Genie GTH-4013 Operator's Manual

Operator's manual

Part N. 57.0007.0200
Rev. 0 01/2006
From serial n. 14518
To serial n. 19104

English

Edition

GTH-4013

CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE

CAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES

TECHNICAL SERVICES

Genie Scandinavia

Phone [phone]

Fax [phone]

Genie France

Phone [phone]

Fax [phone]

Genie Iberica

Phone [phone]

Fax [phone]

Genie Germany

Phone [phone]

Fax [phone]

Genie U.K.

Phone [phone]

Fax [phone]

Genie Mexico City

Phone [phone]

Fax [phone]

Genie North America

Phone [phone]

Toll Free USA and Canada

800.536.1800

Fax [phone]

Genie Australia Pty Ltd.

Phone [phone]

Fax [phone]

Genie China

Phone [phone]

Fax [phone]

Genie Malaysia

Phone [phone]

Fax [phone]

Genie Japan

Phone [phone]

Fax [phone]

Genie Korea

Phone [phone]

Fax [phone]

Genie Brasil

Phone [phone]

Fax [phone]

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Phone [phone]

Fax [phone]

Operator's manual 57.0007.0200 - GTH-4013

No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means without
prior written permission from TEREXLIFT srl.
In pursuing a policy of constant quality improvement, TEREXLIFT srl reserves the right to make changes at any time and
without undertaking to give prior notice; therefore, also this publication may be subject to modifications.
Some photos or drawings have been used to illustrate a specific function; as a result, they may not refer to the machine
treated in this manual.

© Copyright 2006 TEREXLIFT srl - All rights reserved.

Produced by: TEREXLIFT Technical Literature Dept. - Studio VEGA - Forlì

REVISED PAGE LIST

Revision Revised Issued

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Handler with telescopic boom GTH-4013

INTRODUCTION

■ 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
identification of the machine, the technical features of
the machine, etc.

Section B is especially addressed to the personnel,
who shall operate, repair and service the machine, and,
in case of companies with a wide fleet of machines, to
those responsible for safety.
It describes the essential compulsory qualities of the
personnel in charge and other important information
for the safety of persons and things.

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.

IMPORTANT

Any difference between the contents of this manual
and the real functional character of the machine
can be attributed to either a machine manufactured
before the issue of this manual or to a manual going
to be updated after some changed effected on the
machine.
Always contact GENIE Assistance Service for any
updated version of this manual and any additional
information.

Section C is mainly addressed to the operators who
operate the machine. This section illustrates all control
devices.
Additionally, it contains the main use instructions -i.e.
engine starting, machine parking, machine storing.

Section D is addressed to those responsible for
maintenance and the servicemen.
The section describes the maintenance schedule and
the relevant intervals.

Section E deals with the failure diagnostics.
Section F makes a list of the main interchangeable

attachments that can be coupled to the machine:
dimensions, weight, application field and limits of use.

Section G contains tables and various enclosed
documents like load charts, wiring diagrams, hydraulic
schemes, torque wrench setting table, etc.

Document 57.0007.0200 - 01/2006

Page 1

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ATTENTION

INTRODUCTION

■ SYMBOLS

When using the machine, operators could have to face
some situations requiring special care and particular
knowledge.

When these situations involve the safety of operators
or bystanders, the machine efficiency and proper
utilisation, this handbook stresses these specific
instructions by means of SPECIAL SYMBOLS.

CAUTION

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.

Yellow without safety alert symbol: used to indicate
a potentially hazardous situation which, if not
avoided, may result in damage to the machine or
the systems.

PROTECT THE

ENVIRONMENT

Green: used to draw the attention to important
information on environment protection.

IMPORTANT

Green: used to indicate operation and maintenance
information.

WHEN READING THIS MANUAL, PAY THE
GREATEST ATTENTION TO THESE SPECIAL
SYMBOLS AND THE EXPLANATION OF THE

SITUATIONS THEY EMPHASIZE.

DANGER

Red: used to indicate an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.

DANGER

Orange: used to indicate a potentially hazardous
situation which, if not avoided, could result in death
or serious injury.

Document 57.0007.0200 - 01/2006

The manual in electronic format also contains the
following symbol:

which enables the user to return to the
table of contents

Page 2

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GENERAL INDEX

GENERAL INDEX

GENERAL INFORMATION Sect. A

SAFETY PRECAUTIONS Sect. B

OPERATING INSTRUCTIONS Sect. C

MAINTENANCE Sect. D

TROUBLESHOOTING Sect. E

OPTIONAL ATTACHMENTS Sect. F

TABLES AND DOCUMENTS ENCLOSED Sect. G

Page 3

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INTENTIONALLY BLANK PAGE

Page 4

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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-10

A-2 MACHINE IDENTIFICATION....................................................................................... A-12

A-2.1 Machine model and type ............................................................................................ A-12

A-2.2 Manufacturer .............................................................................................................. A-12

A-2.3 Machine identification plates...................................................................................... A-12

A-2.4 CE marking ................................................................................................................. A-13

A-2.5 Chassis serial number ................................................................................................ A-13

A-2.6 Identification plates of the main parts ........................................................................ A-13

A-3 ALLOWED USE .......................................................................................................... A-14

A-3.1 Allowed use ................................................................................................................ A-14

A-3.2 Improper use .............................................................................................................. A-14

A-3.3 Residual hazards ........................................................................................................ A-14

A-3.4 Applicable standards.................................................................................................. A-15

A-3.5 Safety devices ............................................................................................................ A-16

A-4 GENERAL DESCRIPTION .......................................................................................... A-20

A-4.1 List of the main components ...................................................................................... A-20

A-4.2 Description of the main components ......................................................................... A-21

A-4.3 Optional accessories .................................................................................................. A-21

A-5 TECHNICAL DATA AND PERFORMANCE ................................................................. A-22

A-5.1 Main dimensions ........................................................................................................ A-22

A-5.2 Limits of use ............................................................................................................... A-22

A-5.3 Weight ........................................................................................................................ A-22

A-5.4 Speed ......................................................................................................................... A-22

A-5.5 Payload and reach...................................................................................................... A-23

A-5.6 Forks (floating type) .................................................................................................... A-23

A-5.7 Diesel engine .............................................................................................................. A-23

A-5.8 Electrical system ........................................................................................................ A-23

A-5.9 Machine sound levels ................................................................................................. A-23

A-5.10 Vibration levels ........................................................................................................... A-23

A-6 LIFETIME .................................................................................................................... A-24

A-7 ITEMS SUPPLIED....................................................................................................... A-24

A-7.1 Literature supplied...................................................................................................... A-24

Page A-1

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GENERAL INFORMATION

A-1

■ A-1.1 MACHINE POSITION

Conventionally the machine should be considered
positioned as shown in the figure.
This convention is necessary to make any reference of
this handbook to different machine parts (front, rear,
etc.) clear and unmistakable.
Any exception to this rule will always be specified.

CONVENTIONAL REFERENCES

UPPER PART

RIGHT SIDE

FRONT

PART

REAR PART

LEFT SIDE

LOWER PART

Page A-2

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GENERAL INFORMATION

■ A-1.2 LABELS AND WARNING PLATES
APPLIED ON THE MACHINE

IMPORTANT

This paragraph lists the labels and warning plates
normally applied on standard machines or on special
attachments coupled to the machine.

09.4618.0171

09.4616.0040

The familiarisation with these labels is never a
waste of time.
Make sure they are easy to read. For this purpose,
clean them or replace those that become
unreadable (either graphic or text).
To clean labels, use of a soft cloth, water and soap.
Never use solvents, petrol, etc.
When a label is applied on a part to be replaced,
make sure that the replaced part is already labelled
as required or apply a new label.

09.4618.0661

09.4618.0026

09.4618.0230

09.4618.0030

09.4618.0022

09.4618.0361

09.4618.0241

09.4616.0109

09.4618.0230

09.4618.0227

09.4618.0547

09.4618.0061

09.4618.0242

09.4618.0212

09.4618.0547

09.4618.0061

Page A-3

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GENERAL INFORMATION

09.4618.0361

09.4618.0230

09.4618.0663

09.4618.0516

09.4618.0661

09.4616.0068

09.4618.0361

09.4618.0230

09.4618.0212

09.4618.0010

09.4618.0547

09.4618.0061

09.4618.0230

09.4618.0243

09.4618.0662

09.4618.0547

09.4618.0061

Page A-4

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GENERAL INFORMATION

Decal Code Description

KEEP OUT OF

WORKING RANGE

XX

09.4618.0022 Keep out of the working range of the machine.

When the machine is running, entering the working
range of the machine is prohibited.

09.4618.0212 Keep out of the working range of the machine.

When the machine is running, entering the working
range of the machine is prohibited.

Guaranteed sound power level. It indicates the
guaranteed sound power level measured in
accordance with the Directive 2000/14/EC.

09.4618.0516 Quick guide.

09.4618.0663 An overview of the operator's handbook concerning:

- control lever,

- machine starting,

3

4

- overload warning system

- main safety precautions.

The guide also includes the fork load charts with or
without use of the outriggers.

• Load chart for operations without outriggers (or
with outriggers up). It defines the exact working
limits of the machine (in terms of payload and
reach) to be strictly respected by the operator

when using the machine without outriggers (or with
retracted outriggers).

• Load chart for operations with outriggers down.
It defines the exact working limits of the machine
(in terms of payload and reach) to be strictly
respected by the operator when using the machine
with lowered outriggers.

Page A-5

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GENERAL INFORMATION

Decal Code Description

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

VERBODEN KOFFERBAK TE OPENEN WANNEER DE MOTOR DRAAIT.

PROIBIDO ABRIR COM O MOTOR LIGADO

CHANGE MECHANICAL
GEAR ONLY WHEN THE
MACHINE IS STATIONARY

DANGER

ELECTRIC CABLES AND
POWER LINES

KEEP EVERY PART OF THE MACHINE, LOADS AND
ACCESSORIES AT LEAST 6 METERS FROM
OVERHEAD POWER LINES

P max

kg/cm

2

09.4618.0010 Do not open while engine is running.

Do not open the engine bonnet when engine is
running, since this may result in serious injury due to
moving parts or hot components.

09.4618.0030 Do not change mechanical gear when the machine

is running.

09.4618.0026 Use limits close to electric power lines. It defines

the minimum distance to be kept when the machine
works close to aerial power lines.

09.4618.0361 Maximum pressure on the ground. The value

indicates the maximum pressure on the ground of the
outriggers to prevent the machine from sinking into
the ground and avoid instability.

XXX

09.4618.0227 Fork pitching. Warning for road circulation which

indicates the need to pitch back and block the forks.

Page A-6

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GENERAL INFORMATION

Decal Code Description

09.4618.0230 Warning stickers. Applied near coupling points,

silencer, fan belt, hydraulic oil level, tank, etc.

Anchorage points. Applied near the holes envisaged for
machine lifting.

Fuel cap. Applied near the engine oil cap.

Hydraulic oil. Applied near the hydraulic oil plug or level

indicator.

Engine oil level. Applied near the engine oil dipstick.

Moving gears. Applied near the fan of the heat exchanger.

Unscrew the plug with extreme caution: hot water.
Risk of burns! Warns the operator of the risk of burns

when unscrewing the plug of the compensation tank of the
heat exchanger.

P

P

=

=

5,5

4,5

Hot surfaces. Risk of burns. Applied on those surfaces
which during operation can become hot and cause burns.

Risk of crushing injury to the hands. Use extreme
caution when moving the outriggers.

Presence of moving parts. Use extreme caution when
moving the outriggers.

09.4618.0547 Tyre inflation sticker.

(standard) Placed near the wheels, this label shows the

recommended tyre inflation pressure.

bar

09.4618.0061
(optional)

bar

GTH-4013

09.4618.0241 "GENIE" sticker.

09.4618.0242

09.4618.0243

09.4618.0661 "GENIE GTH-4013" sticker.

