service manual - genie

ServiceManual

TechnicalPublications

Second Edition, First PrintingPart No. 48412 (Rev A1)July 2008

S-60®

S-65®

Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition

ii

Introduction

®

Copyright © 1998 by Genie Industries

Second Edition: First Printing, June 1998

"Genie" and "S" are Registered Trademarksof Genie Industries in the USA and many othercountries.

These machines comply withANSI/SIA 92.5-1992.

Printed on recycled paper

Printed in U.S.A.

Genie North AmericaTelephone (425) 881-1800Toll Free 800 536-1800 in U.S.A.Toll Free 800 426-8089 in CanadaFax (425) 556-8649

Genie EuropeOffice Telephone (44) 01636-605030Office FaxFax (44) 01636-611090Parts Telephone (44) 01636-605002Parts Fax (44) 01636-611091

®

®

ImportantRead, understand and obey the safety rules andoperating instructions in the appropriateGenie S-60 & Genie S-65 Operator's Manualbefore attempting any maintenance or repairprocedure.

This service manual covers the Genie S-60 andGenie S-65 2WD and 4WD models.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting andrepair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electrical skillsare required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at a Genie dealer service center.

Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is aGenie policy. Therefore product specifications aresubject to change without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and other manuals. Pleasewrite to the technical publications team in care ofGenie Industries, PO Box 69, Redmond WA98073-0069 U.S.A.

If you have any questions, please call GenieIndustries.

Part No. 48412 Genie S-60 & Genie S-65


iii

Safety Rules

Section 1 - Safety Rules

DangerFailure to obey the instructions and safety rules inthis manual, and the Genie S-60 & Genie S-65Operator's Manual will result in death or seriousinjury.

Many of the hazards identified in the operator'smanual are also safety hazards whenmaintenance and repair procedures areperformed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance on this machine.

You read, understand and obey:- manufacturer’s instructions and safety rules- employer’s safety rules and worksite

regulations- applicable governmental regulations

You have the appropriate tools, liftingequipment and a suitable workshop.



SAFETY RULES

iv

Section 1 - Safety Rules

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free

of debris that could get into machine componentsand cause damage.

Be sure that your workshop or work areais properly ventilated and well lit.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals, on the machine,use signal words to identify the following:

Indicates the presence ofa hazard that will causedeath or serious injury.

Indicates the presence ofa hazard that may causedeath or serious injury.

Indicates the presence ofa hazard that will or maycause serious injury ordamage to the machine.

Indicates specialoperation or maintenanceinformation.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components, and lifting or

placing loads. Always wear approved steel-toedshoes.



Table of Contents

v

IntroductionImportant Information ..................................................................................................... ii

Section One Safety RulesGeneral Safety Rules .................................................................................................... iii

Section Two SpecificationsMachine Specifications ............................................................................................. 2 - 1

Performance Specifications ...................................................................................... 2 - 2

Hydraulic Specifications ........................................................................................... 2 - 3

Ford LRG 423 Engine Specifications ....................................................................... 2 - 4

Deutz F4L 1011F Engine Specifications .................................................................. 2 - 6

Hydraulic Hose and Fitting Torque Specifications .................................................... 2 - 8

Bolt Torque Specifications ........................................................................................ 2 - 9

Section Three Scheduled Maintenance InspectionsIntroduction ............................................................................................................... 3 - 1

Table A ..................................................................................................................... 3 - 2

Table B ..................................................................................................................... 3 - 3

Table C ..................................................................................................................... 3 - 5

Table D ..................................................................................................................... 3 - 6

Maintenance Inspection Report ................................................................................ 3 - 7

Section Four Scheduled Maintenance ProceduresIntroduction ............................................................................................................... 4 - 1

A-1 Inspect the Manuals ........................................................................................ 4 - 2

A-2 Inspect the Decals and Placards .................................................................... 4 - 2

A-3 Inspect for Damage, Loose or Missing Parts .................................................. 4 - 2

A-4 Check the Engine Oil Level............................................................................. 4 - 3

A-5 Check the Engine Coolant Level - Gasoline/LPG Models ............................... 4 - 3

A-6 Check for Fuel Leaks ...................................................................................... 4 - 3

A-7 Check the Hydraulic Oil Level ......................................................................... 4 - 4

A-8 Check for Hydraulic Leaks .............................................................................. 4 - 4



TABLE OF CONTENTS

vi

Section Four Scheduled Maintenance Procedures, continued

A-9 Check the Tire Pressure ................................................................................. 4 - 5

A-10 Test the Oscillate Axle (if equipped) ............................................................... 4 - 5

A-11 Test the Platform and Ground Controls .......................................................... 4 - 6

A-12 Test the Auxiliary Power Operation ................................................................ 4 - 6

A-13 Test the Tilt Sensor ........................................................................................ 4 - 7

A-14 Test the Limit Switches ................................................................................... 4 - 8

A-15 Replace the Engine Oil and Filter - Gasoline/LPG Models ........................... 4 - 10

A-16 Drain the Fuel Filter/Water Separator - Deutz Diesel Models ....................... 4 - 11

A-17 Replace the Engine Air Filter ........................................................................ 4 - 12

B-1 Check the Engine Belt .................................................................................. 4 - 13

B-2 Check the Radiator - Gasoline/LPG Models ................................................. 4 - 14

B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ..................... 4 - 14

B-4 Check the Exhaust System .......................................................................... 4 - 15

B-5 Check the Battery ......................................................................................... 4 - 16

B-6 Check the Hydraulic Tank Filter Condition Indicator ..................................... 4 - 16

B-7 Inspect the Electrical Wiring ......................................................................... 4 - 17

B-8 Inspect the Tires and Wheels (including lug nut torque) ............................... 4 - 17

B-9 Confirm the Proper Brake Configuration ....................................................... 4 - 18

B-10 Check the Oil Level in the Torque Hubs ....................................................... 4 - 18

B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models .............. 4 - 19

B-12 Check and Adjust the Engine RPM............................................................... 4 - 19

B-13 Test the Key Switch ...................................................................................... 4 - 21

B-14 Test the Emergency Stop Buttons ................................................................ 4 - 21

B-15 Test the Ground Control Override ................................................................ 4 - 22

B-16 Check the Directional Valve Linkage ............................................................ 4 - 22

B-17 Test the Platform Self-leveling ...................................................................... 4 - 23

B-18 Test the Horn ................................................................................................ 4 - 23

B-19 Test the Foot Switch ..................................................................................... 4 - 23

B-20 Test the Engine Idle Select ........................................................................... 4 - 24

B-21 Test the Fuel Select Operation - Gasoline/LPG Models ............................... 4 - 24

B-22 Test the Drive Enable System ...................................................................... 4 - 25



TABLE OF CONTENTS

vii

Section Four Scheduled Maintenance Procedures, continued

B-23 Test the Drive Brakes ................................................................................... 4 - 25

B-24 Test the Drive Speed - Stowed Position ....................................................... 4 - 26

B-25 Test the Alarm Package - Optional Equipment ............................................. 4 - 27

B-26 Perform Hydraulic Oil Analysis ..................................................................... 4 - 27

B-27 Replace the Engine Oil and Filter - Deutz Diesel Models ............................. 4 - 27

C-1 Check the Boom Wear Pads ........................................................................ 4 - 29

C-2 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 29

C-3 Check the Free-wheel Configuration ............................................................ 4 - 30

C-4 Grease the Turntable Rotation Bearing and Rotate Gear ............................. 4 - 31

C-5 Replace the Torque Hub Oil ......................................................................... 4 - 31

C-6 Replace the Hydraulic Tank Filter ................................................................. 4 - 33

C-7 Replace the Drive Loop Hydraulic Filter ....................................................... 4 - 33

C-8 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models ....... 4 - 34

C-9 Replace the Gasoline Fuel Filter - Gasoline/LPG Models ............................. 4 - 34

C-10 Replace the PCV Valve - Gasoline/LPG Models .......................................... 4 - 36

C-11 Replace the Spark Plugs - Gasoline/LPG Models ........................................ 4 - 37

C-12 Check and Adjust the Air/LPG Mixture - Gasoline/LPG Models ................... 4 - 37

C-13 Check and Adjust the Ignition Timing - Gasoline/LPG Models ..................... 4 - 38

C-14 Check the Engine Valve Clearances - Deutz Diesel Models ........................ 4 - 38

C-15 Check the Turntable Rotation Gear Backlash ............................................... 4 - 38

D-1 Test or Replace the Hydraulic Oil ................................................................. 4 - 39

D-2 Change or Recondition the Engine Coolant - Gasoline/LPG Models ............ 4 - 39

D-3 Change the Fuel Lines .................................................................................. 4 - 41

D-4 Check the Engine Valve Clearance - Gasoline/LPG Models ........................ 4 - 42

D-5 Check the Engine Cylinder Compression - Gasoline/LPG Models ............... 4 - 42

D-6 Clean the PCV Hoses and Fittings - Gasoline/LPG Models ......................... 4 - 42

D-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models .......... 4 - 43

D-8 Check the Toothed Belt - Deutz Diesel Models ............................................ 4 - 43

D-9 Replace the Timing Belt - Gasoline/LPG Models .......................................... 4 - 43

D-10 Grease the Steer Axle Wheel Bearings - 2WD Models ................................ 4 - 44



TABLE OF CONTENTS

viii

Section Five Troubleshooting Flow ChartsIntroduction ............................................................................................................... 5 - 1

1 Engine Will Not Crank Over ............................................................................ 5 - 3

2 Engine Cranks Over But Will Not Start - Gasoline/LPG Models ..................... 5 - 5

2A Engine Cranks Over But Will Not Start OR Engine RunsWhile Cranking The Dies- Gasoline/LPG Models ........................................... 5 - 8

2B Engine Runs While Cranking Then Dies ....................................................... 5 - 11

3 Engine Cranks Over But Will Not Start - Deutz Diesel Models ..................... 5 - 12

4 Engine Will Not Start On LPG, But Will Start On Gasoline- Gasoline/LPG Models ................................................................................. 5 - 15

5 Engine Will Not Start On Gasoline, But Will Start On LPG- Gasoline/LPG Models ................................................................................. 5 - 17

6 Engine High Idle Inoperative - Gasoline/LPG Models ................................... 5 - 19

7 Engine Low Idle Inoperative - Gasoline/LPG Models .................................... 5 - 22

8 Engine High Idle Inoperative - Deutz Diesel Models ..................................... 5 - 23

9 Engine Low Idle Inoperative - Deutz Diesel Models ...................................... 5 - 25

10 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 26

11 All Lift and Steer Functions Inoperative, Drive Functions Operational .......... 5 - 27

12 Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 28

13 Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 29

14 Boom Up Function Inoperative ..................................................................... 5 - 30

15 Boom Down Function Inoperative ................................................................. 5 - 33

16 Boom Extend Function Inoperative ............................................................... 5 - 36

17 Boom Retract Function Inoperative .............................................................. 5 - 39

18 Turntable Rotate Left Function Inoperative................................................... 5 - 42

19 Turntable Rotate Right Function Inoperative ................................................ 5 - 46

20 All Platform Leveling Functions Inoperative .................................................. 5 - 50

21 Platform Level Up Function Inoperative ........................................................ 5 - 51

22 Platform Level Down Function Inoperative ................................................... 5 - 53

23 Platform Rotate Left Function Inoperative .................................................... 5 - 55

24 Platform Rotate Right Function Inoperative .................................................. 5 - 58

25 Jib Boom Up Inoperative, S-65 Models ........................................................ 5 - 61

26 Jib Boom Down Inoperative, S-65 Models .................................................... 5 - 63



TABLE OF CONTENTS

ix

Section Five Troubleshooting Flow Charts, continued

27 Oscillate Function Inoperative ....................................................................... 5 - 65

28 Steer Left Function Inoperative ...................................................................... 5 - 66

29 Steer Right Function Inoperative ................................................................... 5 - 68

30 All Drive Functions Inoperative, All Other Functions Operate Normally .......... 5 - 70

31 Drive Forward Or Reverse Function Inoperative ............................................. 5 - 73

32 Traction Function Inoperative ........................................................................ 5 - 74

33 Machine Will Not Drive At Full Speed ............................................................ 5 - 75

34 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 76

35 Drive Enable System Is Malfunctioning ......................................................... 5 - 77

36 Auxiliary Functions Inoperative ...................................................................... 5 - 78

Section Six Schematics

Introduction ............................................................................................................... 6 - 1

Electrical Components .............................................................................................. 6 - 2

Electrical Symbols Legend ........................................................................................ 6 - 4

Abbreviation Legend .................................................................................................. 6 - 5

Electrical Schematic - Gasoline/LPG Models (Rev B) ............................................... 6 - 7

Ground Control Box Legend - Gasoline/LPG Models ................................................. 6 - 9

Ground Control Box Wiring Diagram - Gasoline/LPG Models ................................... 6 - 10

Platform Control Box Legend - Gasoline/LPG Models ............................................. 6 - 11

Platform Control Box Wiring Diagram - Gasoline/LPG Models ................................. 6 - 12

Electrical Schematic - Deutz Diesel Models ............................................................ 6 - 13

Ground Control Box Legend - Deutz Diesel Models ................................................. 6 - 15

Ground Control Box Wiring Diagram - Deutz Diesel Models ..................................... 6 - 16

Platform Control Box Legend - Deutz Diesel Models ............................................... 6 - 17

Platform Control Box Wiring Diagram - Deutz Diesel Models ................................... 6 - 18

Hydraulic Symbols Legend ...................................................................................... 6 - 20

2WD Hydraulic Schematic - Non-oscillating axle ..................................................... 6 - 21

2WD Hydraulic Schematic - Oscillating axle ........................................................... 6 - 22

4WD Hydraulic Schematic - Non-oscillating axle ..................................................... 6 - 23

4WD Hydraulic Schematic - Oscillating axle ........................................................... 6 - 24



TABLE OF CONTENTS

x

Section Seven Repair ProceduresIntroduction ............................................................................................................... 7 - 1

Platform Controls

1-1 Joystick Controllers ......................................................................................... 7 - 2

1-2 Horsepower Limiter Board .............................................................................. 7 - 6

1-3 Foot Switch ..................................................................................................... 7 - 8

1-4 Resistors ......................................................................................................... 7 - 9

1-5 Toggle Switches ............................................................................................. 7 - 9

1-6 Control Relays .............................................................................................. 7 - 10

Platform Components

2-1 Platform ........................................................................................................ 7 - 11

2-2 Platform Leveling Slave Cylinder .................................................................. 7 - 11

2-3 Platform Rotator ........................................................................................... 7 - 12

Jib Boom Components, S-65 Models

3-1 Jib Boom, S-65 Models ................................................................................. 7 - 15

3-2 Jib Boom Lift Cylinder, S-65 Models ............................................................. 7 - 16

3-3 Jib Boom / Platform Rotate Manifold Components, S-65 Models ................. 7 - 17

Boom Components

4-1 Boom Cable Track ........................................................................................ 7 - 18

4-2 Boom ............................................................................................................ 7 - 20

4-3 Boom Lift Cylinder ........................................................................................ 7 - 23

4-4 Extension Cylinders ...................................................................................... 7 - 24

4-5 Platform Leveling Master Cylinder ................................................................ 7 - 25

Turntable Covers

5-1 Turntable Covers .......................................................................................... 7 - 26

Deutz Engine F4L 1011F

6-1 RPM Adjustment ........................................................................................... 7 - 27

6-2 Flex Plate ...................................................................................................... 7 - 27

6-3 Oil Temperature and Oil Pressure Gauges................................................... 7 - 27

Ford LRG-423 Engine

7-1 Governor Actuator ........................................................................................ 7 - 28

7-2 Choke Adjustments ....................................................................................... 7 - 29



TABLE OF CONTENTS

xi

Section Seven Repair Procedures, Ford LRG-423 Engine, continued

7-3 Timing Adjustment ........................................................................................ 7 - 30

7-4 Carburetor Adjustment .................................................................................. 7 - 30

7-5 RPM Adjustment ........................................................................................... 7 - 30

7-6 Flex Plate ...................................................................................................... 7 - 30

7-7 Water Temperature and Oil Pressure Gauges ............................................. 7 - 31

7-8 Vacuum Switch ............................................................................................. 7 - 32

Ground Controls

8-1 Control Relays .............................................................................................. 7 - 33

8-2 Toggle Switches, See 1-5, Toggle Switches................................................... 7 - 9

8-3 Wago® Components ..................................................................................... 7 - 33

8-4 Resistors ....................................................................................................... 7 - 33

8-5 Power Relay ................................................................................................. 7 - 34

Hydraulic Pumps

9-1 Lift/Steer Pump ............................................................................................. 7 - 35

9-2 Drive Pump ................................................................................................... 7 - 35

Manifolds

10-1 Function Manifold Components .................................................................... 7 - 38

10-2 Valve Adjustments - Function Manifold......................................................... 7 - 42

10-3 Turntable Rotation Manifold Components..................................................... 7 - 45

10-4 Oscillate Manifold Components .................................................................... 7 - 46

10-5 Valve Adjustments - Oscillate Manifold......................................................... 7 - 47

10-6 Directional Valve Manifold Components ....................................................... 7 - 48

10-7 Steer Manifold Components, S-60/65 Oscillating Models ............................. 7 - 50

10-8 2WD Drive Manifold Components ................................................................. 7 - 52

10-9 Valve Adjustments, 2WD Drive Manifold ...................................................... 7 - 54

10-10 4WD Drive Manifold Components ................................................................. 7 - 56

10-11 Valve Adjustments, 4WD Drive Manifold ...................................................... 7 - 58

. Fuel and Hydraulic Tanks

11-1 Fuel Tank ...................................................................................................... 7 - 59

11-2 Hydraulic Tank .............................................................................................. 7 - 59



TABLE OF CONTENTS

xii

Section Seven Repair Procedures, continued

Turntable Rotation Components

12-1 Rotation Hydraulic Motor .............................................................................. 7 - 62

2WD Steering Axle Components

13-1 Yoke and Hub ............................................................................................... 7 - 65

13-2 Steering Cylinders ........................................................................................ 7 - 66

13-3 Tie Rod ......................................................................................................... 7 - 67


14-1 Yoke and Hub ............................................................................................... 7 - 68

14-2 Steering Cylinders ........................................................................................ 7 - 69

14-3 Tie Rod ......................................................................................................... 7 - 69

Oscillating Axle Components

15-1 Oscillating Axle Lock-out Cylinders ............................................................... 7 - 70

Non-steering Axle Components

16-1 Drive Motor ................................................................................................... 7 - 71

16-2 Torque Hub ................................................................................................... 7 - 71

Part No. 48412 Genie S-60 & Genie S-65 2 - 1

Section 2 - SpecificationsService Manual - Second Edition

Specifications

Machine SpecificationsStowed dimensions S-60 S-65

Length 27 ft 2 in 30 ft 10 in8.3 m 9.4 m

Width 8 ft 8 ft2.43 m 2.43 m

Height 9 ft 9 ft2.74 m 2.74 m

Weight 26,060 lbs 28,400 lbs11,821 kg 12,882 kg

Ground clearance 12 in 12 in30 cm 30 cm

Operational dimensions

Maximum platform height 60 ft 65 ft18.3 m 19.8 m

Maximum horizontal reach 51 ft 3 in 56 ft 4 in15.6 m 17.2 m

Maximum turntable tailswing 3 ft 31/2 in 3 ft 31/2 in100 cm 100 cm

Wheelbase 9 ft 0 in 9 ft 0 in2.7 m 2.7 m

Minimum turning radius, 12 ft 1 in 12 ft 1 ininside 3.7 m 3.7 m

Minimum turning radius, 22 ft 2 in 22 ft 2 inoutside 6.76 m 6.76 m

Turntable rotation continuous continuous

Platform rotation 160° 160°

Maximum capacity 600 lbs 500 lbs6 foot platform 272 kg 227 kg

Maximum capacity 500 lbs 500 lbs8 foot platform 227 kg 227 kg

Maximum allowableside force (ANSI and CSA) 150 lbs 150 lbs

68 kg 68 kg

Continuous improvement of our products is aGenie policy. Product specifications are subject tochange without notice.

Platform dimensions 6 ft 8 ft(Standard) (Optional)

Length 6 ft 8 ft1.83 m 2.44 m

Width 30 in 36 in76.2 cm 91.4 cm

Tires and wheels

Tire size 15-19.5 NHS

Tire ply rating 12

Tire contact area 71 sq in458 sq cm

Overall tire diameter 40 in102 cm

Tire pressure 85 psi5.86 bar

Wheel diameter 191/2 in49.5 cm

Wheel width 121/4 in31 cm

Wheel lugs 10 @ 3/4 -16

Lug nut torque, dry bolts 420 ft-lbs569.5 Nm

Lug nut torque, lubricated bolts 320 ft-lbs433.9 Nm

Fluid capacities

Fuel tank 30 gallons114 liters

LPG tank 33.5 pounds15.2 kg

Hydraulic tank 45 gallons170 liters

Hydraulic system 55 gallons(including tank) 208 liters

Drive torque hubs 44 fl oz1.30 liters

Turntable rotation 17 fl oztorque hub 0.51 liters

2 - 2 Genie S-60 & Genie S-65 Part No. 48412

Section 2 - Specifications Service Manual - Second Edition

SPECIFICATIONS

Boom function speeds, maximumfrom platform controls

Jib boom up 40 to 60 seconds

Jib boom down 50 to 80 seconds

Boom up 55 to 85 seconds

Boom down 90 to 120 seconds

Boom extend 60 to 80 seconds

Boom retract 55 to 85 seconds

Turntable rotate - 360°boom fully stowed 80 to 100 seconds

Turntable rotate - 360°boom extended 130 to 160 seconds

Platform rotate - 160° 10 to 20 seconds

Platform level up 35 to 65 seconds

Platform level down 25 to 55 seconds

Performance SpecificationsDrive speeds, maximum 2WD 4WD

Drive speed, stowed 4.4 mph 3.0 mphGasoline/LPG models 7.1 km/h 4.8 km/h

40 ft/6.2 sec 40 ft/9.1 sec12.2 m/6.2 sec 12.2 m/9.1 sec

Drive speed, stowed 4.0 mph 2.8 mphDeutz Diesel models 6.4 km/h 4.5 km/h

40 ft/6.8 sec 40 ft/9.7 sec12.2 m/6.8 sec12.2 m/9.7 sec

Drive speed, 0.6 mph 0.6 mphraised or extended 1.0 km/h 1.0 km/h- all models 40 ft/40 sec 40 ft/40 sec

12.2 m/40 sec 12.2 m/40 sec

Gradeability (boom stowed) 2WD 4WD

Rough terrain 28% 40%



SPECIFICATIONS

Hydraulic SpecificationsHydraulic fluid Dexron equivalent

Drive pump

Type: bi-directional variable displacement piston pump

Displacement - 2500 rpm 0 to 30.3 gallons per minute0 to 114.7 liters per minute

Maximum drive pressure 3500 psi241.3 bar

Charge pressureneutral position 290 psi 20 bardrive position 250 psi 17 bar

Medium pressure filter 3 micron

Medium pressure filter 50 psibypass pressure 3.4 bar

Drive manifold

Brake 250 psirelief pressure 17.2 bar

Steer end drive motors 4WD models

Displacement 1.52 cu inper revolution 25 cc

Non-steer end drive motors

Displacement per revolution, variable 0.16 to 2.8 cu in4WD (2 speed motor) 2.62 to 45.9 cc

Displacement per revolution, variable 1.12 to 2.8 cu in2WD 18.4 to 45.9 cc

Function pump

Type: pressure balanced gear

Displacement - static 1.14 cu in19 cc

Displacement - 2500 rpm 0 to 12.3 gallons per minute0 to 46.6 liters per minute

Hydraulic tank circuit 10 micron with 25 psireturn line filter (1.7 bar) bypass

Function manifold

Function relief valve pressureS60 2600 psi 179 barS65 2900 psi 200 bar

Boom down 2100 psirelief valve pressure 145 bar

Boom extend 2500 psi172 bar

Oscillate axle 950 psi65 bar

Steer regulatorOscillate models 5 gpm 18.9 liters/minNon-oscillate models 3.5 gpm 13.2 liters/min

Auxiliary pump

Type: fixed displacement gear pump

Displacement - static 0.152 cu in2.5 cc

Displacement 1.4 gallons per minute5.3 liters per minute

Auxiliary pump 2500 psirelief pressure 172 bar



SPECIFICATIONS

Ford Engine LRG-423Displacement 140 cu in

2.3 liters

Number of cylinders 4

Bore & stroke 3.781 x 3.126 inches96.04 x 79.4 mm

Horsepower 63 @ 4000 rpm

Firing order 1 - 3 - 4 - 2

Low idle - carburetor 900 rpm

Low idle - electronic governor 1600 rpm

High idle 2500 rpm

Governor electronic

Compression ratio 9.4:1

Compression pressure (approx.)Pressure (psi) of lowest cylinder must beat least 75% of highest cylinder

Valve clearances - 0.035 to 0.055 inchescollapsed tappet 0.889 to 1.397 mm

Lubrication system

Oil pressure 40 to 60 psi(operating temp. @ 2000 rpm) 2.75 to 4.1 bar

Oil capacity 5 quarts(including filter) 4.7 liters

Oil viscosity requirements

Temperature below 60°F / 15.5°C 5W-30

-10°F to 90°F / -23°C to 32°C 10W-30

Temperature above 10W-40 to 10W-50-10°F / -23°C

Temperature above 20W-40 or 20W-5020°F / -6.6°C

Use oils meeting API classification SG (labeled SG/CCor SG/CD) as they offer improved wear protection.Units ship with 10W-40 SG/CC.

Starter motor

Normal engine cranking speed 200 to 250 rpm

Current draw, normal load 170A

Current draw, maximum load 200A

Current draw, minimum 140A

Maximum circuit voltage drop 0.5V DCwhile starting (normal temperature)

Brush length, new 0.66 in16.8 mm

Brush length wear limit 0.25 in6.35 mm

Brush spring tension 64 ounces18 Newtons

Bolt torque 45 to 84 inch-poundsthrough brush 5.08 to 9.5 Nm

Brush mounting 15 to 20 foot-poundsbolt torque 20 to 27 Nm

Maximum commutator 0.005 inchesrun-out 0.127 mm

Battery

Type 12V, Group 31

Quantity 1

Cold cranking ampere 1000A

Reserve capacity @ 25A rate 200 minutes

Fuel pump

Electronic solenoid 7 psi0.48 bar



SPECIFICATIONS

Ignition System

Spark plug type Motorcraft AWSF-52C

Spark plug gap 0.042 to 0.046 inches1.07 to 1.18 mm

Engine coolant

Capacity 111/2 quarts10.9 liters

Alternator

Output 95A, 14.5V

Bolt torque specificationstorque torque

Bolt description (size) ft-lbs Nm

Timing belt tensioner 29 to 40 40 to 55pivot bolt (M-10)

Timing belt tensioner 25 to 29 35 to 40adjusting bolt (M-8)

Camshaft gear bolt (M-12) 52 to 66 70 to 90

Camshaft thrust plate bolt (M-6) 6 to 9 8 to 12

Carburetor to spacer stud (M-8) 7.5 to 15 10 to 20

Carburetor spacer to 10 to 14 14 to 19manifold bolt (M-8)

Crankshaft damper 92 to 122 125 to 165bolt (M-14)

Cylinder head bolt (M-12): torque in sequencefirst step 50 to 60 68 to 81second step 80 to 90 108 to 122

Bolt torque specificationstorque torque

Bolt description (size) ft-lbs Nm

Exhaust manifold to cylinder head bolt or nut (M-10):torque in sequencefirst step 14 to 19 19 to 26second step 35 to 50 47 to 68

Flywheel to crankshaft 54 to 64 73 to 87bolt (M-10)

Intake manifold to 15 to 22 20 to 30cylinder head bolt or nut (M-8)

Oil pressure sending unit to block 8 to 18 11 to 24

Oil pan drain plug to pan (M-14) 15 to 25 20 to 34

Oil pan to block (M-6) 10 to 13.5 14 to 18

Oil filter insert to block 21 to 26 28 to 35

Rocker arm cover to 7 to 10 9 to 13cylinder head (M-6)

Spark plug to cylinder 7 to 15 9 to 20head (M-14)

Temperature sending 8 to 18 11 to 24unit to block (M-14)

Water jacket drain plug to block 12 to 18 16 to 24

Water pump to block bolt (M-8) 15 to 22 20 to 30

Water outlet connection 15 to 22 20 to 30bolt (M-8)

Cylinder front cover bolt (M-6) 10 to 12 13 to 16

Inner timing belt cover 15 to 22 20 to 30stud (M-8)

Outer timing belt cover 6 to 9 8 to 12bolt (M-6)



SPECIFICATIONS

Injection pump pressure 4351 psi300 bar

Injector opening pressure 3626 psi250 bar

Fuel requirement diesel number 2-D

Alternator output 55A, 14V

Starter motor

Current draw, no load 90A

Brush length, new 0.7480 in19 mm

Brush length, minimum 0.5 in12.7 mm

Battery

Type 12V, Group 31

Quantity 1

Cold cranking ampere 1000A

Reserve capacity @ 25A rate 200 minutes

Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

Bolt tightening specificationstorque torque

Bolt description (size, grade) ft-lbs Nm

Camshaft/thrust bearing bolt 15 to 18 20 to 24(M-8 x 35, 8.8)

Rocker arm bolts 15 to 18 20 to 24(M-8 x 45, 8.8)

Rocker arm set screw nut 15 to 18 20 to 24

Cylinder head cover 6 to 7 8 to 10

Blower rotor nut 33 to 41 45 to 55(M-17 Valeo or M-18 Bosch)

Blower carrier bolts 15 to 18 20 to 24(M-8 x 50 Torx, 8.8)

V-belt pulley bolts 28 to 34 38 to 46(M-10 x 16, 8.8)

Deutz Engine F4L 1011FDisplacement 166.7 cu in

2.732 liters

Number of cylinders 4

Bore and stroke 3.58 x 4.13 inches91 x 105 mm

Horsepower 56 @ 3000 rpm

Firing order 1 - 3 - 4 - 2

Compression ratio 18.5:1

Compression pressure 362 to 435 psi25 to 30 bar

Low idle 1300 rpm

High idle 2300 rpm

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.012 in0.3 mm

Exhaust 0.020 in0.5 mm

Lubrication system

Oil pressure 26 to 87 psi1.8 to 6.0 bar

Oil capacity 11 quarts(including filter) 10.5 liters

Oil viscosity requirements

Temperature below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C 10W-40

Temperature above -4°F / -34°C 15W-40

Engine oil should have properties of API classificationCC/SG or CD/SG grades.Units ship with 10W-40 SG/CC.

Injection system

Injection pump make OMAP



SPECIFICATIONS

Bolt tightening specifications, continuedtorque torque

Bolt description (size, grade) ft-lbs Nm

Idler pulley/V-belt pulley bolt 27 to 32 36 to 44(M-10 x 25, 8.8)

Idler pulley for toothed belt 30 to 36 41 to 49(M-10 x 50, 8.8)

Oil pump bolts 15 to 18 20 to 24(M-8 x 35 Torx)

Oil filter bracket bolts 7 to 8 9 to 11(M-8 x 20 Torx, 8.8)

Oil intake housing bolts 15 to 18 20 to 24(M-8 x 75 Torx)

Fuel pump bolts 15 to 18 20 to 24

Injection pump bolts 15 to 18 20 to 24

Injector cap nut 30 to 37 40 to 50

Injector fastening bolt 15 to 18 20 to 24

Injection line 10 to 12 13.5 to 16.5

Air intake manifold bolts 15 to 18 20 to 24(M-8 x 30, 8.8)

Air intake manifold, 3-hole 15 to 18 20 to 24flange bolts (M-8 x 35 Torx, 8.8)

Exhaust manifold bolts 27 to 32 36 to 44(M-10 x 30 Torx, 10.9)

Starter fastening bolts 28 to 34 38 to 46(M-10 x 28, 8.8)

Starter carrier bolts 50 to 60 68 to 82(M-12 x 28, 8.8)

Oil pan bolts 15 to 18 20 to 24(M-8 x 16 Torx, 8.8)

Oil drain bolts 37 to 44 50 to 60

torque torqueft-lbs Nm

Oil thermostat housing screw 37 to 44 50 to 60plug (M-38 x 1.5)

Oil thermostat housing bolts 5.5 to 7 7.5 to 9(M-6 x 35 Torx, 8.8)

Oil thermostat housing bolts 5.5 to 7 7.5 to 9(M-6 x 80 Torx, 8.8)

Oil thermostat housing bolts 14 to 16 19 to 22(M-6 x 105 Torx, 8.8)

Valve plunger housing bolts 14 to 16 19 to 22(M-8 x 30 Torx, 8.8)

Alternator nuts (M-5) 3 4

Fuel bracket bolts (M-8 x 20, 8.8) 15 20

Adapter housing bolts 70 to 77 95 to 105(M-12 x 35, 10.9 or M-12 x 75, 10.9)

first step second steptightening tightening

torque angles

ft-lbs Nm 1st 2nd

Main bearing bolts 37 50 60° 45°

Big end bolts 22 30 60° 60°

Flywheel bolts 22 30 60° 30°

Cylinder head step 1 22 30studs step 2 59 80

step 3 118 160 120° NA

Camshaft/central bolt 22 30 150° NA

Crankshaft/central bolt 96 130 210° NA



Hydraulic Hose and Fitting Torque SpecificationsYour machine is equipped with Parker Seal-Lok® O-ring face seal fittings and hose ends. Machines thatutilize Parker Seal-Lok® O-ring face seal fittings and hose ends require that the fittings and hose ends betorqued to specification when they are removed and installed or when new hoses or fittings are installed.

Torque Procedure1 Replace the O-ring. The O-ring must be

replaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.

The O-rings used in the ParkerSeal Lok® fittings and hose endsare a custom-size O-ring. Theyare not a standard SAE size O-ring. They are available in the O-ring field service kit (Genie pn.49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the tableabove.

6 Operate all machine functions and inspect thehoses and fittings and related components tobe sure that there are no leaks.

Hydraulic Hose and Fitting Torque SpecificationsSAE O-ring Boss Port - tube fitting Seal-Lok® - hose end

SAE Dash Size

Installing into... ft. lbs. Nm

SAE Dash Size ft. lbs. Nm

-4 Aluminum 11 14.9 -4 18 24.4Steel 16 21.7 -6 27 36.6

-6 Aluminum 23 31.2 -8 40 54.2Steel 35 47.5 -10 63 85.4

-8 Aluminum 40 54.2 -12 90 122Steel 60 81.3 -16 120 162.7

-10 Aluminum 69 93.6 -20 140 190Steel 105 142.4 -24 165 223.7

-12 Aluminum 93 126.1Steel 140 190

-16 Aluminum 139 188.5Steel 210 284.7

-20 Aluminum 172 233.2Steel 260 352.5

-24 Aluminum 208 282Steel 315 427.1

SPECIFICATIONS



SPECIFICATIONS

24

32

20

28

18

24

16

24

14

20

13

20

12

18

11

18

10

16

9

14

8

12

Torque - Dry

inch-pounds

Torque - Dry

foot-pounds

Torque - Dry

Newton meters

Torque - Dry

inch-pounds

Torque - Dry

foot-pounds

Torque - Dry

Newton meters

43

49

96

120

17

19

30

35

50

55

75

90

110

120

150

170

260

300

430

470

640

700

5

6

11

14

23

28

41

48

68

75

102

122

149

163

204

231

353

407

583

637

868

949

60

68

144

168

25

25

45

50

70

80

110

120

150

170

220

240

380

420

600

660

900

1000

7

8

16

19

34

34

61

68

95

109

149

163

204

231

298

326

515

570

814

895

1221

1356

Size Threads SAE Grade 5 Bolts SAE Grade 8 Bolts

Bolt Torque Specifications

No. 10

1/4 inch

5/16 inch

3/8 inch

7/16 inch

1/2 inch

9/16 inch

5/8 inch

3/4 inch

7/8 inch

1 inch

Torque specifications for lubricated bolts are 25% less than dry torque specifications for each bolt size.

These bolt torque specifications are for general use only. Specification may vary depending on application of bolt.



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Section 3 - Scheduled Maintenance InspectionsService Manual - Second Edition

Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested

Scheduled Maintenance Inspections

Observe and Obey:Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, annually and every2 years as specified on the MaintenanceInspection Report.

Failure to properly complete eachinspection when required maycause death, serious injury orsubstantial damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Keep records on all inspections for three years.

