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(Note: SN 20631 included) (PN 57.0009.0536_11)

1. 1 2 3 4 5 AIR CONDITION SWITCH S10 CABIN FAN SWITCH S9 HEATING FAN M11 WORK LIGHT WORK FLASHING CABIN CABIN ROOF CABIN REAR SWITCH S6 LIGHT E1 2 INTERIOR WINDSCREEN WINDOW 615 LIGHT E3 WIPER M4 WIPER M4A 45 45 n m gt 25 ml 5 5 122 72 N xn S m El OLIO ps 5 5 E2 E3 2 2n 4 2 4 m uU 9 2 3 2 n i 1 0 2 9 3 8 5 7 D x x ox 5 xs X6 X6 v X6 X6 X6 X6 X6 X6 X6 a 2 az 2 ox 3 E 25 15 45 gt e 55 pa t S7 SWITCH 1 2 1 n B10 MECHANICAL GEAR x Je 9_ OPERATOR CN SEAT SWITCH B10 1 1 rm F13 n F15 xo pi w m B qa 5 1 25 Ex 10A z 5114 15 15 15 25 25 15 amp A A i lt lt x LR E RELAY BOARD ous i 2 de GO a ki z a m al 2 lt i S 1 11 a adi gt 15 5 jj a EB 1 Nest
2. 1 2 4 S MAIN GAUGES CLUSTER P25 ENGINE IGNITION SWITCH S24 EMERGENCY STOP S17 2 P25 A F102 s17 A 20A 576 M M adu 3 45385 PE bes bed boo oops sos Sse a sissies eee 1 gt gt z EG 5 4 OR GM PP LBI 10 23B B PP BKT WS a Y ai BLI 330 8 38 ware amp amp 2 2 ay Mi 3 9 1 20 YE 1 To 790 P LO uc START ENGINE F20 20 F18 ABILITATION YA 21 TA RELAY iw D3 UG D6 x 15 1 15 C K8 21 2 3 15 ix ix F8 1 tA a 3 RELAY CARD u E alt l Je 5 gt T 7 5 amp 1 1 1 n 1 1 3 s dis is xs As Mes Nes 2s ae 2 2 E 1 g E 5 2 E D s 5 5 D RD6 4854 e gt z 5 dess n q PREHEATING Q FGI rh STARTER Fa GLOW AINS HA 50A RELAY 5 RELAY K02 K01 B B all ENGINE POWER BOX 1 m dm m x B35 B6 R36 4 X fey erm Xoyog amp YB YQ Y4 1 sai B10A UM ka A DISCONNETTING BATTERYIPK1 5 E
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4. 1 2 3 4 5 ROAD LIGHTS SELECTOR LEVER S57 WINDSCREEN WINDSCREEN ROAD LIGHTS SWTCH SS STOP LIGHT WIPER MOTOR M22 WASHER PUMP M12 PRESSURE SWITCH S18 25 pe gu BKI su 0 qp p 1 29691 1 eh ps d de 50 Dep me 18 518 xX N he 2 SON NN vem D 21 1 i q sy ar mis ls 557 it 2 2 a gt amp 5 258 181 51 2 EE 2 g g z z a 3 2 2 2 B m amp 5 a gt e E gt gt 5 E 5 u 5 5 10 6 1 2098 16 0 xh DN UE 5 5 g z a 3 2 P s s gt E gt s a gt a gt d 1 258 LB R01 33 gt 815 we 51 18 239 PNI 2 2 a 5 6 10 9 2 5 4 Is E L C F19 F6 F7 F17 F16 10 5A 5A 10 10A mi a 15 15 15 K2 30 30 Fh F3 F2 12 5 L i BC RELAYS BOARD 4 9 8 3 B 1 i n x Oe de 8 D t 158 158 gt on 158 m 615 LAMPS LEGEND 284 LOW BEAM LIGHT wu cls zzz z tis 56b gt S 9 HIGH BEAM LIGHT 5 5 gt s 5 gt 57 l 6 5 FEAR POSTON GeT da inia ils lg 28 FRONT POSITION LIGHT 225 STOP LIGHT
5. 1 2 3 4 5 BOOM FUNCTIONS JOYSTICK S137 2 ENABLING BOOM AUXILIARY CONTINUOS lt FUNCTIONS JUMPER FLOW KNOB S136 5 28 5137 pins 1 I I EN 5136 Lj 1 oe We X137 l L I o T RD GNI e ss EXER WA 258 ae WH RD1 Bo 2 Ka ba da B B RD1 3C gt WH GN1 o6 p E ts Por Pan Tan Tan 9 5 4B 3B 58 1 20 3 2 48 5 P P 9 s t s F x pa amp B E 02 5 a 1 3 C DT04 6P P M 0706 65 P F 5 388 3 2 E 45 5 6 5 s o M1 Alarm 2 1 16 x gt 9 2 Cont flow enabling switch 2 lt 5 3 Alarm 2 3 E x Z Out ev lowering 5 dg 5 Out ev tilt lowering 5 FC p LS x 2 2 5 89 z s 9 5 5 5 amp gt s E s oL ou 2 8 88 8 8 8A 6B _ 8 8B 4A 28 7B 2A i Vo bee bn ban don be xn SOUL gt o o 5 p p D D p Ko p B p p o P B B B p J L 1B JIJA JL 2A JL 2B J L 3A J L 3B JILA J T ABI 1 2 2 1 1 2 2 1 1 2 1
6. 09 4618 0061 Tyre inflation sticker P 4 5 bar 65 psi 09 4618 0918 Falling Object Hazard 09 4618 0919 09 4618 0257 Guaranteed sound power level Compartment Access 10 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Labels And Plates Applied On The Machine Deal Code Description Qt 09 4618 0786 Label Testing ports 09 4618 1399 Label Upper Door Internal Unlock System 09 4618 1368 Control lever for GTH 2506 09 4618 0921 ws Use limits close to electric power 09 4618 0792 Label Engine Cover Closing P 09 4618 0922 Crush Hazard 09 4618 0240 09 0803 0424 Cosmetic GENIE Logo 09 4618 0242 2 09 4618 0390 I Genie ctH 2506 09 4618 0930 Cosmetic Genie 2506 Genie Part No 57 0009 0536 GTH 2506 GTH 3007 11 Operator s Manual First Edition First Printing Labels And Plates Applied On The Machine Decal Code Description 09 4618 0924 Burn Explosion Hazard 09 4618 0925 Crush Hazard m Lift Point Diesel Fuel Cap Hydraulic Oil Label Engine Fuses amp Relays Board 12 GTH 2506 GTH 3007 Part No 57 0009 0536 Qt First Edition First Printing Operator s Manual Labels And Pl
7. Page 125 ZONA INDUSTRIALE 1 06019 UMBERTIDE Load Page 131 PG ITALY Diagrams And Schemes Page 141 Telephone 39 075 941811 jj CR Page 155 Telefax 39 075 9415382 EC Declaration of Conformity Page 165 Technical Assistance Service Routine Check Schedule Page 167 Telephone 39 075 9418129 39 075 9418175 e mail UMB Service terex com Original Instructions First Edition First Printing July 2010 For the electronic version of this manual visit www genielift com operator manuals asp Copyright 2010 TEREXLIFT srl All rights reserved Produced by TEREXLIFT Technical Literature Dept Umbertide PG Italy Genie 2 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Introduction m Symbols Safety alert symbol used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DA N G E R Red indicates a hazardous situation which if not avoided will result in death or serious injury ZAWARNING orange indicates a hazardous situation which if not avoided could result in death or serious injury ACAUTION Yellow indicates a hazardous situation which if notavoided could result in minor or moderate injury NOTICE Blue indicates a hazardous situation which if not avoi
8. q Buu ls jdn oid h SONEA yoous nuy Soy 1 I suoyisod skem t 10 2 5 1 Em Buueejs 1 ea iepujfo axe 1 I ON bd Jepuyo up zd axe L 4eq og ainssaid Buneedo i jeped uod 389 noso eyeiq soas a B eq e o gz dl 40449581 ceinssaid BuneAnoe exeiq 951195 L759 uojws einsseid eoe 154 First Edition First Printing Operator s Manual p Test ME APPENDIX SUSPENDED LOAD CONDITION The test load shall be located so that the forward edge is 1 000 mm 50 mm from the test boundary the rectangular 1 m boundary on the test surface at a distance of 1 m from the machine boundary It shall be positioned 600 mm 50 mm below and centrally laterally with respect of the raised forks The boom shall be adjusted so that dimensions 2000mm 50mm with the upper face of the forks above and substantially parallel to the test surface and the heel of the forks vertically above the rear face of the test load A rearward tilt of lt 5 is permissible The risks during lorry trailer loading are principally in the rearward direction during the reversing part of the manoeuvre before the boom is lowered Genie Part No 57 0009 0536 GTH 2506 GTH 3007 15
9. 45 45 a 27 MASKING AREA Part No 57 0009 0536 Genie GTH 2506 GTH 3007 159 Operator s Manual First Edition First Printing es Test MS APPENDIX DIAGRAMMATIC REPRESENTATION OF LORRY TRAILER CONDITION TEST RESULTS GTH 3007 r 12m 27 MASKING AREA 160 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Test ME APPENDIX B DIAGRAMMATIC REPRESENTATION OF LORRY TRAILER CONDITION TEST RESULTS GTH 2506 im MASKING AREA Part No 57 0009 0536 GTH 2506 GTH 3007 161 Operator s Manual First Edition First Printing Test MS APPENDIX DIAGRAMMATIC REPRESENTATION OF LORRY TRAILER CONDITION TEST RESULTS GTH 3007 1m 1 kil LI KA all 1m 1m 2 MASKING AREA Genie 162 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Test
10. BACK UP LIGHT 21 GROUND QE RIGHT TURN LIGHT 4 amp LEFT TURN LIGHT 5 s s a 2 zz s P 5 a 3 zi 5 5 2 1 3 4 5 1 2 3 4 6 1 2 3 4 1 1 8 5 55 L m i L E 839 21 5 Pm ET E42 E E x a e e F FU 4 xe lt F Se we ES Kd SS 4 lt eS es lt que ER gr gue 5 o a SES NS je S 2 P lt Ca amp e lt lt lt lt gt 5 ge NG BRAND 144 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual _ ee Diagrams And Schemes GTH 2506 WIRING DIAGRAM 5 6 Rev B P N 57 1800 5126 1 e 3 4 3 AIR CONDITIONING SWITCH S10 CABIN FAN SWITCH S9 HEATING FAN M11 WORK LIGHT WORK LIGHT FLASHING CABIN CABIN ROOF CABIN REAR SWITCH S6 E1 BEACON E2 INTERIOR WINDSCREEN WINDOW LIGHT E3 WPER M4 WPER M4A Alase d
11. G GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual E aE Specifications CENTER OF GRAVITY GTH 3007 I 13205 Ib lt lt lt U 8 lt 8 8 7 2660 130 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual LSS Load Charts GTH 2506 FLOATING FORKS GTH 2506 09 4618 0834 Genie Part No 57 0009 0536 GTH 2506 GTH 3007 131 Operator s Manual First Edition First Printing oo R Load Charts GTH 2506 HOOK GTH 2506 lt N 5 09 4618 0835 132 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual pa ae Load Charts GTH 2506 2000kg JIB GTH 2506 09 4618 0837 Genie Part No 57 0009 0536 GTH 2506 GTH 3007 133 Operator s Manual First Edition First Printing Load Charts GTH 2506 BUCKET GTH 2506 09 4618 1426 134 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual E Load Charts GTH 3007 FLOATING FORKS GTH 3007 09 4618 1103 Genie A TEREX BRAND Part No 57 0009 0536 GTH 2506 GTH 3
12. Operator s Manual First Edition First Printing Labels And Plates Applied On The Machine GTH 3007 Shading indicates decal is hidden from view i e under covers VP m gt amp 6 YZ A e N Genie GTH 2506 GTH 3007 Part No 57 0009 0536 Operator s Manual First Edition First Printing Labels And Plates Applied On The Machine Use the pictures on these pages to verify that all decals are legible and in place The following chart shows quantities and description too Decal ed Description Jo 09 4618 1398 Safety operation The capacity of the truck and attachment 09 4616 1375 combination shall be complied with 09 4618 0547 Tyre inflation sticker P 5 5 bar 80 psi 09 4618 0918 Falling Object Hazard 09 4618 0919 Crush Hazard 09 4618 0563 Guaranteed sound power level 09 4618 0920 Compartment Access 09 4616 0002 Max Capacity 16 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Labels And Plates Applied On The Machine Deal Code Description 0 09 4618 0786 Label Testing ports 09 4618 1399 Label Upper Door Internal Unlock System 09 4618 1368 Control lever decal for GTH 3007 09 4618 0921 Label Use limits close to electric power lines 09 4618 0792 Label Engi
13. amp s s 3 si 9 8 gos s gt gt OR BLISS sir E 8 5 5 1 1 A A 1 1 1 1 1 1 A 1 AM m xi xus x xu PH xa YA M M 8104 8105 850 851 B45 B41 ZI E gt eA PA 5 7 X FX EN 1 fto 196 i Y 846 B B x42 105 2 X512 X45 X365 1 X106 X196 WH BK1 E zl S S a amp ur pm e e c eo 2 ar 55 Se s Se Se SO lt Se 22 ov S Sg SS A S lt C SE SS GA ese SUO amo MR SUO P x as es Su es SESS Se oe 579 SES se S Ss SU NS Qo LO S gv gt SO SE X STRE S s lt RS VO YS S E SS gt lt NS 142 BRAND GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Diagrams And Schemes GTH 2506 WIRING DIAGRAM 3 6 Rev B P N 57 1800 5126 1 d 4 STEERING MODES UNIT X61 ROAD STEERING MODES CONTINUOUS FLOW OPTIONAL MODES SWTCH S3 SELECTOR S13 PARKING BRAKE SWITCH PK1 ENABLING S
14. OVERLOAD TEST PROCEDURE Telehandler coupled to attachments with fixed centre of load Forks Bucket Clamps 1 33 x Q Ref Standard EN1459 Q Nominal Rated Load Capacity Telehandler coupled to attachments with oscillating centre of load Hook Jib Hoist 1 33 x Q 0 1xFb tires 1 25 x Q 0 1 x Fb outriggers Ref Standard EN13000 Nominal Rated Load Capacity Fb Boom weight reduced i e equal overturning moment at boom tip Genie Part No 57 0009 0536 GTH 2506 GTH 3007 163 Operator s Manual First Edition First Printing gE aS ae Intentionally blank page 164 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual EC Declaration Of Conformity EC DECLARATION OF CONFORMITY FULL TEXT Manufacturer and person authorized to compile the technical file TEREXLIFT s r l Zona Industriale Buzzacchero 06019 Umbertide PG Italia Hereby declares that the machinery described below Designation Rough Terrain Variable Reach Truck Function handling loads Model GTH XXXX YY Serial Number XXXXX complies with the relevant previsions of the machinery directive 2006 42 EC complies with the relevant previsions of the directive 2004 108 EC also complies with the provisions of the Directive 2000 14 EC as amended Model n 37 annex directive 2000 14 EC Conformity assessment procedure followed n 2 annex VI Notified body xxxxx Net installed power k
15. Safety Precautions Not observing the instructions and safety rules in this manual may result in death or serious injury Do not operate the machine unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Read and understand the safety instructions before going on to the next chapter 2 Always perform a pre operation inspection 3 Always test the machine functions prior to use 4 Inspect the work place 5 Only use the machine for the intended application e Read understand and obey the manufacturer s instructions and the safety rules the safety and operator s manuals and the decals applied on the machine e Read understand and obey the employer s safety rules and worksite regulations e Read understand and obey the applicable national regulations Only trained personnel informed on the safety rules can operate the machine GENERAL REMARKS Most accidents occurring while working repairing or maintaining machines are caused by not complying with the basic safety precautions Therefore it is necessary to pay steady attention to the potential hazards and the effects that may come of operations carried out on the machine NOTICE If you recognise hazardous situations you can prevent accidents A DANGER The instructions given in this handbook are the ones established by TEREXLIFT They do not exclu
16. Ground clearance 330 mm Overall Length 5040 mm Lifting height max 5790 mm Lifting capacity max 2500 kg Lift capacity at maximum height 2000 kg Lift capacity at maximum reach 900 kg Forward reach max 3350 mm Reach at maximum height 605 mm Fork holder plate rotation 130 4450 kg A B C D E F G H PRODUCTIVITY Lifting lowering speed 7s 4s Extension retraction speed 7s 4s Inside outside turning radius 1700 mm 3350 mm Break out force with 5001 shovel SAE J732 80 3700 kg Towing capacity at dynamometer 4230 kg 3100 kg Travel speed max 24 km h Floating forks L 1200mm section100x40mm Tyres DIN 70631 12 16 5 8 holes wheel disk TEREX BRAND Part No 57 0009 0536 GTH 2506 GTH 3007 125 Operator s Manual First Edition First Printing cc r Specifications POWER Engine DEUTZ D2011 104 Displacement 3600 cm Oylinder arrangement Vertical in line Combustion System In direct injection Max Power Output 50 kW 2600 rpm Max Torque Output 210 Nm 81700 rpm Rated Power 184Nm 50kW 2600rpm Aspiration Naturally aspirated number 4 Hydraulic Hydraulic output pressure 7OL min 270bar VIBRATION LEVEL Mean assessed vibration level transmitted to arms 2 5 m s Mean assessed vibration level transmitted to body 0 44 m s Highest root mean square value of weighted acceleration to which the whole body is subjected XXX Uncertainty of vibration me
17. 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 Operating Instructions section A DANGER When replacing interchangeable attachments keep any person clear of the working area A DANGER 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 Before any maintenance or repair work remove the attachment Genie Part No 57 0009 0536 GTH 2506 GTH 3007 107 Operator s Manual First Edition First Printing Optional Attachments FLOATING FORKS code 55 0750 0059 ONLY FOR GTH 2506 TECHNICAL DATA 2500 kg 1285 mm 1545 mm 940 mm 260 kg 320 mm Application Quick coupling fitted attachment for handling palletized loads Safety Strictly obey the general safety precautions given in section Safety e Do load loose materials Do not move superposed pallets Operation Adjust the distance between the two forks by hand
18. Operation To load unload the material operate the rotation lever of the attachment holding plate Maintenance Visually check the shovel for damage before using it Safety Strictly obey the general safety precautions given in section Safety Model 500 _ 800 LITRES CEREAL TECHNICAL DATA 355 kg 220 kg For the use of this attachment read the specific manual Genie Part No 57 0009 0536 GTH 2506 GTH 3007 115 Operators Manual First Edition First Printing Optional Attachments 250 MIXING BUCKET code 59 0401 2003 CL TIM TOES ri Bern temp L ATTN TECHNICAL DATA Equipment Payload CoG 116 GTH 2506 GTH 3007 Application Quick coupling attachment for mixing and distributing concrete Safety Strictly obey the general safety precautions given in section Safety Operation To load unload the material operate the rotation lever of the attachment holding plate Maintenance Visually check the bucket for damage before using it Wash thoroughly with water after use or in case of prolonged inactivity to prevent the mix or residues from hardening
19. Genie A TEREX BRAND Operator s Manual GTH 2506 GTH 3007 Serial number range From s n 20728 To s n 22479 Plus s n 20610 and 20617 But s n 21687 and 21835 From s n 20710 To s n 22419 Plus s n 20631 With Maintenance Information First Edition First Printing Part No 57 0009 0536 Operator s Manual First Edition First Printing ee ee a a Contents Important 222 2 Page 3 Read unean and Obey ESE Safely rules Machine Identification 5 and operating instructions before operating the machine Only trained and qualified personnel Symbols Used On The Machine Page 7 shall be authorized to operate the machine Labels And Plates Applied On The This manual shall be kept with the machine at 44 240 Page 9 all times Safety Precautions Page 21 For any further information please call Description Of The Machine Page 29 Terexlift Controls And Instruments Page 35 Inspections cerei tee coetus Page 51 Operating Instructions Page 55 Transporting The Machine Page 71 22 4 75 Faults And Troubleshooting Page 101 Optional Attachments Page 107 Contact us Specifications
20. Refit the hose and pour new antifreeze 50 water antifreeze This proportion will provide protection up to 38 C Daily clean the radiator grille using a brush with hard bristles or compressed air at a max pressure of 6 bar Ondelivery the machine is filled with a cooling mixture consisting of 50 water and 50 anti freeze TEREX PRO COOL Protection against boiling freezing Boiling point 33 17 C 123 C 40 24 C 126 C 82 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual 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 Visually check the hydraulic oil level through level A located on the reservoir and visible through the slot on the right side of the chassis When necessary add new oil through filler B PROTECT THE ENVIRONMENT The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres Part No 57 0009 0536 Genie GTH 2506 GTH 3007 83 Maintenance CHANGING THE HYDRAULIC OIL To change the hydraulic oil 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
21. VAT S SSS SES SF SE SS S QW S S a AY gO ME we Rey Ss D a oy S lt S XS lt SS GLH SS x S lt ae ore S ka 5 S lt 148 BRAND GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Diagrams And Schemes 3007 WIRING DIAGRAM 3 6 Rev 0 P N 57 1800 5125 1 2 3 4 5 STEERING MODES UNIT X61 ROAD JOBSITE STEERING MODES PARKING BRAKE SWITCH S1 CONTINUOUS FLOW OPTIONAL MODES SWITCH S3 SELECTOR S13 ENABLING SWITCH S2 25 gt N e P 11 ES gt 3 lt 19 E 1 Ve AH d DES SB Lal d 2 5 B 5 S2 SI i 1 4 4 5 a 6 ED 11 5 0 x zm E s 5 e E 25 RESTI 4 1 F5 10 15 RELAY BOARD 24 gt 5 12 23 gt 515 15 pol 1 x 2 in m ES 5 1 1 1 xs YS 4 52 Y49 is x us 25 31 31 we 1 Ow se we amp so lt ew se oe 99 o we NS CN lt FY V IW dM S x lt e Part No
22. 2506 HYDRAULIC DIAGRAM Rev C P N seug yue uonong pue Bursues peo seul eunsseid pue eunsseud wo1 77 suojouny seujemsseid uoissiuisuen oneisoip H s ul eansseid ubi uedQ VQON3931 SYO109 NDYO Ol In vs GAH seq g ainsseud A seins uonons N anea onus E HW 9 Jeq t i CI seq og 1 56810 Bupjoes 491 00 101 1 anjen Guyysny OM UDISSIUSUER 4z juowese dsip enen uA mrt pes z dl ainsseud ubi ainsseid 184 6
23. 8 N1 15 15 a 2 u z 1 E 4 T E 1 2 5 D x 2 x50 5 1 i z al 2 i E m x i d 5 5 M 1 1 i 4 s 56 X56 5 f A400 asa K402 aa T NECI Jeu boo ACTIX ACO iC 1 CN m Te Ts 5 m u A as 9 9 lt lt A we 2 SE LE 1 Se S S Se lt 54 ee OF Xe ols SS e lt SV 555 LES SS lt e gt lt v lt Se Sw 9 5 Genie Part No 57 0009 0536 GTH 2506 GTH 3007 151 Operator s Manual First Edition First Printing Diagrams And Schemes GTH 3007 WIRING DIAGRAM 6 6 Rev 0 P N 57 1800 5125 1 2 3 4 9 BOOM FUNCTIONS JOYSTICK S137 24 7 ENABLING BOOM AUXILIARY CONTINUOS 52 FUNCTIONS JUMPER FLOW KNOB S136 gs 5137 3 g e lI he tu 1 EN 51 LL L al 2 T5 n lag T8 TA ids 1228 pem Om He KA E 9 4 Rt i Dres B V1 25 p
24. E F lt e z ae gt rd ae gt 3 2 15 F S lt g FT1 lt S L S ue lt lt S lt AV lt S S SUY Se Ss RY Sa 4 So asas os S CS SS S X 9 CE OS ee 59 SS S e 3 Su es ee ser amp s Ue 5 DG ss Xs aes lt e e 45 oy ge we r r r r Part No 57 0009 0536 Genie GTH 250 6 GTH 3007 141 Operators Manual First Edition First Printing Diagrams And Schemes GTH 2506 WIRING DIAGRAM 2 6 Rev B P N 57 1800 5126 I e 3 4 2 AUXILIARY HYDRAULIC HAZARD WARNING LIGHTS S59 FORWARD REVERSE LEVER S58 OVERLOAD SYSTEM LMI BYPASS KEY S20 SWTCH S4 Bis L pee 5 AE BKI 12 51 I 2 21 3 Bye gl
