Terex Genie GTH-4518 ER Operator's Manual
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Terex Genie GTH-4518 ER Operator's Manual

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Operator's Manual
GTH-4518 ER
GTH-4020 ER
GTH-6025 ER
Serial number range
From s/n: 18004
To s/n:
20111
From s/n: 19127
To s/n:
20117
From s/n: 13309
To s/n:
19308
With Maintenance
Information
First Edition
Third Printing
Part No. 57.0009.0404

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Summary of Contents for Terex Genie GTH-4518 ER

  • Page 1 Operator’s Manual Serial number range GTH-4518 ER From s/n: 18004 To s/n: 20111 GTH-4020 ER From s/n: 19127 To s/n: 20117 GTH-6025 ER From s/n: 13309 To s/n: 19308 With Maintenance Information First Edition Third Printing Part No. 57.0009.0404...

  • Page 2: Table Of Contents

    Operator’s Manual First Edition - Third Printing Contents Important Read, understand and obey these safety rules Introduction ..........Page and operating instructions before operating the Machine Identification ......Page machine. Only trained and qualified personnel Symbols Used On The Machine ..Page shall be authorized to operate the machine. Labels And Plates Applied On The This manual shall be kept with the machine at Machine ..........Page...

  • Page 3: Introduction

    First Edition - Third Printing Operator’s Manual Introduction Symbols 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 Red: indicates a hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 4 Operator’s Manual First Edition - Third Printing Intentionally blank page GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404...

  • Page 5: Machine Identification

    First Edition - Third Printing Operator’s Manual Machine Identification Check that the operator handbook refers to the MACHINE IDENTIFICATION PLATES delivered machine. The following data plates are applied on the MODEL AND TYPE machine: Handler with telescopic boom. Models: Machine data plate The identification plate contains the main identification GTH-4518ER - GTH-4020ER - GTH-6025ER data of the machine like model, serial number and...
  • Page 6 Operator’s Manual First Edition - Third Printing Machine Identification IDENTIFICATION PLATES OF THE MAIN PARTS CE MARKING The plates of the main components, not directly This machine fulfils the safety requirements of manufactured by TEREXLIFT srl (for instance, the Machinery Directive.The conformity has been engines, pumps, etc.), are located where originally certified and the placing of the CE marking on the applied by the manufacturers.

  • Page 7: Symbols Used On The Machine

    First Edition - Third Printing Operator’s Manual Symbols Used On The Machine Turret Rotation Parking Brake High Beam Turn Signals Lock Not Active Low Beam Turret Aligned Differential Lock 2° speed engaged 1° speed engaged Machine Sway Retract Outrigger Turret Rotation Right Machine Unlock Lower Outrigger...
  • Page 8 Operator’s Manual First Edition - Third Printing Symbols Used On The Machine HAZARD PICTORIAL DESCRIPTIONS Electrocution Falling Object Maintain required No people under Fall Hazard Hazard Hazard clearance. load. Explosion/Burn Allow system to No riders. No smoking. No Burn Hazard Hazard cool.

  • Page 9: Labels And Plates Applied On The Machine

    First Edition - Third Printing Operator’s Manual Labels And Plates Applied On The Machine Part No. 57.0009.0404 GTH-4518ER - GTH-4020ER - GTH-6025ER...
  • Page 10 Operator’s Manual First Edition - Third 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.
  • Page 11 First Edition - Third Printing Operator’s Manual Labels And Plates Applied On The Machine Ref. Decal Code Description Label - Stabilizer Max Pres. GTH-6025ER 09.4618.1048 Label - Stabilizer Max Pres. P max al suolo 09.4618.1049 6.3 kg/cm P max on the ground GTH-4518ER GTH-4020ER 09.4618.0989 NOTICE...
  • Page 12 Operator’s Manual First Edition - Third Printing Labels And Plates Applied On The Machine Ref. Decal Code Description 09.4618.0824 Cosmetic - Genie GTH-4518 ER GTH-4518 ER 09.4618.0825 09.4618.0826 Cosmetic - Genie GTH-4020 ER GTH-4020 ER 09.4618.0827 09.4618.0828 Cosmetic - Genie GTH-6025 ER GTH-6025 ER 09.4618.0829...
  • Page 13 First Edition - Third Printing Operator’s Manual Labels And Plates Applied On The Machine Ref. Decal Code Description INSTRUCTIONS Operate the levers only in an emergency and with the Diesel engine stopped: 1. press the red emergency stop button in the cab 2.
  • Page 14 Operator’s Manual First Edition - Third Printing Labels and plates applied on the machine Ref. Decal Code Description ROPS-FOPS cab type-approval plate. This plate 09.4616.0100 shows the type-approval data of the driving cab according to ROPS - FOPS regulations. TERE FT srl - ON N STR E - 06019 M ERT E PG - T Tel.

  • Page 15: Safety Precautions

    First Edition - Third Printing Operator’s Manual Safety precautions SAFETY DEVICES 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.
  • Page 16 Operator’s Manual First Edition - Third Printing Safety precautions GENERAL REMARKS Not observing the instructions Most accidents occurring while working, repairing or and safety rules in this manual maintaining machines, are caused by not complying may result in death or serious with the basic safety precautions.
  • Page 17 First Edition - Third Printing Operator’s Manual Safety precautions REQUISITES OF THE PERSONNEL IN CHARGE Requisites of the SERVICEMEN Requisites of the MACHINE OPERATORS The personnel charged with the machine maintenance The operators who use the machine regularly or shall be qualified, specialised in the maintenance occasionally (i.e.
  • Page 18 Operator’s Manual First Edition - Third Printing Safety precautions OTHER DANGERS WORKING CLOTHES Hazards on the JOBSITE During work, but especially when maintaining or Always take into account the features of the job site where you are going to work: repairing the machine, operators must wear suitable protective clothing: •...
  • Page 19 First Edition - Third Printing Operator’s Manual Safety precautions WARNING • The machine shall be parked on a ground adequate to the maximum admissible payload. If the subsoil collapses, the machine could tip over. To avoid any risk of overturning, the following Make sure the machine (wheels and stabilisers) precautions should be taken: rests on a firm ground to prevent hazardous unstable...
  • Page 20 Operator’s Manual First Edition - Third Printing Safety precautions OPERATION or MAINTENANCE hazards • When entering/leaving the cab or other raised Before any operation, following precautions should parts, always face the machine; never turn the be taken: back. • First of all, make sure that the maintenance interventions have been carried out with care according to the established schedule.
  • Page 21 First Edition - Third Printing Operator’s Manual Safety precautions • Do not lubricate, clean or adjust moving parts. • When working, do not give instructions or signs • Do not carry out operations manually when to several people at the same time. Instructions specific tools are provided for this purpose.
  • Page 22 Operator’s Manual First Edition - Third Printing Safety precautions PERSONAL INJURY hazards • Do not operate the machine in dangerous environments or in places with flammable or • Do not operate the machine in case of hydraulic oil explosive gases or materials. or air leak.

  • Page 23: Description Of The Main Components

    First Edition - Third Printing Operator’s Manual Description Of The Main Components 10 - 4 boom section 1 - Cylinder for telescopic boom 11 - 3 boom section 2 - Oil tank compartment 12 - 2 boom section 3 - Fuel tank compartment 13 - 1 boom section 4 - Driving cab according to ROPS-FOPS...
  • Page 24 Operator’s Manual First Edition - Third Printing Intentionally blank page GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404...

