulic oil or air leak. Air or hydraulic oil leaks can penetrate or burn the skin.

• Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning.

• Do not lower the boom if the area underneath is not clear of personnel or obstructions.

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22 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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First Edition - Fourth Printing Operator’s Manual

Description Of The Main Components

1. Forks

2. 2nd boom section

3. 1st boom section

4. Engine hood

5. Driving cab

6. Front axle

7. Chassis

8. Left front wheel mud-guard

9. Left front wheel reduction gear

10. Left rear wheel reduction gear

11. Front towing hitch ONLY FOR AGRI-625

12. Rear towing hitch ONLY FOR AGRI-625

AGRI-625

Part No. 57.0009.0413 GTH-2506 - AGRI-625 23

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NOTICE

Operator’s Manual

Description Of The Main Components

First Edition - Fourth Printing

Hydrostatic transmission

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

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

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

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

- a heat exchanger to cool the circuit down.

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

Engine

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

Steering axles/(front and rear) differential gears

The differential axles transmit the motion to the wheels. The locking device acting on the front axle enables the machine to move also on low grip grounds.

Tyres

The machine is equipped with tyres suitably sized for the maximum load allowed on the handler. When worn, they shall be replaced with new ones having the same dimensions and loading capacity.

Boom hydraulic circuit

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

- boom lifting/lowering

- telescopic boom extension/retraction

- attachment rotation

Braking circuit

It consists of an independent circuit: the pedal directly acts on the brake pump which dispenses oil to the front axle braking unit with discs in oil bath. The parking brake, of negative type, acts on the braking unit of the service brake. This brake is engaged every time the handler's engine is stopped or pressing down the light pushbutton located to the right of the driving place.

Telescopic boom

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

Driving cab

Type-approved driving cab in compliance with standards ISO 3449 and EN 13510 (ROPS and FOPS). User-friendly dashboard. Multipurpose joystick with electro-proportional control and ergonomic handle.

Towing hitch (ONLY FOR AGRI-625)

The machine is equipped with two towing hitches:

- one at the front, to be used in an emergency, for towing the disabled machine

- one at the rear for towing trailers or carts.

OPTIONAL ACCESSORIES

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

Please check the accessories available for your machine.

24 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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First Edition - Fourth Printing Operator’s Manual

Controls And Instruments

7108 5

GTH-2506

09.4618.0834

PROPOSTAGRAFIC A

STRUMENTOECO

30/10/07

1. Fresh Air Flap

2. Forward/reverse Gear Selector - Horn

3. Steering Column Angle Adjustment

4. Turn Signals - Windscreen Washer - Lights

5. Ignition Switch

6. Load Moment Indicator

7. Emergency Stop Pushbutton

8. Hazard Warning Lights Switch

9. Multipurpose Control Lever

Part No. 57.0009.0413 GTH-2506 - AGRI-625 25

10. Gas Pedal

11. Instruments Dashboard

12. Cab Heater Control Knob

13. Fuses And Relays Board

14. Load Charts Holder

15. Load Limiter Disable Selector

16. Service Brake Pedal

17. Windscreen water reservoir

18. Continuous Oil Flow Potentiometer

Page 26

J 0

Operator’s Manual

Controls And Instruments

First Edition - Fourth Printing

Ignition switch

Three-position switch:

No circuit under voltage, key can be removed

and engine is stopped

Circuits under voltage, presetting for the en-

gine starting. Board controls and instruments are on.

The warning light 11.13 signalling the glow

plugs preheating comes on. Wait until the light goes off before starting the engine.

Engine starting; when released, key springs

back to pos.1 automatically.

Forward/reverse gear selector switch

Three-position switch with lock in neutral position:

0 Neutral position; no gear engaged

1 Shift lever to pos. 1 to select the forward

gear

2 Shift lever to pos. 2 to select the reverse

gear

Horn function:

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

26 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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First Edition - Fourth Printing Operator’s Manual

Controls And Instruments

Turn signals - Windscreen wiper - Lights

Lights function:

To switch the handler lights, lever can be set to three

Windscreen washer function:

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

Windscreen wiper function:

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

I Intermittence (not activated)

0 Wiper OFF

J Low speed

I I High speed

different positions along its horizontal axis:

0 low beam ON, stable condition

1 high beam ON, stable condition

2 high beam used for intermittent signalling;

when released, the lever springs back to position 0.



Turn signals function:

Set lever to pos. 1 to indicate a turn leftwards or to pos. 2 to indicate a turn rightwards.





Part No. 57.0009.0413 GTH-2506 - AGRI-625 27

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NOTICE

Operator’s Manual

Controls And Instruments

First Edition - Fourth Printing

Brakes

16 Service Brake Pedal

Gradually step on the brake pedal to decelerate and stop the machine. The pedal operates on the front axle. Fully depressing the brake pedal causes a reset of the displacement of the power drive pump and makes the braking action more powerful.

19 Parking Brake

The parking brake of negative type engages automatically when the engine is stopped. When the handler’s engine is restarted, pressing the pushbutton switch 19 unlocks the parking brake. To stop the handler without shutting down the engine, press the pushbutton switch 19 to engage the parking brake and push it once again to disengage the brake. When starting the engine the light of the pushbutton turns automatically on! When the orange light at the top of the pushbutton and the dashboard warning light are on, the parking brake is engaged.

CAUTION

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

Accelerator control

10 Gas Pedal

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

When starting the engine the lights of all the pushbuttons turn automatically on!

Only the switching-on of the orange warning light sets on the top of the pushbutton will indicate the activation of the function.

Road/Jobsite selection

21 Road/Jobsite switch

Pushbutton with orange glass cap, with two stable positions.

0 Road setting: boom controls are

disabled and only the two-wheel steering is enabled.

1 Jobsite setting: boom controls and all

sterring mode are enabled.

Before switching on the Road Setting, align the

16 10

GTH-2506

09.4618.0834

28 GTH-2506 - AGRI-625 Part No. 57.0009.0413

rear wheels of the machine

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First Edition - Fourth Printing Operator’s Manual

Controls And Instruments

Steering mode selection

20 Steering Mode Switch

Three-position switch for the selection of the steering

Automatic Rear Wheel Alignment Indicator

Sensor (Optional)

This sensor is connected to the warning light 11.12 and indicates when the rear wheels are aligned. Put the steering selector switch is in position 0 and turn the steering wheel: when the rear wheels will be aligned the orange warning light 11.12 will come on.

mode:

1 Crab steering

0 Two-wheel steering

2 Four-wheel steering

PROPOSTA GRAFICA

STRUMENTOECO

30/10/07

Continuous oil flow

22 Flow Button

Pushbutton with orange glass cap, with two stable positions. Press this button to switch the hydraulic circuit feeding the attachments with auxiliary lines.

0 No oil flow

1 Continuous oil flow delivery to the used

attachment.

18 Continuous Oil Flow Potentiometer

By turning the potentiometer clockwise, the flow rate

in the circuit feeding the attachments’ movement lines is increased to one

or the other direction.

Part No. 57.0009.0413 GTH-2506 - AGRI-625 29

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DANGER

Operator’s Manual

Controls And Instruments

Safety and emergency devices

8 Hazard Warning Lights Switch

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

signals simultaneously. When the hazard warning light is lit, the relevant switch and the turn signals light start

flashing.

First Edition - Fourth Printing

15 Load Limiter Disable Selector

The load limiter can be deactivated operating the key-selector placed under the protection cover 15.

7 Emergency Stop Pushbutton

By pressing this button, the engine of the machine

is shut down.

Before restarting the machine, it is

necessary to reset the pushbutton by rotating it clockwise.

GTH-2506

09.4618.0834

WORKING WITH THE LOAD LIMITING SYSTEM CUT OUT CAN RESULT IN A MACHINE OVERTURNING AND IN SERIOUS INJURY.

30 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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Controls And Instruments

Auxiliary drive controls

23 Cab Heater Fan Switch

Three-position switch: 0 Fan OFF

1 Low speed

2 High speed

24 Road Lights Switch

Three-position switch placed on the right side of the dashboard:

0 Lights OFF

1 Position lights ON

2 Low beam ON

30 Work Lights Switch (OPTIONAL)

Two-position switch:

0 Lights OFF

1 Lights ON

31 A/C Switch (OPTIONAL)

Two-position switch:

0 A/C OFF

1 A/C ON

29 Auxiliary Hydraulic Circuit (OPTIONAL)

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

0 Oil to the attachment cylinder

1 Oil to the attachment

12 Cab Heater Control Knob

Located at the bottom of the driving seat base, it adjusts the flow of heated air in the cab.

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Operator’s Manual

Controls And Instruments

Instruments

First Edition - Fourth Printing

25 Engine coolant temperature indicator

This indicates the engine coolant temperature. If the finger is in the red zone and the warning light comes on, you must stop the machine and find and rectify the problem.

26 Hydraulic oil temperature indicator

This indicates the temperature of the hydraulic oil in the tank. If the temperature rises above the permissible value or the red warning light comes on, you must stop the machine and find and rectify the problem.

27 Fuel gauge

This indicates the fuel level in the tank. If the fuel level is low (reserve), the relevant warning light comes on.

28 Hour-meter

Signals the total operating hours of the machine. Use the hour-meter to gauge the routine maintenance jobs.

252627 28

PROPOSTA G RAFIC A

STRUMENTO ECO

30/10/07

32 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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First Edition - Fourth Printing Operator’s Manual

Controls And Instruments

Warning lights (ref. 11)

11.1 Warning light - low battery charge

Signals a low charge by the alternator.