25. I 5 S E a Slal INi D MET LN 21 o BN 51 CVS 31 ES 21 Nt 21 23 IN 94 2 i P 11 Gil yi B V1 gt 21 S Qa 8 2 2 27 3 9 1 20 x x x 3 30 15 D i2 gt 1 START ENGINE 7 F20 pt F18 ABILITATION 2 RELAY E af 03 04 D5 06 E 15 15 21 P 7 gt 23 gt 21 E 0 we 23 10 RELAY CARD u _ 6 1 10 x x BOIS 21 M V1 51 2 o z 2 gt E z z EI 2 1 5 10 B 2 5 u 9 A 1 3 xs xs Xs 5 xs xs E ku Yin 2x S 2 25 E 5 a E 2 lt amp 5 g R6 gt 2 s ot PREHEATING 1 FGI rh FG2 STARTER FS GLOW w A 50A Lr RELAY a xl K02 K01 2 d ENGINE POWER BOX EE 1 2 1 1 H 1 1 1 xs X62 xu XA x B35 B6 HX IPB X ca X lt s t 10 1 X36 c 51 i m DISCONNETTING BATTERY S1 2 z s rod lt Se x s d gt 21 amp gt lt SM 5 m i i E ss se Su w S m gt fy 48 Se ON SMS AUS SS 49 Su SS SS Su SK P ES Se e lt lt s aru lt 9 lt XS 5 S 8 Se QS o S Q amp ee lt Part No 57 0009 0536 Genie GTH 250 6 GTH 3007 147 Operator s Manual First Edition First Printing Diagrams And Schemes 3007
26. I gt So LB 5 CU eu LM gy au 15 a ET R G15 Rt RI si BARI 61 SE E amp z s E 2 G 1 1 3 B u 5 6 5 8 E ye P 1 61 u sP 15 _0 4 F10 F12 F9 lt 10A 5A 1A 10 JE x 02 er H NIC a mL 2 430 i oq Sig 4 yis 3 SE 15 IC s 8 amp iss ra a iss X60 rm 15 88 4 H 10 13 bw 13 RELAY BOARD ME g is 3 I pe em i 1 51 2 ny 1 15 8 Vi 5 15 15 RIS R 5 1 15 eo IR 15 1 u 15 7 1 E 5 an f x er 2 U fn dn x Ei a i pw LL covpressor a m We E xn xls ln in 8 RELAY RELAY Lsr d al K100 K101 Ei et 42 g s i 2 11 d _ a g z I E ka me dis bu Tis ass T M 6 ku 27 27 X47 850 B51 B45 8105 B104 Me E eN 4 ICONDITIONING 5 BA X EN B40 COMPRESSOR BL6 M106 M196 Y36 4 m In 512 36s 2 2 ra in z z z 15 3 rid 5 tm 3 gt 31 9 9 55 v 5 lt M dv oe SF gk Se SPS oF oF YF SS SD S lt S
27. ROAD Low stability Fuse blown F10 System failure NOTICE CAUSES SOLUTIONS Check and replace fuse F5 if necessary Replace the fuse Check the Tecnord Unit and eventually replace it Replace fuse Check the fuse and replace it if necessary Set to JOBSITE 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 authorized service centre Check and replace fuse if necessary In case of faults not listed in this chapter address to the TEREXLIFT Technical Assistance your nearest authorised workshop or dealer 102 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Faults And Troubleshooting Load Limiting System ALARM CODES ALARM CODE SOLUTION DESCRIPTION CRC error in the software memory area ContactTEREXLIFT TechnicalAssistance CRC error in the parameters memory area ContactTEREXLIFT TechnicalAssistance Error in the software flow check Contact TEREXLIFT Technical Assistance Exchange error ContactTEREXLIFT TechnicalAssistance Overrange power supply 7 18 Vdc Check the power supply 1st channel power supply error ContactTEREXLIFT TechnicalAssistance 2st channel power supply error ContactTEREXLIFT TechnicalAssistance CUT OFF 1 error Contact TEREXLIFT Technical Assistance CUT OFF 2 error Contact TEREX
28. is located ona The rear convex mirror is placed on a special special supporting bracket and allows checking bracket located at the back of the boom and the carriageway behind the machine To allows checking the area behind the machine adjust its position manually rotate the joint it is as well as the rear part of the chassis To adjust fitted with its position manually rotate the joint it is fitted with GTH 2506 A DANGER Modification of the telehandler may affect the operator s visibility Genie Part No 57 0009 0536 GTH 2506 GTH 3007 59 Operator s Manual First Edition First Printing Operating Instructions STARTING THE ENGINE Forthe low temperature starting see paragraph Low Temperature Starting Engage the parking brake e Put the forward reverse gear selector to neutral e Step on the gas pedal Tostart the engine turn the ignition switch to position 2 0 1 Release the switch when the engine starts If the 2 engine does not start within 20 seconds release the key and wait at least 2 minutes before attempting again After the start up let the engine run at idle for some seconds before engaging a gear this allows for a gradual warm up of the engine oil and a better lubrication In case of engine jump starting remove the booster cables see following paragraph NOTICE If the light indicators do not switch o
29. to the side by 100 mm Safety Strictly obey the general safety precautions given in section Safety Do not load loose materials Do not move superimposed pallets Operation To adjust the tilting operate the joystick To side shift operate the joystick after connecting the feeding lines of the new attachment to the quick couplings 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 Part No 57 0009 0536 First Edition First Printing Operator s Manual FLOATING FORKS code 55 0750 0041 ONLY FOR GTH 3007 TECHNICAL DATA Payload 3000 kg 1285 mm 1560 mm 950 mm 275 kg 325 mm Genie Part No 57 0009 0536 Optional Attachments Application Quick coupling fitted attachment for handling palletized loads Safety Strictly obey the general safety precautions given in section Safety Do not load loose materials Do not move superposed pallets Operation Adjust the distance between the two forks by hand Operate the joystick to adjust the forks tilting Maintenance Visually check the attachment for damage before using it Daily grease the joints using a greasing gun and smear the sliding guides with graphitized grease GTH 2506 GTH 3007 111 Operator s Manual First Edition First Print
30. 5 Only use the machine as it was intended Part No 57 0009 0536 Genie GTH 2506 GTH 3007 51 Inspections Pre operation Inspection Fundamentals It is the responsibility of the operator to perform a pre operation inspection and routine maintenance The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unauthorized variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going on to the function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications Operator s Manual First Edition First Printing Inspections PRE OPERATION INSPECTION e Make sure the operators manuals are intact legible and placed
31. 57 0009 0536 First Edition First Printing Operator s Manual Operating Instructions Version with HYDRAULIC LOCKING optional To change an attachment operate as follows Drive to the place where you will release the mounted attachment when possible a solid and sheltered site Disconnect the quick connectors of the attachment if any and connect the hydraulic locking pipes of the attachments to couplings 3 Rest the attachment flat on the ground Remove the safety pin 2 placed at its end Free the attachment operating the control of the attachment locking unlocking cylinder e Pitch the attachment holding frame forward and lower the boom to release the attachment upper lock Move back with the machine and drive to the new attachment to be coupled Hold the frame pitched forward and hook the upper lock of the new attachment e Retract and raise the attachment some centimetres It will centre automatically on the quick coupling frame e Operate the attachment locking lever optional and secure the attachment in place with safety pin 2 previously removed e Re couple the connectors of the attachment if any Genie Part No 57 0009 0536 GTH 2506 GTH 3007 69 Operator s Manual First Edition First Printing Operating Instructions ROAD OR SITE TRANSFER When travelling on public roads strictly obey the local or national road traffic regulations Besides take into a
32. A Maschinen garantierter Schalleistungspegel dB A complies with the following European Standards National Standards and technical Est galement conforme aux normes europ ennes aux normes nationales et aux dispositions provisions techniques suivantes Las siguientes normas nacionales internacionales y especificaciones t cnicas fueron aplicadas Ebenfalls mit folgenden europ ischen normen nationalen normen Und technischen Vorschriften bereinstimmt EN 1459 1998 A2 2009 Umbertide 11 12 2009 Ing Maurizio Baldinucci Technical Director Part No 57 0009 0536 G enie GTH 2506 GTH 3007 165 Operator s Manual First Edition First Printing gE aS ae Intentionally blank page 166 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual oo M Routine Check Schedule ME SAFETY DEVICES DAILY CHECKING DATE COMPONENT RESULT NOTE SIGNATURE bem Bee OT CJ negative positive Emergency Stop 0 positive Pushbutton negative positive CJ negative Levelling Cylinder J positive Safety Valve negative Lifting Cylinder J positive Safety Valve CJ negative Boom Extension 0 positive Cylinder Safety Valve O negative Attachment Swinging positive Cylinder Safety Valve CJ negative TEREX BRAND Part No 57 0009 0536 GTH 2506 GTH 3007 167
33. Directiva M quinas g 2006 42 EC 2006 42 EC 2006 42 EC prescnienrei nie 2000 42 65 also complies with the provisions est galement conforme aux est ademas en conformidad con ebenfalls mit den bestimmungen der lof the Directive 2000 14 EC as dispositions de la Directive las exigencias de la Directiva Richtlinie 2000 14 EG ge nderte lamended 2000 14 modifi e 2000 14 incluidas las richtiinie 2005 88 EG modificaciones de la misma Model n 37 annex T directive D sianation n 37 annexe Tipo n 37 anexo I Directiva Bezeichnung n 37 anhang I Richtlinie 2000 14 EC Directive 2000 14 CE 2000 14 CE 2000 14 EG Conformity assessment procedure Proc dure appliqu e pour Procedimiento de evaluaci n de la Angewandtes followed n 2 annex VI l valuation de la conformit n 2 conformidad n 2 anexo VI Konformit tsbewertunasverfahren n 2 lannexe VI lanhang VI Notified body Organisme notifi Organismo notificado und Anschrift der benannten Stelle Net installed power kW Puissance install e KW Potencia neta instalada KW _ Installierte Nutzleistung in kW Measured sound power level Niveau de puissance acoustique Nivel de potencia ac stica Maschinen gemessener dB A mesur dB A medido dB A ISchalleistungspegel dB A Guaranteed sound power level Niveau de puissance acoustique garanti dB A Nivel de potencia ac stica garantizado dB
34. Donotinject ether in engines equipped with glow Always operate the machine in a well ventilated plugs area to avoid carbon monoxide poisoning Do not leave fuel cans or bottles in unsuitable Do not lower the boom if the area underneath is places not clear of personnel or obstructions e Neither smoke nor use open flames in areas subject to fire dangers and in presence of fuel oil or batteries e Carefully handle all flammable or dangerous substances Donottamper with fire extinguishers or pressure accumulators Genie Part No 57 0009 0536 GTH 2506 GTH 3007 27 Operators Manual Se a Safety Precautions 28 SUSPENDED LOAD hazards A suspended load has a dynamic and therefore unpredictable effect on machine stability so extreme caution should always be exercised when operating with suspended loads Only lift the load when the telehandler is on firm level ground Do not operate the machine while people are under a suspended load All movements of the load must be accomplished at lowest possible speed Do not lift loads when wind speeds exceed 20 mph 32 kmh Level the telehandler before lifting the load Use guide ropes or tag lines by qualified personnel to help control the load and prevent it from swinging Do not attempt to use the telehandler frame leveling to compensate for a swinging load Never drag the load Do not try to move fixed or obstructed loads Only lift a load vertically do not p
35. GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Maintenance CAB AIR FILTER Every six months clean the airfilter 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 Pull filter A out of the housing accessible from the inside of the cab Clean the filter bowl Clean the filter cartridge by beating it against a piece of wood Replace the cartridge if damaged NOTICE Paper filters must never be cleaned using compressed air or washed with water and or solvents Genie Part No 57 0009 0536 GTH 2506 GTH 3007 85 Operator s Manual First Edition First Printing Maintenance OIL LEVEL IN THE DIFFERENTIAL GEARS To check the oil level in the front and rear differential gears Stop the machine on a level ground and engage the parking brake Loosen level plug and check if oil is level with the hole If necessary top up through hole until oil comes out from hole G Refit and tighten plugs G and To change the oil Place a container of suitable size under drain plug Loosen the drain plug the level plug and the filler and allow oil to flow out from the reduction gear Refit and tighten drain plug Add new oil through the filler until it is level with hole Refit and tighten plugs G and D Fill
36. 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 12x 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 16 2 35200 70300 98900 119000 102 205 288 346 16 1 5 37400 74800 105000 126000 107 214 302 362 18x 2 5 43000 86000 121000 145000 142 283 398 478 18 1 5 48400 96800 136000 163000 154 308 434 520 20 2 5 54900 110000 154000 185000 200 400 562 674 20 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 24 3 79100 158000 222000 267000 345 691 971 1170 24 2 86000 172000 242000 290000 365 731 1030 1230 27 3 103000 206000 289000 347000 505 1010 1420 1700 27 2 111000 222000 312000 375000 534 1070 1500 1800 30 3 5 126000 251000 353000 424000 686 1370 1930 2310 30 2 139000 278000 391000 469000 738 1480 2080 2490 NOTICE Sensor maximum driving torque 15 Nm Genie Part No 57 0009 0536 GTH 2506 GTH 3007 105 Operator s Manual First Edition First Printing gE aS ae Intentionally blank page 106 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual
37. NOT START manual Solenoid valve engine stop Check the solenoid valve replace if ne cessary Speed selector switch in neutral Set the speed selector switch correctly THE MACHINE Operator is not correctly seated Sit correctly in the driving seat DOES NOT MOVE in the driving seat FORWARD BACK Parking brake engaged Disengage Fuse F9 blown e Check the fuse replace if necessary Fuse F5 controlling the steering Replace the fuse if necessary selection blown Set to JOBSITE OF THE STEERING ROAD JOBSITE switch set to MODE ROAD THE MACHINE DRIVE IS Hydraulic oil filter clogged e Replace the filter NOT ENOUGH Genie Part No 57 0009 0536 GTH 2506 GTH 3007 101 NO SELECTION Operator s Manual First Edition First Printing Faults And Troubleshooting PROBLEM ROAD FUNCTION ON EVEN WHEN SELECTING THE JOBSITE FUNCTION NO BOOM LOWERING AND EXTENSION NO HOLDING FRAME TILTING THE HYDRAULIC OIL THERMOMETER DOES NOT WORK THE PARKING BRAKE LIGHT DOES NOT LIGHT UP BOOM DOES NOT MOVE THE LOAD LIMITING SYSTEM IS BLOCKED RED LED S LIT THE LOAD LIMITING SYSTEM IS IN ALARM No ROAD JOBSITE selection Fuse blown F5 Tecnord Unit This is normal when the outside temperature is low and or the machine is used for short periods since the hydraulic oil cannot warm up over 40 50 C Fuse blown F12 Fuse blown F5 ROAD JOBSITE switch set to
38. Operate the joystick to adjust the forks tilting Maintenance Visually check the attachment for damage before using it Daily grease the joints using a greasing gun and smear the sliding guides with graphitized grease 108 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual FEM 2 FORKS ON PLATE code 55 0750 0000 ONLY FOR GTH 2506 TECHNICAL DATA 2500 kg 1235 mm 1490 mm 970 mm 260 kg 280 mm Genie Optional Attachments Application Quick coupling fitted attachment for handling palletized Safety Strictly obey the general safety precautions given in section Safety Do not load loose materials Do not move superposed pallets Operation Adjust the distance between the two forks by hand Operate the joystick to adjust the forks tilting Maintenance Visually check the attachment for damage before using it Daily grease the joints using a greasing gun and smear the sliding guides with graphitized grease Part No 57 0009 0536 GTH 2506 GTH 3007 109 Operators Manual First Edition First Printing Optional Attachments FEM 2 FORKS WITH HYDRAULIC SIDE SHIFT code 59 0601 5001 ONLY FOR GTH 2506 TECHNICAL DATA 2500 kg 1360 mm 1560 mm 960 mm 355 kg 100 FEM 2 330 mm 110 GTH 2506 GTH 3007 Application Quick coupling fitted attachment for handling palletized loads with possibility of shifting the load
39. WIRING DIAGRAM 2 6 Rev 0 P N 57 1800 5125 1 2 3 4 5 AUXILIARY HYDRAULIC HAZARD WARNING LIGHTS S59 FORWARD REVERSE LEVER S58 OVERLOAD SYSTEM LMI BYPASS KEY S20 SWITCH S4 4 4 e gt 33 1 ERI 3 s 2 1 i25 is LEE E Sex 12 Q 355 22 pase in 1 5 SERTEIE z214 358221 sal o 2Z5355S lt S aclaz 59 ss 1 116 9227 6 81714 2023 15 1 1 1 54 1 5 T 5 ale is BE BE a s zz 4i 4 zS gt amp sb bb ES a d x d 9 d 1 4 EE a e 5 1 go xn sand ka mom aga zs 373z ks 5 m
40. a a 15 15 15 K2 l K 30 30 30 Fh 2 T 5 5 4 13 4 RELAYS BOARD 4 8 n 7 h n x 5 5 5 5 i5 G NI 61 15 is pts LAMPS LEGEND F LOW BEAM LIGHT l s l z 2 a g 5 z 5 2 HIGH BEAM LIGHT 5 57 MARPO Me n k oM 58 FRONT POSITION LIGHT 2 STOP LIGHT i BK BACK UP LIGHT 21 GROUND QE RIGHT TURN LIGHT LEFT TURN LIGHT a2 EIS EC 5 a 5 5 5 Sz gt 2727545 26545 1 qq 6 1 1 E Vepspsps e ard sisters doo gra s P fay ay 5 s x A ox a E38 E35 B55 9 1 L I L 15 EI 839 TES b 63 En js 04 hs k i 2 35 e zx 3 aS 51 AA y AS amp MS lt S lt lt S FS 4 KS g S SS SS lt 9 9 5 9 lt lt lt gt Sos Soe QR gae Y 49 46 we lt e S E lt lt BRAND GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Diagrams And Schemes GTH 3007 WIRING DIAGRAM 5 6 Rev 0 P N 57 1800 5125
41. are located where originally applied by the manufacturers GTH 2506 P 07 17882 EILS MODEL SERIAL NUMBER ENGINE TYPE YEAR OF MANIFACTURER Chassis serial number the chassis serial number is punched on the front right part of the chassis side member 6 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Symbols Used On The Machine A Fuel Level General Alarm Brake Pressure Parking Brake Battery Charge De A M es Engine Oil Pressure Hydraulic Oil Filter Hydraulic Oil Level Turn Signals High Beam Clogged 2 1 Speed Engaged 274 Speed Engaged Glow Plugs Preheating High Coolant only for GTH3007 only for GTH3007 Temperature H ll 2002 Rear Wheel Aligned Air Filter Restricted Hour meter Hydraulic Oil Position Lights Temperature Indicator Steering Mode Cab Ventilation Fan Lifting Point Transfer Mode Hazard Warning Lights le Continuous Oil Flow Auxiliary Hydraulic Air Conditioning Fuel Cap Hydraulic Oil Line HYDRAULIC pe Work Lights Mechanical Gear Genie Part No 57 0009 0536 GTH 2506 GTH 3007 7 Operator s Manual First Edition First Printing Symbols Used On The Machine HAZARD PICTORIAL DESCRIPTIONS Im ES Electrocution Maintain required Hazard clearance Burn Hazard No riders R
42. axis 0 low beam ON stable condition 1 high beam ON stable condition 2 high beam used for intermittent signalling when released the lever springs back to position 0 B Windscreen wiper function To operate the windscreen wiper rotate the lever tip to one of the three positions 0 Wiper OFF Low speed ll High speed Turn signals function Set lever to pos 1 to indicate a turn leftwards or to pos 2 to indicate a turn rightwards Genie Part No 57 0009 0536 GTH 2506 GTH 3007 37 Operator s Manual First Edition First Printing Controls And Instruments Brakes 16 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 ofthe power drive pump and makes the braking 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 Tostopthe handler without shutting down the engine press the pushbutton switch 19 to engage the parking brake and push it once again to disengage the brake When starting the engine the light of the pushbutton turns automatically on When the orange light at the top of the pushbutton and the dashboard warning light are on the parking brake is engaged
43. enclosed graphs and diagrams the identification and warning plates They shall be skilled and trained about the machine functioning NOTICE From a technical point of view the ordinary maintenance of the machine is not a complex intervention and can be carried out by the machine operator too provided he has a basic knowledge of mechanics Operator s Manual First Edition First Printing Safety Precautions WORKING CLOTHES During work but especially when maintaining or repairing the machine operators must wear suitable protective clothing Overalls or any other comfortable garments Operators should not wear clothes with large sleeves or objects that can get stuck in moving parts of the machine Ear protectors or equivalent equipment Protective helmet Protective gloves Working shoes Je Sle 1 OH Use only type approved working clothing in good condition Personal PROTECTIVE EQUIPMENT Under special working conditions the following personal protective equipment should be used Breathing set or dust mask Goggles or facial masks 24 GTH 2506 GTH 3007 OTHER DANGERS Hazards on the JOBSITE Always take into account the features of the job site where you are going to work Always examine the working area and compare it with the machine dimensions in the different configurations A DANGER The machine is not electricall
