500L from SN SHOV50014B-1001 (PN 57.0303
Contents
1. a p oh a PE 20 1 480 e 19 s0 LE 18 20 NF 17 z0 D 16 15 c 14 40 13 F 12 HEE m d w g 9 8 20 JE f GTH 5021R E 2 P Lo 7 24 D uf i 1803 je D f O 4 PR 20 2 g ba a ji 19 60 E 2 18 t on a 1 y D4 f 16 1 j 3 50 45 2 Ul C 19 f8 17 16 15 1413121110 987654321 14 40 18 24m 13 5 Na 09 4618 1708_ 12 304 xi E 10 7 z g 9 8 ar L 7 Ji 2 E 2 O oe 5 si 2 lio lt Tm GTH 5021R pci 3 e o 2 ony 2 TI R 2 uy X s l roe Se o o 20 o a 19 60 LE a ecto 18 2 Ll i 19 8 17 16 15 14 13 121110 9 8 7 6 5 43210 el D x 18 24m 16 T r is Le 09 4618 1709 14 40 13 E 12 n 30 F Tat A 10 A a 9 8 ae 7 z 2 En 5 2 jior 4 7 3 2 p S q Me T o 4 a Haso aii 149 8 17 16 15 14 13 12 1110 9 8 76543210 18 24m 09 4618 1710 J The payload represents the weight of the equipment plus the weight of the handled material i e bricks concrete and so on ATEREX BRAND Part No 57 0303 5193 BUCKET BASKET 49 Operator s Manual First Edition First Printing E Load Charts E BRICK HOLDER BASKET AND CONCRETE BUCKET COUPLED TO GTH 2506 09 4612. BA os Kyo ea ODN 7 T whens 387654321 09 4618 1724 GTH 4018 44 09 4618 1725 The payload represents the weight of the equipment plus the weight of the handled material i e bricks concrete and so on ATEREX BRAND Part No 57 0303 5193 BUCKET BASKET 47 Operator s Manual First Edition First Printing aS EX ea Load Charts m LOADING SHOVEL AND MIXING BUCKET COUPLED TO GTH 4016R amp GTH 4018R The payload represents the weight of the equipment plus the weight of the handled material i e bricks concrete and so on Genie 48 BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual Load Charts E LOADING SHOVEL AND MIXING BUCKET COUPLED TO GTH 5021R
3. CI 2 N 20 19 60 E 18 17 50 D 16 15 Ho 14 o H 13 B 12 F DE O 9 st gt GTH 5021R Pe G dso m 5 oa og Trae Ps a fe igi 70 Se 3 hed s04 E 0 2 a era 1 y E7 H s if un 2 LU 40 19 18 17 16 15 14131211109 8 765432190 18 24m fi Wa 09 4618 1642 30 ta g 3 al 1 8 20 7 2 2 2 2 Hoson 3 i amp E Seas 4 1 Tt 3 2 d 1 i EE o a aor 2 Ll 19 18 17 16 15 1413121110 9 8 765 43 21 18 24 m 09 4618 1643 _ 19 f8 17 16 15 14131211109 8 7654321 Ne 18 24m 09 4618 1644 The payload represents the weight of the equipment plus the weight of the handled material i e bricks concrete and so on Genie 54 BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual Diagrams and Schemes E HYDRAULIC DIAGRAM ONLY for Hydraulic Concrete Bucket Genie Part No 57 0303 5193 BUCKET BASKET 55 Operator s Manual First Edition First Printing I Diagrams and Schemes E HYDRAULIC DIAGRAM ONLY for Mixing Bucket Genie 56 BUCKET BASKET Part No 57 0303 5193 First Edition F
4. oh g Genie 34 BUCKET BASKET E GTH 4016SR and GTH 4018SR controls A DANGER Before discharging the concrete make sure that nobody is within its working range To open close the discharge door WITH RIGHT JOYSTICK Standard Configuration and WITH LEFT JOYSTICK Optional Configuration e Set the control lever to central position and press switch Eg e Press button Ef and hold it pressed until the end of the motion e Smoothly shift the lever to position to open the discharge door e Shiftthe leverto position to close the discharge door P AZ E LUA OF Part No 57 0303 5193 First Edition First Printing Operator s Manual EE LOADING THE EQUIPMENT E LOADING THE SHOVEL Operator have to survey his her field of vision when Cc the telehandler e When using a shovel load the material only when the boom is completely retracted and push against the heap with straight wheels M GES We e Approach the load to be handled perpendicularly and check that the machine is level on the inclinometer Insert the shovel under the load and raise it some centimetres e Pitch the load back to cradle the load When loading round shaped objects as petrol drums etc bind them with straps or ropes and travel at reduced speed Do not use for digging operations A DANGER Don t use th
5. e Read understand and obey the manufacturer s instructions and the safety rules the safety and operator s manuals and the decals applied on the equipment e Read understand and obey the employer s safety rules and worksite regulations e Read understand and obey the applicable national regulations e Only trained personnel informed on the safety rules can operate the equipment Genie 10 BUCKET BASKET E GENERAL REMARKS Most accidents occurring while working repairing or maintaining machines are caused by not complying with the basic safety precautions Therefore it is necessary to pay steady attention to the potential hazards and the effects that may come of operations carried out on the telehandler NICIEIG If you recognise hazardous situations you can prevent accidents A DANGER The instructions given in this handbook are the ones established by TEREX Global GmbH They do not exclude other safe and most convenient ways for the telehandler and or the equipment installation operation and maintenance that take into account the available spaces and means If you decide to follow instructions other than those given in this manual you shall absolutely e be sure that the operations you are going to carry out are not explicitly forbidden e be sure that the methods are safe say in compliance with the rules and provisions given in this section e be sure that the methods cannot damage the
6. 6 bs 4000 kg 5 Ei z i 2 u pl 4 jo me 3 T i 2 T E i 1 j o Han 4 A 15 14 h3 1211109 8 765432410 13 33 m 09 4618 1714 70 60 iE 50 3 D x S SC 40 oy l 30 i ce s 06m S 20 o 10 2 H H Et E Fi 1 0 144931211109 8765 4324 13 36_m 09 4618 1715 The payload represents the weight of the equipment plus the weight of the handled material i e bricks concrete and so on Genie 52 BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual Load Charts E BRICK HOLDER BASKET AND CONCRETE BUCKET COUPLED TO GTH 4016R amp GTH 4018R The payload represents the weight of the equipment plus the weight of the handled material i e bricks concrete and so on ATEREX BRAND Part No 57 0303 5193 BUCKET BASKET 53 Operator s Manual First Edition First Printing Load Charts E BRICK HOLDER BASKET AND CONCRETE BUCKET COUPLED TO GTH 5021R
7. BUCKET BASKET 9 Safety Precautions E SAFETY DEVICES Several safety devices have been fitted to the telehandler They must never be tampered with or removed Regularly check the efficiency of such devices In case of faults stop working immediately and proceed in replacing the modified device For the checking procedures read chap Maintenance of the telehandler Operator s Manual E MOMENT LIMITING SYSTEM The moment limiting system has been developed to help the operator to maintain the telehandler longitudinal stability Audible and visual messages are provided when the limits of longitudinal stability are being approached However this device cannot replace the experience of the operator It is up to the user to adopt the necessary safety measures to work within the rated limits of the machine Operator s Manual First Edition First Printing Safety Precautions Not observing the instructions and safety rules in this manual may result in death or serious injury Do not operate the equipment unless e You learn and practice the principles of safe work equipment operation contained in this operator s manual 1 Avoid hazardous situations Read and understand the safety instructions before going on to the next chapter 2 Always perform a pre operation inspection 3 Always test the equipment functions prior to use 4 Inspect the work place 5 Only use the equipment for the intended application
