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Operator's Manual
GTH-4016 R
Stage 3A
Stage 3B
GTH-4018 R
Stage 3A
Stage 3B
GTH-5021 R
Stage 3A
Stage 3B
Serial number range
From serial n.: GTH4016R15M-101
From serial n.: GTH4018R15M-101
From serial n.: GTH5021R14B-101
Original Instructions
Second Edition
First Printing
Part No. 57.0009.0607

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Summary of Contents for Terex Genie GTH-4016 R

  • Page 1 Operator’s Manual Serial number range GTH-4016 R From serial n.: GTH4016R15M-101 Stage 3A Stage 3B GTH-4018 R From serial n.: GTH4018R15M-101 Stage 3A Stage 3B GTH-5021 R From serial n.: GTH5021R14B-101 Stage 3A Stage 3B Original Instructions Second Edition First Printing Part No.
  • Page 2: Table Of Contents

    Bleicheplatz 2 Second Edition: First Printing, May 2015 8200 Schaffhausen Switzerland Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other Technical Assistance Service countries. “GTH” is a trademark of Terex South Telephone: +39 075 9418129 Dakota, Inc.
  • Page 3: Introduction

    Second Edition - First Printing May 2015 Introduction About This Manual GTH 5021 R Genie appreciates your choice of our machine for Serial number stamp your application. Our number one priority is user safety, which is best achieved by our joint efforts. This book is an operation and daily maintenance manual for the user or operator of a Genie machine.
  • Page 4 May 2015 Second Edition - First Printing Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model number Safety of product users is of paramount importance and serial number of your machine, along with your to Genie.
  • Page 5 Second Edition - First Printing May 2015 Introduction Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury. Do Not Operate Unless:  You learn and practice the principles of safe machine operation contained in this operator’s manual.
  • Page 6 May 2015 Second Edition - First Printing Introduction Hazard Classification Standards Safety alert symbol - used to alert you to potential personal The following standards and/or regulations apply to injury hazards. Obey all safety this machine (only for STAGE 3B machine): messages that follow this symbol to avoid possible injury Directive...
  • Page 7: Symbol And Hazard Pictorials Definitions

    Second Edition - First Printing May 2015 Symbol and Hazard Pictorials Definitions Tip-over hazard Maintain required Electrocution Crush hazard. No people under Read the operator's clearance. manual. hazard load Keep away from slewing upper Apply maintenance Always wear seat Crush hazard Crush hazard.
  • Page 8 May 2015 Second Edition - First Printing Symbol and Hazard Pictorials Definitions Only trained maintenance Boom personell No people under Resequencing should access load compartments GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607...
  • Page 9: General Safety

    Second Edition - First Printing May 2015 General Safety GTH 4016 R - 4018 R Stage 3A Part No. 57.0009.0607 GTH-4016 R - 4018 R - 5021 R...
  • Page 10 May 2015 Second Edition - First Printing General Safety GTH 4016 R - 4018 R Stage 3A GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607...
  • Page 11 Second Edition - First Printing May 2015 General Safety GTH 4016 R - 4018 R Stage 3B Part No. 57.0009.0607 GTH-4016 R - 4018 R - 5021 R...
  • Page 12 May 2015 Second Edition - First Printing General Safety GTH 4016 R - 4018 R Stage 3B GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607...
  • Page 13 Second Edition - First Printing May 2015 General Safety GTH 5021 R Stage 3A Part No. 57.0009.0607 GTH-4016 R - 4018 R - 5021 R...
  • Page 14 May 2015 Second Edition - First Printing General Safety GTH 5021 R Stage 3A GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607...
  • Page 15 Second Edition - First Printing May 2015 General Safety GTH 5021 R Stage 3B Part No. 57.0009.0607 GTH-4016 R - 4018 R - 5021 R...
  • Page 16 May 2015 Second Edition - First Printing General Safety GTH 5021 R Stage 3B GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607...
  • Page 17: Work Area Safety

    Second Edition - First Printing May 2015 Work Area Safety Overturning Hazards Using the load chart, confirm that Do not use the levelling control to position the load is within the rated capacity an elevated load. of the machine. Do not exceed the rated load.
  • Page 18 May 2015 Second Edition - First Printing Work Area Safety Only use the machine on firm ground capable of Make sure the machine (wheels and outriggers) supporting the maximum combined load of the rests on a firm ground to prevent hazardous unstable machine and payload.
  • Page 19 Second Edition - First Printing May 2015 Work Area Safety Traveling on Slopes Hazards Operators must assess the job site variables and avoid exceeding the machine's (or operator's) capabilities for terrain and conditions. When driving, keep the boom at or below horizontal and keep the load close to the ground.
  • Page 20 May 2015 Second Edition - First Printing Work Area Safety Collision Hazards Falling Object Hazards Operate the machine at speeds that will keep the Do not put the transmission into gear unless the load under control. Start and stop movements parking brake is set.
  • Page 21 Second Edition - First Printing May 2015 Work Area Safety Bodily Injury Hazards Damaged Machine Hazards Always adjust the seat and fasten Do not use a damaged or malfunctioning machine. the seat belt before starting the engine. Conduct a thorough pre-operation inspection of the machine and test all functions before each work shift.
  • Page 22 May 2015 Second Edition - First Printing Work Area Safety Component Damage Hazards Burn Hazards Do not use any battery or charger greater than 12V Allow hot surfaces to cool before to jump-start the engine. touching or servicing. Do not use the machine as a ground for welding. Do not steer the front tires on dry pavement when the axle differential lock is activated.
  • Page 23 Second Edition - First Printing May 2015 Work Area Safety Electrocution Hazards This machine is not electrically insulated and will Do not use the machine as a ground for welding. not provide protection from contact with or proximity to electrical current. Always contact the electrical power line owner.
  • Page 24 May 2015 Second Edition - First Printing Work Area Safety Battery Safety Electrocution Hazard Burn Hazards Batteries contain acid. Avoid contact with electrical terminal. Always wear protective Using the Charger (if equipped), be sure the device clothing and eye wear when works at 12 Volt and doesn't exceed 15 Ampere.
  • Page 25: Safety Precautions

