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Terex Genie GTH-4013, Operator'S Manual

The Terex Genie GTH-4013 is a versatile telehandler designed to handle heavy loads with ease. Ensure safe operation by downloading the free Operator's Manual from our website. This comprehensive manual provides essential information for optimal performance and maintenance of the GTH-4013. Download your manual now at manualshive.com.

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G-10

Document 57.0007.0200 - 01/2006

TABLES AND DOCUMENTS ENCLOSED

Handler with telescopic boom  

GTH-4013

 

 G-3.2.4  Sheet 4 of 9

REAR

WORK LIGHTS

REAR RIGHT

WORK

LIGHT

REAR LEFT

WORK 

LIGHT

0

2

1

+15

+30

0

2

1

RELAY

CARD

AUX CIRCUIT

RELAY

HORN

LICENCE

PLATE

LIGHT

REAR

RIGHT

LIGHT

STOP LIGHT

MICRO-SWITCH

REAR

LEFT

LIGHT

FRONT

RIGHT

LIGHT

FRONT

LEFT

LIGHT

t

FUEL

GAUGE

HIDRAULIC

OIL

TEMPERATURE

1

0

K4

86 87a

87

85

30

K3

86 87a

87

85

30

K1

86 87a

87

85

30

K2

86 87a

87

85

30

G/N1

R1.5

R1.5

R1.5

R1.5

N1.5

N1.5

N1.5

N1.5

N1.5

B-N1.5

B-N1.5

B-N1.5

B-N1.5

B-N1.5

B-N1.5

B-N1.5

X26

14

X26

15

X19

8

X19

11

X26

17

X26

16

X340

4

X340

2

X340

3

X340

1

X301

1

X301

2

X303

2

X303

1

E340

E301

E303

B-G1

B-G1

X19

10

G1.5

G1.5

G1.5

N1

B-R1

B-R1

B-R1

H-G1.5

P75

N1

Z/N1

1.5

S308

1

6

8

10

3

2

9

G/N1

1.5

Z-N1

1.5

V1

1.5

F19

10A

X6

3

H-L1

B-R1

6.1

N1

5.1

X20

7

X20

11

X20

8

H-G1.5

B-R1.5

X8

3

F17

10A

Z1

5.1

V-B1

5.1

H-B1

5.1

H-G1.5

5.1

H-G1

5.1

B-R1

B1.5

N1

B-R1.5

H-G1

N1

H-G1.5

B-R1

N1

S80

1

6

8

10

3

2

9

H-G1.5

B1.5

X20

10

X5

2

F12

10A

F21

15A

F3

5A

Z1

X17

14

X17

7

X17

3

F8

3A

X19

19

F10

7.5A

X9

10

S-N1

X21

28

L1

5.1

A1

5.1

L1

5.1

A1

5.1

31

5.1

X5

8

X17

2

X17

1

X17

6

Z1.5

X9

4

M-N1

X22

5

X21

29

Z1.5

M-N1.5

X5

5

G/N1

X21

23

A1

R1

G-N1

M-V1

R1

N1

H23

N1

N1

E6

E2

57

59c

R

31

XE2

1

S16

XE2

6

XE2

5

XE2

3

XE2

2

H/N1

X75

5

B-R1

X75

4

X75

6

X75

2

H/N1

N1

X75

1

G1

X75

3

H/N1

V1

X17

13

F15

10A

F7

3A

V-

B

1

X20

17

H-B1

X17

15

G1

G1

X5

11

F6

15A

X17

16

B-R1

2.5

N1

3.5

H/N1

G1

1.5

X19

3

G1

X5

1

G1

X22

1

X21

22

L1

R1

S-N1

XE9

3

XE9

5

G1

G1

A1

XE9

2

X17

12

V1.5

H1.5

X5

7

X22

11

X17

4

X17

11

V1.5

X5

10

H1.5

X22

9

X22

12

G/N1

L1

H1.5

V1.5

H1.5

V1.5

G-N1

X17

5

X22

2

X22

3

N1

XE9

1

E9

57

59c

L

31

N1.5

N1.5

E25

56b

56a

58

L

31

XE25

1

E24

56b

56a

58

R

31

XE24

1

XE24

5

XE24

4

XE24

3

XE24

2

XE25

5

XE25

4

XE25

3

XE25

2

X21

39

X21

26

H-N1

Z/N1

Z-N1

M-V1

3.5

N1

B13

N1

B15

31

3.5

X21

2

S78

1

10

5

9

X20

6

X17

10

XE9

6

B-R1

3

1

2

4

5

SHIFT-ON-FLY

OPTIONAL

Summary of Contents for Genie GTH-4013

Page 1: ...D UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE CAUTION KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES GTH 4013 Operator s manual Part N 57 0007 0200 Rev 0 01 2006 From serial n 14518 To seria...

