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PN 57.0003.5200 - Genie Industries

1. cjBBSEHBHSEBSSREEB Document 57 0003 5200 10 2004 2 108 Genie Handler with telescopic GTH 2506 TE MAINTENANCE D 4 3 12V DC LAMPS Use Voltage Mount type Power Front low high PAST 45 40 Front position lights 2 osse ees BAYS spec ee Side tail turn signals 15s 21 e Stop lights and rear position lights 12 V iuo BAY 15d 21 5 W e Beacon Work lights OPTIONAL esee NAN ER 55 W Dashboard indicators and cab lighting W 2 4 6 1 2 W nterior lamp nnne nnn nnn nnn 12 SV 8 5 8 License plate lights 2 2 iius BA 155 Back up ntn BA 155 CAUTION When switched lamps get hot Before touching a lamp with your fingers let it cool down IMPORTANT Never touch the bulb of halogen lamps mount type H3 with your fingers this may damage the lamp use of a clean cloth or a paper tissue If you touch it accidentally thoroughly clean with a paper tissue and some ethyl alcoho
2. Explanation of the different symbols used on the machine MACHINE IDENTIFICATION eeeeeneeeee rennen Machine model and CODE siete besoin E Machine ideniicanon i em GE e ope Identification plates of the main parte i nm erba Mo UELLE I IE Alowad USS EET ic m stand EH T GENERAL laici vj Listor Ene maini COmpOnertS saisin isinai aii Description Of the Mail componens IEC cel serras aea e ae aior aa TECHNICAL DATA AND PERFORMANCE ETT lal eterna ener Machine sound Iev lS VIRTON EE aR LIFE TIRE cnno EIL ame Literature Supphed e M Page A 1 Document 57 0003 5200 10 2004
3. Tank lines Xel Shutott valve Hydrostatic transmissionpump max displacement 55 cc rev Check valve Oil tank cracking pressure capacity 70 liters nw Screen A 1 2 5 L ig Shutoff valve Heat exchanger Page G 19 Document 57 0003 5200 10 2004 G 5 ROUTINE CHECK SCHEDULE SAFETY DEVICES Block Valve 1 Block Valve 2 Block Valve 3 Block Valve 4 Block Valve 5 Block Valve 6 Block Valve 7 Block Valve 8 Block Valve 9 COMPONENT SAR Display EMERGENCY Joystick button Result Notes Positive Negative JOJO O JOJO JOO Genie Table key explanation Handler with telescopic GTH 2506 TABLES AND DOCUMENTS ENCLOSED Block valve 1 Block valve 2 Block valve 3 Block valve 4 Block valve 5 Block valve 6 Block valve 7 Block valve 8 Block valve 9 Micro 1 Micro 2 Micro 3 Micro 4 Micro 5 SAR Display EMERGENCY Joystick button Block valve on lifting cylinder Block valve on fork balance cylinder Block valve on telescope extension cylinder Block valve on attachment moving cylinder Block valve on attachment lock
4. Handler with telescopic bbom GTH 2506 OPTIONAL ATTACHMENTS F 1 1 SHOVEL Application Quick coupling fitted attachment for moving soil sand debris cereals etc Code GTH 2506 Litres 500 59 0200 0000 Safely Strictly obey the general safety precautions given in section B SAFETY Operation When using a shovel load the material only when the boom is completely retracted and push against the heap with straight wheels To load unload the material operate the rotation lever of the attachment holding plate Maintenance Visually check the shovel for damage before using it Technical data Capacity litres 500 A Width mm 1850 B Length mm 760 H Height mm 700 Weight kg 290 ATTENTION Attachment suitable for moving loose material Do not use for digging operations Page F 3 Document 57 0003 5200 11 2003 Genie Handler with telescopic bbom GTH 2506 OPTIONAL ATTACHMENTS F 1 2 CEREAL SHOVEL Application Quick coupling attachment for loading cereals or inert materials etc Code GTH 2506 Litres 800 59 0200 1000 Safety Strictly obey the general safety precautions given in section B SAFETY Operation When using a shovel load the material only when the boom is completely retracted and push against the heap with straight wheels To load unload the material operate the rotation lever of the attachment holding plate Maintenance
5. Disconnect the quick connectors of the attachment if any and connect the hydraulic locking pipes of the attachments to couplings A Rest the attachment flat on the ground e Pitch the attachment holding frame forward and lower the boom to release the attachment upper lock Move back with the machine or with the boom and drive to the new attachment to be coupled Hold the frame pitched forward and hook the upper lock of the new attachment e Retract and raise the attachment some centimetres It will centre automatically on the quick coupling frame Operate the control lever to lock the attachment Page C 32 Document 57 0003 5200 10 2004 Genie Couple the connectors of the attachment if any to the quick couplings of the frame After the substitution of an attachment or after any coupling operation visually check the attachment Awrongly coupledattachment may result in damage to persons or things Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS 6 TRANSPORTING THE MACHINE C 6 1 MOVING A DISABLED MACHINE Tow the machine only when no alternative is possible since this operation may result in serious damage to the transmission When possible repair the machine on site When the machine shall absolutely be towed e Unlock the negative brake see chap C 6 1 1 Tow the machine for short distances and at a low speed only
6. S i i HOLIMS AON3OH3IN3 i H 9oqu i H H t i H gody H i x H SLAI C 57 szona H i S 90HM 2 i 5 i i gt lt H 2 S L0QH HM 1098 1ON9 90 o 5 A gt 5 N x lt N x lt 1oquina orody vong x gt 9904 i 90N8 HOLIMS NOILINOI Yoon amp ET Ro 6 000 TA e AZL 5 09028 5 13 31 2 A10 HOSN3S 9NI99019 LINN 104109 SNIIV3H3Hd 5 3514 NOILOALOWd WALSAS ISNAIXYN LINN 104LNO9 SNIIV3H3Hd 3ATVA GION310 dOLS 3NION3 3ATVA GION3 108 71903 1VNOLLIQOV WHOIVNH3ETV 19161 33 8915 AH3LIV8 NOLLO3NNOOSIQ Page G 7 Document 57 0003 5200 10 2004 Genie Handler with telescopic boom GTH 2506 TABLES AND DOCUMENTS ENCLOSED G 3 2 2 WIRING DIAGRAM 2 9 30 1 61 E 3 210 1 61 18 15 3 210 GY WHo1 BN GNo1 TQ RDot BN GNo1 1 1 GYWHo1 swo2 OG BKo1 X2 X8 4 8 i i H
7. C 26 Using the load charts C 27 Load IMO sco ri herr Pete B Rd C 28 Description of the controls C 28 lor iis p 28 Alarm codes and resetting C 29 Handing 0 30 Adjusting the forks C 30 Working phases eiii cunis C 31 Changing the attachment C 32 TRANSPORTING THE MACHINE C 33 Moving a disabled machine C 33 Unlocking the negative brake C 33 Road or site transfer C 34 Lifting the machine 35 Transporting the machine on other pna e m EC C 35 Parking and storage C 36 Short Inc elt oce cst C 36 Machine Storage 36 Cleaning and washing the machine 37 Cleaning instructions C 37 Washing instructions C 37 Machine disposal scie reas C 37 Disposal of batteries C 37 Document 57 0003 5200 10 2004 Genie INTRODUCTION This section provides the operator a practical guide for the gradual learning of the machine use The operator should get into the driving cab and carry out the preliminary adjustments then memorise the position of the different controls and instruments The familiarisation with the controls ensures not only a correct use during the working phases but al
8. 109 6 5 a gt gt Log Ra f 1 8 8 5 8 e 1209 103A 1079 01 Loyd 10g 079 01 L08 3A lt 1099 49 VOL 1Oyg N9 GNo1 5 8 5 88 X10 9 2 1 89 6 08 5 A10 31 3 A1 LHOIY SLHOM 4015 1331 SLHOM 4015 uv3d 1331 HOLVOIGNI G 10 Document 57 0003 5200 10 2004 Handler with telescopic boom GTH 2506 TABLES AND DOCUMENTS ENCLOSED Genie G 3 2 5 WIRING DIAGRAM 5 9 6 610 30 30 41010 6 G10 15 15 4 G10 6 F1 6 A10 GN BKot 5 S3HO1IMS HOLON H3HSVM H3dlIM N3389 S QNIM 090107909 X4 1 19nd 3 C1 TQo1 3 F1 TS 3 95 3 YOLOW H3HSVM N33u9 QNIM 9 S 10yg ng S LOHWOLL 5 YOLVOIGNI S1H9I1 LOLA GY RDo1 5 S LOCY AD 9 LOND 8 1098 N9 W GYo1 5 47 W 4 C9 LOLA e 4 LOLA NHOH x G 11 Document 57 0003 5200 10 2004 Handler with telescopic boom GTH 2506 TABLES AND DOCUMENTS ENCLOSED Genie 30 G 3 2 6 WIRING DIAGRAM 6 9 7IA10 31 YOSNAS A N gt
9. The handbook is divided into seven sections Sect GENERAL INFORMATION SAFETY Sect OPERATING INSTRUCTIONS D MAINTENANCE TROUBLESHOOTING Sect OPTIONAL ATTACHMENTS Sect TABLES AND ENCLOSURES Section A contains general concepts that are decisive for the knowledge of the main parts of the machine It also contains all necessary data for a correct identification of the machine the technical features of the machine etc Section B is especially addressed to the personnel who shall operate repair and service the machine and in case of companies with a wide fleet of machines to the safety responsible It describes the essential compulsory qualities of the personnel in charge and other important information for the safety of persons and things Section C is mainly addressed to the operators who operate the machine This section illustrates all control devices Additionally it contains the main use instructions 1 engine starting machine parking machine storing Section D is addressed to the maintenance responsible and the servicemen The section describes the maintenance schedule and the relevant intervals Section E deals with the failure diagnostics Section F makes a list of the main interchangeable attachments that can be coupled to the machine dimensions weight application field and limits of use Section G contains tables and various enclosed documents like
10. Always engage the parking brake after stopping the machine to prevent possible accidental motions of the vehicle Handler with telescopic GTH 2506 OPERATING INSTRUCTIONS C 5 USING THE HANDLER This chapter describes some techniques and provides instructions for a safe use of the machine fitted with standard forks Before using different attachments thoroughly read the chapter Optional attachments CAUTION Before using the machine inspect the job site and check for possible hazardous conditions Make sure that there are no holes moving banks or debris that may cause you to lose the control of the machine 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 CAUTION For a safe use of the machine always check weight of the loads going to be handled Always refer to the load charts applied on the cab windscreen or to the quick guide with the fork capacity ratings Page C 26 Document 57 0003 5200 10 2004 Genie C 5 1 USING THE LOAD CHARTS The charts indicating the maximum permissible load in relation to the boom extension are installed on the cab windscreen and or illustrated in the quick guide The load chart indicates the payload limits of the machine under safe conditions To operate under safe condit
11. Genie Handler with telescopic GTH 2506 GENERAL INFORMATION A 1 CONVENTIONAL REFERENCES A 1 1 MACHINE POSITION Conventionally the machine should be considered positioned as shown in the figure This convention is necessary to make any reference of this handbook to different machine parts front rear etc clear and unmistakable Any exception to this rule will always be specified UPPER PART RIGHT SIDE FRONT PART LOWER PART Page A 2 Document 57 0003 5200 11 2003 irs REAR PART LEFT SIDE Genie Handler with telescopic GTH 2506 GENERAL INFORMATION 1 2 LABELS AND WARNING PLATES APPLIED ON THE MACHINE This paragraph lists the labels and warning plates normally applied on standard machines or on special attachments coupled to the machine IMPORTANT The familiarisation with these labels is never a waste of time Make sure they are easy to read For this purpose clean them or replace those that become unreadable either graphic or text To clean labels use of a soft cloth water and soap Never use solvents petrol etc When a label is applied on a part to be replaced make sure that the replaced part is already labelled as required or apply a new label Description Printed on PVC it guides the operator through the task of learning the main functions of the handler Meaning An overview of the operator s handbook concerning control lever
12. H ae Hi H a H Es T 1 2 O z 85 87A i Kos H K02 86 30 86 30 H lt H 5 p g 5 5 2 6 5 8 5 5 M 8 1 5 OG GNo1 5 GYMWHo1 d 1 F7 8001 88 4 F5 6 D7 RD BK 1 1 E2 9 C7 1 5 5 8 o 01 1 OG BKo1 H03 Y04 1 1 1 1 M 31 6 2 3 A10 Q 5 az 5 83 a gt gt aa Sz 5 5 2 3 Zu m ao lt x je ae 3 cz gu T ay cc ge a e G 8 Document 57 0003 5200 10 2004 Handler with telescopic boom GTH 2506 TABLES AND DOCUMENTS ENCLOSED Genie G 3 2 3 WIRING DIAGRAM 3 9 2 0 2 61 1009 04 Si j e X L0948 HM 5 X 2 008 4 A10 30010 30010 HOLIMS HOIVOIGNI AON39H3W3 YOLVOIGNI 1 3ON3LLIINH3 LNI Page G 9 Document 57 0003 5200 10 2004 Handler with telescopic boom GTH 2506 TABLES AND DOCUMENTS ENCLOSED Genie G 3 2 4 WIRING DIAGRAM 4 9 30 30 3610 5 010 N gt mE 1048 01 C 3 01 1 5 5 g 5 5 gt 5 lt e x 1034 e e 10983 LO 1034 e E e 1034 193A C sagr
13. machine starting overload warning system main safety precautions and including the fork load charts with or without use of the outriggers Location in the cab fixed to the upright with a magnet Not present in the TCE version GUIDA RAPIDA PER L USO P lt F Wz 2506 w 6 Ow J 0 2 2 aj AVVIAMENTO DELLA MACCHINA USO DELLE LEVE DI COMANDO Posizionare il selettore marce ed il cambio meccanico Premere sempre il pulsante di comando intenzionale Ell prima folle di eseguire un comando Inserire il freno di stazionamento e controllare 5 Abbassamento sollevamento del braccio azionare leva che la spia sia accesa il motore ruotando il commutatore di avviamento in posizione e mantenerlo fino allo 2 spegnimento della spia Ruotarlo e quindi in posizione 3 per l avviamento del motore Qualora dopo circa 20 secondi l awviamento del motore non avesse luogo rilasciare la chiave ed attendere circa due minuti prima di tentare un nuovo avviamento in direzione Brandeggio indietro avanti dell attrezzo terminale azionare la leva in direzione Richiamo sfilo del braccio telescopico premere il pulsante sulla leva ed azionare la leva di comando in direzione Blocco sblocco attrezzi premere il pulsante ed az
14. 4 no m B i o F20 rl d N a 09 31 3l 8 A10 9 4 E 5 5 5 gg 5 lt lt zo lt lt 22 5 lt ES uma ig 2 25 B 2 2 5 8 a na lt 9 2 G 13 Document 57 0003 5200 10 2004 9 210 9 210 9 A10 31 30 15 YE GNo1 5 3 5 12 Handler with telescopic GTH 2506 TABLES AND DOCUMENTS ENCLOSED YE BKo1 5 X10 gt lt LE son x 00 lt c Genie e E vOl e Si 9HW1A C X15 gt lt lt 51 14 15 o X15 BN BKo1 7 08 X16 8 91 11 1 15 30 15 31 RD BKot G 3 2 8 WIRING DIAGRAM 8 9 11010 11010 GIES 1VNOILdO HOLIMS 938 GION3 10S QN31X3 GION310S 133539 AAA GION310S 3574784 ANIN3HOVLLV HOLIMS 1 5 G 14 Document 57 0003 5200 10 2004 Genie Handler with telescopic GTH 2506 TABLES AND DOCUMENTS ENCLOSED 3 2 9 1 WIRING DIAGRAM 9 9 valid up to serial 10739 30 8 G10 8 0910 15 15 DISLPA
15. A Genie A TEREX COMPANY OPERATOR HANDBOOK Cod 57 0003 5200 Rev 4A 05 2007 Handler with telescopic boom GTH 2506 From serial number 17106 Eng To serial number 18956 Edition CAUTION KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES CAUTION THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE Genie EUROPEAN TECHNICAL SERVICES GENIE FRANCE GENIE SCANDINAVIA 10 Z A de la Croix Saint Mathieu Tagenevagen 72 28320 Gallardon 425 37 Hisings Karra France Sweden Tel 0033 0 2 37 26 09 99 Tel 0046 315 751 00 Fax 0033 0 2 37 26 09 98 Fax 0046 315 790 20 GENIE GERMANY GENIE UK Finienweg 3 The Maltings 28832 Achim Bremen Wharf Road Germany Grantham Tel 0049 0 4202 8852 0 Lincs NG31 6BH Fax 0049 0 4202 8852 20 United Kingdom Tel 0044 0 1476 584333 GENIE IBERICA Fax 0044 0 1476 58433 Gaia 31 Poligono Industrial Pla d en Coll 08110 Montcada i Reixac Barcelona Spain Tel 0034 93 579 5090 Fax 0034 93 579 5091 Operator Handbook 57 0003 5200 GTH 2506 All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means without prior written permission from TEREXLIFT srl In pursuing a policy of constant quality improvement TEREXLIFT srl reserves the right to make changes at any time and without undertaking to give prior notice therefore also this publication may be sub
16. G 16 G 3 3 General wiring diagram G 17 G 4 1 PAUP m G 18 G 5 Routine check schedule Safety devices G 20 Page G 1 Document 57 0003 5200 10 2004 Genie Handler with telescopic bbom GTH 2506 TABLES AND DOCUMENTS ENCLOSED G 1 TORQUE WRENCH SETTINGS Document 57 0003 5200 11 2003 Dxp Pre loading N Torque wrench setting Nm 4 8 8 8 10 9 12 9 4 8 8 8 10 9 12 9 M4x0 7 1970 3930 5530 6640 1 5 3 1 4 3 5 2 5 0 8 3180 6360 8950 10700 3 6 8 5 10 1 M6x1 4500 9000 12700 15200 5 2 10 4 14 6 17 5 M 8 x 1 25 8200 16400 23100 27700 12 3 24 6 34 7 41 6 M8x1 8780 17600 24700 29600 13 26 36 6 43 9 M 10 x 1 5 13000 26000 36500 43900 25 1 50 1 70 5 84 6 M 10 x 1 25 13700 27400 38500 46300 26 2 52 4 73 6 88 4 M 12 x 1 75 18900 37800 53000 63700 42 4 84 8 119 143 M 12 x 1 25 20600 41300 58000 69600 45 3 90 6 127 153 14 2 25800 51500 72500 86900 67 4 135 190 228 14 1 5 28000 56000 78800 94500 71 7 143 202 242 M 16x2 35200 70300 98900 119000 102 205 288 346 M 16 x 1 5 37400 74800 105000 126000 107 214 302 362 M 18x 2 5 43000 86000 121000 145000 142 283 398 478 M 18 x 1 5 48400 96800 136000 163000 154 308 434 520 M 20x 2 5 54900 110000 154000 185000 200 400 562 674 M 20 x
17. OPERATING INSTRUCTIONS C 3 DRIVING PLACE C 3 1 CONTROLS AND INSTRUMENTS a MEE a Dashboard Water level Brake oil tank Ignition switch Turn signals windscreen wiper horn switch Fuse compartment Forward reverse speed selection lever Brake pedal Steering column locking lever Hazard lights switch Steering selection switch Road light switch Gas pedal Overload warning system display Fresh air flap Emergency stop button Pushbutton enabling the attachment coupling release Control lever Negative brake on off switch Road Jobsite switch Cab heater cock Optional attachment switch with built in green lamp if any Air conditioning fan switch Storage tray Windscreen water reservoir Seat Storage pocket Warning light glow plugs preheating Warning light air filter clogged Load limiter disabling key Page C 7 Document 57 0003 5200 10 2004 Genie Handler with telescopic boom GTH 2506 a _ OPERATING INSTRUCTIONS 1086 4 2024 6 8 49 0 8 6 2 2 9 2 4 6 61 10 17 11 12 13 8 Document 57 0003 5200 10 2004 OPERATING INSTRUCTIONS Genie Handler with telescopic bbom GTH 2506 Te 3 2 E
18. INSTRUMENT 6 SYSTEM 9 P02 ENGINE OIL TEMPERATURE 06 SOLENOID VALVE OVERLOAD WARNING TRANSDUCER 6 SYSTEM 9 PO3 ENGINE OIL COOLING TEMPERATURE YO7 ENGINE STOP SOLENOID 1 INDICATOR 6 08 WHEEL STEERING SOLENOID VALVE 7 YO9 WHEEL STEERING SOLENOID VALVE 7 R01 GLOW PLUGS 1 Y10 SOLENOID VALVE ATTACHMENT COUPLING RELEASE 8 SWO 1 IGNITION KEY 1 Y11 SOLENOID VALVE DEADMAN 8 SW02 PARKING BRAKE SWITCH 2 Y12 SOLENOID VALVE BOOM EXTENSION 8 SW03 CHANGEOVER OVER SWITCH 1 SW04 MUSHROOM HEAD BUTTON 1 12V BATTERY 1 SWO05 HAZARD WARNING LIGHT TURN A02 PREHEATING CONTROL UNIT 1 SIGNALS SWITCH 3 A08 TURN SIGNALS FLASHING 3 SWO06 LIGHT SWITCH TURN SIGNALS A04 DIODE 3 WINDSCREEN WIPER WASHER 5 A05 DIODE 3 SWO7 LIGHTS SELECTION SWITCH 5 A06 DIODE 7 5 08 STEERING SELECTOR 7 N07 DIODE 7 SWO9 HEATING FAN SWITCH 7 SW10 ROAD SAFETY SWITCH 7 01 4 WAY CONNECTOR ENGINE FUSES LINE SW11 ROAD SAFETY SWITCH 8 4 WAY CONNECTOR STEERING COLUMN SW12 OPTIONAL WORK LIGHT SWITCH 8 6 WAY CONNECTOR SW13 BATTERY CUTOFF 1 X04 6 CONNECTOR STEERING COLUMN SW14 JOYSTICK 8 05 12 WAY CONNECTOR STEERING COLUMN X06 12 WAY CONNECTOR ENGINE 5501 HYDRAULIC STOP 2 X07 15 WAY CONNECTOR STEERING COLUMN SS02 AIR FILTER CLOGGING SENSOR 1 X08 15 WAY CONNECTOR ENGINE 03 WATER TEMPERATURRE SENSOR 6 X09 9 WAY CONNECTOR ENGINE 04 ENGINE OIL PRESSURE TRANSDUCER 6 X10 12 WAY CONNECTOR STEERING COLUMN 5505 NEGATIVE BRAKE PRESSURE SWI
