Service Manual - Manuals - Geniemanuals.gogenielift.com/Parts And Service...

Part No. 72136

Rev B

March 2008

Service ManualRefer to inside cover for additional serial number information

(from serial number 1790 to 7000)

March 2008

S-40 • S-45 Part No. 72136

Introduction

®

Copyright © 1998 by Genie Industries

72136 Rev B December 2007Third Edition, Second Printing

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

Printed on recycled paper

Printed in U.S.A.

ii

Important

Read, understand and obey the safety rules andoperating instructions in the Genie S-40 and S-45Operator's Manual before attempting anymaintenance or repair procedure.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting faultcodes and repair 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 an authorized Genie dealer servicecenter.

Technical Publications

Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. 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 all other manuals.

Contact Us:

http://www.genieindustries.come-mail: [email protected]

Serial Number Information

Genie Industries offers the following ServiceManuals for these models:

Title Part No.

S-40 and S-45 Service Manual(before serial number 832) ................................... 32222

S-40 and S-45 Service Manual(from serial number 832 to 1789) ......................... 52271

S-40 and S-45 Service Manual(from serial number 1790 to 7000) ....................... 72136

March 2008

Part No. 72136 S-40 • S-45

S40 06 - 12345

Model

Model year

Sequencenumber

PN - 77055

Country of manufacture: USA

This machine complies with:

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

ANSI A92.5CAN B.354.4

Model: S-40

Serial number: S4006-12345

Electrical schematic number: ES0274

Machine unladen weight:

Rated work load (including occupants): 500 lb / 227 kg

Maximum allowable inclination of the chassis:

0 deg

Gradeability: N/A

Maximum allowable side force : 150 lb / 670 N

Maximum number of platfrm occupants: 2

Model year: Manufacture date: 01/05/062006

Maximum wind speed : 28 mph/ 12.5 m/s

Maximum platform height : 60 ft 6 in/ 18.3 m

Maximum platform reach : 34 ft 3 in/ 10.4 m

Sequence number(stamped on chassis)

Serial label(located under cover)

Section 1 • Safety Rules

Serial Number LegendINTRODUCTION

iii

March 2008

S-40 • S-45 Part No. 72136

This page intentionally left blank.

iv

March 2008

Part No. 72136 S-40 • S-45 v

Safety Rules


DangerFailure to obey the instructions and safety rules inthis manual, and the Genie S-40 & Genie S-45Operator's Manual will result in death or seriousinjury.

Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.

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.

March 2008

S-40 • S-45 Part No. 72136

SAFETY RULES

vi


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:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.

Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.

Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.

Yellow without safety alertsymbol—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.

Indicates special operation ormaintenance information.

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 when lifting or

placing loads. Always wear approved steel-toedshoes.

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 components andcause damage.

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.

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

March 2008

Part No. 72136 S-40 • S-45

Table of Contents

Introduction

Important Information ............................................................................................ ii

Section 1 Safety Rules

General Safety Rules ........................................................................................... iii

Section 2 Rev Specifications

B Machine Specifications ................................................................................... 2 - 1

Performance Specifications ............................................................................ 2 - 3

Hydraulic Specifications .................................................................................. 2 - 4

Hydraulic Oil Specifications ............................................................................. 2 - 5

Ford LRG 425 EFI Engine Specifications ........................................................ 2 - 6

Deutz F3L 1011F Engine Specifications ......................................................... 2 - 7

Perkins 704-30 Engine Specifications ............................................................. 2 - 8

Machine Torque Specifications ....................................................................... 2 - 9

Hydraulic Hose and Fitting Torque Specifications ......................................... 2 - 10

SAE and Metric Fastener Torque .................................................................. 2 - 11

Section 3 Rev Theory of Operation

A Power Source ................................................................................................. 3 - 1

Hydraulic System ............................................................................................ 3 - 1

Electrical System ............................................................................................ 3 - 1

Limit Switches ................................................................................................. 3 - 2

Electrical System ............................................................................................ 3 - 2

vii

March 2008

S-40 • S-45 Part No. 72136

TABLE OF CONTENTS

viii

Section 4 Rev Scheduled Maintenance Procedures

Introduction ..................................................................................................... 4 - 1

Maintenance Inspection Report ....................................................................... 4 - 3

B Checklist A Procedures

A-1 Inspect the Operator's and Safety Manuals ........................................... 4 - 5

A-2 Inspect the Decals and Placards ........................................................... 4 - 5

A-3 Inspect for Damage, Loose or Missing Parts ......................................... 4 - 6

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

A-5 Check the Engine Coolant Level - Liquid Cooled Models ...................... 4 - 8

A-6 Check for Fuel Leaks ............................................................................ 4 - 8

A-7 Check the Hydraulic Oil Level ............................................................... 4 - 9

A-8 Check for Hydraulic Leaks .................................................................. 4 - 10

A-9 Check the Tire Pressure ...................................................................... 4 - 10

A-10 Test the Oscillate Axle (if equipped) .................................................... 4 - 11

A-11 Test the Platform and Ground Controls ............................................... 4 - 12

A-12 Test the Auxiliary Power Operation ..................................................... 4 - 13

A-13 Test the Tilt Sensor ............................................................................. 4 - 14

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

A-15 Drain the Fuel Filter/Water Separator - Diesel Models ........................ 4 - 17

A-16 Perform 30 Day Service ...................................................................... 4 - 19

A-17 Replace the Engine Oil and Filter - Gasoline/LPG Models .................. 4 - 19

A-18 Check the Engine Belt - Gasoline/LPG and Perkins Models ................ 4 - 21

A-19 Replace the Fuel Filter - Gasoline/LPG Models ................................... 4 - 22

March 2008

Part No. 72136 S-40 • S-45

TABLE OF CONTENTS

ix

Section 4 Rev Scheduled Maintenance Procedures, continued

B Checklist B Procedures

B-1 Check the Exhaust System ................................................................. 4 - 30

B-2 Inspect the Engine Air Filter ................................................................ 4 - 25

B-3 Inspect the Radiator - Liquid Cooled Models ....................................... 4 - 26

B-4 Check the Battery ................................................................................ 4 - 27

B-5 Inspect the Electrical Wiring ................................................................ 4 - 28

B-6 Check the Oil Cooler and Cooling Fins - Deutz Models ....................... 4 - 29

B-7 Check the Hydraulic Tank Return Filter Condition Indicator ................ 4 - 30

B-8 Inspect the Tires, Wheels and Lug Nut Torque ................................... 4 - 31

B-9 Confirm the Proper Brake Configuration .............................................. 4 - 32

B-10 Check the Oil Level in the Drive Hubs ................................................. 4 - 33

B-11 Check and Adjust the Engine RPM ..................................................... 4 - 35

B-12 Test the Key Switch ............................................................................. 4 - 36

B-13 Test the Emergency Stop Buttons ....................................................... 4 - 37

B-14 Test the Ground Control Override ....................................................... 4 - 37

B-15 Check the Directional Valve Linkage ................................................... 4 - 38

B-16 Test the Platform Self-leveling ............................................................. 4 - 38

B-17 Test the Horn ...................................................................................... 4 - 39

B-18 Test the Foot Switch ............................................................................ 4 - 39

B-19 Test the Engine Idle Select Operation ................................................. 4 - 40

B-20 Test the Fuel Select Operation - Gasoline/LPG Models ...................... 4 - 41

B-21 Test the Drive Enable System ............................................................. 4 - 42

B-22 Test the Drive Brakes .......................................................................... 4 - 43

B-23 Test the Drive Speed - Stowed Position .............................................. 4 - 44

B-24 Test the Drive Speed - Raised or Extended Position ........................... 4 - 45

B-25 Test the Alarm Package (if equipped) ................................................. 4 - 46

March 2008

S-40 • S-45 Part No. 72136


B-26 Perform Hydraulic Oil Analysis ............................................................ 4 - 46

B-27 Replace the Hydraulic Tank Return Filter ............................................ 4 - 47

B-28 Replace the Engine Air Filter Element ................................................. 4 - 48

B-29 Replace the Spark Plugs - Gasoline/LPG Models ................................ 4 - 49

A Checklist C Procedures

C-1 Check the Engine Belt - Deutz Models ................................................ 4 - 51

C-2 Check the Engine Valve Clearances - Deutz Models ........................... 4 - 52

C-3 Replace the Fuel Filter/Water Separator Element - Perkins Models .... 4 - 53

C-4 Replace the Fuel Filter Element - Perkins Models ............................... 4 - 54

C-5 Replace the Engine Oil and Filter - Perkins Models ............................. 4 - 56

C-6 Check the Specific Gravity of Engine Coolant - Liquid Cooled Models 4 - 57

C-7 Check the Glow Plugs - Perkins Models .............................................. 4 - 58

C-8 Replace the PCV Valve - Gasoline/LPG Models .................................. 4 - 59

B Checklist D Procedures

D-1 Check the Boom Wear Pads................................................................ 4 - 60

D-2 Check the Free-wheel Configuration .................................................... 4 - 60

D-3 Check the Turntable Rotation Bearing Bolts ........................................ 4 - 62

D-4 Grease the Turntable Rotation Bearing and Rotate Gear .................... 4 - 63

D-5 Replace the Drive Hub Oil ................................................................... 4 - 63

D-6 Replace the Drive Loop Hydraulic Filter ............................................... 4 - 65

D-7 Replace the Engine Oil and Filter - Deutz Models ................................ 4 - 66

D-8 Clean the Fuel Pump Strainer - Deutz Models ..................................... 4 - 68

D-9 Replace the Diesel Fuel Filter/Water Separator - Deutz Models .......... 4 - 69

D-10 Change the Fuel Hoses - Deutz Models .............................................. 4 - 70

D-11 Check the Engine Valve Clearances - Perkins Models ........................ 4 - 71

D-12 Clean the Engine Breather Assembly - Perkins Models ....................... 4 - 72

x

TABLE OF CONTENTS

March 2008

Part No. 72136 S-40 • S-45


B Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil ........................................................ 4 - 73

E-2 Change or Recondition the Engine Coolant - Liquid Cooled Models .... 4 - 75

E-3 Change the Fuel Hoses - Gasoline/LPG Models ................................. 4 - 76

E-4 Replace the Engine Breather - Perkins Models ................................... 4 - 78

E-5 Grease the Steer Axle Wheel Bearings, 2WD Models ......................... 4 - 78

E-6 Check the Fuel Injectors - Perkins Models ........................................... 4 - 80

Section 5 Rev Troubleshooting Flow Charts

B Introduction ..................................................................................................... 5 - 1

Fault Codes .................................................................................................... 5 - 3

1 Engine Will Not Crank Over ...................................................................... 5 - 8

2 Engine Cranks Over But Will Not Start - Gasoline/LPG Models .............. 5 - 10

2A Engine Runs While Cranking then Dies- Gasoline/LPG Models ............. 5 - 12

3 Engine Cranks Over But Will Not Start - Diesel Models .......................... 5 - 13

4 Engine Will Not Start On LPG, But Will Start On Gasoline- Gasoline/LPG Models .......................................................................... 5 - 16

5 Engine Will Not Start On Gasoline, But Will Start On LPG- Gasoline/LPG Models .......................................................................... 5 - 18

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

7 Engine Low Idle Inoperative - Gasoline/LPG Models .............................. 5 - 20

8 Engine High Idle Inoperative - Diesel Models ......................................... 5 - 21

9 Engine Low Idle Inoperative - Diesel Models .......................................... 5 - 23

10 All Functions Inoperative, Engine Starts and Runs ................................. 5 - 24

11 All Lift and Steer Functions Inoperative, Drive Functions Operational .... 5 - 25

xi

TABLE OF CONTENTS

March 2008

S-40 • S-45 Part No. 72136

Section 5 Rev Troubleshooting Flow Charts, continued

12 Ground Controls Inoperative, Platform Controls Operate Normally ........ 5 - 26

13 Platform Controls Inoperative, Ground Controls Operate Normally ........ 5 - 27

14 Boom Up Function Inoperative ............................................................... 5 - 28

15 Boom Down Function Inoperative ........................................................... 5 - 31

16 Boom Extend Function Inoperative ......................................................... 5 - 34

17 Boom Retract Function Inoperative ........................................................ 5 - 36

18 Turntable Rotate Left Function Inoperative ............................................. 5 - 38

19 Turntable Rotate Right Function Inoperative .......................................... 5 - 42

20 All Platform Leveling Functions Inoperative ............................................ 5 - 46

21 Platform Level Up Function Inoperative .................................................. 5 - 47

22 Platform Level Down Function Inoperative ............................................. 5 - 49

23 Platform Rotate Left Function Inoperative ............................................... 5 - 51

24 Platform Rotate Right Function Inoperative ............................................ 5 - 53

25 Oscillate Function Inoperative ................................................................ 5 - 55

26 Jib Boom Up Function Inoperative .......................................................... 5 - 56

27 Jib Boom Down Function Inoperative ..................................................... 5 - 58

28 Steer Left Function Inoperative ............................................................... 5 - 60

29 Steer Right Function Inoperative ............................................................ 5 - 62

30 All Drive Functions Inoperative, All Other Functions Operate Normally .. 5 - 64

31 Drive Forward Or Reverse Function Inoperative..................................... 5 - 67

32 Traction Function Inoperative ................................................................. 5 - 68

33 Machine Will Not Drive At Full Speed ..................................................... 5 - 69

34 Machine Drives At Full Speed With Platform Raised or Extended .......... 5 - 70

35 Drive Enable System Is Malfunctioning .................................................. 5 - 71

36 Auxiliary Functions Inoperative ............................................................... 5 - 72

xii

TABLE OF CONTENTS

March 2008

Part No. 72136 S-40 • S-45

TABLE OF CONTENTS

Section 6 Rev Schematics

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

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

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

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

A Hydraulic Symbols Legend ............................................................................. 6 - 6

A Engine Wire Harness - Gasoline/LPG ............................................................. 6 - 7

A Electrical Schematic - Gasoline/LPG ............................................................ 6 - 10

A Ground Control Box Wiring Diagram - Gasoline/LPG.................................... 6 - 14

A Platform Control Box Wiring Diagram - Gasoline/LPG .................................. 6 - 15

A Electrical Schematic - Deutz Diesel .............................................................. 6 - 18

A Ground Control Box Wiring Diagram - Deutz Diesel ...................................... 6 - 22

A Platform Control Box Wiring Diagram - Deutz Diesel .................................... 6 - 23

A Electrical Schematic - Perkins Diesel ............................................................ 6 - 26

A Ground Control Box Wiring Diagram - Perkins Diesel ................................... 6 - 30

A Platform Control Box Wiring Diagram - Perkins Diesel .................................. 6 - 31

A S-40/45 2WD Hydraulic Schematic - Non-oscillating axle ............................. 6 - 33

A S-40/45 2WD Hydraulic Schematic - Oscillating axle .................................... 6 - 35

A S-40/45 4WD Hydraulic Schematic - Oscillating axle .................................... 6 - 37

xiii

March 2008

S-40 • S-45 Part No. 72136

TABLE OF CONTENTS

Section 7 Rev Repair Procedures

Introduction ..................................................................................................... 7 - 1

A Platform Controls

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

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

1-3 Foot Switch ........................................................................................... 7 - 9

1-4 Toggle Switches .................................................................................. 7 - 10

A Platform Components

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

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

2-3 Platform Rotator .................................................................................. 7 - 13

A Jib Boom Components, S-45 Models

3-1 Jib Boom ............................................................................................. 7 - 15

3-2 Jib Boom Lift Cylinder ......................................................................... 7 - 16

A Boom Components

4-1 Boom Cable Track............................................................................... 7 - 17

4-2 Boom ................................................................................................... 7 - 19

4-3 Boom Lift Cylinder ............................................................................... 7 - 22

4-4 Extension Cylinder .............................................................................. 7 - 23

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

A Turntable Covers

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

xiv

March 2008

Part No. 72136 S-40 • S-45

Section 7 Rev Repair Procedures, continued

A Deutz Engine F3L 1011F

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

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

6-3 Oil Temperature and Oil Pressure Gauges ......................................... 7 - 28

A Perkins 704-30 Engine

7-1 RPM Adjustment ................................................................................. 7 - 29

7-2 Flex Plate ............................................................................................ 7 - 29

7-3 Coolant Temperature and Oil Pressure Gauges .................................. 7 - 30

A Ford LRG-425 EFI Engine

8-1 Timing Adjustment ............................................................................... 7 - 31

8-2 Flex Plate ............................................................................................ 7 - 31

8-3 Coolant Temperature and Oil Pressure Gauges .................................. 7 - 32

A Ground Controls

9-1 Control Relays ..................................................................................... 7 - 33

9-2 Toggle Switches, See 1-4, Toggle Switches ........................................ 7 - 34

9-3 Wago® Components ............................................................................ 7 - 34

9-4 Engine Fault Codes - Gasoline/LPG Models ....................................... 7 - 35

A Hydraulic Pumps

10-1 Lift/Steer Pump.................................................................................... 7 - 36

10-2 Drive Pump ......................................................................................... 7 - 37

xv

TABLE OF CONTENTS

March 2008

S-40 • S-45 Part No. 72136

TABLE OF CONTENTS


B Manifolds

11-1 Function Manifold Components ........................................................... 7 - 40

11-2 Valve Adjustments - Function Manifold ............................................... 7 - 44

11-3 Turntable Rotation Manifold Components ........................................... 7 - 46

11-4 Oscillate Manifold Components ........................................................... 7 - 48

11-5 Valve Adjustments - Oscillate Manifold ............................................... 7 - 49

11-6 Directional Valve Manifold Components .............................................. 7 - 50

11-7 Steer/Oscillate Manifold Components, Oscillating Models ................... 7 - 52

11-8 Steer Manifold Components, Non-oscillating Models .......................... 7 - 53