Page A-7

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GENERAL INFORMATION

Decal Code Description

Kg 4000

TEREXLIFT srl - ZONA INDUSTRIALE - 06019 UMBERTIDE (PG) - ITALY
Tel. [phone] Fax [phone] Telex 66106 ITALMA 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

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

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

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

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

OMOLOGAZIONE

FABBRICATO IN ITALIA - MADE IN ITALY

TEREXL IFT

Tel. [phone] Fax [phone]

__._____._____

.............

s.r.l.

______

____

____

ZONA INDUSTRIALE - 06019 UMBERTIDE (PG) - ITALY

ASSIEME FORCHE-FORKS ASSY
GROUPE FOURCHES-GABELGROUPPE
JUNTO HORQUILLAS

MODELLO - TYPE - DÉSIGNATION
MODELL - MODELO

N° SERIE - SERIAL N°-N° DE SERIE

- SERIEN N°- N° DE BASTIDOR

ANNO DI COSTRUZIONE ­YEAR OF CONSTRUCTION ­ANNÉE DE CONSTRUCTION ­BAUJHAR - AÑO DE CONSTRUCCIÓN

MASSA - MASS - MASSE ­MASSE - MASA

CENTRO DI GRAVITÀ - CENTER OF
GRAVITY - CENTRE DE GRAVITÉ ­SCHWERPUNKT - CENTRO DE GRAVEDAD

PORTATA NOMINALE - PAY LOAD ­PORTEE NOMINALL - NENN
TRAGFÄHIGKEIT - CARGA NOMINAL

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

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

___

___

09.4616.0040 Max capacity. Indicates the maximum capacity of

the machine.

09.4616.0068 Machine data plate. The identification plate contains

the main identification data of the machine.

200

kgkg
kg
kg

09.4616.0109 Fork data plate. This plate shows the main data of

the fork installed on the machine.

ATTENTION

TO PREVENT DAMAGE OF INTERNAL

BOOM HOSES BOOM SECTIONS NEED

TO BE EXTENDED EQUALLY OTHERWISE

RE-SEQUENCING WILL BE REQUIRED.

SEE OPERATORS MANUAL FOR MORE

DETAILS.

09.4618.0171

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

09.4618.0171 Re-sequencing the telescopic boom extension. If,

during normal operation, a change in the boom
extended lengths is noticed, proceed with re­sequencing as indicated in the operator’s manual.

Page A-8

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GENERAL INFORMATION

Decal Code Description

ATTENZIONE!

CAUTION!

IN ATTESA DA

RECIPIENTE IN PRESSIONE

HIGH PRESSURE ACCUMULATOR

TEREX

09.4618.0514 Caution: accumulator under pressure.

09.4618.0673 Emergency controls. Reminds the operator the

correct procedure for the manual operation of the
main valve in an emergency. It also shows the controls
and the relevant controlled movements of all the
levers of the main valve.

Page A-9

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GENERAL INFORMATION

■ A-1.3 EXPLANATION OF THE DIFFERENT
SYMBOLS USED ON THE MACHINE

IMPORTANT

This paragraph illustrates those symbols that are
normally applied on the main control devices and
instruments of a standard machine, and those that can
be applied on accessories or special attachments.
They are mainly (ISO) standardised symbols that are
now part of the common life. But we consider useful to
explain them once again.

Symbol Description

Hazard warning lights

Windscreen washer

Cab ventilation fan

Diesel engine water temperature

Fuel level

Hydraulic oil temperature

Spend the necessary time to become familiar with
these symbols and to learn their meaning.

Symbol Description

Battery charge

Attachment pushbutton (if any)

Steering mode switch

Brake pressure

Engine oil pressure

Boom up

Position lights

High beam

Low beam

Fog lamp

Turn signals

Parking brake

Boom down

Boom out

Boom in

Attachment locked

Attachment unlocked

Fork pitching forward

Fork pitching back

Right outrigger down

Page A-10

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GENERAL INFORMATION

Symbol Description Symbol Description

Right outrigger up

Left outrigger down

Left outrigger up

Sway right

Sway left

Machine sway control

Cab controls

Platform controls

Lifting point

Emergency pump

Road setting

Oil filter clogged

Air filter clogged

Speed selector switch

1st speed engaged

2nd speed engaged

Page A-11

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GENERAL INFORMATION

A-2 MACHINE IDENTIFICATION

IMPORTANT

Check that the operator handbook refers to the
delivered machine.
When asking for information or technical
assistance, always specify model, type and serial
number of the machine.



■ A-2.1 MACHINE MODEL AND TYPE

Handler with telescopic boom:

❑ model GTH-4013

■ 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

■ A-2.3 MACHINE IDENTIFICATION PLATES

The following data plates are applied on the machine.

 Machine data plate

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

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

TEREXLIFT srl - ZONA INDUSTRIALE - 06019 UMBERTIDE (PG) - ITALY
Tel. [phone] Fax [phone] Telex 66106 ITALMA 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

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

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

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

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

OMOLOGAZIONE

FABBRICATO IN ITALIA - MADE IN ITALY



200

kgkg
kg
kg

Page A-12

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

Handler with telescopic boom GTH-4013

GENERAL INFORMATION

 Road traffic data plate

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

 ROPS-FOPS cab type-approval plate

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

 Fork data plate

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

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

■ A-2.4 CE MARKING

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

■ A-2.5 CHASSIS SERIAL NUMBER

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

■ A-2.6 IDENTIFICATION PLATES OF THE MAIN
PARTS

The plates of the main components, not directly
manufactured by TEREXLIFT srl (for instance, engines,
pumps, etc.), are located where originally applied by
the manufacturers.





TEREXLI FT

ZONA INDUSTRIALE - 06019 UMBERTIDE (PG) - ITALY

Tel. [phone] Fax [phone]

ASSIEME FORCHE-FORKS ASSY
GROUPE FOURCHES-GABELGROUPPE
JUNTO HORQUILLAS

MODELLO - TYPE - DÉSIGNATION
MODELL - MODELO

N° SERIE - SER IAL N°-N° DE SERIE

- SERIEN N°- N° DE BASTIDOR

ANNO DI COSTRUZIONE ­YEAR OF CONSTRUCTION ­ANNÉE DE CONSTRUCTION ­BAUJHAR - AÑO DE CONSTRUCCIÓN

MASSA - MASS - MASSE ­MASSE - MASA

CENTRO DI GRAVITÀ - CENTER OF
GRAVITY - CENTRE DE GRAVITÉ ­SCHWERPUNKT - CENTRO DE GRAVEDAD

PORTATA NOMINALE - PAY LOAD ­PORTEE NOMIN ALL - NENN
TRAGFÄHIGKEIT - CARGA NOMINAL

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

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

s.r.l.

__._____._____

.............

______

____

___

____

___



DATI OMOLOGAZIONE STRADALE

TIPO

OMOLOGAZIONE

NUMERO DI IDENTIFICAZIONE

MASSA TOTALE AMMISSIBILE (*)

CARICO MAX ASSE ANTERIORE (*)

CARICO MAX ASSE POSTERIORE (*)
(*) In funzione della gommatura

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



da kg a kg
da kg a kg
da kg a kg

Zona Industriale, I-06019 Umbertide (PG) - Italy
Tel. [phone] - Fax [phone]



kg
kg
kg
kg

-1

m

Page A-13

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GENERAL INFORMATION

A-3 ALLOWED USE

■ A-3.1 ALLOWED USE

The handlers have been designed and manufactured
for lifting, handling and transporting agricultural or
industrial products by means of specific attachments
(see section F) manufactured by TEREXLIFT srl.

Any other use is considered contrary to that established
and, therefore, improper.

The compliance with and the strict respect of the
operation, maintenance and repair conditions, indicated
by the Manufacturer, represent an essential part of the
allowed use.

The handler must be used and serviced only by
operators knowing its characteristics and the safety
procedures in depth.

It is also essential to comply with the safety at work
legislation, the precautions concerning safety and
industrial medicine as well as the local and national
road traffic regulations.

IMPORTANT

Effecting changes or carrying out interventions on
the machine other than those of routine
maintenance is expressly forbidden. Any
modification of the machine not carried out by
GENIE or an authorised assistance centre involves
the automatic invalidation of the conformity of the
machine to the Directive 98/37/EC.

■ A-3.2 IMPROPER USE

Improper use means a utilisation of the handler
following working criteria that do not comply with the
instructions of this manual, and that, in general, may
result in risks for both operators and bystanders.

DANGER

We list below some of the most frequent and
hazardous situations of improper use:

- Carrying passengers on the machine

- Not strictly complying with the operation and

maintenance instructions of this handbook

- Working beyond the handler working limits

- Working on unstable edges of ditches

- Driving crosswise on slopes or hills

- Working during a storm

- Working on steep slopes

- Using attachments other than those

recommended

- Using attachments not approved or directly

manufactured by Terexlift

- Applying loads in different points of the

attachment holding plate

- Working in potentially explosive areas

- Working in confined and non-ventilated

environments.

■ A-3.3 RESIDUAL HAZARDS

Although the machine has been designed and
manufactured according to the latest technology and
all expected hazards have been eliminated, some
operations performed by the machine operator can
result in potentially hazardous situations. Among them:

• Hazards deriving from a too high work or transfer

speed in relation to the load handled or the ground
condition of the jobsite.

• Hazards deriving from work procedures adopted

during the check or replacement of a block valve
(residual pressure - uncontrolled movements).

• Hazards deriving from work procedures adopted

while disassembling parts of the machine -e.g. the
cylinders, without supporting mobile parts suitably
(risk of uncontrolled fall of the mobile part).

• Hazard deriving from an accidental overturning of

the machine in the event the operator has not
fastened the safety belts.

Page A-14

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GENERAL INFORMATION

■ A-3.4 APPLICABLE STANDARDS

For the operator’s safety, the following standards were
obeyed during the risk assessment of the handler fitted
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

Electrical requirements - General
requirements of internal combustion
engine powered trucks

prEN ISO 13564:1996

Test method for measuring visibility from
self-propelled trucks.

EN 50081-1: 1997 Electromagnetic compatibility – Generic

requirements on emissions - Part 1

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 Powered industrial trucks - Terminology.
ISO 6292:1996

Powered industrial trucks and

tractors - Brake performance and

component strength

.

EN 13059:2002 Safety of industrial trucks - Test methods

for measuring vibration

Page A-15

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GENERAL INFORMATION

■ A-3.5 SAFETY DEVICES

• Load limiting device. It consists of a load cell fitted

to the rear axle and a display installed in the driving
place. This device enables the operator to check
the stability variation through a bar with 8 LED's (4
green, 2 yellow and 2 red).

• Limit switch on the outriggers
When the outriggers are lowered to the ground:

- the overload warning system changes the meter
scale

- the man-platform can be used

- the transmission is deactivated

• Emergency stop pushbutton: on the dashboard,

to the right of the steering wheel. Pressing down
this button stops the engine of the machine

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

Page A-16

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GENERAL INFORMATION

• Safety pushbutton on joystick (dead man button).
This button must be pressed and held down while
executing a function with the control lever. If the
button is released, the movement in progress will
be blocked.



• Block valves fitted to all cylinders

A Block valve on attachment coupling cylinder
B Block valve on lifting cylinder
C Block valve on balance cylinder
D Block valve on boom extension cylinder





Page A-17

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

Handler with telescopic boom GTH-4013

GENERAL INFORMATION

E Block valve on attachment pitching cylinder
F Block valve on the outrigger cylinder
G Block valve on the rear axle block cylinder
H Block valve on machine sway cylinders









Page A-18

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GENERAL INFORMATION

• Limit switches and safety switches:
L Limit switch fitted to the left side of the boom

that, through a jack fixed to the chassis, blocks
the rear axle when the boom inclination is above
40°.

M Limit switch fitted to the right side of the boom

that blocks the outriggers and the sway function
(axle oscillation) when the boom is raised more
than 2 metres above the ground.

N Switch on the parking brake which prevents

forward/reverse gear shifting, as well as any
other movements of the machine if the brake is
engaged.







