Genie GTH-4017 Operator's Manual

To serial n: 20449

Operator’s Manual

First Edition - Second Printing

Important

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

For any further information, please call Terexlift.

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

Technical Assistance Service

Telephone: +39 075 9418129 +39 075 9418171

e-mail: im.service@terexlift.it

Contents

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

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

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

Labels And Plates Applied On The

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

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

Description Of The Main Components ...Page 23

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

Inspections ..........................................Page 43

Operating Instructions .........................Page 47

Transporting The Machine...................Page 61

Maintenance ........................................Page 65

Faults And Troubleshooting.................Page 99

Optional Attachments ..........................Page 105

Specifications ......................................Page 117

Load Charts .........................................Page 119

Diagrams And Schemes ......................Page 157

Warranty ..............................................Page 179

First Edition: Second Printing, December 2008

reserved.

Produced by: TEREXLIFT Technical Literature Dept.

Umbertide (PG) Italy

2 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Symbols

Operator’s ManualFirst Edition - Second Printing

Introduction

Safety alert symbol: used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death

DANGER

WARNING

CAUTION

NOTICE

PROTECT THE ENVIRONMENT

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

Orange: indicates a hazardous

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

Yellow : indicates a hazardous

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

Blue: indicates a property damage message.

Green: used to draw the

attention to important

information on environment

protection.

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 3

Operator’s Manual

First Edition - Second Printing

Intentionally blank page

4 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Operator’s ManualFirst Edition - Second Printing

Machine Identification

Check that the operator handbook refers to the delivered machine.

MODEL AND TYPE

Handler with telescopic boom:

GTH-4013EX - GTH-4514EX - GTH-4017EX

MANUFACTURER

TEREXLIFT srl

Zona Industriale - I-06019 UMBERTIDE (PG) ITALY

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

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

APPLICABLE STANDARDS

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

Directive Title

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

Standard Title

EN 1459:1988 Harmonised standard. Safety of

industrial trucks - Self- propelled

variable reach trucks.

EN 281:1988 Self-propelled industrial trucks sit-

down rider-controlled. Rules for the

construction and layout of pedals.

EN 1175-2:1998

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

Electrical requirements - General

requirements of internal combustion

engine powered trucks.

characteristics and testing.

ISO 3287: 1999 Powered industrial trucks - Symbols

for operator controls.

ISO 3449:1992 Earth-moving machinery - Falling-

object protective structures Laboratory tests and performance requirements.

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

protective structures - Laboratory tests and performance requirements.

ISO 6292:1996 Powered industrial trucks and tractors

- Brake performance and component strength.

EN 13059:2002 Safety of Industrial trucks- Test

methods for measuring vibration

ISO 2867:1994 Earth-moving machinery - Access

systems

EN ISO 6683:2005 Earth-moving machinery - Seat

belts and seat belt anchorages

- Performance requirements and tests

ISO 11112: 1995 Earth-moving machinery -

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

requirements

MACHINE IDENTIFICATION PLATES

The following data plates are applied on the machine:

Machine data plate

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

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 5

Operator’s Manual

Machine Identification

First Edition - Second Printing

Road traffic data plate

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

ROPS-FOPS cab type-approval plate

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

Fork data plate

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

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

HOW TO READ YOUR SERIAL NUMBER

CE MARKING

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

CHASSIS SERIAL NUMBER

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

IDENTIFICATION PLATES OF THE MAIN

PARTS

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

Chassis serial number

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

GTH-4514 P 07 17882

MODEL

ENGINE

TYPE

YEAR OF

MANIFACTURER

Machine data plate

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

6 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

SERIAL

NUMBER

Operator’s ManualFirst Edition - Second Printing

Symbols Used On The Machine

Fuel Level

Low Engine Oil

Pressure

Hydraulic Oil

Brake pressure

Hydraulic Oil Filter

Clogged

Air Filter Restricted Glow Plugs Preheating High Coolant Tempe-

Temperature Indicator

Steering Mode Cab Ventilation Fan

09.4618.0917

09.4618.0928

Fuel Cap Hydraulic Oil

Fog lamp

Low Hydraulic Oil

Level

Transfer Mode

09.4618.0916

Lift Point

Parking Brake Battery Charge

Turn Signals High Beam

Low Beam

rature

Hazard Warning Lights Position Lights

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 7

Operator’s Manual

Symbols Used On The Machine

HAZARD PICTORIAL DESCRIPTIONS

First Edition - Second Printing

Electrocution Hazard

No riders.

Read the operator's manual.

Crush Hazard

Maintain required clearance.

Burn Hazard

Support boom when performing maintenance.

Keep away from moving parts.

Falling Object Hazard

Allow system to cool.

Crush Hazard

No people under load.

Explosion/Burn Hazard

Burn Hazard

Keep clear of moving parts.

Fall Hazard

No smoking. No open flame.

Allow surfaces to cool.

Allow compartment access

Crush Hazard

8 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Keep clear of moving outriggers.

Operator’s ManualFirst Edition - Second Printing

Labels And Plates Applied On The Machine

B C

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 9

Operator’s Manual

First Edition - Second Printing

Labels And Plates Applied On The Machine

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

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

The following chart shows quantities and description too.

Ref. Decal Code Description Qt.

SAFETY PIN

WORKING POSITION

1 09.4618.0791 Safety pin operation 1

STORAGE POSITION

09.4618.0791

2 09.4618.0784

09.4618.0061

P= 4.5 bar 65 psi

09.4618.0547

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

Tyre inflat. P=4.5bar GTH-4017 EX

Tyre inflat. P=5.5bar GTH-4013EX & GTH-

4514EX

4 09.4618.0918 Falling Object Hazard 3

09.4618.0918

5 09.4618.0919 Crush Hazard 4

09.4618.0919

6 09.4616.0041 Guaranteed sound power level 1

103

09.4616.0041

7 09.4618.0920 Compartment Access 1

Kg 4000

09.4618.0920

09.4616.0040

Max Cap. GTH-4013EX & GTH-4017EX

Kg 4500

09.4618.0373

Max Cap. GTH-4514EX

10 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Operator’s ManualFirst Edition - Second Printing

Labels And Plates Applied On The Machine

Ref. Decal Code Description Qt.

Label - Stabilizer Max Pres. GTH-4017EX

09.4618.0989

P max al suolo P max on the ground

NOTICE

6.3 kg/cm

09.4618.0989

09.4618.0991

& GTH-4514EX

Label - Stabilizer Max Pres. GTH-4013 EX22

10 09.4618.0776

09.4618.0776

QUICK GUIDE FOR THE USE

4013-

4514-4017

STARTING THE MACHINE

s0UTTHEGEARSWITCHANDTHEMECHANICALGEARLEVERTONEUTRAL s%NGAGETHEPARKINGBRAKEANDENSUREITSLIGHT INDICATORSWITCHESON s4OSTARTTHEENGINEROTATETHEIGNITIONSWITCHTOPOSITIONAND

HOLDITINPOSITIONUNTILTHELIGHTGOESOFF4HENTURNTHE  SWITCHTOPOSITIONANDSTART  THEENGINE s)FTHEENGINEDOESNOTSTARTWITHIN  SECONDSRELEASETHEKEYAND  WAITATLEASTMINUTESBEFORE  ATTEMPTINGAGAIN

OVERLOAD WARNING SYSTEM

$URINGWORKSTEADLYCHECKTHEDISPLAYOFTHEOVERLOADWARNING SYSTEM 4HE8 LED INDICATORSHOW

-ACHINESTABLE

Green LED 1-2-3-4

-ACHINEUNSTABLE4HERED,%$FLASHESAND

Yellow LED 5-6

BUZZERSOUNDSINTERMITTENTLY (AZARDOUSOVERLOAD 2ISKOFOVERTURNING

Red LED 7-8

4HERED,%$ISCONSTANTLYLITANDTHEBUZZER SOUNDS CONTINUOUSLY2ETRACT THELOAD WITHINSAFETYLIMITS



USING THE JOYSTICK

sBoom lowering/liftingSHIFTTHELEVERTO sAttachment frame forward/back pitchingSHIFTTHELEVERTO sTelescope retraction/extensionSHIFTBUTTONTOWITHOUT SHIFTINGTHECONTROLLEVER sAttachment coupling/releasePRESSBUTTONANDSHIFTTHE CONTROLLEVERTO

TOXTORAISETHERIGHTHANDSIDEOF

sMachine swayPRESSBUTTON THEMACHINEORTOYTOLOWERTHERIGHTHANDSIDEOFTHEMACHINE

TOYTORAISETHEOUTRIGGERORTOXTO

sLeft outriggerPRESSBUTTON LOWERTHEOUTRIGGER

TOYTORAISETHEOUTRIGGERORTOX

sRight outriggerPRESSBUTTON TOLOWERTHEOUTRIGGER

WARNING

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

- lower any suspended load to the ground

- set the controls of the boom to neutral position

- set the speed lever to neutral position, engage the parking brake and stop the engine. Safety guidelines for machines equipped with stabilizers: Never use the stabilizers if the load is already raised; the stabilizers can be used only to increase the stability of the machine. Improper use of the stabilizers can cause instability. Ensure that the stabilizer indicator lamp is on before using the boom. Before raising any load, level the machine by means of the level indicator.

09.4618.0851 Quick guide and Control lever decal

12 09.4618.0921

09.4618.0921

Label - Upper Door Internal Unlock System

Label - Use limits close to electric power lines

13 09.4618.0933 Crush Hazard 4

09.4618.0933

14 09.4618.0922 Crush Hazard 6

09.4618.0922

15 16 17

09.4618.0243

09.4618.0241

09.4618.0242

Cosmetic - GENIE Logo in WHITE

1 1 1

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 11

Operator’s Manual

First Edition - Second Printing

Labels And Plates Applied On The Machine

Ref. Decal Code Description Qt.