Page 2: ......

Page 3: ...ture Dept Studio VEGA Forl Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Geni...

Page 4: ...Revision Revised Issued N date pages Notes by 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 REVISED PAGE LIST...

Page 5: ...starting machine parking machine storing Section D is addressed to those responsible for maintenance and the servicemen The section describes the maintenance schedule and the relevant intervals Sectio...

Page 6: ...mbol be alert to the possibility of personal injury Strictly obey all the safety messages accompanying this symbol to avoid the risk of serious injury or death DANGER Red used to indicate an imminentl...

Page 7: ...57 0007 0200 01 2006 Page 3 GENERAL INDEX GENERAL INFORMATION Sect A SAFETY PRECAUTIONS Sect B OPERATING INSTRUCTIONS Sect C MAINTENANCE Sect D TROUBLESHOOTING Sect E OPTIONAL ATTACHMENTS Sect F TABL...

Page 8: ...Document 57 0007 0200 01 2006 Page 4 Handler with telescopic boom GTH 4013 INTENTIONALLY BLANK PAGE...

Page 9: ...6 Identification plates of the main parts A 13 A 3 ALLOWED USE A 14 A 3 1 Allowed use A 14 A 3 2 Improper use A 14 A 3 3 Residual hazards A 14 A 3 4 Applicable standards A 15 A 3 5 Safety devices A 16...

Page 10: ...POSITION Conventionally the machine should be considered positioned as shown in the figure This convention is necessary to make any reference of this handbook to different machine parts front rear etc...

Page 11: ...sure they are easy to read For this purpose clean them or replace those that become unreadable either graphic or text To clean labels use of a soft cloth water and soap Never use solvents petrol etc W...

Page 12: ...Handler with telescopic boom GTH 4013 09 4618 0663 09 4618 0516 09 4618 0230 09 4618 0230 09 4618 0547 09 4618 0061 09 4618 0212 09 4618 0010 09 4618 0662 09 4618 0547 09 4618 0061 09 4618 0661 09 461...

Page 13: ...C 09 4618 0516 Quick guide 09 4618 0663 An overview of the operator s handbook concerning control lever machine starting overload warning system main safety precautions The guide also includes the for...

Page 14: ...parts or hot components 09 4618 0030 Do not change mechanical gear when the machine is running 09 4618 0026 Use limits close to electric power lines It defines the minimum distance to be kept when th...

Page 15: ...ed for machine lifting Fuel cap Applied near the engine oil cap Hydraulic oil Applied near the hydraulic oil plug or level indicator Engine oil level Applied near the engine oil dipstick Moving gears...

Page 16: ...CACI N MATRICOLA SERIAL N N DE SERIE FZ IDENT NR NO DE SERIE OMOLOGAZIONE FABBRICATO IN ITALIA MADE IN ITALY PESO MAX ASSALE ANT MAX FRONT AXLE WEIGHT POIDS MAX ESSIEU AVANT ZUL ACHSLAST VO N ST VZO P...

Page 17: ...accumulator under pressure 09 4618 0673 Emergency controls Reminds the operator the correct procedure for the manual operation of the mainvalveinanemergency Italsoshowsthecontrols and the relevant con...

Page 18: ...mon life But we consider useful to explain them once again Symbol Description IMPORTANT Spend the necessary time to become familiar with these symbols and to learn their meaning Hazard warning lights...

Page 19: ...t outrigger up Left outrigger down Left outrigger up Sway right Sway left Machine sway control Cab controls Platform controls Road setting Oil filter clogged Air filter clogged Speed selector switch 1...

Page 20: ...manufacture On machines destined for the Italian market the data plate is installed in the driving cab on the right and iswell visiblewhenthedoorisopened Onthemachines destined for foreign markets th...

Page 21: ...RENATURA INDIPENDENTE MASSA CON FRENATURA AD INERZIA MASSA CON FRENATURA ASSISTITA COEFFICIENTE DI ASSORBIMENTO CORRETTO DEL MOTORE CARICO MAX ASSE ANTERIORE da kg a kg CARICO MAX ASSE POSTERIORE In f...

Page 22: ...in general may result in risks for both operators and bystanders DANGER We list below some of the most frequent and hazardous situations of improper use Carrying passengers on the machine Not strictly...

Page 23: ...rucks Fork arms Technical characteristics and testing ISO DIS 3287 Poweredindustrialtrucks Pictorialsigns Control symbols ISO 3449 1992 Earth movingmachinery Falling object protective structures Labor...

Page 24: ...rough a bar with 8 LED s 4 green 2 yellow and 2 red Emergency stop pushbutton on the dashboard to the right of the steering wheel Pressing down this button stops the engine of the machine Before start...

