genie gth-5519 parts manual

2.5 GTH-5519 (PN 645054) from SN GTH55M-5800 to GTH55M-11699

This section covers GTH-5519 models with serial numbers from GTH55M-5800 to GTH55M-11699, using part number PN 645054. It lists components specific to these units, ensuring accurate part identification and compatibility. Key systems like engine, hydraulic, and boom parts are detailed, aiding maintenance and repair. Updated regularly, this section helps technicians source the correct parts efficiently, maintaining machine performance and safety. It is essential for anyone servicing these models to refer to this section for precise information.

2.6 GTH-5519 (PN 1299880) from SN GTH55M-11700

This section details parts for GTH-5519 models with serial numbers starting from GTH55M-11700, using part number PN 1299880. It provides a comprehensive list of components specific to these later-model units, ensuring accurate identification and ordering. Key systems, including engine, hydraulic, and boom parts, are covered. Regular updates ensure the information remains current, helping technicians and operators maintain and repair these models effectively. Referencing this section is crucial for ensuring compatibility and correctness when servicing these telehandlers.

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Safety Guidelines and Operating Instructions

This section outlines critical safety rules and operating procedures for the Genie GTH-5519, ensuring safe maintenance and repair practices. Compliance is mandatory for operator safety.

3.1 Safety Rules for Maintenance and Repair

Always read and understand the safety rules in the operator’s manual before performing any maintenance or repair. Wear proper personal protective equipment (PPE) and ensure the machine is on level ground with the boom lowered. Disconnect the battery and engage the parking brake to prevent accidental start-up. Use authorized tools and follow proper lockout/tagout procedures to ensure safety. Never bypass safety devices or attempt repairs without proper training. Adhere to all emissions and environmental guidelines during service.

3.2 Precautions Before Performing Repairs

Before starting any repairs, ensure the telehandler is on level ground with the boom fully lowered and the parking brake engaged. Disconnect the battery to prevent accidental start-up and use proper jack stands for lifting. Always wear personal protective equipment (PPE), including gloves and safety glasses. Ensure all hydraulic and electrical systems are de-energized before servicing. Refer to the operator’s manual for specific precautions and follow all environmental guidelines for parts disposal. Use only authorized tools and adhere to manufacturer recommendations to avoid damage or injury.

3.3 Compliance with Emissions and Safety Standards

The Genie GTH-5519 is designed to meet stringent emissions and safety standards, ensuring environmental compliance and operator safety. The telehandler features a Tier 4-Final Deutz TD 2.9 L4 engine, which incorporates a Diesel Oxidation Catalyst (DOC) system to reduce emissions without requiring a Diesel Particulate Filter (DPF). Adherence to ISO and ANSI safety standards ensures reliability and operator protection. Always verify that repairs and replacements comply with these regulations to maintain certification and avoid potential legal or environmental issues. Proper disposal of parts and materials is also essential for environmental sustainability.

Engine and Powertrain Components

The Genie GTH-5519 features a Deutz TD 2.9 L4 engine, meeting Tier 4-Final emissions standards without a DPF, utilizing a DOC system for efficient emissions control.

4.1 Deutz TD 2.9 L4 Engine Specifications

The Deutz TD 2.9 L4 engine in the Genie GTH-5519 delivers 74 horsepower, ensuring robust performance for heavy-duty tasks. With a displacement of 2.9 liters, this 4-cylinder turbocharged engine offers excellent torque and fuel efficiency. Designed to meet Tier 4-Final emissions standards, it incorporates a Diesel Oxidation Catalyst (DOC) system, eliminating the need for a Diesel Particulate Filter (DPF). This configuration reduces maintenance complexity while maintaining compliance with environmental regulations. The engine’s compact design and reliable operation make it ideal for telehandler applications, providing consistent power and durability.

4.2 Tier 4-Final Emissions Compliance

The Genie GTH-5519’s Deutz TD 2.9 L4 engine meets stringent Tier 4-Final emissions standards, reducing environmental impact by minimizing nitrogen oxides and particulate matter. Utilizing a Diesel Oxidation Catalyst (DOC), the engine eliminates the need for a Diesel Particulate Filter (DPF), simplifying maintenance and reducing operational costs. This emissions solution ensures compliance with current regulations while maintaining optimal performance and fuel efficiency. The system is designed to operate efficiently across various work environments, providing a reliable and eco-friendly power source for the telehandler.

4.3 DOC (Diesel Oxidation Catalyst) System Overview

The DOC (Diesel Oxidation Catalyst) system in the Genie GTH-5519 is a critical component of the emissions control strategy. It works by converting harmful pollutants like carbon monoxide, hydrocarbons, and nitrogen oxides into less harmful emissions through catalytic reactions. The system operates passively, requiring no additional fuel injection or maintenance. By eliminating the need for a Diesel Particulate Filter (DPF), the DOC system simplifies engine operation and reduces long-term maintenance costs. This eco-friendly solution ensures compliance with emissions standards while maintaining engine performance and fuel efficiency.

Hydraulic and Drive Systems

The hydraulic and drive systems are critical for the GTH-5519’s functionality, enabling precise control and mobility. Regular maintenance ensures optimal performance and longevity of components.

