Genie GTH-3007 Operator's Manual
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Genie GTH-3007 Operator's Manual

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Operator's manual
CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE
CAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES
Part N.
57.0008.5200
04/2007
Rev. 0A
From serial n. 15854
To serial n.
17819
GTH-3007
English
Edition

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Summary of Contents for Genie GTH-3007

  • Page 1 Part N. 57.0008.5200 English Operator’s manual 04/2007 Rev. 0A From serial n. 15854 Edition To serial n. 17819 GTH-3007 CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE CAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES...
  • Page 3 +44 (0)1476 584334 +31 183 581 566 Operator’s manual 57.0008.5200 - GTH-3007 No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means without prior written permission from TEREXLIFT srl.
  • Page 4 REVISED PAGE LIST Revision Revised Issued Date pages Notes 04/2007 D-27 Revision...
  • Page 5 If you are unsure about anything, please address to Sect. TABLES AND ENCLOSURES GENIE Assistance Service or to your agent/dealer: addresses, phone and fax numbers are printed in Section A contains general concepts that are decisive the cover and in the title-page of this manual.
  • Page 6 CAUTION CAUTION CAUTION DANGER Handler with telescopic boom GTH-3007 SYMBOLS SYMBOLS ELECTRICAL ELECTRICAL CAUTION ELECTRICAL DANGER DANGER When using the machine, operators could have to face DANGER some situations requiring special care and particular Yellow with safety alert symbol: used to indicate knowledge.
  • Page 7 Handler with telescopic boom GTH-3007 GENERAL INDEX GENERAL INDEX GENERAL INFORMATION Sect. SAFETY PRECAUTIONS Sect. OPERATING INSTRUCTIONS Sect. MAINTENANCE Sect. TROUBLESHOOTING Sect. OPTIONAL ATTACHMENTS Sect. TABLES AND DOCUMENTS ENCLOSED Sect. Page Document 57.0008.5200 - 10/2006...
  • Page 8 Handler with telescopic boom GTH-3007 Intentionally blank page Page Document 57.0008.5200 - 10/2006...

  • Page 9: Table Of Contents

    Handler with telescopic boom GTH-3007 GENERAL INFORMATION Section GENERAL INFORMATION TABLE OF CONTENTS CoNVENTIoNAL REFERENCES .................. A-1.1 machine position ......................A-1.2 Labels and warning plates applied on the machine ............A-1.3 Explanation of the different symbols used on the machine ..........

  • Page 10: Conventional References

    Handler with telescopic boom GTH-3007 GENERAL INFORMATION A-1 CONVENTIONAL REFERENCES A-1.1 MACHINE POSITION Conventionally the machine should be considered positioned as shown in the figure. This convention is necessary to make any reference of this handbook to different machine parts (front, rear, etc.) clear and unmistakable.

  • Page 11: A-1.2 Labels And Warning Plates Applied On The Machine

    PROTECT THE ENVIRONMENT Handler with telescopic boom GTH-3007 GENERAL INFORMATION A-1.2 LABELS AND wARNING PLATES APPLIED IMPORTANT ON THE MACHINE This paragraph lists the labels and warning plates The familiarisation with these labels is never a normally applied on standard machines or on special waste of time.
  • Page 12 09.4618.0230 09.4618.0271 Handler with telescopic boom GTH-3007 09.4618.0230 GENERAL INFORMATION 09.4618.0484 09.4618.0606 09.4618.0555 09.4618.0241 09.4618.0723 09.4618.0489 09.4618.0010 09.4618.0547 09.4618.0547 09.4616.0002 09.4618.0022 09.4618.0485 09.4618.0242 09.4618.0240 09.4618.0230 09.4618.0547 Page Document 57.0008.5200 - 10/2006...
  • Page 13 Handler with telescopic boom GTH-3007 GENERAL INFORMATION Decal Code Description 09.4618.0022 Keep out of the working range of the machine. When the machine is running, entering the working KEEP OUT OF range of the machine is prohibited. WORKING RANGE 09.4618.0555 Guaranteed sound power level.
  • Page 14 ELECTRICAL Handler with telescopic boom GTH-3007 DANGER GENERAL INFORMATION Decal Code Description 09.4618.0723 Quick guide. An overview of the operator’s handbook ATTENTION concerning: - control lever, - machine starting, - overload warning system, - main safety precautions. PROTECT THE ENVIRONMENT 09.4618.0606...
  • Page 15 Handler with telescopic boom GTH-3007 GENERAL INFORMATION Decal Code Description 09.4618.0547 Tyre inflation sticker. Placed near the wheels, this label shows the recommended tyre inflation pressure. 09.4616.0068 Machine data plate. The identification plate contains the main identification data of the machine.

  • Page 16: A-1.3 Explanation Of The Different Symbols Used On The Machine

    PROTECT THE Handler with telescopic boom GTH-3007 ENVIRONMENT GENERAL INFORMATION A-1.3 EXPLANATION OF THE DIFFERENT SYMBOLS USED ON THE MACHINE This paragraph illustrates those symbols that are IMPORTANT normally applied on the main control devices and instruments of a standard machine, and those that Spend the necessary time to become familiar with can be applied on accessories or special attachments.
  • Page 17 Handler with telescopic boom GTH-3007 GENERAL INFORMATION Symbol Description Symbol Description Front (optional) work light Road/jobsite selector switch Lifting point Fuel plug Engine oil filler Engine oil dipstick Page Document 57.0008.5200 - 10/2006...

