Operator’s manual
Part N. 57.0008.3200
Rev. 0 09/2006
From serial n. 15641
To serial n. 19093
English
Edition
GTH-4013 SX
CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE
CAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES
TECHNICAL SERVICES
Genie Scandinavia
Phone +46 31 575100
Fax +46 31 579020
Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Genie Germany
Phone +49 (0)4202 88520
Fax +49 (0)4202 8852-20
Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Mexico City
Phone +52 55 5666 5242
Fax +52 55 5666 3241
Genie North America
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.
Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544
Genie Japan
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910
Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754
Genie Holland
Phone +31 183 581 102
Fax +31 183 581 566
Operator’s manual 57.0008.3200 - GTH-4013 SX
No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means without
prior written permission from TEREXLIFT srl.
In pursuing a policy of constant quality improvement, TEREXLIFT srl reserves the right to make changes at any time and
without undertaking to give prior notice; therefore, also this publication may be subject to modications.
Some photos or drawings have been used to illustrate a specic function; as a result, they may not refer to the machine
treated in this manual.
© Copyright 2006 TEREXLIFT srl - All rights reserved.
Produced by: TEREXLIFT Technical Literature Dept. - Studio VEGA - Forlì
REVISED PAGE LIST
Revision Revised Issued
N. Date pages Notes by
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INTRODUCTION
GTH-4013 SX
INTRODUCTION
This manual provides information for a safe and proper
operation and maintenance of the machine.
STRICTLY COMPLY WITH THE
INSTRUCTIONS GIVEN IN THIS HANDBOOK!
READ AND UNDERSTAND THIS HANDBOOK
BEFORE STARTING, USING AND
CARRYING OUT ANY OPERATION WITH
AND ON THE MACHINE.
The handbook is divided into seven sections:
Sect. A GENERAL INFORMATION
Sect. B SAFETY PRECAUTIONS
Sect. C OPERATING INSTRUCTIONS
Sect. D MAINTENANCE
Sect. E TROUBLESHOOTING
Sect. F OPTIONAL ATTACHMENTS
Sect. G TABLES AND ENCLOSURES
Section A contains general concepts that are decisive
for the knowledge of the main parts of the machine.
It also contains all necessary data for a correct
identication of the machine, the technical features of
the machine, etc.
Section B is especially addressed to the personnel, who
shall operate, repair and service the machine, and, in
case of companies with a wide eet of machines, to
those responsible for safety.
It describes the essential compulsory qualities of the
personnel in charge and other important information
for the safety of persons and things.
Section C is mainly addressed to the operators who
operate the machine. This section illustrates all control
devices.
Additionally, it contains the main use instructions -i.e.
engine starting, machine parking, machine storing.
Section D is addressed to those responsible for
maintenance and the servicemen.
The section describes the maintenance schedule and
the relevant intervals.
Section G contains tables and various enclosed
documents like load charts, wiring diagrams, hydraulic
schemes, torque wrench setting table, etc.
Sections are subdivided into chapters and paragraphs
that are numbered progressively.
The quickest way to look for information is the reference
to the general index or the titles of the single chapters
and paragraphs that represent keys for an easy
consultation.
Take care of this manual and keep it in an
accessible place within the machine, even
after its reading, so that it will always be within
reach if in doubt.
If you are unsure about anything, please address to
GENIE Assistance Service or to your agent/dealer:
addresses, phone and fax numbers are printed in
the cover and in the title-page of this manual.
Any difference between the contents of this manual
and the real functional character of the machine
can be attributed to either a machine manufactured
before the issue of this manual or to a manual going
to be updated after some changed effected on the
machine.
Always contact GENIE Assistance Service for any
updated version of this manual and any additional
information.
Section E deals with the failure diagnostics.
Section F makes a list of the main interchangeable
attachments that can be coupled to the machine:
dimensions, weight, application eld and limits of use.
Document 57.0008.3200 - 09/2006
Page 1
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CAUTION
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ENVIRONMENT
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IMPORTANT
DANGER
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ELECTRICAL
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CAUTION
DANGER
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ENVIRONMENT
ATTENTION
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IMPORTANT
DANGER
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ELECTRICAL
DANGER
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ATTENTION
CAUTION
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IMPORTANT
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IMPORTANT
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IMPORTANT
SYMBOLS
SYMBOLS
When using the machine, operators could have to face
some situations requiring special care and particular
knowledge.
When these situations involve the safety of operators or
bystanders, the machine efciency and proper utilisation,
this handbook stresses these specic instructions by
means of SPECIAL SYMBOLS.
GTH-4013 SX
Yellow with safety alert symbol: used to indicate
a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
There are seven special (or safety) symbols in this
manual, always combined with keywords that class the
situations according to their danger degree.
The symbols are always followed by a text explaining
the situation taken into account, the attention to be paid
to such situation, the method and the behaviour to be
adopted. When necessary, it stresses prohibitions or
supplies instructions to prevent dangers.
Sometimes, it can be followed by illustrations.
We list below the special (or safety) symbols according
to the relative degree of a hazard:
Safety Alert symbol: when you see this symbol, be
alert to the possibility of personal injury. Strictly obey
all the safety messages accompanying this symbol
to avoid the risk of serious injury or death.
Red: used to indicate an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
Yellow without safety alert symbol: used to indicate
a potentially hazardous situation which, if not
avoided, may result in damage to the machine or
the systems.
Green: used to draw the attention to important
information on environment protection.
Green: used to indicate operation and maintenance
information
WHEN READING THIS MANUAL, PAY THE
GREATEST ATTENTION TO THESE SPECIAL
SYMBOLS AND THE EXPLANATION OF THE
SITUATIONS THEY EMPHASIZE.
The manual in electronic format also contains the
following symbol:
which enables the user to return to the
table of contents.
Orange: used to indicate a potentially hazardous
situation which, if not avoided, could result in death
or serious injury.
Page 2
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GENERAL INDEX
GTH-4013 SX
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
GTH-4013 SX
Page 4
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GTH-4013 SX
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 identication plates ........................................................................................... A-12
A-2.4 CE marking ..................................................................................................................... A-13
A-2.5 Chassis serial number .................................................................................................... A-13
A-2.6 Identication 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 (oating 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
GTH-4013 SX
A-1
CONVENTIONAL REFERENCES
A-1.1 MACHINE POSITION
Conventionally the machine should be considered
positioned as shown in the gure.
This convention is necessary to make any reference
of this handbook to different machine parts (front, rear,
etc.) clear and unmistakable.
Any exception to this rule will always be specied.
UPPER PART
RIGHT SIDE
FRONT
PART
REAR
PART
LEFT SIDE
LOWER PART
Page A-2
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09.4616.0109
09.4618.0721
09.4618.0597
09.4618.0547
09.4618.0061
09.4618.0597
09.4616.0040
09.4618.0242
09.4618.0227
09.4618.0361
09.4618.0026
09.4618.0361
09.4618.0022
09.4618.0547
09.4618.0061
09.4618.0241
GENERAL INFORMATION
A-1.2 LABELS AND WARNING PLATES APPLIED
ON THE MACHINE
This paragraph lists the labels and warning plates
normally applied on standard machines or on special
attachments coupled to the machine.
GTH-4013 SX
The familiarisation with these labels is never a
waste of time.
Make sure they are easy to read. For this purpose,
clean them or replace those that become unreadable
(either graphic or text).
To clean labels, use of a soft cloth, water and soap.
Never use solvents, petrol, etc.
When a label is applied on a part to be replaced,
make sure that the replaced part is already labelled
as required or apply a new label.
Page A-3
Document 57.0008.3200 - 09/2006
09.4616.0109
09.4618.0712
09.4618.0714
09.4618.0597
09.4618.0597
09.4618.0547
09.4618.0061
09.4618.0242
09.4618.0597
09.4618.0547
09.4618.0061
09.4618.0010
09.4618.0722
09.4618.0547
09.4618.0061
09.4618.0227
09.4618.0361
09.4618.0597
09.4618.0721
09.4616.0068
09.4618.0361
09.4618.0361
09.4618.0022
09.4618.0597
09.4618.0547
09.4618.0061
09.4618.0243
09.4618.0271
09.4618.0241
09.4618.0563
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GENERAL INFORMATION
GTH-4013 SX
Document 57.0008.3200 - 09/2006
Page A-4
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KEEP OUT OF
WORKING RANGE
XX
USO DELLA LEVA DI COMANDO
• Abbassamento/sollevamento del braccio: azio-
nare la leva in direzione -
• Richiamo/sfilo del braccio telescopico: azionare
la leva in direzione -
• Bran deggi o ind ietro /ava nti d ell'a ttrez zo
terminale: premere il pulsante ed azionare la
leva in direzione -
• Livellamento macchina: azionare la leva in C
per per sollev are il lato destro op pure in D per
abbassare il lato destro
• Stabilizzatore destro: azionare la leva in B per
sollevare oppure in A per abbassare lo stabilizzatore
• Stabilizzatore sinistro: azionare la leva in B per
sollevare oppure in A per abbassare lo stabilizzatore
• Blocco/sblocco attrezzi (OPZIONALE): azionare
la leva in direzione C per bloccare gli attrezzi, in
direzione D per sbloccarli.
AVVIAMENTO DELLA MACCHINA
• Posiz ionar e il sel ettor e marc e ed il c ambio
meccanico in folle.
• Inseri re il freno di sta zionam ento e
controllare che la spia sia accesa.
• Avviare il motore ruotando
il comm ut at o re di
avviamento in posizione
e man tene rlo fi no al lo
spegnimento della spia.
Ruot ar l o quin di i n
pos i z io n e p e r
l’avviamento del motore.
• Qualor a, dopo circ a 20
secondi, l'avviamento del
motore non avesse luogo, r ilasciare la ch iave ed
attendere circa due minuti prima di tentare un nuovo
avviamento.
1 2 3 4 5
6
7
8
4013 SX 4013 SX
P
ATTENZIONE
È vietato utilizzare la macchina e gli accessori se nza
prima aver letto e compreso le norme di utilizzo e di
sicurezza contenute nel manuale di istruzioni.
Il mancato rispetto delle norme di utilizzo e di sicurezza
può causare pericolo grave all’operatore e a terzi.
Le istruzioni sono consegnate con la macchina e copie
aggiuntive possono e ssere richies te al rive nditore o
direttamente a Terexlift.
L’operatore è respons abile del rispetto delle no rme
sopra riportate.
Non sollevare carichi se la macchina appoggia su terreno
instabile o inclinato. Non sollevare mai carichi superiori
a quelli indicati in tabella. Non sono ammesse manovre
di sollevamento con macchina in movimento.
Prima di abbandonare il posto di manovra:
- abbassare eventuali carichi sospesi
- portare in posizione di riposo gli organi di comando
del braccio
- posizionar e la lev a marcia avanti-indietro in foll e,
inserire il freno a mano e arrestare il motore.
Norme per l'utilizzo di macchine dotate di stabilizzatori:
È vietato utilizzare gli stabilizzatori se il carico è già
sollevato: gli stabi lizzato ri s ervono sola mente ad
aumentare la stabilità della macchina. L’uso scorretto
degli stabilizzatori pu ò causare i l ribaltamento della
macchina.
Un’apposita spia sul cruscotto indica che gli stabilizzatori
sono abbassati: accertarsi che la spia sia accesa.
Prima di so llevare il car ico livella re la macchin a
controllando l’apposito indicatore di livello.
09.4618.0713 09.4618.0712
GUIDA RAPIDA PER L’USO
INDICATORE DI STABILITÀ
Durante il lavoro mantenere sotto controllo l’indicatore
di stabilità.
Gli 8 LED indicano:
LED verdi 1-2-3-4Macchina stabile.
LED gialli 5-6 Macc hina instabile. Spia rossa
lampeggiante ed allarme acustico
intermittente.
LED rossi 7-8 Macchina i n allarme. Peri colo di
ribaltamento. Spia rossa accesa
ed allar me acustic o continu o.
Eseguire il rientro in condizioni di
sicurezza.