8. Printing Operator s Manual E SHOVEL GENERAL DESCRIPTION The shovel consists of a welded concave shaped steel structure designed to move and load loose material such as soil sand debris cereals inert material The main components of this structure are the front blade which works as the leading edge of the shovel cutting the material volume and separating the part which is gathered by the shovel itself the central concave shell which provides the volume for the material to be gathered and the side walls which laterally close the useful volume of the shovel On the rear area of the shovel there are two shaped plates welded to its main structure and designed to be mechanically interfaced with the GTH telehandlers standard attachments articulation Considering the typical limitation in the maximum rotation of the attachments articulation the design of the shovel and its mechanical interface with the attachments articulation is optimized to provide the best compromise in terms of material loading and unloading capabilities NIC EITC This equipment is coupled to the telehandler through the coupling frame B Part No 57 0303 5193 Genie BUCKET BASKET 17 Equipment Description E BRICK HOLDER BASKET GENERAL DESCRIPTION This attachment is designed to handle bricks pallets and to place them where are necessary in the construction working sites It consists of a main cage made by welded steel square sha
9. e shift the lever to position to load the material Part No 57 0303 5193 First Edition First Printing Operator s Manual Operating Instructions EE CONTROLS with the MIXING BUCKET Proceed as follow 1 Set the Hydraulic Mixing Bucket Oil Direction switch A to position 0 and press the Mixing Bucket switch B to enables the movement of the internal mixer of the bucket The selector has a block to keep the switch pressed Before switching the selector to another position unlock the block at the top of the selector 2 Setting switch A to position 2 or 1 regulate the oil flow direction towards right or left 3 To discharge the concrete set switch A to position 0 and press the Auxiliary Hidraulic Circuit switch C For the use of this equipment and its remote control please read the specific manual Genie Part No 57 0303 5193 BUCKET BASKET 33 Operator s Manual First Edition First Printing Operating Instructions EE CONTROLS with the HYDRAULIC CONCRETE BUCKET E GTH 2506 GTH 4014 and GTH 4018 controls A DANGER Before discharging the concrete make sure that nobody is within its working range To open close the discharge door set the control lever to central position e press button E e shift the control lever to position to open the discharge door e shift the control lever to position to close the discharge door lt AT
10. shackle which must be secured before to start any operation with the bucket NICHTS This equipment is coupled to the telehandler through the forks slots A Part No 57 0303 5193 Genie BUCKET BASKET 19 Equipment Description E IMPROPER USE Improper use means an utilisation of the equipment following working criteria which do not comply with the instructions of this manual and which in general may result in risks for both operator and bystanders The compliance with and the strict respect of the use maintenance and repair instructions ofthe Manufacturer represent an essential part of the allowed use A DANGER We list below some improper use of the buckets baskets Others may exist Notstrictly complying with the operation and maintenance instructions of this handbook and of the telehandler handbook Never use the buckets baskets to lift and or transport people Working beyond the operation limits of the euipment Working the machine resting on unstable or yielding grounds Working on steep slopes or working with a nonlevelled telehandler Fit mobile guards that may increase the wind action and jeopardise the stability of the machine Using telescopic handlers not approved or not manufactured by TEREX Global GmbH in combination with these attachments Attach loads to the boom anywhere other than on the quick coupling frame It is also essential to comply with the natio
11. telehandler and or the equipment directly or indirectly or make it unsafe e contact TEREX Global GmbH Assistance Service for any suggestion and the necessary written permission Part No 57 0303 5193 First Edition First Printing Operator s Manual E REQUISITES OF THE PERSONNEL IN CHARGE E Requisites of the TELEHANDLER OPERATORS The operators who use the telehandler and or the equipment regularly or occasionally shall have the following prerequisites health before and during any operation operators shall never take alcoholic beverages medicines or other substances that may alter their psycho physical conditions and consequently their working abilities physical good eyesight acute hearing good co ordination and ability to carry out all required operations in a safe way according to the instructions of this manual mental ability to understand and apply the enforced rules regulations and safety precautions They shall be careful and sensible for their own as well as for the others safety and shall desire to carry out the work correctly and in a responsible way emotional they shall keep calm and always be able to evaluate their own physical and mental conditions training they shall read and be familiar with this handbook its enclosed graphs and diagrams They shall be skilled and trained about the telehandler and or the equipment use NiCw RIG The operator shall have a licence or a dri
12. using it If before disposal the battery is left in the open air it will be necessary to dry smear the box and the elements with a coat of grease and tighten the plugs Do not rest the battery on the ground it is always advisable to rest it on a pallet and cover it The disposal of batteries shall be as rapid as possible Operator s Manual First Edition First Printing M Intentionally blank page Genie 40 BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual Observe and obey The operator can only perform the routine maintenance operations in this manual Scheduled maintenance procedures shall be completed by qualified technical personnel according to the manufacturer s specifications Maintenance symbol legend The following symbol is used in this manual to Indicates the time interval for the maintenance jobs expressed in working hours Part No 57 0303 5193 Genie BUCKET BASKET 41 Maintenance EE INTRODUCTION A thorough and regular maintenance keeps the machine in a safe and efficient working condition For this reason it is advisable to wash grease and service the machine properly especially after having worked under particular conditions muddy or dusty environments heavy operations etc Always ensure all machine components are in good condition Check for oil leaks or loosening of guards and make sure that the safety de
13. 6 BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual Labels And Plates Applied IDENTIFICATION PLATE Al Y Genie Part No 57 0303 5193 BUCKET BASKET 7 Operator s Manual First Edition First Printing M Intentionally blank page Genie 8 BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual E DAMAGED MACHINE HAZARDS e Do not use a damaged or modified equipment e Do a thorough pre operation inspection of the equipment and test all functions before each work shift Tag and remove from service a damaged or modified equipment e Make sure that all maintenance jobs have been carried out as specified in this manual and in the telehandler s specific manuals e Make sure that all plates are in place and legible e Make sure that the operators manual is intact legible and placed in the special container located in the machine E PERSONAL INJURY HAZARDS e Do not operate the equipment in case of hydraulic oil or air leak of the telehandler Air or hydraulic oil leaks can penetrate or burn the skin e Always operate the telehandler in a well ventilated area to avoid carbon monoxide poisoning e Do not lower the boom if the area underneath is not clear of personnel or obstructions Part No 57 0303 5193 Genie