  • Page 25: Controls And Instruments

    First Edition - Third Printing Operator’s Manual Controls And Instruments VOLT MODE 17 Differential locking switch 1 Fresh air flap 18 Hazard warning light switch 2 Forward/reverse gear selector 19 Emergency pump pushbutton 3 Control panel 20 Ignition switch 4 Locking lever - steering column angle 21 Cab-Road-Platform switch adjustment 22 Emergency stop switch...
  • Page 26 Operator’s Manual First Edition - Third Printing Controls And Instruments Control Panel 51 Turntable rotation locking/unlocking button 61 Button 3: rear left stabilizer selection/de- selection 52 Machine sway button: lifts the right side 62 Button 4: rear right stabilizer selection/de- 53 Machine sway button: lifts the left side selection 54 Mechanical gearbox button...
  • Page 27 First Edition - Third Printing Operator’s Manual Controls And Instruments 2 _ Forward/Reverse Gear Selector Switch 20 _ Ignition Switch The lever lets you select the forward or reverse Three-position switch: speed. The lever must be pulled upwards before No circuit under voltage, key can be removed engaging the selected speed.
  • Page 28 Operator’s Manual First Edition - Third Printing Controls And Instruments 5 _ Turn Signals - Windscreen Wiper - Horn - Lights Lights function: Horn function: To switch the handler lights, lever can be set to three When sliding the lever along its axis, horn switches different positions along its horizontal axis: on, independently from other pre-set functions.
  • Page 29 First Edition - Third Printing Operator’s Manual Controls And Instruments Accelerator control Brakes 26 _ Service Brake Pedal 25 _ Throttle Pedal Its pressure controls the engine rpm and the machine By gradually pressing the pedal, translation is slowed speed. It is fitted with an adjustable stop in the lower down and, by stepping the pedal down to end of part.
  • Page 30 Operator’s Manual First Edition - Third Printing Controls And Instruments Safety and Emergency Devices 19 _ Emergency Pump Control 22 _ Emergency Stop Pushbutton It is located on the left side of the dashboard and has By pressing this button, the engine of the machine two positions with automatic return to centre.
  • Page 31 First Edition - Third Printing Operator’s Manual Controls And Instruments Speed Controls Shift-On-Fly Pushbutton MECHANICAL Gear Change Control Pushbutton 54 lets you select the mechanical speed you wish. The Shift-on-fly system lets you shift from one gear • Pressing the button lets you shift from the first to another when the machine is travelling.
  • Page 32 Operator’s Manual First Edition - Third Printing Controls And Instruments Steering Mode Selection Road/Jobsite/Platform Selection 21 _ Road/Jobsite/Platform Selector 7 _ Steering Mode Selector Three-position switch located on the dashboard, to The three-position switch for the selection of the the right: steering mode is located on the dashboard to the right,: •...
  • Page 33 First Edition - Third Printing Operator’s Manual Controls And Instruments Auxiliary Drive Controls 14 _ Road Lights Switch 17 _ Differential Lock Switch Three-position switch placed on the right side of the The button is located on the right side of the dashboard: dashboard and has two stable positions: 0 Lights OFF...
  • Page 34 Operator’s Manual First Edition - Third Printing Controls And Instruments 34 _ Optional switches dashboard Auxiliary Hidraulic Circuit (OPTIONAL) Air Condition Switch (OPTIONAL) Two-position switch. The pressure of this button Two-position switch: causes the switching of the hydraulic circuit for the movement of the attachments equipped with 0 OFF auxiliary lines.
  • Page 35 First Edition - Third Printing Operator’s Manual Controls And Instruments Instruments 10 _ Multipurpose Display 8 _ Fuel Gauge When the machine is started, the graphic display This indicates the fuel level in the tank. When the shows: indicator reaches the red zone, there are roughly •...
  • Page 36 Operator’s Manual First Edition - Third Printing Controls And Instruments Multipurpose Display When the machine is started, the display shown in FIG. A fig. A will appear: SERVICE °C VOLT • The black bars 41 on the left indicate the hydraulic 50 h oil temperature.
  • Page 37 First Edition - Third Printing Operator’s Manual Controls And Instruments Use of menus and sub-menus Use the two buttons MODE 1 and MODE 2 to gain Press button MODE 2 to scroll through the menu access and scroll through menus and sub-menus. lists (when the last item of the list is reached, the first item is displayed).
  • Page 38 Operator’s Manual First Edition - Third Printing Controls And Instruments Language selection sub-menu Password protected service sub-menu • Select SELECT LANGUAGE using button MODE (reserved to authorised service centres) • Access to this sub-menu is reserved to authorised service centres and is therefore password °C protected.
  • Page 39 First Edition - Third Printing Operator’s Manual Controls And Instruments Error display sub-menu • Select DISPLAY ERRORS using button MODE °C VOLT ESCI °C VOLT SELEZIONA LINGUA SERVICE VISUALIZZA ERRORI ESCI • By quitting the sub-menu, you will go back to the EXIT window of the main menu.
  • Page 40 Operator’s Manual First Edition - Third Printing Controls And Instruments Right Panel Luminous Indicators (ref.6) 6.7 Warning light - hydraulic oil filter clogged 6.1 Warning light - fuel reserve When this lamp sets to on, immediately change This red light comes on to alert to a low fuel the oil filter on the return line to the tank.
  • Page 41 First Edition - Third Printing Operator’s Manual Controls And Instruments Left Panel Luminous Indicators Warning light - not active Warning light - differential lock Warning light - parking brake engaged This red light comes on to warn that the This red light comes on to warn that the lever of differential lock has been activated.
  • Page 42 Operator’s Manual First Edition - Third Printing Controls And Instruments CONTROL LEVERS The handlers are equipped with two multipurpose joysticks 27 and 32 that let you operate all the machine movements. The right joystick 27 is installed to one side of the driver’s seat;...
  • Page 43 First Edition - Third Printing Operator’s Manual Controls And Instruments Function Selection Right Joystick: Once the intentional control pushbutton 4 has been pressed, you can use the joystick to activate the following functions: • Boom lowering/lifting To activate the function, shift the joystick to A - B.
  • Page 44 Operator’s Manual First Edition - Third Printing Controls And Instruments Left Joystick: Once the intentional control pushbutton 4 has been pressed, you can use the joystick to activate the following functions: • Turntable rotation to activate the function, shift the joystick to C or If, during operation, button 4 is released for more than 0.5 seconds, the movement stops.
  • Page 45 First Edition - Third Printing Operator’s Manual Controls And Instruments Lifting/Lowering The Boom RIGHT JOYSTICK DANGER Before operating the boom, make sure that nobody is within the working range of the machine. To lift or lower the boom: • Set thecontrol lever to central position and press button 4.
  • Page 46 Operator’s Manual First Edition - Third Printing Controls And Instruments Extending/Retracting The Boom RIGHT JOYSTICK DANGER Before operating the boom, make sure that nobody is within the working range of the machine. To extend or retract the boom telescopes: • Set the control lever to central position and press button 4.
  • Page 47 First Edition - Third Printing Operator’s Manual Controls And Instruments Pitching The Attachment Holding Frame Forward/Back RIGHT JOYSTICK DANGER Before operating the boom, make sure that nobody is within the working range of the machine. To pitch forward/back the attachment holding frame: •...
  • Page 48 Operator’s Manual First Edition - Third Printing Controls And Instruments Quick-Coupling The Attachments RIGHT JOYSTICK DANGER Before operating the boom, make sure that nobody is within the working range of the machine. To lock the attachments: • Set the control lever to central position and press button 4.
  • Page 49 First Edition - Third Printing Operator’s Manual Controls And Instruments Turntable Rotation Control LEFT JOYSTICK NOTICE Before operating the turntable rotation control, check that the locking pin has been removed. To rotate the turntable: • Shift the control lever to central position and press button 4.
  • Page 50 Operator’s Manual First Edition - Third Printing Controls And Instruments MACHINE SWAY CONTROL Automatic levelling NOTICE To level the machine: • Press button 52 to raise the right side of the machine. • Press button 53 to raise the left side of the Operate the sway control only when the turntable machine.
  • Page 51 First Edition - Third Printing Operator’s Manual Controls And Instruments STABILIZER CONTROL On the left control panel, there are a series of controls for operating the stabilizers. Pressing or releasing buttons 1 - 2 - 3 - 4 lets you select or de-select the corresponding stabilizer: 1 Front left stabilizer 2 Front right stabilizer...
  • Page 52 Operator’s Manual First Edition - Third Printing Controls And Instruments Using the stabilizers: WARNING • Select the stabilizer you wish to use by pressing the relevant selection button 1 - 2 - 3 - 4, and check that the indicator light of the selected stabilizer comes on.
  • Page 53 First Edition - Third Printing Operator’s Manual Controls And Instruments TURNTABLE ROTATION LOCKING CONTROL To lock/unlock the turntable rotation: Rotation locking • Rotate the turntable until the light indicator 76 signalling that the machine is lined up, comes • Hold button 51 pressed down for some seconds to lock the turntable.
  • Page 54 Operator’s Manual First Edition - Third Printing Controls And Instruments MANUAL CONTROLS In order to operate the emergency pump with the If the control lever is defective or a function cannot manual controls, follow the instructions below: be operated, it is possible to use the emergency controls of the main valve.
  • Page 55 First Edition - Third Printing Operator’s Manual Inspection Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection Make sure: performed by the operator prior to each work shift. The inspection is designed to discover if anything You learn and practice the principles of safe is apparently wrong with a machine before the...
  • Page 56 Operator’s Manual First Edition - Third Printing Inspection PRE-OPERATION INSPECTION • Make sure the operator’s manual is intact, legible * Make sure that all structural and other critical and placed inside the machine. components are present and the relevant • Make sure all decals are present and legible.