    Second Edition - First Printing May 2015 Safety Precautions Requirements for Machine Requirements for Service Operators Personnel Operators who use the machine regularly or Personnel in charge of the machine maintenance occasionally (i.e. for transport reasons) shall have shall be qualified, specialised in the maintenance the following prerequisites: of telehandlers, and shall have the following health:...
  • Page 26 May 2015 Second Edition - First Printing Safety Precautions Working clothes Personal protective equipment During work, but especially when maintaining or Under special working conditions, the following repairing the machine, operators must wear suitable personal protective equipment should be used: protective clothing: •...
  • Page 27 Second Edition - First Printing May 2015 Safety Precautions Control Indicators and Interlocks Seat Interlock This micro switch is located inside the seat cushion, Several control indicators and interlocks have been and it prevents any machine transmission movements fitted to the machine. They must never be tampered if the operator is not correctly seated in the driving seat.
  • Page 28: Legend

    May 2015 Second Edition - First Printing Legend GTH 4016 R - 4018 R 1. Left/right level indicator 10. Forks 2. Operator’s manual storage 11. Seat belt (door internal side) 12. Outriggers pads (if equipped) 3. Right functions joystick 13. Front/rear level indicator 4.
  • Page 29 Second Edition - First Printing May 2015 Legend GTH 5021 R ¡ ¦ © ¡ ¤ ¦ § © ¥ ¨ ¦ ¢ £ ¦ ¥ ¥ £ 1. Left/right level indicator 10. Forks 2. Operator’s manual storage 11. Seat belt (door internal side) 12.
  • Page 30: Controls

    May 2015 Second Edition - First Printing Controls FORCHE STAB. FRONTALE PESO SOLL....... 50.3t CARICO MAX ....10.2t RAGGIO ......12.3m ENTER GTH 4016 R - GTH 4018 R - GTH-5021 R Part No. 57.0009.0607...
  • Page 31 Second Edition - First Printing May 2015 Controls Control Panel 19. Job-site/road/platform selector 1. Steering wheel 20. A/C switch (if equipped) 2. Transmission control lever - Horn button 21. Cab heater fan switch 3. Seat controls 22. Auxiliary hydraulic circuit switch (if equipped) 4.
  • Page 32 May 2015 Second Edition - First Printing Controls Steering wheel Instrument panel Turn the steering wheel to the right to turn the 10 Parking brake switch front wheels to the right. Turn the steering wheel Push the bottom of the rocker switch to turn the to the left to turn the front wheels to the left.
  • Page 33 Second Edition - First Printing May 2015 Controls 21 Cab heater fan switch 29. Outriggers switches Push the bottom of the switch to turn the cab Push the top of the switches to extend and lower heater fan on: first position for low speed and the outriggers.
  • Page 34 May 2015 Second Edition - First Printing Controls GTH 4016 R - 4018 R - 5021 R Stage 3A " " Instrument Panel 13. Turn signal indicator light 1. Low engine oil pressure indicator light 14. Fuel level gauge with low fuel indicator light 2.
  • Page 35 Second Edition - First Printing May 2015 Controls GTH 4016 R - 4018 R - 5021 R Stage 3A 1 Low engine oil pressure indicator light 12 High hydraulic oil temperature indicator light When illuminated this light indicates that the engine This indicates the temperature of the hydraulic oil oil pressure is too low which can lead to machine in the tank which can lead to machine damage.
  • Page 36 May 2015 Second Edition - First Printing Controls GTH 4016 R - 4018 R - 5021 R Stage 3B 1230 & engine rpm 000000.0 Instrument Panel 14. 1st gear engaged indicator light 1. Low engine oil pressure indicator light 15. Engine coolant temperature gauge with high 2.
  • Page 37 Second Edition - First Printing May 2015 Controls GTH 4016 R - 4018 R - 5021 R Stage 3B 1 Low engine oil pressure indicator light 10 Engine air filter restricted indicator light When illuminated this light indicates that the engine When this lamp comes on, the engine air filter is oil pressure is too low which can lead to machine clogged proceed with cleaning or changing the air...
  • Page 38: Inspections

