Operator’s manual
Part N. 57.0008.5200
Rev. 0A 04/2007
From serial n. 15854
To serial n.
17819
English
Edition
GTH-3007
CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE
CAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES
TECHNICAL SERVICES
Genie Scandinavia
Phone +46 31 575100
Fax +46 31 579020
Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Genie Germany
Phone +49 (0)4202 88520
Fax +49 (0)4202 8852-20
Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Mexico City
Phone +52 55 5666 5242
Fax +52 55 5666 3241
Genie North America
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.
Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544
Genie Japan
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910
Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754
Genie Holland
Phone +31 183 581 102
Fax +31 183 581 566
Operator’s manual 57.0008.5200 - GTH-3007
No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means without
prior written permission from TEREXLIFT srl.
In pursuing a policy of constant quality improvement, TEREXLIFT srl reserves the right to make changes at any time and
without undertaking to give prior notice; therefore, also this publication may be subject to modications.
Some photos or drawings have been used to illustrate a specic function; as a result, they may not refer to the machine
treated in this manual.
© Copyright 2007 TEREXLIFT srl - All rights reserved.
Produced by: TEREXLIFT Technical Literature Dept. - Studio VEGA - Forlì
REVISED PAGE LIST
Revision Revised Issued
N. Date pages Notes by
0A 04/2007 D-27 Revision
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INTRODUCTION
GTH-3007
INTRODUCTION
This manual provides information for a safe and proper
operation and maintenance of the machine.
STRICTLY COMPLY WITH THE
INSTRUCTIONS GIVEN IN THIS HANDBOOK!
READ AND UNDERSTAND THIS HANDBOOK
BEFORE STARTING, USING AND
CARRYING OUT ANY OPERATION WITH
AND ON THE MACHINE.
The handbook is divided into seven sections:
Sect. A GENERAL INFORMATION
Sect. B SAFETY PRECAUTIONS
Sect. C OPERATING INSTRUCTIONS
Sect. D MAINTENANCE
Sect. E TROUBLESHOOTING
Sect. F OPTIONAL ATTACHMENTS
Sect. G TABLES AND ENCLOSURES
Section A contains general concepts that are decisive
for the knowledge of the main parts of the machine.
It also contains all necessary data for a correct
identication of the machine, the technical features of
the machine, etc.
Section B is especially addressed to the personnel, who
shall operate, repair and service the machine, and, in
case of companies with a wide eet of machines, to
those responsible for safety.
It describes the essential compulsory qualities of the
personnel in charge and other important information
for the safety of persons and things.
Section C is mainly addressed to the operators who
operate the machine. This section illustrates all control
devices.
Additionally, it contains the main use instructions -i.e.
engine starting, machine parking, machine storing.
Section D is addressed to those responsible for
maintenance and the servicemen.
The section describes the maintenance schedule and
the relevant intervals.
Section G contains tables and various enclosed
documents like load charts, wiring diagrams, hydraulic
schemes, torque wrench setting table, etc.
Sections are subdivided into chapters and paragraphs
that are numbered progressively.
The quickest way to look for information is the reference
to the general index or the titles of the single chapters
and paragraphs that represent keys for an easy
consultation.
Take care of this manual and keep it in an
accessible place within the machine, even
after its reading, so that it will always be within
reach if in doubt.
If you are unsure about anything, please address to
GENIE Assistance Service or to your agent/dealer:
addresses, phone and fax numbers are printed in
the cover and in the title-page of this manual.
Any difference between the contents of this manual
and the real functional character of the machine
can be attributed to either a machine manufactured
before the issue of this manual or to a manual going
to be updated after some changed effected on the
machine.
Always contact GENIE Assistance Service for any
updated version of this manual and any additional
information.
Section E deals with the failure diagnostics.
Section F makes a list of the main interchangeable
attachments that can be coupled to the machine:
dimensions, weight, application eld and limits of use.
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SYMBOLS
SYMBOLS
When using the machine, operators could have to face
some situations requiring special care and particular
knowledge.
When these situations involve the safety of operators or
bystanders, the machine efciency and proper utilisation,
this handbook stresses these specic instructions by
means of SPECIAL SYMBOLS.
GTH-3007
Yellow with safety alert symbol: used to indicate
a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
There are seven special (or safety) symbols in this
manual, always combined with keywords that class the
situations according to their danger degree.
The symbols are always followed by a text explaining
the situation taken into account, the attention to be paid
to such situation, the method and the behaviour to be
adopted. When necessary, it stresses prohibitions or
supplies instructions to prevent dangers.
Sometimes, it can be followed by illustrations.
We list below the special (or safety) symbols according
to the relative degree of a hazard:
Safety Alert symbol: when you see this symbol, be
alert to the possibility of personal injury. Strictly obey
all the safety messages accompanying this symbol
to avoid the risk of serious injury or death.
Red: used to indicate an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
Yellow without safety alert symbol: used to indicate
a potentially hazardous situation which, if not
avoided, may result in damage to the machine or
the systems.
Green: used to draw the attention to important
information on environment protection.
Green: used to indicate operation and maintenance
information
WHEN READING THIS MANUAL, PAY THE
GREATEST ATTENTION TO THESE SPECIAL
SYMBOLS AND THE EXPLANATION OF THE
SITUATIONS THEY EMPHASIZE.
The manual in electronic format also contains the
following symbol:
which enables the user to return to the
table of contents.
Orange: used to indicate a potentially hazardous
situation which, if not avoided, could result in death
or serious injury.
Page 2
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GENERAL INDEX
GTH-3007
GENERAL INDEX
GENERAL INFORMATION Sect. A
SAFETY PRECAUTIONS Sect. B
OPERATING INSTRUCTIONS Sect. C
MAINTENANCE Sect. D
TROUBLESHOOTING Sect. E
OPTIONAL ATTACHMENTS Sect. F
TABLES AND DOCUMENTS ENCLOSED Sect. G
Page 3
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GTH-3007
Page 4
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GTH-3007
GENERAL INFORMATION
Section A
GENERAL INFORMATION
TABLE OF CONTENTS
A-1 CONVENTIONAL REFERENCES .................................................................................. A-2
A-1.1 Machine position ............................................................................................................. A-2
A-1.2 Labels and warning plates applied on the machine ........................................................ A-3
A-1.3 Explanation of the different symbols used on the machine ............................................. A-8
A-2 MACHINE IDENTIFICATION .......................................................................................... A-10
A-2.1 Machine model and type ................................................................................................. A-10
A-2.2 Manufacturer ................................................................................................................... A-10
A-2.3 Machine identication plates ........................................................................................... A-10
A-2.4 CE mark .......................................................................................................................... A-11
A-2.5 Chassis serial number .................................................................................................... A-11
A-2.6 Identication plates of the main parts ............................................................................. A-11
A-3 ALLOWED USE .............................................................................................................. A-12
A-3.1 Allowed use ..................................................................................................................... A-12
A-3.2 Improper use ................................................................................................................... A-12
A-3.3 Residual hazards ............................................................................................................ A-12
A-3.4 Applicable standards ....................................................................................................... A-13
A-3.5 Safety devices ................................................................................................................. A-14
A-4 GENERAL DESCRIPTION ............................................................................................. A-16
A-4.1 List of the main components ........................................................................................... A-16
A-4.2 Description of the main components ............................................................................... A-17
A-4.3 Optional accessories ....................................................................................................... A-17
A-5 TECHNICAL DATA AND PERFORMANCE .................................................................... A-18
A-5.1 Main dimensions ............................................................................................................. A-18
A-5.2 Restrictions of use .......................................................................................................... A-18
A-5.3 Weight ............................................................................................................................. A-18
A-5.4 Speed .............................................................................................................................. A-18
A-5.5 Payload and reach .......................................................................................................... A-19
A-5.6 Forks ............................................................................................................................... A-19
A-5.7 Diesel engine .................................................................................................................. A-19
A-5.8 Electrical system ............................................................................................................. A-19
A-5.9 Machine sound levels ..................................................................................................... A-19
A-5.10 Vibration levels ................................................................................................................ A-19
A-6 LIFETIME ........................................................................................................................ A-20
A-7 ITEMS SUPPLIED .......................................................................................................... A-20
A-7.1 Literature supplied .......................................................................................................... A-20
Page A-1
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GENERAL INFORMATION
GTH-3007
A-1
CONVENTIONAL REFERENCES
A-1.1 MACHINE POSITION
Conventionally the machine should be considered
positioned as shown in the gure.
This convention is necessary to make any reference
of this handbook to different machine parts (front, rear,
etc.) clear and unmistakable.
Any exception to this rule will always be specied.
UPPER PART
RIGHT SIDE
FRONT
PART
REAR
PART
LEFT SIDE
LOWER PART
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09.4618.0230
09.4616.0068
09.4618.0230
09.4618.0230
09.4618.0230
09.4618.0026
09.4618.0271
GENERAL INFORMATION
A-1.2 LABELS AND WARNING PLATES APPLIED
ON THE MACHINE
This paragraph lists the labels and warning plates
normally applied on standard machines or on special
attachments coupled to the machine.
GTH-3007
The familiarisation with these labels is never a
waste of time.
Make sure they are easy to read. For this purpose,
clean them or replace those that become unreadable
(either graphic or text).
To clean labels, use of a soft cloth, water and soap.
Never use solvents, petrol, etc.
When a label is applied on a part to be replaced,
make sure that the replaced part is already labelled
as required or apply a new label.
Page A-3
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09.4618.0485
09.4616.0002
09.4618.0022
09.4618.0230
09.4618.0547
09.4618.0242
09.4618.0240
09.4618.0484
09.4618.0241
09.4618.0547
09.4618.0547
09.4618.0010
09.4618.0489
09.4618.0606
09.4618.0555
09.4618.0723
09.4616.0068
09.4618.0230
09.4618.0230
09.4618.0230
09.4618.0271
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GENERAL INFORMATION
GTH-3007
Document 57.0008.5200 - 10/2006
Page A-4
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KEEP OUT OF
WORKING RANGE
VIETATO APRIRE CON MOTORE IN MOTO
DO NOT OPEN WHILE ENGINE IS RUNNING
N'OUVRIR QU'A L'ARRET DU MOTEUR
ÖFFNEN NUR BEI STILLSTEHENDEM MOTOR
ABRIR SOLO CON MOTOR PARADO
PROIBIDO ABRIR COM O MOTOR LIGADO
VERBODEN KOFFERBAK TE OPENEN WANNEER DE MOTOR DRAAIT.
DANGER
ELECTRIC CABLES AND
POWER LINES
KEEP EVERY PART OF THE MACHINE, LOADS AND
ACCESSORIES AT LEAS T 6 METE RS FRO M
OVERHEAD POWER LINES
Staccabatteria
Batterie trennen
Battery cut-out switch
Coupe-batterie
Disyunctor baterìas
Destaque bateria
Uitsluiten accu
09.4618.0271
GTH-3007
GENERAL INFORMATION
Decal Code Description
09.4618.0022 Keep out of the working range of the machine.
When the machine is running, entering the working
range of the machine is prohibited.
09.4618.0555 Guaranteed sound power level. It indicates the
guaranteed sound power level measured in accordance
with the Directive 2000/14/CE.
101
09.4618.0010 Do not open while engine is running.
Do not open the engine bonnet when engine is running,
since this may result in serious injury due to moving
parts or hot components.
09.4618.0026 Use limits close to electric lines. It denes the
minimum distance to be kept when the machine is
used close to aerial electric lines.
09.4618.0271 “Battery disconnect switch” decal. Indicates the
battery disconnect switch.
Page A-5
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GTH-3007
GENERAL INFORMATION
Decal Code Description
09.4618.0723 Quick guide. An overview of the operator’s handbook
concerning:
- control lever,
- machine starting,
- overload warning system,
- main safety precautions.
09.4618.0606 Load chart. It denes the exact working limits of the
machine (in terms of payload and reach) to be strictly
respected by the operator when using the machine.
The load charts shown in these pages are supplied
as mere example. For the payload limits, see the
load charts referring to the specic machine
model.
09.4618.0230 Warning stickers. Applied near coupling points,
silencer, fan belt, hydraulic oil level, tank, etc.
Anchorage points. Applied near the holes envisaged for
machine lifting.
Fuel cap. Applied near the fuel cap.
Hydraulic oil. Applied near the hydraulic oil plug or level
indicator.
Engine oil level. Applied near the engine oil dipstick.
Moving gears. Appl ie d near t he f an o f the heat
exchanger.
Unscrew the plug with extreme caution: hot water.
Risk of burns! Warns the operator of the risk of burns
when unscrewing the plug of the compensation tank of
the heat exchanger.
Hot surfaces. Risk of burns. Applied on those surfaces
which during operation can become hot and cause
burns.
Risk of crushing injury to the hands. Use extreme caution
when moving the outriggers.
Presence of moving parts. Use extreme caution when
moving the outriggers.
Page A-6
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P
=
bar
Lb
Zona I ndustr iale - 0601 9 - U mberti de (PG ) - I taly
TRUCK CAPACITY
UNLADEN TRUCK MAXIMUN WEIGHT
SERIAL NUMBER
MADE IN ITALY
MODEL NUMBER
YEAR OF MANUFACTURE
Lb
THIS TRUCK IS COMPLIANT TO PART III OF ASME B56.6 - 2002 WHERE APPLICABLE
GTH-3007
ATTENZIONE!
CAUTION!
RECIPIENTE IN PRESSIONE
HIGH PRESSURE ACCUMULATOR
GTH-3007
GENERAL INFORMATION
Decal Code Description
09.4618.0547 Tyre ination sticker. Placed near the wheels, this label
shows the recommended tyre ination pressure.
5,5
09.4616.0068 Machine data plate. The identication plate contains
the main identication data of the machine.
09.4618.0240 “GENIE” sticker.
09.4618.0241
09.4618.0242
Kg 3000
09.4618.0484 “GENIE GTH-3007” sticker.
09.4618.0485
09.4618.0489
09.4618.0514 Caution: accumulator under pressure.
09.4616.0002 Max capacity. Indicates the maximum capacity of the
machine.