  • Page 57: Inspections

    First Edition - Third Printing Operator’s Manual Inspections FUNCTION TESTS FUNDAMENTALS Test the Control Levers (always pressing button 4) The function tests are designed to discover any malfunctions before the machine is put into 7 Using the right control lever, momentarily raise service.
  • Page 58 Operator’s Manual First Edition - Third Printing Inspections 16 Straighten the wheels. Test the Outiriggers 17 Push the left side of the steer selector switch to select crab steer. 27 Using the buttons 55, 56, 57 and 58, fully lower and raise the stabilizers.
  • Page 59 First Edition - Third Printing Operator’s Manual Inspections 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.
  • Page 60 Operator’s Manual First Edition - Third Printing Intentionally blank page GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404...

  • Page 61: Operating Instructions

    First Edition - Third Printing Operator’s Manual 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”. For a safe use of the machine, always check the weight of the loads going to be handled.
  • Page 62 Operator’s Manual First Edition - Third Printing Operating Instructions ENTERING THE MACHINE ENTERING THE CAB CAUTION To unlock the door latched in open position:  • Press button 4 to unlock   the door from the catch Always make sure that your hands and shoe soles are clean and dry before getting into the driving •...
  • Page 63 First Edition - Third Printing Operator’s Manual Operating Instructions ADJUSTING THE SEAT Position the seat so you can comfotarbly reach all the controls. The handler seat is fitted with devices which let you adjust the seat springing, height and distance from the controls, the backrest angle and the armrest height.
  • Page 64 Operator’s Manual First Edition - Third Printing Operating Instructions ADJUSTING THE REAR VIEW MIRRORS ADJUSTING THE STEERING COLUMN The machine is fitted with three rear view mirrors: Both steering column and dashboard can be set to • Rear view mirror 1 is located on a special a different angle.
  • Page 65 First Edition - Third Printing Operator’s Manual Operating Instructions STARTING THE ENGINE JUMP-STARTING THE ENGINE • Set the forward/back speed lever to neutral NOTICE position. • To start the engine, rotate the ignition switch to position , and release when the engine starts. Do not start the engine using a quick charge If the engine does not start within 20 seconds, booster to avoid any damage to the electronic...
  • Page 66 Operator’s Manual First Edition - Third Printing Operating Instructions 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. •...
  • Page 67 First Edition - Third Printing Operator’s Manual Operating Instructions STARTING THE MACHINE STOPPING AND PARKING THE MACHINE When the engine reaches the running temperature, When possible, stop the machine on a dry, level and ensure all parts are in transfer position and the gearbox solid ground.
  • Page 68 Operator’s Manual First Edition - Third Printing Operating Instructions WARNING USING THE LOAD CHARTS The charts 1 indicating the maximum permissible load in relation to the boom extension and the type of attachment used are installed on the cab windscreen The load charts applied on the cab windscreen and/or illustrated in the quick guide.
  • Page 69 First Edition - Third Printing Operator’s Manual Operating Instructions 11 _ LOAD LIMITER At the back of the driving place there is a unit which The display of the limiting device is divided into four lets you manage the moment limiting system of the areas: machine.
  • Page 70 Operator’s Manual First Edition - Third Printing Operating Instructions Keys INDEX To change the operating mode I DANGER (E in the display). ENTER To confirm. To set the buzzer off. Before using the machine, make sure that the first Buzzer is reset automatically to on in green LED is ON, and that the operating mode an alarm or pre-alarm condition.
  • Page 71 First Edition - Third Printing Operator’s Manual Operating Instructions HANDLING LOADS Adjusting the forks With FEM forks Forks shall be spaced to suit the load going to be handled. For this purpose: • Lift the clamping lever of the forks. •...
  • Page 72 Operator’s Manual First Edition - Third Printing Operating Instructions WORKING PHASES When forks are correctly spaced, the handler is • When the forks are clear of the load, set them to ready to use. transfer position. Work can be subdivided into three different phases: •...
  • Page 73 First Edition - Third Printing Operator’s Manual Operating Instructions WARNING CHANGING THE ATTACHMENT CAUTION Use only attachments directly manufactured or After substitution, visually check the attachment recommended by Terexlift and detailed in the is correctly coupled to the boom, before operating ”Optional Attachments”...
  • Page 74 Operator’s Manual First Edition - Third Printing Operating Instructions ROAD OR SITE TRANSFER USE OF THE MAN-PLATFORM When travelling on public roads, strictly obey the local or national road traffic regulations. For the use of the man-platform, proceed as Besides, take into account the following general follows: precautions: 1.