Page 25: ...e on attachment coupling cylinder B Block valve on lifting cylinder C Block valve on balance cylinder D Block valve on boom extension cylinder Safety pushbutton on joystick dead man button This button...

Page 26: ...ent 57 0007 0200 01 2006 Handler with telescopic boom GTH 4013 E Block valve on attachment pitching cylinder F Block valve on the outrigger cylinder G Block valve on the rear axle block cylinder H Blo...

Page 27: ...fixed to the chassis blocks the rear axle when the boom inclination is above 40 M Limit switch fitted to the right side of the boom that blocks the outriggers and the sway function axle oscillation w...

Page 28: ...A 4 GENERAL DESCRIPTION A 4 1 LIST OF THE MAIN COMPONENTS 1 3rd boom section 2 2nd boom section 3 1st boom section 5 Rear view mirror left side 6 Chassis 7 Forks 8 Attachment holding frame 9 Left swa...

Page 29: ...with a pressure accumulator Steering Servo assisted steering system with extremely reduced turning radius and three steering modes T WAY Tyres The machine is equipped with tyres suitably sized for the...

Page 30: ...2950 G Length to the front tyres mm 4830 H Length to the attachment holding plate mm 6100 I Ground clearance mm 430 J Max width with extended outriggers mm 2890 Internal steering radius mm 1140 Extern...

Page 31: ...ersion Make CUMMINS Model Type 4B 4 5T Features Diesel 4 cylinders in line 4 strokes direct injection Bore x Stroke mm 102 x 120 Total displacement cc 4500 Power at 2200 rpm kW 74 A 5 8 ELECTRICAL SYS...

Page 32: ...ORTANT Five years or 6000 hours after the first placing into operation of the machine whichever occurs first check the state of the structure paying an extreme attention to the welded supporting joint...

Page 33: ...erators B 3 B 2 2 Requisites of the servicemen B 3 B 2 3 Working clothes B 4 B 2 4 Personal protective equipment B 4 B 3 SAFETY PRECAUTIONS B 4 B 3 1 Hazards on the jobsite B 4 B 3 2 Operation or main...

Page 34: ...in this section be sure that the methods cannot damage the machine directly or indirectly or make it unsafe contact GENIE Assistance Service for any suggestion and the necessary written permission IM...

Page 35: ...fication and hazard warning plates They shall be skilled and trained about the machine use IMPORTANT The operator shall have a licence or a driving licence when provided for by the laws enforced in th...

Page 36: ...lescopic boom and the lifted load Electrical hazards 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 ener...

Page 37: ...make sure that the maintenance interventions have been carried out with care according to the established schedule see section D Maintenance DANGER Set the machine to working configuration and sway it...

Page 38: ...ntain any hot fluid DANGER 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 othe...

Page 39: ...rked 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 s...

Page 40: ...pene trate 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 obstructi...

Page 41: ...acting the boom C 20 C 3 4 6 Pitching the attachment holding frame forward back C 21 C 3 4 7 Quick coupling the attachments C 22 C 3 5 Machine sway control C 23 C 3 6 Outrigger control C 24 C 3 7 Manu...

Page 42: ...eration inspection Read and understand the safety rules before going on to the next chapter 3 Always test the machine functions prior to use 4 Inspect the work place 5 Only use the machine for the int...

Page 43: ...les steering system braking system boom telescopes sliding pads clean glasses lights and rear view mirrors engine and relevant components limit switches and horn lights moment limiter joystick pushbut...

Page 44: ...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...

Page 45: ...ng 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 th...

Page 46: ...upper post of the windscreen and allows checking the area behind the machine on the left hand side To adjust its position manually rotate the joint it is fitted with 56 55 C 2 6 SWITCHING ON THE CAB...

Page 47: ...or 13 Mechanical gearbox switch 14 Hazard warning lights switch 15 Fog lamp switch 16 Air conditioning fan switch 17 Emergency pump switch only with man platform 18 Road lights switch 19 Hydraulic oil...

Page 48: ...4013 K K K K K K K K K K K K K K K K K K K K F22 F23 F24 F25 F26 F27 F16 F17 F18 F19 F20 F21 F13 F14 F15 F7 F8 F9 F10 F11 F12 F1 F2 F3 F4 F5 F6 INT INT K K2 3 P 0 5 10 15 30 25 20 RPM x 100 1 2 3 5 6...

Page 49: ...this position and wait until the warning light 7 2 signalling the glow plugs preheating goes off then rotate it to stroke end and start the engine Engine starting when released key springs back to pos...

Page 50: ...een wiper function To operate the windscreen wiper rotate the lever tip to one of the four positions I Wiper OFF 0 Wiper OFF J Low speed I High speed I J 0 I I I J 0 I I I J 0 I I I J 0 I I Lights fun...