14. 8 1637 The payload represents the weight of the equipment plus the weight of the handled material i e bricks concrete and so on Genie 50 BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual E Load Charts E BRICK HOLDER BASKET AND CONCRETE BUCKET COUPLED TO GTH 4014 GTH 4014 09 4618 1639 GTH 4014 a D uid Pea 17409876543 24106 9 02 m 13 57 m Fon nr wen anoweo 09 4618 1641 The payload represents the weight of the equipment plus the weight of the handled material i e bricks concrete and so on ATEREX BRAND Part No 57 0303 5193 BUCKET BASKET 51 Operator s Manual First Edition First Printing Load Charts E BRICK HOLDER BASKET AND CONCRETE BUCKET COUPLED TO GTH 4018 19 ae 774 5 17 1 1 16 m Le 15 14 p 13 lo 12 40 y 11 B 10 2 uf a 8 com 7 ON
15. EL v 500L Loading Shovel v 800L Loading Shovel v Brick Holder Basket v 250L Mixing Bucket vy 500L Mixing Bucket v 500L Man Concrete Bucket v 500L Hyd Concrete Bucket v 800L Man Concrete Bucket v 800L Hyd Concrete Bucket E PRODUCT IDENTIFICATION The attachment serial number is located on the serial label e 500L Loading Shovel 59 0201 9009 GT e 800L Loading Shovel 59 0201 9010 GT e 800L Loading Shovel 59 0201 9013 GT e 800L Loading Shovel 59 0201 9008 GT e Brick Holder Basket 59 0401 2013 GT e 250L Mixing Bucket 59 0401 2018 GT e 500L Mixing Bucket 59 0401 2016 GT e 500L Man Concrete Bucket 59 0401 2012 GT e 500L Hyd Concrete Bucket 59 0401 2013 GT e 800L Man Concrete Bucket 59 0401 2014 GT e 800L Hyd Concrete Bucket 59 0401 2015 GT Part No 57 0303 5193 Genie BUCKET BASKET 5 Equipment Identification E APPLICABLE STANDARDS Forthe operator s safety the following standards were obeyed during the risk assessment of the handler fitted with telescopic boom norme Directive Title 2006 42 EC Machinery Directive Standard Title EN 1459 1988 A2 2009 Safety of Industrial trucks Self propelled variable reach trucks E IDENTIFICATION PLATE The data plate is applied on the equipment The identification plate contains model designation serial number weight payload and year of manufacture Operator s Manual First Edition First Printing M Intentionally blank page Genie
16. Genie A TEREX BRAND Operator s Manual Serial number range 500L Loading Shovel from serial n SHOV50014B 1001 800L Loading Shovel from serial n SHOV80014B 1001 Brick Holder Basket from serial n BBSKET14B 1001 250L Mixing Bucket from serial n MXBC25014B 1001 500L Mixing Bucket from serial n MXBC50014B 1001 500L Man Conc Bucket ison s n cCB500MA14B 1001 With Maintenance 500L Hyd Conc Bucket tom sin cB500HY14B 1001 Information 800L Man Conc Bucket jrom s n cBs00ma14B 1001 800L Hyd Conc Bucket irom sin cBs00Hy 148 1001 First Edition First Printing Part No 57 0303 5193 Operator s Manual First Edition First Printing T Contents INtrodUCtiO Minniin Page 3 Equipment Identification 220 Page 5 Labels And Plates Applied Page 7 Safety Precautions eee Page 9 Equipment Description cceee Page 17 INSPOCHONS sic stsncavecsctiznedesascceastoveadesie Page 21 Operating Instructions eee Page 25 Maintenance cccsesceeeesesseeeeeeseens Page 41 LOad Charts cccivccetecects site ssereenctienseseene Page 45 Diagrams And Schemes Page 55 EC Declaration of Conformity Page 57 TEREX Global GmbH Copyright 2014 by Terex Corporation Muhlenstrasse 26 First Edition First Printing August 2014 8200 Schaffhausen Switzerland Genie is a registered trademark
17. Keep the machine handholds and access steps always clean from oil grease or dirt to prevent falls or slips ATEREX ARAND Safety Precautions When entering leaving the cab or other raised parts always face the machine never turn the back When carrying out operations at hazardous heights over 1 5 meters from the ground always use approved fall restraint or fall arrest devices Do not enter leave the machine while it is running Do not leave the driving place when the machine is running Neither stop nor carry out interventions under or between the machine wheels when engine is running When maintenance in this area is required stop the engine Do not carry out maintenance or repair works without a sufficient lighting When using the machine lights the beam should be oriented in order not to blind the personnel at work Before applying voltage to electric cables or components check their connection and proper functioning Do not carry out interventions on electric components with voltage over 48V Do not connect wet plugs or sockets Plates and hazard warning stickers shall never be removed hidden or become unreadable Except for maintenance purposes do not remove safety devices shields protection cases etc Should their removal be necessary stop the engine remove them with the greatest care and always remember to refit them before starting the engine and using the machine again Before
18. WER LINES MOVED oR one TED BEFORE MACHINE OPERATIONS IN POWER LINE VOLTAGE REQUIRED CLEARANCE 0 50 kV 10 ft 300m 50 200 kV 15 ft 460m 200 350 kV 20 ft 610m 350 500 kV 25 ft 762m 500 750 kV 35 ft 10 67 m 750 1000 kV 45 ft 13 72 m A DANGER Do not at any time use the machine during a storm Operator have to survey his her field of vision when operating the telehandler Part No 57 0303 5193 First Edition First Printing Operator s Manual E OPERATION or MAINTENANCE hazards Before any operation following precautions should be taken e First of all make sure that the maintenance interventions have been carried out with care according to the established schedule Set the telehandler to working configuration and level it e Ensure you have enough fuel to avoid a sudden stop of the engine especially during a crucial z manoeuvre e Clean instruments data plates lights and the cab windscreen thoroughly e Check the correct functioning of all the safety devices installed on the telehandler and or on the equipment e In case of troubles or difficulties inform the foreman at once Never start working under unsafe conditions e Do not carry out any repair work in a makeshift way to start working During work and especially maintenance always pay the greatest attention e Donotwalk or stop under raised loads or machine s parts supported by hydraulic cylinders or ropes only e
19. any maintenance or repair work stop the engine and disconnect the batteries Do not lubricate clean or adjust moving parts Part No 57 0303 5193 BUCKET BASKET 13 Operator s Manual First Edition First Printing Safety Precautions e Do not carry out operations manually when specific tools are provided for this purpose e Avoid the use of tools in bad condition or use in an improper way i e pliers instead of adjustable wrenches etc e Applying loads in different points of the attachment holding plate is forbidden Any intervention on the hydraulic circuit must be carried out by authorised personnel The hydraulic circuit of this machine is fitted with pressure accumulators You and others could be seriously injured if accumulators are not completely depressurised For this purpose shut the engine down and step on the brake pedal 8 10 times e Before carrying out operations on hydraulic lines under pressure or disconnecting hydraulic components ensure the relevant line has been previously depressurised and does not contain any hot fluid Do not empty catalytic mufflers or other vessels containing burning materials without taking the necessary precautions e After any maintenance or repair work make sure that no tool cloth or other object has been left within machine compartments fitted with moving parts or where suction and cooling air circulates Genie 14 BUCKET BASKET e When working do n
