PDF Operator Manual Genie GTH-3013 GTH-3517 Telescopic Handler - 2 MB
Master the operation of your Genie GTH-3013 or GTH-3517 telescopic handler with this official operator's manual.
It provides essential safety protocols, detailed control layouts, and proper operating techniques.
The manual also outlines daily maintenance checks to ensure the machine is always in safe working condition.
This is a must-read for all operators to ensure safety and efficiency on the job site.
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OPERATOR HANDBOOK
Code 57.0002.3200 - 12/2002
Handler with telescopic boom
GTH-3013 - GTH-3517
Version
English
CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE
CAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES
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Handler with telescopic boom GTH-3013 - GTH-3517
GENERAL INFORMATION
■ A-1.2 LABELS AND WARNING PLATES
APPLIED ON THE MACHINE
KEEP OUT OF
This paragraph lists the labels and warning plates
normally applied on standard machines or on special WORKING RANGE
attachments coupled to the machine.
Description:
IMPORTANT red/white label “Keep out of the working range of
the machine”.
The familiarisation with these labels is never a Meaning:
waste of time. when the machine is running, entering the working
Make sure they are easy to read. For this purpose, range of the machine is prohibited.
clean them or replace those that become
unreadable (either graphic or text). Location:
To clean labels, use of a soft cloth, water and soap. on the telescopic boom, both on the right and on the
Never use solvents, petrol, etc. left.
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:
Description: label with white background “Keep out of the working
label with transparent background explaining the use range of the machine”.
of the control lever.
Meaning:
Meaning: when the machine is running, entering the working
through the use of special symbols, this label explains range of the machine is prohibited.
all possible functions and motions of the control lever
and the built-in pushbuttons. Location:
one on the right side in the casing of the engine
Location: compartment
in the cab, on the windscreen, to the right of the driving one on the left side on the fuel tank
place.
GTH-3013 - GTH-3517
Y
Push
Push
Page A-3
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Handler with telescopic boom GTH-3013 - GTH-3517
GENERAL INFORMATION
■ A-3.4 APPLICABLE STANDARDS ISO 5053:1987 Powered industrial trucks - Terminology.
ISO 6055:1997 High-lift rider trucks - Overhead guards
For the operator’s safety, the following standards were - Specification and testing.
obeyed during the risk assessment of the handler fitted
with telescopic boom: ISO 6292:1996 Powered industrial trucks and
tractors - Brake performance and
Directive Title component strength.
98/37/CE Machinery Directive ISO 9533:1989 Earth-moving machinery - Machine-
89/336/CEE Electromagnetic compatibility mounted forward and reverse audible
warning alarm - Sound test method.
73/23/CEE Low Voltage
prEN 13059:1997 Safety of industrial trucks - Test methods
2000/14/CE Environment Acoustic Emissions for measuring vibration
Standard Title EN 50081-1: 1997 Electromagnetic compatibility – Generic
EN 1459:1988 Harmonised standard. Safety of industrial requirements on emissions - Part 1
trucks - Self- propelled variable reach EN 50082-1: 1997 Electromagnetic compatibility – Generic
trucks. requirements on immunity - Part 1
EN 281:1988 Self-propelled industrial trucks sit- down EN 60204-1:1998 Safety of machinery - Electrical
rider-controlled. Rules for the equipment of machines - Part 1
construction and layout of pedals.
EN 292-1:1991 Safety of machinery. Basic concepts,
general principles for design. Basic
terminology, methodology.
EN 292-2:1991 Safety of machinery. Basic concepts,
principles for design. Technical principles
and specification.
EN 1175-2:1998 Electrical requirements - General
requirements of internal combustion
engine powered trucks
prEN ISO 13564:1996 Test method for measuring
visibility from self-propelled trucks.
ISO 2330:1995 Fork-lift trucks - Fork arms - Technical
characteristics and testing.
ISO/DIS 3287 Powered industrial trucks. Pictorial signs.
Control symbols.
ISO 3449:1992 Earth-moving machinery - Falling-object
protective structures - Laboratory tests
and performance requirements.
EN 13510: 2002 Earth-moving machinery - Roll-over
protective structures - Laboratory tests
and performance requirements.
ISO 3776:1989 Tractors for agriculture - Seat belt
anchorages.
ISO 3795:1989 Road vehicles, tractors and machinery
for agriculture and forestry -
Determination of burning behaviour of
interior materials.
