Genie GTH-6622 Operator's Handbook Manual
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Genie GTH-6622 Operator's Handbook Manual

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OPERATOR HANDBOOK
Code 57.0005.8200 - Rev.0 12/2005
Handler with telescopic boom
GTH-6622
English
Before Serial Number: 18723
Edition
CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE
CAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES

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  • Page 1 OPERATOR HANDBOOK Code 57.0005.8200 - Rev.0 12/2005 Handler with telescopic boom GTH-6622 English Before Serial Number: 18723 Edition CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE CAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES...
  • Page 2 +44 (0)1476 584334 +31 183 581 566 Operator Handbook 57.0005.8200 - GTH-6622 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means without prior written permission from TEREXLIFT srl.
  • Page 3 LIST OF REVISED PAGES Revision Revised Issued date pages Notes...
  • Page 4 LIST OF REVISED PAGES Revision Revised Issued date pages Notes...
  • Page 5 GENERAL INFORMATION Sect. SAFETY If you are unsure about anything, please address to Sect. OPERATING INSTRUCTIONS GENIE Assistance Service or to your agent/dealer: Sect. MAINTENANCE addresses, phone and fax numbers are printed in Sect. TROUBLESHOOTING the cover and in the title-page of this manual.
  • Page 6 Handler with telescopic boom GTH-6622 INTRODUCTION ■ SYMBOLS ATTENTION When using the machine, operators could have to face some situations requiring special care and particular knowledge. Draws the attention to situations that involve the machine efficiency. When these situations involve the safety of operators...
  • Page 7 Handler with telescopic boom GTH-6622 GENERAL INDEX GENERAL INDEX GENERAL INFORMATION Sect. SAFETY Sect. OPERATING INSTRUCTIONS Sect. MAINTENANCE Sect. TROUBLESHOOTING Sect. OPTIONAL ATTACHMENTS Sect. TABLES AND DOCUMENTS ENCLOSED Sect. Page Document 57.0005.8200 - 12/2005...
  • Page 8 Handler with telescopic boom GTH-6622 Intentionally blank page Page Document 57.0005.8200 - 12/2005...

  • Page 9: Table Of Contents

    Handler with telescopic boom GTH-6622 GENERAL INFORMATION Section GENERAL INFORMATION TABLE OF CONTENTS CONVENTIONAL REFERENCES ................A-1.1 Machine position ......................A-1.2 Labels and warning plates applied on the machine ........... A-1.2.1 Position ........................A-1.3 Explanation of the different symbols used on the machine ........

  • Page 10: Conventional References

    Handler with telescopic boom GTH-6622 GENERAL INFORMATION A-1 CONVENTIONAL REFERENCES ■ A-1.1 MACHINE POSITION Conventionally the machine should be considered positioned as shown in the figure. This convention is necessary to make any reference of this handbook to different machine parts (front, rear, etc.) clear and unmistakable.

  • Page 11: A-1.2 Labels And Warning Plates Applied On The Machine

    Handler with telescopic boom GTH-6622 GENERAL INFORMATION ■ A-1.2 LABELS AND WARNING PLATES APPLIED ON THE MACHINE This paragraph lists the labels and warning plates normally applied on standard machines or on special attachments coupled to the machine. IMPORTANT The familiarisation with these labels is never a waste of time.
  • Page 12 Handler with telescopic boom GTH-6622 GENERAL INFORMATION 09.4616.0051 0 1 2 3 4 5 6 7 97673 09.4618.0646 09.4618.0389 09.4618.0639 97667 97671 97675 97664 97667 09.4618.0205 0° 09.4618.0642 09.4618.0640 97664 09.4618.0010 09.4618.0641 09.4618.0547 09.4618.0547 82558 09.4618.0109 97674 97664 97668 97665...
  • Page 13 Handler with telescopic boom GTH-6622 GENERAL INFORMATION Code Description 82558 Fluid at pressure 97664 Risk of crushing hands 97665 Safety belts 97666 Read the user’s manual 97667 Risk of burns and scalds 97668 Risk of overturning 97669 Risk due to falling objects...

  • Page 14: A-1.3 Explanation Of The Different Symbols Used On The Machine

    Handler with telescopic boom GTH-6622 GENERAL INFORMATION ■ A-1.3 EXPLANATION OF THE DIFFERENT SYMBOLS USED ON THE MACHINE IMPORTANT This paragraph illustrates those symbols that are normally applied on the main control devices and Spend the necessary time to become familiar with instruments of a standard machine, and those that can these symbols and to learn their meaning.
  • Page 15 Handler with telescopic boom GTH-6622 GENERAL INFORMATION Symbol Description Symbol Description Front (optional) work light Lifting point Fuel plug Engine oil filler Continuous flow selector Pushbutton enabling the attachment coupling/release Horn pushbutton Mechanical gear selector Warning light - gear put Page Document 57.0005.8200 - 12/2005...

  • Page 16: Machine Identification

    Handler with telescopic boom GTH-6622 GENERAL INFORMATION A-2 MACHINE IDENTIFICATION IMPORTANT Check that the operator handbook refers to the delivered machine. When asking for information or technical assistance, always specify model, type and serial number of the machine. ■ A-2.1...

  • Page 17: A-2.4 Chassis Serial Number

    Handler with telescopic boom GTH-6622 GENERAL INFORMATION ■ A-2.4 CHASSIS SERIAL NUMBER The chassis serial number is punched on the front left part of the chassis side member. ■ A-2.5 IDENTIFICATION PLATES OF THE MAIN PARTS The plates of the main components, not directly manufactured by TEREXLIFT srl (for instance, engines, pumps, etc.), are located where originally applied by...

  • Page 18: Allowed Use

    Any Working in confined and non-ventilated modification of the machine not carried out by environments. GENIE or an authorised assistance centre involves the automatic invalidation of the conformity of the machine to the Directive 98/37/EC. ■ A-3.3...

  • Page 19: A-3.4 Applicable Standards

    Handler with telescopic boom GTH-6622 GENERAL INFORMATION ■ A-3.4 APPLICABLE STANDARDS EN 50081-1: 1997 Electromagnetic compatibility – Generic requirements on emissions - Part 1 For the operator’s safety, the following standards were EN 50082-1: 1997 Electromagnetic compatibility – Generic obeyed during the risk assessment of the handler fitted...

  • Page 20: A-3.5 Safety Devices

    Handler with telescopic boom GTH-6622 GENERAL INFORMATION ■ A-3.5 SAFETY DEVICES • The machine is equipped with a negative brake on the front axle which engages automatically when the engine stops. When this brake is disengaged, the engine start- up is inhibited.

  • Page 21: General Description

    Handler with telescopic boom GTH-6622 GENERAL INFORMATION A-4 GENERAL DESCRIPTION ■ A-4.1 LIST OF THE MAIN COMPONENTS µ ¸ ¹ 1 - Forks 2 - Attachment holding frame 3 - 2 boom section 4 - 1 boom section 5 - Engine hood...

  • Page 22: A-4.2 Description Of The Main Components

    The differential axles transmit the motion to the wheels. The machine can be fitted with a wide range of optional The locking device acting on the front axle enables accessories: please address to Genie sales network. the machine to move also on low grip grounds. Tyres...

  • Page 23: Technical Data And Performance

    Handler with telescopic boom GTH-6622 GENERAL INFORMATION A-5 TECHNICAL DATA AND PERFORMANCE ■ A-5.1 MAIN DIMENSIONS GTH-6622 Overall height 6' - 9" Overall width 6' - 7" Track 5' - 3" Cab width 2' - 10" Wheel-base 8' - 8"...

  • Page 24: A-5.5 Payload And Reach

    Handler with telescopic boom GTH-6622 GENERAL INFORMATION ■ A-5.5 PAYLOAD AND REACH GTH-6622 Max lifting height 22' - 6" Reach at max height 2' - 8" Max reach forward 12' - 6" Attachment holding plate rotation 135° Maximum payload 6600...

  • Page 25: Lifetime

    Handler with telescopic boom GTH-6622 GENERAL INFORMATION A-7 ITEMS SUPPLIED A-6 LIFETIME Following items are supplied together with the The lifetime of the machine is 10 000 hours provided machine: all checks, service jobs and overhauls are done at the times scheduled.
  • Page 26 Handler with telescopic boom GTH-6622 GENERAL INFORMATION Intentionally blank page A-18 Page Document 57.0005.8200 - 12/2005...
  • Page 27 Handler with telescopic boom GTH-6622 SAFETY Section SAFETY TABLE OF CONTENTS GENERAL REMARKS ....................PREREQUISITES OF THE PERSONNEL IN CHARGE ..........B-2.1 Requisites of the machine operators ................. B-2.2 Requisites of the servicemen ..................B-2.3 Working clothes ......................B-2.4 Personal protective equipment ..................

  • Page 28: General Remarks

    The instructions given in this handbook are the emotional: ones established by GENIE. They do not exclude they shall keep calm and always be able to evaluate other safe and most convenient ways for the their own physical and mental conditions.

  • Page 29: B-2.2 Requisites Of The Servicemen

    Handler with telescopic boom GTH-6622 SAFETY ■ B-2.2 ■ B-2.4 REQUISITES OF THE SERVICEMEN PERSONAL PROTECTIVE EQUIPMENT The personnel charged with the machine maintenance Under special working conditions, the following shall be qualified, specialised in the maintenance of personal protective equipment should be used: earth-moving machines, and shall have the following •...

  • Page 30: Safety Precautions

    Handler with telescopic boom GTH-6622 SAFETY • Look for the best route to the job site. B-3 SAFETY PRECAUTIONS • When the machine is running, nobody can enter ■ B-3.1 its working range. JOB SITE • While working, keep the working area in order.

  • Page 31: B-3.2 Getting Ready To Work

    Handler with telescopic boom GTH-6622 SAFETY ■ B-3.2 GETTING READY TO WORK • When entering/leaving the cab or other raised Before any operation, following precautions should be parts, always face the machine; never turn the taken: back. • First of all, make sure that the maintenance •...
  • Page 32 Handler with telescopic boom GTH-6622 SAFETY • Except for maintenance purposes, do not remove safety devices, shields, protection cases, etc. DANGER Should their removal be necessary, stop the engine, remove them with the greatest care and always remember to refit them before starting the engine Any intervention on the hydraulic circuit must be and using the machine again.

  • Page 33: Safety Devices

    Handler with telescopic boom GTH-6622 SAFETY • Do not leave fuel cans or bottles in unsuitable B-4 SAFETY DEVICES places. • Do not empty catalytic mufflers or other vessels DANGER containing burning materials without taking the necessary precautions. • Carefully handle all flammable or dangerous substances.
  • Page 34 Handler with telescopic boom GTH-6622 SAFETY Intentionally blank page Page Document 57.0005.8200 - 12/2005...
  • Page 35 Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS Section OPERATING INSTRUCTIONS TABLE OF CONTENTS BEFORE ENTERING THE MACHINE ..C-2 C-3.4.4 Extending/retracting the boom ... C-18 ENTERING THE MACHINE ....C-3 C-3.4.5 Quick-coupling the attachments ..C-19 C-2.1 Entering the cab (only with cabin SETUP ..........

  • Page 36: Before Entering The Machine

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS BEFORE ENTERING THE INTRODUCTION MACHINE This section provides the operator a practical guide Checks and cleaning for the gradual learning of the machine use. • Clean glasses, lights and rear view mirrors. The operator should get into the driving cab and carry •...

  • Page 37: Entering The Machine

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS C-2 ENTERING THE MACHINE CAUTION ■ C-2.1 ENTERING THE CAB (ONLY WITH CABIN CLOSED OR GLASS KIT INSTALLED) The upper section of the door must be secured to the rear part of the driving cab or latched to the lower section of the same door.
  • Page 38 Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-2.1.1 Leaving the cab in an emergency (ONLY WITH CABIN CLOSED OR GLASS KIT INSTALLED) In an emergency, the operator can use he front or the rear window as safety exit-ways. The rear window has handles for partially opening the glass.

  • Page 39: C-2.2 Adjusting The Seat

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-2.2 ADJUSTING THE SEAT A correct adjustment of the seat ensures the operator a safe and comfortable driving. The handler seat is fitted with devices which allow for the adjustment of the springing, the height and the distance from the controls.

  • Page 40: C-2.4 Adjusting The Steering Column

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-2.4 ■ C-2.5 ADJUSTING THE STEERING COLUMN ADJUSTING THE REAR VIEW MIRRORS Both steering column and dashboard can be set to a The machine is fitted with two rear view mirrors: different angle. For this purpose: •...

  • Page 41: Driving Place

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS DRIVING PLACE 2 4 6 8 10 8 6 °C °C 0 1 2 3 4 5 6 7 13 14 15 Page Document 57.0005.8200 - 12/2005...

  • Page 42: C-3.1 Controls And Instruments

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-3.1 CONTROLS AND INSTRUMENTS 1 Dashboard 2 Water level 3 Warning light - gear put 4 Brake oil tank 5 Ignition switch 6 Warning light - glow plugs preheating 7 Warning light - air filter clogged...

  • Page 43: C-3.2 Engine Controls And Instruments

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-3.2.2 C-3.2 ENGINE CONTROLS AND Forward/reverse gear selector switch INSTRUMENTS Three-position switch with lock in neutral position: ■ C-3.2.1 Ignition switch Neutral position; no gear engaged Three-position switch: Shift lever to pos. F to select the forward gear...

  • Page 44: C-3.2.3 Brakes

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-3.2.3 ■ C-3.2.4 Brakes Accelerator control Service brake pedal Gas pedal Gradually step on the brake pedal to decelerate and stop the machine. The pedal operates on the front axle. Its pressure controls the engine rpm and, coupled to Fully depressing the brake pedal causes a reset of the the gearbox, the machine speed.

  • Page 45: C-3.2.5 Pushbutton Enabling The Attachment

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-3.2.7 ■ C-3.2.5 Pushbutton enabling the attachment Continuous flow selector coupling/release Selection button Selection button Button with two stable positions: Pushbutton with two stable positions. 1 Pressing this selector delivers a Pressing this button activates the attachment continuous flow of oil to the attachment coupling and release.

  • Page 46: C-3.2.9 Auxiliary Drive Controls

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-3.2.9 Auxiliary drive controls Horn pushbutton Pushbutton with green glass Press this button to operate the horn. Windscreen washer button When pushed, it sprays a jet of detergent solution on the windscreen and makes the wiper functioning easier.

  • Page 47: C-3.3 Instruments And Light Indicators

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS C-3.3 INSTRUMENTS AND LIGHT Indicator light - parking brake engaged INDICATORS This light comes on to warn that the negative ■ C-3.3.1 parking brake is engaged. Instruments Engine coolant temperature indicator Signals the engine coolant temperature.

  • Page 48: C-3.4 Control Lever

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS C-3.4 CONTROL LEVER Handlers are equipped with a hydraulically driven servo-controlled lever. The lever has two pushbuttons: one for coupling/ releasing the attachments and the other for pitching the attachment frame forwards/backwards Shifting the lever to one of the four directions (right/ left, forwards/backwards) moves the boom up and down and the telescope out and in.

  • Page 49: C-3.4.1 Function Selection

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-3.4.1 Function selection The lever is enabled to carry out the following motions: • Boom lowering/lifting shift the control lever to • Boom extraction/retraction shift the control lever to • Attachment back/forward tilting...

  • Page 50: C-3.4.2 Lifting/Lowering The Boom

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-3.4.2 Lifting/lowering the boom CAUTION Before operating the boom, make sure that nobody is within the working range of the machine. To lift or lower the boom: • Smoothly shift the lever to position...

  • Page 51: C-3.4.3 Pitching The Attachment Holding

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-3.4.3 Pitching the attachment holding frame forwards/backwards CAUTION Before operating the boom, make sure that nobody is within the working range of the machine. To tilt the attachment holding frame forwards/ backwards: •...
  • Page 52 Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-3.4.4 Extending/retracting the telescope CAUTION Before operating the boom, make sure that nobody is within the working range of the machine. To extend or retract the boom telescope: • Smoothly shift the lever to position...

  • Page 53: C-3.4.5 Quick-Coupling The Attachments

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-3.4.5 Quick-coupling the attachments CAUTION Before operating the boom, make sure that nobody is within the working range of the machine. To lock the attachments: • Press button together with the button the dashboard to enable the function.

  • Page 54: Setup

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-4.2 STARTING THE ENGINE C-4 SETUP For the low temperature starting, see paragraph C-4.4. ■ C-4.1 BEFORE STARTING THE ENGINE • Put the forward/reverse speed selection lever to • To ensure safe conditions to the operators and the neutral.

  • Page 55: C-4.3 Jump-Starting The Engine

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-4.3 JUMP-STARTING THE ENGINE ATTENTION Do not start the engine using a quick charge booster to avoid any damage to the electronic boards. DANGER When jump-starting the engine through the battery of another machine, make sure that the two vehicles cannot collide to prevent formation of sparks.

  • Page 56: C-4.4 Low Temperature Starting

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-4.4 ■ C-4.5 LOW TEMPERATURE STARTING DISCONNECTING THE BATTERY In case of cold starting, use an oil with a SAE viscosity Before any maintenance or repair work, and especially adequate to the ambient temperature.

  • Page 57: Stopping And Parking The Machine

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-4.7 STOPPING AND PARKING THE C-5 USING THE HANDLER MACHINE This chapter describes some techniques and provides instructions for a safe use of the machine fitted with When possible, stop the machine on a dry, level and standard forks.

  • Page 58: C-5.1 Using The Load Charts

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-5.1 USING THE LOAD CHARTS The charts indicating the maximum permissible load in CAUTION relation to the boom extension and the lifting height of the same load are installed on the cab windscreen and/ or illustrated in the quick guide.

  • Page 59: C-5.2 Handling Loads

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-5.2 HANDLING LOADS ■ C-5.2.1 Adjusting the forks Forks shall be spaced to suit the load going to be handled. For this purpose: • Loosen the nut of the locking screws. •...

  • Page 60: C-5.2.2 Working Phases

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-5.2.2 Working phases • Release the parking brake and start a new working cycle. When forks are correctly spaced, the handler is ready to use. Work can be subdivided into three different phases: CAUTION loading, transfer and unloading.

  • Page 61: C-5.3 Changing The Attachment

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-5.3 CHANGING THE ATTACHMENT CAUTION ATTENTION After substitution, visually check the attachment is correctly coupled to the boom, before operating Use only attachments directly manufactured or the machine. A wrongly coupled attachment may recommended by Terexlift and detailed in the result in damage to persons or things.

  • Page 62: Transporting The Machine

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS • Couple the connectors of the attachment, if any, C-6 TRANSPORTING THE MACHINE to the quick couplings of the frame. ■ C-6.1 MOVING A DISABLED MACHINE Tow the machine only when no alternative is possible,...

  • Page 63: C-6.2 Road Or Site Transfer

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-6.2 ROAD OR SITE TRANSFER ■ C-6.3 LIFTING THE MACHINE When the machine shall be lifted, use only means When travelling on public roads, strictly obey the local having a suitable capacity. The characteristic data are or national road traffic regulations.

  • Page 64: Transporting The Machine On Other Vehicles

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ C-6.4 TRANSPORTING THE MACHINE ON OTHER VEHICLES To transport the machine on another vehicle, follow the steps below: • Put chocks at the machine wheels. • Ensure ramps are correctly positioned. •...

  • Page 65: C-6.5 Parking And Storage

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ ■ C-6.5.2 Machine storage C-6.5 PARKING AND STORAGE In case of extended inactivity of the machine, follow ■ C-6.5.1 Short inactivity the above precautions. Additionally: • Wash the machine thoroughly. For a better...

  • Page 66: C-6.6 Cleaning And Washing The Machine

    Handler with telescopic boom GTH-6622 OPERATING INSTRUCTIONS ■ ■ C-6.6 CLEANING WASHING C-6.7 MACHINE DISPOSAL MACHINE ■ C-6.6.1 Cleaning instructions PROTECT THE Clean the machine in accordance with the following ENVIRONMENT instructions: • Remove any oil or grease traces with a dry solvent...
  • Page 67 Handler with telescopic boom GTH-6622 MAINTENANCE Section MAINTENANCE TABLE OF CONTENTS LUBRICANTS - HEALTH AND SAFETY PRECAUTIONS ......D-2 ROUTINE MAINTENANCE ................D-3 D-2.1 Oil change schedule ..................D-4 MAINTENANCE JOBS .................. D-5 D-3.1 Disconnecting the battery ................D-5 D-3.2 Access to the engine and tanks compartments ...........

  • Page 68: Lubricants - Health And Safety Precautions

    Handler with telescopic boom GTH-6622 MAINTENANCE LUBRICANTS - HEALTH AND INTRODUCTION SAFETY PRECAUTIONS A thorough and regular maintenance keeps the machine in a safe and efficient working condition. Health A prolonged skin contact with oil can cause irritation. For this reason, it is advisable to wash, grease and Use rubber gloves and protective goggles.

  • Page 69: Routine Maintenance

    Handler with telescopic boom GTH-6622 MAINTENANCE D-2 ROUTINE MAINTENANCE Every 50 working hours or weekly Jobs to be done in addition to those above Check the tension of the alternator belt A wrong or neglected maintenance can result in possible risks for both operator and bystanders. Make...

  • Page 70: Oil Change Schedule

    Handler with telescopic boom GTH-6622 MAINTENANCE Every 500 working hours or every six months Jobs to be done in addition to those above. Visually check the smoke quantity evacuated from the engine exhaust Check the tightening of the engine fixing screws...

  • Page 71: Maintenance Jobs

    Handler with telescopic boom GTH-6622 MAINTENANCE D-3 MAINTENANCE JOBS ATTENTION DANGER High pressure lines must be replaced by qualified personnel only. Any foreign matters entering the closed circuit may All maintenance interventions must be carried out result in a sudden deterioration of the transmission.

  • Page 72: Access To The Engine And Tanks Compartments

    Handler with telescopic boom GTH-6622 MAINTENANCE ■ D-3.2 ACCESS TO THE ENGINE AND TANKS COMPARTMENTS ■ Engine compartment For any operation within the engine compartment, open the protection bonnet. Hood is equipped with lock & key and a supporting rod that holds it in position.

  • Page 73: Greasing

    Handler with telescopic boom GTH-6622 MAINTENANCE ■ D-3.3 GREASING ATTENTION Before injecting grease into the greasers, thoroughly clean them to avoid that mud, dust or other matters can mix with the lubricant and reduce or annihilate the lubrication effect. Remove any old grease with a degreaser from the telescopes before smearing them with new grease.

  • Page 74: Tyres And Wheels

    Handler with telescopic boom GTH-6622 MAINTENANCE ■ D-3.4 TYRES AND WHEELS DANGER Over-inflated or overheated tyres can burst. Do not flame-cut or weld the wheel rims. For any repair work, call in a qualified technician. RIGHT WAY WRONG WAY For the tyre inflation or substitution, please refer to the...

  • Page 75: D-3.5 Brakes

    Handler with telescopic boom GTH-6622 MAINTENANCE D-3.5 BRAKES • For any intervention on the braking system (adjustment and/or substitution of the brake discs) call in a specialised technician. The malfunctioning of the braking system may depend on the presence of air within the hydraulic circuit.

  • Page 76: Engine Air Filter

    Handler with telescopic boom GTH-6622 MAINTENANCE ■ D-3.6 ENGINE AIR FILTER Clean the engine air filter every 10 hours; replace the filtering element, if necessary. Cleaning and changing the external element: - Stop the engine and engage the parking brake.

  • Page 77: Cab Air Filter (Only With Cabin Closed Or Glass Kit Installed

    Handler with telescopic boom GTH-6622 MAINTENANCE ■ D-3.7 CAB AIR FILTER (ONLY WITH CABIN CLOSED OR GLASS KIT INSTALLED) Every six months clean the air filter in the cab. Replace the cartridge if the filtering cloth is damged. Cleaning and changing the cartridge: - Shut the engine down and engage the parking brake.
  • Page 78 Handler with telescopic boom GTH-6622 MAINTENANCE ■ D-3.9 CHECKING THE OIL LEVEL IN THE TANK DANGER Fine jets of hydraulic oil under pressure can penetrate the skin. Do not use your fingers, but a piece of cardboard to detect oil leaks.

  • Page 79: Changing The Oil Filter Canisters On The Intake Line

    Handler with telescopic boom GTH-6622 MAINTENANCE ■ D-3.10 CHANGING THE OIL FILTER CANISTERS ON THE INTAKE LINE ■ D-3.10.1 Transmission oil filter Every 50 hours, check the clogging degree of the filtering element using the vacuometer The indexed scale of the vacuometer is divided into 3...

  • Page 80: D-3.10.2 Auxiliary Circuits Oil Filter

    Handler with telescopic boom GTH-6622 MAINTENANCE ■ D-3.10.2 Auxiliary circuits oil filter To change the hydraulic oil filter cartridge of the service circuits, proceed as follows: Stop the machine on a level ground and engage the parking brake. Remove the inspection hatch and unscrew the oil filter fitted inside the tank.

  • Page 81: D-3.11 Oil Level In The Differential Gears And The Rducer

    Handler with telescopic boom GTH-6622 MAINTENANCE D-3.11 OIL LEVEL IN THE DIFFERENTIAL GEARS AND THE REDUCER ■ D-3.11.1 Front and differential gears To check the oil level in the front and rear differential gears: • Stop the machine on a level ground and engage the parking brake.

  • Page 82: D-3.12 Oil Level In The (Front/Rear) Wheel Reduction Gears

    Handler with telescopic boom GTH-6622 MAINTENANCE ■ D-3.12 OIL LEVEL IN THE (front/rear) WHEEL PROTECT THE REDUCTION GEARS ENVIRONMENT To check the oil level within the wheel reduction gears: • Stop the machine on a level ground and ensure the...

  • Page 83: D-3.13 Shafting Alignment

    Handler with telescopic boom GTH-6622 MAINTENANCE D-3.13 SHAFTING ALIGNMENT During operation, the alignment of the front and rear axles of the machine can be subject to variations. This °C °C can depend on an oil blow-by from the steering control...

  • Page 84: D-3.14 Adjusting The Sliding Pads Of The Boom Sections

    Handler with telescopic boom GTH-6622 MAINTENANCE ■ D-3.14 ADJUSTING THE SLIDING PADS OF THE BOOM SECTIONS Any boom section is fitted with adjustable pads located on the four sides of the profile. These pads are secured to both fixed and mobile part of every section.

  • Page 85: Checking The Safety Devices

    Handler with telescopic boom GTH-6622 MAINTENANCE ■ D-3.15 CHECKING THE SAFETY DEVICES Attachment coupling cylinder ■ Checking the block valves (every 3 months) The piloted blocking valves allow to held the load in position in case of burst of a flexible hose.
  • Page 86 Handler with telescopic boom GTH-6622 MAINTENANCE ■ Checking the machine start control (at every use) Attempt to start the engine with the forward or reverse gear put. The engine must not start. If the engine starts, contact the GENIE Technical Service.

  • Page 87: Electrical System

    Handler with telescopic boom GTH-6622 MAINTENANCE D-4 ELECTRICAL SYSTEM • Before disconnecting the battery, set all switches within the cab to OFF. • To disconnect the battery, disconnect the DANGER negative (-) lead from the frame earth first. • To connect the battery, connect the positive (+) lead first.

  • Page 88: D-4.2 Fuses And Relays

    Handler with telescopic boom GTH-6622 MAINTENANCE D-4.2 FUSES AND RELAYS Rif. Circuito Amp. Not used The electrical system is protected by fuses placed in the driving cab, on the left. Before replacing a blown Not used fuse with a new one having the same amperage, find Not used out and rectify the fault.
  • Page 89 Handler with telescopic boom GTH-6622 MAINTENANCE ■ Fuse box relays Ref. Circuit Starting enabling command Forward speed enabling command Inhibition with brake pedal stepped down Overload warning system control unit enabling command Reverse speed enabling command Overload warning system solenoid valve enabling...

  • Page 90: D-4.3 12V Dc Lamps (Only With Lights Kit Installed

    Handler with telescopic boom GTH-6622 MAINTENANCE ■ D-4.3 12V DC LAMPS (ONLY WITH LIGHTS KIT INSTALLED) Voltage Mount type Power • Front low/high beam ............12 V ....... P45t ....45/40 W • Front position lights ............. 12 V ..... BA 9s ......3 W •...

  • Page 91: Refuelling

    Handler with telescopic boom GTH-6622 MAINTENANCE D-5 REFUELLING ■ D-5.1 REFUELLING Product Capacity specifications Part Product (litres) see par. Diesel engine Engine oil 11 + 3.5 D-5.2.1 Fuel tank Diesel fuel D-5.2.3 Hydraulic system tank Hydraulic oil D-5.2.2 Front differential gear with reduction gear D-5.2.2...

  • Page 92: D-5.2.3 Fuel

    Handler with telescopic boom GTH-6622 MAINTENANCE ■ D-5.2.3 Fuel Use only Diesel fuel with less than 0.5% sulphur content, according to the specifications of the diesel engine operation handbook. ATTENTION In cold climates (temperature under -20°C) use only “Arctic” type Diesel fuel, or oil-diesel fuel, or oil- diesel fuel mixtures.
  • Page 93 Handler with telescopic boom GTH-6622 FAULTS AND TROUBLESHOOTING Section FAULTS AND TROUBLESHOOTING TABLE OF CONTENTS FAULTS AND TROUBLESHOOTING .............. E-2 E-1.1 Fault - Cause - Solution ................. E-2 Page Document 57.0005.8200 - 12/2005...
  • Page 94 Handler with telescopic boom GTH-6622 FAULTS AND TROUBLESHOOTING FAULTS AND TROUBLESHOOTING This chapter represents a practical guide for the operator for fixing the most common failures and, at DANGER the same time, detecting those interventions which must be carried out by qualified technical engineers.
  • Page 95 • Set to “CAB” “ROAD” • Emergency button ON • Reset the button ATTENTION In case of faults not listed in this chapter, address to the GENIE Technical Assistance, your nearest authorised workshop or dealer. Page Document 57.0005.8200 - 12/2005...
  • Page 96 Handler with telescopic boom GTH-6622 FAULTS AND TROUBLESHOOTING NOTES ..........................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 97 Handler with telescopic boom GTH-6622 OPTIONAL ATTACHMENTS Section OPTIONAL ATTACHMENTS TABLE OF CONTENTS F-1.1 Shovel ....................F-1.2 Cereal shovel ..................F-1.3 Fixed hook on plate ................F-1.4 Extension jib ..................F-1.5 Forks with hydraulic side-shift .............. Page Document 57.0005.8200 - 12/2005...
  • Page 98 Handler with telescopic boom GTH-6622 OPTIONAL ATTACHMENTS INTRODUCTION This section provides information on the optional interchangeable attachments, especially manufactured for the handlers. Use only genuine attachments, described in this section, after having read their features thoroughly and understood their use.

  • Page 99: Shovel

    Handler with telescopic boom GTH-6622 OPTIONAL ATTACHMENTS ■ Application F-1.1 SHOVEL Quick-coupling fitted attachment for moving soil, sand, debris, cereals, etc. Code GTH-6622 Safety Litres 500 59.0200.0000 Strictly obey the general safety precautions given in section B “SAFETY”. Operation ATTENTION...

  • Page 100: Cereal Shovel

    Handler with telescopic boom GTH-6622 OPTIONAL ATTACHMENTS ■ Application F-1.2 CEREAL SHOVEL Quick coupling attachment for loading cereals or inert materials, etc. Code GTH-6622 Safety Litres 800 59.0200.1000 Strictly obey the general safety precautions given in section B “SAFETY”. Operation...

  • Page 101: Fixed Hook On Plate

    Handler with telescopic boom GTH-6622 OPTIONAL ATTACHMENTS ■ Application F-1.3 FIXED HOOK ON PLATE Quick-coupling fitted attachment for lifting loads by means of special slings. Payload Code GTH-6622 Safety 3000 kg 59.0700.4000 Strictly obey the general safety precautions given in section B “SAFETY”.

  • Page 102: Extension Jib

    Handler with telescopic boom GTH-6622 OPTIONAL ATTACHMENTS ■ Application F-1.5 EXTENSION JIB Quick-coupling fitted attachment for maintenance interventions at high working heights. Safety Code GTH-6622 Strictly obey the general safety precautions given in 400 kg 59.0800.0000 section B “SAFETY”. Never lift wrongly slung loads.

  • Page 103: Forks With Hydraulic Side-Shift

    Handler with telescopic boom GTH-6622 OPTIONAL ATTACHMENTS ■ Application F-1.6 FORKS WITH HYDRAULIC SIDE-SHIFT Quick-coupling fitted attachment for handling palletised loads with possibility of shifting the load to the side by ± 100 mm. Safety Strictly obey the general safety precautions given in section B “SAFETY”.
  • Page 104 Handler with telescopic boom GTH-6622 OPTIONAL ATTACHMENTS Intentionally blank page Page Document 57.0005.8200 - 12/2005...
  • Page 105 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED Section TABLES AND DOCUMENTS ENCLOSED TABLE OF CONTENTS TORQUE WRENCH SETTING ............... G-2.1 Load Chart with forks ................G-3.1 Wiring diagram - Fuses and relays ............G-3.1.1 Fuse and relay box ................

  • Page 106: Torque Wrench Setting

    Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-1 TORQUE WRENCH SETTINGS D x p Pre-loading (N) Torque wrench setting (Nm) 10.9 12.9 10.9 12.9 M 4 x 0,7 1970 3930 5530 6640 M 5 x 0,8 3180 6360...

  • Page 107: Load Chart With Forks

    Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-2.1 LOAD CHART WITH FORKS - GTH-6622 GTH-6622 CAPACITY CHART 67 deg 60 deg 50 deg 40 deg 30 deg 20 deg 10 deg 0 deg -3 deg Forward reach, ft Page Document 57.0005.8200 - 12/2005...
  • Page 108 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-3.1 WIRING DIAGRAM - FUSES AND RELAYS Ref. Circuit Amp. Power supply: interior lamp, emergency switch, turn signals +30 Power supply: relay K04 Optional Front right/rear left position lights, license plate...

  • Page 109: Fuse And Relay Box

    Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-3.1.1 FUSE AND RELAY BOX 7,5A 7,5A 7,5A 7,5A 7,5A 7,5A Page Document 57.0005.8200 - 12/2005...
  • Page 110 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED Intentionally blank page Page Document 57.0005.8200 - 12/2005...
  • Page 111 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-3.2 WIRING DIAGRAM tab. 1/8 COLOUR TABLE Acronym Colour Black 2/G10 Brown 2/G10 2/F5 Orange VT/WHø1 Yellow RD/BKø1 GY/BUø1 Green RD/BKø1 Blue Purple ACC 0 SW01 SW03 Grey BU/RDø1 OG/GNø1.5 4/E8...
  • Page 112 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-3.2 WIRING DIAGRAM tab. 2/8 COLOUR TABLE Acronym Colour 1/G1 3/G10 Black 1/G1 3/G10 Brown Orange Yellow Green Blue Purple Grey BN/BKø1.5 BN/BKø1 White 1/G5 OG/BKø1 OG/BKø1 8/B5 Pink Light blue...
  • Page 113 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-3.2 WIRING DIAGRAM tab. 3/8 COLOUR TABLE 2/G10 4/G10 Acronym Colour 2/G10 4/G10 Black Brown Orange GY/RDø1.5 VTø1 Yellow Green Blue Purple BN/RDø1 BKø1 BKø1 Grey WH/BKø1.5 White BN/RDø1 Pink SW11...
  • Page 114 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-3.2 WIRING DIAGRAM tab. 4/8 COLOUR TABLE 3/G10 5/G10 Acronym Colour 3/G10 5/G10 Black Brown Orange Yellow Green Blue WH/BUø1 Purple Grey White Pink Light blue BU/RDø1 RD/BKø1 1/F8 1/E1 GY/WHø1 RD/BKø1...
  • Page 115 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-3.2 WIRING DIAGRAM tab. 5/8 COLOUR TABLE 4/G10 6/G10 Acronym Colour 4/G10 6/G10 Black Brown Orange Yellow TQ/RDø1 2/C8 Green Blue OG/YEø1 Purple WH/YEø1 RD/BKø1 TQ/GNø1 BKø1 GY/WHø1 BN/GNø1 Grey RD/BKø1 RDø1...
  • Page 116 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-3.2 WIRING DIAGRAM tab. 6/8 COLOUR TABLE 5/G10 7/G10 Acronym Colour 5/G10 7/G10 Black Brown Orange Yellow YE/BKø1.5 YE/BKø1.5 Green YE/GNø1.5 YEø1.5 Blue Purple Grey White BKø1 YE/GNø1 BKø1 YEø1 Pink...
  • Page 117 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-3.2 WIRING DIAGRAM tab. 7/8 COLOUR TABLE 6/G10 8/G10 Acronym Colour 6/G10 8/G10 Black WH/YEø1 BN/BKø1 Brown 5/C8 Orange Yellow SW13 Green Blue Purple Grey White Pink SW08 Light blue BU/RDø1...
  • Page 118 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-3.2 WIRING DIAGRAM tab. 8/8 9/G10 COLOUR TABLE 9/G10 Acronym Colour Black Brown Orange Yellow Green Blue PK/YEø1.5 VT/BKø1 Purple Grey TQ/RDø1 TQ/YEø1 White Pink Light blue SW12 87A 87 LIST OF ABBREVIATIONS...

  • Page 119: Wiring Diagram

    Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-3.2.1 GENERAL WIRING DIAGRAM (description) Ref. Description Sheet Ref. Description Sheet PERMISSION SWITCH-ON LIGHT-WORK DX AND SX WHEEL STEERING SOLENOID VALVE Ref. Description Sheet SWITCH-ON RELAY WHEEL STEERING SOLENOID VALVE FORWARD SPEED RELAY...

  • Page 120: Wiring Diagram - Connectors

    Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-3.3 WIRING DIAGRAM - CONNECTORS Colour Connector Engine Line Fuse Line Description Colour WH/OGø1 FROM X7 PIN A TO Y09 Connector Engine Line Fuse Line Description WH/BUø1 FROM X4 PIN 2 TO N.C.
  • Page 121 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED Colour Connector Engine Line Fuse Line Description WH/OGø1 FROM Y09 AND X2 PIN 29 TO JOYSTICK JOYSTICK WH/YEø1 FROM X5 PIN 5 AND JOYSTICK CONNECTOR BN/BKø1 FROM F12 TO JOYSTICK TQ/YEø1...

  • Page 122: Hydraulic Scheme

    Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-4 HYDRAULIC SCHEME - Drw. 57.2201.1200 rev. A Hydraulic piloting line test port Pressure reducing Service brake Parking brake valve circuit reservoir selector valve Service brake Load handling 406 psi pedal pump...
  • Page 123 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED G-5 ROUTINE CHECK SCHEDULE - SAFETY DEVICES Table key explanation: COMPONENT Block valve 1 Block valve on lifting cylinder Block valve 2 Block valve on fork balance cylinder Block valve 3...
  • Page 124 Handler with telescopic boom GTH-6622 TABLES AND DOCUMENTS ENCLOSED Intentionally blank page G-20 Page Document 57.0005.8200 - 12/2005...

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