20. bed above disconnect the hydraulic hoselines of the attachment locking release cylinder from quick couplings 3 e store the removed hoselines in rest position e connect the hydraulic hoselines of the equipment to the quick couplings 3 This hydraulic connection allows the equipment operation that is performed with the controls usually used for locking and releasing the attachments as described in the relative paragraphes Operator s Manual First Edition First Printing Operating Instructions EE STABILITY CONTROL SYSTEM All the telehandlers are equipped with an automatic stability control system which warns the operator of the variation of stability of the machine and blocks any manoeuvre before the same reaches a critical condition A display inside the cabin shows the stability status of the machine and the relative equipment LLMI LLMC HAZARDS The LLMI LLMC will only function to the design specification e when the truck is static e when the truck is on consolidated stable and level ground e when the truck is performing loading or placing functions e when the LLMI LLMC is activated not overridden The LLMI will only warn the operator in the event of inadequate stability in the longitudinal plane in the forward direction The LLMI LLMC is not intended for warning of the risk of overturning in the case of e a sudden overload e travelling with the load in the elevated position e t
21. e shovel for rising or transporting people Part No 57 0303 5193 Genie BUCKET BASKET 35 Operating Instructions E LOADING THE BRICK HOLDER BASKET e Approach the place where the material is stocked e lower the brick holder basket on the ground e open the gate e insert the material e close the gate and secure it through the dedicated Ml pin 1 i Mw py Potential loose objects falling out A DANGER The brick holder basket is designed to handle bricks pallets IT IS NOT A MAN PLATFORM Don t use for rising or transporting people Operator s Manual First Edition First Printing Operating Instructions E LOADING THE CONCRETE BUCKET E LOADING THE MIXING BUCKET e Approach the place where the material is stocked e lower the concrete bucket on the ground e check the discharge door is closed if not move the lever 2 clockwise for the manual version or the joystick for the hydraulic one For the use of this equipment please read the specific manual e introduce the concrete through the top end Genie 36 BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual E TRANSPORTING THE LOADED MATERIAL Once the material is loaded operate as follow e raise the equipment to the transport height of 300 500mm from the ground make sure a load is high enough to clear all objects before starting to move identify any ris
22. ere are two shaped plates welded to its main structure and designed to be mechanically interfaced with the GTH telehandlers standard attachments articulation Genie 18 BUCKET BASKET NICR EC This equipment is coupled to the telehandler through the coupling frame B Part No 57 0303 5193 First Edition First Printing Operator s Manual E CONCRETE BUCKET GENERAL DESCRIPTION The bucket mainly consists of a welded pyramid shaped steel structure designed to handle limited volumes of concrete from one place to another place inside the typical construction working sites and to discharge such volumes of concrete where are necessary This pyramidal structure is open on the top to allow the concrete to be easily loaded and has a section regularly reducing towards the bottom to make easier the discharge of the concrete This latter operation is allowed by a dedicated steel door located on the bottom of the bucket which can be activated by a mechanical lever manually moved by the operator or according to the models selected by a mechanical articulation which is hydraulically operated through the hydraulic auxiliary line available on the top of the boom The overall bucket and door mechanism is installed on a bottom structure having two rectangular hollow shaped steel tubes working as slots for the telehandlers forks The longitudinal movement of the bucket when engaged with the forks is controlled by a chain and a
23. erous manoeuvres Load limiting system general alarm indicator light stays on together with LED L8 which starts flashing representing an alarm code The meaning of these alarm codes is shown in section Faults and Troubleshooting A DANGER Before using the machine make sure that the first green LED of the overload warning system is ON Part No 57 0303 5193 Genie BUCKET BASKET 29 Operating Instructions E MODEL N 2 1 Green LED ON Stability condition The raised load does not exceed 90 of maximum allowed load of the chart in that defined working position 2 Yellow LED ON Pre alarm condition The raised load exceeds 90 of maximum allowed load butitis still inferior to it the boom movements are slow down and the acoustic alarm emits short bips 3 Red LED ON Alarm condition The raised load exceeds the maximum allowed load the acoustic alarm emits long bips and the machine motions are stopped but for those allowing to return the load within safety limits The display of the limiting device is divided into three areas LED s area Three LED s warn of the variation of the working condition 1 green LED machine stable 2 yellow LED machine in pre alarm 3 red LED machine in alarm Control Keys ESC Togo back to the previous screen page ENTER To confirm and open the screen page linked ARROWS To scroll the lines up or down PLUS Additional selection button MINUS Additional selection but
24. es These pages can only be consulted Use the ARROWS to pass from one page to another B LANGUAGE EXTENSION SENSOR ANGLE SENSOR CLOCK LANGUAGE EXTENSION SENSOR ANGLE SENSOR 15 25 42 ENGLISH 10 01 09 FRAN AIS ESPA OL LANGUAGE EXTENSION SENSOR LANGUAGE EXTENSION SENSOR ANGLE SENSOR CLOCK ANGLE SENSOR CLOCK N MIN1 20 MIN2 20 MAX1 1000 MAX2 1000 NI SaN2S 91 3 ZERO1511 ZERO2511 Ni 52 N25 A DANGER Before using the machine make sure that the green LED is ON and that the operating mode shown in line 3 and the attachment shown in line 2 are those actually used BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual E USING THE LOAD CHARTS The load charts 1 indicates the maximum permissible load in relation to the boom extension and the type of attachment used To operate under safe conditions always refer to these charts The extension level of the boom can be checked with the help of the letters A B C D E painted on the same boom pos 3 while the actual degrees of inclination of the boom are shown by the angle indicator 2 Allthe load charts are placed into a dedicated holder installed in the cabin The tag 4 located at the top of each load chart indicates the type of attachment used The load chart illustrated in this chapter is given only as a mere example To define the payload limits refer to the l
25. he irritation persists seek medical advice Intake In case of oil intake do not induce vomiting but seek medical advice Skin Incase of a prolonged contact wash with soap and water Fire In case of fire use carbon dioxide dry chemical or foam extinguishers Do not use water Genie 42 BUCKET BASKET EE ORDINARY MAINTENANCE A wrong or neglected maintenance can result in possible risks for both operator and bystanders Make sure maintenance and lubrication are carried out according to the manufacturer s instructions to keep the machine or the equipmentsafe and efficient The maintenance interventions are based on the machine working hours Regularly check the hour meter and keep it in good conditions to define the maintenance intervals correctly Make sure any damage detected during the maintenance is promptly rectified before using the machine At every use 1 Visually check the equipment for damage before using it 2 Wash with water after use or in case of prolonged inactivity to prevent the mix or residues from hardening 3 Check for oil leaks from hoses and connectors if any 4 Carefully protect the quick connectors once disconnected to prevent impurities from entering the circuit if any 5 Check the chains after every use and replace them if worn or damaged if any Part No 57 0303 5193 First Edition First Printing Operator s Manual EE MAINTENANCE INTERVENTIONS All main