Machines that have been out of service for aperiod longer than 3 months must complete thequarterly inspection.

About This SectionThe Schedule

There are four types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, annual, two year. To account forrepeated procedures, the Maintenance Tables andthe Maintenance Inspection Report have beendivided into four subsections—A, B, C, D. Use thefollowing chart to determine which group(s) ofprocedures are required to perform a scheduledinspection.

Inspection Table or Checklist

Daily A

Quarterly A + B

Annual A + B + C

Two year A + B + C + D

Maintenance Tables

The maintenance tables contained in this sectionprovide summary information on the specificphysical requirements for each inspection.

Complete step-by-step instructions for eachscheduled maintenance procedure are provided insection 4, Scheduled Maintenance Procedures.

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance InspectionReport to use for each inspection. Storecompleted forms for three years.


Section 3 - Scheduled Maintenance Inspections Service Manual - Second Edition

Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested

Table A

A-1 Inspect the Manuals

A-2 Inspect the Decals and Placards

A-3 Inspect for Damage, Loose or Missing Parts

A-4 Check the Engine Oil Level

A-5 Check the Engine Coolant Level -Gasoline/LPG Models

A-6 Check for Fuel Leaks

A-7 Check the Hydraulic Oil Level

A-8 Check for Hydraulic Leaks

A-9 Check the Tire Pressure

A-10 Test the Oscillate Axle (if equipped)

A-11 Test the Platform and Ground Controls

A-12 Test the Auxiliary Power Operation

A-13 Test the Tilt Sensor

A-14 Test the Limit Switches

Every 100 hours, perform the following three enginemaintenance procedures.

A-15 Replace the Engine Oil and FilterGasoline/LPG Models

Maintenance Tables



Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested

MAINTENANCE TABLES

Table A, continued

A-16 Drain the Fuel Filter/Water Separator -Deutz Diesel Models

A-17 Replace the Engine Air Filter

Table B

B-1 Check the Engine Belt

B-2 Check the Radiator -Gasoline/LPG Models

B-3 Check the Oil Cooler and Cooling Fins -Deutz Diesel Models

B-4 Check the Exhaust System

B-5 Check the Battery

B-6 Check the Hydraulic TankFilter Condition Indicator

B-7 Inspect the Electrical Wiring

B-8 Inspect the Tires and Wheels(including lug nut torque)

B-9 Confirm the Proper Brake Configuration

B-10 Check the Oil Level in the Torque Hubs

B-11 Check and Adjust the Engine Idle Mixture -Gasoline/LPG Models

B-12 Check and Adjust the Engine RPM



Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested

Table B, continued

B-13 Test the Key Switch

B-14 Test the Emergency Stop Buttons

B-15 Test the Ground Control Override

B-16 Check the Directional Valve Linkage

B-17 Test the Platform Self-leveling

B-18 Test the Horn

B-19 Test the Foot Switch

B-20 Test the Engine Idle Select

B-21 Test the Fuel Select Operation -Gasoline/LPG Models

B-22 Test the Drive Enable System

B-23 Test the Drive Brakes

B-24 Test the Drive Speed -Stowed Position

B-25 Test the Alarm Package -Optional Equipment

B-26 Perform Hydraulic Oil AnaysisSee D-1 Test or Replace the Hydraulic Oil

Every 500 hours, perform the following enginemaintenance procedure.

B-27 Replace the Engine Oil and Filter -Deutz Diesel Models

MAINTENANCE TABLES



Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested

MAINTENANCE TABLES

Table C

C-1 Check the Boom Wear Pads

C-2 Check the Turntable Rotation Bearing Bolts

C-3 Check the Free-wheel Configuration

C-4 Grease the Turntable Rotation Bearingand Rotate Gear

C-5 Replace the Torque Hub Oil

C-6 Replace the Hydraulic Tank Filter

C-7 Replace the Drive Loop Hydraulic Filter

C-8 Replace the Diesel Fuel Filter/Water SeparatorDeutz Diesel Models

C-9 Replace the Gasoline Fuel Filter -Gasoline/LPG Models

C-10 Replace the PCV Valve -Gasoline/LPG Models

C-11 Replace the Spark Plugs -Gasoline/LPG Models

C-12 Check and Adjust the Air/LPG Mixture -Gasoline/LPG Models

C-13 Check and Adjust the Ignition Timing -Gasoline/LPG Models

C-14 Check the Engine Valve Clearances -Deutz Diesel Models

C-15 Check the Turntable Rotation Gear Backlash



Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested

MAINTENANCE TABLES

Table D

D-1 Test or Replace the Hydraulic Oil

D-2 Change or Recondition the Engine Coolant -Gasoline/LPG Models

D-3 Change the Fuel Lines

D-4 Check the Engine Valve Clearance -Gasoline/LPG Models

D-5 Check the Engine Cylinder Compression -Gasoline/LPG Models

D-6 Clean the PCV Hoses and Fittings -Gasoline/LPG Models

D-7 Check the Fuel Injection Pumps and Injectors- Deutz Diesel Models

D-8 Check the Toothed Belt -Deutz Diesel Models

D-9 Replace the Timing Belt -Gasoline/LPG Models

D-10 Grease the Steer Axle Wheel Bearings -2WD Models



Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested

B-18 Horn

B-19 Foot switch

B-20 Engine idle select

B-21 Fuel select-Gas/LPG

B-22 Drive enable system

B-23 Drive brakes

B-24 Drive speed-stowed

B-25 Alarm package

B-26 Hydraulic oil analysis

Perform every 500 hours:B-27 Replace engine oiland filter-Deutz Diesel

Checklist C Y N RRefer to Table C

C-1 Boom wear pads

C-2 Turntable bearing bolts

C-3 Free-wheel configuration

C-4 Grease rotation bearing

C-5 Torque hub oil

C-6 Hydraulic tank filter

C-7 Drive loop hydraulic filter

C-8 Fuel filter-Deutz Diesel

C-9 Fuel filter-Gas/LPG

C-10 PCV valve-Gas/LPG

C-11 Spark plugs-Gas/LPG

C-12 Air/LPG mixture

C-13 Ignition timing-Gas/LPG

C-14 Valves-Deutz Diesel

C-15 Turntable backlash

Checklist D Y N RRefer to Table D

D-1 Hydraulic oil

D-2 Engine coolant-Gas/LPG

D-3 Change fuel lines

D-4 Valves-Gas/LPG

D-5 Compression-Gas/LPG

D-6 PCV hoses-Gas/LPG

D-7 Fuel injection-Diesel

D-8 Toothed belt-Diesel

D-9 Timing belt-Gas/LPG

D-10 Wheel bearings

Checklist A Y N RRefer to Table A

A-1 Manuals

A-2 Decals and placards

A-3 Damage, loose ormissing parts

A-4 Engine oil level

A-5 Engine coolant-Gas/LPG

A-6 Fuel leaks

A-7 Hydraulic oil level

A-8 Hydraulic leaks

A-9 Tire pressure

A-10 Oscillate axle

A-11 Platform andground controls

A-12 Auxiliary power

A-13 Tilt sensor

A-14 Limit switches

Perform every 100 hours:A-15 Replace engine oiland filter-Gas/LPG Models

A-16 Drain filter/separatorDeutz Diesel

A-17 Replace air filter

Checklist B Y N RRefer to Table B

B-1 Engine belt

B-2 Engine radiator-Gas/LPG

B-3 Oil cooler and fins-Diesel

B-4 Exhaust system

B-5 Battery

B-6 Hydraulic tank filter

B-7 Electrical wiring

B-8 Tires and wheels

B-9 Brake configuration

B-10 Torque hub oil level

B-11 Idle mixture-Gas/LPG

B-12 Engine RPM

B-13 Key switch

B-14 Emergency Stop

B-15 Ground control override

B-16 Directional valve

B-17 Platform leveling

Instructions· Make copies of this page to use for

each inspection.

· Select the appropriate checklist(s) forthe type of inspection to be performed.

Daily Inspection: AQuarterly Inspection: A+BAnnual Inspection: A+B+C2 Year Inspection: A+B+C+D

· Place a check in the appropriate boxafter each inspection procedure iscompleted.

· Use the maintenance tables in thissection and the step-by-stepprocedures in section 4 to learn how toperform these inspections.

· If any inspection receives an “N”, tagand remove the machine from service,repair and re-inspect it. After repair,place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from service

R = repaired

Comments

Maintenance Inspection Report

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company



Tools arerequired

New partsrequired

Warmengine

required

Coldengine

required

Dealerservice

suggested



Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

Observe and Obey:Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, annually and every 2years as specified on the MaintenanceInspection Report.

Failure to perform each procedureas presented and scheduled maycause death, serious injury orsubstantial damage.


Repair any machine damage or malfunctionbefore operating machine.

Keep records on all inspections for three years.

Unless otherwise specified, perform eachmaintenance procedure with the machine in thefollowing configuration:

· Machine parked on a flat, level surface

· Boom in stowed position

· Turntable rotated with the boom betweenthe non-steering wheels

· Turntable secured with the turntablerotation lock pin

· Key switch in the OFF position with thekey removed

· Wheels chocked

About This SectionThis section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetyinformation and step-by-step instructions.

Symbols Legend

Indicates the presence of a hazardthat will cause death or seriousinjury.

Indicates the presence of a hazardthat may cause death or seriousinjury.

Indicates the presence of a hazardthat will or may cause seriousinjury or damage to the machine.

Indicates special operation ormaintenance information.

Indicates that a specific result is expected afterperforming a step.


Service Manual - Second EditionSection 4 - Scheduled Maintenance Procedures

A-1Inspect the ManualsMaintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

1 Check to be sure that the storage container ispresent and in good condition.

2 Check to make sure that the operator's,responsibilities and safety manual are presentand complete in the storage container in theplatform.

3 Examine the pages of each manual to be surethat they are legible and in good condition.

4 Always return the manuals to the storagecontainer after use.

Contact your authorized Geniedistributor or Genie Industries ifreplacement manuals are needed.

A-2Inspect theDecals and PlacardsMaintaining all of the safety and instructionaldecals and placards in good condition ismandatory for safe machine operation. Decalsalert operators and personnel to the many possiblehazards associated with using this machine. Theyalso provide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.

1 Refer to the Decals section in theGenie S-60 & Genie S-65 Operator's Manualand use the decal list and illustrations todetermine that all decals and placards are inplace.

Table A Procedures

2 Inspect all decals for legibility and damage.Replace any damaged or illegible decalimmediately.

Contact your authorized Geniedistributor or Genie Industries ifreplacement decals are needed.

A-3Inspect for Damage, Loose orMissing PartsDaily machine condition inspections are essentialto safe machine operation and good machineperformance. Failure to locate and repair damage,and discover loose or missing parts may result inan unsafe operating condition.

1 Inspect the entire machine for damage andimproperly installed or missing parts including:

· Electrical components, wiring and electrical cables

· Hydraulic hoses, fittings, cylinders and manifolds

· Fuel and hydraulic tanks

· Drive and turntable rotation motors and torque hubs

· Axle components

· Boom components and wear pads

· Dents or damage to machine

· Tires and wheels

· Engine and related components

· Limit switches

· Alarms, horn and beacon (if equipped)

· Nuts, bolts and other fasteners

· Platform entry mid-rail or gate

· Cracks in welds or structural components

· Compartment covers and latches



TABLE A PROCEDURES

A-4Check the Engine Oil LevelMaintaining the proper engine oil level is essentialto good engine performance and service life.Operating the machine with an improper oil levelcan damage engine components.

Check the oil level with theengine off.

1 Check the oil dipstick. Add oil as needed.

Result: The oil level should be in the "safe"zone.

Ford LRG-423 Engine 5 quartsOil capacity (including filter) 4.7 liters

Ford LRG-423 EngineOil viscosity requirements

below 60°F / 15.5°C 5W-30

-10° to 90°F / -23° to 32°C 10W-30

above -10°F / -23°C 10W-40 or 10W-50

above 25°F / -4°C 20W-40 or 20W-50

Use oils meeting API classification SF (labeled SF/CCor SF/CD) as they offer improved wear protection.

Deutz Engine F4L 1011F 11 quartsOil capacity (including filter) 10.5 liters

Deutz Engine F4L 1011F Oil viscosity requirements

below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C 10W-40

above -4°F / -34°C 15W-40

Engine oil should have properties of API classificationCC/SE, CD/SE, SF/CC or SF/CD grades.

A-5Check the Engine Coolant Level- Gasoline/LPG ModelsMaintaining the engine coolant at the proper levelis essential to engine service life. Improper coolantlevel will affect the engine's cooling capability anddamage engine components. Daily checks willallow the inspector to identify changes in coolantlevel that might indicate cooling system problems.

1 Check the fluid level in the coolant recoverytank. Add fluid as needed.

Result: The fluid level should be in theNORMAL range.

Fluids in the radiator are underpressure and extremely hot. Usecaution when removing cap andadding fluids.

A-6Check for Fuel LeaksFailure to detect and correct fuel leaks will result inan unsafe condition. An explosion or fuel fire maycause death or serious injury.

Engine fuels are combustible.Inspect the machine in an open,well-ventilated area away fromheaters, sparks, flames andlighted tobacco. Always have anapproved fire extinguisher withineasy reach.

1 Open the shutoff valve on the liquid petroleumgas (LPG) tank by turning it counterclockwise.

2 Perform a visual inspection around the followingareas. (An LPG detector may be necessary tolocate LPG leaks.)



TABLE A PROCEDURES

Gasoline/LPG models:

· LPG tank, hoses and fittings, solenoid shutoffvalve, LPG regulator and carburetor

· Gasoline tank, manual shutoff valve, fuelpump solenoid shutoff valve, hoses andfittings and carburetor

Deutz Diesel models:

· Fuel tank, shutoff valve, hoses and fittings,fuel pump, fuel filter, fuel injection pumps andfuel injectors

If a fuel leak is discovered, keepany additional personnel fromentering the area and do notoperate the machine. Repair theleak immediately.

A-7Check the Hydraulic Oil LevelMaintaining the hydraulic oil at the proper level isessential to machine operation. Improper hydraulicoil levels can damage hydraulic components. Dailychecks allow the inspector to identify changes in oillevel that might indicate the presence of hydraulicsystem problems.

1 Be sure that the boom is in the stowed position,then visually inspect the sight gauge located onthe side of the hydraulic oil tank.

Result: The hydraulic oil level should be withinthe top 2 inches (5 cm) of the sight gauge.

Hydraulic oil specifications

Hydraulic oil type Dexron equivalent

Tank capacity 45 gallons170 liters

Hydraulic system 55 gallons(including tank) 208 liters

A-8Check for Hydraulic LeaksDetecting hydraulic fluid leaks is essential tooperational safety and good machine performance.Undiscovered leaks can develop into hazardoussituations, impair machine functions and damagemachine components.

1 Inspect for hydraulic oil puddles, dripping orresidue on or around the following areas:

· Hydraulic tank—filter, fittings, hoses, auxiliarypower unit and turntable surface

· Engine compartment—fittings, hoses,pumps, filter and turntable surface

· All hydraulic cylinders

· All hydraulic manifolds

· Boom(s)

· The underside of the turntable

· The underside of the drive chassis

· Ground area under the machine



TABLE A PROCEDURES

A-9Check the Tire Pressure

This procedure does not needto be performed on machinesequipped with the foam-filledtire option.

An over-inflated tire can explodeand may cause death or seriousinjury.

To safeguard maximum stability, achieveoptimum machine handling and minimize tirewear, it is essential to maintain proper pressurein all air-filled tires.

1 Check each tire with an air pressure gauge andadd air as needed.

Tire specifications

Tire size 15-19.5 NHS

Pressure 85 psi5.86 bar

A-10Test the Oscillate Axle(if equipped)Proper axle oscillation is essential to safe machineoperation. If the axle oscillation system is notoperating correctly, the stability of the machine iscompromised and it may tip over.

1 Start the engine from the platform controls.

2 Drive the right steer tire up onto a 6 inch(15.2 cm) block or curb.

Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.

3 Drive the left steer tire up onto a 6 inch(15.2 cm) block or curb.

Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.

4 Drive both steer tires up onto a 6 inch(15.2 cm) block or curb.

Result: The non-steer tires should stay in firmcontact with the ground.

If the chassis does not remainlevel during test, see RepairProcedure 10-6, How to Set Upthe Directional Valve Linkage ORsee Repair Procedure 10-5, Howto Adjust the Sequence ValvePressure.



TABLE A PROCEDURES

A-11Test the Platform andGround ControlsTesting the machine functions and the EmergencyStop buttons for malfunctions is essential for safemachine operation. An unsafe working conditionexists if any function fails to operate properly oreither Emergency Stop button fails to stop all themachine functions and shut off the engine. Eachfunction should activate, operate smoothly and befree of hesitation, jerking and unusual noise.

1 Pull out the Emergency Stop button at theground controls to the ON position.

2 Start the engine from the ground controls.

3 Do not hold the function enable switch to eitherside. Attempt to activate each boom andplatform function toggle switch.

Result: All boom and platform functions shouldnot operate.

4 Hold the function enable switch to either sideand activate each boom and platform functiontoggle switch.

Result: All boom and platform functions shouldoperate through a full cycle. Descent alarm (ifequipped) should sound while the boom islowering.

5 Push in the Emergency Stop button to the OFF

position.

Result: No function should operate, the engineshould stop.

Machines equipped with PlatformLevel Control Disable Function:The platform level function will notoperate when the boom is raisedor extended past the drive speedlimit switches.

Deutz Diesel models:All functions should stopimmediately. The engine willshut off after 2 to 3 seconds.


7 Do not press down on the footswitch.

8 Attempt to operate all machine functions.

Result: All machine functions should notoperate.

9 Press down on the footswitch and activate eachmachine function.

Result: All machine functions should operatethrough a full cycle.

10 Push in the Emergency Stop button to the OFF

position at the platform controls.

Result: No function should operate, the engineshould stop.

As a safety feature, selectingand operating the groundcontrols will override theplatform controls, includingthe Emergency Stop switch.

Deutz Diesel models:All functions should stopimmediately. The engine willshut off after 2 to 3 seconds.

A-12Test the Auxiliary PowerOperationDetection of auxiliary power system malfunctions isessential for safe machine operation. An unsafeworking condition exists if the auxiliary poweredfunctions do not operate in the event of a mainpower loss. When operating the machine onengine power, selecting auxiliary power will stopthe engine immediately. Auxiliary power isdesigned for short term emergency use only,and excessive use will result in battery drainand component damage.

1 Turn the key switch to ground control and pullout the Emergency Stop button to the ON

position at the ground controls.



TABLE A PROCEDURES

2 Lift the red auxiliary power switch cover.

3 Simultaneously hold the auxiliary power switchON and activate each boom function toggleswitch.

To conserve battery power, testeach function through a partialcycle.

Result: All boom functions should operate.

4 Turn the key switch to platform control.

5 Pull out the Emergency Stop switch to the ON

position at the platform controls, then pressdown the foot switch.

6 Lift the red auxiliary power switch cover.

7 Simultaneously hold the auxiliary power switchON and activate each function control handle ortoggle switch

To conserve battery power, testeach function through a partialcycle.

Result: All boom and steer functions shouldoperate. Drive functions should not operate withauxiliary power.

A-13Test the Tilt SensorThe tilt sensor sounds an alarm located in theplatform when the incline of the turntable exceeds4.5 degrees.

Select a level test area. The tiltalarm should not be sounding priorto the test.


2 Open the tank side turntable cover and pressdown on one side of the tilt sensor.

Result: After a 1.5 second delay, the alarm inthe platform should sound.

Tip-over hazard. The alarm shouldbe audible at the ground controls.If the alarm is not audible at theground controls, replace thealarm.

a fuel tankb tilt sensorc ground control box

cba



TABLE A PROCEDURES

a

A-14Test the Limit SwitchesDrive Limit Switches

Detecting limit switch malfunctions is essential tosafe machine operation. The drive limit switchesare used to restrict drive speed when the boom israised or extended. An improperly functioning drivelimit switch will allow the machine to operate at anunsafe drive speed.

1 Remove the cover from the rear of the turntableto access the drive limit switch.

2 Visually inspect the drive limit switch mountedto the turntable side plate at the pivot end of theboom. Inspect for the following:

· Broken or missing roller or roller head

· Missing fasteners

· Loose wiring

a turntable riserb boomc boom drive limit switch

3 Visually inspect the boom extend drive limitswitch located on the end of the cable track onthe boom. Inspect for the following:

· Broken or missing roller or arm


· Loose wiring

a boom extend drive limit switchb cable track


5 Extend the boom approximately 3 feet (0.9 m).

6 Manually activate the boom extend drive limitswitch.

Result: The boom extend drive limit switch armshould move freely and spring return to center.A distinct click should be felt and heard.

7 Turn the keyswitch to platform control.

8 Fully retract the boom.

9 Slowly move the drive control handleoff center.

Result: The machine should move at normaldrive speeds.

10 Raise the boom to just above horizontal.

11 Slowly move the drive control handle off center.

Result: The machine should move at a reduceddrive speed.

ba

b

c



TABLE A PROCEDURES

a

bc

12 Lower the boom to the stowed position, thenextend the boom 3 feet (91 cm).


Result: The machine should move at a reduceddrive speed.

Drive speed, maximum,raised or extended

All models 1 foot per second0.31 meter per second

Drive Enable Limit Switch

1 With the engine off and the boom in betweenthe steer and non-steer tires, visually inspectthe drive enable limit switch for the following:

· Broken or missing roller or arm


· Loose wiring

a turntableb drive enable limit switchc turntable rotation bearing

2 Manually activate the drive enable limit switch.

Result: The drive enable limit switch rollershould move freely and spring return to center.A distinct click should be felt and heard.

3 Start the engine from the platform controls androtate the turntable so the boom is between thenon-steer tires.

4 Rotate the turntable to the left until the boom ispast the left non-steer wheel.

Result: The drive enable indicator light shouldbe on. Drive function should not operate untilthe drive enable toggle switch is activated.

5 Rotate the turntable to the right until the boom ispast the right non-steer wheel.

Result: The drive enable indicator light shouldbe on. Drive function should not operate untilthe drive enable toggle switch is activated.



A-15Replace the Engine Oil andFilter - Gasoline/LPG Models

Ford engine specifications requirethat this procedure be performedevery 100 hours. Perform thisprocedure more often if dustyconditions exist or the machine issubjected to extended low idleoperation.

Periodic replacement of the engine oil and filteris essential to good engine performance. Operatingthe machine with an improper oil level orneglecting periodic oil and filter changes candamage engine components. A daily check ofelapsed machine hours against the hours notedon the oil filter will allow the inspector to anticipateand perform oil and filter changes at the 100 hourinterval.

Perform this procedure afterwarming the engine to normaloperating temperature.

Beware of hot engine parts and oil.Contact with hot engine oil and/orengine parts may cause severeburns.

1 Remove the oil filler cap located on thevalve cover.

2 Place a suitable container under the enginepivot plate directly below the oil pan drain plug.

a engine pivot plateb pivot plate retaining boltsc oil drain hose

3 Remove the plug from the oil pan and allow allof the oil from the engine to drain into a suitablecontainer. See capacity specifications below.

4 Install the plug into the oil pan.

5 Remove the 2 engine pivot plate retaining boltsfrom under the engine pivot plate. Swing theengine pivot plate away from the machine toaccess the oil filter.

6 Use an oil filter wrench and remove the filter.

7 Apply a thin layer of oil to the new oil filtergasket (Genie part no. 28656). Then install thefilter and tighten it securely by hand.

8 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter.

9 Fill the engine with new oil per specificationsand install the filler cap. See capacityspecifications below.

10 Start the engine from the ground controls.Allow the engine to run for 30 seconds, thenturn the engine off.

a b c b

TABLE A PROCEDURES



11 Check the oil filter and the oil pan drain plug forleaks.

12 Swing the engine pivot plate back to its originalposition and replace the two pivot plateretaining bolts.

13 Check the engine oil level dipstick. Add oilif needed.

Ford LRG-423 Engine 5 quartsOil capacity (including filter) 4.7 liters

Ford LRG-423 EngineOil viscosity requirements

below 60°F / 15.5°C 5W-30

-10° to 90°F / -23° to 32°C 10W-30

above -10°F / -23°C 10W-40 or 10W-50

above 25°F / -4°C 20W-40 or 20W-50

Use oils meeting API classification SF (labeled SF/CCor SF/CD) as they offer improved wear protection.

A-16Drain the Fuel Filter/ WaterSeparator - Deutz Diesel Models

Engine specifications require thatthis procedure be performed every100 hours. Poor fuel quality orvery wet conditions maynecessitate performing thisprocedure more often.

Proper maintenance of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and componentdamage.

Engine fuels are combustible.Perform this procedure in an open,well-ventilated area away fromheaters, sparks, flames andlighted tobacco. Always have anapproved fire extinguisher withineasy reach.

Perform this procedure with theengine off.

1 Loosen the drain plug located at the bottom ofthe filter. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

a fuel filterb drain plug

TABLE A PROCEDURES

b

a



2 Clean up any fuel that may have spilled.

If the fuel filter is completelydrained, you must prime the fuelfilter/water separator beforestarting the engine. Refer to C-8 inthis section, Replace The DieselFuel Filter/Water Separator, forinstructions on how to prime thefuel filter/water separator.

3 Start the engine from the ground controls andcheck the fuel filter/water separator for leaks.

A-17Replace the Engine Air Filter

Engine specifications require thatthis procedure be performed every100 hours. Perform this proceduremore often if dusty conditionsexist.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.


1 Remove the retaining ring from the end cap ofthe air filter canister.

2 Remove the end cap from the air cleanercanister.

3 Remove the air filter retaining fastener, thenremove the filter.

4 Clean the inside of the canister and the gasketwith a damp cloth.

5 Insert the new filter and replace the mountingfastener.

6 Replace the end cap on the canister, thenreplace the retaining ring.

Air filters - Genie part numbersFord LRG-423 Engine 27916Deutz F4L 1011F Engine 27916

TABLE A PROCEDURES



B-1Check the Engine BeltMaintaining the engine belt(s) is essential to goodengine performance and service life. The machinewill not operate properly with a loose or defectivebelt and continued use may cause componentdamage.

Do not inspect while the engineis running. Remove the key tosecure from operation.

Beware of hot enginecomponents. Contact with hotengine components may causesevere burns.

1 Deutz Diesel models: Remove the 2 bolts fromunder the engine pivot plate. Swing the enginepivot plate away from the machine to accessthe front engine access cover mountingfasteners.

2 Remove the front engine access covermounting fasteners.

3 All models: Inspect the engine belt for:

· Cracking

· Glazing

· Separation

· Breaks

4 Replace belt if any damage is found.

Table B Procedures

Deutz Diesel engine

5 Check the engine belt for proper tension.

Ford LRG-423 engines areequipped with a serpentine beltand incorporate a self adjustingpulley tensioner. No adjustment isrequired.

Belt deflection - 3/8 inch to 1/2 inchDeutz Diesel models 9 mm to 12 mm



TABLE B PROCEDURES

a cb

B-2Check the Radiator- Gasoline/LPG ModelsMaintaining the radiator in good condition isessential for good engine performance. Operatinga machine with a damaged or leaking radiator mayresult in engine damage. Also, restricting air flowthrough the radiator (i.e., dirt or debris) will affectthe performance of the cooling system. A frequentcheck allows the inspector to identify changes inthe condition of the radiator that might indicatecooling system problems.


Beware of hot engine parts andcoolant. Contact with hot engineparts and/or coolant may causesevere burns.

1 Remove the 2 engine pivot plate retaining boltsfrom under the engine pivot plate. Swing theengine pivot plate away from the machine toaccess the radiator.

2 Inspect the radiator for leaks and physicaldamage.

3 Clean the radiator fins of debris and foreignmaterials.

B-3Check the Oil Cooler and CoolingFins - Deutz Diesel ModelsMaintaining the oil cooler in good condition isessential for good engine performance. Operatinga machine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.



Oil Cooler

1 Remove the fasteners from the engine sidecover, then remove the cover.

2 Inspect the oil cooler for leaks and physicaldamage.

a oil coolerb cylinder head cooling finsc fan blower fins

3 Clean the oil cooler of debris and foreignmaterial.



TABLE B PROCEDURES

Cooling and Fan Blower Fins

4 Inspect the fan blower fins for physical damage.

5 Clean the fan blower fins of debris and foreignmaterial.

6 Inspect the head cooling passages and fins forphysical damage or foreign material, using aflashlight.

7 Clean the cylinder head cooling passages ofdebris and foreign material.

B-4Check the Exhaust SystemMaintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.



1 Deutz Diesel models: Remove the 2 bolts fromunder the engine pivot plate. Swing the enginepivot plate away from the machine to accessthe exhaust system.

a engine pivot plateb pivot plate retaining bolts

2 All models: Be sure that all nuts and bolts aretight.

3 Inspect all welds for cracks.

4 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.

a bb



TABLE B PROCEDURES

B-5Check the BatteryProper battery condition is essential to goodengine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and hazardous conditions.

Electrocution hazard. Contact withhot or live circuits may result indeath or serious injury. Remove allrings, watches and other jewelry.

Batteries contain acid. Avoidspilling or contacting battery acid.Neutralize battery acid spills withbaking soda and water.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections arefree of corrosion.

3 Be sure that the battery hold downs and cableconnections are tight.

4 Remove the battery vent caps and check thespecific gravity with a hydrometer.

5 Check the battery acid level. If needed,replenish with distilled water to the bottom ofthe battery fill tube. Do not overfill.

6 Install the vent caps.

Adding terminal protectors and acorrosion preventative sealant willhelp eliminate corrosion on thebattery terminals and cables.

B-6Check the Hydraulic Tank FilterCondition IndicatorMaintaining the hydraulic tank filter in goodcondition is essential to good system performanceand safe machine operation. The filter conditionindicator will show when the hydraulic flow isbypassing a clogged filter. If the filter is notfrequently checked and replaced, impuritieswill remain in the hydraulic system and causecomponent damage.


2 Move the engine speed control switch to highidle (rabbit symbol).

3 Inspect the filter condition indicator.

a filter condition indicatorb filterc hydraulic tank

Result: The filter should be operating with theplunger in the green area. If the display showsthe plunger in the red area, this indicates thatthe hydraulic filter is being bypassed and thefilter should be replaced. See C-6, Replace theHydraulic Tank Filter.

a

b

c



TABLE B PROCEDURES

B-7Inspect the Electrical WiringMaintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution hazard. Contact withhot or live circuits may result indeath or serious injury. Remove allrings, watches and other jewelry.

1 Inspect the following areas for burnt, chafed,corroded and loose wires:

· Engine compartment electrical panel(Gasoline/LPG models)

· Engine wiring harness

· Inside of the ground control box

· Turntable manifold wiring

2 Start the engine from the ground controls andraise the boom above the turntable covers.

3 Inspect the turntable area for burnt, chafed andpinched cables.

4 Lower the boom into the stowed position andturn the engine off.

5 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

· Cable track on the boom

· Boom to platform cable harness

· Inside of the platform control box

· Jib boom cable cover (S-65 models)

B-8Inspect the Tires and Wheels(including lug nut torque)Maintaining the tires and wheels in goodcondition is essential to safe operation and goodperformance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired in a timely fashion.

An over-inflated tire canexplode and may cause deathor serious injury.

Tip-over hazard. Do not usetemporary flat tire repair products.

1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracked welds.

3 Check each lug nut for proper torque.

4 Check the pressure in each air-filled tire.

Tires and wheelsTire size 15-19.5 NHS

Tire ply rating 12

Tire pressure 85 psi5.86 bar

Wheel lugs 10 @ 3/4 -16

Lug nut torque, dry 420 ft-lbs569.5 Nm

Lug nut torque, lubricated 320 ft-lbs433.9 Nm



B-9Confirm the ProperBrake ConfigurationProper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.

1 Check each torque hub disconnect cap to besure it is in the engaged position.

2 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

The free-wheel valve is located onthe bottom of the drive pump.

a drive pumpb free-wheel valvec lift pumpd screwdriver

The free-wheel valve shouldalways remain closed.

TABLE B PROCEDURES

B-10Check the Oil Levelin the Torque HubsFailure to maintain proper torque hub oil levelsmay cause the machine to perform poorly andcontinued use may cause component damage.

Drive Torque Hubs

1 Drive the machine to rotate the hub until theplugs are located one on top and the other at90 degrees.

2 Remove the plug located at 90 degrees andcheck the oil level.

Result: The oil level should be even with thebottom of the plug hole.

3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole.

4 Apply pipe thread sealant to the plug, and theninstall it in the torque hub.

5 Repeat this procedure for each drive torquehub.

Drive torque hub oil

Capacity 44 fl oz1.30 liters

Type: SAE 90 multipurpose hypoid gear oil - API serviceclassification GL5

brake disengage position

brake engage position

a

b

c

d



TABLE B PROCEDURES

Turntable Rotate Torque Hub

1 Remove the plug located on the side of the huband check the oil level.

Result: The oil level should be even with thebottom of the plug hole.

a torque hubb plug

2 If necessary, add oil until the oil level is evenwith the bottom of the side plug hole.

3 Apply pipe thread sealant to the plug, and theninstall it in the torque hub.

Turntable rotate torque hub oil

Capacity 17 fluid ounces0.51 liters

Type SAE 90 multipurpose hypoid gear oil - API serviceclassification GL5

B-11Check and Adjust the Engine IdleMixture - Gasoline/LPG ModelsComplete information to perform this procedure isavailable in the Ford LRG-423 2.3 Liter IndustrialEngine Service Manual (Ford number: PPD-194-287). Genie part number 33907.

B-12Check and Adjust theEngine RPMMaintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.

Gasoline/LPG Models:Perform this procedure in gasolinemode with the engine at normaloperating temperature.

1 Disconnect the blue/black wire from thegovernor actuator.

2 Connect an rpm gauge to the engine, then startthe engine from the ground controls.

Result: Carburetor low idle should be 900 rpm.

Skip to step 4 if the low idle rpm is correct.

3 Turn the idle adjustment screw on thecarburetor clockwise to increase rpm orcounterclockwise to decrease rpm.

a carburetorb adjustment screw

4 Turn the engine off and reconnect theblue/black wire to the governor actuator.


Result: Electronic governor low idle shouldbe 1600 rpm.

b

a

b

a



TABLE B PROCEDURES

6 Move the function enable toggle switch to thehigh idle (rabbit symbol) at the ground controls.

Result: High idle should be 2500 rpm.

7 Turn the engine off.

If low and high idle rpm’s are correct,disregard adjustment steps 8 and 9.

8 Remove the mounting fasteners from theelectronic governor located on the engineside bulkhead, then remove the back panelfrom the governor.

9 Restart the engine, turn the low or high speedtrimpot screw clockwise to increase the rpm orcounterclockwise to decrease the rpm.

Do not adjust any trimpot otherthan specified in this procedure.

a low idle adjustmentb high idle adjustment

10 Apply a drop of silicone to the top of the trimpotscrew. Apply a bead of silicone to the surface ofthe back panel prior to re-assembly.

11 Re-assemble the governor and recheck low andhigh idle.

Gasoline/LPG models

Low idle - carburetor 900 rpm

Low idle - electronic governor 1600 rpm

High idle 2500 rpm

Deutz Diesel models:1 Connect an rpm gauge to the engine, and then

start the engine from the ground controls.

Result: Low idle should be 1300 rpm.

Skip to step 3 if the low idle rpm is correct.

2 Loosen the low idle lock nut, then turn the lowidle adjustment screw clockwise to increase therpm or counterclockwise to decrease the rpm.Tighten the low idle lock nut and recheck therpm.

a solenoid bootb high idle adjustment nutc yoke lock nutd yokee low idle adjustment screwf low idle lock nut

3 Move the function enable toggle switch to thehigh idle (rabbit symbol) position at the groundcontrols.

Result: High idle should be 2300 rpm.

If high idle rpm is correct, disregardadjustment step 4.

b

a

f

e

c dba



TABLE B PROCEDURES

4 Loosen the yoke lock nut, then turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Be sure the solenoid fully retractswhen activating high idle.

Deutz Diesel models

Low idle 1300 rpm

High idle 2300 rpm

B-13Test the Key SwitchProper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could causea hazardous operating situation.

1 Pull out the Emergency Stop button to the ON

position at both the ground and platformcontrols.

2 Turn the key switch to ground control, start theengine and then turn the key switch to platformcontrol.

3 Check any machine function from the groundcontrols.

Result: The machine functions should notoperate.