11.2 Warning light - low engine oil pressure

It lights when the engine oil pressure is too low

11.3 Warning light - air filter restricted

When this lamp come on, proceed with cleaning or changing the air filter cartridge.

11.4 Warning light - low brake pressure

It lights when the pressure of the brake circuit is too low for a correct functioning.

11.5 Warning light - parking brake engaged

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

11.6 Warning light - high coolant temperature

This red light comes on to alert to a too high temperature of the cooling medium.Stop the engine and find and rectify the problem.

11.7 Warning light - high beam

Blue warning light that signals when high beam is ON.

11.8 Warning light - hydraulic oil filter

clogged

When this lamp sets to on, immediately change the oil filter on the return line to the tank.

11.9 Warning light - low hydraulic oil level

This light comes on to alert to a low level of the hydraulic oil for a correct functioning. Replenish and

eliminate the oil leak.

11.10 General alarm warning light

This red light comes on to warn of a problem of the machine. Contact the TEREXLIFT Service Centre.

11.11 Warning light - low fuel level

If the fuel level is low (reserve), the relevant warning light comes on.

11.12 OPTIONAL Warning light - rear wheel aligned

When ON, this light indicates that the rear wheel are aligned.

11.13 Warning light - glow plugs preheating

This amber light indicates the pre-heating of the engine glow plugs. Before starting the engine wait for this light to go off. If the light fails to go off, a glow plug could be broken. The machine can be started normally without pre-heating up to a temperature of -12°C.

11.14 Warning light - low beam

Green warning light that signals when low beam is ON.

11.15 Not active

11.1011.11

11.1 11.2 11.3 11.711.911.8

Part No. 57.0009.0413 GTH-2506 - AGRI-625 33

11.4 11.5

11.15 11.1511.13

PROPOSTA G RAFIC A

STRUMENTO ECO

30/10/07

11.12 11.14

11.6

Page 34

Operator’s Manual

Controls And Instruments

CONTROL LEVER

Handlers are equipped with a multipurpose electroproportional lever which allows operating all machine movements. When shifted to one of the four directions (right/left, forwards/backwards) it controls the boom lifting/ lowering and the forward/back pitching .of the attachment frame. Pressing buttons 1 or 2 you move the boom telescope out and in and, when the function is present, you lock/unlock the attachment fitted to the machine.

Seize the control lever correctly and move it gently. The motion speed of the actuators depends on the lever position: a small motion results in a slow motion of the actuators; vice versa, a full range motion of the lever corresponds to the max. speed of the actuator.



First Edition - Fourth Printing



WARNING

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

WARNING

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

34 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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Controls And Instruments

Function selection

The lever is enabled to carry out the following motions:

• Boom lowering/lifting

shift the control lever to A or B

• Boom extraction/retraction

press button 2 and shift to A or B without moving

the control lever

• Attachment back/forward tilting

shift the control lever to C or D

• Attachment coupling/release (optional)

press button 1 and shift the lever to C or D

2506 - 3007

Part No. 57.0009.0413 GTH-2506 - AGRI-625 35

Optional

Page 36

Operator’s Manual

Controls And Instruments

Lifting/lowering the boom

DANGER

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

To lift or lower the boom:

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

First Edition - Fourth Printing





36 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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First Edition - Fourth Printing Operator’s Manual

Controls And Instruments

Extending/retracting the boom

DANGER

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

To extend or retract the telescopic elements of the boom:

• Press button 2 and smoothly shift the lever to position A to extend the boom or to position B to retract it.





Part No. 57.0009.0413 GTH-2506 - AGRI-625 37

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Operator’s Manual

Controls And Instruments

Pitching the attachment holding frame

forward/back

DANGER

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

To tilt forward/back the attachment holding frame:

• Shift the lever to position D to tilt the frame forwards or to position C to tilt it backwards.

First Edition - Fourth Printing





38 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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First Edition - Fourth Printing Operator’s Manual

Controls And Instruments

Attachment coupling/release (optional)

DANGER

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

To coupling or release the attachment:

• Press button 1 and smoothly shift the lever to position C to coupling or to position D to release it.

Optional





Part No. 57.0009.0413 GTH-2506 - AGRI-625 39

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First Edition - Fourth Printing

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40 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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First Edition - Fourth Printing 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.

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 machine as it was 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 machine 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.

Refer to the list on the next page and check each of the items.

If damage or any unauthorized variation from factory delivered condition is 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 again before going on to the function tests.

Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications.

Part No. 57.0009.0413 GTH-2506 - AGRI-625 41

Page 42

CAUTION

Operator’s Manual

Inspections

PRE-OPERATION INSPECTION

First Edition - Fourth Printing

• Make sure the operator’s manuals are intact, legible and placed inside the machine.

• Make sure all decals are present and legible. See “Labels and plates applied on the machine” chapter.

• Check for engine oil leaks and proper oil level. Top up if necessary. See “Maintenance” chapter.

• Check for axle oil leaks and proper oil level. Top up if necessary. See “Maintenance” chapter.

• Check for hydraulic oil leaks and proper oil level. Top up if necessary. See “Maintenance” chapter.

• Check for engine coolant leaks and proper coolant level. Add coolant if necessary. See “Maintenance” chapter.

• Check for battery fluid leaks and proper fluid level. Add distilled water if necessary. See “Maintenance” chapter.

Check the following components or zones for damage, missing or wrongly fitted parts or nonauthorised modifications:

• electrical components, wiring and electrical

cables

• hydraulic hoses, fittings, cylinders and main

valves

• fuel and hydraulic oil tanks

• drive pump and motor and transmission

axles

• steering system

• braking system

• boom telescopes sliding pads

• clean glasses, lights and rear view mirrors

• engine and relevant components

• horn

• lights

• machine ignition control

• nuts, bolts and other fasteners

Check the entire machine for:

• cracks on welds or structural components

• dents or damage to the machine

* Make sure that all structural and other critical

components are present and the relevant fasteners and pins are fitted and properly tightened.

* After inspection, check that all the compartment

covers are in place and latched.

WARNING

If even one single item is damaged or defective, do not start work. Stop the machine and repair the fault.

Checking the tyres

* Check the correct inflation of the tyres; see

par. “Tyres and Wheels” in the Maintenance section.

* Make sure that the tyre plies are not cut or

worn.

WARNING

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

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.

42 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 43

CAUTION

First Edition - Fourth Printing Operator’s Manual

Inspections

FUNCTION TESTS

Test the Control Lever

The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step 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.

TESTS

1 Select a test area that is firm, level and free

of obstruction. Be sure there is no load on the forks or attachment.

2 Enter the operator's compartment and sit on the

seat.

3 Fasten the seat belt.

4 Adjust the interior rear view mirror and the

exterior right hand mirror, if required.

5 Be sure the parking brake is on and the

transmission control is in neutral.

6 Start the engine. See Starting the Engine in the

Operating Instructions section.

7 Using the control lever, momentarily raise and

lower the boom, tilt the forks up and tilt the forks down.

Result: All functions should operate smoothly.

8 Using the control lever and the yellow button,

momentarily extend and retract the boom.

Result: The function should operate smoothly.

9 Using the control lever and the white button,

momentarily lock and unlock the attachment.

Result: The function should operate smoothly.

Test the Steering

9 Push the right side of the steer selector switch

to select four-wheel steer.

10 Check the steering operation by turning the

steering wheel approximately¼ turn in each direction.

Result: The front wheels should turn in the

same direction as the steering wheel. The rear wheels should turn in the opposite direction.

11 Straighten the wheels.

12 Push the steer selector switch to the middle

position to select two-wheel steer.

13 Check the steering operation by turning the

steering wheel approximately ¼ turn in each direction.

Result: The front wheels should turn in the

same direction as the steering wheel. The rear wheels should not turn.

14 Straighten the wheels.

15 Push the left side of the steer selector switch to

select crab steer.

Part No. 57.0009.0413 GTH-2506 - AGRI-625 43

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WARNING

Operator’s Manual

Inspections

First Edition - Fourth Printing

16 Check the steering operation by turning the

steering wheel approximately ¼ turn in each direction.

Result: The front wheels and rear wheels

should turn in the same direction as the steering wheel.

Test the Transmission and Brakes

17 Be sure the boom is fully lowered and retracted.

18 Step on the service brake pedal.

19 Move the transmission control lever to forward.

Slowly let up on the service brake pedal. As soon as the machine starts to move, push the service brake pedal.

Result: The machine should move forward,

then come to an abrupt stop.

20 Move the transmission control lever to reverse.

Slowly let up on the service brake pedal. As soon as the machine starts to move, push the service brake pedal.

Result: The machine should move in reverse,

then come to an abrupt stop. The back-up alarm should sound when the transmission control lever is in reverse.

21 Move the transmission control lever to neutral.

22 Push the top of the parking brake switch.

Result: The red parking brake indicator light

should come on, indicating the parking brake is on.

23 Move the transmission control lever forward,

then in reverse.

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

Result: The machine should not move.

24 Push the bottom of the parking brake switch.

The parking brake is off when the indicator light is off.

Test the Road Lights

25 Verify that all lights are functional.

44 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 45

Operating Instructions

WARNING

First Edition - Fourth Printing Operator’s Manual

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

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

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

DANGER

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

Part No. 57.0009.0413 GTH-2506 - AGRI-625 45

Page 46

CAUTION









Operator’s Manual

Operating Instructions

ENTERING THE MACHINE

(only for closed cabin)

First Edition - Fourth Printing

ENTERING THE CAB

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

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

Door opening from outside:

• Insert the key and release lock 1.

• Press the pushbutton 1 and open the door.

Door closing from inside:

Pull the door with force: it locks automatically.