4013 SX
1
OPTIONAL
2
3
4
5
D
C
A
B
13000
1
0
1
2
3
4
5
6
7
8
9
10
0°
10°
50°
02345678910
11
12
13
14
A
B
C
D
E
6270
1980
9020
70°
60°
40°
30°
20°
1500 kg
2000 kg
2500 kg
3000 kg
3500 kg
4000 kg
1250 kg
LOAD CENTRE = 600 mm
12810
6200
1
0
1
2
3
4
5
6
7
8
9
10
0°
10°
50°
02345678910
11
12
13
14
LOAD CENTRE = 600 mm
250 kg
A
B
C
D
E
2040
9080
20°
30°
40°
60°
70°
500 kg
1500 kg
1000 kg
2000 kg
2500 kg
3000 kg
3500 k
g
4000 kg
C
D
A
B
GTH-4013 SX
GENERAL INFORMATION
Decal Code Description
09.4618.0022 Keep out of the working range of the machine.
When the machine is running, entering the working
range of the machine is prohibited.
09.4618.0212 Keep out of the working range of the machine.
When the machine is running, entering the working
range of the machine is prohibited.
09.4618.0563 Guaranteed sound power level. It indicates the
guaranteed sound power level measured in accordance
with the Directive 2000/14/EC.
09.4618.0712 Quick guide.
09.4618.0714 An overview of the operator’s handbook concerning:
- control lever,
- machine starting,
- 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 denes the exact working
limits of the machine (in terms of payload and reach)
to be strictly respected by the operator when using
the machine without outriggers (or with retracted
outriggers).
• Load chart for operations with outriggers down.
It denes the exact working limits of the machine (in
terms of payload and reach) to be strictly respected
by the operator when using the machine with lowered
outriggers.
Document 57.0008.3200 - 09/2006
Page A-5
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VIETATO APRIRE CON MOTORE IN MOTO
DO NOT OPEN WHILE ENGINE IS RUNNING
N'OUVRIR QU'A L'ARRET DU MOTEUR
ÖFFNEN NUR BEI STILLSTEHENDEM MOTOR
ABRIR SOLO CON MOTOR PARADO
PROIBIDO ABRIR COM O MOTOR LIGADO
VERBODEN KOFFERBAK TE OPENEN WANNEER DE MOTOR DRAAIT.
DANGER
ELECTRIC CABLES AND
POWER LINES
KEEP EVERY PART OF THE MACHINE, LOADS AND
ACCESSO RIES AT LE AST 6 ME TERS F ROM
OVERHEAD POWER LINES
P max
kg/cm
2
XXX
P max
kg/cm
2
4,0
GTH-4013 SX
GENERAL INFORMATION
Decal Code Description
09.4618.0010 Do not open while engine is running
Do not open the engine bonnet when engine is running,
since this may result in serious injury due to moving
parts or hot components.
09.4618.0026 Use limits close to electric power lines. It denes
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.
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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P
=
bar
P
=
bar
GTH-4013 SX
GENERAL INFORMATION
Decal Code Description
09.4618.0597 Warning stickers. Applied near coupling points,
silencer, fan belt, hydraulic oil level, tank, etc.
Anchorage points. Applied near the holes envisaged for
machine lifting.
Fuel cap. Applied near the fuel cap.
Hydraulic oil. Applied near the hydraulic oil plug or level
indicator.
Engine oil level. Applied near the engine oil dipstick.
Moving gears. Appli ed n ear the fan of the h ea t
exchanger.
Unscrew the plug with extreme caution: hot water.
Risk of burns! Warns the operator of the risk of burns
when unscrewing the plug of the compensation tank of
the heat exchanger.
Hot surfaces. Risk of burns. Applied on those surfaces
which during operation can become hot and cause
burns.
4,5
5,5
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 ination sticker.
(standard) Placed near the wheels, this label shows the
recommended tyre ination pressure.
09.4618.0061
(optional)
09.4618.0241 "GENIE" sticker.
09.4618.0242
09.4618.0243
Page A-7
Document 57.0008.3200 - 09/2006
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MODELLO - TYPE - DÉSIGNATION
MODELL - MODELO
ANNO DI COSTRUZIONE YEAR OF CONSTRUCTION ANNÉE DE CONSTRUCTION BAUJHAR - AÑO DE CONSTRUCCIÓN
MASSA - MASS - MASSE MASSE - MASA
PORTATA NOMINALE - PAY LOAD PORTEE NOMINALL - NENN
TRAGFÄHIGKEIT - CARGA NOMINAL
CENTRO DI GRAVITÀ - CENTER OF
GRAVITY - CENTRE DE GRAVITÉ SCHWERPUNKT - CENTRO DE GRAVEDAD
CENTRO DI CARICO - LOAD CENTER CENTRE DE CHARGE - LASTPUNKT CENTRO DE CARGA
MODELLO MACCHINA - MACHINE MODEL DESOGNATION MACHINE - MASCHINEN MODELL
MODELO MÁQUINA
N° SERIE - SERIAL N°-N° DE SERIE
- SERIEN N°- N° DE BASTIDOR
JUNTO HORQUILLAS
GROUPE FOURCHES-GABELGROUPPE
ASSIEME FORCHE-FORKS ASSY
200
kgkg
kg
kg
TEREXL IFT s rl - ZONA INDUS TRIAL E - 06019 UMBER TIDE ( PG) - ITALY
Tel. (07 5) 94 1.811 Fax (075) 941.5 3.82 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
OMOLOGAZIONE
FABBRICATO IN ITALIA - MADE IN ITALY
PESO MAX ASSALE ANT. - MAX FRONT AXLE WEIGHT - POIDS MAX ESSIEU AVANT
ZUL. ACHSLAST VO. N. ST VZO - PESO MAX EJE ANTERIOR
PESO MAX ASSALE POST. - MAX REAR AXLE WEIGHT - POIDS MAX ESSIEU ARRIERE
ZUL. ACHSLAST HI. N. ST VZO - PESO MAX EJE POSTERIOR
PESO TOTALE - TOTAL WEIGHT - POIDS TOTAL - ZUL. GESAMTGEWICHT N. ST VZO
PESO TOTAL
MATRICOLA MOTORE TERMICO - ENGINE SERIAL N. - N. MOTEUR THERMIQUE
FABRIK NR. DIESEL MOTOR - NO. DE SERIE MOTOR TERMICO
GTH-4013 SX
GENERAL INFORMATION
Decal Code Description
GTH-4013 SX
Kg 4000
09.4618.0721 "GENIE GTH-4013 SX" sticker.
09.4618.0722
09.4616.0040 Max capacity. Indicates the maximum capacity of the
machine.
09.4616.0068 Machine data plate. The identication plate contains
the main identication data of the machine.
09.4616.0109 Fork data plate. This plate shows the main data of
the fork installed on the machine.
ROPS-FOPS cab type-approval plate. This plate
shows the type-approval data of the driving cab
according to ROPS - FOPS regulations.
Page A-8
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ATTENZIONE!
CAUTION!
RECIPIENTE IN PRESSIONE
HIGH PRESSURE ACCUMULATOR
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
GTH-4013 SX
GENERAL INFORMATION
Decal Code Description
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.
09.4618.0514 Caution: accumulator under pressure.
Page A-9
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GENERAL INFORMATION
A-1.3 EXPLANATION OF THE DIFFERENT
SYMBOLS USED ON THE MACHINE
This paragraph illustrates those symbols that are
normally applied on the main control devices and
instruments of a standard machine, and those that
can be applied on accessories or special attachments.
They are mainly (ISO) standardised symbols that are
now part of the common life. But we consider useful to
explain them once again.
Symbol Description Symbol Description
GTH-4013 SX
Spend the necessary time to become familiar with
these symbols and to learn their meaning.
Hazard warning lights
Windscreen washer
Hazard warning lights
Diesel engine water temperature
Fuel level
Hydraulic oil temperature
Position lights
Battery charge
Attachment pushbutton (if any)
Steering mode switch
Brake pressure
Engine oil pressure
Boom up
Boom down
Boom out
Boom in
High beam
Low beam
Fog lamp
Turn signals
Parking brake
Attachment locked
Attachment unlocked
Fork pitching forward
Fork pitching back
Page A-10
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GTH-4013 SX
GENERAL INFORMATION
Symbol Description Symbol Description
Right outrigger down
Right outrigger up
Left outrigger down
Left outrigger up
Sway right
Sway left
Machine sway control
Road setting
Oil lter clogged
Air lter clogged
Lifting point
Page A-11
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200
kgkg
kg
kg
TER EXLIFT srl - ZO NA IND USTRI ALE - 060 19 UMB ERTIDE (PG) - I TALY
Tel. ( 075) 941.81 1 F ax (07 5) 94 1.53.8 2 Tele x 661 06 ITAL MA I
MODELLO - MODEL - MODELE - TYP - MODELO
ANNO DI COSTRUZIONE - YEAR OF MANUFACTURE - ANNEE DE FABRICATION
BAUJAHR - AÑO DE FABRICACIÓN
MATRICOLA - SERIAL N. - N. DE SERIE - FZ.-IDENT NR. - NO. DE SERIE
OMOLOGAZIONE
FABBRICATO IN ITALIA - MADE IN ITALY
PESO MAX ASSALE ANT. - MAX FRONT AXLE WEIGHT - POIDS MAX ESSIEU AVANT
ZUL. ACHSLAST VO. N. ST VZO - PESO MAX EJE ANTERIOR
PESO MAX ASSALE POST. - MAX REAR AXLE WEIGHT - POIDS MAX ESSIEU ARRIERE
ZUL. ACHSLAST HI. N. ST VZO - PESO MAX EJE POSTERIOR
PESO TOTALE - TOTAL WEIGHT - POIDS TOTAL - ZUL. GESAMTGEWICHT N. ST VZO
PESO TOTAL
MATRICOLA MOTORE TERMICO - ENGINE SERIAL N. - N. MOTEUR THERMIQUE
FABRIK NR. DIESEL MOTOR - NO. DE SERIE MOTOR TERMICO
GENERAL INFORMATION
A-2 MACHINE IDENTIFICATION
Check that the operator handbook refers to the
delivered machine.
When asking for information or technical assistance,
always specify model, type and serial number of
the machine.
A-2.1 MACHINE MODEL AND TYPE
Handler with telescopic boom:
❑ model GTH-4013 SX
A-2.2 MANUFACTURER
TEREXLIFT srl
Zona Industriale - I-06019 UMBERTIDE (PG) - ITALY
Enrolled in the register of companies at the Court of
Perugia under no. 4823
C.C.I.A.A. 102886
Fiscal Code/V.A.T. no. 00249210543
GTH-4013 SX
A-2.3 MACHINE IDENTIFICATION PLATES
The following data plates are applied on the machine:
Machine data plate
The identication plate contains the main identication
data of the machine like model, serial number and year
of manufacture.
On machines destined for the Italian market, the data
plate is installed in the driving cab, on the right, and
is well-visible when the door is opened.
On the machines destined for foreign markets, the data
plate is applied on the front right side of the chassis.