4 Turn the key switch to ground control.

5 Check any machine function from the platformcontrols.


6 Turn the key switch to the OFF position.

Result: The engine should stop and nofunctions should operate.

Deutz Diesel models: All functionsshould stop immediately. Theengine will shut off after 2 to 3seconds.

B-14Test the EmergencyStop ButtonsProperly functioning Emergency Stop buttonsare essential for safe machine operation. Animproperly operating Emergency Stop buttonwill fail to shut off power and stop all machinefunctions, resulting in a hazardous situation forground and platform personnel.

As a safety feature, selectingand operating the ground controlswill override the platform controls,including the Emergency Stopbutton.


2 Push down the Emergency Stop button to theOFF position.

Result: The engine should shut off and nomachine functions should operate.

Deutz Diesel models: Allfunctions should stop immediately.The engine will shut off after 2 to 3seconds.


4 Push down the Emergency Stop button to theOFF position.

Result: The engine should shut off and nomachine functions should operate.

The ground Emergency Stopbutton will stop all machineoperation, even if the key switchis switched to platform control.



TABLE B PROCEDURES

B-15Test the Ground Control OverrideA properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allowground personnel to operate the machine from theground controls whether or not the EmergencyStop button on the platform controls is in the ON orOFF position. This function is particularly useful ifthe operator at the platform controls cannot returnthe boom to the stowed position.

1 Push in the platform Emergency Stop buttonto the OFF position.


3 Operate each boom function through apartial cycle.

Result: All boom functions should operate.

B-16Check the Directional ValveLinkage

Perform this test only on modelsequipped with a oscillating axle.

Proper axle oscillation is essential to safe machineoperation. If the directional valve linkage is notoperating correctly, the stability of the machine iscompromised and it may tip over.

1 Remove the drive chassis cover from thenon-steer end.

2 Inspect the linkage for the following:

· Lock nut is tight against yoke

· Yoke clevis pins are installed

· Cotter pins are installed through clevis pins

· Linkage is properly attached todirectional valve

a directional valveb clevis pin with cotter pin (hidden)c yoked lock nut

a

b

c

d



TABLE B PROCEDURES

B-17Test the Platform Self-levelingAutomatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained at level by the platformleveling slave cylinder which operates in a closedloop hydraulic circuit with the master cylinderlocated at the base of the boom. A platform self-leveling failure creates an unsafe working conditionfor platform and ground personnel.

1 Start the engine from the ground controls andlower the boom into the stowed position.

2 Hold the function enable toggle switch to eitherside and adjust the platform to a level positionusing the platform level toggle switch.

3 Raise and lower the boom througha full cycle.

Result: The platform should remain level atall times to within ±5 degrees.

B-18Test the HornA functional horn is essential to safe machineoperation. The horn is activated at the platformcontrols and sounds at the ground as a warning toground personnel. An improperly functioning hornwill prevent the operator from alerting groundpersonnel of hazards or unsafe conditions.

1 Turn the key switch to platform control andpull out the Emergency Stop button to theON position at both the ground andplatform controls.

2 Push down the horn button at the platformcontrols.

Result: The horn should sound.

If necessary, the horn can beadjusted to obtain the loudestvolume by turning the adjustmentscrew near the wire terminals onthe horn.

B-19Test the Foot SwitchA properly functioning foot switch is essential tosafe machine operation. Machine functions shouldactivate and operate smoothly as long as the footswitch is pressed down, and promptly stop whenthe foot switch is released. The foot switch will alsoshift the engine into high idle if the idle select isswitched to the rabbit and foot switch symbol. Animproperly functioning foot switch can cause anunsafe working condition and endanger platformand ground personnel.

The engine should not start if thefoot switch is pressed down.

1 Turn the keyswitch to platform controls and pullout the Emergency Stop button to the ON


2 Press down the footswitch and attempt to startthe engine by moving the start toggle switch toeither side.

Result: The engine should not start.

3 Do not press down the footswitch and start theengine.

4 Do not press down the footswitch. Check themachine functions.


5 Press down the foot switch and operate themachine functions.

Result: The machine functions should operate.



TABLE B PROCEDURES

B-20Test the Engine Idle SelectA properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are three settings.

Low idle (turtle symbol) allows the operator tocontrol individual boom functions only. Drivefunctions do not operate at low idle.

High idle (rabbit symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously. This setting maintains aconsistent high idle and is usually selected onlywhen the generator option is being used.

Foot switch activated high idle (rabbit and footswitch symbols) should be used for normalmachine operation. This selection activates highidle only when the foot switch is pressed down.

1 Pull out the Emergency Stop button to theON position at both the ground and platformcontrols.

2 Start the engine from the ground controls. Thenmove the function enable toggle switch to thehigh idle (rabbit symbol) position and hold in theON position.

Result: The engine should change to high idle.

3 Release the function enable toggle switch.

Result: The engine should return to low idle.

4 Turn the key switch to platform controls.

5 At the platform controls, move the engine idlecontrol switch to high idle (rabbit symbol).


6 Move the engine idle control switch to low idle(turtle symbol).

Result: The engine should change to low idle.

7 Move the engine idle control switch to footswitch activated high idle (rabbit and foot switchsymbol).

Result: The engine should not change tohigh idle.

8 Press down the foot switch.


B-21Test the Fuel Select Operation- Gasoline/LPG ModelsThe ability to select and switch betweengasoline and LPG fuels as needed is essential tosafe machine operation. A fuel selection can bemade when the engine is running or not.Switching malfunctions and/or the failure of theengine to start and run properly in both fuelmodes and through all idle speeds can indicatefuel system problems that could develop into ahazardous situation.

Perform this test after checkingthe gasoline and LPG fuel levels,and warming the engine to normaloperating temperature.

1 Move the fuel select switch to gasoline and thenmove the engine idle control switch to footswitch activated high idle (rabbit and foot switchsymbol).

2 Start the engine from the platform controls andallow it to run at low idle.

3 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

4 Release the foot switch and shut the engine offby pushing the Emergency Stop button in to theOFF position.

5 Move the fuel select switch to LPG.



TABLE B PROCEDURES

6 Restart the engine and allow it to run atlow idle.

7 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

The engine may hesitatemomentarily and then continueto run on the selected fuel if thefuel source is switched whilethe engine is running.

B-22Test the Drive Enable SystemProper drive enable system operation isessential to safe machine operation. When theboom is past the non-steering wheels, drivemovement is stopped and the indicator light turnson. The drive enable switch must be to either sideto reactivate the drive function and should informthe operator that the machine will move in theopposite direction that the drive and steer controlsare moved. An improperly functioning drive enablesystem may allow the machine to be moved intoan unsafe position.


2 Rotate the turntable to the right until the boom ispast the right non-steering wheel.

Result: The drive enable indicator light shouldturn on.


Result: The drive function should not operate.

4 Hold the drive enable toggle switch to eitherside and slowly move the drive control handleoff center.

Always use the color-codeddirection arrows on theplatform control panel and thedrive chassis to identify whichdirection the machine will travel.

Result: The drive function should operate.

5 Rotate the turntable to the left until the boom ispast the left non-steering wheel.

Result: The drive enable indicator light shouldcome on.

6 Repeat steps 3 and 4.

B-23Test the Drive BrakesProper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydrostatic brakes and hydraulically-released individual wheel brakes can appear tooperate normally when they are actually not fullyoperational.

Be sure that the machine is not infree-wheel or partial free-wheelconfiguration. Refer to B-9 in thissection, Confirm the Proper BrakeConfiguration.

Select a test area that is firm, leveland free of obstructions.

1 Mark a test line on the ground for reference.




TABLE B PROCEDURES

3 Move the engine idle control switch tofoot switch activated high idle (rabbit andfoot switch), then lower the boom into thestowed position.

4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.

5 Bring the machine to top drive speed beforereaching the test line. Release the drive joystickwhen your reference point on the machinecrosses the test line.

6 Measure the distance between the test line andyour machine reference point.

Braking:paved surface 2WD 4WD

Stopping distance 3 to 5 ft 3 to 5 ft0.9 to 1.5 m 0.9 to 1.5 m

The brakes must be able to holdthe machine on any slope it is ableto climb.

B-24Test the Drive Speed- Stowed PositionProper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.

Select a test area that is firm, leveland free of obstructions.

1 Create start and finish lines by marking twolines on the ground 40 feet (12.2 m) apart.


3 Move the engine idle control switch tofoot switch activated high idle (rabbit and footswitch), then lower the boom into the stowedposition.

4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

5 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

6 Continue at full speed and note the time whenthe machine reference point crosses the finishline.

Drive speed:stowed position 2WD 4WD

Gasoline/LPG models 40 ft/6.2 sec 40 ft/9.1 sec12.2 m/6.2 sec 12.2 m/9.1 sec

Deutz Diesel models 40 ft/6.8 sec 40 ft/9.1 sec12.2 m/6.8 sec 12.2 m/9.1 sec



TABLE B PROCEDURES

B-25Test the Alarm Package- Optional EquipmentThe alarm package includes:

· Travel alarm

· Descent alarm

· Flashing beacon

Alarms and a beacon are installed to alertoperators and ground personnel of machineproximity and motion. The alarm package isinstalled on the turntable covers.

The alarms and beacon willoperate with the enginerunning or not running.

1 Turn the key switch to ground control and pullout the Emergency Stop button to the ON


Result: The flashing beacon should be on andflashing.

2 Move the function enable toggle switch to eitherside and activate the boom toggle switch in theDOWN position, hold for a moment and thenrelease it.

Result: The descent alarm should sound whenthe switch is held down.

3 Turn the key switch to platform control.

Result: The flashing beacon should be onand flashing.

4 Press down the foot switch. Move the boomcontrol handle to the DOWN position, hold for amoment and then release it.

Result: The descent alarm should sound whenthe control handle is held down.

5 Press down the foot switch. Move the drivecontrol handle off center, hold for a momentand then release it. Move the drive controlhandle off center in the opposite direction, holdfor a moment and then release it.

Result: The travel alarm should sound when thedrive control handle is moved off center ineither direction.

B-26Perform Hydraulic Oil AnalysisSee D-1, Test or Replace the Hydraulic Oil.

B-27Replace the Engine Oil andFilter - Deutz Diesel Models

Engine specifications requirethat this procedure be performedevery 500 hours. Perform thisprocedure more often if dustyconditions exist.

Periodic replacement of the engine oil andfilter is essential to good engine performance.Operating the machine with an improper oil level orneglecting periodic oil and filter changes candamage engine components. A frequent checkof elapsed machine hours against the hoursnoted on the oil filter will allow the inspector toanticipate and perform oil and filter changes atthe 500 hour interval.

Perform this procedure afterwarming the engine to normaloperating temperature.

Beware of hot engine parts and oil.Contact with hot engine oil and/orengine parts may cause severeburns.

1 Remove the oil filler cap located above thedipstick.



2 Pull the end of the drain hose out from underthe engine.

3 Remove the plug from the end of the drain hoseand allow all of the oil from the engine to draininto a suitable container. See capacityspecifications below.

4 Install the plug into the drain hose.

5 Use an oil wrench and remove the oil filter.

a engine oil level dipstickb fuel filterc oil filter

6 Apply a thin layer of oil to the new filter gasket(Genie part no. 49924). Then install the filterand tighten it securely by hand.


8 Fill the engine with new oil per specificationsand install the oil filler cap.

9 Start the engine from the ground controls. Allowthe engine to run for 30 seconds then turn theengine off.

10 Check the oil filter and oil drain hose for leaks.

11 Check the engine oil level dipstick. Add oil ifneeded.

Deutz Engine F4L 1011F 11 quartsOil capacity (including filter) 10.5 liters

Deutz Engine F4L 1011F Oil viscosity requirements

Temperature below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C 10W-40

Temperature above -4°F / -34°C 15W-40

Engine oil should have properties of API classificationCC/SE, CD/SE, CC/SF or CD/SF grades.

2 Clean up any fuel that may have spilled.

TABLE B PROCEDURES

a

bc



C-1Check the BoomWear PadsMaintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of worn out wear pads may result incomponent damage and unsafe operatingconditions.

If the wear pads are not wornbelow specification but are stillwithin specification, see RepairProcedure 4-2, How to Shim theBoom.


2 Raise the end of the boom to a comfortableworking height (chest high), then extend theboom 1 foot (30 cm).

3 Measure each wear pad. Replace the wear padif it is less than specification. If the wear pad isnot less than specification, shim as necessaryto obtain zero clearance and zero drag.

4 Extend and retract the boom through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the boom.

Always maintain squarenessbetween the boom outer and innertubes.

Wear pad specifications

Upper wear pads 9/16 inch 14.3 mmBottom and side wear pads 11/16 inch 17.5 mm

Table C Procedures

1

2

3

4

5

6

7

8

9

10

11

1213

14 15

1617

18

22

26

30

192327

2024 28

21

25

29

C-2Check the Turntable RotationBearing BoltsMaintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.

1 Raise the boom and place a safety chock onthe lift cylinder rod. Carefully lower the boomonto the lift cylinder safety chock.

Crushing hazard. Keep handsaway from cylinder and all movingparts when lowering the boom.

The lift cylinder safety chock isavailable through Genie(part no. 33484).

2 Be sure that each turntable mounting bolt istorqued in sequence to 210 foot-pounds(285 Newton meters).

Bolt torque sequence



TABLE C PROCEDURES

1 15

7

12

4

17

5

14

9216

8

11

3

18

6

13

10

disengage position

engage position

disengage position

engage position

3 Lower the boom to the stowed position.

4 Check to ensure that each bearing mountingbolt under the drive chassis is torqued insequence to 210 foot-pounds(285 Newton meters).

Bolt torque sequence

C-3Check the Free-wheelConfigurationProper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily fortowing. A machine configured to free-wheel withoutoperator knowledge may cause death or seriousinjury and property damage.

Collision hazard. Select a worksite that is firm and level.

Non-steering wheels: All models

1 Chock the steer wheels to prevent the machinefrom rolling.

2 Center a lifting jack of ample capacity(20,000 lbs/9072 kg) under the drive chassisbetween the non-steer tires.

3 Lift the wheels off the ground and then placejack stands under the drive chassis for support.

4 Disengage the torque hubs by turning over thetorque hub disconnect caps on eachnon-steering wheel hub.

5 Manually rotate each non-steering wheel.

Result: Each non-steering wheel should rotatewith minimum effort.

6 Re-engage the torque hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the jack stands.

Collision hazard. Failure tore-engage the torque hubs maycause death or serious injury andproperty damage.

Steer wheels: 4WD models

7 Chock the non-steering wheels to prevent themachine from rolling.

8 Center a lifting jack of ample capacity(20,000 lbs/9072 kg) under the drive chassisbetween the non-steer tires.

9 Lift the wheels off the ground and then placejack stands under the drive chassis for support.

10 Disengage the torque hubs by turning over thetorque hub disconnect caps on eachsteer wheel hub.

11 Manually rotate each steer wheel.

Result: Each steer wheel should rotate withminimum effort.



TABLE C PROCEDURES

12 Re-engage the torque hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the jack stands.

Collision hazard. Failure tore-engage the torque hubs maycause death or serious injury andproperty damage.

All models:

13 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

The free-wheel valve is located onthe bottom of the drive pump.

a drive pumpb free-wheel valvec lift pumpd screwdriver

The free-wheel valve shouldalways remain closed.

C-4Grease the Turntable RotationBearing and Rotate GearYearly application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.

1 Locate the grease fitting on the platform end ofthe tank side bulkhead.

2 Pump grease into the turntable rotation bearing.Rotate the turntable in incrementsof 4 to 5 inches (10 to 13 cm) at a time andrepeat this step until the entire bearing hasbeen greased.

3 Apply grease to each tooth of the drive gear,located under the turntable.

Grease type Multipurpose grease

C-5Replace the Torque Hub OilReplacing the torque hub oil is essential for goodmachine performance and service life. Failure toreplace the torque hub oil at yearly intervals maycause the machine to perform poorly andcontinued use may cause component damage.

Drive Torque Hubs:

1 Select the torque hub to be serviced. Then drivethe machine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil.

a

b

c

d



TABLE C PROCEDURES

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Apply pipe thread sealant to the plugs, and theninstall the plugs.

5 Repeat steps 1 through 4 for all the other drivetorque hubs.

Oil capacity per hub 44 fl oz1.30 liters

Type: SAE 90 multipurpose hypoid gear oil - APIservice classification GL5

Turntable Rotate Torque Hub:

1 Secure the turntable from rotating with theturntable rotation lock pin.

unlocked locked

2 Remove the motor/brake mounting bolts, andthen remove the motor and brake from thetorque hub and set them to the side.

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

a motor/brake mounting boltb motorc torque hubd torque hub mounting bolte plugf brake

3 Remove the torque hub mounting bolts, andthen use a lifting device to remove the torquehub from the machine.

b

c

de

f

a



TABLE C PROCEDURES

4 Remove the plug from the side of the torquehub. Then drain the oil from the hub.

5 Install the torque hub. Torque the hub mountingbolts to 180 foot-pounds (244 Newton meters).

6 Install the brake and motor onto the torque hub.

7 Fill the hub with oil from the side hole until theoil level is even with the bottom of the hole.Apply pipe thread sealant to the plugs, and theninstall the plugs.

8 Adjust turntable rotation gear backlash. SeeRepair Procedure 12-1, How to Adjust theTurntable Rotation Gear Backlash.

Turntable rotate torque hub

Oil capacity 17 fluid ounces0.51 liters


C-6Replace the Hydraulic Tank FilterReplacement of the hydraulic tank filter isessential for good machine performance andservice life. A dirty or clogged filter may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.

Beware of hot oil. Contact withhot oil may cause severe burns.


1 Remove the filter with an oil filter wrench.

2 Apply a thin layer of oil to the new oil filtergasket.

3 Install the new filter (Genie part no. 46014) andtighten it securely by hand. Clean up any oilthat may have spilled during the installationprocedure.



6 Inspect the filter and related components tobe sure that there are no leaks.

C-7Replace the Drive LoopHydraulic FilterReplacing the drive loop hydraulic filter is essentialto good machine performance and service life. Adirty or clogged filter may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require that the filter be replaced more often.

Beware of hot oil. Contact withhot oil may cause severe burns.


1 Open the engine side turntable cover and locatethe drive loop hydraulic filter mounted on theengine near the main pump.

2 Remove the filter housing by using a wrench onthe nut provided on the bottom of the housing.

3 Remove the filter element from the housing.

4 Inspect the housing seal and replace it ifnecessary.

5 Install the new filter (Genie part no. 20880) andhand tighten the housing onto the filter head.Clean up any oil that may have spilled duringthe installation procedure.


7 Inspect the filter assembly to be sure that thereare no leaks.

8 Clean up any oil that may have spilled.



TABLE C PROCEDURES

ab

C-8Replace the Diesel FuelFilter/Water Separator - DeutzDiesel ModelsReplacing the diesel fuel filter is essential to goodengine performance and service life. A dirty orclogged filter may cause the engine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more often.

Engine fuels are combustible.Replace the fuel filter in an open,well-ventilated area away fromheaters, sparks, flames andlighted tobacco. Always have anapproved fire extinguisher withineasy reach.


1 Turn the manual fuel shutoff valve, located atthe fuel tank, to the CLOSED position.

2 Remove the fuel filter with a filter wrench.

a oil filterb fuel filter/water separator

3 Fill the new filter (Genie part no. 29560) withfresh diesel fuel and apply a thin layer of oil ordiesel fuel to the new fuel filter gasket.

4 Install the new filter and tighten it securely byhand. Clean up any diesel fuel that might havespilled during the procedure.

5 Turn the manual fuel shutoff valve, located atthe fuel tank, to the OPEN position.

6 Start the engine from the ground controls, theninspect the fuel filter for leaks.

If a fuel leak is discovered, keepany additional personnel fromentering the area and do notoperate the machine. Repairthe leak immediately.

C-9Replace the Gasoline FuelFilter - Gasoline/LPG ModelsReplacing the gasoline fuel filter is essential togood engine performance and service life. A dirtyor clogged filter may cause the engine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more often.

Engine fuels are combustible.Replace the fuel filter in an open,well-ventilated area away fromheaters, sparks, flames andlighted tobacco. Always have anapproved fire extinguisher withineasy reach.




TABLE C PROCEDURES

1 Remove the 2 bolts from under the engine pivotplate. Swing the engine pivot plate away fromthe machine to access the fuel filter, locatednear the carburetor.

a pivot plate retaining boltsb engine pivot plate

2 Disconnect the fuel hose from the filter, thenremove the filter from the fitting.

a fuel filterb hose from the fuel pump to

the fuel filter

3 Install the new fuel filter (Genie part no. 33971)into the fitting on the carburetor.

4 Connect the fuel hose to the filter.

5 Clean up any fuel that may have spilled duringthe installation procedure.

6 Start the machine from the ground controls,then inspect the fuel filter and hose for leaks.


7 Swing the engine pivot plate back to its originalposition and replace the two retaining bolts.

a b

ba a



TABLE C PROCEDURES

C-10Replace the PCV Valve- Gasoline/LPG ModelsYearly replacement of the PCV valve is essential togood engine performance. A malfunctioning PCVvalve can impair crankcase ventilation and maycause engine damage.


1 Remove the 2 engine pivot plate retaining boltsfrom under the engine pivot plate. Swing theengine pivot plate away from the machine toaccess the PCV valve.


2 Remove the hose from the PCV valve, thenremove the valve.

a PCV valve

3 Install the new PCV valve. Connect the hoses.

4 Swing the engine pivot plate back to its originalposition and replace the two retaining bolts.

ba a

a



TABLE C PROCEDURES

C-11Replace the Spark Plugs- Gasoline/LPG ModelsPeriodic replacement of the spark plugs isessential to good engine performance andservice life. Worn, loose or corroded spark plugswill cause the engine to perform poorly and mayresult in component damage.


1 Label, then disconnect the plug wires from thespark plugs by grasping the molded boot. Donot pull on the plug wire.

2 Blow out any debris around spark plugs.

3 Remove all the spark plugs from the engine.

4 Adjust the gap on each new spark plug.

5 Install the new spark plugs, then connect thewires. Be sure that each spark plug wire isattached to the correct spark plug.

Spark plug specifications

Spark plug type Motorcraft AWSF-52C

Spark plug gap 0.042 to 0.046 inches1.07 to 1.18 mm

Spark plug torque 5 to 10 foot-pounds7 to 14 Nm

C-12Check and Adjust the Air/LPGMixture - Gasoline/LPG ModelsMaintaining the proper air-to-fuel mixture duringLPG operation is essential to good engineperformance.

Engine fuels are combustible.Perform this procedure in an open,well-ventilated area away fromheaters, sparks, flames andlighted tobacco. Always have anapproved fire extinguisher withineasy reach.

The engine rpm needs to bepreset for gasoline fuel operationbefore adjusting the LPG idlemixture. Refer to B-12, Check andAdjust the Engine RPM.

The engine should be warmed tonormal operating temperaturebefore performing this procedure.

1 Move the fuel select switch to LPG fuel andstart the engine from the ground controls.

2 Loosen the high idle mixture adjustmentlock nut.

a high idle mixtureadjustment screw

a



TABLE C PROCEDURES

a

3 Load the system by activating the boom retractfunction, then move the function enable toggleswitch to the high idle (rabbit symbol) position.

4 Adjust the high idle adjustment screw to obtainan air-to-fuel mixture ratio of 13.0:1 to 13.2:1,using an exhaust gas analyzer.

Preliminary setting is 1/4 inch ofthreads showing. Measure fromtop of lock nut to top of adjustmentscrew.

If an exhaust gas analyzer is notavailable, adjust to obtain peak oroptimum rpm.

5 Hold the adjustment screw and tighten thelock nut.

6 Move the engine idle control switch to low idle(turtle symbol) and adjust the low idle screw toobtain an air-to-fuel mixture ratioof 13.0:1 to 13.2:1.

a low idle mixture adjustment screw

Preliminary setting: turn low idleadjustment screw clockwise all theway in. Turn low idle adjustmentscrew counterclockwise 2 3/4turns.

C-13Check and Adjust the IgnitionTiming - Gasoline/LPG ModelsComplete information to perform this procedure isavailable in the Ford LRG-423 2.3 Liter IndustrialEngine Service Manual (Ford number: PPD-194-287). Genie part number 33907.

C-14Check the Engine ValveClearances - Deutz Diesel ModelsComplete information to perform this procedureis available in the Deutz FL 1011F WorkshopManual (Deutz Number 0297 7195).Genie part number 52229.

C-15Check the Turntable RotationGear BacklashThe turntable rotation torque hub is mounted on anadjustable plate that controls the gap between therotation motor gear and the turntable bearing.Maintaining proper backlash of the turntablebearing is essential to safe machine operation.Improper backlash could result in an unsafeoperating condition and component damage.

See 12-1, How to Adjust theTurntable Rotation Gear Backlash.



D-2Change or Recondition theEngine Coolant- Gasoline/LPG ModelsReplacing or reconditioning the engine coolant isessential to good engine performance and servicelife. Old or dirty coolant may cause the engine toperform poorly and continued use may causeengine damage. Extremely dirty conditions mayrequire coolant to be changed more frequently.

Beware of hot engine parts andcoolant. Contact with hot engineparts and/or coolant will causesevere burns.

Perform this procedure with theengine off and cooled.

1 Put on protective clothing and eye wear.

2 Disconnect the coolant return hose at theradiator and drain the coolant return tank into asuitable container.

3 Slowly remove the radiator cap from theradiator.

Bodily injury hazard. Allow anypressure to dissipate graduallybefore removing the radiator cap.

D-1Test or Replace the Hydraulic OilReplacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

The machine uses Dexronequivalent hydraulic oil. Beforereplacing the hydraulic oil, the oilmay be tested by an oil distributorfor specific levels of contaminationto verify that changing the oil isnecessary. If the hydraulic oil isnot replaced at the two yearinspection, test the oil quarterly.Replace the oil when it fails thetest.

Perform this procedure with theboom in the stowed position.

1 Remove the hydraulic tank. See RepairProcedure 11-2, How to Remove the HydraulicTank.

The pump needs to primed beforestarting the engine. See RepairProcedure 11-2, How to Removethe Hydraulic Tank.

Component damage hazard. Besure that the hydraulic tank shutoffvalves are in the OPEN positionbefore priming the pump. Theengine must not be started withthe hydraulic tank shutoff valves inthe CLOSED position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

Table D Procedures



4 Remove the 2 engine pivot plate retaining boltsfrom under the engine pivot plate. Swing theengine pivot plate away from the machine toaccess the radiator drain valve.


5 Open the drain valve on the radiator and allowall the coolant to drain into a suitable container.

6 After all the coolant has drained, close the drainvalve. Connect the coolant return hose tothe radiator.

7 Open the drain valve on the engine block andallow the coolant to drain into a container.After the fluid is drained, close the drain valve.

8 Replace all coolant hoses and clamps.

9 Pour the proper coolant mixture (anti-freeze andwater) for your climate into the radiator until it isfull.

TABLE D PROCEDURES

10 Disconnect the hose coupler at the fan end fromthe tube that is connected to the water pumpand hold it until coolant starts to come out of theopen hose. Then immediately reconnect thehose.

a tube connected to water pumpb hose coupler

11 Fill the radiator and then fill the coolant recoverytank to the NORMAL range.

12 Clean up any coolant spilled during thisprocedure.

13 Start the engine from the ground controls,run it for 30 seconds, and then turn it off.

14 Inspect for leaks and then check the fluidlevel in the coolant recovery tank. Addwater if needed.

15 Start the engine from the ground controlsand run it until reaching normal operatingtemperature.

16 Allow engine to cool and check the fluid level inthe coolant recovery tank. Add water if needed.

Ford Engine 11.5 quartsCoolant capacity 10.9 liters

ab

ba a



TABLE D PROCEDURES

D-3Change the Fuel LinesMaintaining the fuel lines in good condition isessential to safe operation and good engineperformance. Failure to detect a worn, cracked orleaking fuel line may cause an unsafe operatingcondition.

Engine fuels are combustible.Replace the fuel lines in an open,well-ventilated area away fromheaters, sparks, flames andlighted tobacco. Always have anapproved fire extinguisher withineasy reach.


1 Close the manual fuel shutoff valve, locatednext to the fuel tank.

2 Remove and replace the fuel line hoses andclamps according to the following illustrations:

Fuel may be expelled underpressure. Wrap a cloth around fuelhoses to absorb leaking fuelbefore disconnecting them.

Deutz Diesel modelsa hose from the injector to

the fuel tankb hoses connecting injectorsc hose from the fuel shutoff valve

to the fuel pumpd hose from the fuel pump to

the fuel filtere hose from the fuel filter to the

injection pumpf hose from the injection pump

to the injectors

b b b b b b

e d cf

ba



TABLE D PROCEDURES

Gasoline/LPGa carburetorb fuel filterc hose from the fuel filter to

the fuel pumpd hose from the fuel pump

to the fuel tank (not shown)

3 Clean up any fuel that may have spilled duringthis procedure.

4 Start the engine from the ground controls, theninspect the fuel filter and hoses for leaks.


D-4Check the Engine ValveClearance - Gasoline/LPG ModelsComplete information to perform this procedure isavailable in the Ford LRG-423 2.3 Liter IndustrialEngine Service Manual (Ford number: PPD-194-287). Genie part number 33907.

D-5Check the Engine CylinderCompression- Gasoline/LPG ModelsComplete information to perform this procedure isavailable in the Ford LRG-423 2.3 Liter IndustrialEngine Service Manual (Ford number: PPD-194-287). Genie part number 33907.

D-6Clean the PCV Hoses andFittings - Gasoline/LPG ModelsMaintaining PCV hoses is essential to good engineperformance. Improperly functioning PCV hoseswill fail to ventilate the crankcase and continueduse of neglected hoses could result in componentdamage.


a b c

d



TABLE D PROCEDURES

1 Remove the 2 engine pivot plate retaining boltsfrom under the engine pivot plate. Swing theengine pivot plate away from the machine toaccess the PCV hoses.


2 Disconnect the hose from the PCV valve, thendisconnect the hose from the engine.

a carburetor to valve cover hoseb PCV valvec PCV valve to carburetor hose

3 Disconnect the hose from the carburetor, thendisconnect the hose from the valve cover.

4 Clean the hoses with a mild cleaning solvent.

ba a

5 Dry both hoses and inspect them for cracks anddamage. Replace the hoses if they aredamaged.

D-7Check the Fuel Injection Pumpand Injectors - Deutz DieselModelsComplete information to perform this procedure isavailable in the Deutz FL 1011F Workshop Manual(Deutz number: 0297 7195).Genie part number 52229.

D-8Check the Toothed Belt- Deutz Diesel ModelsComplete information to perform this procedure isavailable in the Deutz FL 1011 Operation Manual(Deutz number: 0297 4706 EN).Genie part number 29790.

D-9Replace the Timing Belt- Gasoline/LPG ModelsComplete information to perform this procedure isavailable in the Ford LRG-423 2.3 Liter IndustrialEngine Service Manual (Ford number: PPD-194-287). Genie part number 33907.

c

b

a



D-10Grease the Steer AxleWheel Bearings - 2WD ModelsMaintaining the steer axle wheel bearings isessential for safe machine operation and servicelife. Operating the machine with loose or wornwheel bearings may cause an unsafe operatingcondition and continued use may result incomponent damage. Extremely wet or dirtyconditions or regular steam cleaning and pressurewashing of the machine may require that thisprocedure be performed more often.

1 Loosen the wheel lug nuts. Do not removethem.

2 Block the non-steering wheels, then center alifting jack under the steer axle.

3 Raise the machine 6 inches (15 cm) and placeblocks under the drive chassis for support.

4 Remove the lug nuts, then remove the tire andwheel assembly.

5 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: There should not be any side to side orup and down movement.

Skip to step 10 if there is no movement.

6 Remove the dust cap from the hub, thenremove the cotter pin from the castle nut.

7 Tighten the castle nut to 35 foot-pounds(47 Nm) to seat the bearings.

8 Loosen the castle nut, then re-tighten to8 foot-pounds (11 Nm).

9 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: If there is side to side or up and downmovement, proceed to step 10 to replace thewheel bearings with new ones.

When replacing a wheel bearing,both the inner and outer bearings,including the pressed-in races,must be replaced.

Result: If there is no side to side or up anddown movement, grease the wheel bearings.

10 Remove the castle nut.

11 Pull the hub off of the spindle. The washer andouter bearing should fall loose from the hub.

12 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.

13 Pack both bearings with clean, fresh grease.

14 Place the large inner bearing into the rear of thehub.

15 Install a new bearing grease seal into the hubby pressing it evenly into the hub until it is flush.

Always replace the bearing greaseseal when removing the hub.

16 Slide the hub onto the yoke spindle.

Component damage. Do notapply excessive force or damageto the lip of the seal may occur.

17 Place the outer bearing into the hub.

18 Install the washer and slotted nut.

19 Tighten the slotted nut to 35 foot-pounds(47 Nm) to seat the bearings.

20 Loosen the slotted nut, then re-tighten to8 foot-pounds (11 Nm).

21 Install a new cotter pin. Bend the cotter pinto lock it in.

22 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts to420 foot-pounds (569.5 Nm).

TABLE D PROCEDURES


Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Before Troubleshooting:Read, understand and obey the safety rulesand operating instructions printed in theGenie S-60 & Genie S-65 Operator’s Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate flow chart thoroughly.Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.

Electrocution hazard. Contactwith electrically charged circuitsmay result in death or seriousinjury. Remove all rings, watchesand other jewelry.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

Perform all troubleshooting on afirm level surface.

Two persons will be required tosafely perform sometroubleshooting procedures.

Troubleshooting Flow Charts

Observe and Obey:Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.


Repair any machine damage or malfunctionbefore operating the machine.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

· Machine parked on a flat level surface


· Turntable rotated with the boom between the non-steering wheels

· Turntable secured with the turntable rotation lock pin

· Key switch in the OFF position with the key removed

· Wheels chocked


Service Manual - Second EditionSection 5 - Troubleshooting Flow Charts

General Repair Process

TROUBLESHOOTING FLOW CHARTS

About This SectionWhen a malfunction is discovered, the flow chartsin this section will help a service professionalpinpoint the cause of the problem. To use thissection, basic hand tools and certain pieces of testequipment are required—voltmeter, ohmmeter,pressure gauges.

The location of terminals mentioned in this sectioncan be found on the appropriate electrical orhydraulic schematics provided in Section 6,Schematics.

Since various degrees of a particular functionloss may occur, selecting the appropriate flowchart may be troublesome. When a function will notoperate with the same speed or power as amachine in good working condition, refer to theflow chart which most closely describes theproblem.

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test



Engine Will NotCrank OverBe sure the key switchis in the appropriateposition.

Be sure that bothEmergency Stopbuttons are pulled out tothe ON position.

Be sure the circuitbreakers are nottripped.

Be sure the battery isfully charged.

Chart 1

Check battery voltage.Check battery conditionOR check alternatorOR check battery cablesOR replace the battery.

less than12V

12V or more

0VTrace circuit backthrough the key switch,emergency stop buttonand CB2, repair open.

12V

Hold the start toggleswitch to either side andcheck the voltage ateither side terminal onstart switch.

0VRepair open in jumperwire from one side of theswitch to the other ORreplace start toggleswitch TS11.

12V

Hold the start switch toeither side and checkvoltage at terminalTB33.

0V Repair blk wire circuitfrom start switch TS11to TB33.

12V

Hold the start switch toeither side and checkvoltage at terminal #3 onignition/start module.

0VRepair blk wire circuitfrom TB33 to terminal#3 on ignition/startmodule.

Continued on the nextpage.

12V

Hold the start switch toeither side and checkvoltage at terminal #6 onthe ignition/start module.

0VRepair open in redpower supply wire circuitfrom CB1 to CR1 to CR2then to terminal #6 toon ignition/start module.

12V

With the keyswitchturned to groundcontrols and bothEmergency Stop buttonsare pulled out to the ONposition, check thevoltage at the centerterminal on the starttoggle switch TS11.



CHART 1

Continued from theprevious page.

Hold the start switch toeither side and checkvoltage at the black wireon the starter solenoid.

0V Repair open in blk wirecircuit from CR1 tostarter solenoid.

12V

Repair or replace starteror starter solenoid.

Check voltage atterminal #30 on CR1.

0V Repair open in red wirecircuit from battery toCB1 to CR1 terminal#30.

12V

Hold the start switch toeither side and checkvoltage at terminal #87on CR1.

