Genie GTH-3512 User manual

Operator's manual
Part N. 57.0008.7200
Rev. 0 05/2007
From serial n.16248
To serial n. 17660
English
Edition
CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE
CAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES
GTH-3512
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Operator's manual 57.0008.7200 - GTH-3512
No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means without
prior written permission from TEREXLIFT srl.
In pursuing a policy of constant quality improvement, TEREXLIFT srl reserves the right to make changes at any time and
without undertaking to give prior notice; therefore, also this publication may be subject to modifications.
Some photos or drawings have been used to illustrate a specific function; as a result, they may not refer to the machine
treated in this manual.
© Copyright 2007 TEREXLIFT srl - All rights reserved.
Produced by: TEREXLIFT Technical Literature Dept. - Studio VEGA - Forlì
Genie Scandinavia
Phone [phone]
Fax [phone]
Genie France
Phone [phone]
Fax [phone]
Genie Iberica
Phone [phone]
Fax [phone]
Genie Germany
Phone [phone]
Fax [phone]
Genie U.K.
Phone [phone]
Fax [phone]
Genie Mexico City
Phone [phone]
Fax [phone]
Genie North America
Phone [phone]
Toll Free USA and Canada
800.536.1800
Fax [phone]
Genie Australia Pty Ltd.
Phone [phone]
Fax [phone]
Genie China
Phone [phone]
Fax [phone]
Genie Malaysia
Phone [phone]
Fax [phone]
Genie Japan
Phone [phone]
Fax [phone]
Genie Korea
Phone [phone]
Fax [phone]
Genie Brasil
Phone [phone]
Fax [phone]
Genie Holland
Phone [phone]
Fax [phone]
TECHNICAL SERVICES
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Revision Revised Issued
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REVISED PAGE LIST
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Document 57.0008.7200 - 05/2007
Page 1
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■ I NTRODUCTION
This handbook provides information for a safe and
proper operation and maintenance of the machine.
STRICTLY COMPLY WITH THE INSTRUCTIONS
GIVEN IN THIS HANDBOOK!
READ AND UNDERSTAND THIS HANDBOOK
BEFORE STARTING, USING AND CARRYING
OUT ANY OPERATION WITH AND ON THE
MACHINE.
The handbook is divided into seven sections:
Sect. A GENERAL INFORMATION
Sect. B SAFETY
Sect. C OPERATING INSTRUCTIONS
Sect. D MAINTENANCE
Sect. E TROUBLESHOOTING
Sect. F OPTIONAL ATTACHMENTS
Sect. G TABLES AND ENCLOSURES
Section Acontains general concepts that are decisive
for the knowledge of the main parts of the machine.
It also contains all necessary data for a correct
identification of the machine, the technical features of
the machine, etc.
Section Bis especially addressed to the personnel,
who shall operate, repair and service the machine, and,
in case of companies with a wide fleet of machines, to
those responsible for safety.
It describes the essential compulsory qualities of the
personnel in charge and other important information
for the safety of persons and things.
Section Cis mainly addressed to the operators who
operate the machine. This section illustrates all control
devices.
Additionally, it contains the main use instructions -i.e.
engine starting, machine parking, machine storing.
Section Dis addressed to those responsible for
maintenance and the servicemen.
The section describes the maintenance schedule and
the relevant intervals.
Section E deals with the failure diagnostics.
Section Fmakes a list of the main interchangeable
attachments that can be coupled to the machine:
dimensions, weight, application field and limits of use.
Section Gcontains tables and various enclosed
documents like load charts, wiring diagrams, hydraulic
schemes, torque wrench setting table, etc.
Sections are subdivided into chapters and paragraphs
that are numbered progressively.
The quickest way to look for information is the reference
to the general index or the titles of the single chapters
and paragraphs that represent keys for an easy
consultation.
Take care of this handbook and keep it in an
accessible place within the machine, even
after its reading, so that it will always be
within reach if in doubt.
If you are unsure about anything, please address to
GENIE Assistance Service or to your agent/dealer:
addresses, phone and fax numbers are printed in
the cover and in the title-page of this manual.
IMPORTANT
Any difference between the contents of this manual
and the real functional character of the machine
can be attributed to either a machine manufactured
before the issue of this manual or to a manual going
to be updated after some changed effected on the
machine.
Always contact GENIE Assistance Service for any
updated version of this manual and any additional
information.
INTRODUCTION
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■SYMBOLS
When using the machine, operators could have to face
some situations requiring special care and particular
knowledge.
When these situations involve the safety of operators
or bystanders, the machine efficiency and proper
utilisation, this handbook stresses these specific
instructions by means of SPECIAL SYMBOLS.
There are six special (or safety) symbols in this manual,
always combined with keywords that class the situations
according to their danger degree.
The symbols are always followed by a text explaining
the situation taken into account, the attention to be
paid to such situation, the method and the behaviour to
be adopted. When necessary, it stresses prohibitions
or supplies instructions to prevent dangers.
Sometimes, it can be followed by illustrations.
We list below the special (or safety) symbols according
to the relative seriousness of the hazard situation:
DANGER
Draws the attention to situations that involve your
own as well as the others’ safety and that can result
in serious or lethal injury.
ELECTRICAL
DANGER
Draws the attention to situations that involve your
own as well as the others’ safety and that can result
in serious injury or lethal injury.
CAUTION
Draws the attention either to situations that involve
your own as well as the others’ safety and that can
result in minor or moderate injury or to situations
that involve the machine efficiency.
ATTENTION
Draws the attention to situations that involve the
machine efficiency.
IMPORTANT
Draws the attention to important technical
information or practical advice that allows for a
safer and more efficient use of the machine.
PROTECT THE
ENVIRONMENT
Draws the attention to important environment-
related information.
WHEN READING THIS MANUAL, PAY THE
GREATEST ATTENTION TO THESE SPECIAL
SYMBOLS AND THE EXPLANATION OF THE
SITUATIONS THEY EMPHASIZE.
The manual in electronic format also contains the
following symbol:
which enables the user to return to the
table of contents
INTRODUCTION
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Document 57.0008.7200 - 05/2007
Page 3
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GENERAL INDEX
GENERAL INFORMATION Sect. A
SAFETY Sect. B
OPERATING INSTRUCTIONS Sect. C
MAINTENANCE Sect. D
TROUBLESHOOTING Sect. E
OPTIONAL ATTACHMENTS Sect. F
TABLES AND DOCUMENTS ENCLOSED Sect. G
GENERAL INDEX
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INTENTIONALLY BLANK PAGE
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Page A - 1
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GENERAL INFORMATION
Section A
GENERAL INFORMATION
TABLE OF CONTENTS
A-1 CONVENTIONAL REFERENCES ................................................................................ A-2
A-1.1 Machine position ........................................................................................................ A-2
A-1.2 Labels and warning plates applied on the machine ................................................... A-3
A-1.3 Explanation of the different symbols used on the machine ....................................... A-8
A-2 MACHINE IDENTIFICATION ....................................................................................... A-10
A-2.1 Machine model and type ............................................................................................ A-10
A-2.2 Manufacturer .............................................................................................................. A-10
A-2.3 Machine identification plates...................................................................................... A-11
A-2.4 CE marking ................................................................................................................. A-11
A-2.5 Chassis serial number ................................................................................................ A-11
A-2.6 Identification plates of the main parts ........................................................................ A-11
A-3 ALLOWED USE .......................................................................................................... A-12
A-3.1 Allowed use ................................................................................................................ A-12
A-3.2 Improper use .............................................................................................................. A-12
A-3.3 Residual hazards ........................................................................................................ A-12
A-3.4 Applicable standards.................................................................................................. A-13
A-3.5 Safety devices ............................................................................................................ A-14
A-4 GENERAL DESCRIPTION .......................................................................................... A-17
A-4.1 List of the main components ...................................................................................... A-17
A-4.2 Description of the main components ......................................................................... A-18
A-4.3 Optional accessories .................................................................................................. A-18
A-5 TECHNICAL DATA AND PERFORMANCE ................................................................. A-19
A-5.1 Main dimensions ........................................................................................................ A-19
A-5.2 Limits of use ............................................................................................................... A-19
A-5.3 Weight ........................................................................................................................ A-19
A-5.4 Speed ......................................................................................................................... A-20
A-5.5 Payload and reach...................................................................................................... A-20
A-5.6 Forks........................................................................................................................... A-20
A-5.7 Diesel engine .............................................................................................................. A-20
A-5.8 Electrical system ........................................................................................................ A-20
A-5.9 Machine sound levels ................................................................................................. A-20
A-5.10 Vibration levels ........................................................................................................... A-20
A-6 LIFETIME .................................................................................................................... A-21
A-7 ITEMS SUPPLIED ....................................................................................................... A-21
A-7.1 Literature supplied ...................................................................................................... A-21
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Page A - 2
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GENERAL INFORMATION
A-1 CONVENTIONAL REFERENCES
■A-1.1 MACHINE POSITION
Conventionally the machine should be considered
positioned as shown in the figure.
This convention is necessary to make any reference of
this handbook to different machine parts (front, rear,
etc.) clear and unmistakable.
Any exception to this rule will always be specified.
RIGHT SIDE
LEFT SIDE
LOWER PART
UPPER PART
FRONT PART
REAR PART
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Page A - 3
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GENERAL INFORMATION
■A-1.2 LABELS AND WARNING PLATES
APPLIED ON THE MACHINE
This paragraph lists the labels and warning plates
normally applied on standard machines or on special
attachments coupled to the machine.
IMPORTANT
The familiarisation with these labels is never a
waste of time.
Make sure they are easy to read. For this purpose,
clean them or replace those that become
unreadable (either graphic or text).
To clean labels, use a soft cloth, water and soap.
Never use solvents, petrol, etc.
When a label is applied on a part to be replaced,
make sure that the replaced part is already labelled
as required or apply a new label.
Description:
Labels with transparent background giving a quick
overview of the main functions of the handler.
Meaning:
An overview of the operator's handbook concerning:
- control lever,
- machine starting,
- overload warning system
- main safety precautions,
and including the fork load charts with or without use
of the outriggers.
Location:
in the cab, on the windscreen, to the right of the driving
place.
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GENERAL INFORMATION
XX
Description:
label with yellow background and black inscription
showing the “Guaranteed sound power level”.
Meaning:
it indicates the guaranteed sound power level measured
in accordance with the Directive 2000/14/EC
Location:
in the cab, on the rear left-side glass.
Description:
label with transparent background “Use limits close
to electric lines”.
Meaning:
it defines the minimum distance to be kept when the
machine is used close to aerial electric lines.
Location:
in the cab, on the windscreen
DANGER
ELECTRIC CABLES AND
POWER LINES
KEEP EVERY PART OF THE MACHINE, LOADS AND
ACCESSORIES AT LEAST 6.4 METERS FROM
DISTRIBUTION POWER LINES
DURANTE LA CIRCOLAZIONE SU STRADA:
• BLOCCARE LE FORCHE CON I PERNI;
• POSIZIONARE VERTICALMENTE LA
STRUTTURA PORTAFORCHE
ATTENZIONE
Description:
label with yellow background and black inscription.
Meaning:
Warning for road circulation which indicates the need
to retract and block the forks.
Location:
in the cab, on the windscreen
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Page A - 5
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GENERAL INFORMATION
with outriggers without outriggers
Description:
label with transparent background “Load chart for
operations without outriggers” (or with outriggers
up).
Meaning:
it defines the exact working limits of the machine (in
terms of payload and reach) to be strictly respected
by the operator when using the machine without
outriggers (or with retracted outriggers).
Location:
in the cab, inside the quick-guide .
IMPORTANT
The load charts shown in these pages are supplied
as mere example. For the payload limits, see the
load charts referring to the specific machine model.
Description:
label with transparent background “Load chart for
operations with outriggers down”.
Meaning:
it defines the exact working limits of the machine (in
terms of payload and reach) to be strictly respected
by the operator when using the machine with lowered
outriggers.
Location:
in the cab, inside the quick-guide .
13
12
11
10
9
8
7
6
5
4
3
2
1
0
012345678m 10 9
5,7 m
A
LOAD CENTRE
AT 0,6 m
- 1
B
C
D
E
2500 Kg
2,10 m
8,55 m
30°
50°
40°
60°
70°
20°
0°
10°
250 Kg
500 Kg
1000 Kg
3000 Kg
3500 Kg
2000 Kg
1500 Kg
12,0 m
13
12
11
10
9
8
7
6
5
4
3
2
1
0
0123456789
12,12 m
5,82
m
A
B
C
D
E
-1
m 10
2,05 m
8,53 m
50°
40°
30°
20°
10°
0°
1000 Kg
2000 Kg
73,5°
70°
60°
3500 Kg
3000 Kg
2500 Kg
1500 Kg
LOAD CENTRE
AT 0,6 m
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Page A - 6
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GENERAL INFORMATION
Description:
label on yellow background “Do not open while
engine is running”.
Meaning:
do not open the engine bonnet when engine is running,
since this may result in serious injury due to moving
parts or hot components.
Location:
on the engine bonnet.
Description:
label on yellow background with
black drawing "Hotsurfaces. Risk
of burns".
Meaning:
Applied on those surfaces which during operation can
become hot and cause burns.
Location:
In all parts involved such as exhaust silencer, thermal
engine, heat exchanger.
Description:
label on yellow background with
black drawing "Unscrew the plug
with extreme caution: hot water.
Risk of burns!".
Meaning:
Warns the operator of the risk of burns when unscrewing
the plug of the compensation tank of the heat exchanger.
Location:
Applied on the compensation tank of the fluid of the
heat exchanger.
VIETATO APRIRE CON MOTORE IN MOTO
DO NOT OPEN WHILE ENGINE IS RUNNING
N'OUVRIR QU'A L'ARRET DU MOTEUR
ÖFFNEN NUR BEI STILLSTEHENDEM MOTOR
ABRIR SOLO CON MOTOR PARADO
PROIBIDO ABRIR COM O MOTOR LIGADO
VERBODEN KOFFERBAK TE OPENEN WANNEER DE MOTOR DRAAIT.
KEEP OUT OF
WORKING RANGE
Description:
red/white label “Keep out of the working range of
the machine”.
Meaning:
when the machine is running, entering the working
range of the machine is prohibited.
Location:
on the telescopic boom, both on the right and on the
left.
Description:
label with white background “Keep out of the working
range of the machine”.
Meaning:
when the machine is running, entering the working
range of the machine is prohibited.
Location:
right and left on the machine
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Page A - 7
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GENERAL INFORMATION
Description:
label on yellow background
"Maximum pressure on the
ground".
Meaning:
the value indicates the maximum pressure on the
ground of the outriggers to prevent the machine from
sinking into the ground and avoid instability.
Location:
near each outrigger.
Description:
sticker with black inscription on
yellow background warning of the
presence of moving parts.
Meaning:
Use extreme caution when moving the outriggers.
Presence of moving parts.
Location:
near each outrigger.
Description:
sticker with black inscription on
yellow background warning of the
risk of crushing injury to the
hands.
Meaning:
Use extreme caution when moving the outriggers.
Presence of moving gears and risk of crushing
injury to your hands.
Location:
near each outrigger.
P max kg/cm2
XXX
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Page A - 8
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GENERAL INFORMATION
■A-1.3 EXPLANATION OF THE DIFFERENT
SYMBOLS USED ON THE MACHINE
This paragraph illustrates those symbols that are
normally applied on the main control devices and
instruments of a standard machine, and those that can
be applied on accessories or special attachments.
They are mainly (ISO) standardised symbols that are
now part of the common life. But we consider useful to
explain them once again.
Symbol Description
IMPORTANT
Spend the necessary time to become familiar with
these symbols and to learn their meaning.
Hazard warning lights
Windscreen wiper
Windscreen washer
Cab ventilation fan
Engine coolant temperature
Lights switch
Position lights
High beam
Fog lamp
Turn signals
Parking brake
Battery charge
Attachment pushbutton
Steering mode switch
Symbol Description
Brake pressure
Engine oil pressure
Oil filter soiled
Boom up
Boom down
Boom out
Boom in
Attachment locked
Attachment unlocked
Fork pitching forward
Fork pitching back
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Page A - 9
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GENERAL INFORMATION
Right stabilizer down
Right stabilizer up
Left stabilizer down
Left stabilizer up
Road/jobsite selector switch
Lifting point
Air filter soiled
Speed selector switch
1st speed engaged
2nd speed engaged
Hydraulic oil temperature
Fuel gauge
Symbol Description Symbol Description
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Page A - 10
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GENERAL INFORMATION
A-2 MACHINE IDENTIFICATION
IMPORTANT
Check that the operator handbook refers to the
delivered machine.
When asking for information or technical
assistance, always specify model, type and serial
number of the machine.
■A-2.1 MACHINE MODEL AND TYPE
Handler with telescopic boom:
❑model GTH-3512
■A-2.2 MANUFACTURER
TEREXLIFT srl
Zona Industriale (Ind. Estate) - I-06019 UMBERTIDE
(PG) - ITALY
Enrolled in the register of companies at the Court of
Perugia under no. 4823
C.C.I.A.A. n°102886
Fiscal Code/V.A.T. no. 00249210543
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GENERAL INFORMATION
■A-2.3 MACHINE IDENTIFICATION PLATES
Two identification plates are applied on the machine.
They are:
Machine data plate and road traffic data plate
Placed on the front right side of the chassis.
The identification plate contains the main
identification data of the machine like model, serial
number and year of manufacture.
On the machines destined for the Italian market,
this plate also contains the road traffic related data
and the weights of the specific model of the machine.
ROPS-FOPS cab type-approval plate.
This plate is located on the top strut at the back of
the driving cab.
■A-2.4 CE 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 marking is placed directly on the identification
plate of the machine .
■A-2.5 CHASSIS SERIAL NUMBER
The chassis serial number is punched on the front left
part of the chassis side member .
■A-2.6 IDENTIFICATION PLATES OF THE MAIN
PARTS
The plates of the main components, not directly
manufactured by TEREXLIFT srl (for instance, engines,
pumps, etc.), are located where originally applied by
the manufacturers.
200
kgkg
kg
kg
ZONA INDUSTRIALE - 06019 UMBERTIDE (PG) - ITALY
Tel. [phone] Fax [phone]
MODELLO - MODEL - MODELE - TYP - MODELO
ANNO DI COSTRUZIONE - YEAR OF CONSTRUCTION - ANNEE DE CONSTRUCTION
BAUJAHR - AÑO DE FABRICACIÓN
MATRICOLA - SERIAL N. - N. DE SERIE - FZ.-IDENT NR. - NO. DE SERIE
OMOLOGAZIONE
FABBRICATO IN ITALIA - MADE IN ITALY
PESO MAX ASSALE ANT. - MAX FRONT AXLE WEIGHT - POIDS MAX ESSIEU AVANT
ZUL. ACHSLAST VO. N. ST VZO - PESO MAX EJE ANTERIOR
PESO MAX ASSALE POST. - MAX REAR AXLE WEIGHT - POIDS MAX ESSIEU ARRIERE
ZUL. ACHSLAST HI. N. ST VZO - PESO MAX EJE POSTERIOR
PESO TOTALE - TOTAL WEIGHT - POIDS TOTAL - ZUL. GESAMTGEWICHT N. ST VZO
PESO TOTAL
MATRICOLA MOTORE TERMICO - ENGINE SERIAL N. - N. MOTEUR THERMIQUE
FABRIK NR. DIESEL MOTOR - NO. DE SERIE MOTOR TERMICO
POTENZA MOTORE TERMICO - ENGINE POWER - PUISSANCE MOTEUR
MOTORLEISTUNG - POTENCIA MOTOR
CARICO STATICO VERT. GANCIO DI TRAINO-MAX.VERTICAL LOAD ON
THE COUPLING HOOK-EFFORT VERTICAL MAXIMAL SUR LE CROCHET D'ATTELAGE
MAXIMALE STUTZLASTBEANSPRUCHUNG DES ZUGHAKENS IN VERTIKALER RICHTUNG-
ESFUERZO VERTICAL SOBRE EL GANCHO DE TRACCION
MASSA MAX. RIMORCHIABILE - MAX.DRAWBAR PULL AT THE COUPLING HOOK
EFFORT THE TRACTION - MAXI AU CROCHET D'ATTELAGE-MAXIMALE
ZUGBEANSPRUCHUNG AM ZUGHAKEN-MAXIMO ESFUERZO DE TRACCION EN EL
GANCHO DE TRACCION
kW
kg
kg



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Page A - 12
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GENERAL INFORMATION
A-3 ALLOWED USE
■A-3.1 ALLOWED USE
The handlers have been designed and manufactured
for lifting, handling and transporting agricultural or
industrial products by means of specific attachments
(see section F) manufactured by TEREXLIFT srl.
Any other use is considered contrary to that established
and, therefore, improper.
The compliance with and the strict respect of the
operation, maintenance and repair conditions, indicated
by the Manufacturer, represent an essential part of the
allowed use.
The handler must be used and serviced only by
operators knowing its characteristics and the safety
procedures in depth.
It is also essential to comply with the safety at work
legislation, the precautions concerning the equipment,
substances and the environment as well as the local
and national road traffic regulations.
ATTENTION
Effecting changes or carrying out interventions on
the machine other than those of routine
maintenance is expressly forbidden. Any
modification of the machine not carried out by
GENIE or an authorised assistance centre involves
the automatic invalidation of the conformity of the
machine to the Directive 98/37/EC.
■A-3.2 IMPROPER USE
Improper use means a utilisation of the handler
following working criteria that do not comply with the
instructions of this manual, and that, in general, may
result in risks for both operators and bystanders.
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.
■A-3.3 RESIDUAL HAZARDS
Although the machine has been designed and
manufactured according to the latest technology and
all expected hazards have been eliminated, some
operations performed by the machine operator can
result in potentially hazardous situations. Among them:
• Hazards deriving from a high work or transfer
speed in relation to the load handled or the ground
condition of the jobsite.
• Hazards deriving from work procedures adopted
during the check or replacement of a block valve
(residual pressure - uncontrolled movements).
• Hazards deriving from work procedures adopted
while disassembling parts of the machine -e.g. the
cylinders, without supporting mobile parts suitably
(risk of uncontrolled fall of the part).
• Hazard deriving from an accidental overturning of
the machine in the event the operator has not
fastened the safety belt.
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