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Page A-12
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MODELLO - TYPE - DÉSIGNATION
MODELL - MODELO
ANNO DI COSTRUZIONE YEAR OF CONSTRUCTION ANNÉE DE CONSTRUCTION BAUJHAR - AÑO DE CONSTRUCCIÓN
MASSA - MASS - MASSE MASSE - MASA
PORTATA NOMINALE - PAY LOAD PORTEE NOMINALL - NENN
TRAGFÄHIGKEIT - CARGA NOMINAL
CENTRO DI GRAVITÀ - CENTER OF
GRAVITY - CENTRE DE GRAVITÉ SCHWERPUNKT - CENTRO DE GRAVEDAD
CENTRO DI CARICO - LOAD CENTER CENTRE DE CHARGE - LASTPUNKT CENTRO DE CARGA
MODELLO MACCHINA - MACHINE MODEL DESOGNATION MACHINE - MASCHINEN MODELL
MODELO MÁQUINA
N° SERIE - SERIAL N°-N° DE SERIE
- SERIEN N°- N° DE BASTIDOR
JUNTO HORQUILLAS
GROUPE FOURCHES-GABELGROUPPE
ASSIEME FORCHE-FORKS ASSY
da kg a kg
kg
OMOLOGAZIONE
NUMERO DI IDENTIFICAZIONE
DATI OMOLOGAZIONE STRADALE
MASSA TOTALE AMMISSIBILE (*)
MASSA RIMORCHIABILE AMMISSIBILE:
- MASSA NON FRENATA
- MASSA CON FRENATURA INDIPENDENTE
- MASSA CON FRENATURA AD INERZIA
- MASSA CON FRENATURA ASSISTITA
COEFFICIENTE DI ASSORBIMENTO
CORRETTO DEL MOTORE
CARICO MAX ASSE ANTERIORE (*)
da kg a kg
CARICO MAX ASSE POSTERIORE (*)
(*) In funzione della gommatura
da kg a kg
kg
kg
kg
m
-1
TIPO
Zona Indust riale , I-0 6019 Umbert ide (P G) - Italy
Tel. +3 9 (0)7 5 9418 11 - Fax +3 9 (0) 75 941 5382
GENERAL INFORMATION
GTH-4013 SX
Road trafc data plate
The road trafc 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 trafc related data and the
weights of the specic 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 identication 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
certied and the placing of the CE marking on the
machine demonstrates compliance with the regulatory
requirements.
The CE marking is placed directly on the identication
plate of the machine .
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.
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Page A-13
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GENERAL INFORMATION
GTH-4013 SX
A-3 ALLOWED USE
A-3.1 ALLOWED USE
The handlers have been designed and manufactured for
lifting, handling and transporting agricultural or industrial
products by means of specic attachments (see section
F) manufactured by TEREXLIFT srl.
Any other use is considered contrary to that established
and, therefore, improper.
The compliance with and the strict respect of the
operation, maintenance and repair conditions, indicated
by the Manufacturer, represent an essential part of the
allowed use.
The handler must be used and serviced only by
operators knowing its characteristics and the safety
procedures in depth.
It is also essential to comply with the safety at work
legislation, the precautions concerning safety and
industrial medicine as well as the local and national
road trafc regulations.
Effecting changes or carrying out interventions on
the machine other than those of routine maintenance
is expressly forbidden. Any modification of
the machine not carried out by GENIE or an
authorised assistance centre involves the automatic
invalidation of the conformity of the machine to the
Directive 98/37/EC.
A-3.2 IMPROPER USE
Improper use means a utilisation of the handler following
working criteria that do not comply with the instructions
of this manual, and that, in general, may result in risks
for both operators and bystanders.
We list below some of the most frequent and
hazardous situations of improper use:
- Carrying passengers on the machine
- Not strictly complying with the operation and
maintenance instructions of this handbook
- Working beyond the handler working limits
- Working on unstable edges of ditches
- Driving crosswise on slopes or hills
- Working during a storm
- Working on steep slopes
- Us i n g a t t a c h m en t s o t h e r th a n t ho s e
recommended
- Using attachments not approved or directly
manufactured by Terexlift
- Apply ing loads in diff erent points of the
attachment holding plate
- Working in potentially explosive areas
- Working in conf i n e d and no n- v en t i la t e d
environments
A-3.3 RESIDUAL HAZARDS
Although the machine has been designed and
manufactured according to the latest technology and
all expected hazards have been eliminated, some
operations performed by the machine operator can result
in potentially hazardous situations. Among them:
• Hazards deriving from a too high work or transfer
speed in relation to the load handled or the ground
condition of the jobsite.
• Hazards deriving from work procedures adopted
during the check or replacement of a block valve
(residual pressure - uncontrolled movements).
• Hazards deriving from work procedures adopted
while disassembling parts of the machine -e.g. the
cylinders, without supporting mobile parts suitably
(risk of uncontrolled fall of the mobile part).
• Hazard deriving from an accidental overturning
of the machine in the event the operator has not
fastened the safety belts.
Page A-14
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GENERAL INFORMATION
GTH-4013 SX
A-3.4 APPLICABLE STANDARDS
For the operator’s safety, the following standards were
obeyed during the risk assessment of the handler tted
with telescopic boom norme:
Directive Title
98/37/CE Machinery Directive
89/336/CEE Electromagnetic compatibility
2000/14/CE Environment Acoustic Emissions
Standard Title
EN 1459:1988 Har m o nised stand a r d . Safety o f
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 50082-1: 1997 Electromagnetic compatibility – Generic
requirements on immunity - Part 1.
EN 60204-1:1998 S afety o f machi nery - Electri cal
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 b u r n i n g behaviour of inte r i o r
materials.
ISO 5053:1987 P o w e r e d i n d u s t r i a l t r u c k s -
Terminology.
ISO 6292:1996 Powered industrial trucks and tractors
- Brake performance and component
strength.
EN 13059:1997 Safety of industrial trucks - Test methods
for measuring vibration.
EN 50081-1: 1997 Electromagnetic compatibility – Generic
requirements on emissions - Part 1.
Page A-15
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GENERAL INFORMATION
GTH-4013 SX
A-3.5 SAFETY DEVICES
• Load limiting device. It consists of a load cell tted
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, nd and rectify the
relevant causes, then reset the button to neutral
position turning it clockwise.
Page A-16
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GENERAL INFORMATION
• Block valves tted to all cylinders
A Block valve on attachment coupling cylinder (if
present; the hydraulic cylinder is supplied as
optional part).
B Block valve on lifting cylinder
C Block valve on balance cylinder
D Block valve on boom extension cylinder
GTH-4013 SX
Page A-17
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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
GTH-4013 SX
Page A-18
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2 metri
GENERAL INFORMATION
• Limit switches and safety switches:
L Limit switch tted to the left side of the boom
that, through a jack xed to the chassis, blocks
the rear axle when the boom inclination is above
40°.
M Limit switch tted 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.
GTH-4013 SX
2 metres
Page A-19
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1 2 3
6
510
8 9
7
11 12 13 14 15
GENERAL INFORMATION
A-4 GENERAL DESCRIPTION
A-4.1 LIST OF THE MAIN COMPONENTS
GTH-4013 SX
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 outrigger
10 - Driving cab according to ROPS-FOPS provisions
11 - Front axle
12 - Fuel tank
13 - Access step
14 - Hydraulic oil tank
15 - Rear axle
Page A-20
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GENERAL INFORMATION
GTH-4013 SX
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 lter, 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.
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.
Brake circuit
The brake system is the multidisc type in oil bath, with
self-adjustment, built in the 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. Fork
plate that can be tilted by 138°.
Boom hydraulic circuit
It consists of a pump connected to the thermal engine
which, through a valve, delivers oil to the hydraulic drive
and an actuator for the following functions:
- telescopic boom movements
- attachment rotation
- machine swaying
- attachment locking (optional)
- outrigger operation.
Service hydraulic circuit
It consists of a pump connected to the thermal engine
and delivering oil to the brake system.
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 tted with a wide range of
optional accessories: please address to GENIE sales
network.
Page A-21
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GTH-4013 SX
GENERAL INFORMATION
A-5 TECHNICAL DATA AND PERFORMANCE
I
D
A
B
F
G
H
E
C
J
GTH-4013 SX
A-5.1 MAIN DIMENSIONS
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
GTH-4013 SX
A-5.5 PAYLOAD AND REACH
- 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
GTH-4013 SX
A-5.8 ELECTRICAL SYSTEM
- Voltage ..........................................................................................................................V 12
- 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/s2 < 2.5
- Mean assessed vibration level transmitted to body .................................................. m/s2 < 0.5
Values calculated in accordance with standard prEN13059
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.
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GTH-4013 SX
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.
After this time, the machine must compulsorily be
inspected and tested by the Manufacturer before
being used again.
Five years or 6000 hours after the rst placing
into operation of the machine (whichever occurs
rst), 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
Follow ing items are supplied toge ther with the
machine:
Description GTH-4013 SX
- 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 certicate
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GTH-4013 SX
SAFETY PRECAUTIONS
Section B
SAFETY PRECAUTIONS
TABLE OF CONTENTS
B-1 GENERAL REMARKS .................................................................................................... B-2
B-2 PREREQUISITES OF THE PERSONNEL IN CHARGE ................................................. B-3
B-2.1 Requisites of the machine operators .............................................................................. B-3
B-2.2 Requisites of the servicemen .......................................................................................... B-3
B-2.3 Working clothes .............................................................................................................. B-4
B-2.4 Personal protective equipment ....................................................................................... B-4
B-3 SAFETY PRECAUTIONS ............................................................................................... B-4
B-3.1 Hazards on the jobsite .................................................................................................... B-4
B-3.2 Operation or maintenance hazards ................................................................................. B-5
B-3.3 Machine operation hazards ............................................................................................. B-7
B-3.4 Damaged component hazards ........................................................................................ B-7
B-3.5 Explosion or re hazards ................................................................................................ B-7
B-3.6 Damaged machine hazards ............................................................................................ B-8
B-3.7 Personal injury hazards .................................................................................................. B-8
B-4 SAFETY DEVICES ......................................................................................................... B-8
B-5 MOMENT LIMITING SYSTEM ........................................................................................ B-8
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SAFETY PRECAUTIONS
GTH-4013 SX
DANGER
Not observing the instructions
and safety rules in this manual
may result in death or serious
injury.
Do not operate the machine unless:
* You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1 Avoid hazardous situations.
Read and understand the safety instructions
before going on to the next chapter.
2 Always perform a pre-operation inspection.
3 Always test the machine functions prior to
use.
4 Inspect the work place.
5 Only use the machine for the intended
application.
* Read, understand and obey the manufacturer’s
instructions and the safety rules, the safety and
operator’s manuals, and the decals applied on the
machine.
* Read, understand and obey the employer’s safety
rules and worksite regulations.
* Read, understand and obey the applicable national
regulations.
* Only trained personnel informed on the safety rules
can operate the machine.
B-1 GENERAL REMARKS
Most accidents occurring while working, repairing or
maintaining machines, are caused by not complying
with the basic safety precautions.
Therefore, it is necessary to pay steady attention to
the potential hazards and the effects that may come
of operations carried out on the machine.
If you recognise hazardous situations, you can
prevent accidents!
For instance, this handbook makes use of special
safety symbols to stress any potentially hazardous
situation.
The instructions given in this handbook are the ones
established by GENIE. They do not exclude other
safe and most convenient ways for the machine
installation, operation and maintenance that take
into account the available spaces and means.
If you decide to follow instructions other than those
given in this manual, you shall absolutely:
• be sure that the operations you are going to carry
out are not explicitly forbidden;
• be sure that the methods are safe, say, in compliance
with the rules and provisions given in this section;
• be sure that the methods cannot damage the
machine directly or indirectly or make it unsafe;
• contact GENIE Assistance Service for any suggestion
and the necessary written permission.
If in doubt, it is always better to ask! For this
purpose, contact GENIE: the assistance service is at
your disposal. Addresses, phone and fax numbers
are given in the cover and in the title-page of this
manual.
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B-2 R EQ U I S I T ES O F T H E
PERSONNEL IN CHARGE
B-2.1 RE Q U IS I T ES OF TH E M A CH I N E
OPERATORS
The operators who use the machine regularly or
occasionally (i.e. for transport reasons) shall have the
following prerequisites:
health:
before and during any operation, operators shall
never take alcoholic beverages, medicines or other
substances that may alter their psycho-physical
conditions and, consequently, their working abilities.
physical:
good eyesight, acute hearing, good co-ordination and
ability to carry out all required operations in a safe way,
according to the instructions of this manual.
mental:
ability to understand and apply the enforced rules,
regulations and safety precautions. They shall be
careful and sensible for their own as well as for the
others’ safety and shall desire to carry out the work
correctly and in a responsible way.
emotional:
they shall keep calm and always be able to evaluate
their own physical and mental conditions.
training:
they shall read and be familiar with this handbook, its
enclosed graphs and diagrams, the identication and
hazard warning plates. They shall be skilled and trained
about the machine use.