Page 51: ...e pull the lever upward while holding the locking button pressed down Release the button when reaching the required braking tension It operates on the axle shafts of the front axle and when engaged it...

Page 52: ...see C 3 3 2 C 3 2 7 Steering mode selection 6 Steering mode switch Three position switch for the selection of the steering mode 1 Crab steering 0 Two wheel steering 2 Four wheel steering C 3 2 8 Cab r...

Page 53: ...h man platform Two position switch 0 OFF 1 Hold pressed down to turn on the electric pump ad operate the controls ATTENTION Check the operation of the emergency pump every week as it could get damaged...

Page 54: ...first shows the revs counter total operating time of the machine The second line displays the travel speed of the machine in km h 10 19 8 11 12 12 Engine coolant temperature indicator This indicates...

Page 55: ...When this lamp sets to on immediately change the oil filter on the return line to the tank 7 8 Warning light air filters restricted When this lamp come on proceed with cleaning or changing the air fil...

Page 56: ...the machine It is also equipped with an intentional control button that must be pressed and held in position until the movement is completed If the button is not pressed down the lever though operated...

Page 57: ...hift the control lever to or For any further information see paragraph C 3 4 4 Attachment frame forward back pitching shift the control lever to or For any further information see paragraph C 3 4 6 Te...

Page 58: ...find and rectify the faults that caused the emergency C 3 4 3 Disabling the overload warning system The key switch nder cap 22 is used to deactivate the load limiter DANGER WORKING WITH THE OVERLOAD...

Page 59: ...3 C 3 4 4 Lifting lowering the boom DANGER Before operating the boom make sure that nobody is within the working range of the machine To lift or lower the boom Set the control lever to central positio...

Page 60: ...sure that nobody is within the working range of the machine To extend or retract the telescopic elements of the boom Set the control lever to central position and press button Press button to to move...

Page 61: ...back DANGER Before operating the boom make sure that nobody is within the working range of the machine To tilt forward back the attachment holding frame Set the control lever to central position and...

Page 62: ...attachments DANGER Before operating the boom make sure that nobody is within the working range of the machine To lock the attachments Shift the control lever to central position and press button Press...

Page 63: ...f 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 IMPORTANT Do not operate the control lever The sway control is activat...

Page 64: ...tion of the right outrigger select Y to lower the outrigger select X to raise the outrigger Left outrigger Press button 2 and hold it down to enable the motion of the left outrigger select Y to lower...

Page 65: ...position Attachment locked IMPORTANT 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 con...

Page 66: ...rm 0 forks or any other attachment If during the check phase the load limiting system finds a fault it enters the safety mode automatically blocking any dangerous manoeuvres and an error message start...

Page 67: ...trol 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 regula...

Page 68: ...th oil SAE 15W 40 To start the engine from cold proceed as follows Put the mechanical gear lever to neutral Turn the ignition switch to position and wait until the warning light 7 2 signalling the glo...

Page 69: ...the cab 3 Level the platform floor IMPORTANT The platform floor cannot be levelled once the controls have been switched from the driving cabin to the platform Before starting using the platform make s...

Page 70: ...the load charts applied on the cab windscreen or to the quick guide with the fork capacity ratings C 4 7 STOPPING AND PARKING THE MACHINE When possible stop the machine on a dry level and solid ground...

Page 71: ...tual degrees of inclination of the boom are shown by the angle indicator DANGER The load charts illustrated in this manual are given only as a mere example To define the payload limits refer to the lo...

Page 72: ...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...

Page 73: ...hing the buzzer start sounding and an error message is shown on the display The meaning of the error messages is shown in Section E Faults and Troubleshooting DANGER Before using the machine make sure...

Page 74: ...f floating forks Loosen the nut of the locking screws Raise the forks and slide them on the pivot until correct spacing Lock the screws re tightening the nut DANGER The centre of gravity of the load m...

Page 75: ...verload warning system LEDs are in limits Transfer phase Do not start or brake abruptly Drive to the unloading point cautiously and keep the load 20 30 cm from the ground Suit the machine speed to the...

Page 76: ...nt 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...

Page 77: ...S Handler with telescopic boom GTH 4013 Operate the control lever to lock the attachment DANGER After the substitution of an attachment or after any coupling operation visually check the attachment Aw...

Page 78: ...d only Use a rigid drawbar Select the two wheel steer Put the transmission selection lever to neutral Put the gearbox lever to neutral see chap C 6 1 1 Raise the front wheels of the machine and remove...

Page 79: ...UCTIONS Handler with telescopic boom GTH 4013 C 6 1 2 Dismantling the Cardan shaft Before towing a disabled machine dismatle the two front and rear Cardan shafts loosening the screws that fix them to...