11-9 2WD Drive Manifold Components ....................................................... 7 - 54

11-10 Valve Adjustments, 2WD Drive Manifold ............................................. 7 - 55

11-11 4WD Drive Manifold Components ....................................................... 7 - 56

11-12 Valve Adjustments, 4WD Drive Manifold ............................................. 7 - 58

11-13 Jib Boom/Platform Rotate Manifold Components, S-45 Models(before serial number 5593) ................................................................ 7 - 59

11-14 Jib Boom/Platform Rotate Manifold Components, S-45 Models(after serial number 5592) ................................................................... 7 - 60

A Fuel and Hydraulic Tanks

12-1 Fuel Tank ............................................................................................ 7 - 62

12-2 Hydraulic Tank .................................................................................... 7 - 63

A Turntable Rotation Components

13-1 Rotation Hydraulic Motor ..................................................................... 7 - 66

xvi

March 2008

Part No. 72136 S-40 • S-45


B 2WD Steering Axle Components

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

14-2 Steering Cylinders ............................................................................... 7 - 70

14-3 Tie Rod................................................................................................ 7 - 71

B 4WD Steering Axle Components

15-1 Yoke and Hub ..................................................................................... 7 - 72

15-2 Steering Cylinders, See 14-2, Steering Cylinders ................................ 7 - 73

15-3 Tie Rod, See 14-3, Tie Rod ................................................................. 7 - 73

A Oscillating Axle Components

16-1 Oscillating Axle Lock-out Cylinders ..................................................... 7 - 74

B Non-steering Axle Components

17-1 Drive Motor .......................................................................................... 7 - 75

17-2 Drive Hub ............................................................................................ 7 - 76

17-3 Wheel Brake ........................................................................................ 7 - 77

TABLE OF CONTENTS

xvii

March 2008

S-40 • S-45 Part No. 72136xviii


Section 2 • SpecificationsMarch 2008

Part No. 72136 S-40 • S-45 2 - 1

Specifications

Machine SpecificationsS-40 Models

Stowed dimensions 2WD/RT 4WD/RT

Length 23 ft 11 in 23 ft 11 in7.3 m 7.3 m

Width 7 ft 6 in 7 ft 6 in2.3 m 2.3 m

Height 8 ft 2 in 8 ft 2 in2.5 m 2.5 m

Weight 11,650 lbs 11,650 lbs5284 kg 5284 kg

Ground clearance 12 1/2 in 12 1/2 in31.8 cm 31.8 cm

Operational dimensions

Maximum platform height 40 ft 40 ft12.2 m 12.2 m

Maximum horizontal reach 31 ft 8 in 31 ft 8 in9.7 m 9.7 m

Maximum turntable tailswing 34 in 34 in86.4 cm 86.4 cm

Wheelbase 7 ft 3 in 7 ft 3 in2.2 m 2.2 m

Minimum turning radius, 15 ft 8 in 15 ft 8 inoutside 4.8 m 4.8 m

Minimum turning radius, 6 ft 8 in 6 ft 8 ininside 2 m 2 m

Turntable rotation continuous continuous

Platform rotation 160° 160°

Platform dimensions 6 ft (Standard) 6 ft (Standard)

8 ft (Optional) 8 ft (Optional)

Length x width, 6 ft 72 in x 30 in 72 in x 30 in1.8m x 76 cm 1.8m x 76 cm


Maximum capacity 500 lbs 500 lbs227 kg 227 kg

2WD/RT 4WD/RT

Maximum allowable side forceANSI and CSA 150 lbs 150 lbs

667 N 667 NCE 90 lbs 90 lbs

400 N 400 N

Tires and wheels 2WD Rear,2WD Front 4WD FrontTires Only and Rear

Tire size 12.5L-16SL 12-16.5 NHS

Tire ply rating 12 8

Tire contact area 88 sq in 57 sq in568 sq cm 368 sq cm

Overall tire diameter 33.7 in 33.2 in85.6 cm 84.3 cm

Tire pressure 45 psi 45 psi3.1 bar 3.1 bar

Wheel diameter 16 in 161/2 in40.6 cm 41.9 cm

Wheel width 10 in 9 3/4 in25.4 cm 24.8 cm

Wheel lugs 8@ 5/8 -18 9@ 5/8 -18

Lug nut torque, dry 170 ft-lbs 230 NmLug nut torque, lubricated 130 ft-lbs 176 Nm

Fluid capacities

Fuel tank 30 gallons114 liters

LPG tank 33.5 pounds15.2 kg

Hydraulic tank 45 gallons170 liters

Hydraulic system 50 gallons(including tank) 189 liters

Drive hubs 17 fl oz0.5 liters

Turntable rotation 8 fl ozdrive hub 0.24 liters

Continuous improvement of our products is a Geniepolicy. Product specifications are subject to changewithout notice.

REV B

Section 2 • Specifications March 2008

2 - 2 S-40 • S-45 Part No. 72136

Machine SpecificationsS-45 Models

Stowed dimensions 2WD/RT 4WD/RT

Length 27 ft 10 in 27 ft 10 in8.5 m 8.5 m

Width 7 ft 6 in 7 ft 6 in2.3 m 2.3 m

Height 8 ft 2 in 8 ft 2 in2.5 m 2.5 m

Weight 14,970 lbs 14,970 lbs6,790 kg 6,790 kg

Ground clearance 12 1/2 in 12 1/2 in31.8 cm 31.8 cm

Operational dimensions

Maximum platform height 45 ft 45 ft13.7 m 13.7 m

Maximum horizontal reach 36 ft 8 in 36 ft 8 in11.2 m 11.2 m

Maximum turntable tailswing 34 in 34 in86.4 cm 86.4 cm

Wheelbase 7 ft 3 in 7 ft 3 in2.2 m 2.2 m

Minimum turning radius, 15 ft 8 in 15 ft 8 inoutside 4.8 m 4.8 m

Minimum turning radius, 6 ft 8 in 6 ft 8 ininside 2 m 2 m

Turntable rotation continuous continuous

Platform rotation 160° 160°

Platform dimensions 6 ft (Standard) 6 ft (Standard)

8 ft (Optional) 8 ft (Optional)



Maximum capacity 500 lbs 500 lbs227 kg 227 kg

2WD/RT 4WD/RT

Maximum allowable side forceANSI and CSA 150 lbs 150 lbs

667 N 667 NCE 90 lbs 90 lbs

400 N 400 N

Tires and wheels 2WD Rear,2WD Front 4WD FrontTires Only and Rear

Tire size 12.5L-16SL 12-16.5 NHS


Tire contact area 88 sq in 57 sq in568 sq cm 368 sq cm

Overall tire diameter 33.7 in 33.2 in85.6 cm 84.3 cm

Tire pressure 45 psi 45 psi3.1 bar 3.1 bar

Wheel diameter 16 in 161/2 in40.6 cm 41.9 cm

Wheel width 10 in 9 3/4 in25.4 cm 24.8 cm

Wheel lugs 8@ 5/8 -18 9@ 5/8 -18

Lug nut torque, dry 170 ft-lbs 230 NmLug nut torque, lubricated 130 ft-lbs 176 Nm

Fluid capacities

Fuel tank 30 gallons114 liters

LPG tank 33.5 pounds15.2 kg

Hydraulic tank 45 gallons170 liters

Hydraulic system 50 gallons(including tank) 189 liters

Drive hubs 17 fl oz0.5 liters

Turntable rotation 8 fl ozdrive hub 0.24 liters

SPECIFICATIONS REV B



Part No. 72136 S-40 • S-45 2 - 3

SPECIFICATIONS

Boom function speeds, maximumfrom platform controls

Boom up 40 to 60 seconds

Boom down 50 to 80 seconds

Boom extend 30 to 60 seconds

Boom retract 25 to 55 seconds

Turntable rotate, 360°boom fully stowed 70 to 110 seconds

Platform rotate, 160° 6 to 12 seconds

Platform level up 25 to 50 seconds

Platform level down 15 to 35 seconds

Jib boom up, S-45 models 35 to 45 seconds

Jib boom down, S-45 models 20 to 30 seconds

Performance SpecificationsAll Models

Drive speeds, maximum 2WD 4WD

Drive speed, stowed 4 mph 3.5 mphGasoline/LPG models 6.4 km/h 5.6 km/h

40 ft/6.8 sec 40 ft/7.8 sec12.2 m/6.8 sec 12.2 m/7.8 sec

Drive speed, stowed 3.5 mph 3 mphDeutz Diesel models 5.6 km/h 4.8 km/h

40 ft/7.8 sec 40 ft/9.1 sec12.2 m/7.8 sec 12.2 m/9.1 sec

Drive speed, 0.6 mph 0.6 mphraised or extended 1 km/h 1 km/h- all models 40 ft/40 sec 40 ft/40 sec

12.2 m/40 sec 12.2 m/40 sec

Gradeability See Operator's Manual

REV A



2 - 4 S-40 • S-45 Part No. 72136

SPECIFICATIONS

Hydraulic Specifications

Drive pump

Type: bi-directional variable displacement piston pump

Displacement @ 2500 rpm 0 to 31.6 gallons per minute0 to 119.6 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 relief pressure 250 psi17.2 bar

Steer end drive motors 4WD models

4WD front motor 2.5 to 8 gallons per minuteflow regulators 9.4 to 30.2 liters per minute

4WD rear motor 5 to 15 gallons per minuteflow regulators 18.9 to 56.7 liters per minute

2WD rear motor 8 to 22 gallons per minuteflow regulators 30.2 to 83.2 liters per minute

Front drive motors 4WD models

Displacementper revolution 1.52 cu in 25 cc

Non-steer end drive motors

Displacementper revolution 2.13 cu in 35 cc

Function pump

Type: pressure balanced gear

Displacement - static 1.03 cu in17 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 pressureS-40 2600 psi 179 barS-45 2900 psi 200 bar

Boom down 2200 psirelief valve pressure 152 bar

Boom extend 1950 psi134 bar

Oscillate axle 950 psi66 bar

Steer regulator,2WD non-oscillating models 2 gallons per minute

7.6 liters per minute2WD oscillating modelsand 4WD models 1.5 gallons per minute

5.7 liters per minute

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 2000 psirelief pressure 138 bar

REV B



Part No. 72136 S-40 • S-45 2 - 5

Hydraulic Oil Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rykon MV equivalentViscosity grade Multi-viscosityViscosity index 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rykon MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and the viscosity index shouldexceed 140. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Environ MV46Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046Quintolubric 822

Mineral based Shell Tellus T32Shell Tellus T46

Chevron Aviation A

Continued use of ChevronAviation A hydraulic oil whenambient temperatures areconsistently above 32°F / 0°C mayresult in component damage.

Use Chevron Aviation A hydraulicoil when ambient temperatures areconsistentlybelow 0°F / -18°C.

Use Shell Tellus T46 hydraulic oilwhen oil temperatures consistentlyexceed 205°F / 96°C.

Genie specifications requireadditional equipment and specialinstallation instructions for theapproved optional fluids. Consultthe Genie Industries ServiceDepartment before use.

REV B



2 - 6 S-40 • S-45 Part No. 72136

SPECIFICATIONS REV A

Ford LRG-425 EFI Engine

Displacement 153 cu in2.5 liters

Number of cylinders 4

Bore & stroke 3.78 x 3.4 inches96.01 x 86.36 mm

Horsepower,gross intermittent 97continuous 82horsepower @ 2500 rpm 70

Firing order 1 - 3 - 4 - 2

Low idle 1600 rpm396.8 Hz

High idle 2500 rpm620 Hz

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 temperature @ 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.

Starter motor

Normal engine cranking speed 200 to 250 rpm

Current draw, normal load 140-200A

Current draw, maximum load 800A

Current draw, minimum 60-80A

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

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

Electronic fuel pump

Fuel pressure, static 64 psi4.4 bar

Fuel flow rate 0.58 gpm2.18 liters per minute

Ignition System

Spark plug type Motorcraft AWSF-52-C

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


Part No. 72136 S-40 • S-45 2 - 7

Injection system

Injection pump make OMAP

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



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

Deutz F3L 1011F Engine



Bore and stroke 3.58 x 4.13 inches91 x 105 mm

Horsepower 36 @ 3000 rpm

Firing order 1 - 2 - 3


Compression pressure 362 to 435 psi25 to 30 bar

Low idle 1500 rpmFrequency 313 Hz

High idle 2500 rpmFrequency 521.7 Hz

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 8.5 quarts(including filter) 8 liters


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 classificationSG/CC or CD/SG grades.

SPECIFICATIONSREV A



2 - 8 S-40 • S-45 Part No. 72136

SPECIFICATIONS REV A

Perkins 704-30 Engine



Bore and stroke 3.82 x 3.94 inches97 x 100 mm

Horsepower 63 @ 2600 rpm

Firing order 1 - 3 - 4 - 2


Compression pressure 300 to 500 psi20.7 to 34.5 bar

Pressure (psi) of lowest cylinder must be within50 psi (3.45 bar) of highest cylinder

Low idle 1600 rpmFrequency 246.7 Hz

High idle 2200 rpmFrequency 339.2 Hz

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.014 in0.35 mm

Exhaust 0.014 in0.35 mm

Lubrication system

Oil pressure 41 psi(at 2600 rpm) 2.8 bar

Oil capacity 9.6 quarts(including filter) 9 liters


below 68°F / 20°C (synthetic) 5W-20

5°F to 104°F / -15°C to 40°C 10W-30

above 14°F / -10°C 15W-40

Engine oil should have properties of API classificationCC/SE. API classification CD/SE or CCMC D4 can beused, but is not recommended during the first 50 hoursnor for light load applications.

Injection system

Injection pump make Zexel PFR-KX

Injection pump pressure(stage one) 2755 psi 190 bar(stage two) 3336 psi 230 bar

Injector opening pressure 3626 psi 250 bar

Fuel requirement diesel number 2-D

Engine coolant

Capacity 111/2 quarts10.9 liters

Alternator output 65A, 12V

Battery

Type 12V, Group 31

Quantity 1



Fan belt deflection 3/8 in10 mm



Part No. 72136 S-40 • S-45 2 - 9

Machine Torque Specifications

Platform rotator

1-8 center bolt, GR 5, dry 640 ft-lbs868 Nm

1-8 center bolt, GR 5, lubricated 480 ft-lbs651 Nm

3/8 -16 bolts, GR 8, lubricated 35 ft-lbs**use blue thread-locking compound 47.5 Nm

Turntable rotator

Drive hub mounting bolts, dry 210 ft-lbs284 Nm

Drive hub mounting bolts, lubricated* 160 ft-lbs*use blue thread-locking compound 217 Nm

Drive motor and hubs

Before serial number 5370


Drive hub mounting bolts, lubricated 110 ft-lbs149 Nm

Drive motor mounting bolts, dry 75 ft-lbs102 Nm

Drive motor mounting bolts, lubricated 56 ft-lbs76 Nm

After serial number 5369





Turntable bearing

Turntable bearing mounting bolts, lubricated 180 ft-lbs244 Nm

SPECIFICATIONSREV B



2 - 10 S-40 • S-45 Part No. 72136

SPECIFICATIONS REV B

Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®

fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must bereplaced 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 sizeO-ring. They are available in theO-ring field service kit(Genie part number 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 table.

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

SAE O-ring Boss Port(tube fitting - installed into Aluminum)

SAE Dash size Torque

-4 14 ft-lbs / 18.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 36 ft-lbs / 48.8 Nm

-10 62 ft-lbs / 84.1 Nm

-12 84 ft-lbs / 113.9 Nm

-16 125 ft-lbs / 169.5 Nm

-20 151 ft-lbs / 204.7 Nm

-24 184 ft-lbs / 250 Nm

SAE O-ring Boss Port(tube fitting - installed into Steel)


-4 15 ft-lbs / 20.3 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 100 ft-lbs / 135.6 Nm

-12 135 ft-lbs / 183 Nm

-16 200 ft-lbs / 271 Nm

-20 250 ft-lbs / 334 Nm

-24 305 ft-lbs / 414 Nm

Seal-Lok® Fittings (ORFS)(hose end)


-4 18 ft-lbs / 24.4 Nm

-6 30 ft-lbs / 40.7 Nm

-8 40 ft-lbs / 54.2 Nm

-10 60 ft-lbs / 81.3 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 149 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 244 Nm


Part No. 72136 S-40 • S-45 2 - 11

SIZE THREAD

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm20 80 9 100 11.3 110 12.4 140 15.8 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 69114 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 104412 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 207412 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5DRYLUBED

• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide BoltsGrade 8

LUBED

1/4

LUBED DRY LUBED DRY

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

5/16

3/8

7/16

1/2

Size

(mm)in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm

5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.67 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.610 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.412 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36518 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71322 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 97024 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

LUBED DRY LUBED DRYLUBED DRY LUBED DRY

LUBEDDRYLUBED

Class 12.9Class 4.6

DRYLUBED

METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •

LUBED DRY

Class 10.9Class 8.8

DRY

10.9 12.98.84.6

REV A SPECIFICATIONS


2 - 12 S-40 • S-45 Part No. 72136


March 2008 Section 3 • Theory of Operation

REV A

Part No. 72136 S-40 • S-45 3 - 1

Theory Of Operation

Power SourceThe Genie S-40 and Genie S-45 are powered byeither a gasoline/LPG engine or one of two dieselengines. The gasoline/LPG option uses a FordLRG-425 EFI rated at 70 horsepower @ 2500 rpm.The diesel options include a Deutz F3L 1011Frated at 36 horsepower @ 3000 rpm, and aPerkins 704-30 rated at 63 horsepower @ 2600rpm.

Hydraulic SystemAll machine functions are performed by thehydraulic system. The hydraulic system can bedivided into two groups: Boom/Steer functions andDrive functions.

