Genie GTH-5519 Service Manual: Comprehensive Overview
This manual provides essential guidance for the safe and efficient operation, maintenance, and troubleshooting of the Genie GTH-5519 telescopic handler,
ensuring optimal performance and longevity of this versatile machine.
The Genie GTH-5519 is a compact, rough-terrain telescopic handler designed for a wide range of material handling applications. Manufactured in Italy by Genie Industries, Redmond, Washington, this machine offers a blend of power, maneuverability, and versatility. This service manual is dedicated to providing comprehensive information for owners, operators, and maintenance personnel.
It details procedures for safe operation, routine maintenance, and effective troubleshooting. The GTH-5519 boasts selectable auxiliary-hydraulic flow modes, adapting to diverse task requirements. Recent enhancements, showcased at ICUEE 2008, demonstrate Genie’s commitment to continuous improvement. Furthermore, the machine’s Tier 4-Final Deutz TD 2.9 L4 engine ensures compliance with stringent emissions standards, utilizing a DOC system without a DPF, simplifying maintenance.
Safety Precautions and Guidelines
Prior to operating or maintaining the Genie GTH-5519, thoroughly review all safety precautions outlined in this manual. Always wear appropriate personal protective equipment (PPE), including safety glasses, gloves, and sturdy footwear. Ensure the surrounding area is clear of personnel and obstructions before operation.
Never exceed the machine’s rated load capacity, and always follow the load chart guidelines. Be aware of overhead power lines and maintain a safe distance. Regular inspections are crucial; check for damaged components and address them immediately. Proper training is essential for all operators and maintenance staff. Adherence to these guidelines will minimize the risk of accidents and ensure a safe working environment. Remember, responsible operation is paramount for preventing injuries and equipment damage.
Technical Specifications
The Genie GTH-5519 boasts a Tier 4-Final Deutz TD 2.9 L4 engine delivering 74 horsepower, alongside detailed dimensional data and weight specifications for optimal use.
Engine Details: Deutz TD 2.9 L4
The Genie GTH-5519 is powered by a robust Deutz TD 2.9 L4 diesel engine, renowned for its reliability and performance in demanding applications; This engine delivers a rated horsepower of 74 hp, providing ample power for various lifting and maneuvering tasks. A key feature of this engine is its Tier 4-Final emissions compliance, achieved without the need for a Diesel Particulate Filter (DPF).
Instead, the engine utilizes a Diesel Oxidation Catalyst (DOC) for effective emissions control, simplifying maintenance and reducing overall operating costs. This engine design contributes to a cleaner environmental footprint while maintaining optimal power output. Detailed specifications regarding fuel consumption, cooling system capacity, and recommended oil types are crucial for proper engine maintenance and longevity, and are outlined within this service manual for technicians and operators.
Hydraulic System Overview
The Genie GTH-5519’s hydraulic system is a central component, enabling precise and powerful boom operation and auxiliary functions. This system features multiple flow modes, selectable by the operator to match the requirements of the attached implement. These modes allow for optimized performance and control when handling diverse loads and applications.
The system incorporates a high-capacity hydraulic pump, delivering consistent flow and pressure for smooth, responsive operation. Regular inspection of hydraulic fluid levels, hoses, and fittings is critical to prevent leaks and maintain system efficiency. Troubleshooting sections within this manual detail procedures for diagnosing and resolving common hydraulic issues, ensuring minimal downtime and maximizing productivity. Understanding the hydraulic system’s components and operation is vital for safe and effective machine utilization.
Dimensional Specifications & Weight
Understanding the Genie GTH-5519’s dimensions and weight is crucial for safe operation and transport planning. Key specifications include overall length, width, and height, vital for navigating job sites and ensuring clearance under obstacles. The machine’s turning radius is also a critical factor for maneuverability in confined spaces.
The GTH-5519’s weight, both operating and shipping, impacts trailer selection and load capacity considerations. Detailed charts within this manual provide precise measurements for all relevant dimensions. Accurate knowledge of these specifications is essential for proper load handling, stability calculations, and adherence to transportation regulations. Always consult these figures before undertaking any lifting or transport operation to prevent accidents and ensure compliance.