Page 80: ...eel steering using the special pins if any Cover the teeth of the conventional forks with the special guard or withdraw the floating forks ATTENTION With the floating forks pitched back do not move th...

Page 81: ...ow C 6 4 TRANSPORTING THE MACHINE ON OTHER VEHICLES To transport the machine on another vehicle follow the steps below Put chocks at the machine wheels Ensure ramps are correctly positioned Retract th...

Page 82: ...utes at least once a month When weather is particularly cold empty the radiator IMPORTANT Always remember that the ordinary maintenance must be carried out even during the machine inactivity Pay parti...

Page 83: ...be used in a marine or equivalent environment protect it against salt deposits with an adequate treatment against saltiness to prevent rust formation C 6 7 MACHINE DISPOSAL PROTECT THE ENVIRONMENT At...

Page 84: ...Page C 44 Document 57 0007 0200 01 2006 OPERATING INSTRUCTIONS Handler with telescopic boom GTH 4013 INTENTIONALLY BLANK PAGE...

Page 85: ...14 D 3 10 Changing the oil filter cartridge D 15 D 3 11 Oil level in the differential gears D 16 D 3 12 Oil level in the front rear wheel reduction gears D 16 D 3 13 Oil level in the gearbox D 17 D 3...

Page 86: ...nce schedule of this manual automatically voids GENIE warranty IMPORTANT For the engine maintenance please refer to the specific Operator handbook supplied with the machine Observe and obey The operat...

Page 87: ...r 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 cas...

Page 88: ...ion shafts the front and rear axles and any equipment of the machine 9 Checktheefficiencyoftheoverloadwarningsystem 10 Check the efficiency of the lighting electric system 11 Check the efficiency of b...

Page 89: ...Change the safety element of engine air filter 2 Change the oil of the gearbox 3 Change the oil in the four wheel reduction gears 4 Change the hydraulic oil Every 2000 working hours or every two year...

Page 90: ...y depressurised For this purpose shut the engine down and step on the brake pedal 8 10 times DANGER Before any operation on hydraulic lines or components make sure there is no residual pressure Forthi...

Page 91: ...n 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 T...

Page 92: ...e special greasers As the fresh grease comes out stop the operation The greasing points are shown in the following figures thesymbol representsthepointstobegreased by a pump the symbol represents the...

Page 93: ...imensions indicated in the vehicle registration card SERVICE INTERVAL Running in _________ Within the first 10 hours Ordinary __________________ Every 250 hours RIGHT WAY WRONG WAY WRONG OKAY GTH 4013...

Page 94: ...he cartridge and make sure it is properly positioned Refit cap B ATTENTION As soon as the warning lamp 7 8 on the cab dashboard switches on replace the outer element Never wash the cartridge with wate...

Page 95: ...ng 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...

Page 96: ...two years To drain the antifreeze Let the engine cool down Unscrew the plug at the bottom of the radiator or disconnect the rubber hose if no plug is present Allow the coolant to flow out into a speci...

Page 97: ...to detect oil leaks Visually check the hydraulic oil level through level located on the reservoir and visible through the slot on the right side of the chassis When necessary add new oil through fill...

Page 98: ...er the drain plug placed in the lower part of the reservoir and collect any oil leaks 4 Remove the drain plug and allow oil to flow out into the container 5 Remove the inspection cover of tank 6 Caref...

Page 99: ...filter element 4 Change the filter element then before fitting a new one thoroughly clean and grease both seat and gasket 5 Refit and tighten the filter cover ATTENTION Hydraulic oil filter canisters...

Page 100: ...CE INTERVAL Running in _________ Within the first 10 hours Ordinary __________________ Every 250 hours D 3 12 OILLEVELINTHE front rear WHEEL REDUCTION GEARS To check the oil level within the wheel red...

Page 101: ...ith the hole When necessary add new oil through plug A 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 l...

Page 102: ...gnment visually follow the procedure below 1 Move to a solid and level ground 2 Set the steering selection switch 6 to four wheel steer pos 2 3 Rotate the steering up to its stop either to the right o...

Page 103: ...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 wr...

Page 104: ...ero position fully retract the boom and hold the retract system over relief for approx 20 seconds 3 Raise the boom to approx 60 and operate the retract function over relief for approx 20 seconds 4 Low...

Page 105: ...ad a weight exceeding the maximum permitted with the boom fully out and attempt to lift it The system shall enter in alarm should that not be the case contact GENIE Technical Service Checking the emer...

Page 106: ...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 Tochecktheefficiencyoftheblockvalvesoftheoutriggers low...

Page 107: ...at the action generated does not result in an uncontrolled movement of the machine TO REMOVE THE BLOCK VALVES OR THE CYLINDERS Lower the boom to the ground in a firm way since the removal of the block...