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GENERAL INFORMATION
A-1.3 EX P LANATION OF THE DIFFERENT
SYMBOLS USED ON THE MACHINE
This paragraph illustrates those symbols that are
normally applied on the main control devices and
instruments of a standard machine, and those that
can be applied on accessories or special attachments.
They are mainly (ISO) standardised symbols that are
now part of the common life. But we consider useful to
explain them once again.
GTH-3007
Spend the necessary time to become familiar with
these symbols and to learn their meaning.
Symbol Description
Hazard warning lights
Windscreen wiper
Windscreen washer
Cab ventilation fan
Fuel gauge
Hydraulic oil temperature
Position lights
High beam
Symbol Description
Steering mode switch
Engine oil pressure
Boom up
Boom down
Boom out
Boom in
Attachment locked
Attachment unlocked
Turn signals
Parking brake
Battery charge
Attachment pushbutton
Fork pitching forward
Fork pitching back
Oil lter clogged
Air lter clogged
Glow plug preheating
Page A-8
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LED
LED
GENERAL INFORMATION
Symbol Description Symbol Description
Front (optional) work light
Road/jobsite selector switch
Lifting point
Fuel plug
Engine oil ller
GTH-3007
Engine oil dipstick
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200
kgkg
kg
kg
TER EXLIFT srl - ZO NA IND USTRI ALE - 060 19 UMB ERTIDE (PG) - I TALY
Tel. ( 075) 941.81 1 F ax (07 5) 94 1.53.8 2 Tele x 661 06 ITAL MA I
MODELLO - MODEL - MODELE - TYP - MODELO
ANNO DI COSTRUZIONE - YEAR OF MANUFACTURE - ANNEE DE FABRICATION
BAUJAHR - AÑO DE FABRICACIÓN
MATRICOLA - SERIAL N. - N. DE SERIE - FZ.-IDENT NR. - NO. DE SERIE
OMOLOGAZIONE
FABBRICATO IN ITALIA - MADE IN ITALY
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
GENERAL INFORMATION
A-2 MACHINE IDENTIFICATION
Check that the operator handbook refers to the
delivered machine.
When asking for information or technical assistance,
always specify model, type and serial number of
the machine.
A-2.1 MACHINE MODEL AND TYPE
Handler with telescopic boom:
❑ model GTH-3007
A-2.2 MANUFACTURER
TEREXLIFT srl
Zona Industriale (Ind. Estate) - I-06019 UMBERTIDE
(PG) - ITALY
Enrolled in the register of companies at the Court of
Perugia under no. 4823
C.C.I.A.A. n° 102886
Fiscal Code/V.A.T. no. 00249210543
GTH-3007
Fig. A 8
A-2.3 MACHINE IDENTIFICATION PLATES
Three identication plates are applied on the machine.
They are:
Machine data plate.
Placed on the driving seat base in a well visible
position when opening the cab door (Fig. A8) or
instead of the road trafc data plate (Fig. A10) on
machines destined for foreign markets.
The identication plate (Fig. A9) contains the main
identication data of the machine like model, serial
number and year of manufacture.
ROPS-FOPS cab type-approval plate.
Placed on the driving seat base in a well visible
position when opening the cab door (Fig. A8).
Page A-10
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Fig. A 9
Fig. A10
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200
kgkg
kg
kg
TER EXLIFT srl - ZO NA IND USTRI ALE - 060 19 UMB ERTIDE (PG) - I TALY
Tel. ( 075) 941.81 1 F ax (07 5) 94 1.53.8 2 Tele x 661 06 ITAL MA I
MODELLO - MODEL - MODELE - TYP - MODELO
ANNO DI COSTRUZIONE - YEAR OF MANUFACTURE - ANNEE DE FABRICATION
BAUJAHR - AÑO DE FABRICACIÓN
MATRICOLA - SERIAL N. - N. DE SERIE - FZ.-IDENT NR. - NO. DE SERIE
OMOLOGAZIONE
FABBRICATO IN ITALIA - MADE IN ITALY
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
da kg a kg
kg
OMOLOGAZIONE
NUMERO DI IDENTIFICAZIONE
DATI OMOLOGAZIONE STRADALE
MASSA TOTALE AMMISSIBILE (*)
MASSA RIMORCHIABILE AMMISSIBILE:
- MASSA NON FRENATA
- MASSA CON FRENATURA INDIPENDENTE
- MASSA CON FRENATURA AD INERZIA
- MASSA CON FRENATURA ASSISTITA
COEFFICIENTE DI ASSORBIMENTO
CORRETTO DEL MOTORE
CARICO MAX ASSE ANTERIORE (*)
da kg a kg
CARICO MAX ASSE POSTERIORE (*)
(*) In funzione della gommatura
da kg a kg
kg
kg
kg
m
-1
TIPO
Zona Indus trial e, I- 06019 Umber tide (PG) - Italy
Tel. + 39 (0) 75 94 1811 - Fax + 39 (0 )75 94 15382
GENERAL INFORMATION
Road trafc data plate.
Placed on the front right side of the chassis (
Fig. A8) (only for machines destined for the Italian
market).
This plate contains the road trafc related data and
the weights of the specic machine model (Fig.
A11).
GTH-3007
Fig. A 8
A-2.4 CE MARK
This machine fulfils the safety requirements of
the Machinery Directive.The conformity has been
certied and the placing of the CE marking on the
machine demonstrates compliance with the regulatory
requirements.
The CE marking is placed directly on the identication
plate of the machine ( Fig. A8 and A9).
A-2.5 CHASSIS SERIAL NUMBER
The chassis serial number is punched on the front left
part of the chassis side member ( Fig. A10).
A-2.6 IDENTIFICATION PLATES OF THE MAIN
PARTS
The plates of the main components, not directly
manufactured by TEREXLIFT srl (for instance, engines,
pumps, etc.), are located where originally applied by
the manufacturers.
Fig. A11
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Page A-11
Fig. A 9
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A-3 ALLOWED USE
A-3.1 ALLOWED USE
The handlers have been designed and manufactured for
lifting, handling and transporting agricultural or industrial
products by means of specic attachments (see section
F) manufactured by TEREXLIFT srl.
Any other use is considered contrary to that established
and, therefore, improper.
The compliance with and the strict respect of the
operation, maintenance and repair conditions, indicated
by the Manufacturer, represent an essential part of the
allowed use.
The handler must be used and serviced only by operators
knowing its characteristics and the safety procedures
in depth.
It is also essential to comply with the safety at work
legislation, the precautions concerning safety and
industrial medicine as well as the local and national
road trafc regulations.
Effecting changes or carrying out interventions on
the machine other than those of routine maintenance
is expressly forbidden. Any modification of
the machine not carried out by GENIE or an
authorised assistance centre involves the automatic
invalidation of the conformity of the machine to the
Directive 98/37/EC.
A-3.2 IMPROPER USE
Improper use means a utilisation of the handler following
working criteria that do not comply with the instructions
of this manual, and that, in general, may result in risks
for both operators and bystanders.
We list below some of the most frequent and
hazardous situations of improper use:
- Carrying passengers on the machine
- Not strictly complying with the operation and
maintenance instructions of this handbook
- Working beyond the handler working limits
- Working on unstable edges of ditches
- Driving crosswise on slopes or hills
- Working during a storm
- Working on steep slopes
- U s in g a tt a c h m e n t s o th e r t h a n t h o s e
recommended
- Using attachments not approved or directly
manufactured by Terexlift
- A pplying loads in diff erent points of the
attachment holding plate
- Working in potentially explosive areas
- W o r k i n g in co n f i ne d and no n- v e nt i l at e d
environments.
A-3.3 RESIDUAL HAZARDS
Although the machine has been designed and
manufactured according to the latest technology and
all expected hazards have been eliminated, some
operations performed by the machine operator can result
in potentially hazardous situations. Among them:
• Hazards deriving from a too high work or transfer
speed in relation to the load handled or the ground
condition of the jobsite.
• Hazards deriving from work procedures adopted
during the check or replacement of a block valve
(residual pressure - uncontrolled movements).
• Hazards deriving from work procedures adopted
while disassembling parts of the machine -e.g. the
cylinders, without supporting mobile parts suitably
(risk of uncontrolled fall of the mobile part).
• Hazard deriving from an accidental overturning
of the machine in the event the operator has not
fastened the safety belts.
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GENERAL INFORMATION
GTH-3007
A-3.4 APPLICABLE STANDARDS
For the operator’s safety, the following standards were
obeyed during the risk assessment of the handler tted
with telescopic boom:
Directive Title
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 E lectrica l requi r ements - Gener a l
requirements of internal combustion
engine powered trucks
prEN ISO 13564:1996
Test method for measuring visibility from
self-propelled trucks.
EN 50082-1: 1997 Electromagnetic compatibility – Generic
requirements on immunity - Part 1
EN 60204-1:1998 Safety of machinery - Electrical equipment
of machines - Part 1
ISO 2330:1995 Fork-lift trucks - Fork arms - Technical
characteristics and testing.
ISO/DIS 3287 Powered industrial trucks. Pictorial signs.
Control symbols.
ISO 3449:1992 Earth-moving machinery - Falling-object
protective structures - Laboratory tests
and performance requirements.
EN 13510: 2002 Earth-moving machinery - Roll-over
protective structures - Laboratory tests
and performance requirements.
ISO 3776:1989 Tractors for agriculture - Seat belt
anchorages.
ISO 3795:1989 Road vehicles, tractors and machinery for
agriculture and forestry - Determination of
burning behaviour of interior materials.
ISO 5053:1987 Po w e r e d in d u s t r ia l t r u c ks -
Terminology.
ISO 6292:1996 Powered industrial trucks and tractors
- Brake performance and component
strength.
EN 13059:2002 Safety of industrial trucks - Test methods
for measuring vibration
EN 50081-1: 1997 Electromagnetic compatibility – Generic
requirements on emissions - Part 1
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GENERAL INFORMATION
GTH-3007
A-3.5 SAFETY DEVICES
• Load limiter. It consists of an extensometric cell
tted to the rear axle and a control panel in the
driving cab which displays the operating messages
and the bar wih green, yellow and red LED’s showing
the percentage of the overturning moment.
• Emergency stop pushbutton: when pressed
down, it stops the engine and blocks the movements
of the machine.
Before starting work again, nd and rectify the
causes which compelled to an emergency stop, then
reset the button to neutral position pressing it down
while turning clockwise.
• Presence micro-switch in the driving seat.
Located inside the seat cushion, it prevents any
machine movement if the operator is not correctly
seated in the driving seat.
• Safety pushbutton on joystick (dead man button).
This button must be pressed and held down while
executing a function with the control lever. If the
button is released, the movement in progress will
be blocked.
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GENERAL INFORMATION
• Block valves tted to all cylinders:
A Block valve on attachment coupling cylinder
B Block valve on lifting cylinder
C Block valve on balance cylinder
D Block valve on boom extension cylinder
E Block valve on attachment pitching cylinder
GTH-3007
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5
GENERAL INFORMATION
A-4 GENERAL DESCRIPTION
A-4.1 LIST OF THE MAIN COMPONENTS
GTH-3007
1 - Forks
2 - Attachment holding frame
3 - 2nd boom section
4 - 1st boom section
5 - Engine hood
6 - Driving ca b ac c o r di ng to ROPS - F O PS
provisions
7 - Left rear view mirror
8 - Beacon
9 - Front axle
10 - Chassis
11 - Left front wheel mud-guard
12 - Left front wheel reduction gear
13 - Access door
14 - Left rear wheel reduction gear
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A-4.2 DESCRIPTION OF THE MAIN
COMPONENTS
Hydrostatic transmission
This unit consists of parts which drive the machine
shifting, and namely:
- a variable displacement pump connected to the
thermal engine by an elastic joint
- a motor with variable displacement and automatic
adjustment in relation to the wheel torque required;
it is directly installed on the front axle together with
the two-speed gearbox
- a hydraulic oil lter, placed on the injection line from
the tank
- a heat exchanger to cool the circuit down.
Motion is transmitted to the rear axle from the gearbox
through a Cardan shaft.
Engine
The thermal engine is equipped with a heat exchanger
which uses the engine oil as cooling medium.
Steering axles/(front and rear) differential gears
The differential axles transmit the motion to the wheels.
The locking device acting on the front axle enables the
machine to move also on low grip grounds.
Tyres
The machine is equipped with tyres suitably sized for
the maximum load allowed on the handler.
When worn, they shall be replaced with new ones having
the same dimensions and loading capacity.
Overload warning system
The overload warning system installed on the vehicle
enables the operator to work under absolute safety
conditions. A eight-LED display shows the stability
variation. When the 7th red LED lights up, all machine
movements are stopped, but for the boom retraction
under safe conditions.
Boom hydraulic circuit
It consists of a gear pump connected to the thermal
engine which, through a special valve, dispenses oil
to the hydraulic drive and a distributor for the following
functions:
- boom lifting/lowering
- telescopic boom extension/retraction
- attachment rotation
- attachment locking
Braking circuit
It consists of an independent circuit: the pedal directly
acts on the brake pump which dispenses oil to the front
axle braking unit with discs in oil bath.
The parking brake, of negative type, acts on the braking
unit of the service brake. This brake is engaged every
time the handler’s engine is stopped or pressing down
the light pushbutton located to the right of the driving
place.
Telescopic boom
The machine is equipped with a telescopic boom with
hydraulic-driven extension. The telescopes slides on
interchangeable pads made of wearproof material.
Driving cab
Type-approved driving cab in compliance with standards
ISO 3449 and EN 13510 (ROPS and FOPS).
A-4.3 OPTIONAL ACCESSORIES
The machine can be tted with a wide range of
optional accessories: please address to GENIE sales
network.
Please check the accessories available for your
machine.