Boom/Steer functions are powered by a single-section gear pump, rated at 10 gpm / 37.9 L/min.When the engine is running, this pump supplieshydraulic fluid under pressure to the functionmanifold, where the directional and flow controlvalves are located. To protect from over-pressurization of the Boom/Steer system, thepump is provided with a pressure relief valve, setat 2900 psi / 200 bar for the S-45 and2600 psi / 180 bar for the S-40.

Drive functions are powered by a bi-directional,variable output piston pump rated at0 to 31.6 gpm /0 to 119.6 L/min @ 2500 rpm. Twointernal 3500 psi / 241 bar relief valves are used toprevent over-pressurization of the closed loopdrive system.

The boom lift cylinder, boom extend cylinder,platform leveling slave cylinder, platform rotatorand jib boom cylinder (S-45 only) incorporatecounterbalance valves to prevent movement in theevent of a hydraulic line failure.

Electrical SystemBoom/Steer functions are accomplished bymoving a toggle switch or a controller, which sendsvoltage to the appropriate directional control valve.These directional valves determine which directionthe hydraulic fluid will travel. The amount ofhydraulic fluid volume is determined by aproportional valve or flow regulator valve. Aproportional valve receives a variable voltagesignal and delivers more hydraulic fluid as thevoltage increases. A flow regulator valve is amechanical valve and delivers a predeterminedamount of hydraulic fluid.

Drive forward or reverse is accomplished bypressing down the foot switch in the platform andmoving the drive controller (joystick) in theappropriate direction. When activated, the drivecontroller completes a circuit to the electronicdisplacement controller (EDC). The EDC regulatesdrive pump displacement in direct relation to thedrive controller position. A horsepower limiterprinted circuit board (located in the platform controlbox) is provided to maintain engine RPM as drivesystem loads become greater. This is done bysensing engine RPM (via an AC tap on thealternator) and limiting the amount of currentsupplied to the drive controller/EDC, whichdestrokes the pump, reducing pump output.

March 2008Section 3 • Theory of Operation

REV A

3 - 2 S-40 • S-45 Part No. 72136

THEORY OF OPERATION

Limit switches

There are two types of limit switches which arefound in various locations on the machine: drivespeed limit switches and a drive enable limitswitch. The function of a drive speed limit switch isto limit the raised or extended drive speed to 0.6miles per hour / 1 km/h when the primary boom israised more than 2 feet / 0.6 m OR when theprimary boom is extended more than18 inches / 45.7 cm. The function of the driveenable limit switch is to limit the ability of themachine to drive when the boom is rotated beyondthe non-steer wheels.

Machine ControlsThe Genie S-40 and Genie S-45 machines areequipped with operational controls which are foundin two locations: the ground controls, located onthe tank side of the machine, and the platformcontrols, located in the platform. All lift and drivefunctions are available at the platform controls.Only boom functions are available at the groundcontrols.

Ground controls are activated by holding thefunction enable toggle switch to either side, thenmoving a boom function toggle switch in thedirection indicated on the control panel decal.This will determine which boom function willoperate and its direction of travel.

Platform controls use toggle switches and boomfunction controllers (joysticks) to operate the boomfunctions. The drive controller (joystick) regulatesthe drive pump displacement through the EDC indirect relation to the drive controller position. Athumb rocker switch on the top of the drivecontroller is used for steering.

Washing electronic components isnot suggested. Instead, usecompressed air to remove debris.

March 2008 Section 4 • Scheduled Maintenance Procedures

Part No. 72136 S-40 • S-45 4 - 1

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 machine damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Use only Genie approved replacement parts.

Machines that have been out of service for aperiod longer than three months must completethe quarterly inspection.

Unless otherwise specified, perform eachprocedure with the machine in the followingconfiguration:

· Machine parked on a flat, level surface

· Boom in the 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 Section

This section contains detailed procedures for eachscheduled maintenance inspection.

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

Symbols Legend






Green—used to indicate operationor maintenance information.

Indicates that a specific result is expected afterperforming a series of steps.

March 2008Section 4 • Scheduled Maintenance Procedures

4 - 2 S-40 • S-45 Part No. 72136

Maintenance Symbols Legend

The following symbols have beenused in this manual to helpcommunicate the intent of theinstructions. When one or more ofthe symbols appear at thebeginning of a maintenanceprocedure, it conveys the meaningbelow.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold engine will berequired to perform this procedure.

Indicates that a warm engine will berequired to perform this procedure.

Indicates that dealer service is requiredto perform this procedure.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, six months, annual, and two year.The Scheduled Maintenance Procedures Sectionand the Maintenance Inspection Report have beendivided into five subsections—A, B, C, D and E.Use the following chart to determine whichgroup(s) of procedures are required to perform ascheduled inspection.

Inspection Table or Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Six months or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two year or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

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

Make copies of the Maintenance Inspection Reportto use for each inspection. Maintain completedforms for a minimum of 4 years or in compliancewith employer, jobsite and governmental regulationsand requirements.

SCHEDULED MAINTENANCE PROCEDURES


Part No. 72136 S-40 • S-45 4 - 3

Checklist A - Rev B Y N RA-1 ManualsA-2 Decals and placards

A-3 Damage and loose ormissing parts

A-4 Engine oil level

A-5 Engine coolant-Ford/Perkins Models

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

A-15 Drain filter/separatorDeutz/Perkins Models

A-16 30 Day Service

Perform every 100 hours:

A-17 Replace engine oiland filter-Ford Models

Perform every 200 hours:A-18 Engine belt -

Ford/Perkins Models

A-19 Fuel filter-Ford Models

Instructions· Make copies of this report to use for

each inspection.

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

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hoursInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

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

· Use the step-by-step procedures insection 4 to learn how to performthese inspections.

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

LegendY = yes, acceptableN = no, remove from service

R = repaired

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Checklist B - Rev B Y N R

B-1 Exhaust system

B-2 Air Filter

B-3 Radiator

B-4 Battery

B-5 Electrical Wiring

B-6 Oil Cooler Fins- Deutz

B-7 Hydraulic tank condition

B-8 Tires and wheels

B-9 Brake configuration

B-10 Drive hub oil level

B-11 Engine RPM

B-12 Key switch

B-13 Emergency Stop

B-14 Ground control override

B-15 Directional valve

B-16 Platform leveling

B-17 Foot switch

B-18 Horn

B-19 Engine idle select

B-20 Fuel select-Gas/LPG

B-21 Drive enable system

B-22 Drive brakes

B-23 Drive speed-stowed

B-24 Drive speed-raised

B-25 Alarm package

B-26 Hydraulic oil analysis

B-27 Replace hydraulictank return filter

Perform every 400 hours:B-28 Replace engine air filter

B-29 Replace spark plugs-Ford Models

Maintenance Inspection Report

Comments


4 - 4 S-40 • S-45 Part No. 72136

MAINTENANCE INSPECTION REPORT

Instructions· Make copies of this report to use for

each inspection.

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

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hoursInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

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

· Use the step-by-step procedures insection 4 to learn how to performthese inspections.

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

LegendY = yes, acceptableN = no, remove from service

R = repaired

Comments

Checklist E - Rev B Y N RE-1 Hydraulic oil

E-2 Engine coolant-Ford/Perkins Models

E-3 Fuel hoses-Ford Models

E-4 Replace enginebreather-Perkins Models

E-5 Wheel bearings

Perform every 3000 hours:

E-6 Fuel injectors-Perkins Models

Checklist C- Rev A Y N RC-1 Engine belt-

Deutz Models

C-2 Valves-Deutz Models

C-3 Fuel filter/waterseparator-Perkins Models

C-4 Fuel filter-Perkins Models

C-5 Replace engine oiland filter-Perkins Models

C-6 Check the coolant-Ford/Perkins Models

C-7 Glow plugs-Perkins

C-8 PCV valve-Ford Models

Checklist D - Rev B

D-1 Boom wear pads

D-2 Free-wheel configuration

D-3 Turntable bearing bolts

D-4 Grease rotation bearing

D-5 Drive hub oil

D-6 Drive loop hydraulic filter

D-7 Replace engine oiland filter-Deutz Models

D-8 Fuel strainer-Deutz

D-9 Fuel filter/waterseparator-Deutz Models

D-10 Change fuel lines-Duetz

D-11 Valves-Deutz Models

D-12 Clean engine breather-Perkins Models


Part No. 72136 S-40 • S-45 4 - 5

A-1Inspect the Manuals

Genie specifications require thatthis procedure be performed daily.

Maintaining 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 manuals 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.

Checklist A Procedures

A-2Inspect theDecals and Placards


Maintaining 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 the Genie S-40 &Genie S-45 Operator's Manual and use the decallist and illustrations to determine that all decalsand placards are in place.

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.

REV B


4 - 6 S-40 • S-45 Part No. 72136

A-3Inspect for Damage and Looseor Missing Parts

Daily 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, power units, fittings, cylinders and manifolds

· Fuel and hydraulic tanks

· Drive and turntable motors and drive hubs

· Boom wear pads

· Tires and wheels

· Engine and related components

· Limit switches, alarms, horn and beacon

· Nuts, bolts and other fasteners

· Platform entry mid-rail or gate

Check entire machine for:

· Cracks in welds or structural components

· Dents or damage to machine

· Battery and connections

· Compartment covers and latches

Be sure that all structural and other criticalcomponents are present and all associatedfasteners and pins are in place and properlytightened.

After you complete each inspection, be sure that allcompartment covers are in place and secured.

REV BCHECKLIST A PROCEDURES


Part No. 72136 S-40 • S-45 4 - 7

A-4Check the Engine Oil Level


Maintaining 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.

Gasoline/LPG Engine: located above thebellhousing on the bulkhead side of the engine.

Diesel Engine: located on the engine block nearthe engine oil filter.

Result: The oil level should be at the full markon the dipstick. Add oil as needed.

Ford LRG-425 EFI EngineOil capacity (including filter) 5 quarts / 4.7 liters


below 60°F / 15.5°C 5W-30

-10° to 90°F / -23° to 32°C 5W-30

above -10°F / -23°C 5W-30

above 25°F / -4°C 10W-30

Use oils meeting API classification SH or SG grade.

Deutz F3L 1011F EngineOil capacity (including filter) 8.5 quarts / 8 liters


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 or CC/SF grades.

Perkins 704-30 EngineOil capacity (including filter) 9.5 quarts / 8.9 liters


below 60°F / 15.5°C 15W-40

-10°F to 90°F / -23°C to 32°C 10W-30

above -4°F / -34°C 15W-40

Engine oil should have properties of API classificationCF4 grade.

REV B CHECKLIST A PROCEDURES


4 - 8 S-40 • S-45 Part No. 72136

A-5Check the Engine Coolant Level -Liquid Cooled Models


Maintaining the engine coolant at the proper level isessential 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.

Burn hazard. Beware of hotengine parts and coolant. Contactwith hot engine parts and/orcoolant may cause severe burns.

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

Result: The fluid level should be at theFULL mark.

Do not remove the radiator cap.

A-6Check for Fuel Leaks


Failure to detect and correct fuel leaks will result inan unsafe condition. An explosion or fuel fire maycause death or serious injury.

Explosion and fire hazard. Enginefuels are combustible. Inspect themachine in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

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

2 Perform a visual inspection around the followingareas.



Part No. 72136 S-40 • S-45 4 - 9

A-7Check the Hydraulic Oil Level


Maintaining 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. Add oil asneeded.

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

Gasoline/LPG models:

· LPG tank, hoses and fittings, solenoid shutoffvalve, LPG regulator and throttle body.

An LPG detector may benecessary to locate LPG leaks.

· Gasoline tank, manual shutoff valve, fuelpump, fuel filters, fuel rail and fuel injectors,hoses and fittings and throttle body.

Diesel models:

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

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.

REV B CHECKLIS A PROCEDURES


4 - 10 S-40 • S-45 Part No. 72136

A-8Check for Hydraulic Leaks


Detecting hydraulic fluid leaks is essential tooperational safety and good machine performance.Undiscovered leaks can develop into hazardoussituations, impair machine functions and damagemachine components.

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.

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

· Hydraulic tank—filter, fittings, hoses, auxiliarypower unit, filters, and component tray

· Engine compartment—hydraulic filters,fittings, hoses, pumps, and component tray

· All hydraulic cylinders

· All hydraulic manifolds

· Primary, and jib booms

· The underside of the turntable

· The underside of the drive chassis

· Ground area under the machine

A-9Check the Tire Pressure


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

Bodily injury hazard. An over-inflated tire can explode and couldcause death or serious injury.

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

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.Add air as needed.

Tire specifications

Tire size2WD (front tires only) 12.5-16 SL2WD and 4WD (front and rear tires) 12-16.5 NHS

Pressure 45 psi3.1 bar



Part No. 72136 S-40 • S-45 4 - 11

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 cmblock 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 cmblock 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 cmblock or curb.

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

If the chassis does not remainlevel during test, see RepairProcedure 11-6, How to Set Up theDirectional Valve Linkage OR seeRepair Procedure 11-5, How toAdjust the Oscillate SequencingValve Pressure.



4 - 12 S-40 • S-45 Part No. 72136

A-11Test the Platform andGround Controls


Testing the machine functions and the redEmergency Stop buttons for malfunctions isessential for safe machine operation. An unsafeworking condition exists if any function fails tooperate properly or either Emergency Stop buttonfails to stop all the machine functions and shut offthe engine. Each function should activate, operatesmoothly and be free of hesitation, jerking andunusual noise.

1 Pull out the red 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 red Emergency Stop button to theoff position.

Result: No function should operate, the engineshould stop.

Machines equipped with PlatformLevel Control Disable Function:The platform level toggle switchwill not operate when the boom israised or extended past the drivespeed limit switches.

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 the footswitch and activate eachmachine function.

Result: All machine functions should operatethrough a full cycle.

10 Push in the red Emergency Stop button to theoff 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 red Emergency Stop switch.

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



Part No. 72136 S-40 • S-45 4 - 13

A-12Test the Auxiliary PowerOperation


Detection 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 on enginepower, selecting auxiliary power will stop the engineimmediately. Auxiliary power is designed for shortterm use only,and excessive use will result in battery drainand component damage.

1 Turn the key switch to groundcontrol and pull out the redEmergency Stop button to theon position.

2 Lift the red auxiliary powertoggle switch cover.

3 Simultaneously hold theauxiliary power toggle switch ON and activateeach boom function toggle switch.

Result: All boom functions should operate.

To conserve battery power, testeach function through a partialcycle.

4 Turn the key switch to platform control.

5 Pull out the red Emergency Stop button to theon position at the platform controls, then pressdown the foot switch.

6 Lift the red auxiliary power toggle switch cover.

7 Simultaneouslyhold theauxiliary powertoggle switchon and activateeach functioncontrol handleor toggle switch

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

To conserve battery power, testeach function through a partialcycle.



4 - 14 S-40 • S-45 Part No. 72136

A-13Test the Tilt Sensor


The tilt sensor sounds an alarm located in theplatform only when the machine is on a slope.

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 the alarmin the platform.

a fuel tankb tilt sensorc ground control box

cba

A-14Test the Limit Switches


Drive 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 in anunsafe position.

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

2 Visually inspect the boom up drive limit switchmounted to the turntable riser at the pivot endof the boom. Inspect for the following:

· Broken or missing roller or arm

· Missing fasteners

· Loose wiring

a turntable riserb boomc boom up drive limit switch (LS2)

REV B

a b

c

CHECKLIST A PROCEDURES


Part No. 72136 S-40 • S-45 4 - 15

3 Manually activate the boom up drive limitswitch.

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

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



· Loose wiring

a boom extend drive limit switch (LS1)b cable track


6 Extend the boom approximately 3 feet / 0.9 m.

7 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.

8 Turn the key switch to platform controls andfully retract the boom.

9 Move the lift/drive selector switch to the driveposition, if equipped.

10 Press down the foot switch and slowly move thedrive control handle off center.

Result: The machine should move at normaldrive speeds.

11 Move the lift/drive selector switch to the liftposition, if equipped.

12 Raise the boom to just above horizontal.


14 Slowly move the drive control handle off center.

Result: The machine should move at a reduceddrive speed.

15 Move the lift/drive selector switch to the liftposition (if equipped).

16 Lower the boom to the stowed position, thenextend the boom 3 feet / 0.9 m.



Result: The machine should move at a reduceddrive speed.

Drive speed, maximum,raised or extended position

All models 1 foot per second 0.6 mph0.3 meter per second 0.97 km/h

ba



4 - 16 S-40 • S-45 Part No. 72136

Drive Enable Limit Switch

A properly functioning drive enable limit switch isessential for safe machine operation andworkplace safety. The drive enable limit switchstops the drive function when the boom is rotatedpast a non-steer tire and alerts the operator thatthe machine may drive in the opposite directionthat the drive and steer control handle is moved.

1 Start the engine from the platform controls androtate the turntable to the left until the boom ispast the left non-steer wheel. Turn the engineoff.

2 Visually inspect the drive enable limit switch forthe following:



· Loose wiring

a turntableb drive enable limit switch (LS3)c turntable rotation bearing

3 Manually activate the drive enable limit switch.

Result: The drive enable limit switch arm shouldmove freely and spring return to center. Adistinct click should be felt and heard.

4 Start the engine from the platform controls, andpress down the foot switch.

Result: The drive enable indicator light shouldbe on.

5 Rotate the turntable so the boom is between thenon-steer tires.

Result: The drive enable indicator light shouldbe off and drive function should operate.

6 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 override toggle switch isactivated.

7 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 override toggle switch isactivated.

a

bc



Part No. 72136 S-40 • S-45 4 - 17

A-15Drain the Fuel Filter/ WaterSeparator - Diesel Models

Genie specifications require thatthis procedure be performed every100 hours or monthly, whichevercomes first.

Proper maintenance of the fuel filter/water separatoris essential for good engine performance. Failure toperform this procedure can lead to poor engineperformance and component damage.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Perform this procedure with theengine off.