  • Page 18: Machine Identification

    PROTECT THE Handler with telescopic boom GTH-3007 ENVIRONMENT GENERAL INFORMATION A-2 MACHINE IDENTIFICATION IMPORTANT Check that the operator handbook refers to the delivered machine. When asking for information or technical assistance,  always specify model, type and serial number of the machine.

  • Page 19: A-2.4 Ce Mark

    Handler with telescopic boom GTH-3007 GENERAL INFORMATION  Road traffic data plate. Placed on the front right side of the chassis ( Fig. A8) (only for machines destined for the Italian market). This plate contains the road traffic related data and the weights of the specific machine model (Fig.

  • Page 20: Allowed Use

    ELECTRICAL is expressly forbidden. Any modification of Working in potentially explosive areas DANGER the machine not carried out by GENIE or an Working in confined and non-ventilated authorised assistance centre involves the automatic environments. invalidation of the conformity of the machine to the Directive 98/37/EC.

  • Page 21: A-3.4 Applicable Standards

    Handler with telescopic boom GTH-3007 GENERAL INFORMATION A-3.4 APPLICABLE STANDARDS EN 50082-1: 1997 Electromagnetic compatibility – Generic requirements on immunity - Part 1 For the operator’s safety, the following standards were obeyed during the risk assessment of the handler fitted...

  • Page 22: A-3.5 Safety Devices

    Handler with telescopic boom GTH-3007 GENERAL INFORMATION A-3.5 SAFETY DEVICES • Emergency stop pushbutton: when pressed down, it stops the engine and blocks the movements of the machine. • Load limiter. It consists of an extensometric cell Before starting work again, find and rectify the...
  • Page 23 Handler with telescopic boom GTH-3007 GENERAL INFORMATION • Block valves fitted to all cylinders: A block valve on attachment coupling cylinder B block valve on lifting cylinder C block valve on balance cylinder D block valve on boom extension cylinder E block valve on attachment pitching cylinder ...

  • Page 24: General Description

    Handler with telescopic boom GTH-3007 GENERAL INFORMATION A-4 GENERAL DESCRIPTION A-4.1 LIST OF THE MAIN COMPONENTS              1 - Forks 2 - Attachment holding frame 3 - 2...

  • Page 25: A-4.2 Description Of The Main Components

    When worn, they shall be replaced with new ones having The machine can be fitted with a wide range of the same dimensions and loading capacity. optional accessories: please address to GENIE sales network. Overload warning system The overload warning system installed on the vehicle...

  • Page 26: Technical Data And Performance

    Handler with telescopic boom GTH-3007 GENERAL INFORMATION A-5 TECHNICAL DATA AND PERFORMANCE GTH-3007 A-5.1 MAIN DIMENSIONS overall height 2050 overall width 2000 Track 1600 Cab width Wheel-base 2650 Length to the front tyres 4090 Length to the attachment holding plate...

  • Page 27: A-5.5 Payload And Reach

    Handler with telescopic boom GTH-3007 GENERAL INFORMATION GTH-3007 A-5.5 PAYLOAD AND REACH max lifting height 6850 Reach at max height max reach forward 3800 Attachment holding plate rotation 135° DANGER maximum payload 3000 Payload at max height 2500 DANGER Payload at max reach...

  • Page 28: Lifetime

    ELECTRICAL DANGER Handler with telescopic boom GTH-3007 GENERAL INFORMATION A-6 LIFETIME ATTENTION A-7 ITEMS SUPPLIED The lifetime of the machine is 10000 hours provided Following items are supplied together with the all checks, service jobs and overhauls are done at the machine: times scheduled.
  • Page 29 Handler with telescopic boom GTH-3007 SAFETY PRECAUTIONS Section SAFETY PRECAUTIONS TABLE OF CONTENTS GENERAL REmARKS ....................PREREQUISITES oF THE PERSoNNEL IN CHARGE ..........B-2.1 Requisites of the machine operators ................B-2.2 Requisites of the servicemen ..................B-2.3 Working clothes ......................

  • Page 30: General Remarks

    5 Only use the machine for the intended The instructions given in this handbook are the ones application. established by GENIE. They do not exclude other safe and most convenient ways for the machine * Read, understand and obey the manufacturer’s...

  • Page 31: B-2.1 Requisites Of The Machine Operators

    DANGER CAUTION DANGER Handler with telescopic boom GTH-3007 DANGER SAFETY PRECAUTIONS CAUTION DANGER B-2 R E Q U I S I T E S T H E B-2.2 REQUISITES OF THE SERVICEMEN ELECTRICAL ELECTRICAL DANGER PERSONNEL IN CHARGE The personnel charged with the machine maintenance...

  • Page 32: B-2.3 Working Clothes

    DANGER DANGER DANGER DANGER Handler with telescopic boom GTH-3007 DANGER CAUTION SAFETY PRECAUTIONS DANGER ELECTRICAL DANGER SAFETY PRECAUTIONS B-2.3 wORKING CLOTHES ATTENTION During work, but especially when maintaining or B-3.1 HAZARDS ON THE JOBSITE repairing the machine, operators must wear suitable...
  • Page 33 DANGER Handler with telescopic boom GTH-3007 DANGER SAFETY PRECAUTIONS DANGER B-3.2 O P E R AT I O N O R M A I N T E N A N C E CAUTION DANGER HAZARDS ELECTRICAL before any operation, following precautions should be...
  • Page 34 Handler with telescopic boom GTH-3007 SAFETY PRECAUTIONS • When entering/leaving the cab or other raised parts, • Except for maintenance purposes, do not remove always face the machine; never turn the back. safety devices, shields, protection cases, etc. Should their removal be necessary, stop the engine,...