Page A-13
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SAFETY
Section B
SAFETY
TABLE OF CONTENTS
B-1 GENERAL REMARKS ................................................................................................. B-2
B-2 PREREQUISITES OF THE PERSONNEL IN CHARGE ............................................... B-2
B-2.1 Prerequisites of the machine operators ..................................................................... B-2
B-2.2 Prerequisites of the servicemen ................................................................................. B-3
B-2.3 Working clothes .......................................................................................................... B-3
B-2.4 Personal protective equipment .................................................................................. B-3
B-3 SAFETY PRECAUTIONS ............................................................................................ B-4
B-3.1 Job site ....................................................................................................................... B-4
B-3.2 Getting ready to work ................................................................................................. B-5
B-3.3 During work or maintenance ...................................................................................... B-5
B-4 Safety devices ............................................................................................................ B-7
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OPERATING INSTRUCTIONS
C-2 ENTERING THE MACHINE
■ C-2.1 ENTERING THE CAB
CAUTION
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.
• Open the door using the built-in handle.
CAUTION
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.
■ C-2.1.1 Leaving the cab in an emergency
In an emergency, use the rear window of the cab as
safety exit-way.
This window has special locking handles with plastic
pins easy to pull out when you need to fully open the
glass.
Door closing from inside:
• Pull the door with force: it locks automatically.
Door opening from inside:
• Lift lever 1 and release the lock to open the door
completely.
• Hold button 3 pressed down and rotate handle 2
to open and lock the upper door section against
the catch located outside the driving cab.
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OPERATING INSTRUCTIONS
C-3.3 INSTRUMENTS AND LIGHT ■ C-3.3.2 Light indicators
INDICATORS 16 Fuel reserve indicator
■ C-3.3.1 Instruments This light comes on to signal a limited fuel
autonomy of the machine. When the
36 Engine coolant temperature indicator
indicator comes on, the fuel reserve is
80
Signals the engine coolant temperature
40 120 about 10 litres.
°C
37 Fuel gauge 23 Indicator light - hydraulic oil filter clogged
Signals the fuel level within the tank. When this lamp sets to on, immediately
1/2
0 4/4 change the oil filter on the return line to
the tank.
38 Hydraulic oil temperature indicator 24 Indicator light - air filter clogged
Signals the temperature of the hydraulic When this lamp sets to on, clean or
oil within the reservoir. change the filter elements.
39 Hour-meter 25 Indicator light - low battery charge
80 Signals the total operating hours of the Signals a low charge by the alternator
40 120
°C
machine.
26 Indicator light - low brake pressure
It lights when the pressure of the braking
circuit is too low for a correct functioning
27 Indicator light - low engine oil pressure
It lights when the engine oil pressure is
too low.
25 26 27 28 29 30 31 32
35
36
37
38
39
23 24 16
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OPERATING INSTRUCTIONS
C-3.6 OUTRIGGER CONTROL
CAUTION
Before lowering the outriggers, make sure that
nobody is within the working range of the machine.
To operate the outriggers:
• Shift the control lever to central position and press
button
• Press button 15 and hold it down to enable the
motion of the right outrigger:
select 1 to lower the outrigger
select 2 to raise the outrigger
• Press button 13 and hold it down to enable the
motion of the left outrigger:
select 1 to lower the outrigger
select 2 to raise the outrigger
• Shift the control lever to the position selected by
means of the enabling pushbutton:
select A to lower the outrigger
select B to raise the outrigger
IMPORTANT Push
In an alarm condition (red stability LED indicator
ON) or when the boom is raised beyond the
horizontal position, the function-keys 13 and 15 are
not enabled.
IMPORTANT
If the command is not executed correctly, e.g.
button pressed to the up-position and lever shifted
to the down-position, no movement will be
operated.
Page C-23
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Handler with telescopic boom GTH-3013 - GTH-3517
OPERATING INSTRUCTIONS
SWITCHING ON THE MACHINE
Starting the machine the system automatically switches on
and, for a few seconds, the display shows the machine model
and the software version (dd.mm.yy= software date of IL11 mm/dd/yy
development)
About 10 seconds later, the message PLEASE CONFIRM
starts flashing on the display:
- Press SET
- With key select the attachment installed among those
available:
FORCHE FORK
please confirm
NAVICELLA BASKET
VERRICELLO WINCH
FALCONE JIB
- The message PLEASE CONFIRMshows up
- Confirm the selection pressing the SET key
The machine is ready to work.