Page A-19

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GENERAL INFORMATION

A-4 GENERAL DESCRIPTION

■ A-4.1 LIST OF THE MAIN COMPONENTS

1 2 3

7

510

6

8 9

1 -3rd boom section
2 -2nd boom section
3 -1st boom section
5 - Rear view mirror, left side
6 - Chassis
7 - Forks
8 - Attachment holding frame

9 - Left sway cylinder
10 - Driving cab according to ROPS-FOPS provisions
11 - Front axle
12 - Fuel tank
13 - Access step
14 - Hydraulic oil tank
15 - Rear axle

11 12 13 14 15

Page A-20

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GENERAL INFORMATION

■ A-4.2 DESCRIPTION OF THE MAIN

COMPONENTS

Chassis

Made of high tensile steel to improve robustness and
durability, it is equipped, at the front, with two
independent outriggers. A hydraulic cylinder between
chassis and rear axle allows compensating side slopes
up to ± 6°.

Hydrostatic transmission unit

Closed circuit hydrostatic transmission with continuous
speed adjustment, mainly consisting of:

- a variable displacement pump connected to the

thermal engine by an elastic joint

- a variable displacement motor connected to the

power divider-gearbox.

- a hydraulic oil filter, placed on the injection line from

the tank

- a water/oil heat exchanger to cool the circuit down.
This transmission with permanent 4 wheel drive
improves the traction force, thus resulting in an
increased climbing ability on slopes up to 60% at a
max speed of 35 km/h.

Power divider/Two-speed gearbox

The power divider/mechanical gearbox has two speeds
that can be selected by pressing the relevant button in
the driving cab, a work speed and a travel speed.
Speeds can only be selected when the machine stands
still. From the gearbox, through two Cardan shafts,
motion is transmitted to the front and rear axles fitted
with differentials.

Axles

Equipped with an automatic differential lock acting on
the rear axle which lets the machine move also on low
grip grounds. The front axle is the steer type; the rear
axle is the steer/oscillating type. When the high speed
is engaged, only the front wheels are allowed to steer.

Brake circuit

The brake system is the multidisc type in oil bath, with
self-adjustment, built in the front and rear axle and
acting on every wheel. The pedal directly acts on the
brake pump which delivers oil to the blocking cylinders
through a line with a pressure accumulator.

Steering

Servo-assisted steering system with extremely reduced
turning radius and three steering modes (T-WAY).

Tyres

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

.

Overload warning system

The machine is equipped with a system controlling the
longitudinal stability which enables the operator to work
under absolute safety conditions. A bar with green,
yellow and red LED's indicates the percentage of
applied load with respect to the maximum payload of
the machine. When the second red LED comes on,
the machine movements are blocked, except for boom
retraction, and an audible alarm starts sounding to alert
to the risk.

Telescopic boom

In order to improve visibility, the boom is placed under
the visual angle of the operator. Made of high tensile
steel, it consists of two telescopic sections sliding on
long-life pads, easily accessible for maintenance. The
attachment holding plate with a 138° inclination is
equipped with a hydraulic coupling system that can
be operated from the driving place.

Boom hydraulic circuit

It consists of a gear pump connected to the thermal
engine which, through a valve, distributes oil to the
hydraulic drive and an electro-proportional main valve
for the following functions:

- telescopic boom movements

- attachment rotation

- machine swaying

- attachment locking

- outrigger operation.

Driving cab

Large and comfortable cab mounted on vibration-proof
supports to improve the driver's comfort. Adjustable
seat with air-suspension and built-in armrest. User­friendly dashboard. Multipurpose joystick with electro­proportional control and ergonomic handle. The cab
comes complete with connections for the A/C system
and the CD player-radio set. Cab complies with
standards ISO 3449 and EN 13510 (ROPS and FOPS).

■ A-4.3 OPTIONAL ACCESSORIES

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

Page A-21

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GENERAL INFORMATION

A-5 TECHNICAL DATA AND PERFORMANCE

I

D

A

B

F

G

H

E
C

J

■ A-5.1 MAIN DIMENSIONS

GTH-4013

A Overall height ............................................................................................................ mm 2425

B Height to the steering wheel ..................................................................................... mm 1600

C Overall width .............................................................................................................mm 2330

D Cab width.................................................................................................................. mm 910

E Track ......................................................................................................................... mm 1920

F Wheel-base ...............................................................................................................mm 2950

G Length to the front tyres ........................................................................................... mm 4830

H Length to the attachment holding plate.................................................................... mm 6100

I Ground clearance ..................................................................................................... mm 430

J Max width with extended outriggers ........................................................................ mm 2890

• Internal steering radius ............................................................................................. mm 1140

• External steering radius ............................................................................................ mm 3790

■ A-5.2 LIMITS OF USE

• Angle of approach........................................................................................................... 38°

• Departure angle .............................................................................................................. 46°

• Min/max ambient temperature.................................................................................... °C -20°/+40°

■ A-5.3 WEIGHT

• Weight in working order .............................................................................................. kg 9820

■ A-5.4 SPEED

- Working speed (*) .................................................................................................... km/h 8

- Travel speed (*) ........................................................................................................ km/h 35

- Max. slope with full load ............................................................................................. % 60

(*) = either forward or reverse motion.

Page A-22

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GENERAL INFORMATION

■ A-5.5 PAYLOAD AND REACH GTH-4013

- Max lifting height:

with outriggers .......................................................................................................... mm 13000

without outriggers .....................................................................................................mm 12810

- Reach at max height without outriggers ................................................................... mm 650

- Max reach forward with outriggers ........................................................................... mm 9020

- Attachment holding plate rotation .................................................................................. 138°

- Maximum payload with outriggers ............................................................................. kg 4000

- Payload at max height with outriggers ....................................................................... kg 3000

- Payload at max reach with outriggers ........................................................................ kg 1250

■ A-5.6 FORKS (FLOATING TYPE)

- Dimensions ............................................................................................................... mm 1200x120x50

- Weight ..................................................................................................................... kg 70

- Fork holding frame - class .............................................................................................. FEM III

■ A-5.7 DIESEL ENGINE Turbo version

- Make ........................................................................................................ CUMMINS

- Model/Type ..................................................................................................................... 4B 4,5T

- Features: ......................................................................................................................... Diesel

4 cylinders in line

4 strokes

direct injection

- Bore x Stroke ............................................................................................................ mm 102 x 120

- Total displacement ...................................................................................................... cc 4500

- Power at 2200 rpm .................................................................................................... kW 74

■ A-5.8 ELECTRICAL SYSTEM

- Voltage ....................................................................................................................... V12

- Battery .....................................................................................................................Ah 120

■ A-5.9 MACHINE SOUND LEVELS

- Guaranteed sound power level

(in accordance with the Directive 2000/14/CE)................................................................. dB Lwa = .....

- Measured sound pressure level

(in accordance with the Directive 98/37/CE) .................................................................... dB Lpa = .....

■ A-5.10 VIBRATION LEVELS

- Mean assessed vibration level transmitted to arms ................................................ m/s

- Mean assessed vibration level transmitted to body ................................................ m/s

Values calculated in accordance with standard prEN13059

2

2

< 2.5
< 0.5

IMPORTANT

This is a Class A device. In a residential environment, such device can cause radio disturbance. In such
cases, the operator is required to take suitable measures.

Page A-23

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GENERAL INFORMATION

A-6 LIFETIME

The lifetime of the machine is 10000 hours provided
all checks, service jobs and overhauls are done at the
times scheduled.
This lifetime should be halved if the handler is used
with an aerial man-platform.

DANGER

After this time, the machine must compulsorily be
inspected and tested by the Manufacturer before
being used again.

IMPORTANT

Five years or 6000 hours after the first placing into
operation of the machine (whichever occurs first),
check the state of the structure paying an extreme
attention to the welded supporting joints and the
pins of both boom and platform (see chap. D-3.18).

A-7 ITEMS SUPPLIED

Following items are supplied together with the
machine:

Description GTH-4013

- Spanner CH 19 ✘
(for fork positioning)

- Allen wrench CH 6 ✘
(for fork positioning)

- 12 V lamps ✘
(spare)

■ A-7.1 LITERATURE SUPPLIED

The machines comes with the following literature:

- Machine operator's handbook

- Engine use and maintenance manual

- Spare parts catalogue

- Warranty and handing over certificate

Page A-24

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SAFETY PRECAUTIONS

Section B

SAFETY PRECAUTIONS

TABLE OF CONTENTS

B-1 GENERAL REMARKS ................................................................................................. B-2

B-2 PREREQUISITES OF THE PERSONNEL IN CHARGE ............................................... B-3

B-2.1 Requisites of the machine operators ......................................................................... B-3

B-2.2 Requisites of the servicemen ..................................................................................... B-3

B-2.3 Working clothes .......................................................................................................... B-4

B-2.4 Personal protective equipment .................................................................................. B-4

B-3 SAFETY PRECAUTIONS ............................................................................................ B-4

B-3.1 Hazards on the jobsite ............................................................................................... B-4

B-3.2 Operation or maintenance hazards ............................................................................ B-5

B-3.3 Machine operation hazards ........................................................................................ B-7

B-3.4 Damaged component hazards ................................................................................... B-7

B-3.5 Explosion or fire hazards ............................................................................................ B-7

B-3.6 Damaged machine hazards ........................................................................................ B-8

B-3.7 Personal injury hazards .............................................................................................. B-8

B-4 SAFETY DEVICES ...................................................................................................... B-8

B-5 MOMENT LIMITING SYSTEM .................................................................................... B-8

Page B-1

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SAFETY PRECAUTIONS

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.

IMPORTANT

If you recognise hazardous situations, you can
prevent accidents!

For instance, this handbook makes use of special
safety symbols to stress any potentially hazardous
situation.

DANGER

The instructions given in this handbook are the
ones established by GENIE. They do not exclude
other safe and most convenient ways for the
machine installation, operation and maintenance
that take into account the available spaces and
means.

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

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

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

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

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

If in doubt, it is always better to ask! For this
purpose, contact GENIE: the assistance service is
at your disposal. Addresses, phone and fax numbers
are given in the cover and in the title-page of this
manual.

Page B-2

Document 57.0007.0200 - 01/2006

IMPORTANT

Handler with telescopic boom GTH-4013

SAFETY PRECAUTIONS

B-2 REQUISITES OF THE

PERSONNEL IN CHARGE

■ B-2.1 REQUISITES OF THE MACHINE
OPERATORS

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

health:

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

physical:

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

mental:

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

emotional:

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

training:

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

■ B-2.2 REQUISITES OF THE SERVICEMEN
The personnel charged with the machine maintenance
shall be qualified, specialised in the maintenance of
earth-moving machines, and shall have the following
prerequisites:

physical:

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

mental:

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

training:

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

IMPORTANT

From a technical point of view, the ordinary
maintenance of the machine is not a complex
intervention and can be carried out by the machine
operator, too, provided he has a basic knowledge
of mechanics.

IMPORTANT

The operator shall have a licence (or a driving
licence) when provided for by the laws enforced in
the country where the machine works. Please, ask
the competent bodies. In Italy the operator must
be at least 18 year old.

Page B-3

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DANGER

DEATH OR INJURY CAN RESULT FROM
CONTACTING ELECTRIC POWER LINES.

ALWAYS CONTACT THE ELECTRIC POWER LINES
OWNER. THE ELECTRIC POWER SHALL BE
DISCONNECTED OR THE POWER LINES MOVED
OR INSULATED BEFORE MACHINE OPERATIONS
BEGIN

POWER LINE VOLTAGE REQUIRED CLEARANCE

0to 50kV 10ft 3.00m

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

SAFETY PRECAUTIONS

■ B-2.3 WORKING CLOTHES
During work, but especially when maintaining or
repairing the machine, operators must wear suitable
protective clothing:

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

• Protective helmet.

• Protective gloves.

• Working shoes.

B-3 SAFETY PRECAUTIONS

■ B-3.1 HAZARDS ON THE JOBSITE
Always take into account the features of the job site
where you are going to work:

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

DANGER

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

IMPORTANT

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.