  • Page 75: Transporting The Machine

    First Edition - Third Printing Operator’s Manual Transporting The Machine MOVING A DISABLED MACHINE Setting the gear lever in neutral Tow the machine only when no alternative is possible, since this operation may result in serious damage to NOTICE the transmission. When possible, repair the machine on site.
  • Page 76 Operator’s Manual First Edition - Third Printing Transporting The Machine LIFTING THE MACHINE TRANSPORTING THE MACHINE ON OTHER VEHICLES When the machine shall be lifted, use only means To transport the machine on another vehicle, follow having a suitable capacity. The characteristic data the steps below: are detailed in the relevant chapter of this manual and on the identification plate.
  • Page 77 First Edition - Third Printing Operator’s Manual Transporting The Machine PARKING AND STORAGE Machine storage Short inactivity In case of extended inactivity of the machine, follow Always park the machine in a safe way after a working the above precautions. Additionally: day, a shift and at night.
  • Page 78 Operator’s Manual First Edition - Third Printing Transporting the machine CLEANING AND WASHING THE MACHINE MACHINE DISPOSAL PROTECT THE Clean the machine in accordance with the following instructions: ENVIRONMENT • Remove any oil or grease traces with a dry solvent or a volatile mineral alcohol At the end of the machine life, call in a specialised •...

  • Page 79: Maintenance

    First Edition - Third Printing Operator’s Manual Maintenance Observe and obey: INTRODUCTION The operator can only perform t h e r o u t i n e m a i n t e n a n c e A thorough and regular maintenance keeps the operations envisaged in this machine in a safe and efficient working condition.
  • Page 80 Operator’s Manual First Edition - Third Printing Maintenance LUBRICANTS - HEALTH AND SAFETY PRECAUTIONS Health First aid A prolonged skin contact with oil can cause irritation. Eyes : In case of accidental contact with Use rubber gloves and protective goggles. After the eyes, wash with fresh water.
  • Page 81 First Edition - Third Printing Operator’s Manual Maintenance ORDINARY MAINTENANCE A wrong or neglected maintenance can result in Every 10 working hours or daily possible risks for both operator and bystanders. Check the engine oil level Make sure maintenance and lubrication are carried Clean the air suction filter out according to the manufacturer’s instructions to Clean the air suction pre-filter...
  • Page 82 Operator’s Manual First Edition - Third Printing Maintenance Every 50 working hours or weekly 14  Adjust the parking brake Jobs to be done in addition to those above. 15 Check the level of the battery electrolyte Check the tension of the alternator belt Check the tyre inflation Every 3 working months Check the tightening of the wheel nuts...
  • Page 83 First Edition - Third Printing Operator’s Manual Maintenance Every 2000 working hours or yearly Jobs to be done in addition to those above. Change the engine coolant Every 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 attention to the welded supporting joints and the boom pins.
  • Page 84 Operator’s Manual First Edition - Third Printing Maintenance MAINTENANCE INTERVENTIONS CAUTION WARNING High pressure lines must be replaced by qualified personnel only. All maintenance interventions must be carried Any foreign matters entering the closed circuit out with engine stopped, parking brake engaged, may result in a sudden deterioration of the working attachments flat on the ground and gear transmission.
  • Page 85 First Edition - Third Printing Operator’s Manual Maintenance 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 T a k e a l l p r e c a u t i o n s w h e n raised position.
  • Page 86 Operator’s Manual First Edition - Third Printing Maintenance ENGINE AIR FILTER (FOR GTH-4518 ER - GTH-4020 ER) 3 Changing the cyclone pre-filter Daily clean the cyclone pre-filter: Clean the engine air filter and replace the elements, Shut the engine down and engage the parking when necessary.
  • Page 87 First Edition - Third Printing Operator’s Manual Maintenance ENGINE AIR FILTER (FOR GTH-6025 ER) Clean the engine air filter and replace the elements, when necessary. 1 Cleaning and changing the outer element: Raise the boom and secure it in a stable and safe way.
  • Page 88 On delivery, the machine is filled with a cooling mixture of 6 bar. consisting of 50% water and 50% anti-freeze. TEREX PRO COOL Protection against boiling / freezing Product % Freezing point Boiling point -17°C...
  • Page 89 First Edition - Third Printing Operator’s Manual Maintenance CHECKING THE OIL LEVEL IN THE TANK CHANGING THE HYDRAULIC OIL CAUTION 1 Stop the machine on a level ground and make Fine jets of hydraulic oil under pressure can sure the parking brake is engaged. penetrate the skin.
  • Page 90 Operator’s Manual First Edition - Third Printing Maintenance CHANGING THE OIL FILTER CARTRIDGE To change the hydraulic oil filter element, proceed as follows: 1 Stop the machine on a level ground and engage the parking brake. 2 Place a container of suitable size under the filter to collect any oil leaks.
  • Page 91 First Edition - Third Printing 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. Cleaning and changing the cartridge: - Shut the engine down and engage the parking brake.
  • Page 92 Operator’s Manual First Edition - Third Printing Maintenance OIL LEVEL IN THE (front/rear) WHEEL OIL LEVEL IN THE DIFFERENTIAL GEARS REDUCTION 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 93 First Edition - Third Printing Operator’s Manual Maintenance OIL LEVEL IN THE POWER DIVIDER GEARBOX To check the oil level in the power diver gearbox:  Filling plug • Stop the machine on a level ground and make  Drain plug sure the parking brake is engaged.
  • Page 94 Operator’s Manual First Edition - Third Printing Maintenance TURNTABLE ROTATION REDUCTION GEAR Checking the oil level of the turntable rotation reduction gear To check the oil level of the turntable rotation reduction gear: • Stop the machine on a level ground and engage the parking brake.
  • Page 95 First Edition - Third Printing Operator’s Manual Maintenance GREASING CAUTION SERVICE INTERVAL Before injecting grease into the greasers, Running-in __________________________ None thoroughly clean them to avoid that mud, dust Ordinary __________________ Every hours or other matters can mix with the lubricant and reduce or annihilate the lubrication effect.
  • Page 96 Operator’s Manual First Edition - Third Printing Maintenance TYRES AND WHEELS On new machines, and when a wheel has been disassembled or replaced, check the nut torque of the wheels every 2 hours until they stay correct. Torque: 400 N/m. Always use tyres having the dimensions indicated Over-inflated tyres can burst.
  • Page 97 First Edition - Third Printing Operator’s Manual Maintenance 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.
  • Page 98 Operator’s Manual First Edition - Third Printing 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.
  • Page 99 First Edition - Third Printing Operator’s Manual Maintenance ADJUSTING THE SENSOR DISTANCE In case of a failure or complete malfunctioning of the sensors due to a loosening of their fixing ring nuts, re-adjust their position: 1 Loosen nuts A fixing sensor B. 2 Set the mobile part C of the machine, controlled by the sensor, as close as possible to it.
  • Page 100 Operator’s Manual First Edition - Third Printing Maintenance TENSIONING THE BOOM CHAINS To tighten the boom chains, follow the instructions below: Fully extend the boom Retract the boom by some 20/30 cm. Tighten the chain up to a maximum tension value of 25 Nm.
  • Page 101 First Edition - Third Printing Operator’s Manual Maintenance CHECKING THE SAFETY DEVICES Checking the MOMENT LIMITING SYSTEM SAFETY PUSHBUTTON on JOYSTICKS (at every use) Both joysticks are equipped with a safety system At the machine start-up, the moment limiting system (deadman system).
  • Page 102 Operator’s Manual First Edition - Third Printing Maintenance EMERGENCY STOP PUSHBUTTON (22) Checking the machine START CONTROL Set on the dashboard, to the right of the steering (20) wheel.Pressing down this button stops the engine (at every use) of the machine. Attempt to start the engine with the forward or reverse Before starting work again, find and rectify the gear put.
  • Page 103 First Edition - Third Printing Operator’s Manual Maintenance Sensors on STABILISERS WARNING Each stabiliser is equipped with two micro-switches and one position potentiometer. A Stabiliser extension potentiometer: It indicates the moment limiting system when a stabiliser is If a limit switch is faulty or a lever is deformed, extended and adapts the stabilising area of the immediately replace the part.
  • Page 104 Operator’s Manual First Edition - Third Printing Maintenance DANGER BLOCK VALVES fitted to all CYLINDERS All machine’s cylinders are equipped with block valves: Always use the lock ring of the lift cylinder (see • Block valve on attachment coupling cylinder picture below), when carrying out maintenance on the lift cylinder block valve or, in general, •...
  • Page 105 First Edition - Third Printing Operator’s Manual Maintenance Checking the block valves (every 3 months) To remove the block valves or the cylinders Lower the boom to the ground in a firm way since The piloted blocking valves allow to held the load in the removal of the block valve or the cylinder can position in case of burst of a flexible hose.
  • Page 106 Operator’s Manual First Edition - Third Printing Maintenance Pressure switch on parking brake (1) Boom strain gauge (2) (at every use) When the parking brake is engaged, this pressure switch stops the machine travel but the engine can To verify the effi ciency of the strain gauge on the still be started.
  • Page 107 First Edition - Third Printing Operator’s Manual Maintenance C H E C K I N G T H E S T A T E T H E 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).
  • Page 108 Operator’s Manual First Edition - Third Printing Maintenance ELECTRICAL SYSTEM WARNING WARNING All maintenance interventions must be carried Battery electrolyte contains sulphuric acid. It • out with engine stopped, parking brake engaged, can burn you if it touches your skin and eyes. working attachments on the ground and gearbox Always wear goggles and protective gloves, lever in neutral.
  • Page 109 First Edition - Third Printing Operator’s Manual Maintenance FUSES AND RELAYS Relays The electrical system is protected by fuses placed in the driving cab, on the left. Before replacing a blown Ref. Circuit fuse with a new one having the same amperage, find IGNITION out and rectify the fault.
  • Page 110 Operator’s Manual First Edition - Third Printing Maintenance Engine compartment fuses and relays NOTICE Amp. Ref. Circuit • Do not use fuses having a higher amperage FG1 IGNITION BOARD than that recommended, since they can FG2 AUX CIRCUIT damage the electric system seriously. UNDER FG3 IGNITION •...
  • Page 111 First Edition - Third Printing Operator’s Manual Maintenance REFUELLING REFUELLING Capacity (L) Capacity (L) Capacity (L) Part Product GTH-4518 ER GTH-4020 ER GTH-6025 ER Diesel engine Engine oil 11.5 11.5 Engine cooling system Water+antifreeze Fuel tank Diesel fuel Hydraulic system tank Hydraulic oil Gearbox Differential gears...
  • Page 112 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 this product guarantees protection to the  circuit for 3 years or 7000 hours without having to add any dry coolant additive.

