Home

before SN 18723, GTH-6622 (PN 57.0005.8200)

1. Hydraulic piloting line test port TP 5 1 Service brake Pressure reducing Parking brake circuit reservoir valve mer P_ selector valve DR NENNEN y Service brake Load handling 1 TTE B _ Ed oops control lever X Ho L Gr keen 1 es flow 0 02 in F i Shutle _ __ selector valve M 7 psi Se Hydraulic valve 0 5 0 5 bar Check valve collector Q l a Front axle L 7psi 05bar 7 3 J s Parking brake Co 2 control valve P2 Al B od 4 2 1 m Lem 4h 4350 psi Forks attachment P1 uick coupling cylinder 300 bar q pling cy pp Lu 11 Quick coupling Ghob nU
2. COLOUR TABLE is Acronym Colour id ue BK Black 1 51 gt 15 gt 3 810 BN Brown RD Red OG Orange YE Yellow GN Green BU Blue VT Purple GY Grey BN BK 1 5 1 i 1 05 gt li gs OG BKot OG BK t WH White Pink TQ Light blue 13 10 11 85 att 85 tn K03 5 m Ka 85 SP K04 86 30 86 30 3 E LIST OF ABBREVIATIONS LL Label Description Fuses X2 OG GNo1 S i H Lamps lights TO RDot ia warning lights HA Clacson or back up RDot 1 5 horn Ls K Relays Motor or pump 8 8 Indicators HAOI JAN Ritt Resistance L gt OG BKo T v RP Potentiometers 2 2 o Y02 SWiHt Switches selectors SS Sensors micro 5 5 switches pressure switches um 91 i i 4 as AIO transducers as H 85 Yit Solenoid valves F 5 28 83 Xii Connectors 5 58 8 Other components Page G 8 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 TE TABLES AND DOCUMENTS ENCLOSED G 3 2 WIRING DIAGRAM tab 3 8 610 2 TER COLOUR TABLE NESE gt
3. COLOUR TABLE Acronym Colour 21610 BK Black eee BN Brown RD Red OG Orange YE Yellow TX TX 1 p E GN Green 2 os 2 we 5 A 9 BU Blue e ACC 0 IGN ST 8 s a S8 2 S VT Purple Swoi NY 7 5 SW03 2 z n GY G zZz BUR OG GNo1 5 se 3 I 4 E8 n 2 07 2 WH White 5 5 3 2 2 j SE 2 e OG GNo1 E i PK Pink 50 4 PKot 5 TQ Light blue X3 2 07 X3 m X3 T 1 V g 3 P 7 3 amp 8 8 F5 LIST OF ABBREVIATIONS PU RR ERE RR E pp Label Description lt Fit Fuses TX xo HiHE Lamps lights 15 25 6 E warning lights Clacson or back up amp m K Relays Z E Mitt Motor or pump 5 P Indicators m r 5 Ritt Resistance RP Potentiometers Switches selectors DOE A fe a SS Sensors micro switches pressure switches transducers gu 2 2 A10 i is 5 E 22 S y p s YHH Solenoid valves GE EB z 22 28 582 Boe Ea Sg zb 282 Connectors 35 ES E 5 og B 98 EL 3 am o z 88 g E s 8 Other components Page G 7 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 TE EE TABLES AND DOCUMENTS ENCLOSED G 3 2 WIRING DIAGRAM tab 2 8
4. seo 80 cea COLOUR TABLE 15 Acronym Colour 3 G10 9 5 810 BK Black BN Brown RD Red 1 Orange YE Yellow GN Green BU Blue VT Purple 2 GY Grey M WH White X5 1 8 a 25 2 PK Pink 2 7 L TQ Light blue 2 5 5 5 5 5 5 2 gt gt 5 5 2 5 T T d 2855 n J 1 1 8 m 1 1 x4 4 4 1 RD BKot L Xa 5 C5 4 9 5 AR es 3 E 2 5 LIST OF ABBREVIATIONS a 2 Label Description RD BKot 5 5 2 ip X2 Fit Fuses m 6 89 x4 n H L ligh THE amps lights 5 2 RD BKot 4 1 warning lights x 14 Clacson or back up xe x2 2 4 22 1 E E 8 Relays d Motor or pump 5 5 5 5 P Indicators 6 RD BKot l R Resistance 5 10 L1 5502 He SS07 5504 P 5508 SS06 N 5501 RP Potentiometers I SW Switches selectors 5 2 SS Sensors micro 2 switches pressure 9 08 switches EE i l transducers I a zi i g g 5g 5 awh EE Se E T YHH Solenoid valves T 955 943 3 228 E 2569 ag 252 Connectors 228 See C5 rad 26 ges SEE 5 Deg fag F Sp Other components Page G 10 Document 57 0005 8200 12 2005 enie A TEREX COMPANY Handler with telescopic boom GTH 6622 TABLES AND DOCUMENTS ENCLOSED G 3 2 WIRING DIAGRAM t
5. D 6 EC EEE e T p D 7 Tyres e D 8 eee er eee uUi ET D 9 Checking the brake Lasse ect anneni D 9 ME Scie uoi ee D 10 Cab air filter only with cabin closed or glass kit installed D 11 Engine F DT ST aee D 11 Checking the oil level in the Tank D 12 Changing the oil filter canisters on the intake line D 13 0 13 SEE ee EIC E oo D 14 Oil level in the differential gears and the D 15 Front and rear differential D 15 PER wm ES D 15 Oil level in the front rear wheel reduction D 16 Shana orla LI EE RE EEE D 17 Adjusting the sliding pads of the boom sections D 18 hiet bee 0 19 BLECTRICAL SYSTEM 0 21 0 21 Fuses and POLIS t D 22 12V DC lamps only with lights kit installed D 24 JE SR tige HM FER CU ELDER EL ACER COD M FR HERE E OH HD D 25 SE RR D 25 ee ee UTR TRO D 25 See ett TS D 25 Lubrication oils and relevant filtering elements D 25 GE em ET RE D 26 0 26 D 1 Document 57 0005 8200 12 2005 IG Handler with telescopic boom GTH 6622 TE
6. xod T Q7 Windscreen washer Boom down ae Cab ventilation fan Boom out Fuel gauge i Boom in n Hydraulic oil temperature Attachment locked DE Position lights Attachment unlocked High beam Turn signals Fork pitching forward 5 Parking brake Battery charge Fork pitching back Oil filter clogged Air filter clogged Glow plug preheating Oe bereketle 6 Document 57 0005 8200 12 2005 enie A TEREX COMPANY Symbol iD ND EG EG Handler with telescopic boom GTH 6622 GENERAL INFORMATION 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 Document 57 0005 8200 12 2005 Symbol Page 7 Description fee Handler with telescopic boom GTH 6622 GENERAL INFORMATION Ie A TEREX COMPANY 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 1 06019 UMBERTIDE PG ITALY Enrolled
7. C 6 C 4 6 Starting the machine C 22 Switching on the cab interior lamp C 6 C 4 7 Stopping and parking the machine C 23 DRIVING PLAGE iii C 7 C 5 USING THE HANDLER C 23 Controls and instruments C 8 C 5 1 Using the load charts C 24 Engine controls and instruments C 9 G 5 2 Handling 6908 sii C 25 SWHON ooo o catis C 9 C 5 2 1 Adjusting the forks C 25 Forward reverse gear switch C 9 C 5 2 2 Working C 26 DURS aisi iis aer PRODR EP C 10 C 5 3 Changing the attachment C 27 Accelerator control C 10 C 6 TRANSPORTING THE MACHINE C 28 Pushbutton enabling the attachment C 6 1 Moving a disabled machine C 28 coupling release C 11 C 6 1 1 Unlocking the negative brake C 28 Steering mode selection C 11 C 6 2 Road or site transfer C 29 Continuous flow selector C 11 C 6 3 Lifting the machine C 29 Speed COMMONS e 11 6 4 Transporting the machine on other Auxiliary drive controls C 12 VI ge me C 30 Instruments and light indica
8. J12 MC J13 PK t FUEL WARNING LIGHT FROM SS08 J14 WH BU t BRAKE PRESSURE X01 1 RDo6 POWER SUPPLY 12 V FROM F30 ENGINE CONNECTOR 2 WAYS LINE FUSES X02 1 PK YEo1 FROM Y08 TO PIN 4 AND 54 08 ENGINE 2 YE RDot FROM Y09 TO X5 PIN 7 AND 54 08 CONNECTOR 3 TQ GNe1 FROM 54 06 TO Y04 31 WAYS 4 GY RDot FROM X3 PIN 9 TO SS03 LINE FUSES 5 OGo1 FROM TO YO1 6 GY BU t1 FROM 5509 TO PIN 12 AND H01 7 VT t FROM SW11 AND X5 PIN 3 TO 2 8 TQ YE 1 FROM K07 TO Y12 9 PKo1 FROM X3 PIN 5 TO SS08 10 OG BK 1 FROM 5 TO N C 11 OG BK 1 FROM 5 TO Y04 12 OG YE 1 FROM X5 PIN 6 TO Y10 13 OG BK 1 FROM K05 TO HA01 14 WH GNo1 FROM X3 PIN 17 TO SS02 15 WH RD 1 FROM F5 TO A02 16 GY GNo1 FROM X3 PIN 11 5501 17 BUot FROM 54 07 TO Y08 18 TQ RDo1 5 TQ RDot FROM 5505 TO X8 PIN 2 AND SW12 19 VT TQo1 FROM K08 TO SS04 20 OG BU t1 FROM K08 TO Y08 21 YE 1 5 FROM TO X5 PIN 10 AND SW10 22 GY YE 1 FROM X3 PIN 14 TO SS08 23 BU RDot FROM M02 TO PIN 16 AND P01 24 WH RDet 5 FROM F5 TO YO7 25 VT WH 1 VT WH 1 5 FROM A02 TO H01 26 GN RD 1 FROM X4 PIN1 TO SS06 27 BUg1 5 FROM 2 TO K11 28 YE RD 1 5 FROM X9 PIN 3 TO M05 Colour Connector Pin Engine Line Fuse Line Description 29 WH OGe1 FROM X7 PIN A TO Y09 30 WH BUe1 FROM X4 PIN 2 TO X03 1 RDo6 POWER SUPPLY 12 V FROM F30 COLUMN 2 BN BK 1 5 FROM 54 03 TO K01 AND K02 CONNECTOR 3 PK BK 1 5 FROM F13 TO SW03 18 WAYS 4 PK YEo1 FROM SW08 X2 PIN 1 AND
9. oi Acronym Colour BK Black BN Brown RD Red i OG Orange GY RD 1 5 E 3 2368 Yellow x GN Green REE i i BU Blue wa VT Purple Bkat 8 6 7j BN RDot X9 GY Gray 3 _ WH White ic P P P E PK Pink Swit SW05 TQ Light blue F10 5 F6 F9 I LIST OF ABBREVIATIONS Label Description T E FiHE Fuses X2 ji 5 Lamps lights warning lights Clacson or back up horn 2 KHH Relays 5 2 M Motor or pump 8 PHH Indicators amp E Rit Resistance T RP Potentiometers lt gt SW Switches selectors HANE zo SS Sensors micro switches pressure switches am i i 4 i i 9 acini transducers 7 amp 7 amp zg 2 Vit Solenoid valves 5 LE 3 3 2s 5 22 Sg X Connectors 5 TofS 2595 g Other components Page G 9 Document 57 0005 8200 12 2005 io Handler with telescopic boom GTH 6622 EE TABLES AND DOCUMENTS ENCLOSED G 3 2 WIRING DIAGRAM tab 4 8
10. C 6 6 2 Washing instructions 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 fee C 6 7 MACHINE DISPOSAL PROTECT THE ENVIRONMENT At the end of the machine life call in a specialised firm to dispose of it in compliance with the local or national regulations C 6 7 1 Battery disposal PROTECT THE ENVIRONMENT 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 orrecycled in accordance with the laws of the UE In Italy used or discarded batteries have been classified as Toxic wastes in accordance with Presidential decree n 397 of 09 09 1988 and Law n 475 O G n 18 of 09 11 1988 because they contain lead and sulphuric acid Their disposal through recycling must be done only through companies authorised and belonging to the Consorzio
11. 9 E I 5 xe E 8 29 E X2 X2 1 2 X6 X6 2 3 12 fv 1 o AI ET 1 X6 X6 2 je Yoe Y05 lt aD tw o 09 IX HA04 2 p ea e x a is T 5 a ea 1 NE 4 1 4 4 gt 8 A10 E E a a a lt oe nose lt o uta ufa 5 8 Q ru9 zug mee a 55 vir d m YS 758 58 758 F m 5 3 e 72 72 Page G 13 Document 57 0005 8200 12 2005 COLOUR TABLE Acronym Colour BK Black BN Brown RD Red OG Orange YE Yellow GN Green BU Blue VT Purple GY Grey WH White PK Pink TQ Light blue LIST OF ABBREVIATIONS Label Description Fit Fuses Lamps lights warning lights HA Clacson or back up horn K Relays Mitt Motor or pump P Indicators R Resistance RP Potentiometers Switches selectors SS Sensors micro switches pressure switches transducers Y Solenoid valves Xi Connectors Other components G 3 2 WIRING DIAGRAM tab 8 8 30 9 010 W 9 G10 enie A TEREX COMPANY 30 15 PD 8 5 X8 PK YEot 5
12. Micro 1 Micro 2 Micro 3 Micro 4 Micro 5 SAR Display EMERGENCY Joystick button D D O Page G 19 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 ra TABLES AND DOCUMENTS ENCLOSED Intentionally blank page Page G 20 Document 57 0005 8200 12 2005
13. 1 8 5 3 TQ RD 1 69 5 E X8 a Nx Par 3 2 8 SW12 SE E 28 X8 2 z 8 7 4 up eo 3 5 o a 3 5 s 2d amp 2 E Sob 85 87 a KOG gt gt 85 87A 87 85 87 87 864 30 F16 13 KO7 86 30 864 305 Ow Q E x iu 5 x a 2 9 5 E lt gt aa le sa x I X2 x2 20 19 18 OG GNot 3 5 3 2 09 5 8 S E 5 5 5 3 E b oO x 3 BN BKot 4 m L v O e 1 Tv 2 F4 SS05 A F o Y12 Y13 A 2 de 5504 io Kol co z 2 5 5 en H04 31 e e e e 31 a E e gt ex E gt lt H gt g i5 Bx 2E 55 8 558 58 59 Ef d a2 a zm 5 REDE ENE a t a cn amp a Bu t5 lt 2 9 8 TUM Page G 14 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 TABLES AND DOCUMENTS ENCLOSED 5 COLOUR TABLE Acronym Colour BK Black BN Brown RD Red OG Orange YE Yellow GN Green BU Blue VT Purple GY Grey WH White PK Pink TQ Light blue LIST OF ABBREVIATIONS Label Description Fit Fuses Hit Lamps lights warning lights HA Clacson or back up horn K Relays M Motor or pump P Indicators R Resistance RP Potentiometers Switches selectors SS Sensors micro switches pressure switches
14. Genie A TEREX COMPANY OPERATOR HANDBOOK Code 57 0005 8200 Rev 0 12 2005 Handler with telescopic boom GTH 6622 Before Serial Number 18723 English Edi tion CAUTION THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE CAUTION KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES Genie A TEREX COMPANY Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 TECHNICAL SERVICES Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 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 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3
15. hydraulic ports nih Boom functions Rear axle E piloting selector valve steering cylinder BL E yes Ec e m d cylinder T Steering mode H Selector valve 1 1 H PI PHT Piloted check umm valve 4 1 C Slave I Front axle cylinder 4 1 steering cylinder 4350 psi 300 bar 3262 psi OI Bal 1 225bar L LI 1 1 r 4 T 1 11 1 gt E Steering fo 4350 psi I Ka 1 rotating 300 bar J actuator Boom lift Anti cavitation LI I 4 l lind valves Boom extend 4850psi X iy cylinder 72 psi 5 bar retract cylinder 300 bar B2 3 M l N 41 AJ pO TH x 4350 psi XIF Ego elt xii 1 pep 300 bar 2 9 B Ai 2465psi T LP F F ll 144 170 bar E Accumulator 1 capacity 0 13 gallons 0 5 Liters m pre charge pressure 725 psi 50 bar T n E Load handling functions hydraulic 4060 psi controls circuit test port TP 280 bar main valve puc 4 i Hydrostatic transmission high pressure test port I Flushing valve I Hydrostatic Ps Fa Fa Fe e transmission il M B ME paesi I ee ee se B LS Je A 1 Gear speeds Function pump sele
16. type Diesel fuel or oil diesel fuel or oil diesel fuel mixtures The composition of the latter can vary in relation to the ambient temperature up to max 80 oil D 5 2 4 Grease For the machine greasing use e Lithium based When greasing by pump Vanguard LIKO grease type EP2 Graphitized SHELL When greasing by brush grease type GR NG 3 INTERFLON FIN For the telescopic boom GREASE LS 2 sliding blocks ATTENTION Avoid mixing greases of different type or features and do not use greases of lower quality Page D 26 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 TE FAULTS AND TROUBLESHOOTING Section E FAULTS AND TROUBLESHOOTING TABLE OF CONTENTS E 1 FAULTS AND TROUBLESHOOTING E 2 E 1 1 Fault Cause nixa cose tasa rv teri pro rra E 2 Page E 1 Document 57 0005 8200 12 2005 TEREX COMPANY EN E 1 This chapter represents a practical guide for the operator for fixing the most common failures and at the same time detecting those interventions which must be carried out by qualified technical engineers If you are unsure about anything do not carry out operations on the machine but call in a skilled technician Handler with telescopic boom GTH 6622 FAULTS AND TROUBLESHOOTING fee FAULTS AND TROUBLESHOOTING Any repair work maintenance or troubleshooting mu
17. 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 familiarise with this handbook its enclosed graphs and diagrams the identification and hazard warning plates They shall be skilled and trained about the machine use IMPORTANT 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 Page B 2 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 SAFETY e A TEREX COMPANY B B 2 2 REQUISITES OF THE SERVICEMEN The personnel charged with the machine maintenance shall be quali
18. 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 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 vega enig LIST OF REVISED PAGES A TEREX COMPANY Revision Revised Issued No date pages by md mp ND ow on bt M LIST OF REVISED PAGES mu Revised No mu pages Issued by Q Handler with telescopic boom GTH 6622 INTRODUCTION A TEREX COMPANY B INTRODUCTION 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 A GENERAL INFORMATION Sect SAFETY Sect C OP
19. 8 1 amm 12 13 14 15 16 17 23 B4 _ 7 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS A TEREX COMPANY C 3 1 CONTROLS AND INSTRUMENTS Dashboard Water level Warning light gear put Brake oil tank Ignition switch Warning light glow plugs preheating Warning light air filter clogged Fuse compartment Forward reverse speed selection lever Steering column locking lever Brake pedal Pushbutton enabling the attachment coupling release 13 Blank spaces for pushbuttons 14 Steering selection switch 15 Horn pushbutton 16 Mechanical gear selector 17 Gas pedal 18 Fresh air flap 19 Control lever 20 Continuous flow selector 21 Negative brake on off switch 22 Storage tray 23 Seat 24 Storage pocket 25 Windscreen washer pushbutton only with cabin closed 26 Airconditioning fan switch only with cabin closed 27 Cab heater cock only with cabin closed IMPORTANT The warning lights controls and instruments not indicated in this list or in the drawings on the following pages are part of the optional assembly kits When looking for one of such devices please refer to the pages of the specific assembly kit at the end of this manual or to the specific installation instructions 2 Oak OWODND a N Page C 8
