PDF Service Manual Genie GTH-6622 GTH-6622S Telescopic Handler - 2 MB
This service manual provides comprehensive instructions for repairing and maintaining the Genie GTH-6622 and GTH-6622S telescopic handlers.
It contains detailed procedures for troubleshooting, disassembly, and repair of all major systems, including hydraulics and electronics.
This guide is essential for service technicians to ensure the telehandler operates safely and reliably.
Follow factory-approved methods to keep your equipment performing at its best.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
WORKSHOP MANUAL
Code 57.4401.2200 - 1st Edition 03/2006
Handler with telescopic boom
GTH 66-22 (From serial n. 11982)
GTH 66-22S (From serial n. 10816)
English
Edition INDEX
--- Page 3 ---
GTH 66-22 • GTH 66-22S 1
SAFETY
Section 1
SAFETY INFORMATION
SECTION INDEX
1.1 Safety rules ...........................................................................................page 2
1.1-1 Personal safety ............................................................................................. 2
1.1-2 Workplace safety .......................................................................................... 2
1.2 General remarks............................................................................................ 4
1.3 Servicemen's requisites .............................................................................. 4
1.3-1 Personal protective equipment ................................................................... 5
1.4 General safety precautions ......................................................................... 5
1.4-1 Working areas . ............................................................................................. 5
1.4-2 Precautions during work ............................................................................. 5
Document 57.4401.2200 - 1st Edition 03/2006 INDEX
--- Page 4 ---
GTH 66-22 • GTH 66-22S 2
TECHNICAL SPECIFICATIONS
2.11 VIBRATION LEVELS
GTH 66-22 • GTH 66-22S
• Mean assessed vibration level transmitted to arms m/s2 < 2.5
• Mean assessed vibration level transmitted to body m/s2 < 0.5
Values calculated in accordance with standard prEN13059
This is a Class A device. In a residential environ-
ment, such device can cause radio disturbance. In
such cases, the operator is required to take suitable
measures.
2.12 REFUELLING
GTH 66-22 • GTH 66-22S
• Diesel engine l 11+3,5
• Fuel tank l 92
• Hydraulic oil tank l 90
• Front differential gear with reduction gear l 6
• Rear differential gear l 5
• Front wheel reduction gears l 1,5 + 1,5
• Rear wheel reduction gears l 0.7 + 0.7
• Brake oil tank l 0.1
Products:
Engine oil: SHELL RIMULA SAE 15W-40 (API CH-4/ CG-4/ CF-4/CF, ACEA E3, MB 228.3)
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. 2 e 3)
Document 57.4401.2200 - 1st Edition 03/2006 INDEX
--- Page 5 ---
GTH 66-22 • GTH 66-22S 2
TECHNICAL SPECIFICATIONS 15
Code Description Q.ty
07.0721.0019 Ball joint 1
07.4529.0091 Gasket kit 1
07.0705.0082 Gasket kit 1
54.0201.0008 Bushing 2
640096 Gasket kit 1
54.0201.0011 Bushing 2
639993 Gasket kit 1
04.0605.0249 Flexible hose 1
07.0703.0096 Removing battery 1
07.4501.0059 Relay 1
07.0703.0061 Fuse 70 A 2
07.0703.0060 Fuse 50 A 2
07.0703.0178 Relay 1
07.0703.0081 Fuse 2 A 5
07.0703.0080 Fuse 5 A 5
634972 Fuse 7,5 A 5
07.0703.0079 Fuse 10 A 5
634973 Fuse 15 A 5
07.0703.0179 Relay 1
07.0709.0117 Wheel stud 8
017.0709.0118 Nut 8
56.0013.0015 Proximity switch 1
07.0709.0417 Gasket kit 1
07.0723.0288 Glass 1
07.0703.0088 Switch 1
07.0723.0144 Handle lock 1
641019 Handle 1
07.0723.0188 Lock 1
07.0723.0140 Stop belt 1
07.0723.0219 Glass 1
07.0723.0221 Wiper motor 1
07.0723.0036 Wiper arm 1
07.0723.0037 Wiper blade 1
GTH 66-22 • 66-22S filters
Code Description Q.ty
07.0723.0149 Filter 2
07.4501.0067 Oil filter 2
07.4501.0068 Fuel filter 2
640885 Cartridge 2
07.4501.0041 Cartridge 2
09.4604.0004 Filter 2
07.0700.0000 Filter cartridge 2
Document 57.4401.2200 - 1st Edition 03/2006 INDEX
--- Page 6 ---
GTH 66-22 • GTH 66-22S 2
TECHNICAL SPECIFICATIONS 25
HY
HYDRAULIC SYSTEM - FORK BALANCING annex 4
C
D
Document 57.4401.2200 - 1st Edition 03/2006 INDEX
--- Page 7 ---
GTH 66-22 • GTH 66-22S 4
SCHEDULED MAINTENANCE PROCEDURES
Section 4
SCHEDULED MAINTENANCE
PROCEDURES
SECTION INDEX
4.1 Introduction............................................................................................page 2
4.2 About this section......................................................................................... 3
4.3 TABLE A procedures..................................................................................... 4
4.4 TABLE B procedures..................................................................................... 20
4.5 TABLE C procedures..................................................................................... 25
4.6 TABLE D procedures..................................................................................... 39
4.7 TABLE E procedures..................................................................................... 46
Document 57.4401.2200 - 1st Edition 03/2006 INDEX
--- Page 9 ---
GTH 66-22 • GTH 66-22S 4
SCHEDULED MAINTENANCE PROCEDURES 11
A-10 CHECK THE HYDRAULIC 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 A
cardboard to detect oil leaks.
Check the hydraulic oil level (visually) through the special
level B fitted into the tank.