19. SAFETY e Do not load loose materials e not move superposed pallets Operation To adjust the tilting operate the rotation lever of the attachment holding plate To side shift operate the attachment locking lever after connecting the feeding lines of the new attachment to the quick couplings See page F 2 Maintenance Visually check the attachment for damage before using it Check for hydraulic oil leaks Daily grease the joints using a greasing gun and smear the sliding guides with graphitized grease Machine GTH 2506 Code 59 0600 0000 Technical data Payload kg 2600 Width mm 1240 Length mm 1600 Height with protection mm 1000 Weight kg 180 Stroke mm 100 Fork attachments FEM 2 Page F 8 Document 57 0003 5200 11 2003 Genie 17 FORK WITH JAW Handler with telescopic GTH 2506 TE OPTIONAL ATTACHMENTS Machine GTH 2506 Fork with jaw 59 1300 1000 Application Interchangeable quick coupling attachment for loading and handling manure shrubs and other loose agricultural products Safety Strictly obey the general safety precautions given in section B SAFETY Operation To adjust the fork tilting operate the rotation lever of the holding plate For loading operations act on the locking lever after connecting the feeding lines of the new attachment to the quick couplings see page F 2 Ma
20. e Use rigid drawbar e Select two wheel steer e Set the gearbox lever to neutral e When possible start the engine and use the hydraulic drive and the braking system e Raise the front wheels of the machine and remove the Cardan shaft of the transmission C 6 1 1 Unlocking the negative brake To unlock the negative brake of a faulty machine proceed as follows e Loosen the two opposite screws located on the front axle in order to remove the washers e Remove the horseshoe shaped washers located under the two screws e Re tighten screws turning alternately the front screw and the rear screw 1 2 turn to unlock the brake To relock the brake loosen the screws turning alternately the front screw and the rear screw 1 2 turn refit the horseshoe washers and re tighten screws Page C 33 Document 57 0003 5200 10 2004 Genie Handler with telescopic bbom GTH 2506 OPERATING INSTRUCTIONS 6 2 ROAD OR SITE TRANSFER When travelling on public roads strictly obey the local or national road traffic regulations Besides take into account the following general precautions e Align the rear wheels e Select the two wheel steer e Set the ROAD JOBSITE switch 20 to ROAD the light on the pushbutton comes on e Lock the machine as indicated in the Registration Card Lock the boom sections the lifting cylinder and the attachment rotation cylinder see photo e Cover
21. enough space to operate the boom e Put the parking brake and set the transmission to neutral e Position the load some centimetres above the desired position and set the forks level e Lower the load and make sure it is level Carefully withdraw the forks by operating the boom retraction control and if necessary raise or lower the boom as forks come out Handler with telescopic GTH 2506 OPERATING INSTRUCTIONS irs e When the forks are clear of the load set them to transfer position e Release the parking brake and start a new working cycle Do not move off when the load is raised 20 30 above the ground Risk of machine overturning or load fall Page C 31 Document 57 0003 5200 10 2004 Genie Handler with telescopic bbom GTH 2506 OPERATING INSTRUCTIONS CAUTION 5 4 CHANGING THE ATTACHMENT After substitution visually check the attachment is ATTENTION correctly coupled to the boom before operating Use only attachments directly manufactured or the machine A wrongly coupled attachment Optional attachments section 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
22. optional work light Road jobsite selector switch Lifting point Fuel plug Engine oil filler Engine oil dipstick Page A 9 Document 57 0003 5200 10 2004 Genie 2 MACHINE IDENTIFICATION IMPORTANT Check that the operator handbook refers to the delivered machine When asking for information or technical assistance always specify model type and serial number of the machine A 2 1 MACHINE MODEL AND Handler with telescopic boom model GTH 2506 A 2 2 MANUFACTURER TEREXLIFT srl Zona Industriale Ind Estate 06019 UMBERTIDE PG ITALY Enrolled in the register of companies at the Court of Perugia under no 4823 C C I A A n 102886 Fiscal Code V A T no 00249210543 W A 2 3 MACHINE IDENTIFICATION PLATES Three identification plates are applied on the machine They are Machine data plate Placed on the driving seat base in a well visible position when opening the cab door Fig A8 or instead of the road traffic data plate Fig A10 on machines destined for foreign markets The identification plate Fig A9 contains the main identification data of the machine like model serial number and year of manufacture ROPS FOPS cab type approval plate Placed on the driving seat base in a well visible position when opening the cab door Fig A8 Handler with telescopic boom GTH 2506 GENERAL INFORMATION TEREXUI d TEREXLIFT srl Z
23. 1 5 60900 122000 171000 206000 216 431 607 728 22 x 2 5 67900 136000 191000 229000 266 532 748 897 22 x 1 5 74600 149000 210000 252000 286 571 803 964 24x3 79100 158000 222000 267000 345 691 971 1170 24 2 86000 172000 242000 290000 365 731 1030 1230 M27x3 103000 206000 289000 347000 505 1010 1420 1700 M27x2 111000 222000 312000 375000 534 1070 1500 1800 M 30x 3 5 126000 251000 353000 424000 686 1370 1930 2310 30 x 2 139000 278000 391000 469000 738 1480 2080 2490 IMPORTANT Sensor maximum driving torque 15 Nm Page G 2 Genie Handler with telescopic bbom GTH 2506 TABLES AND DOCUMENTS ENCLOSED 2 1 LOAD CHART WITH FORKS GTH 2506 GTH 2506 From serial no To serial no 15272 Page G 3 Document 57 0003 5200 11 2003 Genie Handler with telescopic bbom GTH 2506 TABLES AND DOCUMENTS ENCLOSED G 22 LOAD CHART WITH FORKS GTH 2506 GTH 2506 From serial no 15273 To serial no XXXXX Page G 4 Document 57 0003 5200 11 2003 Genie G 3 1 WIRING DIAGRAM FUSES AND RELAYS Ref F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 221 222 223 224 225 226 227 228 229 Circuit Power supply interior lamp emergency switch turn signals 30 Power supply K04 relay Optional Front right rear left position lights license plate lights position lights indicat
24. 5 3 2 coupling relBase sesiones 12 5 4 C 3 2 7 Steering mode selection C 12 C 6 C 3 2 8 Road Jobsite switch C 12 C 6 1 C 3 2 9 Auxiliary drive controls C 13 C 6 1 1 C 3 3 Instruments and light indicators C 14 C 6 2 C 3 3 1 Instruments C 14 C 6 3 3 3 2 Light indicators C 14 C 6 4 C 3 4 Control lever C 15 C 3 41 Function selection C 16 C 6 5 C 3 4 1 1Function selection version C 17 C 6 5 1 C342 Emergency Stop eene C 18 C 6 5 2 C 3 4 2 1Disabling the overload warning system C 18 C 6 6 C 3 4 3 Lifting lowering the boom C 19 C 6 6 1 C 3 4 4 Pitching the attachment holding frame C 6 6 2 forward Dack neni m eres C 20 C 6 7 C 3 4 5 Extending retracting the boom C 21 C 6 7 1 Page C 1 Quick coupling the attachments C 22 SETUP aa eniro EH C 23 Before starting the engine C 23 Checks at the machine start up C 23 Starting the engine C 23 Jump starting the engine C 24 Low temperature starting C 25 Disconnecting the battery C 25 Starting the machine C 25 Stopping and parking the machine C 26 USING THE HANDLER
25. 5 bar P1 activating pressure 2 8 6 3 bar Forks attachment quick coupling cylinder Emergency brake i iti minimum pressure Quick coupling 3 ways 2 postions Ev6 GHCDEF Ev7 pressure switch hydraulic ports lockout telescoping out 1 Rear axle E pressure 2 Boom functions n i piloting selector valve steering cylinder BLA kt i 8 ways 3 positions m HT Steering mode 3 2 selector valve 4 ways 3 positions T Forks levelling 5 7 Hydraulically piloted slave cylinder double check valve 1 lol 5 piloting ratio 4 1 Front axle Anti shock steering cylinder valves Accumulator Single overcenter safety valve cracking capacity piloting ratio 4 2 1 pressure 0 5 liters cracking pressure 350 bar 225 bar precharge pressure 5 0 mM L R L Anticavitation valves ___ p 1 cracking pressure 1 5 15 Steering rotating actuator 1 displacement 125 1 IL 7 L 1 4 3 ways 2 positions Ev8 selector valve lockout boom down P relief valve E cracking d l Boom functions hydraulic 4 circuit test port H Q Single overcenter safety valve P 170 bar piloting ratio 4 2 1 TP crackin
26. AG Model Type F4M 2011 Features Diesel 4 cylinders in line 4 strokes direct injection Bore x Stroke mm 94 x 112 Total displacement 3108 A Power at 2600 rpm ISO 3046 IFN kW 46 5 B A 5 8 ELECTRICAL SYSTEM Voltage V 12 Battery Ah 100 B A 5 9 MACHINE SOUND LEVELS Guaranteed sound power level in accordance with the Directive 2000 14 CE dB Lwa 103 E Measured sound pressure level in accordance with the Directive 98 37 CE dB A 5 10 VIBRATION LEVELS Mean assessed vibration level transmitted to arms m s 2 5 Mean assessed vibration level transmitted to body m s 0 5 Values calculated in accordance with standard prEN13059 IMPORTANT This is a device of Class A In a residential environment such device can cause radio disturbance In such cases the operator is required to take suitable measures Page A 19 Document 57 0003 5200 10 2004 Genie 6 LIFETIME The lifetime of the machine is 10 000 hours provided all checks service jobs and overhauls are done at the times scheduled After this time the machine must compulsorily be inspected and tested by the Manufacturer before being used again Handler with telescopic boom GTH 2506 GENERAL INFORMATION Following items are supplied together with the machine 7 ITEMS SUPPLIED Description GTH 2506 Spanner CH 19 X for fork positioning Allen wrench CH 6 X for fork posi
27. LONS AD _____ LOND AQ C E 39nv5 Log 3unive3diaL 110 1Oyg 3A 108 04 YOSNAS 3unuvdadWal 110 e LOND CY T 108 39nv9 IO 4 108 103A 5 x le TAL H LIMS 3unss3ud 3 vu8 3ALIVO3N 2 108 Xo Pr ES NHM e o 5 Ex g C d _ 0yd 10y8 3A g LOND 7 LOHWAS 2 Loyg 10747903 193A A9 103 9 103A 0 PAIR So 1 u3onasNvuL LOGH AD 0Qu A9 39055399 110 Lequ ng E e e w gt Pa o 5 2 Eo 5 miu 8 8 TT 5 m c n Bg E Qo HOSN3S OND HM 72 YOLVOICNI b 1 QuvoaHsva 31 5 1 Page G 12 Document 57 0003 5200 10 2004 Genie Handler with telescopic GTH 2506 TABLES AND DOCUMENTS ENCLOSED G 3 2 7 WIRING DIAGRAM 7 9 6 810 8 G10 6 G10 15 7 5 8 G10 1 X5 8 7 1 BN BKot 93 5 09 1 YE BKo1 1 WH BKo1 5 OG GNo1 BU RDot 5 OG GNo1 XT 6 BU RDo1 5 PK BUo1 eee
28. NUMBER The chassis serial number is punched on the front left part of the chassis side member 6 Fig A10 A 2 6 IDENTIFICATION PLATES OF THE MAIN PARTS The plates of the main components not directly manufactured by TEREXLIFT srl for instance engines pumps etc are located where originally applied by the manufacturers Fig A10 Page 11 Document 57 0003 5200 10 2004 Genie 3 ALLOWED USE A 3 1 ALLOWED USE The handlers have been designed and manufactured for lifting handling and transporting agricultural or industrial products by means of specific attachments see section F manufactured by TEREXLIFT srl Any other use is considered contrary to that established and therefore improper The compliance with and the strict respect of the operation maintenance and repair conditions indicated by the Manufacturer represent an essential part of the allowed use The handler must be used and serviced only by operators knowing its characteristics and the safety procedures in depth It is also essential to comply with the safety at work legislation the precautions concerning safety and industrial medicine as well as the local and national road traffic regulations IMPORTANT Effecting changes or carrying out interventions on the machine other than those of routine maintenance is expressly forbidden Any modification of the machine not carried out by GENIE or an authorised assistance
29. Visually check the shovel for damage before using it Technical data Capacity litres 800 A Width mm 1850 B Length mm 800 H Height mm 1150 Weight kg 350 ATTENTION Attachment suitable for moving loose material Do not use for digging operations Page F 4 Document 57 0003 5200 11 2003 OPTIONAL ATTACHMENTS Genie Handler with telescopic bbom GTH 2506 TE F 1 3 FIXED HOOK ON PLATE Application Quick coupling fitted attachment for lifting loads by means of special slings Payload Code GTH 2506 2500 kg 59 0700 0000 ate MEME Strictly obey the general safety precautions given in section B SAFETY Do not oscillate the load Do not drag hooked loads Lift the load before extending the boom Operation Fork the hook and hold it in position by means of the locking cylinder All loads must be bridled with special textile slings or chains in compliance with all pertinent regulations To handle the load raise and rotate the telescopic boom of the handler Maintenance Visually check the hook for damage before using it Check the safety catch is in good working order Technical data Payload kg 2500 Width mm 920 Length mm 615 Height mm 500 Weight kg 120 IMPORTANT Make sure this attachment can be used in the destination country of the machine In Italy this attachment must be enrolled at ISPESL and submitted to yearly test Application must be subm
30. brake circuit reservoir brake selector valve ways 2 positions Ev5 1 Pressure reducing valve setting pressure 28 bar Service brake DR pedal pump max operating Boom functions control lever X ji Double overcenter safety valve Boom lit cylinder piloting ratio 4 2 1 Boom telescoping cylinder cracking pressure 350 bar pressure 80 bar gi X Piloting lines ils hydraulic collectors 1 Front axle Ee Parking emergency R Double overcenter safety valve brake control valve P2 350 b orifice dia 0 5 Service brake i cracking pressure ar cracking pressure pressure switch Forks tilt cylinder 0
31. by a skilled technician 8 Change the main cartridge of the engine air filter 9 Cleanorreplace if nececessary the air filter in the cab Every 1000 working hours or yearly Jobs to be done in addition to those above 1 Changetheoilinthefront and rear differential units and in the power divider 2 Change the oil in the four wheel reduction gears 3 Change the hydraulic oil 0 21 CHANGE SCHEDULE operating service Oil type hours interval Oil level check 10 daily SHELL RIMULA 15W 40 First change 50 Subsequent changes monthly Axles and Oil level check monthly FUCHS TITAN GEAR LS 85 W 90 peau First change GL 5 LS GL 5 divider Subsequent changes 1000 yearly Hydraulic Oil level check monthly SHELL TELLUS T 46 on Subsequent changes 1000 yearly DENISON HF 1 DIN 51524 part 3 Cat HV whichever occurs first D 4 Document 57 0003 5200 11 2003 Genie 0 3 MAINTENANCE JOBS All maintenance interventions must be carried out with engine stopped parking brake engaged working attachments flat on the ground and gear lever in neutral CAUTION When raising component for maintenance purposes secure it in a safe way before any maintenance intervention CAUTION Any intervention on the hydraulic circuit must be carried out by skilled personnel The hydraulic circuit of this machine is fitted with pressure accumulators You and others could be ser
32. its motion axis Such unbalances may also be caused by an abrupt operation of the levers during the load handling If during work several indicators light up operate the levers more smoothly Handler with telescopic GTH 2506 OPERATING INSTRUCTIONS The limiter has diagnostic facilities to aid in the identification of failures of the transducers breakages of the cables or defects of the electronic system When a failure is signalled the limiter enters the safety mode blocking any dangerous manoeuvres Lights 5 8 and 10 start flashing the buzzer start sounding and an error message is shown on the display The meaning of the error messages is shown in Section E Faults and Troubleshooting C 5 2 3 Alarm codes and resetting 4 9 420 29 Document 57 0003 5200 10 2004 OPERATING INSTRUCTIONS Genie Handler with telescopic bbom GTH 2506 TE C 5 3 HANDLING LOADS C 5 3 1 Adjusting the forks VN CAUTI O N Forks shall be spaced to suit the load going to be handled For this purpose e The centre of gravity of the load must always be halfway between the forks e Lift the clamping lever of the forks e Ensure you exactly know the weight of the load e Slide the forks to the desired position then re lock before handling it the lever When extending the boom do not exceed the payload limit e Refer to the payload limits give
33. operation the led bar 3 lights up gradually depending on the variation of stability Green LED s during normal operation when the percentage of overturning moment is between 0 and 89 these LED s are ON The machine is stable Yellow LED s they light up when the machine tends to overturn and the percentage of overturning moment with respect to the threshold value is between 90 and 100 The system enters the pre alarm mode light 10 flashes and the buzzer sounds with an intermittent sound Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS Toler Red LED s risk of overturning the percentage of overturning moment is above 100 with respect to the threshold value The machine enters the alarm mode light 10 is lit the buzzer sounds continuously and any dangerous manoeuvre is blocked The operator can only retract the load within safety limits Example of use of the stability indicator Boom extension Overload warning system in alarm Y Boom retraction Alarm ceases Y Reduction of the load to be handled Page C 28 Document 57 0003 5200 10 2004 Genie Before using the machine make sure that the first green LED of the overload warning system is ON The overload warning system must not be used to check the load going to be lifted it has only been designed to signal possible unbalances of the machine along
34. periodically check its charge level Refuel the tank to prevent internal oxidation Store the machine in a sheltered and well ventilated place e Start the engine for about 10 minutes at least once a month When weather is particularly cold empty the radiator IMPORTANT Always remember that the ordinary maintenance must be carried out even during the machine inactivity Pay particular attention to the fluid levels and to those parts subject to ageing Before re starting the machine carry out an extraordinary maintenance and carefully check all mechanical hydraulic and electrical components Page C 36 Document 57 0003 5200 10 2004 Genie 66 CLEANING AND WASHING THE MACHINE C 6 6 1 Cleaning instructions Clean the machine in accordance with the following instructions Remove any oil or grease traces with a dry solvent or a volatile mineral alcohol Before assembling a new part remove any protection product rust preventer grease wax etc Remove any trace of rust from metal parts with some emery cloth before smearing the part with a protection product rust preventer paint oil etc C 6 6 2 Washing instructions External washing Before washing the machine check that the engine is shut down and the doors and windows are closed Do not at any times use fuel to clean the machine Use water or some steam In cold climates dry the locks after washing or smear
35. telescopic boom GTH 2506 TABLES AND DOCUMENTS ENCLOSED G 3 3 GENERAL WIRING DIAGRAM description Ref Description Sheet Ref Description Sheet F1 POWER SUPPLY INTERIOR LAMP F21 POWER SUPPLY BEACON 8 EMERGENCY SWITCH F22 ENGINE STOP MUSHROOM HEAD TURN SIGNALS 30 9 BUTTON POWER SUPPLY 1 F2 POWER SUPPLY K04 RELAY 9 23 POWER SUPPLY RELAY 2 1 F3 OPTIONAL 9 F24 RELAY K06 POWER SUPPLY 2 F4 FRONT RIGHT REAR LEFT POSITION F25 PARKING BRAKE SWITCH LIGHTS LICENSE PLATE LIGHTS POWER SUPPLY 2 POSITION LIGHTS INDICATOR 26 OPTIONAL ENGINE OIL TEMPERATURE INDICATOR 4 F27 OPTIONAL F5 FRONT LEFT REAR RIGHT POSITION 258 OPTIONAL ERR 21 F30 PREHEATING CONTROL UNIT MAXIFUSE 1 ENGINE OIL COOLING TEMPERATURE 1 SYSTEM PROTECTION FUSE 1 INDICATOR LIGHT FAN SWITCH LIGHTS SELECTION SWITCH 4 01 WARNING LIGHTS AIR FILTER SOILED F7 LEFT LOW BEAM 4 ee 1 F8 RIGHT HIGH 4 H02 CABLGHTING 9 F9 LEFT HIGH BEAM HIGH BEAM LAMPS 2 WARNING LAMP 4 04 REARRIGHT HAND LIGHT 4 F10 HORN 5 05 LICENSE PLATE LAMP 4 11 WINDSCREEN WASHER KIT 5 H06 REAR LEFT HAND LIGHT 4 F12 OPTIONAL HO7 FRONT LIGHT LAMP LEFT TURN F13 OPTIONAL SIGNAL 4