    May 2015 Second Edition - First Printing 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 Do Not Operate Unless: 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 You learn and practice the principles of safe...
  • Page 39 Second Edition - First Printing May 2015 Inspections Pre-operation Inspection Limit switches Be sure that the operator’s and safety manuals are complete, legible and in the storage container Lights, alarms and beacons located in the cab. Pins, nuts, bolts and other fasteners Be sure that all decals are legible and in place.
  • Page 40 May 2015 Second Edition - First Printing Inspections Function Test 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 Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 41 Second Edition - First Printing May 2015 Inspections Function Tests Test the Single Functions Joystick Using the functions joystick, momentarily raise Select a test area that is firm, level and free of the boom and extend the boom, tilt the forks up obstruction.
  • Page 42 May 2015 Second Edition - First Printing Inspections Test the Steering Test the Transmission and Brakes 15 Rotate the steering mode selector to the right 23 Be sure the boom is fully lowered and retracted. side to select four-wheel steer. 24 Step on the brake pedal.
  • Page 43 Second Edition - First Printing May 2015 Inspections Test the Parking Brake Test the Road Transfer Mode 30 Push the bottom of the rocker switch to turn the 38 Set the steering mode selector to road transfer parking brake on: the parking brake warning light mode.
  • Page 44 May 2015 Second Edition - First Printing Inspections Test the Joystick Enabling Function Test the Outriggers Sensors Switch 57 Lower or raise all the outriggers. 47 Operate the joystick without pressing this button. Result: the load limiting display will accordingly change the scale of the admissible payloads.
  • Page 45 Second Edition - First Printing May 2015 Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations: drop-offs or holes bumps, floor obstructions or debris Do Not Operate Unless: sloped surfaces You learn and practice the principles of safe unstable or slippery surfaces machine operation contained in this operator’s manual.
  • Page 46 Part No. Decal Description Danger – Explosion/Burn Hazard, 09.4618.1458 Warning - Tip Over, Respect Capacity 215645 Fueling 09.4618.1945 Cosmetic - Genie GTH-4016 R 215646 Warning – Electrocution Hazard 09.4618.0243 Cosmetic - Genie 215648 Danger - No Riders 09.4618.1693 Cosmetic - Genie Warning –...
  • Page 47 Second Edition - First Printing May 2015 Inspections Part No. Decal Description Part No. Decal Description Label - Load Chart Fork Front on Label - Load Chart Shovel 360° on 09.4618.1923 09.4618.1941 outriggers Wheels Label - Load Chart Shovel Front on Label - Load Chart Fork 360°...
  • Page 48 May 2015 Second Edition - First Printing Inspections Inspection for GTH 4018 R Decals Use the pictures on the next page to verify that all decals are legible and in place. Below is a numerical list with quantities and descriptions. Part No.
  • Page 49 Second Edition - First Printing May 2015 Inspections Part No. Decal Description Part No. Decal Description Label - Load Chart Fork Front on Label - Load Chart Man Platform 09.4618.1849 09.4618.1951 Wheels 2P/300Kg Label - Load Chart Man Platform Label - Load Chart Fork 360° on 09.4618.1950 09.4618.1850 3P/700Kg...
  • Page 50 May 2015 Second Edition - First Printing Inspections 09.4618.1386 only GTH 4016R 09.4618.1771 09.4618.1829 09.4618.1694 only STAGE 3B 09.4618.1263 09.4618.1679 09.4618.1645 09.4618.1264 09.4618.1418 09.4618.1945 09.4618.1399 09.4618.1839 09.4618.1120 09.4618.0040 237721 237720 09.4618.1820 215646 09.4618.1819 09.4618.1673 09.4618.1821 09.4618.1740 215648 09.4618.1693 09.4618.1188 09.4618.1375 09.4618.1673 09.4618.1946 215645...
  • Page 51 Second Edition - First Printing May 2015 Inspections Inspection for Road Homologation Configuration GTH 4016 R - GTH 4018 R Pos. Part Number Spain Switzerland Italy Max Speed ??km/h 09.4618.0339 Max Speed 20km/h 09.4610.0028 Rear Mirror Fish-eye 09.0803.0081 Wheel Chock 09.4618.0276 Reflecting Yellow Decal 56.0010.0020...
  • Page 52 May 2015 Second Edition - First Printing Inspections Inspection for GTH 5021 R Decals Use the pictures on the next page to verify that all decals are legible and in place. Below is a numerical list with quantities and descriptions. Part No.
  • Page 53 Second Edition - First Printing May 2015 Inspections Part No. Decal Description Part No. Decal Description 09.4618.1642 Label - Load Chart Fork Front Label - Load Chart 2P300 F 09.4618.1712 Manplatform on Outriggers (for NOT EU 09.4618.1644 Label - Load Chart Fork Side Market) Label - Load Chart Fork 360°...
  • Page 54 May 2015 Second Edition - First Printing Inspections 09.4618.1423 09.4618.1769 09.4618.1820 09.4618.1770 09.4618.1819 09.4618.1399 09.4618.1821 09.4618.1670 09.4618.1645 09.4618.1120 09.4618.1840 09.4618.1740 09.4618.1264 09.4618.1693 09.4616.0010 09.4618.1423 09.4618.1677 215645 215646 09.4618.1675 09.4618.1673 09.4618.1671 or 28159 215648 237721 09.4618.1375 09.4618.1676 237720 09.4618.1594 09.4618.1676 215646 09.4618.1398 09.4618.1827 09.4618.1675...
  • Page 55 Second Edition - First Printing May 2015 Inspections Inspection for Road Homologation Configuration GTH 5021 R Pos. Part Number Spain Switzerland Italy 09.4618.1491 Max Speed 30km/h 09.4618.0339 Max Speed 20km/h 09.4610.0028 Rear Mirror fish-eye 09.0803.0081 Wheel Chock 09.4618.0276 Reflecting Yellow Decal 56.0010.0020 Orange Reflector 56.0010.0029...
  • Page 56: Operating Instructions

