Genie GTH-5021 R Rough Terrain Forklift Operator’s Manual

Operator’s Manual
Serial number range
GTH-5021 R
From serial n.: GTH5021R14-101
Stage 3A
Stage 3B
Original Instructions
First Edition
Second Printing
Part No. 57.0009.0607
December 2014
First Edition - Second Printing
Contents
Introduction .......................................................... 1
Symbol and Hazard Pictorials Definitions............ 5
General Safety..................................................... 6
Work Area Safety ............................................... 10
Safety Precautions ............................................ 18
Legend............................................................... 21
Controls ............................................................. 22
Inspections ........................................................ 30
Operating Instructions ....................................... 42
Parking and Storage .......................................... 62
Transport and Lifting Instructions ...................... 64
Maintenance ...................................................... 67
Attachments....................................................... 76
Specifications .................................................... 84
Load Charts ....................................................... 85
Test.................................................................... 92
EC Declaration of Conformity ............................ 93
TEREX Global GmbH
Copyright © 2014 by Terex Corporation
Muhlenstrasse 26
8200 Schaffhausen
Switzerland
First Edition: Second Printing, December 2014
Technical Assistance Service
Telephone: +39 075 9418129
+39 075 9418175
e-mail: [email protected]
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.
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Introduction
About This Manual
Product Identification
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.
The machine serial number is located on the serial
label.
Serial number stamp
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
Homologation
label
(if required)
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.
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December 2014
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Introduction
Bulletin Distribution and
Compliance
Contacting the Manufacturer
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.
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.
2
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Part No. 57.0009.0607
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December 2014
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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Introduction
Hazard Classification
Standards
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
NOTICE
4
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
The following standards and/or regulations apply to
this 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.
Indicates a property damage
message.
GTH-5021 R
Part No. 57.0009.0607
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Symbol and Hazard Pictorials Definitions
Tip-over hazard
Maintain required Crush hazard.
clearance.
No people under
load
Read the operator's
manual.
Crush hazard.
Apply maintenance
collar
Always wear seat
belt.
Crush hazard
Crush hazard.
Keep away from
moving parts.
Crush Hazard
Keep clear of
moving parts.
Burn hazard.
Do not loosen cap
until cool.
Explosion/burn
hazard
No smoking.
No open flame.
Burn Hazard
Allow surfaces to
cool.
Crush hazard
Keep away from
moving parts
Allow engine
compartment
access
Explosion/burn
hazard
No smoking. No
open flame.
Fall hazard
Keep load low
Do not use
starting aids
Explosion hazard Tip-over hazard
Keep away from
outriggers.
Crush hazard.
Keep clear from
moving belt.
Electrocution
hazard
Levelling
operation
Crush hazard.
Part No. 57.0009.0607
Crush hazard.
GTH-5021 R
Keep away from
slewing upper
structure.
Work platform use Refer to load charts
and manual
Tip-over hazard
Explosion hazard Do not use.
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Work Area Safety
Overturning Hazards
Do not use the levelling control to position
an elevated load.
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.
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.
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 operate the machine if the load chart is missing.
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.
Do not exceed the rated capacity for each
configuration.
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 raise the boom unless the
machine is level. The machine level
indicator should be at zero degrees.
Do not alter or disable machine components that in
any way affect safety and stability.
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.
10
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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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.
• A rough estimate of the ground consistency can
be done using the tables and picture in this page.
• The resistance of the subsoil is in relation
to the ground type and geomorphological
characteristics.
Table 1 indicates the superficial pressure which is
allowed under the outriggers of the machine.
Type of ground,
geomorphological
features
Allowable
superficial pressure
loose, non-compact soil
generally speaking,
not solid;
special precautions
needed
loamy, peaty,pasty soil
rippable, soft ground
non-cohesive, well compact soil, sand, gravel
rippable
soil
kg/cm2
N/mm2
2.0
0.2
solid
1.0
0.1
semisolid
2.0
0.2
hard
4.0
0.4
above
10.0
above
1.0
Rocks, concrete, heavy
traffic paved roads
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.
In presence of 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 overhang.
If the ground fulfils the required conditions:
a:h=1:1
(values with a grey background in table 1)
In the case of doubts:
a:h=2:1
Table 1
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Work Area Safety
Traveling on Slopes Hazards
When driving, keep the boom at
or below horizontal and keep the
load close to the ground.
Operators must assess the job site variables and
avoid exceeding the machine's (or operator's)
capabilities for terrain and conditions.
Fall Hazards
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.
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.
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.
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Work Area Safety
Collision Hazards
Falling Object Hazards
Do not put the transmission into gear unless the
parking brake is set.
Operate the machine at speeds that will keep the
load under control. Start and stop movements
smoothly.
Do not drive the machine if visibility is obstructed.
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.
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.
Be sure the load is secure before lifting it.
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.
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Work Area Safety
Bodily Injury Hazards
Damaged Machine Hazards
Always adjust the seat and fasten
the seat belt before starting the
engine.
Do not operate the machine with a
hydraulic oil or air leak.
An air leak or hydraulic leak can
penetrate and/or burn skin.
Relieve pressure before
disconnecting hydraulic lines.
Keep away from leaks and pin
holes. Use a piece of cardboard or
paper to search for leaks. Do not
use your hand.
Fluid injected into skin must be surgically removed
within a few hours by a doctor familiar with this type
of injury or gangrene will result.
Stay clear of belts and fans when the
engine is running.
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work shift.
Immediately tag and remove from service a damaged
or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the appropriate Genie
service manual.
Be sure all decals are in place and legible.
Be sure the operator's and safety manuals are
complete, legible and in the storage container located
in the cab.
Do not attempt to start the machine by towing or
pushing.
Do not attempt to use the forks or attachments for
prying wedged or frozen loads free.
Do not push or pull objects or loads with the forks,
attachment or boom.
Always operate the machine in a well-ventilated
area to avoid carbon monoxide poisoning.
Improper contact with components under any cover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access by
the operator is only advised when performing a preoperation inspection. All compartments must remain
closed and secured during operation.
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Work Area Safety
Component Damage Hazards
Burn Hazards
Do not use any battery or charger greater than 12V
to jump-start the engine.
Allow hot surfaces to cool before
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.
Do not lock the axle differential when the machine
is moving.
Crush Hazards
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleum gas (LPG), gasoline, diesel fuel or other
explosive substances.
Do not refuel the machine with the engine running.
Do not operate the outriggers while people are in the
path of movement.
Refuel the machine and charge
the battery only in an open,
well-ventilated area away from
sparks, flames and lighted
tobacco.
Keep clear of moving parts during machine operation.
Set the parking brake, put the transmission in neutral
and lower the carriage or the attachment to the ground
before leaving the machine.
Keep clear of elevated components.
Do not operate the machine in hazardous locations
or locations where potentially flammable or explosive
gases or particles may be present.
Support components before performing service. Keep
clear of moving parts during machine operation.
Do not spray ether into engines equipped with glow
plugs or air intake grid heaters.
Do not operate the slewing function while people are
in the path of movement.
Do not use air or oxygen for charging the accumulators.
Do not operate the outrigger, transmission, chassis
levelling or steering controls when the slewing upper
structure is rotated over 90° from center, without first
verifying the direction of movement according to the
operating instructions. All movements are reversed
when the slewing upper structure is rotated beyond
90° from center.
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Work Area Safety
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Obey all local and governmental
regulations regarding required
clearance from electrical power
lines. At a minimum, the
required clearance contained in
the chart below must be
followed.
Do not use the machine as a ground for welding.
Always contact the electrical power line owner. The
electrical power shall be disconnected or the power
lines moved or insulated before machine
operations begin.
Allow for boom movement, electrical line levelling or
sag, and beware of strong or gusty winds.
Keep away from the machine if it contacts
energized power lines. Personnel on the ground or
in the cab must not touch or operate the
machine until energized power lines are shut off.
Do not operate the machine during lightning or
storms.
Line Voltage
Required
Clearance
0 to 50kV
10 ft
3.05 m
>50 to 200kV
15 ft
4.06 m
>200 to 350kV
20 ft
6.10 m
>350 to 500kV
25 ft
7.62 m
>500 to 750kV
35 ft
10.67 m
>750 to 1000kV
45 ft
13.72 m
over 1000kV
see below
For power lines over 1000kV, the minimum
clearance distance must be established by the
utility owner or operator or by a registered
professional engineer who is a qualified person
with respect to electrical power transmission and
distribution.
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Work Area Safety
Battery Safety
Electrocution Hazard
Burn Hazards
Batteries contain acid.
Always wear protective
clothing and eye wear when
working with batteries.
Avoid contact with electrical terminal.
Avoid spilling or contacting
battery acid. Neutralize
battery acid spills with baking
soda and water.
During maintenance or repair works, and while
welding, disconnect the battery by turning the cut-out
switch (see Inspection for Decals section).
Using the Charger (if equipped), be sure the device
works at 12 Volt and doesn't exceed 15 Ampere.
Explosion Hazards
Keep sparks, flames and
lighted tobacco away from
batteries. Batteries emit
explosive gas.
Employer's Responsibilities
Employers are responsible for providing a safe
work environment and for complying with local and
national governmental regulations.
Personal Safety
Be sure that everyone working on or near this machine
is familiar with the applicable safety precautions.
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Safety Precautions
Requisites Of The Machine
Operators
Requisites of the servicemen
The operators who use the machine regularly or
occasionally (i.e. for transport reasons) shall have
the following prerequisites:
health:
before and during any operation, operators shall
never take alcoholic beverages, medicines or other
substances that may alter their psycho-physical
conditions and, consequently, their working abilities.
physical:
good eyesight, acute hearing, good co-ordination
and ability to carry out all required operations in
a safe way, according to the instructions of this
manual.
mental:
ability to understand and apply the enforced rules,
regulations and safety precautions. They shall be
careful and sensible for their own as well as for the
others’ safety and shall desire to carry out the work
correctly and in a responsible way.
emotional:
they shall keep calm and always be able to evaluate
their own physical and mental conditions.
training:
they shall read and be familiar with this handbook,
its enclosed graphs and diagrams, the identification
and hazard warning plates. They shall be skilled and
trained about the machine use.
The personnel charged with the machine maintenance
shall be qualified, specialised in the maintenance
of telehandlers, and shall have the following
prerequisites:
physical:
good eyesight, acute hearing, good co-ordination
and ability to carry out all required maintenance
operations in a safe way, according to this manual.
mental:
ability to understand and apply the enforced rules,
regulations and safety precautions. They shall be
careful and sensible for their own as well as for the
others’ safety and shall desire to carry out the work
correctly and in a responsible way.
training:
they shall read and be familiar with this handbook,
its enclosed graphs and diagrams, the identification
and warning plates. They shall be skilled and trained
about the machine functioning.
From a technical point of view, the ordinary
maintenance of the machine is not a complex
intervention and can be carried out by the machine
operator, too, provided he has a basic knowledge
of mechanics.
The operator shall have a licence (or a driving
licence) when provided for by the laws enforced in
the country where the machine works. Please, ask
the competent bodies. In Italy the operator must be
at least 18 year old.
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Safety Precautions
Working clothes
Personal protective equipment
During work, but especially when maintaining or
repairing the machine, operators must wear suitable
protective clothing:
•
•
•
•
Overalls or any other comfortable garments.
Operators should not wear clothes with large
sleeves or objects that can get stuck in moving
parts of the machine.
Protective helmet.
Protective gloves.
Working shoes.
Under special working conditions, the following
personal protective equipment should be used:
•
•
•
Breathing set (or dust mask).
Ear-protectors or equivalent equipment.
Goggles or facial masks.
Use only type-approved working clothing in good
condition.
Part No. 57.0009.0607
GTH-5021 R
19
December 2014
First Edition - Second Printing
Safety Precautions
Control Indicators and
Interlocks
Several control indicators and interlocks have been
fitted to the machine. They must never be tampered
with or removed.
Always perform a function test to check the proper
operation of these devices.
Never operate a machine that is malfunctioning. If
the machine starts to malfunction, immediately stop
using it and have it repaired.
Load Limiting system
The Load Limiting System has been developed to
help the operator to maintain the machine longitudinal
stability. Audible and visual messages are provided
when the limits of longitudinal stability are being
approached.
However this device cannot replace the experience
of the operator. It is up to the user to adopt the
necessary safety measures to work within the rated
limits of the machine.
The Load Limiting System is designed to function
only:
when the truck is static;
• when the truck is on consolidated, stable and
level ground;
• when the truck is performing loading or placing
functions;
• when the Load Limiting System is activated (not
overridden).
The Load Limiting System will only warn the operator
in the event of inadequate stability in the longitudinal
plane in the forward direction.