26. irst Printing Operator s Manual EC Declaration of Conformity TEREX Global GmbH hereby declares that the machinery described below complies with the provisions of the following Directives 1 EC Directive 2006 42 EC Machinery Directive The machinery described below is suitable for Genie telehandlers models specified in the user manual Model Type Description Serial Number Manufacture Date Country of Manufacture Manufacturer TEREX Global GmbH Muhlenstrasse 26 8200 Schaffhausen Switzerland European representative Genie UK LTD The Maltings Wharf Road Grantham Lincolnshire NG31 6BH United Kingdom Empowered signatory Place of issue Date of issue Part No 57 0303 5193 Genie BUCKET BASKET 57
27. ks present on the route to be travelled e avoid excessively undulating ground when travelling e consider that when transporting load permissible gradients are 10 downhill 15 uphill 5 side e initiate movements of the load with the lowest available speed e travel at walking speed 1 5 km h A DANGER e Do not allow workers to walk or work under the load e Do not leave the load unattended e Warn all people out of the load area before starting the handling Operating Instructions When driving on a rise with loaded material proceed in forward gear and travel with load in the lowest possible position When sloping downward with loaded mate rial proceed into reverse When driving on a rise with empty shovel proceed into reverse When sloping downward with empty shovel proceed in forward gear EE LOAD LANDING Before a load is lifted a place should be prepared where it is to be put down The nature of the load will determine the type of preparation necessary Genie Part No 57 0303 5193 BUCKET BASKET 37 Operator s Manual First Edition First Printing Operating Instructions E STOPPING and STORING the EQUIPMENT and the TELEHANDLER RICA EIS Lay the equipment on a dry and level ground To release the attachment from the telehandler e Approach the place where you will release the equipment e Lower the e
28. l the tests provided for the telehandler and listed in the machine Operator s Manual H Test the Control Lever 7 Using the control lever momentarily lock and unlock the attachment for those telehandlers with hydraulic cylinder Result All functions should operate smoothly Operator s Manual First Edition First Printing M Inspections E WORKPLACE INSPECTION The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Be aware of and avoid the following hazardous situations e drop offs or holes e bumps floor obstructions or debris e sloped surfaces e unstable or slippery surfaces e overhead obstructions and high voltage conductors e hazardous locations e inadequate surface support to withstand all load forces imposed by the machine e wind and weather conditions e the presence of unauthorized personnel e other possible unsafe conditions Genie 24 BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual Operating Instructions This section provides the operator and the ground staff a practical guide for the gradual learning of the use of the telehandler fitted wi
29. nal safety at work legislation the provisions concerning the safety and health of workers at work and the road traffic regulations NiCR EIS Effecting changes or carrying out interventions on the telehandler and or on the equipment other than those of routine maintenance is expressly forbidden Any modification of the telehandler and or of the equipment not carried out by TEREX Global GmbH or an authorised assistance centre involves the automatic invalidation of the conformity of the machine Operator s Manual First Edition First Printing M Equipment Description E EQUIPMENT APPLICATION FIELD The following table represents the application field of equipment installed on TEREX Global GmbH telehandlers GTH 2506 GTH 4014 GTH 4018 stage 3A stage 3A stage 3A 3B 3B 3B GTH 4016R GTH 4018R GTH 5021R stage 3B stage 3B stage 3B 500 L Loading Shovel 800 L Loading Shovel e e Brick Holder Basket 250 L Mixing Bucket 500 L Mixing Bucket 500 L Manual Concrete Bucket 500 L Hydraulic Concrete Bucket 800 L Manual Concrete Bucket 800 L Hydraulic Concrete Bucket Genie 20 BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual Make sure M You learn and practice the principles of safe machine operation contained in this operator s manual and in the telehandler one 1 Avoid hazardous situations 2 Always
30. nt Operator s Manual First Edition First Printing M Intentionally blank page Genie 44 BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual Load Charts E LOADING SHOVEL AND MIXING BUCKET COUPLED TO GTH 2506 GTH 2506 09 4618 1426 The payload represents the weight of the equipment plus the weight of the handled material i e bricks concrete and so on ATEREX BRAND Part No 57 0303 5193 BUCKET BASKET 45 Operator s Manual First Edition First Printing Load Charts m LOADING SHOVEL AND MIXING BUCKET COUPLED TO GTH 4014 JA fo M GTH 4014 9 8 7 6 5 4 3 2 1 0 4 2 ole 765432106 8 61m C 09 4618 1751 _ GTH 4014 Ao a NWR DN amp O o 10 9 8 76543210 8 55 m 09 4618 1752 The payload represents the weight of the equipment plus the weight of the handled material i e bricks concrete and so on Genie 46 BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual Load Charts LOADING SHOVEL AND MIXING BUCKET COUPLED TO GTH 4018 GTH 4018 70
31. oad charts applied within the cab of your machine Part No 57 0303 5193 Genie BUCKET BASKET 31 Operating Instructions The load charts applied on the cab refer to a stationary machine standing on a solid and level ground The load charts to be used with Man amp Hyd Concrete Bucket Brick Holder Basket are the ones with FORKS GTH 4017 SX iA O A 14 13 1211109 8 76543 214 13 33 m C aan y Operator s Manual First Edition First Printing Operating Instructions EE CONTROLS with the SHOVEL ri GTH 2506 GTH 4014 GTH 4018 controls and Before discharging the material make sure that nobody is within its working range To load unload the material e set the control lever to central position e shift the control lever to position to unload the material e shift the control lever to position to load the material Genie 32 BUCKET BASKET E GTH 4016R GTH 4018R GTH 5021R controls A DANGER Before discharging the material make sure that nobody is within its working range To load unload the material WITH RIGHT JOYSTICK Standard Configuration and with LEFT JOYSTICK Optional Configuration e Set the control lever to central position and press switch B e shift the lever to position to unload the material
32. of Terex South Dakota Inc in the U S A and many other Technical Assistance Service countries GTH is a trademark of Terex South Telephone 39 075 9418129 Dakota Inc 39 075 9418175 e mail UMB Service terex com Genie 2 BUCKET BASKET Part No 57 0303 5193 First Edition First 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 A DANGER Red indicates a hazardous situation which if not avoided will result in death or serious injury AWARNING oange indicates a hazardous situation which if notavoided could result in death or serious injury AACAUTION Yellow indicates a hazardous situation which if notavoided could result in minor or moderate injury NOTICE Blue indicates a hazardous situation which if not avoided could result in property damage attention to important information on environment protection Genie Part No 57 0303 5193 BUCKET BASKET 3 Operator s Manual First Edition First Printing M Intentionally blank page Genie 4 BUCKET BASKET Part No 57 0303 5193 First Edition First Printing Operator s Manual Check that the Operator s Manual refers to the delivered equipment E DESIGNATION v LOADING SHOVEL v BRICK HOLDER BASKET v MIXING BUCKET y CONCRETE BUCKET E MOD
