Terex Genie GTH4016 SR User manual

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

Copyright © 2015 by Terex Corporation
Second Edition: First Printing, May 2015
Genie is a registered trademark of Terex South
Dakota, Inc. in the U.S.A. and many other
countries. “GTH” is a trademark of Terex South
Dakota, Inc.
May 2015
GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607
Second Edition - First Printing
TEREX Global GmbH
Bleicheplatz 2
8200 Schaffhausen
Switzerland
Technical Assistance Service
Telephone: [phone]
[phone]
e-mail: [email protected]
Contents
Introduction.......................................................... 1
Symbol and Hazard Pictorials Definitions............ 5
General Safety..................................................... 7
Work Area Safety ............................................... 15
Safety Precautions ............................................ 23
Legend............................................................... 26
Controls ............................................................. 28
Inspections ........................................................ 36
Operating Instructions ....................................... 54
Parking and Storage.......................................... 74
Transport and Lifting Instructions ...................... 76
Maintenance...................................................... 81
Attachments....................................................... 91
Specifications .................................................. 100
Load Charts..................................................... 103
Test.................................................................. 148
EC Declaration of Conformity.......................... 149

May 2015Second Edition - First Printing
Part No. 57.0009.0607 GTH-4016 R - 4018 R - 5021 R 1
Introduction
About This Manual
Genie appreciates your choice of our machine for
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.
This manual should be considered a permanent part
of your machine and should remain with the machine
at all times. If you have any questions, contact Genie.
For Options Manuals (if equipped):
• Key Pad Unlocking Device
(Option part number 58.2513.1089)
• Radio Remote Control
(Option part number 58.2513.1038)
• Radio Mp3
(Option part number 58.2513.1093)
PLS visit our webpage at
www.genielift.com/en/service-support/manuals
Product Identification
The machine serial number is located on the serial
label.
Intended Use
A slewing variable reach rough terrain forklift truck
is defined as a wheeled type truck with a slewing
upper structure which can rotate more than 5° left/
right, a pivoting boom, which may be equipped with
various attachments for picking, transporting and
placing loads with the established load range charts.
In standard configuration the machine rotates 200°
left and 200° right; the 360° continuous rotation is
optional.
Use of this product in any other way is prohibited
and contrary to its intended use.
Serial number stamp
Serial label
Homologation
label
(if required)
GTH 4016 R - GTH 4018 R
Serial number stamp
Serial label Homologation label
(if required)
GTH 5021 R

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2 GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607
Second Edition - First Printing
Contacting the Manufacturer
At times it may be necessary to contact Genie.
When you do, be ready to supply the model number
and serial number of your machine, along with your
name and contact information. At minimum, Genie
should be contacted for:
• Accident reporting
• Questions regarding product applications and
safety
• Standards and regulatory compliance information
• Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that applies
to your machine.
Please register your machine by visiting us on the
web at www.genielift.co.uk.
Introduction
Bulletin Distribution and
Compliance
Safety of product users is of paramount importance
to Genie. Various bulletins are used by Genie
to communicate important safety and product
information to dealers and machine owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most current
owner on record along with their associated dealer,
so it is important to register your machine and keep
your contact information up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.

May 2015Second Edition - First Printing
Part No. 57.0009.0607 GTH-4016 R - 4018 R - 5021 R 3
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.
1.Avoid hazardous situations.
Know and understand the safety rules
before going on to the next section.
2. Always perform a pre-operation inspection.
3. Always perform function tests prior to use.
4. Inspect the workplace.
5. Only use the machine as it was intended.
You 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.
You read, understand and obey the employer’s
safety rules and work-site regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

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4 GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607
Second Edition - First Printing
Hazard Classification
Safety alert symbol - used to
alert you to potential personal
injury hazards. Obey all safety
messages that follow this
symbol to avoid possible injury
or death
DANGER
Indicates a hazardous situation
which, if not avoided, will result
in death or serious injury.
WARNING
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
CAUTION
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
NOTICE
Indicates a property damage
message.
Introduction
Standards
The following standards and/or regulations apply to
this machine (only for STAGE 3B machine):
Directive
2006/42/EC Machinery Directive
2008/104/EC Electromagnetic compatibility
2000/14/CE Environment Acoustic Emissions
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.