44. especially do not move the load from the vertical pull line Do not pull crosswise and do not tow Operation Couple the jib and hold it in position by means of the attachment locking system mechanical or hydraulic e Setthe attachment supports in working position 1 using the dedicated pins A e Lift the attachment support 3 locking it in working position by means of the dedicated pin B 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 To remove the attachment set the supports in resting position 2 lower the attachment support 3 locking it in resting position by means of the dedicated pin B carefully tilt the attachment forward lower the boom resting the attachment on the ground then retract the boom Once the attachment quick connectors have been disconnected from the boom connectors take care to reconnect them to the proper rest connectors that are present on the jib in order to prevent impurities from entering the circuit Carefully protect the rest connectors with the proper plugs when they are not used 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 Operator s Manual First Edition First Printing Optional Attachments 2000 KG EXTENSION JI
45. forks back to retract the load The risks during load handling are principally in the rearward direction during the reversing part of the manoeuvre Transfer phase Do not start or brake abruptly Drive to the unloading point cautiously and keep the load 20 30 cm from the ground Suit the machine speed to the ground conditions to avoid dangerous jumps side skids of the vehicle and possible load falls When driving on slopes or ramps hold the load uphill If a suspended load or the resulting boom geometry creates a substantial blockage that the user should consider alternative carrying means A DANGER Do not drive on slopes sideways this wrong manoeuvre is one of the main reasons for accidents due to vehicle overturning Genie 66 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Operating Instructions Unloading phase Drive to the unloading point with straight wheels and bring the machine to a smooth stop leaving enough space to operate the boom Put the parking brake and set the transmission to neutral Position the load some centimetres above the desired position and set the forks level Lower the load and make sure it is level e Carefully withdraw the forks by operating the boom retraction control and if necessary raise or lower the boom as forks come out When the forks are clear of the load set them to transfer position Re
46. if accumulators are not completely depressurised For this purpose shut the engine down and step on the brake pedal 8 10 times Before carrying out operations on hydraulic lines under pressure or disconnecting hydraulic components ensure the relevant line has been previously depressurised and does not contain any hot fluid Do not empty catalytic mufflers or other vessels containing burning materials without taking the necessary precautions 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 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 Always pay due attention to the instructions given by the foreman e Never distract the operator during working phases or crucial manoeuvres Do not call an operator suddenly if unnecessary Do not frighten an operator or throw objects by any means After work never leave the machine under potentially dangerous conditions Before any maintenance or repair work remove the attachment MACHINE OPERATION hazards Absolutely avoid the following work situations Do not handle loads beyond the maximum capacity of the machine Do not raise or extend the boom if the machine is not on a firm level surface
47. in the elevated position e travelling on rough terrain or on grounds with obstacles and holes e travelling across a slope or turning on a slope driving in bends too fast or too sharp Adjustments affecting the setting of the LLMI LLMC shall be performed only by authorised personnel GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Description Of The Machine p TA SS ff Ss e f A gt J E Zn 2 AY AN m C Dl h b NS OR uy J Tos S gt 1 Forks 2 2 d boom section 3 1 tboom section 4 Engine hood 5 Driving cab 6 Front axle 7 Chassis 8 Left front wheel mud guard 9 Left front wheel reduction gear 10 Left rear wheel reduction gear Part No 57 0009 0536 GTH 2506 GTH 3007 29 Operator s Manual First Edition First Printing Description Of The Machine Machine General Description GTH 2506 The machine mainly consists of a mobile carriage equipped with an operator s cabin and a telescopic boom with a load handling attachment articulation capable to handle and carry payloads not exceeding the rated capacity of the machine The mechanical power necessary to move the machine and to operate the load handling mechanism is provided by a diesel engine installed on the right side of the machine and controlled by a mechanical pedal
48. intervals correctly Make sure any malfunction detected during the maintenance is promptly rectified before using the machine All A marked operations must be carried out by a skilled technician During the first 10 working hours 1 Checkthe oil level within reduction gears power divider and differential gears 2 Regularly check the tightening of the wheel bolts Check the tightening of all bolts and nuts 4 Check the couplings for oil leaks e 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 Checkthe efficiency ofthe lighting electric system 9 Check the efficiency of braking system and parking brake 10 Check the efficiency of the steering selection system 11 Checkthe efficiency of the fork balancing system NOaPoN gt Part No 57 0009 0536 Genie GTH 2506 GTH 3007 77 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 Check the tyre inflation 3 Check the tightening of the wheel nuts 4 Check the tightening of the Cardan shaft screws Every 250 working hours or
49. 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 C 6 Carefully wash the tank with Diesel oil and blow a jet of compressed air 7 Refit the drain plug and the inspection cover 8 Add new oil by making sure that it matches the recommended type until it is level with A Operator s Manual First Edition First Printing Maintenance CHANGING THE OIL FILTER CARTRIDGE To change the hydraulic oil filter element proceed as follows 1 Stop the machine on a level ground and engage the parking brake Place a container of suitable size under the filter to collect any oil leaks Remove the filter cover to get access to the filter element A Change the filter element then before fitting a new one thoroughly clean and grease both seat and gasket Refit and tighten the filter cover A NOTICE The hydraulic oilfilter cartridge shallbe replaced as soon as the clogging indicator light on the control board comes on see par Controls and instruments NOTICE Hydraulic oil filter canisters cannot be cleaned or washed and refitted They must be replaced with new ones of the type recommended by the manufacturer PROTECT THE J ENVIRONMENT The handling and disposing of used oils may be ruled by local or national regulations Address to authorised centres 84
50. moment with respect to the threshold value is between 90 and 99 The system enters the pre alarm mode the buzzer sounds with an intermittent sound and the boom extension lowering and forks forwards tilting movements slow down Red LED s L5 and L6 risk of overturning The percentage of overturning momentis above 100 with respect to the threshold value The machine enters the alarm mode the buzzer sounds continuously and any dangerous manoeuvre is blocked boom up boom down boom out forks frame forwards The operator can only retract the load within safety limits Genie 64 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Alarm codes and resetting The limiter has diagnostic facilities to aid in the identification of failures of the transducers breakages of the cables or malfunction of the electronic system When a failure is signalled the limiter enters the safety mode blocking any dangerous manoeuvres LED L6 starts flashing representing an alarm code The meaning ofthese alarm codes is shown in section Faults and Troubleshooting DANGER 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 its motion axis Such unbalances may also be caused by an abru
51. stopped parking brake engaged working attachments flat on the ground and gear lever in neutral When raising a component for maintenance purposes secure it in a safe way before any maintenance intervention 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 seriously injured if accumulators are not completely depressurised For this purpose shut the engine down and step on the brake pedal 8 10 times Before any operation on hydraulic lines or components make sure there is no residual pressure For this purpose stop the engine engage the parking brake and operate the control levers of the main valve in both working directions alternately to depressurise the hydraulic circuit Part No 57 0009 0536 Genie GTH 2506 GTH 3007 79 Maintenance High pressure lines must be replaced by qualified personnel only Any foreign matters entering the closed circuit may result in a sudden deterioration of the transmission The qualified staff charged with the maintenance ofthe 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 NOTICE During maintenance or repair works and while weldin
52. the operator and to the maximum visibility The operatoris seatedona cushioned and adjustable seat and can operate the machine using the specific controls which have been properly located inside the cabin A dedicated dashboard is provided with all the necessary controls and gauges necessary to properly and safely operate the machine Genie Part No 57 0009 0536 GTH 2506 GTH 3007 31 Operator s Manual First Edition First Printing Description Of The Machine Machine General Description GTH 3007 The machine mainly consists of a mobile carriage equipped with an operator s cabin and a telescopic boom with a load handling attachment articulation capable to handle and carry payloads not exceeding the rated capacity of the machine The mechanical power necessary to move the machine and to operate the load handling mechanism is provided by a diesel engine installed on the right side of the machine and controlled by a mechanical pedal located inside the operator s cabin The diesel fuel feeding the engine is contained in a plastic tank located on the back of the chassis immediately underneath the boom hinge articulation The engine powers two hydraulic pumps The bigger oneis a piston type variable displacement pump is directly flanged to the engine flywheel housing and is hydraulically linked to a piston type variable displacement hydraulic motor which generates the torque necessary for the machine translat
53. the operator s cabin are the steering wheel to control the machine steering function the service brake pedal and the parking brake activation switch Genie 32 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Description Of The Machine The steering wheel is mechanically connected to a steering unit which feeds the steering cylinders installed on the front and rear axles in such a way the steering angle is proportional to the steering wheel turns The service brake pedal is linked to a brake pump which according to the pushing force on the pedal generates a hydraulic pressure activating the service brakes disks package wet type which is installed inside the front axle and works on the axle internal shafts The same brake disks package is operated by the parking brake system through an electrical switch located on the cabin dashboard together with the electrical two speed gear box shifting switch The operator s cabin is of full enclosed type and provided with windshield and glasses to protect the operator and to the maximum visibility The operator is seated ona cushioned and adjustable seat and can operate the machine using the specific controls which have been properly located inside the cabin A dedicated dashboard is provided with all the necessary controls and gauges necessary to properly and safely operate the machine Genie Part No 57 0009 0536 GTH 2506 GTH 3
54. the same side as in point 7 so that the front axle reaches its stop 10 Resetthe steering selection switch to four wheel steering pos 1 Now the wheels should be re aligned BRAN 90 GTH 2506 GTH 3007 If the machine is equipped with the optional Automatic Rear Wheel Alignment Indicator Sensor see paragraphControls and instruments the orange warning light 11 12 comes on automatically when by turning the steering wheel with the selector switch is in position 0 the rear wheels are aligned Part No 57 0009 0536 First Edition First Printing Operator s Manual Maintenance ADJUSTING THE SLIDING PADS OF THE BOOM SECTIONS Any boom section is fitted with adjustable pads located on the four sides of the profile These pads are secured to both fixed and mobile part of every section All pads can be adjusted by the special shims supplied by TEREXLIFT upon demand Adjusting the pads Remove or loosen the screws fixing the pads in relation to type of shims used with or without slots Fit the necessary amount of shims If the residual thickness of the pad is insufficient or near the maximum wearing limit renew the pad Tighten the screws fixing the pads at the recommended torque see below Use a dynamometric wrench Tightening torques of the pad screws in relation to the screw diameter Screws M10 Nm 30 Screws M14 Nm 50 Tightening torques higher th
55. tightened and the electrolyte level is regular Genie 60 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual 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 If the booster supply is installed on a second vehicle make sure that the latter does not touch the handler To avoid damage to the electronic instruments of the machine the engine of the machine where the booster supply is installed must be stopped Turn the ignition key and start the handler Disconnect the cables Remove first the negative terminal from the frame earth then from the booster supply Disconnect the positive terminal from the machine battery then from the booster supply A DANGER 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 Part No 57 0009 0536 Operating Instructions LOW TEMPERATURE STARTING In case of cold starting use an oil with a SAE viscosity adequate to the ambient temperature Please refer to the engine use and maintenance manual The machine is supplied with oil SAE 15W 40 Ay 10 15 To start the engine from cold proceed as follows Genie GTH 2506 GTH 3007 61 Set the forward reverse gear selector to n
56. 0009 0536 GTH 2506 GTH 3007 99 Operator s Manual First Edition First Printing Maintenance Filtering elements Filter Flow rate 1 Filtering Coupling Oil filter 150 101 1 1 4 B Fuel B Grease Refuel opening cover A Use only diesel fuel For the machine greasing use with less than 0 596 sulphur content according to the specifications of the diesel engine operation handbook NOTICE In cold climates temperature under 20 C use only Arctic type Diesel fuel or oil diesel fuel or oif diesel fuel mixtures The composition of the latter can vary in relation to the ambient temperature up to max 80 oil Lithium based Vanguard LIKO grease type EP2 When greasing by pump Graphitized AGIP When greasing by grease type GR NG brush On the telescopic boom GREASE LS 2 NOTICE Avoid mixing greases of different type or features and do not use greases of lower quality Engine coolant It is advisable to use an antifreeze mixture 50 water 50 antifreeze At the delivery the machine is refilled with TEREX PRO COOL by VALVOLINE The use of this product guarantees protection to the circuit for 3 years or 7000 hours without having to add any dry coolant additive TEREX PRO COOL Protection against boiling freezing 33 40 50 70 NOTICE Use an antifreeze mixture in the proportions recommended by the manufacturer in relation to the ambient temperature of the jo
57. 007 135 Operator s Manual First Edition First Printing Load Charts GTH 3007 HOOK GTH 3007 09 4618 1104 Genie 136 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Load Charts GTH 3007 900KG JIB GTH 3007 09 4618 1105 TEREX BRAND Part No 57 0009 0536 GTH 2506 GTH 3007 137 Operator s Manual First Edition First Printing Load Charts GTH 3007 2000 KG EXTENSION JIB GTH 3007 09 4618 1106 Genie 138 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual E Load Charts GTH 3007 BUCKET GTH 3007 09 4618 1156 Part No 57 0009 0536 GTH 2506 GTH 3007 139 Operator s Manual First Edition First Printing gE aS ae Intentionally blank page 140 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Diagrams And Schemes 2506 WIRING DIAGRAM 1 6 Rev B P N 57 1800 5126
58. 007 33 Operator s Manual First Edition First Printing Description Of The Machine Allowed use The telehandlers have been designed and manufactured for lifting handling and transporting agricultural or industrial products by means of specific attachments See Optional Attachments chapter manufactured by TEREXLIFT 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 telehandler 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 The telehandler can be used in residential and commercial environment light industry and industry 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 TEREXLIFT or an authorised assistance centre involves the automatic invalidation of the conformity of the machine to the Directive 2006 42 EC NOTICE Please check the accessories available for your machine Improper use Improper use means a utilisation of
59. 1 2 1 1 c o m tu gt gt c X3 x x x m mn gt gt 8 s 5 8 8 gt 8 B a mE gu amp TO i 5 Dds E 2 s z 5 lt E 3 E 5 gt 5 z 2 m S m m 5 5 5 2 z lt B F 5 5 z gt 5 8 F 5 2 lt lt gt m gt lt lt 5 5 4SF 31 enie 146 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Diagrams And Schemes 3007 WIRING DIAGRAM 1 6 Rev 0 P N 57 1800 5125 1 2 3 4 5 ENGINE IGNITION SWITCH S24 MAIN GAUGES CLUSTER P25 Oh en EMERGENCY STOP S17 ala 2 zs P29 F102 a m tm 511 SN 3 wn 5 L 20 A 22 72 26 R 29 4 7 E aja ss abs kiki 5
60. 127 Operator s Manual First Edition First Printing Specifications POWER Engine DEUTZ TD2011 LO4W Displacement 3600 cm Cylinder arrangement Vertical in line Combustion System Direct injection Max Power Output 68 kW 2600 rpm Max Torque Output 288 Nm 1600 rpm Aspiration Turbocharged Cylinder s number 4 Hydraulic Hydraulic output pressure 87L min 280bar VIBRATION LEVEL Mean assessed vibration level transmitted to arms 2 5 m s Mean assessed vibration level transmitted to body 0 44 m s Highest root mean square value of weighted acceleration to which the whole body is subjected XXX Uncertainty of vibration measurements 0 13 m s Values calculated in accordance with standard EN13059 SOUND LEVEL Sound pressure level at the operator position in accordance with the standard EN12053 82 dB Guaranteed sound power level in accordance with the Directive 2000 14 CE LwA 102 dB FLOOR LOADING SPECIFICATIONS Occupied Floor Area 4 20 m Occupied Floor Pressure 13 95 kPa Max Tire Load 4045 kg Max Axle Load 8090 kg Tire Contact Pressure 310 kPa Load With Fork 128 GTH 2506 GTH 3007 Part No 57 0009 0536 Operator s Manual First Edition First Printing Specifications CENTER OF GRAVITY GTH 2506 004 ZEZ 174 09rr WW OEY 874 129
61. 36 GTH 2506 GTH 3007 19 Operator s Manual First Edition First Printing Labels And Plates Applied On The Machine Decal Code Description t iia Label Road Traffic Warnings only for machines destined for the Italian market 09 4618 1419 Biodegradable Hydraulic Oil optional 09 4618 1458 Tip over Machine data plate The identification plate contains the main identification data of the machine Fork data plate This plate shows the main data of the fork installed on the machine 09 0803 0357 Boom tilting degree Road Traffic Data Plate This plate contains 09 4616 0000 the road traffic related data andthe weights of s the specificmachine model onlyfor machines destined for the Italian market oTEREX augen 20 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual DAMAGED MACHINE HAZARDS Do not use a damaged or malfunctioning machine Do a thorough pre operation inspection of the machine and test all functions before each work shift Tag and remove from service a damaged or malfunctioning machine sure that all maintenance jobs have been carried out as specified in this manual and the appropriate service manual Make sure that all decals in place and legible Make sure that the operator s is intact legible and placed in th