20. A TEREX COMPANY MAI NTENANCE INTRODUCTION EE 0 1 LUBRICANTS HEALTH AND SAFETY PRECAUTIONS A thorough and regular maintenance keeps the machine in a safe and efficient working condition Health For this reason it is advisable to wash grease and service the machine properly especially after having worked under particular conditions muddy or dusty environments heavy operations etc Always ensure all machine components are in good condition Check for oil leaks or loosening of guards and make sure that the safety devices are efficient In case of defects find and rectify them before using the machine again The maintenance interventions are based on the machine working hours Regularly check the hour meter and keep it in good condition to define the maintenance intervals correctly Not respecting the ordinary maintenance schedule of this manual automatically voids GENIE warranty IMPORTANT For the engine maintenance please refer to the specific Operator handbook supplied with the machine A prolonged skin contact with oil can cause irritation Use rubber gloves and protective goggles After handling oil carefully wash your hands with soap and water Storage Always keep lubricants in a closed place out of the children s reach Never store lubricants on the open air and without a label indicating their contents Disposal New or exhausted oil is always polluting Never drain oil on the ground Store new
21. Document 57 0005 8200 12 2005 fee enie Handler with telescopic boom GTH 6622 ra OPERATING INSTRUCTIONS 3 2 ENGINE CONTROLS AND C 3 2 2 Forward reverse gear selector switch INSTRUMENTS Three position switch with lock in neutral position C 3 2 1 Ignition switch Three position switch N Neutral position no gear engaged O No circuit under voltage key can be removed F Shift lever to pos F to select the forward gear and engine is stopped R Shift lever to pos R to select the reverse gear Circuits under voltage presetting for the engine starting Board controls and instruments are on The warning light 6 signalling the glow plugs preheating comes on Wait until the light goes off before starting the engine Engine starting when released key springs C back to pos 6 automatically Page C 9 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS A TEREX COMPANY 3 2 3 Brakes 11 Service brake pedal Gradually step on the brake pedal to decelerate and stop the machine The pedal operates on the front axle Fully depressing the brake pedal causes a reset of the displacement of the power drive pump making the brake action more powerful 21 Parking brake The parking brake of negative type engages automatically when the engine is stopped When the handler s engine is restarted pressing the pushbutton
22. For the oil change Stop the machine and ensure the plug is oriented along the vertical axis Place a container of suitable size under the reduction gear plug Unscrew plug and drain any oil from the reduction gear Rotate the wheel by 90 until the plug finds again on the horizontal axis Add new oil through hole Refit and tighten plug PROTECT THE ENVIRONMENT The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres IMPORTANT When changing the oil drain it when it is still hot and the polluting substances are in suspension Page D 16 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 ra A TEREX COMPANY 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 can depend on an oil blow by from the steering control circuit or on a steering of both axles when front and rear wheels are not perfectly aligned To fix this problem rather than checking the alignment visually follow the procedure below 1 Move to a solid and level ground 2 Setthesteering selection switch 14 to four wheel steer pos 2 3 Rotatethe steering up to its stop either to the right or to the left 4 Set the steering selection switch to two wheel steer pos 0 5 Rotate the steering up to its sto
23. Lubricate the machine thoroughly Do 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 well ventilated place e Startthe engine for about 10 minutes at least once a month IMPORTANT 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 re starting the machine carry out an extraordinary maintenance and carefully check all mechanical hydraulic and electrical components Page C 31 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS A TEREX COMPANY C 6 6 CLEANING AND WASHING THE MACHINE C 6 6 1 Cleaning instructions 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
24. Y06 LINE FUSES 5 1 FROM X2 PIN 9 TO P01 J13 6 RD 2 5 RD 4 POWER SUPPLY 12 V TO K01 7 BNo4 POWER SUPPLY 12 V TO FUSES 8 BK 2 5 GROUND 9 GY RDo1 FROM X2 PIN 4 TO P01 J9 10 GY RD 1 5 FROM F6 TO SW11 11 GY GNe1 FROM X2 PIN 16 TO 12 GY BUe1 FROM X2 PIN 6 TO H01 13 GY WH 1 FROM SW07 TO P01 J10 14 GY YE 1 FROM X2 PIN 22 TO P01 J4 15 BN BK 1 FROM F12 TO SW08 16 BU RD 1 FROM X02 PIN 16 TO P01 17 WH GN 1 FROM X2 PIN 14 TO P01 J6 18 VT WH 1 5 FROM X02 PIN 25 TO H01 X04 1 RD GN 1 FROM X2 PIN 26 TO P02 COLUMN 2 WH BUet FROM P01 J14 TO X2 PIN 30 CONNECTOR 3 OG BUe1 FROM K07 TO H04 6 WAYS 4 RD BK 1 FROM F04 TO P01 J1 LINE FUSES 5 RD BK 1 FROM F04 TO P02 6 RD BK 1 FROM F04 TO SW04 X05 1 OGo1 OG GN 1 5 FROM K02 SW03 CAB CONNECTOR 2 GN BK 1 5 FROM SW10 TO F03 12 WAYS 3 VT 1 FROM SW11 TO X2 PIN 7 AND HA02 LINE COLUMN 4 VT 1 5 FROM SW01 TO K02 5 WH YE 1 FROM SW04 TO X7 PIN B 6 OG YE 1 FROM X2 PIN 12 TO SW04 F YE RD 1 FROM SW08 TO X2 PIN 2 AND Y09 8 YEot FROM F15 TO P01 J2 9 YEot FROM F15 TO P02 10 YE GN 1 5 FROM SW10 TO X2 PIN 21 AND H03 11 YE BK 1 5 FROM F2 54 09 12 YE GNo1 5 FROM SW09 TO H02 X06 1 YE GNo1 5 FROM X5 PIN 12 TO 2 CABCONNECTOR 2 VT WHe1 FROM F11 TO HA03 6 WAYS 3 RDo1 5 FROM F14 TO HA04 LINE FUSES 4 BKo1 FROM TO GROUND 5 BKot FROM HA04 TO GROUND 6 BK 1 5 FROM H02 TO GROUND Page G 16 Document 57 0005 8200 12 2005 QNIG Handler with telescopic boom GTH 6
25. adequate to the ambient temperature Please referto the DEUTZ engine use and maintenance manual The machine is supplied with oil SAE 15W 40 40 Er 0 10 15 25 To start the engine from cold proceed as follows e Put the forward reverse speed selection lever to neutral e Turn the ignition switch to position and wait until the warning light 6 signalling the glow plugs preheating goes off Step down on the gas pedal and start the engine turning the ignition switch to C3 Release as soon as the engine starts e Let the engine run at idle for a few seconds before putting a gear this allows for a gradual warm up of the engine oil and a better lubrication e Incase of engine jump starting remove the booster ables see chapter C 4 3 fee B C 45 DISCONNECTING THE BATTERY Before any maintenance or repair work and especially before welding any components on the machine remove the cables at the battery CAUTION Before disconnecting the battery set all switches within the cab to OFF To disconnect the battery disconnect the negative lead from the frame earth first To connect the battery connect the positive 4 lead first C 4 6 STARTING THE MACHINE When the engine reaches the running temperature ensure all parts are in transfer position and the gearbox lever is in neutral Then proceed as follows e Select the required steering mode e Select the required gear forward or rever
26. 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 Ifyou 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 orto 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 Page 1 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 INTRODUCTION A TEREX COMPANY 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 Thereare six special or
27. handle 3 to open the upper section of the door and lock it against the special catch To unlock the door latched in open position e Press button 4 to unlock the door from the catch close and latch the door to the lower section using handle 3 Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS CAUTION 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 C 3 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS 0 A TEREX COMPANY 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 Such handles are locked in position by some wing nuts 5 which if driven out allow opening the glass completely The front window has two handles 6 which if turned enable the operator to pass through Page C 4 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS A TEREX COMPANY 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 e Sea
28. must have the same rated voltage and output of the battery installed on the handler To jump start the engine e Turn any users off by the special control levers e Putthe gear lever to neutral and engage the parking brake e Ensure the machine battery A is connected to the frame earth the terminals are well tightened and the electrolyte level is regular e Connect the two batteries as shown in the figure Connect first the positive terminals of the two batteries then the negative terminal of the booster supply B to the machine frame earth e f the booster supply is installed on a second vehicle make sure that the latter does not touch the handler then start the vehicle and reach an rpm corresponding to 1 4 of full throttle Turn the ignition key and start the handler then follow the procedure explained in chapter C 4 2 Starting the engine e Disconnect the cables Remove first the negative terminal from the frame earth then from the booster supply Disconnect the positive terminal from the machine battery then from the booster supply Use only a 12V battery other devices like battery chargers etc may cause an explosion of the battery or result in damage to the electrical system Page C 21 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS A TEREX COMPANY C 4 4 LOW TEMPERATURE STARTING In case of cold starting use an oil with a SAE viscosity
29. of reduction gears gearbox and differential gears 2 Regularly check the tightening of the wheel bolts 3 Checkthe tightening of all bolts and nuts 4 Checkthe couplings for oil leaks Within the first 50 working hours 1 Change the oil for the first time Every 10 working hours or daily Check the engine oil level Clean the air suction filter Clean the radiator if necessary Check the hydraulic oil level in the tank Check the greasing of the boom section pads Grease the attachment holding frame Grease all joints of the boom the rear axle shaft joint the transmission shafts the front and rear axles and any equipment of the machine Check the efficiency of the lighting electric system 9 Checktheefficiency of braking system and parking brake 10 Check the efficiency of the steering selection system 11 Checkthe efficiency of the fork balancing system 12 Makesurethe safety devices installed are in efficient working order see procedure in chap D 3 15 NO of OD Every 50 working hours or weekly Jobs to be done in addition to those above 1 Check the tension of the alternator belt 2 Checkthe tyre inflation 3 Checkthe tightening of the wheel nuts 4 Checkthe tightening of the Cardan shaft screws Every 250 working hours or monthly Jobs to be done in addition to those above 1 Change the engine oil and relevant filter 2 Check the oil level of the front and rear differential gears and the gearbo
30. of the type recommended by the manufacturer see par D 5 2 2 PROTECT THE ENVIRONMENT The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres IMPORTANT When changing the oil drain it when it is still hot and the polluting substances are in suspension Page D 13 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 MAINTENANCE D 3 10 2 Auxiliary circuits oil filter Tochangethe hydraulic oil filter cartridge of the service circuits proceed as follows 1 Stopthemachineonalevel ground and engage the parking brake 2 Remove the inspection hatch and unscrew the oil filter fitted inside the tank 3 Check the tank is clean then fit a new filtering element and refit the inspection hatch 4 Check the oil level within the tank Add new oil if necessary Page D 14 Document 57 0005 8200 12 2005 Q 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 e Stopthemachineonalevel ground and engage the parking brake Loosen level plug and check if oil is level with the hole e If necessary add new oil through the hole of the level plug until it comes out e Refit and tighten plug For the oil change e Place contai
31. oil in a suitable warehouse Pour exhausted oil into cans and deliver them to specialised firms for disposal Oil leaks In case of accidental oil leaks cover with sand or type approved granulate Then scrape off and dispose of it as chemical waste First aid Eyes n case of accidental contact with the eyes wash with fresh water If the irritation persists seek medical advice Intake In case of oil intake do not induce vomiting but seek medical advice Skin n case of a prolonged contact wash with soap and water Fire In case of fire use carbon dioxide dry chemical or foam extinguishers Do not use water Page D 2 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 MAINTENANCE A TEREX COMPANY D 2 ROUTINE MAINTENANCE A wrong or neglected maintenance can result in possible risks for both operator and bystanders Make sure maintenance and lubrication are carried out according to the manufacturer s instructions to keep the machine safe and efficient The maintenance interventions are based on the machine working hours Regularly check the hour meter and keep it in good conditions to define the maintenance intervals correctly Make sure any defect detected during the maintenance is promptly rectified before using the machine ATTENTION All marked operations must be carried out by a skilled technician During the first 10 working hours 1 Checkthe oil level
32. 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 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 G
33. some techniques and provides instructions for a safe use of the machine fitted with standard forks Before using different attachments thoroughly read the chapter Optional attachments CAUTION Before using the machine inspect the job site and check for possible hazardous conditions Make sure that there are no holes moving banks or debris that may cause you to lose the control of the machine ELECTRICAL DANGER Pay the greatest attention when working close to electric lines Check their position and ensure that no part of the machine operates at less than 6 meters from the power lines CAUTION For a safe use of the machine always check the weight of the loads going to be handled Always refer to the load charts applied on the cab windscreen or to the quick guide with the fork capacity ratings Page C 23 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS A TEREX COMPANY C 5 1 USING THE LOAD CHARTS The charts indicating the maximum permissible load in 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 The load chart indicates the payload limits of the machine under safe conditions To operate under safe conditions always referto these charts CAUTION The load charts illustrated in this manual are given only as a mere example To define the p