IMPORTANT

Use only type-approved protective equipment in
good condition.

Document 57.0007.0200 - 01/2006

Page B-4

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

DANGER

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

Handler with telescopic boom GTH-4013

SAFETY PRECAUTIONS

DANGER

Make sure the machine (wheels and stabilisers)
rests on a firm ground to prevent hazardous
unstable conditions.
If the ground is not firm enough, position some
supporting planks under the stabilisers or the
wheels. These plates must grant a specific pressure
of 1.2 to 1.5 kg/cm2 (500x500mm plates are
sufficient).

• Look for the best route to the job site.

• When the machine is running, nobody can enter
its working range.

• While working, keep the working area in order.
Never leave objects scattered: they could hinder
the machine movements and represent a danger
for personnel.

• In presence of trenches, lower the outriggers at a
safe distance from the trench edge.

A

■ B-3.2 OPERATION OR MAINTENANCE
HAZARDS

Before any operation, following precautions should be
taken:

• First of all, make sure that the maintenance

interventions have been carried out with care
according to the established schedule (see section

D - Maintenance).

DANGER

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

• 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!

A ≥ B

B

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.

Page B-5

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SAFETY PRECAUTIONS

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

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

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

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

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

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

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

• Do not lubricate, clean or adjust moving parts.

• Do not carry out operations manually when specific
tools are provided for this purpose.

• Avoid the use of tools in bad condition or use in an
improper way i.e. pliers instead of adjustable
wrenches, etc.

• Applying loads in different points of the attachment
holding plate is forbidden.

• Before carrying out operations on hydraulic lines
under pressure or disconnecting hydraulic
components, ensure the relevant line has been
previously depressurised and does not contain any
hot fluid.

DANGER

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

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

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

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

• Do not connect wet plugs or sockets.

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

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

Page B-6

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SAFETY PRECAUTIONS

• Do not empty catalytic mufflers or other vessels
containing burning materials without taking the
necessary precautions.

• After any maintenance or repair work, make sure
that no tool, cloth or other object has been left
within machine compartments, fitted with moving
parts, or where suction and cooling air circulates.

• When working, do not give instructions or signs to
several people at the same time. Instructions and
signs must be given by one person only.

• Always pay due attention to the instructions given
by the foreman.

• Never distract the operator during working phases
or crucial manoeuvres.

• Do not call an operator suddenly, if unnecessary.

• Do not frighten an operator or throw objects by
any means.

• After work, never leave the machine under
potentially dangerous conditions.

■ B-3.3 MACHINE OPERATION HAZARDS

Absolutely avoid the following work situations:

• Do not handle loads beyond the maximum
capacity of the machine

• Do not raise or extend the boom if the machine is
not on a firm, level surface.

• Do not operate the machine in strong wind. Do
not increase the surface area of the machine or
forked load exposed to the wind. Increasing the
area exposed to the wind will decrease machine
stability.

• Use extreme caution and slow speeds when the
machine is driven across uneven or unstable
grounds, slippery surfaces or near trenches or
drop-offs.

• Limit travel speed according to ground conditions,
slopes, presence of personnel or other factors
which may cause collision.

• Do not place or attach overhanging loads to any
part of the machine.

■ B-3.4 DAMAGED COMPONENT HAZARDS

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

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

■ B-3.5 EXPLOSION OR FIRE HAZARDS

• Do not start the engine if you smell or detect LPG,
gasoline, diesel fule or other explosive substances.

• Do not refuel the machine with the engine running.

• Refuel the machine and charge the battery only in
a well ventilated area away from sparks, naked
flames and lighted cigarettes.

• Do not operate the machine in dangerous
environments or in places with flammable or
explosive gases or materials.

• Do not inject ether in engines equipped with glow
plugs.

• Do not leave fuel cans or bottles in unsuitable
places.

• Neither smoke nor use open flames in areas subject
to fire dangers and in presence of fuel, oil or
batteries.

• Carefully handle all flammable or dangerous
substances.

• Do not tamper with fire-extinguishers or pressure
accumulators: explosion hazard!

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SAFETY PRECAUTIONS

■ B-3.6 DAMAGED MACHINE HAZARDS

• Do not use a damaged or defective machine.

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

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

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

• Make sure that the operator’s, safety and
responsibilities manuals are intact, legible and
placed in the special container located in the

machine.

■ B-3.7 PERSONAL INJURY HAZARDS

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

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

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

■ B-4 SAFETY DEVICES

DANGER

Several safety devices have been fitted to the
machine. They must never be tampered with or
removed (see chap. A-3.5).

Regularly check the efficiency of such devices (see

check card, chap. G-5).

In case of faults, stop working immediately and
proceed in replacing the defective device.

For the checking procedures, read chap. D-3.17.

■ B-5 MOMENT LIMITING SYSTEM

The moment limiting system has been developed to
help the operator to maintain the machine longitudinal
stability. Audible and visual messages are provided
when the limits of longitudinal stability are being
approached.
However this device cannot replace the experience of
the operator. It is up to the user to adopt the necessary
safety measures to work within the rated limits of the
machine.

Page B-8

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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-4

C-2.2 Adjusting the seat .................................. C-5

C-2.3 Fastening the seat belts ......................... C-5

C-2.4 Adjusting the steering column ................ C-6

C-2.5 Adjusting the rear view mirrors .............. C-6

C-2.6 Switching on the cab interior lamp ........ C-6

C-3 DRIVING PLACE..................................... C-7

C-3.1 Controls and instruments ....................... C-7

C-3.2 Engine controls and instruments ........... C-9

C-3.2.1 Ignition switch ........................................ C-9

C-3.2.2 Forward/reverse gear switch .................. C-9

C-3.2.3 Turn signals - windscreen wiper -

lights - horn switch ............................... C-10

C-3.2.4 Brakes .................................................. C-11

C-3.2.5 Accelerator control ............................... C-11

C-3.2.6 Gearbox controls .................................. C-12

C-3.2.7 Steering mode selection ...................... C-12

C-3.2.8 Cab/road/platform changeover switch .. C-12

C-3.2.9 Auxiliary drive controls ......................... C-13

C-3.3 Instruments and warning lights ............ C-14

C-3.3.1 Instruments .......................................... C-14

C-3.3.2 Warning lights ...................................... 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-3.4.3 Disabling the overload warning system . C-18

C-3.4.4 Lifting/lowering the boom .................... C-19

C-3.4.5 Extending/retracting the boom ............ C-20

C-3.4.6 Pitching the attachment holding frame

forward/back ........................................ C-21

C-3.4.7 Quick-coupling the attachments ..........C-22

C-3.5 Machine sway control .......................... C-23

C-3.6 Outrigger control .................................. C-24

C-3.7 Manual controls .................................... C-25

C-4 SETUP .................................................. C-26

C-4.1 Before starting the engine .................... C-26

C-4.1.1 Checks at the machine start-up ...........C-26

C-4.2 Starting the engine ............................... C-26

C-4.3 Jump-starting the engine ..................... C-27

C-4.4 Low temperature starting ..................... C-28

C-4.5 Starting the machine ............................ C-29

C-4.6 Use of the man-platform ...................... C-29

C-4.7 Stopping and parking the machine ...... C-30

C-5 USING THE HANDLER......................... C-30

C-5.1 Using the load charts ........................... C-31

C-5.2 Load limiter ........................................... C-32

C-5.2.1 Description of the controls ................... C-32

C-5.2.2 Operation ............................................. C-32

C-5.2.2 Alarm codes and resetting ................... C-33

C-5.3 Handling loads ..................................... C-34

C-5.3.1 Adjusting the forks ............................... C-34

C-5.3.2 Working phases ................................... C-35

C-5.4 Changing the optional attachment ....... C-36

C-6 TRANSPORTING THE MACHINE ........ C-38

C-6.1 Moving a disabled machine ................. C-38

C-6.1.1 Setting the gear lever in neutral ........... C-38

C-6.1.2 Dismantling the Cardan shaft ............... C-39

C-6.2 Road or site transfer ............................. C-40

C-6.3 Lifting the machine ...............................C-41

C-6.4 Transporting the machine on other

vehicles ................................................ C-41

C-6.5 Parking and storage ............................. C-42

C-6.5.1 Short inactivity ...................................... C-42

C-6.5.2 Machine storage ................................... C-42

C-6.6 Cleaning and washing the machine ..... C-43

C-6.6.1 Cleaning instructions ............................ C-43

C-6.6.2 Washing instructions ............................C-43

C-6.7 Machine disposal ................................. C-43

C-6.7.1 Disposal of batteries ............................ C-43

Page C-1

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OPERATING INSTRUCTIONS

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
modification has been done, the machine must be
tagged and removed from service.

Repairs must be carried out by qualified technical
personnel according to the manufacturer’s
specifications. After any repair, the operator should
repeat the pre-operation inspection before testing the
machine functions.

Do not operate the machine, unless:

☛ You learn and practice the principles of safe

machine operation contained in this operator’s
manual.
1 Avoid hazardous situations.

Read and understand the safety rules before
going on to the next chapter.

2 Always perform a pre-operation inspection.

Read and understand the safety rules before
going on to the next chapter.

3 Always test the machine functions prior to use.
4 Inspect the work place.
5 Only use the machine for the intended

application.

Scheduled maintenance procedures must be
performed by qualified technical personnel according
to the technical specifications of the manufacturer and
the requirements envisaged in the responsibilities
manual.

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OPERATING INSTRUCTIONS

Pre-operation inspection

☛ Make sure the operator’s manuals are intact, legible

and placed inside the machine.

☛ Make sure all decals are present and legible. See

“Decals” chapter.

☛ Check for engine oil leaks and proper oil level. Top

up if necessary. See “Maintenance” chapter.

☛ Check for axle oil leaks and proper oil level. Top

up if necessary. See “Maintenance” chapter.

☛ Check for hydraulic oil leaks and proper oil level.

Top up if necessary. See “Maintenance” chapter.

☛ Check for engine coolant leaks and proper coolant

level. Add coolant if necessary. See “Maintenance”
chapter.

☛ Check for battery fluid leaks and proper fluid level.

Add distilled water if necessary. See “Maintenance”
chapter.

Check the following components or zones for damage,
missing or wrongly fitted parts or non-authorised
modifications:

• electrical components, wiring and electrical

cables

• hydraulic hoses, fittings, cylinders and main

valves

• fuel and hydraulic oil tanks

• drive pump and motor and transmission axles

• steering system

• braking system

• boom telescopes sliding pads

• clean glasses, lights and rear view mirrors

• engine and relevant components

• limit switches and horn

• lights

• moment limiter

• joystick pushbutton

• emergency stop button

• machine ignition control

• emergency pump (if any)

• nuts, bolts and other fasteners.

• protective bar or access gate to the platform (if

any)

Check the entire machine for:

• cracks on welds or structural components

• dents or damage to the machine.

☛ Make sure that all structural and other critical

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

☛ After inspection, check that all the compartment

covers are in place and latched.

DANGER

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

Checking the tyres

☛ Check the correct inflation of the tyres; see par. “Tyre

inflation” in the Maintenance section

☛ Make sure that the tyre plies are not cut or worn.

DANGER

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

ATTENTION

If the machine shall be used in a marine or
equivalent environment, protect it against salt
deposits with an adequate treatment against
saltiness to prevent rust formation.

Page C-3

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OPERATING INSTRUCTIONS

■ C-2 ENTERING THE MACHINE

■ C-2.1 ENTERING THE CAB

DANGER

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

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

Door opening from outside:

• Insert the key and release lock 1.

• Press the pushbutton 1 and open the door.









Door closing from inside:

• Pull the door with force: it locks automatically.

Door opening from inside:

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

completely.

• Rotate handle 3 to open the upper section of the

door and lock it against the special catch.

To unlock the door latched in open position:

• Press button 4 to unlock the door from the catch

• Once released, re-close the upper section of the

door by means of handle 3.