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D
G
I
F
E
B
C
A
GTH-3007
GENERAL INFORMATION
A-5 TECHNICAL DATA AND PERFORMANCE
GTH-3007
A-5.1 MAIN DIMENSIONS
A Overall height mm 2050
B Overall width mm 2000
C Track mm 1600
D Cab width mm 860
E Wheel-base mm 2650
F Length to the front tyres mm 4090
G Length to the attachment holding plate mm 4690
H Ground clearance mm 410
• Internal steering radius mm 2200
• External steering radius mm 4050
A-5.2 RESTRICTIONS OF USE
- Angle of approach 90°
- Departure angle 52°
- Ambient temperature °C -20°/+40°
A-5.3 WEIGHT
- Weight in working order kg 6000
A-5.4 SPEED
- Travel speed km/h 0÷35
- Max. slope with full load 60%
- Traction to the dynamometer kg 6500
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A-5.5 PAYLOAD AND REACH
- Max lifting height mm 6850
- Reach at max height mm 700
- Max reach forward mm 3800
- Attachment holding plate rotation 135°
- Maximum payload kg 3000
- Payload at max height kg 2500
- Payload at max reach kg 1250
A-5.6 FORKS
Floating type
- Dimensions mm 130x45x1200
- Weight kg 75+75
- Fork holding frame - class FEM II A
A-5.7 DIESEL ENGINE
Turbo version
- Make DEUTZ AG
- Model/Type BF4M 2011
- Features: Diesel
4 cylinders in line
4 strokes
direct injection
- Bore x Stroke mm 94 x 112
- Total displacement cc 3108
- Power at 2500 rpm (ISO 3046 IFN) kW 60
GTH-3007
A-5.8 ELECTRICAL SYSTEM
- Voltage V 12
- Battery Ah 100
A-5.9
- Guaranteed sound power level
- Measured sound pressure level
(in accordance with the Directive 98/37/CE) dB Lpa = 80
MACHINE SOUND LEVELS
(in accordance with the Directive 2000/14/CE) dB Lwa = 101
A-5.10
-
- Mean assessed vibration level transmitted to body m/s2 < 0.5
Values calculated in accordance with standard prEN13059
VIBRATION LEVELS
Mean assessed vibration level transmitted to arms
m/s2 < 2.5
This is a device of Class A. In a residential environment, such device can cause radio disturbance. In such
cases, the operator is required to take suitable measures.
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A-6 LIFETIME
The lifetime of the machine is 10000 hours provided
all checks, service jobs and overhauls are done at the
times scheduled.
After this time, the machine must compulsorily be
inspected and tested by the Manufacturer before
being used again.
Five years after the rst placing into operation of the
machine or after 6000 hours (whichever occurs rst),
check the state of the structure paying attention to
the welded supporting joints and the boom pins
(see chap. D-3.16).
A-7 ITEMS SUPPLIED
Following items are supplied together with the
machine:
Description GTH-3007
- Spanner CH 19 ✘
(for fork positioning)
- Allen wrench CH 6 ✘
(for fork positioning)
- 12 V lamps ✘
(spare)
A-7.1 LITERATURE SUPPLIED
The machines comes with the following literature:
- Warranty and handing over certicate
- Machine operator’s handbook
- Spare parts catalogue
- DEUTZ engine use and maintenance manual
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GTH-3007
SAFETY PRECAUTIONS
Section B
SAFETY PRECAUTIONS
TABLE OF CONTENTS
B-1 GENERAL REMARKS .................................................................................................... B-2
B-2 PREREQUISITES OF THE PERSONNEL IN CHARGE ................................................. B-3
B-2.1 Requisites of the machine operators .............................................................................. B-3
B-2.2 Requisites of the servicemen .......................................................................................... B-3
B-2.3 Working clothes .............................................................................................................. B-4
B-2.4 Personal protective equipment ....................................................................................... B-4
B-3 SAFETY PRECAUTIONS ............................................................................................... B-4
B-3.1 Hazards on the jobsite .................................................................................................... B-4
B-3.2 Operation or maintenance hazards ................................................................................. B-5
B-3.3 Machine operation hazards ............................................................................................. B-7
B-3.4 Damaged component hazards ........................................................................................ B-7
B-3.5 Explosion or re hazards ................................................................................................ B-7
B-3.6 Damaged machine hazards ............................................................................................ B-8
B-3.7 Personal injury hazards .................................................................................................. B-8
B-4 SAFETY DEVICES ......................................................................................................... B-8
B-5 MOMENT LIMITING SYSTEM ........................................................................................ B-8
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DANGER
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.
B-1 GENERAL REMARKS
Most accidents occurring while working, repairing or
maintaining machines, are caused by not complying
with the basic safety precautions.
Therefore, it is necessary to pay steady attention to
the potential hazards and the effects that may come
of operations carried out on the machine.
If you recognise hazardous situations, you can
prevent accidents!
For instance, this handbook makes use of special
safety symbols to stress any potentially hazardous
situation.
The instructions given in this handbook are the ones
established by GENIE. They do not exclude other
safe and most convenient ways for the machine
installation, operation and maintenance that take
into account the available spaces and means.
If you decide to follow instructions other than those
given in this manual, you shall absolutely:
• be sure that the operations you are going to carry
out are not explicitly forbidden;
• be sure that the methods are safe, say, in compliance
with the rules and provisions given in this section;
• be sure that the methods cannot damage the
machine directly or indirectly or make it unsafe;
• contact GENIE Assistance Service for any suggestion
and the necessary written permission.
If in doubt, it is always better to ask! For this
purpose, contact GENIE: the assistance service is at
your disposal. Addresses, phone and fax numbers
are given in the cover and in the title-page of this
manual.
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B-2 R E Q U I S I T E S O F T H E
PERSONNEL IN CHARGE
B-2.1 R E Q U I S I T E S O F T H E M A C H I N E
OPERATORS
The operators who use the machine regularly or
occasionally (i.e. for transport reasons) shall have the
following prerequisites:
health:
before and during any operation, operators shall
never take alcoholic beverages, medicines or other
substances that may alter their psycho-physical
conditions and, consequently, their working abilities.
physical:
good eyesight, acute hearing, good co-ordination and
ability to carry out all required operations in a safe way,
according to the instructions of this manual.
mental:
ability to understand and apply the enforced rules,
regulations and safety precautions. They shall be
careful and sensible for their own as well as for the
others’ safety and shall desire to carry out the work
correctly and in a responsible way.
emotional:
they shall keep calm and always be able to evaluate
their own physical and mental conditions.
training:
they shall read and be familiar with this handbook, its
enclosed graphs and diagrams, the identication and
hazard warning plates. They shall be skilled and trained
about the machine use.
B-2.2 REQUISITES OF THE SERVICEMEN
The personnel charged with the machine maintenance
shall be qualied, specialised in the maintenance of
earth-moving machines, and shall have the following
prerequisites:
physical:
good eyesight, acute hearing, good co-ordination and
ability to carry out all required maintenance operations
in a safe way, according to this manual.
mental:
ability to understand and apply the enforced rules,
regulations and safety precautions. They shall be
careful and sensible for their own as well as for the
others’ safety and shall desire to carry out the work
correctly and in a responsible way
training:
they shall read and be familiar with this handbook, its
enclosed graphs and diagrams, the identication and
warning plates. They shall be skilled and trained about
the machine functioning.
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.
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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DE A TH OR INJ U RY CA N R E SUL T FRO M
CONTACTING ELECTRIC POWER LINES.
ALWAYS CONTACT THE ELECTRIC POWER LINES
OWN ER. THE ELECT RIC POWER SHA LL BE
DISCONNECTED OR THE POWER LINES MOVED
OR INSULATED BEFORE MACHINE OPERATIONS
BEGIN
POWER LINE VOLTAGE REQUIRED CLEARANCE
0 to 50 kV 10 ft 3.00 m
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
SAFETY PRECAUTIONS
GTH-3007
B-2.3 WORKING CLOTHES
During work, but especially when maintaining or
repairing the machine, operators must wear suitable
protective clothing:
• Overalls or any other comfortable garments.
Operators should not wear clothes with large
sleeves or objects that can get stuck in moving
parts of the machine.
• Protective helmet.
• Protective gloves.
• Working shoes.
B-3 SAFETY PRECAUTIONS
B-3.1 HAZARDS ON THE JOBSITE
Always take into account the features of the job site
where you are going to work:
• Always examine the working area and compare
it with the machine dimensions in the different
congurations.
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!
Use only type-approved working clothing in good
condition.
B-2.4 PERSONAL PROTECTIVE EQUIPMENT
Under special working conditions, the following personal
protective equipment should be used:
• Breathing set (or dust mask).
• Ear-protectors or equivalent equipment.
• Goggles or facial masks.
Use only type-approved protective equipment in
good condition.
• 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.
Do not at any time use the machine during a
storm.
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A ≥ B
A
B
SAFETY PRECAUTIONS
Make sure the machine (wheels and stabilisers)
rests on a firm ground to prevent hazardous
unstable conditions.
If the ground is not rm enough, position some
supporting planks under the stabilisers or the
wh eels. These plates must gra n t a speci fic
pressure of 1.2 to 1.5 kg/cm2 (500x500mm plates
are sufcient).
GTH-3007
B-3.2 O P E R AT I O N O R M A I N T E N A N C E
HAZARDS
Before any operation, following precautions should be
taken:
• First of all, make sure that the maintenance
interventions have been carried out with care
according to the established schedule (see section
D - Maintenance).
• Look for the best route to the job site.
• When the machine is running, nobody can enter its
working range.
• While working, keep the working area in order.
Never leave objects scattered: they could hinder
the machine movements and represent a danger
for personnel.
• In presence of trenches, space the wheels to keep
at a safe distance from the trench edge.
Set the machine to working conguration 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.
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• When entering/leaving the cab or other raised parts,
always face the machine; never turn the back.
• When carrying out operations at hazardous heights
(over 1.5 meters from the ground), always use
approved fall restraint or fall arrest devices.
• Do not enter/leave the machine while it is running.
• Do not leave the driving place when the machine is
running.
• Neither stop nor carry out interventions under
or between the machine wheels when engine is
running. When maintenance in this area is required,
stop the engine.
• Except for maintenance purposes, do not remove
safety devices, shields, protection cases, etc.
Should their removal be necessary, stop the engine,
remove them with the greatest care and always
remember to ret them before starting the engine
and using the machine again.
• Before any maintenance or repair work, stop the
engine and disconnect the batteries.
• Do not lubricate, clean or adjust moving parts.
• Do not carry out operations manually when specic
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.
• Befor e carrying out opera tions on hyd rauli c
lines under pressure or disconnecting hydraulic
components, ensure the relevant line has been
previously depressurised and does not contain any
hot uid.
• Do not carry out maintenance or repair works without
a sufcient 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.
Any intervention on the hydraulic circuit must be
carried out by authorised personnel.
The hydraulic circuit of this machine is tted 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.
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SAFETY PRECAUTIONS
GTH-3007
• Do not empty catalytic mufers 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, tted with moving parts, or
where suction and cooling air circulates.
• When working, do not give instructions or signs to
several people at the same time. Instructions and
signs must be given by one person only.
• Always pay due attention to the instructions given
by the foreman.
• Never distract the operator during working phases
or crucial manoeuvres.
• Do not call an operator suddenly, if unnecessary.
• Do not frighten an operator or throw objects by any
means.
• After work, never leave the machine under potentially
dangerous conditions.
B-3.3 MACHINE OPERATION HAZARDS
Absolutely avoid the following work situations:
• Do not handle loads beyond the maximum capacity
of the machine.
• Do not raise or extend the boom if the machine is
not on a rm, 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 dropoffs.
• 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.
B-3.4 DAMAGED COMPONENT HAZARDS
• Do not use battery chargers or batteries with a
voltage above 12V to start the engine.
• Do not use the machine as a ground for welding.
B-3.5 EXPLOSION OR FIRE HAZARDS
• Do not start the engine if you smell or detect
LPG, gasoline, diesel fule or other explosive
substances.
• Do not refuel the machine with the engine
running.
• Refuel the machine and charge the battery only in a
well ventilated area away from sparks, naked ames
and lighted cigarettes.
• D o not op e r a t e the ma c h i n e in da n g e r o us
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 re dangers and in presence of fuel, oil
or batteries.
• Carefully handle all flammable or dangerous
substances.
• Do not tamper with re-extinguishers or pressure
accumulators: explosion hazard!
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GTH-3007
B-3.6 DAMAGED MACHINE HAZARDS
• Do not use a damaged or defective machine.
• Do a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Tag and remove from service a damaged or
defective machine.
• Make sure that all maintenance jobs have been
carried out as specied in this manual and the
appropriate service manual.
• Make sure that all decals are in place and legible.
• M a k e sure that th e operat o r ’s , safety and
responsibilities manuals are intact, legible and
placed in the special container located in the
machine.
B-3.7 PERSONAL INJURY HAZARDS
• Do not operate the machine in case of hydraulic oil
or air leak. Air or hydraulic oil leaks can penetrate
or burn the skin.
• Always operate the machine in a well ventilated area
to avoid carbon monoxide poisoning.
• Do not lower the boom if the area underneath is not
clear of personnel or obstructions.
B-4 SAFETY DEVICES
Several safety devices have been fitted to the
machine. They must never be tampered with or
removed (see chap. A-3.5).
Regularly check the efciency of such devices (see
check card, chap. G-5).
In case of faults, stop working immediately and
proceed in replacing the defective device.
For the checking procedures, read chap. D-3.15.
B-5 MOMENT LIMITING SYSTEM
The moment limiting system has been developed to
help the operator to maintain the machine longitudinal
stability. Audible and visual messages are provided
when the limits of longitudinal stability are being
approached.
However this device cannot replace the experience of
the operator. It is up to the user to adopt the necessary
safety measures to work within the rated limits of the
machine.