Door opening from inside:

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

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

WARNING





To unlock the door latched in open position:

• Press button 4to unlock the door from the catch



• Once released, re-close the upper section of the door by means of handle



Leaving the cab in an emergency

In an emergency, the operator can use the front or the rear window as safety exit-ways. The rear window has handles for partially opening the glass. Such handles are locked in position by some wing nuts which, if driven out, allow opening the glass completely. The front window has two handles which, if turned, enable the operator to pass through.

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

46 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 47







First Edition - Fourth Printing Operator’s Manual

Operating Instructions

ADJUSTING THE SEAT

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

• Seat distance from the controls The seat is equipped with an adjusting device to

slide the same seat forward or back with respect to the steering column.

To adjust the seat, pull lever 1 outwards and push

the seat to the desired direction. Then release the lever and make sure that the seat locks in position.





• Springing adjustment (optional) Rotate lever 2 clockwise or anticlockwise

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

• Height adjustment (optional) Turn knob 3 clockwise to lift the seat; turn it

counter-clockwise to lower the seat.

In some seats height can be adjusted to three different positions. Lift the seat until you hear the click signalling that the seat is locked in position. To lower the seat, raise to end of stroke to release the mechanism, then release the seat: it will return to the bottom position.

DANGER

• The seat is for one person only.

• Don’t adjust the seat when the machine is moving.



FASTENING THE SEAT BELTS

Sit correctly in the driving seat; then:

• The safety belts are equipped with reel retractor. To fasten the belt, pull tab 1 and push it into buckle

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

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

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

Part No. 57.0009.0413 GTH-2506 - AGRI-625 47

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Operator’s Manual

Operating Instructions

First Edition - Fourth Printing

3 STEERING COLUMN ANGE ADJUSTMENT

Both steering column and dashboard can be set to a different angle. To adjust the steering wheel angle, unlock lever 3 and pull or push the steering wheel to the required position, then re-lock lever 3.

WARNING

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

GTH-2506

09.4618.0834

ADJUSTING THE REAR VIEW MIRRORS

The machine is fitted with two rear view mirrors:

• The right rear view mirror 2 is located on a special supporting bracket in advanced position and allows checking the area behind the machine, on the right-hand side. To adjust its position, manually rotate the joint it is fitted with.

• The left rear view mirror 3 is placed on the left upper post of the windscreen and allows checking the area behind the machine, on the left- hand side. To adjust its position, manually rotate the joint it is fitted with.

➌

➋

SWITCHING ON THE CAB INTERIOR LAMP

The ceiling light fixture is fixed to the rear top strut of the cab. The relevant lamp is switched on/off by

switch.

48 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 49

First Edition - Fourth Printing Operator’s Manual

Operating Instructions

STARTING THE ENGINE

For the low temperature starting, see paragraph “Low Temperature Starting”.

• Engage the parking brake.

• Put the forward/reverse speed selection lever to neutral.

• Step on the gas pedal.

• To start the engine, turn the ignition switch to position 2.

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

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

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

CAUTION

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

WARNING

Once it has been started, the engine continues to run even if you leave the driving place. DO NOT LEAVE THE DRIVING PLACE BEFORE HAVING SHUT THE ENGINE DOWN, LOWERED THE BOOM TO THE GROUND, TURNED THE SPEED SWITCH TO THE NEUTRAL POSITION AND ENGAGED THE PARKING BRAKE.

Engine cannot be started if the speed switch is not in the neutral position.

JUMP-STARTING THE ENGINE

CAUTION

Do not start the engine using a quick charge booster to avoid any damage to the electronic boards.

DANGER

When jump-starting the engine through the battery of another machine, make sure that the two vehicles cannot collide to prevent formation of sparks. Batteries give off a flammable gas and sparks may burn it and cause an explosion

Do not smoke when checking the electrolyte level.

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

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

To jump-start the engine:

• Turn any users off by the special control levers.

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

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

Part No. 57.0009.0413 GTH-2506 - AGRI-625 49

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Operator’s Manual

Operating Instructions

First Edition - Fourth Printing

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

• If the booster supply is installed on a second vehicle, make sure that the latter does not touch the handler. To avoid damage to the electronic

instruments of the machine, the engine of the machine where the booster supply is installed, must be stopped.





LOW TEMPERATURE STARTING

In case of cold starting, use an oil with a SAE viscosity adequate to the ambient temperature. Please refer to the engine use and maintenance manual. The machine is supplied with oil SAE 15W/40.

To start the engine from cold, proceed as follows:

• Turn the ignition key and start the handler.

• Disconnect the cables. Remove first the negative

terminal from the frame earth, then from the

booster supply. Disconnect the positive terminal from the machine battery, then from the booster supply.

DANGER

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

50 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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

• Turn the ignition switch to the glow plugs preheating position and wait until the relevant warning light 11.13 goes off. Step down on the gas pedal and start the engine by turning the ignition switch. Release the switch as soon as the engine fires.

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

Page 51

First Edition - Fourth Printing Operator’s Manual

Operating Instructions

STARTING THE MACHINE

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

• Select the required steering mode.

• Select the required gear (forward or reverse).

• Release the parking brake.

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

WARNING

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

STOPPING AND PARKING THE MACHINE

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

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

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

• Engage the parking brake and ensure its indicator light switches on.

• Release the service brake pedal.

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

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

• Leave the driving cab and lock the cab door.

WARNING

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

WARNING

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

Part No. 57.0009.0413 GTH-2506 - AGRI-625 51

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Operator’s Manual

Operating Instructions

USING THE LOAD CHARTS

The load charts 1 indicates the maximum permissible load in relation to the boom extension and the type of attachment used. To operate under safe conditions, always refer to these charts. The extension level of the boom can be checked with the help of the letters (A, B, C, D, E) painted on the same boom (pos.3), while the actual degrees of inclination of the boom are shown by the angle indicator 2. All the load charts are placed into a dedicated holder installed in the right side of the cabin, on the top of the dashbord. The tag 4 located at the bottom of each load chart represents the type of attachment used.

WARNING

First Edition - Fourth Printing

WARNING

The load charts applied on the cab windscreen refer to a stationary machine standing on a solid and level ground. Raise the load some centimetres and check its stability before raising it completely.

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

GTH-2506

10°

20°

50°

40°

30°

k 0

0°

60°

k 0

3.34 m

70°

0.6 m

k 0

013

5.79 m



09.4618.0834





B C



52 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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First Edition - Fourth Printing Operator’s Manual

Operating Instructions

LOAD LIMITER

On the front top strut of the cab, there is limiter 6 which warns the operator of the variation of stability of the machine and blocks any manoeuvre before the same reaches a critical condition.

Description of the controls

1 Calibration selection button

2 Display 3 Stability indicator with LED-bar 4 Green light - power OK 5 Yellow light - calibration mode 6 Calibration confirmation button 7 Not used 8 Red light - outrigger position 9 Buzzer ON/OFF pushbutton 10 Red light - overload pre-alarm/alarm The digit on display 2 shows the selected attachment. The user can choose among:

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 the digit corresponding to the used attachment 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.

1 2 3

5 6 7 8

The machine enters the alarm mode: light

10 is lit, the buzzer sounds continuously and

any dangerous manoeuvre is blocked. The operator can only retract the load within safety limits.

Example of use of the overload warning system

Boom extension

Overload warning

system in alarm

Boom retraction

Alarm ceases

Reduction of the load

to be handled

Part No. 57.0009.0413 GTH-2506 - AGRI-625 53

Page 54

DANGER

Operator’s Manual

Operating Instructions

First Edition - Fourth Printing

HANDLING LOADS

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”.

Adjusting the forks

With FEM forks (optional)

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

• Lift the clamping lever of the forks.

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

With floating forks

In the case of floating forks:

• Loosen the nut of the locking screws.

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

• Lock the screws retightening the nut.

5 8

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

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

Before using the machine, make sure that the first green LED of the overload warning system is ON. The overload warning system must not be used to check the load going to be lifted: it has only been designed to signal possible unbalances of the machine along its motion axis. Such unbalances may also be caused by an abrupt operation of the levers during the load handling. If, during work, several indicators light up, operate the levers more smoothly.

54 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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

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

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

Page 55

Operating Instructions

DANGER

First Edition - Fourth Printing Operator’s Manual

WORKING PHASES

When forks are correctly spaced, the handler is ready to use. Work can be subdivided into three different phases: loading, transfer and unloading.

Loading phase

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

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

• Pitch the forks back to retract the load.

Transfer phase

• Do not start or brake abruptly.

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

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

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

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

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

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

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

Unloading phase

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

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

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

• Lower the load and make sure it is level.

Part No. 57.0009.0413 GTH-2506 - AGRI-625 55

Page 56





Operator’s Manual

Operating Instructions

CHANGING THE ATTACHMENT

First Edition - Fourth Printing

CAUTION

Use only attachments directly manufactured or recommended by Terexlift and detailed in the “Optional attachments” section.

Version with MECHANICAL LOCKING

To change an attachment, operate as follows:

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

• Disconnect the quick connectors of the attachment (if any).

• Pull out pin 1 locking the attachment after removing the safety split-pin 2 at its end.



WARNING

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



• Rest the attachment flat on the ground.

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

• Move back with the machine and drive to the new attachment to be coupled.

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

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

• Refit pin 1 fixing it with its safety split-pin 2.

• Re-couple the connectors of the attachment (if any).

56 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 57



Operating Instructions

First Edition - Fourth Printing Operator’s Manual

REAR TOWING HITCH _ ONLY AGRI-625

Version with HYDRAULIC LOCKING (optional)

To change an attachment, operate as follows:

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

• Disconnect the quick connectors of the attachment (if any), and connect the hydraulic locking pipes of the attachments to couplings 3.