Perkins Models:

1 Open the engine side cover and locate the fuelfilter/water separator.

2 Loosen the vent plug located on the fuel filter/water separator head.

Fuel filter/water separatora head boltb vent plugc drain plugd filter bowle separator head

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

4 Tighten the vent plug.

If the fuel filter/water separator iscompletely drained, you mustprime the fuel filter/waterseparator before starting theengine. Refer to C-4 in thissection, Replace The Fuel FilterElement - Perkins Diesel Models,for instructions on how to prime thefuel filter/water separator.

d

c

e

b

a



4 - 18 S-40 • S-45 Part No. 72136

5 Clean up any fuel that may have spilled.

6 Start the engine from the ground controls andcheck the fuel filter/water separator and ventplug for leaks.


Deutz Models:

1 Open the engine side cover and locate the fuelfilter/water separator.

2 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

3 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 D-9 inthis section, Replace The DieselFuel Filter/Water Separator -Deutz Diesel Models, forinstructions on how to prime thefuel filter/water separator.

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


a

b



Part No. 72136 S-40 • S-45 4 - 19

A-16Perform 30 Day Service

The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 50 hours of usage. After thisinterval, refer to the maintenance tables forcontinued scheduled maintenance.

1 Perform the following maintenance procedures:· A-17 Replace the Engine Oil and Filter -

Gasoline/LPG Models (if applicable) OR· C-5 Replace the Engine Oil and Filter -

Perkins Models (if applicable) OR· D-7 Replace the Engine Oil Filter -

Deutz Models (if applicable)· B-8 Inspect the Tires, Wheels

and Lug Nut Torque· B-27 Replace the Hydraulic Tank Return

Filter· D-3 Check the Turnable Rotation Bearing

Bolts

REV B

A-17

Replace 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 ofmachine hours against the hours noted on the oilfilter will allow the inspector to anticipate andperform oil and filter changes at the 100 hourinterval.

Perform this procedure afterwarming the engine to normaloperating temperature.

Bodily injury hazard. Beware ofhot engine parts and oil. Contactwith hot engine oil and/or engineparts may cause severe burns.

1 Open the engine side cover and remove the oilfiller cap located on the valve cover.

2 Pull the oil drain hose out from underneath theengine.



4 - 20 S-40 • S-45 Part No. 72136

REV B

3 Open the engine oil drain valve on the engine oilpan and allow all of the oil from the engine todrain into a suitable container. Seespecifications.

a engine pivot plateb pivot plate retaining boltsc oil drain hosed air baffle

4 Close the engine oil drain valve.

5 Remove the air baffle retaining fasteners.Remove the air baffle.

6 Remove the 2 engine pivot plate retaining bolts.Pull the engine pivot plate away from themachine to access the oil filter.

7 Place a container under the oil filter.

8 Use an oil filter wrench and remove the filter.

9 Apply a thin layer of fresh oil on the gasket ofthe new oil filter. Install the filter and tighten itsecurely by hand.

a bcb d

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

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

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

13 Check the oil filter, oil pan drain hose and drainvalve for leaks.

14 Swing the engine pivot plate back to its originalposition and install the two engine pivot plateretaining bolts.

15 Install the air baffle and the air baffle retainingfasteners.

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

17 Clean up any oil that may have spilled. Properlydispose of the oil and filter.

Ford LRG-425 EFI Engine 5 quartsOil capacity (including filter) 4.7 liters


below 60°F / 15.5°C 5W-30

-10° to 90°F / -23° to 32°C 5W-30

above -10°F / -23°C 5W-30

above 25°F / -4°C 10W-30

Use oils meeting API classification SH or SG grade.

Oil filter - Genie part number 52581



Part No. 72136 S-40 • S-45 4 - 21

A-18Check the Engine Belt -Gasoline/LPG andPerkins Diesel Models

Engine specifications require thatthis procedure be performed every200 hours.

Maintaining the engine belt is essential to goodengine performance and service life. The machinewill not operate properly with a loose or defectivebelt and continued use may cause componentdamage.

Bodily injury hazard. Do notinspect while the engine isrunning. Remove the key tosecure from operation.

Bodily injury hazard. Beware ofhot engine components. Contactwith hot engine components maycause severe burns.


2 Remove the 2 engine pivot plate retaining bolts.Swing the engine pivot plate away from themachine to access the front engine accesscover mounting fasteners.

a engine pivot plateb pivot plate retaining boltsc air baffle

3 Remove the front engine access covermounting fasteners.

All models:

4 Inspect the engine belt for:

· Cracking

· Glazing

· Separation

· Breaks

a b cb



4 - 22 S-40 • S-45 Part No. 72136

REV B

5 Replace belt if any damage is found.

Ford LRG-425 EFI engines areequipped with a serpentine beltand incorporate a self adjustingbelt tensioner. No adjustment isrequired.

Perkins Diesel models:

6 Check the engine belt for proper tension.

Perkins Diesel engine

7 Install the front engine access cover.


9 Replace the air baffle and install the air baffleretaining fasteners.

Belt deflection - Diesel models 3/8 inch to 1/2 inch9 mm to 12 mm

Engine belts - Genie part numbersGasoline/LPG models 52580Perkins Diesel models 62423

A-19Replace the Gasoline Fuel Filter -Gasoline/LPG Models

Replacing 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.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel filter in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.


1 Locate the fuel pre-filter to the left of the groundcontrol box.

2 Turn the manual shutoff valve, located at thefuel tank to the closed position.

3 At the pre-filter, disconnect the fuel hose thatgoes to the fuel tank.

4 Disconnect and plug the fuel hose from the fuelpre-filter to the fuel pump, then remove the pre-filter.



Part No. 72136 S-40 • S-45 4 - 23

5 Install the new fuel pre-filter (Genie part number52179) and connect the fuel hoses to the filter.

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


8 Remove the 2 engine pivot plate retaining bolts.Swing the engine pivot plate away from themachine to access the fuel pressure regulator/filter.

9 Locate the fuel pressure regulator/filter installedon the engine mounting leg.

10 Disconnect and plug the hoses from the fuelpressure regulator/filter.

Explosion and fire hazard.Electronic Fuel Injection (EFI)systems operate at a very highpressure. Fuel may be expelledunder pressure if the hoses areremoved too quickly. Loosen thefuel hoses very slowly to allow thefuel pressure to dissipategradually. Wrap a cloth aroundfuel hoses to absorb leaking fuelbefore disconnecting them.

11 Remove the fuel pressure regulator/filtermounting fasteners. Then remove the regulator/filter from the engine mounting leg.

12 Install the new fuel pressure regulator/filter(Genie part number 58967) onto the enginemounting leg and connect the hoses to theregulator/filter.

Component damage hazard. Besure the correct regulator/filter isinstalled or component damagemay occur.

13 Turn the manual shutoff valve, located at thefuel tank, to the open position.

14 Start the machine from the ground controls,then inspect the fuel filters and hoses for leaks.






4 - 24 S-40 • S-45 Part No. 72136

Checklist B Procedures

B-1Check the Exhaust System

Genie specifications require thatthis procedure be performed every250 hours or quarterly, whichevercomes first.

Maintaining 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.

Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.


1 Diesel models: Remove the air baffle retainingfasteners. Remove the air baffle.

2 Diesel models: Remove the 2 bolts from underthe engine pivot plate. Swing the engine pivotplate away from the machine to access theexhaust system.


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

4 Inspect all welds for cracks.

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

6 Diesel models: Swing the engine pivot plateback to its original position and install the twoengine pivot plate retaining bolts.

7 Diesel models: Replace the air baffle andinstall the air baffle retaining fasteners.

a b cb

REV B


Part No. 72136 S-40 • S-45 4 - 25

B-2Inspect the Engine Air Filter


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.


Gasoline/LPG and Deutz Diesel Models:

1 Open the engine side cover and remove theretaining ring from the end cap of the air filtercanister.

2 Remove the end cap from the air cleanercanister.

3 Remove the air filter retaining fastener. Removethe filter element.

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

5 Inspect the filter element. If needed, blow outfrom inside out using low pressure drycompressed air, or tap out dust taking care notto damage the element.

6 Install the air filter element and install themounting fastener.

7 Install the end cap onto the canister. Install andtighten the retaining ring.


1 Open the engine side cover and disconnect theretaining fasteners from the end cap of the airfilter canister. Remove the end cap.

2 Remove the filter element.

3 Empty the dust discharge valve by pressingtogether the sides of the discharge slot. Cleandischarge slot as needed.

a air filterb dust discharge valve

4 Clean the inside of the canister and the canisterend cap with a damp cloth.

5 Inspect the filter element. If needed, blow outfrom inside out using low pressure drycompressed air, or tap out dust taking care notto damage the element.

6 Install the filter element

7 Install the end cap onto the canister. Secure theretaining fasteners.

Air filters - Genie part numbersFord LRG-425 EFI Engine 27916Deutz F3L 1011F Engine 27916Perkins 704-30 Engine 62420

CHECKLIST B PROCEDURESREV B


4 - 26 S-40 • S-45 Part No. 72136

B-3Inspect the Radiator -Liquid Cooled Models

Genie specifications require thatthis procedure be performed every250 hours or quarterly, whichevercomes first. Perform thisprocedure more often if dustyconditions exist.

Maintaining 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.


Bodily injury hazard. Beware ofhot engine parts and coolant.Contact with hot engine partsand/or coolant may cause severeburns.


2 Remove the 2 engine pivot plate retaining bolts.Swing the engine pivot plate away from themachine to access the radiator.


3 Inspect the radiator for leaks and physicaldamage.

4 Clean the radiator fins of debris and foreignmaterials.

5 Inspect all radiator hoses and connections.



a b cb

CHECKLIST B PROCEDURES REV B


Part No. 72136 S-40 • S-45 4 - 27


B-4Inspect the Battery


Proper battery condition is essential to good engineperformance and operational safety. Improper fluidlevels or damaged cables and connections canresult in engine component damage and hazardousconditions.

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

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

1 Put on protective clothing and eye wear.

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

Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosion onthe battery terminals and cables.

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

4 Be sure that the battery separator wireconnections are tight.

5 Fully charge the batteries and allow the batteriesto rest at least 6 hours.

6 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

7 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display an adjustedspecific gravity of 1.277 or higher. The batteryis fully charged. Proceed to step 11.

Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceed tostep 8.

8 Perform an equalizing charge, OR fully chargethe batteries and allow the batteries to rest atleast 6 hours.

9 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

10 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display a specificgravity of 1.277 or greater. The battery is fullycharged. Proceed to step 11.

Result: The difference in specific gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is lessthan 1.217. Replace the battery.

11 Check the battery acid level. If needed,replenish with distilled water to 1/

8 inch / 3 mm

below the bottom of the battery fill tube. Do notoverfill.

12 Install the vent caps and neutralize anyelectrolyte that may have spilled with bakingsoda.


4 - 28 S-40 • S-45 Part No. 72136

B-5Inspect the Electrical Wiring


Maintaining 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 could result indeath or serious injury. Remove allrings, watches and other jewelry.

1 Open the engine side turntable cover.


3 Remove the 2 engine pivot plate retaining boltsand swing the engine out away from themachine to access the wiring.


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

· Engine wiring harness

· Hydraulic manifold wiring

5 Open the ground controls side turntable cover.

6 Inspect the following areas for burnt, chafed,corroded and loose wires:· Inside of the ground control box· Hydraulic manifold wiring

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

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

9 Lower the boom to the stowed position and turnthe engine off.

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

· Cable track on the primary boom

· Cables on the primary, and jib booms

· Jib/rotate manifold

· Inside of the platform control box



a b cb

REV BCHECKLIST B PROCEDURES


Part No. 72136 S-40 • S-45 4 - 29

B-6Check the Oil Cooler andCooling Fins -Deutz Diesel Models


Maintaining 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 engine side cover mountingfasteners. Remove the engine side 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.

Cooling and Fan Blower Fins


5 Remove the 2 bolts from under the engine pivotplate. Swing the engine pivot plate away fromthe machine to access the fan blower.


a cb

REV B CHECKLIST B PROCEDURES

a b cb


4 - 30 S-40 • S-45 Part No. 72136

B-7Check the Hydraulic Tank ReturnFilter Condition Indicator


Maintaining the hydraulic tank return 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.

Perform this procedure with theengine running.


2 Move the engine idle speed select switch tohigh idle (rabbit symbol).

REV B

6 Inspect the fan blower fins for physical damage.

7 Clean the fan blower fins of debris and foreignmaterial.

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

9 Clean the cylinder head cooling passages andfins of debris and foreign material.

10 Install the engine side cover.



CHECKLIST B PROCEDURES


Part No. 72136 S-40 • S-45 4 - 31

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 B-27, Replace theHydraulic Tank Return Filter.

REV B

b

c

a


B-8Inspect the Tires, Wheelsand 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.

Bodily injury hazard. An over-inflated tire can explode and maycause death or 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.


4 - 32 S-40 • S-45 Part No. 72136

3 Check each lug nut for proper torque.

4 Check the pressure in each air-filled tire. Add airas necessary.

Tires and wheels 2WD Front 2WD Rear4WD Front

and Rear

Tire size 12.5-16 SL 12-16.5 NHS

Pressure 45 psi 45 psi3.1 bar 3.1 bar


Wheel lugs 8 @ 5/8 -18 9 @ 5/8 -18

Lug nut torque, dry 170 ft-lbs 170 ft-lbs230 Nm 230 Nm

Lug nut torque, lubricated 130 ft-lbs 130 ft-lbs176 Nm 176 Nm

B-9Confirm the ProperBrake Configuration


Proper 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 drive hub disconnect cap to besure it is in the engaged position.

brake disengageposition

brake engage position

CHECKLIST B PROCEDURES REV B


Part No. 72136 S-40 • S-45 4 - 33

a

b

c

d

2 Be sure the free-wheel valve isclosed (clockwise).

The free-wheel valve is located onthe drive pump.

a drive pumpb free-wheel valvec lift pumpd screwdriver

The free-wheel valve shouldalways remain closed.

B-10Check the Oil Level inthe Drive Hubs


Failure to maintain proper drive hub oil levels maycause the machine to perform poorly and continueduse may cause component damage.

Drive 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.



4 - 34 S-40 • S-45 Part No. 72136

a

b

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(s), andthen install the plug(s) in the drive hub.

5 Repeat this procedure for each drive hub.

Drive hub oil

Capacity 17 fl oz0.5 liters

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

Turntable Rotate Drive 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 drive 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, andinstall the plug in the drive hub.

Turntable rotate drive hub oil

Capacity 8 fluid ounces0.24 liters

Type SAE 90 multipurpose hypoid gear oil - APIservice classification GL5



Part No. 72136 S-40 • S-45 4 - 35

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

2 Loosen the low idle lock nut and turn the low idleadjustment screw clockwise to increase therpm, or counterclockwise to decrease the rpm.Tighten the low idle lock nut and confirm 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.

Result: High idle should be 2500 rpm for Deutzmodels, 2200 rpm for Perkins models.

f

e

c dba

B-11Check and Adjust theEngine RPM


Maintaining 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:

The engine rpm is controlled bythe ECM and can only be adjustedby re-programming the ECM. Ifrpm adjustment or service isrequired, please contact the GenieIndustries Service Department ORyour local Ford dealer.

Gasoline/LPG models

Low idle 1600 rpm

High idle 2500 rpm

Diesel models:

This procedure will require twopeople.

1 Connect a tachometer to the engine. Start theengine from the ground controls.

Result: Low idle should be 1500 rpm for Deutzmodels, 1600 rpm for Perkins models.



4 - 36 S-40 • S-45 Part No. 72136

B-12Test the Key Switch


Proper 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 cause ahazardous operating situation.

1 Pull out the red Emergency Stop button to theon 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.

Diesel models: All functions shouldstop immediately. The engine willshut off after 2 to 3 seconds.

If high idle rpm is correct, disregard adjustmentstep 4.

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 1500 rpm

High idle 2300 rpm

Perkins Diesel models

Low idle 1600 rpm

High idle 2200 rpm



Part No. 72136 S-40 • S-45 4 - 37

B-13Test the EmergencyStop Buttons


Properly 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 platform EmergencyStop button.

1 Start the engine from ground controls.

2 Push down the red Emergency Stop button tothe OFF position.

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

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

3 Start the engine from platform controls.

4 Push down the red Emergency Stop button tothe OFF position.

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

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

REV B

B-14Test the Ground ControlOverride


A properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allow groundpersonnel to operate the machine from the groundcontrols whether or not the Emergency Stop buttonon the platform controls is in the ON or OFF position.This function is particularly useful if the operator atthe platform controls cannot return the boom to thestowed position.

1 Push in the platform red Emergency Stop buttonto the off position.


3 At the ground controls, operate each boomfunction through a partial cycle.

Result: All boom functions should operate.



4 - 38 S-40 • S-45 Part No. 72136

a

b

c

d

B-15Check 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

B-16Test the Platform Self-leveling


Automatic 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 unsafeworking condition for platform andground personnel.

1 Start the engine from the ground controls andlower the boom to 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.



Part No. 72136 S-40 • S-45 4 - 39

B-17Test the Foot Switch


A 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 key switch to platform controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

2 Press down the foot switch 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 foot switch and attemptto start the engine.

Result: The engine should start.

4 Do not press down the foot switch and operatethe machine functions.


5 Press down the foot switch and operate themachine functions.

Result: The machine functions should operate.

REV B

B-18Test the Horn


A 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 controls andpull out the red 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.



4 - 40 S-40 • S-45 Part No. 72136

B-19Test the Engine Idle SelectOperation


A 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 red Emergency Stop button to theon position at both the ground and platformcontrols.

2 Start the engine from the ground controls. Moveand hold the function enable toggle switch inthe high idle (rabbit symbol) position.