B-2.2 REQUISITES OF THE SERVICEMEN
The personnel charged with the machine maintenance
shall be qualied, specialised in the maintenance of
earth-moving machines, and shall have the following
prerequisites:
physical:
good eyesight, acute hearing, good co-ordination and
ability to carry out all required maintenance operations
in a safe way, according to this manual.
mental:
ability to understand and apply the enforced rules,
regulations and safety precautions. They shall be
careful and sensible for their own as well as for the
others’ safety and shall desire to carry out the work
correctly and in a responsible way
training:
they shall read and be familiar with this handbook, its
enclosed graphs and diagrams, the identication and
warning plates. They shall be skilled and trained about
the machine functioning.
From a technical point of view, the ordinary
maintenance of the machine is not a complex
intervention and can be carried out by the machine
operator, too, provided he has a basic knowledge
of mechanics.
The operator shall have a licence (or a driving
licence) when provided for by the laws enforced in
the country where the machine works. Please, ask
the competent bodies. In Italy the operator must be
at least 18 year old.
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DE A TH OR I NJU R Y C AN R ES U L T FR O M
CONTACTING ELECTRIC POWER LINES.
ALWAYS CONTACT THE ELECTRIC POWER LINES
OWN ER. THE ELECT RIC POWER SHA LL BE
DISCONNECTED OR THE POWER LINES MOVED
OR INSULATED BEFORE MACHINE OPERATIONS
BEGIN
POWER LINE VOLTAGE REQUIRED CLEARANCE
0 to 50 kV 10 ft 3.00 m
50 to 200 kV 15 ft 4.60 m
200 to 350 kV 20 ft 6.10 m
350 to 500 kV 25 ft 7.62 m
500 to 750 kV 35 ft 10.67 m
750 to 1000 kV 45 ft 13.72 m
SAFETY PRECAUTIONS
GTH-4013 SX
B-2.3 WORKING CLOTHES
During work, but especially when maintaining or
repairing the machine, operators must wear suitable
protective clothing:
• Overalls or any other comfortable garments.
Operators should not wear clothes with large
sleeves or objects that can get stuck in moving
parts of the machine.
• Protective helmet.
• Protective gloves.
• Working shoes.
B-3 SAFETY PRECAUTIONS
B-3.1 HAZARDS ON THE JOBSITE
Always take into account the features of the job site
where you are going to work:
• Always examine the working area and compare
it with the machine dimensions in the different
congurations.
The machine is not electrically insulated and
does not provide protection from contact with or
proximity to electrical power lines.
Always keep at a minimum safe distance from
the telescopic boom and the lifted load. Electrical
hazards!
Use only type-approved working clothing in good
condition.
B-2.4 PERSONAL PROTECTIVE EQUIPMENT
Under special working conditions, the following personal
protective equipment should be used:
• Breathing set (or dust mask).
• Ear-protectors or equivalent equipment.
• Goggles or facial masks.
Use only type-approved protective equipment in
good condition.
• Keep away from the machine in case of contact with
energized power lines. Personnel on the ground
must never touch or operate the machine until
energized power lines are shut off.
Do not at any time use the machine during a
storm.
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A ≥ B
A
B
SAFETY PRECAUTIONS
Make sure the machine (wheels and stabilisers)
rests on a firm ground to prevent hazardous
unstable conditions.
If the ground is not rm enough, position some
supporting planks under the stabilisers or the
wh eels. These plates must gra n t a speci fic
pressure of 1.2 to 1.5 kg/cm2 (500x500mm plates
are sufcient).
GTH-4013 SX
B-3.2 OP E R AT I O N O R M AI N T EN A N CE
HAZARDS
Before any operation, following precautions should be
taken:
• First of all, make sure that the maintenance
interventions have been carried out with care
according to the established schedule (see section
D - Maintenance).
• Look for the best route to the job site.
• When the machine is running, nobody can enter its
working range.
• While working, keep the working area in order.
Never leave objects scattered: they could hinder
the machine movements and represent a danger
for personnel.
• In presence of trenches, lower the outriggers at a
safe distance from the trench edge.
Set the machine to working conguration and sway
it. Use the special inclinometer to the right of the
driving place to check that the machine is level
before operating it.
• Ensure you have enough fuel to avoid a sudden
stop of the engine, especially during a crucial
manoeuvre.
• Clean instruments, data plates, lights and the cab
windscreen thoroughly.
• Check the correct functioning of all the safety
devices installed on the machine and in the job
site.
• In case of troubles or difficulties, inform the
foreman at once. Never start working under unsafe
conditions.
• Do not carry out any repair work in a makeshift way
to start working!
During work, and especially maintenance, always pay
the greatest attention:
• Do not walk or stop under raised loads or machine
parts supported by hydraulic cylinders or ropes
only.
• Keep the machine handholds and access steps
always clean from oil, grease or dirt to prevent falls
or slips.
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• When entering/leaving the cab or other raised parts,
always face the machine; never turn the back.
• When carrying out operations at hazardous heights
(over 1.5 meters from the ground), always use
approved fall restraint or fall arrest devices.
• Do not enter/leave the machine while it is running.
• Do not leave the driving place when the machine is
running.
• Neither stop nor carry out interventions under
or between the machine wheels when engine is
running. When maintenance in this area is required,
stop the engine.
• Except for maintenance purposes, do not remove
safety devices, shields, protection cases, etc.
Should their removal be necessary, stop the engine,
remove them with the greatest care and always
remember to ret them before starting the engine
and using the machine again.
• Before any maintenance or repair work, stop the
engine and disconnect the batteries.
• Do not lubricate, clean or adjust moving parts.
• Do not carry out operations manually when specic
tools are provided for this purpose.
• Avoid the use of tools in bad condition or use in
an improper way i.e. pliers instead of adjustable
wrenches, etc.
• Applying loads in different points of the attachment
holding plate is forbidden.
• B efore carry ing out oper ations on hydra ulic
lines under pressure or disconnecting hydraulic
components, ensure the relevant line has been
previously depressurised and does not contain any
hot uid.
• Do not carry out maintenance or repair works without
a sufcient lighting.
• When using the machine lights, the beam should
be oriented in order not to blind the personnel at
work.
• Before applying voltage to electric cables or
components, check their connection and proper
functioning.
• Do not carry out interventions on electric components
with voltage over 48V.
• Do not connect wet plugs or sockets.
• Plates and hazard warning stickers shall never be
removed, hidden or become unreadable.
Any intervention on the hydraulic circuit must be
carried out by authorised personnel.
The hydraulic circuit of this machine is tted with
pressure accumulators. You and others could be
seriously injured if accumulators are not completely
depressurised.
For this purpose, shut the engine down and step
on the brake pedal 8÷10 times.
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SAFETY PRECAUTIONS
GTH-4013 SX
• Do not empty catalytic mufers or other vessels
containing burning materials without taking the
necessary precautions.
• After any maintenance or repair work, make sure
that no tool, cloth or other object has been left within
machine compartments, tted with moving parts, or
where suction and cooling air circulates.
• When working, do not give instructions or signs to
several people at the same time. Instructions and
signs must be given by one person only.
• Always pay due attention to the instructions given
by the foreman.
• Never distract the operator during working phases
or crucial manoeuvres.
• Do not call an operator suddenly, if unnecessary.
• Do not frighten an operator or throw objects by any
means.
• After work, never leave the machine under potentially
dangerous conditions.
B-3.3 MACHINE OPERATION HAZARDS
Absolutely avoid the following work situations:
• Do not handle loads beyond the maximum capacity
of the machine.
• Do not raise or extend the boom if the machine is
not on a rm, level surface.
• Do not operate the machine in strong wind. Do
not increase the surface area of the machine or
forked load exposed to the wind. Increasing the
area exposed to the wind will decrease machine
stability.
• Use extreme caution and slow speeds when the
machine is driven across uneven or unstable
grounds, slippery surfaces or near trenches or dropoffs.
• Limit travel speed according to ground conditions,
slopes, presence of personnel or other factors which
may cause collision.
• Do not place or attach overhanging loads to any part
of the machine.
B-3.4 DAMAGED COMPONENT HAZARDS
• Do not use battery chargers or batteries with a
voltage above 12V to start the engine.
• Do not use the machine as a ground for welding.
B-3.5 EXPLOSION OR FIRE HAZARDS
• Do not start the engine if you smell or detect
LPG, gasoline, diesel fule or other explosive
substances.
• D o no t re f u el the machine with the engine
running.
• Refuel the machine and charge the battery only in a
well ventilated area away from sparks, naked ames
and lighted cigarettes.
• D o n o t operate the mach i n e in da n g e r ou s
environments or in places with flammable or
explosive gases or materials.
• Do not inject ether in engines equipped with glow
plugs.
• Do not leave fuel cans or bottles in unsuitable
places.
• Neither smoke nor use open flames in areas
subject to re dangers and in presence of fuel, oil
or batteries.
• Carefully handle all flammable or dangerous
substances.
• Do not tamper with re-extinguishers or pressure
accumulators: explosion hazard!
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B-3.6 DAMAGED MACHINE HAZARDS
• Do not use a damaged or defective machine.
• Do a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Tag and remove from service a damaged or
defective machine.
• Make sure that all maintenance jobs have been
carried out as specied in this manual and the
appropriate service manual.
• Make sure that all decals are in place and legible.
• M a ke sure that th e operat o r ’s , safety and
responsibilities manuals are intact, legible and
placed in the special container located in the
machine.
B-3.7 PERSONAL INJURY HAZARDS
• Do not operate the machine in case of hydraulic oil
or air leak. Air or hydraulic oil leaks can penetrate
or burn the skin.
• Always operate the machine in a well ventilated area
to avoid carbon monoxide poisoning.
• Do not lower the boom if the area underneath is not
clear of personnel or obstructions.
B-4 SAFETY DEVICES
Several safety devices have been fitted to the
machine. They must never be tampered with or
removed (see chap. A-3.5).
Regularly check the efciency of such devices (see
check card, chap. G-5).
In case of faults, stop working immediately and
proceed in replacing the defective device.
For the checking procedures, read chap. D-3.17.
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.
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GTH-4013 SX
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 Steering mode selection ............................ C-12
C-3.2.7 Road/Jobsite switch ................................... 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-4 SETUP .......................................................C-25
C-4.1 Before starting the engine .........................C-25
C-4.1.1 Checks at the machine start-up ................. C-25
C-4.2 Starting the engine ....................................C-25
C-4.3 Jump-starting the engine ........................... C-26
C-4.4 Low temperature starting ........................... C-27
C-4.5 Starting the machine .................................. C-28
C-4.6 Stopping and parking the machine ............ C-28
C-5 USING THE HANDLER ............................C-29
C-5.1 Using the load charts ................................. C-30
C-5.2 Load limiter ................................................C-31
C-5.2.1 Description of the controls ......................... C-31
C-5.2.2 Operation ................................................... C-31
C-5.2.2 Alarm codes and resetting ......................... C-32
C-5.3 Handling loads ........................................... C-33
C-5.3.1 Adjusting the forks .....................................C-33
C-5.3.2 Working phases ......................................... C-34
C-5.4 Changing the optional attachment ............. C-35
C-6 TRANSPORTING THE MACHINE ............C-37
C-6.1 Moving a disabled machine ...................... C-37
C-6.1.1 Dismantling the Cardan shaft ....................C-37
C-6.2
C-6.3 Lifting the machine ....................................C-39
C-6.4 Transporting the machine .......................... C-39
C-6.4.1 Transporting the machine on other
vehicles ......................................................C-39
C-6.5 Parking and storage ..................................C-40
C-6.5.1 Short inactivity ...........................................C-40
C-6.5.2 Machine storage ........................................C-40
C-6.6 Cleaning and washing the machine ........... C-41
C-6.6.1 Cleaning instructions .................................C-41
C-6.6.2 Washing instructions..................................C-41
C-6.7 Machine disposal ....................................... C-41
C-6.7.1 Disposal of batteries .................................. C-41
Road or site transfer
.................................... C-38
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INTRODUCTION
This section provides the operator a practical guide for
the gradual learning of the machine use.