When necessary, add new oil through filler A.
Check the oil level with the machine in the travel
position, tha is boom lowered and telescopes fully
in.
The handling and disposing of used oils can be
ruled by local or national regulations. Address to
authorised centres.
B
Document 57.4401.2200 - 1st Edition 03/2006 INDEX
--- Page 10 ---
GTH 66-22 • GTH 66-22S 4
SCHEDULED MAINTENANCE PROCEDURES 21
B-3 CHECK THE TYRE INFLATION
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.
OKAY WRONG
For the tyre inflation or substitution, please refer to the
table below:
Standard OpTional
GTH 66-22 • 66-22S GTH 66-22 • 66-22S
Dimensions (front and rear) 405/70 R24 400/70 R20
P.R. (or load index) 14 pr -
Wheel disc 8 holes DIN 70361 8 holes DIN 70361
Pressure bar/Psi 4.0/58 -
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.
Always use tyres having the dimensions indicated
in the vehicle registration card.
Document 57.4401.2200 - 1st Edition 03/2006 INDEX
--- Page 11 ---
GTH 66-22 • GTH 66-22S 4
SCHEDULED MAINTENANCE PROCEDURES 31
C-8 CHECK THE CYLINDER CHROMIUM-
PLATED RODS
Visually check the cylinder rods for scoring every
month.
For this operation, fully extend all of the cylinders and
check that their rods are intact.
Document 57.4401.2200 - 1st Edition 03/2006 INDEX
--- Page 12 ---
GTH 66-22 • GTH 66-22S 4
SCHEDULED MAINTENANCE PROCEDURES 41
D-5 CHANGE THE HYDRAULIC OIL FILTER
OF THE TRANSMISSION
Every 50 hours, check the clogging degree of the filte-
ring element using the vacuometer A.
The indexed scale of the vacuometer is divided into 3 B
areas:
1 - Green area: Normal condition
2 - Yellow area: Replace the filter as soon as possi-
ble C
3 - Red area: Shut the engine down to prevent
damage to the hydraulic system.
Change the filter and/or check for
the fault reasons.
A
To change the hydraulic oil filter element on the suction
line, proceed as follows: Hydraulic oil filter canisters cannot be cleaned or
washed and refitted.
- Stop the machine on a level ground and engage the They must be replaced with new ones of the type
parking brake. recommended by the manufacturer:
- Place a container of suitable size under the filter to Flow rate l/1’ = MPS 150
collect any oil leaks, then close cock B. Filtering = 10 �
- Remove the filtering element C using a wrench. code = 09.4604.0001
- Change the filtering element, then, before fitting a
new one, thoroughly clean and grease both seat and
gasket.
When changing the oil, drain it when it is still hot and
- Hand-tighten and re-open cock B. the polluting substances are in suspension.
The handling and disposing of used oils may be
ruled by local or national regulations. Address to
authorised centres.
Document 57.4401.2200 - 1st Edition 03/2006 INDEX
--- Page 13 ---
GTH 66-22 • GTH 66-22S 5
TROUBLESHOOTING
Section 5
TROUBLESHOOTING
SECTION INDEX
5.1 Introduction............................................................................................page 2
5.2 About this section......................................................................................... 3
5.3 Problems-Causes-Solutions........................................................................ 4
5.3.1 Hydraulic faults............................................................................................. 4
5.3.2 Electrical faults.............................................................................................. 9
Document 57.4401.2200 - 1st Edition 03/2006 INDEX
--- Page 14 ---
GTH 66-22 • GTH 66-22S 5
TROUBLESHOOTING 11
Problem Cause Solution
The engine coolant thermometer Fuse F4 blown Change the fuse
does not work
Indicator defective Change the part
Temperature sensor defective Check and replace the sensor if
necessary
Broken or damaged wiring Reconnect or replace the wiring
High hydraulic oil temperature Hydraulic oil bulb damaged Check or replace the bulb if
necessary
Indicator defective Change the part
Radiador clogged Check the radiator and eliminate any
impurities from the fins
The joystick does not operate the Fuse F12 blown Change the fuse
boom extension/retraction
Road-jobsite-platform selector Check and replace the selector if
damaged necessary
Yellow button on control lever Check the efficiency of the yellow
pushbutton
Main valve selection valve Check the efficiency of the solenoids
and replace if they are damaged
Broken or damaged wiring Reconnect or replace the wiring
The joystick does not operate the Fuse F12 blown Change the fuse
attachment locking/unlocking
Red button on control lever Check the efficiency of the red
pushbutton
Main valve selection valve Check the efficiency of the electrical
coils and replace if they are
damaged
Mouvement selection button Check the efficiency or replace
Document 57.4401.2200 - 1st Edition 03/2006 INDEX
--- Page 15 ---
GTH 66-22 • GTH 66-22S 6
SCHEMES
6.4 WIRING DIAGRAMS
6.4.1 Sheet 1 of 8
30 30
2/G10 LIST OF ABBREVIATIONS
15 15
2/G10
2/F5 Label Description
F## Fuses
VT/WHø1
RD/BKø1
H## Lamps, lights,
X5
warning lights
VTø1.5
X5 H01
BN/BKø1.5
BNø4
GY/BUø1
CHANGE OVER
1 4 X3
HA## Clacson or back-
OGø1
2
SWITCH
RD/BKø1
OG/GNø1.5
ACC IGN ST 3 4 up horn
BN/BKø1.5
WARNING LIGHT
PREHEATING
VTø1.5
GLOW PLUGS
AIR FILTER
R N F
K## Relays
ACC 0 IGN ST
RNF
SW01
SW03
BAT
BU/RDø1
OG/GNø1.5