  • Page 35: B-3.3 Machine Operation Hazards

    Handler with telescopic boom GTH-3007 SAFETY PRECAUTIONS B-3.4 DAMAGED COMPONENT HAZARDS • Do not empty catalytic mufflers or other vessels containing burning materials without taking the • Do not use battery chargers or batteries with a necessary precautions. voltage above 12V to start the engine.

  • Page 36: B-3.6 Damaged Machine Hazards

    Handler with telescopic boom GTH-3007 SAFETY PRECAUTIONS B-4 SAFETY DEVICES B-3.6 DAMAGED MACHINE HAZARDS • Do not use a damaged or defective machine. • Do a thorough pre-operation inspection of the DANGER machine and test all functions before each work shift.
  • Page 37 Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS Section OPERATING INSTRUCTIONS TABLE OF CONTENTS PRE-oPERATIoN INSPECTIoN ....C-2 SETUP ............C-23 ENTERING THE mACHINE ......C-4 C-4.1 before starting the engine ......C-23 C-2.1 Entering the cab ..........C-4 C-4.1.1 Checks at the machine start-up ....C-23 C-2.1.1 Emergency exit-way ........C-5...

  • Page 38: Pre-Operation Inspection

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS Fundamentals INTRODUCTION It is the operator responsibility to perform a pre- This section provides the operator a practical guide for operation inspection and routine maintenance. the gradual learning of the machine use. The operator should get into the driving cab and carry...
  • Page 39 Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS Pre-operation inspection Check the entire machine for: • cracks on welds or structural components * make sure the operator’s manuals are intact, legible • dents or damage to the machine. and placed inside the machine.

  • Page 40: Entering The Machine

    ELECTRICAL DANGER Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS DANGER DANGER C-2 ENTERING THE MACHINE ATTENTION DANGER C-2.1 ENTERING THE CAB The upper section of the door must be secured to CAUTION DANGER the rear part of the driving cab or latched to the lower section of the same door.
  • Page 41 Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-2.1.1 Leaving the cab in an emergency In an emergency, the operator can use he front or the rear window as safety exit-ways. The rear window has handles for partially opening the glass. Such handles are locked in position by some wing nuts 5 which, if driven out, allow opening the glass completely.

  • Page 42: C-2.2 Adjusting The Seat

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-2.2 ADJUSTING THE SEAT A correct adjustment of the seat ensures the operator a safe and comfortable driving. The handler seat is  fitted with devices which allow for the adjustment of the springing, the height and the distance from the ...

  • Page 43: C-2.4 Adjusting The Steering Column

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-2.4 ADJUSTING THE STEERING COLUMN C-2.5 ADJUSTING THE REAR VIEw MIRRORS DANGER both steering column and dashboard can be set to a The machine is fitted with two rear view mirrors: different angle. For this purpose: •...

  • Page 44: Driving Place

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-3 DRIVING PLACE 2 4 6 8 10 8 6 ϒ C ϒ C 0 1 2 3 4 5 6 7 17 11 12 Page Document 57.0008.5200 - 10/2006...

  • Page 45: C-3.1 Controls And Instruments

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-3.1 CONTROLS AND INSTRUMENTS 1 Dashboard 2 Water level 3 brake oil tank 4 Ignition switch 5 Turn signals - windscreen wiper - horn switch 6 Fuse compartment 7 Forward/reverse speed selection lever...

  • Page 46: C-3.2 Engine Controls And Instruments

    ATTENTION Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-3.2 ENGINE CONTROLS AND INSTRUMENTS C-3.2.2 Forward/reverse gear selector switch PROTECT THE Three-position switch with lock in neutral position: ENVIRONMENT C-3.2.1 Ignition switch Neutral position; no gear engaged Three-position switch: Shift lever to pos. F to select the forward gear No circuit under voltage, key can be removed Shift lever to pos.

  • Page 47: C-3.2.3 Turn Signals - Windscreen Wiper

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-3.2.3 Turn signals - windscreen wiper - Horn Lights function: - Lights The lever operates the light switching and shall be used in conjuntion with pushbutton 12. Horn function: When sliding the lever along its axis, horn switches on, independently from other pre-set functions.

  • Page 48: C-3.2.4 Brakes

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-3.2.4 Brakes C-3.2.5 Accelerator control Service brake pedal Gas pedal Gradually step on the brake pedal to decelerate and Its pressure controls the engine rpm and, coupled to stop the machine. The pedal operates on the front axle.

  • Page 49: C-3.2.6 Pushbutton Enabling The Attachment

    DANGER Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-3.2.6 Pushbutton enabling the attachment C-3.2.8 Road/Jobsite switch CAUTION coupling/release Selection button Selection button button with two stable positions: Pushbutton with two stable positions. 1 Press to select the road setting. The...

  • Page 50: C-3.2.11 Auxiliary Drive Controls

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-3.2.11 Auxiliary drive controls Road lights switch This switch is located above the ignition switch Beacon and is used in conjunction with lever 5 (see When the machine is started up, the beacon chap.

  • Page 51: C-3.3 Instruments And Light Indicators

    0 1 2 3 4 5 6 7 Handler with telescopic boom GTH-3007 ϒ C OPERATING INSTRUCTIONS ϒ C ϒ C 60 61 62 63 64 65 66 ϒ C 60 61 62 63 64 65 66 0 1 2 3 4 5 6 7 C-3.3 INSTRUMENTS AND LIGHT...