ATTENTION

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

■ C-2.1.1 Leaving the cab in an emergency

In an emergency, use the rear window of the cab as
safety exit-way.
This window has special locking handles with plastic
pins 5 easy to pull out when you need to fully open the
glass.



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OPERATING INSTRUCTIONS

■ C-2.2 ADJUSTING THE SEAT

Position the seat so you can comfotarbly reach all the
controls. The handler seat is fitted with devices which
let you adjust the seat springing, height and distance
from the controls, the backrest angle and the armrest
height.

• Adjusting the seat distance from the controls

To slide the seat forward or back, rotate lever A
and push the seat to the desired direction. Then
release the bar and make sure that the seat locks
in position.

• Adjusting seat height and springing

Free the lever of knob B and turn clockwise or
counter-clockwise until reaching the desired
springing. Once you'are correctly seated in the seat
check that the yellow indicator C is in the green
field.

• Adjusting the backrest angle

Operate lever D, press your back firmly against the
backrest and put the backrest at the angle you
wish, then release the lever.

• Adjusting the armrest height

Raise armrest E and turn wheel F to put the armrest
at the height you want.

DANGER

• 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.

3

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OPERATING INSTRUCTIONS

■ C-2.4 ADJUSTING THE STEERING COLUMN

Both steering column and dashboard can be set to a
different angle.
To adjust the steering wheel angle, unlock lever 1 and
pull or push the steering wheel to the required position,
then re-lock lever 1.

DANGER

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

■ C-2.5 ADJUSTING THE REAR VIEW MIRRORS

The machine is fitted with two rear view mirrors:

• Rear view mirror 55 is located on a special
supporting bracket in advanced position and allows
checking the area behind the machine, on the right­hand side. To adjust its position, manually rotate
the joint it is fitted with.

• Rear view mirror 56 is placed on the left upper post
of the windscreen and allows checking the area
behind the machine, on the left-hand side. To adjust
its position, manually rotate the joint it is fitted with.

56

55





■ C-2.6 SWITCHING ON THE CAB INTERIOR

LAMP

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

Page C-6

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OPERATING INSTRUCTIONS

C-3 DRIVING PLACE

■ C-3.1 CONTROLS AND INSTRUMENTS
1 Fresh air flap

2 Left outrigger switch
3 Right outrigger switch
4 Locking lever - steering column angle adjustment

5 Switch: turn signals - windscreen washer - horn
6 Steering selector switch
7 Light indicators and warning lights
8 Fuel gauge
9 Turn signals

10 Revs counter / Hourmeter
11 Display
12 Water temperature indicator
13 Mechanical gearbox switch
14 Hazard warning lights switch
15 Fog lamp switch
16 Air conditioning fan switch
17 Emergency pump switch (only with man-platform)
18 Road lights switch
19 Hydraulic oil temperature indicator
20 Ignition switch
21 Emergency stop pushbutton
22 Load limiter disabling key
23 Brake pedal
24 Gas pedal
25 Multipurpose control lever
26 Manual accelerator
27 Parking brake
28 Fuse and relay box
29 Cab heater control cock
30 Adjustable seat
31 Forward/reverse gear selector switch
32 Sway control (right/left)
33 Cab/road/platform switch
34 Load moment indicator
35 Windscreen water reservoir
36 Storage pocket
37 Inclinometer

Page C-7

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☞

See on next page

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OPERATING INSTRUCTIONS

1 2 3568

4

7

9

34

10

9

11

32

33

31

15

10

20

RPM x 100

5

25

0

30

13
14
15
16

12

P

17

18

19

2423

K2
3

K

K

K

K

K

K

K

K

F12

F6

F11

F5

F10

F4

F9

F3

F8

F2

F7

F1

K

INT

K

K

K

K

K

K

K

K

K

K

K

K

F27

F21

F15

F26

F20

F14

F25

F19

F13

F24

F18

INT

F23

F17

F22

F16

29 30

20

21

22

37

25

28

27

26

1

35 36

Page C-8

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OPERATING INSTRUCTIONS

C-3.2 ENGINE CONTROLS AND

INSTRUMENTS

■ C-3.2.1 Ignition switch

Five-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.

Thermal starter for cold climates. Rotate the key
in this position and wait until the warning light

7.2 signalling the glow plugs preheating goes
off; then rotate it to stroke end and start the
engine

Engine starting; when released, key springs back
to pos. I automatically.

Position of the ignition key to switch the controls

P

from cab to platform.

■ C-3.2.2 Forward/reverse gear selector switch

Three-position switch with lock in neutral position:

0 Neutral position; no gear engaged
1 Shift lever to pos. 1 to select the forward gear
2 Shift lever to pos. 2 to select the reverse gear

IMPORTANT

The engine can be started only if selector 31 is to
the neutral "0" position.

P

31

1

0

2

Page C-9

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OPERATING INSTRUCTIONS

■ C-3.2.3 Turn signals - Windscreen wiper - Horn

- Lights

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

I

0

I

J

I

■ Windscreen washer function:
Push the second stage of the lever along its axis to
direct a jet of water onto the cab windscreen.

■ Lights function:
To switch the handler lights, lever can be set to three
different positions along its vertical axis:

0 low beam ON, stable condition

1 high beam ON, stable condition

2 high beam used for intermittent signalling; when

released, the lever springs back to position 0.

I

0

I

J

I



I

0

I

J

I

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

I Wiper OFF

0 Wiper OFF
J Low speed

I High speed

I

I

0

I

J

I

0

I

J

I

■ Turn signals function:
Set lever to pos. 1 to indicate a turn leftwards or to
pos. 2 to indicate a turn rightwards.



I

0

I

J

I



Page C-10

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OPERATING INSTRUCTIONS

■ C-3.2.4 Brakes

23 Service brake pedal

Gradually step on the brake pedal to decelerate and
stop the machine. The pedal operates on the axle
shafts of both axles.

27 Parking brake

To engage the parking brake, pull the lever upward
while holding the locking button pressed down.
Release the button when reaching the required braking
tension. It operates on the axle shafts of the front axle
and, when engaged, it cuts both forward and reverse
gear off.

DANGER

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

■ C-3.2.5 Accelerator control

24 Gas pedal

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

26 Gas lever

By pulling the lever up, the engine rpm increases
gradually.

To reduce the rpm, set the lever down.

K

K

K

K

F6

F5

F4

F3

F2

F1

27

K2
3

K

K

K

K

F12

F11

F10

F9

F8

F7

K

INT

K

K

K

K

K

K

K

K

K

K

K

K

F27

F21

F15

F26

F20

F14

F25

F19

F13

F24

F18

INT

F23

F17

F22

F16

23

24

26

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OPERATING INSTRUCTIONS

■ C-3.2.6 Speed controls

13 Mechanical gearbox pushbutton

Used to engage the 1st or 2nd gear.
Push the button to select the required
speed.
Each pressure corresponds to the
selection of a new speed.

ATTENTION

Do not change gear when the machine is running.

IMPORTANT

When a gear is not correctly put, the warning light

7.14 comes on (see C-3.3.2).

■ C-3.2.7 Steering mode selection

6 Steering mode switch

0

1

Three-position switch for the selection

2

of the steering mode:

1 Crab steering

0 Two-wheel steering

2 Four-wheel steering

■ C-3.2.8 Cab/road/platform switch
33 Switch

Three-position switch:

0

1

1 Rotate the switch to position 1 to

select the job-site setting and ope-

2

rate the handler by the cab controls

2 Rotate the selector switch to

position 0 to select the road setting

3 Rotate the switch to position 2 to



remove the ignition switch key and
operate the handler by the platform
controls. The green light indicator

 lights up.





Page C-12

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

15

20

10

RPM x 100

5

0

25

30

P

Handler with telescopic boom GTH-4013

OPERATING INSTRUCTIONS

■ C-3.2.9 Auxiliary drive controls

They are located on the dashboard, to the right.

14 Hazard warning lights switch

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

15 Fog lamp switch

Two-position switch:

0 Fog lamp OFF
1 Fog lamp ON (the switch indicator lights

up).

16 Air conditioning fan switch

Three-position switch:

0 OFF
1 Low speed
2 High speed

18 Road lights switch

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

0 Lights OFF
1 Position lights ON (the switch indicator

lights up partially)

2 Low beam ON (the switch indicator fully

lights up).

29 Cab heater control cock

Located on the left side of the driving seat base.

• Turn the cock clockwise to switch off heated air.

• Turn the cock clockwise to switch on the cab

heater.

• Adjust the flow of heated air in the cab operating

the A/C fan switch 16.

17 Emergency pump switch

(only with man-platform)
Two-position switch:

0 OFF
1 Hold pressed down to turn on the electric

pump ad operate the controls.

ATTENTION

Check the operation of the emergency pump every
week as it could get damaged if it is not used.

14

15

18

16

29

29

17

P

Page C-13

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OPERATING INSTRUCTIONS

C-3.3 INSTRUMENTS AND WARNING

LIGHTS

■ C-3.3.1 Instruments

8 Fuel gauge

This indicates the fuel level in the tank. When
the indicator reaches the red zone, there are
roughly 15 litres in the tank and the warning
light 7.1 comes on.

10 Revs counter

It shows the engine rpm.

11 Display

The display has two text lines.

• The first shows the revs counter (total
operating time of the machine).

• The second line displays the travel speed of
the machine in km/h.

12 Engine coolant temperature indicator

This indicates the engine coolant tempera­ture.
If the red warning light 7.15 comes on (tem­perature above 100 °C), stop the engine and
find and rectify the problem (radiator dirty,
low engine coolant level, etc.).

19 Hydraulic oil temperature indicator

This indicates the temperature of the
hydraulic oil in the tank.
If the red warning light on the instrument
comes on, stop the machine and find and
rectify the problem (filters restricted, pump
damaged, valves blocked, etc.)).

10

8

15

10

20

RPM x 100

5

0

25

30

12

11

P

19

Page C-14

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■ C-3.3.2 Warning lights (ref. 7)

Handler with telescopic boom GTH-4013

OPERATING INSTRUCTIONS

7.1 Warning light - fuel reserve

This light comes on to alert to a low fuel level in
the tank.

7.2 Warning light - glow plugs preheating

This light indicates the pre-heating of the engine
glow plugs. Before starting the engine wait for
this light to go off.
If the light fails to go off, a glow plug could be
broken.

7.3 Warning light - low battery charge

Signals a low charge by the alternator.

7.4 Warning light - low engine oil pressure

This red light comes on to warn that the pressure
in the engine lubrication system is not enough
for a proper operation.
Stop the engine and find and rectify the problem.

7.5 Warning light - parking brake engaged

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

7.6 Warning light - low brake pressure

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

7.7 Warning light - hydraulic oil filter clogged

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

7.8 Warning light - air filters restricted

When this lamp come on, proceed with cleaning
or changing the air filter cartridge (see
"Maintenance" section).

7.9 Warning light - electronic gearbox
malfunction

This light comes on to alert to a failure of the
electronic gearbox. Contact GENIE Service
Centre or your dealer.

7.10 Warning light - water in fuel

This light comes on to alert to the presence of
water in fuel.

7.11 Warning light - low hydraulic oil level

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

7.12 Warning light - high beam

Blue warning light that signals when high beam
is ON.

7.13 Warning light - position lights

Green warning light that signals when position
lights are ON.

7.14 General alarm warning light

This light comes on to alert to a failure of the
machine. The light also comes on when the
mechanical gear is not put. Contact GENIE
Service Centre.

7.15 Warning light - high coolant temperature

This light comes on to alert to a too high tempe­rature of the cooling medium.

5

7.1 7.2 7.14 7.15

7.3 7.4 7.5 7.6 7.7 7.9 7.107.8 7.11 7.12 7.13

0

Page C-15

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25

30

Handler with telescopic boom GTH-4013

OPERATING INSTRUCTIONS

C-3.4 CONTROL LEVER

The handlers are equipped with a multipurpose electro­proportional lever that allows operating all machine
movements.