36. the machine when entering and leaving it and hold to the suitable handles The handler cab is equipped with an access door on the left hand side Door opening from outside e Insert the key and release lock 1 e Press the pushbutton and open the door Door closing from inside e Pull the door with force it locks automatically Door opening from inside e Lift lever 2 and release the lock to open the door completely e Rotate handle 3 to open the upper section of the door and lock it against the special catch To unlock the door latched in open position e Press button 4 to unlock the door from the catch close and latch the door to the lower section using handle 3 Page 3 Document 57 0003 5200 11 2003 Genie Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS C 2 1 1 Leaving the cab an emergency In an emergency the operator can use he front or the rear window as safety exit ways The rear window has handles for partially opening the glass Such handles are locked in position by some wing nuts 5 which if driven out allow opening the glass completely The front window has two handles 6 which if turned enable the operator to pass through Page C 4 Document 57 0003 5200 11 2003 Genie Handler with telescopic bbom GTH 2506 OPERATING INSTRUCTIONS C 2 2 ADJUSTING THE SEAT A correct adjustment of the seat ensures the operator a safe and comfortable driving Th
37. the teeth of the conventional forks with the special guard or withdraw the floating forks e Retract boom and attachment to transfer position e sure that lights horn and turn signals are in working order Start the machine the beacon will switch on automatically e Select the forward or reverse speed Thetransfer speed ofthe vehicle will depend on the engine rpm CAUTION Public road circulation is allowed only for transferring an unloaded machine Do not use the GTH 2506 for towing purposes Page C 34 Document 57 0003 5200 10 2004 Genie E 6 3 LIFTING THE MACHINE When the machine shall be lifted use only means having a suitable capacity The characteristic data are detailed in the relevant chapter of this manual and on the identification plate Forthe machine lifting anchorthe chains to the special lugs on the machine marked with the decal below Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS 6 4 TRANSPORTING THE MACHINE OTHER VEHICLES Totransport the machine on another vehicle follow the steps below Put chocks at the machine wheels Ensure ramps are correctly positioned Retract the boom to transfer position Carefully drive the machine onto the transporting vehicle Put the parking brake and rest the attachment flat on the vehicle platform Ensure the overall dimensions do not exceed
38. to flow out from the reduction gear e Refit and tighten drain plug e Add new oil through plug Q until it is level with the hole e Refit and tighten plug Page D 15 Document 57 0003 5200 11 2003 Genie D 3 12 OIL LEVEL IN THE front rear WHEEL REDUCTION GEARS To check the oil level within the wheel reduction gears Stop the machine on a level ground and ensure the parking brake is engaged and plug finds on the horizontal axis Cleanthe plug all around then remove it and check if oil is level with the hole If necessary add new oil through hole until it is level Refit the plug For the oil change Stop the machine and ensure the plug is oriented along the vertical axis Place a container of suitable size under the reduction gear plug Unscrew plug and drain any oil from the reduction gear Rotate the wheel by 90 until the plug finds again on the horizontal axis Add new oil through hole Refit and tighten plug Handler with telescopic boom GTH 2506 MAINTENANCE PROTECT THE ENVIRONMENT The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres IMPORTANT When changing the oil drain it when it is still hot and the polluting substances are in suspension Page D 16 Document 57 0003 5200 12 2003 Genie Handler with telescopic GTH 2506 MAINTENANCE D 3 13 S
39. utilisation this handbook stresses these specific instructions by means of SPECIAL SYMBOLS There are six special or safety symbols in this manual always combined with keywords that class the situations according to their danger degree The symbols are always followed by a text explaining the situation taken into account the attention to be paid to such situation the method and the behaviour to be adopted When necessary it stresses prohibitions or supplies instructions to prevent dangers Sometimes it can be followed by illustrations We list below the special or safety symbols according to the relative seriousness of the hazard situation Draws the attention to situations that involve your own as well as the others safety and that can result in serious or lethal injury DANGER Draws the attention to situations that involve your own as well as the others safety and that can result in serious injury or lethal injury CAUTION Draws the attention either to situations that involve your own as well as the others safety and that can result in minor or moderate injury or to situations that involve the machine efficiency Handler with telescopic boom GTH 2506 INTRODUCTION Draws the attention to situations that involve the machine efficiency IMPORTANT Draws the attention to important technical information or practical advice that allows f
40. 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 familiarise with this handbook its enclosed graphs and diagrams the identification and warning plates They shall be skilled and trained about the machine functioning IMPORTANT From a technical point of view the ordinary maintenance of the machine is not a complex intervention and can be carried out by the machine operator too provided he has a basic knowledge of mechanics B 2 3 WORKING CLOTHES During work but especially when maintaining or repairing the machine operators must wear suitable protective clothing e Overalls or any other comfortable garments Operators should wear neither clothes with large sleeves nor objects that can get stuck in moving parts of the machine Protective helmet Protective gloves e Working shoes IMPORTANT Use only type approved working clothing in good condition Handler with telescopic GTH 2506 SAFETY irs B 2 4 PERSONAL PROTECTIVE EQUIPMENT Under special working conditions the following personal protective equipment should be used e Breathing set or dust mask Ear protectors or equivalent equipment e Goggles or facial masks
41. 2003 Genie Handler with telescopic boom GTH 2506 MAINTENANCE D 5 2 3 Fuel Use only Diesel fuel with less than 0 5 sulphur content according to the specifications of the diesel engine operation handbook In cold climates temperature under 20 use only Arctic type Diesel fuel or oil diesel fuel or oil diesel fuel mixtures The composition of the latter can vary in relation to the ambient temperature up to max 80 oil 0 5 2 4 Grease For the machine greasing use e Lithium based When greasing by pump Vanguard LIKO grease type EP2 Graphitized SHELL When greasing by brush grease type GR NG 3 e INTERFLON FIN For the telescopic boom GREASE LS 2 sliding blocks Avoid mixing greases of different type or features and do not use greases of lower quality Page D 26 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 TE FAULTS AND TROUBLESHOOTING Section FAULTS AND TROUBLESHOOTING TABLE OF CONTENTS E 1 FAULTS AND 22 0 2 1 1 Fault Cause aN TEED RAEE E 2 Page E 1 Document 57 0003 5200 11 2003 Genie E 1 This chapter represents a practical guide for the operator for fixing the most common failures and at the same time detecting those interventions which must be carried out by qualified techni
42. 6 red LED comes on the machine movements are blocked except for the boom retraction under safe conditions Boom hydraulic circuit It consists of a gear pump connected to the thermal engine which through a special valve dispenses oil to the hydraulic drive and a distributor for the following functions boom lifting lowering telescopic boom extension retraction attachment rotation attachment locking Handler with telescopic GTH 2506 GENERAL INFORMATION Braking circuit It consists of an independent circuit the pedal directly acts on the brake pump which dispenses oil to the front axle braking unit with discs in oil bath The parking brake of negative type acts on the braking unit of the service brake This brake is engaged every time the handler s engine is stopped or pressing down the light pushbutton located to the right of the driving place Telescopic boom The machine is equipped with a telescopic boom with hydraulic driven extension The telescopes slides on interchangeable pads made of wearproof material Driving cab Type approved driving cab in compliance with standards ISO 3449 and EN 13510 ROPS and FOPS 4 3 OPTIONAL ACCESSORIES The machine can be fitted with a wide range of optional accessories please address to Genie sales network IMPORTANT Please check the accessories available for your machine Page A 17 Document 57 0003 5200 10 2004 Genie Handler with telesco
43. COPIES MAY BE OBTAINED FROM YOUR DEALER OR DIRECTLY FROM TEREXLIFT WARNING DO NOT RAISE BOOM ON UNSTABLE OR SLOPING GROUND NEVER EXCEED MAXIMUM PERMITTED LOADS SEE LOAD CHARTS EXERCISE CAUTION WHILE USING THE BOOM IN RAISED POSITION BEFORE LEAVING THE CAB ENSURE THE FOLLOWING TRANSMISSION IS NEUTRAL PHAND BRAKE IS ON WARNING SAFETY GUIDELINES FOR MACHINES EQUIPPED WITH STABILIZERS NEVER USE THE STABILIZERS IF THE LOAD IS ALREADY RAISED THESTABILIZERS CAN BEUSED ONLY TO INCREASE THE STABILITY OF THE MACHINE MPROPER USE OF THE STABILIZERS CAN CAUSE INSTABILITY ENSURE THAT THE STABILIZER INDICATOR LAMP IS ON BEFORE USING THE BOOM BRING ANY LOAD TO THE GROUND IGNITION SWITCH IS OFF AND KEY REMOVED BEFORERAISING ANY LOAD LEVELTHE MACHINE BY MEANS OF THE LEVEL INDICATOR p Description label with transparent background General application limits Meaning it defines the main limits to be strictly obeyed by the operator when using the machine Location Present only in the TCE version within the cab on the windscreen to the right of the driving place Description label with transparent background explaining the use of the control lever Meaning by means of special symbols this label explains all pfunctions and motions of the control lever and the pushbuttons Location Present only in the TCE version in the cab on the windscreen to the right
44. Check the oil level with handler set to transfer position lowered boom and retracted telescopic element If oil must be changed proceed as follows 1 Stop the machine on a level ground and make sure the parking brake is engaged 2 Release the pressure from the hydraulic circuit 3 Place a container of suitable size under the drain plug placed in the lower part of the reservoir and collect any oil leaks 4 Remove the drain plug and allow oil to flow out into the container 5 Remove the inspection cover of tank Q9 6 Carefully wash the tank with Diesel oil and blow jet of compressed air 7 the drain plug and the inspection cover 8 Add new oil by making sure that it matches the recommended type indicated in paragraph D 5 2 2 until it is level with Q TH The handling disposing of used oils be ruled by local or national regulations Address to authorised centres Page D 12 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 MAINTENANCE D 3 10 CHANGING THE OIL FILTER CANISTERS ON THE INTAKE LINE D 3 10 1 Transmission oil filter Every 50 hours check the clogging degree of the filtering element using the vacuometer The indexed scale of the vacuometer is divided into 3 areas 1 Green area Normal condition 2 Yellow area Replace the filter as soon as possible 3 Red area Shut the en
45. HAFTING ALIGNMENT During operation the alignment of the front and rear axles of the machine can be subject to variations This can depend on an oil blow by from the steering control circuit or on a steering of both axles when front and rear wheels are not perfectly aligned To fix this problem rather than checking the alignment visually follow the procedure below 1 Move to a solid and level ground 2 Setthesteering selection switch 11 to four wheel steer 2 3 Rotatethe steering up to its stop either to the right or to the left 4 Set the steering selection switch to two wheel steer pos 0 5 Rotate the steering up to its stop turn in the same direction as above 6 Resetthe steering selection switch to four wheel steer pos 2 7 Rotate the steering to the side opposite to point 3 so that the rear axle reaches its stop 8 Reset the steering selection switch to two wheel steer pos 0 9 Rotate the steering to the same side as in point 7 so that the front axle reaches its stop 10 Reset steering selection switch to four wheel steer pos 2 Now the wheels should be re aligned Page D 17 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 MAINTENANCE D 3 14 ADJUSTING THE SLIDING PADS OF THE BOOM SECTIONS Any boom section is fitted with adjustable pads located on the four sides of the profile Th
46. IMPORTANT Use only type approved protective equipment in good condition 9 8 OD Page 3 Document 57 0003 5200 11 2003 Genie B 3 SAFETY PRECAUTIONS B 3 1 JOB SITE 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 machine dimensions in the different configurations ELECTRICAL DANGER Pay the greatest attention to overhead electric lines Always keep at a minimum safe distance from the telescopic boom and the lifted load Electrical hazards DEATH OR INJURY CAN RESULT FROM CONTACTING ELECTRIC POWER LINES ALWAYS CONTACT THE ELECTRIC POWER LINES OWNER THE ELECTRIC POWER SHALL BE DISCONNECTED OR THE POWER LINES MOVED OR INSULATED BEFORE MACHINE OPERATIONS BEGIN POWER LINE VOLTAGE REQUIRED CLEARANCE 0 a 50 kV 10 ft 200 kV 15 ft 350 kV 20 ft 500 kV 25 ft 750 kV 35 ft 1000 kV 45 ft CAUTION Make sure the machine wheels and stabilisers rests on a firm ground to prevent hazardous unstable conditions If the ground is not firm enough position some supporting planks under the stabilisers or the wheels These plates must grant a specific pressure of 1 2 to 1 5 kg cm 500x500mm plates are sufficient Handler with telescopic boom GTH 2506 SAFETY Look for the best route to the job site e When the machine is running nobody can enter
47. ING INSTRUCTIONS Genie Handler with telescopic bbom GTH 2506 TE C 3 3 INSTRUMENTS AND LIGHT 66 Indicator light parking brake engaged INDICATORS When ON this light indicates that parking C 3 3 1 Instruments 2 brake is engaged 54 Engine coolant temperature indicator 67 Indicator light negative brake 6 accumulator This light indicates that the accumulator of the negative brake is getting discharged Signals the engine coolant temperature Fuel gauge Signals the fuel level within the tank Indicator light turn signals Green indicator light that signals when turn signals are ON 68 Hour meter Signals the total operating hours ofthe 28 Indicator light glow plugs preheating n Green light indicators which signal the preheating phase of the engine glow plugs Before starting the engine wait for these lights machine 51 Hydraulic oil temperature indicator to go off Signals the temperature of the hydraulic 29 Indicator light air filter soiled Orange light indicator which signals when the air intake filter of the engine is getting soiled B 3 3 2 Light indicators Clean or replace the filtering cartridge Indicator light high beam 60 Blue indicator light that signals when high immediately beam is ON 61 Indicator light position lights D Green indicator light that signals when position lights are ON 63 Indicator light air filter so
48. LM uL uU i D 9 Checking the brake oll ceti etate rte D 9 EC SIE DIOE iiis e Som ict UE LAU LAM EL EL Luar D 10 0 11 PIAS COCHIN 0 11 Checking the oll level tank rt rt ba i dr ete D 12 Changing the oil filter canisters on the intake line D 13 En D 13 E o o IS D 14 Oil level in the differential gears and the D 15 Front and rear differential gears i ke bed letkt bres ions ede Idee koe ni dae D 15 PER O MTS D 15 Oil level in the front rear wheel reduction D 16 channa orani LI ERR ELS ES D 17 Adjusting the sliding pads of the boom sections D 18 bas 0 19 BLECTRICAL SYSTEM 0 21 cor HT IM D 21 Fuses and n 22 0 24 etae ug CE OD FREE E OH D 25 cu ENS D 25 Tec Ls Ne ENT UR UTR REDE D 25 ENOO ette D 25 Lubrication oils and relevant filtering elements D 25 eM D 26 0 26 D 1 Document 57 0003 5200 12 2003 Genie INTRODUCTION A thorough and regular mai
49. NGINE CONTROLS AND C 3 2 2 Forward reverse gear selector switch INSTRUMENTS Three position switch with lock in neutral position C 3 2 1 Ignition switch Three position switch N Neutral position no gear engaged No circuit under voltage key can be removed F Shift lever to pos F to select the forward gear and engine is stopped R Shift lever to pos R to select the reverse gear Circuits under voltage presetting for the engine starting Board controls and instruments are on The warning light 28 signalling the glow plugs preheating comes on Wait until the light goes off before starting the engine Engine starting when released key springs back to pos automatically Page C 9 Document 57 0003 5200 05 2004 Genie C 3 2 3 Turn signals Windscreen wiper Horn Lights function When sliding the lever along its axis horn switches on independently from other pre set functions Te B Windscreen washer function Push the second stage of the lever along its axis to direct a jet of water onto the cab windscreen e gt B Windscreen wiper function To operate the windscreen wiper rotate the lever tip to one of the three positions X Wiper OFF Low speed High speed B Turn signals function Set lever to pos to indicate a turn leftwards or to pos to indicate a turn rightwards Handler with telesc
50. OAD LIMITER CUT OUT CAN RESULT IN A MACHINE OVERTURNING AND IN SERIOUS INJURY USE THIS OPTION ONLY IN CASE OF NEED AND DON T FORGET TO REACTIVATE THE LOAD LIMI TER AFTER THE EMERGENCY Page C 18 Document 57 0003 5200 11 2003 Genie Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS C 3 4 3 Lifting lowering the boom Before operating the boom make sure that nobody is within the working range of the machine To lift or lower the boom Set control lever to central position and press button 4 Smoothly shift the lever to position B to lift the boom or to position A to lower it IMPORTANT For the functions of the control lever in the TCE version please refer to par C 3 4 1 1 Page C 19 Document 57 0003 5200 11 2003 Genie Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS C 3 4 4 Extending retracting the boom Before operating the boom make sure that nobody is within the working range of the machine Set control lever to central position and press button 4 Smoothly shift the lever to position D to extend or to position C to retract the boom IMPORTANT For the functions of the control lever in the TCE version please refer to par C 3 4 1 1 Page C 20 Document 57 0003 5200 11 2003 Genie Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS C 3 4 5