  • Page 52: C-3.4 Control Lever

    ELECTRICAL Handler with telescopic boom GTH-3007 DANGER OPERATING INSTRUCTIONS C-3.4 Control lever Handlers are equipped with an hydraulically driven servo-controlled lever. ATTENTION The lever is equipped with a button for locking/releasing the attachments  and a wheel  to operate the boom telescope extension.

  • Page 53: C-3.4.1 Function Selection

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-3.4.1 Function selection After pressing the intentional control pushbutton , the lever is enabled to carry out the following motions: • Boom lowering/lifting shift the control lever to  or  • Attachment back/forward tilting shift the control lever to ...

  • Page 54: C-3.4.2 Emergency Stop

    Handler with telescopic boom GTH-3007 DANGER OPERATING INSTRUCTIONS DANGER C-3.4.2 Emergency stop C-3.4.2.1 Disabling the load limiting system DANGER The operated functions can be stopped at any time by The key-switch 32 lets you disable the load limiter. CAUTION pressing the emergency stop button 16.

  • Page 55: C-3.4.3 Lifting/Lowering The Boom

    Handler with telescopic boom GTH-3007 DANGER OPERATING INSTRUCTIONS DANGER C-3.4.3 Lifting/lowering the boom DANGER CAUTION DANGER ELECTRICAL DANGER Before operating the boom, make sure that nobody ATTENTION is within the working range of the machine. PROTECT THE To lift or lower the boom:...

  • Page 56: C-3.4.4 Pitching The Attachment Holding Frame

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS DANGER DANGER C-3.4.4 Pitching the attachment holding frame forward/back DANGER CAUTION DANGER ELECTRICAL DANGER Before operating the boom, make sure that nobody ATTENTION is within the working range of the machine. PROTECT THE...

  • Page 57: C-3.4.5 Extending/Retracting The Boom

    Handler with telescopic boom GTH-3007 DANGER OPERATING INSTRUCTIONS DANGER C-3.4.5 Extending/retracting the boom DANGER CAUTION DANGER ELECTRICAL DANGER Before operating the boom, make sure that nobody ATTENTION is within the working range of the machine. PROTECT THE To extend or retract the telescopic elements of the...

  • Page 58: C-3.4.6 Quick-Coupling The Attachments

    Handler with telescopic boom GTH-3007 DANGER OPERATING INSTRUCTIONS DANGER C-3.4.6 Quick-coupling the attachments DANGER CAUTION DANGER ELECTRICAL DANGER Before operating the boom, make sure that nobody ATTENTION is within the working range of the machine. PROTECT THE To lock/unlock the attachments:...

  • Page 59: Setup

    DANGER Handler with telescopic boom GTH-3007 DANGER OPERATING INSTRUCTIONS C-4 SETUP C-4.2 STARTING THE ENGINE For the low temperature starting, see paragraph C- C-4.1 BEFORE STARTING THE ENGINE 4.4. CAUTION • Set the forward/back speed lever to neutral • To ensure safe conditions to the operators and position.

  • Page 60: C-4.3 Jump-Starting The Engine

    ELECTRICAL Handler with telescopic boom GTH-3007 DANGER OPERATING INSTRUCTIONS C-4.3 JUMP-STARTING THE ENGINE ATTENTION Do not start the engine using a quick charge booster to avoid any damage to the electronic boards. DANGER PROTECT THE ENVIRONMENT DANGER When jump-starting the engine through the battery...

  • Page 61: C-4.4 Low Temperature Starting

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-4.4 LOw TEMPERATURE STARTING C-4.5 DISCONNECTING THE BATTERY In case of cold starting, use an oil with a SAE viscosity During maintenance or repair works, and while welding, adequate to the ambient temperature.

  • Page 62: C-4.7 Stopping And Parking The Machine

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS DANGER C-5 USING THE HANDLER C-4.7 S T O P P I N G A N D PA R K I N G T H E MACHINE DANGER This chapter describes some techniques and provides...
  • Page 63 Handler with telescopic boom GTH-3007 MAINTENANCE D-5 REFUELLING D-5.1 REFUELLING Product Capacity specifications Part Product (litres) see par. Diesel engine Engine oil 11 + 3.5 D-5.2.1 Fuel tank Diesel fuel D-5.2.3 Hydraulic system tank Hydraulic oil D-5.2.2 Gearbox D-5.2.2 DANGER Front differential gear with reduction gear Oil D-5.2.2...

  • Page 64: C-5.2 Load Limiter

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-5.2 LOAD LIMITER on the front top strut of the cab, there is limiter 34 which warns the operator of the variation of stability of the machine and blocks any manoeuvre before the same reaches a critical condition.

  • Page 65: C-5.2.3 Alarm Codes And Resetting

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-5.2.3 Alarm codes and resetting Example of use of the overload warning system 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.

  • Page 66: C-5.3.1 Adjusting The Forks

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-5.3 HANDLING LOADS DANGER C-5.3.1 Adjusting the forks Forks shall be spaced to suit the load going to be • The centre of gravity of the load must always be handled. For this purpose: halfway between the forks.

  • Page 67: C-5.3.2 Working Phases

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-5.3.2 working phases DANGER When forks are correctly spaced, the handler is ready to use. Work can be subdivided into three different phases: Do not move off when the load is raised 20÷30 cm loading, transfer and unloading.