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GTH-3007
OPERATING INSTRUCTIONS
Section C
OPERATING INSTRUCTIONS
TABLE OF CONTENTS
C-1 PRE-OPERATION INSPECTION ................ C-2
C-2 ENTERING THE MACHINE ........................ C-4
C-2.1 Entering the cab ..........................................C-4
C-2.1.1 Emergency exit-way ....................................C-5
C-2.2 Adjusting the seat ........................................C-6
C-2.3 Fastening the seat belts ..............................C-6
C-2.4 Adjusting the steering column ..................... C-7
C-2.5 Adjusting the rear view mirrors ....................C-7
C-2.6 Switching on the cab interior lamp ............... C-7
C-3 DRIVING PLACE ......................................... C-8
C-3.1 Controls and instruments ............................. C-9
C-3.2 Engine controls and instruments ............... C-10
C-3.2.1 Ignition switch ............................................C-10
C-3.2.2 Forward/reverse gear switch .....................C-10
C-3.2.3 Turn signals - windscreen wiper
lights - horn switch ..................................... C-11
C-3.2.4 Brakes .......................................................C-12
C-3.2.5 Accelerator control .....................................C-12
C-3.2.6 Pushbutton enabling the attachment
coupling/release ........................................C-13
C-3.2.7 Steering mode selection ............................ C-13
C-3.2.8 Road/Jobsite switch ...................................C-13
C-3.2.9 Speed controls ...........................................C-13
C-3.2.10 Switch - transmission always engaged .....C-13
C-3.2.11
C-3.3 Instruments and light indicators ................. C-15
C-3.3.1 Instruments ................................................ C-15
C-3.3.2 Light indicators ..........................................C-15
C-3.4 Control lever ..............................................C-16
C-3.4.1 Function selection ......................................C-17
C-3.4.2 Emergency stop .........................................C-18
C-3.4.2.1 Disabling the overload warning system
C-3.4.3 Lifting/lowering the boom ...........................C-19
C-3.4.4 Pitching the attachment holding frame
forward/back ..............................................C-20
C-3.4.5 Extending/retracting the boom ...................C-21
C-3.4.6 Quick-coupling the attachments ................C-22
Auxiliary drive controls ............................... C-14
..C-18
C-4 SETUP .......................................................C-23
C-4.1 Before starting the engine .........................C-23
C-4.1.1 Checks at the machine start-up ................. C-23
C-4.2 Starting the engine ....................................C-23
C-4.3 Jump-starting the engine ...........................C-24
C-4.4
C-4.5 Disconnecting the battery .......................... C-25
C-4.6 Starting the machine ..................................C-25
C-4.7 Stopping and parking the machine ............ C-26
C-5 USING THE HANDLER ............................. C-26
C-5.1 Using the load charts ................................. C-27
C-5.2 Load limiter ................................................C-28
C-5.2.1 Description of the controls ......................... C-28
C-5.2.2 Operation ...................................................C-28
C-5.2.3 Alarm codes and resetting ......................... C-29
C-5.3 Movimentazione dei carichi .......................C-30
C-5.3.1 Adjusting the forks .....................................C-30
C-5.3.2 Working phases ......................................... C-31
C-5.4 Changing the attachment .......................... C-32
C-6 TRANSPORTING THE MACHINE ............ C-34
C-6.1 Moving a disabled machine ....................... C-34
C-6.1.1 Unlocking the negative brake ....................C-34
C-6.2 Road or site transfer .................................. C-35
C-6.3 Lifting the machine ....................................C-36
C-6.4 Transporting the machine on other
vehicles ...................................................... C-36
C-6.5 Parking and storage .................................. C-37
C-6.5.1 Short inactivity ........................................... C-37
C-6.5.2 Machine storage ........................................ C-37
C-6.6 Cleaning and washing the machine ...........C-38
C-6.6.1 Cleaning instructions ................................. C-38
C-6.6.2 Washing instructions..................................C-38
C-6.7 Machine disposal ....................................... C-38
C-6.7.1 Disposal of batteries .................................. C-38
Low temperature starting
............................. C-25
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INTRODUCTION
This section provides the operator a practical guide for
the gradual learning of the machine use.
The operator should get into the driving cab and carry
out the preliminary adjustments, then memorise the
position of the different controls and instruments.
The familiarisation with the controls ensures not only
a correct use during the working phases, but also a
prompt and timely intervention of the operator, when
he shall carry out sudden manoeuvres to safeguard his
safety and the machine integrity.
It is necessary to learn how to use and foresee the
machine reactions. Learn how to operate the machine
controls in a safe and open place, without obstacles
and anybody standing around. Do not ram the controls.
Operate them slowly to understand their effect on the
machine.
C-1 PRE-OPERATION INSPECTION
Fundamentals
It is the operator responsibility to perform a preoperation inspection and routine maintenance.
Pre-operation inspection means a visual inspection
performed by the operator prior to each work shift.
The inspection has to be carried out on the machine to
detect possible faults before the operator starts testing
the machine functions.
The pre-operation inspection also helps understand if
some routine maintenance procedures are required.
The operator can only perform the routine maintenance
procedures envisaged in this manual.
See the list on the next page and check each single
component.
If the machine is damaged or a non-authorized
modication has been done, the machine must be
tagged and removed from service.
Repairs must be carried out by qualied technical
personnel according to the manufacturer’s specications.
After any repair, the operator should repeat the preoperation inspection before testing the machine
functions.
Do n o t o per a te t h e m achi n e,
unless:
* You learn and practice the principles of safe
1 Avoid hazardous situations.
Read and understand the safety rules before
2 Always perform a pre-operation inspection.
Read and understand the safety rules before
3 Always test the machine functions prior to use.
4 Inspect the work place.
5 Only use the machi n e fo r the int e n de d
Scheduled maintenance procedures must be performed
by qualied technical personnel according to the technical
specications of the manufacturer and the requirements
envisaged in the responsibilities manual.
machine operation contained in this operator’s
manual.
going on to the next chapter.
going on to the next chapter.
application.
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GTH-3007
Pre-operation inspection
* Make sure the operator’s manuals are intact, legible
and placed inside the machine.
* Make sure all decals are present and legible. See
“Decals” chapter.
* Check for engine oil leaks and proper oil level. Top
up if necessary. See “Maintenance” chapter.
* Check for axle oil leaks and proper oil level. Top up
if necessary. See “Maintenance” chapter.
* Check for hydraulic oil leaks and proper oil level.
Top up if necessary. See “Maintenance” chapter.
* Check for battery uid leaks and proper uid level.
Add distilled water if necessary. See “Maintenance”
chapter.
Check the following components or zones for damage,
missing or wrongly fitted parts or non-authorised
modications:
• electrical components, wiring and electrical
cables
• hydraulic hoses, ttings, cylinders and main
valves
• fuel and hydraulic oil tanks
• drive pump and motor and transmission axles
• steering system
• braking system
• boom telescopes sliding pads
• clean glasses, lights and rear view mirrors
• engine and relevant components
• limit switches and horn
• lights
• moment limiter
• joystick pushbutton
• emergency stop button
• machine ignition control
• 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 tted and properly tightened.
* After inspection, check that all the compartment
covers are in place and latched.
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 ination of the tyres; see par. “Tyre
ination” in the Maintenance section
* Make sure that the tyre plies are not cut or worn.
A tyre burst may result in serious injury; never use
the machine if tyres are worn, wrongly inated 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.
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C-2 ENTERING THE MACHINE
GTH-3007
C-2.1 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 and open the door.
The upper section of the door must be secured to
the rear part of the driving cab or latched to the
lower section of the same door.
Door closing from inside:
• Pull the door with force: it locks automatically.
Door opening from inside:
• Lift lever 2 and release the lock to open the door
completely.
• Rotate handle 3 to open the upper section of the
door and lock it against the special catch.
To unlock the door latched in open position:
• Press button 4 to unlock the door from the catch,
close and latch the door to the lower section using
handle 3.
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OPERATING INSTRUCTIONS
C-2.1.1 Leaving the cab in an emergency
In an emergency, the operator can use he front or the
rear window as safety exit-ways.
The rear window has handles for partially opening the
glass. Such handles are locked in position by some
wing nuts 5 which, if driven out, allow opening the glass
completely.
The front window has a handle 6 which, if turned, enable
the operator to pass through.
GTH-3007
5
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C-2.2 ADJUSTING THE SEAT
A correct adjustment of the seat ensures the operator
a safe and comfortable driving. The handler seat is
tted with devices which allow for the adjustment of
the springing, the height and the distance from the
controls.
• Seat distance from the controls
The seat is equipped with an adjusting device to
slide the same seat forward or back with respect to
the steering column.
To adjust the seat, pull lever 1 outwards and push the
seat to the desired direction. Then release the lever
and make sure that the seat locks in position.
• Springing adjustment
Rotate lever 2 clockwise or anticlockwise according
to the springing degree required. Rotate clockwise/
anticlockwise to increase/reduce the seat springing.
To reverse this control, pull out and rotate the lever
knob by 180°.
• Height adjustment
Turn knob 3 clockwise to lift the seat; turn it counter-
clockwise to lower the seat.
GTH-3007
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.
The seat is for one person only.
Don’ t adjust the seat when the machine is
moving.
C-2.3 FASTENING THE SEAT BELTS
Sit correctly in the driving seat; then:
• The safety belts are equipped with reel retractor. To
fasten the belt, pull tab 1 and push it into buckle 2.
• To release the belt, push button 3 and remove the
tab from the buckle.
• Make sure that the buckle is correctly located at the
hip point and not on the stomach.
• Operate the end adjusters to reach the length you
wish and make sure the buckle is always in the
middle.
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C-2.4 ADJUSTING THE STEERING COLUMN
Both steering column and dashboard can be set to a
different angle. For this purpose:
• Loosen lever 1 and adjust as required, then retighten lever 1.
Before driving the machine, ensure the steering
wheel is perfectly clamped.
C-2.5 ADJUSTING THE REAR VIEW MIRRORS
The machine is tted with two rear view mirrors:
• The right rear view mirror is located on a special
supporting bracket in advanced position and allows
checking the area behind the machine, on the righthand side. To adjust its position, manually rotate the
joint it is tted with.
• The left rear view mirror is placed on the left upper
post of the windscreen and allows checking the
area behind the machine, on the left- hand side. To
adjust its position, manually rotate the joint it is tted
with.
C-2.6 SWITCHING ON THE CAB LIGHTS
The ceiling light xture of the cab has an internal lamp
and a courtesy lamp.
To switch on the cab interior lights:
• Switch 4 in pos. A cab interior lights OFF
• Switch 4 in pos. B cab interior lights ON
• Switch 4 in pos. C courtesy lamp ON
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OPERATING INSTRUCTIONS
C-3.1 CONTROLS AND INSTRUMENTS
1 Dashboard
2 Water level
3 Brake oil tank
4 Ignition switch
5 Turn signals - windscreen wiper - horn switch
6 Fuse compartment
7 Forward/reverse speed selection lever
8 Brake pedal
9 Steering column locking lever
10 Hazard lights switch
11 Steering selection switch
12 Road light switch
13 Gas pedal
14 Overload warning system display
15 Fresh air ap
16 Emergency stop button
17 Pushbutton enabling the attachment coupling/
release
18 Control lever
19 Negative brake on/off switch
20 Road/Jobsite switch
21 Cab heater cock
22 Optional attachment switch with built-in green
lamp (if any)
23 Air conditioning fan switch
24 Storage tray
25 Windscreen water reservoir
26 Seat
27 Storage pocket
28 Warning light - glow plugs preheating
29 Warning light - air lter clogged
30 Warning light - gear put
31 Mechanical gear selector
32 Load limiter disabling key
33 Switch - transmission always engaged
GTH-3007
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C-3.2
ENGINE CONTROLS AND INSTRUMENTS
C-3.2.1 Ignition switch
Three-position switch:
No circuit under voltage, key can be removed
and engine is stopped
Circuits under voltage, presetting for the engine
starting. Board controls and instruments are
on.
The warning light 28 signalling the glow plugs
preheating comes on. Wait until the light goes
off before starting the engine.
Engine starting; when released, key springs back
to pos. automatically.
C-3.2.2 Forward/reverse gear selector switch
Three-position switch with lock in neutral position:
N Neutral position; no gear engaged
F Shift lever to pos. F to select the forward gear
R Shift lever to pos. R to select the reverse gear
The engine can be started only if selector 7 is to
the neutral “0” position.
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GTH-3007
C-3.2.3 Turn signals - Windscreen wiper - Horn
- Lights
Horn function:
When sliding the lever along its axis, horn switches on,
independently from other pre-set functions.
Windscreen washer function:
Push the second stage of the lever along its axis to
direct a jet of water onto the cab windscreen.
Lights function:
The lever operates the light switching and shall be used
in conjuntion with pushbutton 12.
12 Road lights switch
Three-position switch placed on the
Pushbutton in pos. 1:
• Lever in position or : Lights OFF
Pushbutton in pos. 2 (the warning light 61 comes on):
• Lever in position or : Position lights ON
2
dashboard on the right-hand side
1
3
over the ignition switch.
Windscreen wiper function:
To operate the windscreen wiper, rotate the lever tip to
one of the three positions:
Wiper OFF
Low speed
High speed.
Turn signals function:
Set lever to pos. to indicate a turn leftwards or to
pos. to indicate a turn rightwards.
Pushbutton in pos. 3:
• Lever in position : high beam ON (the warning
lights 60 and 61 come on).
• Lever in position : low beam ON (the warning light
61 comes on).
• Lever in position : high beam intermittent signalling
(releasing the lever, it springs back to position ).
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C-3.2.4 Brakes
8 Service brake pedal
Gradually step on the brake pedal to decelerate and
stop the machine. The pedal operates on the front axle.
Fully depressing the brake pedal causes a reset of the
C-3.2.5 Accelerator control
13 Gas pedal
Its pressure controls the engine rpm and, coupled to
the gearbox, the machine speed. It is tted with an
adjustable stop in the lower part.
displacement of the power drive pump making the brake
action more powerful.
19 Parking brake
Th e park ing brake of nega tive t ype en gages
automatically when the engine is stopped.
When the handler’s engine is restarted, pressing the
pushbutton switch 19 unlocks the parking brake.
To stop the handler without shutting down the engine,
press the pushbutton switch 19 to engage the parking
brake and push it once again to disengage the brake.
Every pressure of the pushbutton switches the warning
light on and off. When the red warning light is on, the
parking brake is engaged.
Never use the parking brake to slow down the
machine, unless in an emergency. It may reduce
the brake efciency.
19
8
13
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C-3.2.6 Pushbutton enabling the attachment
coupling/release
17 Selection button
Pushbutton with two stable positions.
Pressing this button activates the attachment
coupling and release. The built-in button light
switches on.
C-3.2.7 Steering mode selection
11 Steering mode switch
Three-position switch for the selection of the
steering mode:
1 Crab steering
0 Two-wheel steering
2 Four-wheel steering
C-3.2.8 Road/Jobsite switch
20 Selection button
Button with two stable positions:
1 Press to select the road setting. The
high speed can be engaged, the boom
control is disabled and only the two-wheel
steering is enabled. The built-in button
light switches on.