When shifted to one of the four directions (right/left,
forward/back), it controls the boom lifting/lowering and
the forward/back pitching of the attachment frame.
Pressing buttons  or , you move the boom
telescopes out and in and you lock/unlock the
attachment fitted to the machine.

It is also equipped with an intentional control button
 that must be pressed and held in position until the
movement is completed.
If the button is not pressed down, the lever, though
operated, does not perform any function.

IMPORTANT

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

DANGER

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

DANGER

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

Page C-16

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OPERATING INSTRUCTIONS

■ C-3.4.1 Function selection

After pressing the intentional control pushbutton ,
the lever is enabled to carry out the following motions:

• Boom lowering/lifting

shift the control lever to  or .
For any further information see paragraph C-3.4.4

• Attachment frame forward/back pitching

shift the control lever to  or .
For any further information see paragraph C-3.4.6

• Telescope retraction/extension

press button  to  or  without shifting the
control lever

For any further information see paragraph C-3.4.5

• Attachment coupling/release

press button  and shift the control lever to 
or 
For any further information see paragraph C-3.4.7

Page C-17

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OPERATING INSTRUCTIONS

■ C-3.4.2 Emergency stop

The operated functions can be stopped at any time by
pressing the emergency stop button 21.

By pressing this button, the engine of the machine is
shut down.

Before restarting the engine, reset the button by
rotating clockwise.

CAUTION

Before restarting the machine, find and rectify the
faults that caused the emergency.

■ C-3.4.3 Disabling the overload warning system

The key switch nder cap 22 is used to deactivate the
load limiter.

DANGER

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

IMPORTANT

The load limiting system disconnect key is active
only in the jobsite mode.
When the machine is in the “Platform” mode, the
limiting system cannot be deactivated.

IMPORTANT

22

The moment limiter disconnect key should be kept
by the site manager or the person responsible for
the jobsite safety.

21

Page C-18

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OPERATING INSTRUCTIONS

■ C-3.4.4 Lifting/lowering the boom

DANGER

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

To lift or lower the boom:

• Set the control lever to central position and press
button 

• Smoothly shift the lever to position  to lift the
boom or to position  to lower it.





Page C-19

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OPERATING INSTRUCTIONS

■ C-3.4.5 Extending/retracting the boom

DANGER

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

To extend or retract the telescopic elements of the
boom:

• Set the control lever to central position and press
button 

• Press button  to  to move out the boom
telescope; press the same button to  to move
in the boom telescope.

IMPORTANT

Do not operate the control lever. Boom is moved in
and out by simply pressing buttons  or .





Page C-20

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OPERATING INSTRUCTIONS

■ C-3.4.6 Pitching the attachment holding frame

forward/back

DANGER

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

To tilt forward/back the attachment holding frame:

• Set the control lever to central position and press
button 

• Smoothly shift the lever to position  to pitch
the holding frame forward

• Smoothly shift the lever to position  to pitch
the holding frame back





Page C-21

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OPERATING INSTRUCTIONS

■ C-3.4.7 Quick-coupling the attachments

DANGER

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

To lock the attachments:

• Shift the control lever to central position and press
button 

• Press button 

• Shift the control lever to position  to lock the
attachment

• Shift the control lever to position  to release
the attachment





Page C-22

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OPERATING INSTRUCTIONS

C-3.5 MACHINE SWAY CONTROL

IMPORTANT

Do not operate the sway control, when boom is
raised beyond the horizontal position.

To sway the machine:

DANGER

Check that the machine is level on inclinometer 37.
The water level must be right in the middle of the
instrument.

• Press button 32 and hold it down until the
coòplete execution of the function selected:

select X to raise the right-hand side of the
machine

select Y
machine

to lower the right-hand side of the

.

IMPORTANT

Do not operate the control lever. The sway control
is activated by simply pressing button .







IMPORTANT

In an alarm condition (red stability LED indicator
ON) or when the boom is raised beyond the
horizontal position, the function-key 32 is not
enabled.

Page C-23

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C-3.6 OUTRIGGER CONTROL

OPERATING INSTRUCTIONS

IMPORTANT

DANGER

Before lowering the outriggers, make sure that
nobody is within the working range of the machine.

To operate the outriggers:

Right outrigger

• Press button 3 and hold it down to enable the

motion of the right outrigger:
select Y to lower the outrigger
select X to raise the outrigger

Left outrigger

• Press button 2 and hold it down to enable the

motion of the left outrigger:
select Y to lower the outrigger
select X to raise the outrigger

In an alarm condition (red stability LED indicator
ON) or when the boom is raised beyond the
horizontal position, the function-keys 2 and 3 are
not enabled.

IMPORTANT

Do not operate the control lever. The outriggers
are moved in and out by simply pressing buttons

 or .







Page C-24

Document 57.0007.0200 - 01/2006







Handler with telescopic boom GTH-4013

OPERATING INSTRUCTIONS

C-3.7 MANUAL CONTROLS

In case of a malfunction of the control lever, it is
possible to use the emergency manual controls of the
main valve.
The main valve has four control levers that operate the
following functions:

Lever  In position  Boom down

In position  Boom up

Lever  In position 

In position  Fork holding frame pitched forwards

Lever  In position  Boom telescope in

In position  Boom telescope out

Lever  In position  Attachment unlocked

In position  Attachment locked

Fork holding frame pitched backwards

IMPORTANT

1234

The manual controls can be used only if the
machine is running or it is equipped with the
emergency pump.

In order to operate the emergency pump with the
manual controls, follow the instructions below:

• Open the rear cover to reach the main valve.

• Fit the control levers (supplied) to the elements of

the main valve.

• Activate the emergency pump by holding button Z

pressed down. If the button is released, the pump
stops.

• Shift the lever of the main valve to the position

corresponding to the movement you wish to obtain.

DANGER

• When operating the emergency controls in

manual mode, the load limiting device is disabled.

Z

DANGER

For the use of the emergency controls, observe the
following sequence:

Lever  in  Boom fully retracted
Lever  in  Boom lowered

Page C-25

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OPERATING INSTRUCTIONS

■ 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,

and especially from pedals and control levers.

• Remove oil, grease and mud from pedals and

control levers.

• Make sure that your hands and shoe soles are clean

and dry.

• Check the seat belts can be fastened properly.

• Check that lights, indicators, side/tail lights, hazard

indicator lights, wipers and horn are in working
order.

• Adjust the driving seat so that you can reach all

control levers comfortably and fully depress the
brake pedal without moving your back from the
driving seat.

• Adjust the rear view mirrors to give you a good

view close behind the machine when you are
correctly seated.

• Check the parking brake is engaged.

■ C-4.2 STARTING THE ENGINE

• Put the mechanical gear lever to neutral.

• Step on the gas pedal.

• To start the engine, rotate the ignition switch to
position , and release when the engine starts.
If the engine does not start within 20 seconds,
release the key and wait at least 2 minutes before
attempting again.

• After the engine starting,
slow down the rpm and
wait some seconds
before engaging a gear;
this allows for a gradual
warm up of the engine
oil and a better
lubrication.

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

P

CAUTION

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

■ C-4.1.1 Checks at the machine start-up

When power is turned on, the load limiting system
activates automatically. If the power supplied is correct,
the green light above the Terex logo comes on. The
display remains off while the system runs a self-test.
After that, the display shows 1 or 0 depending on the
attachment selected (1 = platform; 0 = forks or any
other attachment).

If during the check phase, the load limiting system finds
a fault, it enters the safety mode automatically blocking
any dangerous manoeuvres and an error message
starts flashing on the display. For any further
information, refer to chap. C-5.2.

Also check the efficiency of the safety devices as
described in chap. D-3.17, namely:

• overload warning system

• joystick pushbutton

• emergency pushbutton

• machine start control

• emergency pump

IMPORTANT

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

DANGER

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

Page C-26

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OPERATING INSTRUCTIONS

■ C-4.3 JUMP-STARTING THE ENGINE

ATTENTION

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

DANGER

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

Do not smoke when checking the electrolyte level.

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

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

To jump-start the engine:

• Turn any users off by the special control levers.

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

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

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

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

To avoid damage to the electronic instruments
of the machine, the engine of the machine where
the booster supply is installed, must be stopped.

• Turn the ignition key and start the handler, then
follow the procedure explained in chapter C-4.2
“Starting the engine”.

B

A

• Disconnect the cables. Remove first the negative
terminal from the frame earth, then from the booster
supply. Disconnect the positive terminal from the
machine battery, then from the booster supply.

DANGER

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

Page C-27

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OPERATING INSTRUCTIONS

■ C-4.4 LOW TEMPERATURE STARTING

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

To start the engine from cold, proceed as follows:

• Put the mechanical gear lever to neutral.

• Turn the ignition switch to position and wait
until the warning light 7.2 signalling the glow plugs
preheating goes off. Step down on the gas pedal
and start the engine turning the ignition switch to
position . Release as soon as the engine starts..

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

Page C-28

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OPERATING INSTRUCTIONS

■ C-4.5 STARTING THE MACHINE

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

• Select a gear suiting the job you are going to carry

out and the conditions of the job site.

• Select the required steering mode.

• Select the required gear (forward or reverse).

• Release the parking brake.

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

DANGER

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

■ C-4.6 USE OF THE MAN-PLATFORM

For the use of the man-platform, proceed as follows:
1 Couple the man-platform to the attachment holding

frame.

2 Sway the machine; check the operation on the

water level in the cab.

3 Level the platform floor.

IMPORTANT

The platform floor cannot be levelled once the
controls have been switched from the driving cabin
to the platform. Before starting using the platform,
make sure the floor is level.

4 Turn the cab/road/platform switch to platform

position (the green indicator comes on).

5 The display of the load limiter shows n. 1 to warn

that the man-platform is installed.

6 Stop the engine, turn the ignition switch to P

position and engage the parking brake.

7 Remove the key from the cab/road/platform switch

to use it for the platform controls.

8 Open the protection cover of the power socket on

the boom and plug in the platform plug.

9 Enter the man-platform and insert the key,

previously removed, in the controls switch.

IMPORTANT

If the platform controls remain disabled once the
key has been inserted, check the correct position
of the sensors of the attachment coupling pin (see
relevant manual) and the efficiency of the
outriggers' limit switches (see D-3.17).

IMPORTANT

For the use and maintenance of the man-platform,
read the specific manual - code 57.0302.9200.

Page C-29

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OPERATING INSTRUCTIONS

■ C-4.7 STOPPING AND PARKING THE

MACHINE

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

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

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

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

• Release the service brake pedal.

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

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

• Leave the driving cab and lock the cab door.

• Disconnect the power cables of the battery.

C-5 USING THE HANDLER

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

DANGER

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

DANGER

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

DANGER

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

DANGER

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

ATTENTION

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

DANGER

For a safe use of the machine, always check the
weight of the loads going to be handled.
Always refer to the load charts applied on the cab
windscreen or to the quick guide with the fork
capacity ratings.

Page C-30

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■ C-5.1 USING THE LOAD CHARTS

OPERATING INSTRUCTIONS

The charts indicating the maximum permissible load
in relation to the boom extension and the type of
attachment used are installed on the cab windscreen
and/or illustrated in the quick guide.
Chart A must be used when working with outriggers,
whilst chart B shows the payload limits when operating
without outriggers.
To operate under safe conditions, always refer to these
charts.

The extension level of the boom can be checked with
the help of the letters  (A, B, C, D, E) painted on the
same boom and compared with the load chart, while
the actual degrees of inclination of the boom are
shown by the angle indicator .