34. sure that it matches the recommended type indicated in paragraph D 5 2 2 until it is level with Q PROTECT THE ENVIRONMENT The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres Page D 12 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 MAINTENANCE A TEREX COMPANY 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 areas 1 Green area 2 Yellow area Normal condition Replace the filter as soon as possible 3 Red area Shut the engine down to prevent damage to the hydraulic system Change the filter and or check for the fault reasons To change the hydraulic oil filter element on the suction line proceed as follows 1 Stop the machine on a level ground and engage the parking brake 2 Placeacontainer of suitable size under the filter to collect any oil leaks then close cock Q 3 Remove the filtering element using a wrench 4 Change the filtering element then before fitting a new one thoroughly clean and grease both seat and gasket 5 Hand tighten and re open cock IMPORTANT Hydraulic oil filter cartridges cannot be cleaned or washed and refitted They must be replaced with new ones
35. the following standards were obeyed during the risk assessment ofthe handler fitted with telescopic boom Directive 98 37 CE 89 336 CEE 2000 14 CE Standard EN 1459 1988 EN 281 1988 EN 1175 2 1998 prEN ISO 13564 1996 ISO 2330 1995 ISO DIS 3287 ISO 3449 1992 EN 13510 2002 ISO 3776 1989 ISO 3795 1989 ISO 5053 1987 ISO 6292 1996 EN 13059 2002 Title Machinery Directive Electromagnetic compatibility Environment Acoustic Emissions Title Harmonised standard Safety of industrial trucks Self propelled variable reach trucks Self propelled industrial trucks sit down rider controlled Rules for the construction and layout of pedals Electrical requirements General requirements of internal combustion engine powered trucks Test method for measuring visibility from self propelled trucks Fork lift trucks Fork arms Technical characteristics and testing Powered industrial trucks Pictorial signs Control symbols Earth moving machinery Falling object protective structures Laboratory tests and performance requirements Earth moving machinery Roll over protective structures Laboratory tests and performance requirements Tractors for agriculture Seat belt anchorages Road vehicles tractors and machinery for agriculture and forestry Determination of burning behaviour of interior materials Powered industrial trucks Terminology Powered industrial trucks and
36. tractors Brake performance and component strength 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 Ill where applicable Page A 11 Document 57 0005 8200 12 2005 io Handler with telescopic boom GTH 6622 GENERAL INFORMATION A 3 5 SAFETY DEVICES e 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 A Block valve on attachment coupling cylinder B Block valve on lifting cylinder C Block valve on balance cylinder D Block valve on boom extension cylinder E Block valve on attachment pitching cylinder Page A 12 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 TE GENERAL INFORMATION 4 GENERAL DESCRIPTION A 4 1 LIST OF THE MAIN COMPONENTS Forks Attachment holding frame 219 boom section 1 boom section Engine hood Driving cab Left rear view mirror Front axle Chassis Left front wheel mud guard Left front wheel reduction gear Left rear
37. transducers Y Solenoid valves Xii Connectors Other components A TEREX COMPANY G 3 2 1 GENERAL WIRING DIAGRAM description Ref Description Sheet A01 12V BATTERY 1 A02 PREHEATING CONTROL UNIT 1 A03 DIODE 7 A04 DIODE 7 F1 X OPTIONAL 1 F2 POWER SUPPLY CHANGE GEAR SWITCH 6 F3 POWER SUPPLY LIGHTS WORK 6 FA POWER SUPPLY E1 RELAY HYDRAULIC OIL INDICATOR LIGHT INSTRUMENTS STOPPED ATTACHMENT SWITCH 1 F5 POWER SUPPLY ENGINE STOP SOLENOID VALVE CONTROL UNIT GLOW PLUGS 1 F6 3 F POWER SUPPLY ANTI OVERTURN 5 F8 POWER SUPPLY PARKING BRAKE SWITCH 5 F9 POWER SUPPLY REAR WIND SCREEN WIPERAWASHER 3 F10 POWER SUPPLY FRONT WIND SCREEN WIPERAWASHER 3 F11 POWER SUPPLY BEACON 6 F12 POWER SUPPLY STEERING SELECTOR MANIPULATOR 7 F13 POWER SUPPLY RELAY 3 RELAY 5 CHANGHE OVER SWITCH 1 F14 POWER SUPPLY INTERIOR LAMP 6 F15 LIGHTINING INSTRUMENT PANEL HYDRAULIC OIL TEMPERATURE INSTRUMENT MOTOR OIL INSTRUMENT 4 F16 POWER SUPPLY RELAY 7 REALY 8 CHANGE GEAR SWITCH 8 F17 OPTIONAL 8 F18 OPTIONAL F19 OPTIONAL F20 OPTIONAL F21 OPTIONAL F22 OPTIONAL F23 OPTIONAL F24 OPTIONAL F25 OPTIONAL F26 OPTIONAL F27 OPTIONAL F28 OPTIONAL F30 PREHEATING CONTROL UNIT MAXIFUSE 1 F31 POWER SUPPLY WARM AIR VENTILATOR SWITCH 1 H01 WARNING LIGHTS AIR FILTER AND PREHEATING GLOW PLUGS 1 H02 LIGHTING 6 WORK LIGHT 6 H04 LIGHTS CHANGE GEAR 8 HA01 BACK UP HORN 2 HA02 HORN 3 BEACON 6 HA04 CAB LIGHT
38. wheel reduction gear OONOAARWDND 1 ok Nao 1 Page A 13 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 GENERAL INFORMATION A TEREX COMPANY A 4 2 DESCRIPTION OF THE MAIN COMPONENTS Hydrostatic transmission This unit consists of parts which drive the machine shifting and namely variable displacement pump connected to the thermal engine by an elastic joint amotor with variable displacement and automatic adjustment in relation to the wheel torque required itis directly installed on the front axle together with the two speed gearbox oil filter placed on the injection line from the tank aheat exchanger to cool the circuit down Motion is transmitted to the rear axle from the gearbox through a Cardan shaft Engine The thermal engine is equipped with a heat exchanger which uses the engine oil as cooling medium Steering axles front and rear differential gears The differential axles transmit the motion to the wheels The locking device acting on the front axle enables the machine to move also on low grip grounds Tyres The machine is equipped with tyres suitably sized for the maximum load allowed on the handler When worn they shall be replaced with new ones having the same dimensions and loading capacity Boom hydraulic circuit It consists of a gear pump connected to the thermal engine which through a special valve dispense
39. 0 59 0200 1000 Safety Strictly obey the general safety precautions given in section B SAFETY Operation When using a shovel load the material only when the boom is completely retracted and push against the heap with straight wheels To load unload the material operate the rotation lever of the attachment holding plate Maintenance Visually check the shovel for damage before using it Technical data Capacity litres 800 A Width mm 1850 B Length mm 800 H Height mm 1150 Weight kg 350 ATTENTION Attachment suitable for moving loose material Do not use for digging operations Page F 4 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 ra OPTIONAL ATTACHMENTS F 1 3 FIXED HOOK ON PLATE Payload Code GTH 6622 3000 kg 59 0700 4000 Technical data Payload kg 3000 Width Length Height Weight mm 970 mm 620 mm 600 kg 132 Application Quick coupling fitted attachment for lifting loads by means of special slings Safety Strictly obey the general safety precautions given in section B SAFETY Do not oscillate the load Do not drag hooked loads Lift the load before extending the boom Operation Fork the hook and hold it in position by means of the locking cylinder All loads must be bridled with special textile slings or chains in compliance with all pertin
40. 1 Starting enabling command F18 Not used 15 K02 Forward speed enabling command F19 Notused 7 5 Inhibition with brake pedal stepped down F20 used 10 K04 Overload warning system control unit F21 Not used 10 enabling command F22 used 10 K05 Reverse speed enabling command F23 used 7 5 KO6 Overload warning system solenoid valve F24 Notused 5 enabling command F25 Not used 10 7 1 and 2 speed control relay F26 Not used 10 KO8 Shaft stop control unit F27 Notused 10 K09 K08 power relay F28 Not used 25 F29 Spare fuses Engine compartment fuses and relays A02 F30 1 11 Ref Circuit Amp F30 Preheating control unit maxifuse 70 F31 System protection fuse 50 A02 Preheating control unit K11 Start relay Page G 4 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 TABLES AND DOCUMENTS ENCLOSED enie G A TEREX COMPANY G 3 1 1 FUSE AND RELAY BOX EL BL EL BL 14 DS eee F Ss Sa er eo 2 E 86 86 86 30758 86 86 Er E Page G 5 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 ra i TABLES AND DOCUMENTS ENCLOSED Intentionally blank page Page G 6 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 Tor TABLES AND DOCUMENTS ENCLOSED G 3 2 WIRING DIAGRAM tab 1 8
41. 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 TE A TEREX COMPANY SAFETY e Except for maintenance purposes do not remove safety devices shields protection cases etc Should their removal be necessary stop the engine remove them with the greatest care and always remember to refit them before starting the engine and using the machine again e Before any maintenance or repair work stop the engine and disconnect the batteries e Do not lubricate clean or adjust moving parts Do not carry out operations manually when specific tools are provided for this purpose e Absolutely avoid to use tools in bad conditions or in an improper way i e pliers instead of adjustable wrenches etc e Before carrying out operations on hydraulic lines under pressure or disconnecting hydraulic components ensure the relevant line has been previously depressurised and does not contain any hot fluid Any intervention on the hydraulic circuit must be carried out by authorised personnel The hydraulic circuit of this machine is fitted with pressure accumulators You and others could be seriously injured if accumulators are not completely depressurised For this purpose shut the engine down and step on the brake pedal 8 10 times e Neither smoke nor use open flames in areas subject to fire dangers and in presence of fuel oil or batteries asm Page B 6 Document 57 0005 8200 12 2005 enie Handler with te
42. 6 Page G 15 TABLES AND DOCUMENTS ENCLOSED Ref K01 K02 K04 K05 K07 K09 K10 Kt1 M01 M02 M03 M04 M05 02 P03 R01 QNIG Handler with telescopic boom GTH 6622 ra Description PERMISSION SWITCH ON LIGHT WORK DX AND SX SWITCH ON RELAY FORWARD SPEED RELAY PARKING RELAY REVERSE SPEED RELAY COMMAND 1 AND 2 SPEED RELAY 2 GEAR RELAY 1 GEAR RELAY OPTIONAL OPTIONAL STARTING RELAY STARTER MOTOR ALTERNATOR REAR WIND SCREEN WIPER WASHER MOTOR FRONT WIND SCREEN WIPER WASHER MOTOR AIR CONDITIONING MOTOR WARNING LIGHTS FUEL GAUGE HYDRAULIC OIL TEMPERATURE GAUGE ENGINE OIL TEMPERATURE GAUGE GLOW PLUGS SWO1 IGNITION KEY SWITCH SW02 DISCONNECTION BATTERY SW03 CHANGE OVER SWITCH SW04 ROAD SAFETY SWITCH SW05 WINDSCREEN WIPER SWITCHES 9 06 V S E SOLENOID VALVE SWITCH 9 07 PARKING BRAKE SWITCH SW08 STEERING SELECTOR SW09 CAB WORK LIGHT SWITCH SW10 WORK LIGHT SWITCH SW11 HORN SW12 1 AND 2 SPEED SWITCH SW13 JOYSTICK SS01 5502 5503 5504 5505 5506 5507 5508 5509 Y01 Y02 Y03 Y04 OIL TEMPERATURE GAUGE SENSOR HIGH TEMPERATURE OIL COOLING MOTOR SENSOR ENGINE OIL PRESSURE TRANSDUCER STOP SHAFT SENSOR GEAR ENGAGED SENSOR HYDRAULIC OIL TEMPERATURE GAUGE SENSOR HYDRAULIC STOP FUEL FLOAT AIR FILTER CLOGGING SENSOR FORWARD SPEED SOLENOID VALVE REVERSE SPEED SOLENOID VALVE ADDITIONAL FUEL SOLENOID VALVE OPTIONAL SOLENOID VALVE Doc
43. 622 ra TABLES AND DOCUMENTS ENCLOSED Colour Connector Pin Engine Line Fuse Line Description X07 A WH OGe1 FROM Y09 AND X2 PIN 29 TO JOYSTICK JOYSTICK B WH YE t FROM X5 PIN 5 AND JOYSTICK CONNECTOR C BN BKe1 FROM F12 TO JOYSTICK X08 1 TQ YE t FROM K07 TO SW12 COLUMN 2 TQ RD 1 TQ RD 1 5 FROM SW12 TO SS05 CONNECTOR 3 PK YE 1 5 FROM K06 TO SW12 4 WAYS 4 VT BK 1 FROM F16 TO SW12 LINE FUSES X09 1 OPTIONAL 2 INTERMITTENCE 3 YE RD 1 5 FROM N C TO X2 PIN 28 AND M05 CONNECTOR 4 5 6 Page G 17 Document 57 0005 8200 12 2005 enie A TEREX COMPANY Handler with telescopic boom GTH 6622 TABLES AND DOCUMENTS ENCLOSED G 4 HYDRAULIC SCHEME Drw 57 2201 1200 rev A
44. 700 3 6 8 5 10 1 M6x1 4500 9000 12700 15200 5 2 10 4 14 6 17 5 M 8 x 1 25 8200 16400 23100 27700 12 3 24 6 34 7 41 6 M8x1 8780 17600 24700 29600 13 26 36 6 43 9 M 10 x 1 5 13000 26000 36500 43900 25 1 50 1 70 5 84 6 M 10 x 1 25 13700 27400 38500 46300 26 2 52 4 73 6 88 4 M 12 x 1 75 18900 37800 53000 63700 42 4 84 8 119 143 M 12 x 1 25 20600 41300 58000 69600 45 8 90 6 127 153 14 2 25800 51500 72500 86900 67 4 135 190 228 14 1 5 28000 56000 78800 94500 71 7 143 202 242 16x2 35200 70300 98900 119000 102 205 288 346 M 16 x 1 5 37400 74800 105000 126000 107 214 302 362 M 18x 2 5 43000 86000 121000 145000 142 283 398 478 M 18 x 1 5 48400 96800 136000 163000 154 308 434 520 M 20x 2 5 54900 110000 154000 185000 200 400 562 674 M 20 x 1 5 60900 122000 171000 206000 216 431 607 728 M22x2 5 67900 136000 191000 229000 266 532 748 897 M 22 x 1 5 74600 149000 210000 252000 286 571 803 964 24 3 79100 158000 222000 267000 345 691 971 1170 24 2 86000 172000 242000 290000 365 731 1030 1230 M27x3 103000 206000 289000 347000 505 1010 1420 1700 M27x2 111000 222000 312000 375000 534 1070 1500 1800 M 30x 3 5 126000 251000 353000 424000 686 1370 1930 2310 M30x2 139000 278000 391000 469000 738 1480 2080 2490 IMPORTANT Sensor maximum driving torque 15 Nm Page G 2 Document 57 0005 8200 12 2005 G 7 nio Handler with telescopic boom GTH 6622 A TEREX COMPANY TABLES AND DOCUM
45. 8 0646 gt 0 o 1 0946180300 C b o sm Genie 6622 09 4618 0639 r3 E 97675 97664 97667 97671 0946180205 Genie 6622 09 4618 0640 97667 GTH 6622 09 4618 0642 tZ 97664 09 4618 0010 09 4618 0641 09 4618 0547 09 4618 0547 Em E 09 4618 0109 97674 97664 top ofchassis boom rest Genie 97665 97668 97676 71 ba ENN pati A U o 2 97670 1 09 4618 0642 97664 09 4618 0547 09 4618 0547 p 5 5 bar Page A 4 Document 57 0005 8200 12 2005 GTH 6622 A TEREX COMPANY 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 97670 Risk of crushing 97671 Risk of explosion burns 97672 Risk of crushing 97673 Prohibition to lif
46. Avoid abrupt acceleration or deceleration Avoid load oscillations and especially do not move the load from the vertical pull line Do not pull crosswise and do not tow Operation To change the working height operate the rotation lever of the attachment holding plate Maintenance Visually check the jib for damage before using it Check the safety catch is in good working order Daily grease the joints using the greasing gun Page F 6 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 TE OPTIONAL ATTACHMENTS F 1 6 FORKS WITH HYDRAULIC SIDE SHIFT Application Quick coupling fitted attachment for handling palletised loads with possibility of shifting the load to the side by x 100 mm Safety Strictly obey the general safety precautions given in section B SAFETY e Do not load loose materials e not move superposed pallets Operation To adjust the tilting operate the rotation lever of the attachment holding plate To side shift operate the attachment locking lever after connecting the feeding lines of the new attachment to the quick couplings See page F 2 Maintenance Visually check the attachment for damage before using it Check for hydraulic oil leaks Daily grease the joints using a greasing gun and smear the sliding guides with graphitized grease Machine GTH 6622 Code 59 0600 0000 Tech
