Terex Genie GTH4016 SR User manual

Operator's Manual
Radio Remote Control
GTH4016 SR
GTH4018 SR
GTH5021 R
Serial number range
Original Instructions
First Edition
Second Printing
Part. No. 57.0303.5116
With Maintenance
Information
From serial n.: 17857
From serial n.: 17888
From serial n.: GTH 5021R14B-101

Operator's Manual
2 RADIO REMOTE CONTROL Cod. 57.0303.5116
First Edition - Second Printing
Contents
Introduction...........................................Pag. 3
Symbols Used On The Remote ControlPag. 5
Safety Precaution .................................Pag. 7
Radio Remote Control Description.......Pag. 15
Inspections ...........................................Pag. 17
Operating Instructions ..........................Pag. 21
Maintenance.........................................Pag. 27
Copyright © 2014 by Terex Corporation
First Edition: Second Printing, December 2014
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.
TEREX Global GmbH
Bleicheplatz 2
8200 Schaffhausen
Switzerland
Technical Assistance Service
Telephone: [phone]
[phone]
e-mail: [email protected]

First Edition - Second Printing Operator's Manual
Cod. 57.0303.5116 RADIO REMOTE CONTROL 3
Introduction
Symbols
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
Red: indicates a hazardous
situation which, if not avoided,
will result in death or serious
injury.
WARNING
Orange: indicates a hazardous
situation which, if not avoided,
could result in death or serious
injury.
CAUTION
Yellow : indicates a hazardous
situation which, if not avoided,
could result in minor or
moderate injury.
NOTICE
Blue: indicates a hazardous
situation which, if not avoided,
could result in property
damage.
PROTECT THE
ENVIRONMENT
Green: used to draw the
attention to important
information on environment
protection.
INTRODUCTION
This document is a quick guide for using the radio
remote control in conjunction with the TEREX
GLOBAL GmbH telehandlers. The operators must
read all the manuals supplied since these instructions
are an integral part of the original manual provided
by the radio remote control manufacturer.
RADIO FREQUENCIES
The radio frequencies programmed in the radio
remote control are among those admitted by the
European regulations in force when the control is
put on the market.
NOTICE
It should be remembered that in some countries
the use and possession of a radio remote control
is regulated by specific rules. There may also
be some national limitations for the use of the
frequencies. Before using the radio remote
control, verify if its operating frequency band is
permitted by the national radiocommunication
laws. The radio remote control dealt with in this
manual uses frequencies of 434 MHz.

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First Edition - Second Printing Operator's Manual
Cod. 57.0303.5116 RADIO REMOTE CONTROL 5
Symbols Used On The Radio Remote Control
Boom Extension Boom Retraction
Forks Forwards
Tilting
Forks Backwards
Tilting Boom Lifting
Boom Lowering
Winch Rope
Lowering/Lifting
Winch Rope
Lowering
Winch Rope
Lifting
Clockwise
Turret Rotation
Counter Clockwise
Turret Rotation Attachment Unlock Attachment Lock Hare Position Tortoise Position
Battery
Radio Remote
Control Start and
Horn

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First Edition - Second Printing Operator's Manual
Cod. 57.0303.5116 RADIO REMOTE CONTROL 7
Safety Precaution
DAMAGED MACHINE HAZARDS
• Do not use a damaged or defective radio remote
control.
• Do a thorough pre-operation inspection of the
radio remote control and test all functions before
each work shift. Tag and remove from service a
damaged or defective radio remote control.
• Make sure that all maintenance jobs have been
carried out as specified in this manual and in the
telehandler's specific manuals.
• Make sure that all plates are in place and legible.
• Make sure that the operator’s manual is intact,
legible and placed in the special container located
in the machine.
PERSONAL INJURY HAZARDS
• Do not operate the telehandler in case of hydraulic
oil or air leak. Air or hydraulic oil leaks can
penetrate or burn the skin.
• Always operate the telehandler 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
telehandler. 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" of the telehandler Operator's
Manual.
MOMENT LIMITING SYSTEM
The moment limiting system has been developed
to help the operator to maintain the telehandler
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.

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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 telehandler.
NOTICE
If you recognise hazardous situations, you can
prevent accidents!
DANGER
The instructions given in this handbook are the
ones establishedby TEREXGLOBAL GmbH. They
do not exclude other safe and most convenient
ways for the telehandler and/or the radio remote
control installation, operation and maintenance
that take into account the 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
telehandler and/or the radio remote control,
directly or indirectly, or make it unsafe;
• contact TEREX GLOBAL GmbH 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.
DANGER
It is forbidden to use the radio remote control
with an aerial work platform.
Safety Precautions

First Edition - Second Printing Operator's Manual
Cod. 57.0303.5116 RADIO REMOTE CONTROL 9
REQUISITES OF THE PERSONNEL IN CHARGE
Requisites of the TELEHANDLER OPERATORS
The operators who use the telehandler and/or the
equipment, regularly or occasionally, 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. They shall be
skilled and trained about the telehandler and/or the
equipment use.
NOTICE
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.
Requisites of the SERVICEMEN
The personnel charged with the telehandler and
the equipment maintenance shall be qualified,
specialized in their maintenance, 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 telehandler and/or the radio
remote control is not a complex intervention and
can be carried out by the operator too, provided
he has a basic knowledge of mechanics.
Safety Precautions

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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.
• Ear-protectors or equivalent equipment.
• 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 telehandler dimensions in the different
configurations.
DANGER
The telehandler 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
telehandler until energized power lines are shut
off.
DANGER
Do not, at any time, use the machine during a
storm.
WARNING
Operator have to survey his/her field of vision
when operating the telehandler.
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).
• Goggles or facial masks.
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
Safety Precautions