2 Press the button again to select the work
setting and enable the boom control and
the four-wheel steering. The built-in button
light switches off.
Before switching on the ROAD function, align the
rear wheels of the machine.
C-3.2.9 Speed controls
31 Mechanical gearbox pushbutton
Used to engage the 1st or 2nd gear.
Push the button to select the required
speed.
Each pr e s s u r e correspon d s to th e
selection of a new speed.
11
17
20
30
31
33
The selection is signalled by warning
light 30 which illuminates the glass
corresponding to the selected speed.
C-3.2.10 S w it ch - t r a n s mi s s i o n a l w a y s
33 Selection button
engaged
Button with two stable positions:
1 OFF position (the built-in button light
sw itches off): by step ping down on
the brake pedal , th e tra n s mi ss io n
disengages
2 ON position (the built-in button light
switches on): by stepping down on the
brake pedal, the transmission remains
engaged.
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GTH-3007
C-3.2.11 Auxiliary drive controls
Beacon
When the machine is started up, the beacon
activates automatically.
22 Optional attachment pushbutton (if any)
Pushbutton with orange glass.
The pressure of this button causes the
switching of the hydraulic circuit for the
movement of the attachments equipped with
auxiliary lines.
10 Hazard warning lights switch
Fitted with on-off position, it switches on the
turn signals simultaneously.
12 Road lights switch
This switch is located above the ignition switch
and is used in conjunction with lever 5 (see
chap. C-3.2.3).
23 Air conditioning fan switch
Three-position switch:
0 OFF
1 Low speed
2 High speed
21 Cab heater control cock
To the right of the driving seat.
• Turn the cock clockwise to switch off heated air.
• Turn the cock clockwise to switch on the cab
heater.
• Adjust the ow of warm air within the cab by the air
conditioning fan switch 23.
5
21
10 12
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C-3.3 INSTRUMENTS AND LIGHT
INDICATORS
C-3.3.1 Instruments
54 Engine coolant temperature indicator
Signals the engine coolant temperature.
53 Fuel gauge
Signals the fuel level within the tank.
52 Hour-meter
Signa ls the total operating hours of the
51 Hydraulic oil temperature indicator
Signals the temperature of the hydraulic
machine.
oil within the reservoir.
C-3.3.2 Light indicators
60 Indicator light - high beam
Blue indicator light that signals when high beam
is ON.
67 I nd i c a t o r l i g h t - n e g a t i v e b r a k e
accumulator
This light indicates that the accumulator of the
negative brake is getting discharged.
68 Indicator light - turn signals
Green indicator light that signals when turn signals
are ON.
28 Indicator light - glow plugs preheating
Green light indicators which signal the preheating
phase of the engine glow plugs. Before starting
the engine wait for these lights to go off.
29 Indicator light - air lter soiled
Orange light indicator which signals when the air
intake lter of the engine is getting soiled.
Cl e an or r epl a ce th e fil t er ca rtr i dge
immediately.
61 Indicator light - position lights
Green indicator light that signals when position
lights are ON.
63 Indicator light - air lter soiled
Not activated.
64 Indicator light - low battery charge
Signals a low charge by the alternator.
65 Indicator light - low engine oil pressure
It lights when the engine oil pressure is too
low.
66 Indicator light - parking brake engaged
When ON, this light indicates that the parking
brake is engaged.
28
29
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C-3.4 Control lever
Handlers are equipped with an hydraulically driven
servo-controlled lever.
The lever is equipped with a button for locking/releasing
the attachments and a wheel to operate the boom
telescope extension.
When shifted to one of the four directions (right/left,
forward/back), it controls the boom lifting/lowering and
the forward/back pitching of the attachment frame.
It is also equipped with an intentional control button
that must be pressed and held in position until the
movement is completed.
If the button is not pressed down, the lever, though
operated, does not perform any function.
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.
GTH-3007
The control lever shall be operated only when
correctly seated in the driving place.
Before operating the control lever, make sure
that nobody is within the working range of the
machine.
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C-3.4.1 Function selection
After pressing the intentional control pushbutton , the
lever is enabled to carry out the following motions:
• Boom lowering/lifting
shift the control lever to or
• Attachment back/forward tilting
shift the control lever to or
• Boom extraction/retraction
Rotate wheel to position or
• Attachment coupling/release
press button together with the dashboard enabling
button (17) and shift the lever to or
GTH-3007
When pressing the intentional control button
and the lever is not correctly set to central position,
the control of the selected actuator is operated
immediately.
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GTH-3007
C-3.4.2 Emergency stop
The operated functions can be stopped at any time by
C-3.4.2.1 Disabling the load limiting system
The key-switch 32 lets you disable the load limiter.
pressing the emergency stop button 16.
By pressing this button, the engine of the machine is
shut down.
Before restarting the machine, it is necessary to reset
the pushbutton by rotating clockwise.
WORKING WITH THE LOAD LIMITER CUT OUT
CAN RESULT IN A MACHINE OVERTURNING AND
IN SERIOUS INJURY.
USE THIS OPTION ONLY IN CASE OF NEED AND
DON’T FORGET TO REACTIVATE THE LOAD
Before restarting the machine, nd and rectify the
LIMITER AFTER THE EMERGENCY.
faults that caused the emergency.
32
16
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C-3.4.3 Lifting/lowering the boom
Before operating the boom, make sure that nobody
is within the working range of the machine.
To lift or lower the boom:
• Set the control lever to central position and press
button
• Smoothly shift the lever to position to lift the boom
or to position to lower it.
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C-3.4.4 Pitching the attachment holding frame
forward/back
Before operating the boom, make sure that nobody
is within the working range of the machine.
To tilt forward/back the attachment holding frame:
• Set the control lever to central position and press
button
• Smoothly shift the lever to position to tilt the frame
forward or to position to tilt it back.
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C-3.4.5 Extending/retracting the boom
Before operating the boom, make sure that nobody
is within the working range of the machine.
To extend or retract the telescopic elements of the
boom:
• Set the control lever to central position and press
button
• Rotate wheel to position to extend the boom
or to position to retract it.
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C-3.4.6 Quick-coupling the attachments
Before operating the boom, make sure that nobody
is within the working range of the machine.
To lock/unlock the attachments:
• Set the control lever to central position and press
button
• Press button together with the dashboard
enabling button (17) and shift the lever to position
to unlock the attachment or to position to lock
the attachment.
GTH-3007
17
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GTH-3007
C-4 SETUP
C-4.1 BEFORE STARTING THE ENGINE
• To ensure safe conditions to the operators and
the bystanders, and a longer life to your machine,
perform a walk-around inspection before starting
the engine.
• Remove any dirt or rubbish from the cab interior,
especially from pedals and control levers.
• Remove oil, grease and mud from pedals and control
levers.
• Make sure that your hands and shoe soles are clean
and dry.
• Check the seat belts can be fastened properly.
• Check that lights, indicators, side/tail lights, hazard
indicator lights, wipers and horn are in working
order.
• Adjust the driving seat so that you can reach all
control levers comfortably and fully depress the
brake pedal without moving your back from the
driving seat.
• Adjust the rear view mirrors to give you a good view
close behind the machine when you are correctly
seated.
• Check the parking brake is engaged.
C-4.1.1 Checks at the machine start-up
When power is turned on, the load limiting system
activates automatically. If the power supplied is correct,
the green light 4 above the Terex logo comes on. The
display remains off while the system runs a self-test.
After that, the system is activated and 0 appears on
the display.
If during the check phase, the load limiting system nds
a fault, it enters the safety mode automatically blocking
any dangerous manoeuvres and an error message starts
ashing on the display. For any further information, refer
to chap. C-5.2.
Also check the efciency of the safety devices as
described in chap. D-3.15, namely:
• overload warning system
• joystick pushbutton
• parking brake proximity switch
• emergency pushbutton
• machine start control
• seat micro-switch.
C-4.2 STARTING THE ENGINE
For the low temperature starting, see paragraph C-
4.4.
• Set the forward/ back spee d lever to neutral
position.
• Step on the gas pedal.
• To start the engine, turn the ignition switch to position
. Release the switch when the engine starts. If the
engine does not start within 20 seconds, release the
key and wait at least 2 minutes before attempting
again.
• After the start-up, let the
engine run at idle for some
seconds before engaging a
gear; this allows for a gradual
warm up of the engine oil and
a better lubrication.
• In case of engine jumpstarting, remove the booster
c a b l e s ( s e e f ol l ow i n g
chapter).
If the light indicators do not switch off/on when
engine is running, immediately stop the machine
and nd and rectify the fault.
Engine cannot be started if the speed switch is not
in the neutral position.
After the start-up, when leaving the driving place,
the engine continues to run. DO NOT LEAVE THE
DRIVING PLACE BEFORE HAVING SHUT THE
ENGINE DOWN, LOWERED THE BOOM TO THE
GROUND AND ENGAGED THE PARKING BRAKE.
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C-4.3 JUMP-STARTING THE ENGINE
Do not start the engine using a quick charge booster
to avoid any damage to the electronic boards.
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 ammable 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.
GTH-3007
B
A
• Disconnect the cables. Remove rst 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.
To jump-start the engine:
• Turn any users off by the special control levers.
• Put the gear lever to neutral and engage the parking
brake.
• Ensure the machine battery A is connected to the
frame earth, the terminals are well tightened and
the electrolyte level is regular.
• Connect the two batteries as shown in the gure.
Connect first the positive terminals of the two
batteries, then the negative terminal of the booster
supply B to the machine frame earth.
• If the booster supply is installed on a second vehicle,
make sure that the latter does not touch the handler.
To avoid damage to the electronic instruments
of the machine, the engine of the machine
where the booster supply is installed, must be
stopped.
• Turn the ignition key and start the handler, then
follow the procedure explained in chapter C-4.2
“Starting the engine”.
Use only a 12V battery; other devices like battery
chargers, etc. may cause an explosion of the battery
or result in damage to the electrical system.
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GTH-3007
C-4.4 LOW TEMPERATURE STARTING
In case of cold starting, use an oil with a SAE viscosity
adequate to the ambient temperature.
Please refer to the DEUTZ engine use and maintenance
manual.
The machine is supplied with oil SAE 15W/40.
To start the engine from cold, proceed as follows:
• Set the forward/ back spee d lever to neutral
position.
• Turn the ignition switch to position and wait
until the warning light 28 signalling the glow plugs
preheating goes off. Step down on the gas pedal
and start the engine turning the ignition switch to
. Release as soon as the engine starts.
• Let the engine run at idle for a few seconds before
putting a gear; this allows for a gradual warm up of
the engine oil and a better lubrication.
• In case of engine jump-starting, remove the booster
cables (see chapter C-4.3).
C-4.5 DISCONNECTING THE BATTERY
During maintenance or repair works, and while welding,
turn off the battery main switch , located behind the
rear right wheel compartment.
C-4.6 STARTING THE MACHINE
When the engine reaches the running temperature,
ensure all parts are in transfer position and the gearbox
lever is in neutral. Then, proceed as follows:
• Select the required steering mode.
• Select the required gear (forward or reverse).
• Release the parking brake pressing button 19 (the
warning light on the pushbutton must be off).
• Slowly step on the gas pedal to start moving off.
Do not operate the forward/reverse gear lever
when the machine is running. The machine would
reverse the running direction abruptly and you could
seriously be injured.
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GTH-3007
C-4.7 S T O P P I N G A ND P A RK I N G T H E
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 spee d lever to neutral
position.
• Engage the parking brake pressing button 19 (the
warning light on the pushbutton must be on).
• Release the service brake pedal.
• Rest the attachment coupled to the boom at on the
ground.
• Rotate the ignition key to “0” and remove the key.
• Leave the driving cab and lock the cab door.
• Set the battery cut-out switch to OFF position.
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.
C-5 USING THE HANDLER
This chapter describes some techniques and provides
instructions for a safe use of the machine tted 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.
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.
Always engage the parking brake after stopping the
machine to prevent possible accidental motions of
the vehicle.
Leaving a battery connected can result in shorts
and, as a consequence, in a re.
Document 57.0008.5200 - 10/2006
For a safe use of the machine, always check the
weight of the loads going to be handled.
Always refer to the load charts in the quick guide
placed in the driving cab.
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MAINTENANCE
D-5 REFUELLING
D-5.1 REFUELLING
Product
Capacity specications
Part Product (litres) see par.
Diesel engine Engine oil 11 + 3.5 D-5.2.1
Fuel tank Diesel fuel 92 D-5.2.3
Hydraulic system tank Hydraulic oil 90 D-5.2.2
Gearbox Oil 1.3 D-5.2.2
Front differential gear with reduction gear Oil 4.1 D-5.2.2
Front differential gear Oil 4.1 D-5.2.2
Front wheel reduction gears Oil 0.9 + 0.9 D-5.2.2
Rear wheel reduction gears Oil 0.9 + 0.9 D-5.2.2
Brake oil tank Hydraulic oil 0.1 D-5.2.2
D-5.2 PRODUCT SPECIFICATIONS
D-5.2.1 Engine oil
Use the oil recommended by the Diesel engine Manufacturer (see the relevant handbook delivered with the
machine).
At the delivery, the machine is relled with:
SHELL
Rell the machine with following lubricants:
Use Product Denition
Hydraulic system and brakes SHELL TELLUS T 46 DENISON HF-1 DIN 51524 part 3 Cat. HV
Nevermixdifferentoils:thismayresultintroublesandcomponentbreaks.
Filtering elements:
Filter Flowl/1’ Filtering Code
Transmission oil lter MPS 150 10 µ 09.4604.0001
Auxiliary circuit oil lter (inside the tank) STR 100/1 60 µ 09.4604.0004
RIMULA 15W-40
D-5.2.2 Lubricationoilsandrelevantlteringelements
Power divider-Differential gearsReduction gears
THFI 208 LF SAE 80W Massey Ferguson M 1135
TRACTORENAULT API GL4 / FORD M2C 86B
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GTH-3007
C-5.2 LOAD LIMITER
On the front top strut of the cab, there is limiter 34 which
warns the operator of the variation of stability of the
machine and blocks any manoeuvre before the same
reaches a critical condition.