  • Page 68: C-5.4 Changing The Attachment

    DANGER ELECTRICAL Handler with telescopic boom GTH-3007 DANGER OPERATING INSTRUCTIONS C-5.4 CHANGING THE ATTACHMENT DANGER ATTENTION After substitution, visually check the attachment is correctly coupled to the boom, before operating Use only attachments directly manufactured or the machine. A wrongly coupled attachment may recommended by Terexlift and detailed in the result in damage to persons or things.
  • Page 69 DANGER Handler with telescopic boom GTH-3007 DANGER OPERATING INSTRUCTIONS DANGER CAUTION DANGER ELECTRICAL DANGER After the substitution of an attachment or after any ATTENTION coupling operation, visually check the attachment. A wrongly coupled attachment may result in damage PROTECT THE to persons or things.

  • Page 70: Transporting The Machine

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-6 TRANSPORTING THE C-6.1.1 Unlocking the negative brake MACHINE To unlock the negative brake of a faulty machine, proceed as follows: C-6.1 MOVING A DISABLED MACHINE • Loosen the two opposite screws  located on the front axle in order to remove the washers.

  • Page 71: C-6.2 Road Or Site Transfer

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS DANGER DANGER C-6.2 ROAD OR SITE TRANSFER DANGER Only for the Italian market When travelling on public roads, strictly obey the local or national DANGER road traffic regulations. DANGER besides, take into account the following general precautions:...

  • Page 72: C-6.3 Lifting The Machine

    Handler with telescopic boom GTH-3007 OPERATING INSTRUCTIONS C-6.3 LIFTING THE MACHINE C-6.4 TRANSPORTING THE MACHINE ON OTHER VEHICLES When the machine shall be lifted, use only means having a suitable capacity. The characteristic data are To transport the machine on another vehicle, follow...

  • Page 73: C-6.5 Parking And Storage

    DANGER DANGER DANGER DANGER Handler with telescopic boom GTH-3007 CAUTION CAUTION DANGER OPERATING INSTRUCTIONS ELECTRICAL DANGER C-6.5 PARKING AND STORAGE C-6.5.2 Machine storage ATTENTION In case of extended inactivity of the machine, follow the C-6.5.1 Short inactivity above precautions. Additionally:...

  • Page 74: C-6.6 Cleaning And Washing The Machine

    DANGER CAUTION DANGER Handler with telescopic boom GTH-3007 DANGER ATTENTION OPERATING INSTRUCTIONS CAUTION DANGER ELECTRICAL ELECTRICAL C-6.6 C L E A N I N G A N D wA S H I N G T H E C-6.7 MACHINE DISPOSAL...
  • Page 75 Handler with telescopic boom GTH-3007 MAINTENANCE Section MAINTENANCE TABLE OF CONTENTS LUbRICANTS - HEALTH AND SAFETy PRECAUTIoNS ..........RoUTINE mAINTENANCE ..................... D-2.1 oil change schedule ....................... mAINTENANCE JobS ....................D-3.1 Disconnecting the battery ....................D-3.2 Access to the engine and tanks compartments ..............
  • Page 76 ATTENTION CAUTION PROTECT THE ENVIRONMENT ELECTRICAL Handler with telescopic boom GTH-3007 DANGER MAINTENANCE IMPORTANT ELECTRICAL INTRODUCTION DANGER A thorough and regular maintenance keeps the machine ATTENTION in a safe and efficient working condition. For this reason, it is advisable to wash, grease and...

  • Page 77: Lubricants - Health And Safety Precautions

    Handler with telescopic boom GTH-3007 MAINTENANCE D-1 LUBRICANTS - HEALTH AND SAFETY PRECAUTIONS Health A prolonged skin contact with oil can cause irritation. Use rubber gloves and protective goggles. After handling oil, carefully wash your hands with soap and water.
  • Page 78 DANGER CAUTION DANGER Handler with telescopic boom GTH-3007 ELECTRICAL DANGER MAINTENANCE ATTENTION PROTECT THE D-2 ORDINARY MAINTENANCE Every 50 working hours or weekly CAUTION ENVIRONMENT Jobs to be done in addition to those above IMPORTANT A wrong or neglected maintenance can result in possible Check the tension of the alternator belt risks for both operator and bystanders.

  • Page 79: D-2.1 Oil Change Schedule

    Handler with telescopic boom GTH-3007 MAINTENANCE Every 500 working hours or every six months At 6000 hours or 5 years and, subsequently, every 2 years Jobs to be done in addition to those above Jobs to be done in addition to those above...

  • Page 80: Maintenance Jobs

    ELECTRICAL ELECTRICAL DANGER DANGER Handler with telescopic boom GTH-3007 DANGER MAINTENANCE DANGER D-3 MAINTENANCE JOBS DANGER ATTENTION ATTENTION CAUTION DANGER The qualified staff charged with the maintenance of the hydraulic circuit must clean all areas around ELECTRICAL DANGER DANGER with care before any intervention.

  • Page 81: D-3.2 Access To The Engine And Tanks Compartments

    Handler with telescopic boom GTH-3007 MAINTENANCE D-3.2 ACCESS TO THE ENGINE AND TANKS COMPARTMENTS Engine compartment For any operation within the engine compartment, open the protection bonnet. Hood is equipped with lock & key and a supporting rod that holds it in position.

  • Page 82: D-3.3 Greasing

    ELECTRICAL Handler with telescopic boom GTH-3007 DANGER MAINTENANCE D-3.3 GREASING ATTENTION Before injecting grease into the greasers, thoroughly clean them to avoid that mud, dust or other matters can mix with the lubricant and reduce or annihilate the lubrication effect.