0V

Replace CR1 relay.12V


0VRepair open in blk wirefrom terminal #1 onignition/start module toCR1.

12V

Check brown groundwire to terminal #85 onCR1.

good

bad Repair open in brownground wire circuit toCR1.

12V

Hold the start switch toeither side and checkvoltage at terminal #1 onignition/start module.

0V Check ground wire toterminal #5 on startlockout module.

bad Repair open in groundwire.

good

Consult Genie IndustriesService Department.

Check voltage at startercable.

Repair open in batterycable to starter.

0V

12V



Chart 2

Engine CranksOver But WillNot Start -Gasoline/LPGModelsBe sure to check theengine oil level and fillas needed.

Be sure to check fuellevels and enginecoolant level.

Be sure the gasolineshut-off valve is in theON or OPEN position.

Be sure that automaticchoke is not stickingclosed.

Perform following testsin gasoline mode only.

Be sure that the watertemperature gaugedoes not show anoverheated condition.

With the keyswitchturned to groundcontrols and bothEmergency Stop buttonspulled out to the onposition, hold startswitch to either side andcheck battery voltagewhile engine is cranking.

lessthan11V

Check battery conditionOR check alternator ORcheck for short circuitsOR check battery cablesOR replace the battery.

more than 11V

Check if engine coolanttemperature sendingunit signal post hascontinuity to ground.

continuity Check if radiator and/orengine block feelsexcessively hot.

hot Check engine coolantlevel OR check radiatorfins for clogging ORcheck engine fan beltsOR see Ford servicemanual fortroubleshooting anoverheating engine.not hot

Remove wht wire fromtemperature sendingunit, check continuity toground on temperaturesending unit.

continuity Replace temperatureswitch sender.

no continuity

Remove wht wire fromTB24 and checkcontinuity to ground.

continuity Repair short in wht wirecircuit from TB24 totemperature sender.

no continuity

Repair short in wht wirecircuit from terminal #10on ignition/start moduleto TB24 OR consultGenie Industries ServiceDepartment.

no continuity

Remove #1 spark plugand ground spark plugbody. Crank engine andobserve spark.

goodspark Go to Chart 2A.

weak or no spark




CHART 2


Hold the start switch toeither side and checkvoltage at wht #21 onterminal #87 of CR2.

12V Repair open in wht #21wire from CR2 to ignitioncoil.

0V

Check voltage at redwire on terminal #30 ofCR2.

0V Repair open in red wirecircuit from battery toTB20 to CB1 to CR1 toCR2.

12V

Hold the start switch toeither side and checkvoltage at terminal #86of CR2.

0VRepair open in blk wirefrom terminal #86 onCR2 to terminal #9 onignition/start module.

12V

Hold start switch andcheck voltage atterminal #9 on ignition/start module.

12V


0V

Check voltage atterminal #6 on ignition/start module.

12V

0V Repair open in powersupply wires from CB1to CR1 to CR2 toterminal #6 on ignition/start module.

Check continuity fromground wire at terminal#5 on start lockoutmodule to ground.

continuity

nocontinuity Repair open in brown

ground wire to startlockout module.

Disable starter byremoving blk wire at thestarter solenoid, hold thestart switch to eitherside and check voltageat the white wire on theignition coil plug.

See Ford servicemanual fortroubleshooting ignitionsystem.

less than 12V

12V




CHART 2

Check continuity fromground to terminal #85on CR2.


ground wire circuit toCR2.

continuity

If weak spark still exists,consult Ford engineservice manual fortroubleshooting enginewith weak spark ORconsult Genie IndustriesService.




Chart 2A

Engine CranksOver But WillNot Start -Gasoline/LPGModelsorEngine RunsWhile CrankingThen DiesPerform these tests ingasoline mode only.

With keyswitch on andboth Emergency Stopbuttons pulled out to theON position, checkvoltage at red/wht #23wire on vacuum switch.

0V Repair open in red/wht#23 wire circuit fromTB23 to vacuum switch.

12V

Remove the blk wirewith diode from terminal#86 on CR3, hold thestart switch to eitherside and crank theengine over for 15seconds and checkvoltage at red/blk wireon vacuum switch(reconnect blk wire aftertest).

0VTurn machine off. SeeRepair section for howthe test the vacuumswitch.

bad Replace vacuum switch.

ok

Check vacuum line forrestrictions or damage.

bad Replace vacuum line.

ok

See Ford servicemanual to troubleshootlow manifold vacuum.

12V

With keyswitch on andboth Emergency Stopbuttons pulled out to theON position, disconnectwires from vacuumswitch and connect thewires together. Checkthe voltage at terminal#86 on CR6.

0V Repair open in red/blkwire circuit from vacuumswitch to CR6.

12V


Check automatic chokefor proper adjustment orinternal damage.

bad Adjust or replaceautomatic choke ORconsult Genie IndustriesService Department.

Hold the start switch toeither side and checkthe voltage at the whitewire on the choke whilecranking the engine.

12V

0V

Repair open in white#21 wire circuit from theignition coil plug to theautomatic choke.

good



CHART 2A


With keyswitch on andboth Emergency Stopbuttons pulled out to theON position, crank theengine and checkvoltage at terminal #87on CR6.

0V Check brown groundwire on terminal #85 ofCR6.

good

no good Repair open in brownground wire circuit toCR6.

Replace CR6.

With keyswitch on andboth Emergency Stopbuttons pulled out to theON position, crankengine and checkvoltage at centerterminal on fuel selectswitch TS3 in platformcontrol box.

0VRepair open in redpower wire circuit withdiode to fuel selecttoggle switch TS3.

12V

With keyswitch on andboth Emergency Stopbuttons pulled out to theON position, crankengine and checkvoltage on gasoline side(blu/wht wire) of fuelselect switch.

0V Replace toggle switch.

12V

With keyswitch on andboth Emergency Stopbuttons pulled out to theon position, crankengine and checkvoltage at terminalTB38.

0VRepair open in blu/whtwire circuit from toggleTS3 toggle switch toTP38 to TB38.

12V

With keyswitch on andboth Emergency Stopbuttons pulled out to theON position, crankengine and checkvoltage at blu/wht wireat terminal #30 on CR6.

Repair open in blu/whtwire circuit from TB38 toterminal #30 on CR6.

12V

0V


12V



CHART 2A

Hold the start switch toeither side and checkvoltage at blu/wht wireon anti-diesel valve (onengine carburetor).

0V Repair open in blu/wht#38 wire circuit CR6 toanti-diesel valve.

12V

Hold the start switch toeither side and checkvoltage at blu/wht #38wire on gasolinesolenoid (at gasolinetank).

0VRepair open in blu/wht#38 wire circuit from fuelpump to gasolinesolenoid.

Reconnect the two wiresto vacuum switch andcheck for fuel lineblockage OR replaceanti-diesel valve OR seeFord service manual fortroubleshooting fuelpump and/or carburetorOR Consult GenieIndustries ServiceDepartment.


12V

Hold the start switch toeither side, does enginestart?

no

yes

Go to chart 2B.

Hold the start switch toeither side and checkvoltage at blu/wht #38wire on fuel pump.

0V

Repair open in blu/wht#38 wire circuit fromanti-diesel valve to fuelpump.

12V

Check continuity frombrown ground wire onfuel pump to ground.

continuity


ground wire circuit tofuel pump.



Chart 2B

Engine RunsWhile CrankingThen Dies

Hold start switch toeither side and checkvoltage at terminal #2 onstart lockout module.

0V Crank engine and checkvoltage at org/blk #41wire on alternator.

0V Check alternator wiringOR repair or replacealternator OR contactGenie Industries ServiceDepartment.6 to 7V

Repair open in org/blk#41 wire circuit fromalternator to TB41 toterminal #2 on startlockout module.

6 to 7V

While cranking enginefor 15 seconds, checkcontinuity to ground onterminal #10 startlockout module. Iscontinuity maintained?

yes

Disconnect wht #24 wirefrom oil pressure senderand check continuity toground on signal post ofsender, while crankingthe engine. Is continuitymaintained?

yes

Check oil level ORreplace oil pressuresending unit OR refer toFord service manual fortroubleshooting low oilpressure.

no

Repair short to groundin wht #24 wire fromsending units to TB24 toterminal #10 on ignition/start module.

no


12V Disconnect red wirefrom terminal #4 onignition/start module andcheck voltage atterminal #4.

12VReplace ignition/startmodule OR consultGenie Industries ServiceDepartment.

0V0V

Replace start lockoutmodule OR consultGenie Industries ServiceDepartment.

Disconnect wht #24 wirefrom water temperaturesender and checkcontinuity to ground onsignal post of sender,while cranking theengine. Is continuitymaintained?

yes

Check coolant level ORreplace watertemperature sendingunit OR refer to Fordservice manual fortroubleshooting aoverheated engine.

no

Test auxiliary powertoggle switches TS1 andTS10. See RepairSection.



Engine CranksOver But WillNot Start -Deutz DieselModelsBe sure to check theengine oil level and fillas needed.

Be sure to checkfuel level.

Be sure the diesel fuelshut-off valve is inthe on position.

Be sure that the batteryis fully charged.

Chart 3

Hold the start switch toeither side and checkbattery voltage whileengine is cranking.

lessthan11V

Check battery conditionOR check alternator ORcheck for short circuitsOR check battery cablesOR replace the battery.

11V or more

Check if engine over-temperature sendingsignal post hascontinuity to ground.

continuity Check if oil coolerand/or engine blockfeels excessively hot.

hot Check engine oil levelOR oil cooler fins forclogging OR checkengine fan belts OR seeDeutz service manualfor troubleshooting anoverheating engine.not hot

Remove wht wire fromtemperature sendingunit, check continuity toground (on sendingunit).

continuity Replace temperatureswitch sending unit.

no continuity

Remove wht wire fromTB24.

continuity Repair short in wht wirecircuit from TB24 totemperature sender.

no continuity

Repair short in wht wirecircuit from ignition/startmodule to TB24 ORconsult Genie IndustriesService Department.

no continuity

Disable the starter byremoving the blk wire atthe starter solenoid.Hold the start switch toeither side and checkthe voltage at positiveterminal on fuelsolenoid.

12V

See Deutz servicemanual fortroubleshooting fuelsystem.

0V


Turn the machine offand isolate the fuelsolenoid. Check theresistance of thesolenoid.

3.50 ohms

0 orinfiniteohms

Replace the fuelsolenoid.



CHART 3


Hold start switch andcheck voltage at wht#21 wire on terminal #87of CR2.

12VRepair open in wht #21wire from CR2 to fuelsolenoid.

0V

Check voltage at redwire on terminal #30 ofCR2.

0V Repair open in red wirecircuit from battery toCB1 to CR1 to CR2.

12V

Hold the start switch toeither side and checkvoltage at terminal #86of CR2.

0V Repair open in blk wirefrom terminal #86 onCR2 to terminal #9 onthe ignition/start module.

12V

Check continuity fromground to terminal #85on CR2.


ground wire circuit toCR2.

good

Hold the start switch toeither side and checkvoltage at terminal #9 onthe ignition/start module.

12V

Replace the ignition/start module OR consultGenie Industries ServiceDepartment.

0V

Check voltage atterminal #6 and 7 onignition/start module.

12V

0V Repair open in powersupply wires to terminal#6 and 7 on ignition/startmodule.

Check continuity fromground to brown wire atterminal #5 on ignition/start module.

continuity

nocontinuity

Repair open in brownground wire circuit toterminal #5 on ignition/start module.




CHART 3

Crank engine and checkvoltage at terminal #2 onstart lockout module.

0V Crank engine and checkvoltage at org/blk #41wire on alternator.

0V Repair or replacealternator OR contactGenie Industries ServiceDepartment.

6 to 7V

Repair open in org/blk#41 wire circuit fromalternator to TB41 toterminal #2 on startlockout module.

6 to 7V

While cranking enginefor 15 seconds, checkcontinuity to ground onterminal #10 on startlockout module. Iscontinuity maintained?

yes

Disconnect wht #24 wirefrom oil pressure senderand check continuity toground on signal post ofsender, while crankingthe engine. Is continuitymaintained?

yes

Check oil level ORreplace oil pressuresending unit OR refer toDeutz service manualfor troubleshooting lowoil pressure.

no

no


12V Disconnect red wirefrom terminal #4 onignition/start module andcheck voltage atterminal #4.

12VReplace ignition/startmodule OR consultGenie Industries ServiceDepartment.

0V

Test auxiliary powertoggle switches TS1 andTS10. See RepairSection.

0V

Replace ignition/startmodule OR consultGenie Industries ServiceDepartment.


Repair short to groundin wht #24 wire fromsending units to TB24 toterminal #10 on ignition/start module.

Disconnect wht #24 wirefrom engine temperaturesender and checkcontinuity to ground onsignal post of sender,while cranking theengine. Is continuitymaintained?

yes

Check oil level ORreplace enginetemperature sendingunit OR refer to Deutzservice manual fortroubleshooting aoverheated engine.

no



Engine Will NotStart On LPG,But Will StartOn Gasoline -Gasoline/LPGModelsBe sure fuel selectswitch is switchedto LPG.

Be sure to checkLPG fuel level.

Chart 4

Disconnect LPG supplyline from LPG tank andbleed pressure fromline.

With keyswitch on andboth Emergency Stopbuttons pulled out to theON position, checkvoltage at LPG side(blu/red wire) of fuelselect switch.

0V Replace fuel selectswitch.

12V

With keyswitch on andboth Emergency Stopbuttons pulled out to theON position, checkvoltage at TB39.

0VRepair open in blu/redwire circuit from fuelselect switch to TP39 toTB39.

12V

With keyswitch on andboth Emergency Stopbuttons pulled out to theON position, checkvoltage at terminal #30on CR7.

0V Repair open in blu/redwire circuit from TB39 toterminal #30 on CR7.

12V

Crank engine for 15seconds and checkvoltage at terminal #86on CR7.

0V Repair open in red/blkwire circuit from vacuumswitch to CR6 to CR7.

12V

Check continuity fromground to brown wire onterminal #85 on CR7.

bad Repair open in brownground wire circuit toterminal #85 on CR7.

good




CHART 4



0V Replace CR7 relay.

Hold the start switch toeither side and checkvoltage at blu/red wireon LPG solenoid.

0VRepair open in blu/redwire circuit from CR7terminal #87 to LPGsolenoid.

12V

Check resistance ofLPG solenoid.

0 orinfiniteohms

Replace LPG solenoid.

9 to 10 ohms

Reconnect LPG tankand starter then seeMaintenance section forLPG adjustments ORconsult Genie IndustriesService Department.

12V



Chart 5

Engine WillNot Start OnGasoline,But Will StartOn LPG -Gasoline/LPGModelsBe sure fuel selectswitch is switchedto gasoline.

Be sure to checkgasoline fuel level.

Be sure that enginechoke is operatingproperly.

With keyswitch on andboth Emergency Stopswitches pulled out tothe ON position, checkvoltage at gasoline side(blu/wht wire) of fuelselect switch.

0V Replace fuel selectswitch.

12V

With keyswitch on andboth Emergency Stopbuttons pulled out to theON position, checkvoltage at TB38.

0VRepair open in blu/whtwire circuit from fuelselect switch toTP38 to TB38.

12V

Hold the start switch toeither side and checkvoltage at blu/wht wireon anti-diesel valve (oncarburetor).

0VRepair open in blu/whtwire circuit from CR6terminal #87to anti-diesel valve ORreplace CR6.

12V

With keyswitch on andboth Emergency Stopbuttons pulled out to theON position, checkvoltage at terminal #30on CR6.

0V Repair open in blu/whtwire circuit from TB38 toterminal #30 on CR6.

12V

Crank engine for 15seconds and checkvoltage at terminal #86on CR6 while cranking.

0V Repair open in red/blkwire circuit from vacuumswitch to CR6.

12V

Check continuity fromground to brown wire atterminal #85 on CR6.


ground wire circuit toterminal #85 on CR6.

continuity




CHART 5

Hold the start switch toeither side and checkvoltage at blu/wht wireon the fuel pump.

0V

12V

Check resistance ofgasoline solenoid.

0 orinfiniteohms Replace gasoline

solenoid.

18 to 19 ohms

Check resistance ofanti-diesel valve.

0 orinfiniteohms Replace anti-diesel

valve.

24 to 25 ohms

Reconnect starter andsee Ford service manualfor carburetortroubleshooting ORconsult Genie IndustriesService Department.


Install a pressure gaugeto the fuel pump. Holdstart switch to eitherside and observe thepressure on the gauge.

less than7 psi Replace fuel pump OR

check anti-diesel andfuel valve for defects

more than 7 psi

Hold the start switch toeither side and checkvoltage at blu/wht wireon gasoline solenoid (atfuel tank).

0V

12V

Check continuity fromground to brown wire atfuel pump.


ground wire circuit to thefuel pump.

continuity

Repair open in blu/whtwire from anti-dieselsolenoid to fuel pumpOR replace fuel pump.

Check continuity fromground to brown wire atgasoline solenoid.


ground wire circuit to thegasoline solenoid.

continuity

Repair open in blu/whtwire from fuel pump togasoline solenoid ORreplace gasolinesolenoid.



Chart 6

EngineHigh IdleInoperative -Gasoline/LPGModelsIf high idle operateson LPG but not ongasoline, see Fordservice manual forcarburetortroubleshooting.

If high idle operateson gasoline but noton LPG, see Repairsection for LPGregulator adjustments.

Be sure throttlelinkage from governorto carburetor is notbinding.

Be sure high idle canbe achieved by graspingthe governor actuatorarm and momentarilypulling to throttle thecarburetor.

Start engine and movethe rpm select to highidle (rabbit symbol) forfollowing checks. Checkvoltage at blk/red wireon rpm select switchTS4 and TS13.

0V Check voltage at centerterminal on rpm selectswitch TS4 and TS13.

0V Repair open in powersupply circuit to centerterminal of switch.

12V

Replace rpm selecttoggle switch.

12V

Check voltage at TB35. 0V Repair open in blk/redwire circuit from toggleswitch to TP35 to TB35.

12V

Check voltage atterminal #85 (blk/red) onCR4.

0V Repair open in blk/redwire circuit fromTB35 to CR4.

12V


Check continuity fromground to the brownwire on terminal #86 ofCR4.



continuity


0V Repair open in white#21 power wire fromterminal 87 on CR2 toCR3 to CR4.

12V

Check voltage atterminal 87A on CR4.


0V

Check voltage atterminal 7 on electronicgovernor.

12V Repair short in blk/red#R4 wire to terminal #7on precision governor.

0V



CHART 6


Repair open in red/whtwire circuit from terminal#87 on CR3 to terminal#1 on electronicgovernor.

Check voltage atterminal 1 (red/wht wire)on electronic governor.

0V

12V

Check voltage atterminal 1 (red/wht wire)on governor actuator.

0V Repair open in red/whtwire circuit fromelectronic governorterminal #5 to governoractuator terminal #1.

12V

Check continuity fromterminal #6 on precisiongovernor to blu/blkterminal #2 on governoractuator.

nocontinuity

Repair open in blu/blkwire circuit fromgovernor actuator toelectronic governor.

full continuity


0V Repair open in rd/blk#R6 wire circuit fromvacuumn switch to CR6to CR7 to terminal #86on CR3.

12V

Check continuity fromground to brown wire onterminal #85 of CR3.

nocontinuity Repair open in ground

wire to terminal #85 onCR3.

continuity

Check voltage toterminal #87 on CR3.

0V

Replace CR3 relay.

12V


Repair open in wht wirecircuit from CR2terminal #87 to CR3#30.

12V

0V




CHART 6


Turn machine off,remove both wiresfrom governor actuatorand check resistanceacross governoractuator terminals.

0 orinfiniteohms Replace governor

actuator.

2 to 3 ohms

Reconnect governorwires and restart engineand check voltage atelectronic governorterminal 3 and 4 (brownwires).

0VRepair open in brownwire circuit from ignitioncoil plug to electronicgovernor.

12V

See Maintenancesection for governoradjustments OR replaceelectronic governor.

Check voltage on red/wht wire on governoractuator.

0V

12V

Repair open in red/whtwire from governorcontroller to governoractuator.



Engine Low IdleInoperative -Gasoline/LPGModelsIf low idle operateson LPG but not ongasoline, see Fordservice manual forcarburetortroubleshooting.

If low idle operateson gasoline but noton LPG, see Repairsection for LPGregulator adjustments.

Be sure throttlelinkage from governorto carburetor is notbinding, see Repairsection.

Chart 7

Start engine and switchrpm select to low idle(turtle symbol). Checkvoltage at terminal #86(blk/rd wire) on CR4.

12VIsolate the ground andplatform rpm toggleswitches TS4 and TS13,check individually andreplace defective switch.

0V

Check voltage atterminal #7 onelectronic governor.

0V Repair open in blk/redwire circuit from CR4terminal #87A toelectronic governorterminal #7.

12V

Check voltage atelectronic governorterminal 3 and 4 (brownwires).

0VRepair open in brownwire circuit from ignitionmodule to electronicgovernor.

12V

Turn machine off,remove blu/blk wire fromterminal #6 on electronicgovernor and restartengine.

engine goes to high idleRecheck throttle linkage(see Repair section) ORcheck and/or replacegovernor actuator ORsee Ford service manualfor carburetortroubleshooting.engine goes to low idle

Recheck electronicgovernor adjustmentsOR replace electronicgovernor.


0V Repair open in wht wirecircuit from terminal #87on CR2 to CR4 terminal#30.

12V

Check voltage atterminal #87A on CR4.


12V



Chart 8

EngineHigh IdleInoperative -Deutz DieselModelsBe sure mechanicallinkage is not bindingor defective.

Be sure 2-speedsolenoid groundingwires are free ofcorrosion and have fullcontinuity to ground.

Start engine, switch rpmselect switch to high idle(rabbit symbol) andcheck if 2-speedsolenoid pulls in.

solenoidpulls in

Check high idleadjustment (seeMaintenance section) orsee Deutz workshopmanual to troubleshootfuel injection system.

solenoid doesnot pull in

Check voltage at blk/redwire on rpm selectswitch TS4 and TS13.

0V Check voltage on redwire at center terminal ofrpm select switch.

0V Repair open in circuitsupplying 12V to centerterminal of switch.

12V

Replace toggle switch12V

Check voltage at TB35. 0V Repair open in blk/redwire circuit from toggleswitch to TP35 to TB35.

12V


0V Repair open in blk/redwire circuit from TB35 toterminal #30 on CR3.

12V


12V

0V Repair open in wht wirecircuit from terminal #87on CR2 to terminal #86on CR3.




continuity



12V




CHART 8

Check voltage at theblk/red wire on the2-speed solenoid.

0V Replace CR4 relayOR repair open inblk/red wire circuit fromterminal #87 on CR4 to2-speed solenoid.

12V

Check if 2-speedsolenoid moves in andout freely.

solenoidbinds Check linkage or

replace solenoid.

moves freely

Replace 2-speedsolenoid. Note:resistance acrosssolenoid terminalsshould be approximately0.3 ohms.



bad Repair open in brownground wire circuit toterminal #85 on CR4.

good


0V Repair open in wht wirecircuit from CR2 to CR3to CR4.

12V


0V Repair open in blk/redwire circuit fromCR3 to CR4.

12V



Chart 9

EngineLow IdleInoperative -Deutz DieselModelsCheck ifmechanical linkagefrom 2-speedsolenoid to fuelinjection system isbinding or defective.

At platform controls,start engine and switchrpm select switch TS4 tomaintained low idle(turtle symbol). Checkvoltage at blk/red wireon rpm select switch.

12VIsolate the platform andground rpm switches,check individually andreplace defective switch.

0V

Check voltage at thered wire on the2-speed solenoid.

12VReplace CR4 relay.

0V

Check if 2-speedsolenoid moves in andout freely.

solenoidbinds Check linkage or

replace solenoid.

moves freely

Check adjustment oflinkage and fuel injectionsystem low idle. SeeMaintenance section.

ok

See Deutz workshopmanual to troubleshootfuel injection system ORconsult Genie IndustriesService Department.



Chart 10

All FunctionsInoperative,Engine Startsand Runs

Check hydraulicfluid level.

low Fill with Dexronequivalent hydraulicfluid.

ok

Check pump suction lineshutoff valves. In theopen position, the valvehandles should beparallel with hose.

closed

Open valves and startthe engine. Check allmachine functions forcorrect operation.

open

Disconnect ignition coilconnector plug fromignition coils. On Deutzdiesel models, holdmanual fuel shutoff leverto the closed position(clockwise).Remove function pumpfrom main pump butleave all hosesconnected. Hold startswitch and crank engineover while observingspline drive at rear ofmain pump.

splineturns

Troubleshootinoperative boomfunctions andinoperative drivefunctions separately.

spline does not turn

Engine to pump flexplate coupling isdefective OR mainpump is defective.Consult Genie IndustriesService Department.

Do the pumps feelexcessively hot?

no

yes If engine has been runwith valves closed, itmay have damaged oneor both pumps. Pleasecontact the GenieIndustries ServiceDepartment.



Chart 11

All Lift andSteer FunctionsInoperative,Drive FunctionsOperationalBe sure the hydraulicsuction line shutoffvalve for the lift/steerpump is in the openposition.

Be sure all groundingwires for the hydraulicmanifold valves are freeof corrosion and havefull continuity to ground.

Install a 0 to 5000 PSI(345 bar) pressuregauge on the functionmanifold. Start engine,move the functionenable toggle switch toeither side and hold theboom retract functionand check the hydraulicpressure.

2600psi ormore

Troubleshoot eachfunction individually orconsult Genie IndustriesService Department.

less than2600 psi

Adjust the functionmanifold system reliefvalve (item W) all theway in (clockwise)counting the number ofturns. Move the functionenable switch to eitherside and hold the boomretract switch andrecheck the pressure.

2600psi ormore

Move the functionenable switch to eitherside and hold the boomretract switch andreadjust the reliefpressure to 2600 psi forS-60 or 2900 psi forS-65 .

less than2600 psi

Check the functionpump, see Repairsection.

ok Replace the relief valve(item W) OR manifoldhas an internal defect.Consult the GenieIndustries ServiceDepartment.

bad

Replace the functionpump.

Check steer functions.steeringoperates Repair or replace

differential sensing valve(item V) OR repair orreplace flow regulatorvalve (item AA) ORmanifold has an internaldefect, consult GenieIndustries ServiceDepartment.

steering inoperative



Chart 12

GroundControlsInoperative,PlatformControlsOperateNormallyBe sure all otherfunctions operatenormally, includingthe platformcontrols.

Does the engine startfrom the groundcontrols?

yes Start the engine fromthe ground controls.Move the functionenable toggle switch toeither side and checkthe voltage on thecenter terminal of theplatform level toggleswitch TS16.

0VRepair open in red wirecircuit from key switch tofunction enable toggleswitch to each functiontoggle switch.

12V

Troubleshoot eachfunction individually.

no

With both EmergencyStop buttons pulled outto the ON position, checkvoltage at red wire onthe input side of theground controls contactof the key switch KS1(the red wire checkedshould originate fromthe Emergency Stopbutton).

0VRepair open in red wirecircuit from emergencystop button to thekey switch.

12V

With the keyswitchturned to groundcontrols and bothEmergency Stop buttonsare pulled out to the ONposition, check voltageat red wire at the outputside of the groundcontrols contact on thekey switch.

0V Check if key switchinternal cam is activatingground contact.

yes Replace key switchcontact for groundcontrols.

no

Replace key switchKS1.

12V

Repair open in red wirecircuit from key switch tofunction enable toggleswitch to each functiontoggle switch.



Chart 13

PlatformControlsInoperative,GroundControlsOperateNormallyBe sure allcables from chassisthrough the cabletrack are in goodcondition with nokinks or abrasions.

Does engine start fromthe platform controls?

yes Start engine from theplatform controls, thenpress down the footswitch and checkvoltage at TP24.

0VTest or replace footswitch (see RepairSection) OR repair openin wht wire circuit fromfoot switch to TP24.

12V

Repair open in wht wirecircuit from TP24 tofunction toggle switchesand function controllers.

no

Check voltage at TB22. 0V Repair open in red wirecircuit from key switch toTB22 OR Replace theplatform controls contactat the key switch.12V

Check voltage at TP22. 0V Repair open in blk-2wire circuit from TB22TP22.

12V

Check voltage at blkwire on input side ofplatform EmergencyStop button contact P2.

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the onposition, check thevoltage on the outputside of the platformEmergency Stop buttoncontact.

12V

Check voltage at TP23. 0V Repair open in blk wirewith diode fromEmergency Stop buttonto TP23.12V

Repair open in blk wirecircuit from platformEmergency Stop buttonto TP26 to foot switchOR replace foot switchOR consult GenieIndustries ServiceDepartment.

Replace contact onEmergency Stop buttonP2.

0V

12V

Repair open in blk wirefrom TP22 toEmergency Stop buttonP2.

Check if EmergencyStop switch the contact.

no

Replace the platformEmergency Stop button.

yes



Chart 14

Boom UpFunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch inground position andboth Emergency Stopbuttons pulled out to theON position, move thefunction enable switch toeither side and hold theboom up toggle switch(TS17) on ground panelin up direction andcheck voltage on red/wht wire on boom up/down proportional valvecoil (item O).

0V

20V or more

Move the functionenable switch to eitherside and hold the boomup toggle switch (TS17)on ground panel in theup direction and checkvoltage at TB3.

8 to 9V

Repair open in red/whtwire circuit from TB3 toboom up/downproportional valve coil(item O) OR repair openin brown ground wirecircuit to valve coil.

0V

With the keyswitch inplatform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and boomfunction controller (BP1)on platform controlpanel in up direction andcheck voltage at TP3.


8 to 9V Repair open in red/whtwire from TP3 to TB3.

0V

Activate footswitch andcheck voltage at "+"terminal on BP1.

12V or more

0V Repair open in powersupply circuit from TP24to BP1 OR repair openin brown ground wirecircuit from ground toBP1.

Re-adjust controller (seeRepair Section) ORreplace controller BP1OR consult GenieIndustries ServiceDepartment.



CHART 14

With key switch inground position andboth Emergency Stopbuttons pulled out to theON position, move thefunction enable switch toeither side and hold theboom up toggle switch(TS17) on ground panelin up direction andcheck voltage on red #1wire on boom up/downdirectional valve coil(item B).

0V

20V or more

Move the functionenable switch to eitherside and hold the boomup toggle switch (TS17)on ground panel in updirection and checkvoltage at TB1.

12V ormore

Repair open in red #1wire circuit from TB1 toboom up functiondirectional valve coil(item B) OR repair openin brown ground wirecircuit to valve coil.

0V

With key switch inplatform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and boomfunction controller (BP1)on platform controlpanel in up direction andcheck voltage TB1.

12V ormore

0V

Activate footswitch andboom function controller(BP1) on platformcontrol panel in updirection and checkvoltage TP1.


Troubleshoot boom upfunction toggle switch(TS17) on groundcontrol panel OR repairopen in red #1 wirecircuit from TS17 to TB1OR consult GenieIndustries ServiceDepartment.


12V ormore Repair open in red wire

from TP1 to TB1.

0V


12V or more





CHART 14

Disconnect wires toboom up directionalvalve coil (item B) andtest the resistance of thevalve coil. See RepairSection.


0 orinfiniteohms

2.5 to 3.5 ohms

Replace boom updirectional valve coil(item B).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and start theengine. Move thefunction enable switch toeither side and hold theboom up toggle switchat the ground controls inthe up direction andcheck the pressure.

2500PSI ormore

less than 2500 PSI

Repair cylinder orcylinder counterbalancevalve OR boom functionmanifold could have aninternal defect. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingboom from moving ORrepair cylinder orcylinder counterbalancevalve OR consult GenieIndustries ServiceDepartment.

Move function enableswitch to either side andhold the boom up toggleswitch at the groundcontrols in the updirection. Manuallyoverride the directionalvalve by pushing in onthe end of the valvespool.

function inoperative

functionoperates Replace defective

directional valve.

Exchange flow regulatorvalve (item H) with a likevalve (item G). Checkboom up function.

functionoperates Replace defective flow

regulator valve.




Boom DownFunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 15

With key switch inground position andboth Emergency Stopbuttons pulled out to theON position, move thefunction enable switch toeither side and hold theboom down toggleswitch (TS17) on groundpanel in down directionand check voltage onred/wht wire on boomup/down proportionalvalve coil (item O).

0V

20V or more

Move the functionenable switch to eitherside and hold the boomdown toggle switch(TS17) on ground panelin the down directionand check voltage atTB3.

6 to 7V

Repair open in red/whtwire circuit from TB3 toboom up/downproportional valve coil(item O) OR repair openin brown ground wirecircuit to valve coil.

0V

With the keyswitch inthe platform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and boomfunction controller (BP1)on platform controlpanel in down directionand check voltage atTP3.


6 to 7V Repair open in red/whtwire from TP3 to TB3.

0V


12V or more





CHART 15

With key switch inground position andboth Emergency Stopbuttons pulled out to theON position, move thefunction enable switch toeither side and hold theboom down toggleswitch (TS17) on groundpanel in down directionand check voltage onred/blk #2 wire on boomfunction directional valvecoil (item B).

0V

20V or more

Move the functionenable switch to eitherside and hold the boomdown toggle switch(TS17) on ground panelin down direction andcheck voltage at TB2.

12V ormore

Repair open in red/blk#2 wire circuit from TB2to boom down functiondirectional valve coil(item B) OR repair openin brown ground wirecircuit to valve coil.

0V

With key switch inplatform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and boomfunction controller (BP1)on platform controlpanel in down directionand check voltage TB2.

12V ormore

0V

Activate footswitch andboom function controller(BP1) on platformcontrol panel in downdirection and checkvoltage TP2.


Troubleshoot boomdown function toggleswitch (TS17) on groundcontrol panel OR repairopen in red/blk #2 wirecircuit from TS17 to TB2OR consult GenieIndustries ServiceDepartment.


12V ormore Repair open in red/blk

wire from TP2 to TB2.

0V


12V or more





CHART 15

Disconnect wires toboom down directionalvalve coil (item B) andtest the resistance of thevalve coil. See RepairSection.


0 orinfiniteohms

2.5 to 3.5 ohms

Replace boom downdirectional valve coil(item B).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and start theengine. Move thefunction enable switch toeither side and hold theboom down toggleswitch at the groundcontrols in the downdirection and check thepressure.

2100PSI

less than 2100 PSI

Reset boom down reliefvalve (item F) pressure(see Repair Section) ORreplace boom downrelief valve OR repaircylinder or cylindercounterbalance valveOR function manifoldcould have an internaldefect. Consult GenieIndustries ServiceDepartment.

Check for mechanicalrestrictions keepingboom from moving ORrepair cylinder orcylinder counterbalancevalve OR consult GenieIndustries ServiceDepartment.

Move function enableswitch to either side andhold the boom downtoggle switch at theground controls in thedown direction.Manually override thedirectional valve bypushing in on the end ofthe valve spool.



directional valve.



Chart 16

Boom ExtendFunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch inground position andboth Emergency Stopbuttons pulled out to theON position, move thefunction enable switch toeither side and hold theboom extend toggleswitch (TS19) on groundpanel in extend directionand check voltage onblk/red wire on boomextend/retractproportional valve coil(item M).

0V

20V or more

Move the functionenable switch to eitherside and hold the boomextend toggle switch(TS19) on ground panelin the extend directionand check voltage atTB9.

9 to 10V

Repair open in blk/redwire circuit from TB9 toboom extend/retractproportional valve coil(item M) OR repair openin brown ground wirecircuit to valve coil.

0V

With keyswitch inplatform position andboth Emergency Stopbuttons pulled out to theon position, activatefootswitch and boomextend/retractproportional controller(BP2) on platformcontrol panel in extenddirection and checkvoltage at TP9.


9 to 10V Repair open in blk/redwire from TP9 to TB9.

0V


12V or more

0V Repair open in powersupply circuit from TP24to BP1 to BP2 OR repairopen in brown groundwire circuit from groundto BP2.




CHART 16

With key switch inground position andboth Emergency Stopbuttons pulled out to theON position, move thefunction enable switch toeither side and hold theboom extend/retracttoggle switch (TS19) onground panel in theextend direction andcheck voltage on blkwire on boom functiondirectional valve coil(item C).

0V

20V or more

Move the functionenable switch to eitherside and hold the boomextend toggle switch(TS19) on ground panelin the extend directionand check voltage atTB7.