GTH-4514 EX

09.4618.0815

09.4618.0816

Cosmetic - Genie GTH-4514 EX

2 1

18 19

GTH-4017 EX

GTH-4013 EX

09.4618.0817

09.4618.0818

09.4618.0813

09.4618.0814

Cosmetic - Genie GTH-4017 EX

Cosmetic - Genie GTH-4013 EX

20 09.4618.0923 Burn Hazard 2

09.4618.0923

21 09.4618.0924 Burn/Explosion Hazard 1

09.4618.0924

22 09.4618.0925 Crush Hazard 1

09.4618.0925

23 09.4618.0926 No Riders 1

09.4618.0926

2 1

24 09.4618.0927 Burn Hazard 1

09.4618.0927

25 09.4618.0916 Lift Point 4

09.4618.0916

26 09.4618.0917 Diesel Fuel Cap 1

09.4618.0917

27 09.4618.0928 Hydraulic Oil 2

09.4618.0928

12 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Operator’s ManualFirst Edition - Second Printing

Labels And Plates Applied On The Machine

Ref. Decal Code Description Qt.

Ref. Description

K04

K01

F6G F5G

F5G

INSTRUCTIONS

09.4618.1001

09.4618.0986

K01 Engine Start

K02 Glow Plugs Preheating

K03 Fuel Pump

K04 Emergency Pump

F1G Starter Enabling Switch

F2G Engine Ignition Key

F3G Cabin Fuse-Relay Board

F4G Glow Plugs

F5G Fuel Pump

F6G Emergency Pump

09.4618.1181

Label - Emergency Manual Controls Of The Main Valve

F1G F4G

28 09.4618.1181 Label - Engine Fuses & Relays Board 1

F2G F3G

K03

K02

29 09.4618.1001 Label - Maintenance Collar 1

30 09.4618.1124

31 09.4618.0986 Crush Hazard 1

32 09.4618.1028 Label - Parking Brake 1

09.4618.1028

NOTICE

TO PREVENT DAMAGE OF INTERNAL

33 09.4618.0171

35 09.4618.1033 Label - Mechanical Gear Instructions 1

36 09.4618.1122 Tip-over Hazard 1

BOOM HOSES BOOM SECTIONS NEED

TO BE EXTENDED EQUALLY OTHERWISE

RE-SEQUENCING WILL BE REQUIRED. SEE OPERATORS MANUAL FOR MORE

DETAILS.

Ref. Circuit Ref. Circuit Ref. Circuit

K1 High Beam K9 -------------- K17 --------------

K2 Low Beam K10 -------------- K18 Outriggers

K3 Horn K11 Start-Up Enabling Command K19 LMI Control

K4 Light Power Supply K12 Emergency Pump Enabling Com. K20 ---------

K5 Shift 1°/2° Mechanical Speed K13 Emergency Pump K21 Rear Axle Lock

K6 Backwards Buzzer K14 -------------- K22 Optional

K7 -------------- K15 Boom Out Enabling (LMI) K23 Timer

K8 -------------- K16 Boom Down Enabling (LMI) K24 Timer

K24

K15

K16

K11

K12

K10

K13

F21

F15

F12

F20

F14

F11

F19

F13

F10

F18

K23

F17

F16

J3 J2 J1

09.4618.0171

.feR Circuit

F1 Front Wiper

K19

F2 Heating - A/C

F3 Stop Light Micro-Switch

K18

F4 Rear/Roof Wiper

F5 Optional

F6 Low Beam

F7 Position Lights

F8 Instrument Lighting

Indicator Lights Power Supply

K21

F10 Road Lights Switch

F11 Flashing Beacon

F12 Stop Light

F13 Jobsite/Manplatform Sel.

F27

F14 Backwards Light

F15 High Beam

F26

F16 Hazard Warning Light

F17 Road Lights

F25

F18 Outriggers Micro-Switch

F19 Transmission Contr. Unit

F24

F20 +12v On The Boom

F21 Horn

F23

F22 Manplatform Power Sup.

F23 Cab Interior Lights

F22

F24 Jobsite/Manplatform Sel.

F25 LMI Control Unit

F26 ???????

F27 Work Lights

09.4618.1180

INSTRUCTIONS

CHANGE MECHANICAL GEAR ONLY WHEN THE MACHINE IS STATIONARY

AND THE FOWARD/REVERSE GEAR

SELECTOR IS ON NEUTRAL POSITION

DANGER

Tip-over Hazard

Incorrect emergency lowering sequence will result in machine tip-over

Read, understand and obey the instructions below or in the Operator’s Manual before lowering

09.4618.1033

09.4618.1122

09.4618.1182

09.4618.1180

Re-sequencing the telescopic boom extension. If, during normal operation, a

change in the boom extended lengths is noticed, proceed with re-sequencing as indicated in the operator’s manual.

ONLY FOR GTH 4013 EX

Label - Cabin Fuses & Relays Board GTH-

4013 EX

Label - Cabin Fuses & Relays Board GTH-4017EX & GTH-4514EX

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 13

Operator’s Manual

First Edition - Second Printing

Labels and plates applied on the machine

Ref. Decal Code Description

ROPS-FOPS cab type-approval plate. This plate

A 09.4616.0100

TEREX FT srl - ON N STR E - 06019 M ERT E PG - T Tel. 075 941.811 Fa 075 941.53.82 Tele 66106 T M

MOE O - MO E - MO E E - T P - MO E O

NNO OSTR ONE - E R OF M N F TRE - NNEE E F R TON

HR - ÑO E F R ÓN

B 09.4616.0122

MTR O - SER N. - N. E SER E - F .- ENT NR. - NO. E SER E

PESO MX SS E NT. - M X FRONT X E E GHT - PO S MX ESS E NT

. HS ST O. N. ST O - PESO M X E E NTER OR

PESO MX SS E POST. - M X RE R X E E GHT - PO S MX ESS E RR ERE

. HS ST H . N. ST O - PESO M X E E POSTER OR

PESO TOT E - TOT E GHT - PO S TOT - . GESMTGE HT N. ST O PESO TOT

MTR O MOTORE TERM O - ENGNE SER N. - N. MOTER THERM E F R NR. ESE MOTOR - NO. E SER E MOTOR TERM O

OMOOG ONE

F R TO N T - M E N T

200

kgkg kg kg

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

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

ASSIEME FORCHE-FORKS ASSY GROUPE FOURCHES-GABELGROUPPE JUNTO HORQUILLAS

MODELLO - TYPE - DƒSIGNATION MODELL - MODELO

N¡ SERIE - SERIAL N¡-N¡ DE SERIE

- SERIEN N¡- N¡ DE BASTIDOR

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

C 09.4616.0109

MASSA - MASS - MASSE MASSE - MASA

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

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

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

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

Fork data plate. This plate shows the main data of

the fork installed on the machine.

D 09.0803.0357 Boom Tilting Degree

14 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Operator’s ManualFirst Edition - Second Printing

Safety Precautions

DAMAGED MACHINE HAZARDS

• Do not use a damaged or defective machine.

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

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

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

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

PERSONAL INJURY HAZARDS

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

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

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

SAFETY DEVICES

Several safety devices have been fitted to the machine. They must never be tampered with or removed. Regularly check the efficiency of such devices. In case of faults, stop working immediately and proceed in replacing the defective device. For the checking procedures, read chap. "Maintenance"

MOMENT LIMITING SYSTEM

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 15

Operator’s Manual

Safety Precautions

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.

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

Always perform a pre-operation 2. inspection. Always test the machine functions prior 3. to use. Inspect the work place.4. Only use the machine for the intended 5. 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.

First Edition - Second Printing

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!

DANGER

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

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

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

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

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

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

16 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

REQUISITES OF THE PERSONNEL IN CHARGE

Operator’s ManualFirst Edition - Second Printing

Safety Precautions

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

health:

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

physical:

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

mental:

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

emotional:

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

training:

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

Requisites of the SERVICEMEN The personnel charged with the machine maintenance shall be qualified, specialised in the maintenance of telehandlers, and shall have the following prerequisites: physical: good eyesight, acute hearing, good co-ordination and ability to carry out all required maintenance operations in a safe way, according to this manual. mental: ability to understand and apply the enforced rules, regulations and safety precautions. They shall be careful and sensible for their own as well as for the others’ safety and shall desire to carry out the work correctly and in a responsible way. training: they shall read and be familiar with this handbook, its enclosed graphs and diagrams, the identification and warning plates. They shall be skilled and trained about the machine functioning.

NOTICE

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

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 17

Operator’s Manual

Safety Precautions

First Edition - Second Printing

OTHER DANGERS

WORKING CLOTHES

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

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

• Protective helmet.

• Protective gloves.

• Working shoes.

Use only type-approved working clothing in good condition.

Hazards on the JOBSITE

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

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

DANGER

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

DEATH OR INJURY CAN RESULT FROM CONTACTING ELECTRIC POWER LINES.

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

POWER LINE VOLTAGE REQUIRED CLEARANCE

0 to 50kV 10ft 3.00m

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

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.

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

DANGER

Use only type-approved protective equipment in good condition.

18 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

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

WARNING

Make sure the machine (wheels and stabilisers) rests on a firm ground to prevent hazardous unstable conditions. If the ground is not firm enough, position some supporting planks under the stabilisers or the wheels.

Operator’s ManualFirst Edition - Second Printing

Safety precautions

OPERATION or MAINTENANCE hazards

Before any operation, following precautions should be taken:

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

WARNING

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

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

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

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

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

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

During work, and especially maintenance, always pay the greatest attention:

• Do not walk or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only.

• Keep the machine handholds and access steps always clean from oil, grease or dirt to prevent falls or slips.

A ³ B

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 19

Operator’s Manual

WARNING

Safety precautions

First Edition - Second Printing

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

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

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

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

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

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

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

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

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

• Do not connect wet plugs or sockets.

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

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

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

• Do not lubricate, clean or adjust moving parts.

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

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

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

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

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

• Do not empty catalytic mufflers or other vessels

containing burning materials without taking the necessary precautions.

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

20 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Operator’s ManualFirst Edition - Second Printing

Safety precautions

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

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

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

• Do not call an operator suddenly, if unnecessary.

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

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

MACHINE OPERATION hazards

Absolutely avoid the following work situations:

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

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

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

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

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

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

EXPLOSION OR FIRE hazards

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

• Do not refuel the machine with the engine running.

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

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

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

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

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

• Carefully handle all flammable or dangerous substances.