62. 5 Operator s Manual First Edition First Printing _ ass Test MS APPENDIX A DIAGRAMMATIC REPRESENTATION OF SUSPENDED LOAD CONDITION TEST RESULTS GTH 2506 45 45 27 MASKING AREA 156 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Test MS APPENDIX A DIAGRAMMATIC REPRESENTATION OF SUSPENDED LOAD CONDITION TEST RESULTS GTH 3007 m pata FS 45 MASKING AREA Genie Part No 57 0009 0536 GTH 2506 GTH 3007 157 Operator s Manual First Edition First Printing n Test APPENDIX LORRY TRAILER CONDITION This condition is referred to the machine with the boom be fully retracted and its height adjusted so that the upper face of the forks above and substantially parallel to the test surface is 1000 mm 50 mm rearward tilt of lt 5 is permissible The risks during lorry trailer loading are principally in the rearward direction during the reversing part of the manoeuvre before the boom is lowered Geen _ 158 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual SSS SSS E APPENDIX GTH 2506 Test r 12m DIAGRAMMATIC REPRESENTATION OF LORRY TRAILER CONDITION TEST RESULTS
63. 57 0009 0536 Genie REX BRA GTH 2506 GTH 3007 149 Operator s Manual Diagrams And Schemes GTH 3007 WIRING DIAGRAM 4 6 Rev 0 P N 57 1800 5125 150 First Edition First Printing 1 2 3 4 ROAD LIGHTS SELECTOR LEVER S57 WINDSCREEN WINDSCREEN ROAD LIGHTS SWTCH S5 STOP LIGHT WIPER MOTOR M22 WASHER PUMP M12 PRESSURE SWITCH S18 25 gt se o si 0 1 29 1 E 56 3009 A E SU UI lt 1 ie m 2 2 1 25 4 2 Aw a 2 2 a gt lt 5 2 2 zi gt alex z lt 5 gs 1 2008 6 0 xh nbn xanax X at 814 8 ES 2 a zu 2 re E EE a 51593 z lt 25 33 gt N 2 NUS 51 21 TEL NEN in 6 0 3 5 1 5 E 1 Ls F19 F6 F17 F16 10 SA 5A 10 10 n vi al 9 aL aU m
64. Application must be submitted directly by the user For the use of this attachment read the specific manual Part No 57 0009 0536 First Edition First Printing Operator s Manual BASKET FOR BRICKS code 59 0400 7000 TECHNICAL DATA 800 mm 1100 mm 1150 mm 1201 500 550 mm For the use of this attachment read the specific manual Part No 57 0009 0536 Genie GTH 2506 GTH 3007 123 Optional Attachments Application Attachmentused to handle construction manufactured products to be fixed to the standard forks of the handler and locked in position with the chains with shackles supplied Safety Strictly obey the general safety precautions given in section Safety Operation Fork the basket from the rear side being careful that the door that can be opened is at the front Secure the basket to the forks using the chains supplied Maintenance Visually check the attachment for damage before using it Operator s Manual First Edition First Printing gE aS ae Intentionally blank page 124 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Specifications GTH 2506 ew MEASUREMENTS 1920 mm 1250 mm 1810 mm 750 mm 1500 mm 2320 mm Length at fork holder plate 3840
65. B z 17 6 SES gx 5 7 xse 5 xs tose 45 Ses il ov 355 25 b R 18 9 5 22z25lc S20 T y 12 68853545 855241 5 9 i 116 9 2276 1714 102353 18 s 1 bie sl ds bbbbbbb bibbbl Y 54 55 as E m amp 2 5555 58 2 ele EE a 181 we HERD aac B s sb bb bbbbb ania dai Je da Ce 5 a e WH i 3983 a S s WH BLI gg PP WHI LEM 158 OK RD Y15 RDI sip WHO S zia z 5 z WHS 5 2 amp 1 1 5 6 a 5 8 x ape Ju x BE 1 A 6 1C 130 a 15 150 gt 0 220 F10 F12 F9 10 SA WA 104 e 5 x D2 v al al a og nl C 5 aT aL 15 15 K5 KT K6 X60 15 5 F H 10 136 13C mE 4 RELAY BOARD n x n yn x x sac Es 2 uy D D 1 158 158 pe PP L 158 p_WH ORT 158 VH GNI Sg Yb 1 PPRD 5 TO a 31 158 ae PP BKt e 5 225 PP BK1 Sg ki 3 7 18 a gt gt 5 amp 2 FAN 26 4 2 B 3 x 28129 X27 xn RELAY Ct xn xn XIX 8
66. B code 59 0802 3007 Mechanical Version TECHNICAL DATA A DANGER e Do not allow suspended loads to oscillate Do not drag loads when they are hooked up A suspended load has a dynamic and therefore an unpredictable effect on machine stability operate with caution 122 GTH 2506 GTH 3007 Application Quick coupling fitted attachment for maintenance interventions at high working heights Safety Strictly obey the general safety precautions given in section Safety Never lift wrongly slung loads 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 e Couple the jib and hold it in position by means of the attachment locking system mechanical or hydraulic Set the attachment supports in working position 1 using the dedicated pins A e To change the working height operate the lever according to the Quick Coupling The Attachments function To remove the attachment set the supports in resting position 2 then carefully tilt the attachment forward lower the boom resting the attachment on the ground and retract the boom 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 Make sure this attachment can be used in the destination country of the machine
67. Check for oil leaks from hoses and connectors Once the attachment quick connectors have been disconnected from the boom connectors take care to reconnect them to the proper rest connectors that are present on the bucket in order to prevent impurities from entering the circuit Carefully protect the rest connectors with the proper plugs when they are not used 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 For the use of this attachment read the specific manual and the Operator s Manual supplied with this equipment Part No 57 0009 0536 First Edition First Printing Operator s Manual 500 LITRES CONCRETE BUCKET code 59 0400 0000 _ Manual Version code 59 0400 1000 _ Hydraulic Version TECHNICAL DATA 500 ires 10mm 1110 mm 1320 mm 230 kg 0 5 m 700 mm For the use of this attachment read the specific manual Part No 57 0009 0536 Genie GTH 2506 GTH 3007 117 Optional Attachments Application Attachment coupled to the standard forks of the handler and fixed by means of the special chains with shackle provided Safety Strictly obey the general safety precautions given in section Safety Operation Fork the bucket bearing in mind the side where the product will be unloaded Secure the bucket to the forks using the chains provided To unload t
68. Do not operate the machine in strong wind Do not increase the surface area of the machine or forked load exposed to the wind Increasing the area exposed to the wind will decrease machine stability Use extreme caution and slow speeds when the machine is driven across uneven or unstable grounds slippery surfaces or near trenches or drop offs e Limit travel speed according to ground conditions slopes presence of personnel or other factors which may cause collision Do not place or attach overhanging loads to any part of the machine Genie 26 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing E N EXPLOSION OR FIRE hazards Do not start the engine if you smell or detect LPG gasoline diesel fuel or other explosive substances Do not refuel the machine with the engine running Refuel the machine and charge the battery only Operator s Manual Safety Precautions DAMAGED COMPONENT hazards Do not use battery chargers or batteries with a voltage above 12V to start the engine Do not use the machine as a ground for welding ina well ventilated area away from sparks naked PERSONAL INJURY hazards flames and lighted cigarettes Do not operate the machine in dangerous e Do not operate the machine in case of hydraulic environments or in places with flammable or oil or air leak Air or hydraulic oil leaks can explosive gases or materials penetrate or burn the skin
69. 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 Check the correct functioning of all the safety devices installed on the machine and in the job site n case of troubles or difficulties inform the foreman at once Never start working under unsafe conditions Do not carry out any repair work in a makeshift way to start working During work and especially maintenance always pay the greatest attention Do not walk or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only Keep the machine handholds and access steps always clean from oil grease or dirt to prevent falls or slips Part No 57 0009 0536 Genie GTH 2506 GTH 3007 25 Safety Precautions When entering leaving the cab or other raised parts always face the machine never turn the back When carrying out operations at hazardous heights over 1 5 meters from the ground always use approved fall restraint or fall arrest devices Donotenter leave the machine while it is running Donotleave the driving place when the machine is running e 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 suf
70. LIFT Technical Assistance Contact TEREXLIFT Technical Assistance OUTPUT 1 error Contact TEREXLIFT Technical Assistance OUTPUT 2 error Contact TEREXLIFT Technical Assistance Contact TEREXLIFT Technical Assistance Load cell A CRC error Contact TEREXLIFT Technical Assistance Load cell A overrange signal ContactTEREXLIFT TechnicalAssistance Load cell A offset error Contact TEREXLIFT Technical Assistance Load cell A power supply error 5 Vdc ContactTEREXLIFT TechnicalAssistance Load cell A error thermal calibration not present ContactTEREXLIFT TechnicalAssistance Load cell A LIN bus message check error ContactTEREXLIFT TechnicalAssistance 37 Load cell A CRC error ContactTEREXLIFT TechnicalAssistance Load cell A LIN bus error Contact TEREXLIFT Technical Assistance Load cell A LIN bus message counter error ContactTEREXLIFT TechnicalAssistance Genie Part No 57 0009 0536 GTH 2506 GTH 3007 103 Operator s Manual First Edition First Printing Faults And Troubleshooting Load cell BCRC error Contact TEREXLIFT Technical Assistance 42 Load cell B overrange signal Contact TEREXLIFT Technical Assistance Load cell B offset error Contact TEREXLIFT Technical Assistance Load col B power supply onor 5 Vas Contact TEREXLIFT TechnicalAssisance 45 Load cell error thermal calibration not present Contact TEREXLIFT Technical Assistance 46 Load cell B LIN bus message check e
71. LSA gt 2 i 25D pn z 2 E 1 5 192 E Ed S 5 a 1 4 S10 r3 p M TRE 1 1 1 H M M 9 La SiL 5 1 4 pl RI Mn of om B M MLA E 5 Xu 2 a gt Ld a2 E a z z z B 9 2 2 Ej B z a n n 1 n 2 9 3 8 5 2 4 xs XI XT xs xs X6 X6 X6 X6 X6 X6 X6 X6 X6 X6 SE 28 g 8 E s z 5 T amp gt a RDI 258 258 p PP WHI 25 w RBLS LSC gt BK15 La 1 in injin in B10 gt zz OPERATOR ON N am als SEAT SWTCH B10 C7 SW 2 ala n 1 5 s Ay ds ay 1 1 2 x x 2 xn at 2 WH GNI Ft FB F15 250 m ENT 25 _ Sd 10A 25D 73 a K4 15 15 15 25 RELAY BOARD D D F EREX BRAND G Part No 57 0009 0536 GTH 2506 GTH 3007 145 Operator s Manual First Edition First Printing Diagrams And Schemes 2506 WIRING DIAGRAM 6 6 Rev B P N 57 1800 5126
72. Never use the parking brake to slow down the machine unless in an emergency It may reduce the brake efficiency Accelerator control 10 Gas Pedal Its pressure controls the engine rpm and the machine speed Itis fitted with an adjustable stop in the lower part A When starting the engine the lights of all the pushbuttons turn automatically on Only the switching on of the orange warning light sets on the top of the pushbutton will indicate the activation of the function Road Jobsite selection 21 Road Jobsite switch Pushbutton with orange glass cap with two stable positions 0 Road setting boom controls are disabled and only the two wheel steering is enabled J 1 Jobsite setting boom controls and all steering mode are enabled NOTICE Before switching on the Road Setting align the rear wheels of the machine Genie 38 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Speed control only for GTH 3007 29 Mechanical Gear switch Pushbutton with red glass cap it is used to engage 1st or 2nd gear Push the button to select the required speed each pressure corresponds to the selection of a new speed 0 No speed change 1 Engage a new speed The selection is signalled by the warning lights 11 15 and 11 16 which come on accordingly to the gear enagaged 11 15 for first speed 11 16 for second speed To select a new speed you m
73. TON Located on the dashboard to the right of the steering wheel Pressing down this button stops the engine of the machine Before starting work again find and rectify the relevant causes then reset the button to neutral position turning it clockwise 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 Part No 57 0009 0536 Genie GTH 2506 GTH 3007 93 Maintenance SEAT SWITCH Located inside the seat cushion this micro switch prevents any machine transmission movements if the operator is not correctly seated in the driving seat Checking the seat switch at every use Tocheck ifthe seat switch is in efficient working order it will be enough to attempt to make the machine to move without sitting on the drive seat In this condition the machine shall not move Should that not be the case contact TEREXLIFT Technical Service Operator s Manual First Edition First Printing Maintenance SAFETY VALVES fitted to all CYLINDERS DANGER Always use the lock ring of the lift cylinder see picture below when carrying out maintenance on the lift cylinder block valve or in general any operation in the area under the boom 1 Lift and extend the boom I Unscrew the two screws on the frame pos A to r
74. W Measured sound power level dB A Guaranteed sound power level dB A Also complies with the following European Standards National Standards and technical provisions EN 1459 1998 A2 2009 EXAMPLE OF LAYOUT Documento cod FATT Original Original Original Original EC DECLARATION OF DECLARATION CE DE DECLARACION CE DE CONFORMITY CONFORMITE CONFORMIDAD EGCKONFORMEITATEERKERRUNG Manufacturer and person fabricante y la persona Hersteller und Person berechtigt die Fabricant et personne autoris e lauthorized to compile the autorizada para elaborar el Itechnischen Unterlagen constituer le dossier technique technical file lexpediente t cnico Izusammenzustellen TEREXLIFT s r l Zona Industriale Buzzacchero 06019 Umbertide PG Italia Hereby declares that the que la machine d sign e que el equipo Erklart dass die nachfolgende machinery described below ci dessous maschine Designation Rough Terrain Variable Reach Truck D signation Designaci n Bezeichnung Function handling loads Fonction manipuler des charges Funci n manejar las cargas Funktion handhabung von lasten Model Mod le Modelo Modell Serial number e rie Seriennummer complies with the provisions of Jest conforme aux dispositions de Corresponde a las exigencias un gen pestimmungen der the machinery directive la directive machines basicas de la
75. WITCH S2 25 P LLA z 21 9 e a d T V DE PN isma Y 31 S13 La 4 5 1 n 2 ex x E ols i 9 m 42 5 8 zR gt X LB Y1 4 4 2 ITE 2 5 1 12 5 XSI 5 X5 xs X5 X5 xs 5 gt Eu 9 ide z n gt 250 pe E501 peat 1 F5 YA 15 RELAY BOARD D D 7248 LI P 420 Y BL1 158 gt 238 p Liu 1 2 23 m in 5 z 5 5 5 1 1 X51 x2 Y51 Y52 Y49 E ns F 257 a 3 5 3 QA S 15 ee ae ge 55 OF gS es N 4 lt amp S 9 je lt S S 4 ey Genie Part No 57 0009 0536 REX BRA GTH 2506 GTH 3007 143 Operators Manual First Edition First Printing Diagrams And Schemes GTH 2506 WIRING DIAGRAM 4 6 Rev B P N 57 1800 5126
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77. ace when the machine is not used for a long time 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 spillage Keep metal objects watch straps rings necklaces clear of the battery leads since they can short the terminals and burn you 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 BRAN disconnect the battery disconnect the negative lead from the frame earth first To connect the battery connect the positive lead first Recharge the battery far from the machine in a well ventilated place Keep out of items which can produce sparks of naked flames or lit cigarettes Do not rest metal objects onto the battery This can result in a dangerous short especially during a recharge Risk of explosion or shorts During the recharge an explosive mixture with release of hydrogen gas forms Donotadd sulphuric acid add only distilled water GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Maintenance REFUELLING Capacity litres Capacity litres GTH 2506 GTH 3007 Engine cooling system Water antifree
78. achine follow the above precautions Additionally Wash the machine thoroughly For a better cleaning remove grills and protection casings e Carefully dry all machine parts by blowing some compressed air e Lubricate the machine thoroughly Do a 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 periodically check its charge level Refuel the tank to prevent internal oxidation Store the machine a sheltered and well ventilated place e Start the engine for about 10 minutes at least once a month e When weather is particularly cold empty the radiator NOTICE Always rememberthatthe ordinary maintenance must be carried out even during the machine inactivity Pay particular attention to the fluid levels andto those parts subjectto ageing Before re starting the machine carry outan extraordinary maintenance and carefully check all mechanical hydraulic and electrical components Operator s Manual First Edition First Printing Transporting The Machine CLEANING AND WASHING THE MACHINE 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 preven
79. all be careful and sensible for their own as well as for the others safety and shall desire to carry out the work correctly and in a responsible way emotional they shall keep calm and always be able to evaluate their own physical and mental conditions training they shall read and be familiar with this handbook its enclosed graphs and diagrams the identification and hazard warning plates They shall be skilled and trained about the machine use NOTICE 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 Part No 57 0009 0536 Genie GTH 2506 GTH 3007 23 Safety Precautions Requisites of the SERVICEMEN The personnel charged withthe machine maintenance shall be qualified specialised in the maintenance of telehandlers and shall have the following prerequisites physical good eyesight acute hearing good co ordination and ability to carry out all required maintenance operations in a safe way according to this manual mental ability to understand and apply the enforced rules regulations and safety precautions They shall be careful and sensible for their own as well as for the others safety and shall desire to carry out the work correctly and in a responsible way training they shall read and be familiar with this handbook its
80. an those Max wearing thickness recommended can cause the break of the pad or of the locking threaded bush Pads mustcompulsorily 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 Minimum 1 mm Genie Part No 57 0009 0536 GTH 2506 GTH 3007 91 Operator s Manual First Edition First Printing Maintenance CHECKING THE SAFETY DEVICES B LOAD LIMITING SYSTEM It consists of a load cell fitted to the rear axle and a display installed in the driving place This device enables the operator to check the stability variation through a bar with 6 LED s 2 green 2 orange and 2 red Checking the LOAD LIMITING SYSTEM at every use When power is turned on the load limiting system runs a self test In the case of troubles the limiter enters the safety mode blocking any dangerous manoeuvres LED L6 starts flashing representing an alarm code The meaning ofthese alarm codes is shownin section Faults and Troubleshooting To do a manual check it will be enough to load a weight exceeding the maximum permitted with the boom fully out and attempt to lift it The system shall enter in alarm should that not be the case contact TEREXLIFT Technical Service 92 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual EMERGENCY STOP PUSHBUT
81. anen Buidoos l woog 4 e oineip u aunssaud 5140959191 pod is pagod AjeoyneipAH Val Mae 096 einsseid Duppoero Mz t onea Bujold ejqnop eq 096 ainssaid Buppeio p Bujold 49PUIIAD UH woog 01 zanssasd spod Buydnos Buyjdndo 5104 anea lqnoq AGI jeuondo r BRAND GTH 2506 GTH 3007 G Bungjoi Buu ls I 1 SN qs eunsseid 1
82. asurements 0 13 m s Values calculated in accordance with standard EN13059 SOUND LEVEL Sound pressure level at the operator position in accordance with the standard EN12053 Guaranteed sound power level in accordance with the Directive 2000 14 CE LWA FLOOR LOADING SPECIFICATIONS Occupied Floor Area Occupied Floor Pressure Max Tire Load Max Axle Load Tire Contact Pressure Max Load With Fork 126 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual m Specifications GTH 3007 MEASUREMENTS A 2070 mm 1350 mm 1990 mm 750 mm 1590 mm 2660 mm Length at fork holder plate 4715 mm Ground clearance center 500 mm Overall Length 5915 mm Lifting height max 6900 mm Lifting capacity max 3000 kg Lift capacity at maximum height 2500 kg Lift capacity at maximum reach 1250 kg Forward reach max 3900 mm Reach at maximum height 760 mm Fork holder plate rotation 128 5900 kg Ti I PRODUCTIVITY Lifting lowering speed 9s 7s Extension retraction speed 85 55 Attachments tilting speed 35 35 Inside outside turning radius 2200mm 3800mm Break out force with 800It shovel SAE J732 80 4270 kg Towing capacity at dynamometer 5200kg 3900kg Floor loading 292kPa Max speed 5km h Floating forks 1240x100x50mm Tyres DIN 70631 405 70 20 Genie Part No 57 0009 0536 GTH 2506 GTH 3007