DANGER

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





DANGER

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

AB

14

13

12

11

10

9

8

7

6

20°

5

4

3

10°

2

1

0°

0

30°

250 kg

40°

50°

500 kg

1000 kg

9080

60°

1500 kg

0

0

0

2

70°

g

k

2500 kg

0

0

3

0

k

3

0

4

2040

g

g

k

0

0

5

k

0

0

1

E

D

C

B

A

g

LOAD CENTRE = 600 mm

02345678910

6200

12810

14

13

12

11

10

9

8

7

30°

6

5

20°

4

3

10°

2

1

0°

0

40°

1250 kg

50°

1500 kg

2000 kg

9020

60°

2500 kg

3000 kg

70°

3500 kg

1980

g

k

0

0

0

4

1

02345678910

E

D

C

B

A

13000

6270

LOAD CENTRE = 600 mm

Page C-31

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OPERATING INSTRUCTIONS

■ C-5.2 LOAD LIMITER

On the front top strut of the cab, there is limiter 34
which warns the operator of the variation of stability of
the machine and blocks any manoeuvre before the
same reaches a critical condition.

■ 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 confirmation button
7 Not used
8 Red light – outrigger position
9 Buzzer ON/OFF pushbutton

10 Red light –overload pre-alarm / alarm

The digit on display 2 shows the selected attachment.
The user can choose among:

0: Generic
1: Platform

■ C-5.2.2 Operation

When power is turned on, light 4 comes on. The display
2 remains off and the monitoring system runs a self­test before displaying the digit corresponding to the
used attachment on display 2. At this time, the system
is activated.

1 2 3

4

5 6 7 8

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.

Example of use of the overload warning system

10

9

During operation, the led-bar 3 lights up gradually
depending on the variation of stability.

Green LED’s: during normal operation when the

percentage of overturning moment is
between 0 and 89, these LED’s are ON.
The machine is stable.

Yellow LED’s:they light up when the machine tends

to overturn and the percentage of
overturning moment with respect to the
threshold value is between 90 and 100.
The system enters the pre-alarm mode,
light 10 flashes and the buzzer sounds
with an intermittent sound.

Page C-32

Document 57.0007.0200 - 01/2006

Boom extension

without outriggers

Overload warning

system in alarm

Boom retraction

Alarm ceases

Lowering of the outriggers

or reduction of the load to

be handled

Handler with telescopic boom GTH-4013

OPERATING INSTRUCTIONS

■ C-5.2.3 Alarm codes and resetting

DANGER

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

The limiter has diagnostic facilities to aid in the
identification of failures of the transducers, breakages
of the cables or defects of the electronic system.
When a failure is signalled, the limiter enters the safety
mode blocking any dangerous manoeuvres. Lights 5,
8 and 10 start flashing, the buzzer start sounding and
an error message is shown on the display.

The meaning of the error messages is shown in Section

E “Faults and Troubleshooting”.

10

5 8

Page C-33

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■ C-5.3 HANDLING LOADS

Handler with telescopic boom GTH-4013

OPERATING INSTRUCTIONS

■ 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.

DANGER

• 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 floating forks:

• Loosen the nut of the locking screws.

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

• Lock the screws re-tightening the nut.

Page C-34

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OPERATING INSTRUCTIONS

■ C-5.3.2 Working phases

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

Loading phase

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

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

• Pitch the forks back and make sure that the overload
warning system LEDs are in limits.

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

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

DANGER

Do not move off when the load is raised 20÷30 cm
above the ground. Risk of machine overturning or
load fall.

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

DANGER

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

Unloading phase

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

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

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

• Lower the load and make sure it is level.

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

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OPERATING INSTRUCTIONS

■ C-5.4 CHANGING THE ATTACHMENT

DANGER

ATTENTION

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

To change an attachment, operate as follows:

• Drive to the place where you will release the

mounted attachment (when possible, a solid and
sheltered site).

• Disconnect the quick connectors of the

attachment (if any), and connect the hydraulic
locking pipes of the attachments to couplings A.

• Rest the attachment flat on the ground.

• Pitch the attachment holding frame forward and

lower the boom to release the attachment upper
lock.

• Move back with the machine (or with the boom)

and drive to the new attachment to be coupled.

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.

• 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.



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OPERATING INSTRUCTIONS

• Operate the control lever to lock the attachment.

DANGER

After the substitution of an attachment or after any
coupling operation, visually check the attachment.
A wrongly coupled attachment may result in damage
to persons or things.

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OPERATING INSTRUCTIONS

C-6 TRANSPORTING THE MACHINE

■ C-6.1 MOVING A DISABLED MACHINE

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

When the machine shall absolutely be towed:

• Unlock the parking brake.

• Tow the machine for short distances and at a low
speed only.

• Use a rigid drawbar.

• Select the two-wheel steer.

• Put the transmission selection lever to neutral.

• Put the gearbox lever to neutral (see chap. C-

6.1.1)

• Raise the front wheels of the machine and remove
the Cardan shaft of the transmission (see chap. C-

6.1.2).

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

■ C-6.1.1 Setting the gear lever in neutral

CAUTION

Do not tow the machine without setting the
mechanical gear lever to neutral position.

To set the gear lever to neutral:

• Disconnect the cylinder feeding pipes  and 
and plug them.

• Pry the cursor of the gear lever  to neutral
position.

• Plug holes  and  of the cylinder.







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OPERATING INSTRUCTIONS

■ C-6.1.2 Dismantling the Cardan shaft

Before towing a disabled machine, dismatle the two
(front and rear) Cardan shafts loosening the screws
that fix them to the axle and the reduction gear as
shown in the picture.

Page C-39

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OPERATING INSTRUCTIONS

■ C-6.2 ROAD OR SITE TRANSFER

When travelling on public roads, strictly obey the local or national
road traffic regulations.

Besides, take into account the following general precautions:

• Align the rear wheels.

• Select the two-wheel steer.

• Sway the machine.

• Lock the machine as indicated in the Registration Card (only
for the Italian market):

Lock the boom sections, the lifting cylinder, the attachment
rotation cylinder, the outriggers (see photo).

• Lock the rear wheel steering using the special pins (if any).

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

ATTENTION

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

Only for the Italian market

• Retract boom and attachment to transfer position.

• Set the ROAD-CAB-PLATFORM switch to “ROAD".

• Make sure that lights, horn and turn signals are in working
order.

• Engage a high speed.

• Do not change mechanical gear when the machine is running.

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

IMPORTANT

Public road circulation is allowed only for transferring an
unloaded machine.

Do not use the machine to tow trailers.

Page C-40

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OPERATING INSTRUCTIONS

■ C-6.3 LIFTING THE MACHINE

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

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

■ C-6.4 TRANSPORTING THE MACHINE ON
OTHER VEHICLES

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

• Put chocks at the machine wheels.

• Ensure ramps are correctly positioned.

• Retract the boom to transfer position.

• Carefully drive the machine onto the transporting

vehicle.

• Put the parking brake and rest the attachment flat

on the vehicle platform.

• Ensure the overall dimensions do not exceed the

allowed limits.

• Shut the engine down and close the driving cab of

the machine.

• Secure the machine to the vehicle platform by

wheel-chocks.

• Anchor the machine to the transporting vehicle with

suitable chains.

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OPERATING INSTRUCTIONS

■ C-6.5 PARKING AND STORAGE

■ C-6.5.1 Short inactivity

Always park the machine in a safe way after a working
day, a shift and at night.

Take all precautions to prevent damage to those persons
who will approach the machine while stationary:

• Park the machine so that it does not hinder other
operations.

• Lower the boom fitted with attachment on the
ground.

• Disengage the transmission and put the parking
brake.

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

• Disconnect the power cables of the battery.

ATTENTION

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

■ 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 well­ventilated place.

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

• When weather is particularly cold, empty the
radiator.

IMPORTANT

Always remember that the ordinary maintenance
must be carried out even during the machine
inactivity. Pay particular attention to the fluid levels
and to those parts subject to ageing. Before re­starting the machine, carry out an extraordinary
maintenance and carefully check all mechanical,
hydraulic and electrical components.

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OPERATING INSTRUCTIONS

■ C-6.6 CLEANING AND WASHING THE

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

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

■ C-6.6.2 Washing instructions

ATTENTION

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

External washing

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

Internal washing

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

Washing the engine

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

■ C-6.7 MACHINE DISPOSAL

PROTECT THE

ENVIRONMENT

At the end of the machine life, call in a specialised
firm to dispose of it in compliance with the local or
national regulations.

■ C-6.7.1 Battery disposal

PROTECT THE

ENVIRONMENT

Used lead-acid batteries cannot be disposed of as
normal industrial solid wastes. Because of the
presence of harmful substances, they must be
collected, eliminated and/or recycled in accordance
with the laws of the UE.

In Italy, used or discarded batteries have been
classified as “Toxic wastes” in accordance with
Presidential decree n. 397 of 09/09/1988 and Law n.
475 O.G. n. 18 of 09/11/1988 because they contain
lead and sulphuric acid. Their disposal through
recycling must be done only through companies
authorised and belonging to the “Consorzio
Obbligatorio Batterie Esauste e dei rifiuti piombosi”
(Cobat) which collect and dispose of used lead-acid
batteries throughout the national territory.

Used batteries must be kept in a dry and confined
place. Make sure the battery is dry and the cell
plugs are tight. Place a sign on the battery to warn
of not using it. If before disposal the battery is left
in the open air, it will be necessary to dry, smear the
box and the elements with a coat of grease and
tighten the plugs. Do not rest the battery on the
ground; it is always advisable to rest it on a pallet
and cover it. The disposal of batteries shall be as
rapid as possible.

ATTENTION

If the machine shall be used in a marine or
equivalent environment, protect it against salt
deposits with an adequate treatment against
saltiness to prevent rust formation.

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OPERATING INSTRUCTIONS

INTENTIONALLY BLANK PAGE

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MAINTENANCE

Section D

MAINTENANCE

TABLE OF CONTENTS

D-1 LUBRICANTS - HEALTH AND SAFETY PRECAUTIONS .............................. D-2

D-2 ORDINARY MAINTENANCE ......................................................................... D-4

D-2.1 Oil change schedule ...................................................................................... D-5

D-3 MAINTENANCE INTERVENTIONS ................................................................ D-6

D-3.1 Access to the engine compartment .............................................................. D-7

D-3.2 Greasing ........................................................................................................ D-8

D-3.3 Tyres and wheels .......................................................................................... D-9

D-3.4 Brakes ........................................................................................................... D-9

D-3.5 Engine air filter............................................................................................. D-10

D-3.6 Cab air filter ................................................................................................. D-11

D-3.7 Engine cooling system ................................................................................ D-12

D-3.8 Checking the oil level in the tank ................................................................ D-13

D-3.9 Changing the hydraulic oil ........................................................................... D-14

D-3.10 Changing the oil filter cartridge ................................................................... D-15

D-3.11 Oil level in the differential gears .................................................................. D-16

D-3.12 Oil level in the (front/rear) wheel reduction gears ........................................ D-16

D-3.13 Oil level in the gearbox ................................................................................ D-17

D-3.14 Shafting alignment ...................................................................................... D-18

D-3.15 Adjusting the sliding pads of the boom sections ........................................ D-19

D-3.16 Re-sequencing the telescopic boom .......................................................... D-20

D-3.17 Checking the safety devices ....................................................................... D-21

D-3.18 Checking the state of the structure ............................................................. D-26

D-4 ELECTRICAL SYSTEM................................................................................ D-27

D-4.1 Battery ......................................................................................................... D-27

D-4.2 Fuses and relays ......................................................................................... D-28

D-4.3 12V DC lamps ............................................................................................. D-30

D-5 REFUELLING............................................................................................... D-31

D-5.1 Refuelling..................................................................................................... D-31

D-5.2 Product specifications ................................................................................ D-31

D-5.2.1 Engine oil ..................................................................................................... D-31

D-5.2.2 Lubrication oils and relevant filtering elements ........................................... D-31

D-5.2.3 Fuel.............................................................................................................. D-32

D-5.2.4 Grease ......................................................................................................... D-32

D-5.2.5 Engine coolant ............................................................................................ D-32

Page D-1

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MAINTENANCE

Observe and obey:

☛ The operator can only perform the routine

maintenance operations envisaged in this manual.

☛ Scheduled maintenance procedures shall be

completed by qualified technical personnel
according to the manufacturer’s specifications.