12V ormore

Repair open in blk wirecircuit from TB7 to boomextend functiondirectional valve coil(item C) OR repair openin brown ground wirecircuit to valve coil.

0V

With key switch inplatform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and boomextend/retractproportional controller(BP2) on platformcontrol panel in extenddirection and checkvoltage TB7.

12V ormore

0V

Activate footswitch andboom extend/retractproportional controller(BP2) on platformcontrol panel in extenddirection and checkvoltage TP7.


Troubleshoot boomextend/retract functiontoggle switch (TS19) onground control panel ORrepair open in blk wirecircuit from TS19 to TB7OR consult GenieIndustries ServiceDepartment.


12V ormore Repair open in blk wire

from TP7 to TB7.

0V


12V or more





CHART 16

Disconnect wires toboom extend directionalvalve coil (item C) andtest the resistance of thevalve coil. See RepairSection.


0 orinfiniteohms

2.5 to 3.5 ohms

Replace boom extenddirectional valve coil(item C).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and start theengine. Move thefunction enable switch toeither side and hold theboom extend toggleswitch at the groundcontrols in the extenddirection and check thepressure.

2500PSI ormore

less than 2500 PSI

Repair cylinder orcylinder counterbalancevalve OR functionmanifold could have aninternal defect. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingboom from extendingOR repair cylinder orcylinder counterbalancevalves OR consultGenie Industries ServiceDepartment.

Move function enableswitch to either side andhold the boom extendtoggle switch at theground controls in theextend direction.Manually override thedirectional valve bypushing in on the end ofthe valve spool.



directional valve.

Exchange flow regulatorvalve (item H) with a likevalve (item G). Checkboom extend function.


regulator valve.




Chart 17

Boom RetractFunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch inground position andboth Emergency Stopbuttons pulled out to theON position, move thefunction enable switch toeither side and hold theboom retract toggleswitch (TS19) on groundpanel in the retractdirection and checkvoltage on blk/red wireon boom extend/retractproportional valve coil(item M).

0V

20V or more

Move the functionenable switch to eitherside and hold the boomretract toggle switch(TS19) on ground panelin the retract directionand check voltage atTB9.

9 to 9.5V

Repair open in blk/redwire circuit from TB9 toboom extend/retractproportional valve coil(item M) OR repair openin brown ground wirecircuit to valve coil.

0V

With keyswitch inplatform position andboth Emergency Stopbuttons pulled out to theon position, activatefootswitch and boomextend/retractproportional controller(BP2) on platformcontrol panel in theretract direction andcheck voltage at TP9.


Repair open in blk/redwire from TP9 to TB9.

0V


12V or more



9 to 9.5V



CHART 17

With key switch inground position andboth Emergency Stopswitches pulled out tothe ON position, movethe function enableswitch to either side andhold the boom extend/retract toggle switch(TS19) on ground panelin the retract directionand check voltage onblk/wht wire on boomfunction directional valvecoil (item C).

0V

20V or more

Move the functionenable switch to eitherside and hold the boomretract toggle switch(TS19) on ground panelin the retract directionand check voltage atTB8.

12V ormore

Repair open in blk/whtwire circuit from TB8 toboom retract functiondirectional valve coil(item C) OR repair openin brown ground wirecircuit to valve coil.

0V

With key switch inplatform position andboth Emergency Stopswitches pulled out tothe ON position, activatefootswitch and boomextend/retractproportional controller(BP2) on platformcontrol panel in theretract direction andcheck voltage TB8.

12V ormore

0V

Activate footswitch andboom extend/retractproportional controller(BP2) on platformcontrol panel in theretract direction andcheck voltage TP8.


Troubleshoot boomextend/retract functiontoggle switch (TS19) onground control panel ORrepair open in blk/whtwire circuit from TS19 toTB8 OR consult GenieIndustries ServiceDepartment.


12V ormore Repair open in blk/wht


0V


12V or more





CHART 17

Disconnect wires toboom retract directionalvalve coil (item C) andtest the resistance of thevalve coil. See RepairSection.


0 orinfiniteohms

2.5 to 3.5 ohms

Replace boom retractdirectional valve coil(item C).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and start theengine. Move thefunction enable switch toeither side and hold theboom retract toggleswitch at the groundcontrols in the retractdirection and check thepressure.

2500PSI ormore

less than 2500 PSI


Check for mechanicalrestrictions keepingboom from retractingOR repair cylinder orcylinder counterbalancevalves OR consultGenie Industries ServiceDepartment.

Move function enableswitch to either side andhold the boom retracttoggle switch at theground controls in theretract direction.Manually override thedirectional valve bypushing in on the end ofthe valve spool.



directional valve.

Exchange flow regulatorvalve (item G) with a likevalve (item H). Checkboom retract function.


regulator valve.




Chart 18

TurntableRotate LeftFunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch inground position andboth Emergency Stopbuttons pulled out to theON position, move thefunction enable switch toeither side and hold theturntable rotate toggleswitch (TS18) on groundpanel in the left directionand check voltage onwht/red wire on turntablerotate left/rightproportional valve coil(item R).

0V

20V or more

Move the functionenable switch to eitherside and hold theturntable rotate toggleswitch (TS18) on groundpanel in the left directionand check voltage atTB6.

4 to 6V

Repair open in wht/redwire circuit from TB6 toturntable rotate left/rightproportional valve coil(item R) OR repair openin brown ground wirecircuit to valve coil.

0V

With keyswitch inplatform position andboth Emergency Stopbuttons pulled out to theon position, activatefootswitch and turntablerotate left/rightproportional controller(BP1) on platformcontrol panel in the leftdirection and checkvoltage at TP6.


Repair open in wht/redwire from TP6 to TB6.

0V


12V or more



4 to 6V



CHART 18

With key switch inground position andboth Emergency Stopbuttons pulled out to theON position, move thefunction enable switch toeither side and hold theturntable rotate left/righttoggle switch (TS18) onground panel in the leftdirection and checkvoltage onwht/blk wire on boomfunction directional valvecoil (item A).

0V

20V or more

Move the functionenable switch to eitherside and hold theturntable rotate left/righttoggle switch (TS18) onground panel in the leftdirection and checkvoltage at TB5.

12V ormore

Repair open in wht/blkwire circuit from TB5 toturntable rotate leftfunction directional valvecoil (item A) OR repairopen in brown groundwire circuit to valve coil.

0V

With key switch inplatform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and turntablerotate left/rightproportional controller(BP1) on platformcontrol panel in the leftdirection and checkvoltage TB5.

12V ormore

0V

Activate footswitch andturntable rotate left/rightproportional controller(BP1) on platformcontrol panel in the leftdirection and checkvoltage TP5.


Troubleshoot turntablerotate left/right functiontoggle switch (TS18) onground control panel ORrepair open in wht/blkwire circuit from TS18 toTB5 OR consult GenieIndustries ServiceDepartment.


12V ormore Repair open in wht/blk


0V


12V or more





CHART 18

Disconnect wires toturntable rotate leftdirectional valve coil(item A) and test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

2.5 to 3.5 ohms

Replace turntable rotateleft directional valve coil(item A).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and start theengine. Move thefunction enable switch toeither side and hold theturntable rotate lefttoggle switch at theground controls in theleft direction and checkthe pressure.

Move function enableswitch to either side andhold the turntable rotateleft/right toggle switch atthe ground controls inthe left direction.Manually override thedirectional valve bypushing in on the end ofthe valve spool.



directional valve.

2600PSI ormore

less than 2600 PSI


Exchange flow regulatorvalve (item I) with a likevalve (item H). Checkturntable rotate leftfunction.


regulator valve.





CHART 18

Check for mechanicalrestrictions keepingturntable rotate leftfunction from operatingOR replace shuttle valve(item HH) OR consultGenie Industries ServiceDepartment.

Plumb a 0 to 5000 psi(0 to 345 bar) pressuregauge into the hosefrom the functionmanifold to the turntablerotation brake. Move thefunction enable switch toeither side and activatethe turntable rotate leftfunction.

lessthan250 psi

250 psi or more

Exchange turntablerotate left and rightcounterbalance valves(items II and JJ).Activate turntable rotateleft function.



counterbalance valve.

Function manifold couldhave an internal defect.Consult Genie IndustriesService Department.




Chart 19

TurntableRotate RightFunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch inground position andboth Emergency Stopbuttons pulled out to theON position, move thefunction enable switch toeither side and hold theturntable rotate toggleswitch (TS18) on groundpanel in the rightdirection and checkvoltage on wht/red wireon turntable rotate left/right proportional valvecoil (item R).

0V

20V or more

Move the functionenable switch to eitherside and hold theturntable rotate toggleswitch (TS18) on groundpanel in the rightdirection and checkvoltage at TB6.

4 to 6V

Repair open in wht/redwire circuit from TB6 toturntable rotate left/rightproportional valve coil(item R) OR repair openin brown ground wirecircuit to valve coil.

0V

With keyswitch inplatform position andboth Emergency Stopbuttons pulled out to theon position, activatefootswitch and turntablerotate left/rightproportional controller(BP1) on platformcontrol panel in the rightdirection and checkvoltage at TP6.


Repair open in wht/redwire from TP6 to TB6.

0V


12V or more



4 to 6V



CHART 19

With key switch inground position andboth Emergency Stopbuttons pulled out to theON position, move thefunction enable switch toeither side and hold theturntable rotate left/righttoggle switch (TS18) onground panel in the rightdirection and checkvoltage onwht wire on boomfunction directional valvecoil (item A).

0V

20V or more

Move the functionenable switch to eitherside and hold theturntable rotate left/righttoggle switch (TS18) onground panel in the rightdirection and checkvoltage at TB4.

12V ormore

Repair open in wht wirecircuit from TB4 toturntable rotate rightfunction directional valvecoil (item A) OR repairopen in brown groundwire circuit to valve coil.

0V

With key switch inplatform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and turntablerotate left/rightproportional controller(BP1) on platformcontrol panel in the rightdirection and checkvoltage TB4.

12V ormore

0V

Activate footswitch andturntable rotate left/rightproportional controller(BP1) on platformcontrol panel in the rightdirection and checkvoltage TP4.


Troubleshoot turntablerotate left/right functiontoggle switch (TS18) onground control panel ORrepair open in wht wirecircuit from TS18 to TB4OR consult GenieIndustries ServiceDepartment.


12V ormore Repair open in wht/blk


0V


12V or more





CHART 19

Disconnect wires toturntable rotate rightdirectional valve coil(item A) and test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

2.5 to 3.5 ohms

Replace turntable rotateright directional valvecoil (item A).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and start theengine. Move thefunction enable switch toeither side and hold theturntable rotate righttoggle switch at theground controls in theright direction and checkthe pressure.

Move function enableswitch to either side andhold the turntable rotateleft/right toggle switch atthe ground controls inthe right direction.Manually override thedirectional valve bypushing in on the end ofthe valve spool.



directional valve.

2600PSI ormore

less than 2600 PSI


Exchange flow regulatorvalve (item I) with a likevalve (item H). Checkturntable rotate rightfunction.


regulator valve.





CHART 19

Check for mechanicalrestrictions keepingturntable rotate rightfunction from operatingOR replace shuttle valve(item HH) OR consultGenie Industries ServiceDepartment.

Plumb a 0 to 5000 psi(0 to 345 bar) pressuregauge into the hosefrom the functionmanifold to the turntablerotation brake. Move thefunction enable switch toeither side and activatethe turntable rotate rightfunction.

lessthan250 psi

250 psi or more

Exchange turntablerotate right and leftcounterbalance valves(items JJ and II).Activate turntable rotateright function.




Function manifold couldhave an internal defect.Consult Genie IndustriesService Department.




Chart 20

All PlatformLevelingFunctionsInoperativeBe sure all otherfunctions operatenormally.

Remove both hydraulichoses from the manifold(ports PL1 & PL2). Plugthe hoses and cap themanifold fittings. Movethe function enableswitch to either side andactivate the boom upfunction and check tosee if platform levels.

no

Plumb a 0 to 5000 psi(0 to 345 bar) pressuregauge into mastercylinder rod-endhydraulic hose (hoseconnected to port PL2)using a tee fitting.Activate boom upfunction and check thepressure.

less than 2000 PSI

Install a 0 to 5000 psi(0 to 345 bar) pressuregauge into the barrel-end hydraulic hose fromthe master cylinder andraise the primary boomone inch at a time.Continually monitor thepressure gauge duringboom up. Do not allowthe pressure to exceed2500 PSI.

2000 PSI or more

Repair or replace theslave cylinder.

Replace thecounterbalance valveson function manifold(items A & B).

yes

2000PSI

Check for mechanicalrestrictions OR replacethe slave cylindercounterbalance valves.

less than2000 PSI Repair or replace the

master cylinder.



Chart 21

Platform LevelUp FunctionInoperativeBe sure all otherfunctions operatenormally.

With the keyswitchturned to ground controland both EmergencyStop buttons pulled outto the ON position, movethe function enableswitch to either side andactivate the platformlevel toggle switch TS16in the up direction andcheck the voltage at orgwire on platform level upfunction directional valve(item S).

0V

With the keyswitchturned to ground controland both EmergencyStop buttons pulled outto the on position, movethe function enableswitch to either side andactivate the platformlevel toggle switch TS16in the up direction andcheck the voltage atTB14.

0V

With the keyswitchturned to platformcontrol and bothEmergency Stop buttonspulled out to the onposition, activate thefootswitch and theplatform level toggleswitch TS7 in the updirection and check thevoltage at TB14.

Repair open in org wirefrom TB14 to platformlevel up directional valvecoil (item S) OR repairopen in brown groundwire circuit to valve coil.

12V ormore

0V

Troubleshoot platformlevel toggle switchesTS16 and TS7 onground and platformcontrol panels OR repairopen in red power wirecircuit to TS16 and TS7OR repair open in orgwire circuit from TS16and TS7 to TB14 ORconsult Genie IndustriesService Department.

12V or more

Troubleshoot platformlevel toggle switch TS16on ground control panelOR repair open in redpower wire circuit toTS16 OR repair open inorg wire circuit fromTS16 to TB14 ORconsult Genie IndustriesService Department.

12V or more




Disconnect the wiresfrom the platform levelup directional valve coil(item S) and test theresistance of the valvecoil.

0 orinfiniteohms Replace the platform

level up directional valvecoil (item S).

6 to 7 ohms


Exchange platform levelup and down directionalvalves (items S and U)and activate the platformlevel up function.


functionoperates Replace the defective

directional valve.

Exchange platform levelup and downcounterbalance valves(items EE and FF) andactivate the platformlevel up function.




Install a 0 to 3000(0 to 207 bar) pressuregauge at the quickdisconnect coupling onthe function manifoldand activate the platformlevel up function.

less than 2600 psi

2600 psior more

Check for mechanicalrestrictions keepingplatform level upfunction from operatingOR replace slavecylinder OR replaceslave cylindercounterbalance valvesOR consult GenieIndustries ServiceDepartment.

Test master cylinder(see Chart 16) ORrepair or replace slavecylinder or slavecylinder counterbalancevalves OR functionmanifold may have aninternal defect. ConsultGenie Industries ServiceDepartment.

CHART 21



Chart 22

Platform LevelDown FunctionInoperativeBe sure all otherfunctions operatenormally.

With the keyswitchturned to ground controland both EmergencyStop buttons pulled outto the ON position, movethe function enableswitch to either side andactivate the platformlevel toggle switch TS16in the down directionand check the voltage atorg/blk wire on platformlevel down functiondirectional valve(item U).

0V

With the keyswitchturned to ground controland both EmergencyStop buttons pulled outto the on position, movethe function enableswitch to either side andactivate the platformlevel toggle switch TS16in the down directionand check the voltage atTB15.

0V

With the keyswitchturned to platformcontrol and bothEmergency Stop buttonspulled out to the onposition, activate thefootswitch and theplatform level toggleswitch TS7 in the downdirection and check thevoltage at TB15.

Repair open in org/blkwire from TB15 toplatform level downdirectional valve coil(item U) OR repair openin brown ground wirecircuit to valve coil.

12V ormore

0V

Troubleshoot platformlevel toggle switchesTS16 and TS7 onground and platformcontrol panels OR repairopen in red power wirecircuit to TS16 and TS7OR repair open in org/blk wire circuit fromTS16 and TS7 to TB15OR consult GenieIndustries ServiceDepartment.

12V or more

Troubleshoot platformlevel toggle switch TS16on ground control panelOR repair open in redpower wire circuit toTS16 OR repair open inorg/blk wire circuit fromTS16 to TB15 ORconsult Genie IndustriesService Department.

12V or more




CHART 22

Disconnect the wiresfrom the platform leveldown directional valvecoil (item U) and test theresistance of the valvecoil.

0 orinfiniteohms Replace the platform

level down directionalvalve coil (item U).

6 to 7 ohms


Exchange platform leveldown and up directionalvalves (items U and S)and activate the platformlevel down function.



directional valve.

Exchange platform leveldown and upcounterbalance valves(items FF and EE) andactivate the platformlevel down function.




Install a 0 to 3000(0 to 207 bar) pressuregauge at the quickdisconnect coupling onthe function manifoldand activate the platformlevel down function.

less than 2600 psi

2600 psior more

Check for mechanicalrestrictions keepingplatform level downfunction from operatingOR replace slavecylinder OR replaceslave cylindercounterbalance valvesOR consult GenieIndustries ServiceDepartment.

Test master cylinder(see Chart 16) ORrepair or replace slavecylinder or slavecylinder counterbalancevalves OR functionmanifold may have aninternal defect. ConsultGenie Industries ServiceDepartment.



Chart 23

Platform RotateLeft FunctionInoperativeBe sure all otherfunctions operatenormally.

With the keyswitchturned to ground controland both EmergencyStop buttons pulled outto the ON position, movethe function enableswitch to either side andactivate the platformrotate toggle switchTS14 in the left directionand check voltage atgrn/wht wire at TP19 atthe platform controls.

0V

With keyswitch turned toplatform control andboth Emergency Stopbuttons pulled out to theon position, activatefootswitch and platformrotate toggle switch TS5in the left direction andcheck voltage at the grn/wht wire at the jib delaycapacitor.

12V

Repair open in grn/whtwire from TP19 to jibdelay capacitor.


Repair open in grn/whtwire from TS14 to TB19to TP19 OR test toggleswitch. See RepairSection.

0V

12V

With keyswitch turned toplatform control andboth Emergency Stopbuttons pulled out to theon position, activatefootswitch and platformrotate toggle switch TS5in the left direction andcheck voltage at TP19.

12V

0V

Test toggle switch. SeeRepair Section ORreplace platform rotatetoggle switch TS5.

Activate footswitch andplatform rotate toggleswitch TS5 in the leftdirection and checkvoltage at the grn/whtwire on TS5.

12V

0V

Repair open in grn/whtwire from TS5 to TP19.

Check voltage on centerterminal of TS5.

0V

12V

Repair open in redpower wire circuitthrough controllers andfunction toggle switchesto TS5.



CHART 23


With keyswitch turned toplatform control andboth Emergency Stopbuttons pulled out to theon position, activatefootswitch and platformrotate toggle switch TS5in the left direction andcheck voltage at the redwire at the jib delaycapacitor.

0V

12V

Replace the jib delaycapacitor OR repairopen in brown groundwire from capacitor toground.

Activate footswitch andplatform rotate toggleswitch TS5 in the leftdirection and checkvoltage on the red wireat terminal #86 onCR14.

Repair open in red wirefrom jib delay capacitorto CR14.

Activate footswitch andplatform rotate toggleswitch TS5 in the leftdirection and checkvoltage on the red andblack wires at terminal#87 on CR14.

12V

0VReplace relay CR14 ORrepair open in powersupply from P2 to CR14OR repair open in brownground wire to CR14.

0V

12V

Activate footswitch andplatform rotate toggleswitch TS5 in the leftdirection and checkvoltage on the red andblack wires at the jib/platform rotate selectvalves (item AM).

12V

0V

Test the resistance ofthe valve coils.

0 orinfiniteohms

5.5 to 6.5ohms

Replace defective valvecoil.

Repair open in cablecontaining red and blackwires from CR14 to jibboom/platform rotateselect valves.




CHART 23


Check continuity frombrown ground wires onvalve coils to ground.

nocontinuity

continuity

Repair open in brownground wire circuit tovalve coils.

Exchange jib boom/platform rotate selectvalves (item AM).Activate footswitch andplatform rotate leftfunction.

functionoperates



Repair or replaceplatform rotator OR0.030" orifice fittings injib manifold are pluggedOR jib manifold mayhave an internal defect.Consult Genie IndustriesService Department.



Chart 24

Platform RotateRight FunctionInoperativeBe sure all otherfunctions operatenormally.

With the keyswitchturned to ground controland both EmergencyStop buttons pulled outto the ON position, movethe function enableswitch to either side andactivate the platformrotate toggle switchTS14 in the rightdirection and checkvoltage at grn/wht wireat TP19 at the platformcontrols.

0V

With keyswitch turned toplatform control andboth Emergency Stopbuttons pulled out to theon position, activatefootswitch and platformrotate toggle switch TS5in the right direction andcheck voltage at the grn/wht wire at the jib delaycapacitor.

12V

Repair open in grn/whtwire from TP19 to jibdelay capacitor.


Repair open in grn/whtwire from TS14 to TB19to TP19 OR test toggleswitch. See RepairSection.

0V

12V

With keyswitch turned toplatform control andboth Emergency Stopbuttons pulled out to theon position, activatefootswitch and platformrotate toggle switch TS5in the right direction andcheck voltage at TP19.

12V

0V

Test toggle switch. SeeRepair Section ORreplace platform rotatetoggle switch TS5.

Activate footswitch andplatform rotate toggleswitch TS5 in the rightdirection and checkvoltage at the grn/whtwire on TS5.

12V

0V

Repair open in grn/whtwire from TS5 to TP19.

Check voltage on centerterminal of TS5.

0V

12V

Repair open in redpower wire circuitthrough controllers andfunction toggle switchesto TS5.



CHART 24


With keyswitch turned toplatform control andboth Emergency Stopbuttons pulled out to theon position, activatefootswitch and platformrotate toggle switch TS5in the right direction andcheck voltage at the redwire at the jib delaycapacitor.

0V

12V

Replace the jib delaycapacitor OR repairopen in brown groundwire from capacitor toground.

Activate footswitch andplatform rotate toggleswitch TS5 in the rightdirection and checkvoltage on the red wireat terminal #86 onCR14.

Repair open in red wirefrom jib delay capacitorto CR14.

Activate footswitch andplatform rotate toggleswitch TS5 in the rightdirection and checkvoltage on the red andblack wires at terminal#87 on CR14.

12V

0VReplace relay CR14 ORrepair open in powersupply from P2 to CR14OR repair open in brownground wire to CR14.

0V

12V

Activate footswitch andplatform rotate toggleswitch TS5 in the rightdirection and checkvoltage on the red andblack wires at the jib/platform rotate selectvalves (item AM).

12V

0V

Test the resistance ofthe valve coils.

0 orinfiniteohms

5.5 to 6.5ohms

Replace defective valvecoil.

Repair open in cablecontaining red and blackwires from CR14 to jibboom/platform rotateselect valves.




CHART 24


Check continuity frombrown ground wires onvalve coils to ground.

nocontinuity

continuity


Exchange jib boom/platform rotate selectvalves (item AM).Activate footswitch andplatform rotate rightfunction.

functionoperates



Repair or replaceplatform rotator OR0.030" orifice fitting in jibmanifold are pluggedOR jib manifold mayhave an internal defect.Consult Genie IndustriesService Department.



Jib Boom UpFunctionInoperative,S-65 ModelsBe sure all otherfunctions operatenormally.

Chart 25

With the keyswitchturned to ground controland both EmergencyStop buttons pulled outto the ON position, movethe function enableswitch to either side andactivate the jib boomtoggle switch TS15 inthe up direction andcheck voltage at the grnwire on the jib boom updirectional valve(item BB).

0V

12V

Move the functionenable switch to eitherside and activate the jibboom toggle switchTS15 in the up directionand check voltage atTB17.

12V

0V

Repair open in grn wirefrom TB17 to jib boomup directional valve ORrepair open in brownground wire circuit todirectional valve.

Repair open in redpower wire circuit fromkeyswitch to TS15 ORreplace toggle switchTS15.

With the keyswitchturned to platformcontrol and bothEmergency Stop buttonspulled out to the ONposition, activate thefootswitch and the jibboom toggle switch TS6in the up direction andcheck voltage at TB17.

12V

0VActivate the footswitchand the jib boom toggleswitch TS6 in the updirection and checkvoltage at TP17.

Repair open in grn wirefrom TP17 to TB17.

12V

0V

With the keyswitchturned to platformcontrol and bothEmergency Stop buttonspulled out to the ONposition, activate thefootswitch and check thevoltage on the centerterminal of the jib boomtoggle switch TS6.

Check the voltage atterminal #30 on CR13.

0V

12VRepair open in grn wirefrom TS6 to TP17 ORreplace jib boom toggleswitch TS6.

0V

12V

Repair open in red wirefrom BP1 to CR13 ORrepair open in brownground wire circuit toCR13.

Check the voltage atterminal #87a on CR13.

12V

0V Replace CR13.

Repair open in red wirefrom terminal#87a onCR13 to TS6 ORconsult Genie IndustriesService Department.




CHART 25


Activate footswitch andjib boom toggle switchTS6 in the up directionand check voltage onthe red and black wiresat the jib/platform rotateselect valves (item AM).

0V

12V Replace CR13.

Exchange jib boom/platform rotate selectvalves (item AM).Activate footswitch andjib boom up function.

2500 psior more

less than 2500 psi

Install a 0 to 5000 psi (0to 345 bar) pressuregauge at the quickdisconnect coupling onthe function manifoldand activate the jibboom up function.

functionoperates


Replace defective valve.

Check for mechanicalrestrictions keeping jibboom up function fromoperating OR repair orreplace jib boomcylinder OR replacecounterbalance valveOR 0.035" orifice maybe plugged OR jibboom/platform rotateselect manifold has aninternal defect ORconsult Genie IndustriesService Department.

Exchange jib boomcounterbalance valvesand activate jib boom upfunction.

functionoperates


Replace defectivecounterbalance valve.




Jib Boom DownFunctionInoperative,S-65 ModelsBe sure all otherfunctions operatenormally.

Chart 26

With the keyswitchturned to ground controland both EmergencyStop buttons pulled outto the ON position, movethe function enableswitch to either side andactivate the jib boomtoggle switch TS15 inthe down direction andcheck voltage at thegrn/blk wire on the jibboom down directionalvalve (item BB).

0V

12V

Move the functionenable switch to eitherside and activate the jibboom toggle switchTS15 in the downdirection and checkvoltage at TB18.

12V

0V

Repair open in grn/blkwire from TB18 to jibboom down directionalvalve OR repair open inbrown ground wirecircuit to directionalvalve.

Repair open in redpower wire circuit fromkeyswitch to TS15 ORreplace toggle switchTS15.

With the keyswitchturned to platformcontrol and bothEmergency Stop buttonspulled out to the ONposition, activate thefootswitch and the jibboom toggle switch TS6in the down directionand check voltage atTB18.

12V

0VActivate the footswitchand the jib boom toggleswitch TS6 in the downdirection and checkvoltage at TP18.

Repair open in grn/blkwire from TP18 to TB18.

12V

0V

With the keyswitchturned to platformcontrol and bothEmergency Stop buttonspulled out to the ONposition, activate thefootswitch and check thevoltage on the centerterminal of the jib boomtoggle switch TS6.

Check the voltage atterminal #30 on CR13.

0V

12VRepair open in grn/blkwire from TS6 to TP18OR replace jib boomtoggle switch TS6.

0V

12V

Repair open in red wirefrom BP1 to CR13 ORrepair open in brownground wire circuit toCR13.

Check the voltage atterminal #87a on CR13.

12V

0V Replace CR13.

Repair open in red wirefrom terminal#87a onCR13 to TS6 ORconsult Genie IndustriesService Department.




CHART 26


Activate footswitch andjib boom toggle switchTS6 in the downdirection and checkvoltage on the red andblack wires at the jib/platform rotate selectvalves (item AM).

0V

12V Replace CR13.

Exchange jib boom/platform rotate selectvalves (item AM).Activate footswitch andjib boom down function.

2500 psior more

less than 2500 psi

Install a 0 to 5000 psi (0to 345 bar) pressuregauge at the quickdisconnect coupling onthe function manifoldand activate the jibboom down function.

functionoperates


Replace defective valve.

Check for mechanicalrestrictions keeping jibboom down functionfrom operating ORrepair or replace jibboom cylinder ORreplace counterbalancevalve OR 0.035" orificemay be plugged OR jibboom/platform rotateselect manifold has aninternal defect ORconsult Genie IndustriesService Department.

Exchange jib boomcounterbalance valvesand activate jib boomdown function.

functionoperates


Replace defectivecounterbalance valve.




Chart 27

OscillateFunctionInoperativeBe sure all otherfunction operatenormally.

Remove the chassiscover at the non-steerend. Check the linkagefor damage or improperlinkage adjustment. SeeRepair section, 10-6How to Set Up theDirectional ValveLinkage.

bad Re-adjust or replacelinkage.

good

Install a 0 to 2000 psi(0 to 138 bar) pressuregauge at the quickdisconnect coupling onthe oscillate manifold.Disconnect the oscillatelinkage from non-steeraxle. Start the engineand manually activatethe directional valve.Check the pressure.

lessthan950 psi

Adjust the sequencevalve. See Repairprocedure 10-5, How toAdjust the OscillateSequencing ValvePressure OR consultGenie Industries ServiceDepartment.

950 psi




Chart 28

Steer LeftFunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch inplatform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and steerrocker switch on drivecontroller (DP1) in leftdirection and checkvoltage on TB36.

0V

12V or more

With key switch inplatform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and steerrocker switch on drivecontroller (DP1) in leftdirection and checkvoltage at the controllerterminal with the bluwire attached.

12V ormore

Repair open in blu #36wire circuit from drivecontroller (DP1) to TP36then to TB36.

0V

Repair or replace steermicroswitch on drivecontroller. ConsultGenie Industries ServiceDepartment.


With key switch inplatform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and steerrocker switch on drivecontroller (DP1) in leftdirection and checkvoltage on blu #36 wireon steer left directionalvalve coil (item SS) onsteer manifold.

12V or more

0VRepair open in blu #36wire circuit that runsfrom TB36 to steer leftdirectional valve coil onsteer manifold.

Disconnect wires tosteer left directionalvalve coil (item SS) onsteer manifold and testthe resistance of thevalve coil.

0 orinfiniteohms

Replace steer leftdirectional valve coil(item SS) OR repairopen in brown groundwire to steer left valvecoil.

5 to 6 ohms




Install a 0 to 5000 PSI(0 to 345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and activatethe steer left function.

2600PSI ormore

less than 2600 PSI

Repair or replace steercylinder OR steermanifold could have aninternal defect. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingsteer left function fromoperating OR repair orreplace steer cylinderOR consult GenieIndustries ServiceDepartment.

CHART 28



Chart 29

Steer RightFunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch inplatform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and steerrocker switch on drivecontroller (DP1) in rightdirection and checkvoltage on TB37.

0V

12V or more

With key switch inplatform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and steerrocker switch on drivecontroller (DP1) in rightdirection and checkvoltage at the controllerterminal with the blu/blkwire attached.

12V ormore

Repair open in blu/blk#37 wire circuit fromdrive controller (DP1) toTP37 then to TB37.

0V

Repair or replace steermicroswitch on drivecontroller. ConsultGenie Industries ServiceDepartment.


With key switch inplatform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and steerrocker switch on drivecontroller (DP1) in rightdirection and checkvoltage on blu/blk #37wire on steer rightdirectional valve coil(item SS) on steermanifold.

12V or more

0VRepair open in blu/blk#37 wire circuit that runsfrom TB37 to steer rightdirectional valve coil onsteer manifold.

Disconnect wires tosteer right directionalvalve coil (item SS) onsteer manifold and testthe resistance of thevalve coil.

0 orinfiniteohms

Replace steer rightdirectional valve coil(item SS) OR repairopen in brown groundwire to steer right valvecoil.

5 to 6 ohms



CHART 29


Install a 0 to 5000 PSI(0 to 345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and activatethe steer right function.

2600PSI ormore

less than 2600 PSI

Repair or replace steercylinder OR steermanifold could have aninternal defect. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingsteer right function fromoperating OR repair orreplace steer cylinderOR consult GenieIndustries ServiceDepartment.



All DriveFunctionsInoperative,All OtherFunctionsOperateNormallyBe sure the rpm toggleswitch is in thefootswitch activatedhigh idle position.

Be sure the hydraulictank shut off valves arein the OPEN position.

Be sure machine isnot in the free wheelconfiguration.

Chart 30

With the drive speedselector toggle switch(TS8) in the highposition, activate thefootswitch and hold thedrive joystick in the fullforward position andcheck the voltage atterminal #10 on thehorsepower limiterboard.

0V

9 to 12V


With the keyswitchturned to platformcontrol and bothEmergency Stop buttonspulled out to the ONposition, activate thefootswitch and check thevoltage at terminal #2 onthe drive joystick (DP1).

lessthan12V

Repair open in powersupply circuit from TP24to terminal #2 on drivejoystick (DP1).

12V or more

Check continuity ofbrown ground wire fromterminal #3 on DP1 toground.

continuity

no continuity

Repair open in brownground wire circuit fromground to DP1.

With the keyswitchturned to platformcontrol and bothEmergency Stop buttonspulled out to the ONposition, activate thefootswitch and check thevoltage at terminal #1 onthe horsepower limitercircuit board.

12V or more

lessthan12V

Repair open in powersupply circuit from TP24to terminal #1 on thehorsepower limitercircuit board.

Check continuity ofbrown ground wire fromterminal #2 on thehorsepower limitercircuit board to ground.

continuity

no continuity

Repair open in brownground wire circuit fromground to thehorsepower limitercircuit board.

Replace horsepowerlimiter board.

With the drive speedselector toggle switch(TS8) in the highposition, activate thefootswitch and check thevoltage at terminal #3 onthe horsepower limiterboard.

7 to 8V

0V

With the drive speedselector toggle switch(TS8) in the highposition, activate thefootswitch and check thevoltage on the org/blkwire on the alterator.

7 to 8V

0V

Repair or replacealternator.

Repair open in org/blkwire from alternator toTB41 to TP41 toterminal #3 onhorsepower limiterboard.



CHART 30


Repair open in wire fromterminal #10 onhorsepower limiterboard to terminal #6 ondrive joystick.

Activate the footswitchand hold the drivejoystick in the fullforward position andcheck the voltage atterminal #6 on thejoystick controller.

9 to 12V

Connect the positvelead from a voltmeter toterminal #4 on thejoystick and the negativelead to terminal #5 onthe joystick. Activate thefootswitch and hold thedrive joystick in the fullforward position andcheck the voltageacross the #4 and #5terminals on the drivejoystick controller.

0V

2V

Replace drive joystickcontroller OR consultGenie Industries ServiceDepartment.

0V

nocontinuity

continuity

Check continuity fromterminal #3 on drivejoystick to ground.

Repair open in brownground wire circuit fromterminal #3 on drivejoystick to ground.

Connect the positvelead from a voltmeter toterminal #5 on thejoystick and the negativelead to terminal #4 onthe joystick. Activate thefootswitch and hold thedrive joystick in the fullreverse position andcheck the voltageacross the #5 and #4terminals on the drivejoystick controller.

0V

Replace drive joystickcontroller OR consultGenie Industries ServiceDepartment.

nocontinuity

continuity

Check continuity fromterminal #3 on drivejoystick to ground.

Repair open in brownground wire circuit fromterminal #3 on drivejoystick to ground.

2V





Activate the footswitchand hold the drivejoystick in the fullforward position andcheck the voltageacross the wht #12 wireand the wht/blk #31 wireon EDC.

0V

2V

Repair open in blu/whtwire from TS9 to TP12to TB12.

With the footswitchactivated and the drivejoystick in the fullforward position, movethe drive enable toggleswitch (TS9) to eitherside and check thevoltage across the wht#12 wire and the wht/blk#31on EDC.

2V

0V

Repair open in wht wirefrom terminal #4 ondrive joystick to TS9 toTP30 to TB30 throughdrive enable limit switch(LS3) to TB12 to wht#12 wire on EDC quickdisconnect plug.

With the footswitchactivated and the drivejoystick in the fullforward position, movethe drive enable toggleswitch (TS9) to eitherside and check thevoltage at the blu/whtwire on TS9.