Operation & Controls
This section details the proper procedures for starting, stopping, driving, and maneuvering the GTH-5519, alongside explanations of all operational controls and auxiliary functions.
Starting and Stopping Procedures
Prior to starting, ensure the parking brake is engaged, all controls are in neutral, and the area around the machine is clear of personnel. Turn the ignition key to the ‘ON’ position, allowing the system to self-check. Observe the instrument panel for any warning lights. Once the self-check completes, turn the key to the ‘START’ position and release it immediately upon engine ignition.
To stop the GTH-5519, gently lower the boom and any attached load to the ground. Bring all controls to neutral. Engage the parking brake firmly. Turn the ignition key to the ‘OFF’ position. Always allow the engine to cool down before performing any maintenance. Failure to follow these procedures could result in damage to the machine or personal injury. Remember to consult the full manual for detailed safety instructions and specific operational nuances.
Driving and Maneuvering
Before driving, verify a clear path and check for overhead obstructions. Gently depress the travel pedal to initiate movement. Steering is accomplished via the steering wheel, exercising caution during turns, especially when the boom is extended or a load is lifted. Reduce speed when navigating uneven terrain or slopes. Avoid abrupt stops or turns that could destabilize the machine.
When maneuvering in tight spaces, utilize the optional four-wheel steering mode for enhanced agility. Regularly inspect tires for proper inflation and wear. Be mindful of the machine’s dimensions and turning radius. Always prioritize safety and maintain a safe distance from personnel and obstacles. Refer to the load chart for limitations when traveling with a load. Proper driving technique ensures stability and prevents accidents.
Auxiliary Hydraulic Flow Modes
The Genie GTH-5519 offers selectable auxiliary hydraulic flow modes to match the requirements of various attachments. These modes allow operators to optimize performance and control for specific tasks. Typically, options include low, medium, and high flow settings, accessible through an in-cab control panel. Selecting the appropriate flow rate is crucial for attachment functionality and preventing damage.
Low flow is ideal for attachments requiring precise control, while high flow is suited for applications demanding rapid operation. Always consult the attachment manufacturer’s recommendations for the correct flow rate. Incorrect settings can lead to inefficient operation or attachment malfunction. Regularly inspect hydraulic hoses and connections for leaks or damage. Proper flow mode selection maximizes productivity and extends the lifespan of both the machine and its attachments.
Boom Operation and Load Charts
Safe boom operation with the Genie GTH-5519 hinges on strict adherence to the provided load charts. These charts detail the machine’s lifting capacity at various boom angles and extensions, crucial for preventing instability and potential tip-overs. Operators must understand that lifting capacity decreases as the boom extends and elevates. Always verify the load weight before lifting and ensure it does not exceed the chart’s specified limits.
Smooth, controlled boom movements are essential. Avoid abrupt starts and stops, which can shift the load and compromise stability. Regularly inspect boom components for wear or damage. Familiarize yourself with the machine’s tilt sensors and warning systems. Prioritize load stability and maintain a clear understanding of the GTH-5519’s operational limits for safe and efficient lifting.
Maintenance Schedule
Consistent adherence to the outlined maintenance schedule is paramount for maximizing the Genie GTH-5519’s lifespan and ensuring reliable, safe operational performance.
Daily Inspection Checklist
Before each operational shift, a thorough daily inspection is crucial for identifying potential issues and ensuring safe operation of the Genie GTH-5519. This checklist should include verifying fluid levels – engine oil, hydraulic fluid, coolant, and fuel – checking for any leaks or damage to hoses and fittings. Inspect tires for proper inflation and wear, and examine the boom for cracks or deformation.
Ensure all safety devices, including the horn, backup alarm, and seatbelt, are functioning correctly. Test the steering and braking systems for responsiveness and effectiveness. Visually inspect the carriage and forks for any signs of damage or wear. Confirm that all gauges and indicators are operating within normal ranges. Document all findings and address any concerns before commencing work; A proactive approach to daily inspections minimizes downtime and promotes a safe working environment.