  • Page 83: D-3.4 Tyres And Wheels

    Handler with telescopic boom GTH-3007 MAINTENANCE DANGER D-3.4 TYRES AND wHEELS DANGER DANGER DANGER CAUTION DANGER DANGER Over-inflated or overheated tyres can burst. Do not ELECTRICAL DANGER flame-cut or weld the wheel rims. For any repair DANGER work, call in a qualified technician.

  • Page 84: D-3.5 Brakes

    Handler with telescopic boom GTH-3007 MAINTENANCE D-3.5 BRAKES • For any intervention on the braking system (adjustment and/or substitution of the brake discs) call in a specialised technician.   The malfunctioning of the braking system may depend on the presence of air within the hydraulic circuit.

  • Page 85: D-3.6 Engine Air Filter

    DANGER Handler with telescopic boom GTH-3007 DANGER MAINTENANCE DANGER CAUTION DANGER D-3.6 ENGINE AIR FILTER ELECTRICAL Clean the engine air filter every 10 hours; replace the DANGER filtering element, if necessary. ATTENTION Cleaning and changing the external element:  - Stop the engine and engage the parking brake.

  • Page 86: D-3.7 Cab Air Filter

    CAUTION DANGER ELECTRICAL DANGER Handler with telescopic boom GTH-3007 ATTENTION MAINTENANCE PROTECT THE CAUTION ENVIRONMENT D-3.7 CAB AIR FILTER IMPORTANT Every six months clean the air filter in the cab. Replace the cartridge if the filtering cloth is damged. Cleaning and changing the cartridge:...

  • Page 87: D-3.9 Checking The Oil Level In The Tank

    Handler with telescopic boom GTH-3007 MAINTENANCE D-3.9 CHECKING THE OIL LEVEL IN THE TANK DANGER DANGER  DANGER DANGER Fine jets of hydraulic oil under pressure can DANGER penetrate the skin. Do not use your fingers, but a DANGER CAUTION piece of cardboard to detect oil leaks.

  • Page 88: D-3.10 Changing The Oil Filter Canisters On The Intake Line

    DANGER DANGER DANGER Handler with telescopic boom GTH-3007 MAINTENANCE DANGER DANGER D-3.10 CHANGING THE OIL FILTER CANISTERS DANGER ON THE INTAKE LINE  D-3.10.1 Transmission oil filter Every 50 hours, check the clogging degree of the filtering CAUTION element using the vacuometer .

  • Page 89: D-3.10.2 Auxiliary Circuits Oil Filter

    Handler with telescopic boom GTH-3007 MAINTENANCE D-3.10.2 Auxiliary circuits oil filter To change the hydraulic oil filter cartridge of the service circuits, proceed as follows: Stop the machine on a level ground and engage the parking brake. Remove the inspection hatch  and unscrew the oil filter fitted inside the tank.

  • Page 90: D-3.11 Oil Level In The Differential Gears And The Rducer

    Handler with telescopic boom GTH-3007 MAINTENANCE D-3.11 OIL LEVEL IN THE DIFFERENTIAL GEARS AND THE REDUCER D-3.11.1 Front and differential gears To check the oil level in the front and rear differential gears: • Stop the machine on a level ground and engage the parking brake.

  • Page 91: D-3.12 Oil Level In The (Front/Rear) Wheel Reduction Gears

    ATTENTION ATTENTION Handler with telescopic boom GTH-3007 MAINTENANCE D-3.12 OIL LEVEL IN THE (front/rear) wHEEL PROTECT THE PROTECT THE REDUCTION GEARS ENVIRONMENT To check the oil level within the wheel reduction ENVIRONMENT gears: The handling and disposing of used oils can be •...

  • Page 92: D-3.13 Shafting Alignment

    Handler with telescopic boom GTH-3007 2 4 6 8 10 8 6 MAINTENANCE D-3.13 SHAFTING ALIGNMENT During operation, the alignment of the front and rear axles of the machine can be subject to variations. This can depend on an oil blow-by from the steering control circuit, or on a steering of both axles when front and ϒ...

  • Page 93: D-3.14 Adjusting The Sliding Pads Of The Boom Sections

    Handler with telescopic boom GTH-3007 MAINTENANCE D-3.14 ADjusTINg THE slIDINg pADs of THE booM sECTIoNs DANGER Any boom section is fitted with adjustable pads located on the four sides of the profile. These pads are secured DANGER to both fixed and mobile part of every section.

  • Page 94: D-3.15 Checking The Safety Devices

    To do a manual check, it will be enough to load a weight exceeding the maximum permitted with the boom fully out and attempt to lift it. The system shall enter in alarm; should that not be the case, contact GENIE Technical Service. Checking the joystick pushbutton...
  • Page 95 Handler with telescopic boom GTH-3007 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: •...

  • Page 96: D-3.16 Checking The State Of The Structure

    Handler with telescopic boom GTH-3007 MAINTENANCE D-3.16 C H E C K I N G T H E S TAT E O F T H E STRUCTURE DANGER Five years after the first placing into operation of the machine or after 6000 hours (whichever occurs first),...

  • Page 97: Electrical System

    DANGER Handler with telescopic boom GTH-3007 DANGER MAINTENANCE DANGER D-4 ELECTRICAL SYSTEM DANGER DANGER CAUTION DANGER • Battery electrolyte contains sulphuric acid. It can ELECTRICAL DANGER DANGER burn you if it touches your skin and eyes. Always All maintenance interventions must be carried...