9 to 12V

0V

Replace drive enabletoggle switch TS9.

0V

9 to 12V

With the footswitchactivated and the drivejoystick in the fullforward position, checkthe voltage on thecenter terminal of thedrive enable toggleswitch (TS9).

Repair open in wire fromterminal #4 from drivejoystick DP1 OR replacedrive joystick controllerOR consult GenieIndustries ServiceDepartment.

Troubleshoot driveforward and drivereverse functionsseparately OR replacepump OR consult GenieIndustries ServiceDepartment.

CHART 30



Chart 31

Drive ForwardOr ReverseFunctionInoperativeBe sure all otherfunctions operatenormally includingdrive in oppositedirection ofmalfunction.

Disconnect the EDCwire connector from thedrive pump, startengine, move the drivecontroller to full forwardposition and note thevoltage across terminalsTB30 and TB31.Reverse the volt meterleads and move thedrive controller to fullreverse position andnote the voltage.

voltage readings different Repair or replace thedrive controller.

voltage readingsthe same

Adjust the drive pumpnull (neutral). ConsultGenie Industries ServiceDepartment.

no improvementDefective Sundstranddrive pump, contactSundstrand authorizedrepair facility.

symptoms improve

Re-adjust drive joystickcontroller OR if problemstill persists, consultGenie Industries ServiceDepartment.

Check the resistance ofthe EDC.

0 orinfiniteohms Replace the EDC.

20 to 24 ohms



Chart 32

TractionFunctionInoperativeBe sure all otherfunctions operatenormally.

Any type of tractionproblem, consult GenieIndustries ServiceDepartment.



Chart 33

Machine WillNot Drive AtFull SpeedBe sure all otherfunctions operatenormally.

Be sure the machine isnot raised above orextended beyond thedrive limit switches.

Be sure the boom drivelimit switch is clear ofany debris and is notactivated when theboom is in the stowedposition.

Be sure that the boomextend drive limit switcharm is being held downwhen the boom isretracted.

Be sure the wiring tolimit switches is intactand show no sign ofdamage or corrosion.

Be sure the free-wheelvalve is closed on thedrive pump.

Be sure the drive speedselect switch is on highrange (machine on levelsurface symbol).

With the boom in thestowed position, checkcontinuity from TB40 toground.

continuityCheck for correct wiringof limit switches(LS1 and LS2) ORrepair or replace boomlift drive limit switch orboom extend limitswitch.

no continuity

With the boom in thestowed position, checkterminal #6 onhorsepower limiterboard for continuity toground.

continuity

Repair short to groundin orange wire shortedto ground from TB40 toTP40 to terminal #6 onhorsepower limitercircuit board.

no continuity

Re-adjust or replacehorsepower limiterboard OR check formisalignment of limitswitches (LS1 and LS2)OR consult GenieIndustries ServiceDepartment.



Chart 34

Machine DrivesAt Full SpeedWith PlatformRaised orExtendedBe sure boom drive limitswitch is being activatedby the cam on the boomwhen the boom israised.

Be sure that the boomextend drive limit switchis not being held downor being activated whenthe boom is extended.

Be sure the wiring tolimit switches is intactand show no sign ofdamage or corrosion.

Extend the boom pastthe drive limit switch andcheck continuity fromground to terminal #6 onthe horsepower limiterboard.

continuity

no continuity

Check continuity fromground to TB40.

continuity Repair open in org wirecircuit from TB40 toTP40 to terminal #6 onhorsepower limitercircuit board.

no continuity

Repair open from whtwires at TB40 to drivelimit switches (LS1 andLS2), then from brownground wires to ground.

bad

good

Test limit switches. Seeprocedure A-14 in theMaintenance Section.

Replace defective limitswitch contact ORreplace limit switch.

Replace horsepowerlimiter board OR re-adjust horsepowerlimiter board OR consultGenie Industries ServiceDepartment.



Chart 35

Drive EnableSystem IsMalfunctioningBe sure the boom is inthe stowed position.

With keyswitch inplatform position andboth Emergency Stopbuttons pulled out to theON position and theboom rotated betweenthe non-steer tires,activate footswitch anddrive controller inforward direction. Willunit drive?

no

yes

no continuity

continuity

0V

Repair open fromterminal #4 on DP1 tocenter terminal on TS9OR refer to Chart 30 ORconsult Genie IndustriesService Department.

12V or more

Repair open in powersupply circuit fromTP24.

yes

Repair open in blu/whtwire from drive enabletoggle switch (TS9) toTP12 to TB12 ORreplace drive enabletoggle switch (TS9).

With keyswitch inplatform position andboth Emergency Stopbuttons pulled out to theON position, activatefootswitch and drivecontroller in forwarddirection and checkvoltage at terminal #2 ondrive controller (DP1).

With keyswitch inplatform position andboth Emergency Stopbuttons pulled out to theON position and theboom rotated betweenthe steer end tires,activate footswitch anddrive controller inforward direction. Willunit drive?

yes

no

Hold the drive enableswitch (TS9) to eitherside and activate thefootswitch and driveforward function. Willunit drive?

The machine isoperating correctly. Ifmachine does notoperate properly,consult Genie IndustriesService Department.

no

Check for continuityfrom TB30 to TB12.

Replace drive enablelimit switch contact ORreplace drive enablelimit switch (LS3).

Activate limit switch byhand and checkcontinuity from TB30 toTB12.

continuity

no continuity

Repair open from TB30through red wire to LS3then from LS3 throughblk wire to TB12.

Please begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.



Chart 36

AuxiliaryFunctionsInoperativeBe sure all otherfunctions operatenormally.

Be sure key switchis in the appropriateposition and theEmergency Stopbuttons are pulledout to the ON

position.

Be sure engine isnot running whenusing auxiliarypower.

Note: Operatingauxiliary power withthe engine runningshould immediatelykill the engine.

Lift the red auxiliarypump switch coverswitch cover, holdauxiliary switch andlisten for sound ofauxiliary pump motoroperating.

motoroperates

Install a 0 to 5000 psi(0 to 345 bar) pressuregauge into the pressureport of the auxiliarypump and hold theauxiliary power toggleswitch and note thepressure.

2500 psi

Repair or replace pumpOR relief valve is out ofadjustment. ConsultGenie Industries ServiceDepartment.

less than2500 psi

Reconnect pressureline and check batterycondition. There ispossibly not enoughbattery capacity tooperate both aux. pumpand function valves.

motor doesnot operate

With the keyswitchturned to ground controland both EmergencyStop buttons pulled outto the ON position,activate the auxiliarypump toggle switch andcheck the voltage on thered cable on theauxiliary power unit.

goodCheck for a positiveconnection betweenelectric motor and thepump by removing thepump from the motor,but leave all the hosesconnected. Visuallycheck couplingconnection.

bad

Replace the auxiliarypower unit.

12V

0V Test PR1. See RepairProcedure 8-5.

bad Replace PR1.

good

Activate the auxiliarypump toggle switch andcheck the voltage atTB27.

12V ormore

0V

Repair open from TB27to PR1.

Activate the auxiliarypump toggle switch andcheck the voltage at thecenter terminal of TS10.

0VRepair open fromkeyswitch (KS1) toauxiliary toggle switch(TS10).

12V or more

Repair open in red #27wire from TS10 to TB27OR replace TS10 ORrepair open in brownground wire to PR1.




Check continuity fromnegative terminal onauxiliary power unit toground.


good

bad Replace negative cablefrom auxiliary pump toground.

Replace auxiliary pumpmotor.

CHART 36

Schematics

Observe and Obey:Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:Read, understand and obey the safety rulesand operating instructions printed in theGenie S-60 and Genie S-65 Operator'sManual.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.

Electrical Schematics

Electrocution hazard. Contact withelectrically charged circuits mayresult in death or serious injury.Remove all rings, watches andother jewelry.

Hydraulic Schematics

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.



Identifysymptoms

Troubleshoot

Performrepair


solved

problemstill exists

Inspectand test


Service Manual - Second Edition Section 6 - Schematics

Item Description Genie Manufacturer Manufacturer QtyPart Number Part Number

BAT ................ Battery, 1000 CCA, 12V DC.. 30143 ........... Trojan ................................... C31XH-2 ........................ 1

BP1 ................ Joystick controllerSingle axis, up/down.............. 24495 ........... OEM Controls ...................... EMS4M6883 .................. 1

BP2 ................ Joystick controllerDual axis, Swing/extend ........ 40613 ........... OEM Controls ...................... EJS5M10089 ................. 1

CB1, CB2 ....... Circuit breaker ....................... 24018 ........... ETA ...................................... 45-700-IG1-P10 ............. 2

CR1 throughCR7 ................ Relay, SPDT, 12V DC ........... 34052 ........... Potter-Brumfield .................. VF4-15F11-CO5 ............ 6

CR13, 14,17 and 18 ....... Relay, SPDT, 12V DC ........... 19274 ........... Potter-Brumfield .................. VF4-45F11-CO5 ............ 4

Diode .............. Diode, 6 amp, 200 PIV .......... 45782 ........... Motorola ............................... MOTMR752 ................. 43

DP1 ................ Joystick controller-Drive ........ 20424 ........... OEM Controls ...................... MCH1159AD1386 .......... 1

FB .................. Flashing beacon .................... 20189 ........... ECCO Electronic Controls ... 6400X ............................. 2

FS1 ................ Footswitch .............................. 13482 ........... Linemaster Switch Corp. ..... 632-S ............................. 1

G1 .................. Gauge - Voltage .................... 30789 ........... VDO ..................................... 332-502 .......................... 1

G2 .................. Gauge - Oil Pressure ............. 30786 ........... VDO ..................................... 350-516 .......................... 1

G3 .................. Gauge - Water Temp. ........... 30787 ........... VDO ..................................... 310-502 .......................... 1

H1 .................. Alarm, Warble tone ................ 19270 ........... Floyd Bell Inc. ...................... MW-09-616-Q ................ 1

H2 .................. Horn, 12V DC, 130 dB ........... 19145 ........... Sparton Engineered Prod. ... 7431A-24823-5 .............. 1

H3 .................. Alarm, intermittent ................. 18963 ........... Floyd Bell Inc. ...................... XB-09-630-Q .................. 1

H4 .................. Alarm, chime tone ................. 45462 ........... Floyd Bell Inc. ...................... CH-09-525-Q ................. 1

HM ................. Hourmeter .............................. 19506 ........... ENM Corporation ................. T40A4508 ...................... 1

KS1 ................ Contact - Keyswitch, N.O. ..... 45081 ........... Telemecanique .................... ZB2-BE101 .................... 2

L1 ................... LED - Red, 12V DC ............... 32335 ........... Arctolectric Corp. ................. LE177C39007 ................ 1

LS1, 2, 3 ........ Contact - Limit switch,N.C.H.O. ................................ 19491 ........... Telemecanique .................... XESP2051 ..................... 3

Level sensor .. Level sensor, 4.5° .................. 44586 ........... Power Comp. of Midwest .... LS36 ............................... 1

This list continues on the next page.

Service Manual - Second EditionSection 6 - Schematics

Electrical Components




ELECTRICAL COMPONENTS

Item Description Genie Manufacturer Manufacturer QtyPart Number Part Number

P1, P2 ............ Contact, N.C. ......................... 29732 ........... Telemecanique .................... ZB2-BE102 .................... 4

P3 ................... Contact, N.O. ......................... 45081 ........... Telemecanique .................... ZB2-BE101 .................... 1

PR1 ................ Relay, 12V DC continuous .... 27155 ........... Stancor ................................ 70-902 ............................ 1

R1 .................. Resistor, 100Ω 25 watt .......... 27116 ........... Dale ..................................... RH25-100R-1% ............. 1Resistor, 150Ω 25 watt .......... 34798 ........... Dale ..................................... RH25-150-1% ................ 1

R2 .................. Resistor, 10Ω 25 watt ............ 27287 ........... Dale ..................................... RH25-10R-1% ............... 1

TS1, TS10 ...... Toggle switch, DPST2 position momentary ............ 13480 ........... Microswitch Control Inc. ...... 2NT1-8 ........................... 2

TS2, 6, 9, 11,13, 15 ............. Toggle switch, SPDT

3 position momentary ............ 13037 ........... Microswitch Control Inc. ...... 1NT1-7 ........................... 6

TS3, 8,12, 20 ............. Toggle switch, DPST

2 position maintained ............ 27378 ........... Microswitch Control Inc. ...... 2NT1-3 ........................... 4

TS4 ................ Toggle switch, DPDT3 position maintained ............ 13038 ........... Microswitch Control Inc. ...... 2NT1-1 ........................... 1

TS5,7,14,16, 17,18, 19 ....... Toggle switch, DPDT

3 position momentary ............ 16397 ........... Microswitch Control Inc. ...... 2NT1-7 ........................... 7

VAC ................ Vacuum switch ...................... 22278 ........... Peterson Industrial .............. 1501-L ............................ 1



Electrical Symbols Legend

+

-

ORG

/BLK-1

15AMP.

TB20

ALARMTILT

L4 OP

TP29

BLK

GRN/BLK

TB17

10

BLK #21 TB21

Battery

Wire colorwith cablenumber

TB=Terminal baseTP=Terminal platform

Dual axisRamp up and downproportional controller

Horsepowerlimiter board

Single axisdrive controller

Ignition startmodule

Circuit breaker

Connectionno terminal

Spark plug

Terminal

P1

Emergency Stopbuttonnormally closed

KS1

GRND

PLAT

Key switch

PR4

Relay panelcontactor

Solenoid orrelay coil

Horn

Tilt sensor

NCLS2

Limit switchnormally closedheld open

NOLS1

Limit switchnormally openheld closed

HORN P4

Horn buttonnormally open

T-circuitsconnect

T

WHT

#51

TR2

1

2

36

Time delay relay

OPS1

N.C.

Oil pressureswitchnormally closed

Light

WTS1

N.O.

Water temperatureswitchnormally open

Quick disconnectterminal

Diode

REDBLK

FS1

Foot switch

CR4

Relay contactnormally open

TS3

STARTENGINE

Toggle switch SPDT

Circuits crossingno connection

TS6

RIGHT

LEFT

Toggle switch DPDT

Groundsupressioncircuit

Glow plug

T-circuits connectat terminal

R

X-+APWM

BP2

Single axisproportionalcontroller

Resistor

VAC

Vacuum switch

Auxiliary pump

PUMPAUX.

2 TACHOMETER

10

789

KEY PWR.KEY BYPASS

ENG. FAULTIGN./FUEL ON

56

43

AUX. ONSTART INPUT

GROUNDBATTERY

1 START RELAY

7

98

10

2

45

3

6

1

56

87

DP1

1

34

2

Limit switch

WH

T-5

RE

D-5

BLK

-5

NOG

RN

-5

LS3

NC

RD1

A-

D2

++RD1

AD2

-

BP1

LABEL DESCRIPTION

BAT ............. Battery

BP ............... Proportional controller

CB ............... Circuit breaker

CR ............... Control relay

DP ............... Drive proportional controller

FB................Flashing beacon

FS................Foot switch

G .................Gauge

H.................. Horn or Alarm

HM............... Hour meter

KS ............... Keyswitch

L .................. LED

LS ................ Limit switch

P .................. Power switch

PR ............... Power relay

R.................. Resistor

TB................Terminal base location

TP................Terminal platform location

TS................Toggle switch

VAC ............. Vacuum switch



Abbreviation Legend

Service ManualSection 6 - Schematics

Electrical Schematic-Gasoline/LPG Models

1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N


REV B

Service Manual Section 6 - Schematics


Electrical Schematic-Gasoline/LPG Models

1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A

REV B



Ground Control Box Legend-Gasoline/LPG Models


Ground Control Box Wiring Diagram-Gasoline/LPG Models




Platform Control Box Legend-Gasoline/LPG Models


Platform Control Box Wiring Diagram-Gasoline/LPG Models


Service ManualSection 6 - Schematics

Electrical Schematic-Diesel Models

1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N




Electrical Schematic-Diesel Models

1

2

3

4

5

6

7

8




Ground Control Box Legend-Diesel Models


Ground Control Box Wiring Diagram-Diesel Models




Platform Control Box Legend-Diesel Models


Platform Control Box Wiring Diagram-Diesel Models



Hydraulic Symbols Legend


E

Pressure gauge

Filter

Fixed displacement pump

Bi-directional, variable displacement pump

Bi-directional motor

2-speed, bi-directional motor

Pump prime mover (engine or motor)

Cylinder

Accumulator

Orifice with size

0.035

Variable orifice or shut-off valve

Check valve

Relief valve

Priority flow divider

Solenoid operated dump valve

Differential sensing valve

Solenoid operated proportional valve

Flow regulator valve

Solenoid operated 2 pos., 3 way, directional valve

Solenoid operated 2 pos., 4 way, directional valve

Solenoid operated 3 pos., 4 way, directional valve (DO1)

2 pos., 3 way, shuttle valve

3 pos., 4 way, directional valve

Sequencing valve

Unloader valve

Pressure compensating valve

Counterbalance valve

Pilot operated flowcontrol valve

1

2

3

4

5

6

7

8




2WD Hydraulic SchematicNon-Oscillating Axle

3500

14 GPM.

PRESSURE

FILTER

MEDIUM

FUNCTION

RESERVOIR

DRIVE PUMP

3500PSI

290PSI

3PSI

3PSI

E

25PSI

PUMP

50PSI

STEERINGCYLINDER

PSI

AUX. PUMP

SEC

PRESS.

T1

2500PSI

PSI

REG

TANK

PRESS.

PR2PR1 PL1

X

PL2

X

P1 P2S1 S2

3.5GPM

TEST

.025”

REAR

RIGHT

M7

M5

LEFT

REAR

M1

M3

OPTIONAL

GENERATOR

STEER MANIFOLD

MASTERCYLINDER

ROTATE

BOOM EXTENSION CYLINDER

BOOM UP/DOWNSLAVECYLINDER

FUNCTION

MANIFOLD

MANIFOLD

TURNTABLE

PRIMARY SECONDARY

SELECT

GENERATOR

250PSI

JIB BOOM

.030”

.030”JIB BOOM

MANIFOLD

PLATFORM ROTATE

HYDRAULICROTARYCOUPLER

.035”

DRIVE

M

.070”

* S-60 Models = 2600 psiS-65 Models = 2900 psi

OIL

COOLER

OPTIONAL

CASE DRAINS

250 PSI

ACCUM.

1200

PSI

*

GPM0.6

GPM0.1

GPM0.6

PSI2100

2500PSI

BRAKE 2 SPEED

TWO SPEED/

BRAKE MANIFOLD

A B

F

G

K

M

L

O

NT

QY

P

Z

S

UHI

R

JV

X

W

C

D

E

GG

AACC

BB

EE

II JJ

HH

FF

AN

AM AM

AN

RR

VV

WW

YY

XX

DD

1

1SECOND COUNTERBALANCE VALVE ADDEDAFTER SERIAL NUMBER 4862

1

2

3

4

5

6

7

8




2WD Hydraulic SchematicOscillating Axle

14 GPM.

PRESSURE

FILTER

MEDIUM

FUNCTION

RESERVOIR

DRIVE PUMP

3500

PSI

290

PSI

33PSIPSI

E

25PSI

PUMP

50

PSI

STEERING

AUX. PUMP

2500PSI

REARRIGHT

M7

M5

LEFTREAR

M1

M3

3.5 gpm

OPTIONAL

MOTOR/GEN.

STEER MANIFOLD

MANIFOLD

SELECTGENERATOR

250PSI


DRIVE

M

* S-60 Models = 2600 psiS-65 Models = 2900 psi

.070”

OIL

COOLER

OPTIONAL

CASE DRAINS

.030”

TEST

T1

PRESS.

.030”

SEC

*PSI

REG

5.0

GPM0.6

GPM

GPM

0.1

0.6

GPM

PR2PR1

MANIFOLD

FUNCTION

MANIFOLD

JIB BOOM

2500

PSI

PL1 PL2

MASTERCYLINDER

.035”

JIB BOOM PLATFORM ROTATE

SLAVEX

X

PSI1200

PSI2500

S2S1 P1

250 PSI

2100PSI

P2

ACCUM.

PRESS.

TANK

TURNTABLE

ROTATE

PRIMARY SECONDARY

BOOM EXTENSIONCYLINDER

B VALVE

A VALVE

OSCILLATE CYLINDERS

OSCILLATE MANIFOLD

P

B CYL

A CYL

PSI950

P8.052”

2 SPEED

BRAKE MANIFOLD

TWO SPEED/

P

.025”

T

BRAKE

.025”

W

Y Z

CC

BB

VV

YY

XX

WW

FF EE

II JJ

HH

AA

DD

RR

LL KK

NN

OO

PP

MM

QQ

UUTT SS

V J

T

U

S

Q PA

R

HIG

MO

KLN

F

D

GG

ECB

X

BOOM UP/DOWN

1


1

2

3

4

5

6

7

8




4WD Hydraulic SchematicNon-Oscillating Axle

14 GPM.

PRESS.FILTER

MED.

FUNCTION

RESERVOIR

DRIVE PUMP

3500PSI

290PSI

3PSI

3PSI

E

25PSI

PUMP

50PSI

STEERING

AUXILIARY PUMP

2500PSI

OPTIONALMOTOR/GENERATOR

STEER MANIFOLD

SELECTGENERATOR

HYDRAULICROTARY

M

* 2900 PSI WITH JIB* 2600 PSI W/O JIB

OILCOOLER

OPTIONAL

TURNTABLE

0.030”

0.030”

0.035”

TEST

T1

PRESS.

SEC

*PSI

REG

3.5GPM 0.6

GPM

GPM0.1

0.6GPM

PR2PR1

MANIFOLDFUNCTION

MANIFOLD

JIB BOOM

PLATFORM

LEVEL

3500PSI

PL1 PL2

MASTER


SLAVEX

X

PSI PSI

1200 1200

PSI2500

RETRACTS2S1BOOM

P1

250 PSI

EXTEND

2100PSI

P2

ACCUM.

PRESS.

TANK

TURNTABLEROTATE

PRIMARY SECONDARY

BOOM EXTENSIONCYLINDER

2 SPEED

BRAKE MANIFOLDTWO SPEED/

BRAKE

P

0.025”

.052”

.070”

.070”

T

M7

CASE DRAINS

P

LEFTREAR

RIGHTREAR

M1

M3

M5

MANIFOLDDRIVE

A

M8

M2

M4

LEFTFRONT

M6

RIGHTFRONT

COUPLER

250PSI

T

B

HI

R

A

P

EE FF

S

X Z Y

U

TDD

AM AM

AA

BB

AB

AE

AL

AC

AH

AI

AJ

AF

AG

AD

AK

HH

II JJ

CC

GG

Q

JV

W

SS

F

B C

K

O

LN

E

D

G

M

BOOM UP/DOWN

1


1

2

3

4

5

6

7

8




4WD Hydraulic SchematicOscillating Axle

14 GPM.

PRESS.

FILTER

MED.

FUNCTION

RESERVOIR

DRIVE PUMP

3500PSI

290PSI

3PSI

3PSI

E

25PSI

PUMP

50PSI

STEERING

AUX. PUMP

2500PSI

3.5

OPTIONAL

MOTOR/GEN.

STEER MANIFOLD

SELECTGENERATOR


M

* 2600 W/O JIB* 2900 WITH JIB

OIL COOLER

OPTIONAL

B VALVE

A VALVE

PX

PSI950

B CYL

A CYL

X

P8

TURNTABLEROTATE

T1

TEST

0.030”

0.030”

PRESS.

PSI*

5.0GPM

GPM0.6

GPM

GPM

0.1

GPM0.6

PR2PR1

MANIFOLD

FUNCTION

JIB BOOM

MANIFOLD

PLATFORM

3500

LEVEL

PSI

PL1 PL2

MASTER

0.035”


SLAVEX

X

1200PSI

RETRACT

2500PSI

S2S1BOOM

P1

250 PSI

EXTEND

PSI2100

P2

ACCUM.

TANK

PRESS.X

ROTATE

TURNTABLE

PRIMARY SECONDARY

BOOM EXTENSION

SEC REG

2 SPEED

BRAKE MANIFOLD

TWO SPEED/

BRAKE

P

0.025”

T

0.025”

0.070”

0.070” 0.052”

0.052”

RIGHT

REAR

LEFT

REAR

CASE DRAINS

RIGHT

FRONT

FRONT

B

P

M1

M3

M5

M7

M2

M4

LEFT

M6

M8

MANIFOLDDRIVE

A

250PSI

T

HI

R

A

P

EE FF

S

X Z Y

U

TDD

AM AM

AA

BB

AB

AE

AL

AC

AH

AI

AJ

AF

AG

AD

AK

HH

II JJ

CC

GG

Q

JV

W

SS

UU TT

VV

KK

MM

OO

QQ

PP

NN

LL

F

B C

K

O

LN

E

D

G

M


BOOM UP/DOWN

1


Service Manual - Second Edition Section 7 - Repair Procedures

Repair Procedures

About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the pointwhere repairs can be completed. Then tore-assemble, perform the disassembly steps inreverse order.


Symbols Legend

Indicates the presence of a hazardthat will cause deathor serious injury.

Indicates the presence of a hazardthat may cause deathor serious injury.

Indicates the presence of a hazardthat will or may cause seriouspersonal injury ordamage to the machine.

Indicates special operation ormaintenance information.

Indicates that a specific result is expectedafter performing a series of steps.

Observe and Obey:Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.



Before Repairs Start:Read, understand and obey the safety rulesand operating instructions in theGenie S-60 & Genie S-65 Operator’s Manual.

Be sure that all necessary tools and parts areavailable and ready for use.

Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

· Machine parked on a flat, level surface


· Turntable rotated with the boom between the non-steering wheels

· Turntable secured with the turntable rotation lock pin

· Key switch in the OFF position with the key removed

· Wheels chocked


Identifysymptoms

Troubleshoot

Performrepair


solved

problemstill exists

Inspectand test


Service Manual - Second EditionSection 7 - Repair Procedures

1-1Joystick Controllers

Maintaining joystick controllers at the propersettings is essential to safe machine operation.Every joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.

Platform control boxa horsepower limiter boardb terminalsc drive proportional controllerd extend/retract proportional controllere boom proportional controllerf turntable rotate proportional controller

Boom Up/Down ControllerAdjustments

Do not adjust the joystickcontrollers unless the static batteryvoltage is above12V DC and the alternatoris operating properly with13.6 to 14.5V DC output.


1 Check the battery condition with a volt meter.The reading should be 12V DC or more toaccurately adjust the controller.

2 Turn the key switch to platform control andpull out the Emergency Stop button to theON position at both the ground and platformcontrols. Do not start the engine.

3 Open the platform control box lid and locatethe boom up/down controller.

a terminal "D2" directional outputb terminal "A" proportional outputc terminal "-" groundd terminal "+" positivee terminal "R" activates max-out rangef terminal "D1" directional outputg ramp rate adjustable trimpoth lo range adjustable trimpoti threshold adjustable trimpotj hi range adjustable trimpot

4 Set the preliminary ramp rate: Turn the trimpotadjustment screw counterclockwise 15 turns oruntil you hear a repeated click.

5 Connect the red(+) lead from a volt meter tothe “A” terminal on the controller printed circuitboard. Connect the black(-) lead to ground.

6 Set the threshold: Press down the foot switch,then slowly move the control handle off centeruntil the moment a voltage reading appears.Adjust the voltage to 3.5V DC. Turn thethreshold trimpot adjustment screw clockwise toincrease the voltage or counterclockwise todecrease the voltage.

Platform Controls

a b c d e f g h i j

b

c

a

def



16 Start a timer and simultaneously move thecontrol handle all the way to the UP position.Note how long it takes to reach the maximumvoltage recorded in step 14. This is theramp rate.

17 Set the ramp rate: turn the trimpot to obtaina 3 to 4 second ramp speed. Turn thetrimpot clockwise to increase the time orcounterclockwise to decrease the time.

Boom up/down specifications

Threshold 3.5V DC

Boom up - hi range 8.5V DCCycle time 55 to 85 seconds

Boom down - lo range 6.2V DCCycle time 90 to 120 seconds

Ramp rate 3 to 4 seconds

Turntable Rotation ControllerAdjustments

Do not adjust the joystickcontrollers unless the static batteryvoltage is above12V DC and the alternator isoperating properly with13.6 to 14.5V DC output.



2 Turn the key switch to platform control andpull out the Emergency Stop button tothe ON position at both the ground andplatform controls. Do not start the engine.

7 Set the hi range: Press down the foot switch,then move the control handle all the way tothe UP position. Adjust the voltage to 8.5V DC.Turn the max-out trimpot adjustment screwclockwise to increase the voltage orcounterclockwise to decrease the voltage.

8 Set the lo range: Press down the foot switch,then move the control handle all the way to theDOWN position. Adjust the voltageto 6.2V DC. Turn the dual range trimpotadjustment screw clockwise to increase thevoltage or counterclockwise to decreasethe voltage.

9 Start the engine and move the engine idlecontrol switch to foot switch activated highidle (rabbit and foot switch symbol). Lowerthe boom to the stowed position.

Engine should be at normaloperating temperature.

10 Start a timer and record how long it takes forthe boom to fully raise. Adjust themax-out trimpot to achieve a 55 to 85 secondcycle time.

11 Start a timer and record how long it takes forthe boom to fully lower. Adjust the dual rangetrimpot to achieve an 90 to 120 second cycletime.

If the function cycle time is notachievable, check the relief valvepressure. See 10-2, ValveAdjustments - Function Manifold.

12 Turn the engine off and re-connect thevolt meter.

13 Pull out the Emergency Stop button tothe ON position.

14 Press down the foot switch and then move thecontrol handle all the way to the UP position.Record the maximum voltage reading.

15 Start the engine.

PLATFORM CONTROLS



PLATFORM CONTROLS

3 Open the platform control box lid and locatethe turntable rotation controller. Refer to theplatform control box illustration, page 7-2.

a terminal "D2" directional outputb terminal "A" proportional outputc terminal "-" groundd terminal "+" positivee terminal "R" activates max-out rangef terminal "D1" directional outputg ramp rate adjustable trimpoth lo range adjustable trimpoti threshold adjustable trimpotj hi range adjustable trimpot


5 Connect the red(+) lead from a volt meter to the“A” terminal on the controller printed circuitboard. Connect the black(-) lead to ground.

6 Set the threshold: Press down the foot switch,then slowly move the control handle off centeruntil the moment a voltage reading appears.Adjust the voltage to 3.5V DC. Turn thethreshold trimpot adjustment screw clockwise toincrease the voltage or counterclockwiseto decrease the voltage.

a b c d e f g h i j

7 Set the hi range: Press down the foot switch,fully retract the boom, then move the controlhandle all the way to the left or right. Adjust thevoltage to 5.5V DC. Turn the max-out trimpotadjustment screw clockwise to increase thevoltage or counterclockwise to decrease thevoltage.

8 Set the lo range: Press down the foot switch,extend the boom 3 feet, then move the controlhandle all the way to the left or right. Adjust thevoltage to 4.5V DC. Turn the lo range trimpotadjustment screw clockwise to increase thevoltage or counterclockwise to decrease thevoltage.

9 Start the engine and move the engine idlecontrol switch to foot switch activated high idle(rabbit and foot switch symbol).


10 Fully retract the boom, then start a timer andrecord how long it takes the turntable to rotatethrough a complete circle. Adjust the max-outtrimpot to achieve a 80 to 100 second cycletime.

11 Extend the boom, then start a timer and recordhow long it takes the turntable to rotate througha complete circle. Adjust the lo range trimpot toachieve a 130 to 160 second cycle time.



14 Press down the foot switch and then move thecontrol handle all the way to the left or right.Record the maximum voltage reading.




PLATFORM CONTROLS

a b c d e f g h i j

16 Start a timer and simultaneously move thecontrol handle all the way to the left or right.Note how long it takes to reach the maximumvoltage recorded in step 14. This is theramp rate.

17 Set the ramp rate: Turn the trimpot to obtaina 5 second ramp speed. Turn the trimpotclockwise to increase the time orcounterclockwise to decrease the time.

Turntable rotation specifications

Threshold 3.5V DC

Turntable rotation -hi range (boom retracted) 5.5V DCCycle time 80 to 100 secondslo range (boom extended) 4.5V DCCycle time 130 to 160 seconds

Ramp rate 5 seconds

Boom Extend/Retract ControllerAdjustments

Do not adjust the joystickcontrollers unless the static batteryvoltage is above12V DC and the alternatoris operating properly with13.6 to 14.5V DC output.



2 Turn the key switch to platform control andpull out the Emergency Stop button to theON position at both the ground and platformcontrols. Do not start the engine.

3 Open the platform control box lid and locatethe boom extend/retract controller.

a ramp rate adjustable trimpotb dual (lo) range adjustable trimpotc terminal "R", activates max-out ranged terminal unusede terminal "X", auxiliaryf terminal "-", groundg terminal "+", battery, positiveh terminal "A", proportional outputi threshold adjustable trimpotj max-out adjustable trimpot


5 Connect the red(+) lead from a volt meter tothe “A” terminal on the controller printed circuitboard. Connect the black(-) lead to ground.

6 Set the threshold: Press down the foot switch,then slowly move the control handle off centeruntil the moment a voltage reading appears.Adjust the voltage to 3.5V DC. Turn thethreshold trimpot adjustment screw clockwise toincrease the voltage or counterclockwise todecrease the voltage.

7 Set the max-out: Press down the foot switch,then move the control handle all the way tothe EXTEND position. Adjust the voltage to9.75V DC. Turn the max-out trimpot adjustmentscrew clockwise to increase the voltage orcounterclockwise to decrease the voltage.



PLATFORM CONTROLS

8 Set the dual (lo) range: Press down the footswitch, then move the control handle all the wayto the RETRACT position. Adjust the voltageto 9.2V DC. Turn the dual range trimpotadjustment screw clockwise to increase thevoltage or counterclockwise to decreasethe voltage.

9 Start the engine and move the engine idlecontrol switch to foot switch activated highidle (rabbit and foot switch symbol). Lowerthe boom to the stowed position.


10 Start a timer and record how long it takes forthe boom to fully extend. Adjust themax-out trimpot to achieve a 60 to 80 secondcycle time.

11 Start a timer and record how long it takes forthe boom to fully retract. Adjust the dual rangetrimpot to achieve an 55 to 85 second cycletime.

If the function cycle time is notachievable, check the relief valvepressure. See 10-2, ValveAdjustments - Function Manifold.



14 Press down the foot switch and then move thecontrol handle all the way to the EXTEND position.Record the maximum voltage reading.


16 Start a timer and simultaneously move thecontrol handle all the way to the EXTEND position.Note how long it takes to reach the maximumvoltage recorded in step 14. This is the rampspeed.

17 Set the ramp rate: turn the trimpot to obtaina 3 second ramp speed. Turn thetrimpot clockwise to increase the time orcounterclockwise to decrease the time.

Boom extend/retract specifications

Threshold 3.5V DC

Boom extend - Max-out 9.75V DCCycle time 60 to 80 seconds

Boom retract - Dual (lo) range 9.2V DCCycle time 55 to 85 seconds

Ramp rate 3 seconds

1-2Horsepower Limiter Board

The horsepower limiter board is responsible forgoverning drive pump output. It senses engine rpmfrom the alternator. The horsepower limiter boardsenses drops in rpm normally due to increaseddrive resistance (rough terrain or incline), anddecreases voltage to the drive controller which inturn decreases voltage to the drive pump, therebyreducing pump output to maintain optimum enginerpm and horsepower. Three adjustments arerequired for optimum performance.

How to Adjust the HorsepowerLimiter Board

The engine rpm must becorrect before performing thisprocedure. See MaintenanceProcedure B-12, Check andAdjust the Engine RPM.

Do not adjust the horsepowerlimiter board unless the staticbattery voltage is above 12V DCand the alternator is operatingproperly with 12.5 to 14.5V DCoutput.

Gasoline/LPG models: Performthis procedure in gasoline mode.



PLATFORM CONTROLS

12V DC or greatergroundengine rpm sensornot usednot usedlow drive speed limit switchnot usednot usednot usedoutput to drive controller

b

a

c

a

1 Remove the fasteners from the platformcontrol box lid.

2 Open the control box lid and locate thehorsepower limiter board.


Platform control boxa horsepower limiter board

3 Connect the black(-) lead from a DC volt meterto the no. 2 terminal, and the red(+) lead to theno. 10 terminal.

Horsepower limiter board

a "A" potentiometer maximum voltageoutput to the controller in the stowedposition

b "B" potentiometer maximum voltageoutput to the drive controller in theboom raised position

c "C" potentiometer reaction rate orhow fast the voltage output reacts tothe change in engine rpm



6 Press down the foot switch and adjust the"A" potentiometer counterclockwise to increasevoltage or clockwise to decrease voltage.