51. ONA INDUSTRIALE 06019 UMBERTIDE PG ITALY Tel 075 941 811 Fax 075 941 53 82 Telex 66106 ITALMA I MODELLO MODEL MODELE TYP MODELO ANNO DI COSTRUZIONE YEAR OF MANUFACTURE ANNEE DE FABRICATION BAUJAHR ANO DE FABRICACI N 200 MATRICOLA SERIAL N N DE SERIE FZ IDENT NR NO DE SERIE PESO MAX ASSALE ANT MAX FRONT AXLE WEIGHT POIDS MAX ESSIEU AVANT ZUL ACHSLAST VO N ST VZO PESO MAX EJE ANTERIOR PESO MAX ASSALE POST MAX REAR AXLE WEIGHT POIDS MAX ESSIEU ARRIERE ZUL ACHSLAST HI N ST VZO PESO MAX EJE POSTERIOR PESO TOTALE TOTAL WEIGHT POIDS TOTAL ZUL GESAMTGEWICHT N ST VZO PESO TOTAL MATRICOLA MOTORE TERMICO ENGINE SERIAL MOTEUR THERMIQUE FABRIK NR DIESEL MOTOR NO DE SERIE MOTOR TERMICO OMOLOGAZIONE FABBRICATO IN ITALIA MADE IN ITALY C O Fig A9 Fig A10 Page A 10 Document 57 0003 5200 10 2004 Genie Handler with telescopic GTH 2506 GENERAL INFORMATION Road traffic data plate Placed on the front right side of the chassis only for lk machines destined for the Italian market This 45 plate contains the road traffic related data and the weights of the specific machine model Fig A1 1 DATI OMOLOGAZIONE STRADALE TIPO OMOLOGAZIONE NUMERO DI IDENTIFICAZIONE MASSA TOTALE AMMISSIBILE CARICO MAX ASSE ANTERIORE CARICO MAX ASSE PO
52. OPTIONAL Hos LAMP RIGHT TURN F15 aa UNIT 4 09 WORK LIGHT 8 F16 POWER SUPPLY HYDRAULIC STOP FUEL GAUGE HOURMETER WARNING LAMPS HA01 BACK UP HORN 2 INDICATOR ENGINE OIL COOLING HA02 HORN 5 TEMPERATURE INDICATOR ENGINE OIL BEACON 8 TEMPERATURE INDICATOR K04 RELAY PICKUP AIR FILTER WARNING LIGHT STARTING ENABLING COMMAND 1 PREHEATING WARNING LIGHT FORWARD SPEED ENABLING COMMAND 2 ROAD SAFETY SWITCH 1 03 INHIBITION WITH BRAKE PEDAL 17 POWER SUPPLY HAZARD WARNING STEPPED DOWN 2 LIGHT AND TURN SIGNALS SWITCH 15 OVERLOAD WARNING SYSTEM 18 POWER SUPPLY LIGHT SWITCH CONTROL UNIT ENABLING COMMAND 9 WINDSCREEN WASHER SWITCH K05 REVERSE SPEED ENABLING COMMAND 2 WINDSCREEN WASHER MOTOR 5 F19 HEATING SYSTEM FAN POWER SUPPLY 7 06 OVERLOAD WARNING SYSTEM SOLENOID VALVE ENABLING COMMAND 9 F20 ROAD SAFETY SWITCH POWER SUPPLY 7 441 eta RET AY G 17 Document 57 0003 5200 10 2004 Ref Description Sheet Ref Description Sheet MO1 STARTER MOTOR 1 5508 FUELFLOAT 6 M02 ALTERNATOR 1 5509 LOADING CELL 9 WINDSCREEN WIPER WASHER MOTOR 5 M04 WINDSCREEN WIPER WASHER MOTOR 5 01 SOLENOID VALVE STARTER 1 05 COMPRESSED AIR COMPRESSOR 1 Y02 SOLENOID VALVE FWD SPEED 2 06 MOTOR 7 Y03 SOLENOID VALVE PARKING BRAKE 2 04 SOLENOID VALVE REVERSE SPEED 2 01 WARNING LIGHTS FUEL GAUGE 05 SOLENOID VALVE OVERLOAD WARNING
53. Optional out and rectify the fault F27 Optional 228 Optional F29 Spare fuses B Fuses Ref Circuit Amp F1 Power supply interior lamp emergency switch turn signals 30 15 F2 Power supply K04 relay 7 5 F3 Optional 15 F4 Front right rear left position lights license plate lights position lights indicator engine temperature indicator 5 F5 Front left rear right position lights fuel gauge hourmeter warning lamps lighting engine oil cooling temperature indicator light fan switch lights selection switch 5 F6 Right low beam 7 5 F7 Leftlow beam 7 5 F14 F28 F8 Right high beam 10 INT F9 Left high beam High beam warning lamp 10 nm ae eo F10 Horn 15 F12 F26 F11 Windscreen washer kit 10 F12 Optional Epl 13 Optional F10 F24 F14 Optional F15 control unit power supply 5 2 F16 Power supply hydraulic stop fuel gauge hourmeter warning lamps indicator engine oil cooling temperature indicator engine oil temperature indicator K04 relay pickup air filter warning light F8 F22 F7 F21 e s a jesse lt preheating warning light road safety switch 5 F17 Power supply hazard warning light and turn ERN CPI signals switch 15 15 F18 F18 Power supply light switch windscreen washer switch windscreen washer mot
54. Pitching the attachment holding frame forward back Before operating the boom make sure that nobody is within the working range of the machine Set the control lever to central position and press button El e Press button and shift the lever to position 6 to extend the boom or to position 8 to retract it IMPORTANT For the functions of the control lever in the TCE version please refer to par C 3 4 1 1 Page C 21 Document 57 0003 5200 11 2003 Genie Handler with telescopic bbom GTH 2506 OPERATING INSTRUCTIONS C 3 4 6 Quick coupling the attachments CAUTION Before operating the boom make sure that nobody P d is within the working range of the machine To lock the attachments Shift the control lever to central position and press button Press button together with the dashboard enabling button 17 and shift the lever to position 6 to unlock the attachment or to position 9 to lock the attachment IMPORTANT For the functions of the control lever in the TCE version please refer to par C 3 4 1 1 Page C 22 Document 57 0003 5200 10 2004 Genie C 4 SETUP 4 1 BEFORE STARTING THE ENGINE e To ensure safe conditions to the operators and the bystanders and a longer life to your machine perform a walk around inspection before starting the engine e Remove any dirt or rubbish from t
55. S F 1 5 EXTENSION JIB Application Quick coupling fitted attachment for maintenance interventions at high working heights Safety pue Strictly obey the general safety precautions given 400 kg 59 0800 0000 section B SAFETY Characteristics Payload kg 400 A Length mm 2100 B Wiath mm 920 Height mm 630 Weight kg 115 IMPORTANT Make sure this attachment can be used in the destination country of the machine Italy this attachment must be enrolled at ISPESL and submitted to yearly test Application must be submitted directly by the user Never lift wrongly slung loads Avoid abrupt acceleration or deceleration Avoid load oscillations and especially do not move the load from the vertical pull line Do not pull crosswise and do not tow Operation To change the working height operate the rotation lever of the attachment holding plate Maintenance Visually check the jib for damage before using it Check the safety catch is in good working order Daily grease the joints using the greasing gun Page F 7 Document 57 0003 5200 11 2003 OPTIONAL ATTACHMENTS Genie Handler with telescopic bbom GTH 2506 TE F 1 6 FORKS WITH HYDRAULIC SIDE SHIFT Application Quick coupling fitted attachment for handling palletised loads with possibility of shifting the load to the side by x 100 mm Safety Strictly obey the general safety precautions given in section B
56. STERIORE 9 In funzione della gommatura MASSA RIMORCHIABILE AMMISSIBILE MASSA FRENATA MASSA CON FRENATURA INDIPENDENTE MASSA FRENATURA AD INERZIA MASSA CON FRENATURA ASSISTITA COEFFICIENTE DI ASSORBIMENTO CORRETTO DEL MOTORE TEREX Mo TEREX Tel 39 0 75 941811 Fax 39 0 75 9415382 TEREXLIFT srl ZONA INDUSTRIALE 06019 UMBERTIDE PG ITALY Tel 075 941 811 Fax 075 941 53 82 Telex 66106 ITALMA I Fig A 1 1 MODELLO MODEL MODELE TYP MODELO ANNO DI COSTRUZIONE YEAR OF MANUFACTURE DE FABRICATION BAUJAHR ANO DE FABRICACI N 200 MATRICOLA SERIAL N N DE SERIE FZ IDENT NR NO DE SERIE Ld 2 4 ZUL ACHSLAST VO N ST VZO PESO MAX EJE ANTERIOR i kg This machine fulfils the safety requirements of the ee PESO TOTALE TOTAL WEIGHT POIDS TOTAL ZUL GESAMTGEWICHT N ST VZO kg Machi nery Directive The conform ity has been certified MATRICOLA MOTORE TERMICO ENGINE SERIAL N MOTEUR THERMIQUE d th laci f th th hi FABRIK NR DIESEL MOTOR NO DE SERIE MOTOR TERMICO 2 e placing o 5 ing is ine 4 SS emonstrates compliance with the regulator requirements 9 FABBRICATO IN ITALIA MADE IN ITALY C iS The CE marking is placed directly on the identification plate of the machine Fig A8 and A9 A 2 5 CHASSIS SERIAL
57. TCH 6 X11 2 WAY CONNECTOR OVERLOAD SS06 HYDRAULIC OIL TEMPERATURE WARNING SYSTEM CONTROL UNIT 9 TRANSDUCER 6 X12 CONNECTOR OVERLOAD WARNING SS07 WATER TEMPERATURRE SENSOR 6 SYSTEM CONTROL UNIT 9 Ref Description Sheet X13 3 WAY CONNECTOR STEERING COLUMN X14 2 WAY CONNECTOR STEERING COLUMN X15 4 WAY CONNECTOR JOYSTICK X16 2 WAY CONNECTOR STEERING COLUMN X17 2 WAY CONNECTOR OVERLOAD WARNING SYSTEM CONTROL UNIT CALIBRATION 9 X18 4 WAY CONNECTOR OVERLOAD WARNING SYSTEM CONTROL UNIT 9 COLOUR TABLE Acronym Colour BK Black BN Brown RD Red OG Orange YE Yellow GN Green BU Blue VT Purple GY Grey WH White PK Pink TQ Light blue LIST OF ABBREVIATIONS Label Description Lamps lights warning lights Clacson or back up horn K Relays Motor pump P Indicators R Resistance RP Potentiometers SW Switches selectors SS Sensors micro switches pressure switches transducers YHH Solenoid valves X Connectors Other components Genie Handler with telescopic GTH 2506 TABLES AND DOCUMENTS ENCLOSED Page G 18 Document 57 0003 5200 10 2004 Genie Handler with telescopic GTH 2506 TABLES AND DOCUMENTS ENCLOSED G 4 1 HYDRAULIC SCHEME Drw 57 2201 1300 A Hydraulic piloting line test port TP 5 4 Parking emergency Service
58. THE MACHINE When the engine reaches the running temperature ensure all parts are in transfer position and the gearbox lever is in neutral Then proceed as follows e Select the required steering mode e Select the required gear forward or reverse Release the parking brake pressing button 19 the warning light on the pushbutton must be off e Slowly step on the gas pedal to start moving off CAUTION Donot operate the forward reverse gear lever when the machine is running The machine would reverse the running direction abruptly and you could seriously be injured Page C 25 Document 57 0003 5200 10 2004 Genie 4 7 STOPPING AND PARKING THE MACHINE When possible stop the machine on a dry level and solid ground Then e Bring the machine to a smooth stop by easing up the gas pedal and stepping down on the brake pedal e Set the forward back speed lever to neutral position e Engage the parking brake pressing button 19 the warning light on the pushbutton must be on e Release the service brake pedal e Rest the attachment coupled to the boom flat on the ground e Rotate the ignition key to 0 and remove the key e Leave the driving cab and lock the cab door Setthe battery cut out switch to OFF position Always face the machine when getting off the driving cab make sure that your hands and shoe soles are clean and dry and hold to the handholds to prevent falls or slips
59. The control lever shall be operated only when correctly seated in the driving place CAUTION Before operating the control lever make sure that nobody is within the working range of the machine Page C 15 Document 57 0003 5200 10 2004 3 4 1 Function selection IMPORTANT For the functions of the control lever in the TCE version please refer to par C 3 4 1 1 After pressing the intentional control pushbutton 4 the lever is enabled to carry out the following motions Boom lowering lifting shift the control lever to A or B Attachment back forward tilting press button 2 and shift the control lever to C or D Boom extraction retraction shift the control lever to C or D Attachment coupling release press button 3 together with the dashboard ena bling button 17 and shift the lever to C or D When pressing the intentional control button 4 and the lever is not correctly set to central position the control of the selected actuator is operated immediately Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS Page C 16 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 OPERATING INSTRUCTIONS C 3 4 1 1 Function selection For TCE version The lever is enabled to carry out the following mo tions Boom lifting lowering Smoothly shift the lever to position B to lift the boom or to position A to lower it B
60. Y PER ANTIRIBALTAMENTO X17 Xt 3 55855 555 38 es 8 568 88 88 558 5 gt 992 5 gt 5 A gt H 5 g 5 5 5 5 2 T F B 1 85 F 85 87A H 86 FA i i 2 2 x 2 5 a a S i oa 1 27 5 5 4 5 5 x 31 Wes i 2 2 e gt gt 2 gs EE 5 DE J 5 5 28 g Page G 15 Document 57 0003 5200 10 2004 Genie Handler with telescopic GTH 2506 TABLES AND DOCUMENTS ENCLOSED G 3 2 9 2 WIRING DIAGRAM 9 9 valid from serial no 10740 30 8 G10 8 G10 15 E DISLPAY 386 PER ANTIRIBALTAMENTO xe X2 3 55555555535 Q H X18 i i d i i s E 5 E 5 5 _ 12 5 8 2 3 H m e i E S z B KoA F2 F1 F3 5 F24 4 86 _ 30 86 30 id 9 5 2 uo 5 2 dl 5 5 5 8 T RD BKot 27 5 5 5 5 e s 5 E Se 31 8 A1 31 zu zu c o gt 2 gs ps 92 92 lt Ba 53 Q 5 29 29 Page G 16 Document 57 0003 5200 10 2004 Genie Handler with
61. again to select the work setting and enable the boom control and the four wheel steering The built in button light switches off Before switching on the ROAD function align the rear wheels of the machine E 4 12 Document 57 0003 5200 11 2003 Genie C 3 2 9 Auxiliary drive controls Beacon When the machine is started up the beacon activates automatically 22 Optional attachment pushbutton if any Pushbutton with orange glass The pressure of this button causes the switching of the hydraulic circuit for the movement of the attachments equipped with auxiliary lines 10 Hazard warning lights switch Fitted with on off position it switches on the turn signals simultaneously Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS This switch is located above the ignition Switch and is used in conjunction with lever 5 see C 3 2 3 12 Road lights switch 23 Air conditioning fan switch Three position switch 1 Low speed 2 High speed 21 heater control cock To the right of the driving seat e Rotate clockwise for fresh air e Rotate anticlockwise for warm air e Adjust the flow of warm air within the cab by the air conditioning fan switch 23 Page C 13 Document 57 0003 5200 11 2003 OPERAT
62. ble 4 Block relay error during operation 5 6 7 8 Block relay error when power is turned on 9 CELL 1 and CELL 2 reading incongruence The values read from the two cells are different Stop and restart the machine to RESET the system If the error message is still shown address to the GENIE service centre to re calibrate the machine Check the wiring between control panel and load cell Check that the load cell is fixed correctly Check the connecting cable or the connectors is are not shorted If the error message is still shown address to the GENIE service centre and let the load cell be checked Check the wiring between control panel and load cell Check that the load cell is fixed correctly Check the connecting cable or the connectors is are not shorted If the error message is still shown address to the GENIE service centre and let the load cell be checked Check the efficiency of relay and wiring Stop and restart the machine and check the outputs If the error message is still shown address to the GENIE service centre to replace the DLE unit Check the efficiency of relay and wiring Stop and restart the machine and run a new test If the error message is still shown address to the GENIE service centre to replace the DLE unit Checkthatthe cells are intact and fixed correctly If the error message is still shown address to the GENIE service centre to replace the load cell or re calibrate the ma
63. cal engineers If you are unsure about anything do not carry out operations on the machine but call in a skilled technician Handler with telescopic boom GTH 2506 FAULTS AND TROUBLESHOOTING FAULTS AND TROUBLESHOOTING Any repair work maintenance or troubleshooting must be carried out with machine stopped boom in rest position or laid on the ground parking brake 1 1 Fault Cause Solution engaged and ignition key removed DASHBOARD DOES NOT SWITCH ON The 50A fuse F31 supplying power to the dashboard is blown engine compartment Battery disconnected Battery down Battery cut out switch OFF Replace the fuse Connect the battery using the relevant switch Check the battery Switch it on ENGINE DOES NOT START Starter does not run Parking brake not engaged Battery down Battery cut out switch OFF Engage the parking brake and ensure the relevant indicator on the dashboard switches on Recharge or replace the battery Switch it on ENGINE DOES NOT START Starter runs but engine does not start Fuse F15 blown No fuel Diesel fuel filter clogged Diesel fuel hose empty fuel used up Solenoid valve engine stop Check the fuse Refuel See DEUTZ engine operator manual Refuel then refer to DEUTZ engine operator manual Check the solenoid valve replace if necessary Speed selector switch in neutral Parking brake engaged Fuse F23 blown Set the speed sel
64. centre involves the automatic invalidation of the conformity of the machine to the Directive 98 37 EC Handler with telescopic GTH 2506 GENERAL INFORMATION A 3 2 IMPROPER USE Improper use means a utilisation of the handler following working criteria that do not comply with the instructions of this manual and that in general may result in risks for both operators and bystanders We list below some of the most frequent and hazardous situations of improper use Carrying passengers on the machine Not strictly complying with the operation and maintenance instructions of this handbook Working beyond the handler working limits Working on unstable edges of ditches Driving crosswise on slopes or hills Working during a storm Working on steep slopes Using attachments other than those recommended Using attachments not approved or directly manufactured by Terexlift Working in potentially explosive areas Working in confined and non ventilated environments 3 3 RESIDUAL HAZARDS Although the machine has been designed and manufactured according to the latest technology and all expected hazards have been eliminated some operations performed by the machine operator can result in potentially hazardous situations Among them e Hazards deriving from a too high work or transfer speed in relation to the load handled or the ground condition of the jobsite e Hazards deriving from work p
65. chine Page E 4 Document 57 0003 5200 05 2004 Genie Handler with telescopic GTH 2506 FAULTS AND TROUBLESHOOTING A Data error in RAM Stop and restart the machine If the error message is still shown address to the GENIE service centre B Outrigger incongruence An input is not read Check the wiring the power cord and the connector of the DLE unit If the error message is still shown address to the GENIE service centre C Error in A D C reading check Stop and restart the machine If the error message is still shown address to the GENIE service centre In case of faults not listed this chapter address to the GENIE Technical Assistance your nearest authorised workshop or dealer Page E 5 Document 57 0003 5200 05 2004 Genie Handler with telescopic GTH 2506 TE FAULTS AND TROUBLESHOOTING Page E 6 Document 57 0003 5200 05 2004 Genie 1 1 1 2 1 3 1 4 1 5 1 6 1 7 Handler with telescopic boom GTH 2506 OPTIONAL ATTACHMENTS Section F OPTIONAL ATTACHMENTS Shovel TABLE OF CONTENTS Fixed hook on plateis PP ele c te Extension jib Forks with hydraulic side shift eet ER Fork with jaw Page F 1 Document 57 0003 5200 11 2003 F 3 F 4 F 5 F 6 7 8 9 Geni
66. e Handler with telescopic bbom GTH 2506 OPTIONAL ATTACHMENTS INTRODUCTION This section provides information on the optional interchangeable attachments especially manufactured for the handlers Use only genuine attachments described in this section after having read their features thoroughly and understood their use To install and remove the attachments follow the instructions supplied in the OPERATION section par C 5 4 When replacing interchangeable attachments keep any person clear of the working area Mounting optional attachments and especially the extension jib can change the centre of gravity of the machine Before handling a load check its weight and compare it with the values on the load charts The weight of the used attachment must always be deducted from the rated payload Procedure to connect hydraulic lines e Couplethe new attachment and lockit hydraulically e Disconnect the quick couplings of the attachment locking cylinder and connect them to the false connectors Q to prevent them from getting dirty e Connect the feeding hoses of the new attachment to the quick couplings previously set free When the new attachment has two hydraulic motions like for instance the pole and pipe planter a flow selecting valve 8 shall be installed on the machine or the attachment and operated from the cab by means of switch 22 Page F 2 Document 57 0003 5200 11 2003 Genie