33. oline diesel fuel or other explosive substances Do not refuel the machine with the engine running Refuel the machine and charge the battery only in a well ventilated area away from sparks naked flames and lighted cigarettes Do not operate the machine in dangerous environments or in places with flammable or explosive gases or materials Do not inject ether in engines equipped with glow plugs Do not leave fuel cans or bottles in unsuitable places Neither smoke nor use open flames in areas subject to fire dangers and in presence of fuel oil or batteries Carefully handle all flammable or dangerous substances Do not tamper with fire extinguishers or pressure accumulators Part No 57 0303 5193 Genie Operator s Manual Safety Precautions DAMAGED COMPONENT hazards Do not use battery chargers or batteries with a voltage above 12V to start the engine Do not use the machine as a ground for welding PERSONAL INJURY hazards Do not operate the machine in case of hydraulic oil or air leak Air or hydraulic oil leaks can penetrate or burn the skin Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning Do not lower the boom if the area underneath is not clear of personnel or obstructions BUCKET BASKET 15 Operator s Manual First Edition First Printing M Intentionally blank page Genie 16 BUCKET BASKET Part No 57 0303 5193 First Edition First
34. on tests are designed to discover any malfunctions before the machine is put into service The operator must follow the step by step instructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection and function tests again before putting the machine into service Make sure M You learn and practice the principles of safe machine operation contained in this operator s manual and in the telehandler one 1 Avoid hazardous situations 2 Always perform a pre operation inspection Know and understand the pre operation inspection before going on to the next section 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the telehandler and the equipment as they were intended Part No 57 0303 5193 Genie BUCKET BASKET 23 Inspections E TESTS About the telehandler 1 Select a test area that is firm level and free of obstruction 2 Enter the operator s compartment and sit on the seat io Fasten the seat belt it Adjust all the mirrors 5 Be sure the parking brake is on and the transmission control is in neutral 6 Start the engine Perform al
35. ot give instructions or signs to several people at the same time Instructions and signs must be given by one person only e Always pay due attention to the instructions given by the foreman e Never distract the operator during working phases or crucial manoeuvres e Do not call an operator suddenly if unnecessary e Do not frighten an operator or throw objects by any means e After work never leave the machine under potentially dangerous conditions e Before any maintenance or repair work remove the attachment E MACHINE OPERATION hazards Absolutely avoid the following work situations e Do not handle loads beyond the maximum capacity of the machine e Do not raise or extend the boom if the machine is not on a firm level surface e Do not operate the machine in strong wind Do not increase the surface area of the machine or forked load exposed to the wind Increasing the area exposed to the wind will decrease machine stability e Use extreme caution and slow speeds when the machine is driven across uneven or unstable grounds slippery surfaces or near trenches or drop offs e Limit travel speed according to ground conditions slopes presence of personnel or other factors which may cause collision e Do not place or attach overhanging loads to any part of the machine Part No 57 0303 5193 First Edition First Printing E EXPLOSION OR FIRE hazards Do not start the engine if you smell or detect LPG gas
36. ped tubes and steel grids preventing any debris exceeding small sizes can accidentally drop from the cage when this is operated at height A door is hinged on the right side of the cage to make easier the load and unload of the bricks pallets on from the cage The door can be secured in the closed position by a dedicated latch The overall cage is installed on a bottom structure having two rectangular hollow shaped steel tubes working as slots for the telehandlers forks The longitudinal movement of the cage when engaged with the forks is controlled by a chain and a shackle which must be secured before to start any operation with the cage Q NICA EC This equipment is coupled to the telehandler through the forks slots A Operator s Manual First Edition First Printing Equipment Description E MIXING BUCKET GENERAL DESCRIPTION This bucket is designed to produce limited volumes of concrete by mixing its main components cement aggregates sand and water and to discharge such volumes when the concrete is ready where is necessary in the working sites It mainly consists of a welded concave shaped steel structure designed to gather from ground aggregates cement and sand before the concrete mixing phase is started and then to mix these components with water in order to produce concrete The main components of this welded structure are the front blade which works as
37. perform a pre operation inspection Know and understand the pre operation inspection before going on to the next section 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the telehandler and the equipment as they were intended Part No 57 0303 5193 Genie BUCKET BASKET 21 Inspections 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 performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a telehandler and or with an equipment before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator If damage or any unauthorized variation from factory delivered condition is discovered the telehandler and or the equipment must be tagged and removed from service Repairs to the telehandler and or the equipment may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going on to the function tests Scheduled maintenance inspections shall be performed by qualified
38. quipment on the ground e Stop the engine of the telehandler e Disconnect the hydraulic pipes of the equipment from the boom fittings e Restart the engine e Operate the joystick to release the equipment from the quick coupling plate e Tilt the coupling plate forward and lower the boom to release the upper lock of the equipment e Move back with the telehandler The equipment itself can be handled by means of the telehandler to which it is coupled or by means of machines equipped with forks that have a Suitable rated capacity Genie 38 BUCKET BASKET E Parking for Short Periods Always park the telehandler in a safe way after a working day a shift and at night Take all precautions to prevent damage to those persons who will approach the machine while stationary e Park the machine so that it does not hinder other operations e Put the parking brake e Remove the key from the ignition switch and lock the cab door E Parking for Long Periods In case of extended inactivity of the telehandler and or the equipment follow the above precautions and additionally e Wash the machine thoroughly For a better cleaning remove grills and protection casings Do not use gasoline solvents or other flammable products for cleaning purposes Use only authorized non flammable and harmless solvents Wear safety goggles and a protection mask when you use compressed air In case of washing do not direct the jet of
39. ravelling on rough terrain or on grounds with obstacles and holes e travelling across a slope or turning on a slope e driving in bends too fast or too sharp Adjustments affecting the setting of the LLMI LLMC shall be performed only by authorised personnel Genie 28 BUCKET BASKET The system changes according with the telehandler and can easly be recognized depending on the display fitted into the cabin E MODEL N 1 z ys Genie P A TEREX BRAND L7 L6 L5 _ S 1 Calibration button 2 Stability indicator with LED bar 3 Green light power OK 4 L8 functional led Operation When power is turned on the load limiting system runs a self test e LED bar 2 gradually lights from green to red the display buzzes L8 andthe Load limiting system general alarm indicator light stay on e then LED bar 2 gradually switches off e L8andthe Load limiting system general alarm indicator light switch off During operation the LED bar 2 lights up gradually depending on the variation of stability Alarm codes and resetting The limiter has diagnostic facilities to aid in the identification of failures of the transducers breakages of the cables or malfunction of the electronic system Part No 57 0303 5193 First Edition First Printing Operator s Manual When a failure is signalled the limiter enters the safety mode blocking any dang