• Do not tamper with fire-extinguishers or pressure accumulators.

DAMAGED COMPONENT hazards

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

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

PERSONAL INJURY hazards

Do not operate the machine in case of hydraulic oil

or air leak. Air or hydraulic oil leaks can penetrate or burn the skin.

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

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 21

Operator’s Manual

First Edition - Second Printing

Intentionally blank page

22 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Operator’s ManualFirst Edition - Second Printing

Description Of The Main Components

Boom 1.

2. Chassis Forks3. Attachment holding frame4. Outrigger5.

6. Driving cab according to ROPS-FOPS provisions Front axle7.

8. Fuel tank

9. Access step

Rear axle10. Engine11.

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 23

Operator’s Manual

First Edition - Second Printing

Intentionally blank page

24 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

ERROR

Operator’s ManualFirst Edition - Second Printing

Controls and Instruments

K23

F12

F11

F10

INT

F27

F21

F15

F26

F20

F14

F25

F19

F13

F24

F18

INT

F23

F17

F22

F16

Fresh Air Flap1. Forward/Reverse Gear Selector 2. Steering Column Angle Adjustment3. Turn Signals - Windscreen Washer - Horn - 4.

Lights Auxiliary Drive Controls5. Load Limiter Disable Selector6. Load Moment Indicator7. Emergency Stop Pushbutton8.

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 25

Instruments Dashboard9. Inclinometer 10. Multipurpose Control Lever11. Parking Brake Lever 12. Gas Pedal13. Service Brake Pedal14. Cab Heater Control Cock15. Fuses And Relays Board16. Manual Accelerator17.

Operator’s Manual

Controls and Instruments

First Edition - Second Printing

26.1

GTH-4013 EX

ERROR

Chassis Levelling Switch19. Transmission Warning Light20. Outriggers Switches21. Auxiliary Hydraulic Circuit Switch 22. (OPTIONAL) Mixing Bucket Switch (23. OPTIONAL) Work Lights Switch (24. OPTIONAL) Cab/Road/Platform Selector25. Steering Mode Selector26.

RPM x 100

Ignition Switch27. Mechanical Gear Switch28. Emergency Pump Switch (29. ONLY

with MAN-PLATFORM)

Road Lights Switch30. Cab Heater Fan Switch31. Air Condition Switch (32. OPTIONAL) Hazard Warning Lights Switch33.

26.1

GTH-4514 EX GTH-4017 EX

ERROR

2322

27 3024 31

26 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Operator’s ManualFirst Edition - Second Printing

Controls and Instruments

27 _ Ignition Switch

Four-position switch:

No circuit under voltage, key can be removed

and engine is stopped.

Circuits under voltage, presetting for

the engine starting. Board controls and instruments are on.

Thermal starter for cold climates. Turn the key

to this position and hold it for 10÷15 seconds, then turn it to pos. I to start the engine.

Engine starting; when released, key springs

back to pos. I automatically.

2 _ Forward/Reverse Gear Selector

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 27

Operator’s Manual

Controls and Instruments

4 _ Turn Signals - Windscreen Wiper - Horn -

Lights

First Edition - Second Printing

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.

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

Lights function:

To switch the handler lights, lever can be set to three different positions along its horizontal axis:

0 low beam ON, stable condition

1 high beam ON, stable condition

2 high beam used for intermittent signalling;

when released, the lever springs back to position 0.



Turn signals function:

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





28 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

CAUTION

DANGER

Operator’s ManualFirst Edition - Second Printing

Controls and Instruments

Brakes

14 _ Service Brake Pedal

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

12 _ Parking Brake Lever

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 efficiency.

Safety and Emergency Devices

33 _ Hazard Warning Lights Switch

Fitted with on-off position, it switches

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

start flashing.

8 _ Emergency Stop Pushbutton

By pressing this button, the engine of the machine is shut down. Before restarting the machine, it is necessary to reset the pushbutton by rotating it clockwise.

29 _ Emergency Pump Switch

Two position switch:

0 OFF

1 Hold pressed down to turn on the

electric pump and operate the controls

Accelerator Control

13 _ Throttle Pedal

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

17 _ Manual Accelerator

By pulling the lever up, the engine rpm increases gradually. To reduce the rpm, set the lever down.

The manual gas control can only be used with man-platform, winch, mixing bucket, hook and maintenance jib.

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 29

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

6 _ Load Limiter Disable Selector

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

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

The load limiting system disconnect key is active only in the Jobsite mode. In the Platform mode, the limiting system cannot be deactivated.

Operator’s Manual

Controls and Instruments

First Edition - Second Printing

28 _ Mechanical Gear Switch

Pushbutton with green glass cap, it is used to engage 1st or 2nd gear. Push the button to select the required speed: each pressure corresponds to the selection of a new speed.

0 No speed change

1 Engage a new speed

The green glass cap swtiches on only when the second speed is engaged.

To select a new speed you must control that the

machine is not moving and that the forward/ reverse gear selector switch is in neutral position.

Steering Mode Selection

26 _ Steering Mode Selector

Three-position switch for the selection of the steering

26.1 _ Rear wheel alignment indicator light

(OPTIONAL)

The indicator light comes on when turning the steering selector switch from position 1 to position 0 or from position 2 to position 0, and wheels are aligned.

Job-site/Road/Platform Selection

25 _ Job-site/Road/Platform Selector

Three-position switch:

mode:

1 Crab steering

0 Two-wheel steering

2 Four-wheel steering

1 Job-site setting (operate the

handler by the cab controls)

0 Road setting 2 Platform setting (operate the

handler by the platform controls) The green light indicator lights up.

In Jobsite mode:

• all the machine functions are enabled

In Road transfer mode:

• the boom movements, outriggers and sway controls are disabled

• only the two-wheel steering mode is enabled

• fuel saving

In Platform mode:

• the only enabled functions are: boom lowering/ lifting and boom extraction/retraction

• all the controls from the cabin are disadleb

30 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Auxiliary drive controls

Operator’s ManualFirst Edition - Second Printing

Controls and Instruments

31 _ Cab Heater Fan switch

Three-position switch:

0 OFF 1 Low speed 2 High speed

32 _ Air Condition Switch (OPTIONAL)

Two-position switch:

0 OFF

1 ON

24 _ Work Lights Switch (OPTIONAL)

Two-position switch

0 Lights OFF

1 Lights ON

22 _ Auxiliary Hidraulic Circuit (OPTIONAL)

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

0 Oil to the main circuit

1 Attachments hydraulic circuit

Switching

The selector has a block to keep the switch pressed. Before switching the selector to another position, unlock control B at the top of the selector.

23 _ Mixing Bucket Switch (OPTIONAL)

Two-position switch. The pressure of this button enables the movement of the internal mixer of the bucket.

0 Mixer OFF

1 Mixer ON

30 _ Road lights switch

Three-position switch

0 Lights OFF 1 Position lights ON (the switch indicator

lights up partially).

2 Low beam ON (the switch indicator fully

lights up).

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 31

The selector has a block to keep the switch pressed. Before switching the selector to another position, unlock control B at the top of the selector.

15 _ 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 flow of heated air in the cab operating the switch 31.

Operator’s Manual

Controls and Instruments

Warning Lights and Instruments (ref. 9)

First Edition - Second Printing

GTH-4013 EX

36.1

37 3436 44

RPM x 100

34.1

35.1

42413938 40 51 43 44 45

GTH-4514 EX GTH-4017 EX

3734 35 3646 50

32 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

36.134.1 35.1

DESCRIPTIONS

Operator’s ManualFirst Edition - Second Printing

Controls and Instruments

34 _ Engine coolant temperature indicator

This indicates the engine coolant temperature. If the finger is in the red zone and the warning light 34.1 comes on, you must stop the machine and find and rectify the problem.

35 _ 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 warning light 35.1 comes on, you must stop the machine and find and rectify the problem.

36 _ Fuel gauge

This indicates the fuel level in the tank. If the fuel level is low (reserve), the relevant warning light 36.1 comes on.

37 _ Hour-meter

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

38 _ Warning light - low battery charge

Signals a low charge by the alternator.

39 _ Warning light - low engine oil pressure It lights when the engine oil pressure is too low.

43 _ Warning light - high beam

Warning light that signals when high beam is ON.

44 _ Warning light - turn signals

Indicator light that signals when turn signals are ON.

45 _ Warning light - position lights

Warning light that signals when position lights are ON.

46 _ Warning light - glow plugs preheating

This light comes on during the pre-heating of the engine glow plugs.

47 _ Warning light - low hydraulic oil level

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

48 _ Warning light - boom sensors

This red light comes on to warn of a problem of one of the three boom sensors (low, high, extended boom sensors). Contact the TEREXLIFT Service Centre.

49 _ Warning light - hydraulic oil filter clogged

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

40 _ Warning light - air filter restricted

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

41 _ Warning light - parking brake engaged

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

42 _ Warning light - low brake pressure

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 33

50 _ General alarm warning light

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

51 _ NOT ACTIVE

WARNING

DANGER

Operator’s Manual

Controls and Instruments

CONTROL LEVER

Handlers are equipped with a multipurpose electroproportional lever which allows operating all machine movements. When shifted to one of the four directions (right/left, forwards/backwards) it controls the boom lifting/ lowering and the forward/back pitching .of the attachment frame. Moving roller 2 or pressing button 1 you can make all boom movements

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



First Edition - Second Printing



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

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

34 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Function selection

4013 - 4514

4017

The lever is enabled to carry out the following motions:

• Boom lowering/lifting shift the control lever to A or B

• Boom extraction/retraction press button 2 and shift to A or B without moving

the control lever

• Attachment back/forward tilting shift the control lever to C or D

• Attachment coupling/release press button 1 and shift the lever to C or D

Operator’s ManualFirst Edition - Second Printing

Controls and Instruments

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 35

Operator’s Manual

Controls and Instruments

Lifting/lowering the boom

DANGER

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

To lift or lower the boom:

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

First Edition - Second Printing





36 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Extending/retracting the boom

DANGER

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

To extend or retract the telescopic elements of the boom:

• Smoothly press the button 2 and shift to position A to extend the boom or to position B to retract it, without shifting the joystick.