C-5.2.1 Description of the controls
1 Calibration selection button
2 Display
3 Stability indicator with LED-bar
4 Green light - power OK
5 Yellow light - calibration mode
6 Calibration conrmation button
7 Calibration programming button
8 Not used
9 Buzzer ON/OFF pushbutton
10 Red light - overload pre-alarm / alarm
The digit on display 2 shows the selected attachment
or the alarm code.
C-5.2.2 Operation
When power is turned on, light 4 comes on. The display
2 remains off and the monitoring system runs a self-
test before displaying digit 0 to warn that the system
is activated.
1 2 3
4
10
9
5 6 7 8
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 ashes and the buzzer sounds
with an intermittent sound.
Red LED’s: risk of overturning: the percentage of
overturning moment is above 100 with
respect to the threshold value.
The machine enters the alarm mode: light
10 is lit, the buzzer sounds continuously
and any dangerous manoeuvre is
blocked. The operator can only retract
the load within safety limits.
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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
C-5.2.3 Alarm codes and resetting
The limiter has diagnostic facilities to aid in the
identication 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 ashing, the buzzer start sounding and
an error message is shown on the display.
The meaning of the error messages is shown in Section
E “Faults and Troubleshooting”.
10
Before using the machine, make sure that the rst
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.
5 8
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C-5.3 HANDLING LOADS
C-5.3.1 Adjusting the forks
Forks shall be spaced to suit the load going to be
handled. For this purpose:
• Lift the clamping lever of the forks.
• Slide the forks to the desired position, then re-lock
the lever.
GTH-3007
• The centre of gravity of the load must always be
halfway between the forks.
• Ensure you exactly know the weight of the load
before handling it.
• When extending the boom, do not exceed the
payload limit.
• Refer to the payload limits given in the load chart
applied on the cab windscreen or in the quick
user’s guide.
• Space the forks as wide as possible to suit the
load being handled.
In the case of oating forks:
• Loosen the nut of the locking screws.
• Raise the forks and slide them on the pivot until
correct spacing.
• Lock the screws re-tightening the nut.
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C-5.3.2 Working phases
When forks are correctly spaced, the handler is ready
to use.
Work can be subdivided into three different phases:
loading, transfer and unloading.
Loading phase
• Approach the load to the handled perpendicularly
an d check that the machi ne is level on the
inclinometer.
• Insert the forks under the load and raise the load
some centimetres.
• Pitch the forks back and make sure that the overload
warning system LEDs are in limits.
Transfer phase
• Do not start or brake abruptly.
• Drive to the unloading point cautiously and keep the
load 20÷30 cm from the ground.
• Suit the machine speed to the ground conditions to
avoid dangerous jumps, side skids of the vehicle
and possible load falls.
• When driving on slopes or ramps, hold the load
uphill.
GTH-3007
Do not move off when the load is raised 20÷30 cm
above the ground. Risk of machine overturning or
load fall.
Do not drive on slopes sideways; this wrong
manoeuvre is one of the main reasons for accidents
due to vehicle overturning.
Unloading phase
• Drive to the unloading point with straight wheels and
bring the machine to a smooth stop leaving enough
space to operate the boom.
• Put the parking brake and set the transmission to
neutral.
• Position the load some centimetres above the
desired position and set the forks level.
• Lower the load and make sure it is level.
• Carefully withdraw the forks by operating the boom
retraction control and, if necessary, raise or lower
the boom as forks come out.
• When the forks are clear of the load, set them to
transfer position.
• Release the parking brake and start a new working
cycle.
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C-5.4 CHANGING THE ATTACHMENT
Use only attachments directly manufactured or
recommended by Terexlift and detailed in the
“Optional attachments” section.
To change an attachment, operate as follows:
• Drive to the place where you will release the
mounted attachment (when possible, a solid and
sheltered site).
• Disconnect the quick connectors of the attachment
(if any), and connect the hydraulic locking pipes of
the attachments to couplings A.
• Rest the attachment at on the ground.
• Pitch the attachment holding frame forward and
lower the boom to release the attachment upper
lock.
• Move back with the machine (or with the boom) and
drive to the new attachment to be coupled.
• Hold the frame pitched forward and hook the upper
lock of the new attachment.
• Retract and raise the attachment some centimetres.
It will centre automatically on the quick coupling
frame.
• Operate the control lever to lock the attachment.
• Couple the connectors of the attachment, if any, to
the quick couplings of the frame.
GTH-3007
After substitution, visually check the attachment
is correctly coupled to the boom, before operating
the machine. A wrongly coupled attachment may
result in damage to persons or things.
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After the substitution of an attachment or after any
coupling operation, visually check the attachment. A
wrongly coupled attachment may result in damage
to persons or things.
GTH-3007
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GTH-3007
C-6 TRANSPORTING THE
MACHINE
C-6.1 MOVING A DISABLED MACHINE
Tow the machine only when no alternative is possible,
since this operation may result in serious damage to
the transmission. When possible, repair the machine
on site.
When the machine shall absolutely be towed:
• Unlock the negative brake (see chap. C-6.1.1)
• Tow the machine for short distances and at a low
speed only.
• Use a rigid drawbar.
• Select the two-wheel steer.
• Set the gearbox lever to neutral.
• When possible, start the engine and use the
hydraulic drive and the braking system.
• Raise the front wheels of the machine and remove
the Cardan shaft of the transmission.
C-6.1.1 Unlocking the negative brake
To unlock the negative brake of a faulty machine,
proceed as follows:
• Loosen the two opposite screws located on the
front axle in order to remove the washers.
• Remove the horseshoe-shaped washers located
under the two screws.
• Re-tighten screws turning alternately the front
screw and the rear screw 1/2 turn to unlock the
brake.
To relock the nagetive brake, loosen the screws
turning alternately the front screw and the rear screw
1/2 turn, ret the horseshoe washers and re-tighten
screws .
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C-6.2 ROAD OR SITE TRANSFER
When travelling on public roads, strictly obey the local or national
road trafc regulations.
Besides, take into account the following general precautions:
• Align the rear wheels.
• Select the two-wheel steer.
• Set the ROAD-JOBSITE switch 20 to “ROAD” (the light on the
pushbutton comes on).
• Lock the machine as indicated in the Registration Card (only
for the Italian market):
Lock the boom sections, the lifting cylinder, and the attachment
rotation cylinder (see photo).
• Cover the teeth of the conventional forks with the special guard;
or withdraw the oating forks.
With the oating forks pitched
back, do not move the fork
pitching cylinder as the machine
could suffer from damage.
Only for the Italian market
• Retract boom and attachment to transfer position.
• Make sure that lights, horn and turn signals are in working
order.
• Start the machine (the beacon will switch on automatically).
• Select the forward or reverse speed.
• The transfer speed of the vehicle will depend on the engine
rpm.
Public road circulation is allowed only for transferring an
unloaded machine.
Do not use the machine for towing purposes.
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OPERATING INSTRUCTIONS
GTH-3007
C-6.3 LIFTING THE MACHINE
When the machine shall be lifted, use only means
having a suitable capacity. The characteristic data are
detailed in the relevant chapter of this manual and on
the identication plate.
For the machine lifting, anchor the chains to the special
lugs on the machine (marked with the decal below).
C-6.4 TR A NSPORTING TH E MACHINE ON
OTHER VEHICLES
To transport the machine on another vehicle, follow
the steps below:
• Put chocks at the machine wheels.
• Ensure ramps are correctly positioned.
• Retract the boom to transfer position.
• Carefully drive the machine onto the transporting
vehicle.
• Put the parking brake and rest the attachment at
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 wheelchocks.
• Anchor the machine to the transporting vehicle with
suitable chains.
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C-6.5 PARKING AND STORAGE
C-6.5.1 Short inactivity
Always park the machine in a safe way after a working
day, a shift and at night.
Take all precautions to prevent damage to those persons
who will approach the machine while stationary:
• Park the machine so that it does not hinder other
operations.
• Lower the boom fitted with attachment on the
ground.
• Remove the key from the ignition switch and lock
the cab door.
• Disconnect the battery by the appropriate switch
(“Battery cut-out switch”).
Leaving a battery connected can result in shorts
and, as a consequence, in a re.
C-6.5.2 Machine storage
In case of extended inactivity of the machine, follow the
above precautions. Additionally:
• Wash the machine thoroughly. For a better cleaning,
remove grills and protection casings
• Carefully dry all machine parts by blowing some
compressed air.
• Lubricate the machine thoroughly.
• Do a walk-around inspection and replace any worn
or damaged part.
• Re-paint any worn or damaged part.
• Remove the battery, smear its terminals with
vaseline and store it in a dry place. Battery can be
used for other purposes. Otherwise, periodically
check its charge level.
• Refuel the tank to prevent internal oxidation.
• Store the machine in a sheltered and well-ventilated
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 uid levels
and to those parts subject to ageing. Before restarting the machine, carry out an extraordinary
maintenance and carefully check all mechanical,
hydraulic and electrical components.
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C-6.6 C L E A N I N G A N D WA S H I N G T H E
MACHINE
C-6.6.1 Cleaning instructions
Clean the machine in accordance with the following
instructions:
• Remove any oil or grease traces with a dry solvent
or a volatile mineral alcohol
• Before assemb ling a new part, remove any
protection product (rust-preventer, grease, wax
etc.).
• Remove any trace of rust from metal parts with
some emery cloth before smearing the part with a
protection product (rust-preventer, paint, oil, etc.).
C-6.6.2 Washing instructions
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 lter
to prevent water from entering the circuit.
C-6.7 MACHINE DISPOSAL
At the end of the machine life, call in a specialised
rm to dispose of it in compliance with the local or
national regulations.
C-6.7.1 Battery disposal
Used lead-acid batteries cannot be disposed of
as normal industrial solid wastes. Because of the
presence of harmful substances, they must be
collected, eliminated and/or recycled in accordance
with the laws of the UE.
In Italy, used or discarded batteries have been
classed as “Toxic wastes” in accordance with
Presidential decree n. 397 of 09/09/1988 and Law
n. 475 O.G. n. 18 of 09/11/1988 because they contain
lead and sulphuric acid. Their disposal through
recycling must be done only through companies
authorised to do so and belonging to the “Consorzio
Obbligatorio Batterie Esauste e dei riuti piombosi”
(Cobat) which collect and dispose of used lead-acid
batteries throughout the national territory.
Used batteries must be kept in a dry and conned
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.
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.
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GTH-3007
MAINTENANCE
Section D
MAINTENANCE
TABLE OF CONTENTS
D-1 LUBRICANTS - HEALTH AND SAFETY PRECAUTIONS .............................................. D-3
D-2 ROUTINE MAINTENANCE ............................................................................................. D-4
D-2.1 Oil change schedule ....................................................................................................... D-5
D-3 MAINTENANCE JOBS ................................................................................................... D-6
D-3.1 Disconnecting the battery ............................................................................................... D-6
D-3.2 Access to the engine and tanks compartments .............................................................. D-7
D-3.3 Greasing ......................................................................................................................... D-8
D-3.4 Tyres and wheels ............................................................................................................ D-9
D-3.5 Brakes ............................................................................................................................. D-10
D-3.5.1 Checking the brake oil level ............................................................................................ D-10
D-3.6 Engine air lter ................................................................................................................ D-11
D-3.7 Cab air lter ..................................................................................................................... D-12
D-3.8 Engine cooling system .................................................................................................... D-12
D-3.9 Checking the oil level in the tank .................................................................................... D-13
D-3.10 Changing the oil lter canisters on the intake line ........................................................... D-14
D-3.10.1 Transmission oil lter ...................................................................................................... D-14
D-3.10.2 Auxiliary circuits oil lter .................................................................................................. D-15
D-3.11 Oil level in the differential gears and the rducer .............................................................. D-16
D-3.11.1 Front and rear differential gears ...................................................................................... D-16
D-3.11.2 Reducer .......................................................................................................................... D-16
D-3.12 Oil level in the (front/rear) wheel reduction gears ........................................................... D-17
D-3.13 Shafting alignment .......................................................................................................... D-18
D-3.14 Adjusting the sliding pads of the boom sections ............................................................. D-19
D-3.15 Checking the safety devices ........................................................................................... D-20
D-3.16 Checking the state of the structure ................................................................................. D-22
D-4 ELECTRICAL SYSTEM .................................................................................................. D-23
D-4.1 Battery ............................................................................................................................. D-24
D-4.2 Fuses and relays ............................................................................................................. D-24
D-4.3 12V DC lamps ................................................................................................................. D-26
D-5 REFUELLING ................................................................................................................. D-27
D-5.1 Refuelling ........................................................................................................................ D-27
D-5.2 Product specications ..................................................................................................... D-27
D-5.2.1 Engine oil ........................................................................................................................ D-27
D-5.2.2 Lubrication oils and relevant ltering elements ............................................................... D-27
D-5.2.3 Fuel ................................................................................................................................. D-28
D-5.2.4 Grease ............................................................................................................................ D-28
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Observe and obey:
* The operat o r can only perf o r m the routine
maintenance op e r at i o n s e n v i s a g e d in this
manual.
* Scheduled maintenance procedures shall be
co mpleted by quali fied tec hnical personne l
according to the manufacturer’s specications.
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 too ls are required to
perform the procedure.
GTH-3007
INTRODUCTION
A thorough and regular maintenance keeps the machine
in a safe and efcient 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 efcient. In
case of defects, nd and rectify them before using the
machine again.
The maintenance interventions are based on the
machine working hours. Regularly check the hour-meter
and keep it in good condition to dene the maintenance
intervals correctly.
Not respecting the ordinary maintenance schedule of
this manual automatically voids GENIE warranty.
For the engine maintenance, please refer to the
specic Operator handbook supplied with the
machine.
Indicates that new parts are required to
perform the procedure.
Running-in _____________________________
Ordinary _______________________________
Indicates that a cold engine is required to
perform the procedure.
SERVICE INTERVAL
Indicates the ti m e interval for th e
maintenance jobs expressed in working
hours.
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MAINTENANCE
D-1 LUBRICANTS - HEALTH AND
SAFETY PRECAUTIONS
Health
A prolonged skin contact with oil can cause irritation. Use
rubber gloves and protective goggles. After handling oil,
carefully wash your hands with soap and water.