Page 108: ...l Service DANGER If a limit switch is faulty or a lever is deformed immediately replace the part Checking the machine start control at every use Attempt to start the engine with the forward or reverse...

Page 109: ...oom Raise the boom beyond the horizontal and ensure the sway control and the outrigger conttrol are blocked Should this not be the case contact the GENIE Technical Assistance Service Checking the micr...

Page 110: ...E STRUCTURE Five years or 6000 hours after the first placing into operation of the machine whichever occurs first check the state of the structure paying an extreme at tention to the welded supporting...

Page 111: ...te 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 s...

Page 112: ...same amperage find out and rectify the fault Fuses Ref Circuit Amp F1 EMERGENCY LIGHT 10 F2 HEATING 15 F3 STOP LIGHTS MICRO SWITCH 5 F4 REAR WINDSCREEN WIPER 7 5 F5 WORK MODE SELECTOR 10 F6 LOW BEAM...

Page 113: ...use box relays Ref Circuit Amp FM1 MAXI FUSE 1 50 FM2 MAXI FUSE 2 70 K01 RELAY START UP Ref Circuit K1 RELAY HIGH BEAM K2 RELAY LOW BEAM K3 RELAY HORN K4 RELAY WORK LIGHTS K5 RELAY 1ST 2ND MECHANICAL...

Page 114: ...rk lights OPTIONAL 12 V H3 55 W Dashboard indicators and cab lighting 12 V W 2x4 6d 1 2 W Interior lamp 12 V SV 8 5 8 5 W License plate lights 12 V BA 15s 5 W Back up lamps 12 V BA 15s 21W CAUTION Whe...

Page 115: ...livery the machine is refilled with SHELL RIMULA SAE 15W 40 API CH 4 CG 4 CF 4 CF ACEA E3 MB 228 3 D 5 2 2 Lubrication oils and relevant filtering elements Refill the machine with following lubricants...

Page 116: ...reases of lower quality D 5 2 5 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 The use of t...

Page 117: ...ument 57 0007 0200 01 2006 FAULTS AND TROUBLESHOOTING Handler with telescopic boom GTH 4013 E 1 FAULTS AND TROUBLESHOOTING E 2 E 1 1 Fault Cause Solution E 2 Section E FAULTS AND TROUBLESHOOTING TABLE...

Page 118: ...BACK Battery disconnected Battery down Fuse in the engine compartment box blown F2G Forward reverse gear selector not in neutral position Battery down Battery cut out switch ON Emergency button ON En...

Page 119: ...ility Select CAB Check the selactor reconnect or replace Check the 10A fuse F13 and replace if necessary Retract or raise the boom within safe limits If the alarm condition persists retract the boom o...

Page 120: ...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 GENIE service centre and le...

Page 121: ...nd run a new test If the error message is still shown address to the GENIE service centre to replace the DLE unit Check that the cells are intact and fixed correctly If the error message is still show...

Page 122: ...Page E 6 Document 57 0007 0200 01 2006 FAULTS AND TROUBLESHOOTING Handler with telescopic boom GTH 4013 Notes...

Page 123: ...copic boom GTH 4013 Section F OPTIONAL ATTACHMENTS TABLE OF CONTENTS F 1 1 Shovel F 3 F 1 2 Concrete skip F 4 F 1 3 Mixing bucket F 5 F 1 4 Fixed hook on plate F 6 F 1 5 Hydraulic winch F 7 F 1 6 Exte...

Page 124: ...especially the extension jib can change the centre of gravity of the machine Before handling a load check its weight and compare it with the values on the load charts The weight of the used attachmen...

Page 125: ...material Do not use for digging operations Application Quick coupling fitted attachment for moving soil sand debris cereals etc Safety Strictly obey the general safety precautions given in section B...

Page 126: ...the gate opening operate the attachment locking lever after connecting the feeding lines of the new attachment to the quick couplings see page F 2 Maintenance Visually check the skip for damage befor...

Page 127: ...ad the material operate the rotation lever of the attachment holding plate To start the mixing auger operate the attachment locking lever after connecting the feeding lines of the new attachment to th...

Page 128: ...e locking cylinder All loads must be bridled with special textile slings or chains in compliance with all pertinent regulations To handle the load raise and rotate the telescopic boom of the handler M...

Page 129: ...900 For the use of this attachment read the specific manual supplied code 57 0300 9200 For the use of this attachment read the specific manual supplied code 57 0300 9200 IMPORTANT Make sure this attac...

Page 130: ...d attachment for handling palletised loads Safety Strictly obey the general safety precautions given in section B SAFETY Operation To adjust the tilting operate the rotation lever of the attachment ho...