The operator should get into the driving cab and carry
out the preliminary adjustments, then memorise the
position of the different controls and instruments.
The familiarisation with the controls ensures not only
a correct use during the working phases, but also a
prompt and timely intervention of the operator, when
he shall carry out sudden manoeuvres to safeguard his
safety and the machine integrity.
It is necessary to learn how to use and foresee the
machine reactions. Learn how to operate the machine
controls in a safe and open place, without obstacles
and anybody standing around. Do not ram the controls.
Operate them slowly to understand their effect on the
machine.
C-1
PRE-OPERATION INSPECTION
Fundamentals
It is the operator responsibility to perform a preoperation inspection and routine maintenance.
Pre-operation inspection means a visual inspection
performed by the operator prior to each work shift.
The inspection has to be carried out on the machine to
detect possible faults before the operator starts testing
the machine functions.
The pre-operation inspection also helps understand if
some routine maintenance procedures are required.
The operator can only perform the routine maintenance
procedures envisaged in this manual.
See the list on the next page and check each single
component.
If the machine is damaged or a non-authorized
modication has been done, the machine must be
tagged and removed from service.
Repairs must be carried out by qualied technical
pe r so n ne l a c cor din g t o t h e m an u fac tur er ’s
specications. After any repair, the operator should
repeat the pre-operation inspection before testing the
machine functions.
Do not op erat e t he mach ine,
unless:
* You learn and practice the principles of safe
1 Avoid hazardous situations.
Read and understand the safety rules before
2 Always perform a pre-operation inspection.
Read and understand the safety rules before
3 Always test the machine functions prior to use.
4 Inspect the work place.
5 Only use the machi n e fo r the int e n de d
Schedul e d mai n t e na n ce pro c e d ur e s must be
performed by qualied technical personnel according
to the technical specications of the manufacturer
and the requirements envisaged in the responsibilities
manual.
machine operation contained in this operator’s
manual.
going on to the next chapter.
going on to the next chapter.
application.
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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 uid leaks and proper uid level.
Add distilled water if necessary. See “Maintenance”
chapter.
Check the following components or zones for damage,
missing or wrongly fitted parts or non-authorised
modications:
• electrical components, wiring and electrical
cables
• hydraulic hoses, ttings, cylinders and main
valves
• fuel and hydraulic oil tanks
• drive pump and motor and transmission axles
• steering system
• braking system
• boom telescopes sliding pads
• clean glasses, lights and rear view mirrors
• engine and relevant components
• limit switches and horn
• lights
• machine ignition control
• nuts, bolts and other fasteners
Check the entire machine for:
• cracks on welds or structural components
• dents or damage to the machine.
* Make sure that all structural and other critical
components are present and the relevant fasteners
and pins are tted and properly tightened.
* After inspection, check that all the compartment
covers are in place and latched.
If even one single item is damaged or defective,
do not start work. Stop the machine and repair the
fault.
Checking the tyres
* Check the correct ination of the tyres; see par. “Tyre
ination” in the Maintenance section
* Make sure that the tyre plies are not cut or worn.
A tyre burst may result in serious injury; never use
the machine if tyres are worn, wrongly inated or
damaged.
If the machine shall be used in a marine or equivalent
environment, protect it against salt deposits with
an adequate treatment against saltiness to prevent
rust formation.
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C-2 ENTERING THE MACHINE
C-2.1 ENTERING THE CAB
Always make sure that your hands and shoe soles
are clean and dry before getting into the driving
cab. Always face the machine when entering and
leaving it and hold to the suitable handles.
The handler cab is equipped with an access door on
the left-hand side.
Door opening from outside:
• Insert the key and release lock 1.
• Press the pushbutton 1 and open the door.
GTH-4013 SX
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.
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.
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.
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C-2.2 ADJUSTING THE SEAT
Position the seat so you can comfotarbly reach all the
controls. The handler seat is tted 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
eld.
GTH-4013 SX
• Adjusting the backrest angle
Operate lever D, press your back rmly 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.
• 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
GTH-4013 SX
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.
Before driving the machine, ensure the steering
wheel is perfectly clamped.
C-2.5 ADJUSTING THE REAR VIEW MIRRORS
The machine is tted with two rear view mirrors:
• Rear view mirror 55 is located on a special supporting
bracket in advanced position and allows checking
the area behind the machine, on the right-hand side.
To adjust its position, manually rotate the joint it is
tted 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 tted with.
56
55
C-2.6 SWITCHING ON THE CAB INTERIOR
LAMP
The ceiling light xture is xed to the rear top strut of
the cab. The relevant lamp is switched on/off by switch
A.
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OPERATING INSTRUCTIONS
C-3 DRIVING PLACE
C-3.1 CONTROLS AND INSTRUMENTSC-3.1 CONTROLS AND INSTRUMENTS CONTROLS AND INSTRUMENTSCONTROLS AND INSTRUMENTS
1 Fresh air ap
2 Road/Jobsite switch
3 Forward/reverse gear selector switch
4 Locking lever - steering column angle
adjustment
5 Switch: turn signals - windscreen washer - horn
6 Load limiter disabling key
7 Ignition switch
8 Engine coolant temperature indicator
9 Hydraulic oil temperature indicator
10 Load moment indicator
11 Light indicators and warning lights
12 Fuel gauge
13 Steering selector switch
14 Hourmeter
15 Emergency stop pushbutton
16 Hazard warning lights switch
17 Air conditioning fan switch
18 Road lights switch
19 Fog lamp switch
20 Inclinometer
21 Multipurpose control lever
22 Machine sway control lever
23 Left outrigger control lever
24 Right outrigger control lever
25 Attachment locking/unlocking lever (optional)
26 Gas pedal
27 Brake pedal
28 Cab heater control cock
29 Adjustable seat
30 Fuses and relays board
31 Parking brake lever
32 Windscreen water reservoir
33 Storage pocket
34 Rear wiper
GTH-4013 SX
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OPERATING INSTRUCTIONS
GTH-4013 SX
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OPERATING INSTRUCTIONS
GTH-4013 SX
C-3.2
C-3.2.1 Ignition switch
Five-position switch:
No circuit under voltage, key can be removed
Circuits under voltage, presetting for the engine
Thermal starter for cold climates. Turn the key to
Engine starting; when released, key springs back
ENGINE CONTROLS AND INSTRUMENTS
and engine is stopped.
starting. Board controls and instruments are
on.
this position and hold it for 10÷15 seconds, then
turn it to pos. I to start the engine.
to pos. I automatically.
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
3
1
0
2
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OPERATING INSTRUCTIONS
GTH-4013 SX
C-3.2.3 Turn signals - Windscreen wiper - Horn
- Lights
Horn function:
When sliding the lever along its axis, horn switches on,
independently from other pre-set functions.
Windscreen washer function:
Push the second stage of the lever along its axis to
direct a jet of water onto the cab windscreen.
Lights function:
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.
Windscreen wiper function:
To operate the windscreen wiper, rotate the lever tip to
one of the four positions:
I Intermittence (not activated)
0 Wiper OFF
J Low speed
I I High speed
Turn signals function:
Set lever to pos. 1 to indicate a turn leftwards or to pos.
2 to indicate a turn rightwards.
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OPERATING INSTRUCTIONS
GTH-4013 SX
C-3.2.4 Brakes
27 Service brake pedal
Gradually step on the brake pedal to decelerate and stop
the machine. The pedal operates on the rear axle.
31 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 rear axle and, when
engaged, it cuts both forward and reverse gear off.
Never use the parking brake to slow down the
machine, unless in an emergency. It may reduce
the brake efciency.
C-3.2.5 Accelerator control
26 Gas pedal
Its pressure controls the engine rpm and the machine
speed. It is tted with an adjustable stop in the lower
part.
31
27
26
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OPERATING INSTRUCTIONS
C-3.2.6 Steering mode selection
13 Steering mode switch
Three-position switch for the selection
of the steering mode:
1 Crab steering
0 Two-wheel steering
2 Four-wheel steering
C-3.2.7 Road/Jobsite switch
Switch 2 has two positions and is tted
B
with a position locking device:
1 The switch is on and the jobsite mode
is enabled.
2 The switch is off and the machine is
set to road transfer mode.
The selector has a safety block to avoid any accidental
switching. Before switching the selector to another
position, unlock control B at the top of the selector.
GTH-4013 SX
In Jobsite mode:
• all the machine functions are enabled.
In Road transfer mode:
• the boom movement is disabled
• only the two-wheel steering mode is enabled.
2
13
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OPERATING INSTRUCTIONS
GTH-4013 SX
C-3.2.7 Auxiliary drive controls
They are located on the dashboard, to the right.
16 Hazard warning lights switch
Fitted with on-off position, it switches on the
turn signals simultaneously. When the hazard
warning light is lit, the relevant switch and the
turn signals light start ashing.
.
17 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).
28 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 counter-clockwise to switch on the
cab heater.
• Adjust the ow of heated air in the cab operating the
A/C fan switch 17.
28
19 Fog lamp switch
Two-position switch placed on the right side
of the dashboard:
0 Fog lamp OFF
1 Fog lamp ON (the switch indicator lights
up).
19 18 17 16
28
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OPERATING INSTRUCTIONS
GTH-4013 SX
C-3.3
INSTRUMENTS AND WARNING LIGHTS
C-3.3.1 Instruments
8 Engine coolant temperature indicator
This indicates the engine coolant temperature. If the
nger is in the red zone and the warning light comes
on, you must stop the machine and nd and rectify the
problem.
9 Hydraulic oil temperature indicator
This indicates the temperature of the hydraulic oil in
the tank. If the temperature rises above the permissible
value or the red warning light comes on, you must stop
the machine and nd and rectify the problem.
12 Fuel gauge
This indicates the fuel level in the tank.
If the fuel level is low (reserve), the relevant warning
light comes on.
14 Hour-meter
Signals the total operating hours of the machine. Use the
hour-meter to gauge the routine maintenance jobs.
8 9 12
14
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OPERATING INSTRUCTIONS
GTH-4013 SX
C-3.3.2 Warning lights (ref. 11)
11.1 Warning light - low battery charge
Signals a low charge by the alternator.
11.2 Warning light - hydraulic oil lter clogged
When this lamp sets to on, immediately change the oil
lter on the return line to the tank.
11.3 Warning light - air lter restricted
When this lamp come on, proceed with cleaning or
changing the air lter cartridge.
11.4 Warning light - low engine oil pressure
It lights when the engine oil pressure is too low.
11.5 Warning light - parking brake engaged
When ON, this light indicates that the parking brake
is engaged.
11.6 Warning light - low brake pressure
It lights when the pressure of the braking circuit is too
low for a correct functioning.
11.8 Warning light - turn signals
Green indicator light that signals when turn signals
are ON.
11.9 Warning light - position lights
Green warning light that signals when position lights
are ON.
11.10 General alarm warning light
This red light comes on to warn of a problem of the
machine. Contact the GENIE Service Centre.
11.11 Warning light - glow plugs preheating
This orange light comes on during the pre-heating of
the engine glow plugs. Before starting the engine wait
for this light to go off.
11.7 Warning light - high beam
Blue warning light that signals when high beam is
ON.
11.11
11.1 11.2 11.3 11.4 11.5 11.7 11.8 11.9
11.6
11.10
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OPERATING INSTRUCTIONS
C-3.4 CONTROL LEVER
The handlers are equipped with a joystick with servoassisted hydraulic control for the boom lifting/lowering
movements and the boom telescopes in/out movements.
Pressing the red button 1 on the joystick switches the
telescope out/in-movement to the attachment frame
pitching.
On the right side, near the joystick, there are four levers
2 for the independent operation of the following functions:
machine sway control, attachment locking/unlocking
(optional), left and right outrigger movement.
Seize the control lever correctly and move it
gently.