Result: The engine RPM should change to highidle.

3 Release the function enable toggle switch.

Result: The engine RPM should change to lowidle.

4 Turn the key switch to platform controls.

5 At the platform controls, move the engine idleselect toggle switch to high idle (rabbit symbol).Do not press down the foot switch.


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

Result: The engine RPM should change to lowidle.

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

Result: The engine RPM should not change tohigh idle.

8 Press down the foot switch.




Part No. 72136 S-40 • S-45 4 - 41

B-20Test the Fuel Select Operation -Gasoline/LPG Models


The ability to select and switch betweengasoline and LPG fuels as needed is essential tosafe machine operation. A fuel selection can bemade while 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 indicate fuelsystem 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 toggle switch to gasolineand then move the engine idle select switch tofoot switch activated high idle (rabbit and footswitch symbol).

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 red Emergency Stop button in tothe off position.

5 Move the fuel select switch to LPG.

6 Start the engine and allow it to run at low 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.



4 - 42 S-40 • S-45 Part No. 72136

B-21Test the Drive Enable System


Proper 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 held to eitherside to reactivate the drive function and should alertthe 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 into anunsafe position.


2 Move the lift/drive selector toggle switch to thelift position (if equipped).

3 Press down the foot switch.

4 Rotate the turntable to theright until the boom movespast the right non-steeringwheel.

Result: The drive enable indicator light shouldturn on and remain on while the boom isanywhere in the range shown.

5 Move the lift/drive select toggle switch to thedrive position (if equipped).


Result: The drive function should not operate.

7 Hold the drive enabletoggle switch to eitherside and slowly movethe drive control handleoff center.

Collision hazard. Always use thecolor-coded direction arrows on theplatform control panel and the drivechassis to identify which directionthe machine will travel.

Result: The drive function should operate.

8 Rotate the turntable to the left until the boommoves past the left non-steering wheel.

Result: The drive enableindicator light should comeon and remain on while theboom is anywhere in therange shown.

9 Repeat steps 6 and 7.



Part No. 72136 S-40 • S-45 4 - 43

B-22Test the Drive Brakes


Proper 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.

Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.Refer to B-9 in this section,Confirm the Proper BrakeConfiguration.

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

Be sure the boom is fully retractedand lowered to the stowed position.

1 Mark a test line on the ground for reference.


3 Move the lift/drive select switch to the driveposition (if equipped).

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 drivecontroller when your reference point on themachine crosses the test line.

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

Braking:paved surface

Stopping distance 2 to 4 ft0.6 to 1.2 m

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



4 - 44 S-40 • S-45 Part No. 72136

B-23Test the Drive Speed -Stowed Position


Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.


Be sure the boom is fully retractedand lowered to the stowed position.

1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.


3 Move the lift/drive select switch to the driveposition (if equipped).

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/6.8 sec 40 ft/7.8 sec12.2 m/6.8 sec 12.2 m/7.8 sec

Diesel models 40 ft/7.8 sec 40 ft/9.1 sec12.2 m/7.8 sec 12.2 m/9.1 sec



Part No. 72136 S-40 • S-45 4 - 45

B-24Test the Drive Speed -Raised or Extended Position


Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over the entireproportionally controlled speed range.


1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.


3 Move the lift/drive select switch to the liftposition, if equipped.

4 Move the engine idle select switch tofoot switch activated high idle (rabbit and footswitch). Press down the foot switch and raisethe boom above horizontal.

5 Move the lift/drive select switch to the driveposition, if equipped.



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

9 Move the lift/drive select switch to the liftposition, if equipped.

10 Press down the foot switch and lower the boomto the stowed position.

11 Extend the boom 1 foot / 30 cm.

12 Move the lift/drive select switch to the driveposition, if equipped.



15 Continue at top speed and note the time whenthe machine reference point crosses the finishline.

Drive speed, maximum.raised or extended position

All models 1 foot per second (0.6 mph) 0.13 meter per second (0.97 km/h)



4 - 46 S-40 • S-45 Part No. 72136

B-25Test the Alarm Package(if equipped)


The alarm package includes:

· Travel alarm

· Descent alarm

· Flashing beacon

Alarms and a beacon are installed to alert operatorsand ground personnel of machine proximity andmotion. The alarm package is installed on theturntable covers.

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

1 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

Result: The flashing beacon should be on andflashing.

2 Hold the function enable switch to either sideand activate the boom toggle switch in the downposition, hold for a moment and then release it.

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

3 Turn the key switch to platform controls.

Result: The flashing beacon should be ON

and flashing.

4 Move the lift/drive selector switch to the liftposition, if equipped.

5 Press down the foot switch. Move the boomcontroller to the down position, hold for amoment and then release it.

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


7 Press down the foot switch. Move the drivecontroller off center, hold for a moment andthen release it. Move the drive controller offcenter in the opposite direction, hold for amoment and then release it.

Result: The travel alarm should sound when thedrive controller is moved off center in eitherdirection.

B-26Perform Hydraulic Oil Analysis

See E-1, Test or Replace the Hydraulic Oil.



Part No. 72136 S-40 • S-45 4 - 47

B-27Replace the Hydraulic TankReturn Filter

Genie requires that this procedurebe performed quarterly or every250 hours, whichever comes first.Perform this procedure more oftenif dusty conditions exist.

Replacement of the hydraulic tank return 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.

Bodily injury hazard. Beware of hotoil. Contact with hot oil may causesevere burns.


1 Place a suitable container under the hydraulictank return filter.

2 Remove the filter with an oil filter wrench.

3 Apply a thin layer of fresh oil to the new oil filtergasket.

4 Install the new filter and tighten it securely byhand. Clean up any oil that may have spilledduring the installation procedure.



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

Hydraulic tank return filter

Genie part number 46014



4 - 48 S-40 • S-45 Part No. 72136

a

b

B-28Replace the Engine Air FilterElement

Engine specifications requires thatthis procedure be performed every400 hours or annually, whichevercomes first. Perform thisprocedure more often if dustyconditions exist.

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.


Gasoline/LPG and Deutz Diesel Models:

1 Open the engine side cover and remove theretaining ring from the end cap of the air filtercanister.

2 Remove the end cap from the air cleanercanister.

3 Remove the air filter retaining fastener. Removethe filter element.

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

5 Install the new air filter element and install themounting fastener.

6 Install the end cap onto the canister. Install andtighten the retaining ring.


1 Open the engine side cover and disconnect theretaining fasteners from the end cap of the airfilter canister. Remove the end cap.

2 Remove the filter element.

3 Empty the dust discharge valve by pressingapart the lips of the discharge slot. Cleandischarge slot as needed.

a air filterb dust discharge valve

4 Clean the inside of the canister and the canisterend cap with a damp cloth.

5 Install the new filter element.

6 Install the end cap onto the canister. Secure theretaining fasteners.

Air filters - Genie part numbersFord LRG-425 EFI Engine 27916Deutz F3L 1011F Engine 27916Perkins 704-30 Engine 62420



Part No. 72136 S-40 • S-45 4 - 49

B-29Replace the Spark Plugs -Gasoline/LPG Models

Engine specifications requires thatthis procedure be performed every400 hours.

Periodic 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.



2 Remove the 2 engine pivot plate retaining bolts.Swing the engine pivot plate away from themachine to access the spark plugs.

3 Label, then disconnect the plug wires from thespark plugs by grasping the handle on thespark plug boot. Do not pull on the plug wire.

4 Blow out any debris around spark plugs.

5 Remove all the spark plugs from the engine.

6 Adjust the gap on each new spark plug.

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



Ford LRG-425 EFI EngineSpark 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 - 10 ft-lbs7 - 14 Nm



4 - 50 S-40 • S-45 Part No. 72136



Part No. 72136 S-40 • S-45 4 - 51

Checklist C Procedures

C-1Check the Engine Belt -Deutz Diesel Models

Engine specifications require thatthis procedure be performed every500 hours.

Maintaining the engine belt is essential to goodengine performance and service life. The machinewill not operate properly with a loose or defectivebelt and continued use may cause componentdamage.

Bodily injury hazard. Do notinspect while the engine isrunning. Remove the key tosecure from operation.



2 Remove the 2 engine pivot plate retaining bolts.Swing the engine pivot plate away from themachine to access the engine belt.


3 Remove the front engine access covermounting fasteners.

4 Inspect the engine belt for:

· Cracking

· Glazing

· Separation

· Breaks

5 Replace belt if any damage is found.

a b cb

REV A


4 - 52 S-40 • S-45 Part No. 72136

6 Check the engine belt for proper tension. Adjustas necessary.

Deutz Diesel engine

7 Install the front engine access cover.



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

Deutz Diesel modelsEngine Belt - Genie part number 32698

CHECKLIST C PROCEDURES

C-2Check the Engine ValveClearances -Deutz Diesel Models

Engine specifications requirethat this procedure be performedinitially at 500 hours, at 1000hours and every 1000 hoursthereafter.

Complete information to perform this procedure isavailable in the Deutz F3L 1011F OperationManual, Deutz part number 0297 7343 (Genie partnumber 52883).

REV A


Part No. 72136 S-40 • S-45 4 - 53

CHECKLIS C PROCEDURES

C-3Replace the Fuel Filter/ WaterSeparator Element -Perkins Diesel Models

Engine specifications requirethat this procedure be performedevery 500 hours or 12 months,whichever comes first.

Replacing the diesel fuel filter/water separatorelement is essential for good engine performanceand service life. A dirty or clogged filter may causethe engine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may required that the filter be replacedmore often.



Immediately clean up any fuel thatmay have spilled during thisprocedure.

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


Fuel filter/water separatora head boltb vent plugc drain plugd filter bowle separator head

3 Place a suitable container under the filter bowl.Loosen the drain plug located at the bottom ofthe bowl. Completely drain the fuel. Tighten thedrain plug.

4 Loosen the head bolt. Rotate the filter bowlcounterclockwise and remove it from theelement.

5 Rotate the filter element counterclockwise andremove it from the filter head.

6 Install the bowl onto the new filter element(Genie part number 22942).

d

c

e

b

a

REV A


4 - 54 S-40 • S-45 Part No. 72136

7 Fill the filter/bowl assembly with clean dieselfuel. Apply a thin layer of diesel fuel onto theelement gasket. Install the filter/bowl assemblyonto the filter head.

8 Tighten the head bolt to 65 inch-pounds / 7 Nm.

9 Clean up any diesel fuel that may have spilledduring the installation procedure.

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

11 Turn the manual fuel shutoff valve, located atthe fuel tank, to the open position.

Bleed the fuel system:

Before bleeding the system, fill thefuel tank.


13 Operate the priming lever of the fuel lift pumpuntil fuel, free from air, comes from the ventpoint. Tighten the vent plug.

14 Loosen the air vent screw, located on top of thefuel injection pump.

15 Tighten the air vent screw when air stopscoming through the air vent.

16 Clean up any diesel fuel that may have spilledduring the bleeding procedure and dispose ofproperly.

17 Start the engine from ground controls and checkfor leaks.

C-4Replace the Fuel Filter Element -Perkins Diesel Models


Replacing the diesel fuel filter element is essentialfor good engine performance and service life. Adirty or clogged filter may cause the engine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay required that the filter be replaced more often.




1 Open the engine side cover and locate the fuelfilter.

2 Thoroughly clean the outside surfaces of thefuel filter assembly.

REV ACHECKLIST C PROCEDURES


Part No. 72136 S-40 • S-45 4 - 55

3 Hold the bottom cover of the filter element andrelease the setscrew which is fitted through thefilter head above the center of the element.

a setscrewb upper sealc O-ringd filter elemente lower sealf bottom cover

4 Lower the bottom cover of the filter.

5 Remove the element and dispose of properly.

6 Clean the inside surfaces of the filter head andthe cover.

7 Lightly lubricate the upper seal and the O-ringwith clean fuel and install them into the filterhead.

8 Lightly lubricate the lower seal with clean fueland install it into the bottom cover.

b

c

f

e

d

a

9 Put the bottom cover under the new element andhold the element squarely to the filter head.Ensure that the element is fitted in the centeragainst the O-ring in the filter head. With theassembly in this position, engage and tightenthe setscrew.

Bleed the system:

10 Loosen the vent plug on the side of the fuelinjection pump.


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

13 Operate the starter motor for intervals of 15seconds until the engine starts.

It is important to allow the startermotor to cool for 30 secondsbetween each 15 second intervalof operation.

If the engine runs correctly for ashort time and then stops or runsroughly, check for air in the fuelsystem. If there is air in the fuelsystem, there is probably a leak inthe low pressure side of thesystem.

REV A CHECKLIST C PROCEDURES


4 - 56 S-40 • S-45 Part No. 72136

C-5Replace the Engine Oil andFilter- Perkins Diesel Models

Engine specifications requirethat this procedure be performedevery 500 hours or 12 months,whichever comes first. Performthis procedure 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.



1 Remove the oil filler cap, located next to thedipstick.

2 Pull the end of the engine oil drain hose outfrom under the 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.

Do not remove the drain pluglocated on the side of the oil pan.

4 Install and tighten the plug in the drain hose.

5 Use an oil filter wrench and remove the oil filter,located below the fuel filter. Clean inside thefilter head.

6 Apply a thin layer of fresh oil to the new filtergasket. Install the filter and tighten it securelyby hand.


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

9 Start the engine from the ground controls andallow the engine to run for 30 seconds. Stop theengine.

10 Check the oil filter and drain hose for leaks.



Part No. 72136 S-40 • S-45 4 - 57

11 Wait 15 minutes after stopping the engine andcheck the engine oil level on the dipstick. Addoil if needed.

12 Dispose of the used oil and filter properly.

Perkins 704-30 EngineOil capacity (including filter) 9.6 quarts / 8.9 liters


below 60°F / 15.5°C 15W-40

-10°F to 90°F / -23°C to 32°C 10W-30

above -4°F / -34°C 15W-40

Engine oil should have properties of API classificationCF4 grade.


C-6Check the Specific Gravity of theCoolant -Liquid Cooled Models

Engine specifications requirethat this procedure be performedevery 500 hours or 12 months,whichever comes first. Performthis procedure more often if dustyconditions exist.

The quality of the coolant which is used can have agreat effect on the efficiency and life of the coolingsystem. Old or dirty coolant may cause the engineto perform poorly and continued use may causeengine damage.

Burn hazard. Beware of hotengine parts and coolant. Contactwith hot engine parts and/orcoolant may cause severe burns.

Perform this procedure with themachine on level ground.


1 Put on protective clothing and eyewear.

2 Operate the engine until it is warm enough toopen the thermostat. Continue to run the engineuntil the coolant has circulated the coolingsystem.



4 - 58 S-40 • S-45 Part No. 72136

3 Stop the engine.

4 Allow the engine to cool until the temperature ofthe coolant is below 140° F / 60° C.

Burn hazard. Beware of hotcoolant. Contact with hot coolantmay cause severe burns.

5 Remove the radiator filler cap. Inspect the capfor wear. Replace as necessary.

Burn hazard. Allow any pressureto dissipate gradually beforeremoving the radiator cap.

6 Drain some coolant from the cooling systeminto a suitable container.

7 Use a special coolant hydrometer to check thetemperature and the specific gravity of thecoolant.

8 Adjust the strength of the coolant as necessaryfor your climate.

9 Install the radiator filler cap.

C-7Check the Glow Plugs -Perkins Diesel Models

Engine specifications requirethat this procedure be performedinitially at 500 hours or every 12months, whichever comes first.

Complete information to perform this procedure isavailable in the Perkins 700 Series WorkshopManual, Perkins part number TPD 1359E (Geniepart number 62424).



Part No. 72136 S-40 • S-45 4 - 59

C-8Replace the PCV Valve -Gasoline/LPG Models

Engine specifications requirethat this procedure be performedevery 800 hours.

Yearly replacement of the PCV valve is essential togood engine performance. A malfunctioning PCVvalve can impair crankcase ventilation and maycause engine damage.


1 Open the engine side turntable cover.


3 Remove the 2 engine pivot plate retaining boltsand swing the engine out away from themachine to access the PCV valve.


4 Locate the PCV valve on the engine under theintake manifold. Detach the hose from the PCVvalve.

a PCV valveb PCV valve hose

5 Remove the PCV valve from the valve cover.Discard the valve.

6 Thoroughly clean the inside and outside of thehose, tubes and fittings

7 Install the new PCV valve and connect thehose.



PCV Valve - Genie part number 33957

a

b

a b cb



4 - 60 S-40 • S-45 Part No. 72136

D-1Check the Boom Wear Pads

Genie specifications requirethat this procedure be performedevery 1000 hours or every 12months, whichever comes first.

Maintaining 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 extremely worn wear pads may result incomponent damage and unsafe operatingconditions.

If the wear pads are still withinspecification, see RepairProcedure 4-2, How to Shimthe Boom.


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 pad ifit is less than specification. If the wear pad isstill within specification, shim as necessary toobtain 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 outer and innerboom tubes.

Wear pad specifications

Upper and side wear pads 9/16 inch 14.3 mmBottom wear pads, S-40 11/16 inch 17.5 mmBottom wear pads, S-45 9/16 inch 14.3 mm

Checklist D Procedures

D-2Check the Free-wheelConfiguration


Proper 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 work sitethat is firm and level.

Component damage hazard. If themachine must be towed, do notexceed 2 mph / 3.2 km/h.

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 / 10,000 kg) under the drive chassisbetween the non-steer wheels.

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

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

REV B


Part No. 72136 S-40 • S-45 4 - 61

CHECKLIST D PROCEDURES

5 Manually rotate each non-steering wheel.

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

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

Collision hazard. Failure tore-engage the drive 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/10,000 kg) under the drive chassisbetween the steer wheels.