• Rest the attachment flat on the ground.

• Remove the safety pin 2 placed at its end.

• Free the attachment operating the control of the attachment locking/unlocking cylinder

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

• Move back with the machine and drive to the new attachment to be coupled.

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

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

• Operate the attachment locking lever (optional) and secure the attachment in place with safety pin 2 previously removed.

• Re-couple the connectors of the attachment (if any).

The machine is equipped with a fixed towing hitch of class B.

This hitch can tow 2 or 4 axle trailers with a maximum weight of 4000 kg.

Additionally it can be used for towing two-wheel carts with a maximum weight of 1500 kg.



AGRI-625

WARNING

• Do not tow too heavy trailers or loads.

• The load on the drawbar must never be higher

than 500 kg.

• Avoid abrupt starts due to the high risks of rearing.

• For your safety, do not tow trailers without an independent braking system.

• Before moving back with the machine to hook the trailer, check that no one and nothing is between the machine and the trailer. The persons given the task of signalling must keep a safe distance and in a well visible position for the operator in the cab.

Part No. 57.0009.0413 GTH-2506 - AGRI-625 57

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Operator’s Manual

First Edition - Fourth Printing

Intentionally blank page

58 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 59

NOTICE

First Edition - Fourth Printing Operator’s Manual

Transporting The Machine

MOVING A DISABLED MACHINE

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

• Unlock the parking brake.

• Tow the machine for short distances and at a low speed only (less than 5 km/h).

• Use a rigid drawbar.

• Select the two-wheel steer.

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

• Raise the front wheels of the machine.

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

In the AGRI-625 model, there is a front towing hitch to be used to tow the machine.

ROAD OR SITE TRANSFER

When travelling on public roads, strictly obey the local or national road traffic regulations. Besides, take into account the following general precautions:

• Align the rear wheels.

• Select the two-wheel steering setting.

• Set the Road/Jobsite switch 21 to “ROAD”.

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

With the floating forks pitched back, do not move the fork pitching cylinder as the machine could suffer from damage.

• Retract boom and attachment to transfer position.

• Start the engine: the flashing flashing beacon will switch on automatically.

• The transfer speed of the vehicle will depend on the engine rpm and the position of the control lever.

Part No. 57.0009.0413 GTH-2506 - AGRI-625 59



AGRI-625

Public road circulation is allowed only for transferring an unloaded machine. Do not use the machine to tow trailers.

Page 60

Operator’s Manual

Transporting The Machine

First Edition - Fourth Printing

LIFTING THE MACHINE

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

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

TRANSPORTING THE MACHINE ON OTHER

VEHICLES

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

• Ensure ramps are correctly positioned.

• Retract the boom to transfer position.

• Carefully drive the machine onto the transporting vehicle.

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

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

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

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

• Anchor the machine to the transporter's platform by fixing the chains to the special eyebolts A on the chassis.

09.4618.0916



60 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 61

NOTICE

First Edition - Fourth Printing Operator’s Manual

Transporting The Machine

PARKING AND STORAGE

Short inactivity

Always park the machine in a safe way after a working day, a shift and at night. Take all precautions to prevent damage to those persons who will approach the machine while stationary:

• Park the machine so that it does not hinder other

operations.

• Lower the boom fitted with attachment on the ground.

• Disengage the transmission and put the parking brake.

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

CAUTION

Leaving a battery connected can result in shorts and, as a consequence, in a ﬁ re.

Machine storage

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

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

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

• Lubricate the machine thoroughly.

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

• Re-paint any worn or damaged part.

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

• Refuel the tank to prevent internal oxidation.

• Store the machine in a sheltered and wellventilated place.

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

• When weather is particularly cold, empty the radiator.

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, carry out an extraordinary maintenance and carefully check all mechanical, hydraulic and electrical components.

Part No. 57.0009.0413 GTH-2506 - AGRI-625 61

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Operator’s Manual

Transporting The Machine

First Edition - Fourth Printing

CLEANING AND WASHING THE MACHINE

Clean the machine in accordance with the following instructions:

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

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

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

CAUTION

Do not use water at high pressure for washing the machine and especially the main valve, the solenoid valves and electrical parts.

External washing

Before washing the machine, check that the engine is shut down and the doors and windows are closed. Do not, at any times, use fuel to clean the machine. Use water or some steam. In cold climates, dry the locks after washing or smear them with an antifreeze. Before using the machine again, check its conditions.

Internal washing

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

Washing the engine

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

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

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.

CAUTION

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.

62 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 63

NOTICE

First Edition - Fourth Printing Operator’s Manual

Maintenance

Observe and obey:

* The operator can only perform

the routine maintenance operations envisaged in this

manual.

* Scheduled maintenance

procedures shall be completed by qualified technical personnel according to the manufacturer’s

specifications.

Maintenance symbol legend:

The following symbols are used in this manual to help you understand better the instructions provided. When one or more symbols appear at the beginning of a maintenance procedure, they indicate the following:

Indicates that tools are required to perform the procedure.

INTRODUCTION

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

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

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

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

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

Indicates that new parts are required to perform the procedure.

Indicates that a cold engine is required to perform the procedure.

SERVICE INTERVAL

Running-in ____________________________ Ordinary ______________________________

Indicates the time interval for the maintenance jobs expressed in working hours.

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Operator’s Manual

Maintenance

LUBRICANTS - HEALTH AND

SAFETY PRECAUTIONS

First Edition - Fourth Printing

Health

A prolonged skin contact with oil can cause irritation. Use rubber gloves and protective goggles. After handling oil, carefully wash your hands with soap and water.

Storage

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

Disposal

New or exhausted oil is always polluting! Never drain oil on the ground. Store new oil in a suitable warehouse. Pour exhausted oil into cans and deliver them to specialised firms for disposal.

Oil leaks

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

First aid Eyes : In case of accidental contact with

the eyes, wash with fresh water. If the irritation persists, seek medical advice.

Intake : In case of oil intake, do not induce

vomiting, but seek medical advice.

Skin : 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.

64 GTH-2506 - AGRI-625 Part No. 57.0009.0413

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First Edition - Fourth Printing Operator’s Manual

Maintenance

ORDINARY MAINTENANCE

A wrong or neglected maintenance can result in possible risks for both operator and bystanders. Make sure maintenance and lubrication are carried out according to the manufacturer’s instructions to keep the machine safe and efficient. The maintenance interventions are based on the machine working hours. Regularly check the hourmeter and keep it in good conditions to define the maintenance intervals correctly. Make sure any defect detected during the maintenance is promptly rectified before using the machine.

CAUTION

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

During the first 10 working hours

1. Check the oil level within reduction gears, power

divider and differential gears

2. Regularly check the tightening of the wheel bolts

3. Check the tightening of all bolts and nuts

4. Check the couplings for oil leaks

Every 10 working hours or daily

1. Check the engine oil level

2. Clean the air suction filter

3. Clean the radiator, if necessary

4. Check the hydraulic oil level in the tank

5. Check the greasing of the boom section pads

6. Grease the attachment holding frame

7. Grease all joints of the boom, the rear axle shaft

joint, the transmission shafts, the front and rear axles and any equipment of the machine

8. Check the efficiency of the lighting electric

system

9. Check the efficiency of braking system and

parking brake

10. Check the efficiency of the steering selection

system

11. Check the efficiency of the fork balancing sy-

stem.

Every 50 working hours or weekly

Jobs to be done in addition to those above

1. Check the tension of the alternator belt.

2. Check the tyre inflation.

3. Check the tightening of the wheel nuts.

4. Check the tightening of the Cardan shaft

screws.

Every 250 working hours or monthly

Jobs to be done in addition to those above

1. Change the engine oil and relevant filter

2. Check the oil level in the front and rear

differential gears and the reducer

3. Check the oil level in the four wheel reduction gears

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

5. Check the clamping of the cableheads to the battery terminals

6. Check the air suction hose between engine and filter

7. Check the cylinder chromium-plated rods

8. Check the hydraulic lines are not worn because

of rubbing against the frame or other mechanical components

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

10.  Check the wear of the sliding pads of the boom sections.

11. Adjust the play of the sliding pads of the boom sections.

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

13. Check the level of the battery electrolyte.

Every 3 working months

Jobs to be done in addition to those above

1. Check the efficiency of the block valves.

Part No. 57.0009.0413 GTH-2506 - AGRI-625 65

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Operator’s Manual

Maintenance

First Edition - Fourth Printing

Every 500 working hours or every six months

Jobs to be done in addition to those above

1. Visually check the smoke quantity evacuated from the engine exhaust.

2. Check the tightening of the engine fixing screws.

3. Check the tightening of the cab fixing screws.

4. Check the backlash between pins and bushings

in all joints.

5. Change the hydraulic oil filter in the tank.

6. Have the hydraulic system checked by a skilled

technician.

7. Change the main cartridge of the engine air filter.

8. Change the hydraulic oil filter of the transmission

9. Clean or replace, if necessary, the air filter in the cab.

Every 500 working hours or yearly

Jobs to be done in addition to those above

1. Change the engine oil and renew the fuel filter.

Every 1000 working hours or yearly

Jobs to be done in addition to those above

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

2. Change the oil in the four wheel reduction gears.

3. Change the hydraulic oil.

OIL CHANGE SCHEDULE

Job

Oil level check 10 daily SHELL RIMULA 15W-40

Engine

Axles and

power

divider

Hydraulic

oil

* whichever occurs ﬁ rst.