67. e emergency pushbutton e machine start control Checks at the machine start up Handler with telescopic GTH 2506 OPERATING INSTRUCTIONS C 4 2 STARTING THE ENGINE For the low temperature starting see paragraph C 4 4 e Put the mechanical gear lever to neutral e Step on the gas pedal e To start the engine turn the ignition switch to position Release the switch when the engine starts If the engine does not start within 20 seconds release the key and wait at least 2 minutes before attempting again e After the start up let the engine run at idle for some seconds before engaging a gear this allows for a gradual warm up ofthe engine oil and a better lubrication In case of engine jump starting remove the booster cables see following chapter If the light indicators do not switch when engine is running immediately stop the machine and find and rectify the fault IMPORTANT Engine cannot be started if the speed switch is not in the neutral position and the operator is not correctly seated in the driving seat After the start up when leaving the driving place the engine continues to run DO NOT LEAVE THE DRIVING PLACE BEFORE HAVING SHUT THE ENGINE DOWN LOWERED THE BOOM TO THE GROUND AND ENGAGED THE PARKING BRAKE Page C 23 Document 57 0003 5200 10 2004 Genie 4 3 When ump starting the engine through the battery ofanothermachine make sure that
68. e handler seat is fitted with devices which allow for the adjustment of the springing the height and the distance from the controls e Seat distance from the controls The seat is equipped with an adjusting device to slide the same seat forward or back with respect to the steering column To adjust the seat pull lever 1 outwards and push the seat to the desired direction Then release the lever and make sure that the seat locks in position e Springing adjustment Rotate lever 2 clockwise or anticlockwise Toa In some seats height can be adjusted to three different positions Lift the seat until you hear the click signalling that the seat is locked in position To lower the seat raise to end of stroke to release the mechanism then release the seat it will return to the bottom position according to the springing degree required Rotate 23 FASTENING THE SEAT BELTS clockwise anticlockwise to increase reduce the seat springing To reverse this control pull out and Sit correctly in the driving seat then rotate the lever knob by 180 e Height adjustment Turn knob 3 clockwise to lift the seat turn it counter clockwise to lower the seat The safety belts are equipped with reel retractor To fasten the belt pull tab 1 and push it into buckle 2 To release the belt push button 3 and remove the tab from the buckle Make sure that the buckle is correctly located at the hip point and not on the stomach Opera
69. e reducer 3 Check the oil level in the four wheel reduction gears 4 Checkthe condition of the canister of the engine air filter renew the canister if necessary 5 Check the clamping of the cableheads to the battery terminals 6 Check the air suction hose between engine and filter 7 Checkthe cylinder chromium plated rods 8 Check the hydraulic lines are not worn because of rubbing against the frame or other mechanical components 9 Check the electric cables do not rub against the frame or other mechanical components 10 A Checkthe wear of the sliding pads of the boom sections 11 A Adjust the play of the sliding pads of the boom sections 12 Remove any grease from the boom then re grease the sliding parts of the boom sections 13 Check the level of the battery electrolyte Every 3 working months 1 Check the efficiency of the block valves see chap D 3 15 Every 500 working hours or every six months Jobs to be done in addition to those above 1 Visually checkthe smoke quantity evacuated from the engine exhaust 2 Check the tightening of the engine fixing screws 3 Checkthe tightening of the cab fixing screws 4 Check the backlash between pins and bushings in all joints 5 Change the hydraulic oil filter of the transmission Page D 3 Document 57 0003 5200 11 2003 MAINTENANCE Genie Handler with telescopic bbom GTH 2506 TH 6 Change the hydraulic oil filter in the tank 7 Have the hydraulic system checked
70. ector switch correctly Disengage Check the fuse necessary replace if MACHINE DOES NOT MOVE THE MACHINE DRIVE IS NOT ENOUGH Hydraulic oil filter clogged Replace the filter NO SELECTION OF THE STEERING MODE Fuse F20 controlling the steering selection blown ROAD JOBSITE switch set to ROAD Sostituire il fusibile Set to JOBSITE ROAD FUNCTION ON EVEN WHEN SELECTING THE JOBSITE FUNCTION No ROAD JOBSITE selection Check and replace fuse F20 if necessary Page E 2 Document 57 0003 5200 12 2003 Handler with telescopic boom GTH 2506 FAULTS AND TROUBLESHOOTING Genie LOWERING AND EXTENSION HOLDING FRAME TILTING Fuse blown Emergency button ON Replace fuses F2 and or F24 Reset the button THE HYDRAULIC OIL THERMOMETER DOES NOT WORK This is normal when the outside tem perature is low and or the machine is used for short periods since the hydraulic oil cannot warm up over 40 50 THE PARKING BRAKE LIGHT Fuse blown Check and replace fuse F2 if DOES NOT LIGHT UP necessary BOOM DOES NOT MOVE Fuse blown Check and replace fuse F22 if ROAD JOBSITE switch set to ROAD Emergency button ON necessary Set to Reset the button THE LOAD LIMITING SYSTEM DOES NOT CHANGE WORK SCALE Outriggers limit switches inefficient Check the efficiency of the out
71. element Check for cracks in the filtering element by introducing a lamp inside Smearthe seal with grease then refit the element Tighten wingnut C close cover B and tighten with wingnut A ATTENTION As soon as the warning lamp on the cab dashboard switches on replace the outer element Page D 10 Document 57 0003 5200 11 2003 Genie Handler with telescopic boom GTH 2506 MAINTENANCE B D 3 7 CAB AIR FILTER Every six months clean the air filter in the cab Replace the cartridge if the filtering cloth is damged 1 Cleaning and changing the cartridge Shut the engine down and engage the parking brake Pulloutthe filter A located to the left of the driving place Clean the filter bowl Do not dry clean the filtering cartridge Do not atany times dry clean the filters Use some water and or solvent D 3 8 ENGINE COOLING CIRCUIT The cooling radiator is lubricated with the engine oil and does not need any maintenance Page D 11 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 MAINTENANCE B D 3 9 CHECKING THE OIL LEVEL IN THE TANK Fine jets of hydraulic oil under pressure can penetrate the skin Do not use your fingers but a piece of cardboard to detect oil leaks Check the hydraulic oil level visually through the special level Q fitted into the tank When necessary add new oil through filler CAUTION
72. ese pads are secured to both fixed and mobile part of every section All pads can be adjusted by the special shims supplied by GENIE upon demand Adjusting the pads e Remove or loosen the screws fixing the pads in relation to type of shims used with or without slots e Fit the necessary amount of shims e If the residual thickness of the pad is insufficient or near the maximum wearing limit renew the pad e Tighten the screws fixing the pads at the recommended torque see below Use a dynamometric wrench Tightening torques of the pad screws in relation to the screw diameter Screws M10 Nm 30 Screws M14 Nm 50 Tightening torques higher than those recommended can cause the break of the pad or of the locking threaded bush Pads must compulsorily be replaced if the residual thickness of the plastic layer with respect to the iron bush fixing the block is equal or inferior to 1 mm Page D 18 Max wearing thickness Eni Minimum 1 mm f Document 57 0003 5200 11 2003 Genie E 0 3 15 CHECKING THE SAFETY DEVICES Checking the load limiting system at every use When power is turned on the DLE load limiting system runs a self test In the case of troubles LED s 5 8 and 10 start flashing the buzzer sounds an error code is shown on the display and the machine enters the alarm mode and cannot be operated The meani
73. g pressure 300 bar oom functions Chek valve main valve Hydrostatic transmission motor COLORS LEGENDA max displacement 105 cc rev cracking pressure 4 sections f 0 5 bar TP Hydrostatic transmission i 4 boost pressure test port L H Check valve ERE 2 bar cracking pressure 0 5 bar Hydrostatic transmission TP high pressure test port HYDRAULIC CIRCUIT Boom steering pump pressure lines Hydrostatic transmission Diesel engine high pressure lines 19 bar Boom steering Y M functions lines Low pressure and transmission charge pressure lines Hydrostatic transmission and boom functions valve piloting lines Boom steering and transmission pumps suction lines Boom functions pump with integrated priority valve displacement 27 cc rev
74. gage the brake Every pressure of the pushbutton switches the warning light on and off When the red warning light is on the parking brake is engaged CAUTION Never use the parking brake to slow down the machine unless in an emergency It may reduce the brake efficiency Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS 3 2 5 Accelerator control 13 Gas pedal Its pressure controls the engine rpm and coupled to the gearbox the machine speed It is fitted with an adjustable stop in the lower part olg 9 Page C 11 Document 57 0003 5200 11 2003 Genie 3 2 6 Pushbutton enabling the attachment coupling release 17 Selection button Pushbutton with two stable positions Pressing this button activates the attachment coupling and release The built in button light switches on 3 2 7 Steering mode selection 11 Steering mode switch Three position switch for the selection of the steering mode 1 Crab steering 0 Two wheel steering 2 Four wheel steering Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS HC 3 2 8 Road Jobsite switch 20 Selection button Button with two stable positions 1 Pressto select the road setting The high speed can be engaged the boom control is disabled and only the two wheel steering is enabled The built in button light switches on 2 Pressthe button
75. gine down to prevent damage to the hydraulic system Change the filter and or check for the fault reasons Hydraulic filter cartridges cannot be cleaned washed and refitted They must be replaced with new ones of the type recommended by the manufacturer see par D 5 2 2 PROTECT THE ENVIRONMENT The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres To change the hydraulic oil filter element on the suction line proceed as follows 1 2 on a level ground and engage IM PO 2 container of suitable size under the filter to collect any oil leaks then close cock When changing the oil drain it when it is still hot 3 Remove the filtering element using a wrench and the polluting substances are in suspension 4 Change the filtering element then before fitting new one thoroughly clean and grease both seat and gasket 5 Hand tighten and re open cock Page D 13 Document 57 0003 5200 12 2003 Genie Handler with telescopic bbom GTH 2506 MAINTENANCE D 3 10 2 Auxiliary circuits oil filter To change the hydraulic oil filter cartridge of the service circuits proceed as follows 1 Stop the machine ona level ground and engage the parking brake 2 Remove the inspection hatch 6 and unscrew the oil filter fitted inside the tank 3 Check the tank is clean then fit a new filteri
76. he battery is dry and the cell plugs are tight Place a sign on the battery to warn of not using it If before disposal the battery is left in the open air it will be necessary to dry smearthe 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 Page C 37 Document 57 0003 5200 10 2004 Genie Handler with telescopic GTH 2506 TH OPERATING INSTRUCTIONS Intentionally blank page Page C 38 Document 57 0003 5200 10 2004 Genie D 1 D 2 D 2 1 D 3 D 3 1 D 3 2 D 3 3 D 3 4 D 3 5 D 3 5 1 D 3 6 D 3 7 D 3 8 D 3 9 D 3 10 D 3 10 1 D 3 10 2 D 3 11 D 3 11 1 D 3 11 2 D 3 12 D 3 13 D 3 14 D 3 15 D 4 D 4 1 D 4 2 D 4 3 D 5 D 5 1 D 5 2 D 5 2 1 D 5 2 2 D 5 2 3 D 5 2 4 Handler with telescopic GTH 2506 MAINTENANCE Section D MAINTENANCE TABLE OF CONTENTS LUBRICANTS HEALTH AND SAFETY PRECAUTIONS D 2 ROUTINE MAINTENANCE Kaya o Fw YR RP beet D 3 il SHAS spit me D 4 MAINTENANCE JOBS D 5 Disconnecting ihe batery eorr ee D 5 Access to the engine and tanks compartments D 6 EC REED e T p D 7 D 8 Bd suut
77. he cab interior and especially from pedals and control levers e Remove oil grease and mud from pedals and control levers e Make sure that your hands and shoe soles are clean and dry e Check the seat belts can be fastened properly e Check that lights indicators side tail lights hazard indicator lights wipers and horn are in working order e Adjust the driving seat so that you can reach all control levers comfortably and fully depress the brake pedal without moving your back from the driving seat e Adjust the rear view mirrors to give you a good view close behind the machine when you are correctly seated e Check the parking brake is engaged 4 1 1 When power is turned on the load limiting system activates automatically Ifthe power supplied is correct the green light 4 above the Terex logo comes on The display remains off while the system runs a self test After that the system is activated and 0 appears on the display If during the check phase the load limiting system finds a fault it enters the safety mode automatically blocking any dangerous manoeuvres and an error message starts flashing on the display For any further information refer to chap C 5 2 Also check the efficiency of the safety devices as described in chap D 3 15 namely e overload warning system e joystick pushbutton not present in the TCE version e seat micro switch only in the TCE version e parking brake proximity switch
78. he greatest care and always remember to refit them before starting the engine and using the machine again e Before any maintenance or repair work stop the engine and disconnect the batteries e Do not lubricate clean or adjust moving parts Do not carry out operations manually when specific tools are provided for this purpose e Absolutely avoid to use tools in bad conditions or in an improper way i e pliers instead of adjustable wrenches etc 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 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 Neither smoke nor use open flames in areas subject to fire dangers and in presence of fuel oil or batteries asm Page B 6 Document 57 0003 5200 11 2003 Genie Do not leave fuel cans or bottles in unsuitable places Do not empty catalytic mufflers or other vessels containing burning materials without taking the necessary precautions e Carefully handle all flammable or dangerous substances e Do not tamper with fire ex
79. he hydraulic circuit The braking system has two bleeding valves valve for the service brake circuit and valve for the negative parking brake circuit To bleed the circuit of the service brake e Make sure that the oil is level within the feeding tank 0 e Step on the brake pedal repeatedly Slowly unscrew valve and re close it as soon as oil mixed with air bubbles comes out e Repeat the operation until bubble free oil comes out e Bleed from both sides of the machine To bleed the circuit of the negative parking brake Press the parking brake button 9 As soon as the light indicator on the button goes off start bleeding through valve Q until air free oil comes out D 3 5 1 Checking the brake oil level The oil within the braking circuit must be at about 2 cm from the tank plug 0 Page D 9 Document 57 0003 5200 12 2003 Genie Handler with telescopic GTH 2506 D 3 6 ENGINE AIR FILTER Clean the engine air filter every 10 hours replace the filtering element if necessary 1 Cleaning and changing the external element Stop the engine and engage the parking brake Unscrew wingnut A and remove cover B Unscrew wingnut C and remove the outer element D Clean the filter bowl Clean the cartridge by beating it some times on the ground paying attention not to damage the filtering element Do not dry clean the filtering
80. hine to grant it efficient conditions and a long life By means of a pump inject grease into the special greasers As the fresh grease comes out stop the operation The greasing points are shown in the following figures thesymbol represents the points to be greased by a pump the symbol EN represents the points to be greased by a brush Page D 7 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 MAINTENANCE D 3 4 TYRES AND WHEELS Over inflated or overheated tyres can burst Do not flame cut or weld the wheel rims For any repair work call in a qualified technician YES NO For the tyre inflation or substitution please refer to the table below GTH 2506 Dimensions 12 16 5 EM14 Load index pr 10 Rim 9 75x16 Wheel disc 8 holes DIN 70361 Pressure 4 5 65 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 ATTENTION Always use tyres having the dimensions indicated in the vehicle registration card Page D 8 Document 57 0003 5200 12 2003 Genie Handler with telescopic bbom GTH 2506 MAINTENANCE D 3 5 BRAKES e For any intervention on the braking system adjustment and or substitution of the brake discs call in a specialised technician The malfunctioning of the braking system may depend on the presence of air within t
81. iled Not activated Indicator light low battery charge Signals a low charge by the alternator 64 65 Indicator light low engine oil pressure It lights when the engine oil pressure is too low Page C 14 Document 57 0003 5200 11 2003 Genie Handler with telescopic bbom GTH 2506 OPERATING INSTRUCTIONS C 3 4 CONTROL LEVER Handlers are equipped with an hydraulically driven servo controlled lever The lever is equipped with two buttons for locking releasing the attachments and for extending retracting the telescopic boom When shifted to one of the four directions right left forward back it controls the boom lifting lowering and the forward back pitching of the attachment frame It is also equipped with an intentional control button that must be pressed and held in position until the movement is completed If the button is not pressed down the lever though operated does not perform any function IMPORTANT In the TCE version the intentional control pushbutton is not installed For the functions of the control lever in the TCE version please refer to par C 3 4 1 1 IMPORTANT Seize the control lever correctly and move it gently The motion speed of the actuators depends on the lever position a small motion results in a slow motion of the actuators vice versa a full range motion of the lever corresponds to the max speed of the actuator CAUTION