  • Page 113: Faults And Troubleshooting

    DANGER First Edition - Third Printing Operator’s Manual Faults and Troubleshooting FAULTS AND TROUBLESHOOTING WARNING 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.
  • Page 114 Operator’s Manual First Edition - Third Printing Faults and Troubleshooting PROBLEM CAUSES SOLUTIONS BOOM MOVEMENTS • ROAD/JOSITE/PLATFORM CANNOT BE • Turn to JOBSITE selector turned to ROAD DANGER OPERATED MACHINE IN ALARM • Retract or raise the boom whitin safe (red LED on the IDR •...
  • Page 115 First Edition - Third Printing Operator’s Manual Faults and Troubleshooting ERROR MESSAGES ON "IDR" DISPLAY The following codes indicate the reason why a manoeuvre cannot be performed. DANGER 1001 Machine not stopped 1002 Emergency pressed or no power supply 1003 Alarm - see code list WARNING 1004...
  • Page 116 Operator’s Manual First Edition - Third Printing Faults and Troubleshooting Alarms from Midac Code Description Data saved in E2PROM corrupted Signal from angle transducer A below the minimum threshold Signal from angle transducer A above the maximum threshold Signal from extension transducer A below the minimum threshold Signal from extension transducer A above the maximum threshold Value of extension A below the value with the boom retracted Value of extension B below the value with the boom retracted...
  • Page 117 First Edition - Third Printing Operator’s Manual Faults and Troubleshooting Alarms from CLIO A CRC error - parameter area CLIOA CPU link alarm Error on the watch dog relay control Error on the block relay control Error on the output control Error on the + 5V check Lower cell reading at minimum Upper cell reading at minimum...
  • Page 118 Operator’s Manual First Edition - Third Printing Faults and Troubleshooting Head alarm list Code Sub Code Description 1001 Error in the CRC control of the calibration data 1032 The readings of the 2 main boom angle transducers, read by the winders, are not congruent.
  • Page 119 First Edition - Third Printing Operator’s Manual Faults and Troubleshooting Code Sub Code Description 1221 No CanBus 5 message from ARM 1221 No CanBus 6 message from ARM 1300 Error or fault detected on Lifting driver 1301 No CanBus message 1310 Error or fault detected on Extension driver 1311...
  • Page 120 Operator’s Manual First Edition - Third Printing Faults and Troubleshooting “cummins” ERROR MESSAGES LIST CUMMINS CanBus Error 524287 2623 All Other Values 1347 2623 UNIDECK 1347 1043 1347 1563 Error Error 1347 1563 1043 Cluster Internal Error 1377 Idraulic Oil OverTemp REXROTH 2981...
  • Page 121 First Edition - Third Printing Operator’s Manual Faults and Troubleshooting “cummins” ERROR MESSAGES DESCRIPTIONS Engine Control Module Critical internal failure - Bad Controller #1 intelligent Device or Component Engine Speed/Position Sensor Circuit lost both of two signals from the magnetic pickup sensor - Data System Diagnostic Code # 2 Erratic, Intermittent, or incorrect Intake Manifold Pressure Sensor Circuit –...
  • Page 122 Operator’s Manual First Edition - Third Printing Faults and Troubleshooting Barometric Pressure Sensor Circuit – Voltage Above Amber Barometric Pressure Normal, or Shorted to High Source Barometric Pressure Sensor Circuit – Voltage Below Amber Barometric Pressure Normal, or Shorted to Low Source Sensor Supply Voltage #2 Circuit –...
  • Page 123 First Edition - Third Printing Operator’s Manual Faults and Troubleshooting Intermittent, or Incorrect Auxiliary Pressure Sensor Input 1 - Special 1388 Auxiliary Pressure Instructions Auxiliary Pressure Sensor Input # 2 Circuit - Voltage 1388 Amber Auxiliary Pressure Above Normal, or Shorted to High Source Auxiliary Pressure Sensor Input # 2 Circuit - Voltage 1388 Amber...
  • Page 124 Operator’s Manual First Edition - Third Printing Faults and Troubleshooting Oil Pressure Sensor Circuit - Data Erratic, Amber Engine Oil Pressure Intermittent, or Incorrect Battery #1 Voltage Low - Data Valid but Below Normal Operational Range – Moderately Severe Amber Electrical Potential (Voltage) Level Battery #1 Voltage High - Data Valid but Above...
  • Page 125 First Edition - Third Printing Operator’s Manual Faults and Troubleshooting Turbocharger #1 Compressor Inlet Temperature Turbocharger #1Compressor Sensor Circuit – Voltage Below Normal, or Shorted to 1172 Amber Inlet Temperature Low Source ECM Internal Temperature Sensor Circuit - Voltage 1136 Amber Sensor Circuit - Voltage Above Normal, or Shorted to High Source...
  • Page 126 Operator’s Manual First Edition - Third Printing Faults and Troubleshooting Coolant Pressure 2 - Data Valid but Below Normal 2117 2981 Amber Coolant Pressure Operational Range - Moderately Severe Level Sensor Supply Voltage #4 Circuit – Voltage Above 2185 611 Amber System Diagnostic code # 1 Normal, or Shorted to High Source...
  • Page 127 First Edition - Third Printing Operator’s Manual Faults and Troubleshooting Engine Coolant Temperature High - Data Valid but Above Normal Operational Range - Least 2963 110 None Engine Coolant Temperature Severe Level Intake Manifold Temperature High - Data Valid but Above Normal Operational Range - Least 2964 105 None...
  • Page 128 Operator’s Manual First Edition - Third Printing Faults and Troubleshooting 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 8950 10700 10,1...