Operator’s ManualFirst Edition - Second Printing

Controls and Instruments







Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 37

Operator’s Manual

Controls and Instruments

Pitching the attachment holding frame

forward/back

DANGER

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

To tilt forward/back the attachment holding frame:

• Smoothly shift the lever to position D to pitch the holding frame forward or to position C to pitch the holding frame back.

First Edition - Second Printing





38 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Quick-coupling the attachments

DANGER

WARNING

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

To lock/unlock the attachments:

• Press the button 1

• Shift the lever toward the cab windscreen D to release the attachment

• Shift the lever toward the operator’s seat C to lock the attachment.

Operator’s ManualFirst Edition - Second Printing

Controls and Instruments



Before using the machine, visually check the attachment is correctly coupled.

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 39

Operator’s Manual

Controls and Instruments

First Edition - Second Printing

Outrigger movements

DANGER

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

To operate the outriggers:

Right outrigger

• Press button 52 and hold it down to enable the motion of the right outrigger: select Y to lower the outrigger select X to raise the outrigger

Left outrigger

• Press button 53 and hold it down to enable the motion of the left outrigger: select Y to lower the outrigger select X to raise the outrigger

5254 53

 



ERROR



Chassis Levelling Function

Check that the machine is level on inclinometer

10. The water level must be right in the middle of the instrument.

To sway the machine:

• Press button 54 and hold it down until the complete execution of the function selected:

select X to raise the right-hand side of the

machine

select Y to lower the right-hand side of the

machine.

Outrigger controls and chassis levelling activation is affected by the boom position and extension, as shown in the chart below:

AREA A, within this area controls can be • always activated, regardless of boom angle and extension.

AREA B, within this area controls cannot be • activated unless the boom is fully retracted.

AREA C, within this area controls cannot be • activated.

X°

40 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

20°

0°

Manual Controls

DANGER

WARNING

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

Lever 1 In position A Boom down In position B Boom up Lever 2 In position A Fork holding frame pitched

backwards

In position B Fork holding frame pitched

forwards Lever 3 In position A Boom telescope in In position B Boom telescope out Lever 4 In position A Attachment unlocked In position B Attachment locked

Operator’s ManualFirst Edition - Second Printing

Controls and Instruments

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

Lever 3 in A Boom fully retracted Lever 1 in A Boom lowered

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

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

• Open the rear cover to reach the main valve.

• Fit the control levers (supplied) to the elements

of the main valve.

• If present, activate the emergency pump by

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

• Shift the lever of the main valve to the position

corresponding to the movement you wish to obtain.

When operating the emergency controls in manual mode, the load limiting device is disabled.

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 41

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42 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Operator’s ManualFirst Edition - Second Printing

Inspections

Pre-operation Inspection Fundamentals

It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance.

Make sure:

You learn and practice the principles of safe

machine operation contained in this operator's manual.

1 Avoid hazardous situations.

2 Always perform a pre-operation

inspection.

Know and understand the pre-operation

inspection before going on to the next section.

3 Always perform function tests prior to use.

4 Inspect the workplace.

5 Only use the machine as it was intended.

The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests.

The pre-operation inspection also serves to determine if routine maintenance procedures are required. Only routine maintenance items specified in this manual may be performed by the operator.

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

If damage or any unauthorized variation from factory delivered condition is discovered, the machine must be tagged and removed from service.

Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications. After repairs are completed, the operator must perform a pre-operation inspection again before going on to the function tests.

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 43

NOTICE

Operator’s Manual

Inspections

PRE-OPERATION INSPECTION

First Edition - Second Printing

Make sure the operator’s manual is intact, legible • and placed inside the machine. Make sure all decals are present and legible. See • “Labels and plates applied on the machine” chapter. Check for engine oil leaks and proper oil level. Top • up if necessary. See “Maintenance” chapter. Check for axle oil leaks and proper oil level. Top • up if necessary. See “Maintenance” chapter. Check for hydraulic oil leaks and proper oil • level. Top up if necessary. See “Maintenance” chapter. Check for engine coolant leaks and proper • coolant level. Add coolant if necessary. See “Maintenance” chapter. Check for battery fluid leaks and proper fluid • level. Add distilled water if necessary. See “Maintenance” chapter.

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

• electrical components, wiring and electrical

cables

• hydraulic hoses, fittings, cylinders and main

valves

• fuel and hydraulic oil tanks

• drive pump and motor and transmission

axles

• steering system

• braking system

• boom telescopes sliding pads

• clean glasses, lights and rear view mirrors

• engine and relevant components

• horn

• lights

• machine ignition control

• nuts, bolts and other fasteners Check the entire machine for:

• cracks on welds or structural components

• dents or damage to the machine

* Make sure that all structural and other critical

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

* After inspection, check that all the compartment

covers are in place and latched.

WARNING

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

Checking the tyres

* Check the correct inflation of the tyres; see

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

* Make sure that the tyre plies are not cut or

worn.

WARNING

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

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

44 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Operator’s ManualFirst Edition - Second Printing

Inspections

FUNCTION TESTS FUNDAMENTALS

The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-bystep instructions to test all machine functions. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service. Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications. After repairs are completed, the operator must perform a pre-operation inspection and function tests again before putting the machine into service.

Make sure:

You learn and practice the principles of safe

machine operation contained in this operator’s

manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation

inspection. Know and understand the pre-operation

inspection before going on to the next

section.

3 Always perform function tests prior to use. 4 Inspect the workplace. 5 Only use the machine as it was intended.

TESTS

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

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

2 Enter the operator's compartment and sit on the

seat.

3 Fasten the seat belt.

4 Adjust the interior rear view mirror and the

exterior right hand mirror, if required.

5 Be sure the parking brake is on and the

transmission control is in neutral.

6 Start the engine. See par. “Starting the

Engine” in the Operating Instructions section.

Test the Control Lever

7 Using the control lever, momentarily raise and

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

Result: All functions should operate smoothly.

8 Using the yellow button, momentarily extend

and retract the boom.

Result: The function should operate smoothly.

9 Using the control lever and the white button,

momentarily lock and unlock the attachment.

Result: The function should operate smoothly.

Test the Steering

10 Push the right side of the steer selector switch

to select four-wheel steer.

11 Check the steering operation by turning the

steering wheel approximately ¼ turn in each direction.

Result: The front wheels should turn in the

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

12 Straighten the wheels.

13 Push the steer selector switch to the middle

position to select two-wheel steer.

14 Check the steering operation by turning the

steering wheel approximately ¼ turn in each direction.

Result: The front wheels should turn in the

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

15 Straighten the wheels.

16 Push the left side of the steer selector switch to

select crab steer.

17 Check the steering operation by turning the

steering wheel approximately ¼ turn in each direction.

Result: The front wheels and rear wheels

should turn in the same direction as the steering wheel.

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 45

Operator’s Manual

Inspections

First Edition - Second Printing

Test the Transmission and Brakes

18 Be sure the boom is fully lowered and

retracted.

19 Step on the service brake pedal.

20 Move the transmission control lever to forward.

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

Result: The machine should move forward,

then come to an abrupt stop.

21 Move the transmission control lever to reverse.

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

Result: The machine should move in reverse,

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

22 Move the transmission control lever to neutral.

23 Pull the parking brake lever upward.

Test the Road Lights

29 Verify that all lights are functional.

WORKPLACE INSPECTION

The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation. It should be performed by the operator prior to moving the machine to the workplace.

It is the operator's responsibility to read and remember the workplace hazards, then watch for and avoid them while moving, setting up and operating the machine

Be aware of and avoid the following hazardous situations:

drop-offs or holes•

Result: The parking brake indicator light should

come on, indicating the parking brake is on.

24 Move the transmission control lever forward,

then in reverse.

Result: The machine should not move.

25 Push the parking brake lever downward. The

parking brake is off when the indicator light is off.

Test the Outiriggers

26 Using the buttons 52 and 53, fully lower and raise the stabilizers.

Result: The stabilizers should operate moothly.

27 Raise the boom over 20° and extend it.

Result: The stabilizers should not work.

bumps, floor obstructions or debris•

sloped surfaces•

unstable or slippery surfaces•

overhead obstructions and high voltage •

conductors

hazardous locations•

inadequate surface support to withstand all •

load forces imposed by the machine

wind and weather conditions•

the presence of unauthorized personnel•

other possible unsafe conditions•

46 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Operating Instructions

This chapter describes some techniques and

WARNING

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

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

Operator’s ManualFirst Edition - Second Printing

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

DANGER

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 47

CAUTION











Operator’s Manual

Operating Instructions

ENTERING THE MACHINE

First Edition - Second Printing

ENTERING THE CAB

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

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

Door opening from outside:

• Insert the key and release lock 1.

• Press the pushbutton 1 and open the door.

Door closing from inside:

Pull the door with force: it locks automatically.

Door opening from inside:

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

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





To unlock the door latched in open position:

• Press button 4 the door from the catch

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

to unlock





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.



CAUTION

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.

48 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

ADJUSTING THE SEAT

Operating Instructions

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

• Adjusting the seat distance from the

controls

To slide the seat forward or back, rotate lever A

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

• Adjusting seat height and springing Free the lever of knob B and turn clockwise or

counter-clockwise until reaching the desired springing. Once you’are correctly seated in the seat check that the yellow indicator C is in the green field.

• Adjusting the backrest angle Operate lever D, press your back firmly against

the backrest and put the backrest at the angle you wish, then release the lever.

• Adjusting the armrest height Raise armrest E and turn wheel F to put the

armrest at the height you want.

Operator’s ManualFirst Edition - Second Printing

FASTENING THE SEAT BELTS

Sit correctly in the driving seat; then:

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

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

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

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

CAUTION

• The seat is for one person only.

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 49



WARNING

Operator’s Manual

Operating Instructions

First Edition - Second Printing

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.



ADJUSTING THE REAR VIEW MIRRORS

The machine is fitted with two rear view mirrors:

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

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

SWITCHING ON THE CAB INTERIOR LAMP

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

switch.

50 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

NOTICE

Operator’s ManualFirst Edition - Second Printing

Operating Instructions

STARTING THE ENGINE

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

• To start the engine, rotate the ignition switch to position , and release when the engine starts.

