November 2015Second Edition - First PrintingPart No. 57.0009.0619 GTH-5519 17Legend1. Left/right level indicator2. Steering wheel3. Control handle4. Left rear view mirror5. Boom angle indicator6. Boom7. Cab8. Hydraulic oil level gauge9. Engine10. Forks11. Seat belt12. Seat13. Brake pedal14. Accelerator pedal15. Transmission control lever16. Right rear view mirror17. Operators manual storage12311869141615513210 14717

Introduction

Symbol and Hazard Pictorials Definitions

General Safety

Work Area Safety

Legend

Controls

Inspections

Operating Instructions

Transport and Lifting Instructions

Maintenance

Attachments

Specifications

Load Charts

Genie GTH-5519 Original Instructions Manual

September

Performance Specifications

Deutz Engine Models

Perkins Engine Models

Transmission Specifications

Axle Specifications

Hydraulic Specifications

Hydraulic Oil Specifications

Hydraulic Hose and Fitting Torque Specifications

Section 3 Maintenance Procedures

Maintenance Schedule

Pre-Delivery Preparation Report

Scheduled and Programmed Maintenance Inspection Report

Commissioning Procedures

C-3 Perform 150 Hour Service

Quarterly Maintenance Procedures

Q-2 Battery inspection

Q-3 Inspect the Electrical Wiring

Q-4 Check the Boom Wear Pads

Q-5 Check the Exhaust System

Q-7 Inspect the Fork Level and Auxiliary Hydraulic Hoses Tension

Q-9 Visual Inspection of the Hydraulic Oil

Q-10 Inspect the Engine Air Filter

Q-12 Inspect and Lubricate the Sequencing Chains

Annual Maintenance Procedures

A-3 Adjust the Boom Sequencing Chains - GTH-1056

A-4 Adjust the Boom Sequencing Chains - GTH-1256 and GTH-1544

A-5 Replace Hydraulic Tank Return Filter Element

Programmed Maintenance Procedures

P0-2 Deutz Engine Maintenance – Under 1000 Hours

P0-3 Perkins Engine Maintenance – Under 1000 Hours

P0-4 John Deere Engine Maintenance – Under 1000 Hours

P0-5 Axle Maintenance – Under 1000 Hours

P0-6 Transmission Maintenance – Under 1000 Hours

P1-1 Perform Engine Maintenance – 1000 Hours

P1-3 Perform Axle Maintenance – 1000 Hours

P2-1 Perform Engine Maintenance – 2000 Hours

P2-2 Test or Replace the Hydraulic Oil

P3-1 Perform Engine Maintenance – 3000 Hours

P6-1 Perform Engine Maintenance – 6000 Hours

GTH-5519

Part

Deutz TD 2.9 L4 Engine

Comer Axle

Boom

Boom Lift Cylinder

Boom Extend Cylinder

Fork Level Cylinder

Fork Tilt Cylinder

Operator's Compartment

Machine Controls

Fuel Tank

Hydraulic Tank

Engines

Axle

Boom and Steering Function Pump

Hydrostatic Transmission Pump

Function Manifold

Valve Coils

Diagnostic Display

Engine Fault Codes - Models with Deutz TD 2.9 L4

Electrical and Hydraulic Symbol Legends

Electrical Schematic

Hydraulic Schematic