82. inal from the machine battery then from the booster supply Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS Use only a 12V battery other devices like battery chargers etc may cause an explosion of the battery or result in damage to the electrical system Page C 24 Document 57 0003 5200 10 2004 Genie C 4 4 LOW TEMPERATURE STARTING In case of cold starting use an oil with a SAE viscosity adequate to the ambient temperature Please refer to the DEUTZ engine use and maintenance manual 40 Er 0 10 15 25 The machine is supplied with oil SAE 15W 40 To start the engine from cold proceed as follows e Put the mechanical gear lever to neutral e Turn theignition switch to position and wait until the warning light 28 signalling the glow plugs preheating goes off Step down on the gas pedal and start the engine turning the ignition switch to Release as soon as the engine starts e Let the engine run at idle for a few seconds before putting a gear this allows for a gradual warm up of the engine oil and a better lubrication e Incase of engine jump starting remove the booster ables see chapter C 4 3 Handler with telescopic GTH 2506 OPERATING INSTRUCTIONS irs C 45 DISCONNECTING THE BATTERY During maintenance or repair works and while welding turn off the battery main switch located behind the rear right wheel compartment 46 STARTING
83. ing cylinder Presence micro switch in driving seat only in the TCE version Overload warning system Electronic card and display Emergency stop pushbutton Dead man pushbutton on control lever not present in the TCE version Page G 20 Document 57 0003 5200 10 2004
84. intenance Visually check for damage before using the fork Check for hydraulic oil leaks Daily grease the joints using a greasing pump and the sliding profiles with graphitized grease Characteristics Width mm 1980 Length mm 900 Height mm 800 Weight kg 315 Teeth 9 13 9 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 TH OPTIONAL ATTACHMENTS Intentionally blank page Page F 10 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 TABLES AND DOCUMENTS ENCLOSED Section G TABLES AND DOCUMENTS ENCLOSED TABLE OF CONTENTS G 1 TORQUE WRENCH SETTING was ie ta n ERE FEDERE E bs Pn S G 2 G 2 1 Load Charl ATOKE eem E G 3 G 2 2 Load Chart WUT TOKS eae a G 4 G 3 1 Wiring diagram Fuses dac ret es nasa kei s G 5 G 3 2 1 PO G 7 G 3 2 2 2 n G 8 G 3 2 3 G 9 G 3 2 4 vir rui eR G 10 G 3 2 5 Leder bol e G 11 G 3 2 6 sa e ar EE or LU UHR G 12 G 3 2 7 dagta n 13 G 3 2 8 G 14 G 3 2 9 1 Wiring diagram 9 9 valid up to serial no 10739 G 15 G 3 2 9 2 Wiring diagram 9 9 valid from serial no 10740
85. ionare la leva in direzione per bloccare gli attrezzi in direzione per sbloccarli ATTENZIONE E vietato utilizzare la macchina e gli accessori senza prima aver letto e compreso le norme di utilizzo e di sicurezza contenute nel manuale di istruzioni 1 mancato rispetto delle norme di utilizzo di sicurezza puo causare pericolo grave all operatore a terzi INDICATORE DI STABILITA ARB Durante il lavoro mantenere sotto controllo l indicatore di stabilit Gli 8 LED indicano LED verdi 1 2 3 4 Macchina stabile Le istruzioni sono consegnate con la macchina e copie aggiuntive LED gialli 5 6 Macchina instabile Spia rossa possono essere richieste al rivenditore o direttamente a Terexiift lampeggiante ed allarme acustico operatore responsabile del rispetto delle norme sopra riportate intermittente een f LEDross emitente alarme Pericolo gi 9 Sollevare carichi se la macchina appoggia su terreno l instabile o inclinato ribaltamento Spia rossa accesa ed sollevare mai carichi superiori a quelli indicati in allarme acustico continuo Eseguire il Non 50 Non sono ammesse manovre di sollevamento con macchina in movimento Prima di abbandonare il posto di manovra abbassare eventuali carichi sospesi portare in posizione di riposo gli organi di comando del braccio posizionare la leva marcia avanti indietro in folle inserire il freno a mano e arrestare il motore Xx rientro in cond
86. ions always referto these charts CAUTION The load charts illustrated this manual are given only as a mere example To define the payload limits refer to the load charts applied within the cab of your machine Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS raj CAUTION The load charts applied on the cab windscreen refer to a stationary machine standing on a solid and level ground Raise the load some centimetres and check its stability before raising it completely Page C 27 Document 57 0003 5200 10 2004 Genie C 5 2 LOAD LIMITER On the front top strut of the cab there is limiter 34 which warns the operator of the variation of stability of the machine and blocks any manoeuvre before the same reaches a critical condition C 5 2 1 Description of the controls Calibration selection button Display Stability indicator with LED bar Green light power OK Yellow light calibration mode Calibration confirmation button Not used Yellow light outrigger position Buzzer ON OFF pushbutton Red light overload pre alarm alarm The digit on display 2 shows the selected attachment or the alarm code C 5 2 2 Operation When power is turned on light 4 comes on The display 2 remains off and the monitoring system runs a self test before displaying digit to warn that the system is activated During
87. iously injured if accumulators are not completely depressurised To depressurise the accumators just steer the machine wheels some times with engine shut down until noticing a gradual binding of the handwheel CAUTION Before any operation on hydraulic lines or components make sure there is no residual pressure Forthis purpose stop the engine engage the parking brake and operate the control levers of the distributors in both working directions alternately to depressurise the hydraulic circuit Handler with telescopic boom GTH 2506 MAINTENANCE ATTENTION 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 ATTENTION 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 D 3 1 DISCONNECTING THE BATTERY During maintenance or repair works and while welding turn off the battery main switch located behind the rear right wheel compartment C 4 5 p C 25 Page D 5 Document 57 0003 5200 11 2003 Handler with telescopic boom GTH 2506 MAINTENANCE B D 32 ACCESS TO THE ENGINE AND TANKS COMPARTMENTS Engine compartment For any operatio
88. its working range e While working keep the working area in order Never leave objects scattered they could hinder the machine movements and represent a danger for personnel Do not at any time use the machine during a storm Page B 4 Document 57 0003 5200 11 2003 Genie B 3 2 GETTING READY TO WORK 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 see section D Maintenance CAUTION Set the machine to working configuration and sway it Use the special inclinometer to the right of the driving place to check that the machine is level before operating it e Ensure you have enough fuel to avoid a sudden stop of the engine especially during a crucial 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 machine and in the job site e Incase 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 B 3 3 DURING WORK OR MAINTENANCE During work and especially maintenance always pay the greatest attention e Donot walk or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only e Keep the machine handhold
89. itted directly by the user Page F 5 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 TE OPTIONAL ATTACHMENTS Application 14 MIXING BUCKET Code GTH 2506 Litres 250 59 0400 9000 Quick coupling fitted attachment for mixing and distributing concrete Safety Strictly obey the general safety precautions given in section B SAFETY Operation To load unload the material operate the rotation lever of the attachment holding plate To start the mixing auger operate the attachment locking lever after connecting the feeding lines of the new attachment to the quick couplings see page F 2 Maintenance CAUTION Before any maintenance rest the bucket on the ground stop the machine remove the starter key and lock the cab door to prevent anybody from gaining access to the control panel Visually check the bucket for damage before using it Technical data Wash thoroughly with water after use or in case of 5 prolonged inactivity to prevent the mix or residues from Litres 250 hardening Width mm Check for oil leaks from hoses and connectors Carefully protect the quick connectors once Length disconnected to prevent impurities from entering the Height mm circuit Weight kg SAE capacity m Page F 6 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 OPTIONAL ATTACHMENT
90. izioni di sicurezza Norme per l utilizzo di macchine dotate di stabilizzatori E vietato utilizzare gli stabilizzatori se il carico gi il sollevato gli stabilizzatori servono solamente ad aumentare la stabilit della macchina L uso scorretto degli stabilizzatori causare ribaltamento della macchina Cz D Una apposita spia sul cruscotto indica che gli stabilizzatori E sono abbassati accertarsi che la spia sia Prima di sollevare il carico livellare la macchina controllando l apposito indicatore di livello 2506 i 6 5750 5 500 4 T 3 2 FRE ECT MU o Eds 2 1 ANZ 4 m 4 3 2 1 3340 Document 57 0003 5200 10 2004 Genie Lw dB Description label with yellow background and black inscription showing the Guaranteed sound power level Meaning itindicates the guaranteed sound power level measured in accordance with the Directive 2000 14 EC Location in the cab on the rear left side glass Handler with telescopic GTH 2506 GENERAL INFORMATION rs DANGER ELECTRIC CABLES AND POWER LINES KEEP EVERY PART OF THE MACHINE LOADS AND ACCESSORIES AT LEAST 6 METERS FROM OVERHEAD POWER LINES Description label with transparent background Use limits close to electric lines Meaning it defines the minimum dista
91. ject to modifications Some photos or drawings have been used to illustrate a specific function as a result they may not refer to the machine treated in this manual Copyright 2004 TEREXLIFT srl All rights reserved Produced by vega 12 2003 LIST OF REVISED PAGES 3 C 16 20 C 21 Revision 12 2003 D 1 D 8 D 9 D 13 D 16 Revision 12 2003 E 2 Revision 12 2003 G 9 Revision 05 2004 A 3 A 4 A 5 A 6 A 13 A 18 B 1 B 7 1 C 8 C 9 C 17 C 22 C 24 C 27 C 28 D 19 E 3 Revised pages E 4 E 5 Added pages 10 2004 C 23 C 28 Revised pages 10 2004 A 1 A 3 A 5 A 14 C 1 C 15 C 16 C 19 C 20 C 21 C 22 C 23 D 19 G 10 Revised pages TCE version A 7 C 17 Added pages TCE version 10 2004 D 22 D 23 G 1 G 4 G 5 G 6 G 7 G 8 Revised pages wiring diagram G 9 G 10 G 11 G 12 G 13 G 14 G 15 G 16 Added pages wiring diagram 10 2004 C 1 C 7 C 8 C 18 Revised pages disabling the overload warning system Genie INTRODUCTION This handbook provides information for a safe and proper operation and maintenance of the machine STRICTLY COMPLY WITH THE INSTRUCTIONS GIVEN IN THIS HANDBOOK READ AND UNDERSTAND THIS HANDBOOK BEFORE STARTING USING AND CARRYING OUT ANY OPERATION WITH AND ON THE MACHINE
92. l Page D 24 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 TE MAINTENANCE 0 5 REFUELLING D 5 1 REFUELLING Product Capacity specifications Part Product litres see par Diesel engine Engine oil 11 3 5 0 5 2 1 Fuel tank Diesel fuel 60 D 5 2 3 Hydraulic system tank Hydraulic oil 120 D 5 2 2 Front differential gear with reduction gear 6 D 5 2 2 Front differential gear Oil 5 D 5 2 2 Front wheel reduction gears Oil 1 5 1 5 D 5 2 2 Rear wheel reduction gears Oil 0 7 0 7 D 5 2 2 Brake oil tank Hydraulic oil 0 1 D 5 2 2 D 5 2 PRODUCT SPECIFICATIONS D 5 2 1 Engine oil Use the oil recommended by the Diesel engine Manufacturer see the relevant handbook delivered with the machine At the delivery the machine is refilled with SHELL RIMULA 15W 40 D 5 2 2 Lubrication oils and relevant filtering elements Refill the machine with following lubricants Use Product Definition Power divider Differential gears Reduction gears FUCHS TITAN GEAR LS 85 W 90 API GL 5 LS GL 5 Hydraulic system and brakes SHELL TELLUS T 46 DENISON HF 1 DIN 51524 part 3 Cat HV ATTENTION Never mix different oils this may result in troubles and component breaks Filtering elements Filter Flow 1 1 Filtering Code Transmission oil filter MPS 150 10u 09 4604 0001 Auxiliary circuit oil filter inside the tank STR 100 1 60 u 09 4604 0004 Page D 25 Document 57 0003 5200 11
93. l in a suitable warehouse Pour exhausted oil into cans and deliver them to specialised firms for disposal Oil leaks In case of accidental oil leaks cover with sand or type approved granulate Then scrape off and dispose of it as chemical waste First aid Eyes n case of accidental contact with the eyes wash with fresh water If the irritation persists seek medical advice Intake In case of oil intake do not induce vomiting but seek medical advice Skin n case of a prolonged contact wash with soap and water Fire In case of fire use carbon dioxide dry chemical or foam extinguishers Do not use water Page D 2 Document 57 0003 5200 11 2003 Genie D 2 ROUTINE MAINTENANCE A wrong or neglected maintenance can result in possible risks for both operator and bystanders Make sure maintenance and lubrication are carried out according to the manufacturer s instructions to keep the machine safe and efficient The maintenance interventions are based on the machine working hours Regularly check the hour meter and keep it in good conditions to define the maintenance intervals correctly Make sure any defect detected during the maintenance is promptly rectified before using the machine marked operations must be carried out a skilled technician During the first 10 working hours 1 Check the oil level within reduction gears power divider and differential gear
94. llage Keep metal objects watch straps rings necklaces clear of the battery leads since they can short the terminals and burn you e Before disconnecting the battery set all switches within the cab to OFF To disconnect the battery disconnect the negative lead from the frame earth first Toconnect the battery connect the positive lead first e Recharge the battery far from the machine in a well ventilated place e Keep out of items which can produce sparks of naked flames or lit cigarettes Donotrest metal objects onto the battery This a dangerous short especially during a recharge Because the electrolyte is highly corrosive it must never come in contact with the frame of the handler or electric electronic parts If the electrolyte comes in contact with these parts contact the nearest authorised assistance centre Risk of explosion or shorts During the recharge an explosive mixture with release of hydrogen gas forms Do not add sulphuric acid add only distilled water Page D 21 Document 57 0003 5200 11 2003 Genie Handler with telescopic bbom GTH 2506 TE MAINTENANCE D 4 2 FUSES AND RELAYS Ref Circuit Amp The electrical system is protected by fuses placed in ii inel iod power supply 2 the driving cab on the left Before replacing a blown F25 Parking brake switch power supply 10 fuse with a new one having the same amperage find F26
95. load charts wiring diagrams hydraulic schemes torque wrench setting table etc Handler with telescopic GTH 2506 INTRODUCTION irs Sections are subdivided into chapters and paragraphs that are numbered progressively The quickest way to look for an information is the reference to the general index or the titles of the single chapters and paragraphs that represent keys for an easy consultation Take care of this handbook and keep it in an accessible place within the machine even its reading so that it will always be within reach if in doubt If you are unsure about anything please address to GENIE Assistance Service or to your agent dealer addresses phone and fax numbers are printed in the cover and in the title page of this manual IMPORTANT Any difference between the contents of this manual and the real functional character of the machine be attributed to either a machine manufactured before the issue of this manual orto a manual going to be updated after some changed effected on the machine Always contact Genie Assistance Service for any updated version of this manual and any additional information Page 1 Document 57 0003 5200 11 2003 Genie SYMBOLS When using the machine operators could have to face some situations requiring special care and particular knowledge When these situations involve the safety of operators or bystanders the machine efficiency and proper
96. n in the load chart applied on the cab windscreen or in the quick user s guide e Space the forks as wide as possible to suit the load being handled In the case of floating forks Loosen the nut of the locking screws e Raise the forks and slide them on the pivot until correct spacing Lockthe screws re tightening the nut Page C 30 Document 57 0003 5200 10 2004 Genie C 5 3 2 Working phases When forks are correctly spaced the handler is ready to use Work can be subdivided into three different phases loading transfer and unloading Loading phase e Approach the load to the handled perpendicularly and check that the machine is level on the inclinometer e Insert the forks under the load and raise the load some centimetres e Pitch the forks back and make sure that the overload warning system LEDs are in limits Transfer phase e Do not start or brake abruptly e Drive to the unloading point cautiously and keep the load 20 30 cm from the ground e Suitthe machine speed to the ground conditions to avoid dangerous jumps side skids of the vehicle and possible load falls e When driving on slopes or ramps hold the load uphill Do not drive on slopes sideways this wrong manoeuvre is one ofthe main reasons for accidents due to vehicle overturning Unloading phase e Drive to the unloading point with straight wheels and bring the machine to a smooth stop leaving
97. n within the engine compartment open the protection bonnet Hood is equipped with lock amp key and a supporting rod that holds it in position From the engine compartment you get access to e Thermal engine Engine air filter 9 e Hydraulic oil tank plug e Radiator fluid compensation cup e Battery To get access to the engine compartment e Shut the engine down and put the parking brake e Unlock the bonnet lock e Lift the bonnet using the special handle until it latches in the gas spring close the bonnet press on the green locking device on the gas spring and lower the bonnet Takeallprecautions when approaching the engine compartment Some parts of the engine may be very hot Always use protective gloves Diesel fuel tank compartment To gain access to the fuel tank open the rear cover of the machine as follows e Shut the engine down and put the parking brake e Fully raise the cover by means of the special handle Page D 6 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 TE MAINTENANCE B D 3 3 GREASING Beforeinjecting grease into the greasers thoroughly clean them to avoid that mud dust or other matters can mix with the lubricant and reduce or annihilate the lubrication effect Remove any old grease with a degreaser from the telescopes before smearing them with new grease Regularly grease the mac