The Load Limiting System is not intended for warning
of the risk of overturning in the case of:
• a sudden overload;
• travelling with the load in the elevated position;
• travelling on rough terrain or on grounds with
obstacles and holes;
• travelling across a slope or turning on a slope;
• driving in bends too fast or too sharp;
Adjustments affecting the setting of the Load Limiting
System shall be performed only by authorised
personnel.
20
Seat Interlock
This micro switch is located inside the seat cushion,
and it prevents any machine transmission movements
if the operator is not correctly seated in the driving seat.
Emergency Stop Push-button
This device have to be used to stop the machine
during an emergency situation.
By pressing this button, the engine shuts down while
the Load Limiting System stays active.
Before restarting the machine, it is necessary to reset
the push-button by rotating it clockwise.
Enabling Function Switch on Joystick
The joystick is equipped with an enabling function
switch. This red finger switch must be held pressed
down until the joystick functions have been completed;
if it is released, the manoeuvre stops.
Sensors on Outriggers
Each outrigger is equipped with one sensor and one
load pin:
• Magnetic micro with target: it tells the load limiting
system when the outrigger is fully lowered, cutting
out the transmission;
• Load pin: it tells when the outrigger reaches the
ground recording the pressure of the machine
weight on the ground.
The load limiting system changes configuration from
“NOT STABILIZED” to “ STABILIZED” only when
both conditions occur.
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Legend
1
13
15
3
2
4
14
18
5
6
9
12
17
10
16
16
7
8
11
1. Left/right level indicator
2. Operator’s manual storage
(door internal side)
10. Forks
11. Seat belt
12. Outriggers pads (if equipped)
3.
4.
5.
6.
13. Front/rear level indicator
14. Right rear view mirror
15. Left rear view mirror
16. Outriggers
Right control handle
Rear fish eye mirror
Boom angle indicator
Maintenance collar (on
opposite side of machine)
7. Fuel filler
17. Main valve housing
18. Slewing upper structure locking
8. Hydraulic oil level gauge
9. Engine (on opposite side of
machine)
Part No. 57.0009.0607
pin
GTH-5021 R
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December 2014
First Edition - Second Printing
Controls
31 22
1
29
2
4
6
36 16 17
ESC
55%
+
-
7
FORCHE
STAB. FRONTALE
PESO SOLL. ...................... 50.3t
CARICO MAX .................... 10.2t
RAGGIO ............................ 12.3m
ENTER
9
27
13
5
20
P
25
28
26
19
24
33
21
23
30
8
32
15
10
34
14
12
18
11
3
22
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Controls
Control Panel
1. Steering wheel
19. Job-site/road/platform selector
2. Transmission control lever - Horn button
20. A/C switch (if equipped)
3. Seat controls
21. Cab heater fan switch
4. Turn signal - Windshield washer/wiper - High
beams
22. Auxiliary hydraulic circuit switch (if equipped)
5. Steer select switch
6. Load limiting disable selector
7. Load limiting indicator
8. Emergency stop push-button
9. Instruments panel
10. Parking brake switch
11. Right control handle
12. Left control handle (if equipped)
13. Axle differential lock switch
14. Accelerator pedal
15. Brake pedal
23. Mixing bucket switch (if equipped)
24. Work lights switch (if equipped)
25. Hazard warning lights switch
26. Emergency pump switch (if equipped)
27. Gear selection switch
28. Chassis levelling switch (if equipped)
29. Outriggers switches
30. Road lights switch
31. Hydraulic mixing bucket oil direction switch (if
equipped)
32. Outriggers lowering switch
16. Ignition switch
33. Hydraulic quick coupling enabling switch (if
equipped)
17. DPF switch (EU model)
34. Heater and air conditioning controls
18. Slewing upper structure rotation speed
35. Steering column control
potentiometer
Part No. 57.0009.0607
36. Diagnostic button
GTH-5021 R
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December 2014
First Edition - Second Printing
Controls
1
2
Steering wheel
9
Turn the steering wheel to the right to turn the
front wheels to the right. Turn the steering wheel
to the left to turn the front wheels to the left.
10 Parking brake switch
Transmission control lever - Horn button
Move the transmission control lever away from
you for forward gear. Move the lever toward you
for reverse gear. Move the lever to the center
position for neutral.
Press the top end lever button and the horn will
sound. Release the button and the horn will stop.
3
Seat controls
See “Adjusting the Seat” section.
4
Turn signal - Windshield washer/wiper - High
beams
Move the lever forward to activate the right turn
signal. Move the lever backward to activate the
left turn signal.
Press the top button at the end of the lever to
direct a jet of water onto the cab windscreen.
Rotate the lever tip to operate the windscreen
wiper.
Push the lever down to turn the high beams on
(after pushing the Road lights switch 30). Push
the lever up to use high beams for intermittent
signalling.
5
Steer select switch
Rotate the steer selector to the right side to select
four-wheel steer. Rotate the steer selector to the
middle position to select two-wheel steer. Rotate
the steer selector to the left to select crab steer.
6
Load limiting indicator
Emergency stop push-button
See “Control Indicators and Interlocks” section.
24
11 Right control handle (single)
See “Controller movements” section.
12 Left control handle (if equipped)
See “Controller movements” section.
13 Axle differential lock switch
Push and hold the switch to activate the axle
differential lock. Release the switch to release
the axle differential lock.
14 Accelerator pedal
15 Brake pedal
16 Ignition switch
position and hold until
Turn the key to the
the glow plugs preheating indicator light turns
off; when released, key springs back to pos. I
automatically. Turn the key to position P to switch
the control from the cab to platform.
17 DPF switch (EU model)
Push the bottom of the rocker switch to enable
the DPF regeneration. Push the top of the switch
to inhibit the DPF regeneration.
18 Slewing upper structure rotation speed
potentiometer
Turn the potentiometer clockwise to increase the
turret rotation speed.
Rotate the steer selector to the left to select jobsite mode. Rotate the steer selector to the middle
position to select road transfer mode. Rotate the
steer selector to the right side to select platform
mode (if present).
See “Load Limiting Indicator” section.
8
Push the bottom of the rocker switch to turn the
parking brake on. Push the top of the switch to
turn the parking brake off.
19 Job-site/road/platform selector
Load limiter disable selector
See “Load Limiting Indicator” section.
7
Instrument panel
20 A/C switch
Push the switch to turn the A/C on. Push the
switch to turn the A/C off.
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Controls
21 Cab heater fan switch
29. Outriggers switches
Push the bottom of the switch to turn the cab
heater fan on: first position for low speed and
second position for high speed. Push the top of
the switch to turn the cab heater fan off.
22 Auxiliary hydraulic circuit switch (if equipped)
Push the button to switch the hydraulic directional
flow between the two auxiliary lines.
23 Mixing bucket switch (if equipped)
Push the bottom of the rocker switch to enable
the hydraulic mixing bucket functioning. Push
the top of the switch to stop the hydraulic mixing
bucket functioning.
24. Work lights switch (if equipped)
Push the rocker switch to turn the work lights on:
first position for front & boom working lights and
second position for front, boom & rear working
lights.
25 Hazard warning lights switch (if equipped)
Push the bottom of the switch to turn the hazard
warning lights on. Push the top of the switch to
turn the hazard warning lights off.
Push the top of the switches to extend and lower
the outriggers. Push the bottom of the switches
to raise and retract the outriggers
30. Road lights switch
Push the rocker switch to turn the road lights
on: first position for position lights and second
position for low beams.
31. Hydraulic mixing bucket oil direction switch (if
equipped)
Press the switch to regulate the oil flow direction
towards right or left: push the top to direct the
oil towards left; push the bottom to direct the oil
towards right.
32. Outriggers lowering switch
33. Hydraulic quick attach enabling switch (if
equipped)
Push and hold the switch to enable the coupling
or the release of the attachment, managed by
the Right control handle or by the Left control
handle (if equipped)
34 Heater and air conditioning controls
26 Emergency pump switch (if equipped)
Push the switch to activate the emergency pump.
Release the switch to release the emergency
pump.
27 Mechanical Gear Switch
Push the bottom of the rocker switch to select
the required speed: each pressure corresponds
to the selection of a new speed.
35 Steering column control
Unlock the lever on the right-bottom side and
pull or push the steering wheel to the required
position, then re-lock it.
36 Diagnostic button
Push the button to scroll the LCD screen menu.
28. Chassis levelling switch (if equipped)
Push and hold the switch until the complete
execution of the function selected: push the left
side to raise the right-hand side of the machine;
push the right side to lower the right-hand side
of the machine.
Part No. 57.0009.0607
GTH-5021 R
25
December 2014
First Edition - Second Printing
Controls
Stage 3A
2
3
6
15
16
13
1
10
17
19
5
9
14
12
11
8
4
7
18
Instrument Panel
1. Low engine oil pressure indicator light
13. Turn signal indicator light
2. Parking brake engaged indicator light
14. Fuel level gauge with low fuel indicator light
3. Hydraulic oil filter clogged indicator light
15. Brake pressure low indicator light
4. Low hydraulic oil level indicator light
16. High beam indicator light
5. Glow plugs preheating indicator light
17. Battery voltage low indicator light
6. Engine air filter restricted indicator light
18. Machine levelling indicator light
7. 2nd gear engaged indicator light
19. Warning lights indicator light
8. 1st gear engaged indicator light
9. Engine coolant temperature gauge with high
coolant temperature indicator light
10. Position light indicator light
11. Hour-meter
12. High hydraulic oil temperature indicator light
26
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Controls
Stage 3A
1 Low engine oil pressure indicator light
12 High hydraulic oil temperature indicator light
When illuminated this light indicates that the engine
oil pressure is too low which can lead to machine
damage. Discontinue use of the machine and service.
This indicates the temperature of the hydraulic oil
in the tank which can lead to machine damage.
Discontinue use of the machine and service.
3 Hydraulic oil filter clogged indicator light
15 Brake pressure low indicator light
When illuminated this light indicates that the hydraulic
oil filter is clogged which can lead to machine damage.
Discontinue use of the machine and service.
It lights when the pressure of the braking circuit is
too low for a correct functioning which can lead to
machine damage. Discontinue use of the machine
and service.
4 Low hydraulic oil level indicator light
When illuminated this light indicates that the hydraulic
oil level is too low which can lead to machine damage.
Replenish and eliminate any oil leaks.
6 Engine air filter restricted indicator light
When this lamp comes on, the engine air filter is
clogged proceed with cleaning or changing the air
filter cartridge.
9 Engine coolant temperature gauge with high coolant
temperature indicator light
When gauge reaches red, the engine coolant is too
hot which can lead to engine damage. Discontinue
use and service the engine
Part No. 57.0009.0607
GTH-5021 R
27
December 2014
First Edition - Second Printing
Controls
Stage 3B
21
20
19
18
17
16
15
°c
22
1230
105
14
engine rpm
000000.0
60
23
13
12
24
1
2
3
4
5
6
7
8
9
10 11
25
Instrument Panel
1. Low engine oil pressure indicator light
14. 1st gear engaged indicator light
2. Parking brake engaged indicator light
15. Engine coolant temperature gauge with high
coolant temperature indicator light
3. Hydraulic oil filter clogged indicator light
4. Low hydraulic oil level indicator light
16. Position light indicator light
5. Lowered outriggers indicator light
17. Hour-meter
6. Glow plugs preheating indicator light
18. Tachometer
7. Diesel particulate filter (DPF) indicator light
19. High hydraulic oil temperature indicator light
8. DPF disabled indicator light
20. Turn signal indicator light
9. High exhaust system temperature indicator light
21. Fuel level gauge with low fuel indicator light
10. Engine air filter restricted indicator light
22. Brake pressure low indicator light
11. DPF Alert indicator light
23. High beam indicator light
12. Engine Critical Fault indicator light
24. Battery voltage low indicator light
13. 2nd gear engaged indicator light
25. Machine levelling indicator light
28
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Controls
Stage 3B
1 Low engine oil pressure indicator light
10 Engine air filter restricted indicator light
When illuminated this light indicates that the engine
oil pressure is too low which can lead to machine
damage. Discontinue use of the machine and service.
When this lamp comes on, the engine air filter is
clogged proceed with cleaning or changing the air
filter cartridge.
3 Hydraulic oil filter clogged indicator light
11 DPF Alert indicator light
When illuminated this light indicates that the hydraulic
oil filter is clogged which can lead to machine damage.
Discontinue use of the machine and service.
This light flashes to warn with a problem of the engine.
To identify the problem, see the two sections “Engine
Lamp Logic”
4 Low hydraulic oil level indicator light
12 Engine Critical Fault indicator light
When illuminated this light indicates that the hydraulic
oil level is too low which can lead to machine damage.
Replenish and eliminate any oil leaks.