Storage
Always keep lubricants in a closed place, out of the
children’s reach. Never store lubricants on the open air
and without a label indicating their contents.
Disposal
New or exhausted oil is always polluting! Never drain oil
on the ground. Store new oil in a suitable warehouse.
Pour exhausted oil into cans and deliver them to
specialised rms for disposal.
Oil leaks
In case of accidental oil leaks, cover with sand or typeapproved granulate. Then scrape off and dispose of it
as chemical waste.
GTH-3007
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 re, use carbon dioxide, dry chemical or foam
extinguishers. Do not use water.
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D-2 ORDINARY MAINTENANCE
A wrong or neglected maintenance can result in possible
risks for both operator and bystanders. Make sure
maintenance and lubrication are carried out according
to the manufacturer’s instructions to keep the machine
safe and efcient.
The maintenance interventions are based on the
machine working hours. Regularly check the hour-
meter and keep it in good conditions to dene the
maintenance intervals correctly. Make sure any defect
detected during the maintenance is promptly rectied
before using the machine.
All "▲" marked operations must be carried out by
a skilled technician.
During the rst 10 working hours
1 Check the oil level within reduction gears, power
divider and differential gears
2 Regularly check the tightening of the wheel bolts
3 Check the tightening of all bolts and nuts
4 Check the couplings for oil leaks
Within the rst 50 working hours
1 Change the oil for the rst time
Within the rst 100 working hours
1 Check the engine oil level
2 Clean the air suction lter
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 efciency of braking system and parking
brake
10 Check the efficiency of the steering selection
system
11 Check the efciency of the fork balancing system.
12 Make sure the safety devices installed are in
efcient working order - see procedure in chap.
D-3.15.
Every 50 working hours or weekly
Jobs to be done in addition to those above
1 Check the tension of the alternator belt
2 Check the tyre ination
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 lter
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 lter; 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
lter
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 re-grease
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 efciency of the block valves - see chap.
D-3.15.
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GTH-3007
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 xing screws
3 Check the tightening of the cab xing screws
4 Check the backlash between pins and bushings in
all joints
5 Change the hydraulic oil lter of the transmission
6 Change the hydraulic oil lter in the tank
7 Have the hydraulic system checked by a skilled
technician
8 Change the main cartridge of the engine air lter
9 Clean or replace, if nececessary, the air lter in the
cab
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
4 Change the safety cartridge of the engine air lter
At 6000 hours or 5 years and, subsequently,
every 2 years
Jobs to be done in addition to those above
1 Check that the structure is intact paying a special
attention to the welded supporting joints and the
boom pins (see chap. D-3.16).
D-2.1 OIL CHANGE SCHEDULE
Job Operating Service Oil type
hours* interval*
Oil level check 10 daily
Engine
SHELL
RIMULA 15W-40
First change 50 -
Subsequent changes 250 monthly
Oil level check 250 monthly
Axles and
power
First change - - API GL4 / FORD M2C 86B
divider
Subsequent changes 1000 yearly MASSEY FERGUSON M 1135
Oil level check 250 monthly
Hydraulic
oil
Subsequent changes 1000 yearly
TRACTORENAULT THFI 208 LF SAE 80W
SHELL TELLUS T 46
DENISON HF-1, DIN 51524 part 3 Cat. HV
* whichever occurs rst.
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D-3 MAINTENANCE JOBS
All maintenance interventions must be carried
out with engine stopped, parking brake engaged,
working attachments at on the ground and gear
lever in neutral.
When raising a component for maintenance
purposes, secure it in a safe way before any
maintenance intervention.
GTH-3007
The qualied staff charged with the maintenance
of the hydraulic circuit must clean all areas around
with care before any intervention.
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
D-3.1 DISCONNECTING THE BATTERY
During maintenance or repair works, and while welding,
turn off the battery main switch, located behind the rear
right wheel compartment (C-4.5, page C-25).
Any intervention on the hydraulic circuit must be
carried out by skilled personnel.
The hydraulic circuit of this machine is tted with
pressure accumulators. You and others could be
seriously injured if accumulators are not completely
depressurised.
To depressurise the accumators, just steer the
machine wheels some times with engine shut down
until noticing a gradual binding of the handwheel.
Before any operation on hydraulic lines or
components, make sure there is no residual
pressure. For this purpose, stop the engine, engage
the parking brake and operate the control levers
of the distributors in both working directions
(alternately) to depressurise the hydraulic circuit.
High pressure lines must be replaced by qualied
personnel only.
Any foreign matters entering the closed circuit
may result in a sudden deterioration of the
transmission.
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D-3.2 ACCESS TO THE ENGINE AND TANKS
COMPARTMENTS
Engine compartment
For any operation within the engine compartment, open
the protection bonnet.
Hood is equipped with lock & key and a supporting rod
that holds it in position.
From the engine compartment, you get access to:
• Thermal engine
• Engine air lter
• Hydraulic oil tank plug
• Battery
To get access to the engine compartment:
• Shut the engine down and put the parking brake
• Unlock the bonnet lock
• Lift the bonnet using the special handle until it
latches in the gas spring
• To close the bonnet: press on the green locking
device on the gas spring and lower the bonnet
GTH-3007
Take all precautions when approaching
the engine compartment. Some parts of
the engine may be very hot. Always use
protective gloves.
Diesel fuel tank compartment
To gain access to the fuel tank, open the rear cover of
the machine as follows:
• Shut the engine down and put the parking brake
• Fully raise the cover by means of the special
handle
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D-3.3 GREASING
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 efcient
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
gures:
GTH-3007
- the symbol represents the points to be greased
by a pump
- the symbol represents the points to be
greased by a brush.
SERVICE INTERVAL
Running-in _________________________ None
Ordinary _________________ Every 10 hours
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WRONG WAY
MAINTENANCE
D-3.4 TYRES AND WHEELS
Over-inated or overheated tyres can burst. Do not
ame-cut or weld the wheel rims. For any repair
work, call in a qualied technician.
WRONGOKAY
GTH-3007
For the tyre ination or substitution, please refer to the
table below:
GTH-3007
Dimensions 405/70 R20
P.R. (or load index) 14 pr
Wheel disc 8 holes DIN 70361
Pressure bar/Psi 5.5/80
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.
Always use tyres having the dimensions indicated
in the vehicle registration card.
SERVICE INTERVAL
Running-in ________ Within the rst 10 hours
Ordinary ________________ Every 250 hours
Page D-9
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CA
MAINTENANCE
D-3.5 BRAKES
• For any interv ention on the braking system
(adjustment and/or substitution of the brake discs)
call in a specialised technician.
GTH-3007
The malfunctioning of the braking system may depend
on the presence of air within the hydraulic circuit.
The braking system has two bleeding valves: valve
for the service brake circuit and valve for the negative
parking brake circuit.
To bleed the circuit of the service brake, follow the
instructions below and ask the assistance of another
technician:
• Make sure that the oil is level within the feeding tank
.
• The operator in the cab shall step on the brake pedal
repeatedly and, as soon as a certain resistance is
noticed, he shall hold the pedal stepped down.
• At this time, the operator on the ground shall loosen
valve slowly and then re-close the valve as soon
as oil mixed with air bubbles starti owing out.
• The two operations mentioned above shall be
repeated until bubble-free oil starti owing out.
• Bleed from both sides of the machine.
• Once the circuit has been bled, rell the small tank
up to the level mark shown in the photo.
To bleed the circuit of the negative parking brake:
• Press the parking brake button . As soon as the
light indicator on the button goes off, start bleeding
through valve until air-free oil comes out.
D-3.5.1 Checking the brake oil level
The oil within the braking circuit must be at about 2 cm
from the tank plug .
Page D-10
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D-3.6 ENGINE AIR FILTER
Clean the engine air lter every 10 hours; replace the
ltering element, if necessary.
1 Cleaning and changing the external element:
- Stop the engine and engage the parking brake.
- Unscrew wingnut A and remove cover B.
- Unscrew wingnut C and remove the outer element
D.
- Clean the lter bowl.
- Dry clean the cartridge (max. pressure: 6 bar)
and direct the air jet from inside to outside.
- Check for cracks in the ltering element by
introducing a lamp inside.
- Smear the seal with grease, then refit the
element.
- Tighten wingnut C, close cover B and tighten with
wingnut A.
GTH-3007
As soon as the warning lamp 24 on the cab dashboard
switches on, replace the outer element.
2 Changing the internal element:
- See step 1 for removing the outer element.
- Loosen wing nut E and remove the inner element
F.
- Clean the lter bowl.
- Smear the seal with grease, then mount the
new element and make sure it is correctly
positioned.
- Ret the outer element and the cover (see step
1).
The inner element should be replaced every two
times the outer element is replaced.
Daily remove any dust collected in the lter by
pressing the rubber cap G.
SERVICE INTERVAL
Running-in _____________________________ None
Cleaning _____________________ Every 10 hours
Outer element change __________Every 500 hours
Inner element change ________ Every 1000 hours
Page D-11
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D-3.7 CAB AIR FILTER
Every six months clean the air lter in the cab. Replace
the cartridge if the ltering cloth is damged.
Cleaning and changing the cartridge:
- Shut the engine down and engage the parking
brake.
- Pull out the lter A located to the left of the driving
place.
- Clean the lter bowl.
- Clean the lter cartridge by beating it against a piece
of wood. Replace the cartridge if damaged.
Paper filters must never b e cl eaned using
compressed air or washed with water and/or
solvents.
GTH-3007
D-3.8 ENGINE COOLING SYSTEM
Engine oil circulates in the radiator. Check the engine
oil level and clean the core of the heat exchanger
at regular intervals.
To clean the core of the heat exchanger, blow some
compressed air from inside outwards. Do not use
brushes or other tools. The cooling ns could get
damaged.
Take any safety measures and use the adequate
personal protective equipment when operating near
the engine or the radiator.
SERVICE INTERVAL
Running-in _________________________ None
Ordinary _________________ Every 50 hours
Document 57.0008.5200 - 10/2006
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D-3.9 CH E C KING THE OIL LEVEL IN THE
TANK
Fine jets of hydraulic oil under pressure can
penetrate the skin. Do not use your ngers, but a
piece of cardboard to detect oil leaks.
Check the hydraulic oil level (visually) through the special
level tted into the tank.
When necessary, add new oil through ller .
Check the oil level with handler set to transfer
position (lowered boom and retracted telescopic
element).
GTH-3007
SERVICE INTERVAL
Running-in ________ Within the rst 10 hours
Ordinary _________________ Every 50 hours
If oil must be changed, proceed as follows:
1 Stop the machine on a level ground and make sure
the parking brake is engaged.
2 Release the pressure from the hydraulic circuit.
3 Place a container of suitable size under the drain
plug, placed in the lower part of the reservoir, and
collect any oil leaks.
4 Remove the drain plug and allow oil to ow out into
the container.
5 Remove the inspection cover of tank .
6 Carefully wash the tank with Diesel oil and blow a
jet of compressed air.
7 Ret the drain plug and the inspection cover.
8 Add new oil by making sure that it matches the
recommended type indicated in paragraph D-5.2.2.
until it is level with .
SERVICE INTERVAL
Running-in _________________________ None
Ordinary _______________Every 1000 hours
Document 57.0008.5200 - 10/2006
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
Page D-13
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in Hg
cm Hg
10
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30
40
50
60
70
76 0
5
10
15
20
25
30
MAINTENANCE
D-3.10 CHANGING THE OIL FILTER CANISTERS
ON THE INTAKE LINE
D-3.10.1 Transmission oil lter
Every 50 hours, check the clogging degree of the ltering
element using the vacuometer .
The indexed scale of the vacuometer is divided into
3 areas:
1 - Green area: Normal condition
2 - Yellow area:
3 - Red area: Shut the engine down to prevent
Replace the lter as soon as possible
damage to the hydraulic system.
Change the lter and/or check for the
fault reasons.
GTH-3007
To change the hydraulic oil lter element on the suction
line, proceed as follows:
1 Stop the machine on a level ground and engage
the parking brake.
2 Place a container of suitable size under the lter to
collect any oil leaks, then close cock .
3 Remove the ltering element using a wrench.
4 Change the ltering element, then, before tting a
new one, thoroughly clean and grease both seat
and gasket.
5 Hand-tighten and re-open cock .
Hydraulic oil lter cartridges cannot be cleaned or
washed and retted.
They must be replaced with new ones of the type
recommended by the manufacturer (see par. D-
5.2.2).
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
When changing the oil, drain it when it is still hot
and the polluting substances are in suspension.
Open and close the cocks using the special handles
supplied which are located inside the driving
cabin.
Running-in _________________________ None
Ordinary ________________ Every 500 hours
When the dashboard indicator switches on
Page D-14
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MAINTENANCE
D-3.10.2 Auxiliary circuits oil lter
To change the hydraulic oil lter cartridge of the service
circuits, proceed as follows:
1 Stop the machine on a level ground and engage
the parking brake.
2 Remove the inspection hatch and unscrew the
oil lter tted inside the tank.
3 Check the tank is clean, then t a new ltering
element and ret the inspection hatch.
4 Check the oil level within the tank. Add new oil, if
necessary.
GTH-3007
SERVICE INTERVAL
Running-in _________________________ None
Ordinary ________________ Every 500 hours
Page D-15
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MAINTENANCE
D-3.11 OIL LEVEL IN THE DIFFERENTIAL GEARS
AND THE REDUCER
D-3.11.1 Front and differential gears
To check the oil level in the front and rear differential
gears:
• Stop the machine on a level ground and engage the
parking brake.
• Loosen level plug and check if oil is level with the
hole.
• If necessary, add new oil through the hole of the
level plug until it comes out.
• Ret and tighten plug .
For the oil change:
• Place a container of suitable size under drain plug
.
• Loosen the drain plug and the level plug and allow
oil to ow out from the differential gears.
• Ret and tighten drain plug .
• Add new oil through plug until it is level with the
hole.
• Ret and tighten level/ller plug.
GTH-3007
SERVICE INTERVAL
Running-in ________ Within the rst 10 hours
Ordinary ________________ Every 250 hours
D-3.11.2 Reducer
To check the oil level in the reducer:
• Stop the machine on a level ground and engage the
parking brake.