Maintenance symbol legend:

IMPORTANT

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

INTRODUCTION

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

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

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

The maintenance interventions are based on the
machine working hours. Regularly check the hour­meter and keep it in good condition to define the
maintenance intervals correctly.

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

Indicates that tools are required to
perform the procedure.

Indicates that new parts are required to
perform the procedure.

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

SERVICE INTERVAL

Running-in _________________________________

Ordinary ___________________________________

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

IMPORTANT

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

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MAINTENANCE

D-1 LUBRICANTS - HEALTH AND

SAFETY PRECAUTIONS

Health

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

Storage

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

Disposal

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

Oil leaks

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

First aid
Eyes : In case of accidental contact with the

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

Intake : In case of oil intake, do not induce

vomiting, but seek medical advice.

Skin : In case of a prolonged contact, wash

with soap and water

Fire

In case of fire, use carbon dioxide, dry chemical or
foam extinguishers. Do not use water.

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MAINTENANCE

D-2

ORDINARY MAINTENANCE

A wrong or neglected maintenance can result in
possible risks for both operator and bystanders. Make
sure maintenance and lubrication are carried out
according to the manufacturer’s instructions to keep
the machine safe and efficient.

The maintenance interventions are based on the
machine working hours. Regularly check the hour­meter and keep it in good conditions to define the
maintenance intervals correctly. Make sure any defect
detected during the maintenance is promptly rectified
before using the machine.

ATTENTION

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

During the first 10 working hours

1 Check the oil level within reduction gears, power

divider and differential gears

2 Regularly check the tightening of the wheel bolts
3 Check the tightening of all bolts and nuts
4 Check the couplings for oil leaks

Within the first 50 working hours

1 Change the engine oil and renew the fuel filter

Within the first 100 working hours

1 Change the oil of the differential casing, the wheel

reducer and the gearbox

Every 10 working hours or daily

1 Check the engine oil level
2 Clean the air suction filter
3 Check the engine coolant level
4 Clean the radiator, if necessary
5 Check the hydraulic oil level in the tank
6 Check the greasing of the boom section pads
7 Grease the attachment holding frame
8 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

9 Check the efficiency of the overload warning system

10 Check the efficiency of the lighting electric system
11 Check the efficiency of braking system and parking

brake

12 Check the efficiency of the steering selection

system

13 Check the efficiency of the fork balancing system.
14 Make sure the safety devices installed are in

efficient working order - see procedure in chap.

D-3.17.

Every 50 working hours or weekly

Jobs to be done in addition to those above

1 Check the tension of the alternator belt
2 Check the tyre inflation
3 Check the tightening of the wheel nuts
4 Check the tightening of the Cardan shaft screws
5 Check the operation of the emergency pump (if it

is installed).

6 Clean the radiator fins

Every 250 working hours or monthly

Jobs to be done in addition to those above

1 Change the engine oil and relevant filter
2 Check the oil level in the front and rear differential

gears

3 Check the oil level in the four wheel reduction

gears

4 Check the main filtering element of the engine air

filter. Replace, if necessary

5 Check the clamping of the cableheads to the

battery terminals

6 Check the air suction hose between engine and

filter

7 Check the cylinder chromium-plated rods
8 Check the hydraulic lines are not worn because of

rubbing against the frame or other mechanical
components

9 Check the electric cables do not rub against the

frame or other mechanical components

10 ▲ Check the wear of the sliding pads of the boom

sections

11 ▲ Adjust the play of the sliding pads of the boom

sections

12 Remove any grease from the boom, then re-

grease the sliding parts of the boom sections

13 Check the level of the battery electrolyte

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MAINTENANCE

Every 3 working months

1 Check the efficiency of the block valves - see

chap. D-3.17

Every 500 working hours or every six months

Jobs to be done in addition to those above.

1 Visually check the smoke quantity evacuated from

the engine exhaust

2 Check the tightening of the engine fixing screws
3 Check the tightening of the cab fixing screws
4 Check the backlash between pins and bushings

in all joints

5 Change the hydraulic oil filter in the tank
6 Have the hydraulic system checked by a skilled

technician

7 Change the main cartridge of the engine air filter
8 Renew the cartridge of the engine oil filter and the

fuel filter

9 Change the oil of the front and rear differential

casings

Every 1000 working hours or yearly

Jobs to be done in addition to those above

1 Change the safety element of engine air filter
2 Change the oil of the gearbox
3 Change the oil in the four wheel reduction gears
4 Change the hydraulic oil

Every 2000 working hours or every two years

Jobs to be done in addition to those above

1 Change the engine coolant

Every 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-3.18).

■ D-2.1 OIL CHANGE SCHEDULE

Intervento ore di intervalli di Tipo olio

Engine

Axles and
power
divider

Hydraulic
oil

* whichever occurs first

Oil level check 10 daily SHELL RIMULA 15W-40
First change 50 - (API CH-4/CG-4/CF-4/CF; ACEA E3;
Subsequent changes 250 monthly MB228.3)

Oil level check 250 monthly
First change - - API GL4 / FORD M2C 86B
Subsequent changes 1000 yearly MASSEY FERGUSON M 1135

Oil level check 10 daily
First change - ­Subsequent changes 1000 yearly

lavoro* tempo*

Page D-5

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TRACTORENAULT THFI 208 LF SAE 80W

SHELL TELLUS T 46
DENISON HF-1, DIN 51524

part 2 & 3

Handler with telescopic boom GTH-4013

MAINTENANCE

D-3

MAINTENANCE INTERVENTIONS

DANGER

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

DANGER

ATTENTION

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

ATTENTION

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

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

DANGER

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

DANGER

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

PROTECT THE

ENVIRONMENT

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

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MAINTENANCE

■ D-3.1 ACCESS TO THE ENGINE

COMPARTMENT

For any operation within the engine compartment,
open the protection bonnet.

The bonnet is equipped with pneumatic shock
absorbers which unburdens and hold the bonnet in

raised position. To open the bonnet:

• Shut the engine down and put the parking brake.

• Turn the key to unlock and open the bonnet.

DANGER

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

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MAINTENANCE

■ D-3.2 GREASING

ATTENTION

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

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

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

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

ATTENTION

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

• After the first 50 operating hours (1 week)

• After the first 250 operating hours (1 month)

• Every 1000 operating hours (6 months)

Remove any old grease from the boom and smear
the sliding area of the blocks with a thin coat of
grease.

- 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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MAINTENANCE

■ D-3.3 TYRES AND WHEELS

DANGER

Over-inflated or overheated tyres can burst. Do not
flame-cut or weld the wheel rims. For any repair
work, call in a qualified technician.

RIGHT WAY

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

STANDARD OPTIONAL

WRONG WAY

WRONGOKAY

GTH-4013

■ D-3.4 BRAKES

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

Dimensions (front and rear) 405/70-20 405/70-24

P.R. (or load index) 14 pr 14 pr

Rim 13x20 13x24

Wheel disc 8 holes DIN 70361

Pressure bar/Psi 5.5/80 4.5/65

SERVICE INTERVAL

Running-in _________ Within the first 10 hours
Ordinary __________________ Every 250 hours

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

IMPORTANT

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

Page D-9

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■ D-3.5 ENGINE AIR FILTER

Handler with telescopic boom GTH-4013

MAINTENANCE

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

1 Cleaning and changing the external element:

- Stop the engine and engage the parking brake.

- Open the four latches A.

- Remove the protection cap B.

- Extract the external cartridge C.

- Clean the filter bowl.

- Beat the cartridge against a piece of wood surface
to eliminate any dust.

- Dry clean the cartridge (max. pressure: 6 bar).

- Check for cracks in the filtering element.

- Before refitting the cleaned cartridge or a new
one, smear its seal with a thin coat of grease; fit
the cartridge and make sure it is properly
positioned.

- Refit cap B.

ATTENTION

As soon as the warning lamp 7.8 on the cab
dashboard switches on, replace the outer element.
Never wash the cartridge with water or solvents.









2 Changing the internal element:

- See step 1 for removing the outer element

- Extract the internal cartridge D.

- Clean the filter bowl.

- Smear the seal with grease, then mount the new
element and make sure it is correctly positioned.

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

ATTENTION

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



SERVICE INTERVAL

Running-in ____________________________None
Cleaning ___________________ Every
Outer element change ______ Every
Inner element change _____ Every

10

500

1000

hours
hours
hours

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MAINTENANCE

■ D-3.6 CAB AIR FILTER

Every six months clean the air filter in the cab. Replace
the cartridge if the filtering cloth is damged.

1 Cleaning and changing the cartridge:

- Shut the engine down and engage the parking
brake.

- Pull filter A out of the housing accessible from the
outside of the cab.

- Clean the filter bowl.

- Clean the filter cartridge by beating it against a
piece of wood. Replace the cartridge if damaged.

ATTENTION

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

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Handler with telescopic boom GTH-4013

■ D-3.7 ENGINE COOLING SYSTEM

MAINTENANCE

DANGER

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

• Every week, before starting working (when the
coolant is cold), check the coolant level which shall
be kept at 2 centimetres from plug .

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

• Change the antifreeze mixture every two years.
To drain the antifreeze:

- Let the engine cool down

- Unscrew the plug  at the bottom of the radiator

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



- Refit the hose and pour new antifreeze (50%

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

• Daily clean the radiator grille using a brush with
hard bristles or compressed air at a max pressure
of 6 bar.

SERVICE INTERVAL

Running-in ____________________________ None
Ordinary ____________________ Every 50 hours



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

TEREX PRO COOL

Protection against boiling / freezing

Product Freezing Boiling

% point point

33 -17 °C 123 °C
40 -24 °C 126 °C
50 -36 °C 128 °C
70 -67 °C 135 °C

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MAINTENANCE

■ D-3.8 CHECKING THE OIL LEVEL IN THE TANK

DANGER

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

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

When necessary, add new oil through filler .

SERVICE INTERVAL

Running-in _________ Within the first 10 hours
Ordinary ____________________ Every 50 hours

PROTECT THE

ENVIRONMENT

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









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MAINTENANCE

■ D-3.9 CHANGING THE HYDRAULIC OIL

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

the parking brake is engaged.

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

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

4 Remove the drain plug  and allow oil to flow out

into the container.

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

jet of compressed air.

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

recommended type indicated in paragraph D-

5.2.2 until it is level with .

SERVICE INTERVAL

Running-in ____________________________ None
Ordinary ________________ Every 1000 hours







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MAINTENANCE

■ D-3.10 CHANGING THE OIL FILTER CARTRIDGE

To change the hydraulic oil filter element, proceed as follows:
1 Stop the machine on a level ground and engage the parking

brake.

2 Place a container of suitable size under the filter to collect

any oil leaks.

3 Remove the filter cover  to get access to the filter element.
4 Change the filter element, then, before fitting a new one,

thoroughly clean and grease both seat and gasket.

5 Refit and tighten the filter cover.

ATTENTION

Hydraulic oil filter canisters cannot be cleaned or washed
and refitted.
They must be replaced with new ones of the type
recommended by the manufacturer (see par. D-5.2.2).

PROTECT THE

ENVIRONMENT

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

SERVICE INTERVAL

Running-in ____________________________ None
Ordinary __________________ Every 500 hours



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MAINTENANCE

■ D-3.11

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

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

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

• If necessary, top-up through hole  until oil comes
out from hole .

• Refit and tighten plugs  and .

To change the oil:

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

• Loosen the drain plug, the level plug  and the filler
 and allow oil to flow out from the reduction gear.

• Refit and tighten drain plug .

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

• Refit and tighten plugs  and .

OIL LEVEL IN THE DIFFERENTIAL GEARS

■ 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  finds on the
horizontal axis.

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

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

• Refit the plug.

To change the oil:

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

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

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

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

• Add new oil through hole .

• Refit and tighten plug .







SERVICE INTERVAL

Running-in _________ Within the first 10 hours
Ordinary __________________ Every 250 hours

Document 57.0007.0200 - 01/2006

SERVICE INTERVAL

Running-in _________ Within the first 10 hours
Ordinary __________________ Every 250 hours





Page D-16