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

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

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

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

JUMP-STARTING THE ENGINE

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

DANGER

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

Do not smoke when checking the electrolyte level.

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

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

To jump-start the engine:

WARNING

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

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 51

• Turn any users off by the special control levers.

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

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

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

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

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

Operator’s Manual

Operating Instructions





• Turn the ignition key and start the handler.

• Disconnect the cables. Remove first the negative

terminal from the frame earth, then from the

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

First Edition - Second Printing

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.

DANGER

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

52 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

To start the engine from cold, proceed as follows:

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

• Turn the ignition switch to the glow plugs preheating position: the relevant warning light 46 goes on. Step down on the gas pedal and start the engine by turning the ignition switch. Release the switch as soon as the engine fires.

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

WARNING

Operator’s ManualFirst Edition - Second Printing

Operating Instructions

STARTING THE MACHINE

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

• Select the required steering mode.

• Select the required gear (forward or reverse).

• Release the parking brake.

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

WARNING

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

■ USE OF THE MAN-PLATFORM

For the use of the man-platform, proceed as follows:

1 Couple the man-platform to the attachment

holding frame.

2 Sway the machine; check the operation on

inclinometer 10 in the cab.

3 Level the platform floor.

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

4 Turn the jobsite/road/platform selector to platform

position (the green indicator comes on).

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

that the man-platform is installed.

6 Stop the engine, turn the ignition switch to P

position and engage the parking brake.

7 Remove the key from the jobsite/road/platform

selector to use it from the platform controls.

8 Open the protection cover of the power socket

on the boom and plug in the platform plug.

9 Enter the man-platform and insert the key,

previously removed, in the controls switch.

If the platform controls remain disabled once the key has been inserted, check the correct position of the sensors of the attachment coupling pin (see relevant manual) and the efficiency of the outriggers limit switches (see dedicated paragraph on ”Maintenance” section).

For the use and maintenance of the man-platform, read the specific manual - code 57.0302.8200.

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 53

Operator’s Manual

Operating Instructions

STOPPING AND PARKING THE MACHINE

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

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

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

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

• Release the service brake pedal.

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

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

• Leave the driving cab and lock the cab door.

First Edition - Second Printing

WARNING

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

WARNING

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

54 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

USING THE LOAD CHARTS

EXAMPLE

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

Operator’s ManualFirst Edition - Second Printing

Operating Instructions

WARNING

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



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







GTH-4013 EX - SX

EXAMPLE

09.4618.0866

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 55

Operator’s Manual

Operating Instructions

LOAD LIMITER

On the front top strut of the cab, there is limiter 7 which warns the operator of the variation of stability of the machine and blocks any manoeuvre before the same reaches a critical condition.

Description of the controls

1 Calibration selection button

2 Display 3 Stability indicator with LED-bar 4 Green light - power OK 5 Yellow light - calibration mode 6 Calibration confirmation button 7 Not used 8 Red light - outrigger position 9 Buzzer ON/OFF pushbutton 10 Red light - overload pre-alarm/alarm

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

0: Generic 1: Platform

Operation

First Edition - Second Printing

1 2 3

5 6 7 8

Red LED’s: risk of overturning: the percentage of

overturning moment is above 100 with respect to the threshold value. The machine enters the alarm mode: light 10 is lit, the buzzer sounds continuously and any dangerous manoeuvre is blocked. The operator can only retract the load within safety limits.

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

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

Green LED’s: during normal operation when the

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

Yellow LED’s: they light up when the machine

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

56 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

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

DANGER

WARNING

Operator’s ManualFirst Edition - Second Printing

Operating Instructions

HANDLING LOADS

Alarm codes and resetting

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

Adjusting the forks

With FEM forks (OPTIONAL)

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

• Lift the clamping lever of the forks.

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

With floating forks

In the case of floating forks:

• Loosen the nut of the locking screws.

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

• Lock the screws retightening the nut.

5 8

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

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

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 57

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

• Refer to the payload limits given in the load chart applied on the cab.

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

DANGER

Operator’s Manual

Operating Instructions

WORKING PHASES

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

Loading phase

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

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

• Pitch the forks back to retract the load.

Transfer phase

• Do not start or brake abruptly.

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

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

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

First Edition - Second Printing

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

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

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

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

Unloading phase

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

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

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

• Lower the load and make sure it is level.

58 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

CHANGING THE ATTACHMENT

CAUTION





Operator’s ManualFirst Edition - Second Printing

Operating Instructions

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

Version with MECHANICAL 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).

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





WARNING

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

• Rest the attachment flat on the ground.

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

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

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

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

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

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 59



NOTICE

Operator’s Manual

Operating Instructions

First Edition - Second Printing

Version with HYDRAULIC 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), and connect the hydraulic locking pipes of the attachments to couplings 3.



• Rest the attachment flat on the ground.

• Remove the safety pin 2 placed at its end.

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

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

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

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

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

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

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

ROAD OR SITE TRANSFER

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

Align the rear wheels.• Select the two-wheel steering setting.• Set the • Jobsite/Road/Platform selector 25 to

“ROAD”. Cover the teeth of the conventional forks with the •

special guard; or withdraw the floating forks.

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

Retract boom and attachment to transfer • position.

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

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

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

60 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

MOVING A DISABLED MACHINE

NOTICE

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

• Unlock the parking brake.

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

• Use a rigid drawbar.

• Select the two-wheel steer.

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

• Put the gearbox lever to neutral (see below)

• Raise the front wheels of the machine.

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

Operator’s ManualFirst Edition - Second Printing

Transporting The Machine

Setting the gear lever in neutral

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

To set the gear lever to neutral:

• Disconnect the cylinder hoses A and B.

• Pry the cursor of the gearbox lever C to neutral position (L = 20 mm).

• Riconnect the cylinder hoses A and B.

Unlocking the negative brake (only for GTH-4017 EX - GTH-4514 EX)

To unlock the negative brake of a faulty machine, use the four screws 31 on the two sides of the front differential casing as follows:

Loosen the four counter-nuts fixing screws • 31, then move the nuts backwards by approx. 8 mm.

Tighten screws • 31 so as to fasten them onto the pressure plate.

Using a wrench, tighten the screws • 31 in an alternate sequence by 1/4 turn a time so as to compress the Belleville washers and disengage the braking disks. Tighten max. by one turn.

After the manual release, adjust screws • 31 to ob- tain a jut of 30 ± 0.5 mm in relation to the arm.

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



Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 61

09.4618.0916

Operator’s Manual

Transporting The Machine

First Edition - Second Printing

LIFTING THE MACHINE

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

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

GTH-4013 EX

TRANSPORTING THE MACHINE ON OTHER

VEHICLES

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

• Ensure ramps are correctly positioned.

• Retract the boom to transfer position.

• Carefully drive the machine onto the transporting

vehicle.

• Put the parking brake and rest the attachment flat

on the vehicle platform.

• Ensure the overall dimensions do not exceed the

allowed limits.

• Shut the engine down and close the driving cab

of the machine.

• Secure the machine to the vehicle platform by

wheel-chocks.

• Anchor the machine to the transporter's platform

by fixing the chains to the special eyebolts A on the chassis.

GTH-4514 EX & GTH-4017 EX



62 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

PARKING AND STORAGE

CAUTION

NOTICE

Operator’s ManualFirst Edition - Second Printing

Transporting The Machine

Short inactivity

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

• Park the machine so that it does not hinder other

operations.

• Lower the boom fitted with attachment on the ground.

• Disengage the transmission and put the parking brake.

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

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

Machine storage

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

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

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

• Lubricate the machine thoroughly.

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

• Re-paint any worn or damaged part.

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

• Refuel the tank to prevent internal oxidation.

• Store the machine in a sheltered and wellventilated place.

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

• When weather is particularly cold, empty the radiator.

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 63

NOTICE

PROTECT THE ENVIRONMENT

Operator’s Manual

Transporting The Machine

First Edition - Second Printing

CLEANING AND WASHING THE MACHINE

Clean the machine in accordance with the following instructions:

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

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

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

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

External washing

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

Internal washing

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

Washing the engine

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

MACHINE DISPOSAL

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

Battery disposal

Used lead-acid batteries cannot be disposed of as normal industrial solid wastes. Because of the presence of harmful substances, they must be collected, eliminated and/or recycled in accordance with the laws of the UE. Used batteries must be kept in a dry and confined place. Make sure the battery is dry and the cell plugs are tight. Place a sign on the battery to warn of not using it. If before disposal the battery is left in the open air, it will be necessary to dry, smear the box and the elements with a coat of grease and tighten the plugs. Do not rest the battery on the ground; it is always advisable to rest it on a pallet and cover it. The disposal of batteries shall be as rapid as possible.

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.

64 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

NOTICE

Operator’s ManualFirst Edition - Second Printing

Maintenance

Observe and obey:

* The operator can only perform

the routine maintenance operations envisaged in this

manual.

* Scheduled maintenance

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

specifications.

Maintenance symbol legend:

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

Indicates that tools are required to perform the procedure.

INTRODUCTION

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

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

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

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

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

Indicates that new parts are required to perform the procedure.

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

SERVICE INTERVAL

Running-in ____________________________ Ordinary ______________________________

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 65

Operator’s Manual

Maintenance

LUBRICANTS - HEALTH AND

SAFETY PRECAUTIONS

First Edition - Second Printing

Health

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

Storage

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

Disposal

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

Oil leaks

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

First aid Eyes : In case of accidental contact with

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

Intake : In case of oil intake, do not induce

vomiting, but seek medical advice.

Skin : In case of a prolonged contact, wash

with soap and water.

Fire

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

66 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Operator’s ManualFirst Edition - Second Printing

Maintenance

ORDINARY MAINTENANCE

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

CAUTION

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

During the first 10 working hours

Check the oil level within reduction gears, power 1. divider and differential gears

Regularly check the tightening of the wheel 2. bolts

Check the tightening of all bolts and nuts3. Check the couplings for oil leaks4.

Within the first 100 working hours

Change the oil of the differential casing, the 1. wheel reducer and the power divider gearbox.