83. ates Applied On The Machine Description t 09 4618 1001 Label Maintenance Collar 09 4618 1400 Label Upper Door External Unlock System 09 4618 0986 Crush Hazard 09 4618 1030 Label Cabin Fuses amp Relays Board 09 4618 1256 Instruction Emergency Exit 09 4618 1331 Battery Cut Out Switch 09 4618 1423 Accumulator Hazard Genie Part No 57 0009 0536 GTH 2506 GTH 3007 13 Operator s Manual First Edition First Printing Labels And Plates Applied On The Machine Ret Dea Code Description Label Road Traffic Warnings only for machines destined for the Italian market 09 4618 1419 Biodegradable Hydraulic Oil optional 09 4618 1458 Tip over Machine data plate The identification plate contains the main identification data of the 1 machine 09 4618 1029 Fork data plate This plate shows the main data of the fork installed on the machine 09 0803 0357 Boom tilting degree Road Traffic Data Plate This plate contains 09 4616 0000 the road traffic related data andthe weights of the specific machine model only for machines destined for the Italian market 14 GTH 2506 GTH 3007 Part No 57 0009 0536
84. bsite Genie 100 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual SSS Faults And Troubleshooting FAULTS AND TROUBLESHOOTING This chapter represents a practical guide for the operator for fixing the most common failures and at the same time detecting those interventions that must be carried out by qualified technical engineers Any repair work maintenance or troubleshooting If you are unsure about anything do not carry out must be carried out with machine stopped boom operations on the machine but call in a skilled in rest position or laid on the ground parking technician brake engaged and ignition key removed PROBLEM CAUSES SOLUTIONS The 50A fuse FG1 supplying power Replace the fuse to the dashboard is blown engine compartment Battery disconnected Connect the battery using the relevant Switch Battery down Checkthe battery Battery cut out switch OFF Switch it on Parking brake not engaged Engage the parking brake and ensure the relevant indicator on the dashboard Switches on Battery down Recharge or replace the battery Battery cut out switch OFF Switch it on Fuse F18 blown e Check the fuse No fuel Refuel THE DASHBOARD DOES NOT TURN ON THE STARTER DOES NOT RUN THE STARTER RUNS Diesel fuel filter clogged See engine operator manual BUT THE ENGINE Diesel fuel hose empty fuel used up Refuel then refer to engine operator DOES
85. cal or hydraulic Set the attachment supports in working position 1 using the dedicated pins A All loads must be bridled with special textile slings or chains in compliance with all pertinent regulations e To handle the load raise and rotate the telescopic boom of the handler To remove the attachment set the supports in resting position 2 then carefully tilt the attachment forward lower the boom resting the attachment on the ground and retract the boom Maintenance Visually check the hook for damage before using it Check the safety catch is in good working order The fixed hook has been designed to support the load declared beside The max payload corresponds to the nominal capacity rating of the handler on which it is installed and is indicated on the load charts supplied with the equipment Make sure this attachment can be used in the destination country of the machine Application must be submitted directly by the user Part No 57 0009 0536 First Edition First Printing Operator s Manual 3000 KG FIXED HOOK ON PLATE code 59 0700 9002 ONLY FOR GTH 3007 A DANGER e Do not allow suspended loads to oscillate Do not drag loads when they are hooked up A suspended load has a dynamic and therefore an unpredictable effect on machine stability operate with caution For the use of this attachment read the specific manual Part No 57 0009 0536 Gen
86. ccount the following general precautions e G N 70 Start the engine Align the rear wheels Only for the italian market install the locking devices provided for the machine registration document as follows install the boom extension locking cable A install the locking collar B on the tilting cylinder install the locking collar C on the lifting cylinder Cover the teeth of the conventional forks with the special guard Retract boom and attachment to transfer position Set the Road Jobsite switch to ROAD Make sure that lights horn and turn signals are in working order Engage the gear The transfer speed of the vehicle will depend on the engine rpm and the position of the control lever Genie GTH 2506 GTH 3007 NOTICE Public road circulation is allowed only for transferring an unloaded machine Do not use the machine to tow trailers ONLY FOR THE ITALIAN MARKET Part No 57 0009 0536 First Edition First Printing Operator s Manual Transporting The Machine MOVING A DISABLED MACHINE Tow the machine only when noalternative 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 Unlock the parking brake Tow the machine for short distances and at a low speed only less than 5 km h e Use a rigid drawbar Select the two wheel steer Set the
87. ce of harmful substances they must be collected eliminated and or recycled in accordance with the laws of the UE Used batteries must be keptina dry and confined place Make sure the battery is dry and the cell plugs 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 smear the box and the elements with a coat of grease and tighten the plugs Do not rest the battery on the ground it is always advisable to rest itona pallet and cover it The disposal of batteries shall be as rapid as possible Genie 74 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Observe and obey The operator can only perform the routine maintenance operations envisaged in this manual Scheduled maintenance procedures shall be completed by qualified technical personnel according to the manufacturer s specifications Maintenance symbol legend The following symbols are used in this manual to help you understand better the instructions Maintenance HE INTRODUCTION A thorough and regular maintenance keeps the machine in a safe and efficient working condition For this reason it is advisable to wash grease and service the machine properly especially after having worked under particular conditions muddy or dusty environments heavy operations etc Always ensure all machine componen
88. ch Operate the end adjusters to reach the length you wish and make sure the buckle is always in the middle Not fasting the seat belts could result in death or serious injury Operator s Manual First Edition First Printing Operating Instructions E 3 STEERING COLUMN ANGLE ADJUSTMENT Both steering column and dashboard can be set to a different angle To adjust the steering wheel angle unlock lever 3 and pull or push the steering wheel to the required position then re lock lever 3 Before driving the machine ensure the steering wheel is perfectly clamped SWITCHING ON THE CAB INTERIOR LAMP The ceiling light fixture is fixed to the rear top strut of the cab The relevant lamp is switched on off by Switch Genie 58 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Operating Instructions ADJUSTING THE MIRRORS The machine is fitted with four mirrors The right convex mirror is located on a speciai The left rear view mirror is placed on the supporting bracket in advanced position and left upper post of the windscreen and allows allows checking the area behind the machine checking the area behind the machine on the on the right hand side To adjust its position left hand side To adjust its position manually manually rotate the joint it is fitted with rotate the joint it is fitted with The right rear view mirror
89. d is engaged 11 16 Warning light second speed only for GTH 3007 Amber warning light that signals when second speed is engaged Part No 57 0009 0536 Genie GTH 2506 GTH 3007 43 Operator s Manual First Edition First Printing Controls And Instruments CONTROL LEVER Handlers are equipped with a multipurpose electro proportional lever which allows operating all machine movements When shifted to one of the four directions right left forwards backwards it controls the boom lifting NN lowering and the forward back pitching of the attachment frame Pressing buttons 1 or2 you movethe boomtelescope out and in and when the function is present you lock unlock the attachment fitted to the machine 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 The control lever shall be operated only when the operator is correctly seated in the driving place Before operating the control lever make sure that nobody is within the working range of the machine Goe 44 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Controls And Instruments Function selection The leveris enabled to carry out the follow
90. d new oil through plug until it is level with the hole e Refit and tighten the plug To change the oil e Place acontainer of suitable size under the drain plug Remove the plug Remove the drain plug Q and empty the power divider gearbox Refit and tighten the drain plug Pour in new oil through the filler C placed at the top of the reduction gear of the power divider Stop when oil is level with hole Refit and tighten plug Genie Part No 57 0009 0536 GTH 2506 GTH 3007 87 Operator s Manual First Edition First Printing Maintenance GREASING Before injecting grease into the greasers thoroughly clean them to avoid that mud dust or other matters can mix with the lubricant and reduce or annihilate the lubrication effect Remove any old grease with a degreaser from the telescopes before smearing them with new grease Regularly grease the machine 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 the symbol amp represents the points to be greased by a pump the symbol 5 represents the points to be greased by a brush 88 GTH 2506 GTH 3007 Use only PTFE INTERFLON FIN GREASE LS 2 to lubricate the sliding parts of the telescopic section Observe the following sch
91. de 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 be sure that the operations you are going to carry out are not explicitly forbidden be sure that the methods are safe say in compliance with the rules and provisions given in this section be sure that the methods cannot damage the machine directly or indirectly or make it unsafe contact TEREXLIFT Assistance Service for any suggestion and the necessary written permission Genie 22 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operators Manual REQUISITES OF THE PERSONNEL IN CHARGE 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 substances that may alter their psycho physical conditions and consequently their working abilities physical good eyesight acute hearing good co ordination and ability to carry out all required operations in a safe way according to the instructions of this manual mental ability to understand and apply the enforced rules regulations and safety precautions They sh
92. de 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 Springing adjustment optional Tilt the lever 2 toward the machine front side of about 45 then rotate it clockwise to increase the seat springing or rotate it anticlockwise to reduce the seat springing Once the desired springing has been reached put the lever back to the rest position Height adjustment optional Turn knob 3 clockwise to lift the seat turn it counter clockwise to lower the seat 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 The seat is for one person only Don t adjust the seat when the machine is moving Part No 57 0009 0536 Genie GTH 2506 GTH 3007 57 Operating Instructions FASTENING THE SEAT BELTS Sit correctly in the driving seat then 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 sure that the buckle is correctly located at the hip point and not on the stoma
93. ded could result in property damage PROTECT THE Green used to draw the attention to important information on environment protection e Genie Part No 57 0009 0536 GTH 2506 GTH 3007 3 Operator s Manual First Edition First Printing gE aS ae Intentionally blank page 4 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Check that the operator handbook refers to the delivered machine DESIGNATION ROUGH TERRAIN VARIABLE REACH TRUCK MODEL GTH 2506 GTH 3007 MANUFACTURER TEREXLIFT srl Zona Industriale 06019 UMBERTIDE PG ITALY Enrolled in the register of companies at the Court of Perugia under no 4823 1 102886 Fiscal Code V A T no 00249210543 APPLICABLE STANDARDS Forthe operator s safety the following standards were obeyed during the risk assessment of the handler fitted with telescopic boom Directive Title 2006 42 EC Machinery Directive 2008 104 EC Electromagnetic compatibility 2000 14 CE Environment Acoustic Emissions Standard Title EN 1459 1988 Harmonised standard Safety of A2 2009 Industrial trucks Self propelled variable reach trucks Part No 57 0009 0536 Genie GTH 2506 GTH 3007 5 Machine Identification MACHINE IDENTIFICATION PLATES The following data plates are applied on the machine Machine data plate The identification plate contains the ma
94. der 1 Oil to the attachment Part No 57 0009 0536 Genie GTH 2506 GTH 3007 41 Operator s Manual First Edition First Printing Controls And Instruments Instruments 25 Engine coolant temperature indicator This indicates the engine coolant temperature If the finger is in the red zone and the warning light comes on you must stop the machine and find and rectify the problem 26 Hydraulic oil temperature indicator This indicates the temperature of the hydraulic oil in the tank If the temperature rises above the permissible value or the red warning light comes on you must stop the machine and find and rectify the problem 27 Fuel gauge This indicates the fuel level in the tank If the fuel level is low reserve the relevant warning light comes on 28 Hour meter Signals the total operating hours of the machine Use the hour meter to gauge the routine maintenance jobs Genie 42 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Warning lights ref 11 11 1 Warning light low battery charge Signals a low charge by the alternator 11 2 Warning light low engine oil pressure It lights when the engine oil pressure is too low 11 3 Warning light air filter restricted When this lamp come on proceed with cleaning or changing the air filter cartridge 11 4 Warning light low brake pressure It lights whe
95. e push the service brake pedal Result The machine should move in reverse then come to an abrupt stop The back up alarm should sound when the transmission control lever is in reverse 22 Move the transmission control lever to neutral 23 Push the top of the parking brake switch Result The red parking brake indicator light should come on indicating the parking brake is on 24 Move the transmission control lever forward then in reverse Result The machine should not move 25 Push the bottom of the parking brake switch The parking brake is off when the indicator light is off Test the Road Lights 26 Verify that all lights are functional WORKPLACE INSPECTION The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Be aware of and avoid the following hazardous situations drop offs or holes bumps floor obstructions or debris sloped surfaces e unstable or slippery surfaces overhead obstructions and high voltage conductors hazardous locations inadequate surface support to withstand all load forces imposed by the machine wind and weather conditions the presence of u
96. e special container located in the machine PERSONAL INJURY HAZARDS Donotoperate the machine in case of hydraulic oil or air leak Air or hydraulic oil leaks can penetrate or burn the skin Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning Do not lower the boom if the area underneath is not clear of personnel or obstructions Part No 57 0009 0536 Genie GTH 2506 GTH 3007 21 Safety Precautions SAFETY DEVICES Several safety devices have been fitted to the machine They must never be tampered with or removed Regularly check the efficiency of such devices In case of faults stop working immediately and proceed in replacing the malfunctioning device For the checking procedures read chap Maintenance MOMENT LIMITING SYSTEM LLMI LLMC The moment limiting system has been developed to help the operator to maintain the machine longitudinal stability Audible and visual messages are provided when the limits of longitudinal stability are being approached However this device cannot replace the experience of the operator It is up to the user to adopt the necessary safety measures to work within the rated limits of the machine SEAT SWITCH This micro switch is located inside the seat cushion and it prevents any machine transmission movements ifthe operator is notcorrectly seated in the driving seat Operator s Manual First Edition First Printing
97. ead the operator s Support boom manual maintenance Keep away from Crush Hazard moving parts Keep away from Crush Hazard belt Falling Object Hazard Allow system to cool when performing Crush Hazard Insert Maintenance Collar GTH 2506 GTH 3007 n load Explosion Burn Hazard Am Burn Hazard M Keep clear of moving parts Battery Cut Out Fall Hazard Sg No smoking No open flame Allow surfaces to cool E Allow compartment access Safety Alert Simbol Part No 57 0009 0536 Operator s Manual Labels And Plates Applied On The Machine Shading indicates decal is hidden from view i e under covers First Edition First Printing GTH 2506 VA N lt _ wv AD RA j G ON Wie o Lh ITH TT D 42 2 5 TAN N7 NX Je NN lt 2 5 J Genie GTH 2506 GTH 3007 Part No 57 0009 0536 Operator s Manual First Edition First Printing Labels And Plates Applied On The Machine Use the pictures on these pages to verify that all decals are legible and in place The following chart shows quantities and description too Decal Code Bescrpton 09 4618 1398 Safety pin operation The capacity of the truck and attachment 09 4618 1375 combination shall be complied with
98. edule After the first 50 operating hours 1 week After the first 250 operating hours 1 month Every 1000 operating hours 6 months Remove any old grease from the boom and smear the sliding area of the blocks with a thin coat of grease J 2 NEC s J B Part No 57 0009 0536 First Edition First Printing Operator s Manual TYRES AND WHEELS Over inflated tyres can burst Overheated can burst Do not weld the wheel rims For any repair work call a qualified technician For the tyre inflation or substitution please refer to the table below Dimensions front and rear 12 16 5 P R or load index Rm 975465 8 holes DIN 70361 Pressure bar Psi 4 5 65 Maintenance Always use tyres having the dimensions indicated in the vehicle registration card On new machines and when a wheel has been disassembled or replaced check the nut torque of the wheels every 2 hours until they stay correct Torque 400 N m BRAKES For any inte
99. eft Before replacing a blown fuse with anew one having the same amperage find out and rectify the fault Cabin compartment fuses and relays ame wang f 56 ros Roanne f o POSITION LIGHTS ros powensummvoer 9 99 ros zwvomauucomcum w EB oo oo 5 CS rm Geansetecton eee 06 00 Fw REARAKLESENSOR t _ 90 rw FLASHINGBEACON za O0 re seu f o ee C 888888 COS LIGHT SWITCHES rm ewemaewcvsroe w WIPER INSTRUMENT PANEL 10 B Engine Fuses MAIN FUSE IB GLOW PLUGS FUSE K02 K01 STARTER ENABLING SWITCH GLOW PLUGS PREHEATING Genie Part No 57 0009 0536 GTH 2506 GTH 3007 97 Operators Manual First Edition First Printing Maintenance BATTERY STARTER BATTERY SPECIFICATIONS Length width Height 25 kg 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 pl
100. elease the ring Put the ring on the lift cylinder rod pos B IV Lock the ring by tightening the screws provided on the ring 94 GTH 2506 GTH 3007 All machine s cylinders are equipped with block valves Compensation cylinder Lifting cylinder Telescopic boom extension cylinder Attachment swinging cylinder 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 Load a weight near the maximum payload 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 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 TEREXLIFT Technical Service Part No 57 0009 0536 First Edition First Printing Operator s Manual To remove the block valves or the cylinders Lower the boom to the ground a firm way since the removal of the block valve or the cylinder can cause an uncontrolled down movement After refitting the valve or the cylinder replenish the circuit and eliminate any air before starting worki