5.1 Hydraulic System Components and Functions

The Genie GTH-5519’s hydraulic system consists of key components like pumps, motors, valves, and cylinders; The pump generates pressure, driving fluid through the system. Motors convert hydraulic energy into mechanical power, enabling movement. Valves regulate fluid flow, ensuring precise control. Cylinders execute tasks such as lifting and extending the boom. The system’s design maximizes efficiency and reliability, with components working together to handle heavy loads. Proper maintenance ensures optimal performance and longevity of the hydraulic system.

5.2 Drive Chassis Parts and Maintenance

The drive chassis of the Genie GTH-5519 includes critical components such as axles, wheels, and transmission systems. Regular maintenance involves inspecting axles for wear, ensuring wheel alignment, and checking transmission fluid levels. Lubrication of moving parts is essential to prevent premature wear. Operators should refer to the parts manual for specific maintenance schedules and part numbers. Proper care of the drive chassis ensures smooth operation and extends the lifespan of the telehandler. Always follow safety guidelines when performing inspections or repairs.

5.3 Hydraulic System Service and Repair

The hydraulic system of the Genie GTH-5519 requires regular service to maintain optimal performance. This includes checking hydraulic fluid levels, inspecting hoses for leaks, and replacing filters as specified in the parts manual. Repairing damaged components promptly is crucial to prevent system failure. Refer to the hydraulic system diagrams and part numbers in the manual for accurate servicing. Proper maintenance ensures reliable operation and extends the lifespan of the hydraulic system. Always use genuine parts for repairs to guarantee compatibility and performance.

Boom and Lifting Mechanisms

The Genie GTH-5519’s boom and lifting mechanisms are critical for precise load handling. Regular inspection of cylinders, hoses, and pivot pins ensures safe and efficient operation.

6.1 Boom Components and Their Functions

The Genie GTH-5519 parts manual details the essential components of the boom, including the boom cylinder, extension cables, pivot pins, and end caps. The boom cylinder provides the lifting force, while extension cables enable telescoping functionality. Pivot pins ensure smooth movement between boom sections, and end caps protect internal mechanisms from debris. These components are critical for safe and efficient operation, with materials like heavy-duty steel ensuring durability. Regular inspection and maintenance of these parts are vital to uphold the telehandler’s performance and longevity.

6.2 Lifting Capacity and Safety Considerations

The Genie GTH-5519 parts manual emphasizes adhering to the specified lifting capacity to ensure safe operation. Load charts provided in the manual outline maximum weights at various boom extensions. Exceeding these limits can compromise stability and safety. Proper load securement and even distribution are critical. Operators must also consider environmental factors like wind and uneven terrain. Regular inspection of wire ropes and boom components is essential to prevent accidents. Always refer to the operator’s manual for detailed safety guidelines and load calculations to maintain operational integrity and prevent potential hazards.

6.3 Boom Maintenance and Inspection

Regular maintenance and inspection of the boom are crucial to ensure optimal performance and safety. Lubricate pivot points and check wire ropes for damage or wear. Inspect hydraulic cylinders, pins, and bushings for excessive wear. Tighten all bolts and fasteners to specified torque values. Apply grease to moving parts as recommended. Replace any damaged or worn components promptly to prevent failure. Always follow the manufacturer’s guidelines for maintenance intervals and procedures to maintain the integrity and reliability of the boom system. Proper care extends equipment lifespan and ensures operator safety.

Electrical and Electronic Systems

The section covers the electrical and electronic systems of the Genie GTH-5519, including fuse box diagrams, wiring harnesses, and troubleshooting common issues.

7.1 Fuse Box Diagram and Electrical Components

This section provides a detailed diagram of the fuse box and identifies key electrical components, including relays, connectors, and wiring harnesses. It helps operators locate and understand the electrical system layout, ensuring safe and efficient troubleshooting. The fuse box diagram is essential for diagnosing blown fuses or electrical faults. Proper identification of components prevents incorrect repairs and maintains system integrity. Always refer to this section before performing any electrical maintenance or repairs on the Genie GTH-5519 telehandler. Regular inspection of these components is crucial for optimal performance.

7.2 Troubleshooting Common Electrical Issues

This section guides users through diagnosing and resolving common electrical problems in the Genie GTH-5519. Issues such as blown fuses, faulty sensors, or loose connections are addressed with step-by-step solutions. The manual emphasizes using diagnostic tools and referencing the wiring harness diagram for accurate repairs. Troubleshooting procedures ensure operators can identify and fix electrical faults efficiently, minimizing downtime. Always follow safety protocols, such as disconnecting the battery, before attempting repairs. Regular inspections can prevent many electrical issues from occurring;

7.3 Wiring Harness and Connectors

The wiring harness in the Genie GTH-5519 is designed to ensure reliable electrical connections across all systems. This section provides detailed diagrams and part numbers for connectors, highlighting their locations and functions. Regular inspection of the wiring harness is crucial to prevent damage or corrosion. Operators should refer to the manual for proper connector torque specifications and replacement procedures. Always use genuine Genie parts to maintain system integrity. Damaged or worn connectors should be replaced immediately to avoid electrical malfunctions. Consult the part number index for ordering genuine replacements.