  • Page 98: D-4.2 Fuses And Relays

    Handler with telescopic boom GTH-3007 MAINTENANCE D-4.2 FUSES AND RELAYS Ref. Circuit Amp. The electrical system is protected by fuses placed in K6 RELAy PoWER SUPPLy the driving cab, on the left. before replacing a blown PARKING bRAKE INDICAToR fuse with a new one having the same amperage, find out and rectify the fault.
  • Page 99 Handler with telescopic boom GTH-3007 MAINTENANCE Relays Ref. Circuit mUSHRoom-HEAD SWITCH PoWER SUPPLy FWD SPEED SoLENoID VALVE K2, K5 RELAy ENERGIzING CoIL oVERLoAD WARNING SySTEm DISCoNNECT KEy - oVERLoAD WARNING SySTEm CoNTRoL UNIT REVERSE SPEED SoLENoID VALVE - bACK-UP DANGER...

  • Page 100: D-4.3 12V Dc Lamps

    PROTECT THE CAUTION ENVIRONMENT IMPORTANT Handler with telescopic boom GTH-3007 MAINTENANCE ELECTRICAL D-4.3 12V DC LAMPS DANGER Voltage Mount type Power DANGER • Front low/high beam ............. 12 V ......P45t ....45/40 W DANGER • Front position lights .............. 12 V ...... bA 9s ......3 W •...

  • Page 101: Refuelling

    Handler with telescopic boom GTH-3007 MAINTENANCE D-5 REFUELLING D-5.1 REFUELLING Product Capacity specifications Part Product (litres) see par. Diesel engine Engine oil 11 + 3.5 D-5.2.1 Fuel tank Diesel fuel D-5.2.3 Hydraulic system tank Hydraulic oil D-5.2.2 DANGER Front differential gear with reduction gear oil D-5.2.2...

  • Page 102: D-5.2.3 Fuel

    CAUTION ENVIRONMENT IMPORTANT Handler with telescopic boom GTH-3007 MAINTENANCE ELECTRICAL DANGER D-5.2.3 Fuel Use only Diesel fuel with less than 0.5% sulphur content, DANGER according to the specifications of the diesel engine operation handbook. DANGER ATTENTION DANGER CAUTION In cold climates (temperature under -20°C) use only DANGER “Arctic”...
  • Page 103 Handler with telescopic boom GTH-3007 FAULTS AND TROUBLESHOOTING Section FAULTS AND TROUBLESHOOTING TABLE OF CONTENTS FAULTS AND TRoUbLESHooTING ................E-1.1 Fault - Cause - Solution ....................Page Document 57.0008.5200 - 10/2006...
  • Page 104 Handler with telescopic boom GTH-3007 DANGER FAULTS AND TROUBLESHOOTING E-1 FAULTS AND TROUBLESHOOTING This chapter represents a practical guide for the operator DANGER for fixing the most common failures and, at the same time, detecting those interventions which must be carried out by qualified technical engineers.
  • Page 105 Handler with telescopic boom GTH-3007 FAULTS AND TROUBLESHOOTING PROBLEM CAUSES SOLUTIONS N O B O O M L O w E R I N G A N D • Fuse blown • Replace fuses F2 and/or F24 EXTENSION, NO HOLDING FRAME...
  • Page 106 IMPORTANT to the GENIE service centre. ELECTRICAL DANGER ATTENTION PROTECT THE ENVIRONMENT IMPORTANT In case of faults not listed in this chapter, address to the GENIE Technical Assistance, your nearest authorised workshop or dealer. Page Document 57.0008.5200 - 10/2006...
  • Page 107 Handler with telescopic boom GTH-3007 OPTIONAL ATTACHMENTS Section OPTIONAL ATTACHMENTS TABLE OF CONTENTS F-1.1 Shovel ..........................F-1.2 Cereal shovel ........................F-1.3 Fixed hook on plate ......................F-1.4 mixing bucket ........................F-1.5 Extension jib ........................F-1.6 Forks with hydraulic side-shift ..................
  • Page 108 Handler with telescopic boom GTH-3007 OPTIONAL ATTACHMENTS INTRODUCTION This section provides information on the optional interchangeable attachments, especially manufactured for the handlers. Use only genuine attachments, described in this  section, after having read their features thoroughly and DANGER understood their use.

  • Page 109: F-1.1 Shovel

    CAUTION Handler with telescopic boom GTH-3007 OPTIONAL ATTACHMENTS F-1.1 SHOVEL Application Quick-coupling fitted attachment for moving soil, sand, ELECTRICAL debris, cereals, etc. Code GTH-3007 DANGER Safety Litres 500 59.0200.0000 Strictly obey the general safety precautions given in section B “SAFETy”.

  • Page 110: F-1.2 Cereal Shovel

    CAUTION Handler with telescopic boom GTH-3007 OPTIONAL ATTACHMENTS F-1.2 CEREAL SHOVEL Application Quick coupling attachment for loading cereals or inert ELECTRICAL materials, etc. Code GTH-3007 DANGER Safety litres 800 59.0200.1000 Strictly obey the general safety precautions given in section B “SAFETy”.

  • Page 111: Fixed Hook On Plate

    DANGER Handler with telescopic boom GTH-3007 DANGER OPTIONAL ATTACHMENTS F-1.3 FIXED HOOK ON PLATE Application Quick-coupling fitted attachment for lifting loads by means of special slings. Payload GTH-3007 CAUTION DANGER Safety 3000 kg 59.0700.4000 Strictly obey the general safety precautions given in section B “SAFETy”.