47. ECHNICAL DATA AND PERFORMANCE fee A 5 1 MAIN DIMENSIONS GTH 6622 A Overall height ft 6 9 B Overall width ft 6 7 C Track ft 5 3 D Cab width ft 2 10 E Wheel base ft 8 8 F Length to the front tyres ft 13 5 G Length to the attachment holding plate ft 15 5 H Ground clearance ft 1 4 Internal steering radius ft 7 2 e External steering radius ft 18 3 A 5 2 RESTRICTIONS OF USE Angle of approach 90 Departure angle 42 Ambient temperature 20 40 5 3 e Weight in working order Ib 13245 A 5 4 SPEED Travel speed km h 0 32 Max slope with full load 6096 5 Traction to the dynamometer Ib 13007 Page A 15 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 A TEREX COMPANY GENERAL INFORMATION B A 5 5 PAYLOAD AND REACH Maxlifting height Reach at max height reach forward Attachment holding plate rotation Maximum payload Payload at max height Payload at max reach B A 5 6 FORKS Dimensions Weight Fork holding frame class B A 5 7 DIESEL ENGINE Make Model Type A Features BorexStroke Total displacement Power at 2500 rpm ISO 3046 IFN B A 5 8 ELECTRICAL SYSTEM Voltage Battery B A 5 9 MACHINE SOUND LEVELS Guaranteed sound power level in accordance with the Directive 2000 14 CE Measured sound pressure level in accordance wit
48. ENTS ENCLOSED 2 1 LOAD CHART WITH FORKS GTH 6622 25 GTH 6622 CAPACITY CHART 20 15 10 Forward r h ft 16 1 5 o Forward reach Page G 3 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 TE TABLES AND DOCUMENTS ENCLOSED G 3 1 WIRING DIAGRAM FUSES AND RELAYS ON fOr Ref Circuit Amp n INT F1 Power supply interior lamp emergency switch zz imt turn signals 30 15 F2 Power supply relay K04 7 5 K5 F3 Optional 15 m F4 Front right rear left position lights license plate BS k4 lights position lights indicator engine oil temperature indicator 5 F7 F21 F5 Frontleft rear right position lights fuel gauge F6 man hourmeter warning lamps lighting engine oil F6 FB 3 cooling temperature indicator light fan switch Fi F K2 K7 lights selection switch 5 F3 F6 Rightlow beam 7 5 K6 F7 Left low beam 7 5 zs F8 Right high beam 10 F9 Lefthigh beam High beam warning lamp 10 lol lol F10 15 Fi1 Windscreen washer kit 10 F12 Optional 5 F13 Optional 5 F14 Optional 7 5 RELAYS F15 Preheating control unit power supply 5 F16 used jp JE oe F17 Not used 15 K0
49. ERATING INSTRUCTIONS Sect D MAINTENANCE Sect E TROUBLESHOOTING Sect F OPTIONAL ATTACHMENTS Sect G TABLES AND ENCLOSURES Section A contains 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 B is 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 C is 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 D is 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 F makes a list of the main interchangeable attachments that can be coupled to the machine dimensions weight application field and limits of use Section G contains tables and various enclosed documents like load charts wiring diagrams hydraulic schemes torque wrench setting table etc fee Sections are subdivided into
50. F 1 1 MN F 3 F 1 2 Gs RT F 4 F 1 3 Fixed nol om plate a Ee MEE CPP Ln EAS F 5 F 1 4 SES AEE ERA DERI TEACH RERBA F 6 F 1 5 Forks with hydraulic side shift iaces aco re oiii rosa suut ct F 7 Page F 1 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 OPTIONAL ATTACHMENTS e A TEREX COMPANY 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 To install and remove the attachments follow the instructions supplied in the OPERATION section par C 5 4 When replacing interchangeable attachments keep any person clear of the working area Mounting optional attachments and especially the extension jib can change the centre of gravity of the machine Before handling a load check its weight and compare it with the values on the load charts The weight of the used attachment must always be deducted from the rated payload Procedure to connect hydraulic lines e Couplethe new attachment and lockit hydraulically e Disconnect the quick couplings of the attachment locking cylinder and connect them to the false connectors Q to prevent them from getting dirty e Connect the feeding hoses of the new attachment to the quick coupli
51. NSTRUCTIONS A TEREX COMPANY Couple the connectors of the attachment if any to the quick couplings of the frame After the substitution of an attachment or after any coupling operation visually check the attachment Awrongly coupled attachment may resultin damage to persons or things fee C 6 TRANSPORTING THE MACHINE C 6 1 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 e Unlock the negative brake see chap C 6 1 1 e Tow the machine for short distances and at a low speed only e Usea rigid drawbar e Select the two wheel steer e Set the gearbox lever to neutral e When possible start the engine and use the hydraulic drive and the braking system e Raise the front wheels of the machine and remove the Cardan shaft of the transmission MC 6 1 1 Unlocking the negative brake To unlock the negative brake of a faulty machine proceed as follows e Loosen the two opposite screws located on the front axle in order to remove the washers e Remove the horseshoe shaped washers located under the two screws e Re tighten screws turning alternately the front screw and the rear screw 1 2 turn to unlock the brake To relock the nagetive brake loosen the screws turning alternately the front screw and the r
52. Obbligatorio Batterie Esauste dei rifiuti piombosi Cobat which collect and dispose of used lead acid batteries throughout the national territory 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 smearthe 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 Page C 32 Document 57 0005 8200 12 2005 D 1 D 2 D 2 1 D 3 D 3 1 D 3 2 D 3 3 D 3 4 D 3 5 D 3 5 1 D 3 6 D 3 7 D 3 8 D 3 9 D 3 10 D 3 10 1 D 3 10 2 D 3 11 D 3 11 1 D 3 11 2 D 3 12 D 3 13 D 3 14 D 3 15 D 4 D 4 1 D 4 2 D 4 3 D 5 D 5 1 D 5 2 D 5 2 1 D 5 2 2 D 5 2 3 D 5 2 4 Handler with telescopic boom GTH 6622 MAINTENANCE Section D MAINTENANCE TABLE OF CONTENTS LUBRICANTS HEALTH AND SAFETY PRECAUTIONS D 2 ROUTINE MAINTENANCE images aeo D 3 Jil enangga 627 0219 Ae me D 4 MAINTENANCE JOBS vs ei eo TERR aent D 5 Disconnecting ihe batery ier tinte eo iS EM Saeed D 5 Access to the engine and tanks compartments
53. Pink TQ Light blue LIST OF ABBREVIATIONS Label Description FHH Fuses H Lamps lights HA KHH M Ritt RP SS Vit XH warning lights Clacson or back up horn Relays Motor or pump Indicators Resistance Potentiometers Switches selectors Sensors micro switches pressure switches transducers Solenoid valves Connectors Other components enie Handler with telescopic boom GTH 6622 TE EE TABLES AND DOCUMENTS ENCLOSED G 3 2 WIRING DIAGRAM tab 6 8 5010 gt s gig COLOUR TABLE 15 Acronym Colour 5 0910 9 gt 7 610 BK Black BN Brown OG Orange 1 1 YE Yellow YE BKo1 5 e9 m 1 5 9 2 84 velot 5 veg 5 GN Green 4 BU Blue A 6 EE m VT Purple 0 e 2 d GY Grey 1 1 68 69 1 YEIGNot X5 Bkot 9 6 L YEot X5 WH White 12 10 Pink Ai TQ Light blue amp amp SWO9 3 5 10 X5 a X83 X3 m z 2 6 7 3 3 3 e gt E g 5 85 87 87 I 1 LIST OF ABBREVIATIONS lt t H Label Description E 3 8 EH FHH Fuses T gt S H Lamps lights wa
54. REATEST 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 Page 2 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 GENERAL INDEX GENERAL INDEX GENERAL INFORMATION SAFETY OPERATING INSTRUCTIONS MAINTENANCE TROUBLESHOOTING OPTIONAL ATTACHMENTS TABLES AND DOCUMENTS ENCLOSED Page 3 Document 57 0005 8200 12 2005 Sect Sect Sect Sect Sect Sect Sect W gt A TEREX COMPANY enie Handler with telescopic boom GTH 6622 ra Intentionally blank page Page 4 Document 57 0005 8200 12 2005 A 1 A 1 1 A 1 2 A 1 2 1 A 1 3 A 2 A 2 1 A 2 2 A 2 3 A 2 4 A 2 5 A 3 A 3 1 A 3 2 A 3 3 A 3 4 A 3 5 A 4 A 4 1 A 4 2 A 4 3 A 4 4 A 5 A 5 1 A 5 2 A 5 3 A 5 4 A 5 5 A 5 6 A 5 7 A 5 8 A 5 9 A 5 10 A 6 A 7 A 7 1 Handler with telescopic boom GTH 6622 GENERAL INFORMATION Section A GENERAL INFORMATION TABLE OF CONTENTS CONVENTIONAL REFERENCES Machine Kasserer M H Labels and warning plates applied on the Te ordi rie vencer ql ERE DRE EA Explanation of the diff
55. TE switch set to ROAD Replace the fuse Set to JOBSITE ROAD FUNCTION ON EVEN WHEN SELECTING THE JOBSITE FUNCTION No ROAD JOBSITE selection Check and replace fuse F20 if necessary Page E 2 Document 57 0005 8200 12 2005 enig Handler with telescopic boom GTH 6622 ra FAULTS AND TROUBLESHOOTING NO BOOM LOWERING AND Fuse blown e Replace fuses F2 and or F24 EXTENSION NO HOLDING FRAME Emergency button ON Resetthe button TILTING THE HYDRAULIC OIL This is normal when the outside tem THERMOMETER DOES NOT WORK perature is low and or the machine is used for short periods since the hydraulic oil cannot warm up over 40 50 C THE PARKING BRAKE LIGHT Fuse blown Check and replace fuse F2 if DOES NOT LIGHT UP necessary BOOM DOES NOT MOVE Fuse blown Check and replace fuse F22 if necessary ROAD JOBSITE switch set to Setto 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 E 3 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 TE FAULTS AND TROUBLESHOOTING Page E 4 Document 57 0005 8200 12 2005 G Q io Handler with telescopic boom GTH 6622 TE A TEREX COMPANY OPTIONAL ATTACHMENTS Section F OPTIONAL ATTACHMENTS TABLE OF CONTENTS
56. ab 5 8 30 4 G10 fee 0 6 810 4 1010 15 RD BKo1 4B8 fo Y10 AD es 3 TQ RD t1 208 gt GY WH 1 i 1 4 BN GNo1 TQ RD t m BK l 2 2 Us BN GN 1 3 6 BUo1 GY WH 1 5107 1 F8 10A BNo2 5 1 OG VEo 34 d 3 WH YEo TQ GNoi 2 4 RDot 4 a Sill 4 2 5 BU RD t 5 BU RDot RD 1 4 TQ GNo 3 1 L 5 4 X5 O X5 X3 6 0 5 7 5106 e SW04 Q 8 8 3 3 S o E 9 3 o X2 2 12 3 WH YE t 5 gt I X2 E 7 65 o o BKo1 Y04 pu TQ GN 1 BKot 12 GY WHo1 4 D6 X3 18 X2 17 BU t 12v Y08 RD P BNo4 3 gt 6 610 31 gt 6 A10 ATTACHMENT SOLENOID VALVE ROAD SAFETY SWITCH ANTI OVERTURN SOLENOID VALVE Page G 11 Document 57 0005 8200 12 2005 EV SWITCH SOLENOID VALVE PARKING BRAKE SWITCH NEGATIVE BRAKE SOLENOID VALVE COLOUR TABLE Acronym Colour BK Black BN Brown RD Red OG Orange YE Yellow GN Green BU Blue VT Purple GY Grey WH White PK
57. and remove cover B Unscrew wingnut C and remove the outer element D Clean the filter bowl Drycleanthe cartridge max pressure 6 bar and direct the air jet from inside to outside Check for cracks in the filtering element by introducing a lamp inside Smearthe seal with grease then refit the element Tighten wingnut C close cover B and tighten with wingnut A ATTENTION As soon as the warning lamp 7 on the cab dashboard switches on replace the outer element 2 Changing the internal element See step 1 for removing the outer element Loosen wing nut E and remove the inner element F Clean the filter bowl Smearthe seal with grease then mount the new element and make sure it is correctly positioned Refit the outer element and the cover see step 1 ATTENTION The inner element should be replaced every two times the outer element is replaced Daily remove any dust collected in the filter by pressing the rubber cap G Page D 10 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 MAINTENANCE e A TEREX COMPANY 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 1 Cleaning and changing the cartridge Shut the engine down and engage the parking brake Pull out the filter A located to the left of the driving pla
58. ayload limits refer to the load charts applied in the cab of your machine fee CAUTION The load charts applied on the cab windscreen refer to a stationary machine standing on a solid and level ground Raise the load some centimetres and check its stability before raising it completely 25 20 15 10 15 10 5 GTH 6622 CAPACITY CHART Forward reach ft Page C 24 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 ra Ma OPERATING INSTRUCTIONS C 5 2 HANDLING LOADS B C 5 2 1 Adjusting the forks Forks shall be spaced to suit the load going to be handled For this purpose e Loosen the nut of the locking screws e Raise the forks and slide them on the pivot until correct spacing e Lock the screws re tightening the nut CAUTION e The centre of gravity of the load must always be halfway between the forks e Ensure you exactly know the weight of the load before handling it e When extending the boom do not exceed the payload limit e Refer to the payload limits given in the load chart applied on the cab windscreen or in the quick user s guide e Space the forks as wide as possible to suit the load being handled Page C 25 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS A TEREX COMPANY C 5 2 2 Working phases When forks are correctly spaced the handler i
59. bilisers or the wheels These plates must grant a specific pressure of 1 2 to 1 5 kg cm 500x500mm plates are sufficient 10 67 m 13 72 m Look for the best route to the job site e When the machine is running nobody can enter its working range e While working keep the working area in order Never leave objects scattered they could hinder the machine movements and represent a danger for personnel Do not at any time use the machine during a storm Page B 4 Document 57 0005 8200 12 2005 A TEREX COMPANY enie Handler with telescopic boom GTH 6622 TE SAFETY B B 3 2 GETTING READY TO WORK Before any operation following precautions should be taken e First of all make sure that the maintenance interventions have been carried out with care according to the established schedule see section D Maintenance CAUTION Set the machine to working configuration and sway it Use the special inclinometer to the right of the driving place to check that the machine is level before operating it e Ensure you have enough fuel to avoid a sudden stop of the engine especially during a crucial manoeuvre e Clean instruments data plates lights and the cab windscreen thoroughly e Check the correct functioning of all the safety devices installed on the machine and in the job site e Incase of troubles or difficulties inform the foreman at once Never start working under unsafe conditions e Do no
60. ce Clean the filter bowl Clean the filter cartridge and replace in case of damage ATTENTION Do not at any times dry clean the filters Use some water and or solvent D 3 8 ENGINE COOLING CIRCUIT The cooling radiator is lubricated with the engine oil and does not need any maintenance Page D 11 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 MAINTENANCE e A TEREX COMPANY B D 3 9 CHECKING THE OIL LEVEL IN THE TANK 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 Check the hydraulic oil level visually through the special level Q fitted into the tank When necessary add new oil through filler CAUTION Check the oil level with handler set to transfer position lowered boom and retracted telescopic element If oil must be changed proceed as follows 1 Stop the machine on a level ground and make sure the parking brake is engaged 2 Release the pressure from the hydraulic circuit 3 Place a container of suitable size under the drain plug placed in the lower part of the reservoir and collect any oil leaks 4 Remove the drain plug and allow oil to flow out into the container 5 Remove the inspection cover of tank 6 Carefully wash the tank with Diesel oil and blow a jet of compressed air the drain plug and the inspection cover 8 Add new oil by making
61. chine wheels e Ensure ramps are correctly positioned e Retract the boom to transfer position e Carefully drive the machine onto the transporting vehicle e Put the parking brake and rest the attachment flat on the vehicle platform e Ensure the overall dimensions do not exceed the allowed limits e Shut the engine down and close the driving cab of the machine e Secure the machine to the vehicle platform by wheel chocks e Anchor the machine to the transporting vehicle with suitable chains Page C 30 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS A TEREX COMPANY C 6 5 PARKING AND STORAGE B C 6 5 1 Always park the machine in a safe way after a working day a shift and at night Short inactivity Takeall precautionsto prevent damageto those persons who will approach the machine while stationary Park the machine so that it does not hinder other operations Lower the boom fitted with attachment on the ground Remove the key from the ignition switch Leave the driving cab and lock the cab door Disconnect the battery see chapter C 4 5 C 6 5 2 Machine storage In case of extended inactivity of the machine follow the above precautions Additionally e Wash the machine thoroughly For a better cleaning remove grills and protection casings Carefully dry all machine parts by blowing some compressed air e