Every 10 working hours or daily

Check the engine oil level.1. Clean the air suction filter.2. Check the engine coolant level.3. Clean the radiator, if necessary.4. Check the hydraulic oil level in the tank.5. Check the greasing of the boom section pads6. Grease the attachment holding frame.7. Grease all joints of the boom, the rear axle shaft 8.

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

Check the efficiency of the overload warning 9. system.

Check the efficiency of the lighting electric 10. system.

Check the efficiency of braking system and 11. parking brake.

Check the efficiency of the steering selection 12. system.

Check the efficiency of the fork balancing 13. system.

Make sure the safety devices installed are in 14. efficient working order.

Check or re-sequence the boom telescopes.15.

Every 50 working hours or weekly

Jobs to be done in addition to those above

Check the tension of the alternator belt.1. Check the tyre inflation.2. Check the tightening of the wheel nuts.3. Check the tightening of the Cardan shaft 4.

screws. Clean the radiator fins.5.

Every 250 working hours or monthly

Jobs to be done in addition to those above

Check the oil level in the front and rear differential 1. gears.

Check the oil level in the four wheel reduction 2. gears.

Check the main filtering element of the engine 3. air filter. Replace, if necessary.

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 67

Operator’s Manual

Maintenance

First Edition - Second Printing

Check the clamping of the cableheads to the 4. battery terminals.

Check the air suction hose between engine and 5. filter.

Check the cylinder chromium-plated rods.6. Check the hydraulic lines are not worn because 7.

of rubbing against the frame or other mechanical components.

Check the electric cables do not rub against the 8. frame or other mechanical components.

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

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

Remove any grease from the boom, then re-11. grease the sliding parts of the boom sections.

Check the level of the battery electrolyte.12.

Every 3 working months

Jobs to be done in addition to those above

Check the efficiency of the block valves1. .

Every 500 working hours or every six months

Jobs to be done in addition to those above

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

Check the tightening of the engine fixing 2. screws.

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

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

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

filter. Renew the cartridge of the engine oil filter and 8.

the fuel filter. Change the oil of the front and rear differential 9.

casings. Proceed with boom chain tensioning.10.

Every 500 working hours or yearly

Jobs to be done in addition to those above

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

Every 1000 working hours or yearly

Jobs to be done in addition to those above

Change the safety element of engine air filter.1. Change the oil in the power divider gearbox.2. Change the oil in the four wheel reduction 3.

gears. Change the hydraulic oil.4.

Every 2000 working hours or every two years

Jobs to be done in addition to those above

Change the engine coolant.1.

At 6000 hours or 5 years and, subsequently, every 2 years

Jobs to be done in addition to those above

Check that the structure is intact paying a special 1. attention to the welded supporting joints and the boom pins.

68 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

OIL CHANGE SCHEDULE

Operator’s ManualFirst Edition - Second Printing

Maintenance

Oil level check

Engine

Axles and

power

divider

gearbox

Hydraulic

oil

* whichever occurs ﬁ rst.

First change Subsequent changes Oil level check First change Subsequent changes

Oil level check First change Subsequent changes

Job

Operating

hours *

10 500 500 250

1000

Service

interval *

daily

yearly

monthly

yearly

daily

yearly

Oil type

SHELL RIMULA 15W-40 (API CH-4/CG-4/CF-4/CF; ACEA E3; MB228.3)

TRACTORENAULT THFI 208 LF SAE 80W; API GL4 / FORD M2C 86B; MASSEY FERGUSON M 1135

SHELL TELLUS T 46 DENISON HF-1, DIN 51524 part 2 & 3

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 69

CAUTION

Operator’s Manual

Maintenance

MAINTENANCE INTERVENTIONS

First Edition - Second Printing

WARNING

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

WARNING

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

WARNING

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

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

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

PROTECT THE ENVIRONMENT

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

WARNING

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

70 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

ACCESS TO THE ENGINE COMPARTMENT

CAUTION

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.

Operator’s ManualFirst Edition - Second Printing

Maintenance

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



Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 71

NOTICE

Operator’s Manual

Maintenance

ENGINE AIR FILTER

(FOR GTH-4013 EX)

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

1 Cleaning and changing the external

element

- Shut the engine down and put the parking brake.

- Open the four latches A.

- Remove the protection cap B.

- Extract the external cartridge C.

- Clean the filter bowl.

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

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

- Check for cracks in the filtering element.

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

- Refit cap A.

First Edition - Second Printing

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









As soon as the warning lamp 40 on the cab dashboard switches on, replace the outer element. Never wash the cartridge with water or solvents.

2 Changing the internal element

- See step 1 for removing the outer element.

- Extract the internal cartridge D.

- Clean the filter bowl.

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

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

72 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Running-in _____________________________ None

Cleaning _____________________ Every Outer element change __________Every 500 hours Inner element change ________ Every 1000 hours

SERVICE INTERVAL



10 hours

ENGINE AIR FILTER

NOTICE

(FOR GTH-4017 EX GTH-4514 EX)

Operator’s ManualFirst Edition - Second Printing

Maintenance

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

1 Cleaning and changing the external

element

- Shut the engine down and put the parking brake.

- Unscrew wingnut A and remove cover B.

- Unscrew wingnut C and remove the outer element D.

- Clean the filter bowl.

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

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

- Smear the seal with grease, then refit the element.

- Tighten wingnut C, close cover B and tighten with wingnut A

The inner element should be replaced every two times the outer element is replaced. Daily remove any dust collected in the filter by pressing the rubber cap G.











As soon as the warning lamp 40 on the cab dashboard switches on, replace the outer element. Never wash the cartridge with water or solvents.

2 Changing the internal element

- See step 1 for removing the outer element.

- Loosen wing nut E and remove the inner element F.

- Clean the filter bowl.

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

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 73

Running-in _____________________________ None Cleaning _____________________ Every 10 hours Outer element change __________Every 500 hours Inner element change ________ Every 1000 hours

SERVICE INTERVAL





CAUTION

Operator’s Manual

Maintenance

ENGINE COOLING SYSTEM



First Edition - Second Printing



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

• Weekly check the coolant level through the level

window C, before starting working (when fluid is cold).

• When necessary, add clean water or an antifreeze

mixture through cap A.

• Change the antifreeze mixture every two years.

To drain the antifreeze:

- Let the engine cool down

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

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

- Refit the hose and pour new antifreeze (50%

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

• Daily clean the radiator grille using a brush with

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

GTH-4013 EX







GTH-4514 EX GTH-4017 EX









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

TEREX PRO COOL

Protection against boiling / freezing

Product % Freezing point Boiling point

SERVICE INTERVAL

Running-in

Ordinary

74 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

__________________________ None

__________________ Every 50 hours

40 50 70

-17°C

-24°C

-36°C

-67°C

123°C 126°C 128°C 135°C

CAUTION

PROTECT THE ENVIRONMENT

Operator’s ManualFirst Edition - Second Printing

Maintenance

CHECKING THE OIL LEVEL IN THE TANK

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

Visually check the hydraulic oil level through level A located on the reservoir ( in GTH-4013 EX it’s visible through the slot on the right side of the chassis).

When necessary, add new oil through filler B.

SERVICE INTERVAL

Running-in

Ordinary

_________Within the first 10 hours

__________________ Every 50 hours

CHANGING THE HYDRAULIC OIL

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

sure the parking brake is engaged.

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

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

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

into the container.

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

a jet of compressed air.

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

recommended type until it is level with A.

SERVICE INTERVAL

Running-in

__________________________ None

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

GTH-4514 EX GTH-4017 EX







Ordinary

________________Every 1000 hours

GTH-4013 EX

















Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 75





Operator’s Manual

Maintenance

■ CHANGING THE CANISTERS OF THE OIL

FILTER IN THE INJECTION LINE

FOR GTH-4514 EX & GTH-4017 EX

First Edition - Second Printing

■ Transmission oil filter

To change the hydraulic oil filter of the transmission, proceed as follows:

1 Stop the machine on a level ground and engage

the parking brake.

2 Place a container of suitable size under the filter

to collect any oil leaks, then close cock A.

3 Remove the filter canister B with the special

wrench provided.

4 Renew the canister. Before fitting a new cani-

ster, thoroughly clean and grease both bowl and gasket.

5 Hand-tighten and re-open cock A.

SERVICE INTERVAL

Running-in

Ordinary

__________________________ None

_________________ Every 500 hours

■ Auxiliary circuits oil filter

To change the hydraulic oil filter cartridge of the service circuits, 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 tank,

then allow oil to flow out until its level is under the inspection hatch (90 litres approx).

3 Remove the inspection hatch and unscrew the

oil filter C fitted inside the tank.

4 Check the tank is clean, then fit a new filtering

element and refit the inspection hatch.

5 Check the oil level within the tank. Add new oil,

if necessary.

SERVICE INTERVAL

Running-in

Ordinary

__________________________ None

________________Every 1000 hours













76 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

CHANGING THE OIL FILTER CARTRIDGE

NOTICE

PROTECT THE ENVIRONMENT

FOR GTH-4013 EX

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

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

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

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

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

Refit and tighten the filter cover

Operator’s ManualFirst Edition - Second Printing

Maintenance

NOTICE

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

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

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

SERVICE INTERVAL

Running-in

__________________________ None





Ordinary

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 77

_________________ Every 500 hours

NOTICE

Operator’s Manual

Maintenance

CAB AIR FILTER

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

the cartridge if the filtering cloth is damged.

1 Cleaning and changing the cartridge:

- Shut the engine down and engage the parking brake.

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

- Clean the filter bowl.

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

First Edition - Second Printing

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





78 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Operator’s ManualFirst Edition - Second Printing

Maintenance

OIL LEVEL IN THE DIFFERENTIAL GEARS

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

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

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

• If necessary, top-up through hole  until oil comes out from hole .

• Refit and tighten plugs  and .

To change the oil:

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

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

gear.

• Refit and tighten drain plug .

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

• Refit and tighten plugs  and .

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

OIL LEVEL IN THE (front/rear) WHEEL

REDUCTION GEARS

To check the oil level within the wheel reduction gears:

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

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

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

• Refit the plug.

To change the oil:

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

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

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

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

• Add new oil through hole .