    May 2015 Second Edition - First Printing Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety and responsibilities manuals. Do Not Operate Unless: A variable reach rough terrain forklift truck is defined as a wheeled type truck designated...
  • Page 57 Second Edition - First Printing May 2015 Operating Instructions Adjusting the Seat Comfort Seat (if equipped) Standard Seat (part number 58.2513.1088) To adjust the seat position, move lever A and slide To adjust the seat position, move lever 1 and slide the seat forward or backward.
  • Page 58 May 2015 Second Edition - First Printing Operating Instructions Fastening the Seat Belts Adjusting the Rear View Mirrors The machine is fitted with three rear view mirrors. To adjust their positions, manually rotate them to the position(s) which provides optimal visibility. 1.
  • Page 59 Second Edition - First Printing May 2015 Operating Instructions Parking Brake Starting in Cold Condition Always use the parking brake switch to apply the In cold conditions, 20°F / -6°C and below, warm parking brake before raising the boom. the engine for 5 minutes before operating to prevent hydraulic system damage.
  • Page 60 May 2015 Second Edition - First Printing Operating Instructions Job-Site/Road/Platform Select Raising and Lowering the Outriggers • Job-site mode: all machine functions are enabled; Push the top of the rocker switch to extend/lower the outriggers. Push the bottom of the rocker •...
  • Page 61 Second Edition - First Printing May 2015 Operating Instructions Slewing Upper Structure Locking Transmission Control When the slewing upper structure is slewed in rearward position, all the steering controls are This manual device is placed at the back of the switched! cabin.
  • Page 62 May 2015 Second Edition - First Printing Operating Instructions Axle Differential Lock Access to the Engine Compartment Use the axle differential lock switch to lock the axle differential and gain added traction in certain For any operation within the engine compartment, types of terrain such as sand, mud or snow.
  • Page 63 Second Edition - First Printing May 2015 Operating Instructions DPF Regeneration When the Diesel Particulate Filter indicator light, xii Once the regeneration has been completed, the high exhaust system temperature indicator 7, switches on the operator has to start the DPF light 9, will switch off and the engine will run at regeneration following these instructions: idle.
  • Page 64 May 2015 Second Edition - First Printing Operating Instructions Transporting a Load Raising and Placing a Load Center the load on the forks. Position the load so The load chart in the cab shows the operating that it is completely against the back of the fork limits of a properly maintained and operated frame.
  • Page 65 Second Edition - First Printing May 2015 Operating Instructions Placing the load Gradually move the controller to lower and extend the boom into final position. Lower the Travel to the desired work site and carefully load until the weight is completely off the forks. stop the machine.
  • Page 66 May 2015 Second Edition - First Printing Operating Instructions Controller movements - Single Functions Joystick Functions joystick with Functions joystick with Functions joystick with enable switch (B) enable switch (B) and enable switch (B) and yellow roller switch (D) yellow roller switch (C) Hydraulic quick coupling (if equipped) Lock or unlock hydraulic quick coupling by simultaneously pressing hydraulic quick...
  • Page 67 Second Edition - First Printing May 2015 Operating Instructions Controller movements - Dual Functions Joysticks (if equipped) Functions joystick only Functions joystick only with red finger switch with red finger switch (B) and with yellow roller switch (D) Functions joystick only While pressing the hydraulic quick with red finger switch coupling lock/unlock, functions joystick...
  • Page 68 When using an attachment other than those stated, stopped, but for those allowing to return the load but supplied by Terex Global GmbH, select the within safety limits. FORK in line 2. Operation •...
  • Page 69 Second Edition - First Printing May 2015 Operating Instructions Pressing ESC, go back to the Standard Screen • Using The Load Charts Page. The load charts installed on the cab indicate the Press the two buttons PLUS ( ) and MINUS •...
  • Page 70 May 2015 Second Edition - First Printing Operating Instructions Quick Attach Instructions Version with hydraulic locking (optional) Version with mechanical locking 1. Drive to the place where you will release the 1 Drive to the place where you will release the mounted attachment (when possible, a solid mounted attachment (when possible, a solid and sheltered site).
  • Page 71 Second Edition - First Printing May 2015 Operating Instructions Jump Starting the Machine Driving on a slope Jump starting at the battery or battery replacement is required when the battery is discharged to the When the machine is loaded, always travel with point where the battery will not crank the starter.
  • Page 72 May 2015 Second Edition - First Printing Operating Instructions Manual Controls The manual controls can be used only if the machine is running or it is equipped with the If the joystick is malfunctioning or a function emergency pump. cannot be operated, it is possible to use the In order to operate the emergency pump with the emergency controls at the main valve.
  • Page 73 Second Edition - First Printing May 2015 Operating Instructions Engine Condition Indicator Road or site transfer If the DPF Alert indicator light and/or the Engine When travelling on public roads, strictly obey the Critical Fault indicator light switches on, contact local or national road traffic regulations.
  • Page 74 May 2015 Second Edition - First Printing Operating Instructions Moving a disabled machine Clear the area of any personnel before remove the locking from each of the four tires and tow Tow the machine only when no alternative is possible, the vehicle to a suitable location.
  • Page 75 Second Edition - First Printing May 2015 Operating Instructions Setting the transmission to neutral Do not tow the machine without setting the transmission to neutral. To set the transmission to neutral: • Unscrew the screw M8X25 1 • Remove the Cover 2 •...
  • Page 76: Parking And Storage

    May 2015 Second Edition - First Printing Parking and Storage Short inactivity Machine storage Always park the machine in a safe way after a working In case of extended inactivity of the machine, follow day, a shift and at night. the above precautions.
  • Page 77 Second Edition - First Printing May 2015 Parking and Storage Machine disposal Cleaning and washing the machine At the end of the machine life, call in a specialized firm to dispose of it in compliance Clean the machine in accordance with the following with the local or national regulations.
  • Page 78: Transport And Lifting Instructions

    May 2015 Second Edition - First Printing Transport and Lifting Instructions Before loading for transport, make sure the deck, ramps and machine tires are free of mud, Observe and Obey: snow and ice. Failure to do so could cause the machine to slide.
  • Page 79 Second Edition - First Printing May 2015 Transport and Lifting Instructions Securing to Truck or Trailer for Transit Securing the Chassis Turn the key switch to the off position and remove Use chains of ample load capacity. the key before transporting. Use a minimum of 6 chains.
  • Page 80 May 2015 Second Edition - First Printing Transport and Lifting Instructions GTH 5021 R GTH 4016 R - GTH 4018 R - GTH-5021 R Part No. 57.0009.0607...
  • Page 81 Second Edition - First Printing May 2015 Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Retract the outriggers. Lock the slewing upper structure. Observe and Obey: Determine the center of gravity of your machine using the picture on this page. Only qualified riggers should rig the machine.
  • Page 82 May 2015 Second Edition - First Printing Transport and Lifting Instructions GTH 5021 R 1280 mm Height from ground 1444 mm Rear Offset 874 mm Side Offset GTH 4016 R - GTH 4018 R - GTH-5021 R Part No. 57.0009.0607...
  • Page 83: Maintenance