62. 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 Regularly grease the machine to grant it efficient conditions and a long life By means of a pump inject grease into the special greasers As the fresh grease comes out stop the operation The greasing points are shown in the following figures thesymbol represents the points to be greased by a pump the symbol EN represents the points to be greased by a brush Page D 7 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 MAINTENANCE D 3 4 TYRES AND WHEELS 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 YES NO For the tyre inflation or substitution please refer to the table below GTH 6622 Standard Optional Dimensions 405 70 R24 400 70 R20 P R or load index 14 pr Wheel disc 8 holes DIN 70361 Pressure On new machines and when a wheel has been disassembled or replaced check the nut torque of the wheels every 2 hours until they stay correct ATTENTION Always use tyres having the dimensions indicated in the vehicle registration card Page D 8 Document 57 0005 8200 12 2005 Q Handler with telescopic bo
63. ctor valve with integrated 1 1 priority valve TT mw rt 21 7 gpm 82 L min te Y poy md Ann pud 6525 EE Wi Jd Gear integrated e 450bar ie rf gt ES hydraulic actuator 6235 Hydrostatic poll 430 bar d Mo E transmission 1 OI I L fo xd G MH S Fs r 7l FA Suction I Two speeds L Suction Qn fiter N mechanical Cheek Valve E rey filter Check valve TP 38 gear 7 psi 0 5 bar yc psi 2 Y T 7 psi 0 5 bar Hydrostatic transmission Heat Y boost pressure test port exchanger T Page G 18 Document 57 0005 8200 12 2005 Tank enie Handler with telescopic boom GTH 6622 ra TABLES AND DOCUMENTS ENCLOSED G 5 ROUTINE CHECK SCHEDULE SAFETY DEVICES Table key explanation COMPONENT Block valve 1 Block valve on lifting cylinder E 9 9 9 2 g g g g Block valve 2 Block valve on fork balance cylinder 5155555 51568 Result Notes Block valve 3 Block valve on telescope extension cylinder x xxx 9189198191818 8818 Block valve 4 Block valve on attachment moving cylinder Positive Negative Block valve 5 Block valve on attachment locking cylinder Block valve 6 Block valve 7 Block valve 8 Block valve 9
64. ear screw 1 2 turn refit the horseshoe washers and re tighten screws Page C 28 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 ra UEM OPERATING INSTRUCTIONS C 6 2 ROAD OR SITE TRANSFER E C 6 3 LIFTING THE MACHINE When the machine shall be lifted use only means having a suitable capacity The characteristic data are detailed in the relevant chapter of this manual and on the identification plate For the machine lifting anchor the chains to the special Align the rear wheels lugs on the machine marked with the decal below e Select the two wheel steer When travelling on public roads strictly obey the local or national road traffic regulations Besides take into account the following general precautions e withdraw the floating forks e Retract boom and attachment to transfer position e sure the instruments are in efficient working order e Start the machine e Select the forward or reverse speed e Thetransfer speed ofthe vehicle will depend on the engine rpm PKO ON Public road circulation is allowed only for transferring an unloaded machine Do not use the machine to tow trailers Page C 29 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 ra _ OPERATING INSTRUCTIONS B C 6 4 TRANSPORTING THE MACHINE ON OTHER VEHICLES Totransport the machine on another vehicle follow the steps below e Put chocks at the ma
65. eated air operating switch 26 to select one of the three available speeds e Open the air flaps and adjust their position to direct the air as you want Turn the heated air regulator clockwise to switch off heated air SS Page C 12 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 TE D OPERATING INSTRUCTIONS C 3 3 INSTRUMENTS AND LIGHT 66 Indicator light parking brake engaged INDICATORS This light comes on to warn that the negative C 3 3 1 Instruments parking brake is engaged 54 Engine coolant temperature indicator Signals the engine coolant temperature 67 Indicator light negative brake lator O accumu Not activated Fuel gauge 68 Indicator light turn signals Signals the fuel level within the tank Green indicator light that signals when turn signals are ON This indicator is active only when the Hour meter lights kit is installed Signals the total operating hours of the machine 6 Indicator light glow plugs preheating n Green light indicators which signal the 51 Hydraulic oil temperature indicator preheating phase of the engine glow plugs Signals the temperature of the hydraulic Before starting the engine wait for these lights oil within the reservoir to go off 7 Indicator light air filter soiled C 3 3 2 Light indicators Orange light indicator which signals when the 60 Indicator lig
66. econds before engaging a gear this allows for a gradual warm up of the engine oil and a better lubrication In case of engine jump starting remove the booster cables see following chapter ATTENTION If the light indicators do not switch off on when engine is running immediately stop the machine and find and rectify the fault IMPORTANT Engine cannot be started if the speed switch is not in the neutral position and the operator is not correctly seated in the driving seat After the start up when leaving the driving place the engine continues to run DO NOT LEAVE THE DRIVING PLACE BEFORE HAVING SHUT THE ENGINE DOWN and LOWERED THE BOOM TO THE GROUND Page C 20 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS e A TEREX COMPANY 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 When ump starting the engine through the battery ofanothermachine make sure that the two vehicles cannot collide to prevent formation of sparks Batteries give off a flammable gas and sparks may burn it and cause an explosion Do not smoke when checking the electrolyte level Keep any metal object like buckles watch straps etc clear of the battery positive terminal These elements can short between the terminal and nearby metal work and the operator can get burned The booster supply
67. efore operating the boom make sure that nobody is within the working range of the machine To tilt the attachment holding frame forwards backwards e Press button and smoothly shift the lever to position to tilt the frame forwards or to position to tilt it backwards Page C 17 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 ra OPERATING INSTRUCTIONS C 3 44 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 to extend the boom or to position 9 to retract it Page C 18 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 TE TET OPERATING INSTRUCTIONS B C 3 45 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 e Press button El together with the button 2 on the dashboard to enable the function Shift the lever to position to unlock the attachment or to position to lock the attachment Page C 19 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS A TEREX COMPANY C 4 SETUP B C 4 1 BEFORE STARTING THE ENGINE e Toensure safe conditions t
68. ent 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS A TEREX COMPANY C 24 ADJUSTING THE STEERING COLUMN Both steering column and dashboard can be set to a different angle For this purpose e Loosen lever 1 and adjust as required then re tighten lever 1 Before driving the machine ensure the steering wheel is perfectly clamped fee 2 5 ADJUSTING THE REAR VIEW MIRRORS The machine is fitted with two rear view mirrors e The right rear view mirror is located on a special supporting bracket in advanced position and allows checking the area behind the machine on the right hand side To adjust its position manually rotate the joint it is fitted with e left rear view mirror is placed on the left upper post of the windscreen and allows checking the area behind the machine on the left hand side To adjust its position manually rotate the joint it is fitted with C 26 SWITCHING ON THE CAB LIGHTS The ceiling light fixture of the cab has an internal lamp and a courtesy lamp To switch on the cab interior lights Switch 4 in pos A cab interior lights OFF e Switch 4 in pos B cab interior lights ON e Switch 4 in pos C courtesy lamp ON Page C 6 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS DRIVING PLACE ME MEME er 3 4 5 108 0 2 2 9 2 2 0
69. ent regulations To handle the load raise and rotate the telescopic boom of the handler Maintenance Visually check the hook for damage before using it Check the safety catch is in good working order IMPORTANT The fixed hook has been designed to support a load of 5400 kg The max 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 IMPORTANT Make sure this attachment can be used in the destination country of the machine In Italy this attachment must be enrolled at ISPESL and submitted to yearly test Application must be submitted directly by the user Page F 5 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPTIONAL ATTACHMENTS F 15 EXTENSION JIB Application Code 400 kg GTH 6622 59 0800 0000 Characteristics Payload kg 400 A Length mm 2100 B Wiath mm 920 H Height mm 630 Weight kg 115 IMPORTANT Make sure this attachment can be used in the destination country of the machine In Italy this attachment must be enrolled at ISPESL and submitted to yearly test Application must be submitted directly by the user Quick coupling fitted attachment for maintenance interventions at high working heights Safety Strictly obey the general safety precautions given in section B SAFETY Never lift wrongly slung loads
70. erent symbols used on the machine IDENTIFICATION ET Mere NER ssepe KE e Ge ER auErep n Treicapiecn eai Ghas k eral oe o cai rir PLE EHE Fed a dea Identification plates of the maim parts isis m erp bol soa axe SE SE MU IM I ee c mte T IIT REE TE FESTA NAS e m stand eer erent errr eer ny ert EE TN AN T GENERAL laici vj Listor Ine man GOIm DOES ee NUES dA Description of the mal componens Gpional PIC COB SONNE EE Kiis SPE MEET LE TECHNICAL DATA AND PERFORMANGE inverse ae reden Man EEE deg Erp QE ERES EEE EEE EN EE TH PER ere ETE ETE EET BCT soumo ERR Eee MR ET EE a WS eee E dearer ee ner E E E EAA E M TEMS rp Lic Sopa aed reet ery PH De oA EE Page A 1 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 ra GENERAL INFORMATION 1 CONVENTIONAL REFERENCES A 1 1 MACHINE POSITION Conventionally the machine should be considered positioned as shown in the figure This convention is necessar
71. eyond 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 e Hazards deriving from a too high work or transfer speed in relation to the load handled or the ground condition of the jobsite e Hazards deriving from work procedures adopted during the check or replacement of a block valve residual pressure uncontrolled movements e 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 e Hazard deriving from an accidental overturning of the machine in the event the operator has not fastened the safety belts Page A 10 Document 57 0005 8200 12 2005 A TEREX COMPANY Handler with telescopic boom GTH 6622 ra GENERAL INFORMATION A 3 4 APPLICABLE STANDARDS For the operator s safety
72. fied specialised in the maintenance of earth moving machines 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 familiarise with this handbook its enclosed graphs and diagrams the identification and warning plates They shall be skilled and trained about the machine functioning IMPORTANT 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 B 23 WORKING CLOTHES During work but especially when maintaining or repairing the machine operators must wear suitable protective clothing e Overalls or any other comfortable garments Operators should wear neither clothes with large sleeves nor objects that can get stuck in moving parts of the machine Protective helmet Protective gloves e Working shoes IMPORTANT Use only type approved working clothing in good condition fee B 2 4 PERSONAL PROTECTIVE EQUIPMENT Under special worki
73. gher than those recommended can cause the break of the pad or of the locking threaded bush ATTENTION Pads must compulsorily be replaced if the residual thickness of the plastic layer with respect to the iron bush fixing the block is equal or inferior to 1 mm Page D 18 Max wearing thickness Eni Minimum 1 mm f Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 TE MAINTENANCE E D 3 15 CHECKING THE SAFETY DEVICES B Checking the block valves every months The piloted blocking valves allow to held the load in position in case of burst of a flexible hose To check the efficiency of a valve proceed as follows e Load a weight near the maximum payload 2500 kg roughly onto the boom e Raise the load some centimetres above the ground max 10 cm To check the valve on the telescope extension cylinder move the boom to maximum height and extend it some centimetres e Loosen the oil hoses to the cylinder of which you are checking the valve with caution During the check the oil will flow out of the hoses and the load shall remain blocked in position Should that not be the case the valve must be replaced Contact GENIE Technical Service Wear safety glasses Wear safety gloves Wear safety shoes Wear suitable working clothes Use guards against leaks of oil at high pressure Do the check in a free s
74. h the Directive 98 37 CE A 5 10 VIBRATION LEVELS Mean assessed vibration level transmitted to arms Mean assessed vibration level transmitted to body Values calculated in accordance with standard prEN13059 IMPORTANT dB dB ft ft ft cu in kW Lwa Lpa m s m s fee GTH 6622 22 6 2 8 12 6 135 6600 4400 2700 Floating type 5 1 x1 8 x47 2 165 165 FEM II A Turbo version DEUTZ AG BFAM 2011 Diesel 4 cylinders in line 4 strokes direct injection 3 7 x 4 41 189 65 60 12 100 2 5 0 5 This is a device of Class A In a residential environment such device can cause radio disturbance In such cases the operator is required to take suitable measures Page A 16 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 GENERAL INFORMATION A TEREX COMPANY E A 6 LIFETIME The lifetime of the machine is 10 000 hours provided all checks service jobs and overhauls are done at the times scheduled After this time the machine must compulsorily be inspected and tested by the Manufacturer before being used again Following items are supplied together with the machine 7 ITEMS SUPPLIED Description GTH 6622 Spanner CH 19 X for fork positioning Allen wrench CH 6 X for fork positioning 12Vlamps X spare B A 7 1 LITERATURE SUPPLIED The machines comes with the following literature Wa