DANGER
When the attachment is replaced, it is necessary to set
the new attachment on the control panel by hand and to
select the load chart related to this new attachment
(fforks, basket, winch or jib). During the programming
phase, the system is not activated.
CAUTION
Once set, the attachment remains activated even if the
machine is stopped and until a new manual setting is
done. However, the attachment must always be confirmed
pressing the SET key every time the machine is started
up.
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Handler with telescopic boom GTH-3013 - GTH-3517
MAINTENANCE
Section D
MAINTENANCE
TABLE OF CONTENTS
D-1 LUBRICANTS - HEALTH AND SAFETY PRECAUTIONS .............................. D-2
D-2 ORDINARY MAINTENANCE ......................................................................... D-3
D-3 MAINTENANCE INTERVENTIONS ................................................................ D-5
D-3.1 Disconnecting the battery ............................................................................. D-6
D-3.2 Access to the engine compartment .............................................................. D-6
D-3.3 Greasing ........................................................................................................ D-7
D-3.4 Tyres and wheels .......................................................................................... D-8
D-3.5 Brakes ........................................................................................................... D-8
D-3.6 Engine air filter ............................................................................................... D-9
D-3.7 Engine cooling system ................................................................................ D-10
D-3.8 Checking the oil level in the tank ................................................................ D-11
D-3.9 Changing the canisters of the oil filter in the injection line .......................... D-12
D-3.9.1 Transmission oil filter .................................................................................. D-12
D-3.9.2 Auxiliary circuit oil filter ............................................................................... D-13
D-3.10 Oil level in the differential gears .................................................................. D-13
D-3.11 Oil level in the (front/rear) wheel reduction gears ........................................ D-14
D-3.12 Oil level in the gearbox ................................................................................ D-14
D-3.13 Shafting alignment ...................................................................................... D-15
D-3.14 Adjusting the sensor distance ..................................................................... D-16
D-3.15 Adjusting the sliding pads of the boom sections ........................................ D-17
D-3.16 Re-sequencing the telescopic boom .......................................................... D-18
D-3.16.1 Re-tensioning the telescopic boom chains ................................................ D-18
D-3.17 Checking the safety devices ....................................................................... D-19
D-4 ELECTRICAL SYSTEM ................................................................................ D-23
D-4.1 Battery ......................................................................................................... D-23
D-4.2 Fuses and relays ......................................................................................... D-24
D-4.3 12V DC lamps ............................................................................................. D-26
D-5 REFUELLING ............................................................................................... D-27
D-5.1 Refuelling ..................................................................................................... D-27
D-5.2 Product specifications ................................................................................ D-27
D-5.2.1 Engine oil ..................................................................................................... D-27
D-5.2.2 Lubrication oils and relevant filtering elements ........................................... D-27
D-5.2.3 Fuel .............................................................................................................. D-28
D-5.2.4 Grease ......................................................................................................... D-28
D-5.2.5 Engine coolant ............................................................................................ D-28
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MAINTENANCE
■ D-3.8 CHECKING THE OIL LEVEL IN THE
TANK
DANGER
Fine jets of hydraulic oil under pressure can pene-
trate the skin. Do not use your fingers, but a piece
of cardboard to detect oil leaks.
Check the hydraulic oil level (visually) through the
special level fitted into the tank.
When necessary, add new oil through filler .
SERVICE INTERVAL
Running-in _________ Within the first 10 hours
Ordinary ____________________ Every 50 hours
To change the oil:
1 Stop the machine on a level ground and make sure
the parking brake is engaged.
2 Release the pressure from the hydraulic circuit.
3 Place a container of suitable size under the drain
plug, placed in the lower part of the reservoir, and PROTECT THE
collect any oil leaks. ENVIRONMENT
4 Remove the drain plug and allow oil to flow out into
the container. The handling and disposing of used oils can be
ruled by local or national regulations. Address to
5 Remove the inspection cover of tank .
authorised centres
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 indicated in paragraph D-5.2.2.
until it is level with .
SERVICE INTERVAL
Running-in ____________________________ None
Ordinary ________________ Every 1000 hours
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MAINTENANCE
DANGER
Do the 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 in a 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.