66 GTH-2506 - AGRI-625 Part No. 57.0009.0413

First change 500 Subsequent changes 500 yearly Oil level check 250 monthly TRACTORENAULT First change - Subsequent changes 1000 yearly

Oil level check 10 daily SHELL TELLUS T 46 First change - Subsequent changes 1000 yearly

Operating

hours *

Service

interval *

Oil type

(API CH-4/CG-4/CF-4/CF; ACEA E3; MB228.3)

THFI 208 LF SAE 80W API GL4 / FORD M2C 86B Massey Ferguson M1135

DENISON HF-1, DIN 51524 part 2 & 3

Page 67

CAUTION

First Edition - Fourth Printing Operator’s Manual

Maintenance

MAINTENANCE INTERVENTIONS

WARNING

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

WARNING

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

WARNING

Any intervention on the hydraulic circuit must be carried out by skilled personnel. The hydraulic circuit of this machine is fitted with pressure accumulators. You and others could be seriously injured if accumulators are not completely depressurised. For this purpose, shut the engine down and step on the brake pedal 8÷10 times.

High pressure lines must be replaced by qualified personnel only. Any foreign matters entering the closed circuit may result in a sudden deterioration of the transmission.

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

PROTECT THE ENVIRONMENT

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

WARNING

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

Part No. 57.0009.0413 GTH-2506 - AGRI-625 67

Page 68

Operator’s Manual

Maintenance

ACCESS TO THE ENGINE COMPARTMENT

For any operation within the engine compartment, open the protection bonnet. Hood is equipped with lock & key and a supporting rod that holds it in position. From the engine compartment, you get access to:

• Thermal engine A

• Engine air filter B

• Radiator fluid compensation cup C

• Battery D

To get access to the engine compartment:

• Shut the engine down and put the parking brake.

• Unlock and raise the hatch with handle.

First Edition - Fourth Printing

DANGER

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















68 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 69

CAUTION

First Edition - Fourth Printing Operator’s Manual

Maintenance

ENGINE AIR FILTER

Clean the engine air filter and replace the elements, when necessary.

1 Cleaning and changing the outer element:

- Shut the engine down and engage the parking brake.

- Unlatch the fasteners A and remove cover B

- Pull out the filter cartridge C.

- Clean the filter bowl.

- Dry clean the cartridge (at max. 6 bar pressure) and direct the air jet from inside to outside.

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

- Refit the cartridge and make sure it is properly positioned.

- Close cover B and lock in place with fasteners A.

The inner element should be replaced every two times the outer element is replaced. Never wash the cartridge with water or solvents.













As soon as the warning lamp 11.3 on the cab dashboard switches on, replace the outer element. Never wash the cartridge with water or solvents.

2 Changing the internal element

- See step 1 for removing the outer element.

- Extract the internal cartridge D.

- Clean the filter bowl.

- Mount the new element and make sure it is correctly positioned.

- Fit the main filter and the cap as described in point 1.





SERVICE INTERVAL

Running-in _____________________________ None Cleaning _____________________ Every 10 hours

Outer element change __________Every Inner element change ________ Every 1000 hours

500 hours

Part No. 57.0009.0413 GTH-2506 - AGRI-625 69

Page 70

Operator’s Manual

Maintenance

ENGINE COOLING SYSTEM

DANGER

When the coolant is hot, the cooling system is under pressure. With warm engine, loosen the radiator plug slowly and carefully, without removing it, to drain the pressure. Use protection gloves and keep your face at a safe distance.

• Weekly check the coolant level through the level window C, before starting working (when fluid is cold).

• When necessary, add clean water or an antifreeze mixture through cap A.

• Change the antifreeze mixture every two years.

To drain the antifreeze:

- Let the engine cool down

- Unscrew the plug B at the bottom of the radia-

tor or disconnect the rubber hose, if no plug is present. Allow the coolant to flow out into a special container.

- Refit the hose and pour new antifreeze (50%

water-antifreeze). This proportion will provide protection up to -38°C.

• Daily clean the radiator grille using a brush with

hard bristles or compressed air at a max pressure of 6 bar.





First Edition - Fourth Printing









On delivery, the machine is filled with a cooling mixture consisting of 50% water and 50% anti-freeze.

TEREX PRO COOL

Protection against boiling / freezing

Product % Freezing point Boiling point

SERVICE INTERVAL

Running-in

Ordinary

70 GTH-2506 - AGRI-625 Part No. 57.0009.0413

__________________________ None

__________________ Every 50 hours

-17°C

-24°C

-36°C

-67°C

123°C 126°C

128°C

135°C

Page 71

PROTECT THE ENVIRONMENT

First Edition - Fourth Printing Operator’s Manual

Maintenance

CHECKING THE OIL LEVEL IN THE TANK

DANGER

Fine jets of hydraulic oil under pressure can penetrate the skin. Do not use your fingers, but a piece of cardboard to detect oil leaks.

Visually check the hydraulic oil level through level A located on the reservoir and visible through the slot on the right side of the chassis.

When necessary, add new oil through filler B.

SERVICE INTERVAL

Running-in

Ordinary

_________Within the first 10 hours

__________________ Every 50 hours

CHANGING THE HYDRAULIC OIL

To change the hydraulic oil, proceed as follows: 1 Stop the machine on a level ground and make

sure the parking brake is engaged.

2 Release the pressure from the hydraulic circuit. 3 Place a container of suitable size under the drain

plug, placed in the lower part of the reservoir, and collect any oil leaks.

4 Remove the drain plug and allow oil to flow out

into the container.

5 Remove the inspection cover of tank C. 6 Carefully wash the tank with Diesel oil and blow

a jet of compressed air.

7 Refit the drain plug and the inspection cover. 8 Add new oil by making sure that it matches the

recommended type until it is level with A.

SERVICE INTERVAL

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

Running-in

Ordinary

________________Every 1000 hours

__________________________ None









Part No. 57.0009.0413 GTH-2506 - AGRI-625 71

Page 72

PROTECT THE ENVIRONMENT

Operator’s Manual

Maintenance

CHANGING THE OIL FILTER CARTRIDGE

To change the hydraulic oil filter element, proceed as follows:

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

Place a container of suitable size under the filter to collect any oil leaks

Remove the filter cover to get access to the filter element A

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

Refit and tighten the filter cover

First Edition - Fourth Printing

CAUTION

The hydraulic oil filter cartridge shall be replaced as soon as the clogging indicator light on the control board comes on (see par. Controls and instruments).

CAUTION

Hydraulic oil filter canisters cannot be cleaned or washed and refitted. They must be replaced with new ones of the type recommended by the manufacturer.

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

SERVICE INTERVAL

Running-in

__________________________ None





Ordinary

72 GTH-2506 - AGRI-625 Part No. 57.0009.0413

_________________ Every 500 hours

Page 73

CAUTION

First Edition - Fourth Printing Operator’s Manual

Maintenance

CAB AIR FILTER

Every six months clean the air filter in the cab. Replace

the cartridge if the filtering cloth is damged.

1 Cleaning and changing the cartridge:

- Shut the engine down and engage the parking

brake.

- Pull filter A out of the housing accessible from

the inside of the cab.

- Clean the filter bowl.

- Clean the filter cartridge by beating it against

a piece of wood. Replace the cartridge if damaged.

Paper filters must never be cleaned using compressed air or washed with water and/or solvents.





Part No. 57.0009.0413 GTH-2506 - AGRI-625 73

Page 74

Operator’s Manual

Maintenance

First Edition - Fourth Printing

OIL LEVEL IN THE DIFFERENTIAL GEARS

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

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

• Loosen level plug  and check if oil is level with the hole.

• If necessary, top-up through hole comes out from hole

• Refit and tighten plugs  and .

To change the oil:

• Place a container of suitable size under drain plug .

• Loosen the drain plug, the level plug  and the filler  and allow oil to flow out from the reduction

gear.

• Refit and tighten drain plug .

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

• Refit and tighten plugs  and .

.

 until oil

Filling plug Drain plug Level plug

OIL LEVEL IN THE (front/rear) WHEEL

REDUCTION GEARS

To check the oil level within the wheel reduction gears:

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

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

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

• Refit the plug.

To change the oil:

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

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

• Unscrew plug and drain any oil from the reduction gear.

• Rotate the wheel by 90° until the plug finds again on the horizontal axis.

• Add new oil through hole .

• Refit and tighten plug.

SERVICE INTERVAL

Running-in

Ordinary

74 GTH-2506 - AGRI-625 Part No. 57.0009.0413

_________Within the first 10 hours

_________________ Every 250 hours

Running-in

Ordinary

SERVICE INTERVAL

_________Within the first 10 hours

_________________ Every 250 hours

Page 75

First Edition - Fourth Printing Operator’s Manual

Maintenance

OIL LEVEL IN THE POWER DIVIDER

GEARBOX

To check the oil level in the power diver gearbox:

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

• Clean level plug  all around.

• Remove the plug and check if oil is level with the hole.

• When necessary, add new oil through plug  until it is level with the hole.

• Refit and tighten the plug.

To change the oil:

• Place a container of suitable size under the drain plug.

• Remove the plug .

• Remove the drain plug  and empty the power divider gearbox.

• Refit and tighten the drain plug .

• Pour in new oil through the filler  placed at the top of the reduction gear of the power divider.

Stop when oil is level with hole .

• Refit and tighten plug .

Filling plug Drain plug

SERVICE INTERVAL

Running-in

Ordinary

Part No. 57.0009.0413 GTH-2506 - AGRI-625 75

_________Within the first 10 hours

_________________ Every 250 hours

Page 76

Operator’s Manual

Maintenance

GREASING

First Edition - Fourth Printing

CAUTION

Before injecting grease into the greasers, thoroughly clean them to avoid that mud, dust or other matters can mix with the lubricant and reduce or annihilate the lubrication effect. Remove any old grease with a degreaser from the telescopes before smearing them with new grease.