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

10 Disengage the drive hubs by turning over thedrive hub disconnect caps on each steer wheelhub.

11 Manually rotate each steer wheel.

Result: Each steer wheel should rotate withminimum effort.

12 Re-engage the drive hubs by turning overthe drive hub disconnect caps. Rotate eachwheel to check for engagement. Lift themachine and remove the blocks.

Collision hazard. Failure tore-engage the drive 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 drive pump, and should alwaysremain closed.

a drive pumpb free-wheel valvec lift pumpd screwdriver

disengage position

engage position

a

b

c

d

REV B


4 - 62 S-40 • S-45 Part No. 72136

D-3Check the Turntable RotationBearing Bolts


Maintaining 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 number 33484).

2 Be sure that each turntable mounting bolt istorqued in sequence to 180 ft-lbs / 244 Nm.

Bolt torque sequence

3 Lower the boom to the stowed position.

4 Check to ensure that each bearing mountingbolt under the drive chassis is torqued insequence to 180 ft-lbs / 244 Nm.

Bolt torque sequence


1

713

16

10

4

2

8 14

1711

20 5

3

9

15

18

19

12

6

1

713

16

10

4

2

8 14

1711

20 5

3

9

15

18

19

12

6

REV B


Part No. 72136 S-40 • S-45 4 - 63


D-5Replace the Drive Hub Oil


Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly andcontinued use may cause component damage.

Drive Hubs:

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container.

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

D-4Grease the Turntable RotationBearing and Rotate Gear

Yearly 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

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent

REV B


4 - 64 S-40 • S-45 Part No. 72136

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 drivehubs.

Oil capacity per hub 17 fl oz0.5 liters

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

Turntable Rotate Drive 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 the drivehub and set them to the side.

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

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

3 Remove the drive hub mounting bolts, and use alifting device to remove the drive hub from themachine.

b

c

d

e

f

a

REV BCHECKLIST D PROCEDURES


Part No. 72136 S-40 • S-45 4 - 65

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

5 Install the drive hub. Torque the hub mountingbolts to 180 ft-lbs / 244 Nm.

6 Install the brake and motor onto the drive 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 plug, and theninstall the plug.

Turntable rotate drive hub

Oil capacity 8 fluid ounces0.24 liters


D-6Replace the Drive LoopHydraulic Filter


Replacing 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.

Bodily injury hazard. Beware ofhot oil. Contact with hot oil maycause severe burns.


1 Locate the drive loop hydraulic filter mounted onthe engine near the pump.

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

REV B CHECKLIST D PROCEDURES


4 - 66 S-40 • S-45 Part No. 72136

3 Remove the filter element from the housing.

4 Inspect the housing seal and replace ifnecessary.

5 Install the new filter and hand tighten thehousing onto the filter head. Clean up any oilthat may have spilled during the installationprocedure.


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

8 Clean up any oil that may have spilled.

Drive loop hydraulic filter

Genie part number 20880

D-7Replace the Engine Oil andFilter- Deutz Diesel Models

Engine specifications requirethat this procedure be performedevery 1000 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 1000 hour interval.



1 Remove the oil filler cap, located next to thedipstick.



Part No. 72136 S-40 • S-45 4 - 67

2 Pull the end of the engine oil drain hose out fromunder the 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.

Do not remove the drain pluglocated on the side of the oil pan.

4 Install and tighten the plug in the drain hose.

5 Use an oil filter wrench and remove the oil filter.

Deutz Diesel enginea engine oil level dipstickb fuel filterc oil filter

6 Apply a thin layer of fresh oil to the new filtergasket. Install the filter and tighten it securelyby hand.



cb

a

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 drain hose for leaks.

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

Deutz F3L 1011F EngineOil capacity (including filter) 8.5 quarts 8 liters


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 or CC/SF grades.



4 - 68 S-40 • S-45 Part No. 72136

D-8Clean the Fuel Pump Strainer -Deutz Diesel Models


Cleaning the fuel pump strainer is essential forgood engine performance and service life. A dirty orclogged strainer may cause the engine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions or not operatingthe machine for extended periods of time mayrequired that the strainer be cleaned more often.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.



1 Open the engine side cover and locate the fuelpump, located next to the engine oil dip stick.

2 Close the fuel shut off valve.

3 Remove the fuel pump cover retaining fastener.Remove the cover.

4 Gently clean the fuel strainer with diesel fuel ora mild solvent.

5 Install the fuel strainer/pump cover onto the fuelpump. Install and tighten the fuel pump coverretaining fastener.

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

7 Start the engine from the ground controls andinspect the fuel filter for leaks.


Be sure the fuel filter is full of fuelbefore attempting to start theengine.



Part No. 72136 S-40 • S-45 4 - 69

D-9Replace the Diesel FuelFilter/Water Separator -Deutz Diesel Models

Engine specifications requirethat this procedure be performedevery 1000 hours or every 12months, whichever comes first.

Replacing 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.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel filter/water separator in anopen, well-ventilated area awayfrom heaters, sparks, flames andlighted tobacco. Always have anapproved fire extinguisher withineasy reach.


1 Turn the manual fuel shutoff valve located at thefuel tank to the closed position.

2 Remove the fuel filter/water separator with afilter wrench.

a oil filterb fuel filter/water separator

3 Fill the new filter with clean diesel fuel and applya thin layer of clean diesel fuel to the new fuelfilter 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 andinspect the fuel filter for leaks.


ab



4 - 70 S-40 • S-45 Part No. 72136

D-10Change the Fuel Hoses -Deutz Diesel Models


Maintaining the fuel hoses in good condition isessential to safe operation and good engineperformance. Failure to detect a worn, cracked orleaking fuel hose may cause an unsafe operatingcondition.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel lines in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Component damage hazard. Besure the fuel hoses are routed thesame way the original hoses were.

Perform this procedure with theengine off and cooled.


2 Remove the 2 engine pivot plate retaining boltsand swing the engine out away from themachine to access the fuel hoses.


3 Place a suitable container under the enginepivot plate.

4 At the fuel pump, disconnect the fuel hose tothe fuel tank and drain the fuel tank into thecontainer.

5 Remove and replace all of the fuel hoses andclamps according to the following illustration:

Explosion and fire hazard. FuelInjection systems operate at avery high pressure. Fuel may beexpelled under pressure if thehoses are removed too quickly.Loosen the fuel lines very slowlyto allow the fuel pressure todissipate gradually. Wrap a clotharound fuel hoses to absorbleaking fuel before disconnectingthem.

a b cb



Part No. 72136 S-40 • S-45 4 - 71

a hose from the injector tothe fuel tank

b 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 D-11Check the Engine ValveClearances -Perkins Diesel Models


Complete information to perform this procedure isavailable in the Perkins User's Handbook, Perkinspart number TPD 1359E (Genie part number62424).



4 - 72 S-40 • S-45 Part No. 72136


D-12Clean the Engine BreatherAssembly -Perkins Diesel Models


Cleaning the engine breather assembly is essentialfor good engine performance and service life. Adirty or clogged breather may cause the engine toperform poorly and continued use may causecomponent damage.

1 Remove the rocker cover from the engine.

2 Release the four retaining fasteners securingthe breather cover to the rocker cover.

3 Remove the diaphragm and location ringassembly. Remove the spring.

4 Release the clips that retain the breather pipeand remove the breather pipe.

5 Using a mild solvent, clean the breather cavityin the rocker cover, the passage through therocker cover, the breather pipe and the venthole.

6 Install the spring into the breather cavity in therocker cover.

7 Install the location ring onto the diaphragm.Install this assembly onto the spring.

Be sure that the location ring is onthe spring.

8 Install the breather cover. Install and secure thebreather cover retaining fasteners.

9 Install the breather pipe and secure theretaining clips.

10 Install the rocker cover and tighten the cap nutsto 8 ft-lbs / 11 Nm.

REV B


Part No. 72136 S-40 • S-45 4 - 73

Checklist E Procedures

E-1Test or Replace the Hydraulic Oil

Replacement 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 frequently.

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.

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 Remove the fuel tank. See Repair Section 12-1,How to Remove the Fuel Tank.

2 Close the two hydraulic shutoff 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 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.

open closed

REV B


4 - 74 S-40 • S-45 Part No. 72136

8 Remove the retaining fasteners from thehydraulic tank hold down straps. Remove thehold down straps 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 hydraulictank could become unbalancedand fall if it is not properlysupported and secured to theoverhead 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 pipe threadsealant on the threads.

14 Install the drain plug using pipe thread sealanton the 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.


19 Open the hydraulic tank shutoff valves.

Component damage hazard.Be sure to open the two hydraulictank shutoff valves and prime thepump after installing the hydraulictank. Refer to Repair Section 12-2,How to Prime the Pump.

Always use pipe thread sealantwhen installing the drain plug andstrainers.

Use only Rykon MV equivalenthydraulic fluid.

REV BCHECKLIST E PROCEDURES


Part No. 72136 S-40 • S-45 4 - 75

E-2Change or Recondition theEngine Coolant -Liquid Cooled Models


Replacing 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.

Bodily injury hazard. Beware ofhot engine parts and coolant.Contact with hot engine partsand/or coolant will cause severeburns.



2 Remove the 2 engine pivot plate retaining bolts.Swing the engine pivot plate away from themachine to access the cooling system.


3 Put on protective clothing and eye wear.

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

5 Slowly remove the radiator cap from theradiator.

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

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

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

a b cb

REV B CHECKLIST E PROCEDURES


4 - 76 S-40 • S-45 Part No. 72136

8 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.

9 Replace all coolant hoses and clamps.

10 Fill the radiator with the proper coolant mixture(coolant and water) for your climate until it isfull.

11 Fill the coolant recovery tank to the NORMAL

range.

12 Clean up any coolant that may have spilledduring this procedure.

13 Start the engine from the ground controls andlet it run for 30 seconds. Turn the engine offand inspect for leaks.

14 Check the coolant level in the coolant recoverytank. Add coolant if needed.



17 Start the engine from the ground controlsand let it run until it reaches normal operatingtemperature.

18 Turn the engine off. Allow the engine to cool.

19 Check the coolant level in the coolant recoverytank. Add coolant if needed.

Coolant capacityFord LRG-425 EFI Engine 11.5 quarts 10.9 litersPerkins 704-30 Engine 10 quarts 9.5 liters

E-3Change the Fuel Hoses -Gasoline/LPG Models


Maintaining the fuel hoses in good condition isessential to safe operation and good engineperformance. Failure to detect a worn, cracked orleaking fuel hose may cause an unsafe operatingcondition.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel lines in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Component damage hazard. Besure the fuel hoses are routed thesame way the original hoses were.





Part No. 72136 S-40 • S-45 4 - 77

2 Remove the 2 engine pivot plate retaining boltsand swing the engine out away from themachine to access the fuel hoses.


3 Place a suitable container under the enginepivot plate. See capacity specifications.

4 Locate the fuel pressure regulator/filter and thefuel pump on the engine pivot plate behind theengine.

5 At the fuel pressure regulator/filter, disconnectthe fuel hose to the fuel tank. Drain the fuel tankinto a suitable container.

Explosion and fire hazard.Electronic Fuel Injection (EFI)systems operate at a very highpressure. Fuel may be expelledunder pressure if the hoses areremoved too quickly. Loosen thefuel hoses very slowly to allow thefuel pressure to dissipategradually. Wrap a cloth aroundfuel hoses to absorb leaking fuelbefore disconnecting them.

6 Remove and replace all of the fuel hoses andclamps according to the following hose routingdiagram:

a high pressure hose from fuel pump toregulator/filter

b hose from fuel pre-filter to fuel pumpc hose from fuel tank to fuel pre-filterd high pressure hose from regulator/

filter to enginee hose from regulator/filter to tank


8 Start the engine from the ground controls.Inspect the fuel filter and hoses for leaks.




a b c

e d

a b cb



4 - 78 S-40 • S-45 Part No. 72136

E-4Replace the Engine Air Breather -Perkins Diesel Models


Complete information to perform this procedure isavailable in the Perkins 700 Series WorkshopManual, Perkins part number TPD 1359E (Geniepart number 62424).

E-5Grease the Steer Axle WheelBearings - 2WD Models

Maintaining 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. Center a liftingjack under the steer axle.

3 Raise the machine approximately6 inches / 15 cm. Place blocks under the drivechassis for support.

4 Remove the lug nuts. Remove the tire and wheelassembly.

5 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: There should be no side to side or upand down movement.

Skip to step 10 if there is no movement.



Part No. 72136 S-40 • S-45 4 - 79

REV B

6 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

Always replace the cotter pin witha new one when removing thecastle nut or when checking thetorque of the castle nut.

7 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearings.

Note: Rotate the hub by hand while torqueing thecastle nut to make sure the bearings seat properly.

8 Loosen the castle nut one full turn and thentorque to 35 ft-lbs / 47 Nm.

9 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: If there is no side to side or up anddown movement, continue to step 11 andgrease the wheel bearings.

Result: If there is side to side or up and downmovement, continue to step 11 and 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.

10 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

11 Remove the castle nut.

12 Pull the hub off of the spindle. The washer andouter bearing should fall loose from the hub.

13 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove the rearbearing.

14 Pack both bearings with clean, fresh grease.

15 Place the large inner bearing into the rear of thehub.

16 Install a new bearing grease seal into the hub bypressing it evenly into the hub until it is flush.

Always replace the bearing greaseseal when removing the hub.

17 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

18 Place the outer bearing into the hub.

19 Install the washer and castle nut.

20 Tighten the slotted nut to 158 ft-lbs / 214 Nm toseat the bearings.

21 Loosen the castle nut one full turn and thentorque to 35 ft-lbs / 47 Nm.

22 Install a new cotter pin. Bend the cotter pinto lock it in place.

Always replace the cotter pin witha new one when removing thecastle nut or when checking thetorque of the castle nut.

23 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.

24 Center a lifting jack under the steer axle.

25 Raise the machine approximately 6 inches(15 cm). Remove the blocks from under thedrive chassis.

26 Lower the machine.

CHECKLIST E PROCEDURES


4 - 80 S-40 • S-45 Part No. 72136

E-6Check the Fuel Injectors -Perkins Diesel Models


A dirty or clogged injector may cause the engine toperform poorly and continued use may causecomponent damage. Replacing a faulty injector isessential for good engine performance and servicelife.

Checking the Injectors:

1 After warming the engine, operate the engine ata fast idle speed.

2 Loosen and tighten the union nut of the high-pressure fuel pipe at each injector.

Result: When the union nut of the defectiveinjector is loosened, it has little or no effect onthe engine speed.

Component damage hazard. Use aseparate wrench to preventmovement of the outlets of the fuelinjection pump when the high-pressure pipes are released ortightened.

Replacing an Injector:

1 Thoroughly clean the area around the injector tobe removed.

2 Remove the fuel leak-off line.

Do not allow dirt to enter the fuelsystem. Before a connection isdisconnected, thoroughly cleanthe area around the connection.After a component has beendisconnected, fit a suitable coverto all open connections.

3 Remove the union nuts of the high-pressure linefrom the injector and from the fuel injectionpump. If necessary, remove the pipe clamps.

Component damage hazard. Usea seperate wrench to preventmovement of the outlets of the fuelinjection pump when the high-pressure pipes are released ortightened.

Do not bend the fuel line.

4 Remove the setscrew of the injector clamp andremove the clamp, the spacer, the injector andits seat washer.

a clampb 'O' ringc seat washerd spacere setscrew



Part No. 72136 S-40 • S-45 4 - 81

5 Put the injector in position together with a newseat washer and a new O-ring.

6 Install the injector into the cyliner head with anew clamp, the spacer, and engage thesetscrew.

Component damage hazard.When an injector is installed intothe cylinder head, ensure that anysharp edges on the cylinder headdo not damage the O-ring.

A new clamp must be used everytime an injector is fitted to theengine.

Be sure the injector is not tiltedwhen it is fitted to the cylinderhead.

7 Tighten the setscrew to 16 ft-lbs / 22 Nm.

8 Fit the high pressure fuel pipe and tighten theunion nuts to 16 ft-lbs / 22 Nm. If necessary, fitthe pipe clamps.

9 Clean and replace the sealing washers and fitthe leak off line. Tighten the banjo bolts to7 ft-lbs / 9 Nm.

Bleed the system:

10 Loosen the vent plug on the side of the fuelinjection pump.



13 Operate the starter motor for intervals of 15seconds until the engine starts. Check forleaks.


It is important to allow the startermotor to cool for 30 secondsbetween each 15 second intervalof operation.

If the engine runs correctly for ashort time and then stops or runsroughly, check for air in the fuelsystem. If there is air in the fuelsystem, there is probably a leak inthe low pressure side of thesystem.



4 - 82 S-40 • S-45 Part No. 72136


March 2008 Section 5 • Troubleshooting Flow Charts

REV B

Part No. 72136 S-40 • S-45 5 - 1

Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions printed in theappropriate Genie S-40 & Genie S-45Operator’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 circuitscould 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

· Boom in stowed position

· 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

March 2008Section 5 • Troubleshooting Flow Charts

REV B

5 - 2 S-40 • S-45 Part No. 72136

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


REV B

Part No. 72136 S-40 • S-45 5 - 3

Fault Code Chart

Fault Code Problem Cause Solution11 -- -- Normal operation

12

Throttle Position (TP) sensor low voltage.

Faulty TP sensor OR sensor wires shorted to ground OR poor terminal connection.

Check for poor terminal connections OR shorted wires from the TP sencor to the ECM OR replace the TP sensor.

14

Manifold Absolute Pressure (MAP) sensor low voltage.

Faulty MAP sensor OR sensor wires shorted to ground OR poor terminal connection.

Check for poor terminal connections OR wires shorted to ground OR replace MAP sensor.

21Engine speed exceeded 4000 RPM.

Obsrtruction in throttle body OR faulty ECM.