  • Page 129: Optional Attachments

    First Edition - Third Printing Operator’s Manual Optional Attachments INTRODUCTION This section provides information on the optional interchangeable attachments, especially manufac- tured for the handlers. Use only genuine attachments, described in this section, after having read their features thoroughly and understood their use. To install and remove the attachments, follow the instructions supplied in the “Operating Instructions”...
  • Page 130 DANGER Operator’s Manual First Edition - Third Printing WARNING Optional Attachments 800 LITRES SHOVEL CAUTION (code 59.0200.7000 for GTH-4518ER and GTH-4020ER) (code 59.0202.6000 for GTH-6025ER) Attachment suitable for moving loose material. NOTICE Do not use for digging operations. DANGER Application Quick coupling attachment for moving soil, sand, debris, cereals, etc.
  • Page 131 First Edition - Third Printing Operator’s Manual Optional Attachments 500 LT MIxING BUCKET (code 59.0400.8000) Application Quick coupling attachment for mixing and distributing concrete. Safety Strictly obey the general safety precautions given in section “Safety”. Operation To load/unload the material, operate the rotation lever of the attachment holding plate.
  • Page 132 Operator’s Manual First Edition - Third Printing Optional Attachments 500 LITRES CONCRETE SKIP (code 59.0400.0000 _ Manual Version) Application Attachment coupled to the standard forks of the (code 59.0400.1000 _ Hydraulic Version) handler and fixed by means of the special chains with shackle provided.
  • Page 133 First Edition - Third Printing Operator’s Manual Optional Attachments 800 LITRES CONCRETE SKIP (code 59.0400.2000 _ Manual Version) Application Attachment coupled to the standard forks of the (code 59.0400.3000 _ Hydraulic Version) handler and fixed by means of the special chains with shackle provided.
  • Page 134 Operator’s Manual First Edition - Third Printing Optional Attachments FIxED HOOK ON PLATE (code 59.0700.4000 for GTH-4518ER and Application Quick-coupling fitted attachment for lifting loads by GTH-4020ER) means of special slings. (code 59.0701.0000 for GTH-6025ER) Safety Strictly obey the general safety precautions given in section “Safety”.
  • Page 135 First Edition - Third Printing Operator’s Manual Optional Attachments 900 KG ExTENSION jIB (code 59.0802.0000 _ Mechanical Version) Application Quick-coupling fitted attachment for maintenance (code 59.0802.3000 _ Hydraulic Version interventions at high working heights. for GTH-4518ER and GTH-4020ER) (code 59.0801.8000 _ Hydraulic Version Safety for GTH-6025ER) Strictly obey the general safety precautions given...
  • Page 136 Operator’s Manual First Edition - Third Printing Optional Attachments 2000 KG ExTENSION jIB (code 59.0802.3001 _ Mechanical Version) Application Quick-coupling fitted attachment for maintenance interventions at high working heights. Safety Strictly obey the general safety precautions given in section “Safety”. Never lift wrongly slung loads.
  • Page 137 First Edition - Third Printing Operator’s Manual Optional Attachments 3000 KG HYDRAULIC WINCH (code 59.0901.7000 Application ONLY for GTH-4518ER Quick-coupling fitted attachment for lifting loads by means of special slings. & GTH-4020ER) Safety Strictly obey the general safety precautions given in section “Safety”.
  • Page 138 Operator’s Manual First Edition - Third Printing Optional Attachments 5000 KG HYDRAULIC WINCH (code 59.0901.2000 Application ONLY for GTH-6025ER) Quick-coupling fitted attachment for lifting loads by means of special slings. Safety Strictly obey the general safety precautions given in section “Safety”. Do not oscillate the load.
  • Page 139 First Edition - Third Printing Operator’s Manual Optional Attachments BASKET FOR BRICKS (code 59.0400.7000) Application Attachment used to handle construction manufactured products, to be fixed to the standard forks of the handler and locked in position with the chains with shackles supplied.
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  • Page 141: Specifications

    First Edition - Third Printing Operator’s Manual Specifications GTH-4518 ER GTH 4020 ER GTH 6025 ER MAIN DIMENSIONS A Overall height ............mm 3025 3025 3150 B Height to the steering wheel ........mm 2135 2135 2230 C Overall width ............mm 2430 2430 2470 D Inside cab width ...........mm...
  • Page 142 Operator’s Manual First Edition - Third Printing Specifications GTH-4518 ER GTH 4020 ER GTH 6025 ER PAYLOAD AND REACH • Lifting height (max) ........mm 17230 19640 24840 • Reach at maximum height ......mm 3500 4200 3650 • Forward reach (max) ........mm 14900 17420 20850 • Attachment holding plate rotation ......