The motion speed of the actuators depends on
the lever position: a small motion results in a slow
motion of the actuators; vice versa, a full range
motion of the lever corresponds to the max. speed
of the actuator.
GTH-4013 SX
The control lever shall be operated only when
correctly seated in the driving place.
Before operating the control lever, make sure
that nobody is within the working range of the
machine.
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OPERATING INSTRUCTIONS
GTH-4013 SX
C-3.4 .1 Function selection
the lever 21 is enabled to carry out the following
functions:
Without pressing button :
• Boom lifting/lowering
shift the control lever to or
• Boom extension/retraction
shift the control lever to or
Pressing button :
• Boom lifting/lowering
shift the control lever to or
• Attachment frame forward/back pitching
shift the control lever to or
The four levers control the following functions in an
independent way:
Machine sway function
Attachment locking/unlocking (optional)
Left outrigger movement
Right outrigger movement
21
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OPERATING INSTRUCTIONS
GTH-4013 SX
C-3.4.2 Emergency stop
The operated functions can be stopped at any time by
pressing the emergency stop button 15.
By pressing this button, the engine of the machine is
shut down.
Before restarting the machine, it is necessary to reset
the pushbutton by rotating it clockwise.
Before restarting the machine, nd and rectify the
faults that caused the emergency.
6
C-3.4.3 Disabling the load limiting system
The load limiter can be deactivated operating the keyselector placed under the protection cover 6.
WORKING WITH THE LOAD LIMITING SYSTEM CUT
OUT CAN RESULT IN A MACHINE OVERTURNING
AND IN SERIOUS INJURY.
15
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C-3.4.4 Lifting/lowering the boom
Before operating the boom, make sure that nobody
is within the working range of the machine.
To lift or lower the boom:
• Smoothly shift the lever to position to lift the boom
or to position to lower it.
GTH-4013 SX
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C-3.4.5 Extending/retracting the boom
Before operating the boom, make sure that nobody
is within the working range of the machine.
To extend or retract the telescopic elements of the
boom:
• Smoothly shift the lever to position to extend the
boom or to position to retract it.
GTH-4013 SX
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C-3.4.6 Pitching the attachment holding frame
forward/back
Before operating the boom, make sure that nobody
is within the working range of the machine.
To tilt forward/back the attachment holding frame:
• Press the button on the joystick
• Smoothly shift the lever to position to pitch the
holding frame forward or to position to pitch the
holding frame back.
GTH-4013 SX
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OPERATING INSTRUCTIONS
C-3.4.7 Qu ic k- coupling the att ac hments
(optional)
Before operating the boom, make sure that nobody
is within the working range of the machine.
To lock/unlock the attachments:
• Shift the lever toward the cab windscreen to
release the attachment
• Shift the lever toward the operator’s seat to lock
the attachment.
Before using the machine, visually check the
attachment is correctly coupled.
GTH-4013 SX
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1
D
C
4
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3
A
B
2 metri
OPERATING INSTRUCTIONS
C-3.4.8 Machine sway control
Do not operate the sway control, when boom is
raised beyond the horizontal position.
To sway the machine:
• Shift the lever toward the cab windscreen o
sway the machine by lowering the right side.
• Shift the lever toward the operator’s seat to sway
the machine by lowering the left side.
Check that the machine is level on inclinometer 20.
The water level must be right in the middle of the
instrument.
GTH-4013 SX
When the boom is raised above 2 metres, the
machine sway control is inhibited.
2 metres
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2 metri
OPERATING INSTRUCTIONS
■ C-3.4.9 Outrigger movements
Before lowering the outrig gers, make sure
that nobody is within the working range of the
machine.
To operate the outriggers:
Right outrigger
• Shift the lever to position to lower the right
outrigger.
• Shift the lever to position to raise the right
outrigger.
Left outrigger
• Shift the lever to position to lower the left
outrigger.
• Shift the lever to position to raise the left
outrigger.
GTH-4013 SX
When the boom is raised above 2 metres, the
machine sway control is inhibited.
2 metres
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OPERATING INSTRUCTIONS
GTH-4013 SX
C-4 SETUPC-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-4.1.1 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 system is activated and 0 appears on
the display.
If during the check phase, the load limiting system nds
a fault, it enters the safety mode automatically blocking
any dangerous manoeuvres and an error message starts
ashing on the display. For any further information, refer
to chap. C-5.2.
Also check the efciency of the safety devices as
described in chap. D-3.17, namely:
• overload warning system
• emergency pushbutton
• machine start control
• parking brake proximity switch
C-4.2 STARTING THE ENGINE
• Set the forward/b ack spe ed lever to neutral
position.
• 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
engagin g a gear; th is
allows for a gradual warm
up of the engine oil and a
better lubrication.
• In case of engine jumpst ar t i n g, r em ov e th e
connecting cables (see following chapter).
If the light indicators do not switch off/on when
engine is running, immediately stop the machine
and nd and rectify the fault.
Engine cannot be started if the speed switch is not
in the neutral position.
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.
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C-4.3 JUMP-STARTING THE ENGINEC-4.3 JUMP-STARTING THE ENGINE
Do not start the engine using a quick charge booster
to avoid any damage to the electronic boards.
When jump-starting the engine through the
battery of another machine, make sure that the
two vehicles cannot collide to prevent formation
of sparks. Batteries give off a ammable gas and
sparks may burn it and cause an explosion
Do not smoke when checking the electrolyte
level.
Keep any metal object like buckles, watch straps,
etc. clear of the battery positive (+) terminal.
These elements can short between the terminal
and nearby metal work and the operator can get
burned.
The booster supply must have the same rated
voltage and output of the battery installed on the
handler.
To jump-start the engine:
• Turn any users off by the special control levers.
• Put the gear lever to neutral and engage the parking
brake.
• Ensure the machine battery A is connected to the
frame earth, the terminals are well tightened and
the electrolyte level is regular.
• Connect the two batteries as shown in the gure.
Connect first the positive terminals of the two
batteries, then the negative terminal of the booster
supply B to the machine frame earth.
• If the booster supply is installed on a second vehicle,
make sure that the latter does not touch the handler.
To avoid damage to the electronic instruments
of the machine, the engine of the machine
where the booster supply is installed, must be
stopped.
• Turn the ignition key and start the handler, then
follow the procedure explained in chapter C-4.2
“Starting the engine”.
GTH-4013 SX
• Disconnect the cables. Remove rst the negative
terminal from the frame earth, then from the booster
supply. Disconnect the positive terminal from the
machine battery, then from the booster supply.
Use only a 12V battery; other devices like battery
chargers, etc. may cause an explosion of the battery
or result in damage to the electrical system.
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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.
GTH-4013 SX
To start the engine from cold, proceed as follows:
• Set the forward/b ack spe ed lever to neutral
position.
• Turn the ignition switch to the glow plugs preheating
position and wait until the relevant warning light
11.11 goes off. Step down on the gas pedal and start
the engine by turning the ignition switch. Release
the switch as soon as the engine res.
• 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.
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GTH-4013 SX
C-4.5 STARTING THE MACHINEC-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 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.
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 S T O PP IN G A N D PA R K I N G T H EC-4.6 S T O P P IN G AN D PA R K I N G TH E
MACHINE
When possible, stop the machine on a dry, level and
solid ground. Then:
• Bring the machine to a smooth stop by easing up the
gas pedal and stepping down on the brake pedal.
• Set the forward/b ack spe ed 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 at on the
ground.
• Rotate the ignition key to “0” and remove the key.
• Leave the driving cab and lock the cab door.
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.
Always engage the parking brake after stopping the
machine to prevent possible accidental motions of
the vehicle.
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OPERATING INSTRUCTIONS
C-5 USING THE HANDLER
This chapter describes some techniques and provides
instructions for a safe use of the machine tted with
standard forks. Before using different attachments,
thoroughly read the chapter “Optional attachments”.
Before using the machine, inspect the job site and
check for possible hazardous conditions. Make
sure that there are no holes, moving banks or
debris that may cause you to lose the control of
the machine.
GTH-4013 SX
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.
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.
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1
0
1
2
3
4
5
6
7
8
9
10
0°
10°
50°
02345678910
11
12
13
14
A
B
C
D
E
6270
13000
1980
9020
70°
60°
40°
30°
20°
1500 kg
2000 kg
2500 kg
3000 kg
3500 kg
4000 kg
1250 kg
LOAD CENTRE = 600 mm
1
0
1
2
3
4
5
6
7
8
9
10
0°
10°
50°
02345678910
11
12
13
14
LOAD CENTRE = 600 mm
250 kg
A
B
C
D
E
6200
12810
2040
9080
20°
30°
40°
60°
70°
500 kg
1500 kg
1000 kg
2000 kg
2500 kg
3000 kg
3500 kg
4000 kg
OPERATING INSTRUCTIONS
C-5.1 USING THE LOAD CHARTSC-5.1 USING THE LOAD CHARTS
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 B must be used when working with outriggers,
whilst chart A 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.
The load charts illustrated in this manual are given
only as a mere example. To dene the payload
limits, refer to the load charts applied within the
cab of your machine.
GTH-4013 SX
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.
A B
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OPERATING INSTRUCTIONS
GTH-4013 SX
C-5.2 LOAD LIMITER
On the front top strut of the cab, there is limiter 34 which
warns the operator of the variation of stability of the
machine and blocks any manoeuvre before the same
reaches a critical condition.
C-5.2.1 Description of the controls
1 Calibration selection button
2 Display
3 Stability indicator with LED-bar
4 Green light - power OK
5 Yellow light - calibration mode
6 Calibration conrmation button
7 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
C-5.2.2 Operation
When power is turned on, light 4 comes on. The display
2 remains off and the monitoring system runs a self-
test before displaying 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
continuous ly and any danger ous
manoeuvre is blocked. The operator
can only retract the load within safety
limits.
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 ashes and the buzzer
sounds with an intermittent sound.
Example of use of the overload warning system
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
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Before using the machine, make sure that the rst
green LED of the overload warning system is ON.
The overload warning system must not be used to
check the load going to be lifted: it has only been
designed to signal possible unbalances of the
machine along its motion axis.
Such unbalances may also be caused by an abrupt
operation of the levers during the load handling. If,
during work, several indicators light up, operate the
levers more smoothly.
GTH-4013 SX
C-5.2.3 Alarm codes and resetting
The limiter has diagnostic facilities to aid in the
identication of failures of the transducers, breakages
of the cables or defects of the electronic system.
When a failure is signalled, the limiter enters the safety
mode blocking any dangerous manoeuvres. Lights 5,
8 and 10 start ashing, the buzzer start sounding and
an error message is shown on the display.
The meaning of the error messages is shown in Section
E “Faults and Troubleshooting”.
5 8
10
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C-5.3 HANDLING LOADS
C-5.3.1 Adjusting the forks
With FEM 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.
With oating forks
In the case of oating forks:
• Loosen the nut of the locking screws.
• Raise the forks and slide them on the pivot until
correct spacing.
• Lock the screws re-tightening the nut.
GTH-4013 SX
• 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.
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C-5.4 WORKING PHASES
When forks are correctly spaced, the handler is ready
to use.
Work can be subdivided into three different phases:
loading, transfer and unloading.
Loading phase
• Approach the load to the handled perpendicularly
an d check that the machi ne is level on the
inclinometer.
• Insert the forks under the load and raise the load
some centimetres.
• Pitch the forks back to retract the load.
Transfer phase
• Do not start or brake abruptly.
• Drive to the unloading point cautiously and keep the
load 20÷30 cm from the ground.
• Suit the machine speed to the ground conditions to
avoid dangerous jumps, side skids of the vehicle
and possible load falls.
• When driving on slopes or ramps, hold the load
uphill.
GTH-4013 SX
Do not move off when the load is raised 20÷30 cm
above the ground. Risk of machine overturning or
load fall.
Do not drive on slopes sideways; this wrong
manoeuvre is one of the main reasons for accidents
due to vehicle overturning.
Unloading phase
• Drive to the unloading point with straight wheels and
bring the machine to a smooth stop leaving enough
space to operate the boom.