Regularly grease the machine to grant it efficient conditions and a long life.

By means of a pump, inject grease into the special greasers.

As the fresh grease comes out, stop the operation. The greasing points are shown in the following

figures:

- the symbol

greased by a pump

- the symbol represents the points to be

greased by a brush.

represents the points to be

CAUTION

Use only PTFE INTERFLON FIN GREASE LS 2 to lubricate the sliding parts of the telescopic section. Observe the following schedule:

• After the first 50 operating hours (1 week)

• After the first 250 operating hours (1 month)

• Every 1000 operating hours (6 months) Remove any old grease from the boom and

smear the sliding area of the blocks with a thin coat of grease.

SERVICE INTERVAL

Running-in

Ordinary

76 GTH-2506 - AGRI-625 Part No. 57.0009.0413

__________________________ None

__________________ Every 10 hours

Page 77

First Edition - Fourth Printing Operator’s Manual

Maintenance

TYRES AND WHEELS

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

SERVICE INTERVAL

Over-inflated tyres can burst.

Running-in

_________Within the first 10 hours

Overheated can burst. Do not weld the wheel rims. For any repair work, call in a qualified technician.

OKAY

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

Dimensions (front and rear)

P.R. (or load index) 10 pr Rim 9.75x16.5

Wheel disc

Pressure

bar/Psi

WRONG

GTH-2506 AGRI-625

12-16.5

8 holes DIN

70361

4.5/65

Ordinary

BRAKES

For any intervention on the braking system (adjustment and/or substitution of the brake discs) address to the TEREXLIFT Technical Assistance Service or the nearest TEREXLIFT authorised workshop.

_________________ Every 250 hours

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

Torque: 400 N/m.

Part No. 57.0009.0413 GTH-2506 - AGRI-625 77

Page 78

Operator’s Manual

Maintenance

SHAFTING ALIGNMENT

During operation, the alignment of the front and rear axles of the machine can be subject to variations. This can depend on an oil blow-by from the steering control circuit, or on a steering of both axles when front and rear wheels are not perfectly aligned.

To fix this problem, rather than checking the alignment visually, follow the procedure below:

1) Move to a solid and level ground

First Edition - Fourth Printing

PROPOSTA G RAFIC A

STRUMENTO ECO

30/10/07

2) Set the steering selection switch wheel steer”

(pos. 2)

20 to “four-

3) Rotate the steering up to its stop (either to the

right or to the left)

4) Set the steering selection switch to “two-wheel steer” (pos. 0)

5) Rotate the steering up to its stop (turn in the same direction as above)

6) Reset the steering selection switch to “fourwheel steer" (pos. 2)

7) Rotate the steering (to the side opposite to point

3) so that the rear axle reaches its stop

8) Reset the steering selection switch to “two-wheel steer" (pos. 0)

9) Rotate the steering (to the same side as in point

7) so that the front axle reaches its stop

10) Reset the steering selection switch to “four-

wheel steer" (pos. 2)

Now the wheels should be re-aligned.

0 2

If the machine is equipped with the optional Automatic Rear Wheel Alignment Indicator Sensor (see paragraph Controls and instruments), the orange warning light 11.12 comes on automatically when, by turning the steering wheel with the selector switch is in position 0, the rear

wheels are aligned.

SERVICE INTERVAL

Running-in

Ordinary

__________________________None

__________________ When necessary

78 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 79

CAUTION

First Edition - Fourth Printing Operator’s Manual

Maintenance

ADJUSTING THE SLIDING PADS OF THE BOOM

SECTIONS

Any boom section is fitted with adjustable pads located on the four sides of the profile. These pads are secured to both fixed and mobile part of every section.



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

Adjusting the pads:

• Remove or loosen the screws fixing the pads in

relation to type of shims used (with or without slots).

• Fit the necessary amount of shims.

• If the residual thickness of the pad is insufficient

or near the maximum wearing limit, renew the pad.

• Tighten the screws fixing the pads at the

recommended torque (see below). Use a dynamometric wrench.

Tightening torques of the pad screws in relation to the screw diameter

Screws M10 Nm 30

Screws M14 Nm 50

Tightening torques higher than those recommended can cause the break of the pad or of the locking threaded bush.











Max. wearing thickness

Pads must compulsorily be replaced if the residual thickness of the plastic layer with respect to the iron bush fixing the block is equal or inferior to 1 mm.

SERVICE INTERVAL

Running-in

Ordinary

Part No. 57.0009.0413 GTH-2506 - AGRI-625 79

__________________________None

__________________ When necessary

Minimum 1 mm

Page 80

Operator’s Manual

Maintenance

CHECKING THE SAFETY DEVICES

First Edition - Fourth Printing

LOAD LIMITING SYSTEM. It consists of a load cell fitted to the rear axle and a display installed in the driving place. This device enables the operator to check the stability variation through a bar with 8 LED’s (4 green, 2 yellow and 2 red).

Checking the LOAD LIMITING SYSTEM

(at every use) When power is turned on, the DLE load limiting system

runs a self-test. In the case of troubles, LED’s 5, 8 and 10 start flashing, the buzzer sounds, an error code is shown on the display and the machine enters the alarm mode and cannot be operated. The meaning of the error messages is shown in Section E “Faults and Troubleshooting”. To do a manual check, it will be enough to load a weight exceeding the maximum permitted with the boom fully out and attempt to lift it. The system shall enter in alarm; should that not be the case, contact TEREXLIFT Technical Service.

80 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 81

First Edition - Fourth Printing Operator’s Manual

Maintenance

EMERGENCY STOP PUSHBUTTON

Located on the dashboard, to the right of the steering wheel.Pressing down this button stops the engine of the machine.

Before starting work again, find and rectify the relevant causes, then reset the button to neutral position turning it clockwise.

GTH-2506

09.4618.0834

Checking the emergency stop pushbutton (at

every use)

To check the efficiency of this pushbutton, simply

press it down during a movement. The pressure of

the pushbutton shall cause the movement to stop

and the engine to shut down.

Part No. 57.0009.0413 GTH-2506 - AGRI-625 81

Page 82

DANGER

Operator’s Manual

Maintenance

BLOCK VALVES fitted to all CYLINDERS

First Edition - Fourth Printing

All machine’s cylinders are equipped with block

valves:

Always use the lock ring of the lift cylinder (see picture below), when carrying out maintenance on the lift cylinder block valve 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.





• Compensation cylinder

• Lifting cylinder

• Telescopic boom extension cylinder

• Attachment swinging cylinder

Checking the block valves (every 3 months)

The piloted blocking valves allow to held the load in position in case of burst of a flexible hose. To check the efficiency of a valve, proceed as follows:

• Load a weight near the maximum payload onto

the boom.

• Raise the load some centimetres above the ground (max 10 cm). To check the valve on the telescope extension cylinder move the boom to maximum height and extend it some centimetres.

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

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

82 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 83

WARNING

First Edition - Fourth Printing Operator’s Manual

Maintenance

CHECKING THE STATE OF THE

STRUCTURE

To remove the block valves or the cylinders

- Lower the boom to the ground in a firm way since the removal of the block valve or the cylinder can cause an uncontrolled down-movement.

- After refitting the valve or the cylinder, replenish the circuit and eliminate any air before starting working. To eliminate the air from the circuit, move the involved cylinders to end-of-stroke in the two directions (opening/closing. To eliminate the air from the fork balance cylinder, move the boom up and down and tilt the fork plate forwards/ back.

Five years or 6000 hours after the ﬁ rst placing into operation of the machine (whichever occurs ﬁ rst), check the state of the structure paying an extreme attention to the welded supporting joints and the pins of both boom and platform (if present).

WARNING

After the first 5 years, repeat this check every 2 years.

Do the check of the valves taking all the possible precautionary measures:

- Wear safety glasses

- Wear safety gloves

- Wear safety shoes

- Wear suitable working clothes

- Use guards against leaks of oil at high pressure

- Do the check in a free space with barriers all around to keep non-authorised people away

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

Checking the MACHINE START CONTROL (at

every use)

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

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

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

Part No. 57.0009.0413 GTH-2506 - AGRI-625 83

Page 84

CAUTION

Operator’s Manual

Maintenance

ELECTRICAL SYSTEM

First Edition - Fourth Printing

WARNING

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

WARNING

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

WARNING

Any intervention on the electrical system unless performed by authorized personnel, is expressly forbidden.

BATTERY

• Check the electrolyte level every 250 working

hours; if necessary, add distilled water.

• Ensure the fluid is 5÷6 mm above the plates and the cell levels are correct.

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

• Protect the terminals smearing them with pure vaseline.

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

WARNING

• Battery electrolyte contains sulphuric acid. It

can burn you if it touches your skin and eyes. Always wear goggles and protective gloves, and handle the battery with caution to prevent spillage. Keep metal objects (watch straps, rings, necklaces) clear of the battery leads, since they can short the terminals and burn you.

• Before disconnecting the battery, set all switches within the cab to OFF.

• To disconnect the battery, disconnect the negative (-) lead from the frame earth first.

• To connect the battery, connect the positive (+) lead first.

• Recharge the battery far from the machine, in a well-ventilated place.

• Keep out of items which can produce sparks, of naked flames or lit cigarettes.

• Do not rest metal objects onto the battery. This can result in a dangerous short especially during a recharge.

• Because the electrolyte is highly corrosive, it must never come in contact with the frame of the handler or electric/electronic parts. If the electrolyte comes in contact with these parts, contact the nearest authorised assistance centre.

WARNING

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

Do not add sulphuric acid; add only distilled water.