98. nce to be kept when the machine is used close to aerial electric lines Location in the cab on the windscreen to the right of the driving place Description label on yellow background not open while engine is running Meaning do not open the engine bonnet when engine is running since this may result in serious injury due to moving parts or hot components Location on the engine bonnet Page A 4 Document 57 0003 5200 05 2004 Genie Handler with telescopic GTH 2506 GENERAL INFORMATION Description label with transparent background Load chart Meaning it defines the exact working limits of the machine in terms of payload and reach to be strictly respected by the operator when using the machine Location in the cab inside the quick guide fixed to the upright with a magnet In the TCE version the label is applied on the cab glass to the right of the driving seat IMPORTANT The load charts shown in these pages are supplied as mere example For the payload limits see the load charts referring to the specific machine model Page A 5 Document 57 0003 5200 10 2004 Genie KEEP OUT OF WORKING RANGE Description red white label Keep out of the working range of the machine Meaning when the machine is running entering the working range of the machine is prohibited Location on the telescopic boom both on the righ
99. ng element and refit the inspection hatch 4 Check the oil level within the tank Add new oil if necessary Page D 14 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 MAINTENANCE D 3 11 OIL LEVEL IN THE DIFFERENTIAL GEARS AND THE REDUCER D 3 11 1 Front and differential gears To check the oil level in the front and rear differential gears e Stop the machine on a level ground and engage the parking brake Loosen level plug and check if oil is level with the hole e If necessary add new oil through the hole of the level plug until it comes out e Refit and tighten plug For the oil change e Place a container of suitable size under plug 9 Loosen the plug and the level plug and allow oil to flow out from the differential gears e Refit and tighten drain plug Add new oil through plug until it is level with the hole e Refit and tighten level filler plug D 3 11 2 Reducer To check the oil level in the reducer e Stop the machine on a level ground and engage the parking brake Loosen level plug and check if oil is level with the hole e If necessary add new oil through the hole of the level plug until it comes out e Refit and tighten plug For the oil change e Place a container of suitable size under drain plug Loosen the drain plug 6 and the level plug 9 and allow oil
100. ng of the error messages is shown in Section E Faults and Troubleshooting To do amanual check it will be enough to load a weight exceeding the maximum permitted with the boom fully out and attempt to lift it The system shall enter in alarm should that not be the case contact GENIE Technical Service Checking the machine start control at every use Attempt to start the engine with the forward or reverse gear put The engine must not start If the engine starts contact the GENIE Technical Service Repeat the operation putting first one gear then the other Checkingthe seat micro switch only in the TCE version at every use To check if the seat micro switch is in efficient working order simply attempt to start the machine without being seated The machine must remain stopped Should that not be the case contact GENIE Technical Service Handler with telescopic boom GTH 2506 MAINTENANCE raj Checking the emergency stop pushbutton at every use To check the efficiency of this pushbutton simply press it down during a movement The pressure of the pushbutton shall cause the movement to stop and the engine to shut down Should that not be the case contact GENIE Technical Service Checking the joystick pushbutton not present in the TCE version at every use To check if the pushbutton on the control lever is in efficient working order it will be enough
101. ns F10 F24 15 F9 F23 K04 F8 F22 lf 5 F6 F20 F5 F19 F4 F18 K02 5 F3 F17 QM KO1 K06 7 5 Fi Fi5 7 5 10 lol lol i Ref Circuit Amp 15 10 F30 Preheating control unit maxifuse 50 F31 System protection fuse 50 K11 Start relay A02 Preheating control unit 5 A02 F30 F31 11 5 15 15 15 7 5 10 RELAYS 10 Ref Circuit 7 5 K01 Starting enabling command 5 K02 Forward speed enabling command 10 Inhibition with brake pedal stepped down K04 Overload warning system control unit enabling command K05 Reverse speed enabling command Overload warning system solenoid valve enabling command Page G 5 Document 57 0003 5200 10 2004 Genie Handler with telescopic bbom GTH 2506 ra TABLES AND DOCUMENTS ENCLOSED Intentionally blank page Page G 6 Document 57 0003 5200 10 2004 Handler with telescopic boom GTH 2506 TABLES AND DOCUMENTS ENCLOSED Genie G 3 2 1 WIRING DIAGRAM 1 9 30 30 21010 21010 15 15 VT WHo1 S LOQU HM 59019 ONILV3H3Hd 1H9 19NINHVM wm S LOQU HM HOLIMS 39NVHO 503 2 C10 OG GNo1 5 BU RDo1 6 E8 Eo Se Long AD 108 C oN 5 5 tr pup ee M 1 1098 kong H L HWLA ex 2 om LOCIH HM H i d H i H i 4
102. ntenance keeps the machine in a safe and efficient working condition For this reason it is advisable to wash grease and service the machine properly especially after having worked under particular conditions muddy or dusty environments heavy operations etc Always ensure all machine components are in good condition Check for oil leaks or loosening of guards and make sure that the safety devices are efficient In case of defects find and rectify them before using the machine again The maintenance interventions are based on the machine working hours Regularly check the hour meter and keep it in good condition to define the maintenance intervals correctly Not respecting the ordinary maintenance schedule of this manual automatically voids GENIE warranty IMPORTANT For the engine maintenance please refer to the specific Operator handbook supplied with the machine Handler with telescopic GTH 2506 MAINTENANCE LUBRICANTS HEALTH AND SAFETY PRECAUTIONS EN D 1 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 oi
103. oes not result in an uncontrolled movement of the machine Page D 20 Document 57 0003 5200 11 2003 Genie 0 4 ELECTRICAL SYSTEM All maintenance interventions must be carried out with engine stopped parking brake engaged working attachments on the ground and gearbox lever in neutral When raising a component for maintenance purposes secure it in a safe way before carrying out any maintenance Before any operation on hydraulic lines or components make sure there is no residual pressure Forthis purpose stop the engine engage the parking brake and operate the control levers of the distributors in both working directions alternately to release the pressure from the hydraulic circuit D 4 1 BATTERY e Check the electrolyte level every 250 working hours if necessary add distilled water Ensure the fluid is 5 6 mm above the plates and the cell levels are correct Check the cable clips are well secured to the battery terminals To tighten the clips always use a box wrench never pliers Protect the terminals smearing them with pure vaseline Remove the battery and store it in a dry place when the machine is not used for a long time Handler with telescopic boom GTH 2506 MAINTENANCE Battery electrolyte contains sulphuric acid It can burn you if it touches your skin and eyes Always wear goggles and protective gloves and handle the battery with caution to prevent spi
104. of the driving place Page A 7 Document 57 0003 5200 10 2004 GENERAL INFORMATION Genie Handler with telescopic GTH 2506 1 3 EXPLANATION OF THE DIFFERENT SYMBOLS USED ON THE MACHINE IMPORTANT This paragraph illustrates those symbols that are normally applied on the main control devices and instruments of a standard machine and those that can be applied on accessories or special attachments They are mainly ISO standardised symbols that are now part of the common life But we consider useful to explain them once again Spend the necessary time to become familiar with these symbols and to learn their meaning Symbol Symbol Description Description Hazard warning lights Steering mode switch Engine oil pressure SZ Windscreen wiper 9 P xod T Q7 Windscreen washer Boom down ae Cab ventilation fan Boom out Fuel gauge Boom in n Hydraulic oil temperature Attachment locked 2006 Position lights Attachment unlocked High beam lt gt Turn signals Fork pitching forward 5 Parking brake Battery charge Fork pitching back Oil filter clogged Attachment pushbutton Air filter clogged Glow plug preheating BEES Page A 8 Document 57 0003 5200 10 2004 GENERAL INFORMATION Genie Handler with telescopic bbom GTH 2506 TE Symbol Description Symbol Description Front
105. ok makes use of special safety symbols to stress any potentially hazardous situation CAUTION The instructions given this handbook are the ones established by GENIE They do not exclude other safe and most convenient ways for the machine installation operation and maintenance that take into account the available spaces and means If you decide to follow instructions other than those given in this manual you shall absolutely sure that the operations you are going to carry out are not explicitly forbidden sure that the methods are safe say in compliance with the rules and provisions given in this section sure that the methods cannot damage the machine directly or indirectly or make it unsafe contact GENIE Assistance Service for any suggestion and the necessary written permission IMPORTANT If in doubt it is always better to ask For this purpose contact GENIE the assistance service is atyour disposal Addresses phone andfax numbers are given in the cover and in the title page of this manual Handler with telescopic boom GTH 2506 SAFETY raj EE B 2 REQUISITES OF THE PERSONNEL IN CHARGE B 2 1 REQUISITES OF THE MACHINE OPERATORS The operators who use the machine regularly or occasionally i e for transport reasons shall have the following prerequisites health before and during any operation operators shall never take alcoholic beverages medicines or other sub
106. oom extraction retraction Smoothly shift the lever to position D to extend the boom or to position C to retract it Attachment forward back tilting Press button 2 and shift the lever to position D to tilt the frame forward or to position C to tilt it back e Attachment coupling release Press button 3 together with the dashboard ena bling button 17 and shift the lever to position D to unlock the attachment or to position C to lock the attachment Before operating the boom make sure that no persons or animals are within the working range of the machine Should that be the case wait until the intruders leave the working range before operating the handler Page C 17 Document 57 0003 5200 11 2003 3 4 2 Emergency stop The operated functions can be stopped at any time by pressing the emergency stop button 21 By pressing this button the engine of the machine is shut down Before restarting the machine it is necessary to reset the pushbutton by rotating clockwise CAUTION Before restarting the machine find and rectify the faults that caused the emergency 2 6 8 10 4 Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS rs C 3 4 2 1 Disabling the load limiting system The key switch 30 lets you disable the load limiter WORKING WITH THE L
107. opic boom GTH 2506 OPERATING INSTRUCTIONS Lights function The lever operates the light switching and shall be used in conjuntion with pushbutton 12 S o a M 12 Road lights switch 2 Pushbutton in pos 1 Lever in position or Lights OFF Three position switch placed on the dashboard on the right hand side over the ignition switch Pushbutton in pos 2 the warning light 61 comes on Lever in position or Q Position lights ON Pushbutton in pos 3 e Lever in position high beam ON the warning lights 60 and 61 come on Lever in position low beam ON the warning light 61 comes on Leverin position high beam intermittent signalling releasing the lever it springs back to position Page C 10 Document 57 0003 5200 11 2003 Genie 3 2 4 Brakes 8 Service brake pedal Gradually step on the brake pedal to decelerate and stop the machine The pedal operates on the front axle Fully depressing the brake pedal causes a reset of the displacement of the power drive pump making the brake action more powerful 19 Parking brake The parking brake of negative type engages automatically when the engine is stopped When the handler s engine is restarted pressing the pushbutton switch 19 unlocks the parking brake To stop the handler without shutting down the engine press the pushbutton switch 19 to engage the parking brake and push it once again to disen
108. or engine oil temperature indicator Front left rear right position lights fuel gauge hourmeter warning lamps lighting engine oil cooling temperature indicator light fan switch lights selection switch Right low beam Left low beam Right high beam Left high beam High beam warning lamp Horn Windscreen washer kit Optional Optional Optional Preheating control unit power supply Power supply hydraulic stop fuel gauge hourmeter warning lamps indicator engine oil cooling temperature indicator engine oil temperature indicator K04 relay pickup air filter warning light preheating warning light road safety switch Power supply hazard warning light and turn signals switch 15 Power supply light switch windscreen washer switch windscreen washer motor Heating system fan power supply Road safety switch power supply Power supply beacon Engine stop mushroom head button power supply Relay K02 Relay K05 power supply Relay K06 power supply Parking brake switch power supply Optional Optional Optional Spare fuses Handler with telescopic boom GTH 2506 TABLES AND DOCUMENTS ENCLOSED e Jn A F14 F28 229 1 mp INT em A gt 15 F12 F26 75 a
109. or 15 F3 F17 F19 Heating system fan power supply 15 EN F20 Road safety switch power supply 7 5 m 2 21 Power supply beacon 10 Fi F15 F22 Engine stop mushroom head button power supply 10 F23 Relay K02 Relay KOS power supply 75 0 22 Document 57 0003 5200 10 2004 Genie MAINTENANCE Engine compartment fuses and relays Ref Circuit Amp F30 Preheating control unit maxifuse 50 F31 System protection fuse 50 K11 Start relay A02 Preheating control unit B Fuse boxrelays Ref Circuit 1 Starting enabling command K02 Forward speed enabling command Inhibition with brake pedal stepped down 04 Overload warning system control unit enabling command K05 Reverse speed enabling command Overload warning system solenoid valve enabling command ATTENTION not use fuses having a higher amperage than that recommended since they can damage the electric system seriously e If the fuse blows after a short time look for the fault source by checking the electric system Always keep some spare fuses for an emergency e Never try to repair or short blown fuses e sure the contacts of fuses and fuse sockets ensure a good electric connection and are not oxidised Page D 23 S Handler with telescopic boom GTH 2506 A02 F30 F31
110. or a safer and more efficient use of the machine PROTECT THE ENVIRONMENT Draws the attention to important environment related information WHEN READING THIS MANUAL PAY THE GREATEST ATTENTION TO THESE SPECIAL SYMBOLS AND THE EXPLANATION OF THE SITUATIONS THEY EMPHASIZE The manual in electronic format also contains the following symbol which enables the user to return to the table of contents Page 2 Document 57 0003 5200 11 2003 Genie Handler with telescopic bbom GTH 2506 GENERAL INDEX GENERAL INDEX GENERAL INFORMATION SAFETY OPERATING INSTRUCTIONS MAINTENANCE TROUBLESHOOTING OPTIONAL ATTACHMENTS TABLES AND DOCUMENTS ENCLOSED Page 3 Document 57 0003 5200 11 2003 Sect Sect Sect Sect Sect Sect Sect gt Genie Handler with telescopic bbom GTH 2506 TH Intentionally blank page Page 4 Document 57 0003 5200 11 2003 Genie A 1 A 1 1 A 1 2 A 1 3 A 2 A 2 1 A 2 2 A 2 3 A 2 4 A 2 5 A 2 6 A 3 A 3 1 A 3 2 A 3 3 A 3 4 A 3 5 A 4 A 4 1 A 4 2 A 4 3 A 5 A 5 1 A 5 2 A 5 3 A 5 4 A 5 5 A 5 6 A 5 7 A 5 8 A 5 9 A 5 10 A 6 A 7 A 7 1 Handler with telescopic GTH 2506 GENERAL INFORMATION Section A GENERAL INFORMATION TABLE OF CONTENTS CONVENTIONAL REFERENCES Machine POSION iois aae a Aai aaa a Labels and warning plates applied on the
111. p to the user to adopt the necessary safety measures to work in safety conditions B 7 Document 57 0003 5200 05 2004 Genie Handler with telescopic GTH 2506 TH SAFETY Intentionally blank page Page B 8 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 OPERATING INSTRUCTIONS Section OPERATING INSTRUCTIONS TABLE OF CONTENTS C 1 BEFORE ENTERING THE MACHINE C 2 C 3 4 6 2 ENTERING THE MACHINE C 3 C 4 C 2 1 Entering the C 3 C 4 1 C 2 1 4 Emergency exit way C 4 C 4 1 1 C 2 2 Adjusting the seat C 5 C 4 2 C 2 3 Fastening the seat belts C 5 C 4 3 C 2 4 Adjusting the steering column C 6 C 4 4 C 2 5 Adjusting the rear view mirrors C 6 C 4 5 C 2 6 Switching on the cab interior lamp C 6 C 4 6 C 3 DRIVING PLACE C 7 C 4 7 C 3 1 Controls and instruments Cat C 5 C 3 2 Engine controls and instruments 9 5 1 0321 Ignition 9 5 2 C 3 2 2 Forward reverse gear switch C 9 C 5 2 1 C 3 2 3 Turn signals windscreen wiper C 5 2 2 lights horn Switch essere C 10 C 5 2 3 OS Ie MCs Cr Penner ene oe eee eee 11 5 3 C 3 2 5 Accelerator control C 11 C 5 3 1 C 3 2 6 Pushbutton enabling the attachment C
112. pic GTH 2506 TE GENERAL INFORMATION 5 TECHNICAL DATA AND PERFORMANCE D lt H gt gt A 5 1 MAIN DIMENSIONS GTH 2506 A Overall height mm 1920 B Height to the steering wheel mm 1230 C width mm 1800 D Cab width mm 860 E Track mm 1500 Wheel base mm 2280 G Length to the front tyres mm 3310 H Length to the attachment holding plate mm 3720 Ground clearance mm 360 Internal steering radius mm 1730 e External steering radius mm 3400 B A 5 2 RESTRICTIONS OF USE e Angle of approach 90 e Departure angle 70 e Ambient temperature 20 40 5 3 e Weight in working order kg 4470 A 5 4 SPEED Travel speed km h 23 Max slope with full load 6096 Page A 18 Document 57 0003 5200 10 2004 Genie Handler with telescopic GTH 2506 GENERAL INFORMATION 5 5 PAYLOAD AND REACH 2506 Maxlifting height mm 5750 Reach at max height mm 450 Maxreach forward mm 3340 Attachment holding plate rotation 135 Maximum payload kg 2500 Payload at max height kg 1250 Payload at max reach kg 800 B A 5 6 FORKS Fixed type Floating type Dimensions mm 1200x100x35 1200x100x40 Weight kg 45445 52452 Fork holding frame class FEM II A FEM II A B A 5 7 DIESEL ENGINE Aspirated version Make DEUTZ
113. rigger limit switches or replace if necessary THE LOAD LIMITING SYSTEM IS BLOCKED red lit Low stability Retract the load within safety limits If the error message is still shown move the boom to rest condition operating the overload warning system cutout key and contact your nearest authorised service centre CHECKING THE MICRO SWITCHES WHEN THE ARB IS IN ALARM THE BOOM IN OUT MOVEMENTS THE OUTRIGGER UP MOVEMENT AND THE MACHINE SWAY FUNCTION REMAIN ACTIVATED Check that the connectors are correctly plugged in the actuator If the connectors are plugged in correctly contact the GENIE Technical Assistance CHECKING THE MICRO SWITCHES WITH THE BOOM RAISED 2 METRES ABOVE THE GROUND THE OUTRIGGER UP MOVEMENT AND THE MACHINE SWAY FUNCTION REMAIN ACTIVATED Check that the connectors are correctly plugged in the actuator If the connectors are plugged in correctly contact the GENIE Technical Assistance Page E 3 Document 57 0003 5200 05 2004 Genie Handler with telescopic GTH 2506 FAULTS AND TROUBLESHOOTING irs THE DLE LOAD LIMITING SYSTEM IS IN ALARM Fuse blown F25 10 A System failure Check and necessary replace fuse if ERROR MESSAGES OF THE DLE LOAD LIMITING SYSTEM SHOWN ON THE DISPLAY 1 E2PROM error 2 The value read from CELL 1 is higher than max permissible 3 The value read from CELL 2 is higher than max permissi