• Loosen level plug and check if oil is level with the
hole.
• If necessary, add new oil through the hole of the
level plug until it comes out.
• Ret and tighten plug .
For the oil change:
• Place a container of suitable size under drain plug
.
• Loosen the drain plug and the level plug and
allow oil to ow out from the reduction gear.
• Ret and tighten drain plug .
• Add new oil through plug until it is level with the
hole.
• Ret and tighten plug .
SERVICE INTERVAL
Running-in ________ Within the rst 10 hours
Ordinary ________________ Every 250 hours
Page D-16
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D-3.12 OIL LEVEL IN THE (front/rear) WHEEL
REDUCTION GEARS
To check the oil level within the wheel reduction
gears:
• Stop the machine on a level ground and ensure the
parking brake is engaged and plug nds 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.
• Ret the plug.
For the oil change:
• Stop the machine and ensure the plug is oriented
along the vertical axis.
• Place a container of suitable size under the reduction
gear plug.
• Unscrew plug and drain any oil from the reduction
gear.
• Rotate the wheel by 90° until the plug nds again
on the horizontal axis.
• Add new oil through hole .
• Ret and tighten plug .
GTH-3007
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
When changing the oil, drain it when it is still hot
and the polluting substances are in suspension.
SERVICE INTERVAL
Running-in ________ Within the rst 10 hours
Ordinary ________________ Every 250 hours
Page D-17
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4080120
ϒC
0 1 2 3 4 5 6 7
80
120ϒC40
10
8
6
0
4
2 2
4
6
8
10
F
R
N
MAINTENANCE
GTH-3007
D-3.13
SHAFTING ALIGNMENT
During operation, the alignment of the front and rear
axles of the machine can be subject to variations. This
can depend on an oil blow-by from the steering control
circuit, or on a steering of both axles when front and
rear wheels are not perfectly aligned.
To x this problem, rather than checking the alignment
visually, follow the procedure below:
1) Move to a solid and level ground
2)
Set the steering selection switch 11 to “four-wheel
steer” (pos. 2)
3) Rotate the steering up to its stop (either to the right
or to the left)
4) Set the steering selection switch to “two-wheel
steer” (pos. 0)
5) Rotate the steering up to its stop (turn in the same
direction as above)
6) Reset the steering selection switch to “four-wheel
steer” (pos. 2)
7) Rotate the steering (to the side opposite to point 3)
so that the rear axle reaches its stop
8) Reset the steering selection switch to “two-wheel
steer” (pos. 0)
9) Rotate the steering (to the same side as in point 7)
so that the front axle reaches its stop
10) Reset the steering selection switch to “four-wheel
steer” (pos. 2)
Now the wheels should be re-aligned.
SERVICE INTERVAL
Running-in _________________________ None
Ordinary _________________ When necessary
Page D-18
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D-3.14 ADJUSTING THE SLIDING PADS OF THE
BOOM SECTIONS
Any boom section is tted with adjustable pads located
on the four sides of the prole. These pads are secured
to both xed and mobile part of every section.
All pads can be adjusted by the special shims supplied
by GENIE upon demand.
Adjusting the pads:
• Remove or loosen the screws xing 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 insufcient or
near the maximum wearing limit, renew the pad.
• Tighten the screws xing 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
GTH-3007
Screws M14 Nm 50
Tightening torques higher than those recommended
can cause the break of the pad or of the locking
threaded bush.
Pads must compulsorily be replaced if the residual
thickness of the plastic layer with respect to the iron
bush xing the block is equal or inferior to 1 mm.
Max. wearing thickness
SERVICE INTERVAL
Running-in _________________________ None
Ordinary _________________ When necessary
Minimum 1 mm
Page D-19
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MAINTENANCE
GTH-3007
D-3.15 CHECKING THE SAFETY DEVICES
Checking the load limiting system
(at every use)
When power is turned on, the DLE load limiting system
runs a self-test. In the case of troubles, LED’s 5, 8 and
10 start ashing, the buzzer sounds, an error code is
shown on the display and the machine enters the alarm
mode and cannot be operated.
The meaning of the error messages is shown in Section
E “Faults and Troubleshooting”.
To do a manual check, it will be enough to load a weight
exceeding the maximum permitted with the boom fully
out and attempt to lift it. The system shall enter in alarm;
should that not be the case, contact GENIE Technical
Service.
Checking the emergency stop pushbutton
(at every use)
To check the efciency of this pushbutton, simply
press it down during a movement. The pressure of
the pushbutton shall cause the movement to stop and
the engine to shut down. Should that not be the case,
contact GENIE Technical Service.
10
5 8
Checking the machine start control
(at every use)
Attempt to start the engine with the forward or reverse
gear put.
The engine must not start. If the engine starts, contact
the GENIE Technical Service.
Repeat the operation putting rst one gear, then the
other.
Checking the seat micro-switch
(at every use)
To check if the seat micro-switch is in efcient working
order, simply attempt to move the machine without being
seated. The machine shall stand still. Should that not
be the case, contact GENIE Technical Service.
Checking the joystick pushbutton (at every use)
To check if the pushbutton on the control lever is in
efcient working order, it will be enough to attempt to
operate the lever without pressing this button.
In this condition, the lever shall not operate any
movement. Should that not be the case, contact GENIE
Technical Service.
Page D-20
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Checking the block valves (every 3 months).
The piloted blocking valves allow to held the load in
position in case of burst of a exible hose.
To check the efficiency of a valve, proceed as
follows:
• Load a weight near the maximum payload (3000 kg
roughly) onto the boom.
• Raise the load some centimetres above the ground
(max 10 cm). To check the valve on the telescope
extension cylinder move the boom to maximum
height and extend it some centimetres.
• Loosen the oil hoses to the cylinder of which you
are checking the valve with caution.
During the check, the oil will ow out of the hoses and
the load shall remain blocked in position. Should that
not be the case, the valve must be replaced. Contact
GENIE Technical Service.
GTH-3007
Attachment coupling cylinder
- Wear safety glasses
- Wear safety gloves
- Wear safety shoes
- Wear suitable working clothes
- U s e guards against le a k s of oi l at hi g h
pressure
- Do the check in a free space with barriers all
around to keep non-authorised people away
- D u ri n g the ch e ck procee d with ex t re m e
caution.
- Ensure that the part to be checked is in safe
condition and that the action generated does
not result in an uncontrolled movement of the
machine.
Lifting cylinder
Balance cylinder
Attachment pitching cylinder
Page D-21
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GTH-3007
D-3.16
Five years after the rst placing into operation of the
machine or after 6000 hours (whichever occurs rst),
check the state of the structure paying attention to the
welded supporting joints and the boom pins.
After the rst 5 years, repeat this check every 2
years.
C H E C K I N G T H E S TAT E O F T H E
STRUCTURE
Page D-22
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D-4 ELECTRICAL SYSTEM
All maintenance interventions must be carried
out with engine stopped, parking brake engaged,
working attachments on the ground and gearbox
lever in neutral.
When raising a component for maintenance
purposes, secure it in a safe way before carrying
out any maintenance.
Any intervention on the electrical system unless
performed by authorized personnel, is expressly
forbidden.
D-4.1 BATTERY
• Check the electrolyte level every 250 working hours;
if necessary, add distilled water.
• Ensure the uid 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.
GTH-3007
• 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 rst.
• To connect the battery, connect the positive (+)
lead rst.
• Recharge the battery far from the machine, in a
well-ventilated place.
• Keep out of items which can produce sparks, of
naked ames 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.
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.
Page D-23
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K1
K2
K3
K4
K6
K7
K8
K9
K5
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F29
F29
F29
INT
K10
MAINTENANCE
GTH-3007
D-4.2 FUSES AND RELAYS
The electrical system is protected by fuses placed in
the driving cab, on the left. Before replacing a blown
fuse with a new one having the same amperage, nd
out and rectify the fault.
Fuses
Ref. Circuit Amp.
F1 WORK LIGHT - HAZARD WARNING LAMP SWITCH 15
F2 RELAY POWER SUPPLY 7,5
F3 WORK LIGHT BUTTON 15
F4 HYDRAULIC OIL TEMPERATURE INDICATOR
LIGHT - HYDRAULIC OIL TEMPERATURE SENSOR -
LICENSE PLATE LIGHTS - FRONT RIGHT
POSITION LIGHTS - REAR LEFT POSITION LIGHTS 5
F5 LIGHTING: OIL TEMPERATURE INDICATOR/
CONVERTER, LIGHT SWITCHES, ø100 12V
INDICATOR, FRONT LEFT POSITION LIGHTS,
REAR RIGHT POSITION LIGHTS 5
F6 RIGHT LOW BEAM 7,5
F7 LEFT LOW BEAM 7,5
F8 ø100 12V INDICATOR, RIGHT HIGH BEAM 10
F9 LEFT HIGH BEAM 10
F10 SPEED SELECTOR - BUZZER 15
F11 SPEED SELECTOR - WINDSCREEN WASHER
CONTROL 10
F12 OPTIONAL 5
F13 OPTIONAL 5
F14 OPTIONAL 7,5
F15 ENGINE STOP SOLENOID VALVE 5
F16 E4 RELAY ENERGIZING COIL - HYDRAULIC STOP -
AIR FILTER CLOGGING SENSOR - GLOW PLUGS
WARNING LIGHT - ENGINE AND HYDRAULIC OIL
TEMPERATURE INDICATOR POWER SUPPLY -
ø100 12V INDICATOR - ATTACHMENT
COUPLING/RELEASE CONTROL 5
F17 HAZARD WARNING LAMP SWITCH 15
F18 WIPER SWITCH - WIPER 15
F19 HEATING FAN SWITCH 15
F20 ROAD/SITE SAFETY ROCKER SELECTOR 7,5
F21 BEACON 10
F22 MUSHROOM-HEAD SWITCH 10
F23 K5, K2 RELAY POWER SUPPLY - SPEED SELECTOR
CONTROL POWER SUPPLY 7,5
Page D-24
Document 57.0008.5200 - 10/2006
Ref. Circuit Amp.
F24 K6 RELAY POWER SUPPLY 5
F25 PARKING BRAKE INDICATOR 10
F26 K7 RELAY POWER SUPPLY - K8 RELAY N.O.
CONTACT - SPEED CHANGE BUTTON 10
F27 OPTIONAL 10
F28 OPTIONAL 25
F29 SPARE FUSES
Handler with telescopic boom
DANGER
DANGER
ELECTRICAL
DANGER
ATTENTION
CAUTION
DANGER
DANGER
ELECTRICAL
DANGER
PROTECT THE
ENVIRONMENT
ATTENTION
CAUTION
IMPORTANT
K1
K2
K3
K4
K6
K7
K8
K9
K5
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F29
F29
F29
INT
K10
MAINTENANCE
Relays
Ref. Circuit
K1 MUSHROOM-HEAD SWITCH POWER SUPPLY
K2 FWD SPEED SOLENOID VALVE
K3 K2, K5 RELAY ENERGIZING COIL
K4 OVERLOAD WARNING SYSTEM DISCONNECT KEY
- OVERLOAD WARNING SYSTEM CONTROL UNIT
K5 REVERSE SPEED SOLENOID VALVE - BACK-UP
LIGHT - BACK-UP HORN
K6 OVERLOAD WARNING SYSTEM SOLENOID VALVE 1
AND 2
K7 POWER SUPPLY FOR SPEED CHANGE CONTROL
WARNING LIGHT - 2nd SPEED ENGAGED WARNING
LIGHT - 2nd SPEED SOLENOID VALVE
K8 K7 RELAY ENERGIZING COIL - 1st SPEED SOLENOID
VALVE - 1st SPEED ENGAGED WARNING LIGHT
K9 K7 RELAY POWER SUPPLY - SPEED CHANGE
BUTTON - FUSE F26
K10 RELAY - BOOM EXTENSION
K12 RELAY - DRIVE DISENGAGEMENT FROM SEAT
MICRO-SWITCH
GTH-3007
K12
Engine compartment fuses and relays
Ref. Circuit Amp.
F30 PREHEATING CONTROL UNIT MAXIFUSE 50
F31 SYSTEM PROTECTION FUSE 50
A02 PREHEATING CONTROL UNIT
K11 START RELAY
• 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.
• Al w ays k ee p som e sp a re f use s fo r 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.
Page D-25
Document 57.0008.5200 - 10/2006
F31 K11A02 F30
Handler with telescopic boom
DANGER
DANGER
CAUTION
DANGER
DANGER
ELECTRICAL
DANGER
PROTECT THE
ENVIRONMENT
ATTENTION
CAUTION
IMPORTANT
DANGER
DANGER
ELECTRICAL
DANGER
PROTECT THE
ENVIRONMENT
ATTENTION
CAUTION
IMPORTANT
DANGER
DANGER
ELECTRICAL
DANGER
PROTECT THE
ENVIRONMENT
ATTENTION
CAUTION
IMPORTANT
MAINTENANCE
D-4.3 12V DC LAMPS
Use Voltage Mount type Power
• Front low/high beam ............................................................. 12 V ........................P45t ...................45/40 W
• Front position lights .............................................................. 12 V ......................BA 9s ..........................3 W
• Side/tail turn signals ............................................................. 12 V ....................BA 15s ........................21 W
• Stop lights and rear position lights ....................................... 12 V ................. BAY 15d .....................21/5 W
• Beacon - Work lights (OPTIONAL) ....................................... 12 V ...........................H3 ........................55 W
• Dashboard indicators and cab lighting ................................. 12 V ................W 2x4,6d ..................1,2 W
• Interior lamp ......................................................................... 12 V ................. SV 8,5-8 .....................5 W
• License plate lights ............................................................... 12 V ....................BA 15s .....................5 W
• Back-up lamps ...................................................................... 12 V ....................BA 15s .........................21W
When switched on, lamps get hot. Before touching
a lamp with your ngers, let it cool down.
GTH-3007
Never touch the bulb of halogen lamps (mount type
H3) with your ngers: this may damage the lamp
(use of a clean cloth or a paper tissue). If you touch
it accidentally, thoroughly clean with a paper tissue
and some ethyl alcohol.
Page D-26
Document 57.0008.5200 - 10/2006
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