84 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 85

First Edition - Fourth Printing Operator’s Manual

Maintenance

FUSES AND RELAYS

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

Cabin Fuses

REF. DESCRIPTION AMP.

F01 WARNING 10 F02 HIGH BEAM 15 F03 LOW BEAM 15 F04 HORN 15 F05 ROAD/JOBSITE 10

R-FRONT & L-REAR

F06

POSITION LIGHTS L-FRONT & R-REAR

F07

POSITION LIGHTS F08 POWER SUPPLY OPT 10 F09 2

HYDRAULIC CIRCUIT 10 F10 ARB INSTRUMENT 5 F11 HEATING 25 F12 GEAR SELECTOR 10 F13 WORK LIGHT 15 F14 REAR AXLE SENSOR 10 F15 FLASHING BEACON 10 F16 STOP LIGHT 10 F17 HAZARD WARNING LIGHT 10 F18 EMERGENCY STOP 10 F19 WIPER 10 F20 INSTRUMENT PANEL 10

F 10 F 20 F 09 F 19 F 08 F 18

F 07 F 06 F 05 F 04 F 03

F 02 F 01

F 17 F 16 F 15 F 14 F 13

F 12 F 11

Part No. 57.0009.0413 GTH-2506 - AGRI-625 85

Page 86

Operator’s Manual

Maintenance

Engine compartment fuses and relays

K02

REF DESCRIPTION AMP

FG1 MAIN FUSE 60 FG2 GLOW PLUGS FUSE 40

K02 STARTER ENABLING SWITCH K01 GLOW PLUGS PREHEATING

K01

FG1 FG2

First Edition - Fourth Printing

CAUTION

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

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

• Always keep some spare fuses for an emergency.

• Never try to repair or short blown fuses.

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

86 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 87

CAUTION

First Edition - Fourth Printing Operator’s Manual

Maintenance

REFUELLING

Part Product Capacity (litres)

Diesel engine Engine oil 10

PRODUCT SPECIFICATIONS Engine oil

Use the oil recommended by the Diesel engine Manufacturer (see the relevant handbook delivered with the machine). At the delivery, the machine is refilled with:

Engine cooling system Water+antifreeze 13

Fuel tank Diesel fuel 60 Hydraulic system tank Hydraulic oil 65 Front differential gear with reduction gear Oil Rear differential Oil 4 Front wheel reduction gears Oil 1.6 Rear wheel reduction gears Oil 1.6

4 + 0.7

SHELL RIMULA SAE 15W-40 (API CH-4 / CG-4 / CF-4 / CF, ACEA E3, MB 228.3)

Lubrication oils and relevant filtering elements

Refill the machine with following lubricants:

Use Product Definition

Power divider-Differential gearsReduction gears

Hydraulic system and brakes SHELL TELLUS T46

Never mix different oils: this may result in troubles and component breaks.

Oils for hydraulic system:

Arctic climates: Temperatures below -10°C Use SHELL Tellus T22 Mild climates: Temperatures from -15°C to + 45°C Use SHELL Tellus T46 Tropical climates: Temperatures above +30°C Use SHELL Tellus T68

Filtering elements: Filter Flow rate l/1’ Filtering Coupling

TRACTORENAULT

THFI 208 LF SAE 80W

API GL4 / FORD M2C 86B

Massey Ferguson M1135

DENISON HF-1

DIN51524 part 2 & 3

Oil ﬁ lter 150 10

Part No. 57.0009.0413 GTH-2506 - AGRI-625 87

h 1" 1/4 BSP

Page 88

CAUTION

Operator’s Manual

Maintenance

First Edition - Fourth Printing

Fuel

Refuel opening cover A. Use only diesel fuel with less than 0.5% sulphur content, according to the specifications of the diesel engine operation handbook.

In cold climates (temperature under -20°C) use only “Arctic” type Diesel fuel, or oil-diesel fuel, or oil-diesel fuel mixtures. The composition of the latter can vary in relation to the ambient temperature up to max. 80% oil.





Grease

For the machine greasing, use:

Lithium-based

Vanguard LIKO

grease, type EP2

Graphitized AGIP

grease, type GR NG 3

INTERFLON FIN

GREASE LS 2

Avoid mixing greases of different type or features and do not use greases of lower quality.

Engine coolant

It is advisable to use an antifreeze mixture (50% water-50% antifreeze). At the delivery, the machine is refilled with:

When greasing by

pump.

When greasing by

brush.

On the telescopic

boom

TEREX PRO COOL by VALVOLINE

The use of this product guarantees protection to the circuit for 3 years or 7000 hours without having to add any dry coolant additive.

TEREX PRO COOL

Protection against boiling / freezing

Product % Freezing point Boiling point

33 40 50 70

-17°C

-24°C

-36°C

-67°C

123°C 126°C 128°C 135°C

NOTICE

Use an antifreeze mixture in the proportions recommended by the manufacturer in relation to the ambient temperature of the jobsite.

88 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Page 89

First Edition - Fourth 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 CAUSES SOLUTIONS

Any repair work, maintenance or troubleshooting must be carried out with machine stopped, boom in rest position or laid on the ground, parking brake engaged and ignition key removed.

WARNING

THE DASHBOARD DOES NOT TURN ON

THE STARTER DOES NOT RUN

THE STARTER RUNS, BUT THE ENGINE DOES NOT START

THE MACHINE DOES NOT MOVE FORWARD/BACK

NO SELECTION OF THE STEERING MODE

THE MACHINE DRIVE IS NOT ENOUGH

• The 50A fuse FG1 supplying power to the dashboard is blown (engine compartment)

• Battery disconnected

• Battery down

• Battery cut-out switch OFF

• Parking brake not engaged

• Battery down

• Battery cut-out switch OFF

• Fuse F18 blown

• No fuel

• Diesel fuel filter clogged

• Diesel fuel hose empty (fuel used up)

• Solenoid valve - engine stop

• Speed selector switch in neutral

• Parking brake engaged

• Fuse F9 blown

• Fuse F5 controlling the steering selection blown

• “ROAD/JOBSITE” switch set to “ROAD”

• Hydraulic oil filter clogged • Replace the filter

• Replace the fuse

• Connect the battery using the relevant switch

• Check the battery

• Switch it on

• Engage the parking brake and ensure the relevant indicator on the dashboard switches on

• Recharge or replace the battery

• Switch it on

• Check the fuse

• Refuel

• See engine operator manual

• Refuel, then refer to engine operator manual

• Check the solenoid valve; replace, if necessary

• Set the speed selector switch correctly

• Disengage

• Check the fuse; replace, if necessary

• Sostituire il fusibile

• Set to "JOBSITE"

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Operator’s Manual

First Edition - Fourth Printing

Faults And Troubleshooting

PROBLEM CAUSES SOLUTIONS

“ROAD” FUNCTION ON, EVEN WHEN SELECTING THE “JOBSITE” FUNCTION

NO BOOM LOWERING AND EXTENSION, NO HOLDING FRAME TILTING

THE HYDRAULIC OIL THERMOMETER DOES NOT WORK

THE PARKING BRAKE LIGHT DOES NOT LIGHT UP• Fuse blown F12 • Replace fuse

BOOM DOES NOT MOVE

THE LOAD LIMITING SYSTEM IS BLOCKED (RED LED’S LIT)

• No “ROAD/JOBSITE” selection

• Fuse blown F5

• Tecnord Unit

This is normal, when the outside

temperature is low and/or the machine is used for short periods, since the hydraulic oil cannot warm up over 40÷50°C

• Fuse blown F5

• “ROAD/JOBSITE” switch set to “ROAD”

• Low stability

• Check and replace fuse F5, if necessary

• Replace the fuse

• Check the Tecnord Unit and, eventually, replace it

• Check the fuse and replace it if necessary

• Set to “JOBSITE”

• Retract the load within safety limits.

If the error message is still shown,

move the boom to rest condition operating the overload warning system cutout key and contact your nearest authorised service centre.

THE DLE LOAD LIMITING SYSTEM IS IN ALARM

90 GTH-2506 - AGRI-625 Part No. 57.0009.0413

• Fuse blown F10

• Check and replace fuse, if necessary

• System failure

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First Edition - Fourth Printing Operator’s Manual

NOTICE

Faults And Troubleshooting

PROBLEM CAUSES SOLUTIONS

• Stop and restart the machine to RESET the system. If the error

1 E2PROM error

2 The value read from CELL 1 is

higher than max permissible

ERROR MESSAGES OF THE DLE LOAD LIMITING SYSTEM SHOWN ON THE DISPLAY

4 Block relay error during

operation

5 - 8 Block relay error when

power is turned on

message is still shown, address to the TEREXLIFT service centre to recalibrate the machine.

• Check the wiring between control panel and load cell

• Check that the load cell is fixed correctly

• Check the connecting cable or the connectors is/are not shorted

• If the error message is still shown, address to the TEREXLIFT service centre and let the load cell be checked.

• Check the efficiency of relay and wiring

• Stop and restart the machine and check the outputs. If the error message is still shown, address to the TEREXLIFT service centre to replace the DLE unit.

• Check the efficiency of relay and wiring

• Stop and restart the machine and run a new test. If the error message is still shown, address to the TEREXLIFT service centre to replace the DLE unit.

• Stop and restart the machine. If the

ERROR MESSAGES OF THE DLE LOAD LIMITING SYSTEM SHOWN ON THE DISPLAY

In case of faults not listed in this chapter, address to the TEREXLIFT Technical Assistance, your nearest authorised workshop or dealer.

Part No. 57.0009.0413 GTH-2506 - AGRI-625 91

A Data error in RAM

C Error in A.D.C. reading check

error message is still shown, address to the TEREXLIFT service centre.