This light comes on to warn of a problem with the
engine. To identify the problem, see the two sections
“Engine Lamp Logic”
5 Lowered outriggers indicator light
15 Engine coolant temperature gauge with high
coolant temperature indicator light
When illuminated this light indicates that the four
outriggers are completely lowered.
7 Diesel particulate filter indicator light
When gauge reaches red, the engine coolant is too
hot which can lead to engine damage. Discontinue
use and service the engine
When illuminated this light indicates that the DPF is
in need of regeneration. Park the machine in a safe
location, press the DPF switch and refer to the DPF
regeneration instructions in the supplemental engine
operator’s manual.
This indicates the temperature of the hydraulic oil
in the tank which can lead to machine damage.
Discontinue use of the machine and service.
8 DPF disabled indicator light
22 Brake pressure low indicator light
When illuminated this light indicates that a
regeneration has been inhibited.
It lights when the pressure of the braking circuit is
too low for a correct functioning which can lead to
machine damage. Discontinue use of the machine
and service.
9 High exhaust system temperature indicator light
When illuminated this light indicates that a
regeneration is underway and that emission system
temperatures are elevated.
Part No. 57.0009.0607
19 High hydraulic oil temperature indicator light
GTH-5021 R
29
December 2014
First Edition - Second Printing
Inspections
Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
Do Not Operate Unless:
 You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1. Avoid hazardous situations.
2. Always perform a pre-operation inspection.
Know and understand the pre-operation
inspection before going on to the next
section.
3. Always perform function tests prior to use.
4. Inspect the workplace.
5. Only use the machine as it was intended.
The pre-operation inspection is a visual inspection
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
performs the function tests.
The pre-operation inspection also serves to determine
if routine maintenance procedures are required. Only
routine maintenance items specified in this manual
may be performed by the operator.
Refer to the list on the next page and check each
of the items.
If damage or any unauthorized variation from factory
delivered condition is discovered, the machine must
be tagged and removed from service.
Repairs to the machine may only be made by
a qualified service technician, according to
the manufacturer's specifications. After repairs
are completed, the operator must perform a
pre-operation inspection again before going on to
the function tests.
Scheduled maintenance inspections shall be
performed by qualified service technicians, according
to the manufacturer’s specifications and the
requirements listed in the responsibilities manual.
30
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Inspections
Pre-operation Inspection
 Be sure that the operator’s and safety manuals
are complete, legible and in the storage container
located in the cab.
 Limit switches
 Be sure that all decals are legible and in place.
See Inspections section.
 Pins, nuts, bolts and other fasteners
 Check for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
 Check for battery fluid leaks and proper fluid level.
Add distilled water if needed. See Maintenance
section.
 Check for engine oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
 Air-filled tires models: Check for proper tire
pressure. Add air if needed. See Maintenance
section.
Check the following components or areas for damage,
improperly installed or missing parts and unauthorized
modifications:
 Electrical components, wiring and electrical
cables
 Lights, alarms and beacons
Check entire machine for:
 Cracks in welds or structural components
 Dents or damage to machine
 Excessive rust, corrosion or oxidation
 Be sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
 Be sure the windshield and windows (if equipped)
are clean and free of obstructions that might
limit visibility.
 After you complete your inspection, be sure that
all guards, screens and compartment covers are
in place and secured.
 Hydraulic hoses, fittings, cylinders and
manifolds
 Fuel and hydraulic tanks
 Drive motors and drive hubs
 Boom wear pads
 Tires and wheels
 Mirrors
 Engine and related components
Part No. 57.0009.0607
GTH-5021 R
31
December 2014
First Edition - Second 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.
Do Not Operate Unless:
 You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1. Avoid hazardous situations.
2. Always perform a pre-operation inspection.
A malfunctioning machine must never be used. If
malfunctions are discovered, the machine must
be tagged and removed from service. Repairs
to the machine may only be made by a qualified
service technician, according to the manufacturer’s
specifications.
After repairs are completed, the operator must perform
a pre-operation inspection and function tests again
before putting the machine into service.
Know and understand the pre-operation
inspection before going on to the next
section.
3. Always perform function tests prior to use.
4. Inspect the workplace.
5. Only use the machine as it was intended.
32
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Inspections
Function Tests
Test the Single Control Handle
1
Select a test area that is firm, level and free of
obstruction. Be sure there is no load on the forks
or attachment.
8
2
Enter the cab and sit on the seat.
 Result: All functions should operate smoothly.
3
Adjust the seat and steering column, if needed.
9
4
Fasten and secure the seat belt around your waist.
5
Adjust the cab mounted mirror, the rear fisheye mirror and the exterior right hand mirror, if
required.
6
7
Be sure the parking brake is on and the
transmission control is in neutral.
Start the engine. See Starting the Engine in the
Operating Instructions section.
Using the control handle, momentarily raise the
boom and extend the boom, tilt the forks up
and down.
Using the left roller switch, momentarily extend
and retract the boom.
 Result: All functions should operate smoothly.
10 Using the right roller switch, momentarily rotate
the slewing upper structure to the right and to
the left.
 Result: All functions should operate smoothly.
Test the Dual Control Handles (if
equipped)
11 Using the right control handle, momentarily raise
the boom and extend the boom, tilt the forks up
and down.
 Result: All functions should operate smoothly.
12 Using the left roller switch on the right control
handle, momentarily extend and retract the boom.
 Result: All functions should operate smoothly.
13 Push and hold the lock/unlock enabling switch
together with the white thumb switch of the left
control handle, momentarily lock and unlock the
attachment.
 Result: All functions should operate smoothly.
14 Using the left control handle, momentarily rotate
the slewing upper structure to the right and to
the left.
 Result: All functions should operate smoothly.
Part No. 57.0009.0607
GTH-5021 R
33
December 2014
First Edition - Second Printing
Inspections
Test the Steering
Test the Transmission and Brakes
15 Rotate the steer selector to the right side to select
four-wheel steer.
23 Be sure the boom is fully lowered and retracted.
16 Check the steering operation by turning the
steering wheel approximately ¼ turn in each
direction.
 Result: The front wheels should turn in the same
direction as the steering wheel. The rear wheels
should turn in the opposite direction.
17 Straighten the wheels.
18 Rotate the steer selector to the middle position
to select two-wheel steer.
19 Check the steering operation by turning the
steering wheel approximately ¼ turn in each
direction.
 Result: The front wheels should turn in the same
direction as the steering wheel. The rear wheels
should not turn.
20 Straighten the wheels.
21 Rotate the steer selector to the left to select
crab steer.
22 Check the steering operation by turning the
steering wheel approximately ¼ turn in each
direction.
 Result: The front wheels and the rear wheels
should turn in the same direction as the steering
wheel.
24 Step on the brake pedal. Push the top of the
parking brake switch to turn it off.
25 Move the transmission control lever to the forward
direction. Push down lightly on the accelerator
pedal to increase the RPM’s and slowly let up on
the brake pedal. As soon as the machine starts
to move, push the brake pedal.
 Result: The machine should move forward, and
then come to an abrupt stop.
26 Move the transmission control lever to the reverse
direction. Push down lightly on the accelerator
pedal to increase the RPM’s and slowly let up on
the brake pedal. As soon as the machine starts
to move, push the brake pedal.
 Result: The machine should move in reverse,
and then come to an abrupt stop. The backup alarm should sound when the transmission
control lever is in reverse.
27 Move the transmission control lever to neutral.
28 Push the bottom of the parking brake switch.
 Result: The red parking brake indicator light
should come on, indicating the parking brake
is on.
29 Move the transmission control lever forward, and
then in reverse while increasing the RPM’s with
the accelerator pedal.
 Result: The machine should not move.
34
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Inspections
Test the Parking Brake
Test the Road Transfer Mode
30 Push the bottom of the rocker switch to turn the
parking brake on: the parking brake warning light
should come on.
38 Set the steer select switch to road transfer mode.
31 Push down lightly on the accelerator pedal.
 Result: The machine should not move .
39 Attempt to: operate the boom, rotate the slewing
upper structure and extend/lower the outriggers
functions.
 Result: None of these functions should operate.
Test the Rear Axle Lock
Test the Levelling Cutout (if equipped)
32 Raise the boom above 50°.
40 Raise the boom over 2 meters.
33 Rotate the slewing upper structure more than
10° (the Load Limiting display shows “TURRET
NOT ALIGNED”).
34 Place transmission into gear
41 Put the transmission control lever in neutral.
42 Set parking brake.
Slowly level the machine to the left and to the right.
 Result: The machine should not move
35 Operate the frame levelling function in both
directions.
 Result: The frame levelling function should not
operate.
 Result: The levelling function should not operate.
Test the Lights
43 Verify that all equipped working and road lights
are functional.
Test the Outriggers
36 Push the top of each outriggers switch and fully
extend and lower the outriggers. Push the bottom
of each outrigger switch to fully raise and retract
the outriggers.
 Result: The outriggers should operate smoothly
and in the expected direction.
Test the Outriggers Cutout
Test the Load Limiting System
44 Load a known weight of approximately 1000 kg.
45 Raise the boom about 30 cm above the ground.
46 Extend the boom and check if the system enters
the alarm mode once it has reached the distance
as indicated in the load charts for the attachment
fitted to the machine.
 Result: the system alarm mode should sound.
37 Raise the boom over 2 meters . Attempt to deploy
or retract outriggers
 Result: The outriggers should not work.
Part No. 57.0009.0607
GTH-5021 R
35
December 2014
First Edition - Second Printing
Inspections
Test the Joystick Enabling Function
Switch
Test the Outriggers Sensors
47 Operate the joystick without pressing this button.
 Result: the load limiting display will accordingly
change the scale of the admissible payloads.
 Result: the joystick shall not activate any
movement.
Test the Emergency Stop Push button
48 Press the Emergency Stop Push button down
during a movement.
 Result: the movements shall stop and engine
should shut down.
Test the Emergency Pump (if equipped)
57 Lower or raise all the outriggers.
Test the Slewing Upper Structure
Proximity Switches
58 Raise the boom over 20°.
59 Rotate the Slewing Upper Structure until the
writing “ALIGNED TURRET” appears on the 8th
row of the Load Limiting display.
 Result: the two proximity switches yellow leds
A should come on.
49 Set the ignition switch to position I
50 Press the emergency stop push button
51 Press the Emergency Pump switch for some
seconds.
52 Engage any of the manual levers while pressing
the Emergency Pump switch.

 Result: the corresponding movement of the
machine will indicate the Emergency Pump is
working properly.
Test the Seat Switch
Test the Chassis Levelling (if equipped)
53 Do not sit on the drive seat.
54 Place transmission into either 1st or 2nd gear.
60 Raise the boom over 20°.
55 Release parking and service brakes.
61 Attempt to: level the machine pressing the chassis
levelling switch
56 Push down lightly on the accelerator pedal.
 Result: The levelling function should not work.
 Result: the machine shall not move.
36
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
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
machine operation contained in this operator’s
manual.
1. Avoid hazardous situations.
2. Always perform a pre-operation inspection.
Know and understand the pre-operation
inspection before going on to the next
section.
 unstable or slippery surfaces
 overhead obstructions and high voltage
conductors
 hazardous locations
 inadequate surface support to withstand all load
forces imposed by the machine
 wind and weather conditions
3. Always perform function tests prior to use.
 the presence of unauthorized personnel
4. Inspect the workplace.
 other possible unsafe conditions
5. Only use the machine as it was intended.
Workplace Inspection
Fundamentals
The workplace inspection helps the operator
determine if the workplace is suitable for safe machine
operation. It should be performed by the operator prior
to moving the machine to the workplace.
It is the operator’s responsibility to read and remember
the workplace hazards, then watch for and avoid them
while moving, setting up and operating the machine.
Part No. 57.0009.0607
GTH-5021 R
37
December 2014
First Edition - Second Printing
Inspections
Inspection for Decals
Determine whether the decals on your machine have
words or symbols. Use the appropriate inspection to
verify that all decals are legible and in place.
Part No.
Decal Description
Qty
Part No.