Check for obstructions in the throttle body that could cause binding of the throttle assembly OR replace ECM.

22

Throttle Position (TP) sensor high voltage.

The ECM senses a signal from the TP sensor that is greater than 4.9V DC OR the TP sensor wiring is shorted to ground OR there is a poor terminal connection OR the TP sensor is faulty.

Check for poor terminal connections OR shorted wires from the TP sensor to the ECM OR replace the TP sensor.

24

Manifold Absolute Pressure (MAP) sensor high voltage.

Faulty MAP sensor OR sensor wires shorted to ground OR poor terminal connection.

Check for poor terminal connections OR shorted wires from the MAP sensor to the ECM to ground OR replace MAP sensor.


REV B

5 - 4 S-40 • S-45 Part No. 72136

FAULT CODE CHART

31 Fuel pump low voltage.

Voltage to fuel pump is greater than or equal to 2V DC below ignition voltage.

Test the fuel pump relay, see the Repair Section OR check for poor terminal connection from the fuel pump relay to fuel pump OR replace the fuel pump.

32

Heated Oxygen (HO2) sensor low voltage.

Water in the fuel, misfiring cylinder, plugged fuel filter OR the HO2 sensor wiring is shorted to ground OR there is a poor terminal connection OR the HO2 sensor is faulty.

Check for water in the fuel, misfiring cylinder or plugged fuel filter OR check for poor terminal connections or shorted wires from the HO2 sensor to the ECM to ground OR replace HO2 sensor.

33

Engine Coolant Temperature (ECT) sensor high voltage.

Engine is overheating OR sensor wires shorted to ground or poor terminal connections OR ECT sensor is faulty.

Check engine coolant level OR check for shorted wires or poor terminal connections from the ECT sensor to the ECM OR replace the ECT sensor.

35

Intake Air Temerature (IAT) sensor high voltage.

Engine is overheating OR sensor wires shorted to ground or poor terminal connections OR ECT sensor is faulty.

Check for poor terminal connections or shorted wires from the IAT sensor to the ECM to ground OR replace IAT sensor.

41 Fuel pump high voltage.

Fuel pump is receiving voltage when the ECM is not sending the signal to the fuel pump to turn ON.

Test the fuel pump relay, see the Repair Section OR check for poor terminal connection from the fuel pump relay to fuel pump OR replace the ECM.

Fault Code Problem Cause Solution


REV B

Part No. 72136 S-40 • S-45 5 - 5

FAULT CODE CHART


42

Heated Oxygen (HO2) sensor high voltage.

A leaking or malfunctioning fuel injector, misfiring cylinder, faulty TP sensor or contamination of fuel OR use of improper thread sealant on sensor threads OR sensor wires shorted to ground or poor terminal connections OR HO2 sensor is faulty.

Test for a leaking or malfunctioning fuel injector, misfiring cylinder or bad TP sensor. Remove HO2 sensor and check condition of sensor for contamination OR check for poor terminal connections or shorted wires from the HO2 sensor to the ECM to ground OR replace HO2 sensor.

43

Engine Coolant Temperature (ECT) sensor low voltage.

ECM detects excessively low signal voltage from the ECT sensor.

Check engine coolant level OR check for shorted wires or poor terminal connections from the ECT sensor to the ECM OR replace the ECT sensor.

45

Intake Air Temperature (IAT) sensor low voltage.

ECM detects an excessively low signal voltage from the IAT sensor.

The IAT sensor shares the same ground wire as the ECT and MAP sensors. Check for shorted wires or poor terminal connections from the IAT sensor to the ECT and MAP sensors to the ECM OR replace the IAT sensor.

51 Low oil pressure.

Faulty oil pressure switch, wires shorted to ground or not enough engine oil.

Check engine oil level OR check for shorted wires or poor terminal connections from the oil pressure switch to the ECM OR replace the oil pressure switch


REV B

5 - 6 S-40 • S-45 Part No. 72136

FAULT CODE CHART


52

Crankshaft Position (CKP) sensor senses extra or missing pulses.

The CKP and CMP sensors work together; if one is bad, the other one won't work correctly and causes the ECM to detect a fault. The ECM uses the signal pulses from the CKP and CMP sensors to initiate sequential fuel injection.

Check for shorted wires or poor terminal connections from the CKP and CMP sensors to the ECM OR replace the CKP or CMP sensor.

53

Camshaft Position (CMP) sensor senses unknown pattern.

The CMP and CKP sensors work together; if one is bad, the other one won't work correctly and causes the ECM to detect a fault. The ECM uses the signal pulses from the CKP and CMP sensors to initiate sequential fuel injection.

Check for shorted wires or poor terminal connections from the CKP and CMP sensors to the ECM OR replace the CKP or CMP sensor.

54ECM Fault - Illegal Operation.

The ECM received an illegal instruction signal from one or more of the sensors and has gone into a default program and then return to normal operation

Replace the ECM.


REV B

Part No. 72136 S-40 • S-45 5 - 7

FAULT CODE CHART


55 ECM - Illegal Interuption

The ECM received an illegal interruption signal from one or more engine sensors and has gone into a default program and then return to normal operation.

Replace the ECM.

56

ECM - Computer Operating Properly (COP) failure

Under normal operation the ECM will store numbers into memory. If this does not happen, it will reset itself and set fault code 56.

Replace the ECM.

61 System voltage low.

Battery supply voltage to the ECM is 8V DC or less.

Check battery and/or alternator condition OR check for shorted wires or poor terminal connections from the battery to the ECM.

62 System voltage high.

Battery supply voltage to the ECM is 18V DC or more.

Check battery and/or alternator condition OR check for shorted wires or poor terminal connections from the battery to the ECM.


REV B

5 - 8 S-40 • S-45 Part No. 72136

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

Move the start toggleswitch to either side andcheck the voltage ateither side terminal onstart toggle switch.

0V Replace start toggleswitch.

12V

Move the start toggleswitch to either side andcheck voltage atterminal TB33.

0V Repair open in blk wirecircuit from start toggleswitch to TB33.

12V

Move the start toggleswitch to either side andcheck voltage atterminal #3 on ignition/start module.

0VRepair open in blk wirecircuit from TB33 toterminal #3 on ignition/start module.

Continued on the nextpage.

12V

Check voltage atterminal #6 on theignition/start module.

0V Repair open in redpower supply wire circuitfrom CB1 to CR1 to CR2then to terminal #6 toon ignition/start module.

12V

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, checkvoltage at the centerterminal on the starttoggle switch TS10.


REV B

Part No. 72136 S-40 • S-45 5 - 9

CHART 1

Continued from theprevious page.

Move the start toggleswitch to either side andcheck voltage at the blkwire on the startersolenoid.

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

Move the start toggleswitch to either side andcheck voltage atterminal #87 on CR1.

0V

Replace CR1 relay.12V

Move the start toggleswitch to either side andcheck voltage atterminal #86 on CR1.

0VRepair open in blk wirefrom terminal #1 onignition/start module toCR1.

12V

Check brn ground wireto terminal #85 on CR1.

good

bad Repair open in brnground wire circuit toCR1.

12V

Move the start toggleswitch to either side andcheck voltage atterminal #1 on ignition/start module.

0V Check ground wire toterminal #5 on ignition/start module.

bad Repair open in brnground wire to ignition/start module.

good

Consult Genie IndustriesService Department.

Check voltage at startercable.

Repair open in batterycable to starter.

0V

12V


REV B

5 - 10 S-40 • S-45 Part No. 72136

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.

Perform following testsin gasoline mode only.

Be sure that the watertemperature gaugedoes not show anoverheated condition.

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move the starttoggle switch to eitherside and check batteryvoltage while engine iscranking.

lessthan11V

Check battery conditionOR check alternator ORcheck for short circuitsOR check battery cablesOR replace the battery.

more than 11V

Remove #1 spark plugand ground spark plugbody. Crank engine andobserve spark.

goodspark Consult Genie Industries

Service Department.

weak or no spark


See Repair Section,How to Retrieve FaultCodes. Is there a faultcode stored in the ECMmemory?

yes

no

Refer to the fault codechart in this section fora description of the faultand recommendedrepairs.

With the key switchturned to the OFFposition and bothEmergency Stop buttonspulled out to the ONposition, turn the keyswitch to groundcontrols and listen forthe fuel pump to turn ONfor approximately 2seconds and then shutOFF. Did the fuel pumpturn on?

yes

noTest the fuel pumprelay. See RepairSection OR replace thefuel pump.

Check for poor terminalconnections OR checkfor shorted or damagedwires that go from theECM to the sensor thatis causing the fault ORreplace the sensor ORconsult Genie IndustriesService Department.


REV B

Part No. 72136 S-40 • S-45 5 - 11

CHART 2


Disable starter byremoving blk wire at thestarter solenoid, movethe start toggle switch toeither side and checkvoltage at the light greenwire on the ignition coilplug.

See Ford LRG-425 EFIService Manual fortroubleshooting theignition system ORconsult Genie IndustriesService Department.

less than12V

12V

Repair open in lightgreen wire from theECM to ignition coil ORcheck for loose or badconnections from theECM to the ignition coilOR replace the ignitioncoil OR consult GenieIndustries ServiceDepartment.


REV B

5 - 12 S-40 • S-45 Part No. 72136

Chart 2A

See Repair Section,How to Retreive FaultCodes. Is there a faultcode stored in the ECMmemory?

yesCheck for poor terminalconnections OR checkfor shorted or damagedwires that go from theECM to the sensor thatis causing the fault ORreplace the sensor ORconsult Genie IndustriesService Department.

Refer to the fault codechart in this section for adescription of the faultand recommendedrepairs.

no

Check voltage atterminal #4 on theignition/start module.

12V Disconnect red wirefrom terminal #4 on theignition/start module andcheck voltage atterminal #4.

12VReplace ignition/startmodule OR consultGenie Industries ServiceDepartment.

0V0V

Replace ignition/startmodule OR consultGenie Industries ServiceDepartment.

Test auxiliary powertoggle switches TS1 andTS9. See RepairSection.

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move the starttoggle switch TS2 toeither side and checkvoltage at terminal #2 onignition/start 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 theignition/start module.

6 to 7V

EngineCranks OverBut Will NotStart orEngine RunsWhileCrankingThen Dies-Gasoline/LPG ModelsBe sure to checkthe engine oil leveland fill as needed.

Be sure to checkfuel levels and theengine coolantlevel.

Be sure that theradiator overflowtank is at the FULL

mark.

Be sure that allvacuum hoses areconnected andshow no signs ofgamage.

Perform these testsin gasoline modeonly.


REV B

Part No. 72136 S-40 • S-45 5 - 13

Engine CranksOver But WillNot Start -Diesel ModelsBe sure to check theengine oil level and fillas needed.

Be sure to checkfuel level.

Be sure the fuelshut-off valve is inthe ON position.

Be sure that the batteryis fully charged.

Chart 3

Move the start toggleswitch 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.

11V or more

Disable the starter byremoving the blk wire atthe starter solenoid.Move the start toggleswitch to either side andcheck the voltage atpositive terminal on fuelsolenoid.

12V

See Deutz or Perkinsservice manual fortroubleshooting fuelsystem.0V


Turn the machine offand isolate the fuelsolenoid. Check theresistance of thesolenoid.

3.5 ohms Deutz11.5 ohms Perkins

0 orinfiniteohms Replace the fuel

solenoid.

Move the start toggleswitch to either side 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


REV B

5 - 14 S-40 • S-45 Part No. 72136

CHART 3


Move the start toggleswitch to either side andcheck voltage atterminal #86 of 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.

nocontinuity Repair open in brn

ground wire circuit toCR2.

good

Move the start toggleswitch to either side andcheck voltage atterminal #9 on theignition/start module.

12V

Replace the ignition/start module OR consultGenie Industries ServiceDepartment.

0V

Check voltage atterminal #6 and #7 onignition/start module.

12V

0VRepair open in powersupply wires to terminal#6 and #7 on ignition/start module.

Check continuity fromground to brn wire atterminal #5 on ignition/start module.

continuity

nocontinuity

Repair open in brnground wire circuit toterminal #5 on ignition/start module.


Crank engine and checkvoltage at terminal #2 onignition/start 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 ignition/start module.

6 to 7V


REV B

Part No. 72136 S-40 • S-45 5 - 15

While cranking enginefor 15 seconds, checkcontinuity to ground onterminal #10 on ignition/start 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 or Perkins servicemanual fortroubleshooting low oilpressure.

no

no

Check voltage atterminal #4 on ignition/start module.

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 andTS9. 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 Deutz orPerkins service manualfor troubleshooting aoverheated engine.

no

CHART 3


REV B

5 - 16 S-40 • S-45 Part No. 72136

Engine Will NotStart On LPG,But Will StartOn Gasoline -Gasoline/LPGModelsBe sure fuel selectswitch is switchedto LPG.

Be sure the valve on theLPG tank is fullyopened.

Be sure to checkLPG fuel level.

Chart 4

Turn OFF the valve onthe LPG tank, thendisconnect LPG supplyline from LPG tank andbleed pressure fromline.

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, checkvoltage at LPG side(blu/red wire) of fuelselect toggle switchTS11.

0V Repair open in powersupply circuit to fuelselect toggle switch.

12V

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, checkvoltage at TB39.

0VRepair open in blu/redwire circuit from fuelselect toggle switch toTB39.

12V

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, checkvoltage at terminal #85on CR3.

0VRepair open in red wirecircuit from ECM toterminal #85 on CR3 ORreplace ECM.

12V


no

Check the voltage at thecenter terminal of thefuel select toggle switch.

0V

12V

Replace fuel selecttoggle switch.


yesRefer to the fault codechart in this section fora description of the faultand recommendedrepairs.



REV B

Part No. 72136 S-40 • S-45 5 - 17

CHART 4


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.

Crank engine for 15seconds and check forcontinuity to ground atterminal #86 on CR3.

Replace LPG relay CR3.

continuity

nocontinuity

Repair open in dk grnwire from ECM toterminal #86 on CR3 ORreplace ECM.

Crank engine for 15seconds and check forcontinuity to ground atterminal #30 on CR3.

nocontinuity

continuity


REV B

5 - 18 S-40 • S-45 Part No. 72136

Chart 5

Engine WillNot Start OnGasoline,But Will StartOn LPG -Gasoline/LPGModelsBe sure fuel selectswitch is switchedto gasoline.

Be sure to checkgasoline fuel level.

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, checkvoltage at LPG side (blu/red wire) of fuel selecttoggle switch TS11.

12V Replace fuel selecttoggle switch.

0V

Move the start toggleswitch to either side andcheck voltage acrossthe wires on the fuelpump withoutdisconnecting the wires.

0V

With key switch turnedto the OFF position andboth Emergency Stopbuttons pulled out to theON position, turn the keyswitch to groundcontrols and listen forthe fuel pump to turn ONfor approximately 2seconds. Did the fuelpump turn on?

no

See Ford LRG-425 EFIservice manual for fuelsystem troubleshootingOR consult GenieIndustries ServiceDepartment.

12V

Replace the fuel pumprelay "B" of the engineharness OR consultGenie Industries ServiceDepartment.

yes

Repair open in fuelpump wires from fuelpump relay "B" of theengine harness ORreplace the fuel pump.

no


yesRefer to the fault codechart in this section fora description of the faultand recommendedrepairs.



REV B

Part No. 72136 S-40 • S-45 5 - 19

Chart 6

EngineHigh IdleInoperative -Gasoline/LPGModels

Start the engine thenmove and hold the RPMtoggle switch to the highidle (rabbit symbol)position for the followingtests. Check voltage atblk/red wire on RPMselect toggle switchesTS4 and TS12.

0V Check voltage at centerterminal on both RPMselect toggle switches.

0VRepair open in powersupply circuit to centerterminal of RPM selecttoggle switch.

12V

Replace RPM selecttoggle switch.

12V

Check voltage at TB35. 0V Repair open in blk/redwire circuit from toggleswitch to TB35.

12V

Repair open in tan/bluwire from TB35 to ECMOR consult GenieIndustries ServiceDepartment.


yes

no




REV B

5 - 20 S-40 • S-45 Part No. 72136

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 movethe RPM select toggleswitch TS12 to low idle(turtle symbol). Checkvoltage at TB35.

12VIsolate the ground andplatform RPM toggleswitches TS4 and TS12,check individually andreplace faulty switch.

0V

Replace ECM or consultGenie Industries ServiceDepartment.


yes

no




REV B

Part No. 72136 S-40 • S-45 5 - 21

Chart 8

EngineHigh IdleInoperative -Diesel ModelsBe sure mechanicallinkage is not bindingor defective.

Be sure 2-speedsolenoid groundingwires are free ofcorrosion and have fullcontinuity to ground.

Start engine, move theRPM select toggleswitch TS12 to high idle(rabbit symbol) andcheck if 2-speedsolenoid pulls in.

solenoidpulls in

Check high idleadjustment (seeMaintenance section)OR see Deutz ORPerkins workshopmanual to troubleshootfuel injection system.

solenoid doesnot pull in

Check voltage at blk/redwire on RPM selecttoggle switches TS4 andTS12.

0VCheck voltage on redwire at center terminal ofRPM select toggleswitches.

0VRepair open in circuitsupplying 12V to centerterminal of toggleswitch.

12V

Replace toggle switch12V

Check voltage at TB35. 0V Repair open in blk/redwire circuit from toggleswitch to TB35.

12V


0V Repair open in blk/redwire circuit from TB35 toterminal #30 on CR3.

12V

Check voltage toterminal #86 on CR3.

12V

0V Repair open in wht wirecircuit from terminal #87on CR2 to TB21 toterminal #86 on CR3.

Check continuity fromground to brn wire atterminal #85 on CR3.

nocontinuity Repair open in brn

ground wire circuit toterminal #85 on CR3.

continuity


0V Replace CR3 relay.