40. rotective clothing e Overalls or any other comfortable garments Operators should not wear clothes with large sleeves or objects that can get stuck in moving parts of the machine e Ear protectors or equivalent equipment e Protective helmet e Protective gloves e Working shoes os Use only type approved working clothing in good condition E Personal PROTECTIVE EQUIPMENT Under special working conditions the following personal protective equipment should be used e Breathing set or dust mask e Goggles or facial masks Genie 12 BUCKET BASKET E OTHER DANGERS E Hazards on the JOBSITE Always take into account the features of the job site where you are going to work e Always examine the working area and compare it with the telenandler dimensions in the different configurations A DANGER The telehandler is not electrically insulated and does not provide protection from contact with or proximity to electrical power lines Always keep at a minimum safe distance from the telescopic boom and the lifted load Electrical hazards e Keep away from the machine in case of contact with energized power lines Personnel on the ground must never touch or operate the telehandler until energized power lines are shut off DEATH OR INJURY CAN RESULT FROM CONTACTING ELECTRIC POWER LINES ALWAYS CONTACT THE ELECTRIC POWER LINES OWNER THE ELECTRIC POWER SHALL BE DISCONNECTED OR THE PO
41. service technicians according to the manufacturer s specifications Operator s Manual First Edition First Printing Inspections E PRE OPERATION INSPECTION For the Maintenance and the Pre operation Inspection of the telehandler refer to the specific Operator s Manual presents placed inside the cabin For the equipment e Make sure the operators manuals are intact legible and placed inside the telehandler Make sure all decals are present and legible See Labels And Plates Applied chapter Check for hydraulic oil leaks and proper oil level Top up if necessary See Maintenance chapter Check the following components or zones for damage missing or wrongly fitted parts or non authorised modifications e electrical components and electrical cables e hydraulic hoses and fittings e fuel and hydraulic oil tanks e nuts bolts and other fasteners Check the entire structure for e cracks on welds or structural components e dents or damage to the structure If even one single item is damaged or modified do not start work Stop the machine and repair the fault Genie 22 BUCKET BASKET NICA EC If the machine shall be used in a marine or equivalent environment protect it against salt deposits with an adequate treatment against saltiness to prevent rust formation Part No 57 0303 5193 First Edition First Printing Operator s Manual m FUNCTION TESTS FUNDAMENTALS The functi
42. solid and sheltered site Disconnect the quick connectors of the attachment if any and connect the hydraulic locking pipes of the attachments to couplings 3 Rest the attachment flat on the ground Pitch the attachment holding frame forward and lower the boom to release the attachment upper lock Move back with the machine and drive to the new attachment to be coupled Hold the frame pitched forward and hook the upper lock of the new attachment Retract and raise the attachment some centimetres It will centre automatically on the quick coupling frame Refit pin 1 fixing it with its safety split pin 2 Re couple the connectors of the attachment if any After substitution visually check the attachment is correctly coupled to the boom before operating the machine A wrongly coupled attachment may result in damage to persons or things 26 Genie BUCKET BASKET Rest the attachment flat on the ground Remove the safety pin 2 placed at its end Free the attachment operating the control of the attachment locking unlocking cylinder Pitch the attachment holding frame forward and lower the boom to release the attachment upper lock Move back with the machine and drive to the new attachment to be coupled Hold the frame pitched forward and hook the upper lock of the new attachment Retract and raise the attachment some centimetres It will centre automatically on the quick coupling frame Operate the attachmen
43. t locking lever optional and secure the attachment in place with safety pin 2 previously removed Re couple the connectors of the attachment if any Part No 57 0303 5193 First Edition First Printing Operator s Manual E FOR CONCRETE BUCKET amp BRICK HOLDER BASKET Proceed as follow 1 Adjusting the forks forks shall be spaced to suit the fork slots position For this purpose with FEM forks e Lift the clamping lever of the forks e Slide the forks to the desired position then re lock the lever with FLOATING forks e Loosen the nut of the locking screws e Raise the forks and slide them on the pivot until correct spacing e Lock the screws re tightening the nut Loading phase e Approach the equipment to the load to be handled perpendicularly and check that the machine is level on the inclinometer N Insert the forks in the fork slots and raise the equipment some centimetres Pitch the forks back to retract the load Secure the equipment longitudinal movement by the chain with shackle placed at its back anchoring the equipment to the forks Fork the concrete bucket bearing in mind the side where the product will be unloaded Part No 57 0303 5193 Genie BUCKET BASKET 27 Operating Instructions E CONNECTING THE EQUIPMENT E Hydraulic connection if any To use the equipment these shall be connected hydraulically as follows e after mounting the equipment as descri
44. tenance interventions must be carried out with engine stopped parking brake engaged equipment flat on the ground and gear lever in neutral Any intervention on the hydraulic circuit must be carried out by skilled personnel The hydraulic circuit of the telehandler is fitted with pressure accumulators You and others could be seriously injured if accumulators are not completely depressurised For this purpose shut the engine down and step on the brake pedal 8 10 times Before any operation on hydraulic lines or components make sure there is no residual pressure For this purpose stop the engine engage the parking brake and operate the control levers of the main valve in both working directions alternately to depressurise the hydraulic circuit ATEREX ARAN BUCKET BASKET 43 Part No 57 0303 5193 Maintenance High pressure lines must be replaced by qualified personnel only Any foreign matters entering the closed circuit may result in a sudden deterioration of the transmission The qualified staff charged with the maintenance of the hydraulic circuit must clean all areas around with care before any intervention PROTECT THE ENVIRONMENT The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres NiCw RIG During maintenance or repair works and while welding turn off the disconnected battery switch located into the engine compartme