114. rocedures adopted during the check or replacement of a block valve residual pressure uncontrolled movements e Hazards deriving from work procedures adopted while disassembling parts of the machine e g the cylinders without supporting mobile parts suitably risk of uncontrolled fall of the mobile part e Hazard deriving from an accidental overturning of the machine in the event the operator has not fastened the safety belts Page A 12 Document 57 0003 5200 10 2004 Genie Handler with telescopic bbom GTH 2506 GENERAL INFORMATION A 3 4 APPLICABLE STANDARDS For the operator s safety the following standards were obeyed during the risk assessment ofthe handler fitted with telescopic boom Directive 98 37 CE 89 336 CEE 2000 14 CE Standard EN 1459 1988 EN 281 1988 EN 1175 2 1998 prEN ISO 13564 1996 ISO 2330 1995 ISO DIS 3287 ISO 3449 1992 EN 13510 2002 ISO 3776 1989 ISO 3795 1989 ISO 5053 1987 ISO 6292 1996 EN 13059 2002 Title Machinery Directive Electromagnetic compatibility Environment Acoustic Emissions Title Harmonised standard Safety of industrial trucks Self propelled variable reach trucks Self propelled industrial trucks sit down rider controlled Rules for the construction and layout of pedals Electrical requirements General requirements of internal combustion engine powered trucks Test method for measuring visibility from self propelled truck
115. s Fork lift trucks Fork arms Technical characteristics and testing Powered industrial trucks Pictorial signs Control symbols Earth moving machinery Falling object protective structures Laboratory tests and performance requirements Earth moving machinery Roll over protective structures Laboratory tests and performance requirements Tractors for agriculture Seat belt anchorages Road vehicles tractors and machinery for agriculture and forestry Determination of burning behaviour of interior materials Powered industrial trucks Terminology Powered industrial trucks and tractors Brake performance and component strength Safety of industrial trucks Test methods for measuring vibration EN 50081 1 1997 Electromagnetic compatibility Generic requirements on emissions Part 1 EN 50082 1 1997 Electromagnetic compatibility Generic requirements on immunity Part 1 EN 60204 1 1998 Safety of machinery Electrical equipment of machines Part 1 Page A 13 Document 57 0003 5200 10 2004 Genie Handler with telescopic GTH 2506 GENERAL INFORMATION A 3 5 SAFETY DEVICES Load limiting device A load cell is fitted to the rear axle The cab display with 8 LED s 4 green 2 yellow and 2 red lets you estimate the variation of stability of the machine e Emergency stop pushbutton when pressed down it stops the engine and blocks the movements of the machine Before
116. s 2 Regularly check the tightening of the wheel bolts 3 Checkthe tightening of all bolts and nuts 4 Checkthe couplings for oil leaks Within the first 50 working hours 1 Change the oil for the first time Every 10 working hours or daily Check the engine oil level Clean the air suction filter Clean the radiator if necessary Check the hydraulic oil level in the tank Check the greasing of the boom section pads Grease the attachment holding frame Grease all joints of the boom the rear axle shaft joint the transmission shafts the front and rear axles and any equipment of the machine Check the efficiency of the lighting electric system 9 Checktheefficiency of braking system and parking brake 10 Check the efficiency of the steering selection system 11 Checkthe efficiency of the fork balancing system 12 Makesurethe safety devices installed are in efficient working order see procedure chap D 3 15 NO oa fh OD Handler with telescopic boom GTH 2506 MAINTENANCE Every 50 working hours or weekly Jobs to be done in addition to those above 1 Check the tension of the alternator belt 2 Checkthe tyre inflation 3 Checkthe tightening of the wheel nuts 4 Checkthe tightening of the Cardan shaft screws Every 250 working hours or monthly Jobs to be done addition to those above 1 Change the engine oil and relevant filter 2 Check the oil level in the front and rear differential gears and th
117. s and access steps always clean from oil grease or dirt to prevent falls or slips Page B 5 Handler with telescopic GTH 2506 TE SAFETY 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 type approved safety belts or fall preventing devices al 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 Document 57 0003 5200 11 2003 Genie Handler with telescopic GTH 2506 TE SAFETY e Except for maintenance purposes do not remove safety devices shields protection cases etc Should their removal be necessary stop the engine remove them with t
118. so a prompt and timely intervention of the operator when he shall carry out sudden manoeuvres to safeguard his safety and the machine integrity It is necessary to learn how to use and foresee the machine reactions Learn how to operate the machine controls in a safe and open place without obstacles and anybody standing around Do not ram the controls Operate them slowly to understand their effect on the machine Handler with telescopic GTH 2506 OPERATING INSTRUCTIONS BEFORE ENTERING THE MACHINE Checks and cleaning e Clean glasses lights and rear view mirrors e Check that pins joints and bolts are well tightened in position Check for oil fuel or coolant leaks 1 Checking the tyres Check the correct inflation of the tyres see par Tyre inflation in the Maintenance section e sure that the tyre plies are not cut or worn A tyre burst may result in serious injury never use the machine if tyres are worn wrongly inflated or damaged Page C 2 Document 57 0003 5200 11 2003 Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS C 2 ENTERING THE MACHINE C 2 1 ENTERING THE CAB VN CAUTI ON The upper section of the door must be secured to the rear part of the driving cab or latched to the lower section of the same door Always make sure that your hands and shoe soles are clean and dry before getting into the driving cab Always face
119. stances 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 familiarise with this handbook its enclosed graphs and diagrams the identification and hazard warning plates They shall be skilled and trained about the machine use IMPORTANT The operator shall have a licence or a driving licence when provided for by the laws enforced in the country where the machine works Please ask the competent bodies In Italy the operator must be at least 18 year old Page B 2 Document 57 0003 5200 11 2003 Genie B 2 2 REQUISITES OF THE SERVICEMEN The personnel charged with the machine maintenance shall be qualified specialised in the maintenance of earth moving machines 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
120. starting work again find and rectify the causes which compelled to an emergency stop then reset the button to neutral position pressing it down while turning clockwise e Safety pushbutton on joystick dead man button Not present in the TCE version This button must be pressed and held down while executing a function with the control lever If the 4 Presence micro switch in the driving seat only in the TCE version Located inside the seat cushion it prevents any machine starting if the operator is not correctly seated in the driving seat Page A 14 Document 57 0003 5200 10 2004 Y L nie Handler with telescopic GTH 2506 Ta GENERAL INFORMATION Block valves fitted to all cylinders A Block valve on attachment coupling cylinder B Block valve on lifting cylinder C Block valve on balance cylinder D Block valve on boom extension cylinder E Block valve on attachment pitching cylinder Page 15 Document 57 0003 5200 10 2004 Genie Handler with telescopic GTH 2506 TE GENERAL INFORMATION 4 GENERAL DESCRIPTION A 4 1 LIST COMPONENTS Forks Attachment holding frame 219 boom section 1 boom section Engine hood Driving cab according to ROPS FOPS provisions Left rear view mirror Beacon Front axle 10 Chassis 11 Left front wheel mud guard 12 Left front wheel red
121. t and on the left Description label with white background Keep out of the working range of the machine Meaning when the machine is running entering the working range of the machine is prohibited Location one on the right side in the casing of the engine compartment one on the left side on the fuel tank Handler with telescopic boom GTH 2506 GENERAL INFORMATION Description label on yellow background with black drawing Hotsurfaces Risk of burns Meaning Applied on those surfaces which during operation can become hot and cause burns Location In all parts involved such as exhaust silencer thermal engine heat exchanger Description label on yellow background with black drawing Description Unscrew the plug with extreme caution hot oil Risk of burns Meaning Warnsthe operator ofthe risk of burns when unscrewing the plug ofthe compensation tank ofthe heat exchanger Location on the heat exchanger Page A 6 Document 57 0003 5200 05 2004 Genie Handler with telescopic GTH 2506 GENERAL INFORMATION WARNING ONLY AUTHORIZED PERSONNEL CAN OPERATE THIS EQUIPMENT THE MANUFACTURER DEALER TAKE NO RESPONSABILITY FOR DAMAGE OR INJURY CAUSED BY MISUSE OF THIS EQUIPMENT BEFORE OPERATING THE MACHINE ENSURE YOU HAVE READ AND UNDERSTOOD THE SAFETY GUIDELINES GIVEN IN THE MACHINE S MANUAL THE INSTRUCTIONS ARE DELIVERED WITH THE MACHINE ADDITIONAL
122. te the end adjusters to reach the length you wish and make sure the buckle is always in the middle Page C 5 Document 57 0003 5200 11 2003 Genie C 24 ADJUSTING THE STEERING COLUMN Both steering column and dashboard can be set to a different angle For this purpose e Loosen lever 1 and adjust as required then re tighten lever 1 Before driving the machine ensure the steering wheel is perfectly clamped Handler with telescopic GTH 2506 OPERATING INSTRUCTIONS rs 2 5 ADJUSTING THE REAR VIEW MIRRORS The machine is fitted with two rear view mirrors e The right rear view mirror is located on a special supporting bracket in advanced position and allows checking the area behind the machine on the right hand side To adjust its position manually rotate the joint it is fitted with e rear view mirror is placed on the left upper post of the windscreen and allows checking the area behind the machine on the left hand side To adjust its position manually rotate the joint it is fitted with C 26 SWITCHING ON THE CAB LIGHTS The ceiling light fixture of the cab has an internal lamp and a courtesy lamp To switch on the cab interior lights Switch 4 in pos A cab interior lights OFF e Switch 4 in pos B cab interior lights ON e Switch 4 in pos C courtesy lamp ON Page C 6 Document 57 0003 5200 11 2003 Genie Handler with telescopic bbom GTH 2506
123. the allowed limits Shut the engine down and close the driving cab of the machine Secure the machine to the vehicle platform by wheel chocks Anchor the machine to the transporting vehicle with suitable chains Page C 35 Document 57 0003 5200 10 2004 Genie C 6 5 PARKING AND STORAGE C 6 5 1 Always park the machine in a safe way after a working day a shift and at night Short inactivity Take all precautions to prevent damage to those persons who will approach the machine while stationary Park the machine so that it does not hinder other operations Lower the boom fitted with attachment on the ground Remove the key from the ignition switch and lock the cab door Disconnect battery by the appropriate switch Battery cut out switch Handler with telescopic boom GTH 2506 OPERATING INSTRUCTIONS C 6 5 2 Machine storage In case of extended inactivity of the machine follow the above precautions Additionally e Wash the machine thoroughly For a better cleaning remove grills and protection casings Carefully dry all machine parts by blowing some compressed air e Lubricate the machine thoroughly Do walk around inspection and replace any worn or damaged part Re paint any worn or damaged part Remove the battery smear its terminals with vaseline and store it in a dry place Battery can be used for other purposes Otherwise
124. the two vehicles cannot collide to prevent formation of sparks Batteries give off a flammable gas and sparks may burn it and cause an explosion JUMP STARTING THE ENGINE Do not smoke when checking the electrolyte level Keep any metal object like buckles watch straps etc clear of the battery positive terminal These elements can short between the terminal and nearby metal work and the operator can get burned The booster supply must have the same rated voltage and output of the battery installed on the handler To jump start the engine e Turn any users off by the special control levers Putthe gear lever to neutral and engage the parking brake e Ensure the machine battery A is connected to the frame earth the terminals are well tightened and the electrolyte level is regular e Connect the two batteries as shown in the figure Connect first the positive terminals of the two batteries then the negative terminal of the booster supply B to the machine frame earth e f the booster supply is installed on a second vehicle make sure that the latter does not touch the handler then start the vehicle and reach an rpm corresponding to 1 4 of full throttle e Turn the ignition key and start the handler then follow the procedure explained in chapter C 4 2 Starting the engine e Disconnect the cables Remove first the negative terminal from the frame earth then from the booster supply Disconnect the positive term
125. them with an antifreeze Before using the machine again check its conditions Internal washing Wash the machine interior with some water and a sponge Do not use water at high pressure After washing dry with a clean cloth Washing the engine Before washing the engine protect the air intake filter to prevent water from entering the circuit Handler with telescopic GTH 2506 OPERATING INSTRUCTIONS irs C 6 7 MACHINE DISPOSAL PROTECT THE ENVIRONMENT At the end of the machine life call in a specialised firm to dispose of it in compliance with the local or national regulations C 6 7 1 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 orrecycled in accordance with the laws of the UE In Italy used or discarded batteries have been classified as Toxic wastes in accordance with Presidential decree 397 of 09 09 1988 and Law n 475 O G n 18 of 09 11 1988 because they contain lead and sulphuric acid Their disposal through recycling must be done only through companies authorised and belonging to the Consorzio Obbligatorio Batterie Esauste e dei rifiuti piombosi which collect and dispose of used lead acid batteries throughout the national territory Used batteries must be kept in a dry and confined place Make sure t
126. tinguishers or pressure accumulators explosion hazard 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 e When working do not give instructions or signs to several people at the same time Instructions and signs must be given by one person only e Always pay the 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 no means e After work never leave the machine under potentially dangerous conditions Handler with telescopic GTH 2506 SAFETY irs B 4 SAFETY DEVICES Several safety devices have been fitted to the machine They must never be tampered with or removed see chap A 3 5 Regularly check the efficiency of such devices see check card chap G 5 In case of faults stop working immediately and proceed in replacing the defective device For the checking procedures read chap D 3 15 B 3 5 LOAD LIMITING SYSTEM The load limiting system has been developed to help use the machine in safety conditions and alerting with visual and sound messages when the machine is nearing a danger zone However this device cannot replace the experience of the Operator It is u
127. tioning 12Vlamps X spare B A 7 1 LITERATURE SUPPLIED The machines comes with the following literature Machine operator s handbook DEUTZ engine use and maintenance manual Page A 20 Document 57 0003 5200 10 2004 Genie B 1 B 2 B 2 1 B 2 2 B 2 3 B 2 4 B 3 B 3 1 B 3 2 B 3 3 B 4 B 5 Handler with telescopic GTH 2506 TE SAFETY Section B TABLE OF CONTENTS GENERAL EE Dr EE ARD EROR S EFE DE T Ld B 2 PREREQUISITES OF THE PERSONNEL IN CHARGE B 2 Requisites of the machine operators enne nennt B 2 Redquisites OF The SeIVI ef IT B 3 ee 3 Personal protective 3 4 4 5 During work or TUT NS eT B 5 SAFETY B 7 LOAD LIMITING SN o TEN corrr iioii tert trey eer careers 7 1 Document 57 0003 5200 05 2004 Genie B 1 GENERAL REMARKS Most accidents occurring while working repairing or maintaining operation machines are caused by not complying with the basic safety precautions Therefore it is necessary to pay steady attention to the potential hazards and the effects that may come of operations carried out on the machine IMPORTANT If you recognise hazardous situations you can prevent accidents For instance this handbo
128. to attempt to operate the lever without pressing this button In this condition the lever shall not operate any movement Should that not be the case contact GENIE Technical Service Page D 19 Document 57 0003 5200 10 2004 Genie Handler with telescopic GTH 2506 TE MAINTENANCE Checking the block valves every 3 months The piloted blocking valves allow to held the load in position in case of burst of a flexible hose To check the efficiency of a valve proceed as follows e Load aweight near the maximum payload 2000 kg roughly onto the boom Raise the load some centimetres above the ground max 10 cm To check the valve on the telescope extension cylinder move the boom to maximum height and extend it some centimetres e Loosen the oil hoses to the cylinder of which you are checking the valve with caution During the check the oil will flow out of the hoses and the load shall remain blocked in position Should that not be the case the valve must be replaced Contact GENIE Technical Service Wear safety glasses Wear safety gloves Wear safety shoes Wear suitable working clothes Use guards against leaks of oil at high pressure Do the check in a free space with barriers all around to keep non authorised people away During the check proceed with extreme caution Ensure that the part to be checked is in safe condition and that the action generated d
129. uction gear 13 Access door 14 Left rear wheel reduction gear 16 Document 57 0003 5200 10 2004 Genie A 4 2 DESCRIPTION OF THE MAIN COMPONENTS Hydrostatic transmission This unit consists of parts which drive the machine shifting and namely a variable displacement pump connected to the thermal engine by an elastic joint amotor with variable displacement and automatic adjustment in relation to the wheel torque required complete with power divider directly applied on the rear axle ahydraulic oil filter placed on the discharge line to the tank aheat exchanger to cool the circuit down Motion is transmitted to the rear axle from the power divider through a Cardan shaft Engine The thermal engine is equipped with a heat exchanger which uses the engine oil as cooling medium Steering axles front and rear differential gears The differential axles transmit the motion to the wheels The locking device acting on the front axle enables the machine to move also on low grip grounds Tyres The machine is equipped with tyres suitably sized for the maximum load allowed on the handler When worn they shall be replaced with new ones having the same dimensions and loading capacity Overload warning system The overload warning system installed on the vehicle enables the operator to work in safety conditions A display with 6 LED s hows the stability variation When the

PN 57.0003.5200 - Genie Industries

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