75. ht high beam air intake filter of the engine is getting soiled ES Blue indicator light that signals when high Clean or replace beam is ON the filter cartridge This indicator is active only when the immediately lights kit is installed 61 Indicator light position lights DE Green indicator light that signals when position lights are ON This indicator is active only when the lights kit is installed Indicator light air filter soiled Not activated Indicator light low battery charge Signals a low charge by the alternator Indicator light low engine oil pressure It lights when the engine oil pressure is too low 13 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 TE rn OPERATING INSTRUCTIONS mH 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 E 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 IMPORTANT Seize the control lever correctly and move it gently The motion speed of the actuators depends on the lever position a small motion results in a slow motion of the actuators vice versa a full range motion of the lever corre
76. in the register of companies at the Court of Perugia under no 4823 1 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 I E R EX Ar s r l Zona Industriale 06019 Umbertide PG Italy MODEL NUMBER SERIAL NUMBER YEAR OF MANUFACTURE UNLADEN TRUCK MAXIMUN WEIGHT Lb TRUCK CAPACITY Lb THIS TRUCK IS COMPLIANT TO PART Ill OF ASME B56 6 2002 WHERE APPLICABLE MADE IN ITALY LZ Page A 8 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 GENERAL INFORMATION e A TEREX COMPANY 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 Page A 9 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 GENERAL INFORMATION A TEREX COMPANY A 3 ALLOWED USE A 3 1 ALLOWED USE The handlers have been designed and manufactured for lifting handling and transporting agricultural or i
77. ith telescopic boom GTH 6622 TE A TEREX COMPANY MAINTENANCE D 4 2 FUSES AND RELAYS Rif Circuito Amp The electrical system is protected by fuses placed in F25 Not used 10 the driving cab on the left Before replacing a blown F26 Not used 10 een the same amperage find F27 Not used 10 F28 Not used 25 F29 Spare fuses B Fuses Ref Circuit Amp F1 Power supply interior lamp emergency switch turn signals 30 15 F2 Power supply relay K04 7 5 F3 Optional 15 F4 Front right rear left position lights license plate lights position lights indicator engine oil temperature indicator 5 F5 Front left rear right position lights fuel gauge hourmeter warning lamps lighting engine oil cooling temperature indicator light fan switch lights selection switch 5 F6 Right low beam 7 5 F7 Leftlow beam 7 5 F8 Right high beam 10 F9 Left high beam High beam warning lamp 10 F10 Horn 15 F11 Windscreen washer kit 10 F12 Optional 5 F13 Optional 5 F14 Optional 7 5 F15 Preheating control unit power supply 5 F16 Not used 15 F17 Not used 15 F18 Not used 15 F19 Not used 7 5 F20 Not used 10 F21 Not used 10 F22 Not used 10 F23 Not used 7 5 F24 Not used 5 Page D 22 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 A TEREX COMPANY MAINTENANCE B Fuse boxrelays Ref Circuit K01 Starting enabling command K02 Forward speed enabling c
78. ked by a skilled technician 8 Change the main cartridge of the engine air filter 9 Cleanorreplace if nececessary the air filter in the cab Every 1000 working hours or yearly Jobs to be done in addition to those above 1 Changetheoilinthe front and rear differential units and in the power divider 2 Change the oil in the four wheel reduction gears 3 Change the hydraulic oil 4 Change the safety cartridge of the engine air filter 0 21 CHANGE SCHEDULE operating service Oil type hours interval Oil level check 10 daily SHELL RIMULA 15W 40 First change 50 Subsequent changes monthly Axles and Oil level check monthly FUCHS TITAN GEAR LS 85 W 90 First change API GL 5 LS GL 5 divider Subsequent changes 1000 yearly Hydraulic Oil level check monthly SHELL TELLUS T 46 on Subsequent changes 1000 yearly DENISON HF 1 DIN 51524 part 3 Cat HV whichever occurs first Page D 4 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 MAINTENANCE e A TEREX COMPANY 0 3 MAINTENANCE JOBS All maintenance interventions must be carried out with engine stopped parking brake engaged working attachments flat on the ground and gear lever in neutral CAUTION When raising component for maintenance purposes secure it in a safe way before any maintenance intervention CAUTION Any intervention on the hydraulic circuit must carried out by s
79. killed personnel The hydraulic circuit of this machine is fitted with pressure accumulators You and others could be seriously injured if accumulators are not completely depressurised To depressurise the accumators just steer the machine wheels some times with engine shut down until noticing a gradual binding of the handwheel CAUTION Before any operation on hydraulic lines or components make sure there is no residual pressure Forthis purpose stop the engine engage the parking brake and operate the control levers of the distributors in both working directions alternately to depressurise the hydraulic circuit ATTENTION High pressure lines must be replaced by qualified personnel only Any foreign matters entering the closed circuit may result in a sudden deterioration of the transmission ATTENTION The qualified staff charged with the maintenance of the hydraulic circuit must clean all areas around with care before any intervention PROTECT THE ENVIRONMENT The handling and disposing of used oils can be ruled by local or national regulations Address to authorised centres D 3 1 DISCONNECTING THE BATTERY Before any maintenance or repair work and especially before welding any components on the machine remove the cables at the battery CAUTION Before disconnecting the battery set all switches within the cab to OFF To disconnect the battery disconnect the negative lead fro
80. lescopic boom GTH 6622 TE A TEREX COMPANY SAFETY e Do not leave fuel cans or bottles in unsuitable B 4 SAFETY DEVICES places Do not empty catalytic mufflers or other vessels containing burning materials without taking the necessary precautions e Carefully handle all flammable or dangerous substances Several safety devices have been fitted to the machine They must never be tampered with or removed see chap A 3 5 Regularly check the efficiency of such devices see check card chap G 5 In case of faults stop working immediately and proceed in replacing the defective device For the checking procedures read chap D 3 15 e Do not tamper with fire extinguishers or pressure accumulators explosion hazard e After any maintenance or repair work make sure that no tool cloth or other object has been left within machine compartments fitted with moving parts or where suction and cooling air circulates e When working do not give instructions or signs to several people at the same time Instructions and signs must be given by one person only e Always pay the due attention to the instructions given by the foreman e Never distract the operator during working phases or crucial manoeuvres e Do not call an operator suddenly if unnecessary e Do not frighten an operator or throw objects by no means e After work never leave the machine under potentially dangerous conditions Page B 7 Docu
81. m the frame earth first To connect the battery connect the positive 4 lead first Page D 5 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 MAINTENANCE B D 32 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 amp key and a supporting rod that holds it in position From the engine compartment you get access to e Thermal engine Engine air filter 9 e Hydraulic oil tank plug e Radiator fluid compensation cup e Battery To get access to the engine compartment e Shut the engine down and put the parking brake e Unlock the bonnet lock e Lift the bonnet using the special handle until it latches in the gas spring e To close the bonnet press on the green locking device on the gas spring and lower the bonnet Takeallprecautions when approaching the engine compartment Some parts of the engine may be very hot Always use protective gloves E Diesel fuel tank compartment To gain access to the fuel tank open the rear cover of the machine as follows e Shut the engine down and put the parking brake e Fully raise the cover by means of the special handle Page D 6 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 ra MAINTENANCE B D 3 3 GREASING ATTENTION Before injecting grease into the greasers thoroughly
82. ment 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 ra A TEREX COMPANY SAFETY Intentionally blank page Page B 8 Document 57 0005 8200 12 2005 A TEREX COMPANY C 1 C 2 1 C 2 1 1 C 2 2 C 2 3 C 2 4 C 2 5 C 2 6 C 3 C 3 1 C 3 2 C 3 2 1 C 3 2 2 C 3 2 3 C 3 2 4 C 3 2 5 C 3 2 6 C 3 2 7 C 3 2 8 C 3 2 9 C 3 3 C 3 3 1 C 3 3 2 C 3 4 C 3 4 1 C 3 4 2 C 3 4 3 Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS Section C OPERATING INSTRUCTIONS TABLE OF CONTENTS BEFORE ENTERING THE MACHINE C 2 3 4 4 Extending retracting the boom C 18 ENTERING THE MACHINE C 3 3 4 5 Quick coupling the attachments C 19 Entering the cab only with cabin C 4 SE e ET C 20 closed or glass kit installed C 3 C 4 1 Before starting the engine C 20 Emergency exit way only with cabin C 4 1 1 Checks at the machine start up C 20 closed or glass kit installed C 4 C 4 2 Starting the engine C 20 Adjusting the seat 5 C 4 3 Jump starting the engine C 21 Fastening the seat belts 5 C 4 4 Low temperature starting C 22 Adjusting the steering column C 6 C 4 5 Disconnecting the battery C 22 Adjusting the rear view mirrors
83. ndustrial 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 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 b
84. ner of suitable size under plug Loosen the drain plug and the level plug and allow oil to flow out from the differential gears e Refit and tighten drain plug e Add new oil through plug until it is level with the hole e Refit and tighten level filler plug D 3 11 2 Reducer To check the oil level in the reducer e Stopthemachineonalevel ground and engage the parking brake Loosen level plug and check if oil is level with the hole e If necessary add new oil through the hole of the level plug until it comes out e Refit and tighten plug For the oil change e Place container of suitable size under drain plug Loosen the drain plug and the level plug 9 and allow oil to flow out from the reduction gear e Refit and tighten drain plug e Add new oil through plug Q until it is level with the hole e Refit and tighten plug Page D 15 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 e A TEREX COMPANY MAINTENANCE D 3 12 OIL LEVEL IN THE front rear WHEEL REDUCTION GEARS To check the oil level within the wheel reduction gears Stop the machine on a level ground and ensure the parking brake is engaged and plug finds on the horizontal axis Cleanthe plug all around then remove it and check if oil is level with the hole If necessary add new oil through hole until it is level Refit the plug
85. ng cycle CAUTION Do not move off when the load is raised 20 30 cm above the ground Risk of machine overturning or load fall Page C 26 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS CAUTION 5 3 CHANGING THE ATTACHMENT After substitution visually check the attachment is ATTENTION correctly coupled to the boom before operating Use only attachments directly manufactured or the machine A wrongly coupled attachment may Optional attachments section To change an attachment operate as follows Drive to the place where you will release the mounted attachment when possible a solid and sheltered site Disconnect the quick connectors of the attachment if any and connect the hydraulic locking pipes of the attachments to couplings A Rest the attachment flat on the ground e Pitch the attachment holding frame forward and lower the boom to release the attachment upper lock Move back with the machine or with the boom and drive to the new attachment to be coupled Hold the frame pitched forward and hook the upper lock of the new attachment e Retract and raise the attachment some centimetres It will centre automatically on the quick coupling frame Operate the control lever to lock the attachment Page C 27 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING I
86. ng conditions the following personal protective equipment should be used e Breathing set or dust mask e Ear protectors or equivalent equipment e Goggles or facial masks IMPORTANT Use only type approved protective equipment in good condition 9 8 Page Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 SAFETY A TEREX COMPANY B 3 SAFETY PRECAUTIONS 3 1 JOBSITE Always take into account the features of the job site where you are going to work e Always examine the working area and compare it with the machine dimensions in the different configurations ELECTRICAL DANGER Pay the greatest attention to overhead electric lines Always keep at a minimum safe distance from the telescopic boom and the lifted load Electrical hazards DANGER DEATH OR INJURY CAN RESULT FROM CONTACTING ELECTRIC POWER LINES ALWAYS CONTACT THE ELECTRIC POWER LINES OWNER THE ELECTRIC POWER SHALL BE DISCONNECTED OR THE POWER LINES MOVED OR LP ied BEFORE MACHINE OPERATIONS BEGIN POWER LINE VOLTAGE REQUIRED CLEARANCE 0 to 50 kV 10 ft 300m to 200 kV 15 ft 460 to 350 kV 20ft 610m to 500 kV 25 ft 7 62 m to 750 kV 35 ft to 1000 kV 45 ft CAUTION Make sure the machine wheels and stabilisers rests on a firm ground to prevent hazardous unstable conditions If the ground is not firm enough position some supporting planks under the sta
87. ngs previously set free When the new attachment has two hydraulic motions like for instance the pole and pipe planter a flow selecting valve shall be installed on the machine or the attachment and operated from the cab by means of switch 20 Page F 2 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 e A TEREX COMPANY OPTIONAL ATTACHMENTS F 131 SHOVEL Application Quick coupling fitted attachment for moving soil sand debris cereals etc Code GTH 6622 Litres 500 59 0200 0000 Safely Strictly obey the general safety precautions given in section B SAFETY Operation When using a shovel load the material only when the boom is completely retracted and push against the heap with straight wheels To load unload the material operate the rotation lever of the attachment holding plate Maintenance Visually check the shovel for damage before using it Technical data Capacity litres 500 A Width mm 1850 B Length mm 760 H Height mm 700 Weight kg 290 ATTENTION Attachment suitable for moving loose material Do not use for digging operations Page F 3 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 e A TEREX COMPANY OPTIONAL ATTACHMENTS F 1 2 CEREAL SHOVEL Application Quick coupling attachment for loading cereals or inert materials etc Code GTH 6622 Litres 80
88. nical data Payload kg 2600 Width mm 1240 Length mm 1600 Height with protection mm 1000 Weight kg 180 Stroke mm 100 Fork attachments FEM 2 Page F 7 Document 57 0005 8200 12 2005 G Q io Handler with telescopic boom GTH 6622 ra A TEREX COMPANY OPTIONAL ATTACHMENTS Intentionally blank page Page F 8 Document 57 0005 8200 12 2005 G Q Nie Handler with telescopic boom GTH 6622 TE TABLES AND DOCUMENTS ENCLOSED Section G TABLE OF CONTENTS G 1 TORQUE WRENCH SETTING brass danket G 2 G 2 1 Load Chart WiU RR G 3 G 3 1 Wiring diagram Fuses and relays uiii eme beta G 4 G 3 1 1 FU Ar FEL Had e eger pos G 5 G 3 2 Eia 16 eo REE E G 7 G 3 2 1 Wiring diagram Components description G 15 G 3 3 Wiring diagram SENS cc dedii EE kd E PER ECKE G 16 G 4 REO G 18 G 5 ROUTINE CHECK SCHEDULE SAFETY DEVICES G 19 Page G 1 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 TABLES AND DOCUMENTS ENCLOSED G 1 TORQUE WRENCH SETTINGS fee Dxp Pre loading N Torque wrench setting Nm 4 8 8 8 10 9 12 9 4 8 8 8 10 9 12 9 M4x0 7 1970 3930 5530 6640 1 5 3 1 4 3 5 2 M5x0 8 3180 6360 8950 10