Scheduled Maintenance Intervals
Maintaining the Genie GTH-5519 according to a strict schedule is vital for maximizing its lifespan and minimizing unexpected repairs. Every 250 hours, or 3 months (whichever comes first), perform an oil and filter change, inspect the air filter, and check all hydraulic hoses and fittings for leaks or damage. At 500 hours, or 6 months, replace the fuel filter, coolant, and hydraulic fluid.
A comprehensive inspection of the engine, transmission, and axles should occur every 1000 hours, or annually. This includes valve adjustments, lubrication of all moving parts, and a thorough examination of the electrical system. Regularly inspect and service the Tier 4-Final Deutz TD 2.9 L4 engine, adhering to Deutz’s recommended maintenance guidelines. Detailed records of all maintenance performed should be maintained for future reference and warranty purposes.
Fluid Levels and Capacities
Maintaining correct fluid levels is crucial for the GTH-5519’s optimal performance and preventing component damage. The engine oil capacity is approximately 7.6 liters (2.0 US gallons), utilizing a quality 15W-40 oil meeting Deutz specifications. The hydraulic oil reservoir holds around 45.5 liters (12 US gallons), requiring a hydraulic oil viscosity of ISO VG 46.
Coolant capacity is roughly 10 liters (2.6 US gallons), utilizing a 50/50 mix of ethylene glycol antifreeze. Regularly check the fuel tank capacity, which is around 113.6 liters (30 US gallons). Always refer to the detailed specifications within this manual for precise measurements and recommended fluid types. Proper fluid management ensures the longevity and reliability of the GTH-5519’s systems.
Troubleshooting
This section details common issues encountered with the GTH-5519, offering systematic solutions for engine, hydraulic, and electrical problems, ensuring quick repairs.
Common Issues and Solutions
Addressing typical operational challenges is crucial for maintaining the GTH-5519’s uptime. Frequent concerns include engine starting difficulties, often resolved by checking the battery connections and fuel supply. Hydraulic system malfunctions, such as reduced lifting capacity, may stem from low fluid levels or a faulty pump – regular fluid checks are vital.
Electrical problems, like unresponsive controls, can often be traced to blown fuses; the fuse box diagram (see Component Breakdown) is essential for quick identification and replacement. Intermittent operation might indicate loose wiring connections. Always prioritize safety when diagnosing electrical issues.
For Tier 4-Final engine issues, consult the engine troubleshooting section, as the Deutz TD 2.9 L4 requires specific diagnostic procedures. Remember to document all repairs and maintenance performed for future reference and warranty claims.
Hydraulic System Troubleshooting
Diagnosing hydraulic issues on the GTH-5519 requires a systematic approach. Reduced lifting capacity often points to low hydraulic fluid levels – verify and top up as needed, referencing the Fluid Levels and Capacities section. Inspect hoses and fittings for leaks; even small leaks can significantly impact performance. A faulty hydraulic pump can cause slow or erratic boom movements.
Check the hydraulic oil filter for blockage, as a clogged filter restricts flow. Verify proper operation of the auxiliary hydraulic flow modes; incorrect settings can lead to reduced functionality. Listen for unusual noises, such as whining or hissing, which may indicate a failing component.
Always relieve hydraulic pressure before disconnecting any lines. Consult detailed schematics for accurate component identification and troubleshooting procedures.
Engine Troubleshooting
Addressing engine issues on the GTH-5519 begins with verifying fuel and air supply. A no-start condition could stem from a clogged fuel filter or a faulty fuel pump; inspect and replace as necessary. Check the air filter for restrictions, ensuring adequate airflow to the Deutz TD 2.9 L4 engine. Low engine power may indicate a problem with the fuel injectors or a failing glow plug system.
Monitor engine temperature; overheating can cause significant damage. Listen for unusual engine noises, such as knocking or misfiring, which require immediate attention. The GTH-5519’s Tier 4-Final engine utilizes a DOC, so check for related fault codes.
Refer to the engine manufacturer’s documentation for specific diagnostic procedures and repair guidelines.