• Put the parking brake and set the transmission to
neutral.
• Position the load some centimetres above the
desired position and set the forks level.
• Lower the load and make sure it is level.
• Carefully withdraw the forks by operating the boom
retraction control and, if necessary, raise or lower
the boom as forks come out.
• When the forks are clear of the load, set them to
transfer position.
• Release the parking brake and start a new working
cycle.
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C-5.5 CHANGING THE ATTACHMENT
GTH-4013 SX
Use only attachments directly manufactured or
recommended by Terexlift and detailed in the
“Optional attachments” section.
Version with hydraulic locking (optional)
To change an attachment, operate as follows:
• Drive to the place where you will release the
mounted attachment (when possible, a solid and
sheltered site).
• Disconnect the quick connectors of the attachment
(if any), and connect the hydraulic locking pipes of
the attachments to couplings A.
After substitution, visually check the attachment
is correctly coupled to the boom, before operating
the machine. A wrongly coupled attachment may
result in damage to persons or things.
• Rest the attachment at on the ground.
• Free the attachment operating the control of the
attachment locking/unlocking cylinder
• Pitch the attachment holding frame forward and
lower the boom to release the attachment upper
lock.
• Move back with the machine and drive to the new
attachment to be coupled.
• Hold the frame pitched forward and hook the upper
lock of the new attachment.
• Retract and raise the attachment some centimetres.
It will centre automatically on the quick coupling
frame.
• Operate the (optional) control lever to lock the
attachment.
• Couple the connectors of the attachment, if any, to
the quick couplings of the frame.
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Version with mechanical locking
To change an attachment, operate as follows:
• Drive to the place where you will release the
mounted attachment (when possible, a solid and
sheltered site).
• Disconnect the quick connectors of the attachment
(if any).
• Pull out pin B locking the attachment after removing
the safety split-pin at its end.
• Rest the attachment at on the ground.
• Pitch the attachment holding frame forward and
lower the boom to release the attachment upper
lock.
• Move back with the machine and drive to the new
attachment to be coupled.
• Hold the frame pitched forward and hook the upper
lock of the new attachment.
• Retract and raise the attachment some centimetres.
It will centre automatically on the quick coupling
frame.
• Ret pin B xing it with its safety split-pin.
• Re-couple the connectors of the attachment (if
any).
GTH-4013 SX
After substitution, visually check the attachment
is correctly coupled to the boom, before operating
the machine. A wrongly coupled attachment may
result in damage to persons or things.
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OPERATING INSTRUCTIONS
GTH-4013 SX
C-6 TRANSPORTING THEC-6 TRANSPORTING THE
MACHINE
C-6.1 MOVING A DISABLED MACHINEC-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.
• Set the forward/b ack spe ed lever to neutral
position.
• Raise the front wheels of the machine and remove
the Cardan shaft of the transmission (see chap.
C-6.1.1).
• When possible, start the engine and use the
hydraulic drive and the braking system.
C-6.1.1 Dismantling the Cardan shaft
Before towing a disabled machine, dismatle the two
(front and rear) Cardan shafts loosening the screws that
x them to the axle and the reduction gear as shown
in the picture.
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C-6.2 ROAD OR SITE TRANSFERC-6.2 ROAD OR SITE TRANSFER
When travelling on public roads, strictly obey the local or national
road trafc regulations.
Besides, take into account the following general precautions:
• Allineare le ruote posteriori.
• Align the rear wheels.
• 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 oating forks.
With the oating forks pitched
back, do not move the fork
pitching cylinder as the machine
could suffer from damage.
GTH-4013 SX
Only for the Italian market
• Retract boom and attachment to transfer position.
• Set the Road/Jobsite switch to “ROAD”.
• Make sure that lights, horn and turn signals are in working
order.
• The transfer speed of the vehicle will depend on the engine
rpm and the position of the control lever.
Public road circulation is allowed only for transferring an
unloaded machine.
Do not use the machine to tow trailers.
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OPERATING INSTRUCTIONS
GTH-4013 SX
C-6.3 LIFTING THE MACHINE
When the machine shall be lifted, use only means
having a suitable capacity. The characteristic data are
detailed in the relevant chapter of this manual and on
the identication plate.
For the machine lifting, anchor the chains to the special
lugs on the machine (marked with the decal below).
C-6.4 TRANSPORTING THE MACHINE
C-6.4.1 Transporting the machine on other
vehicles
To transport the machine on another vehicle, follow
the steps below:
• Ensure ramps are correctly positioned.
• Retract the boom to transfer position.
• Carefully drive the machine onto the transporting
vehicle.
• Put the parking brake and rest the attachment at
on the vehicle platform.
• Ensure the overall dimensions do not exceed the
allowed limits.
• Shut the engine down and close the driving cab of
the machine.
• Secure the machine to the vehicle platform by wheelchocks.
• Anchor the machine to the transporter's platform by
xing the chains to the special eyebolts A on the
chassis.
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GTH-4013 SX
C-6.5 PARKING AND STORAGE
C-6.5.1 Short inactivityrt 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.
C-6.5.2 Machine storageC-6.5.2 Machine storage
In case of extended inactivity of the machine, follow the
above precautions. Additionally:
• Wash the machine thoroughly. For a better cleaning,
remove grills and protection casings.
• Carefully dry all machine parts by blowing some
compressed air.
• Lubricate the machine thoroughly.
• Do a walk-around inspection and replace any worn
or damaged part.
• Re-paint any worn or damaged part.
• Remove the battery, smear its terminals with
vaseline and store it in a dry place. Battery can be
used for other purposes. Otherwise, periodically
check its charge level.
• Refuel the tank to prevent internal oxidation.
• Store the machine in a sheltered and well-ventilated
place.
• Start the engine for about 10 minutes at least once
a month.
• When weather is particularly cold, empty the
radiator.
Always remember that the ordinary maintenance
must be carried out even during the machine
inactivity. Pay particular attention to the uid levels
and to those parts subject to ageing. Before restarting the machine, carry out an extraordinary
maintenance and carefully check all mechanical,
hydraulic and electrical components.
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GTH-4013 SX
C-6.6 C LE A N I NG AN D W AS H I N G T HE
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
Do not use water at high pressure for washing the
machine and especially the main valve, the solenoid
valves and electrical parts.
External washing
Before washing the machine, check that the engine is
shut down and the doors and windows are closed.
Do not, at any times, use fuel to clean the machine. Use
water or some steam. In cold climates, dry the locks
after washing or smear them with an antifreeze.
Before using the machine again, check its conditions.
Internal washing
Wash the machine interior with some water and a
sponge. Do not use water at high pressure. After
washing, dry with a clean cloth.
Washing the engine
Before washing the engine, protect the air intake lter
to prevent water from entering the circuit.
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.
C-6.7 MACHINE DISPOSAL
At the end of the machine life, call in a specialised
rm to dispose of it in compliance with the local or
national regulations.
C-6.7.1 BATTERY DISPOSAL
Used lead-acid batteries cannot be disposed of
as normal industrial solid wastes. Because of the
presence of harmful substances, they must be
collected, eliminated and/or recycled in accordance
with the laws of the UE.
In Italy, used or discarded batteries have been
classied 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 riuti piombosi”
(Cobat) which collect and dispose of used lead-acid
batteries throughout the national territory.
Used batteries must be kept in a dry and conned
place. Make sure the battery is dry and the cell
plugs are tight. Place a sign on the battery to warn
of not using it. If before disposal the battery is left
in the open air, it will be necessary to dry, smear
the box and the elements with a coat of grease and
tighten the plugs. Do not rest the battery on the
ground; it is always advisable to rest it on a pallet
and cover it. The disposal of batteries shall be as
rapid as possible.
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GTH-4013 SX
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GTH-4013 SX
MAINTENANCE
Section D
MAINTENANCE
TABLE OF CONTENTS
D-1 LUBRICANTS - HEALTH AND SAFETY PRECAUTIONS .............................................. D-3
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 lter ................................................................................................................ D-10
D-3.6 Cab air lter ..................................................................................................................... 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 lter 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 power divider 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 specications ..................................................................................................... D-31
D-5.2.1 Engine oil ........................................................................................................................ D-31
D-5.2.2 Lubrication oils and relevant ltering elements ............................................................... D-31
D-5.2.3 Fuel ................................................................................................................................. D-32
D-5.2.3.1 Bleeding the diesel circuit ............................................................................................... D-32
D-5.2.4 Grease ............................................................................................................................ D-33
D-5.2.5 Engine coolant ................................................................................................................ D-33
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MAINTENANCE
Observe and obey:
* Th e operator can only perform the routine
maintenance op e r at i o n s e n v i s a g e d in this
manual.
* Scheduled maintenance procedures shall be
co mpleted by quali fied tec hnical personne l
according to the manufacturer’s specications.
Maintenance symbol legend:
The following symbols are used in this manual
to help you understand better the instructions
provided. When one or more symbols appear at
the beginning of a maintenance procedure, they
indicate the following:
GTH-4013 SX
INTRODUCTION
A thorough and regular maintenance keeps the machine
in a safe and efcient working condition.
For this reason, it is advisable to wash, grease and
service the machine properly, especially after having
worked under particular conditions (muddy or dusty
environments, heavy operations, etc.).
Always ensure all machine components are in good
condition. Check for oil leaks or loosening of guards,
and make sure that the safety devices are efcient. In
case of defects, nd and rectify them before using the
machine again.
Not respecting the ordinary maintenance schedule of
this manual automatically voids GENIE warranty.
For the engine maintenance, please refer to the
specic Operator handbook supplied with the
machine.
Indicates that too ls are required to
Running-in _____________________________
Ordinary _______________________________
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
Indicates the ti m e interval for th e
maintenance jobs expressed in working
hours.
Page D-2
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MAINTENANCE
D-1 LUBRICANTS - HEALTH AND
SAFETY PRECAUTIONS
Health
A prolonged skin contact with oil can cause irritation. Use
rubber gloves and protective goggles. After handling oil,
carefully wash your hands with soap and water.
Storage
Always keep lubricants in a closed place, out of the
children’s reach. Never store lubricants on the open air
and without a label indicating their contents.
Disposal
New or exhausted oil is always polluting! Never drain oil
on the ground. Store new oil in a suitable warehouse.
Pour exhausted oil into cans and deliver them to
specialised rms for disposal.
Oil leaks
In case of accidental oil leaks, cover with sand or typeapproved granulate. Then scrape off and dispose of it
as chemical waste.
GTH-4013 SX
First aid
Eyes : In case of accidental contact with the
eyes, wash with fresh water. If the
irritation persists, seek medical advice.
Intake : In case of oil intake, do not induce
vomiting, but seek medical advice.
Skin : In case of a prolonged contact, wash
with soap and water.
Fire
In case of re, use carbon dioxide, dry chemical or foam
extinguishers. Do not use water.
Page D-3
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GTH-4013 SX
D-2 ORDINARY MAINTENANCE
A wrong or neglected maintenance can result in possible
risks for both operator and bystanders. Make sure
maintenance and lubrication are carried out according
to the manufacturer’s instructions to keep the machine
safe and efcient.
The maintenance interventions are based on the
machine working hours. Regularly check the hour-
meter and keep it in good conditions to dene the
maintenance intervals correctly. Make sure any defect
detected during the maintenance is promptly rectied
before using the machine.
All "▲" marked operations must be carried out by
a skilled technician.
During the rst 10 working hours
1 Check the oil level within reduction gears, power
divider and differential gears
2 Regularly check the tightening of the wheel bolts
3 Check the tightening of all bolts and nuts
4 Check the couplings for oil leaks
Within the rst 50 working hours
1 Change the engine oil and renew the fuel lter.
Within the rst 100 working hours
1 Change the oil of the differential casing, the wheel
reducer and the power divider gearbox.
Every 10 working hours or daily
1 Check the engine oil level.
2 Clean the air suction lter.
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 Chec k the eff icien cy of the lighting electric
system.
11 Check the efciency of braking system and parking
brake.
12 Check the efficiency of the steering selection
system.