101. ents 900 KG EXTENSION JIB code 59 0802 3008 _ Mechanical Version ONLY FOR GTH 3007 TECHNICAL DATA A DANGER Do not allow suspended loads to oscillate Do not drag loads when they are hooked up A suspended load has a dynamic and therefore an unpredictable effect on machine stability operate with caution For the use of this attachment read the specific manual 120 GTH 2506 GTH 3007 Application Quick coupling fitted attachment for maintenance interventions at high working heights Safety Strictly obey the general safety precautions given in section Safety Never lift wrongly slung loads 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 Couple the jib and hold it in position by means of the attachment locking system mechanical or hydraulic e Setthe attachment supports in working position 1 using the dedicated pins A Lift the attachment support locking it in working position by means of the dedicated pin B All loads must be bridled with special textile slings or chains in compliance with all pertinent regulations handle the load raise and rotate the telescopic boom of the handler To remove the attachment set the supports in resting position 2 lower the attachment support 3 locking it in restin
102. er to the load charts applied within the cab of your machine GTH 2506 09 4618 0834 Part No 57 0009 0536 Genie GTH 2506 GTH 3007 63 Operating Instructions The load charts applied on the cab refer to a stationary machine standing a solid and level ground Raise the load some centimetres and check its stability before raising it completely s e 2 Operator s Manual First Edition First Printing Operating Instructions LOAD LIMITER On the front top strut of the cab there is limiter 6 which warns the operator of the variation of stability of the machine and blocks any manoeuvre before the same reaches a critical condition Description of the controls Used only for calibration Stability indicator with LED bar Green light power OK Used only for calibration Used only for calibration m p o N Operation When power is turned on light 3 the led bar 2 and button 4 and 5 come on The monitoring system runs a self test During operation the LED bar 2 lights up gradually depending on the variation of stability LED Bar Green LED s L1 and L2 during normal operation when the percentage of overturning moment is between 0 and 89 these LED s are ON The machine is stable Orange LED s L3 and L4 they light up when the machine tends to overturn and the percentage of overturning
103. eutral position Turn the ignition switch to the glow plugs preheating position the relevant warning light 11 13 goes on Step down on the gas pedal and start the engine by turning the ignition switch Release the switch as soon as the engine fires 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 Operator s Manual First Edition First Printing Operating Instructions DISCONNECTING THE BATTERY During maintenance or repair works and while welding turn off the battery cut out switch located into the engine compartment below the engine air filter STARTING THE MACHINE When the engine reaches the running temperature ensure all parts are in transfer position and the forward reverse gear selector is in neutral Then proceed as follows Select the required steering mode Select the required gear forward or reverse e Release the parking brake Slowly step the gas pedal to start moving off Do not operate the forward reverse gear selector when the machine is running The machine would reverse the running direction abruptly and you could seriously be injured STOPPING AND PARKING THE MACHINE When possible stop the machine on a dry level and solid ground Then Bring the machine to a smooth stop by easing up the gas pedal and stepping down on the brake pedal Set the forward reve
104. fe machine operation contained this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection Know and understand the pre operation inspection before going on to the next section 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended TESTS 1 Select a test area that is firm level and free of obstruction Be sure there is no load on the forks or attachment 2 Enter the operator s compartment and sit on the seat Fasten the seat belt 4 Adjust all the mirrors See Adjusting the Mirrors section 5 Be sure the parking brake is on and the transmission control is in neutral 6 Start the engine See par Starting the Engine in the Operating Instructions section Part No 57 0009 0536 Genie GTH 2506 GTH 3007 53 Inspections Test the Control Lever 7 Using the control lever momentarily raise and lower the boom tilt the forks up and tilt the forks down Result All functions should operate smoothly Using the control lever and the yellow button momentarily extend and retract the boom Result The function should operate smoothly Using the control lever and the white button momentarily lock and unlock the attachment Result The function should operate smoothly Test the Steering 10 Push the right side of the steer selector switch to select four wheel steer 11 Chec
105. ff on when engine is running immediately stop the machine and find and rectify the fault Once it has been started the engine continues to run even if you leave the driving place DO NOT LEAVE THE DRIVING PLACE BEFORE HAVING SHUT THE ENGINE DOWN LOWERED THE BOOM TO THE GROUND TURNED THE FORWARD REVERSE GEAR SELECTOR TO THE NEUTRAL POSITION AND ENGAGED THE PARKING BRAKE Engine cannot be started if the forward reverse gear selector switch is not in the neutral position JUMP STARTING THE ENGINE NOTICE Do not start the engine using a quick charge booster to avoid any damage to the electronic boards A DANGER When jump starting the engine through the battery of another machine make sure that 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 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 Turn any users off by the special control levers e Put the gear selector to neutral and engage the parking brake e Ensure the machine battery A is connected to the frame earth the terminals are well
106. ficient 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 e Plates and hazard warning stickers shall never be removed hidden or become unreadable Except for maintenance purposes do not remove safety devices shields protection cases etc Should their removal be necessary stop the engine remove them with the greatest care and always remember to refit them before starting the engine and using the machine again Before any maintenance or repair work stop the engine and disconnect the batteries Do not lubricate clean or adjust moving parts Operator s Manual First Edition First Printing Safety Precautions Do not carry out operations manually when specific tools are provided for this purpose e Avoid the use of tools bad condition or use in an improper way i e pliers instead of adjustable wrenches etc Applying loads in different points of the attachment holding plate is forbidden Any intervention on the hydraulic circuit must be carried out by authorised personnel The hydraulic circuit of this machine is fitted with pressure accumulators You and others could be seriously injured
107. forward reverse gear selector to neutral position e Raise the front wheels of the machine e When possible start the engine and use the hydraulic drive and the braking system Unlocking the parking brake To unlock the negative brake of a faulty machine proceed as follows Loosen the two opposite screws A located on the front axle Remove the shims located under the two screws A Re tighten the screws A turning alternately the front screw and the rear screw 1 2 turn to unlock the brake To relock the nagative brake loosen the screws A turning alternately the front screw and the rear screw 1 2 turn refit the shims B and re tighten the screws A Genie Part No 57 0009 0536 GTH 2506 GTH 3007 71 Operator s Manual First Edition First Printing Transporting The Machine LIFTING THE MACHINE When the machine shall be lifted use only means having a suitable capacity The characteristic data and the center of gravity details are listed in the section Specifications For lifting the machine proceed as follow Retract the boom to transfer position Putthe parking brake andrestthe attachmentflat e Shut the engine down and close the driving cab of the machine e Anchor the chains to the four special lugs on the machine marked with the decal below Lift the machine only when the chains has been anchored to all the lugs TRANSPORTING THE MACHINE ON OTHER VEHICLES T
108. g turn off the disconnected battery switch located into the engine compartment below the engine air filter Operator s Manual First Edition First Printing Maintenance ACCESS TO THE ENGINE COMPARTMENT For any operation 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 Thermal engine A Engine air filter B e Radiator fluid compensation cup C Battery D To get access to the engine compartment Shut the engine down and put the parking brake Unlock and raise the hatch with handle Take all precautions when approachingtheenginecompartment Some parts of the engine may be very hot Always use protective gloves 80 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual ENGINE AIR FILTER Clean the engine air filter and replace the elements when necessary 1 Cleaning and changing the outer element Shutthe engine down and engage the parking brake Unlatch the fasteners A and remove cover B Pull out the filter cartridge C Clean the filter bowl Dry clean the cartridge at max 6 bar pressure and direct the air jet from inside to outside Check the filter element for cracks by introducing a lamp inside Refit the cartridge and make sure it is properly positioned Close cover B and loc
109. g position by means of the dedicated pin B carefully tilt the attachment forward lower the boom resting the attachment on the ground then retract the boom 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 Make sure this attachment can be used in the destination country of the machine Application must be submitted directly by the user Part No 57 0009 0536 First Edition First Printing Operator s Manual 900 KG EXTENSION JIB code 59 0802 3009 _ Hydraulic Version ONLY FOR GTH 3007 TECHNICAL DATA A DANGER Do not allow suspended loads to oscillate Do not drag loads when they are hooked up A suspended load has a dynamic and therefore an unpredictable effect on machine stability operate with caution Make sure this attachment can be used in the destination country of the machine Application must be submitted directly by the user For the use of this attachment read the specific manual Part No 57 0009 0536 Genie GTH 2506 GTH 3007 121 Optional Attachments Application Quick coupling fitted attachment for maintenance interventions at high working heights Safety Strictly obey the general safety precautions given in section Safety Never lift wrongly slung loads Avoid abrupt acceleration or deceleration Avoid load oscillations and
110. he concrete e Manual Version manually operate the gate opening lever e Hydraulic Version operate the attachment locking lever after connecting the feeding lines of the new attachment to the quick couplings Maintenance Visually check the bucket for damage before using it Wash with water after use or in case of prolonged inactivity to prevent the mix or residues from hardening Check for oil leaks from hoses and connectors Carefully protect the quick connectors once disconnected to prevent impurities from entering the circuit Check the chains after every use and replace them if worn or damaged Operator s Manual First Edition First Printing Optional Attachments 2500 KG FIXED HOOK ON PLATE code 59 0700 9004 ONLY FOR GTH 2506 A DANGER Do not allow suspended loads to oscillate Do not drag loads when they are hooked up A suspended load has a dynamic and therefore an unpredictable effect on machine stability operate with caution For the use of this attachment read the specific manual 118 GTH 2506 GTH 3007 Application Attachment for lifting loads by means of special slings Safety Strictly obey the general safety precautions given in section Safety Do not oscillate the load Do not drag hooked loads Lift the load before extending the boom Operation e Couple the hook and hold it in position by means of the attachment locking system mechani
111. ie GTH 2506 GTH 3007 119 Optional Attachments Application Attachment for lifting loads by means of special slings Safety Strictly obey the general safety precautions given in section Safety Do not oscillate the load Do not drag hooked loads Lift the load before extending the boom Operation Couple the hook and hold it in position by means of the attachment locking system mechanical or hydraulic e Setthe attachment supports in working position 1 using the dedicated pins A All loads must be bridled with special textile slings or chains in compliance with all pertinent regulations e To handle the load raise and rotate the telescopic boom of the handler To remove the attachment set the supports in resting position 2 then carefully tilt the attachment forward lower the boom resting the attachment on the ground and retract the boom Maintenance Visually check the hook for damage before using it Check the safety catch is in good working order The fixed hook has been designed to support the load declared beside The max payload corresponds to the nominal capacity rating ofthe handler on which it is installed and is indicated on the load charts supplied with the equipment Make sure this attachment can be used in the destination country of the machine Application must be submitted directly by the user Operator s Manual First Edition First Printing Optional Attachm
112. if present After the first 5 years repeat this check every 2 years Operator s Manual First Edition First Printing Maintenance ELECTRICAL SYSTEM Do not use fuses having a higher amperage than that recommended since they can damage the electric system seriously e Ifthe fuse blows after a short time look for the fault source by checking the electric system Always keep some spare fuses for emergency Never try to repair or short blown fuses Make sure the contacts of fuses and fuse sockets ensure a good electric connection and are not oxidised 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 ina safe way before carrying out any maintenance Any intervention on the electrical system unless performed by authorized personnel is expressly forbidden NOTICE Modifications and or adds to the machine s electroniccomponentsandsystemsmustcomply to the provisions of EN12895 lt gt gt gt gt gt gt gt gt gt gt gt gt gt gt 6 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Maintenance FUSES AND RELAYS The electrical system is protected by fuses placed in the driving cab on the l
113. in identification data of the machine like model serial number and year of manufacture it is applied on the front left side of the chassis Road traffic data plate The road traffic data plate is installed on the front right side of the chassis only on machines destined for the Italian market This plate shows the road traffic related data and the weights of the specific machine model Fork data plate Placed on the left side of the fork frame This plate shows the identification data of fork such as model serial number year of manufacture weight nominal payload centre of the load and model of the machine on which the forks are installed Operators Manual First Edition First Printing Machine Identification MARKING This machine fulfils the safety requirements of the Machinery Directive The conformity has been certified and the placing of the CE marking on the machine demonstrates compliance with the regulatory requirements The CE markingis placed directly on the identification plate of the machine CHASSIS SERIAL NUMBER The chassis serial number is punched on the front right part of the chassis side member Machine data plate the machine data plate is applied on the front left side of the chassis HOW TO READ YOUR SERIAL NUMBER E IDENTIFICATION PLATES OF THE MAIN PARTS The plates of the main components not directly manufactured by TEREXLIFT srl for instance engines pumps etc
114. ing Optional Attachments FEM 3 FORKS ON PLATE code 55 0750 0002 ONLY FOR GTH 3007 TECHNICAL DATA Payload 3000 kg 1390 mm Application Quick coupling fitted attachment for handling palletized Safety Strictly obey the general safety precautions given in section Safety Do not load loose materials Do not move superposed pallets Operation Adjust the distance between the two forks by hand Operate the joystick to adjust the forks tilting Maintenance Visually check the attachment for damage before using it Daily grease the joints using a greasing gun and smear the sliding guides with graphitized grease 112 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual FEM3 FORKS WITH HYDRAULIC SIDE SHIFT code 59 0601 5002 ONLY FOR GTH 3007 TECHNICAL DATA Payload Fork Attachments CoG Part No 57 0009 0536 Genie GTH 2506 GTH 3007 113 Optional Attachments Application Quick coupling fitted attachment for handling palletized loads with possibility of shifting the load to the side by 100 mm Safety Strictly obey the general safety precautions given in section Safety Do not load loose materials Do not move superimposed pallets Operation To adjust the tilting operate the joystick To side shift operate the joystick after connecting the feeding lines of the new attachment to the quick couplings Main
115. ing motions D Am Boom lowering lifting y shift the control lever to A or B O Ap lt 22 Boom extraction retraction lt press button 2 and shift to A or without moving the control lever Caf Attachment back forward tilting shift the control lever to C or D Attachment coupling release optional press button 1 and shift the lever to C or D b Genie Part No 57 0009 0536 GTH 2506 GTH 3007 45 Operators Manual First Edition First Printing Controls And Instruments B Lifting lowering the boom A DANGER Before operating the boom make sure thatnobody e is within the working range of the machine O Wy 2 ZZ To lift or lower the boom e Smoothly shift the lever to position to lift the boom or to position A to lower it Genie 46 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Controls And Instruments Extending retracting the boom Before operating the boom make sure that nobody RE 2 is within the working range of the machine To extend or retract the telescopic elements of the boom Press button 2 and smoothly shift the lever to position A to extend the boom or to position B to retract it Genie Part No 57 0009 0536 GTH 2506 GTH 3007 47 Operators Manual First Edition First Printing Controls And Instruments P
116. ing plug Q Drain plug Level plug 86 GTH 2506 GTH 3007 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 Clean the 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 To change the oil 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 Part No 57 0009 0536 First Edition First Printing Operator s Manual Maintenance OIL LEVEL IN THE POWER DIVIDER GEARBOX To check the oil level in the power diver gearbox Stop the machine on a level ground and make Filling plug sure the parking brake is engaged Drain plug Clean level plug all around Remove the plug and check if oil is level with the hole e When necessary ad
117. inside the machine Make sure all decals are present and legible See Labels and plates applied on the machine chapter e Check for engine oil leaks and proper oil level Top up if necessary See Maintenance chapter e Check for axle oil leaks and proper oil level Top up if necessary See Maintenance chapter Check for hydraulic oil leaks and proper oil level Top up if necessary See Maintenance chapter Check for engine coolant leaks and proper coolant level Add coolant if necessary See Maintenance chapter Check for battery fluid leaks and proper fluid level Add distilled water if necessary See Maintenance chapter Check the following components or zones for damage missing or wrongly fitted parts or non authorised modifications electrical components wiring and electrical cables hydraulic hoses fittings cylinders and main valves fuel and hydraulic oil tanks drive pump and motor and transmission axles steering system braking system boom telescopes sliding pads clean glasses lights and rear view mirrors engine and relevant components horn lights machine ignition control nuts bolts and other fasteners Check the entire machine for cracks on welds or structural components dents or damage to the machine Make sure that all structural and other critical components are present and the relevant fasteners and pins are fitted and properly tightened After inspection check