Component Breakdown
Detailed schematics and parts lists are provided for the GTH-5519’s key assemblies, including the fuse box, electrical system, boom, carriage, and tire/wheel specifications.
Fuse Box Diagram & Electrical System
The Genie GTH-5519’s electrical system is a critical component, and this section details the fuse box diagram for easy identification of circuits and troubleshooting.
A comprehensive wiring diagram illustrates the connections between various electrical components, including the engine control unit, hydraulic system, and operator controls.
This allows technicians to efficiently diagnose and repair electrical faults.
Specific attention is given to the location of the fuse box, the function of each fuse, and the proper procedure for replacing blown fuses.
The manual also covers the battery location, charging system, and starting system, providing detailed instructions for maintenance and repair.
Understanding the electrical system is paramount for safe and effective operation of the GTH-5519, ensuring all functions operate as intended and preventing potential hazards.
Boom and Carriage Assembly
This section provides a detailed breakdown of the Genie GTH-5519’s boom and carriage assembly, essential for maintenance, repair, and component replacement.
Exploded views illustrate the arrangement of all parts, including the boom sections, carriage, rollers, and associated hardware.
Detailed instructions guide technicians through the disassembly and reassembly process, ensuring correct alignment and functionality.
Specific attention is given to the inspection of critical components like boom pins, hoses, and cylinders, highlighting wear patterns and potential failure points.
Torque specifications for all fasteners are clearly outlined to prevent over-tightening or loosening.
Proper boom and carriage maintenance is crucial for safe lifting operations and extending the lifespan of the machine, guaranteeing stability and preventing unexpected mechanical issues.
Tire and Wheel Specifications
This section details the precise tire and wheel specifications for the Genie GTH-5519, crucial for maintaining optimal performance and stability.
It outlines the recommended tire size, ply rating, load capacity, and inflation pressure, ensuring safe operation across various terrains.
Detailed information regarding wheel bolt patterns, offset, and rim dimensions is provided for accurate wheel replacement or upgrades.
Proper tire maintenance, including regular inspection for wear and damage, is emphasized.
Guidance on tire repair and replacement procedures, adhering to safety standards, is included.
Selecting the correct tires and maintaining proper inflation are vital for maximizing traction, minimizing ground disturbance, and extending tire lifespan, contributing to overall machine efficiency and safety.
Updates and Enhancements
Genie continually refines the GTH-5519, incorporating design enhancements like those debuted at ICUEE 2008 and achieving Tier 4-Final emissions compliance.
ICUEE 2008 Design Enhancements
Genie Industries showcased a significant package of design enhancements for the GTH-5519 at ICUEE 2008, held in Louisville, Kentucky. These updates focused on improving overall machine performance and operator convenience. Notably, the overall length of the GTH-5519 was altered, contributing to enhanced maneuverability in confined work spaces.
Specific changes included refinements to the chassis and boom structure, optimizing load capacity and stability. The enhancements aimed to provide a more robust and reliable machine for a wider range of applications. Genie prioritized feedback from operators and industry professionals during the development process, ensuring the modifications addressed real-world needs.
These improvements solidified the GTH-5519’s position as a leading compact rough-terrain telehandler, offering a compelling combination of power, versatility, and ease of use for construction, agriculture, and industrial applications.
Tier 4-Final Emissions Compliance
The Genie GTH-5519 is equipped with a Tier 4-Final compliant Deutz TD 2.9 L4 engine, addressing stringent environmental regulations without compromising performance. This engine achieves compliance utilizing a Diesel Oxidation Catalyst (DOC) system, notably without the need for a Diesel Particulate Filter (DPF).
This design choice simplifies maintenance and reduces the total cost of ownership by eliminating the complexities and potential issues associated with DPF systems. The Deutz engine delivers a reliable 74 horsepower, providing ample power for demanding applications.
Genie’s implementation of Tier 4-Final technology demonstrates a commitment to sustainability while maintaining the GTH-5519’s reputation for durability and productivity. Operators can benefit from reduced emissions and a more environmentally responsible machine.