89. o the operators and the bystanders and a longer life to your machine perform a walk around inspection before starting the engine e Remove any dirt or rubbish from the cab interior and especially from pedals and control levers e Remove oil grease and mud from pedals and control levers e Make sure that your hands and shoe soles are clean and dry e Check the seat belts can be fastened properly e Check that lights indicators side tail lights hazard indicator lights wipers and horn are in working order e Adjust the driving seat so that you can reach all control levers comfortably and fully depress the brake pedal without moving your back from the driving seat e Adjust the rear view mirrors to give you a good view close behind the machine when you are correctly seated e Check the parking brake is engaged C 4 1 1 Checkthe efficiency ofthe safety devices as described in chap D 3 15 namely e machine start control Checks at the machine start up C 42 STARTING THE ENGINE Forthe low temperature starting see paragraph C 4 4 Put the forward reverse speed selection lever to neutral Step on the gas pedal To start the engine turn the ignition switch to position Release the switch when the engine starts Ifthe engine does not start within 20 seconds release the key and wait at least 2 minutes before attempting again After the start up let the engine run at idle for some a C s
90. om GTH 6622 MAINTENANCE D 3 5 BRAKES e 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 The braking system has two bleeding valves valve forthe service brake circuit and valve 9 for the negative parking brake circuit To bleed the circuit of the service brake e sure that the oil is level within the feeding tank e Step on the brake pedal repeatedly Slowly unscrew valve and re close it as soon as oil mixed with air bubbles comes out e Repeat the operation until bubble free oil comes out e Bleed from both sides of the machine To bleed the circuit of the negative parking brake e Press the parking brake button As soon as the light indicator on the button goes off start bleeding through valve Q until air free oil comes out D 3 5 1 Checking the brake oil level The oil within the braking circuit must be at about 2 cm from the tank plug Page D 9 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 ra MAINTENANCE D 3 6 ENGINE AIR FILTER Clean the engine air filter every 10 hours replace the filtering element if necessary 1 Cleaning and changing the external element Stop the engine and engage the parking brake Unscrew wingnut A
91. ommand Inhibition with brake pedal stepped down K04 Overload warning system control unit enabling command K05 Reverse speed enabling command K06 Overload warning system solenoid valve enabling command 7 1 and2 speed control relay K08 Shaft stop control unit K09 K08 power relay B Engine compartment fuses and relays Ref Circuit Amp F30 Preheating control unit maxifuse 70 F31 System protection fuse 50 A02 Preheating control unit K11 Start relay ATTENTION e Do not use fuses having a higher amperage than that recommended since they can damage the electric system seriously e If the fuse blows after a short time look for the fault source by checking the electric system Always keep some spare fuses for an emergency Never try to repair or short blown fuses Make sure the contacts of fuses and fuse sockets ensure a good electric connection and are not oxidised E fee F14 F28 m AINT F27 ae F12 zz F9 F8 Cr E EHE me F5 am fe F3 SEG F1 F15 m e lol A02 0 F31 K11 Page D 23 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 TE A TEREX COMPANY MAI NTENANCE D 4 3 12V DC LAMPS ONLY WITH LIGHTS KIT INSTALLED Use Voltage Mount type Power Fr
92. ont low high VON si rens 5 uu ees 45 40 W Front position lights euro reete ciet Res AE BA 95 3W e Side tail turn signals rrnnnrnronnnnrnnnrnvrnnnnvnnnrnrrennnrnnnnnnrenennn 12 M iicet BA 158 eene 21W e Stop lights and rear position lights BAY 150 21 5 W e Beacon Work lights IAV errr T 55 W e Dashboard indicators and cab lighting TAN issus W 2x4 60 1 2 W Interior lamp iiia 12 SV 8 5 8 5W License plate lights ierit tetra En BA TOS sete 5W Back Up lamps 12 V iie BA 15S eie 21W CAUTION When switched lamps get hot Before touching a lamp with your fingers let it cool down IMPORTANT Never touch the bulb of halogen lamps mount type H3 with your fingers this may damage the lamp use of a clean cloth or a paper tissue If you touch it accidentally thoroughly clean with a paper tissue and some ethyl alcohol Page D 24 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 TE MAINTENANCE mH 0 5 REFUELLING D 5 1 REFUELLING Product Capacity specifications Part Product litres see par Diesel engine Engine oil 11 3 5 0 5 2 1 Fuel tank Diesel fuel 60 D 5 2 3 Hydraulic sys
93. p turn in the same direction as above o 6 Resetthe steering selection switch to four wheel steer pos 2 7 Rotate the steering to the side opposite to point 3 so that the rear axle reaches its stop 8 Reset the steering selection switch to two wheel steer pos 0 9 Rotate the steering to the same side as in point 7 so that the front axle reaches its stop 10 Reset the steering selection switch to four wheel steer pos 2 Now the wheels should be re aligned Page D 17 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 MAINTENANCE A TEREX COMPANY 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 All pads can be adjusted by the special shims supplied by GENIE upon demand Adjusting the pads e Remove or loosen the screws fixing the pads in relation to type of shims used with or without slots e Fit the necessary amount of shims e If the residual thickness of the pad is insufficient or near the maximum wearing limit renew the pad e Tighten the screws fixing the pads at the recommended torque see below Use a dynamometric wrench Tightening torques of the pad screws in relation to the screw diameter Screws M10 Nm 30 Screws M14 Nm 50 Tightening torques hi
94. pace with barriers all around to keep non authorised people away During the check proceed with extreme caution Ensure that the part to be checked is in safe condition and that the action generated does not result in an uncontrolled movement of the machine Attachment coupling cylinder Lifting cylinder Balance cylinder SJ Extension cylinder Page D 19 Document 57 0005 8200 12 2005 Q 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 Repeat the operation putting first one gear then the other Page D 20 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 TE MAINTENANCE 0 4 ELECTRICAL SYSTEM e Before disconnecting the battery set all switches within the cab to OFF To disconnect the battery disconnect the e Toconnect the battery connect the positive lead first All maintenance interventions must be carried out e Recharge the battery far from the machine in a with engine stopped parking brake engaged well ventilated place working attachments on the ground and gearbox e Keep out of items which can produce sparks of lever in neutral naked flames or lit cigarettes e Donotrest metal objects onto the battery This canres
95. reactions Learn how to operate the machine controls in a safe and open place without obstacles and anybody standing around Do not ram the controls Operate them slowly to understand their effect on the machine BEFORE ENTERING THE MACHINE Checks and cleaning e Clean glasses lights and rear view mirrors Check that pins joints and bolts are well tightened in position e Check for oil fuel or coolant leaks C 1 Checking the tyres e Check the correct inflation of the tyres see par Tyre inflation in the Maintenance section e Make sure that the tyre plies are not cut or worn A tyre burst may result in serious injury never use the machine if tyres are worn wrongly inflated or damaged Page C 2 Document 57 0005 8200 12 2005 ENNE C 2 ENTERING THE MACHINE C 2 1 ENTERING THE CAB ONLY WITH CABIN CLOSED OR GLASS KIT INSTALLED PK SOON Always make sure that your hands and shoe soles are clean and dry before getting into the driving cab Always face the machine when entering and leaving it and hold to the suitable handles The handler cab is equipped with an access door on the left hand side Door opening from outside e Insert the key and release lock 1 e Press the pushbutton and open the door Door closing from inside e Pull the door with force it locks automatically Door opening from inside e Lift lever 2 and release the lock to open the door completely e Rotate
96. rning lights 4 Ayo HA Clacson or back up 1 21 Relays Mitt Motor or pump RD BKot 2 Indicators 4 09 A R Resistance SI X6 RP Potentiometers 6 BKot JQ T Switches selectors SS Sensors micro 5 switches pressure switches wi i i SU rin transducers 5 E YHH Solenoid valves 55 ze Es 903509 oz 9 5 95272 Ze i FE X Connectors Pozo E E E Other components Page G 12 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 TABLES AND DOCUMENTS ENCLOSED G 3 2 WIRING DIAGRAM tab 7 8 fee gt gt 8 G10 15 15 6 G10 e 8 610 BN BK 1 WH YEot X3 15 5 8 X7 B m SW13 5 5 9 A03 Z 04 2 P n amp a fo gt 5 5 5 S 3 E B g 4 amp a b p BL GA SS p X3 X3 J l X5 X7 7 4 54 08 7 C E F 7 7 5 e e 5 BU RD 1 5 M n un 3 eo 9 o F12 5 FH 5 F14 13 F17 13 o o o
97. rranty and handing over certificate Machine operator s handbook Spare parts catalogue DEUTZ engine use and maintenance manual Page A 17 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 ra EE GENERAL INFORMATION Intentionally blank page Page A 18 Document 57 0005 8200 12 2005 B 1 B 2 B 2 1 B 2 2 B 2 3 B 2 4 B 3 B 3 1 B 3 2 B 3 3 B 4 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 TE SAFETY Section B SAFETY TABLE OF CONTENTS GENERAL 2 PREREQUISITES OF THE PERSONNEL IN CHARGE 2 Requisites of the machine operators B 2 Redquisites OF The SeIVI ef IT eo ua E B 3 PORT A ee B 3 Personal protective supert HERRERA LEER PE Ela EE EPFL HM RE B 3 SMET PRE AUTONG E B 4 EEE EE EE B 4 Geno road O WOO EE P 5 E uekeddedir cic eT B 5 FET BEN ES uic UL Mu M s B 7 Page B 1 Q Handler with telescopic boom GTH 6622 SAFETY A TEREX COMPANY 1 GENERAL REMARKS Most accidents occurring while working repairing or maintaining operation machines are caused by not complying with the basic safety precautions Therefore it is neces
98. s oil to the hydraulic drive and a distributor for the following functions boom lifting lowering telescopic boom extension retraction attachment rotation attachment locking Braking circuit It consists of an independent circuit the pedal directly acts on the brake pump which dispenses oil to the front axle braking unit with discs in oil bath The parking brake of negative type acts on the braking unit of the service brake This brake is engaged every time the handler s engine is stopped or pressing down the light pushbutton located to the right of the driving place Telescopic boom The machine is equipped with a telescopic boom with hydraulic driven extension The telescopes slides on interchangeable pads made of wearproof material Driving cab Type approved driving cab in compliance with standards ANSI ASME B56 6 2002 4 3 OPTIONAL ACCESSORIES The machine can be fitted with a wide range of optional accessories please address to Genie sales network IMPORTANT Please check the accessories available for your machine B A 4 4 KITS SUPPLIED ON REQUEST The machine is prepared for the installation of the following assembly kits Driving cab glasses including door Heater Air conditioning Work lights including courtesy lamp in the cab Beacon Page A 14 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 A TEREX COMPANY GENERAL INFORMATION 5 T
99. s ready to use Work can be subdivided into three different phases loading transfer and unloading Loading phase e Approach the load to the handled perpendicularly and check that the machine is level on the inclinometer e Insert the forks under the load and raise the load some centimetres e Pitch the forks backwards and check the machine stability before handling a load Transfer phase e Do not start or brake abruptly e Drive to the unloading point cautiously and keep the load 20 30 cm from the ground Suitthemachine speed to the ground conditions to avoid dangerous jumps side skids of the vehicle and possible load falls e When driving on slopes or ramps hold the load uphill Do not drive on slopes sideways this wrong manoeuvre is one ofthe main reasons for accidents due to vehicle overturning Unloading phase e Drive to the unloading point with straight wheels and bring the machine to a smooth stop leaving enough space to operate the boom e Put the parking brake and set the transmission to neutral e Position the load some centimetres above the desired position and set the forks level e Lower the load and make sure it is level e Carefully withdraw the forks by operating the boom retraction control and if necessary raise or lower the boom as forks come out e When the forks are clear of the load set them to transfer position fee e Release the parking brake and start a new worki
100. sary to pay steady attention to the potential hazards and the effects that may come of operations carried out on the machine IMPORTANT If you recognise hazardous situations you can prevent accidents For instance this handbook makes use of special safety symbols to stress any potentially hazardous situation CAUTION The instructions given in this handbook are the ones established by GENIE They do not exclude other safe and most convenient ways for the machine installation operation and maintenance that take into account the available spaces and means If you decide to follow instructions other than those given in this manual you shall absolutely e sure that the operations you are going to carry out are not explicitly forbidden be sure that the methods are safe say in compliance with the rules and provisions given in this section e be sure that the methods cannot damage the machine directly or indirectly or make it unsafe contact GENIE Assistance Service for any suggestion and the necessary written permission IMPORTANT If in doubt it is always better to ask For this purpose contact GENIE the assistance service is atyour disposal Addresses phone andfax numbers are given in the cover and in the title page of this manual fee B 2 REQUISITES OF THE PERSONNEL IN CHARGE B B 21 REQUISITES OF THE MACHINE OPERATORS The operators who use the machine regularly or occasionally
101. se Release the parking brake pressing button 21 the warning light on the pushbutton must be off Slowly step on the gas pedal to start moving off CAUTION Donot operate the forward reverse gear lever when the machine is running The machine would reverse the running direction abruptly and you could seriously be injured Page C 22 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS e A TEREX COMPANY B C 4 7 STOPPING AND PARKING THE MACHINE When possible stop the machine on a dry level and solid ground Then e Bring the machine to a smooth stop by easing up the gas pedal and stepping down on the brake pedal e Set the forward back speed lever to neutral position e Engage the parking brake pressing button 18 the warning light on the pushbutton must be on e Release the service brake pedal e Rest the attachment coupled to the boom flat on the ground e Rotate the ignition key to 0 and remove the key e Leave the driving cab and lock the cab door e Disconnect the battery see chapter C 4 5 Always face the machine when getting off the driving cab make sure that your hands and shoe soles are clean and dry and hold to the handholds to prevent falls or slips Always engage the parking brake after stopping the machine to preventpossible accidental motions of the vehicle fee C 5 USING THE HANDLER This chapter describes