Page 131: ...ATTACHMENTS Handler with telescopic boom GTH 4013 Application and codes Platform model GTH 4013 2P 300F 59 1108 1000 2P 500 REM 4400 59 1108 0000 F 1 8 MAN PLATFORM For the use of this attachment read...

Page 132: ...Page F 10 Document 57 0007 0200 01 2006 OPTIONAL ATTACHMENTS Handler with telescopic boom GTH 4013 INTENTIONALLY BLANK PAGE...

Page 133: ...ystem wiring diagram External connections G 6 G 3 2 Wiring diagram G 7 G 3 2 1 Sheet 1 of 9 G 7 G 3 2 2 Sheet 2 of 9 G 8 G 3 2 3 Sheet 3 of 9 G 9 G 3 2 4 Sheet 4 of 9 G 10 G 3 2 5 Sheet 5 of 9 G 11 G...

Page 134: ...90 228 M 14 x 1 5 28000 56000 78800 94500 71 7 143 202 242 M 16 x 2 35200 70300 98900 119000 102 205 288 346 M 16 x 1 5 37400 74800 105000 126000 107 214 302 362 M 18 x 2 5 43000 86000 121000 145000 1...

Page 135: ...ler with telescopic boom GTH 4013 G 2 1 LOAD CHART WITH FORKS GTH 4013 WITH OUTRIGGERS 1 0 1 2 3 4 5 6 7 8 9 10 0 10 50 0 2 3 4 5 6 7 8 9 10 11 12 13 14 A B C D E 6270 13000 1980 9020 70 60 40 30 20 1...

Page 136: ...escopic boom GTH 4013 G 2 2 LOAD CHART WITH FORKS GTH 4013 ON WHEELS 1 0 1 2 3 4 5 6 7 8 9 10 0 10 50 0 2 3 4 5 6 7 8 9 10 11 12 13 14 LOAD CENTRE 600 mm 250 kg A B C D E 6200 12810 2040 9080 20 30 40...

Page 137: ...DOCUMENTS ENCLOSED Handler with telescopic boom GTH 4013 G 3 1 1 LOAD LIMITING SYSTEM WIRING DIAGRAM Layout Ref Description 1 Control panel 2 Extensometric sensor double bridge 3 Connecting cable 1 X...

Page 138: ...HLD 4 5 12 X4A 6 X1 SHLD 2 10 X2 3 R9 VB VB 1 2 OUTRIGGERS BASKET 4 5 6 7 8 VB VB X3B 1 WHITE VB BROWN VB 2 1 19 PINK INP2 RED OUT4 BLUE OUT3 GREY INP3 14 8 7 3 KB VPFIN 18 15 YELLOW INP1 GREEN OUT1 R...

Page 139: ...1 A G1 A V1 R N1 B R1 L G1 G1 H N1 H1 R6 R6 R1 5 M6 S1 C N1 K11 86 87a 87 85 30 P1 X1 23 A1 5 1 X1 22 L1 5 1 X1 21 X1 19 X1 18 Z N1 4 1 G N1 4 1 X1 17 X1 16 Z N1 4 1 X1 15 V1 4 1 X21 32 X1 14 X1 12 X1...

Page 140: ...G1 K13 86 87a 87 85 30 K12 86 87a 87 85 30 C1 1 2 C1 1 2 S13 S54 B R1 4 1 N1 3 1 C R1 7 1 L G1 9 1 G M1 7 1 L G1 X36 l N1 K36 86 87 85 30 X36 X20 5 X4 9 X4 2 N Z1 M10 31 3 1 L G1 X6 14 B R1 N1 L N1 S...

Page 141: ...87 85 30 C R1 B N1 B N1 M B1 N1 N1 X29 12 X3A 2 X3A 1 XY8 2 XY9 2 XY9 1 XY8 1 Y9 Y8 C R1 X21 36 X21 35 SX12 N1 N1 4 1 S G1 7 1 X19 16 B N1 B N1 S14 1 9 5 10 S G1 X16 8 X19 15 G R1 X16 1 X21 19 C R1 M...

Page 142: ...R1 5 X8 3 F17 10A Z1 5 1 V B1 5 1 H B1 5 1 H G1 5 5 1 H G1 5 1 B R1 B1 5 N1 B R1 5 H G1 N1 H G1 5 B R1 N1 S80 1 6 8 10 3 2 9 H G1 5 B1 5 X20 10 X5 2 F12 10A F21 15A F3 5A Z1 X17 14 X17 7 X17 3 F8 3A X...

Page 143: ...3 1 7 N1 6 1 X20 1 X19 21 X19 20 X9 12 R G1 X8 4 A R1 X20 2 K23 CL P 27 6 1 A N1 X306 2 M306 X13 2 A B1 X13 1 X13 4 X306 1 X13 6 X13 3 L N1 L1 A1 X11 10 X11 8 X11 2 H1 X11 6 A B1 X11 9 M13 53 53a 53b...