• Refit and tighten plug.

SERVICE INTERVAL

Running-in

Ordinary

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 79

_________Within the first 10 hours

_________________ Every 250 hours

Running-in

Ordinary

SERVICE INTERVAL

_________Within the first 10 hours

_________________ Every 250 hours

Operator’s Manual

Maintenance

OIL LEVEL IN THE POWER DIVIDER

GEARBOX

To check the oil level in the power diver gearbox:

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

• Clean level plug  all around.

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

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

• Refit and tighten the plug.

To change the oil:

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

• Remove the plug .

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

• Refit and tighten the drain plug .

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

Stop when oil is level with hole .

• Refit and tighten plug .

First Edition - Second Printing

Filling plug Drain plug

SERVICE INTERVAL

Running-in

Ordinary

80 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

_________Within the first 10 hours

_________________ Every 250 hours

GREASING

Operator’s ManualFirst Edition - Second Printing

Maintenance

CAUTION

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

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

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

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

figures:

- the symbol

greased by a pump

- the symbol represents the points to be

greased by a brush.

represents the points to be

CAUTION

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

• After the first 50 operating hours (1 week)

• After the first 250 operating hours (1 month)

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

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

SERVICE INTERVAL

Running-in

Ordinary

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 81

__________________________ None

__________________ Every 10 hours

Operator’s Manual

Maintenance

TYRES AND WHEELS

First Edition - Second Printing

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.

Over-inflated tyres can burst.

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

RIGHT WAY

OKAY

WRONG WAY

WRONG

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

GTH-4013 EX

GTH-4017 EX

GTH-4514 EX

Dimensions

(front and rear)

405/70-24 405/70-20

P.R. (or load index)

14 pr 14 pr

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

SERVICE INTERVAL

Running-in

Ordinary

_________Within the first 10 hours

_________________ Every 250 hours

BRAKES

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

Rim

13x24 13x20

Wheel disc 8 holes DIN 70361 Pressure

bar/Psi

4.5/65 5.5/80

82 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

SHAFTING ALIGNMENT

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

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

1) Move to a solid and level ground

2) Set the steering selection switch 19 to “four-

wheel steer”

3) Rotate the steering up to its stop (either to the right or to the left)

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

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

(pos. 2)

Operator’s ManualFirst Edition - Second Printing

Maintenance

6) Reset the steering selection switch to “four- wheel steer" (pos. 2)

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

3) so that the rear axle reaches its stop

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

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

7) so that the front axle reaches its stop

10) Reset the steering selection switch to “four-

wheel steer" (pos. 2)

Now the wheels should be re-aligned.

If the machine is equipped with the optional rear wheel shafting indicator light (see paragraph Controls and Instruments), the light comes on automatically when, by turning the steering selector switch from position 1 to position 0 or from position 2 to position 0, rear wheels are aligned.

SERVICE INTERVAL

Running-in

__________________________None

0 2

Ordinary

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 83

__________________ When necessary

CAUTION

Operator’s Manual

Maintenance

ADJUSTING THE SLIDING PADS OF THE BOOM

SECTIONS

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

First Edition - Second Printing



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

Adjusting the pads:

• Remove or loosen the screws fixing the pads in

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

• Fit the necessary amount of shims.

• If the residual thickness of the pad is insufficient

or near the maximum wearing limit, renew the pad.

• Tighten the screws fixing the pads at the

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

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

Screws M10 Nm 30

Screws M14 Nm 50

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











Max. wearing thickness

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

SERVICE INTERVAL

Running-in

Ordinary

84 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

__________________________None

__________________ When necessary

Minimum 1 mm

Operator’s ManualFirst Edition - Second Printing

Maintenance

RE-SEQUENCING THE TELESCOPIC BOOM

(Only for GTH-4013 EX)

If, during normal operation, a change in the boom extended lengths of 150 mm or more is noticed when the boom is retracted, proceed as follows:

Fully retract the telescope cylinder and hold the 1. system over relief (approx. 15 seconds); the boom sections should become equal.

If after performing this procedure the boom still remains out of sequence, proceed with the steps below:

Move the boom to the zero position, fully retract 2. the boom and hold the retract system over relief for approx. 20 seconds.

Raise the boom to approx. 60° and operate the 3. retract function over relief for approx. 20 seconds.

Lower the fully retracted boom to the lowest 4. angle possible without striking the ground and hold the retract system over relief for approx. 20 seconds.

If, despite these procedures, the boom does not return in sequence, raise the boom to approx. 60°, fully extend and retract it to full stroke and hold the system over relief (approx. 20 seconds) in each direction.

By following these procedures the boom resequencing should be correct.

TENSIONING THE BOOM CHAINS

(Only for GTH-4514 EX and GTH-4017 EX)

To tighten the boom chains, follow the instructions below:

Fully extend the boom1.

Retract the boom by some 20/30 cm.2.

Tighten the chain up to a maximum tension 3.

value of:

25 Nm for GTH-4017 EX (n° 4 chains)•

40 Nm for GTH-4514 EX (n° 2 chains)•

Check that all chains have been equally 4. tensioned. If not, repeat the operation described above

Lock the chain tensioners by means of a counter-5. nut and locknut.

SERVICE INTERVAL

Running-in

Ordinary

SERVICE INTERVAL

Running-in

Ordinary

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 85

__________________________None

__________________ When necessary

__________________________ None

_________________ Every 500 hours

Operator’s Manual

Maintenance

CHECKING THE SAFETY DEVICES

First Edition - Second Printing

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

Checking the LOAD LIMITING SYSTEM

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

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

86 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Operator’s ManualFirst Edition - Second Printing

Maintenance

LIMIT SWITCHES on the OUTRIGGERS

When the outriggers are lowered to the ground:

- the overload warning system changes the meter scale

- the transmission is deactivated

Checking the limit switches of the outriggers

(at every use) To check the limit switches of the outriggers:

• Lower the outriggers to the ground and attempt to engage a gear.

If the gear can be engaged, contact the

TEREXLIFT Technical Assistance Service.

Proceed on one outrigger at a time.

• With the outriggers up, light 8 on the load limiter panel must be off; with the outriggers down to the ground, the same light must be on. Should it not be the case, contact the TEREXLIFT Technical Service.

EMERGENCY STOP PUSHBUTTON on the

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

Before starting work again, find and rectify the

relevant causes, then reset the button to neutral position turning it clockwise.

RPM x 100

Checking the emergency stop pushbutton (at

every use)

To check the efficiency of this pushbutton, simply

press it down during a movement. The pressure of the pushbutton shall cause the movement to stop and the engine to shut down.

WARNING

If a limit switch is faulty or a lever is deformed, immediately replace the part.

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 87

DANGER

Operator’s Manual

Maintenance

BLOCK VALVES fitted to all CYLINDERS

All machine’s cylinders are equipped with block

valves:

First Edition - Second Printing

Compensation cylinder• Lifting cylinder• Telescopic boom extension cylinder • Attachment swinging cylinder • Stabilizing cylinders• Machine rear axle locking cylinder • Machine levelling cylinder •

Always use the lock ring of the lift cylinder (see picture below), when carrying out maintenance on the lift cylinder block valve or, in general, any operation in the area under the boom:

Lift and extend the boomI. Unscrew the two screws on the frame (pos. II.

A) to release the ring

Put the ring on the lift cylinder rod (pos. B)III. Lock the ring by tightening the screws IV.

provided on the ring.





88 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

WARNING

Operator’s ManualFirst Edition - Second Printing

Maintenance

Checking the block valves (every 3 months)

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

• Load a weight near the maximum payload onto

the boom.

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

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

• To check the efficiency of the block valves of the outriggers, lower them to the ground and unload the weight of the tyres without raising them. Loosen the cylinder hoses to check the efficiency of the valve.

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

To remove the block valves or the cylinders

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

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

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

- Wear safety glasses

- Wear safety gloves

- Wear safety shoes

- Wear suitable working clothes

- Use guards against leaks of oil at high pressure

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

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 89

Operator’s Manual

Maintenance

SAFETY SWITCHES:

L Low boom sensor: switch installed at the

back of the boom.

M High boom sensor: switch installed at the

back of the boom.

N Extended boom sensor: switch installed at

the back of the boom.

O Switch on the parking brake to prevent

forward-backward transmission engaging.

First Edition - Second Printing



Switch control

(at every use)

Switch L on boom

• Lift the boom with a tilt angle below 20° and check if, regardless of the boom extension, machine sway function and outriggers’ controls can be activated.

If they cannot be activated, call TEREXLIFT

Technical Assistance Service.

Switch M on boom

• Lift the boom with a tilt angle over X° ( 40° for GTH-4514EX and GTH-4017EX; 50° for GTH4013EX) and make sure the machine sway

function and outriggers’ controls are disabled.

If they are not disabled, call TEREXLIFT Technical

Assistance Service.

Switch N on boom

• Lift the boom with a tilt angle over 20°, extend the boom and make sure the machine sway function and outriggers’ controls are disabled.

If they are not disabled, call TEREXLIFT Technical

Assistance Service.

Switch O on the parking brake

• Sit in the driving seat, engage the parking brake and make sure the machine does not move.

If the machine moves, replace or adjust the

distance of the micro-switch on the parking brake



GTH-4013 EX



GTH-4514 EX



GTH-4017 EX







X°

20°

0°

90 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

Checking the MACHINE START CONTROL (at

WARNING

every use)

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

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

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

Operator’s ManualFirst Edition - Second Printing

Maintenance

CHECKING THE STATE OF THE

STRUCTURE

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

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 91

WARNING

CAUTION

Operator’s Manual

Maintenance

ELECTRICAL SYSTEM

First Edition - Second Printing

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

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

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

BATTERY

• Check the electrolyte level every 250 working

hours; if necessary, add distilled water.

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

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

• Protect the terminals smearing them with pure vaseline.

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

• Battery electrolyte contains sulphuric acid. It

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

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

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

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

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

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

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

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

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

Do not add sulphuric acid; add only distilled water.