    Second Edition - First Printing May 2015 Maintenance Check the Tire Pressure Tip-over hazard. An over-inflated tire can explode which may compromise machine Observe and Obey: stability and cause the machine to tip over. Tip-over hazard. The use of temporary flat tire Only routine maintenance items specified in this repair products may lead to tire failure which manual shall be performed by the operator.
  • Page 84 May 2015 Second Edition - First Printing Maintenance Check the Engine Oil Level Check the Hydraulic Oil Level Maintaining the proper engine oil level is essential Maintaining the hydraulic oil at the proper level is to good engine performance and service life. essential to machine operation.
  • Page 85 Second Edition - First Printing May 2015 Maintenance Check the Engine Coolant Level - Check the Battery Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 86 May 2015 Second Edition - First Printing Maintenance Re-Sequencing the Telesopic Boom (only for GTH-4016 R) If, during normal operation, a change in the boom extended lengths of 150mm or more is noticed when the boom is retracted, proceed as follows: 1 Fully retract the telescope cylinder and keep the retraction system under pressure (approx.
  • Page 87 Second Edition - First Printing May 2015 Maintenance Scheduled Maintenance Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service. Model Serial number Date Hour meter Machine owner Inspected by (print) Inspector signature...
  • Page 88 May 2015 Second Edition - First Printing Maintenance Inspect the Manuals and Decals 3 Open the operator's manual to the decals Genie specifications require that this procedure be inspection section. Carefully and thoroughly performed every 8 hours or daily, whichever comes inspect all decals on the machine for legibility first.
  • Page 89 Second Edition - First Printing May 2015 Maintenance Perform Pre-operation Inspection Perform Function Tests Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes performed every 8 hours or daily, whichever comes first.
  • Page 90 May 2015 Second Edition - First Printing Maintenance Lubricate the Boom Perform Engine Maintenance - Perkins Models Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes Note: Engine specifications require that this procedure first. be performed every 8 hours or daily, whichever comes first.
  • Page 91 Second Edition - First Printing May 2015 Maintenance Carraro 26.32M Axle Maintenance and Repair Manual Carraro 26.32M Front Axle Maintenance and Repair Instructions Genie part number 57.4700.0002 (Genie Instructions Library) Carraro 26.32M Rear Axle Maintenance and Repair Instructions Genie part number 57.4700.0003 (Genie Instructions Library) Part No.
  • Page 92 May 2015 Second Edition - First Printing Maintenance Carraro 26.32M Axle Maintenance and Repair Manual GTH 4016 R - GTH 4018 R - GTH-5021 R Part No. 57.0009.0607...
  • Page 93: Attachments

    Second Edition - First Printing May 2015 Attachments Genie GTH 4016 R - GTH 4018 R This machine can be equipped with several attachments. Approved Attachments List: Use only Genie approved attachments specified in • Floating Forks this section. (part number 55.0750.0118) •...
  • Page 94 May 2015 Second Edition - First Printing Attachments Genie GTH 5021 R Approved Attachments List: • Fixed man-platform: 2P/300-F • Floating Forks (part number 59.1111.6013) (part number 55.0750.0082) • Rotating and extendable man-platform: • Forks Side Shift and positioner 3P/700-REM 4400 +/- 90° (part number 59.0601.5027) (part number 59.1111.6014) •...
  • Page 95 Second Edition - First Printing May 2015 Attachments Work Platform Hazards Work Area Safety Platform Occupant Restraint Device Use only a Genie approved personnel work Personal protective equipment (PFPE) is required platform. for all occupants of the work platform. Occupants must wear a Do not lift personnel with a safety belt or harness in telehandler unless it is equipped...
  • Page 96 May 2015 Second Edition - First Printing Attachments Suspended Load Hazards Work Area Safety Overturning Hazards General Safety Do not lift a suspended load without the proper and legible load capacity chart for the attachment/ Do not lift a suspended load without first telehandler combination you are using.
  • Page 97 Second Edition - First Printing May 2015 Attachments Only climb or descend inclines with extreme care Keep the heavy part of the load closest to the as the load center will move towards the tipping attachment. line, thereby reducing stability Never drag or pull a load sideways.
  • Page 98 May 2015 Second Edition - First Printing Attachments Fall Hazards Crush Hazards Do not lift or suspend personnel. Never allow the signal person to come between the suspended load and another object (such as Don’t use the shovel for rising or transporting the telehandler itself).
  • Page 99 Second Edition - First Printing May 2015 Attachments Lifting a Suspended Load Travelling Verify that landing point is level and can safely Be sure that the path of travel is level and capable support the load. of supporting the telehandler with its load. Properly secure the attachment to the telehandler Keep the boom, and load, as low as practical while maintaining visibility in the direction of travel.
  • Page 100 May 2015 Second Edition - First Printing Attachments Placing the Load Signal Person Ask a signal person to assist with placing the A signal person is recommended when: load if visibility will be obstructed at the point of The point of operation, meaning the load travel or operation.
  • Page 101 Second Edition - First Printing May 2015 Attachments STOP. With arm EMERGENCY STOP. With both arms extended HOIST. With upper RAISE BOOM. With extended horizontally to horizontally to the side, palms down, arms are arm extended to the arm extended the side, palm down, swung back and forth.
  • Page 102: Specifications

    May 2015 Second Edition - First Printing Specifications Floor loading information GTH-4016 R Tire load, maximum 7,136 kg Height, stowed 2.99 m Occupied floor pressure 11.4 kPa Length, stowed, at fork-holder plate 6.760 m Width, standard tires 2.40 m Wheelbase 3.00 m Ground clearance, center 0.345 m...
  • Page 103 Second Edition - First Printing May 2015 Specifications Floor loading information GTH-4018 R Tire load, maximum 7,245 kg Height, stowed 2.99 m Occupied floor pressure 11.7 kPa Length, stowed, at fork-holder plate 6.60 m Width, standard tires 2.40 m Wheelbase 3.00 m Ground clearance, center 0.345 m...
  • Page 104 May 2015 Second Edition - First Printing Specifications Floor loading information GTH-5021 R Tire load, maximum 10,500 kg Height, stowed 2.99 m Occupied floor pressure 20.32 kPa Length, stowed, at fork-holder plate 7.17 m Width, standard tires 2.42 m Wheelbase 3.00 m Ground clearance, center 0.36 m...
  • Page 105: Load Charts

    Second Edition - First Printing May 2015 Load Charts GTH-4016 R, Standard Carriage GTH-4016 R GTH-4016 R 0° 180° 0° 70° 180° 75° 60° 50° 40° 30° 0.6 m 20° 10° 0° -3.7° 13.35 m 09.4618.1925 09.4618.1923 GTH-4016 R GTH-4016 R ±90°...
  • Page 106 May 2015 Second Edition - First Printing Load Charts GTH-4016 R, Hook GTH-4016 R GTH-4016 R ±90° 0° 70° 180° 75° 70° 75° 60° 60° 50° 50° 40° 40° 30° 30° 20° 20° 10° 10° 0° 0° -3.7° -3.7° 12.91 m 12.91 m 09.4618.1927 09.4618.1928...
  • Page 107 Second Edition - First Printing May 2015 Load Charts GTH-4016 R, 900Kg Jib GTH-4016 R GTH-4016 R 0° ±90° 180° 09.4618.1935 09.4618.1936 GTH-4016 R GTH-4016 R ±90° 0° 180° 09.4618.1937 09.4618.1938 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 108 May 2015 Second Edition - First Printing Load Charts GTH-4016 R, 2000Kg Jib GTH-4016 R GTH-4016 R 0° ±90° 180° 09.4618.1931 09.4618.1932 GTH-4016 R GTH-4016 R 0° ±90° 180° 09.4618.1933 09.4618.1934 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 109 Second Edition - First Printing May 2015 Load Charts GTH-4016 R, Winch 4000 GTH-4016 R GTH-4016 R 0° ±90° 180° 09.4618.1971 09.4618.1970 GTH-4016 R GTH-4016 R 0° ±90° 180° 09.4618.1969 09.4618.1968 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 110 May 2015 Second Edition - First Printing Load Charts GTH-4016 R, Bucket GTH-4016 R GTH-4016 R 0° ±90° 180° 09.4618.1940 09.4618.1939 GTH-4016 R GTH-4016 R ±90° 0° 180° 09.4618.1942 09.4618.1941 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 111 Second Edition - First Printing May 2015 Load Charts GTH-4016 R, Man Platform Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 112 May 2015 Second Edition - First Printing Load Charts GTH-4016 R, Manitou standard Carriage GTH-4016R GM-1 GTH-4016R GM-1 0° 180° 0° 180° 09.4618.1896 09.4618.1898 GTH-4016R GM-1 GTH-4016R GM-1 ±90° ±90° 09.4618.1897 09.4618.1899 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 113 Second Edition - First Printing May 2015 Load Charts GTH-4016 R, Manitou P1200 Jib 1200 KG 1200 KG GTH-4016R GM-1 GTH-4016R GM-1 0° 0° 180° 180° 09.4618.1902 09.4618.1900 1200 KG 1200 KG GTH-4016R GM-1 GTH-4016R GM-1 ±90° ±90° 09.4618.1903 09.4618.1901 Part No.
  • Page 114 May 2015 Second Edition - First Printing Load Charts GTH-4016 R, Manitou P4000 Jib 4000 KG 4000 KG GTH-4016 R GM-1 GTH-4016 R 0° 0° 180° 180° 09.4618.1906 09.4618.1904 4000 KG 4000 KG GTH-4016R GM-1 GTH-4016R GM-1 ±90° ±90° 09.4618.1907 09.4618.1905 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 115 Second Edition - First Printing May 2015 Load Charts GTH-4016 R, Manitou Fixed Hook PC40 GTH-4016R GM-1 GTH-4016R GM-1 0° 0° 180° 180° 09.4618.1910 09.4618.1908 GTH-4016R GM-1 GTH-4016R GM-1 ±90° ±90° 09.4618.1911 09.4618.1909 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 116 May 2015 Second Edition - First Printing Load Charts GTH-4016 R, Winch H3T S4 GTH-4016R GM-1 GTH-4016R GM-1 0° 0° 180° 180° 09.4618.1914 09.4618.1912 GTH-4016R GM-1 GTH-4016R GM-1 ±90° ±90° 09.4618.1915 09.4618.1913 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 117 Second Edition - First Printing May 2015 Load Charts GTH-4018 R, Standard Carriage GTH-4018 R 0° 180° ±90° 09.4618.1850 GTH-4018 R GTH-4018 R 0° 180° ±90° 09.4618.1851 09.4618.1849 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 118 May 2015 Second Edition - First Printing Load Charts GTH-4018 R, Hook GTH-4018 R 0° 180° ±90° 09.4618.1855 GTH-4018 R GTH-4018 R 0° 180° ±90° 09.4618.1856 09.4618.1857 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No. 57.0009.0607...
  • Page 119 Second Edition - First Printing May 2015 Load Charts GTH-4018 R, 900Kg Jib GTH-4018 R 0° 180° ±90° 09.4618.1861 GTH-4018 R GTH-4018 R ±90° 0° 180° 09.4618.1862 09.4618.1863 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 120 May 2015 Second Edition - First Printing Load Charts GTH-4018 R, 2000Kg Jib GTH-4018 R 0° 180° ±90° 09.4618.1858 GTH-4018 R GTH-4018 R 0° ±90° 180° 09.4618.1859 09.4618.1860 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No. 57.0009.0607...
  • Page 121 Second Edition - First Printing May 2015 Load Charts GTH-4018 R, Winch 4000 GTH-4018 R 0° 180° ±90° 09.4618.1864 GTH-4018 R GTH-4018 R 0° ±90° 180° 09.4618.1865 09.4618.1866 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 122 May 2015 Second Edition - First Printing Load Charts GTH-4018 R, Bucket GTH-4018 R ±90° 0° 180° 09.4618.1852 GTH-4018 R GTH-4018 R 0° ±90° 180° 09.4618.1853 09.4618.1854 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No. 57.0009.0607...
  • Page 123 Second Edition - First Printing May 2015 Load Charts GTH-4018 R, Man Platform Only for stage 3A 300 F GTH-4018 R ±90° 0° 180° 09.4618.1951 3P/700 4400 GTH-4018 R ±90° 0° 180° 09.4618.1950 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 124 May 2015 Second Edition - First Printing Load Charts GTH-4018 R, Manitou Standard Carriage GTH-4018R GM-1 0° 180° 09.4618.1869 GTH-4018R GM-1 GTH-4018R GM-1 ±90° ±90° 0° 180° 09.4618.1870 09.4618.1883 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No. 57.0009.0607...
  • Page 125 Second Edition - First Printing May 2015 Load Charts GTH-4018 R, Manitou P1200 Jib 1200 KG GTH-4018R GM-1 0° 180° 09.4618.1872 1200 KG 1200 KG GTH-4018R GM-1 GTH-4018R GM-1 ±90° ±90° 0° 180° 09.4618.1873 09.4618.1871 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 126 May 2015 Second Edition - First Printing Load Charts GTH-4018 R, Manitou P4000 Jib 4000 KG GTH-4018R GM-1 0° 180° 09.4618.1875 4000 KG 4000 KG GTH-4018R GM-1 GTH-4018R GM-1 ±90° ±90° 0° 180° 09.4618.1876 09.4618.1874 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 127 Second Edition - First Printing May 2015 Load Charts GTH-4018 R, Manitou Fixed Hook PC40 GTH-4018R GM-1 0° 180° 09.4618.1878 GTH-4018R GM-1 GTH-4018R GM-1 ±90° ±90° 0° 180° 09.4618.1879 09.4618.1877 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 128 May 2015 Second Edition - First Printing Load Charts GTH-4018 R, Manitou Winch H3T S4 GTH-4018R GM-1 0° 180° 09.4618.1881 GTH-4018R GM-1 GTH-4018R GM-1 ±90° ±90° 0° 180° 09.4618.1882 09.4618.1880 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 129 Second Edition - First Printing May 2015 Load Charts GTH-5021 R, Standard Carriage GTH-5021 R 0° 180° 77.50° 70° 60° 50° 40° 30° 20° 0.60 m 10° 0° -3.50° 18.24 m 09.4618.1642 GTH-5021 R GTH-5021 R ±90° 77.50° 0° 77.50° 180°...
  • Page 130 May 2015 Second Edition - First Printing Load Charts GTH-5021 R, Forks Side Shift and positioner GTH-5021 R 0° 180° 09.4618.1884 GTH-5021 R GTH-5021 R ±90° 0° 180° ±90° 09.4618.1885 09.4618.1886 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 131 Second Edition - First Printing May 2015 Load Charts GTH-5021 R, Hook GTH-5021 R 0° 180° ±90° 09.4618.1696 GTH-5021 R GTH-5021 R 0° ±90° 180° 09.4618.1697 09.4618.1698 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 132 May 2015 Second Edition - First Printing Load Charts GTH-5021 R, 900kg Jib GTH-5021 R 0° 180° ±90° 09.4618.1699 GTH-5021 R GTH-5021 R 0° ±90° 180° 09.4618.1701 09.4618.1700 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No. 57.0009.0607...
  • Page 133 Second Edition - First Printing May 2015 Load Charts GTH-5021 R, 2000kg Jib GTH-5021 R 0° 180° ±90° 09.4618.1702 GTH-5021 R GTH-5021 R 0° ±90° 180° 09.4618.1703 09.4618.1704 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 134 May 2015 Second Edition - First Printing Load Charts GTH-5021 R, Winch 4000kg GTH-5021 R 0° 180° ±90° 09.4618.1705 GTH-5021 R GTH-5021 R 0° ±90° 180° 09.4618.1706 09.4618.1707 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No. 57.0009.0607...
  • Page 135 Second Edition - First Printing May 2015 Load Charts GTH-5021 R, Winch 5000kg 5000Kg GTH-5021 R 0° 180° ±90° 09.4618.1891 5000Kg 5000Kg GTH-5021 R GTH-5021 R 0° ±90° 180° 09.4618.1889 09.4618.1890 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 136 May 2015 Second Edition - First Printing Load Charts GTH-5021 R, Bucket GTH-5021 R 0° 180° ±90° 09.4618.1708 GTH-5021 R GTH-5021 R 0° ±90° 180° 09.4618.1709 09.4618.1710 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No. 57.0009.0607...
  • Page 137 Second Edition - First Printing May 2015 Load Charts GTH-5021 R, Man-platform 300 F GTH-5021 R ±90° 0° 180° 09.4618.1920 3P/700 4400 GTH-5021 R 0° 180° ±90° 09.4618.1921 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 138 May 2015 Second Edition - First Printing Load Charts GTH-5021 R, Manitou Standard Carriage GTH-5021 R GM-1 0° 180° 09.4618.1972 GTH-5021 R GM-1 GTH-5021 R GM-1 ±90° 0° 180° ±90° 09.4618.1783 09.4618.1973 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 139 Second Edition - First Printing May 2015 Load Charts GTH-5021 R, Manitou Fixed Hook PC40 PC 40 GTH-5021 R GM-1 0° 180° 09.4618.1784 PC 40 PC 40 GTH-5021 R GM-1 GTH-5021 R GM-1 ±90° 0° 180° ±90° 09.4618.1785 09.4618.1786 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 140 May 2015 Second Edition - First Printing Load Charts GTH-5021 R, Manitou Fixed Hook PC50 PC 50 GTH-5021 R GM-1 0° 180° 09.4618.1787 PC 50 PC 50 GTH-5021 R GM-1 GTH-5021 R GM-1 ±90° 0° 180° ±90° 09.4618.1788 09.4618.1789 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 141 Second Edition - First Printing May 2015 Load Charts GTH-5021 R, Manitou P4000 1200KG JIB 1200 KG GTH-5021 R GM-1 0° 180° 09.4618.1799 1200 KG 1200 KG GTH-5021 R GM-1 GTH-5021 R GM-1 ±90° 0° 180° ±90° 09.4618.1800 09.4618.1801 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 142 May 2015 Second Edition - First Printing Load Charts GTH-5021 R, Manitou P4000 4000kg JIB 4000 KG GTH-5021 R GM-1 0° 180° 09.4618.1796 4000 KG 4000 KG GTH-5021 R GM-1 GTH-5021 R GM-1 ±90° 0° 180° ±90° 09.4618.1797 09.4618.1798 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 143 Second Edition - First Printing May 2015 Load Charts GTH-5021 R, Manitou P6000 6000KG JIB 6000 KG GTH-5021 R GM-1 0° 180° 09.4618.1802 6000 KG 6000 KG GTH-5021 R GM-1 GTH-5021 R GM-1 ±90° 0° 180° ±90° 09.4618.1804 09.4618.1803 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 144 May 2015 Second Edition - First Printing Load Charts GTH-5021 R, Manitou P6000 1600kg JIB 1600 KG GTH-5021 R GM-1 0° 180° 09.4618.1805 1600 KG 1600 KG GTH-5021 R GM-1 GTH-5021 R GM-1 ±90° 0° 180° ±90° 09.4618.1807 09.4618.1806 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 145 Second Edition - First Printing May 2015 Load Charts GTH-5021 R, Manitou P2000 Mechanical JIB GTH-5021 R GM-1 0° 180° 09.4618.1808 GTH-5021 R GM-1 GTH-5021 R GM-1 ±90° 0° 180° ±90° 09.4618.1809 09.4618.1810 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 146 May 2015 Second Edition - First Printing Load Charts GTH-5021 R, Manitou PT2000 Hydraulic JIB GTH-5021 R GM-1 0° 180° 09.4618.1811 GTH-5021 R GM-1 GTH-5021 R GM-1 ±90° 0° 180° ±90° 09.4618.1812 09.4618.1813 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 147 Second Edition - First Printing May 2015 Load Charts GTH-5021 R, Manitou Winch HH3T 3000 KG GTH-5021 R GM-1 0° 180° 09.4618.1790 3000 KG 3000 KG GTH-5021 R GM-1 GTH-5021 R GM-1 ±90° 0° 180° ±90° 09.4618.1791 09.4618.1792 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 148 May 2015 Second Edition - First Printing Load Charts GTH-5021 R, Manitou Winch HH5T 5000 KG GTH-5021 R GM-1 0° 180° 09.4618.1793 5000 KG 5000 KG GTH-5021 R GM-1 GTH-5021 R GM-1 ±90° 0° 180° ±90° 09.4618.1794 09.4618.1795 GTH 4016 R - GTH 4018 R - GTH-5021 R Part No.
  • Page 149 Second Edition - First Printing May 2015 Load Charts GTH-5021 R, Manitou Shovel 1000L GTH-5021 R GM-1 0° 180° 09.4618.1814 GTH-5021 R GM-1 GTH-5021 R GM-1 ±90° 09.4618.1815 09.4618.1816 Part No. 57.0009.0607 GTH 4016 R - GTH 4018 R - GTH-5021 R...
  • Page 150: Test

    May 2015 Second Edition - First Printing Test Overload Test Procedure Telehandler coupled to attachments with fixed centre of load (Forks, Bucket, Clamps): 1,33 x Q Q = Nominal Rated Load Capacity Telehandler coupled to attachments with oscillating centre of load (Hook, Jib, Hoist): 1,33 x Q + 0,1 x Fb on tires 1,25 x Q + 0,1 x Fb on outriggers Q = Nominal Rated Load Capacity...
  • Page 151: Ec Declaration Of Conformity

    May 2015 EC Declaration Of Conformity Contents of EC Declaration of Conformity TEREX Global GmbH hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive. The machinery described below is suitable for Genie telehandlers, models specified in the user manual.
  • Page 152 www.genielift.com...

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