Page 144: ...1 N1 H4 H3 H2 H1 R N1 1 5 N1 5 X305 1 X305 4 X305 3 M1 5 N1 B R1 C1 5 M305 X26 12 X26 13 M1 5 X26 1 A R1 5 M1 5 B R1 5 N1 C1 5 A R1 5 A R1 5 N1 N1 R1 E302 S4 1 10 5 9 X20 12 X20 13 X20 14 C1 5 X26 8 R...

Page 145: ...a 87 85 30 N1 H R1 R N1 C1 G M1 H N1 H N1 G M1 S34 S33 S32 S30 S31 A25 S6b S6a A N1 8 1 H N1 9 1 H R1 5 9 1 B N1 9 1 B G1 9 1 G M1 9 1 H9 H N1 C R1 H N1 V1 5 8 1 XJ1 B4 XJ1 A7 A R1 X7 7 X7 6 XJ1 C7 XJ...

Page 146: ...X12A 1 X19A 2 X18A 2 X18A 1 X19A 1 N1 A N1 L N1 5 M N1 5 M N1 5 K14 86 87a 87 85 30 N1 M N1 M N1 M N1 N1 Z M1 X90 XJ2 A6 M N1 5 9 1 L N1 5 9 4 X90 4 X90 1 X90 2 X90 3 M N1 S2 1 7 2 8 9 3 4 10 G1 L1 XJ...

Page 147: ...5 30 K21 86 87a 87 85 30 K17 86 87a 87 85 30 K16 86 87a 87 85 30 K15 86 87a 87 85 30 S G1 Z1 N Z1 C B1 XJ1 C8 XJ2 C5 XJ1 B2 XJ1 B7 14 12 15 16 13 8 9 10 3 4 5 6 7 11 A G1 V B1 G V1 H L1 L N1 B1 V Z1 X...

Page 148: ...1 AV1 M1 M1 GV1 GV1 B1 B1 1st SPEED MICRO SWITCH L1 L1 L1 L1 G1 G1 G1 G1 G1 G1 G1 G1 G1 G1 G1 BR1 BR1 BR1 BR1 31 LG1 LG1 HYDRAULIC MOTOR SOLENOID VALVE RN1 RN1 RN1 5 5 A1 SEAT MICRO SWITCH V1 V1 V1 B...

Page 149: ...F18 10A FUSE OUTRIGGERS 7 F19 10A FUSE WORK MODE SELECTOR 4 F20 10A FUSE PLATFORM EMERGENCY BUTTON 2 F21 15A FUSE HORN 4 F22 15A FUSE PLATFORM FUNCTION 1 F23 10A FUSE CAB LIGHTS 6 F24 FUSE EMERGENCY...

Page 150: ...3 SOLENOID VALVE RIGHT OUTRIGGER UP 8 Y14 SOLENOID VALVE LEFT OUTRIGGER DOWN 8 Y15 SOLENOID VALVE LEFT OUTRIGGER UP 8 Y18 SOLENOID VALVE FOUR WHEEL STEER 8 Y19 SOLENOID VALVE CRAB STEER 8 Y30 SHOCK AB...

Page 151: ...initials as follows G V YELLOW GREEN crosswise colouring G V YELLOW GREEN lengthswise colouring X90 4 WAY DEUTSCH CONNECTOR X300 2 WAY CONNECTOR X301 6 WAY DEUTSCH CONNECTOR X303 6 WAY DEUTSCH CONNEC...

Page 152: ...Page G 20 Document 57 0007 0200 01 2006 TABLES AND DOCUMENTS ENCLOSED Handler with telescopic boom GTH 4013 INTENTIONALLY BLANK PAGE...

Page 153: ...alve 4 ways 3 positions Front axle steering cylinder Rear axle steering cylinder Tp3 Tp2 Tp1 Hydraulically piloted double check valve piloting ratio 4 1 R1 T1 T1 T2 T2 R2 T A P B capacity 0 5 Litri pr...

Page 154: ...Page G 22 Document 57 0007 0200 01 2006 TABLES AND DOCUMENTS ENCLOSED Handler with telescopic boom GTH 4013 INTENTIONALLY BLANK PAGE...

Page 155: ...valve on telescope extension cylinder Block valve 4 Block valve on attachment moving cylinder Block valve 5 Block valve on attachment locking cylinder Block valve 6 Block valve on front right outrigg...

Page 156: ...Page G 24 Document 57 0007 0200 01 2006 TABLES AND DOCUMENTS ENCLOSED Handler with telescopic boom GTH 4013 INTENTIONALLY BLANK PAGE...

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