102. sponds to the max speed of the actuator CAUTION The control lever shall be operated only when correctly seated in the driving place CAUTION Before operating the control lever make sure that nobody is within the working range of the machine Page C 14 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 TE 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 or Boom extraction retraction shift the control lever to 9 or Attachment back forward tilting press button and shift the control lever to or e Attachment coupling release press button together with the dashboard enabling button and shift the lever to or Page C 15 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 ra rn OPERATING INSTRUCTIONS 3 4 2 Lifting lowering the boom Before operating the boom make sure that nobody is within the working range of the machine CAUTION To lift or lower the boom Smoothly shift the lever to position to lift the boom or to position Y to lower it Page C 16 Document 57 0005 8200 12 2005 Genie Handler with telescopic boom GTH 6622 TE T OPERATING INSTRUCTIONS C 3 4 3 Pitching the attachment holding frame forwards backwards CAUTION B
103. st be carried out with machine stopped boom in rest position or laid on the ground parking brake E 1 1 Fault Cause Solution engaged and ignition key removed DASHBOARD DOES NOT SWITCH ON The 50A fuse F31 supplying power to the dashboard is blown engine compartment Battery disconnected Battery down Battery cut out switch OFF Replace the fuse Connect the battery using the relevant switch Check the battery Switch it on ENGINE DOES NOT START Starter does not run Speed selector switch not in neutral position Battery down Battery cut out switch OFF Set the speed selector switch in neutral position Recharge or replace the battery Switch it on ENGINE DOES NOT START Starter runs but engine does not start Fuse F15 blown No fuel Diesel fuel filter clogged Diesel fuel hose empty fuel used up Solenoid valve engine stop Check the fuse Refuel See DEUTZ engine operator manual Refuel then refer to DEUTZ engine operator manual Check the solenoid valve replace if necessary MACHINE DOES NOT MOVE Speed selector switch in neutral Parking brake engaged Fuse F23 blown Set the speed selector switch correctly Disengage Check the fuse necessary replace if THE MACHINE DRIVE IS NOT ENOUGH Hydraulic oil filter clogged Replace the filter NO SELECTION OF THE STEERING MODE Fuse F20 controlling the steering selection blown ROAD JOBSI
104. switch 21 unlocks the parking brake To stop the handler without shutting down the engine press the pushbutton switch 21 to engage the parking brake and push it once again to disengage the brake Every pressure of the pushbutton switches the warning light on and off When the red warning light is on the parking brake is engaged CAUTION Never use the parking brake to slow down the machine unless in an emergency It may reduce the brake efficiency fee MC 3 24 Accelerator control 17 Gas pedal Its pressure controls the engine rpm and coupled to the gearbox the machine speed It is fitted with an adjustable stop in the lower part EL ET Page C 10 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS A TEREX COMPANY B C 3 2 5 Pushbutton enabling the attachment coupling release 12 Selection button Pushbutton with two stable positions Pressing this button activates the attachment coupling and release The built in button light switches on C 3 2 6 Steering mode selection 14 Steering mode switch Three position switch for the selection of the steering mode 1 Crab steering Two wheel steering 2 Four wheel steering C 3 2 7 Continuous flow selector 20 Selection button Button wi
105. t carry out any repair work in a makeshift way to start working B B 3 3 DURING WORK OR MAINTENANCE During work and especially maintenance always pay the greatest attention e Donot walk or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only e Keep the machine handholds and access steps always clean from oil grease or dirt to prevent falls or slips Page B 5 When entering leaving the cab or other raised parts always face the machine never turn the back When carrying out operations at hazardous heights over 1 5 meters from the ground always use type approved safety belts or fall preventing devices Uy al Do not enter leave the machine while it is running Do not leave the driving place when the machine is running Neither stop nor carry out interventions under or between the machine wheels when engine is running When maintenance in this area is required stop the engine Do not carry out maintenance or repair works without a sufficient lighting When using the machine lights the beam should be oriented in order not to blind the personnel at work Before applying voltage to electric cables or components check their connection and proper functioning Do not carry out interventions on electric components with voltage over 48V Do not connect wet plugs or sockets Plates and hazard warning stickers shall never be removed hidden or become unreadable Document
106. t distance from the controls The seat is equipped with an adjusting device to slide the same seat forward or back with respect to the steering column To adjust the seat pull lever 1 outwards and push the seat to the desired direction Then release the lever and make sure that the seat locks in position e Springing adjustment optional Rotate lever 2 clockwise or anticlockwise Toa In some seats height can be adjusted to three different positions Lift the seat until you hear the click signalling that the seat is locked in position To lower the seat raise to end of stroke to release the mechanism then release the seat it will return to the bottom position according to the springing degree required Rotate C 2 3 FASTENING THE SEAT BELTS clockwise anticlockwise to increase reduce the seat springing To reverse this control pull out and Sit correctly in the driving seat then rotate the lever knob by 180 e Height adjustment optional Turn knob 3 clockwise to lift the seat turn it counter clockwise to lower the seat 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 Page C 5 Docum
107. t 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 Page A 5 Document 57 0005 8200 12 2005 fee enie Handler with telescopic boom GTH 6622 ma GENERAL INFORMATION B 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 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 Spend the necessary time to become familiar with these symbols and to learn their meaning 3 c o Symbol Description Description Hazard warning lights Steering mode switch Engine oil pressure SZ Windscreen wiper 9 P
108. tem tank Hydraulic oil 120 D 5 2 2 Front differential gear with reduction gear Oil 6 D 5 2 2 Front differential gear Oil 5 D 5 2 2 Front wheel reduction gears Oil 1 5 1 5 D 5 2 2 Rear wheel reduction gears Oil 0 7 0 7 D 5 2 2 Brake oil tank Hydraulic oil 0 1 D 5 2 2 D 5 2 PRODUCT SPECIFICATIONS D 5 2 1 Engine oil Use the oil recommended by the Diesel engine Manufacturer see the relevant handbook delivered with the machine At the delivery the machine is refilled with SHELL RIMULA 15W 40 D 5 2 2 Lubrication oils and relevant filtering elements Refill the machine with following lubricants Use Product Definition Power divider Differential gears Reduction gears FUCHS TITAN GEAR LS 85 W 90 API GL 5 LS GL 5 Hydraulic system and brakes SHELL TELLUS T 46 DENISON HF 1 DIN 51524 part 3 Cat HV ATTENTION Never mix different oils this may result in troubles and component breaks Filtering elements Filter Flow 1 1 Filtering Code Transmission oil filter MPS 150 10 u 09 4604 0001 Auxiliary circuit oil filter inside the tank STR 100 1 60 09 4604 0004 Page D 25 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 MAINTENANCE e A TEREX COMPANY D 5 2 3 Fuel Use only Diesel fuel with less than 0 596 sulphur content according to the specifications of the diesel engine operation handbook ATTENTION In cold climates temperature under 20 use only Arctic
109. th two stable positions 1 Pressing this selector delivers a continuous flow of oil to the attachment in use The built in light switches on 2 Pressing this selector again lets the circuit returns to normal mode oil is delivered to the attachment only when the control lever is operated The built in light switches off E C 3 2 8 Speed controls 16 Mechanical gearbox pushbutton Used to engage the 1 or 2 gear Push the button to select the required speed Each pressure corresponds to the selection of a new speed The selection is signalled by warning light 3 which illuminates the glass corresponding to the selected speed Page C 11 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 ra rn OPERATING INSTRUCTIONS MC 3 29 Auxiliary drive controls 15 Horn pushbutton EI Pushbutton with green glass Press this button to operate the horn 25 Windscreen washer button m When pushed it sprays a jet of detergent lt solution on the windscreen and makes the wiper functioning easier 26 Air conditioning fan switch only with cabin closed Three position switch 0 OFF 1 Low speed 2 High speed ES 27 Cab heater control cock only with cabin closed To the right of the driving seat Turn the heated air regulator 27 counter clockwise so the air heating fluid starts circulating The amount of heated air will be proportional to the opening of the relevant regulator e Adjust the h
110. tors C 13 C 6 5 Parking and storage C 31 ss c i C Ek ed Cp C 13 C 6 5 4 Short Inactivily ecce C 31 Light indicators smaa C 13 C 6 5 2 Machine storage C 31 Control EVER iacuit ceca C 14 C 6 6 Cleaning and washing the machine C 32 Function Selection 15 C 6 6 1 Cleaning instructions C 32 Lifting lowering the boom C 16 C 6 6 2 Washing instructions C 32 Pitching the attachment holding C 6 7 Machine C 32 frame forward back C 17 C 6 7 1 Disposal of batteries C 32 Page C 1 Document 57 0005 8200 12 2005 Q Handler with telescopic boom GTH 6622 OPERATING INSTRUCTIONS A TEREX COMPANY INTRODUCTION This section provides the operator a practical guide for the gradual learning of the machine use The operator should get into the driving cab and carry out the preliminary adjustments then memorise the position of the different controls and instruments The familiarisation with the controls ensures not only a correct use during the working phases but also a prompt and timely intervention of the operator when he shall carry out sudden manoeuvres to safeguard his safety and the machine integrity It is necessary to learn how to use and foresee the machine
111. ultin a dangerous short especially during a recharge e Because the electrolyte is highly corrosive it must never come in contact with the frame of When raising a component for maintenance the handler or electric electronic parts If the purposes secure it in a safe way before carrying electrolyte comes in contact with these parts out any maintenance contact the nearest authorised assistance centre e Check the electrolyte level every 250 working hours i necessary add distilled veier Risk of explosion or shorts During the recharge e Ensurethefluidis5 6mmabovetheplatesandthe an explosive mixture with release of hydrogen gas cell levels are correct forms Check the cable clips are well secured to the battery terminals To tighten the clips always use Protect the terminals smearing them with pure vaseline Do not add sulphuric acid add only distilled water Remove the battery and store it in a dry place when the machine is not used for a long time e Battery electrolyte contains sulphuric acid It can burn you if it touches your skin and eyes Always wear goggles and protective gloves and handle the battery with caution to prevent spillage Keep metal objects watch straps rings necklaces clear of the battery leads since they can short the terminals and burn you Page D 21 Document 57 0005 8200 12 2005 Q Handler w
112. ument 57 0005 8200 12 2005 Sheet AAA AR n n5 Ref Y05 Y06 Y07 Y08 Y09 Y10 Y12 Y13 X01 X02 X03 X04 X05 X06 X07 X08 X09 Description WHEEL STEERING SOLENOID VALVE WHEEL STEERING SOLENOID VALVE ENGINE STOP SOLENOID VALVE NEGATIVE BRAKE SOLENOID VALVE TILT FORK SOLENOID VALVE ATTACHMENT SOLENOID VALVE 2 SPEED SOLENOID VALVE 1 SPEED SOLENOID VALVE ENGINE CONNECTOR 2 WAYS LINE FUSES ENGINE CONNECTOR 31 WAYS LINE FUSES COLUMN CONNECTOR 18 WAYS LINE FUSES COLUMN CONNECTOR 6 WAYS LINE FUSES CAB CONNECTOR 12 WAYS LINE COLUMN CAB CONNECTOR 6 WAYS LINE FUSES MANIPULATOR CONNECTOR COLUMN CONNECTOR 4 WAYS LINE FUSES OPTIONAL INTERMITTENCE CONNECTOR Sheet II G 3 3 WIRING DIAGRAM CONNECTORS enie Handler with telescopic boom GTH 6622 ra TABLES AND DOCUMENTS ENCLOSED Colour Connector Pin Engine Line Fuse Line Description RD BKot 412 V FROM F04 J2 YEo1 LIGHT INSTUMENTS FROM F15 J3 BU RDot BATTERY LIGHT COUNTER SIGNAL FROM M02 s J4 GY YE 1 FUEL LEVEL FROM SS08 J5 1 GROUND J6 WH GNo1 HIGH TEMPERATURE FROM SS02 eeu J7 N C J8 BU RDot BATTERY LIGHT COUNTER SIGNAL FROM M02 1 J9 GY RD 1 MOTOR OIL PRESSURE FROM SS03 WARNING LIGHTS J40 GY WH 1 PARKING BRAKE FROM SW07 FUEL GAUGE
113. x 3 Check the oil level in the four wheel reduction gears 4 Checkthe condition of the canister of the engine air filter renew the canister if necessary 5 Check the clamping of the cableheads to the battery terminals 6 Check the air suction hose between engine and filter 7 Checkthe cylinder chromium plated rods 8 Check the hydraulic lines are not worn because of rubbing against the frame or other mechanical components 9 Check the electric cables do not rub against the frame or other mechanical components 10 Checkthe wear of the sliding pads of the boom sections 11 A Adjust the play of the sliding pads of the boom sections 12 Remove any grease from the boom then re grease the sliding parts of the boom sections 13 Check the level of the battery electrolyte Every 3 working months 1 Check the efficiency of the block valves see chap D 3 15 Page D 3 Document 57 0005 8200 12 2005 enie Handler with telescopic boom GTH 6622 ra A TEREX COMPANY MAINTENANCE Every 500 working hours or every six months Jobs to be done in addition to those above 1 Visually check the smoke quantity evacuated from the engine exhaust 2 Checkthe tightening of the engine fixing screws 3 Checkthe tightening of the cab fixing screws 4 Check the backlash between pins and bushings in all joints 5 Change the hydraulic oil filter of the transmission 6 Change the hydraulic oil filter in the tank 7 Have the hydraulic system chec
114. y 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 UPPER PART REAR PART zzz i RIGHT SIDE An Bp FRONT PART LEFT SIDE LOWER PART Page A 2 Document 57 0005 8200 12 2005 Handler with telescopic boom GTH 6622 GENERAL INFORMATION e A TEREX COMPANY 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 G 09 4618 0109 09 4618 0109 Page A 3 Document 57 0005 8200 12 2005 IG A TEREX COMPANY Handler with telescopic boom GTH 6622 GENERAL INFORMATION HYDRAULIC OIL 09 4616 0051 5 09 461

before SN 18723, GTH-6622 (PN 57.0005.8200)

Contents

Download Pdf Manuals

Related Search

Related Contents