  • Page 143: Load Charts

    First Edition - Third Printing Operator’s Manual Load Charts LOAD CHART WITH FORKS GTH-4518 ER GTH-4518 ER 78° 70° ±90°° ° ° 60° 0° 180° 50° 40° 30° 0.6 m 20° GTH-4518 ER 78° 10° 70° 60° 0° 180° 0° 50°...
  • Page 144 Operator’s Manual First Edition - Third Printing Load Charts LOAD CHART WITH HOOK GTH-4518 ER GTH-4518 ER 78° 70° ±90°° ° ° 60° 0° 180° 50° 40° 30° 20° GTH-4518 ER 78° 70° 10° 60° 0° 0° 50° 180° -4.4° 40°...
  • Page 145 First Edition - Third Printing Operator’s Manual Load Charts LOAD CHART WITH 900 KG jIB GTH-4518 ER GTH-4518 ER ±90°° ° ° 0° 180° 78° 70° 60° 50° 40° 30° GTH-4518 ER 20° 10° 0° 180° 78° 0° 70° -4.4° 60°...
  • Page 146 Operator’s Manual First Edition - Third Printing Load Charts LOAD CHART WITH WINCH GTH-4518 ER GTH-4518 ER 78° 70° ±90°° ° ° 60° 0° 180° 50° 40° 30° 20° GTH-4518 ER 78° 10° 70° 60° 0° 180° 0° 50° -4.4° 40°...
  • Page 147 First Edition - Third Printing Operator’s Manual Load Charts LOAD CHART WITH MAN-PLATFORM GTH-4518 ER 3P/1300 GTH-4518 ER 78° 70° ±90°° ° ° 60° 0° 180° 50° 40° 30° 2P/1000 5500 20° GTH-4518 ER 78° 70° ±90°° ° ° 10° 60°...
  • Page 148 Operator’s Manual First Edition - Third Printing Load Charts LOAD CHART WITH MAN-PLATFORM GTH-4518 ER 2P/300 GTH-4518 ER 78° 70° ±90°° ° ° 60° 0° 180° 50° 40° 30° 2P/500 4400 20° GTH-4518 ER 78° 70° 10° ±90°° ° ° 60°...
  • Page 149 First Edition - Third Printing Operator’s Manual Load Charts LOAD CHART WITH FORK GTH-4020 ER GTH-4020 ER 78° 70° ±90°° ° ° 60° 0° 180° 50° 40° 30° 0.6 m 20° GTH-4020 ER 78° 70° 0° 180° 10° 60° 50° 0°...
  • Page 150 Operator’s Manual First Edition - Third Printing Load Charts LOAD CHART WITH HOOK GTH-4020 ER GTH-4020 ER 78° 70° ±90°° ° ° 60° 0° 180° 50° 40° 30° 20° GTH-4020 ER 78° 70° 10° 60° 0° 180° 50° 0° -4.4° 40°...
  • Page 151 First Edition - Third Printing Operator’s Manual Load Charts LOAD CHART WITH WINCH GTH-4020 ER GTH-4020 ER 78° 70° ±90°° ° ° 60° 0° 180° 50° 40° 30° 20° GTH-4020 ER 78° 70° 10° 60° 0° 180° 50° 0° -4.4° 40°...
  • Page 152 Operator’s Manual First Edition - Third Printing Load Charts LOAD CHART WITH MAN-PLATFORM GTH-4020 ER 2P/300 F GTH-4020 ER 78° ±90°° ° ° 70° 0° 60° 180° 50° 40° 30° 2P/300 20° GTH-4020 ER 78° ±90°° ° ° 70° 10° 60°...
  • Page 153 First Edition - Third Printing Operator’s Manual Load Charts LOAD CHART WITH MAN-PLATFORM GTH-4020 ER 2P/1000 5500 GTH-4020 ER 78° ±90°° ° ° 70° 0° 60° 180° 50° 40° 30° 3P/1300 GTH-4020 ER 20° 78° ±90°° ° ° 70° 10° 0°...
  • Page 154 Operator’s Manual First Edition - Third Printing Load Charts LOAD CHART WITH 900 KG jIB GTH-4020 ER GTH-4020 ER ±90°° ° ° 0° 180° 78° 70° 60° 50° 40° 30° GTH-4020 ER 20° 10° 0° 180° 78° 70° 0° 60° -4.4°...
  • Page 155 First Edition - Third Printing Operator’s Manual Load Charts LOAD CHART WITH FORK GTH-6025 ER GTH-6025 ER GTH-6025 ER 78° 78° 70° 70° 0° ±90°° ° ° 180° 60° 60° 50° 50° 40° 40° 30° 30° 0.6 m 0.6 m 20°...
  • Page 156 Operator’s Manual First Edition - Third Printing Load Charts LOAD CHART WITH HOOK GTH-6025 ER GTH-6025 ER GTH-6025 ER 78° 70° ±90°° ° ° 0° 180° 60° 50° 40° 30° 20° 10° 0° -5.5° 21.00 m 09.4618.1077 09.4618.1078 GTH-6025 ER GTH-6025 ER 0°...
  • Page 157 First Edition - Third Printing Operator’s Manual Load Charts LOAD CHART WITH 900 KG jIB GTH-6025 ER GTH-6025 ER GTH-6025 ER 0° ±90°° ° ° 180° 09.4618.1081 09.4618.1082 GTH-6025 ER GTH-6025 ER 0° ±90°° ° ° 180° 09.4618.1083 09.4618.1084 Part No. 57.0009.0404 GTH-4518ER - GTH-4020ER - GTH-6025ER...
  • Page 158 Operator’s Manual First Edition - Third Printing Load Charts LOAD CHART WITH 2000 KG jIB GTH-6025 ER GTH-6025 ER GTH-6025 ER 0° ±90°° ° ° 180° 09.4618.1085 09.4618.1086 GTH-6025 ER GTH-6025 ER 0° ±90°° ° ° 180° 09.4618.1087 09.4618.1088 GTH-4518ER - GTH-4020ER - GTH-6025ER Part No.
  • Page 159 First Edition - Third Printing Operator’s Manual Load Charts LOAD CHART WITH WINCH GTH-6025 ER GTH-6025 ER GTH-6025 ER 0° ±90°° ° ° 180° 09.4618.1089 09.4618.1090 GTH-6025 ER GTH-6025 ER 78° 0° ±90°° ° ° 70° 180° 60° 50° 40° 30°...
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  • Page 161: Diagrams And Schemes