118. ion These two units are the main components of the hydrostatic transmission which is mechanically linked to the machine axles and wheels In particular the hydraulic motor is flanged to the mechanical two speed gear box to the center of the front axle which is linked to the real axle by a drive shaft so providing a 4X4 wheels drive capability The four wheels are equipped with tires suitable to operate the machine in all the working conditions which have been foreseen forthis model and capable to withstand the maximum loads generated by the machine weight and payloads The second gear type pump flanged on the back of the bigger one and mechanically linked to that by a passing through PTO produces the flow and pressure to move the telescopic boom and the load handling attachment articulation and to power the steering system These two pumps are fed through oil suction lines which are linked to the hydraulic oil tank installed on the bottom center of the chassis This oil tank steel made is provided also with the oil filter package return type the oil level gauges and the oil charging cap The engine and the two pumps are installed inside a suitable engine compartment consisting of a fixed lower bay made in steel and of a upper bonnet which can be opened to allow servicing activities in the engine compartment The engine compartment also includes the engine and hydraulic system cooler the engine coolant expansion tank the air i
119. itching the attachment holding frame forward back TOM SU 9 Before operating the boom make sure that nobody is within the working range of the machine iS To tilt forward back the attachment holding frame e Shift the lever to position D to tilt the frame 3 forwards or to position C to tilt it backwards Genie Tr 48 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Controls And Instruments Attachment coupling release optional Before operating the boom make sure that nobody z is within the working range of the machine Ll A DANGER zg To coupling or release the attachment Press button 1 and smoothly shift the lever to position C to coupling or to position D to release m it Genie Part No 57 0009 0536 GTH 2506 GTH 3007 49 Operator s Manual First Edition First Printing gE aS ae Intentionally blank page Genie f Tr 50 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Make sure you learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform pre operation inspection Know and understand the pre operation inspection before going on to the next section 3 Always perform function tests prior to use 4 Inspect the workplace
120. k in place with fasteners A NOTICE As soon as the warning lamp 11 3 on the cab dashboard switches on replace the outer element Never wash the cartridge with water or solvents 2 Changing the internal element See step 1 for removing the outer element Extract the internal cartridge D Clean the filter bowl Mount the new element and make sure it is correctly positioned Fit the main filter and the cap as described in point 1 Part No 57 0009 0536 Genie GTH 2506 GTH 3007 81 Maintenance NOTICE The inner element should be replaced every two times the outer element is replaced Never wash the cartridge with water or solvents Operator s Manual First Edition First Printing Maintenance ENGINE COOLING SYSTEM When the coolant is hot the cooling system is under pressure With warm engine loosen the radiator plug slowly and carefully without removing it to drain the pressure Use protection gloves and keep your face at a safe distance Weekly check the coolant level through the level window C before starting working when fluid is cold When necessary add clean water or an antifreeze mixture through cap A Change the antifreeze mixture every two years To drain the antifreeze Letthe engine cool down Unscrew the plug B at the bottom of the radia tor or disconnect the rubber hose if no plug is present Allow the coolant to flow out into a special container
121. k the steering operation by turning the steering wheel approximately turn in each direction Result The front wheels should turn in the same direction as the steering wheel The rear wheels should turn in the opposite direction 12 Straighten the wheels 13 Push the steer selector switch to the middle position to select two wheel steer 14 Check the steering operation by turning the steering wheel approximately turn in each direction O Result The front wheels should turn in the same direction as the steering wheel The rear wheels should not turn 15 Straighten the wheels 16 Push the left side of the steer selector switch to select crab steer Operators Manual First Edition First Printing Inspections 17 Check the steering operation by turning the steering wheel approximately turn in each direction O Result The front wheels and rear wheels should turn in the same direction as the steering wheel Test the Transmission and Brakes 18 Be sure the boom is fully lowered and retracted 19 Step on the service brake pedal 20 Move the transmission control lever to forward Slowly let up on the service brake pedal As soon as the machine starts to move push the service brake pedal O Result The machine should move forward then come to an abrupt stop 2 Move the transmission control lever to reverse Slowly let up on the service brake pedal As soon as the machine starts to mov
122. l Lever 18 Continuous Oil Flow Potentiometer Genie Part No 57 0009 0536 GTH 2506 GTH 3007 35 Operator s Manual First Edition First Printing Controls And Instruments Ignition switch 2 Forward reverse gear selector switch Three position switch Three position switch with lock in neutral position 0 1 36 No circuit under voltage key can be removed 0 Neutral position no gear engaged and engine is stopped 1 Shift lever to pos 1 to select the forward gear Circuits under voltage presetting for the en gine starting Board controls and instruments 2 Shift lever to pos 2 to select the reverse gear are on The warning light 11 13 signalling the glow plugs preheating comes on Wait until the light goes off before starting the engine Engine starting when released key springs L back to pos 1 automatically 2 22 Horn function When sliding the lever along its axis horn switches on independently from other pre set functions Genie gt gt gt GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Controls And Instruments 4 Turn signals Windscreen wiper Lights Windscreen washer function Lights function Push the second stage of the lever along its axis to switch the handler lights lever can be set to three direct a jet of water onto the cab windscreen different positions along its vertical
123. lease the parking brake and start a new working cycle Genie Part No 57 0009 0536 GTH 2506 GTH 3007 67 Operator s Manual First Edition First Printing Operating Instructions CHANGING THE ATTACHMENT Use only attachments directly manufactured or recommended by Terexlift and detailed in the Optional attachments section Version with MECHANICAL LOCKING To change an attachment operate as follows 68 Drive to the place where you will release the mounted attachment when possible a solid and sheltered site Disconnectthe quick connectors of the attachment if any Pull out pin 1 locking the attachment after removing the safety split pin 2 at its end Rest the attachment flat on the ground Pitch the attachment holding frame forward and lower the boom to release the attachment upper lock Move back with the machine and drive to the new attachment to be coupled Hold the frame pitched forward and hook the upper lock of the new attachment Retract and raise the attachment some centimetres It will centre automatically on the quick coupling frame Refit pin 1 fixing it with its safety split pin 2 Re couple the connectors of the attachment if any After substitution visually checkthe attachment iscorrectly coupled to the boom before operating the machine A wrongly coupled attachment may result in damage to persons or things Genie gt gt gt GTH 2506 GTH 3007 Part No
124. located inside the operator s cabin The diesel fuel feeding the engine is contained in a plastic tank located on the back of the chassis immediately underneath the boom hinge articulation The engine powers two hydraulic pumps The bigger oneis a piston type variable displacement pump is directly flanged to the engine flywheel housing and is hydraulically linked to a piston type variable displacement hydraulic motor which generates the torque necessary for the machine translation These two units are the main components of the hydrostatic transmission which is mechanically linked to the machine axles and wheels In particular the hydraulic motor is flanged to the center of the front axle which is linked to the real axle by a drive shaft 0 providing a 4X4 wheels drive capability The four wheels are equipped with tires suitable to operate the machine in all the working conditions which have been foreseen for this model and capable to withstand the maximum loads generated by the machine weight and payloads The second gear type pump flanged on the back of the bigger one and mechanically linked to that by a passing through PTO produces the flow and pressure to move the telescopic boom and the load handling attachment articulation and to power the steering system These two pumps are fed through oil suction lines which are linked to the hydraulic oil tank installed on the bottom center of the chassis This oil tank steel made is pr
125. mber of different attachments and which is activated by another specific cylinder The different attachments selected for this machine can be easily replaced and are secured by a mechanical pin standard feature or by a hydraulic quick lock unlock cylinder The boom cylinders described before are driven through a main valve which is electrically controlled through a joystick located in the operator s cabin The other main controls available in the operator s cabin are the steering wheel to control the machine steering function the service brake pedal and the parking brake activation switch The steering wheel is mechanically connected to Genie 30 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Description Of The Machine a steering unit which feeds the steering cylinders installed on the front and rear axles in such a way the steering angle is proportional to the steering wheel turns The service brake pedal is linked to a brake pump which according to the pushing force on the pedal generates a hydraulic pressure activating the service brakes disks package wet type which is installed inside the front axle and works on the axle internal shafts The same brake disks package is operated by the parking brake system through an electrical switch located on the cabin dashboard The operator s cabin is of full enclosed type and provided with windshield and glasses to protect
126. monthly Jobs to be done in 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 the 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 Checkthe hydraulic lines are not worn because of rubbing against the frame or other mechanical components 9 Checkthe electric cables do not rub against the frame or other mechanical components 10 A Check the wear of the sliding pads of the boom sections 11 AAgjustthe play ofthe 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 Jobs to be done in addition to those above 1 Checkthe efficiency of the block valves Operator s Manual First Edition First Printing Maintenance Every 500 working hours or every six months Jobs to be done in addition to those above 1 2 10 Visually check the smoke quantity evacuated from the engine exhaust Check the tightening of the engine fixing screws Check the tightening of the cab fixing screws Check the backla
127. n the pressure of the brake circuit is too low for a correct functioning 11 5 Warning light parking brake engaged When ON this light indicates that the parking brake is engaged 11 6 Warning light high coolant temperature This red light comes on to alert to a too high temperature of the cooling medium Stop the engine and find and rectify the problem 11 7 Warning light high beam Blue warning light that signals when high beam is ON 11 8 Warning light hydraulic oil filter clogged When this lamp sets to on immediately change the oil filter on the return line to the tank 11 9 Warning light low hydraulic oil level This light comes on to alert to a low level of the hydraulic oil for a correct functioning Replenish and eliminate the oil leak Controls And Instruments 11 10 General alarm warning light This red light comes on to warn of a problem of the machine Contact the TEREXLIFT Service Centre 11 11 Warning light low fuel level If the fuel level is low reserve the relevant warning light comes on 11 12 OPTIONAL Warning light rear wheel aligned When ON this light indicates that the rear wheel are aligned 11 13 Warning light glow plugs preheating This light comes on during the pre heating of the engine glow plugs s 11 14 Warning light low beam Green warning lightthat signals when low beam is ON 11 15 Warning light first speed only for GTH 3007 Amber warning light that signals when first spee
128. nauthorized personnel other possible unsafe conditions Genie 54 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual 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 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 Part No 57 0009 0536 Genie GTH 2506 GTH 3007 55 Operating Instructions For a safe use of the machine always check the weight of the loads going to be handled Operator s Manual First Edition First Printing Operating Instructions ENTERING THE MACHINE ENTERING THE CAB Always make sure that your hands and shoe soles are clean and dry before getting into the driving cab Always face 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 Insert the key and release lock 1 Press the pushbutt
129. ne Cover Closing 09 4618 0922 Crush Hazard 09 4618 0240 09 0803 0529 Cosmetic GENIE Logo 09 4618 0242 Genie Part No 57 0009 0536 GTH 2506 GTH 3007 17 Operator s Manual First Edition First Printing Labels And Plates Applied On The Machine Ref Code Description 09 4618 0484 09 4618 0485 Cosmetic Genie GTH 3007 09 4618 0984 09 4618 0924 Burn Explosion Hazard 09 4618 0925 Crush Hazard 09 4618 0926 No Riders 09 4618 0927 Burn Hazard 09 4618 0916 Lift Point 09 4618 0917 Diesel Fuel Cap 09 4618 0928 Hydraulic Oil 09 4618 0949 Label Engine Fuses amp Relays Board 09 4618 1001 Label Maintenance Collar 18 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Labels And Plates Applied On The Machine Deal Code Description Qt 09 4618 1400 Label Upper Door External Unlock System 09 4618 0986 Crush Hazard 09 4618 1385 Label Mechanical Gear Instructions 09 4618 1030 Label Cabin Fuses amp Relays Board 09 4618 1256 Instruction Emergency Exit 09 4618 1331 Battery Cut Out Switch 09 4618 1423 Accumulator Hazard Genie Part No 57 0009 05
130. ng To eliminate the air from the circuit move the involved cylinders to end of stroke in the two directions opening closing To eliminate the air from the fork balance cylinder move the boom up and down and tilt the fork plate forwards back Dothe check of the valves taking all the possible precautionary measures 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 free space with barriers all around to keep non authorised people away Ensure that the part to be checked is in safe condition and that the action generated does not result in an uncontrolled movement of the machine NOTICE See section ROUTINE CHECK SCHEDULE for noting the result of the daily safety devices checking Part No 57 0009 0536 Genie GTH 2506 GTH 3007 95 Maintenance CHECKING THE MACHINE START CONTROL at every use Attemptto start the engine with the forward or reverse gear put The engine must notstart If the engine starts contact the TEREXLIFT Technical Service Repeat the operation putting first one gear then the other CHECKING THE STATE OF THE STRUCTURE Five years or 6000 hours after the first placing into operation of the machine whichever occurs first check the state of the structure paying an extreme attention to the welded supporting joints andthe pins of both boom and platform
131. ntake duct and filter the electrical alternator the battery the fuel and the engine oil filters The engine exhaust muffler is installed behind the engine compartment and is flanged to the chassis right side The telescopic boom hinged on the back of the chassis mainly consists in two steel tubes having rectangular sections and provided with a load handling attachmentarticulation for payload stuffing unstuffing and transportation purposes The outer section is hinged in the back top area of the chassis and moved by an hydraulic cylinder linked between its bottom surface and the central bottom area of the chassis The extension retraction of this cylinder produces the boom outer section to rotate between the boom up and down limits The boom inner section can telescope with respect the outer one by aboom extension cylinder internally installed At the top of the inner section a load handling attachment articulation is provided with a rotating carriage which can be easily interfaced with anumber of different attachments and which is activated by another specific cylinder The different attachments selected for this machine can be easily replaced and are secured by a mechanical pin standard feature or by a hydraulic quick lock unlock cylinder The boom cylinders described before are driven through a main valve which is electrically controlled through a joystick located in the operator s cabin The other main controls available in
132. o transport the machine on another vehicle follow the steps below Ensure ramps are correctly positioned e Retract the boom to transfer position e Carefully drive the machine onto the transporting vehicle e Putthe parking brake and rest the attachment flat on the vehicle platform e Ensure the overall dimensions do not exceed 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 e Anchor the machine to the transporter s platform by fixing the chains to the special eyebolts on the chassis OMO Genie 72 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operators Manual PARKING AND STORAGE Short inactivity Always park the machine in a safe way after a working day a shift and at night Take all precautions to prevent damage to those persons who will approach the machine while stationary e Park the machine so that it does not hinder other operations Lower the boom fitted with attachment on the ground Disengage the transmission and put the parking brake Remove the key from the ignition switch and lock the cab door Leaving a battery connected can result in shorts and as a consequence in a fire Part No 57 0009 0536 Genie GTH 2506 GTH 3007 73 Transporting The Machine Machine storage In case of extended inactivity of the m
133. oap and water Storage Always keep lubricants in a closed place out of the children s reach Never store lubricants on the open air and without a label indicating their contents Disposal New or exhausted oil is always polluting Never drain oil on the ground Store new oil in a suitable warehouse Pour exhausted oil into cans and deliver them to 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 A TEREX BRAN 76 GTH 2506 GTH 3007 First aid Eyes In 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 In 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 Part No 57 0009 0536 First Edition First Printing Operator s Manual EN ORDINARY MAINTENANCE A wrong or neglected maintenance can result in possible risks for both operator and bystanders Make sure maintenance and lubrication are carried out according to the manufacturer s instructions to keep the machine 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
134. on 1 and open the door Door closing from inside Pull the door with force it locks automatically Door opening from inside Push lever 2 to open the door completely e Rotate handle to open the upper section of the door and lock it against the special catch 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 To unlock the door latched in open position Press button4 tounlock the door from the catch Once released re close the upper section of the door by means of handle 3 Leaving the cab an emergency In an emergency the operator can use the 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 which if driven out allow opening the glass completely The front window has one 5 handle which if turned enables the operator to pass through Genie 56 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual ADJUSTING THE SEAT Acorrect adjustment of the seat ensures the operator a safe and comfortable driving The handler seat is fitted with devices which allow for the adjustment of the springing the height and the distance from the controls Seat distance from the controls The seat is equipped with an adjusting device to sli