May 2015Second Edition - First Printing
Part No. 57.0009.0607 GTH-4016 R - 4018 R - 5021 R 5
Maintain required
clearance.
Read the operator's
manual.
Burn Hazard
Explosion/burn
hazard
No smoking.
No open flame.
Allow surfaces to
cool.
Crush Hazard Keep clear of
moving parts.
Electrocution
hazard
Never exceed rated
lift capacity
Tip-over hazard
Always wear seat
belt.
Keep load low
during travel
Crush hazard.
Crush hazard.
Only use an
approved work
platform
Crush hazard Keep away from
moving parts
Burn hazard. Do not loosen cap
until cool.
Keep away from
moving parts.
No smoking. No
open flame.
Tip-over hazard
Keep away from
slewing upper
structure.
Symbol and Hazard Pictorials Definitions
Explosion hazard
Do not use
starting aids
No people under
load
Apply maintenance
collar
Crush hazard.
Crush hazard
Explosion/burn
hazard
Fall hazard
Do not level the
machine with an
elevated boom
Crush hazard. Keep away from
outriggers.
Crush hazard.
Entanglement
hazard. Keep clear from
moving belt.
Tip-over hazard
Explosion hazard Do not use.
P
max
: 7,9 kg/cm
2
Max Pressure on
ground

May 2015
6 GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607
Second Edition - First Printing
Symbol and Hazard Pictorials Definitions
No people under
load
Only trained
maintenance
personell
should access
compartments
Boom
Resequencing

May 2015Second Edition - First Printing
Part No. 57.0009.0607 GTH-4016 R - 4018 R - 5021 R 7
General Safety
GTH 4016 R - 4018 R Stage 3A
09.4618.0924
09.4618.0924
09.4618.0922
09.4618.0922
09.4618.0920
09.4618.0920
215646
237726
09.4618.0923
09.4618.0923
09.4618.0986
09.4618.0986
09.4618.0923
237726
09.4618.0986
09.4618.1120
09.4618.1674
09.4618.0924
09.4618.0920 09.4618.0923
215646
09.4618.0923
09.4618.1713
09.4618.1458
09.4618.0922
09.4618.1120
09.4618.1120
09.4618.1674
09.4618.1674
09.4618.1946
09.4618.1946
09.4618.1946
Pmax: 7,9 kg/cm2
09.4618.1946
09.4618.1673 09.4618.1673
215646 237720

May 2015
8 GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607
Second Edition - First Printing
General Safety
GTH 4016 R - 4018 R Stage 3A
09.4618.1423
0°
09.4618.1679
09.4618.1679
09.4618.1423
215645237721 237720
215646
09.4618.1458
09.4618.1458
215648 A
215648
09.4618.1375
09.4618.1375
09.4618.1120
09.4618.1120
09.4618.1386
OK
09.4618.1386
09.4618.1673
09.4618.1458
09.4618.1946
09.4618.1673 215646
215645
09.4618.1673
09.4618.1946
215646
237720
09.4618.1120
09.4618.1423
09.4618.1423
09.4618.1679
09.4618.1386 (only for GTH4016 R)
215648
09.4618.1375
215646
237720
237721
09.4618.1673
09.4618.1946
09.4618.1946
Pmax: 7,9 kg/cm2

May 2015Second Edition - First Printing
Part No. 57.0009.0607 GTH-4016 R - 4018 R - 5021 R 9
General Safety
GTH 4016 R - 4018 R Stage 3B
09.4618.0924
09.4618.0924
09.4618.0922
09.4618.0922
09.4618.0920
09.4618.0920
215646
237726
09.4618.0923
09.4618.0923
09.4618.0986
09.4618.0986
237726 09.4618.0986
09.4618.1120
09.4618.0924
09.4618.0920 215646
09.4618.0923
09.4618.1713
09.4618.1458
09.4618.0922
09.4618.1674
09.4618.1946
09.4618.1673
09.4618.1673
09.4618.1946
09.4618.1673
09.4618.1673
09.4618.1120
09.4618.1120
09.4618.1674
09.4618.1674
09.4618.1713
09.4618.1713
09.4618.1946
Pmax: 7,9 kg/cm2
09.4618.1946

May 2015
10 GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607
Second Edition - First Printing
General Safety
GTH 4016 R - 4018 R Stage 3B
09.4618.1423
0°
09.4618.1679
09.4618.1679
09.4618.1423
215645
237721
237720 215646
09.4618.1458
09.4618.1458
215648 A
215648
09.4618.1375
09.4618.1375
09.4618.1120
09.4618.1120
09.4618.1386
OK
09.4618.1386
09.4618.1458
09.4618.1946
09.4618.1673 215646 215645
09.4618.1673
09.4618.1946
215646
237720
09.4618.1120
09.4618.1423
09.4618.1423
09.4618.1679
09.4618.1386 (only for GTH4016 R)
215648
09.4618.1375
215646
237720
237721
09.4618.1673
09.4618.1673

May 2015Second Edition - First Printing
Part No. 57.0009.0607 GTH-4016 R - 4018 R - 5021 R 11
General Safety
09.4618.1674 09.4618.0922
09.4618.1120
09.4618.1120 09.4618.1674
09.4618.0920
09.4618.0920
215646
237726
09.4618.1675
Pmax: 11 kg/cm2
09.4618.1675
09.4618.1673
09.4618.1673
09.4618.0922
09.4618.0923
09.4618.0923
09.4618.1120
09.4618.1674
09.4618.0920
237726
09.4618.1675 09.4618.1673
09.4618.0922
09.4618.0924
09.4618.0924
09.4618.1458
09.4618.1458
09.4618.0924
09.4618.1458
09.4618.0923
09.4618.1675
09.4618.1673
09.4618.0986
09.4618.0986
09.4618.0986
09.4618.1713
09.4618.1713
09.4618.1713
GTH 5021 R Stage 3A

May 2015
12 GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607
Second Edition - First Printing
General Safety
09.4618.1423
0°
09.4618.1679
09.4618.1375
215648 A
09.4618.0923
09.4618.1679
09.4618.1423
215645
09.4618.1375 215648 237721 237720 215646
09.4618.1673
09.4618.1675
09.4618.1673
09.4618.1675
09.4618.1375
215648
237720
215646
215645
215646
09.4618.1120 09.4618.1423
09.4618.1679
237721
GTH 5021 R Stage 3A

May 2015Second Edition - First Printing
Part No. 57.0009.0607 GTH-4016 R - 4018 R - 5021 R 13
General Safety
09.4618.1674 09.4618.0922
09.4618.1120
09.4618.1120 09.4618.1674
09.4618.0920
09.4618.0920
215646
237726
09.4618.1675
Pmax: 11 kg/cm2
09.4618.1675
09.4618.1673
09.4618.1673
09.4618.0922
09.4618.0923
09.4618.0923
09.4618.1120
09.4618.1674
09.4618.0920
237726
09.4618.1675 09.4618.1673
09.4618.0922
09.4618.0923
09.4618.0924
09.4618.0924
09.4618.1458
09.4618.1458
09.4618.0924
09.4618.1458
09.4618.0923
09.4618.1675
09.4618.1673
09.4618.0986
09.4618.0986
09.4618.0986
09.4618.1713
09.4618.1713
09.4618.1713
GTH 5021 R Stage 3B

May 2015
14 GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607
Second Edition - First Printing
General Safety
09.4618.1423
0°
09.4618.1679
09.4618.1375
215648 A
09.4618.1679
09.4618.1423
215645
09.4618.1375 215648 237721 237720 215646
09.4618.1673
09.4618.1675
09.4618.1673
09.4618.1675
09.4618.1375
215648
237720
215646
215645
215646
09.4618.1120 09.4618.1423
09.4618.1679
237721
GTH 5021 R Stage 3B

May 2015Second Edition - First Printing
Part No. 57.0009.0607 GTH-4016 R - 4018 R - 5021 R 15
Work Area Safety
Overturning Hazards
Using the load chart, confirm that
the load is within the rated capacity
of the machine. Do not exceed the
rated load.
The load center of the fork (if equipped) must be
equal to or less than the load center indicated on
the load chart.
All loads shown on the load chart are based on
the machine being on firm ground, the frame being
level, the forks being positioned evenly on the
carriage, the load being centered on the forks, the
tires being properly sized and properly inflated, and
the telehandler being in good operating condition.
If using accessories, read, understand and obey the
decals, instructions and manuals with the accessory.
Do not raise the load unless the ground can support
all forces imposed by the machine.
Do not lower a load without retracting the boom first.
Do not use attachments which are not approved by
Genie
Do not operate the machine if the load chart is missing.
Do not exceed the rated capacity for each
configuration.
Do not raise the boom unless the
machine is level. The machine level
indicator should be at zero degrees.
Do not level the machine using the frame levelling
control unless the boom angle indicator is at zero
degrees or less.
Do not work with the load limiting system cut out.
Do not use the levelling control to position
an elevated load.
Do not raise a load and then drive to
position it.
When driving, keep the boom at
or below horizontal and keep the
load close to the ground.
Operate the machine at speeds that will keep the
load under control. Start and stop movements
smoothly.
Do not raise a load unless the load
is properly positioned or secured on
the forks or approved attachment.
Do not operate the machine in strong or gusty winds.
Do not increase the surface area of the carriage or
load. Increasing the area exposed to the wind will
decrease machine stability.
Use extreme care and slow speeds while driving the
machine in the travel position across uneven terrain,
debris, unstable or slippery surfaces and near holes
and drop-offs.
Do not alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to machine stability with
items of different weight or specification.
Do not replace factory-installed tires with tires of
different specification or ply rating.
Lateral inclination allowed during working
phase ± 0,5°

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16 GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607
Second Edition - First Printing
Work Area Safety
Only use the machine on firm ground capable of
supporting the maximum combined load of the
machine and payload. If the subsoil collapses,
the machine could tip over. To avoid any risk of
overturning, the following precautions should be
taken:
• 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.
• Site ground consistency can be roughly estimated
using the tables and picture in this page.
• The resistance of the subsoil is in relation to the
ground type and soil characteristics.
Table 1 indicates the superficial pressure which may
be allowed under the outriggers of the machine.
Type of ground,
soil characteristics
Allowable
superficial pressure
KPa2
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 200
rippable
soil
solid 100
semi-
solid 200
hard 400
Rocks, concrete, heavy
traffic paved roads above 1000
Table 1
Make sure the machine (wheels and outriggers)
rests on a firm ground to prevent hazardous unstable
conditions. If the ground is not firm enough, position
some support planks, capable of withstanding the
expected loads, under the outriggers or the wheels.
When working near trenches, lower the outriggers
at a safe distance from the trench edge.
a& h= minimum distances
The distance (a) from the foot of the overhang
shall be adequate to height (h) of the same over-
hang.
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

May 2015Second Edition - First Printing
Part No. 57.0009.0607 GTH-4016 R - 4018 R - 5021 R 17
Operators must assess the job site variables and
avoid exceeding the machine's (or operator's)
capabilities for terrain and conditions.
Fall Hazards
Always wear a seat belt when
operating the machine.
Always remain completely inside the cab when
operating the machine.
When getting in and out of the cab, face the machine,
use the steps and handrails provided and always
maintain three-point contact.
Do not use the steering wheel or any other controls
as handrails.
Do not allow riders on the machine
or forks.
Do not transport or lift personnel with
this machine unless it is equipped
with an approved work platform.
Traveling on Slopes Hazards
When driving, keep the boom at
or below horizontal and keep the
load close to the ground.
When the machine is unloaded, travel with the forks
or attachment downhill.
When the machine is loaded and on transfer mode
(boom fully lowered and retracted):
• max inclination driving downhill 9°
• max inclination driving uphill 20°
• max lateral inclination ± 5°
On steep terrain, drive only up and down a hill, and
always keep the machine in gear. Do not turn across
the slope when the machine is traveling up or down
a slope.
Limit travel path and speed according to the condition
of the ground surface, traction, slope, location of
personnel and any other factors which may create
a hazard. Never drive the machine unless the mast
and equipment are in their proper travel position.
Whether a machine will tip over during dynamic
machine operation involves many factors that need
to be considered. Among these are pavement/ground
conditions, stability and slope, as well as machine
equipment, operator skill, load position, tire inflation,
machine speed, etc.
Additionally, tip-over of a machine is dependent in
large part upon operator inputs such as the speed
and smoothness of the operation, as well as the
position of the attachment and its load.
Construction sites and roads will frequently change
slope from place to place, can be hard and soft, and
change due to construction activities and weather.
Operators should be properly trained and use their
best judgment and experience to take the necessary
precautions to prevent a tip-over.
Work Area Safety

May 2015
18 GTH-4016 R - 4018 R - 5021 R Part No. 57.0009.0607
Second Edition - First Printing
Work Area Safety
Collision Hazards
Do not put the transmission into gear unless the
parking brake is set.
Do not drive the machine if visibility is obstructed.
Do not raise the boom unless the parking brake is set.
Do not operate in conditions without fenders to protect
debris from hitting the operator or accumulating on
the cab windows.
Do not operate the machine with a faulty back-up
alarm. The back-up alarm should sound when the
machine is in reverse.
Do not operate the machine in low light conditions.
Operators must comply with employer, job site
and governmental rules regarding use of personal
protective equipment.
Do not drive the machine directly up to anyone.
If a radio and/or mp3 player is equipped, keep the
volume low enough to hear surrounding environment
(i.e. traffic, alarms, people etc.).
Do not adjust the controls while driving or manoeuvring
a load.
Be aware of boom position and tail swing, in proximity
with people and objects, when slewing the turret.
Do not drive when the slewing upper structure is
rotated without first verifying travel machine direction.
Do not drive the machine unless the outriggers are
fully retracted.
Do not realign the wheels while driving. Always realign
wheels before changing steering modes. Refer to
the Steer Select operating instructions.
Falling Object Hazards
Operate the machine at speeds that will keep the
load under control. Start and stop movements
smoothly.
Keep people, equipment and
material out of the work area.
Do not operate the machine
while people are under or near
an elevated boom, whether it is
loaded or unloaded.
Be sure the load is secure before lifting it.