TO REMOVE THE BLOCK VALVES OR THE
CYLINDERS
- Lower the boom to the ground in 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
working. 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.
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Handler with telescopic boom GTH-3013 - GTH-3517
FAULTS AND TROUBLESHOOTING
NO SELECTION OF THE STEERING • “ROAD-CAB-PLATFORM” switch • Select “CAB”
MODE set to “ROAD”
LOW PARKING BRAKE ACTION • Insufficient cable tensioning • Check and adjust the cable
tension by means of the hollow
screws
• Check and adjust the lead
tightening on the cable heads
NO BOOM LOWERING AND • Fuse F13 blown • Replace the fuse
EXTENSION, NO HOLDING FRAME
PITCHING
ALARM OF THE OVERLOAD • Alarm of the overload warning • Retract or raise the boom within
WARNING SYSTEM system safe limits
(red LED ON)
THE HYDRAULIC OIL • This is normal, when the outside tem-
THERMOMETER DOES NOT WORK perature is low and/or the machine is
used for short periods, since the
hydraulic oil cannot warm up over
40÷50°C
THE OVERLOAD WARNING • Fuse F13 blown • Check and replace the fuse if
SYSTEM DOES NOT WORK necessary
THE BOOM DOES NOT MOVE • Fuse F17 blown • Check and replace the fuse if
necessary
• “ROAD-CAB-PLATFORM” switch • Select “CAB”
set to “ROAD”
ATTENTION
In case of faults not listed in this chapter, address to the GENIE Technical Assistance, your nearest
authorised workshop or dealer.
Page E-3
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Handler with telescopic boom GTH-3013 - GTH-3517
OPTIONAL ATTACHMENTS
■ F-1.8 MAN-PLATFORM ■ F-1.9 ROBOT 5000 / 8000
Application and codes Application and codes
GTH GTH
Platform model 3013 3517 ROBOT 3013 3517
2P-200 F 59.1102.8000 59.1102.8000 mod. 5000
2P-200 RNE 59.1102.9000 59.1102.9000 mod. 8000
2P-200 REM 4400 59.1103.0000 59.1103.0000
3P-1000 RNE 59.1103.1000 59.1103.1000
2P-800 REM 5500 59.1103.2000 59.1103.2000
For the use of this attachment, read the speccific For the use of this attachment, read the speccific
manual supplied - code: 57.0300.8200 manual supplied - code: 57.0300.7200
Page F-9
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TABLES AND DOCUMENTS ENCLOSED
Ref. Description
78 JOYSTICK CONNECTOR
79 17 m BOOM RELAY S.V
80 17 m BOOM RELAY S.V
81 SENSOR - 17 m BOOM
82 ROAD SAFETY SWITCH
83 SOLENOID VALVE - ATTACHMENT RELEASED
84 SOLENOID VALVE - ATTACHMENT COUPLED
85 SOLENOID VALVE - FIFTH ELEMENT
86 SOLENOID VALVE - FIFTH ELEMENT
87 SWITCH - AXLE LEVELLING
88 SOLENOID VALVE - BOOM RAISED
89 SOLENOID VALVE - BOOM LOWERED
90 SOLENOID VALVE - BOOM EXTENSION
91 SOLENOID VALVE - BOOM RETRACTION
92 SOLENOID VALVE - FORK PITCHING FORWARD
93 SOLENOID VALVE - FORK PITCHING BACK
94 SWITCH - LEFT STABILIZERS UP/DOWN
95 SWITCH - RIGHT STABILIZERS UP/DOWN
96 BACK-UP HORN
97 BEACON
98 SOLENOID VALVE - RIGHT STABILIZER DOWN
99 SOLENOID VALVE - LEFT STABILIZER DOWN
100 OVERLOAD WARNING SYSTEM CONTROL UNIT
CUTOUT SWITCH
101 REAR WINDSCREEN WIPER MOTOR
102 SWITCH - EMERGENCY PUMP
103 MUSHROOM-HEAD BUTTON
104 SOLENOID VALVE - ENGINE STOP
105 ENGINE STOP SOLENOID
106 S.V. ENABLING THE EMERGENCY PUMP MOTOR
107 EMERGENCY PUMP
108 RELAY ENABLING THE EMERGENCY PUMP
109 EMERGENCY PUMP PROTECTION FUSE
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