45. th bucket and basket Both operator and ground staff shall have all the necessary requisites and shall become familiar with both telehandler and equipment before starting Fora safe use of the telehandler with equipment using them f always check the weight of the loads going to This familiarisation ensures a proper use during work be handled Before using the telehandler inspect the job site and check for possible hazardous conditions Make sure that there are no holes moving banks or debris that may cause you to lose the control of the machine A DANGER Pay the greatest attention when working close to electric lines Check their position and ensure that no part of the machine operates at less than 6 meters from the power lines Genie Part No 57 0303 5193 BUCKET BASKET 25 Operator s Manual First Edition First Printing Operating Instructions E CHANGING THE EQUIPMENT E FOR SHOVEL amp MIXING BUCKET Version with MECHANICAL LOCKING To change an attachment operate as follows Drive to the place where you will release the mounted attachment when possible a solid and sheltered site Disconnect the quick connectors of the attachment if any Pull out pin 1 locking the attachment after removing the safety split pin 2 at its end Version with HYDRAULIC LOCKING To change an attachment operate as follows Drive to the place where you will release the mounted attachment when possible a
46. the leading edge of the bucket cutting the material volume and separating the part which is gathered by the bucket itself the central concave shell which provides the volume for the material to be gathered and mixed and the side walls which laterally close the useful volume of the bucket To mix the concrete components a mixing blade made by welded and shaped plates is provided and installed longitudinally to the main axis of the bucket This blade can rotate on bearings installed on the side walls of the bucket and is powered trough a hydraulic motor and a gear box which are located externally of the right side wall of the bucket The concrete after the mixing phase can be discharged through a dedicated door located on the bottom of the bucket and activated through a mechanism and a hydraulic cylinder The mixing blade and the concrete discharge door are hydraulically powered through the hydraulic auxiliary line available on the top of the boom These two functions are controlled by a dedicated radio remote control device which can be operated also by operators working outside of the machine cabin Before the concrete mixing phase is started the top of the bucket must be closed by a dedicated door made by a steel net and hinged on the top of the rear wall of the bucket with the aim of protection against moving parts The net allows the operator to check when the concrete is ready for discharge On the rear area of the bucket th
47. ton Operator s Manual First Edition First Printing Operating Instructions 1 2 3 4 5 6 vi 8 Display which is divided into 8 lines_ fig A 1 Load percentage strip 2 Indicates the attachment used 3 Indicates the operating mode 4 Indicates the max load that can be raised 5 Indicates the weight raised for the system calibration 6 Indicates the boom angle 7 Indicates the boom extension it ll be 0 meters once the boom is fully retracted 8 Indicates the distance of the load from the slewring axis and in case of necessity it displays the related warning message E Operation At the machine starting the overload warning system runs an automatic check and the software datas are displayed Within 3 4 seconds the list of attachments allowed is displayed using the arrows the operator has to select the right attchment and then press ENTER to confirm Once the attachment has been selected the display shows the Standard Screen Page fig A From this screen page pushing PLUS for some seconds the operator can open the UPPER LEVEL B where other four sub menus are displayed one of these LANGUAGE C can be modified while the other three CLOCK D EXTENTION SENSOR E and ANGLE SENSOR F can only be consulted Pressing ESC go back to the Standard Screen Page 30 Genie e Press the two buttons PLUS and MINUS simultaneously to access to the Diagnostic Screen Pag
48. vices are efficient In case of damages find and rectify them before using the machine again Not respecting the ordinary maintenance schedule of this manual automatically voids TEREX Global GmbH warranty NOTICE Effecting changes or carrying out interventions on the telehndler or the equipment other than those of routine maintenance is expressly forbidden Any modification not carried out by TEREX Global GmbH or an authorized assistance centre involves the automatic invalidation of the conformity of the machine to the Directive 2006 42 EC Operator s Manual First Edition First Printing Maintenance EE LUBRICANTS HEALTH AND SAFETY PRECAUTIONS Health A prolonged skin contact with oil can cause irritation Use rubber gloves and protective goggles After handling oil carefully wash your hands with soap and water Storage Always keep lubricants in a closed place out of the children s reach Never store lubricants on the open air and without a label indicating their contents Disposal New or exhausted oil is always polluting Never drain oil on the ground Store new oil in a suitable warehouse Pour exhausted oil into cans and deliver them to specialized firms for disposal Oil leaks In case of accidental oil leaks cover with sand or type approved granulate Then scrape off and dispose of it as chemical waste First aid Eyes In case of accidental contact with the eyes wash with fresh water If t
49. ving licence when provided for by the laws enforced in the country where the machine works Please ask the competent bodies Part No 57 0303 5193 Genie BUCKET BASKET 11 Safety Precautions E Requisites of the SERVICEMEN The personnel charged with the telehandler and the equipment maintenance shall be qualified specialized in their maintenance and shall have the following prerequisites physical good eyesight acute hearing good co ordination and ability to carry out all required maintenance operations in a safe way according to this manual mental ability to understand and apply the enforced rules regulations and safety precautions They shall be careful and sensible for their own as well as for the others safety and shall desire to carry out the work correctly and in a responsible way training they shall read and be familiar with this handbook its enclosed graphs and diagrams the identification and warning plates They shall be skilled and trained about the machine functioning NOTICE From a technical point of view the ordinary maintenance of the telehandler and or the equipment is nota complex intervention and can be carried out by the operator too provided he has a basic knowledge of mechanics Operator s Manual First Edition First Printing Safety Precautions WORKING CLOTHES During work but especially when maintaining or repairing the machine operators must wear suitable p
50. water towards electrical parts e Carefully dry all machine parts by blowing some compressed air e Lubricate the machine thoroughly e Do a walk around inspection and replace any worn or damaged part e Re paint any worn or damaged part e Store the machine in a sheltered and well ventilated place Part No 57 0303 5193 First Edition First Printing Operator s Manual Always remember that the ordinary maintenance must be carried out even during the machine inactivity Pay particular attention to the fluid levels andto those parts subject to ageing Before re starting the machine and the equipment carry out an extraordinary maintenance and carefully check all mechanical hydraulic and electrical components ATEREX ARAN BUCKET BASKET 39 Part No 57 0303 5193 Operating Instructions E DISPOSAL PROTECT THE ENVIRONMENT At the end of the telehandler and or the equipment life call in a specialised firm to dispose of it in compliance with the local or national regulations E BATTERY DISPOSAL PROTECT THE ENVIRONMENT Used lead acid batteries cannot be disposed of as normal industrial solid wastes Because of the presence of harmful substances they must be collected eliminated and or recycled in accordance with the laws of the UE Used batteries must be keptina dry and confined place Make sure the battery is dry and the cell plugs are tight Place a sign on the battery to warn of not
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