13 Check the efciency of the fork balancing system.
14 Make sure the safety devices installed are in
efcient working order - see procedure in chap.
D-3.17.
15 Check or re-sequence the boom telescopes as
indicated in chap. D-3.16.
Every 50 working hours or weekly
Jobs to be done in addition to those above
1 Check the tension of the alternator belt.
2 Check the tyre ination.
3 Check the tightening of the wheel nuts.
4 Check the tightening of the Cardan shaft screws.
6 Clean the radiator ns.
Every 250 working hours or monthly
Jobs to be done in addition to those above
1 Change the engine oil and relevant lter.
2 Check the oil level in the front and rear differential
gears.
3 Check the oil level in the four wheel reduction
gears.
4 Check the main ltering element of the engine air
lter. Replace, if necessary.
5 Check the clamping of the cableheads to the battery
terminals.
6 Check the air suction hose between engine and
lter.
7 Check the cylinder chromium-plated rods.
8 Check the hydraulic lines are not worn because
of rubbing against the frame or other mechanical
components.
9 Check the electric cables do not rub against the
frame or other mechanical components.
10 ▲ Check the wear of the sliding pads of the boom
sections.
11 ▲ Adjust the play of the sliding pads of the boom
sections.
12 Remove any grease from the boom, then re-grease
the sliding parts of the boom sections.
13 Check the level of the battery electrolyte.
Every 3 working months
Jobs to be done in addition to those above
1 Check the efciency of the block valves - see chap.
D-3.17.
Page D-4
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MAINTENANCE
GTH-4013 SX
Every 500 working hours or every six months
Jobs to be done in addition to those above
1 Visually check the smoke quantity evacuated from
the engine exhaust.
2 Check the tightening of the engine xing screws.
3 Check the tightening of the cab xing screws.
4 Check the backlash between pins and bushings in
all joints.
5 Change the hydraulic oil lter in the tank.
6 Have the hydraulic system checked by a skilled
technician.
7 Change the main cartridge of the engine air lter.
8 Renew the cartridge of the engine oil lter and the
fuel lter.
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 lter.
2 Change the oil in the power divider gearbox.
3 Change the oil in the four wheel reduction gears
4 Change the hydraulic oil
At 6000 hours or 5 years and, subsequently,
every 2 years
Jobs to be done in addition to those above
1 Check that the structure is intact paying a special
attention to the welded supporting joints and the
boom pins (see chap. D-3.18).
Every 2000 working hours or every two years
Jobs to be done in addition to those above
1 Change the engine coolant.
D-2.1 OIL CHANGE SCHEDULE
Job Operating Service Oil type
hours* interval*
Oil level check 10 daily SHELL RIMULA 15W-40
Engine
First change 50 - (API CH-4/CG-4/CF-4/CF; ACEA E3;
Subsequent changes 250 monthly MB228.3)
Oil level check 250 monthly
Axles and
power
First change - - API GL4 / FORD M2C 86B
divider
Subsequent changes 1000 yearly MASSEY FERGUSON M 1135
gearbox
Hydraulic
Oil level check 10 daily
oil
First change
- -
TRACTORENAULT THFI 208 LF SAE 80W
SHELL TELLUS T 46
DENISON HF-1, DIN 51524
part 2 & 3
Subsequent changes 1000 yearly
* whichever occurs rst.
Page D-5
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D-3 MAINTENANCE
INTERVENTIONS
All maintenance interventions must be carried
out with engine stopped, parking brake engaged,
working attachments at on the ground and gear
lever in neutral.
When raising a component for maintenance
purposes, secure it in a safe way before any
maintenance intervention.
Any intervention on the hydraulic circuit must be
carried out by skilled personnel.
The hydraulic circuit of this machine is tted with
pressure accumulators. You and others could be
seriously injured if accumulators are not completely
depressurised.
For this purpose, shut the engine down and step
on the brake pedal 8÷10 times.
GTH-4013 SX
High pressure lines must be replaced by qualied
personnel only.
Any foreign matters entering the closed circuit
may result in a sudden deterioration of the
transmission.
The qualied staff charged with the maintenance
of the hydraulic circuit must clean all areas around
with care before any intervention.
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
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.
Document 57.0008.3200 - 09/2006
Page D-6
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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.
Take all precautions when approaching the engine
compartment. Some parts of the engine may be
very hot.
Always use protective gloves.
GTH-4013 SX
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D-3.2 GREASING
Before injecting grease into the greasers, thoroughly
clean them to avoid that mud, dust or other matters
can mix with the lubricant and reduce or annihilate
the lubrication effect.
Remove any old grease with a degreaser from
the telescopes before smearing them with new
grease.
Regularly grease the machine to grant it efcient
conditions and a long life.
By means of a pump, inject grease into the special
greasers.
As the fresh grease comes out, stop the operation.
The greasing points are shown in the following
gures:
GTH-4013 SX
Use only PTFE INTERFLON FIN GREASE LS 2 to
lubricate the sliding parts of the telescopic section.
Observe the following schedule:
• After the rst 50 operating hours (1 week)
• After the rst 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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RIGHT WAY
WRONG WAY
MAINTENANCE
GTH-4013 SX
D-3.3 TYRES AND WHEELS
Over-inated or overheated tyres can burst. Do not
ame-cut or weld the wheel rims. For any repair
work, call in a qualied technician.
WRONGOKAY
For the tyre ination or substitution, please refer to the
table below:
GTH-4013 SX
Dimensions (front and rear)
STANDARD OPTIONAL
405/70-20 405/70-24
P.R. (or load index) 14 pr 14 pr
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.
Rim 13x20 13x24
Wheel disc 8 holes DIN 70361
Pressure bar/Psi 5.5/80 4.5/65
SERVICE INTERVAL
Running-in ________ Within the rst 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.
Torque: 400 N/m.
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
Clean the engine air lter and replace the elements,
when necessary.
1 Cleaning and changing the external element
- Open the four latches A.
- Remove the protection cap B.
- Extract the external cartridge C.
- Clean the lter 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 ltering element.
- Before retting the cleaned cartridge or a new
one, smear its seal with a thin coat of grease;
t the cartridge and make sure it is properly
positioned.
- Ret cap B.
GTH-4013 SX
As soon as the warning lamp 11.3 on the cab
da s hboard sw i tches on , replace the oute r
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 lter bowl.
- Smear the seal with grease, then mount the
new element and make sure it is correctly
positioned.
- Ret the main lter and the cap as described in
point 1.
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 10 hours
Outer element change _____ Every 500 hours
Inner element change ____ Every 1000 hours
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D-3.6 CAB AIR FILTER
Every six months clean the air lter in the cab. Replace
the cartridge if the ltering cloth is damged.
1 Cleaning and changing the cartridge:
- Shut the engine down and engage the parking
brake.
- Pull lter A out of the housing accessible from
the outside of the cab.
- Clean the lter bowl.
- Clean the lter cartridge by beating it against a piece
of wood. Replace the cartridge if damaged.
Paper filters must never b e cl eaned using
compressed air or washed with water and/or
solvents.
GTH-4013 SX
Page D-11
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D-3.7 ENGINE COOLING SYSTEM
GTH-4013 SX
MAINTENANCE
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 ow out into a special
container.
-
Ret 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
Document 57.0008.3200 - 09/2006
On delivery, the machine is lled 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
Page D-12
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D-3.8 CHECKING THE OIL LEVEL IN THE
TANK
Fine jets of hydraulic oil under pressure can
penetrate the skin. Do not use your ngers, but a
piece of cardboard to detect oil leaks.
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 ller .
SERVICE INTERVAL
Running-in ________ Within the rst 10 hours
GTH-4013 SX
Ordinary _________________ Every 50 hours
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
Page D-13
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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 ow out
into the container.
5 Remove the inspection cover of tank .
6 Carefully wash the tank with Diesel oil and blow a
jet of compressed air.
7 Ret the drain plug and the inspection cover.
8 Add new oil by making sure that it matches the
recommended type indicated in paragraph D-5.2.2
until it is level with .
GTH-4013 SX
SERVICE INTERVAL
Running-in _________________________ None
Ordinary _______________Every 1000 hours
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D-3.10 C H A N G I N G T H E O I L F I L T E R
CARTRIDGE
To change the hydraulic oil lter 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 lter to
collect any oil leaks.
3 Remove the lter cover to get access to the lter
element .
4 Change the lter element, then, before tting a new
one, thoroughly clean and grease both seat and
gasket.
5 Ret and tighten the lter cover.
GTH-4013 SX
Hydraulic oil lter canisters cannot be cleaned or
washed and retted.
They must be replaced with new ones of the type
recommended by the manufacturer (see par. D-
5.2.2).
The handling and disposing of used oils 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
GTH-4013 SX
D-3.11 OIL LEVEL IN THE DI FF ER EN TI AL
GEARS
To check the oil level in the front and rear differential
gears:
• Stop the machine on a level ground and engage the
parking brake.
• Loosen level plug and check if oil is level with the
hole.
• If necessary, top-up through hole until oil comes
out from hole .
• Ret 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
ller and allow oil to ow out from the reduction
gear.
• Ret and tighten drain plug .
• Add new oil through the ller until it is level with hole
.
• Ret and tighten plugs and .
D-3.12 OIL LEVEL IN THE (front/rear) WHEEL
REDUCTION GEARS
To check the oil level within the wheel reduction
gears:
• Stop the machine on a level ground and ensure the
parking brake is engaged and plug nds on the
horizontal axis.
• Clean the plug all around, then remove it and check
if oil is level with the hole.
• If necessary, add new oil through hole until it is
level.
• Ret the plug.
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 nds again
on the horizontal axis.
• Add new oil through hole .
• Ret and tighten plug .
SERVICE INTERVAL
Running-in ________ Within the rst 10 hours
Ordinary ________________ Every 250 hours
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SERVICE INTERVAL
Running-in ________ Within the rst 10 hours
Ordinary ________________ Every 250 hours
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D-3.13 OIL LEVEL IN THE POWER DIVIDER
GEARBOX
To check the oil level in the power diver gearbox:
• Stop the machine on a level ground and make sure
the parking brake is engaged.
• Clean level plug A all around.
• Remove the plug and check if oil is level with the
hole.
• When necessary, add new oil through plug A until
it is level with the hole.
• Ret and tighten the plug.
To change the oil:
• Place a container of suitable size under the drain
plug.
• Remove the level plug A and the ller.
• Remove the drain plug B and empty the power
divider gearbox.
• Ret and tighten the drain plug B.
• Pour in new oil through the ller placed at the top of
the reduction gear of the power divider. Stop when
oil is level with hole A.
• Ret and tighten ller/level plug A.
GTH-4013 SX
SERVICE INTERVAL
Running-in ________ Within the rst 10 hours
Ordinary ________________ Every 250 hours
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MAINTENANCE
GTH-4013 SX
D-3.14
During operation, the alignment of the front and rear
axles of the machine can be subject to variations. This
can depend on an oil blow-by from the steering control
circuit, or on a steering of both axles when front and
rear wheels are not perfectly aligned.
To x this problem, rather than checking the alignment
visually, follow the procedure below:
1) Move to a solid and level ground
2)
3) Rotate the steering up to its stop (either to the right
4) Set the steering selection switch to “two-wheel
5) Rotate the steering up to its stop (turn in the same
6) Reset the steering selection switch to “four-wheel
7)
SHAFTING ALIGNMENT
Set the steering selection switch 13 to “four-wheel
steer” (pos. 2)
or to the left)
steer” (pos. 0)
direction as above
steer" (pos. 2)
Rotate the steering (to the side opposite to point
3) so that the rear axle reaches its stop
8) Reset the steering selection switch to “two-wheel
steer" (pos. 0)
9) Rotate the steering (to the same side as in point
7) so that the front axle reaches its stop
10) Reset the steering selection switch to “four-wheel
steer" (pos. 2)
Now the wheels should be re-aligned.
1 0 2
SERVICE INTERVAL
Running-in _________________________ None
Ordinary _________________ When necessary
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