Decal Description
09.4618.1458
Warning - Tip Over, Respect Capacity
Qty
2
09.4618.1588
Cosmetic - Genie GTH-5021 R
2
09.4618.1593
Cosmetic - Genie GTH-5021 R
1
09.4618.1594
Cosmetic - Genie GTH-5021 R
1
215645
Danger – Explosion/Burn Hazard,
Fueling
1
215646
Warning – Electrocution Hazard
3
215648
Danger - No Riders
1
237720
Warning – Crush Hazard, Moving
Machine
2
09.4618.1645
Label - Load Limiting System Disabling
1
Label - Hydraulic Oil
2
237721
Warning – Dress seat Belt
1
09.4618.1670
237726
Warning – Burn Hazard
1
09.4618.1671
Label - ULSD Fuel (only for EU Market)
1
09.4616.0010
Label – 5000 kg
1
28159
Label - Diesel (for NOT EU Market)
1
09.4618.0243
Cosmetic - Genie
2
09.4618.1673
Warning - Crush Hazard, Outriggers
4
09.4618.0920
Warning – Engine Compartment
1
09.4618.1674
Warning - Crush Hazard, Safety Collar
2
09.4618.0922
Warning – Crush Hazard
2
09.4618.1675
Warning - Tip Over, Outriggers Pmax
4
09.4618.0924
Danger – Explosion/Burn Hazard
1
09.4618.1676
Label - Tyre Pressure 7.5 bar
4
09.4618.0923
Warning – Burn Hazard, Hot Parts
3
09.4618.1677
Label - Anchoring & Lifting
1
09.4618.1051
Label – Engine Compartment Opening
2
09.4618.1678
Label - Cut-off Switch
1
09.4618.1120
Warning – Crush Hazard, Moving Parts
2
09.4618.1679
Warning - 7 decals
1
09.4618.1189
Label - Test Ports
1
09.4618.1693
Cosmetic - Genie
1
09.4618.1263
Label - Slewing Upper Structure Mark
1
09.4618.1694
Label - Right Control Lever
1
09.4618.1264
Label - Chassis Mark
1
09.4618.1695
Warning - Tip Over, Respect Capacity
1
Label - Right Control Lever with Lock/
Unlock
1
09.4618.1375
09.4618.1398
Label - Attachment Locking Pin
1
09.4618.1713
Warning - Burn Hazard
1
Label - Mainvalve Manual Use
1
1
09.4618.1399
Label - Door Unlock
1
09.4618.1740
09.4618.1418
Label - Emergency Exit
1
09.4618.1769
Label - Lock
09.4618.1419
Label - Naturelle Hydraulic Oil
1
09.4618.1770
Label - Unlock
1
Label - Sound Level 103 dB
1
09.4618.1423
Danger – Explosion/Burn Hazard
1
09.4618.1771
09.4618.1456
Label - Left Control Lever
1
09.4618.1819
Label - TP1 Testing Port
1
09.4618.1820
Label - TP5 Testing Port
1
09.4618.1821
Label - TP8 Testing Port
1
09.4618.1642
Label - Load Chart Fork Front
1
09.4618.1457
38
Label - Right Control Lever with Left
Control Lever
1
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Inspections
Part No.
Decal Description
09.4618.1644
Label - Load Chart Fork Side
1
09.4618.1643
Label - Load Chart Fork 360° on
Outriggers
1
09.4618.1696
Label - Load Chart Hook 360° on
Outriggers
1
09.4618.1697
Label - Load Chart Hook Front
1
09.4618.1698
Label - Load Chart Hook Side
1
09.4618.1699
Label - Load Chart 900 kg Jib 360° on
Outriggers
1
09.4618.1700
Label - Load Chart 900 kg Jib Front
1
09.4618.1701
Label - Load Chart 900 kg Jib Side
1
09.4618.1702
Label - Load Chart 2000 kg Jib 360° on
Outriggers
1
09.4618.1703
Label - Load Chart 2000 kg Jib Front
1
09.4618.1704
Label - Load Chart 2000 kg Jib Side
1
09.4618.1705
Label - Load Chart 4000 kg Winch 360°
on Outriggers
1
09.4618.1706
Label - Load Chart 4000 kg Winch Front
1
09.4618.1707
Label - Load Chart 4000 kg Winch Side
1
09.4618.1708
Label - Load Chart Bucket 360° on
Outriggers
1
09.4618.1709
Label - Load Chart Bucket Front
1
09.4618.1710
Label - Load Chart Bucket Side
1
09.4618.1711
Label - Load Chart 3P700 REM4400
Manplatform on Outriggers (for NOT EU
Market)
1
09.4618.1712
Label - Load Chart 2P300 F
Manplatform on Outriggers (for NOT EU
Market)
1
09.4618.1827
Label - Do not use high pressure
2
Part No. 57.0009.0607
Qty
GTH-5021 R
39
December 2014
First Edition - Second Printing
Inspections
09.4618.1423
09.4618.1769
09.4618.1820
09.4618.1770
09.4618.1819
09.4618.1399
09.4618.1670
09.4618.1821
09.4618.1645
09.4618.1120
09.4618.1588
09.4618.1740
09.4618.1264
09.4618.1693
09.4616.0010
215645
09.4618.1677
09.4618.1675
215646
09.4618.1673
09.4618.0243
{
215648
09.4618.1671 or
28159
237721
09.4618.1375
09.4618.1676
237720
09.4618.1594
09.4618.1676
215646
09.4618.1398
09.4618.1675
09.4618.1827
09.4618.1673
09.4618.1263
09.4618.1771
09.4618.1694
09.4618.1588
load chart set
09.4618.1458
09.4618.1418
09.4618.1679
09.4618.0922
09.4618.0243
09.4618.0924
09.4618.0923
09.4618.1674
09.4618.1675
09.4618.1673
237720
09.4618.1051
215646
09.4618.1713
09.4618.0923
NOT EU Market
09.4618.1189
09.4618.1676
09.4618.1120
215646
09.4618.0923
only EU Market
09.4618.1678
237726
09.4618.1676
09.4618.1675
09.4618.0920
09.4618.1673
09.4618.1593
09.4618.1051
Shading indicates decal is hidden from view, i.e. under covers
40
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Inspections
Inspection for Road Homologation Configuration
2
5
3
6
6
5
8
2
4
1
2
6
7
Pos.
Part Number
1
09.4618.1489
2
09.4618.0339
Max Speed 20km/h
3
07.0723.0042
Rear Mirror
4
09.0803.0081
Wheel Chock
5
09.4618.0276
Reflecting Yellow Decal
6
56.0010.0020
Orange Reflector
7
56.0010.0029
Red Reflector
8
09.4616.0114
8
09.4616.0000
Part No. 57.0009.0607
TUV
Spain
Switzerland
Italy
Max Speed 32km/h
Homologation Plate
Homologation Plate
GTH-5021 R
41
December 2014
First Edition - Second 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:
 You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Always wear the seat belt before operating
the machine.
6 Only use the machine as it was
intended.
A variable reach rough terrain forklift truck is
defined as a wheeled type truck designated
primarily as a fork truck with a pivoted boom,
which may be equipped with attachments for lifting
material. Using it for any other purpose is unsafe
and dangerous.
Only trained and authorized personnel should
be permitted to operate a machine. If more than
one operator is expected to use a machine at
different times in the same work shift, they must
all be qualified operators and are all expected
to follow all safety rules and instructions in the
operator’s, safety and responsibilities manuals.
That means every new operator should perform
a pre-operation inspection, function tests, and a
workplace inspection before using the machine.
Additionally, everyone working on or near
the product also needs to be familiar with the
applicable safety precautions.
42
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Operating Instructions
Adjusting the Seat
Comfort Seat (if equipped)
Standard Seat
(part number 58.2513.1088)
4
5
3
1
2
Move the lever A and slide the seat forward or
backward. Release the bar and make sure the
seat locks in position.
Move the lever 1 and slide the seat forward or
backward. Release the bar and make sure the
seat locks in position.
Rotate the knob B clockwise or counter-clockwise
until reaching the desired springing. Once you are
correctly seated check that the yellow indicator C
is in the green field.
Push or pull the height adjustment 2 to bring your
thigh parallel to the seat cushion.
Operate lever D, press your back firmly against
the backrest and put the backrest at the angle you
wish, then release the lever.
Raise armrest E and turn wheel F to put the
armrest at the height you want.
Rotate the knob 4 to put the armrest at the height
you want.
Move the lever 5 and put the joystick holder at the
position you want.
The seat is for one person only.
The seat is for one person only.
Don’t adjust the seat when the machine is moving.
Part No. 57.0009.0607
Operate lever 3, press your back firmly against
the backrest and put the backrest at the angle you
wish, then release the lever.
Don’t adjust the seat when the machine is moving.
GTH-5021 R
43
December 2014
First Edition - Second 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.
3
1. Allows checking the area behind the machine
and on the right-hand side.
2
2. Allows checking the area behind the machine
and on the left-hand side.
1
3. Allows checking the area behind the machine.
Sit correctly in the driving seat; then:
•
The safety belts are equipped with reel
retractor.
•
To fasten the belt, pull tab 1 and push it into
buckle 2.
•
To release the belt, push button 3 and remove
the tab from the buckle.
•
Make sure that the buckle is correctly located
at the hip point and not on the stomach.
•
Operate the end adjusters to reach the length
you wish and make sure the buckle is always
in the middle.
44
1
3
GTH-5021 R
2
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Operating Instructions
Parking Brake
Starting in Cold Condition
Use the parking brake switch to apply the parking
brake before raising the boom or leaving the
machine.
In cold conditions, 20°F / -6°C and below, warm
the engine for 5 minutes before operating to
prevent hydraulic system damage. In extreme
cold conditions, 0°F / -18°C and below, machines
should be equipped with optional cold start kits.
Attempting to start the engine when temperatures
are below 0°F / -18°C may require the use of a
booster battery.
Always engage the parking brake before rising
from the seat, if not the Load Limiting system will
sound an alarm.
Push the bottom of the rocker switch to turn the
parking brake on.
Push the top of the switch to turn the parking
brake off.
Steer Select
When the slewing upper structure is slewed
in rearward position, all the steering controls are
reversed!
Brake Pedal
Use the brake pedal to control the machine speed
and to stop the machine motion.
Push and hold the brake pedal to stop the
machine.
Do not realign the wheels while driving.
To align the rear wheels:
1. Start the engine, and move the Job-Site/Road/
Platform Select to the job-site position.
Push and release the brake pedal to control the
machine speed.
Starting the Engine
2. Rotate the steering wheel until the wheels are
in line with the length of the chassis and the
writing “ALIGNED WHEELS” appears on the
Load Limiting display.
1. Be sure the parking brake is set and the
transmission control lever is in the neutral
position.
1
0
2
2. Insert the key in the ignition switch.
3. Turn the key until the engine starts.
If the engine fails to start after 30 seconds of
cranking, determine the cause and repair any
malfunction. Wait 20 seconds before trying to start
again.
Part No. 57.0009.0607
GTH-5021 R
45
December 2014
First Edition - Second Printing
Operating Instructions
Job-Site/Road/Platform Select
Raising and Lowering the
Outriggers
•
Job-site mode: all machine functions are
enabled;
•
Road transfer mode: boom movement, turret
rotation and outriggers movements are
disabled; only the two-wheel steering mode is
enabled;
•
Platform mode: all controls from the cabin are
disabled, operate the machine by the platform
controls.
Push the top of the rocker switch to extend/lower
the outriggers. Push the bottom of the rocker
switch to raise/retract the outrigger.
Before operating the outriggers, when the
slewing structure is not aligned, verify that the
outrigger control corresponds to the correct
outrigger.
Levelling the chassis ( if
equipped)
Push the right side of the rocker switch to lower
the right side of the chassis. Push the left side
of the rocker switch to lower the left side of the
chassis.
Operator Descent With 90°
Slewing Upper Structure
Emergency Exit
When the slewing upper structure is rotated, the
operator can descend from the machine through
the two dedicated iron steps located at the front
and rear of the chassis.
Extract the retaining levers and push out the
window.
Always hold to the dedicated handholds to
prevent falls or slips.
46
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Operating Instructions
Slewing Upper Structure Locking
Pin
Transmission Control
This manual device is placed at the back of the
cabin.
When the slewing upper structure is slewed
in rearward position, all the steering controls are
switched!
To lock/unlock the slewing upper structure
rotation:
Use the transmission control lever to control the
direction of machine travel.
Rotation locking
To drive forward, move the transmission control
lever toward you and move it up.
1. Rotate the turret until the writing “TURRET
ALIGNED” appears on the Load Limiting
display.
To drive in reverse, move the transmission control
lever toward you and move it down.
2. Turn off the engine and engage the parking
brake.
To return to neutral, move the transmission control
lever to the center position.
3. Working inside the cab, open the rear window
and lift up the locking pin.
4. Set the device in position A to lock the slewing
upper structure: operator will see the lock
symbol on the top handle pin.
Rotation unlocking
1. Set the device in position B to unlock the
slewing upper structure: operator will see the
unlock symbol on the top handle pin.
The speed engagement is signalled by the
dedicated indicator lights, according to the
engaged speed.
 
Part No. 57.0009.0607
GTH-5021 R
47
December 2014
First Edition - Second Printing
Operating Instructions
Axle Differential Lock
Use the axle differential lock switch to lock the
axle differential and gain added traction in certain
types of terrain such as sand, mud or snow.
Come to a complete stop before activating the
axle differential lock. Do not lock the axle when
the machine is moving.
Push and hold the switch to activate the axle
differential lock. Release the switch to release the
axle differential lock.
Access to the Engine
Compartment
For any operation within the engine compartment,
open the engine bonnet.
The bonnet is equipped with pneumatic shock
absorbers which help raise and hold the bonnet in
the raised position. To open the bonnet:
• Shut the engine down and put the parking brake.
• Turn the key to unlock and open the bonnet front
part.
• Release the engine bonnet clasps placed to both
sides of the bonnet upper part (see fig. below).
Rear Axle Lock
This function automatically starts in two situations:
1. the boom is raised above 50°;
2. the slewing upper structure is rotated more
than 10° (the Load Limiting display shows
“TURRET NOT ALIGNED”).
The transmission will shift to neutral and the frame
levelling function will not operate. Boom and fork
functions continue to operate.
To unlock the rear axle and to operate the frame
levelling function, lower the boom and align the
slewing upper structure.
48
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Operating Instructions
DPF Regeneration
When the Diesel Particulate Filter indicator light,
7, switches on the operator has to start the DPF
regeneration following these instructions:
i
Select a safe outdoor parking location:
•
firm level surface
•
clear of obstruction and traffic
•
clear of flammable material
•
clear of explosive atmospheres
ii
Set the parking brake.
iii
Move the transmission control lever to neutral.
iv
Warm up the engine; the coolant temperature
must reach at least 75°C.
v
Keep the engine on.
vi
Activate the DPF regeneration pushing on the
DPF switch: high exhaust system temperature
indicator light 9 switches on with a solid light
and the engine revs up to 1,200 rpm.
xii Once the regeneration has been completed,
the high exhaust system temperature indicator
light 9, will switch off and the engine will run at
idle.
xiii During DPF regeneration:
•
don't handle loads
•
steer clear of explosive atmospheres
•
steer clear of flammable material
When the DPF indicator light starts fast blinking
and the Engine Critical Fault indicator light
becomes a solid red light, the operator has to
contact a qualified service technician.
vii Keep clear of the exhaust muffler area.
viii Don’t leave the machine unattended.
ix
Signpost the area.
x
Machine must remain parked outdoors for 30
minutes approximately.
xi
In case of need, regeneration can be stopped
by pushing the DPF switch and then restarted.
Part No. 57.0009.0607
GTH-5021 R
49
December 2014
First Edition - Second Printing
Operating Instructions
Transporting a Load
Raising and Placing a Load
Center the load on the forks. Position the load so
that it is completely against the back of the fork
frame.
The load chart in the cab shows the operating
limits of a properly maintained and operated
machine. To use the load chart, the operator must
know the weight of the load, its load center and
how far out and up it is to be placed.
The load should be kept as low to the ground as
possible while traveling. Always move a loaded
machine with the boom angle indicator at 0
degrees or less.
Tilt the forks back slightly to help keep the load
secure.
Always bring the machine to a complete stop
before applying the parking brake.
This machine has more than one load chart. Be
sure you are using the load chart that corresponds
to the attachment on the machine, to the
configuration of the outriggers and the slewing
upper structure position.
If you determine that the weight of the load cannot
be placed at the height and angle you want, these
options can be used:
1. If you have not lowered the outriggers, lower
the outriggers and use the load chart for
outriggers down.
If the outriggers are down:
2. Move the machine closer to the loading or pick
point so that the weight of the load will meet
the load chart specifications.
3. Divide the load into smaller pieces so that
each piece meets the load chart specifications.
4. Obtain a larger machine capable of handling
the load within specifications.
50
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Operating Instructions
Placing the load
9
1
Travel to the desired work site and carefully
stop the machine.
2
Put the transmission in neutral.
3
Apply the parking brake.
4
Unlock the slewing upper structure locking pin.
5
Lower the outriggers, if your configuration
requires it.
6
Level the frame, if the left to right level
indicator or the front to back level indicator is
not at 0 degrees.
7
Gradually move the controller to raise and
extend the boom to the required height.
Gradually move the controller to lower and
extend the boom into final position. Lower the
load until the weight is completely off the forks.
Do not apply a downward force with the forks.
10 Gradually move the controller to raise and
retract the boom. This will bring the forks out
of the load.
11 When the forks are clear of the load and
the structure, the boom can be lowered and
retracted.
8
If required, rotate the slewing upper structure
to reach the unloading position. On wheel
configuration, the load limiting system will
apply a different working envelope if the
rotation exceed +/-10°. Refer to the correct
load chart.
Part No. 57.0009.0607
GTH-5021 R
51
December 2014
First Edition - Second Printing
Operating Instructions
Controller movements - Single
Control Handle
D
D
D
Control handle only
with red finger switch
(B)
Control handle only
with red finger switch
(B) and with yellow
roller switch (D)
C
Control handle only
with red finger switch
(B) and with yellow
roller switch (C)
Hydraulic quick coupling (if equipped)
While pressing the hydraulic quick
coupling lock/unlock, control handle with
red finger switch (B) and with white thumb
switch (A)
52
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Operating Instructions
Controller movements - Dual
Control Handles (if equipped)
D
D
D
Control handle only
with red finger switch
(B) and with yellow
roller switch (D)
Control handle only
with red finger switch
(B)
( )
( )
Control handle only
with red finger switch
(B)
Part No. 57.0009.0607
While pressing the hydraulic quick
coupling lock/unlock, control handle with
red finger switch (B) and with white thumb
switch (A)
GTH-5021 R
53
December 2014
First Edition - Second Printing
Operating Instructions
Load Limiting Indicator
Control Keys
At the back of the driving place there is a unit which
lets you manage the load limiting system of the
machine.
The collected data, processed in relation to the
attachment used, are continuously compared with the
data stored in the program memory. The processing
of these data results in three different situations
which are displayed by the warning lights located
at the left side of the display.
1 Green LED ON
Stability condition. The raised load does not
exceed 90% of maximum allowed load of the
chart in that defined working position.
2 Yellow LED ON
Pre-alarm condition. The raised load exceeds
90% of maximum allowed load, but it is still
inferior to it: the boom movements are slowed
down and the acoustic alarm slowly beeps.
3 Red LED ON
Alarm condition. The raised load exceeds the
maximum allowed load, the acoustic alarm
quickly beeps and the machine motions are
stopped, but for those allowing to return the load
within safety limits.

55%
+
-
ENTER
The display is divided into three areas:
LED’s area: Three LED’s warn of the variation of
the working condition:
1 green LED - machine stable
2 yellow LED - machine in pre-alarm
3 red LED - machine in alarm
54
To go back to the previous screen
page
ENTER
To confirm and open the screen
page linked
ARROWS
To scroll the lines up or down
PLUS (+)
Additional selection button
MINUS (-)
Additional selection button
Display, which is divided into 8 lines_ fig.A
1. Load percentage strip
2. Indicates the attachment used
3. Indicates the operating mode
4. Indicates the max load that can be raised
5. Indicates the weight raised for the system
calibration
6. Indicates the boom height (it’ll be = 0 meters
once the boom is fully lowered)
7. Indicates the distance of the load from the
slewing axis and, in case of necessity, it
displays the related warning message
8. Indicates the boom angle
When using an attachment other than those stated,
but supplied by Terex Global GmbH, select the
FORK in line 2.
Operation
• At the machine starting, the load limiting system
runs an automatic check and the software data
are displayed.
• Within 3/4 seconds, the list of attachments
allowed is displayed: using the arrows, the
operator has to select the right attachment and
then press ENTER to confirm.
• Once the attachment has been selected, the
display shows the Standard Screen Page (fig.A).
ESC
FORKS
OUTRIGGERS LATERAL
MAX LOAD ........................ 50.3t
RAISED LOAD ................... 10.2t
HEIGHT............................... 2 m
RADIUS............................... 7 m
ANGLE................................ 15°
ESC
•
From this screen page, pushing PLUS (+)
for some seconds, the operator can open the
UPPER LEVEL (B) where other four sub-menus
are displayed: one of these, LANGUAGE can
be modified while the other three, CLOCK,
EXTENSION SENSOR and ANGLE SENSOR,
can only be consulted.
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Operating Instructions
•
Pressing ESC, go back to the Standard Screen
Page.
•
Press the two buttons PLUS (+) and MINUS
(-) simultaneously to access to the Diagnostic
Screen Pages. These pages can only be
consulted. Use the ARROWS to pass from one
page to another.
Before using the machine, make sure that the
green LED is ON, and that the operating mode
shown in line 3 and the attachment shown
in line 2 are those actually used. The load
limiting system must not be used to check the
load to be handled: it has only been designed
to alert the operator to unstable conditions
of the machine during lifting. Such unstable
conditions may also be caused by an abrupt
operation of the control lever during the load
handling.
Using The Load Charts
The load charts installed on the cab indicate the
maximum allow load in relation to the boom extension,
the slewing upper structure rotation, the outriggers
use and the type of attachment. To operate under
safe conditions, always refer to these charts.
The extension level of the boom can be checked
with the help of the letters (A, B, C, D, E) painted on
the same boom, while the actual boom inclination
degrees are shown by the angle indicator.
Load Limit Warning Light (if
equipped)
This device, fitted on the cab roof, is connected to
the load limiting system and shows the same led
sequence which appears on the load limiting display.
When it reaches the red area, an acoustic alarm
will sound.
Load Limiting Disable Selector
This selector allows to override the load limiting
system in order to recover the machine:
• when it is stuck after the load limiting system
has triggered;
• in case of main machine failures requesting the
unlock of all the machine movements;
In order to prevent any misuse of this device (ie
working outside the load and stability limits of the
machine), the control system is provided with a timer
(calibrated at 10 seconds) which, after this time is
expired, restores automatically the lock-out functions.
The load limiting system disable selector is active
only in the Job-site mode. In the Platform mode, the
load limiting system cannot be deactivated.
Part No. 57.0009.0607
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December 2014
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Operating Instructions
Quick Attach Instructions
Version with mechanical locking
1 Drive to the place where you will release the
mounted attachment (when possible, a solid
and sheltered site).
2 Disconnect the quick connectors of the attachment
(if any).
3 Pull out the mechanical pin locking the attachment
after removing the safety split-pin at its end.
4 Rest the attachment flat on the ground.
5 Pitch the attachment holding frame forward and
lower the boom to release the attachment upper
lock.
6 Move back with the machine and drive to the new
attachment to be coupled.
7 Hold the frame pitched forward and hook the
upper lock of the new attachment.
8 Retract and raise the attachment a small
distance. It will center automatically on the quick
coupling frame.
9 Refit mechanical locking pin fixing it with its safety
split-pin.
10 Re-couple the connectors of the attachment (if
any).
56
Version with hydraulic locking (optional)
1. Drive to the place where you will release the
mounted attachment (when possible, a solid
and sheltered site).
2. Disconnect the quick connectors of the attachment
(if any).
3. Rest the attachment flat on the ground.
4. Press the Lock/Unlock Enabling Switch and keep
it pressed up to the end of Step 5.
5. Free the attachment moving the control handle.
6. Pitch the attachment holding frame forward and
lower the boom to release the attachment upper
lock.
7. Move back with the machine and drive to the new
attachment to be coupled.
8. Hold the frame pitched forward and hook the
upper lock of the new attachment.
9. Retract and raise the attachment a small distance.
It will center automatically on the quick coupling
frame.
10.Coupling the attachment moving the control
handle with the Lock/Unlock Enabling Switch.
11.Re-couple the connectors of the attachment (if
any).
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
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
point where the battery will not crank the starter.
Never jump start the machine directly to the
starter or the starter solenoid. Serious injury or
death could result from the machine moving
forward or backward.
To avoid personal injury when jump starting with
another machine, be certain that the machines are
not touching.
Never jump start a frozen battery as it will explode.
Keep sparks and flames away from the battery.
Lead acid batteries generate explosive gases
when charging. Wear safety glasses when working
near batteries.
The booster battery must be 12V. The machine
used for jump starting must have a negative
ground electrical system.
To jump start the machine
1
Connect the positive (+) jumper cable to the
positive (+) post of the discharged battery.
2
Connect the other end of the same jumper
cable to the positive (+) post of the booster
battery.
3
Connect one end of the second jumper cable
to the negative (-) post of the booster battery.
4
Make the final cable connection to the engine
block or the furthest ground point away from
the battery.
5
Start the engine.
Part No. 57.0009.0607
When the machine is loaded, always travel with
the load uphill. When the machine is unloaded,
travel with the forks or attachment downhill.
On steep terrain, drive only up and down hill, and
always keep the machine in gear. Do not turn
across slope when 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 variables
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 the construction activities
and weather.
Operators should be properly trained and use
their best judgment and experience to take
the necessary precautions to prevent tip over.
Operators must assess the job-site variables and
avoid exceeding the machine’s (or operator’s)
capabilities for terrain and conditions.
GTH-5021 R
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December 2014
First Edition - Second Printing
Operating Instructions
Manual Controls
If the joystick control levers are malfunctioning or
a function cannot be operated, it is possible to use
the emergency controls at the main valve.
The main valve has 3 small control levers that
operate the following functions:
1
2
3
The manual controls can be used only if the
machine is running or it is equipped with the
emergency pump.
In order to operate the emergency pump with the
manual controls, follow the instructions below:
•
Press the emergency stop button in the cabin
or in the platform.
•
Open the main valve compartment at the back
of the cabin to access to the main valve.
•
Fit the control levers (supplied) to the
elements of the main valve.
•
Push Z switch to activate the emergency
pump.
•
Lever 1 :
•
position A, boom down
•
position B, boom up
Lever 2
•
position A, boom telescope in
•
position B, boom telescope out
•
position A, slewing upper structure rotated
counterclockwise
Shift the lever of the main valve to the position
corresponding to the movement you wish to
obtain.
•
position B, slewing upper structure rotated
clockwise
When operating the emergency controls in manual
mode, the load limiting device is disabled.
Lever 3
Z
X
Y
Z
B
A
58
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Operating Instructions
Engine Condition Indicator
Road or site transfer
If the DPF Alert indicator light and/or the Engine
Critical Fault indicator light switch on, contact
service personnel.
When travelling on public roads, strictly obey the
local or national road traffic regulations.
Before traveling on public roads, ensure the following
is precautions are taken:
After Each Use
•
•
•
1
Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2
Retract the outriggers.
3
Retract and lower the boom to the stowed
position.
4
Move the transmission control lever to neutral.
5
Set the parking brake.
6
Set the Slewing upper structure locking pin
7
Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
•
Start the engine.
Align the rear wheels with the chassis.
Lock the slewing upper structure with the locking
pin.
Stow the floating forks as shown below
With the floating forks pitched back, do not move the
fork pitching cylinder as the machine could suffer
from damage.
• Retract and lower the boom.
• Set the Job-site/Road/Platform selector to “Road
mode”.
• Make sure that lights, horn and turn signals are
in working order.
• The transfer speed of the machine will depend
on the engine rpm.
Driving on public loads is only allowed with an
unloaded machine. Do not use the machine to
tow trailers.
Part No. 57.0009.0607
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December 2014
First Edition - Second Printing
Operating Instructions
Moving a disabled machine
Tow the machine only when no alternative is possible,
since this operation may result in serious damage to
the transmission. When possible, repair the machine
on site.
When the machine shall absolutely be towed:
1. Disable the parking brake.
2. Put the gear lever to neutral (see next page).
3. Select the two-wheel steer.
4. Connect a rigid draw bar to one of the two tie
down points present on the front axle.
5. When possible, start the engine and use the
hydraulic drive and the braking system.
6. Tow the machine for short distances and at low
speed (less than 5 km/h).
To re-activate the negative brake:
•
Remove the lock screws (1) and unscrew all
the brake release screws (3) on both sides of
the front axle, until the end of stroke has been
reached (until beating against the special screws
2). Note: do not move the special screws (2).
•
Assemble the lock screws (1) to the special
screws (2).
•
Lock the special screws (2) at 30 Nm tightening
torque and then lock screws (1) at 20 Nm
tightening torque on both sides.
Parking brakes disable
To unlock the negative brake of a faulty machine:
•
remove the three lock screws (1) from both
sides of the front axle, using an 8mm hex key.
Note: during this operation make sure to hold the
special screws (2), using a 25 mm combination
wrench.
•
Screw in the brake release screws (3), 1/2 turn
at a time, in sequence (A, B, C) until the torque
drops off sharply (4÷5 turns).
Parking brakes enable





60
GTH-5021 R

Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Operating Instructions
Setting the gear lever in neutral
Do not tow the machine without setting the
mechanical gear lever to neutral position.
To set the gear lever to neutral:
• Disconnect the hydraulic hoses from the gear
selecting cylinder.
Using an adjustable self-locking pliers, set the
dedicated lever in the position showed below.
2n
dG
EA
R
•
R
EA
tG
1s
Part No. 57.0009.0607
NEUTRAL
POSITION
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December 2014
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Parking and Storage
Short inactivity
Machine storage
Always park the machine in a safe way after a working
day, a shift and at night.
Take all precautions to prevent damage to those
persons who will approach the machine while
stationary:
• Park the machine so that it does not hinder other
operations.
• Retract and lower the boom fitted with attachment
on the ground.
• Disengage the transmission and set the parking
brake.
• Remove the key from the ignition switch and lock
the cab door.
In case of extended inactivity of the machine, follow
the above precautions. Additionally:
• Wash the machine thoroughly. For a better
cleaning, remove grills and protection casings.
• Carefully dry all machine parts by blowing some
compressed air.
• Lubricate the machine thoroughly.
• Do a walk-around inspection and replace any
worn or damaged part.
• Re-paint any worn or damaged part.
• Remove the battery, smear its terminals with
vaseline and store it in a dry place. Battery can be
used for other purposes. Otherwise, periodically
check its charge level.
• Refuel the tank to prevent internal oxidation.
• Store the machine in a sheltered and wellventilated place.
• Start the engine for about 10 minutes at least
once a month.
• When weather is particularly cold, empty the
radiator.
-
+
-
+
Disconnect the battery by turning the cut-out switch
(placed inside the engine housing) to OFF position
(see Inspection for Decals section).
09.4618.1678
62
Always remember that the ordinary maintenance
must be carried out even during the machine
inactivity. Pay particular attention to the fluid levels
and to those parts subject to ageing. Before restarting the machine, carry out an extraordinary
maintenance and carefully check all mechanical,
hydraulic and electrical components.
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Parking and Storage
Machine disposal
Cleaning and washing the
machine
Clean the machine in accordance with the following
instructions:
• Remove any oil or grease traces with a dry
solvent or a volatile mineral alcohol
• Before assembling a new part, remove any
protection product (rust-preventer, grease, wax
etc.).
• Remove any trace of rust from metal parts with
some emery cloth before smearing the part with
a protection product (rust-preventer, paint, oil
etc.).
Do not use water at high pressure for washing the
machine and especially the main valve, the solenoid
valves, electrical parts and the electric rotating joint
if equipped.
External washing
Before washing the machine, check that the engine
is shut down and the doors and windows are closed.
Do not, at any times, use fuel to clean the machine.
Use water or some steam. In cold climates, dry the
locks after washing or smear them with an antifreeze.
Before using the machine again, check its conditions.
Internal washing
Wash the machine interior with some water and a
sponge. Do not use water at high pressure. After
washing, dry with a clean cloth.
Washing the engine
Before washing the engine, protect the air intake filter
to prevent water from entering the circuit.
At the end of the machine life, call in a
specialized firm to dispose of it in compliance
with the local or national regulations.
Battery disposal
Used lead-acid batteries cannot be disposed
of as normal industrial solid wastes. Because
of the presence of harmful substances, they
must be collected, eliminated and/or recycled
in accordance with the laws of the EU.
Used batteries must be kept in a dry and
confined place. Make sure the battery is dry
and the cell plugs are tight. Place a sign on
the battery to warn of not using it. If before
disposal the battery is left in the open air,
it will be necessary to dry, smear the box
and the elements with a coat of grease and
tighten the plugs. Do not rest the battery on
the ground; it is always advisable to rest it on
a pallet and cover it. The disposal of batteries
shall be as rapid as possible.
If the machine shall be used in a marine or
equivalent environment, protect it against
salt deposits with an adequate treatment to
prevent rust formation.
Part No. 57.0009.0607
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December 2014
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Transport and Lifting Instructions
Observe and Obey:
 Genie provides this securement information as a
recommendation. Drivers are solely responsible
for making sure machines are properly secured
and the correct trailer is selected pursuant
to transportation regulations, other localized
regulations, and their company policy.
 Genie customers needing to containerize any
lift or Genie product should source a qualified
freight forwarder with expertise in preparing,
loading and securing construction and lifting
equipment for international shipment.
 Before loading for transport, make sure the
deck, ramps and machine tires are free of mud,
snow and ice. Failure to do so could cause the
machine to slide.
 Be sure the vehicle capacity, loading surfaces
and chains or straps are sufficient to withstand
the machine weight. Genie telehandlers are
very heavy relative to their size. See the
serial label for the machine weight. See the
Inspections section for the serial label location.
 Only qualified operators should move the
machine on or off the truck.
 The transport vehicle must be parked on a level
surface.
 The transport vehicle must be secured to
prevent rolling while the machine is being
loaded.
64
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Transport and Lifting Instructions
Securing to Truck or Trailer for Transit
Securing the Chassis
Turn the key switch to the off position and remove
the key before transporting.
Use chains of ample load capacity.
Inspect the entire machine for loose or unsecured
items.
Use a minimum of 6 chains. There are 8 tie down
points, four on each side of the machine.
Be sure the door and the door windows are
latched and secured (if equipped).
Fully lower the forks or attachment onto the truck
bed. Secure the forks or attachment with a suitable
strap or chain to prevent movement.
Prior to loading, level the telehandler and retract
the boom.
Adjust the rigging to prevent damage to the
chains.
Retract the outriggers.
Note: For center of gravity information see lifting
instructions section of this manual.
Lock the slewing upper structure.
Use a spotter to load and unload the telehandler.
Keep the boom as low as possible when loading
and unloading.
Set the parking brake.
Part No. 57.0009.0607
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December 2014
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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.
 Only certified crane operators should lift the
machine and only in accordance with the
applicable crane regulations.
Remove all loose items on the machine.
Attach the rigging only to the designated lifting
points on the machine.
 Be sure the crane capacity, loading surfaces
and straps or lines are sufficient to withstand
the machine weight. See the serial label for the
machine weight.
Adjust the rigging to prevent damage to the
machine and to keep the machine level.



1280 mm Height from ground
1444 mm Rear Offset
874 mm Side Offset
66
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Maintenance
Check the Tire Pressure
Tip-over hazard. An over-inflated tire can
explode which may compromise machine
stability and cause the machine to tip over.
Observe and Obey:
Tip-over hazard. The use of temporary flat tire
repair products may lead to tire failure which
could compromise machine stability and cause
the machine to tip over.
 Only routine maintenance items specified in this
manual shall be performed by the operator.
 Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer’s specifications
and the requirements specified in the
responsibilities manual.
Bodily injury hazard. An over-inflated tire can
explode and may cause death or serious
injury.
Note: This procedure does not need to be
performed on machines equipped with foam-filled
tires.
Maintenance Symbols Legend
The following symbols have been used in this
manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.
Indicates that tools will be required to
perform this procedure.
1
Check each tire with an air pressure gauge.
Add air as needed.
Wheel and Tire Specifications
Tire
18R x 19.5 TL XF
Rim
14 x 19.5
Wheel
10 holes DIN 70361
Tire pressure
7,5 bar (109 psi)
Indicates that new parts will be
required to perform this procedure.
Indicates that a cold engine will be
required to perform this procedure.
Part No. 57.0009.0607
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December 2014
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Maintenance
Check the Engine Oil Level
Check the Hydraulic Oil Level
Maintaining the proper engine oil level is essential
to good engine performance and service life.
Operating the machine with an improper oil level
can damage engine components.
Maintaining the hydraulic oil at the proper level is
essential to machine operation. Improper hydraulic
oil levels can damage hydraulic components. Daily
checks allow the inspector to identify changes
in oil level that might indicate the presence of
hydraulic system problems.
Note: Check the oil level with the engine off and on
a level surface.
1 Check the oil level dipstick. Add oil as needed.
Perkins 854E-E34TA
Oil type
Be sure that the engine is off, the frame is
level and the boom is in the stowed position.
2
Visually inspect the sight gauge located on the
left side of the hydraulic oil tank.
SHELL RIMULA R4 L 15W-40
 Result: The hydraulic oil level should be
halfway in the sight gauge.
Perkins 1104D-E44T
Oil type
1
SHELL RIMULA R4 L 15W-40
Diesel Fuel Requirements
3
Add oil as needed. Do not overfill.
Hydraulic oil specifications
Satisfactory engine performance is dependent
on the use of a good quality fuel. The use of a
good quality fuel will give the following result: long
engine life and acceptable exhaust emissions
levels.
Hydraulic Oil type
GAZPROMNEFT HYDRAULIC HDZ 46
The diesel engine must be operated using only
Ultra Low Sulfur Fuel. The sulphur content of this
fuel must be lower than 15 PPM.
Fuel
Type
Tank
68
Ultra Low Sulfur Fuel (ULSD)
205 L
54 gal
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Maintenance
Check the Engine Coolant Level Liquid Cooled Models
Maintaining the engine coolant at the proper level
is essential to engine service life. Improper coolant
level will affect the engine’s cooling capability and
damage engine components. Daily checks will
allow the inspector to identify changes in coolant
level that might indicate cooling system problems.
1
Check the Battery
Proper battery condition is essential to good
machine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in component damage and
hazardous conditions.
Electrocution hazard. Contact with hot or live
circuits may result in death or serious injury.
Remove all rings, watches and other jewellery.
Visually inspect the sight gauge located on the
top side of the radiator.
Bodily injury hazard. Batteries contain acid.
Avoid spilling or contacting battery acid.
Neutralize battery acid spills with baking soda
and water.
 Result: The fluid level should be halfway in the
sight gauge.
Bodily Injury Hazard. Fluids in the radiator
are under pressure and extremely hot. Use
caution when removing cap and adding fluids.
1
Put on protective clothing and eye wear.
Check Mirrors
2
Be sure that the battery cable connections are
tight and free of corrosion.
Maintaining the indirect visual aids is essential to
workplace visibility.
3
Be sure that the battery hold-down brackets
are in place and secure.
1. Visually inspect all mirrors to ensure they are
working properly and clean and free from debris.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate the
corrosion on the battery terminals and cables.
Part No. 57.0009.0607
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December 2014
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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.
Checklist A
A-1
Manuals and decals
A-2
Pre-operation inspect
Model
A-3
Function tests
Serial number
A-4
Lubricate the boom
Date
A-5
Engine maintenance - Perkins
models
Hour meter
·
·
Machine owner
Perform after 40 hours:
Inspected by (print)
A-6
Inspector signature
Perform after 50 hours:
Inspector title
A-7
Inspector company
Perform after 150 hours:
Instructions
A-8
Axle maintenance
Interlocks Spare Parts
Enabling Function Switch on
Joystick
07.0741.0012
Emergency Pump Switch
07.0703.0430
Semi-annually or 500 hours
Emergency Stop Pushbutton
07.0703.0441
Inspection:
Seat Switch
07.0703.0484
Magnetic Micro Target
56.0012.0066
Load Pin
09.0802.0042
Inspection:
A+B
A+B+C
Annually or 1000 hours
Inspection:
A+B+C+D
2 Years or 2000 hours
Inspection:
70
Axle maintenance
56.0016.0066
A
Quarterly or 250 hours
·
R
LMI Display & Board
Inspection:
·
N
Emergency pump (if equipped)
Make copies of this report to use for each
inspection.
Select the appropriate checklist(s) for the type of
inspection to be performed.
Daily or 8 hours
·
Y
A+B+C+D+E
Place a check in the appropriate box after each
inspection procedure is completed.
Use the step-by-step procedures in this section
to learn how to perform these inspections.
If any inspection receives an “N”, tag and remove
the machine from service, repair and re-inspect
it. After repair, place a check in the “R” box.
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Maintenance
A-1
Inspect the Manuals and Decals
Genie specifications require that this procedure be
performed every 8 hours or daily, whichever comes
first.
Maintaining the operator’s and safety manuals in
good condition is essential to safe machine operation.
Manuals are included with each machine and should
be stored in the container provided in the operator's
compartment. An illegible or missing manual will not
provide safety and operational information necessary
for a safe operating condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory for
safe machine operation. Decals alert operators and
personnel to the many possible hazards associated
with using this machine. They also provide users
with operation and maintenance information. An
illegible decal will fail to alert personnel of a procedure
or hazard and could result in unsafe operating
conditions.
1 Check to make sure that the operator's and safety
manuals are present and complete in the storage
container in the operator's compartment.
3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
inspect all decals on the machine for legibility
and damage.
 Result: The machine is equipped with all required
decals, and all decals are legible and in good
condition.
 Result: The machine is not equipped with all
required decals, or one or more decals are
illegible or in poor condition. Remove the
machine from service until the decals are
replaced.
4 Always return the manuals to the storage
container after use.
Note: Contact your authorized Genie distributor or
Genie Industries if replacement manuals or decals
are needed.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
 Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
 Result: The operator's manual is not appropriate
for the machine or all manuals are not in good
condition or is illegible. Remove the machine
from service until the manual is replaced.
Part No. 57.0009.0607
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Maintenance
A-2
Perform Pre-operation Inspection
A-3
Perform Function Tests
Genie specifications require that this procedure be
performed every 8 hours or daily, whichever comes
first.
Genie specifications require that this procedure be
performed every 8 hours or daily, whichever comes
first.
Completing a Pre-operation Inspection is essential to
safe machine operation. The Pre-operation Inspection
is a visual inspection 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 performs the function
tests. The Pre-operation Inspection also serves to
determine if routine maintenance procedures are
required.
Completing the function tests is essential to safe
machine operation. Function tests are designed to
discover any malfunctions before the machine is put
into service. A malfunctioning machine must never
be used. If malfunctions are discovered, the machine
must be tagged and removed from service.
72
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Maintenance
A-4
Lubricate the Boom
A-5
Perform Engine Maintenance Perkins Models
Genie specifications require that this procedure be
performed every 8 hours or daily, whichever comes
first.
Greasing the specified locations is essential for good
machine performance and service life.
Operating the machine with little or no grease may
cause the machine to perform poorly and continued
use may cause component damage.
1 Fully extend and raise the boom, then retract the
boom, checking to insure it operates smoothly.
There should be a light film of lubricant on wear
pad contact surfaces.
 Result: Boom operates smoothly and a thin film
of lubricant is visible. Proceed to step 5.
 Result: Boom does not extend or retract smoothly
and no lubricant is visible on wear pad contact
surfaces. Proceed to step 2.
2 Apply a thin layer of grease to the underside of
the number 3 boom tube where it makes contact
with the number 2 boom tube lower wear pads.
Note: Engine specifications require that this procedure
be performed every 8 hours or daily, whichever
comes first.
Engine oil level - check
Coolant level - check/add
Fuel system filter/water separator - drain
Engine tightness - check for leaks
Exhaust system - check for leaks
Required maintenance procedures and additional
engine information is available in the
Perkins 1104D Operation and Maintenance Manual
(Perkins part number SEBU8172-02),
Perkins 854 Operation and Maintenance Manual
(Perkins part number SEBU8726-01).
Perkins 1104D-E Operation and Maintenance Manual
Genie part number
57.4700.0000
Perkins 854 Operation and Maintenance Manual
Genie part number
57.4700.0001
3 Apply a thin layer of grease to the underside of
the number 2 boom tube where it makes contact
with the number 1 boom tube lower wear pads.
4 Lubricate the top and side boom tube wear pads.
5 Return the boom to the stowed position.
Grease Specification
PTFE INTERFLON FIN GREASE LS 2
Genie part number
Part No. 57.0009.0607
09.4693.0000
GTH-5021 R
73
December 2014
First Edition - Second Printing
Maintenance
A-6
Emergency Pump Operation (if equipped)
A-7
Perform Axle Maintenance
1 Stop the engine.
Note: Axle specifications require that this procedure
be performed after 50 hours.
2 Press the red emergency stop button.
3 Press the auxiliary pump on-off button and hold
it pressed down.
 Result: Operate the joystick to move the boom
and verify that movement is performed.
Oil level - check/add
Required maintenance procedures and additional
axle information is available in the
Carraro 26.32M Axle Maintenance and Repair Manual
(Carraro part number CA270015 - Front Axle,
CA270016 - Rear Axle).
Carraro 26.32M Front Axle Maintenance and
Repair Instructions
Genie part number
(Genie Instructions Library)
57.4700.0002
Carraro 26.32M Rear Axle Maintenance and
Repair Instructions
Genie part number
(Genie Instructions Library)
74
GTH-5021 R
57.4700.0003
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Maintenance
A-8
Perform Axle Maintenance
Note: Axle specifications require that this one-time
procedure be performed after 150 hours of operation.
Change axle oil
Clean magnetic oil plugs
Oil breather - clean
Grease axle (if required)
Required maintenance procedures and
additional axle information is available in the
Carraro 26.32M Axle Maintenance and Repair Manual
(Carraro part number CA270015 - Front Axle,
CA270016 - Rear Axle).
Carraro 26.32M Front Axle Maintenance and
Repair Instructions
Genie part number
(Genie Instructions Library)
57.4700.0002
Carraro 26.32M Rear Axle Maintenance and
Repair Instructions
Genie part number
(Genie Instructions Library)
Part No. 57.0009.0607
57.4700.0003
GTH-5021 R
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December 2014
First Edition - Second Printing
Attachments
This machine can be equipped with several
attachments.
Use only Genie approved attachments specified in
this section.
Information about how to fit and replace attachments
on the machine can be found in section “Quick Attach
Instructions”.
Information for use of this attachment is described in
the specific attachments operator’s manual available
on official Genie site www.genielift.com/en/servicesupport/manuals
76
Genie Approved Attachments List:
• Floating Forks
(part number 55.0750.0082)
• FEM3 Forks with Hydraulic SIDE-SHIFT +/100mm
(part number 59.0601.5012)
• UK Floating Forks L1200mm sect.100x65mm
(part number 55.0750.0083)
• Loading shovel 800 Lt
(part number 59.0201.9008)
• Concrete bucket 500 Lt manual discharge
(part number 59.0401.2012)
• Concrete bucket 500 Lt hydraulic discharge
(part number 59.0401.2013)
• Concrete bucket 800 Lt manual discharge
(part number 59.0401.2014)
• Concrete bucket 800 Lt hydraulic discharge
(part number 59.0401.2015)
• Concrete mixing bucket 500 Lt full hydraulic
(part number 59.0401.2016)
• Brick-holder basket
(part number 59.0401.2017)
• Fixed hook on plate
(part number 59.0700.9007)
• Mechanical jib 2m length/ 2000kg capacity
(part number 59.0802.3016)
• Mechanical jib 4m length/900kg capacity
(part number 59.0802.3017)
• Hydraulic jib, 4m length/900kg capacity
(part number 59.0802.3018)
• Hydraulic winch 4000 kg
(part number 59.0901.9005)
• Hydraulic winch 5000 kg
(part number 59.0901.9008)
• Fixed man-platform: 2P/300-F
(part number 59.1111.6013)
• Rotating and extendable man-platform:
3P/700-REM 4400 +/- 90°
(part number 59.1111.6014)
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Attachments
Work Platform Hazards
Work Area Safety
Platform Occupant Restraint Device
Use only a Genie approved personnel work
platform.
Personal protective equipment (PFPE) is required
for all occupants of the work platform.
Occupants must wear a
safety belt or harness in
accordance with
governmental regulations.
Attach the lanyard to the
anchor provided in the
platform.
Do not lift personnel with a
telehandler unless it is equipped
with an approved work platform.
The user or employer and the operator shall
further investigate, and comply with, all applicable
job-site, local, state, provincial, or federal rules,
regulations, and standards related to the use of
the telehandler with a work platform.
Read, understand and obey all warnings and
instructions provided with the approved work
platform.
The operator and the platform occupants must
be instructed regarding the specific hazards
associated with using the telehandler with the work
platform, and utilize all means, including those
provided by the user or employer, to avoid them.
All PFPE must comply with applicable
governmental regulations, and must be
inspected and used in accordance with the PFPE
manufacturer’s instructions.
Telehandler Operation
Always perform a pre-operation inspection of the
platform, per the Genie’s instructions, prior to use.
Do not drive the telehandler
when occupants are in the
platform.
If damage or any unauthorized variation from
factory delivered condition is discovered, the
platform must be tagged and removed from
service.
Do not modify the platform without written approval
by Genie.
Do not use the telehandler with a work platform
attached for any purpose other than positioning
the machine.
Part No. 57.0009.0607
GTH-5021 R
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December 2014
First Edition - Second 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/
telehandler combination you are using.
Do not lift a suspended load without first
understanding the local, state, federal, or
provincial rules, standards and regulations related
to the activity. Additional rules, standard and
regulations may apply. Additional training may be
required.
Do not permit
the load to swing
freely. Always
properly tether
loads to restrict
movement.
Driving across
grades, sudden
starts, stops,
and turns can
cause the load
to swing and
create a hazard
if not externally
stabilized.
If a telehandler must be used to transport a load,
the following precautions for the protection of the
operator shall be taken.
Read, understand and obey all warnings and
instructions provided with the attachment that is
approved for suspending loads.
Only a properly designed, tested and approved
attachment should be used to carry a suspended
load.
The telehandler load charts are designed for
loads where the load center is stationary. As
a suspended load moves, the load center
can change. As a result, extreme caution in
transporting and lifting, or placing, the load must
be observed to minimize the potential for the load
to move.
Keep the boom retracted as much as practical.
Do not lift suspended loads when wind speeds can
cause an unsafe situation.
All movements of the load must be accomplished
gradually and at the slowest practical speed to
prevent the load from swinging.
Keep the heavy part of the load closest to the
attachment.
Never drag or pull a load sideways.
Only lift a load vertically; do not pull a load
horizontally as it could cause excessive swinging
of the load.
The weight of all rigging (slings, shackles etc.)
must be included as part of the load.
78
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Attachments
Identify the proper lifting points of the load, taking
into consideration the center of gravity and load
stability.
Do not attempt to use the telehandler framelevelling to compensate for a swinging load or to
adjust the load after it has been raised.
When driving on a rise with empty shovel, proceed
into reverse.
When sloping downward with empty shovel,
proceed in forward gear.
Do not allow suspended loads to oscillate.
Do not try to move fixed or obstructed loads.
Do not drag loads when they are hooked up.
Do not leave the telehandler unattended with a
suspended load.
A suspended load has a dynamic, and therefore
an unpredictable effect on machine stability,
operate with caution.
Keep the boom and load as low as practical while
maintaining visibility in the direction of travel.
Do not exceed walking speed (2 mph / 3.2 km/h)
with a suspended load.
Start, travel, turn and stop slowly to prevent the
load from becoming unstable or swinging.
The fixed hook has been designed to support
the load declared beside. The maximum payload
corresponds to the nominal capacity rating of the
handler on which it is installed and is indicated on
the load charts supplied with the equipment.
Do not use any controls to re-position the load
when traveling. Come to a gradual and complete
stop before attempting to re-position the load.
Fall Hazards
Do not attempt to cross inclines as the load
center will move towards the tipping line, thereby
reducing stability.
Don’t use the shovel for rising or transporting
people.
Do not lift or suspend personnel.
Only climb or descend inclines with extreme care
as the load center will move towards the tipping
line, thereby reducing stability
Do not park on a slope.
When driving on a rise with loaded material,
proceed in forward gear and travel with load in the
lowest possible position.
When sloping downward with loaded material,
proceed into reverse
Part No. 57.0009.0607
GTH-5021 R
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December 2014
First Edition - Second Printing
Attachments
Collision Hazards
Falling Object Hazards
Be sure that the load is clear of any adjacent
obstacles before lifting.
Do not raise the load into the
fall zone shown.
When visibility is or could be obstructed, near
or at the load placement, the operator shall use
alternative or additional means to safely lift the
load, such as a qualified signal person.
Signal persons must remain in constant
communication (verbal or hand) and be in visual
contact with the operator at all times.
Do not operate the machine while people are
under the load or in the fall zone.
Crush Hazards
Do not suspend loads using slings or chains from
the forks or fork carriage.
Never allow the signal person to come between
the suspended load and another object (such as
the telehandler itself).
Avoid lifting double tiered loads.
Before any maintenance on the mixing bucket,
rest the bucket on the ground, stop the machine,
remove the starter key and lock the cab door
to prevent anybody from gaining access to the
control panel.
80
When loading round-shaped objects (as petrol
drums, etc) bind them with straps or ropes and
travel at reduced speed.
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Attachments
Lifting a Suspended Load
Travelling
Verify that landing point is level and can safely
support the load.
Be sure that the path of travel is level and capable
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.
Level the frame on the telehandler.
Ask a signal person to assist with your travel if
visibility will be obstructed in the direction of travel.
Tether the load to restrict movement.
Ask a signal person to assist with lifting the load if
visibility will be obstructed at the point of operation.
Make sure that the signal person remains in
constant communication and is in visual contact at
all times.
With the boom retracted as far as practical, slowly
and gradually raise the boom and load, making
sure to keep the load and boom as low to the
ground as practical.
Be sure that all boom and attachment movements
are performed as slow as practical to avoid
swinging of the load.
Part No. 57.0009.0607
Crush or Collision Hazard. Make sure that the
signal person remains in constant communication
and be in visual contact at all times.
Only make adjustments to the load after bringing
the telehandler to a complete stop.
Start, stop, travel and turn slowly to prevent the
load from becoming unstable or swinging.
Do not travel faster than walking speed (<2 mph /
3.2 km/h).
GTH-5021 R
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Attachments
Placing the Load
Signal Person
Ask a signal person to assist with placing the
load if visibility will be obstructed at the point of
operation.
A signal person is recommended when:
Make sure that the signal person remains in
constant communication and be in visual contact
at all times.
Come to a complete stop near the landing point.
The point of operation, meaning the load travel or
the area near or at load placement, is not in full
view of the operator.
When the equipment is traveling, the view in the
direction of travel is obstructed.
Set the parking brake and place the transmission
into neutral.
Due to site specific safety concerns, either
the operator or the person handling the load
determines that it is necessary.
Slowly, and gradually, place the load over the
landing point and lower the load until it is safely
supported.
Signal persons must remain in constant
communication (verbal or hand) and be in visual
contact with the operator at all times.
Once the load has been landed, continue to lower
the boom until the rigging and tethers can be
removed.
The hand signal chart below may be used as
reference.
82
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Attachments
STOP. With arm
extended horizontally to
the side, palm down,
arm is swung back and
forth.
EMERGENCY STOP. With both arms extended
horizontally to the side, palms down, arms are
swung back and forth.
HOIST. With upper
arm extended to the
side, forearm and index
finger pointing straight
up, hand and finger
make small circles.
RAISE BOOM. With
arm extended
horizontally to the side,
thumb points up with
other fingers closed.
SWING. With arm
extended horizontally,
index finger points in
direction that boom is to
swing.
RETRACT
TELESCOPING BOOM.
With hands to the front
at waist level, thumbs
point at each other with
other fingers closed.
RAISE THE BOOM
AND LOWER THE
LOAD. With arm
extended horizontally to
the side and thumb
pointing up, fingers
open and close while
load movement is
desired.
DOG EVERYTHING.
Hands held together at
waist level.
LOWER. With arm
and index finger
pointing down, hand
and finger make small
circles.
LOWER BOOM. With
arm extended
horizontally to the side,
thumb points down with
other fingers closed.
EXTENDED
TELESCOPING BOOM.
With hands to the front
at waist level, thumbs
point outward with other
fingers closed.
TRAVEL/TOWER
TRAVEL. With all
fingers pointing up, arm
is extended horizontally
out and back to make a
pushing motion in the
direction of travel.
LOWER THE BOOM
AND RAISE THE
LOAD. With arm
extended horizontally to
the side and thumb
pointing down, fingers
open and close while
load movement is
desired.
MOVE SLOWLY. A
hand is placed in front of
the hand that is giving
the action signal.
Part No. 57.0009.0607
GTH-5021 R
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Specifications
GTH-5021R
Height, stowed
Length, stowed, at fork-holder plate
Width, standard tires
2.99 m
Floor loading information
7.17 m
Tire load, maximum
10,500 kg
Occupied floor pressure
20.32 kPa
2.42 m
Wheelbase
3.00 m
Ground clearance, center
0.36 m
Weight
17,180 kg
Working fork height,
maximum
20.86 m
Horizontal reach maximum
18.24 m
Reach at maximum height
3.91 m
Lift capacity, maximum height
outriggers up
outriggers down
outriggers down & not aligned
2,000 kg
3,000 kg
250 kg
Lift capacity, maximum reach
outriggers up
outriggers down
outriggers down & not aligned
0 kg
475 kg
0 kg
Maximum lift capacity
5,000 kg
Drive speed, maximum,
30 km/h
Chassis Levelling (if equipped)
+/- 6°
Turning radius, outside,
2 wheel steer
7.35 m
Turning radius, outside,
4 wheel steer
4.22 m
Fuel tank capacity
205 L
Maximum grade
38 %
Horn sound level,
manufacturer’s rating
Backup alarm sound level,
manufacturer’s rating
Mean assessed vibration level
transmitted to body
Sound pressure level at the operator
position (in accordance with EN12053)
Guaranteed sound power level LwA
(in accordance with the Directive 2000/14/CE)
84
110 dB
95 dB
0,32 m/s2
74 dB
102 dB
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Load Charts
GTH-5021R, Standard Carriage
GTH-5021 R
0°
180°
22
77.50°
21
70°
20
19
E
60°
18
17
D
50°
16
15
C
40°
14
13
B
11
30°
20.64 m
12
A
10
9
8
4000 kg
3000 kg
1500 kg
2000 kg
1000 kg
5
750 kg
250 kg
0 kg
6
500 kg
20°
7
GTH-5021 R
0.60 m
22
10°
70°
20
2
19
1
E
60°
±90°ĈĈ
18
0°
0
17
-1
0°
180°
77.50°
21
3
-3.50°
D
50°
16
-2
19 18 17 16 15 14 13 12 11 10
9
8
7
6
5
4
3
2
1
15
0
C
40°
14
18.24 m
13
09.4618.1642
B
12
11
30°
20.86 m
4
A
10
9
8
4
22
±90°ĈĈ
77.50°
21
4000 kg
5000 kg
2500 kg
3000 kg
1500 kg
2
1
70°
20
10°
3
0.60 m
475 kg
5
GTH-5021 R
2000 kg
750 kg
6
1000 kg
20°
7
0°
0
19
E
60°
-1
18
-3.50°
-2
17
19 18 17 16 15 14 13 12 11 10
D
50°
9
8
7
6
5
4
3
2
1
0
18.24 m
16
09.4618.1643
15
C
40°
14
13
B
11
30°
20.64 m
12
A
10
9
8
4
0.60 m
2500 kg
5
1500 kg
500 kg
1000 kg
0 kg
6
250 kg
20°
7
10°
3
2
1
0°
0
-1
-3.50°
-2
19 18 17 16 15 14 13 12 11 10
9
18.24 m
Part No. 57.0009.0607
8
7
6
5
4
3
2
1
0
09.4618.1644
GTH-5021 R
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December 2014
First Edition - Second Printing
Load Charts
GTH-5021R, Hook
GTH-5021 R
0°
180°
±90°ĈĈ
GTH-5021 R
0°
180°
09.4618.1696
GTH-5021 R
±90°ĈĈ
09.4618.1697
09.4618.1698
86
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Load Charts
GTH-5021R, 900kg Jib
GTH-5021 R
0°
180°
±90°ĈĈ
GTH-5021 R
0°
180°
09.4618.1699
GTH-5021 R
±90°ĈĈ
09.4618.1700
09.4618.1701
Part No. 57.0009.0607
GTH-5021 R
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Load Charts
GTH-5021R, 2000kg Jib
GTH-5021 R
0°
180°
±90°ĈĈ
GTH-5021 R
0°
180°
09.4618.1702
GTH-5021 R
±90°ĈĈ
09.4618.1703
09.4618.1704
88
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Load Charts
GTH-5021R, Winch
GTH-5021 R
0°
180°
±90°ĈĈ
GTH-5021 R
0°
180°
09.4618.1705
GTH-5021 R
±90°ĈĈ
09.4618.1706
09.4618.1707
Part No. 57.0009.0607
GTH-5021 R
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Load Charts
GTH-5021R, Bucket
GTH-5021 R
0°
180°
±90°
GTH-5021 R
0°
180°
09.4618.1708
GTH-5021 R
±90°ĈĈ
09.4618.1709
09.4618.1710
90
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
Load Charts
GTH-5021R, Man-platform NOT FOR EU MARKET
3P/700
REM
4400
GTH-5021 R
0°
180°
±90°ĈĈ
09.4618.1711
2P/
300 F
GTH-5021 R
±90°ĈĈ
0°
180°
09.4618.1712
Part No. 57.0009.0607
GTH-5021 R
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Test
Overload Test Procedure
Telehandler coupled to attachments with fixed centre of load (Forks, Bucket, Clamps):
1,33 x Q
Ref. Standard EN1459
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
Ref. Standard EN13000
Q = Nominal Rated Load Capacity
Fb = Boom weight reduced (i.e. equal overturning moment) at boom tip.
92
GTH-5021 R
Part No. 57.0009.0607
First Edition - Second Printing
December 2014
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.
Model/Type:
Description:
Serial Number:
Manufacture Date:
Country of Manufacture:
Manufacturer:
TEREX Global GmbH
Muhlenstrasse 26
8200 Schaffhausen
Switzerland
European representative:
Genie UK LTD
The Maltings
Wharf Road, Grantham, Lincolnshire
NG31 6BH United Kingdom
Empowered signatory:
Place of issue:
Date of issue:
Part No. 57.0009.0607
GTH-5021 R
93
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