  • Page 112: Mixing Bucket

    Handler with telescopic boom GTH-3007 OPTIONAL ATTACHMENTS F-1.4 MIXING BUCKET Application Quick-coupling fitted attachment for mixing and distributing concrete. Code GTH-3007 Safety litres 250 59.0400.9000 Strictly obey the general safety precautions given in section B “SAFETy”. Operation To load/unload the material, operate the rotation lever of the attachment holding plate.

  • Page 113: F-1.5 Extension Jib

    Handler with telescopic boom GTH-3007 OPTIONAL ATTACHMENTS F-1.5 EXTENSION JIB Application Quick-coupling fitted attachment for maintenance interventions at high working heights. DANGER Safety Code GTH-3007 Strictly obey the general safety precautions given in DANGER 400 kg 59.0800.0000 section B “SAFETy”.

  • Page 114: F-1.6 Forks With Hydraulic Side-Shift

    Handler with telescopic boom GTH-3007 OPTIONAL ATTACHMENTS F-1.6 FORKS wITH HYDRAULIC SIDE-SHIFT Application Quick-coupling fitted attachment for handling palletised loads with possibility of shifting the load to the side by ± 100 mm. Safety Strictly obey the general safety precautions given in section B “SAFETy”.

  • Page 115: F-1.7 Fork With Jaw

    Handler with telescopic boom GTH-3007 OPTIONAL ATTACHMENTS F-1.7 FORK wITH JAw Application Interchangeable quick-coupling attachment for loading and handling manure, shrubs and other loose agricultural Machine GTH-3007 products. Fork with jaw 59.1300.1000 Safety Strictly obey the general safety precautions given in section B “SAFETy”.
  • Page 116 Handler with telescopic boom GTH-3007 OPTIONAL ATTACHMENTS Intentionally blank page F-10 Page Document 57.0008.5200 - 10/2006...
  • Page 117 Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED Section TABLES AND DOCUMENTS ENCLOSED TABLE OF CONTENTS ToRQUE WRENCH SETTING ..................G-2.1 LoAD CHART WITH FoRKS ..................G-3.1 Fuses and relays box ...................... G-3.2 Wiring diagram ....................... G-3.2.1 Sheet 1 of 9 ........................

  • Page 118: Torque Wrench Setting

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-1 TORQUE wRENCH SETTINGS D x p Pre-loading (N) Torque wrench setting (Nm) 10.9 12.9 10.9 12.9 M 4 x 0,7 1970 3930 5530 6640 M 5 x 0,8 3180 6360...

  • Page 119: G-2.1 Load Chart With Forks

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-2.1 LOAD CHART wITH FORKS 6850 3800 Page Document 57.0008.5200 - 10/2006...

  • Page 120: G-3.1 Fuses And Relays Box

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-3.1 FUSES AND RELAYS BOX 7.5A 7,5A 7,5A 7,5A 7,5A 7,5A Page Document 57.0008.5200 - 10/2006...

  • Page 121: G-3.2 Wiring Diagram

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-3.2 wIRING DIAGRAM G-3.2.1 Sheet 1 of 9 Page Document 57.0008.5200 - 10/2006...

  • Page 122: Sheet 2 Of 9

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-3.2.2 Sheet 2 of 9 TRANSmISSIoN DISCoNNECTED (yELLoW) Page Document 57.0008.5200 - 10/2006...

  • Page 123: Sheet 3 Of 9

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-3.2.3 Sheet 3 of 9 Page Document 57.0008.5200 - 10/2006...

  • Page 124: Sheet 4 Of 9

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-3.2.4 Sheet 4 of 9 Page Document 57.0008.5200 - 10/2006...

  • Page 125: Sheet 5 Of 9

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-3.2.5 Sheet 5 of 9 Page Document 57.0008.5200 - 10/2006...

  • Page 126: Sheet 6

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-3.2.6 Sheet 6 of 9 G-10 Page Document 57.0008.5200 - 10/2006...

  • Page 127: Sheet 7

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-3.2.7 Sheet 7 of 9 G-11 Page Document 57.0008.5200 - 10/2006...

  • Page 128: Sheet 8

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-3.2.8 Sheet 8 of 9 G-12 Page Document 57.0008.5200 - 10/2006...

  • Page 129: Sheet 9

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-3.2.9 Sheet 9 of 9 CONTROL UNIT VALVOIL DIAGNOSTICS VALVOIL DISPLAy Cobo FoR ANTI-oVERTURN G-13 Page Document 57.0008.5200 - 10/2006...
  • Page 130 Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED Intentionally blank page G-14 Page Document 57.0008.5200 - 10/2006...

  • Page 131: G-4.1 Hydraulic Scheme

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-4.1 HYDRAULIC SCHEME Hydraulic piloting line (Drw. 57.2201.2900 - rev. A) test port Service brake Parking/emergency Pressure reducing valve brake selector valve circuit reservoir setting pressure: 28 bar 4 ways / 2 positions...
  • Page 132 Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED Intentionally blank page G-16 Page Document 57.0008.5200 - 10/2006...

  • Page 133: Routine Check Schedule-Safety Devices

    Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED G-5 ROUTINE CHECK SCHEDULE - SAFETY DEVICES COMPONENT Result/Notes Date Positive Negative Signature ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑...
  • Page 134 Handler with telescopic boom GTH-3007 TABLES AND DOCUMENTS ENCLOSED Table key explanation: Block valve 1 Block valve on lifting cylinder Block valve 2 Block valve on fork balance cylinder Block valve 3 Block valve on telescope extension cylinder Block valve 4...

Table of Contents