    First Edition - Third Printing Operator’s Manual Diagrams and Schemes GTH-6025 ER WIRING DIAGRAM 1/13 ELECTRONIC CONTROL PANEL P145 ECO MULTIPURPOSE INSTRUMENT A158 ECO MULTIPURPOSE INSTRUMENT ELECTRONIC CONTROL PANEL 15/54 S142 START-UP PANEL X145 X158 X158 M/N1 B-R0.5 H-N1 CA6 V0.35 Sal41 Sal42 CA6 B0.35...
  • Page 162 Operator’s Manual First Edition - Third Printing Diagrams and Schemes GTH-4518 ER & GTH-4020 ER WIRING DIAGRAM 1/13 ECO MULTIPURPOSE INSTRUMENT ELECTRONIC CONTROL PANEL START-UP PANEL RELAY CARD IGNITION RELAY AUX CIRCUITS RELAY Rexroth control unit box ground HYDR. OIL HYDR.OIL FILTER STARTING CAB BUS...
  • Page 163 First Edition - Third Printing Operator’s Manual Diagrams and Schemes GTH-6025 ER WIRING DIAGRAM 2/13 DRIVE SWITCH GAS PEDAL MANUAL ACCELERATOR HEAD CONTROL UNIT CAN-BUS DIAGNOSIS J1939 H/R1 M/B1 B-N1 A138 A-R1 A138 HEAD CONTROL UNIT M/N1 P155 X192 CAN-BUS B161 S192 DIAGNOSIS...
  • Page 164 Operator’s Manual First Edition - Third Printing Diagrams and Schemes GTH-4018 ER 6 GTH-4020 ER WIRING DIAGRAM 2/13 UNDER CONSTRUCTION GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404...
  • Page 165 First Edition - Third Printing Operator’s Manual Diagrams and Schemes WIRING DIAGRAM 3/13 DISPLAY ARB MIDAC 3B6 CONTROL UNIT HEAD CONTROL UNIT - A138 ARM1 CONTROL UNIT A133 HEAD CONTROL UNIT - A138 P147 ARM1 CONTROL MIDAC 3B6 CONTROL UNIT UNIT - A32 MOMENT LIMITER...
  • Page 166 Operator’s Manual First Edition - Third Printing Diagrams and Schemes WIRING DIAGRAM 4/13 FOG LAMP SWITCH FRONT WORK LIGHTS REAR WORK LIGHTS POSITION LIGHTS SWITCH ELECTRONIC CONTROL PANEL SWITCH SWITCH R/N1 R/N1 R/N1 R/N1 R/N1 M-B1.5 ELECTRONIC CONTROL PANEL CLUSTER A158 S168 S170 S169...
  • Page 167 First Edition - Third Printing Operator’s Manual Diagrams and Schemes WIRING DIAGRAM 5/13 LIGHT SWITCH LIGHT SWITCH WINDSCREEN ROOF WINDSHIELD REAR WINDSCREEN WARNING SWITCH WASHER PUMP WIPER/WASHER WIPER H-G1.5 X179 X185 X193 S144 X146 X146 X146 X146 30 54s HORN WIPER S167 M146...
  • Page 168 Operator’s Manual First Edition - Third Printing Diagrams and Schemes WIRING DIAGRAM 6/13 ERROR BEACON CAB LIGHTS HEATING HEATING AIR CONDITIONING LAMP REXROTH SWITCH SWITCH A-G1.5 C1.5 X181 X181 X181 X356 E356 S171 S172 M181 E184 E182 X356 N1.5 R/N1 R/N1 R/N1 R/N1...
  • Page 169 First Edition - Third Printing Operator’s Manual Diagrams and Schemes WIRING DIAGRAM 7/13 LEFT JOYSTICK RIGHT JOYSTICK HEAD CONTROL UNIT ARM2 CONTROL UNIT ARM1 CONTROL UNIT CAN BUS LINE MIDAC 3B6 CONTROL UNIT TERMINAL HEAD CONTROL UNIT A138 MIDAC 3B6 CONTROL ARM2 ARM1 UNIT...
  • Page 170 Operator’s Manual First Edition - Third Printing Diagrams and Schemes WIRING DIAGRAM 8/13 ELECTRONIC CONTROL PANEL MOMENT EMERGENCY STEERING SWITCH - DIFFERENTIAL HEAD CONTROL UNIT ARM2 CONTROL UNIT ARM1 CONTROL UNIT LIMITER MUSHROOM-HEAD SELECTOR LOCKING ELECTRONIC CONTROL PANEL IGNITION ARM2 CONTROL UNIT HEAD CONTROL ARM1 CONTROL UNIT DISCONNECT...
  • Page 171 First Edition - Third Printing Operator’s Manual Diagrams and Schemes WIRING DIAGRAM 9/13 MODE PUSHBUTTONS ARM1 CONTROL UNIT JOBSITE PLATFORM EMERG. STRAIN GAUGE ARM2 CONTROL UNIT EMERGENCY PUMP ENABLE ENABLE PUMP SWITCH SWITCH MODE 1 MODE 2 ARM1 CONTROL UNIT ARM2 CONTROL UNIT CONTACT CONTACT...
  • Page 172 Operator’s Manual First Edition - Third Printing Diagrams and Schemes WIRING DIAGRAM 10/13 ARM2 CONTROL UNIT ARM1 CONTROL UNIT ARM2 CONTROL UNIT ARM1 CONTROL UNIT S/N1 S/N1 X104 86 87a 86 87a C-R1 RELAY C-N1.5 CARD A/G1 A-G1 N1.5 N2.5 12.2 M-B1 C2.5...
  • Page 173 First Edition - Third Printing Operator’s Manual Diagrams and Schemes WIRING DIAGRAM 11/13 ARM1 CONTROL UNIT CAN-BUS PLUG ARM2 CONTROL UNIT ARM1 CONTROL UNIT ARM2 CONTROL UNIT A101 CAN-BUS PLUG X101p V-Z1 10.5 Sal64 CA7 V0.35 Sal66 CA7 B0.35 Sal65 Sal63 CA4 V0.35 CA4 V0.35...
  • Page 174 Operator’s Manual First Edition - Third Printing Diagrams and Schemes WIRING DIAGRAM 12/13 ELECTRONIC LEVEL ROTAX CAN-BUS OPEN HEAD CONTROL UNIT MIDAC 3B6 CONTROL UNIT ELECTRONIC CONTROL PANEL DIAGNOSTIC HEAD CONTROL UNIT MIDAC 3B6 CONTROL UNIT A138 P154 A133 ELECTRONIC CAN-BUS ROTAX LEVEL...
  • Page 175 First Edition - Third Printing Operator’s Manual Diagrams and Schemes WIRING DIAGRAM 13/13 A192 ARM3 CONTROL UNIT PUSHBUTTON PANEL SYSTEM ARM3 CONTROL UNIT MUSHROOM BUTTON PLATFORM SYSTEM MICRO1 BASKET MOTORDRIVEN in/out IGNITION up/down rotation ROTATION PUMP MICRO2 alarm warning light BUZZER platform platform...
  • Page 176 Operator’s Manual First Edition - Third Printing Diagrams and Schemes WIRING DIAGRAM A/C SYSTEM (OPTIONAL) REF. DESCRIPTION HEATING COMPRESSOR COMPRESSOR FUSE FAN FUSE CONDITIONING SWITCH COMPRESSOR RELAY AIR CONDITIONING RELAY AIR CONDITIONING SWITCH PRESSURE SWITCH A/C SYSTEM FANS AND PRESSURE SWITCH +15 SERVICES COMPRESSOR...
  • Page 177 First Edition - Third Printing Operator’s Manual Diagrams and Schemes WIRING DIAGRAM REMOTE CONTROL (OPTIONAL) HEAD A138 CONTROL UNIT BATTERY CHARGER X2 SERIAL CONN. X1 TERMINAL BOARD REF. DESCRIPTION CAN BUS CONNECTOR REMOTE CONTROL POWER SUPPLY BATTERY CHARGER SERIAL CONNECTOR TERMINAL BOARD Part No.
  • Page 178 Operator’s Manual First Edition - Third Printing Diagrams and Schemes GTH-6025 ER HYDRAULIC DIAGRAM 1/2 GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404...
  • Page 179 First Edition - Third Printing Operator’s Manual Diagrams and Schemes GTH-6025 ER HYDRAULIC DIAGRAM 2/2 Part No. 57.0009.0404 GTH-4518ER - GTH-4020ER - GTH-6025ER...
  • Page 180 Operator’s Manual First Edition - Third Printing Diagrams and Schemes GTH-4518 ER AND GTH-4020 ER HYDRAULIC DIAGRAM 1/2 GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404...
  • Page 181 First Edition - Third Printing Operator’s Manual Diagrams and Schemes GTH-4518 ER AND GTH-4020 ER HYDRAULIC DIAGRAM 2/2 Part No. 57.0009.0404 GTH-4518ER - GTH-4020ER - GTH-6025ER...
  • Page 182 Operator’s Manual First Edition - Third Printing Intentionally blank page GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404...

  • Page 183: Warranty

    First Edition - Third Printing Operator’s Manual Warranty LIMITED PRODUCT WARRANTY or replacing, with new or remanufactured parts Genie Industries (“Seller”) warrants its new equipment manufactured and sold worldwide, to be or components, any part, which appears to Seller free, under normal use and service, of any defects upon inspection to have been defective in material or workmanship.
  • Page 184 Operator’s Manual First Edition - Third Printing Warranty ITEMS NOT COVERED BY SELLER WARRANTY review maintenance procedures to determine if the failure was due to improper maintenance, improper The following items are not covered under the seller use, abuse, improper storage, operation beyond warranty (the following list is not Exhaustive): rated capacity, operation after discovery of defective Lamps, lenses, filters, consumable items, utility...
  • Page 185 First Edition - Third Printing Operator’s Manual Warranty Secondary Failures: should the owner or No action by any party shall operate to extend or operator continue to operate a machine after revive this limited warranty without the prior written It has been noted that a failure has occurred, consent of seller.
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  • Page 187 First Edition - Third Printing Operator’s Manual WARRANTY - HANDING OVER CERTIFICATE Model Serial Number Delivery date Dealer’s stamp and signature ___________________ ___________________ ___________________ We hereby acknowledge that we received the machine in perfect condition, as well as the Operator’s Manual. DATAS OF THE OWNER: Note ___________________________...

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