92 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

K11

K21

K18

F22

F23

F24

F25

F26

F27

F16

F17

F18

F19

F20

F21

F13

F14

F15

F10

F11

F12

K19

K24

J3 J2 J1

K10

K23

K16

K15

K12

K13

Operator’s ManualFirst Edition - Second Printing

Maintenance

FUSES AND RELAYS

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

GTH-4017 EX & GHT-4514 EX

Relays

Ref. Circuit

K1 K2 K3

HIGH BEAM LOW BEAM

HORN K4 LIGHT POWER SUPPLY K5 SHIFT 1°/2° MECHANICAL SPEED

Fuses

Ref. Circuit Amp.

F1 FRONT WIPER F2

HEATING 15

STOP LIGHT MICRO-SWITCH 5 F4 REAR/ROOF WIPER F5 OPTIONAL F6

LOW BEAM 15 F7 POSITION LIGHTS F8

INSTRUMENT LIGHTING 3 F9

INDICATOR LIGHTS POWER SUPPLY

F10 ROAD LIGHTS SWITCH F11 FLASHING BEACON F12 STOP LIGHTS F13 JOBSITE/MANPLATFORM SEL F14 BACKWARDS LIGHT F15

HIGH BEAM 10

F16 HAZARD WARNING LIGHT F17 ROAD LIGHTS F18

OUTRIGGERS MICRO-SWITCH 10

F19 TRANSMISSION CONT. UNIT F20

+12V ON THE BOOM 10

F21

HORN 15

F22 MANPLATFORM POWER SUP. F23 CAB INTERIOR LIGHTS F24 JOBSITE/MANPLATFORM SEL F25 LMI CONTROL UNIT F26 AUXILIARY CIRCUIT F27

WORK LIGHTS 10

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 93

7.5 10

7.5

7.5 10 10 10

15 10

15 10 10 10 10

K6 BACKWARDS BUZZER K7 ------------------------K8 -------------------------

K9 ---------------------------K10 --------------------------K11

START-UP ENABLING COMMAND K12 EMERGENCY PUMP ENABLING COM K13 EMERGENCY PUMP K14 -------------------K15 BOOM OUT ENABLING (LMI) K16 BOOM DOWN ENABLING (LMI) K17 --------------------K18 OUTRIGGERS K19

OVERLOAD WARNING SYSTEM K20 ------------------K21 REAR AXLE LOCK K22 OPTIONAL K23 TIMER K24 TIMER

K1K9K11

K21

K18

F22

F23

F24

F25

F26

F27

F16

F17

F18

F19

F20

F21

F13

F14

F15

F10

F11

F12

K19

K24

J3 J2 J1

K10

K23

K16

K15

K12

K13

Operator’s Manual

Maintenance

First Edition - Second Printing

FUSES AND RELAYS

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

GTH-4013 EX

Fuses

Ref. Circuit Amp.

F1 FRONT WIPER 10 F2 HEATING / AC 15 F3 I/0 CONTROL UNIT 5 F4 REAR/ROOF WIPER 7.5 F5 OPTIONAL 10 F6 LOW BEAM 15 F7 POSITION LIGHTS 3 F8 INSTRUMENT LIGHTING 3

INDICATOR LIGHTS POWER SUPPLY

7.5 F10 ROAD LIGHTS SWITCH 7.5 F11 FLASHING BEACON 7.5 F12 STOP LIGHTS 10 F13 STEERING MODE SELECTOR 10 F14 BACKWARDS BUZZER 10 F15 HIGH BEAM 10 F16 HAZARD WARNING LIGHT 15 F17 POSITION LIGHTS SWITCH 10 F18 OUTRIGGERS MICRO-SWITCH 10 F19 TRANSMISSION CONT. UNIT 10 F20 EMERGENCY STOP SWITCH 10 F21 HORN 15 F22 MANPLATFORM POWER SUP. 15 F23 CAB INTERIOR LIGHTS 10 F24 JOBSITE/MANPLATFORM SEL 10 F25 LMI CONTROL UNIT 10 F26 AUXILIARY CIRCUIT 10 F27 WORK LIGHTS 10

Relays

Ref. Circuit

K1 HIGH BEAM K2 LOW BEAM K3 HORN K4 STOP LIGHT K5 SHIFT 1°/2° MECHANICAL SPEED K6 BACKWARDS BUZZER K7 FOWARD MODE SOLENOID VALVE K8 REVERSE MODE SOLENOID VALVE

K9 SECURITY FOWARD/REVERSE K10 SECURITY FOWARD/REVERSE K11 START-UP ENABLING COMMAND K12 EMERGENCY PUMP ENABLING COM K13 EMERGENCY PUMP K14 -------------------K15 BOOM OUT ENABLING (LMI) K16 BOOM DOWN ENABLING (LMI) K17 --------------------K18 PLATFORM ABIL ROTATING COM. K19 PLATFORM ABILITATION K20 ------------------K21 REAR AXLE LOCK K22 TIMER K23 TIMER K24 TIMER

94 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

NOTICE

Engine compartment fuses and relays

Operator’s ManualFirst Edition - Second Printing

Maintenance

Ref. Circuit

F1G Starter Enabling Switch 30 F2G Engine Ignition Key 40 F3G Cabin Fuses Board 60 F4G Glow Plugs 60 F5G Fuel Pump 15 F6G Emergency Pump 15

K01 Engine Start K02 Glow Plugs Preheating K03 Fuel Pump K04 Emergency

F1G F4G

F2G F3G

K03

K02

K04

F6G F5G

Amp.

K01

F5G

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

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

• Always keep some spare fuses for an emergency.

• Never try to repair or short blown fuses.

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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 95

NOTICE

Operator’s Manual

First Edition - Second Printing

Maintenance

REFUELLING

Part Product Capacity (litres)

PRODUCT SPECIFICATIONS

Diesel engine Engine oil

Engine cooling system Water+antifreeze 15

Fuel tank Diesel fuel

Hydraulic system tank Hydraulic oil

Gearbox Oil 1.5

Differential gears Oil 8.7

Wheel reduction gears Oil 0.75

135

150

Engine oil

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

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

Lubrication oils and relevant filtering elements

Refill the machine with following lubricants:

Use Product Definition

Power divider-Differential gearsReduction gears

Hydraulic system and brakes SHELL TELLUS T46

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

TRACTORENAULT

THFI 208 LF SAE 80W

API GL4 / FORD M2C 86B

Massey Ferguson M1135

DENISON HF-1

DIN51524 part 2 & 3

Oils for hydraulic system:

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

96 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

NOTICE

Operator’s ManualFirst Edition - Second Printing

Maintenance

Fuel

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

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

GTH-4013 EX





Grease

For the machine greasing, use:

Lithium-based

Vanguard LIKO

grease, type EP2

Graphitized AGIP

grease, type GR NG 3

INTERFLON FIN

GREASE LS 2

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

Engine coolant

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

TEREX PRO COOL by VALVOLINE

When greasing by

pump.

When greasing by

brush.

On the telescopic

boom

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

TEREX PRO COOL

-17°C

-24°C

-36°C

-67°C

123°C 126°C 128°C 135°C



GTH-4514 EX GTH-4017 EX

Protection against boiling / freezing

Product % Freezing point Boiling point

33 40 50 70



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

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 97

Operator’s Manual

First Edition - Second Printing

Intentionally blank page

98 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

FAULTS AND TROUBLESHOOTING

This chapter represents a practical guide for the operator for fixing the most common failures and, at the same time, detecting those interventions that must be carried out by qualified technical engineers. If you are unsure about anything, do not carry out operations on the machine, but call in a skilled technician.

PROBLEM CAUSES SOLUTIONS

Operator’s ManualFirst Edition - Second Printing

Faults and Troubleshooting

WARNING

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

THE DASHBOARD DOES NOT TURN ON

THE STARTER DOES NOT RUN

THE STARTER RUNS, BUT THE ENGINE DOES NOT START

THE MACHINE DOES NOT MOVE FORWARD/BACK

NO SELECTION OF THE STEERING MODE

THE DLE LOAD LIMITING SYSTEM IS IN ALARM

Battery down • Fuse in the engine • compartment box blown

Forward/reverse gear selector • not in neutral position Battery down•

Engine start fuse blown: • F56

(GTH-4514 EX & GTH-4017 EX); F1M (GTH-4013 EX)

No fuel• Fuel filter clogged•

Fuel hose empty (fuel used up)•

Changeover switch in neutral•

Parking brake engaged• Fuse • F14 blown

Fuse • F13 blown Check the fuse and replace if •

• Fuse F25 blown

• System failure

Check the battery condition• Check the main fuse in the engine • compartment and replace if necessary

Set the switch to • 0

Recharge or replace the battery•

Check the fuse located i and • replace if necessary

Refuel• Change the filter. See engine • operator handbook) Refuel, then refer to engine • operator handbook

Set the gear switch to correct • position Disengage• Check the fuse and replace if • necessary.

necessary.

Check and replace fuse, if necessary•

Check the load cell functionality •

Part No. 57.0009.0454 GTH-4013EX - GTH-4514EX - GTH-4017EX 99

Operator’s Manual

Faults and Troubleshooting

PROBLEM CAUSES SOLUTIONS

1 E2PROM error

2 The value read from CELL 1 is higher

than max permissible

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

3 The value read from CELL 2 is higher

than max permissible

4 Block relay error during operation

First Edition - Second Printing

Stop and restart the machine to RESET • the system. If the error message is still shown, address to the TEREXLIFT service centre to re-calibrate the machine.

Check the wiring between control panel • and load cell Check that the load cell is fixed correctly• Check the connecting cable or the • connectors is/are not shorted. If the error message is still shown, • address to the TEREXLIFT service centre and let the load cell be checked.

• Check the wiring between control panel and load cell

• Check that the load cell is fixed correctly

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

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

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

Check the efficiency of relay and wiring.•

5-6-7-8 Block relay error when power is

turned on

9 CELL 1 and CELL 2 reading

incongruence. The values read from the two cells are different.

100 GTH-4013EX - GTH-4514EX - GTH-4017EX Part No. 57.0009.0454

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

• Check that the cells are intact and ﬁ xed correctly. If the error message is still shown, address to the TEREXLIFT service centre to replace the load cell or re-calibrate the machine.

Genie GTH-4017 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual