Terex Genie GTH-4518 ER User manual

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

2 GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404
Operator’s Manual First Edition - Third Printing
Contact us:
ZONA INDUSTRIALE I-06019 UMBERTIDE
(PG) - ITALY
Telephone [phone] - Telefax +39 075
9415382
Technical Assistance Service
Telephone: [phone]
[phone]
e-mail: [email protected]
Important
Read, understand and obey these safety rules
and operating instructions before operating the
machine. Only trained and qualified personnel
shall be authorized to operate the machine.
This manual shall be kept with the machine at
all times.
For any further information, please call
Terexlift.
Contents
Introduction..........................................Page 3
Machine Identification..........................Page 5
Symbols Used On The Machine..........Page 7
Labels And Plates Applied On The
Machine...............................................Page 9
Safety Precautions ..............................Page 15
Description Of The Main Components...Page 23
Controls And Instruments....................Page 25
Inspections ..........................................Page 55
Operating Instructions .........................Page 61
Transporting The Machine...................Page 75
Maintenance........................................Page 79
Faults And Troubleshooting.................Page 113
Optional Attachments ..........................Page129
Specifications ......................................Page 141
Load Charts.........................................Page 143
Diagrams and Schemes .....................Page 161
Warranty ..............................................Page 183
First Edition: Third Printing, February 2009
Copyright ©2006 TEREXLIFT srl - All rights
reserved.
Produced by:
TEREXLIFT Technical Literature Dept.
Umbertide (PG) Italy

Part No. 57.0009.0404 GTH-4518ER - GTH-4020ER - GTH-6025ER 3
Operator’s ManualFirst Edition - Third Printing
Introduction
Symbols
Safety alert symbol: used to
alertyoutopotentialpersonal
injuryhazards.Obeyallsafety
messages that follow this
symbol to avoid possible
injury or death
DANGER
Red: indicates a hazardous
situationwhich,ifnotavoided,
will result in death or serious
injury.
WARNING
Orange:indicatesahazardous
situationwhich,ifnotavoided,
couldresultindeathorserious
injury.
CAUTION
Yellow:indicatesahazardous
situationwhich,ifnotavoided,
could result in minor or
moderate injury.
NOTICE
Blue: indicates a property
damage message.
PROTECT THE
ENVIRONMENT
Green: used to draw the
attention to important
information on environment
protection.

4 GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404
Operator’s Manual First Edition - Third Printing
Intentionally blank page

Part No. 57.0009.0404 GTH-4518ER - GTH-4020ER - GTH-6025ER 5
Operator’s ManualFirst Edition - Third Printing
Machine Identification
Check that the operator handbook refers to the
delivered machine.
MODEL AND TYPE
Handler with telescopic boom. Models:
GTH-4518ER - GTH-4020ER - GTH-6025ER
MANUFACTURER
TEREXLIFT srl
Zona Industriale - I-06019 UMBERTIDE (PG) -
ITALY
Enrolled in the register of companies at the Court of
Perugia under no. 4823
C.C.I.A.A. 102886
Fiscal Code/V.A.T. no. 00249210543
APPLICABLE STANDARDS
For the operator’s safety, the following standards were
obeyed during the risk assessment of the handler
fitted with telescopic boom norme:
Directive Title
98/37/CE Machinery Directive
89/336/CEE Electromagnetic compatibility
2000/14/CE Environment Acoustic Emissions
Standard Title
ISO 2330:1995 Fork-lift trucks - Fork arms - Technical
characteristics and testing.ISO 3287:
1999 Powered industrial trucks -
Symbols for operator controls.
ISO 3449:1992 Earth-moving machinery - Falling-
object protective structures -
Laboratory tests and performance
requirements.
EN 13510: 2002 Earth-moving machinery - Roll-over
protectivestructures-Laboratorytests
and performance requirements.
EN 13059:2002 Safety of Industrial trucks- Test
methods for measuring vibration
MACHINE IDENTIFICATION PLATES
The following data plates are applied on the
machine:
Machine data plate
The identification plate contains the main identification
data of the machine like model, serial number and
year of manufacture.
On machines destined for the Italian market, the data
plate is installed in the driving cab, on the right, and
is well-visible when the door is opened.
On the machines destined for foreign markets, the
data plate is applied on the front right 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.
ROPS-FOPS cab type-approval plate
The ROPS - FOPS type-approval plate is located
inside the driving cab above the rear glass.
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.

6 GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404
Operator’s Manual First Edition - Third Printing
Machine Identification
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 demonstratescompliance withthe regulatory
requirements.
The CE marking is placed directly on the identification
plate of the machine.
CHASSIS SERIAL NUMBER
The chassis serial number is punched on the front
left part of the chassis side member.
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.
HOW TO READ
YOUR SERIAL
NUMBER
Chassis serial number
(The chassis serial number is punched on the front right
part of the chassis side member)
Machine data plate
(On machines destined for the Italian market, the machine data plate is
installed in the driving cab, on the right, and is well-visible when the door
is opened. On the machines destined for foreign markets, the data plate
is applied on the front right side of the chassis)
GTH 4518 P 07 17882
MODEL
ENGINE
TYPE
YEAR OF
MANIFACTURER
SERIAL
NUMBER

Part No. 57.0009.0404 GTH-4518ER - GTH-4020ER - GTH-6025ER 7
Operator’s ManualFirst Edition - Third Printing
Symbols Used On The Machine
Not Active Parking Brake High Beam Turn Signals Low Beam
Turret Rotation
Lock
Turret Aligned Differential Lock 2° speed engaged 1° speed engaged Machine Sway Retract Outrigger
Extend Outrigger Raise Outrigger Lower Outrigger
Right Machine
Sway Left Machine Sway
Turret Rotation
Unlock
Fuel Level
Glow Plugs
Preheatinh Service
Engine Coolant
Temperature Battery Charge
Engine Oil
Pressure
Brake Pressure Hydraulic Oil Filter Air Filter Not Active Water in Fuel Hydraulic Oil Level
General Warning Shift-on-Fly
Comando luci
retronebbia Emergency Pump
Hazard Warning
Lights Heating Cab Fan
Job-site mode Man-Platform Road Transfer Steering Mode
P

8 GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404
Operator’s Manual First Edition - Third Printing
Symbols Used On The Machine
HAZARD PICTORIAL DESCRIPTIONS
Crush Hazard
Support boom
when performing
maintenance.
No riders.
Fall Hazard
Maintain required
clearance.
Electrocution
Hazard
No people under
load.
Falling Object
Hazard
Read the operator's
manual.
Burn Hazard
Burn Hazard
Explosion/Burn
Hazard No smoking. No
open flame.
Allow system to
cool.
Allow surfaces to
cool.
Crush Hazard Keep away from
moving parts. Crush Hazard Keep clear of
moving parts.
Allow compartment
access
Crush Hazard Keep clear of
moving outriggers. Tip-over Hazard Crush Hazard Keep away from
obstacles

Part No. 57.0009.0404 GTH-4518ER - GTH-4020ER - GTH-6025ER 9
Operator’s ManualFirst Edition - Third Printing
Labels And Plates Applied On The Machine
8
10
18
9
13
1
6
11
18
B
5
15 5
14
7
25
3
9
13
C
A
32
16
28
4
14
13
2
26
15
25
22
4
3
5
14
34
29
12
3
26
19
514
13
9
27
25
20
25
33
19
30
24
31
21 3
9
14
14
33

10 GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404
Operator’s Manual First Edition - Third Printing
Labels And Plates Applied On The Machine
Use the pictures on these pages to verify that all decals are legible and in place.
The following chart shows quantities and description too.
Ref. Decal Code Description Qt.
109.4618.0791 Safety pin operation 1
209.4618.0784 The capacity of the truck and attachment
combination shall be complied with. 1
3
09.4618.0547
09.4618.0754
Tyre inflat. P=5,5bar / 80psi
GTH-4518 ER / GTH4020 ER
Tyre inflat. P=8bar/116psi GTH-6025 ER
4
409.4618.0918 Falling Object Hazard 3
509.4618.0919 Crush Hazard 4
6
09.4616.0041
09.4618.0260
Sound power level: 103 db for GTH-
4518ER and GTH-4020ER
Sound power level:105 db for GTH-
6025ER
1
709.4618.0920 Compartment Access 1
8
Kg 4000
Kg 4500
Kg 6000
09.4616.0040
09.4618.0373
09.4618.0757
Max Capacity
Kg 4000 (GTH-4020 ER)
Kg 4500 (GTH-4518 ER)
Kg 6000 (GTH-6025 ER)
1
WORKING POSITION STORAGE POSITION
SAFETY PIN
09.4618.0791
P= 5.5 bar
80 psi
Use the pictures on these pages to verify that all decals are legible and in place.
The following chart shows quantities and description too.
103
09.4616.0041
09.4618.0918
09.4618.0919
09.4618.0920

Part No. 57.0009.0404 GTH-4518ER - GTH-4020ER - GTH-6025ER 11
Operator’s ManualFirst Edition - Third Printing
Labels And Plates Applied On The Machine
Ref. Decal Code Description Qt.
9
09.4618.1048
09.4618.1049
Label - Stabilizer Max Pres. GTH-6025ER
Label - Stabilizer Max Pres.
GTH-4518ER GTH-4020ER
4
4
10 09.4618.0776 Label - Upper Door Internal Unlock
System 1
11 09.4618.0770 Quick guide and Control lever decal 1
12 09.4618.0921 Label - Use limits close to electric power
lines 1
13 09.4618.0933 Crush Hazard 4
14 09.4618.0922 Crush Hazard 7
15
16
09.4618.0243
09.4618.0241 Cosmetic - GENIE Logo in WHITE
2
1
17 09.4618.xxxx Label - Engine Fuses & Relays Board 1
09.4618.0776
NOTICE
USO DELLA LEVA DI COMANDO
Premere sempre il pulsante di comando intenzionale , prim
a
eseguire un comando.
LEVA DESTRA
•
Abbassamento/solevamento del braccio:azionare la leva in direzi
o
-
• Brandeggio indietro/avanti dell’attrezzo terminale: azionar
e
leva in direzione -
• Richiamo/sfilo del braccio telescopico: azionare il pulsante

direzione - senza movimentare la leva
• Blocco/sblocco attrezzi: premere il pulsante ed azionare la l
e
in direzione -
LEVA SINISTRA
•
Rotazionetorretta: azionare la leva in direzione -
09.4618.0769
GUIDA RAPIDA PER L’USO
ATTENZIONE
È vietato utilizzare la macchina e gli accessori senza prima aver
letto e compreso le norme di utilizzo e di sicurezza contenute nel
manuale di istruzioni. Il mancato rispetto delle norme di utilizzo
e di sicurezza può causare grave pericolo all’operatore e a terzi.
Le istruzioni sono consegnate con la macchina e copie
aggiuntive possono esere richieste al rivenditore o direttamente
aTerexlift.
L’operatore è responsabile del rispetto delle norme sopra
riportate.
Non sollevare carichi se la macchina appoggia su terreno
instabile o inclinato. Non sollevare mai carichi superiori a quelli
indicati in tabella. Non sono ammesse manovre di sollevamento
con macchina in movimento.
Prima di abbandonare il posto di manovra:
- abbassare eventuali carichi sospesi
- portare in posizione di riposo gli organi di comando del braccio
- posizionare la leva marcia avanti-indietro in folle, inserire il
freno a mano e arrestare il motore.
Norme per l’utilizzo di macchine dotate di stabilizzatori.
È vietato utilizzare gli stabilizzatori se il carico è già sollevato:gli
stabilizzatori servono solamente ad aumentare la stabilità della
macchina; l’uso scorretto degli stabilizzatori può causare il
ribaltamento della macchina.
Un’apposita spia sul cruscotto indica che gli stabilizzatori sono
abbassati: accertarsi che la spia sia accesa.
Prima di sollevare il carico, livellare la macchina controllando
l’apposito indicatore di livello.
CONFERMA DELL’ATTREZZO IN USO PER L’ABILITAZIONE
D
LIMITATORE DI CARICO
Alla messa in moto della macchina il limitatore di carico esegue
check progressivo.
Dopo circa 20 secondi appare la data ed il modello della macchin
a
poco dopo, la prima pagina con selezionato l’ultimo attrezzo utiliz
z
o il nuovo attrezzo dotato di riconoscimento elettrico.
Qualora sia stato installato un attrezzo “meccanico” si dovràeseg
u
la ricerca manuale.Premere INDEX fino a quando, nella casella 
display,non comparirà la lettera corrispondente all’attrezzo in uso.
Premere ENTER per confermare l’attrezzo.
La macchina è pronta per l’uso.
AVVIAMENTODELLA MACCHINA
• Posizionare il selettore marce ed il cambio meccanico in folle.
• Inserire il freno di stazionamento e controllare che la spia sia
accesa.
• Avviare il motore ruotando
il commutatore di avviamento
in posizione ed attendere
che la spia sul cruscotto
si spenga. Con la spia spenta
ruotare il commutatore in
posizione rilasciandolo
non appena il motore verrà
avviato.
• Qualora, dopo circa 20 secondi, l’avviamento del motore non avesse
luogo, rilasciare la chiave ed attendere circa due minuti prima di
tentare un nuovo avviamento.
4518-4020-
6025
4
4
2
3
09.4618.0921
09.4618.0922
09.4618.0989
P max al suolo
P max on the ground 6.3 kg/cm2
09.4618.0933
09.4618.0807
F1G F4G
K04 K02
F2G F3G
K01
F5G
Ref. Descrizione
F1G Starter Enabling Switch
F2G Instruments Panel
F3G Cabin Fuses Board
F4G Glow Plugs
F5G Fuel Pump
Ref. Descrizione
K01 Glow Plugs Preheating
K02 Starter Enabling Switch
K04 Engine Stop

12 GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404
Operator’s Manual First Edition - Third Printing
Ref. Decal Code Description Qt.
18
19
09.4618.0824
09.4618.0825
09.4618.0826
09.4618.0827
09.4618.0828
09.4618.0829
Cosmetic - Genie GTH-4518 ER
Cosmetic - Genie GTH-4020 ER
Cosmetic - Genie GTH-6025 ER
2
2
2
2
2
2
20 09.4618.0923 Burn Hazard 2
21 09.4618.0924 Burn/Explosion Hazard 1
22 09.4618.0925 Crush Hazard 1
23 09.4618.0926 No Riders 1
24 09.4618.0927 Burn Hazard 1
25 09.4618.0916 Lift Point 6
26 09.4618.0917 Diesel Fuel Cap 1
27 09.4618.0928 Hydraulic Oil 2
GTH-4518 ER
09.4618.0923
09.4618.0925
09.4618.0926
09.4618.0927
09.4618.0916
09.4618.0924
09.4618.0917
09.4618.0928
GTH-6025 ER
Labels And Plates Applied On The Machine
GTH-4020 ER

Part No. 57.0009.0404 GTH-4518ER - GTH-4020ER - GTH-6025ER 13
Operator’s ManualFirst Edition - Third Printing
Ref. Decal Code Description Qt.
28 09.4618.1132 Label - Manual Controls Instructions 1
29 09.4618.1001 Label - Maintenance Collar 1
30 09.4618.1122 Manual Controls Danger 1
31 09.4618.0986 Crush Hazard 1
32 09.4618.1028 Label - Parking Brake 1
33 09.4618.1120 Crush Hazard 2
34 09.4618.xxxx Label -Cabin Fuses & Relays Board 1
Labels And Plates Applied On The Machine
09.4618.1001
09.4618.0986
K1
K9
K4
K11
K3
K21
K14
K18
F22
F23
F24
F25
F26
F27
F16
F17
F18
F19
F20
F21
F13
F14
F15
F7
F8
F9
F10
F11
F12
F1
F2
F3
F4
F5
F6
K19
K23
J3 J2 J1
K8
K7
K10
K2
K16 K15
K5
K17
K6
K20K12
K13
K24
RELE’
2
09.4618.1053
.feR Circuit
F1 Front Wiper
F2 Heating
F3 Stop Light Micro-Switch
F4 Rear Wiper
F5 Hydraulic Activation
F6 Low Beam
F7 Right Position Lights
F8 Instrument Lighting
F9
Indicator Lights Power Supply
F10 Lights Switch
F11 Flashing Beacon
F12 Stop Lights
F13 2° Hydr. Circuit Switch
F14 Speed Switch
F15 High Beam
F16 Emergency
F17 Lights And Flashing
F18 Outriggers Micro-Switch
F19 Work Mode Selector
F20 +12v On The Boom
F21 Horn
F22 Optional
F23 Cab Lights
F24 Emergency Stop
F25 Lmi Control
F26 Optional
F27 Work Lights
Ref. Circuit Ref. Circuit Ref. Circuit
K1 High Beam K9 Transmission Disconnected K17 Optional
K2 Low Beam K10 Transmission Disconnected K18 Outriggers
K3 Horn K11 Start-Up Enabling Command K19 Overload Warning System
K4 Speed Switch Power Supply K12 Optional K20 High Boom
K5 Optional K13 Optional K21 Tilt/Ext. Exchange Movements
K6 Optional K14 Outriggers K22 Optional
K7 Forward Speed K15 Optional K23 Intermittence
K8 Reverse Speed K16 Optional K24 Timer
09.4618.1028
09.4618.1120
09.4618.1132
INSTRUCTIONS
Operate the levers only in an emergency and with the Diesel
engine stopped:
1. press the red emergency stop button in the cab
2. hold the button of the emergency pimp, on one side of the
machine, pressed down
3. operate the levers according to the following sequence:
a) Boom in (Lever 1 towards A)
b) Boom down (Lever 2 towards A)
The lever movements correspond to the following commands
Lever 1 A Boom Extension
B Boom Retraction
Lever 2 A Boom Lifting
B Boom Lowering
Lever 3 A Forks Upwards
B Forks Downwards
Lever 4 A Attachment Locking
B Attachment Unlocking
Lever 5 ATurntable rotated counter-
clockwise
B Turntable rotated clockwise
DANGER
Tip-over Hazard
Incorrect
emergency
lowering sequence
will result in
machine tip-over
Read, understand
and obey the
instructions below or
in the
Operator’s Manual
before lowering
09.4618.1122

14 GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404
Operator’s Manual First Edition - Third Printing
Labels and plates applied on the machine
Ref. Decal Code Description
A09.4616.0100
ROPS-FOPS cab type-approval plate. This plate
shows the type-approval data of the driving cab
according to ROPS - FOPS regulations.
B09.4616.0112 Machine data plate. The identification plate contains
the main identification data of the machine.
C09.4616.0109 Fork data plate. This plate shows the main data of
the fork installed on the machine.
200
kgkg
kg
kg
TERE FT srl - ON N STR E - 06019 M ERT E PG - T
Tel. [phone] Fa 075 941.5 .82 Tele 66106 T M
MO E O - MO E - MO E E - T P - MO E O
NNO OSTR ONE - E R OF M N F T RE - NNEE E F R T ON
HR - ÑO E F R ÓN
M TR O - SER N. - N. E SER E - F .- ENT NR. - NO. E SER E
OMO OG ONE
F R TO N T - M E N T
PESO M SS E NT. - M FRONT E E GHT - PO S M ESS E NT
. HS ST O. N. ST O - PESO M E E NTER OR
PESO M SS E POST. - M RE R E E GHT - PO S M ESS E RR ERE
. HS ST H . N. ST O - PESO M E E POSTER OR
PESO TOT E - TOT E GHT - PO S TOT - . GES MTGE HT N. ST O
PESO TOT
M TR O MOTORE TERM O - ENG NE SER N. - N. MOTE R THERM E
F R NR. ESE MOTOR - NO. E SER E MOTOR TERM O
MODELLO - TYPE - DƒSIGNATION
MODELL - MODELO
ANNO DI COSTRUZIONE -
YEAR OF CONSTRUCTION -
ANNƒE DE CONSTRUCTION -
BAUJHAR - A„O DE CONSTRUCCIîN
MASSA - MASS - MASSE -
MASSE - MASA
PORTATA NOMINALE - PAY LOAD -
PORTEE NOMINALL - NENN
TRAGF€HIGKEIT - CARGA NOMINAL
CENTRO DI GRAVITË - CENTER OF
GRAVITY - CENTRE DE GRAVITƒ -
SCHWERPUNKT - CENTRO DE GRAVEDAD
CENTRO DI CARICO - LOAD CENTER -
CENTRE DE CHARGE - LASTPUNKT -
CENTRO DE CARGA
MODELLO MACCHINA - MACHINE MODEL -
DESOGNATION MACHINE - MASCHINEN MODELL
MODELO MçQUINA
N¡SERIE - SERIAL N¡-N¡DE SERIE
- SERIEN N¡- N¡DE BASTIDOR
JUNTO HORQUILLAS
GROUPE FOURCHES-GABELGROUPPE
ASSIEME FORCHE-FORKS ASSY

Part No. 57.0009.0404 GTH-4518ER - GTH-4020ER - GTH-6025ER 15
Operator’s ManualFirst Edition - Third Printing
Safety precautions
DAMAGED MACHINE HAZARDS
• Do not use a damaged or defective machine.
• Do a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Tag and remove from service a damaged
or defective machine.
• Make sure that all maintenance jobs have been
carried out as specified in this manual and the
appropriate service manual.
• Make sure that all decals are in place and
legible.
• Make sure that the operator’s is intact, legible
and placed in the special container located in the
machine.
PERSONAL INJURY HAZARDS
• Do not operate the machine in case of hydraulic
oil or air leak. Air or hydraulic oil leaks can
penetrate or burn the skin.
• Always operate the machine in a well ventilated
area to avoid carbon monoxide poisoning.
• Do not lower the boom if the area underneath is
not clear of personnel or obstructions.
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 defective device.
For the checking procedures, read chap.
"Maintenance"
MOMENT LIMITING SYSTEM
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.

16 GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404
Operator’s Manual First Edition - Third Printing
Safety precautions
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.
If you recognise hazardous situations, you can
prevent accidents!
DANGER
The instructions given in this handbook are the
ones established by TEREXLIFT. They do not
exclude other safe and most convenient ways
for the machine installation, operation and
maintenancethattakeintoaccountthe 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.
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.
• 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.
• Read, understand and obey the employer’s
safety rules and worksite regulations.
• Read, understand and obey the applicable
national regulations.
• Only trained personnel informed on the safety
rules can operate the machine.

Part No. 57.0009.0404 GTH-4518ER - GTH-4020ER - GTH-6025ER 17
Operator’s ManualFirst Edition - Third Printing
Safety precautions
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 shall be
careful and sensible for their own as well as for the
others’ safety and shall desire to carry out the work
correctly and in a responsible way.
emotional:
they shall keep calm and always be able to evaluate
their own physical and mental conditions.
training:
they shall read and be familiar with this handbook,
its enclosed graphs and diagrams, the identification
and hazard warning plates. They shall be skilled and
trained about the machine use.
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.
Requisites of the SERVICEMEN
Thepersonnelchargedwiththemachinemaintenance
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 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.

18 GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404
Operator’s Manual First Edition - Third 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.
• Protective helmet.
• Protective gloves.
• Working shoes.
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.
DANGER
The machine is not electrically insulated and
does not provide protection from contact with
or proximity to electrical power lines.
Always keep at a minimum safe distance from
the telescopic boom and the lifted load. Electrical
hazards!
• 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.
DANGER
Do not at any time use the machine during a
storm.
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).
• Ear-protectors or equivalent equipment.
• Goggles or facial masks.
Use only type-approved protective equipment in
good condition.
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 to 50kV 10ft 3.00m
50 to 200 kV 15 ft 4.60 m
200 to 350 kV 20 ft 6.10 m
350 to 500 kV 25 ft 7.62 m
500 to 750 kV 35 ft 10.67 m
750 to 1000 kV 45 ft 13.72 m

Part No. 57.0009.0404 GTH-4518ER - GTH-4020ER - GTH-6025ER 19
Operator’s ManualFirst Edition - Third Printing
• The machine shall be parked on a ground
adequate to the maximum admissible payload. If
the subsoil collapses, the machine could tip over.
To avoid any risk of overturning, the following
precautions should be taken:
1. Ask your employer (site manager or manager
assistant) if there may be buried pipes, pits,
old tanks, cellar floor, dung yards, etc. under
the ground onto which the outriggers shall be
lowered.
2. A rough estimate of the ground consistency can be
done using the tables and picture in this page.
3. The resistance of the subsoil is in relation
to the ground type and geomorphological
characteristics.
Table 1 indicates the superficial pressure which
can be admitted under the outriggers of the
machine.
Type of ground,
geomorphological
features
Admissible
superficial pressure
kg/cm2N/mm2
loose, non-compact soil generally speaking,
not solid;
special precautions
needed
loamy, peaty,pasty soil
rippable, soft ground
non-cohesive, well com-
pact soil, sand, gravel 2.0 0.2
rippable
soil
solid 1.0 0.1
semi-solid 2.0 0.2
hard 4.0 0.4
Rocks, concrete, heavy
traffic paved roads
above
10.0
above
1.0
Table 1
WARNING
Make sure the machine (wheels and stabilisers)
rests on a firm ground to prevent hazardous unstable
conditions.
If the ground is not firm enough, position some
supporting planks under the stabilisers or the wheels.
These plates must grant a specific pressure of 1.2 to
1.5 kg/cm2(800x800mm plates are sufficient).
• Look for the best route to the job site.
• When the machine is running, nobody can enter
its working range.
• While working, keep the working area in order.
Never leave objects scattered: they could hinder
the machine movements and represent a danger
for personnel.
• In presence of trenches, lower the outriggers at
a safe distance from the trench edge.
Safety precautions
The distance (a) from the foot of the overhang
shall be adequate to height (h) of the same
overhang.
If the ground fulfils the required conditions:
a : h = 1 : 1
(values with a grey background in table 1)
In the case of doubts:
a : h = 2 : 1
Bearing Capacity
Supporting
Surface
Overhang foot

20 GTH-4518ER - GTH-4020ER - GTH-6025ER Part No. 57.0009.0404
Operator’s Manual First Edition - Third Printing
Safety precautions
OPERATION or MAINTENANCE hazards
Before any operation, following precautions should
be taken:
• First of all, make sure that the maintenance
interventions have been carried out with care
according to the established schedule.
WARNING
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.
• Ensure you have enough fuel to avoid a sudden
stop of the engine, especially during a crucial
manoeuvre.
• 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.
• In 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.
• When entering/leaving the cab or other raised
parts, always face the machine; never turn the
back.
• When carrying out operations at hazardous
heights (over 1.5 meters from the ground), always
use approved fall restraint or fall arrest devices.
• Do not enter/leave the machine while it is
running.
• Do not leave the driving place when the machine
is running.
• Neither stop nor carry out interventions under
or between the machine wheels when engine
is running. When maintenance in this area is
required, stop the engine.
• Do not carry out maintenance or repair works
without a sufficient lighting.
• When using the machine lights, the beam should
be oriented in order not to blind the personnel at
work.
• Before applying voltage to electric cables or
components, check their connection and proper
functioning.
• Do not carry out interventions on electric
components with voltage over 48V.
• Do not connect wet plugs or sockets.
• Plates and hazard warning stickers shall never
be removed, hidden or become unreadable.
• Except for maintenance purposes, do not remove
safety devices, shields, protection cases, etc.
Should their removal be necessary, stop the
engine, remove them with the greatest care and
always remember to refit them before starting the
engine and using the machine again.
• Before any maintenance or repair work, stop the
engine and disconnect the batteries.