"A" potentiometer specifications - all models

Voltage setting 10.5 to 11.5V DC

7 Move the engine idle control switch to low idle(turtle symbol).

8 Press down the foot switch and then adjustthe "C" potentiometer to obtain a0.01V DC to 0.03V DC voltage reading.


10 Press down the foot switch and re-adjust the"A" potentiometer to the previous voltagesetting in step 6.

11 Be sure that the boom is in the stowed position,then drive the machine and observe how theengine rpm reacts to drive control handlemovement. If the engine surges or hunts, adjustthe "C" potentiometer counterclockwise untilsurging is minimized.

Under an extreme load, anexcessive counterclockwiseadjustment to the "C"potentiometer will causethe engine to stall. The "C"potentiometer adjustment is acompromise between enginestability (surging) and enginerpm droop.

12 Disconnect the volt meter.



PLATFORM CONTROLS

13 Raise the boom above horizontal.

14 Drive the machine for 40 feet (12 m) andrecord the elapsed time. Repeat this step inthe opposite drive direction.

15 Adjust the "B" potentiometer to obtain thecorrect raised drive speed of 1 foot per second(0.31 m per second). Turn the "B"potentiometer counterclockwise to increasevoltage or clockwise to decrease voltage.

16 Close the platform control box lid and installthe fasteners.

Drive speed specifications

Stowed position distance: 40 ft / 12 m

2WD 4WDGasoline/LPG models 40 ft/6.2 sec 40 ft/9.1 sec

12.2 m/6.2 sec 12.2 m/9.1 sec

Deutz Diesel models 40 ft/6.8 sec 40 ft/9.1 sec12.2 m/6.8 sec 12.2 m/9.1 sec

Boom raised or distance: 40 ft / 12 mextended 1 foot per secondAll models 30.5 cm per second

1-3Foot Switch

How to Test the Foot Switch1 Turn the key switch to the OFF position and

separate the wiring quick disconnect plug fromthe platform toe board.

2 Do not press down the foot switch. Connect theleads from an ohmmeter or continuity tester toeach wire combination listed below and checkfor continuity.

Test Desired result

red to black continuity(zero Ω)

red to white no continuity(infinite Ω)

black to white no continuity

Do not use the color of theconnector as a guide for thesetests. Use the actual wire colorto identify which wire to use fortesting.

3 Press down the foot switch. Connect the leadsfrom an ohmmeter or continuity tester to eachwire combination listed below and check forcontinuity.

Test Desired result

red to black no continuity(infinite Ω)

red to white no continuity

black to white continuity(zero Ω)



PLATFORM CONTROLS

1-4Resistors

The resistors are used on 4WD machines tomaintain low range drive speed. The resistors arelocated in the platform control box.

Refer to the schematic legendsfor resistor locations and values.

How to Test the Resistors1 Turn the key switch to the OFF position.

2 Disconnect either end of one of the wiresconnected to the resistor to be tested.

3 Connect the leads from an ohmmeter to eachend or wiring of the resistor being tested.

4 Compare the ohmmeter reading with theresistance rating printed on the resistor.

1-5Toggle Switches

Toggle switches used for single function switchingare single pole double throw (SPDT) switches.Dual function switching requires a double poledouble throw (DPDT) switch.

How to Test a Toggle SwitchContinuity is the equivalent of 0 to3 ohms. A simple continuity testermay not accurately test the switch.

This procedure covers fundamental switch testingand does not specifically apply to all varieties oftoggle switches.

1 Turn the key switch to the OFF position. Tagand disconnect all wiring from the toggle switchto be tested.

2 Connect the leads of an ohmmeter to the switchterminals in the following combinations listedbelow to check for continuity.

Test Desired result

Left position

terminal 1 to 2, 3, 4, 5 & 6 no continuity(infinite )

terminal 2 to 3 continuity(zero )

terminal 2 to 4, 5 & 6 no continuity


terminal 4 to 5 & 6 no continuity

terminal 5 to 6 continuity

Center position There are no terminal combinationsthat will produce continuity

(infinite )

Right position

terminal 1 to 2 continuity(zero )

terminal 1 to 3, 4, 5 & 6 no continuity(infinite )

terminal 2 to 3, 4, 5 & 6 no continuity


terminal 4 to 5 continuity

terminal 4 to 6 no continuity

terminal 5 to 6 no continuity

1

2

3

4 5 6

1 2 3

1

2

3 1

2

3

1 2 3 1 2 3

1 2 3 1 2 3 1 2 3

4 5 6 4 5 6

CenterLeft Right

Single poledouble throw(SPDT)

Double poledouble throw(DPDT)



PLATFORM CONTROLS

1-6Control Relays

Relays used for single function switching are singlepole double throw (SPDT) relays.

How to Test a Single Pole DoubleThrow Relay

Electrocution hazard.Contact with electrically chargedcircuits may cause death orserious injury. Remove all rings,watches and other jewelry.

Direct Connection Relay

1 Label and then disconnect all the wiring fromthe relay to be tested.

2 Connect the leads from an ohmmeter orcontinuity tester to each terminal combinationand check for continuity. Terminals 85 and 86represent the coil and should not be tested inany other combination.

Test Desired result

terminal 85 to 86 without resistor 85 to 95Ω

terminal 85 to 86 with resistor 75 to 85Ω

terminal 87 to 87a & 30 no continuity(infinite Ω)

terminal 87a to 30 continuity(zero Ω)

3 Connect 12V DC to terminal 85 and a groundwire to terminal 86, then test the followingterminal combinations.

Test Desired result

terminal 87 to 87a & 30 no continuity(infinite Ω)

terminal 87 to 30 continuity(zero Ω)

terminal no. 87a - N.C.terminal no. 85 - groundterminal no. 30 - commonterminal no. 86 - coilterminal no. 87 - N.O.

Control Relay Schematic - without resistor

Control Relay Schematic - with resistor



Platform Components

2-1Platform

How to Remove the Platform1 Separate the foot switch quick disconnect plug.

2 Support the platform support weldment with aappropriate lifting device.

3 Open the platform control box and remove theplatform control box mounting fasteners. Thenlower the control box and set it aside.

If your machine is equipped withan airline to platform option, theairline must be disconnected fromthe platform before removal.

4 Remove the platform mounting fasteners andremove the platform from the machine.

Crushing hazard. The platformmay become unstable and fall if itis not properly supported.

2-2Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through theentire range of boom motion. It operates in aclosed-circuit hydraulic loop with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent movement inthe event of a hydraulic line failure.

How to Remove the PlatformLeveling Slave Cylinder

Before cylinder removal isconsidered, bleed the slavecylinder to be sure there is noair in the closed loop.

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section Two, HydraulicHose and Fitting TorqueSpecifications.

1 Extend the boom until the slave cylinderbarrel-end pivot pin is accessible.

2 Raise the boom slightly and place blocks underthe platform.

3 Lower the boom until the platform is resting onthe blocks just enough to support the platform.

Do not rest the entire weight of theboom on the blocks.



PLATFORM COMPONENTS

4 Tag, disconnect and plug the hydraulic hosesfrom the slave cylinder at the union locatednear the platform rotate counterbalance valvemanifold and connect them together using aconnector. Cap the fittings on the cylinder.


5 Pull the slave cylinder hoses through theplatform rotator.

6 Remove the pin retaining fastener fromthe slave cylinder rod-end pivot pin. Do notremove the pin.

7 Remove the external retaining ring from thebarrel-end pivot pin.

8 Use a soft metal drift to drive the rod-end pivotpin out.

9 Use a soft metal drift and drive the barrel-endpin out.

10 Carefully pull the cylinder out of the boom.


How to Bleed the Slave CylinderDo not start the engine. Useauxiliary power for all machinefunctions in this procedure.

1 Raise the boom to a horizontal position.

2 Move the platform level switch up and downthrough two platform leveling cycles to removeany air that might be in the system.

2-3Platform Rotator

The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the platform160 degrees.

How to Remove thePlatform Rotator

Component damage hazard. Markthe platform mounting weldmentand the rotator flange beforeremoving the platform mountingweldment. The platform mountingweldment must be replaced in theexact same position on the rotatorflange as it was before removal. Ifa new rotator is installed or therotator is disassembled, properalignment can be achieved byrotating the rotator all the way tothe left and then installing theplatform mounting weldment allthe way in the left position.


1 Remove the platform. See 2-1,How to Remove the Platform.



PLATFORM COMPONENTS

2 S-60 models: Tag, disconnect and plug thehydraulic hoses from the platform rotatormanifold. Cap the fittings on the rotator.


S-65 models: Tag, disconnect and plug thehydraulic hoses from the "V1" and "V2" ports onplatform rotator manifold. Cap the fittings on themanifold.


3 Support the platform mounting weldment, but donot apply any lifting pressure.

4 Remove the six mounting bolts from theplatform mounting weldment, then remove thecenter bolt and slide the platform mountingweldment off of the platform rotator.

Crushing hazard. The platformmounting weldment may becomeunbalanced and fall if it is notproperly supported.

5 Support the platform rotator. Do not applyany lifting pressure.

S-60 Models:

6 Support the rod end of the platform levelingslave cylinder.

7 Remove the pin retainer from the slave cylinderrod-end pivot pin and the rotator pivot pin.

8 Use a soft metal drift to drive both pins out, thenremove the platform rotator from the machine.

Crushing hazard. The platformrotator may become unbalancedand fall if it is not properlysupported.

S-65 Models:

6 Remove the pin retaining fasteners from the jibboom and jib boom leveling arms to platformrotator pivot pins. Do not remove the pins.

7 Support the jib boom and leveling arms.

8 Use a soft metal drift to drive both pins out, thenremove the platform rotator from the machine.

Crushing hazard. The platformrotator may become unbalancedand fall if it is not properlysupported.



How to Bleed the PlatformRotator

Do not start the engine. Useauxiliary power for all machinefunctions in this procedure.

1 Move the function enable toggle switch to eitherside and activate the platform rotate toggleswitch to the right then the left through twoplatform rotation cycles, then hold the switch tothe RIGHT position until the platform is fullyrotated to the right.

2 Connect a clear hose to the top bleed valve.Place the other end of the hose in a containerto collect any drainage. Secure the container tothe boom.

3 Open the top bleed valve on the rotator, but donot remove it.

a top bleed valveb bottom bleed valvec clear hosed container

PLATFORM COMPONENTS

a

d c b

4 Move the function enable toggle switch to eitherside and activate and hold the platform rotateswitch to the LEFT position until the platform isfully rotated. Continue holding the switch untilair stops coming out of the bleed valve. Thenclosethe bleed valve.

Crushing hazard. Keep clear ofthe platform during rotation.

5 Connect the clear hose to the bottom bleedvalve and open the valve. Do not remove thebleed valve.

6 Move the function enable toggle switch to eitherside and activate and hold the platform rotateswitch to the RIGHT position until the platform isfully rotated. Continue holding the switch untilair stops coming out of the bleed valve. Thenclose the bleed valve.

Crushing hazard. Keep clear ofthe platform during rotation.

7 Remove the hose from the bleed valve andclean up any hydraulic oil that may have spilled.

8 Rotate the platform full right then left andinspect the bleed valves for leaks.



3-1Jib Boom, S-65 Models

How to Remove the Jib BoomPerform this procedure with theboom in the stowed position.



2 Remove the platform mounting weldmentand the platform rotator. See 2-3, How toRemove the Platform Rotator.

3 Remove the cable tray from the side of thejib boom.

4 Support the jib boom with a lifting device.

5 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


6 Support the barrel end of the cylinder with alifting device.

7 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin.

8 Use a soft metal drift to remove the pin and laythe cylinder onto the ground.

9 Tag, disconnect and plug all the hydraulichoses from the jib boom manifold.


10 Attach a lifting strap from an overhead crane tothe jib boom.

11 Remove the pin retaining fastener from the jibboom pivot pin. Use a soft metal drift to removethe pin, then remove the jib boom from theprimary boom.

Crushing hazard. If the overheadcrane is not properly attached, thejib boom may become unbalancedand fall when it is removed fromthe machine.

12 Remove the pin retaining fastener from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

13 Slide both of the jib boom leveling arms off ofthe jib boom pivot pin.

14 Support the rod end of the jib boom lift cylinderwith a lifting device.

15 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin, then remove the jibboom lift cylinder from the jib boom mountingweldment.

Crushing hazard. If the overheadcrane is not properly attached, thejib boom lift cylinder may becomeunbalanced and fall when it isremoved from the machine.

Jib Boom Components, S-65 Models



JIB BOOM COMPONENTS, S-65 MODELS

3-2Jib Boom Lift Cylinder,S-65 Models

How to Remove the Jib BoomLift Cylinder



1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Thenlower the jib boom until the platform is restingon the blocks just enough to support theplatform.

Do not rest the entire weight of theboom on the blocks.

2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


3 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

4 Use a soft metal drift to tap the jib boom liftcylinder rod-end pivot pin half way out. Thenlower one of the leveling arms to the ground.Tap the pin the other direction and lower theopposite leveling arm. Do not remove the pin.

5 Support the jib boom lift cylinder with a liftingdevice.

6 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the barrel-end pin.

7 Use a soft metal drift to remove the jib boom liftcylinder rod-end pin. Remove the cylinder fromthe machine.

Crushing hazard. The jib boom liftcylinder may become unbalancedand fall when it is removed fromthe machine if it is not properlysupported.



JIB BOOM COMPONENTS, S-65 MODELS

3-3Jib Boom / Platform Rotate Manifold Components, S-65 Models1 2 position 3 way valve ....................... AM ........ Platform rotate/ jib boom select .......... 8-10 ft-lbs / 11-14 Nm

Plug Torque Specifications

Description Hex Size Torque

SAE No. 2 1/8 50 in-lbs / 6 Nm

SAE No. 4 3/16 13 ft-lbs / 18 Nm

How to Check the Resistanceof a Valve Coil1 Turn the key switch to the OFF position and

disconnect the wires from the valve coil tobe tested.

2 Connect the leads from an ohmmeter to thevalve coil terminals.

Valve coil specification

2 position 3 way valve 5.9Ω(schematic item AM)

1 1

AM

AM



4-1Boom Cable Track

The boom cable track guides cables and hosesrunning up the boom. It can be repaired link by linkwithout removing the cables and hoses that runthrough it. Removing the entire boom cable track isnecessary when performing major repairs thatinvolve removing the boom.

How to Remove the BoomCable Track


1 Open the platform control box and remove theplatform control box mounting fasteners.

2 Separate the footswitch quick disconnect thenlower the platform control box and lay it off tothe side.

3 Tag, disconnect and plug the hydraulic hosesfrom the "V1" and "V2" ports on thecounterbalance valve manifold located near theplatform rotator. Cap the fittings on themanifold.


Boom Components

4 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling cylinder at the unionand connect the hoses from the cylindertogether using a connector.


5 S-65 Models: Remove the hose and cablecover from the side of the jib boom.

6 S-65 Models: Remove the jib/rotate manifoldmounting fasteners. Do not disconnect any ofthe hoses.

7 S-65 Models: Tag, disconnect and plug thehydraulic hoses from the jib boom lift cylinder.Cap the fittings on the cylinder.



9 Remove the fasteners from the drive speed limitswitch mounted on the side of the cable track atthe pivot end of the boom. Do not disconnectthe wiring.

10 Remove the fasteners from the side panel onthe lower cable track, then remove the panel.Pull all of the cables out of the channel.

11 Place blocks in between the upper and lowercable tracks and secure the upper and lowertracks together.

Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackmay become unbalanced and fallwhen it is removed from themachine.



BOOM COMPONENTS

12 Remove the mounting fasteners from the largecable track guide at the platform end of thecable track. Remove the guide.

13 Remove the hose and cable clamp at theplatform end of the cable track.

14 Attach a lifting strap from an overhead crane tothe cable track.

15 Remove the cotter pin and clevis pin from theupper cable track at the platform end.

16 Remove the cable track mounting fasteners thatattach the lower cable track to the boom.

17 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackmay become unbalanced and fallif it is not properly attached to theoverhead crane.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.

How to Repair the BoomCable Track

Component damage hazard.The boom cable track can bedamaged if it is twisted.

A cable track repair kit is availablethrough the Genie IndustriesService Parts Department,Part no. 46677. The kit includes a4 link section of cable track,fasteners, other miscellaneousparts and detailed instructions.

1 Remove the boom cable track. See 4-1, How toRemove the Boom Cable Track.

2 Visually inspect the cable track and determinewhich 4 link section needs to be replaced.

3 Drill out the 4 spot welds on each side of thecable track using a 17/64" drill bit. Repeat thisstep for the other end of the 4 link section ofcable track.

Component damage hazard.Cables and hoses can bedamaged if the drill bit comes incontact with them. Protect thehoses and cables with a block ofwood to prevent drilling into thehoses and cables.

4 Remove the retaining fasteners from upperblack rollers from the 4 link section of cabletrack to be replaced. Remove the rollers.

5 Lift up the hoses and cables and carefullyremove the damaged 4 link section of cabletrack.

Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.

6 Remove the upper rollers from the replacementsection of cable track.

7 Lift up the hoses and cables and carefully insertthe new 4 link section of cable track.

Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.

8 Connect the ends of the replacement cabletrack section to the existing cable track usingthe fasteners provided in the kit. Do notovertighten the fasteners.

Component damage hazard.Over tightening the fasteners willresult in the cable track notrotating and may bind duringoperation.

Be sure that the fasteners areinstalled from the inside out so thenuts are on the outside of thecable track.



BOOM COMPONENTS

9 Install the black rollers onto the new section ofcable track.

10 Install cable track onto the machine and operatethe boom/extend function fully to ensuresmooth operation of the new section of cabletrack.

4-2Boom

How to Shim the Boom1 Measure each top wear pad.

Replace the pad if it is less than9/16 inch (14.3 mm) thick. If thepad is more than 9/16 inch(14.3 mm) thick, perform thefollowing procedure.

2 Measure each bottom and side wear pad.

Replace the pad if it is less than11/16 inch (17.5 mm) thick. If thepad is more than 11/16 inch(17.5 mm) thick, perform thefollowing procedure.

3 Extend the boom until the wear pads areaccessible.

4 Loosen the wear pad mounting fasteners.

5 Install the new shims under the wear pad toobtain zero clearance and zero drag.

6 Tighten the mounting fasteners.

7 Extend and retract the boom through an entirecycle. Check for tight spots that may causebinding or scraping of the boom.

Always maintain squarenessbetween the outer and inner boomtubes.

How to Remove the BoomThis procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools may cause death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.




2 Remove the platform rotator and leveling slavecylinder. See 2-3, How to Remove the PlatformRotator.

S-65 Models: Remove the jib boom. See 3-1,How to Remove the Jib Boom.

3 Remove the mounting fasteners from the jibboom/jib rotate valve manifold on the end of theboom. Then remove the manifold and set itaside.

4 Remove the fasteners from the drive speed limitswitch mounted on the side of the cable track.Do not disconnect the wiring.

5 Support the cable track with an overhead crane.

6 Remove the hose/cable clamp from the pivotend of the boom.

7 Remove the hose and cable clamp at theplatform end of the cable track.

8 Remove the fasteners from the large cabletrack guide at the platfrom end of the cabletrack. Remove the guide.



BOOM COMPONENTS

9 Remove the cotter pin from the clevis pin at theplatform end of the cable track and remove theclevis pin.

10 Remove the fasteners from the side panel onthe cable track to access the cable trackmounting fasteners.

11 Remove the cable track mounting fasteners,then remove the cable track from theboom and lay it off to the side.

Component damage hazard.The boom cable trackcan be damaged if it is twisted.


12 Remove the turntable end cover.

13 Remove the retaining fastener from the mastercylinder rod-end pivot pin. Use a soft metal driftto remove the pin. Pull the cylinder back andsecure it from moving.

Component damage hazard.When pulling the master cylinderback, be sure not to damage themaster cylinder hoses or fittings.

14 Remove the fasteners from the drive speed limitswitch mounted to the turntable riser at thepivot end of the boom. Do not disconnect thewiring.

15 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


16 Attach an overhead 5 ton (4536 kg) crane to thecenter point of the boom.

17 Attach a similar lifting device to the lift cylinder.

18 Use the crane to lift the boom to a horizontalposition.

19 Place support blocks under the lift cylinder,across the turntable.

20 Remove the pin retaining fastener from theboom lift cylinder rod-end pin. Use a soft metaldrift to remove the pin.

Crushing hazard. The boom liftcylinder will fall unless it isproperly supported.

21 Lower the rod end of the lift cylinder ontosupport blocks. Protect the cylinder rod fromdamage.

22 Remove the pin retaining fastener from theboom pivot pin.

23 Remove the boom pivot pin with a soft metaldrift, then carefully remove the boom from themachine.

Crushing hazard. If the overheadcrane is not properly attached,the boom may becomeunbalanced and fall when it isremoved from the machine.

How to Disassemble the BoomComplete disassembly of theboom is only necessaryif the outer or inner boom tubesmust be replaced. The extensioncylinder can be removed withoutcompletely disassembling theboom. See 4-4, How to Removethe Extension Cylinder.

1 Remove the boom. See 4-2,How to Remove the Boom.

2 Place blocks under the extension cylinder forsupport.

3 Remove the external snap rings from theextension cylinder barrel-end pivot pin at thebase of the number 1 boom tube. Use a softmetal drift to remove the pin.



BOOM COMPONENTS

4 Remove and label the wear pads from the topside of the number 1 boom tube at the platformend of the boom.

Pay careful attention to thelocation and amount of shimsused with each wear pad.

5 Remove the two wear pad stop bolts from eachside of the number 1 boom tube (located on theoutside).

6 Support the number 2 and 3 boom tubes with alifting strap attached to an overhead crane atthe platform end of the boom.

7 Support and slide the number 2 and 3 boomtubes out of the number 1 boom tube. Place the2 and 3 boom tubes on blocks for support.

Crushing hazard. The number 2and 3 boom tubes may becomeunbalanced and fall when they areremoved from the number 1 boomtube if they are not properlysupported.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.

8 Remove and label the wear pads from the topside of the number 2 boom tube at the platformend of the boom.

9 Remove the trunnion cap mounting fasteners atthe base of the number 2 boom tube. Then usea slide hammer to remove the trunnion caps.

10 Carefully rotate the the base end of theextension cylinder until the pin mounting bore isin a vertical position.

11 Support the number 3 boom tube with a liftingstrap attached to an overhead crane at theplatform end of the boom.

12 Support and slide the number 3 boom tube outof the number 2 boom tube. Place the number 3boom tube on blocks for support.

Crushing hazard. The number 3boom tube may becomeunbalanced and fall when it isremoved from the number 2 boomtube if it is not properly supported.


13 Remove the external snap rings from theextension cylinder rod-end pivot pin at theplatform end of the number 3 boom tube. Use asoft metal drift to remove the pin.

14 Support and slide the extension cylinder out ofthe base end of the number 3 boom tube. Placethe extension cylinder on blocks for support.

Crushing hazard. The extensioncylinder may become unbalancedand fall when it is removed fromthe number 3 boom tube if it is notproperly supported.


15 Remove and label the wear pads from theextension cylinder.

Pay careful attention to thelocation of each wear pad.



4-3Boom Lift Cylinder

How to Remove the BoomLift Cylinder

This procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools may result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.


1 Raise the boom until the boom is horizontal.

2 Place support blocks under the cylinder acrossthe turntable.

3 Attach an overhead 5 ton (4536 kg) crane to theboom. Do not lift the boom.

4 Support the rod end of the boom lift cylinderwith an overhead crane or similar lifting device.

Crushing hazard. If the overheadcrane is not properly attached,the lift cylinder may becomeunbalanced and fall when it isdisconnected from the machine.

BOOM COMPONENTS

5 Tag, disconnect and plug the boom lift cylinderhydraulic hoses. Cap the fittings on thecylinder.


6 Remove the pin retaining fastener from the liftcylinder rod-end pivot pin. Use a soft metal driftto remove the pin, then lower the lift cylinderonto the blocks. Protect the cylinder rod fromdamage.

Crushing hazard. The lift cylindermay become unbalanced and fallif it is not properly supported.

7 Remove the mounting fasteners from the barrel-end cylinder pin retaining plates.

8 With the lift cylinder being supported by theoverhead crane, pull the cylinder toward theplatform until it is out.

Crushing hazard. The lift cylindermay become unbalanced and fallif it is not properly supported.

Component damage hazard. Thecables and hydraulic hoses can bedamaged if the lift cylinder ispulled across them.



4-4Extension Cylinders

The extension cylinder consists of two cylindersthat are fastened together. The first cylinderextends and retracts the number 2 boom tube. Thesecond cylinder extends and retracts the number 3boom tube.The extension cylinders are equippedwith counterbalance valves to prevent movementin the event of a hydraulic line failure.

How to Remove theExtension Cylinders

This procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools may cause death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.


1 Extend the boom until the extension cylinderrod-end pin is accessible in the number 3 boomtube.

2 Remove the platform. See 2-1, How to Removethe Platform.

3 Remove the platform leveling slave cylinder.See 2-2, How to Remove the Slave Cylinder.

S-65 Models: Remove the jib boom. See 3-1, Howto Remove the Jib Boom.


5 Remove the external snap rings from theextension cylinder rod-end pin (at the platformend). Use a soft metal drift to remove the pin.

BOOM COMPONENTS

6 Remove the turntable end cover.

7 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


8 Remove the trunnion pin covers from both sidesof the number 1 boom tube at the pivot end ofthe boom.

9 Remove the trunnion pin retaining fastener anduse a slide hammer to remove the pins.

10 Remove the pin retaining fasteners from bothsides of the extension cylinder at the pivot endof the boom.

11 Use a slide hammer to remove the pins.

12 Support and slide the extension cylinder out ofthe pivot end of the boom.

Crushing hazard. The extensioncylinder will fall when it is removedfrom the extension boom if it is notproperly supported.

Note the length of the cylinderafter removal. The cylinder mustbe at the same length forinstallation.



4-5Platform LevelingMaster Cylinder

The master cylinder acts as a pump for the slavecylinder. It’s part of the closed circuit hydraulic loopthat keeps the platform level through the entirerange of boom motion. The master cylinder islocated at the base of the boom.

How to Remove the PlatformLeveling Master Cylinder


1 Raise the boom until the rod-end pivot pin isaccessible.

2 Remove the turntable end cover to access themaster cylinder.

3 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on thecylinder.


4 Remove the pin retaining fasteners from themaster cylinder barrel-end pivot pin.

5 Place a rod through the barel-end pivot pin andtwist to remove the pin.

6 Attach a lifting strap from an overhead crane tothe lug on the rod end of the master cylinder.

7 Remove the pin retaining fastener from the rod-end pivot pin.

8 Use a soft metal drift to remove the pin.

Crushing hazard. The mastercylinder may become unbalancedand fall if it is not properlysupported by the lifting device.

BOOM COMPONENTS



5-1Turntable Covers

How to Remove aTurntable Cover1 Raise the turntable cover. Support the open

cover with an overhead crane or forklift.Do not lift it.

Crushing hazard. Due to its heavyweight, do not attempt to supportthe cover by hand.

Component damage hazard.Protect the cover from damage byusing carpet or padding on thecrane or forklift forks.

2 Remove the upper and lower retaining clipsfrom the gas strut.

3 Gently pry the strut pivot sockets off of the ballstuds and remove the strut. Protect the strutcylinder rod from damage.

Mark the location of the hingesupport bracket on the bulkhead toensure proper cover alignmentduring installation.

4 Remove the cover hinge bolts, that fasten thehinge support bracket to the bulkhead.

5 Carefully lift and remove the cover fromthe machine.

Crushing hazard. The turntablecover may become unbalancedand fall if it is not properlysupported and secured to aappropriate lifting device.

If a turntable cover must bereplaced, be sure that allappropriate safety andinstructional decals areapplied to the new cover.

Alignment adjustments may benecessary when a new coveris installed.

Turntable Covers



6-1RPM Adjustment

Refer to Maintenance Procedures, B-12,Check and Adjust the Engine RPM.

6-2Flex Plate

The flex plate acts as a coupler between theengine and the pump. It is bolted to the engineflywheel and has a splined center to drivethe pump.

a pumpb pump shaftc couplerd flex plate with raised splinee flywheelf 1/2 inch gap

How to Remove the Flex Plate1 Disconnect the wiring plug at the electronic

displacement controller (EDC), located onthe drive pump.

2 Support the drive pump with an appropriatelifting device. Then remove all of the pumpmounting plate to engine bell housing bolts.

3 Carefully pull the pump away from the engineand secure it from moving.

4 Remove the flex plate mounting fasteners,then remove the flex plate from the flywheel.

Deutz Engine F4L 1011F

How to Install the Flex Plate1 Install the flex plate onto the flywheel with the

raised spline towards the pump. Torque the flexplate mounting bolts to 34 ft-lbs (46 Nm).

2 Install the coupler onto the pump shaft with theset screw toward the pump. Leave a 1/2 inch(12.7 mm) gap between the coupler and pumpend plate.

3 Apply Loctite® removable thread sealant to thecoupler set screw. Torque the set screw to45 ft-lbs (61 Nm).

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

4 Install the pump and torque the pump mountingplate fasteners to 34 ft-lbs (46 Nm).

6-3Oil Temperature and PressureGauges

The oil temperature gauge is an electrical gauge.The sending unit has limit contacts that are factoryset. The contacts will close at 300o F (147o C).When the contacts close, the engine will shut off toprevent damage and will not start until thetemperature drops below the contact point.Temperature will be indicated when the key is onand the Emergency Stop Button is pulled out to theON position.

Component damage hazard.Do not crank the engine withthe over-temperature light on.

The oil pressure gauge is an electrical gauge. Thesending unit has limit contacts that are factory set.The contacts will close at 7 psi (0.48 bar). Whenthe contacts close, the engine will shut off toprevent damage. Oil pressure will be indicatedwhen the engine is running.

Component damage hazard.Do not crank the engine with thelow oil pressure light on.

a b c d e

f



e

b c

f

g

7-1Governor Actuator

How to Set Up the GovernorActuator and Linkage

Adjustment of the governoractuator is only necessary whenthe governor actuator or thelinkage has been replaced.

1 Connect the linkage rod to the throttle plateshaft, then tighten the lock nut.

2 Fasten the lock nut and clevis yoke to thelinkage rod. Do not tighten the lock nutagainst the clevis yoke.

3 Loosen the fastener on the actuator arm. Rotatethe actuator arm until it is at a 110 degree angleto the linkage rod. Then tighten the actuatorarm fastener.

Governor actuator and linkagea clevis yokeb linkage rodc carburetord throttle plate shafte governor actuatorf actuator shaftg actuator arm

4 Position the linkage rod so that the throttle is inthe idle position. Then adjust the clevis yoke onthe linkage rod to obtain the proper length.Install the yoke onto the actuator arm.

5 With the throttle in the idle position and theactuator arm at a 110 degree angle to thelinkage, rotate the clevis yoke on the linkagerod two turns counterclockwise to pre-load thespring. Tighten the lock nut on the linkage rod.

d

110°

a

Ford LRG-423 Engine



6 Manually pull the actuator arm through a fullcycle to be sure that the linkage moves freely.Be sure that the linkage activates the throttleshaft to approximately half throttle.

Component damage hazard.If the throttle linkage is improperlyadjusted and allowed to reach fullthrottle, the engine will over-revand cause component damage.

The linkage must be free of frictionand obstruction. Do notlet it rub against the engine,brackets or hoses.

FORD LRG-423 ENGINE

7-2Choke Adjustments

This engine is equipped with an electrically heatedautomatic choke. The choke has a poppet valve toenhance cold starting ability on LPG fuel.

Choke adjustments are affectedby climate. Richer adjustmentwill be necessary in colderclimates, leaner adjustmentin warmer climates.

Automatic Choke withPoppet ValveThe choke functions in both gasoline and LPGmode. The choke butterfly may be adjusted to afully closed (rich) position for colder climates andthe poppet valve will provide a flow path duringLPG fueled operation.

rich lean



FORD LRG-423 ENGINE

a b c d e

f

7-3Timing Adjustment

Complete information to perform this procedure isavailable in the Ford LRG-423 2.3 Liter IndustrialEngine Service Manual (Ford number: PPD-194-287). Genie part number 33907.

7-4Carburetor Adjustment

Complete information to perform this procedure isavailable in the Ford LRG-423 2.3 Liter IndustrialEngine Service Manual (Ford number: PPD-194-287). Genie part number 33907.

7-5RPM Adjustment

Refer to Maintenance Procedures, B-12, Checkand Adjust the Engine RPM.

7-6Flex Plate

The flex plate acts as a coupler between theengine and the pump. It is bolted to the engineflywheel and has a splined center to drivethe pump.

a pumpb pump shaftc couplerd flex plate with raised splinee flywheelf 1/4 inch gap

Flex Plate Removal1 Disconnect and remove the hose between

the carburetor venturi and the air cleaner.

2 Disconnect the linkage from the governor,then remove the governor linkage fromthe carburetor. Do not alter the length ofthe linkage.

3 Disconnect the wiring plug at the electronicdisplacement controller (EDC), located onthe drive pump.

4 Remove the mounting fasteners from theregulator mounting bracket, then pull thebracket up past the bell housing. Securethe bracket before continuing.

5 Support the drive pump with an appropriatelifting device. Then remove all of the pumpmounting plate to engine bell housing bolts.

6 Carefully pull the pump away from theengine and secure it from moving.

7 Remove the flex plate mounting fasteners,then remove the flex plate from the fly wheel.



FORD LRG-423 ENGINE

How to Install the Flex Plate1 Install the flex plate onto the flywheel with the

raised spline towards the pump. Torque the flexplate mounting bolts to 34 ft-lbs (46 Nm).

2 Install the coupler onto the pump shaft with theset screw towards the pump. Leave a 1/4 inch(6.35 mm) gap between the coupler and pumpend plate.

3 Apply Loctite® removable thread sealant to thecoupler set screw. Torque the set screw to45 ft-lbs (61 Nm).

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

4 Install the pump and torque the pump mountingplate fasteners to 34 ft-lbs (46 Nm).

7-7Water Temperature and OilPressure Gauges

The water temperature gauge is an electricalgauge. The sending unit has limit contacts that arefactory set. The contacts will close at 230°F(109° C). When the contacts close, the engine willshut off to prevent damage and will not start untilthe temperature drops below the contact point.Temperature will be indicated when the key is onand the Emergency Stop Button is pulled out to theON position.

Component damage hazard.Do not crank the engine withthe over-temperature light on.

The oil pressure gauge is an electrical gauge. Thesending unit has limit contacts that are factory set.The contacts will close at 8 psi (0.55 bar). Whenthe contacts close, the engine will shut off toprevent damage. Oil pressure will be indicatedwhen the engine is running.

Component damage hazard.Do not crank the engine with thelow oil pressure light on.



a b

cd

7-8Vacuum Switch

How to Test the Vacuum Switch

a ohmmeterb common terminal (SOL.)c vacuum switchd normally open terminal (ING.)

1 Connect the leads from an ohmmeter orcontinuity tester to the common and normallyopen terminals.

Result: There should be no continuity(infinite Ω).

2 Apply mild suction to the vacuum port.

Result: The switch should close and show fullcontinuity (zero Ω).

Component damage hazard.Do not short the vacuum switchterminals to ground.

FORD LRG-423 ENGINE



Ground Controls

8-1Control Relays

See 1-6, Control Relays

8-2Toggle Switches

See 1-5, Toggle Switches.

8-3Wago® Components

How to Remove a Wago®

ComponentElectrocution hazard.Contact with electrically chargedcircuits may cause death orserious injury. Remove all rings,watches and other jewelry.

A small screwdriver is providedand should be used whenremoving a Wago® component.This screwdriver is located in theoperator’s manual storage box inthe platform.

1 Label the wiring from the component to beremoved.

2 Locate the removal tab on the bottom or topside of the component.

3 Use a small narrow flat blade screwdriver topush in and release the wire from thecomponent.

4 Use the small narrow flat blade screwdriver togently pry up on the tab of the component andremove it.

8-4Resistors

How to Test the ResistorThe resistor is used to maintain proper control ofboom function speeds. A 10 ohm resistor reducesvoltage to all the boom function switches at theground controls.