135. ovided also with the oil filter package return type the oil level gauges and the oil charging cap The engine and the two pumps are installed inside a suitable engine compartment consisting of a fixed lower bay made in steel and of a upper bonnet which can be opened to allow servicing activities in the engine compartment The engine compartment also includes the engine and hydraulic system cooler the engine coolant expansion tank the air intake duct and filter the electrical alternator the battery the fuel and the engine oil filters The engine exhaust muffler is installed behind the engine compartment and is flanged to the chassis right side The telescopic boom hinged on the back of the chassis mainly consists in two steel tubes having rectangular sections and provided with a load handling attachmentarticulation for payload stuffing unstuffing and transportation purposes The outer section is hinged in the back top area of the chassis and moved by an hydraulic cylinder linked between its bottom surface and the central bottom area of the chassis The extension retraction of this cylinder produces the boom outer section to rotate between the boom up and down limits The boom inner section can telescope with respect the outer one by aboom extension cylinder internally installed At the top of the inner section a load handling attachment articulation is provided with a rotating carriage whichcan be easily interfaced with anu
136. p p Por ber par Lo Por 5 SA 4B 38 1 5B 1 20 i 298 75 n 6 2 20 5B Ek Bee E lt pos x E w w ww 9 amp B DT04 6P DT06 65 PF 9 f 8 amp f E fe Z s ow 2 s E 3 Alarm 2 1 s 5 FEE 6 2 Cent flow enabling switch 2 HG MES 8 amp 3 H3 Alarm 2 3 k amp any 4 Out ev lowering E 5 o H 5 Out ev tilt lowering 5 EC E E 6 aut ev telescopic out 6 Le Bop 2 8 Sey z gt 2 9 3 3 2 3s 8 3 Z 5 s I T 5 8 amp 6 86 8 S 6 6 u 5C 68 8C 88 28 78 2A 1 i id d d b b o xn Xn Yxn Yxn AX gt p p P o m Ko p p B P B p B B B p JLB J T 1A J T 2A J T 28 J T 3A 57 38 J T 4A JT 4B 1 2 2 1 1 2 2 1 1 2 2 1 1 2 2 1 x ES gt 4 a gt gt EI m m 3 z g a a a E 5 E 3 i E m 522 E BE OB TD a ik XKS pde bz Dds 5 z s P 5 E 5 S z 5 S 8 E 2 8 lt m lt 5 55 31 31 11 enie 152 GTH 2506 GTH 3007 Part No 57 0009 0536 Operator s Manual First Edition First Printing Diagram And Schemes 57 2201 3300
137. pt operation of the levers during the load handling If during work several indicators light up operate the levers more smoothly Part No 57 0009 0536 Genie GTH 2506 GTH 3007 65 Operating Instructions HANDLING LOADS Adjusting the forks With FEM forks optional Forks shall be spaced to suit the load going to be handled For this purpose e Lift the clamping lever of the forks Slide the forks to the desired position then re lock the lever With floating forks 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 Lock the screws re tightening the nut The centre of gravity of the load must always be halfway between the forks Ensure you exactly know the weight of the load before handling it e When extending the boom do not exceed the payload limit Refer to the payload limits given in the load chart applied inside the cab Space the forks as wide as possible to suit the load being handled Operators Manual First Edition First Printing Operating Instructions WORKING PHASES Operator have to survey his her field of vision when operating the truck Loading phase Approach the load to the handled perpendicularly and check that the machine is level on the inclinometer Insert the forks under the load and raise the load some centimetres Pitch the
138. rror Contact TEREXLIFT Technical Assistance Contact TEREXLIFT Technical Assistance 48 Load cell B LIN bus error Contact TEREXLIFT Technical Assistance 49 Load cell B LIN bus message counter error ContactTEREXLIFT TechnicalAssistance 51 Too big difference between load cell A and B signals ContactTEREXLIFT TechnicalAssistance EJ ES EN Too big difference between the load percentage Contact TEREXLIFT TechnicalAssistance detected by channel 1 and 2 Error LMI bypass key actived during the machine Donotactivate the LMI bypass key before starting the machine starting Contact TEREXLIFT Technical Assistance Contact TEREXLIFT TechnicalAssistance Contact TEREXLIFT Technical Assistance Contact TEREXLIFT Technical Assistance Releasethe LMI buttons turn the machine Error LMI buttons pressed during the machine off andturn iton again If the error message starting is still shown contact TEREXLIFT Technical Assistance 104 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Faults And Troubleshooting TORQUE WRENCH SETTINGS Dxp Pre loading N Torque wrench setting Nm 4 8 8 8 10 9 12 9 4 8 8 8 10 9 12 9 4 0 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 8 x 1 25 8200 16400 23100 27700 12 3 24 6 34 7 41 6
139. rse gear selector to neutral position Engage the parking brake and ensure its indicator light switches on Release the service brake pedal Rest the attachment coupled to the boom flat on the ground Rotate the ignition key to 0 and remove the key Leave the driving cab and lock the cab door 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 Always engage the parking brake after stopping the machine to prevent possible accidental motions of the vehicle 62 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual USING THE LOAD CHARTS Theload charts 1 indicates the maximum permissible loadin relation to the boom extension and the type of attachment used To operate under safe conditions always refer to these charts The extension level of the boom can be checked with the help of the letters A B C D E painted on the same boom pos 3 while the actual degrees of inclination of the boom are shown by the angle indicator 2 All the load charts are placed into a dedicated holder installed in the left side ofthe cabin The tag 4 located at the bottom of each load chart represents the type of attachment used The load charts illustrated in this manual are given only as a mere example To define the payload limits ref
140. rvention onthe braking system adjustment and or substitution of the brake discs address to the TEREXLIFT Technical Assistance Service or the nearest TEREXLIFT authorised workshop Optional PetNamer Polyurethane Filled 55 0403 0055 Tyres 405 70 24 14 pr Tyres Part No 57 0009 0536 Genie GTH 2506 GTH 3007 89 55 0403 0047 Operator s Manual First Edition First Printing Maintenance m SHAFTING ALIGNMENT During operation the alignment of the front and rear axles of the machine can be subject to variations This can depend on an oil blow by from the steering control circuit or on a steering of both axles when front and rear wheels are not perfectly aligned To fix this problem rather than checking the alignment visually follow the procedure below 1 Move toa solid and level ground 2 Set the steering selection switch 20 to four wheel steering pos 1 3 Rotate the steering wheel up to its stop either to the right or to the left 4 Set the steering selection switch to two wheel steering pos 0 5 Rotate the steering wheel up to its stop turn in the same direction as above 6 Resetthe steering selection switch to four wheel steering pos 1 7 Rotate the steering wheel to the side opposite to point 3 so that the rear axle reaches its stop 8 Resetthe steering selection switch to two wheel steering pos 0 9 Rotate the steering wheel to
141. s lit the relevant switch and the turn signals light start flashing 7 Emergency Stop Pushbutton 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 it clockwise 15 Load Limiter Disable Selector The load limiter can be deactivated operating the key selector placed under the protection cover 15 A DANGER Working with the load limiting system cut out can result in a machine overturning and in serious injury 40 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Auxiliary drive controls 23 Cab Heater Fan Switch Three position switch 0 Fan OFF 1 Low speed 98 2 High speed 24 Road Lights Switch Three position switch placed on the right side of the dashboard 0 Lights OFF 1 Position lights ON 2 Low beam ON 30 Work Lights Switch OPTIONAL Two position switch 0 Lights OFF 1 Lights Controls And Instruments 31 Switch OPTIONAL Two position switch 32 Auxiliary Hydraulic Circuit OPTIONAL Two position switch The pressure of this button causes the switching of the hydraulic circuit for the movement of the attachments equipped with auxiliary lines 12 Cab Heater Control Knob Located at the bottom of the driving seat base it adjusts the flow of heated air in the cab 0 A C OFF 1 A C ON 0 Oil to the attachment cylin
142. sh between pins and bushings in all joints Change the hydraulic oil filter in the tank Have the hydraulic system checked by a skilled technician Change the main cartridge of the engine air filter Change the hydraulic oil filter of the transmission Clean or replace if necessary the air filter in the cab First change for the engine oil and renew the fuel filter OIL CHANGE SCHEDULE Operating Service Oil level check Axles and Hydraulic divider Every 1000 working hours or yearly Jobs to be done in addition to those above 1 2 Change the oil in the front and rear differential units and in the power divider Change the oil in the four wheel reduction gears Change the hydraulic oil Change the engine oil and renew the fuel filter SHELL RIMULA 15W 40 API CH 4 CG 4 CF 4 CF daily MB228 Subsequent changes 1000 3 8 3 Oil level check 250000 power GL4 FORD M2C 86B Subsequent changes 1000 Massey Ferguson M1135 Oil level check aulic TFistchange J o oil whichever occurs first 78 GTH 2506 GTH 3007 TRACTORENAULT 208 LF SAE 80W monthly SHELL TELLUS T 46 DENISON HF 1 DIN 51524 daily Subsequent changes 1000 part 2 amp 3 Part No 57 0009 0536 First Edition First Printing Operator s Manual MAINTENANCE INTERVENTIONS All maintenance interventions must be carried out with engine
143. sse d wo lv i n POE eBieyood 1 eAejs ni sann S o 1 i Sumene suog Ajoedeo U Fl L Buueeis soyeinwinooy Al GE suono s p apar wal LLAW a Lm suojoury 5140952151 A via Buueejs un exe 1204 H spod z 1 124 08 einsseud Bungiedo jeped M jeuondo Burupur it ape uos s A Mod ise nao ENS eaves UEBER dh ensseud LX yams einsseid exeiq enie G A TEREX BRAND GTH 2506 GTH 3007 153 Part No 57 0009 0536 First Edition First Printing Operator s Manual Diagrams And Schemes 57 2201 3400 3007 HYDRAULIC DIAGRAM Rev B P N pA A Jena je i Aypedeo yue 10 yue qg l einsseid 42942 speeds z Ieolueuo W 1 usaios uoyong leY _ anea 7T 9 99 96 dund uolssltusuen ONEISOIPAH seuj uonong pue Bulsues peo soul einsseJd pue eanssaid moq seun suogoun4 seujeisse d uDi
144. tenance 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 Operator s Manual First Edition First Printing Optional Attachments SHOVEL Attachment suitable for moving and loading loose material such as soil sand debris cereals inert material e When using a shovel load the material only when the boom is completely retracted and push against the heap with straight wheels Approach the load to the handled perpendicularly and check that the machine is level on the inclinometer Do not use for digging operations BRA 114 GTH 2506 GTH 3007 When driving on a rise with loaded material proceed in forward gear and travel with load in the lowest possible position When sloping downward with loaded mate rial proceed into reverse When driving on a rise with empty shovel proceed into reverse When sloping downward with empty shovel proceed in forward gear Don t use the shovel for rising or transpor ting people When loading round shaped objects as petrol drums etc bind them with straps or ropes and travel at reduced speed Part No 57 0009 0536 First Edition First Printing Operator s Manual Optional Attachments Attachment suitable for moving and loading loose material such as soil sand debris cereals inert material
145. ter grease wax etc Remove any trace of rust from metal parts with some emery cloth before smearing the part witha protection product rust preventer paint oil etc NOTICE Do not use water at high pressure for washing the machine and especially the main valve the solenoid valves and electrical parts 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 afterwashingor smearthem with an antifreeze Before usingthe 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 NOTICE If the machine shall be used in a marine or equivalent environment protect it against salt deposits with an adequate treatment against saltiness to prevent rust formation MACHINE DISPOSAL PROTECT THE ay ENVIRONMENT At the end of the machine life call specialized firm to dispose of it in compliance with the local or national regulations Battery disposal 7 PROTECT THE ENVIRONMENT Used lead acid batteries cannot be disposed of as normal industrial solid wastes Because of the presen
146. that all the compartment covers are in place and latched If even one single item is damaged or malfunctioning do not start work Stop the machine and repair the fault Checking the tyres Check the correct inflation of the tyres see par Tyres and Wheels in the Maintenance section Make 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 NOTICE If the machine shall be used in a marine or equivalent environment protect it against salt deposits with an adequate treatment against saltiness to prevent rust formation Genie 52 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual FUNCTION TESTS FUNDAMENTALS The function tests are designed to discover any malfunctions before the machine is put into service The operator must follow the step by step instructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection and function tests again before putting the machine into service Make sure vou learn and practice the principles of sa
147. the telehandler 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 DANGER 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 Working in poorly enlighted area Genie 34 GTH 2506 GTH 3007 Part No 57 0009 0536 First Edition First Printing Operator s Manual Controls And Instruments 1 Fresh Air Flap 10 Gas Pedal 2 Forward reverse Gear Selector Horn 11 Instruments Dashboard 3 Steering Column Angle Adjustment 12 Cab Heater Control Knob 4 Turn Signals Windscreen Washer Lights 13 Fuses And Relays Board 5 Ignition Switch 14 Load Charts Holder 6 Load Moment Indicator 15 Load Limiter Disable Selector 7 Emergency Stop Pushbutton 16 Service Brake Pedal 8 Hazard Warning Lights Switch 17 Windscreen water reservoir 9 Multipurpose Contro
148. ts are in good condition Check for oil leaks or loosening of guards and make sure that the safety devices are efficient In case of malfunctions find and rectify them before using the machine again Not respecting the ordinary maintenance schedule of this manual automatically voids TEREXLIFT warranty provided When one or more symbols appear at the beginning of a maintenance procedure they indicate the following Indicates that tools are required to perform the procedure NOTICE For the engine maintenance please refer to the specific Operator handbook supplied with the machine Indicates that new parts are required to perform the procedure Use only original spare parts Please refer to the specific Spare Parts Catalogue 64 Indicates that a cold engine is required ST e to perform the procedure Indicates the time interval for the maintenance jobs expressed in working hours Before any maintenance or repair work remove the attachment 04 4239 0005 Boom Extension Cylinder Safety Valve Attachment Swinging Cylinder Safety Valve 04 4239 0052 Genie GTH 2506 GTH 3007 75 Part No 57 0009 0536 Operators Manual First Edition First Printing Maintenance S LUBRICANTS HEALTH AND SAFETY PRECAUTIONS Health A prolonged skin contact with oil can cause irritation Use rubber gloves and protective goggles After handling oil carefully wash your hands with s
149. ull a load horizontally as it could cause excessive swinging of the load When visibility is or could be obstructed the operator shall use alternative additional means to safely transport the load Use of additional personnel to direct the operator in his movements as well as surrounding ground traffic Speed shall be limited by any conditions that could cause any unexpected movement of the load or jeopardize the safe transport of the load The boom shall be fully retracted during travel Only travel on solid surfaces Start travel turn and stop slowly to prevent the load from becoming unstable or swing Do not exceed walking speed The load shall be transported as low to the ground as practical Do not use any controls for re positioning the load when traveling Come to a gradual and complete stop before attempting to re position the load First Edition First Printing LLMI LLMC hazards The LLMI LLMC will only function to the design specification e when the truck is static e when the truck is on consolidated stable and level ground when the truck is performing loading or placing functions when the LLMI LLMC is activated not overridden The LLMI will only warn the operator in the event of inadequate stability in the longitudinal plane in the forward direction The LLMI LLMC is not intended for warning of the risk of overturning in the case of e asudden overload e travelling with the load
150. ust control that the machine is not moving and that the forward reverse gear selector switch is in neutral position Steering mode selection 20 Steering Mode Switch Three position switch for the selection of the steering mode 1 Four wheel steering 0 Two wheel steering 2 Crab steering Automatic Rear Wheel Alignment Indicator Sensor Optional This sensor is connected to the warning light 11 12 and indicates when the rear wheels are aligned Put the steering selector switch is in position 0 and turn the steering wheel when the rear wheels will be aligned the orange warning light 11 12 will come on Part No 57 0009 0536 Genie GTH 2506 GTH 3007 39 Controls And Instruments Continuous oil flow 22 Flow Button Pushbutton with orange glass cap with two stable positions Press this button to switch the hydraulic circuit feeding the attachments with auxiliary lines 0 No oil flow 1 Continuous oil flow delivery to the used 9 attachment 18 Continuous Oil Flow Potentiometer 2 turning the potentiometer clockwise the flow rate N inthe circuit feeding the attachments movement lines is increased to one or the other direction Z Operator s Manual First Edition First Printing Controls And Instruments Safety and emergency devices 8 Hazard Warning Lights Switch with on off position it switches on the turn signals simultaneously When the hazard warning light i
151. y insulated and does not provide protection from contact with or proximity to electrical power lines Always keep at a minimum safe distance from the telescopic boom and the lifted load Electrical hazards Keep away from the machine in case of contact with energized power lines Personnel on the ground must never touch or operate the machine until energized power lines are shut off DEATH OR INJURY CAN RESULT FROM CONTACTING ELECTRIC POWER LINES ALWAYS CONTACT THE ELECTRIC POWER LINES OWNER THE ELECTRIC POWER SHALL BE DISCONNECTED OR THE POWER LINES MOVED OR INSULATED BEFORE MACHINE OPERATIONS BEGIN POWER LINE VOLTAGE REQUIRED CLEARANCE 0 50 kV 10 ft 3 00 50 200 kV 15 ft 200 350 kV 20 ft 350 500 kV 25 ft 500 750 kV 35 ft 750 1000 kV 45 ft A DANGER Do not at any time use the machine during a storm 4 60 m 6 10 m 7 62 m 10 67 m 13 72 m Operator have to survey his her field of vision when operating the truck Part No 57 0009 0536 First Edition First Printing Operators Manual OPERATION or MAINTENANCE hazards Before any operation following precautions should be taken e First of all make sure that the maintenance interventions have been carried out with care according to the established schedule Set the 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
152. ze Fuel tank Deslfud Front diferential gear with reduction oi aor ow Rear differential 4 49 7 Front wheel reductongears 9i e 6o Rear wheel reduction gears 316 6 PRODUCT SPECIFICATIONS B 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 SAE 15W 40 API CH 4 CG 4 4 CF ACEA MB 228 3 Lubrication oils and relevant filtering elements Refill the machine with following lubricants Use Product Definition Power divider Differential gears TRACTORENAULT API GL4 FORD M2C 86B Reduction gears THFI 208 LF SAE 80W Massey Ferguson M1135 DENISON HF 1 Hydraulic system and brakes SHELL TELLUS T46 DIN51524 part 2 amp 3 Never mix different oils this may result in troubles and component breaks Oils for hydraulic system Arctic climates Temperatures below 10 C Use SHELL Tellus T22 Mild climates Temperatures from 15 C to 45 C Use SHELL Tellus T46 Tropical climates Temperatures above 30 C Use SHELL Tellus T68 Biodegradable Oil Use SHELL Naturelle Fluid HF E Shell PROTECT THE j ENVIRONMENT Never mix the biodegradable fluid with conventional mineral oil in order to ensure that biodegradability properties are maintained Genie Part No 57

(Note: SN 20631 included) (PN 57.0009.0536_11)

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