• Stop and restart the machine. If the error message is still shown, address to the TEREXLIFT service centre.

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Operator’s Manual

NOTICE

First Edition - Fourth Printing

Faults And Troubleshooting

TORQUE WRENCH SETTINGS

D x p Pre-loading (N) Torque wrench setting (Nm)

4.8 8.8 10.9 12.9 4.8 8.8 10.9 12.9

M 4 x 0,7 1970 3930 5530 6640 1,5 3,1 4,3 5,2

M 5 x 0,8 3180 6360 8950 10700 3 6 8,5 10,1

M 6 x 1 4500 9000 12700 15200 5,2 10,4 14,6 17,5

M 8 x 1,25 8200 16400 23100 27700 12,3 24,6 34,7 41,6

M 8 x 1 8780 17600 24700 29600 13 26 36,6 43,9

M 10 x 1,5 13000 26000 36500 43900 25,1 50,1 70,5 84,6

M 10 x 1,25 13700 27400 38500 46300 26,2 52,4 73,6 88,4

M 12 x 1,75 18900 37800 53000 63700 42,4 84,8 119 143

M 12 x 1,25 20600 41300 58000 69600 45,3 90,6 127 153

M 14 x 2 25800 51500 72500 86900 67,4 135 190 228

M 14 x 1,5 28000 56000 78800 94500 71,7 143 202 242

M 16 x 2 35200 70300 98900 119000 102 205 288 346

M 16 x 1.5 37400 74800 105000 126000 107 214 302 362

M 18 x 2,5 43000 86000 121000 145000 142 283 398 478

M 18 x 1,5 48400 96800 136000 163000 154 308 434 520

M 20 x 2,5 54900 110000 154000 185000 200 400 562 674

M 20 x 1,5 60900 122000 171000 206000 216 431 607 728

M 22 x 2,5 67900 136000 191000 229000 266 532 748 897

M 22 x 1,5 74600 149000 210000 252000 286 571 803 964

M 24 x 3 79100 158000 222000 267000 345 691 971 1170

M 24 x 2 86000 172000 242000 290000 365 731 1030 1230

M 27 x 3 103000 206000 289000 347000 505 1010 1420 1700

M 27 x 2 111000 222000 312000 375000 534 1070 1500 1800

M 30 x 3,5 126000 251000 353000 424000 686 1370 1930 2310

M 30 x 2 139000 278000 391000 469000 738 1480 2080 2490

Sensor maximum driving torque: 15 Nm.

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Optional Attachments

INTRODUCTION

This section provides information on the optional interchangeable attachments, especially manufactured for the handlers. Use only genuine attachments, described in this section, after having read their features thoroughly and understood their use. To install and remove the attachments, follow the instructions supplied in the “Operating Instructions” section.

DANGER

When replacing interchangeable attachments, keep any person clear of the working area.

DANGER

Mounting optional attachments, and especially the extension jib, can change the centre of gravity of the machine. Before handling a load, check its weight and compare it with the values on the load charts. The weight of the used attachment must always be deducted from the rated payload.

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Operator’s Manual

500 LITRES SHOVEL

(code 59.0202.4000)

First Edition - Fourth Printing

CAUTION

Attachment suitable for moving loose material. Do not use for digging operations.

Application

Quick coupling attachment for moving soil, sand, debris, cereals, etc.

Safety

Strictly obey the general safety precautions given in section “Safety”.

Operation

To load/unload the material, operate the rotation lever of the attachment holding plate.

TECHNICAL DATA

Capacity 500 litres Width 1850 mm Length 890 mm Height 785 mm Weight 300 kg

CAUTION

When using a shovel, load the material only when the boom is completely retracted and push against the heap with straight wheels.

Maintenance

Visually check the shovel for damage before using it.

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First Edition - Fourth Printing Operator’s Manual

Optional Attachments

800 LITRES CEREAL SHOVEL

(code 59.0200.1000)

CAUTION

Attachment suitable for moving loose material. Do not use for digging operations.

Application

Quick coupling attachment for loading cereals or inert materials, etc.

Safety

Strictly obey the general safety precautions given in section “Safety”.

Operation

To load/unload the material, operate the rotation lever of the attachment holding plate.

TECHNICAL DATA

Capacity 800 litres Width 1850 mm Length 800 mm Height 1150 mm Weight 350 kg

CAUTION

When using a shovel, load the material only when the boom is completely retracted and push against the heap with straight wheels.

Maintenance

Visually check the shovel for damage before using it.

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Operator’s Manual

250 MIXING BUCKET (ONLY FOR GTH-

2506)

(code 59.0400.9000)

TECHNICAL DATA

Width (A) Length (B) Height (C) Dead Weight All Up Weight Output Capacity Total capacity Output level from shaft centre (D)

First Edition - Fourth Printing

Application

Quick coupling attachment for mixing and distributing concrete.

Safety

Strictly obey the general safety precautions given in section “Safety”.

Operation

To load/unload the material, operate the rotation lever of the attachment holding plate.

Maintenance

Visually check the bucket for damage before using it. Wash thoroughly with water after use or in case of prolonged inactivity to prevent the mix or residues from hardening. Check for oil leaks from hoses and connectors. Carefully protect the quick connectors once disconnected to prevent impurities from entering the circuit.

CAUTION

Before any maintenance, rest the bucket on the ground, stop the machine, remove the starter key and lock the cab door to prevent anybody from gaining access to the control panel.

96 GTH-2506 - AGRI-625 Part No. 57.0009.0413

REST POSITION

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First Edition - Fourth Printing Operator’s Manual

Optional Attachments

500 LITRES CONCRETE SKIP (ONLY FOR

GTH-2506)

(code 59.0400.0000 _ Manual Version)

(code 59.0400.1000 _ Hydraulic Version)

Application

Attachment coupled to the standard forks of the handler and fixed by means of the special chains with shackle provided.

Safety

Strictly obey the general safety precautions given in section “Safety”.

Operation

Fork the skip bearing in mind the side where the product will be unloaded. Secure the skip to the forks using the chains provided. To unload the concrete:

• Manual Version: manually operate the gate opening lever

• Hydraulic Version: operate the attachment locking lever after connecting the feeding lines of the new attachment to the quick couplings

TECHNICAL DATA

Capacity 500 litres Width 1200 mm Length 1200 mm Height 1270 mm Weight 220 kg SAE Capacity 0.5 m

Maintenance

Visually check the skip for damage before using it. Wash with water after use or in case of prolonged inactivity to prevent the mix or residues from hardening. Check for oil leaks from hoses and connectors. Carefully protect the quick connectors once disconnected to prevent impurities from entering the circuit. Check the chains after every use and replace them if worn or damaged.

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Operator’s Manual

2500 KG FIXED HOOK ON PLATE

First Edition - Fourth Printing

(code 59.0700.0000)

Application

Quick-coupling fitted attachment for lifting loads by means of special slings.

Safety

Strictly obey the general safety precautions given in section “Safety”. Do not oscillate the load. Do not drag hooked loads. Lift the load before extending the boom.

Operation

Fork the hook and hold it in position by means of the locking cylinder. All loads must be bridled with special textile slings or chains in compliance with all pertinent regulations. To handle the load, raise and rotate the telescopic boom of the handler.

Maintenance

Visually check the hook for damage before using it. Check the safety catch is in good working order.

TECHNICAL DATA

Payload 2500 kg Width 970 mm Length 620 mm Height 600 mm Weight 105 kg

The fixed hook has been designed to support a load of 2500 kg. The max payload corresponds to the nominal capacity rating of the handler on which it is installed and is indicated on the load charts supplied with the equipment.

CAUTION

Make sure this attachment can be used in the destination country of the machine. Application must be submitted directly by the user.

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First Edition - Fourth Printing Operator’s Manual

Optional Attachments

400 KG EXTENSION JIB

(code 59.0800.0000)

Application

Quick-coupling fitted attachment for maintenance interventions at high working heights.

Safety

Strictly obey the general safety precautions given in section “Safety”. Never lift wrongly slung loads. Avoid abrupt acceleration or deceleration. Avoid load oscillations, and especially do not move the load from the vertical pull line. Do not pull crosswise and do not tow.

Operation

To change the working height, operate the rotation lever of the attachment holding plate.

Maintenance

Visually check the jib for damage before using it. Check the safety catch is in good working order. Daily grease the joints using the greasing gun.

TECHNICAL DATA

Payload 400 kg Width 920 mm Length 2100 mm Height 630 mm Weight 115 kg

Make sure this attachment can be used in the destination country of the machine. Application must be submitted directly by the user.

CAUTION

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Operator’s Manual

FORKS WITH HYDRAULIC SIDE-SHIFT

First Edition - Fourth Printing

(code 59.0601.3000)

TECHNICAL DATA

Payload 2600 kg Width 1240 mm Length 1600 mm Height (with protection) 1000 mm Weight 108 kg Stroke ± 100 Fork Attachments FEM 2

Application

Quick-coupling fitted attachment for handling palletised loads with possibility of shifting the load to the side by ± 100 mm.

Safety

Strictly obey the general safety precautions given in section “Safety”.

• Do not load loose materials

• Do not move superposed pallets

Operation

To adjust the tilting, operate the rotation lever of the attachment holding plate. To side-shift, operate the attachment locking lever after connecting the feeding lines of the new attachment to the quick couplings (see page F-2).

Maintenance

Visually check the attachment for damage before using it. Check for hydraulic oil leaks. Daily grease the joints using a greasing gun, and smear the sliding guides with graphitized grease.

100 GTH-2506 - AGRI-625 Part No. 57.0009.0413

Genie Agri-625 / Agri-730 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual