Genie GTH-6622 Service manual

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

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.
In pursuing a policy of constant quality improvement, TEREXLIFT srl reserves the right to make changes at any time and
without undertaking to give prior notice; therefore, also this publication may be subject to modifications.
Some photos or drawings have been used to illustrate a specific function; as a result, they may not refer to the machine
treated in this manual.
© Copyright 2005 TEREXLIFT srl - All rights reserved.
Produced by:
Genie Scandinavia
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Genie France
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Genie Iberica
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Genie Germany
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Genie U.K.
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Genie Mexico City
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Genie North America
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Toll Free USA and Canada
800.536.1800
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Genie Australia Pty Ltd.
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Genie China
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Genie Malaysia
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Genie Japan
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Genie Korea
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Genie Brasil
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TECHNICAL SERVICES

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■ I NTRODUCTION
This handbook provides information for a safe and
proper operation and maintenance of the machine.
STRICTLY COMPLY WITH THE INSTRUCTIONS
GIVEN IN THIS HANDBOOK!
READ AND UNDERSTAND THIS HANDBOOK
BEFORE STARTING, USING AND CARRYING
OUT ANY OPERATION WITH AND ON THE
MACHINE.
The handbook is divided into seven sections:
Sect. AGENERAL INFORMATION
Sect. BSAFETY
Sect. COPERATING INSTRUCTIONS
Sect. DMAINTENANCE
Sect. ETROUBLESHOOTING
Sect. FOPTIONAL ATTACHMENTS
Sect. GTABLES AND ENCLOSURES
Section Acontains general concepts that are decisive
for the knowledge of the main parts of the machine.
It also contains all necessary data for a correct
identification of the machine, the technical features of
the machine, etc.
Section Bis especially addressed to the personnel,
who shall operate, repair and service the machine, and,
in case of companies with a wide fleet of machines, to
the safety responsible.
It describes the essential compulsory qualities of the
personnel in charge and other important information
for the safety of persons and things.
Section Cis mainly addressed to the operators who
operate the machine. This section illustrates all control
devices.
Additionally, it contains the main use instructions -i.e.
engine starting, machine parking, machine storing.
Section Dis addressed to the maintenance responsible
and the servicemen.
The section describes the maintenance schedule and
the relevant intervals.
Section E deals with the failure diagnostics.
Section Fmakes a list of the main interchangeable
attachments that can be coupled to the machine:
dimensions, weight, application field and limits of use.
Section Gcontains tables and various enclosed
documents like load charts, wiring diagrams, hydraulic
schemes, torque wrench setting table, etc.
Sections are subdivided into chapters and paragraphs
that are numbered progressively.
The quickest way to look for an information is the
reference to the general index or the titles of the single
chapters and paragraphs that represent keys for an
easy consultation.
Take care of this handbook and keep it in an
accessible place within the machine, even
after its reading, so that it will always be
within reach if in doubt.
If you are unsure about anything, please address to
GENIE Assistance Service or to your agent/dealer:
addresses, phone and fax numbers are printed in
the cover and in the title-page of this manual.
IMPORTANT
Any difference between the contents of this manual
and the real functional character of the machine
can be attributed to either a machine manufactured
before the issue of this manual or to a manual going
to be updated after some changed effected on the
machine.
Always contact GENIE Assistance Service for any
updated version of this manual and any additional
information.
INTRODUCTION

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■SYMBOLS
When using the machine, operators could have to face
some situations requiring special care and particular
knowledge.
When these situations involve the safety of operators
or bystanders, the machine efficiency and proper
utilisation, this handbook stresses these specific
instructions by means of SPECIAL SYMBOLS.
There are six special (or safety) symbols in this manual,
always combined with keywords that class the situations
according to their danger degree.
The symbols are always followed by a text explaining
the situation taken into account, the attention to be
paid to such situation, the method and the behaviour to
be adopted. When necessary, it stresses prohibitions
or supplies instructions to prevent dangers.
Sometimes, it can be followed by illustrations.
We list below the special (or safety) symbols according
to the relative seriousness of the hazard situation:
DANGER
Draws the attention to situations that involve your
own as well as the others’ safety and that can result
in serious or lethal injury.
ELECTRICAL
DANGER
Draws the attention to situations that involve your
own as well as the others’ safety and that can result
in serious injury or lethal injury.
CAUTION
Draws the attention either to situations that involve
your own as well as the others’ safety and that can
result in minor or moderate injury or to situations
that involve the machine efficiency.
ATTENTION
Draws the attention to situations that involve the
machine efficiency.
IMPORTANT
Draws the attention to important technical
information or practical advice that allows for a
safer and more efficient use of the machine.
PROTECT THE
ENVIRONMENT
Draws the attention to important environment-
related information.
WHEN READING THIS MANUAL, PAY THE
GREATEST ATTENTION TO THESE SPECIAL
SYMBOLS AND THE EXPLANATION OF THE
SITUATIONS THEY EMPHASIZE.
The manual in electronic format also contains the
following symbol:
which enables the user to return to the
table of contents
INTRODUCTION

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GENERAL INDEX
GENERAL INFORMATION Sect. A
SAFETY Sect. B
OPERATING INSTRUCTIONS Sect. C
MAINTENANCE Sect. D
TROUBLESHOOTING Sect. E
OPTIONAL ATTACHMENTS Sect. F
TABLES AND DOCUMENTS ENCLOSED Sect. G
GENERAL INDEX

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GENERAL INFORMATION
Section A
GENERAL INFORMATION
TABLE OF CONTENTS
A-1 CONVENTIONAL REFERENCES ................................................................................ A-2
A-1.1 Machine position ........................................................................................................ A-2
A-1.2 Labels and warning plates applied on the machine ................................................... A-3
A-1.2.1 Position....................................................................................................................... A-3
A-1.3 Explanation of the different symbols used on the machine ....................................... A-6
A-2 MACHINE IDENTIFICATION ....................................................................................... A-8
A-2.1 Machine model and type ............................................................................................ A-8
A-2.2 Manufacturer .............................................................................................................. A-8
A-2.3 Machine identification plates...................................................................................... A-8
A-2.4 Chassis serial number ................................................................................................ A-9
A-2.5 Identification plates of the main parts ........................................................................ A-9
A-3 ALLOWED USE .......................................................................................................... A-10
A-3.1 Allowed use ................................................................................................................ A-10
A-3.2 Improper use .............................................................................................................. A-10
A-3.3 Residual hazards ........................................................................................................ A-10
A-3.4 Applicable standards.................................................................................................. A-11
A-3.5 Safety devices ............................................................................................................ A-12
A-4 GENERAL DESCRIPTION .......................................................................................... A-13
A-4.1 List of the main components ...................................................................................... A-13
A-4.2 Description of the main components ......................................................................... A-14
A-4.3 Optional accessories .................................................................................................. A-14
A-4.4 Kits supplied on request............................................................................................. A-14
A-5 TECHNICAL DATA AND PERFORMANCE ................................................................. A-15
A-5.1 Main dimensions ........................................................................................................ A-15
A-5.2 Restrictions of use ...................................................................................................... A-15
A-5.3 Weight ........................................................................................................................ A-15
A-5.4 Speed ......................................................................................................................... A-15
A-5.5 Payload and reach...................................................................................................... A-16
A-5.6 Forks...........................................................................................................................A-16
A-5.7 Diesel engine .............................................................................................................. A-16
A-5.8 Electrical system ........................................................................................................ A-16
A-5.9 Machine sound levels ................................................................................................. A-16
A-5.10 Vibration levels ........................................................................................................... A-16
A-6 LIFETIME .................................................................................................................... A-17
A-7 ITEMS SUPPLIED ....................................................................................................... A-17
A-7.1 Literature supplied ...................................................................................................... A-17

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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.
Any exception to this rule will always be specified.
RIGHT SIDE
LEFT SIDE
LOWER PART
UPPER PART
FRONT PART
REAR PART

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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.
Make sure they are easy to read. For this purpose,
clean them or replace those that become
unreadable (either graphic or text).
To clean labels, use of a soft cloth, water and soap.
Never use solvents, petrol, etc.
When a label is applied on a part to be replaced,
make sure that the replaced part is already labelled
as required or apply a new label.
■A-1.2.1 Position
09.4618.0109
s.r.l.
Zonaindustriale -06019 - Umbertide (PG ) -Italy
MODELNUMBER
SERIALNUMBER
YEAROF MANUFACTURE
UNLADENTRUCK MAXIMUM WEIGHT
TRUCKCAPACITY
MADEIN ITALY
THISTRUCK IS COMPLIANT TO PART III OF ASME B56.6-2002 WHERE APPLICABLE
lb
lb
09.4618.0109
09.4618.0109
09.4618.0109
09.4616.0101
09.4618.0109
09.4618.0109
09.4618.0109
09.4618.0109

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GENERAL INFORMATION
F
R
0 1 2 3 4 5 6 7
09.4618.0646
09.4618.0389
09.4616.0051
09.4618.0010
9767197667 97675 97664
09.4618.0109
09.4618.0642
09.4618.0547
97664
82558
09.4618.0547
97688
97664
97674
(top of chassis)
97664
(boom rest)
97668 97665
97672 97666 97669
0°
20°
40°
60°
80°
P= 5,5 bar P= 5,5 bar
09.4618.0547
P= 5,5 bar
09.4618.0547
P= 5,5 bar
09.4618.0641
97667
97664
09.4618.0205
09.4618.0640
97673
09.4618.0639
97676
97670
09.4618.0642

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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
97670 Risk of crushing
97671 Risk of explosion / burns
97672 Risk of crushing
97673 Prohibition to lift people
97674 Risk of crushing
97675 Risk of explosion / burns
97676 Electrical hazard
97688 Emergency exit handle
09.4616.0051 Hydraulic oil
09.4616.0101 Machine data plate
09.4618.0010 Prohibition to open with the engine running
09.4618.0547 Tyre inflation pressure
09.4618.0109 Sticker with various warnings
09.4618.0205 Boom tilting degree
09.4618.0389 Control lever controls
09.4618.0639 Sticker: "Genie GTH-6622"
09.4618.0640 Sticker: "Genie GTH-6622"
09.4618.0641 Sticker: "Genie"
09.4618.0642 Sticker: "GTH-6622"
09.4618.0646 Load chart

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GENERAL INFORMATION
■A-1.3 EXPLANATION OF THE DIFFERENT
SYMBOLS USED ON THE MACHINE
This paragraph illustrates those symbols that are
normally applied on the main control devices and
instruments of a standard machine, and those that can
be applied on accessories or special attachments.
They are mainly (ISO) standardised symbols that are
now part of the common life. But we consider useful to
explain them once again.
Symbol Description
IMPORTANT
Spend the necessary time to become familiar with
these symbols and to learn their meaning.
Hazard warning lights
Windscreen wiper
Windscreen washer
Cab ventilation fan
Fuel gauge
Hydraulic oil temperature
Position lights
High beam
Turn signals
Parking brake
Battery charge
Symbol Description
Steering mode switch
Engine oil pressure
Boom up
Boom down
Boom out
Boom in
Attachment locked
Attachment unlocked
Fork pitching forward
Fork pitching back
Oil filter clogged
Air filter clogged
Glow plug preheating

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GENERAL INFORMATION
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
Symbol Description Symbol Description

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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 MACHINE MODEL AND TYPE
Handler with telescopic boom:
❑model GTH-6622
■A-2.2 MANUFACTURER
TEREXLIFT srl
Zona Industriale (Ind. Estate) - I-06019 UMBERTIDE
(PG) - ITALY
Enrolled in the register of companies at the Court of
Perugia under no. 4823
C.C.I.A.A. n° 102886
Fiscal Code/V.A.T. no. 00249210543
■A-2.3 MACHINE IDENTIFICATION PLATES
Machine data plate.
At the front, on the right side of the chassis.
The identification plate contains the main
identification data of the machine like model, serial
number and year of manufacture.

Lb
Zona Industriale - 06019 - Umbertide (PG) - Italy
TRUCK CAPACITY
UNLADEN TRUCK MAXIMUN WEIGHT
SERIAL NUMBER
MADE IN ITALY
MODEL NUMBER
YEAR OF MANUFACTURE
Lb
THIS TRUCK IS COMPLIANT TO PART III OF ASME B56.6 - 2002 WHERE APPLICABLE

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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
the manufacturers.

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GENERAL INFORMATION
A-3 ALLOWED USE
■A-3.1 ALLOWED USE
The handlers have been designed and manufactured
for lifting, handling and transporting agricultural or
industrial products by means of specific attachments
(see section F) manufactured by TEREXLIFT srl.
Any other use is considered contrary to that established
and, therefore, improper.
The compliance with and the strict respect of the
operation, maintenance and repair conditions, indicated
by the Manufacturer, represent an essential part of the
allowed use.
The handler must be used and serviced only by
operators knowing its characteristics and the safety
procedures in depth.
It is also essential to comply with the safety at work
legislation, the precautions concerning safety and
industrial medicine as well as the local and national
road traffic regulations.
ATTENTION
Effecting changes or carrying out interventions on
the machine other than those of routine
maintenance is expressly forbidden. Any
modification of the machine not carried out by
GENIE or an authorised assistance centre involves
the automatic invalidation of the conformity of the
machine to the Directive 98/37/EC.
■A-3.2 IMPROPER USE
Improper use means a utilisation of the handler
following working criteria that do not comply with the
instructions of this manual, and that, in general, may
result in risks for both operators and bystanders.
DANGER
We list below some of the most frequent and
hazardous situations of improper use:
-Carrying passengers on the machine
-Not strictly complying with the operation and
maintenance instructions of this handbook
-Working beyond the handler working limits
-Working on unstable edges of ditches
-Driving crosswise on slopes or hills
-Working during a storm
-Working on steep slopes
-Using attachments other than those
recommended
-Using attachments not approved or directly
manufactured by Terexlift
-Working in potentially explosive areas
-Working in confined and non-ventilated
environments.
■A-3.3 RESIDUAL HAZARDS
Although the machine has been designed and
manufactured according to the latest technology and
all expected hazards have been eliminated, some
operations performed by the machine operator can
result in potentially hazardous situations. Among them:
•Hazards deriving from a too high work or transfer
speed in relation to the load handled or the ground
condition of the jobsite.
•Hazards deriving from work procedures adopted
during the check or replacement of a block valve
(residual pressure - uncontrolled movements).
•Hazards deriving from work procedures adopted
while disassembling parts of the machine -e.g. the
cylinders, without supporting mobile parts suitably
(risk of uncontrolled fall of the mobile part).
•Hazard deriving from an accidental overturning of
the machine in the event the operator has not
fastened the safety belts.

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GENERAL INFORMATION
■A-3.4 APPLICABLE STANDARDS
For the operator’s safety, the following standards were
obeyed during the risk assessment of the handler fitted
with telescopic boom:
Directive Title
98/37/CE Machinery Directive
89/336/CEE Electromagnetic compatibility
2000/14/CE Environment Acoustic Emissions
Standard Title
EN 1459:1988 Harmonised standard. Safety of industrial
trucks - Self- propelled variable reach
trucks.
EN 281:1988 Self-propelled industrial trucks sit- down
rider-controlled. Rules for the
construction and layout of pedals.
EN 1175-2:1998 Electrical requirements - General
requirements of internal combustion
engine powered trucks
prEN ISO 13564:1996 Test method for measuring visibility from
self-propelled trucks.
ISO 2330:1995 Fork-lift trucks - Fork arms - Technical
characteristics and testing.
ISO/DIS 3287 Powered industrial trucks. Pictorial signs.
Control symbols.
ISO 3449:1992 Earth-moving machinery - Falling-object
protective structures - Laboratory tests
and performance requirements.
EN 13510: 2002 Earth-moving machinery - Roll-over
protective structures - Laboratory tests
and performance requirements.
ISO 3776:1989 Tractors for agriculture - Seat belt
anchorages.
ISO 3795:1989 Road vehicles, tractors and machinery
for agriculture and forestry -
Determination of burning behaviour of
interior materials.
ISO 5053:1987 Powered industrial trucks - Terminology.
ISO 6292:1996 Powered industrial trucks and
tractors - Brake performance and
component strength .
EN 13059:2002 Safety of industrial trucks - Test methods
for measuring vibration
EN 50081-1: 1997 Electromagnetic compatibility – Generic
requirements on emissions - Part 1
EN 50082-1: 1997 Electromagnetic compatibility – Generic
requirements on immunity - Part 1
EN 60204-1:1998 Safety of machinery - Electrical
equipment of machines - Part 1
ANSI/ASME B56.6-2002 part III where applicable.

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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.
•Block valves fitted to all cylinders:
ABlock valve on attachment coupling cylinder
BBlock valve on lifting cylinder
CBlock valve on balance cylinder
DBlock valve on boom extension cylinder
EBlock valve on attachment pitching cylinder