Refer to the schematic legends forresistor locations and values.

1 Turn the key switch to the OFF position.

2 Disconnect either end of one of the wiresconnected to the resistor to be tested.

3 Connect the leads from an ohmmeter to eachend or wiring of the resistor being tested.

4 Compare the ohmmeter reading with theresistance rating printed on the resistor.



GROUND CONTROLS

8-5Power Relay

Electrocution hazard. Contact withelectrically charged circuits mayresult in death or serious injury.Remove all rings, watches andother jewelry.

The power relay is mounted on thebackside of the ground controlbox.

How to Test the Power RelayElectrocution hazard. Disconnectthe ground cable from the batterybefore performing this procedure.

1 Connect the leads from an ohmmeter to eachterminal combination and check for continuity.

Test Desired result

2 small posts 12 to 16Ω

2 large posts no continuity(infinite Ω)

Any small post to no continuityany large post (infinite Ω)

a b ab

2 Connect 12V DC to one of the small posts anda ground wire to the other small post, then testthe following terminal combination.

Test Desired result

2 large posts continuity (zero Ω)

a high amp power contact terminal(large post)

b solenoid activate coil terminal(small post)



Hydraulic Pumps

9-1Lift/Steer Pump

How to Remove theLift/Steer Pump


1 Close the two hydraulic tank valves located atthe hydraulic tank.

Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe CLOSED position or componentdamage will occur.If the tank valves are closed,remove the key from the keyswitch and tag the machine toinform personnel of the condition.

2 Tag, disconnect and plug the lift/steer pumphydraulic hoses. Cap the fittings on the pump.


3 Remove the pump mounting bolts. Carefullyremove the pump.

Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpafter installing the pump.

9-2Drive Pump

The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electronic displacement controller(EDC), located on the pump. The only adjustmentthat can be made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould only be performed at an authorizedSundstrand-Sauer service center. Call GenieIndustries Service Department to locate your localauthorized service center.

How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.


1 Disconnect the electrical connection at theelectronic displacement controller (EDC)located on the drive pump.

open closed



HYDRAULIC PUMPS

2 Close the two hydraulic tank valves located atthe hydraulic tank.

Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe CLOSED position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

3 Tag and disconnect and plug the hydraulichoses from the drive and lift/steer pumps. Capthe fittings on the pumps.


4 Support the pump with a lifting device andremove the two drive pump mounting fasteners.

5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.

6 Remove the drive pump from the machine.

Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpafter installing the pump.

open closed

How to Prime the Pump1 Connect a 0 to 600 psi (0 to 41 bar) pressure

gauge to the test port on the drive pump.

2 Gasoline/LPG models: Disconnect theelectrical connector at the ignition coils. Theignition coils are located above the alternator.


Deutz Diesel models: Hold the manual fuelshutoff valve clockwise to the CLOSED position.

a manual fuel shutoff valve

3 Crank the engine with the starter motor for15 seconds, wait 15 seconds, then crank theengine an additional 15 seconds or until thepressure reaches 320 psi (22 bar).

4 Gasoline/LPG models: Connect the ignitioncoil wiring and start the engine from the groundcontrols. Check for hydraulic leaks.

a



Manifolds

10-1Function Manifold Components

The function manifold is located on the tank side tray, behind the ground control box.

Index SchematicNo. Description Item Function Torque

1 3 position 4 way D03 valve ................ A ........... Turntable rotate left/right ....................... 30-35 in-lbs / 3-4 Nm

2 3 position 4 way D03 valve ................ B ........... Boom up/down ...................................... 30-35 in-lbs / 3-4 Nm

3 3 position 4 way D03 valve ................ C ........... Boom extend/retract .............................. 30-35 in-lbs / 3-4 Nm

4 Check valve, pilot operated ............... D ........... Boom extend/retract circuit ................11-13 ft-lbs / 15-18 Nm

5 Relief valve, 2500 psi (172 bar) ........ E ........... Boom extend ......................................25-30 ft-lbs / 34-41 Nm

6 Relief valve, 2100 psi (145 bar) ........ F ........... Boom down ........................................25-30 ft-lbs / 34-41 Nm

7 Flow regulator valve,1.5 gpm (5.7 l/min) ............................. G ........... Boom extend/retract circuit

(prevents over flowingthe proportional valve) ...................... 10-12 ft-lbs / 14-16 Nm

8 Flow regulator valve,1.5 gpm (5.7 l/min) ............................. H ........... Boom up/down circuit

(prevents over flowingthe proportional valve) ...................... 10-12 ft-lbs / 14-16 Nm

9 Flow regulator valve,1.5 gpm (5.7 l/min) ............................. I ............ Turntable rotate left/right

(prevents over flowingthe proportional valve) ........................ 10-12 ft-lbs / 14-6 Nm

10 Flow regulator valve,0.1 gpm (0.38 l/min) ........................... J ............ Bleeds off differential

sensing valves to tank ...................... 10-12 ft-lbs / 14-16 Nm

11 Check valve ....................................... K ........... Differential sensing circuit,boom extend/retract .......................... 11-13 ft-lbs / 15-18 Nm

12 Check valve ....................................... L ........... Differential sensing circuit,boom up/down .................................. 11-13 ft-lbs / 15-18 Nm

13 Proportional solenoid valve ............... M .......... Boom extend/retract .......................... 10-12 ft-lbs / 14-16 Nm

14 Check valve ....................................... N ........... Differential sensing circuit,turntable rotate left/right .................... 11-13 ft-lbs / 15-18 Nm

15 Proportional solenoid valve ............... O ........... Boom up/down .................................. 10-12 ft-lbs / 14-16 Nm

16 Check valve ....................................... P ........... Differential sensing circuit,platform level up ............................... 11-13 ft-lbs / 15-18 Nm

17 Check valve ....................................... Q ........... Differential sensing circuit,platform level down ........................... 11-13 ft-lbs / 15-18 Nm

This list continues. Please turn the page



MANIFOLDS



Function Manifold Components, continued


18 Proportional solenoid valve ............... R ........... Turntable rotate left/right ................... 10-12 ft-lbs / 14-16 Nm

19 Solenoid valve - N.O. Poppet ............ S ........... Platform level up ............................... 25-30 ft-lbs / 34-41 Nm

20 Flow regulator valve,0.6 gpm (2.27 l/min) ........................... T ........... Platform level circuit .......................... 10-12 ft-lbs / 14-16 Nm

21 Solenoid valve - N.O. Poppet ............ U ........... Platform level down .......................... 25-30 ft-lbs / 34-41 Nm

22 Differential sensing valve .................. V ........... Meters flow to functions .................... 10-12 ft-lbs / 14-16 Nm

23 Relief valve,2600 psi (179 bar), S-60 models2900 psi (200 bar), S-65 models ....... W .......... System relief ..................................... 35-40 ft-lbs / 47-54 Nm

24 Diagnostic nipple ............................... X ........... Testing

25 Check valve ....................................... Y ........... Differential sensing circuitPlatform rotate left ............................. 11-13 ft-lbs / 15-18 Nm

26 Check valve ....................................... Z ........... Differential sensing circuitPlatform rotate right .......................... 11-13 ft-lbs / 15-18 Nm

27 Priority flow regulator valve, .............. AA ......... Steering ............................................. 10-12 ft-lbs / 14-16 Nm3.5 gpm (13.2 l/min), without oscillate axle5 gpm (18.9 l/min), with oscillate axle

28 Solenoid valve - N.O. Poppet ........... BB ......... Platform rotate left/Jib boom up ........ 25-30 ft-lbs / 34-41 Nm

29 Solenoid valve - N.O. Poppet ........... CC ........ Platform rotate right/Jib boom down . 25-30 ft-lbs / 34-41 Nm

30 Flow regulator valve,0.6 gpm (2.27 l/min) ........................... DD ........ Platform rotate .................................. 10-12 ft-lbs / 14-16 Nm

31 Counterbalance valve ........................ EE ......... Platform level up ............................... 35-40 ft-lbs / 47-54 Nm

32 Counterbalance valve ........................ FF ......... Platform level down .......................... 35-40 ft-lbs / 47-54 Nm

33 Check valve ....................................... GG ........ Boom extend/retract circuit ............... 11-13 ft-lbs / 15-18 Nm

MANIFOLDS


Description Hex size Torque


SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm



MANIFOLDS



10-2Valve Adjustments -Function Manifold

How to Adjust the SystemRelief Valve


1 Connect a 0 to 5000 psi (0 to 345 bar) pressuregauge to the test port (item 23) on the functionmanifold.


3 Hold the function enable switch to either sideand activate and hold the retract switch with theboom fully retracted. Observe the pressurereading on the pressure gauge.

4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap(item 23, function manifold).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then install the reliefvalve cap.

Tip-over hazard. Do not adjustthe relief valves higher thanspecified.

6 Repeat steps 2 through 5 and recheck reliefvalve pressure.

System relief valve specifications

PressureS-60 models 2600 psi 179.3 barS-65 models 2900 psi 200 bar

MANIFOLDS

How to Adjust the Boom DownRelief Valve




3 Hold the function enable switch to either sideand activate and hold the boom down switchwith the boom fully lowered. Observe thepressure reading on the pressure gauge.





Boom down relief valve specifications

Pressure 2100 psi145 bar



MANIFOLDS

How to Adjust the Boom ExtendRelief Valve




3 Hold the function enable switch to either sideand activate and hold the extend switch with theboom fully extended. Observe the pressurereading on the pressure gauge.





Boom extend relief valve specifications

Pressure 2500 psi172 bar

How to Override a ValveA hydraulic valve may need to be manuallyoverridden to troubleshoot a malfunction. Theproportional boom functions (boom up/down,extend/retract and turntable rotate) use a variableposition proportional valve and a three positiondirectional valve. Example: one position for boomup, one position for neutral and one position forboom down. The platform rotate function uses athree position valve. The platform level uses athree position and a two position valve. The threeposition valves and the proportional valves can bemanually overridden. To identify the manifoldvalves see 10-1, Function Manifold, in this section.

1 Push the button on the end of the valve in¼ inch (6 mm).

2 Hold the function enable switch to either sideand move the ground control function switch forthe function being overridden to operatefunction.

Collision hazard. Impact withmoving boom components maycause death or serious injury. Useextreme caution when overriding amachine function. Identify thedirection of machine movementbefore overriding a valve.



MANIFOLDS

How to Check the Resistanceof a Valve Coil1 Turn the key switch to the OFF position and

disconnect the wires from the valve coil to betested.

2 Connect the leads from an ohmmeter to thevalve coil terminals.

Valve coil specifications

Proportional solenoid valve, 12V 8.6Ω(schematic items M, O and R)

3 position 4 way directional valve, 10V 3.2Ω(schematic items A, B and C)

Normally open poppet valve 6.4Ω(schematic item S, U, BB and CC)



10-3Turntable Rotation Manifold ComponentsThe turntable rotation manifold is mounted to the turntable rotation motor on the tank side of the turntable.


1 Shuttle valve 2 position 3 way ........... HH ........ Turntable rotation brake release .......10-13 ft-lbs / 14-18 Nm

2 Counterbalance valve ........................ II ........... Turntable rotate right ........................35-40 ft-lbs / 47-54 Nm

3 Counterbalance valve ........................ JJ .......... Turntable rotate left ...........................35-40 ft-lbs / 47-54 Nm

321




SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

MANIFOLDS

HH

II

JJ



10-4Oscillate Manifold Components

The oscillate manifold is mounted inside the drive chassis at the non-steer end.


1 Orifice Plug, 0.052 inch (1.32 mm) .... KK ......... Differential sensing circuit

2 Differential sensing valve .................. LL ......... Differential sensing ........................... 10-12 ft-lbs / 14-16 Nm

3 Check valve ....................................... MM ....... Oscillate check - left .......................... 35-40 ft-lbs / 47-54 Nm

4 Pilot operated unloader valve950 psi (65 bar) ................................. NN ........ Sequencing ....................................... 10-12 ft-lbs / 14-16 Nm

5 Shuttle valve 2 position 3 way ........... OO ........ Pilot ................................................... 10-12 ft-lbs / 14-16 Nm

6 Piston ................................................................ Check valve circuit(the piston is located betweenindex numbers 3 and 7)

7 Check valve ....................................... PP ......... Oscillate check - right ....................... 35-40 ft-lbs / 47-54 Nm

8 Shuttle valve 2 position 3 way ........... QQ ........ Unloading .......................................... 35-40 ft-lbs / 47-54 Nm

9 Diagnostic fitting ............................................... Testing




SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

MANIFOLDS

1 2

3

6

7

8 4

9

5

KK

LL

MM

NN

OO

PP

QQ



10-5Valve Adjustments -Oscillate Manifold

How to Adjust the OscillateSequencing Valve Pressure


1 Connect a 0 to 2000 psi (0 to 138 bar) pressuregauge to the test port located on the oscillatemanifold.


2 Disconnect the directional valve linkage, byremoving the clevis yoke from the drivechassis.


4 With the engine running, manually activate thevalve and observe the pressure reading on thepressure gauge.

5 Turn the engine off. Hold the unloader valveand remove the cap (item 4).

6 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwiseto decrease the pressure. Then install thevalve cap.

Tip-over hazard. Do not adjust therelief valve higher than specified.

7 Repeat steps 3 through 6 and manually activatethe valve and recheck the valve pressure.

8 Turn the engine off, then remove thepressure gauge and assemble the directionalvalve linkage.

Sequencing valve specifications


MANIFOLDS



10-6Directional Valve Manifold Components

The directional valve manifold is mounted inside the drive chassis at the non-steer end.

IndexNo. Description Function Torque

1 Cap ................................................................... Breather ............................................. 20-25 ft-lbs / 27-33Nm

2 Spool valve ....................................................... Directional control

1

2

MANIFOLDS



How to Set Up the DirectionalValve Linkage

Adjustment of the directional valvelinkage is only necessary whenthe linkage or valve has beenreplaced.

1 Lower the boom to the stowed position.

2 Use a "bubble type" level to be sure the floor iscompletely level.

Failure to perform this procedureon a level floor will compromisethe stability of the machine andmay result in the machine tippingover.

3 Check the tire pressure in all four tires and addair if needed to meet specification.

4 Remove the drive chassis cover from thenon-steer end.

5 Disconnect the linkage clevis yoke from thedrive chassis (if not already disconnected).

6 Place a "bubble type" level across the drivechassis non-steer end. Check to be sure thedrive chassis is completely level.

7 To level the drive chassis, start the engine andpush up or pull down on the linkage adjustmentrod until the machine is completely level.

8 Verify that the ground and drive chassis arecompletely level.

9 Adjust the length of the rod by turning the clevisyoke until the clevis yoke can be pinned to thedrive chassis.

10 Install the clevis yoke pin then the cotter pin. Besure to bend the cotter pin.

11 Measure the distance between the drivechassis and the non-steer axle on both sides(from the inside of the drive chassis).

If the distance is not equal and theadjustment to the linkage wascompleted with the ground anddrive chassis level, consult GenieIndustries Service Department.

MANIFOLDS



10-7Steer Manifold Components, S-60/65 Oscillating Models

The steer manifold is underneath the function manifold.


1 3 position 4 way solenoid valve ......... SS ......... Steer left/right ....................................... 30-35 in-lbs / 3-4 Nm

2 Check valve ....................................... TT ......... Priority flow regulator circuit ..............10-12 ft-lbs / 14-16 Nm

3 Orifice Plug, 0.025 inch (0.635 mm) .. UU ........ Priority flow regulator circuit

4 Priority flowregulator valve, 3.5 gpm (13.2 l/min) . VV ......... Regulates flow to

oscillate manifold .............................. 10-12 ft-lbs / 14-16 Nm

1

2

MANIFOLDS

SS

TTUU

VV3

4






SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

10-82WD Drive Manifold Components

The drive manifold is mounted inside the drive chassis at the non-steer end.


1 Relief valve, 250 psi (17.2 bar) ......... WW....... Charge pressure circuit .....................10-12 ft-lbs / 14-16 Nm

2 Flow divider/combiner valve .............. XX ......... Controls flow to drive motorsin forward and reverse ......................25-30 ft-lbs / 34-41 Nm

3 Orifice 0.070 in (1.78 mm) ................. YY ......... Drive circuit

4 Shuttle valve 3 position 3 way ........... ZZ ......... Charge pressure circuit thatgets hot oil out of low pressureside of drive pump and allowslow pressure flow path forbrake release and 2-speedmotor shift .........................................15-18 ft-lbs / 20-24 Nm


MANIFOLDS

SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/8 75 ft-lbs / 102 Nm



MANIFOLDS



10-9Valve Adjustments, 2WDDrive Manifold

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi (0 to 41 bar) pressure

gauge to the test port located on the drivemanifold.


3 Drive the machine slowly in either direction andobserve the pressure reading on the pressuregauge.

4 Turn the engine off. Hold the charge pressurerelief valve and remove the cap (item 1).


6 Restart the engine. Drive the machine in eitherdirection and recheck the valve pressure.

7 Turn the engine off, then remove thepressure gauge.

Charge Pressure Relief valve specifications


MANIFOLDS



MANIFOLDS




10-104WD Drive Manifold Components

The drive manifold is mounted inside the drive chassis at the non-steer end.


1 Directional valve, 2 position 2 way .... AB ......... High speed divider bypassN.C. Pilot to open .............................. 25-30 ft-lbs / 34-41 Nm

2 Flow divider/combiner valve .............. AC ........ Controls flow to flowdivider/combiner valves 6 and 7 ....... 25-30 ft-lbs / 34-41 Nm

3 Relief valve, 250 psi (17.2 bar) ......... AD ........ Charge pressure circuit ..................... 10-12 ft-lbs / 14-16 Nm

4 Check valve, pilot to close ................. AE ......... Works in conjunction withIndex no.12 in the high speeddivider bypass circuit ........................ 10-12 ft-lbs / 14-16 Nm

5 Orifice - plug, 0.052 inch (1.32 mm) .. AF ......... Front drive motor circuit

6 Flow divider/combiner valve .............. AG ........ Controls flow to steer enddrive motors in forwardand reverse ....................................... 25-30 ft-lbs / 34-41 Nm

7 Flow divider/combiner valve .............. AH ........ Controls flow to non-steer enddrive motors in forwardand reverse ....................................... 25-30 ft-lbs / 34-41 Nm

8 Orifice 0.070 in (1.78 mm) ................. AI .......... Rear drive motor circuit

9 Orifice 0.070 in (1.78 mm) ................. AJ ......... Equalizes pressure on both sidesof flow divider combiner valveIndex no. 2

10 Shuttle valve, 3 position 3 way .......... AK ......... Charge pressure circuitthat gets hot oil out of low pressureside of drive pump and allows lowpressure flow path for brakerelease and 2-speed motor shift ....... 15-18 ft-lbs / 20-24 Nm


12 Check valve ....................................... AL ......... Works in conjunction withIndex no.4 in the high speeddivider bypass circuit ........................ 10-12 ft-lbs / 14-16 Nm




SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/8 75 ft-lbs / 102 Nm

MANIFOLDS



MANIFOLDS



10-11Valve Adjustments, 4WDDrive Manifold

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi (0 to 41 bar) pressure

gauge to the test port located on the drivemanifold.


3 Drive the machine slowly in either direction andobserve the pressure reading on the pressuregauge.

4 Turn the engine off. Hold the charge pressurerelief valve and remove the cap (index 3).


6 Restart the engine. Drive the machine in eitherdirection and recheck the valve pressure.

7 Turn the engine off, then remove thepressure gauge.

Charge Pressure Relief valve specifications


MANIFOLDS



Fuel and Hydraulic Tanks

11-1Fuel Tank

How to Remove the Fuel TankExplosion hazard. Engine fuelsare combustible. Remove the fueltank in an open, well-ventilatedarea away from heaters, sparks,flames and lighted tobacco.Always have an approved fireextinguisher within easy reach.

Explosion hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.

1 Turn the manual fuel shutoff valve to theCLOSED position.

2 Remove the tank side turntable cover. See 5-1,How to Remove a Turntable Cover.

3 Gasoline/LPG models: Disconnect, drain andplug the fuel hose.

Deutz Diesel models: Disconnect, drain andplug the supply and return fuel lines. Cap thefuel return fitting on the fuel tank.

4 Remove the retaining fasteners from the fueltank hold down straps. Remove the straps fromthe fuel tank.

5 Support the fuel tank with 2 lifting straps. Placeone lifting strap at each end of the tank andattach the lifting straps to an overhead crane.

6 Remove the fuel tank from the machine.

Crushing hazard. The fuel tankmay become unbalanced and fallif it is not properly supported andsecured to the overhead crane.

Clean the fuel tank and inspectfor rust and corrosion beforeinstalling.

11-2Hydraulic Tank

The primary functions of the hydraulic tank are tocool, clean and deaerate the hydraulic fluid duringoperation. It utilizes internal suction strainers forthe pump supply lines and has an external returnline filter with a filter condition indicator.

How to Remove theHydraulic Tank

Component damage hazard.The work area and surfaceswhere this procedure will beperformed must be clean andfree of debris that could getinto the hydraulic system.


1 Remove the fuel tank. See 11-1, How toRemove the Fuel Tank.



FUEL AND HYDRAULIC TANKS

2 Close the two hydraulic shutoff valves locatedat the hydraulic tank.

Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe CLOSED position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

3 Remove the drain plug from the hydraulic tank.

4 Completely drain the tank into a suitablecontainer. See capacity specifications.

5 Tag, disconnect and plug the two suction hosesthat are attached to the hydraulic tankshutoff valves.

6 Disconnect and plug the T-fitting located at thereturn filter with the 2 hoses connected to it.Cap the fitting on the return filter housing.

7 Disconnect and plug the supply hose for theauxiliary power unit. Cap the fitting on thehydraulic tank.

8 Remove the retaining fasteners from thehydraulic tank hold down straps. Remove thestraps from the hydraulic tank.

9 Support the hydraulic tank with 2 lifting straps.Place one lifting strap at each end of the tankand attach the lifting straps to an overheadcrane.

10 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulicmay become unbalanced and fallif it is not properly supported andsecured to the overhead crane.

11 Remove the suction strainers from the tank andclean them using a mild solvent.

12 Rinse out the inside of the tank using a mildsolvent.

13 Install the suction strainers using a threadsealant on the threads.

14 Install the drain plug using a thread sealant onthe threads.

15 Install the hydraulic tank onto the machine.

16 Install the two suction hoses and the supplyhose for the auxiliary power unit.

17 Fill the tank with hydraulic oil until the level iswithin the top 2 inches (5 cm) of the sightgauge. Do not overfill.

18 Clean up any oil that may have spilled and openthe hydraulic tank valves.

Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpafter installing the hydraulic tank.

Always use pipe thread sealantwhen installing the drain plug.

Use only Dexron II equivalenthydraulic fluid.

Hydraulic system

Hydraulic tank capacity 45 gallons170 liters

Hydraulic system 55 gallonscapacity (including tank) 208 liters

Hydraulic fluid Dexron equivalent

open closed



How to Prime the PumpComponent damage hazard. Besure that the hydraulic tank shutoffvalves are in the OPEN positionbefore priming the pump. Theengine must not be started withthe hydraulic tank shutoff valves inthe CLOSED position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

1 Connect a 0 to 600 psi (0 to 41 bar) pressuregauge to the test port on the drive pump.

2 Gasoline/LPG models: Disconnect theelectrical connector at the ignition coils. Theignition coils are located above the alternator.


a

Deutz Diesel models: Hold the manual fuelshutoff valve clockwise to the CLOSED position.

a manual fuel shutoff valve

3 Crank the engine with the starter motor for15 seconds, wait 15 seconds, then crank theengine an additional 15 seconds or until thepressure reaches 320 psi (22 bar).

4 Connect the wiring and start the engine fromthe ground controls. Check for hydraulic leaks.

FUEL AND HYDRAULIC TANKS



2 Tag, disconnect and plug the hydraulic hosesfrom the motor, brake and manifold. Cap thefittings on the motor, brake and torque hub.

Bodily injury hazard.Spraying hydraulic oil canpenetrate and burn skin. Loosenhydraulic connections very slowlyto allow the oil pressure todissipate gradually. Do notallow oil to squirt or spray.

3 Remove the motor/brake mounting fasteners,then remove the motor from the brake.

a motor/brake mounting boltsb motorc braked torque hub mounting boltse torque hubf plug

12-1Rotation Hydraulic Motor

How to Remove the RotationHydraulic Motor

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.

1 Secure the turntable from rotating with theturntable rotation lock pin.

Unlocked position

Locked position

Turntable Rotation Components

ba

df

e

c



How to Remove the TurntableRotation Brake or Torque Hub1 Secure the turntable from rotating with the

turntable rotation lock pin.

unlocked locked

2 Remove the motor/brake mounting bolts, andthen remove the motor and brake from thetorque hub and set them to the side.


a motor/brake mounting boltb motorc torque hubd torque hub mounting bolte plugf brake

3 Remove the torque hub mounting bolts, andthen use a lifting device to remove the torquehub from the machine.

b

c

de

f

a

4 Remove the plug from the side of the torquehub. Then drain the oil from the hub.

5 Install the torque hub. Torque the hub mountingbolts to 180 foot-pounds (244 Newton meters).

6 Install the brake and motor onto the torque hub.

7 Fill the hub with oil from the side hole until theoil level is even with the bottom of the hole.Apply pipe thread sealant to the plugs, and theninstall the plugs.

8 Adjust turntable rotation gear backlash. SeeRepair Procedure 18-1, How to Adjust theTurntable Rotation Gear Backlash.

Turntable rotate torque hub

Capacity 17 fluid ounces0.51 liters


TURNTABLE ROTATION COMPONENTS



a

b

c

TURNTABLE ROTATION COMPONENTS

How to Adjust theTurntable Rotation Gear BacklashThe turntable rotation torque hub is mounted on aadjustable plate that controls the gap between therotation motor gear and the turntable bearing.

Be sure to check the backlashwith the machine on a flat levelsurface.

1 Loosen the mounting fasteners on the torquehub pivot plate.

a pivot plate mounting boltsb adjustment bolt with lock nutc torque hub pivot plate

2 Push the torque hub pivot plate towards theturntable as far as possible (this will push therotation gear into the rotation bearing).

3 Loosen the lock nut on the adjustment bolt.

4 Turn the adjustment bolt clockwise until itcontacts the pivot plate.

5 Turn the adjustment bolt 1/2 turncounterclockwise. Then tighten the lock nut onthe adjustment bolt.

6 Rotate the torque hub pivot plate away from theturntable until it contacts the adjustment bolt.Then tighten the mounting fasteners on thetorque hub pivot plate.

7 Rotate the turntable through an entire rotation.Check for tight spots that could cause binding.Readjust if necessary.



6 Remove the pin retaining fasteners from theyoke pivot pins.

7 Support the yoke/hub assembly with a liftingjack.

8 Use a slide hammer to remove the upper yokepivot pin, then use a soft metal drift to drive thelower yoke pivot pin down and out.

Crushing hazard. The yoke/hubassembly may becomeunbalanced and fall when the yokepivot pins are removed if it is notproperly secured and supportedby the lifting jack.

Torque specifications

Lug nut torque, dry 420 ft-lbs569.5 Nm

Lug nut torque, lubricated 320 ft-lbs433.9 Nm

How to Remove theHub and Bearings1 Loosen the wheel lug nuts. Do not remove

them.

2 Block the non-steering wheels and place alifting jack of ample capacity under the steeringaxle.

3 Raise the machine 6 inches (15 cm) and placeblocks under the chassis for support.

4 Remove the lug nuts. Then remove the tireand wheel assembly.

5 Remove the dust cap, cotter pin andslotted nut.

6 Pull the hub off the spindle. The washer andouter bearing should fall loose from the hub.

7 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.


13-1Yoke and Hub

How to Remove the Yokeand Hub1 Remove the pin retaining fasteners from both

the steering cylinder and the tie rod pivot pins.Remove the pins.

a tie rodb axlec yoke pivot pind yokee hubf pivot ping steering cylinder

2 Loosen the wheel lug nuts. Do notremove them.

3 Block the non-steering wheels, and thencenter a lifting jack of ample capacity under thesteering axle.

4 Raise the machine 6 inches (15 cm) and placeblocks under the chassis for support.

5 Remove the lug nuts. Then remove the tireand wheel assembly.

a b

e

d

fg

c

f



How to Install theHub and Bearings

When replacing a wheel bearing,both the inner and outer bearingsincluding the pressed-in racesmust be replaced.

1 Be sure that both bearings are packedwith clean, fresh grease.

2 Place the large inner bearing into the rearof the hub.

3 Press the bearing seal evenly into the hubuntil it is flush.

4 Slide the hub onto the yoke spindle.

Component damage. Do notapply excessive force or damageto the lip of the seal may occur.

5 Place the outer bearing into the hub.

6 Install the washer and slotted nut.

7 Tighten the slotted nut to 35 foot-pounds(47 Nm).

8 Loosen the slotted nut, then re-tighten to8 foot-pounds (11 Nm).

9 Install a new cotter pin. Bend the cotter pinto lock it in.

10 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts to420 foot-pounds (569.5 Nm).

2WD STEERING AXLE COMPONENTS

13-2Steering Cylinders

How to Remove aSteering CylinderThere are two identical steering cylinders thatwork in parallel. They are part of the samehydraulic circuit, but move in opposite directions.The tie rod maintains equal movement of the tires.


1 Tag, disconnect and plug the hydraulic hosesfrom the steering cylinder. Cap the fittings onthe cylinder.


2 Remove the pin retaining fasteners. Thenremove the pivot pin from each end of thesteering cylinder.

3 Remove the steering cylinder from the machine.




13-3Tie Rod

How to Remove the Tie Rod1 Remove the pin retaining fasteners, then

remove the pivot pin from each end of the tierod.

2 Remove the tie rod.

How to Perform the Toe-inAdjustment

Perform this procedure on afirm, level surface. Block thenon-steering tires and be surethat the machine is in thestowed position.

1 Straighten the steer wheels.

2 Measure the steer tires, front to front and backto back, using a measuring fixture.

3 Center a lifting jack of ample capacity under thesteering axle, then raise the machine.

4 Loosen the jam nut on the adjustable endof the tie rod.

5 Remove the pin retaining fasteners, thenremove the pivot pin from the adjustable end ofthe tie rod.

6 Slide the tie rod off the yoke and adjust it byturning the end.

One half turn on the adjustableend equals approximately 1/4 inch(6.4 mm) change in the frontand rear measurements.

7 Slide the tie rod onto the yoke. Install thepivot pin, then install the retaining bolt.

8 Tighten the jam nut against the tie rod.

9 Lower the machine and recheck thefront and back measurements (step 2).If further adjustment is needed, repeatsteps 3 through 8.

Toe-in specification 0 ± 1/8 inch (6.35 mm)



2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittngs on thedrive motor.


3 Loosen the wheel lug nuts. Do notremove them.

4 Block the non-steering wheels, and thencenter a lifting jack of ample capacity under thesteering axle.

5 Raise the machine 6 inches (15.2 cm) andplace blocks under the chassis for support.

6 Remove the lug nuts, then remove the tire andwheel assembly.

7 Remove the hydraulic hose clamp retainingfastener from the top of the yoke.

8 Remove the drive motor mounting fasteners.

9 Slide the drive motor shaft out of the torque huband then remove the drive motor from themachine.

10 Remove the pin retaining fasteners from theupper and lower yoke pivot pins.

12 Support the yoke/torque hub assembly with alifting jack. Secure the yoke/torque hubassembly to the lifting jack.

13 Use a slide hammer to remove the upper yokepivot pin, then use a soft metal drift to drive thelower yoke pivot pin down and out.

Crushing hazard. The yoke/hubassembly may becomeunbalanced and fall when the yokepivot pins are removed if it is notproperly secured and supportedby the lifting jack.


14-1Yoke and Hub

How to Remove the Yokeand HubThe yoke installation utilizes bushings and a thrustwasher that may require periodic replacement. Theyoke must be removed before the torque hub canbe removed.


1 Remove the pin retaining fasteners from boththe steering cylinder and the tie rod pivot pins.Remove the pins.

a oscillate cylinderb king pinc torque hubd yokee pivot pinf tie rodg steer cylinder

a

b

c

defg




14 Place the yoke/torque hub assembly on a flatsurface with the torque hub facing down.

15 Remove the torque hub mounting fasteners thatattach the yoke to the torque hub. Remove theyoke weldment from the torque hub.

Replace the thrust washer wheninstalling the yoke/torque hubassembly onto the axle.


Lug nut,dry 420 ft-lbs 569.5 Nmlubricated 320 ft-lbs 433.9 Nm

Torque hub mounting bolts,dry 120 ft-lbs 163 Nmlubricated 90 ft-lbs 122 Nm

Drive motor mounting bolts,dry 75 ft-lbs 102 Nmlubricated 56 ft-lbs 76 Nm

14-2Steering Cylinders

How to Remove aSteering CylinderThis procedure is the same as the 2WD procedure.See repair procedure 13-2,How to Remove a Steering Cylinder.

14-3Tie Rod

How to Remove the Tie RodThis procedure is the same as the 2WD procedure.See Repair Procedure 13-3,How to Remove the Tie Rod.

How to Perform the Toe-inAdjustmentThis procedure is the same as the 2WD procedure.See Repair Procedure 13-3,How to Perform the Toe-in Adjustment.



15-1Oscillating AxleLock-out Cylinders

The oscillating axle cylinders extend and retractbetween the drive chassis and the oscillating axle.The cylinders are equipped with counterbalancevalves to prevent movement in the event of ahydraulic line failure. The valves are notadjustable.

How to Remove an OscillatingAxle Cylinder

This procedure requires specificrepair skills and a suitableworkshop. Attempting thisprocedure without these skillsand tools may result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

Perform this procedure on a firm,level surface with the boom inthe stowed position.


1 Rotate the boom until the boom is between thesteer tires.

2 Remove the fasteners from drive chassis coverat the steer end. Remove the cover.

Oscillating Axle Components

3 Tag, disconnect and plug the oscillating axlecylinder hydraulic hoses. Cap the fittings on theoscillate cylinder.


4 Remove the pin retaining fasteners from therod-end pivot pin. Use a soft metal drift toremove the pin.

5 Attach a lifting strap from an overhead crane tothe barrel end of the oscillating cylinder.

6 Remove the pin retaining fasteners from thebarrel-end pivot pin. Use a soft metal drift toremove the pin.

Crushing hazard. The oscillatecylinder may become unbalancedand fall when it is removed fromthe machine if it is not properlyattached to the overhead crane.

7 Remove the cylinder from the machine.



16-1Drive Motor

How to Remove a Drive MotorComponent damage hazard.Repairs to the motor should onlybe performed by an authorizedSundstrand-Sauer dealer.

Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.


1 Remove the fasteners from drive chassis coverat the non-steer end. Remove the cover.

2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on thedrive motor.


3 Remove the drive motor mounting fasteners.

Non-steering Axle Components

4 Slide the drive motor shaft out of the brake andthen remove the drive motor from the machine.


Drive motor mounting bolts 75 ft-lbs 102 Nm

16-2Torque Hub

How to Remove a DriveTorque Hub


1 Remove the drive motor. See 22-1, How toRemove a Drive Motor.

2 Tag, disconnect and plug the hydraulic hosefrom the brake. Then remove the hydraulicfitting and the bleed valve.

3 Loosen the wheel lug nuts. Do not removethem.

4 Center a lifting jack of ample capacity under thenon-steering axle. Raise the machine and placeblocks under the drive chassis for support.

5 Remove the wheel lug nuts, then the tire andwheel assembly.

6 Place a second lifting jack under the torque hubfor support and secure the torque hub to thelifting jack.



NON-STEERING AXLE COMPONENTS

7 Remove the torque hub mounting bolts thatattach the torque hub to the chassis. Removethe torque hub.

Crushing hazard. The torquehub may become unbalanced andfall if it is not properly supportedand secured to the lifting jack.


Lug nut,dry 420 ft-lbs 569.5 Nmlubricated 320 ft-lbs 433.9 Nm

Torque hub mounting bolts,dry 120 ft-lbs 163 Nmlubricated 90 ft-lbs 122 Nm

Drive motor mounting bolts,dry 75 ft-lbs 102 Nmlubricated 56 ft-lbs 76 Nm

Genie North America18340 NE 76th Street

P.O. Box 97030

Redmond, Washington

98073-9730

Genie EuropeBrunel Drive

Newark

Nottinghamshire

NG24 2EG England

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