12V



REV B

5 - 22 S-40 • S-45 Part No. 72136

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.


Check continuity fromground to brn wire atterminal #85 on CR4.

bad Repair open in brnground wire circuit toterminal #85 on CR4.

good


0V Repair open in wht wirecircuit from CR2 to TB21to CR3 to CR4.

12V


0V Repair open in blk/redwire circuit fromCR3 to CR4.

12V

Check continuity fromground to brn wire at2-speed solenoid toground.

badRepair open in brnground wire circuit from2-speed solenoid toground.

good


REV B

Part No. 72136 S-40 • S-45 5 - 23

Chart 9

EngineLow IdleInoperative -DieselModelsCheck ifmechanical linkagefrom 2-speedsolenoid to fuelinjection system isbinding or defective.

At the platform controls,start the engine andmove the RPM selecttoggle switch TS4 tomaintained low idle(turtle symbol). Checkvoltage at blk/red wireon RPM select toggleswitch.

12VIsolate the platform andground RPM selecttoggle switches TS4 andTS12, check individuallyand replace faulty toggleswitch.

0V

Check voltage at theblk/red wire on the2-speed solenoid.

12V Replace 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 OR Perkinsworkshop manual totroubleshoot fuelinjection system ORconsult Genie IndustriesService Department.


REV B

5 - 24 S-40 • S-45 Part No. 72136

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 DeutzOR Perkins dieselmodels, hold manualfuel shutoff lever to theclosed position.Remove function pumpfrom main pump butleave all hosesconnected. Hold starttoggle switch and crankengine over whileobserving spline drive atrear of main pump.

splineturns

Troubleshootinoperative boomfunctions andinoperative drivefunctions separately.

spline does not turn

Engine to pump flexplate coupling is faultyOR main pump is faulty.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.


REV B

Part No. 72136 S-40 • S-45 5 - 25

Chart 11

All Lift andSteer FunctionsInoperative,Drive FunctionsOperationalBe sure the generatoron/off toggle switch(if equipped) is in theOFF position.

Be sure the hydraulicsuction line shutoff valvefor the lift/steer pump isin the OPEN position.

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,hold the function enabletoggle switch to eitherside and move the boomretract toggle switchTS7 in the RETRACT

direction. Check thehydraulic pressure.

Troubleshoot eachfunction individually orconsult Genie IndustriesService Department.

lessthan2600 psi

Adjust the functionmanifold system reliefvalve (item X) all theway in (clockwise)counting the number ofturns. Hold the functionenable switch to eitherside and move the boomretract toggle switch inthe RETRACT directionand check the hydraulicpressure.

Hold the function enableswitch to either side andmove the boom retracttoggle switch in theRETRACT direction andadjust the relief pressureto 2600 psi.

Check the functionpump, see Repairsection.

ok Replace the relief valve(item X) OR manifoldhas an internal fault.Consult the GenieIndustries ServiceDepartment.bad

Replace the functionpump.

Check steer functions.

steeringoperates

Repair or replacedifferential sensing valve(item W) OR repair orreplace priority flowregulator valve (itemBB) OR manifold has aninternal fault, consultGenie Industries ServiceDepartment.

steering inoperative

*See Note 2

*SeeNote 1

*Note 2S-40: less than 2600 psiS-45: less than 2900 psi

*Note 1S-40: 2600 psi or moreS-45: 2900 psi or more

*SeeNote 1


REV B

5 - 26 S-40 • S-45 Part No. 72136

Chart 12

GroundControlsInoperative,PlatformControlsOperateNormallyBe sure all otherfunctions operatenormally, includingthe platformcontrols.

Does the engine startfrom ground controls? yes Start the engine from

ground controls. Holdthe function enabletoggle switch to eitherside and check thevoltage on both centerterminals of the platformrotate toggle switchTS13.

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 (thered wire checked shouldoriginate at theEmergency Stopbutton).

0VRepair open in red wirecircuit from EmergencyStop button to keyswitch.

12V

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, check voltageat red wire on 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 switch.

12V

Repair open in red wirecircuit from key switch tofunction enable toggleswitch to each functiontoggle switch.


REV B

Part No. 72136 S-40 • S-45 5 - 27

Chart 13

PlatformControlsInoperative,GroundControlsOperateNormallyBe sure allcables from chassisthrough the cabletrack are in goodcondition with nokinks or abrasions.

Does engine start fromplatform controls?

yes Start engine fromplatform controls, pressdown the foot switch andcheck voltage 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.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, check thevoltage on the outputside of the platformEmergency Stop buttoncontact.

12V

Check voltage at TP23. 0V Repair open in wht 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 button.0V

12V

Repair open in blk wirefrom TP22 toEmergency Stop button.

no

Replace the platformEmergency Stop button.

yesCheck if EmergencyStop button internal camis activating the contact.


REV B

5 - 28 S-40 • S-45 Part No. 72136

Chart 14

Boom UpFunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theboom up/down toggleswitch TS16 in the UPdirection. Check voltageon red/wht wire on boomup/down proportionalvalve coil (item P).

0V

20V or more

Hold the function enableswitch to either side andmove the boom up/downtoggle switch in the UPdirection and checkvoltage at TB3.

8 to 9V

Repair open in red/wht-4wire circuit from TB3 toboom up/downproportional valve coilOR repair open in brnground wire circuit tovalve coil.

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, press down thefoot switch and movethe boom controller inthe UP direction.Checkvoltage at TP3.


8 to 9V Repair open in red/wht-3wire from TP3 to TB3.

0V

Press down the footswitch and checkvoltage at terminal "+"on boom controller.

12V or more

0VRepair open in powersupply circuit from TP24to boom controller ORrepair open in brnground wire circuit fromboom controller toground.

Re-adjust controller (seeRepair Section) ORreplace controller ORconsult Genie IndustriesService Department.


REV B

Part No. 72136 S-40 • S-45 5 - 29

CHART 14

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theboom up/down toggleswitch TS16 in the UPdirection. Check voltageon red -4 wire on boomup/down directionalvalve coil (item B).

0V

20V or more

Hold the function enableswitch to either side andmove the boom up/downtoggle switch in the UPdirection. Check voltageat TB1.

12V ormore

Repair open in red-4wire circuit from TB1 toboom up/downdirectional valve coil ORrepair open in brnground wire circuit tovalve coil.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove the boomcontroller in the UPdirection. Check voltageat TB1.

12V ormore

0V

Press down the footswitch and move theboom controller in theUP direction. Checkvoltage TP1.


Troubleshoot boom up/down toggle switch ORrepair open in red wirecircuit from TS16 to TB1OR consult GenieIndustries ServiceDepartment.


12V ormore Repair open in red-3

wire from TP1 to TB1.

0V

Press down the footswitch and checkvoltage at terminal "+"on the boom controller.

12V or more

0VRepair open in powersupply circuit from TP24to boom controller ORrepair open in brnground wire circuit fromground to boomcontroller.



REV B

5 - 30 S-40 • S-45 Part No. 72136

CHART 14

Disconnect wires fromboom up/downdirectional valve coil(item B) and test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

2.5 to 3.5 ohms

Replace boom up/downdirectional valve coil.

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and start theengine. Hold thefunction enable switch toeither side and move theboom up/down toggleswitch in the UP directionand check the pressure.

Repair cylinder orcylinder counterbalancevalve OR boom functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingboom from moving ORrepair cylinder orcylinder counterbalancevalve OR consult GenieIndustries ServiceDepartment.

Hold function enableswitch to either side andmove the boom up/downtoggle switch in the UP

direction. Manuallyoverride the directionalvalve by pushing in onthe end of the valvespool.

function inoperative

functionoperates Replace the faulty

directional valve.

Exchange boom flowregulator valve (item H)with boom extend/retractflow regulator valve(item G). Check boomup function.

functionoperates

Replace the faulty flowregulator valve.


*See Note 2

*SeeNote 1




REV B

Part No. 72136 S-40 • S-45 5 - 31

Boom DownFunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 15

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theboom up/down toggleswitch TS16 in theDOWN direction. Checkvoltage on red/wht wireon boom up/downproportional valve coil(item P).

0V

20V or more

Hold the function enableswitch to either side andmove the boom up/downtoggle switch in theDOWN direction andcheck voltage at TB3.

6 to 7V

Repair open in red/wht-4wire circuit from TB3 toboom up/downproportional valve coilOR repair open in brnground wire circuit tovalve coil.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove the boomcontroller in DOWNdirection. Check voltageat TP3.


6 to 7V Repair open in red/wht-3wire from TP3 to TB3.

0V


12V or more

0VRepair open in powersupply circuit from TP24to boom controller ORrepair open in brnground wire circuit fromground to boomcontroller.

Re-adjust boomcontroller (see RepairSection) OR replaceboom controller ORconsult Genie IndustriesService Department.


REV B

5 - 32 S-40 • S-45 Part No. 72136

CHART 15

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theboom up/down toggleswitch TS16 in theDOWN direction. Checkvoltage on red/blk-4 wireon boom directionalvalve coil (item B).

0V

20V or more

Hold the function enableswitch to either side andmove the boom up/downtoggle switch in DOWNdirection and checkvoltage at TB2.

12V ormore

Repair open in red/blk-4wire circuit from TB2 toboom directional valvecoil OR repair open inbrn ground wire circuit tovalve coil.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove the boomcontroller in the DOWNdirection. Check voltageat TB2.

12V ormore

0V

Press down the footswitch and move theboom controller in theDOWN direction andcheck voltage at TP2.


Troubleshoot boom up/down toggle switch ORrepair open in red/blkwire circuit from TS16 toTB2 OR consult GenieIndustries ServiceDepartment.


12V ormore Repair open in red/blk-3


0V


12V or more

0VRepair open in powersupply circuit from TP24to boom controller ORrepair open in brnground wire circuit fromground to the boomcontroller.

Re-adjust boomcontroller (see RepairSection) OR replaceboom controller ORconsult Genie IndustriesService Department.


REV B

Part No. 72136 S-40 • S-45 5 - 33

CHART 15

Disconnect both wiresfrom boom downdirectional valve coil(item B) and test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

2.5 to 3.5 ohms

Replace boom downdirectional valve coil.

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and start theengine. Hold thefunction enable switch toeither side and move theboom up/down toggleswitch in the DOWN

direction and check thepressure.

Reset boom down reliefvalve (item F) pressure(see Repair Section) ORreplace boom downrelief valve OR repaircylinder or cylindercounterbalance valveOR function manifoldcould have an internalfault. Consult GenieIndustries ServiceDepartment.

Check for mechanicalrestrictions keepingboom from moving ORrepair cylinder orcylinder counterbalancevalve OR consult GenieIndustries ServiceDepartment.

Hold the function enableswitch to either side andmove the boom up/downtoggle switch in theDOWN direction.Manually override thedirectional valve bypushing in on the end ofthe valve spool.


functionoperates Replace faulty

directional valve.

*See Note 2

*SeeNote 1




REV B

5 - 34 S-40 • S-45 Part No. 72136

Chart 16

Boom ExtendFunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theboom extend toggleswitch TS15 in theEXTEND direction. Checkvoltage on blk/red-4 wireon boom extend/retractproportional valve coil(item G).

0V

20V or more

Hold the function enableswitch to either side andmove the boom extendtoggle switch in theEXTEND direction. Checkvoltage at TB9.

9 to 10V

Repair open in blk/red-3wire circuit from TB9 toboom extend/retractproportional valve coilOR repair open in brnground wire circuit tovalve coil.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove the boom extend/retract toggle switchTS7 in the EXTENDdirection. Check voltageat TP9.


9 to 10V Repair open in blk/red-3wire from TP9 to TB9.

0V

Press down the footswitch and checkvoltage at centerterminal of TS7.

12V or more

0V Repair open in powersupply circuit from TP24to TS7.

Test toggle switch TS7,see Repair Section.

bad

good

Replace toggle switchTS7.

Repair open in blk/redwire circuit from TS7 toTP9.


REV B

Part No. 72136 S-40 • S-45 5 - 35

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.

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and start theengine. Hold thefunction enable switch toeither side and move theboom extend/retracttoggle switch in theEXTEND direction. Checkthe pressure.

1950PSI ormore

less than 1950 PSI

Repair the cylinder orcylinder counterbalancevalve OR functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keeping theboom from extendingOR repair cylinder orcylinder counterbalancevalves OR consultGenie Industries ServiceDepartment.

Hold the function enableswitch to either side andmove the boom extend/retract toggle switchTS15 in the EXTENDdirection. Manuallyoverride the directionalvalve by pushing in onthe end of the valvespool.



directional valve.

Exchange boom extendflow regulator valve(item G) with boom up/down flow regulatorvalve (item H). Checkboom extend function.

functionoperates Replace the faulty flow

regulator valve.



REV B

5 - 36 S-40 • S-45 Part No. 72136

Chart 17

Boom RetractFunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theboom extend/retracttoggle switch TS15 inthe RETRACT direction.Check voltage on blk/red-4 wire on boomextend/retractproportional valve coil(item G).

0V

12V or more

Hold the function enableswitch to either side andmove the boom extend/retract toggle switch inthe EXTEND direction.Check voltage at TB9.

9 to 10V

Repair open in blk/red-4wire circuit from TB9 toboom extend/retractproportional valve coilOR repair open in brnground wire circuit tovalve coil.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove the boom extend/retract toggle switchTS7 in the RETRACTdirection. Check voltageat TP9.


9 to 10V Repair open in blk/red-3wire from TP9 to TB9.

0V

Press down the footswitch and checkvoltage at centerterminal of TS7.

12V or more

0V Repair open in powersupply circuit from TP24to TS7.

Test extend/retracttoggle switch, seeRepair Section.

bad

good

Replace extend/retracttoggle switch.

Repair open in blk/redwire circuit from TS7 toTP9.


REV B

Part No. 72136 S-40 • S-45 5 - 37

CHART 17

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.

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and start theengine. Hold thefunction enable switch toeither side and move theboom extend/retracttoggle switch in theRETRACT direction andcheck the pressure.

1950PSI ormore

less than 1950 PSI

Repair cylinder orcylinder counterbalancevalve OR functionmanifold could have aninternal fault. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keepingboom from retractingOR repair cylinder orcylinder counterbalancevalves OR consultGenie Industries ServiceDepartment.

Hold the function enableswitch to either side andmove the boom extend/retract toggle switch inthe EXTEND direction.Manually override thedirectional valve bypushing in on the end ofthe valve spool.



directional valve.

Exchange extend/retractflow regulator valve(item G) with boom up/down flow regulatorvalve (item H). Checkboom retract function.

functionoperates Replace faulty flow

regulator valve.



REV B

5 - 38 S-40 • S-45 Part No. 72136

Chart 18

TurntableRotate LeftFunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theturntable rotate toggleswitch TS17 in the LEFTdirection. Check voltageon wht/red-4 wire onturntable rotateproportional valve coil(item S).

0V

12V or more

Hold the function enableswitch to either side andmove the turntablerotate toggle switch inthe LEFT direction andcheck voltage at TB6.

4 to 6V

Repair open in wht/red-4wire circuit from TB6 toturntable rotateproportional valve coilOR repair open in brnground wire circuit tovalve coil.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove turntable rotatecontroller in the LEFTdirection and checkvoltage at TP6.


Repair open in wht/redwire from TP6 to TB6.

0V

Press down the footswitch and checkvoltage at terminal "+"on controller.

12V or more

0VRepair open in powersupply circuit from TP24to the controller ORrepair open in brnground wire circuit fromground to controller.


4 to 6V


REV B

Part No. 72136 S-40 • S-45 5 - 39

CHART 18

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theturntable rotate toggleswitch TS17 in the LEFTdirection. Check voltageon wht/blk-4 wire onboom rotate directionalvalve coil (item A).

0V

12V or more

Hold the function enableswitch to either side andmove the turntablerotate toggle switch inthe LEFT direction.Check voltage at TB5.

12V ormore

Repair open in wht/blk-4wire circuit from TB5 toturntable rotate leftdirectional valve coil(item A) OR repair openin brn ground wire circuitto valve coil.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove the turntablerotate controller in theLEFT direction. Checkvoltage at TB5.

12V ormore

0V

Press down the footswitch and move theturntable rotatecontroller in the LEFTdirection. Check voltageat TP5.


Troubleshoot turntablerotate toggle switch ORrepair open in wht/blkwire circuit from TS17 toTB5 OR consult GenieIndustries ServiceDepartment.


12V ormore Repair open in wht/blk-3


0V


12V or more

0VRepair open in powersupply circuit from TP24to controller OR repairopen in brn ground wirecircuit from ground tocontroller.



REV B

5 - 40 S-40 • S-45 Part No. 72136

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.

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and start theengine. Hold thefunction enable switch toeither side and move theturntable rotate toggleswitch in the LEFT


Hold function enableswitch to either side andmove the turntablerotate toggle switch inthe LEFT direction.Manually override thedirectional valve bypushing in on the end ofthe valve spool.



directional valve.

Exchange boom rotateflow regulator valve(item I) with boomup/down flow regulatorvalve (item H). Checkturntable rotate leftfunction.

functionoperates

Replace faulty flowregulator valve.



Repair turntable rotationmotor OR functionmanifold may have aninternal fault. ConsultGenie Industries ServiceDepartment.

*See Note 2

*SeeNote 1

*Note 2S-40 less than 2600 psiS-45 less than 2900 psi

*Note 1S-40 2600 psi or moreS-45 2900 psi or more


REV B

Part No. 72136 S-40 • S-45 5 - 41

CHART 18

Check for mechanicalrestrictions keepingturntable rotate left fromoperating OR replaceshuttle valve (item II)OR consult GenieIndustries ServiceDepartment.

Plumb a 0 to 5000 psi(0 to 345 bar) pressuregauge into the hosefrom the functionmanifold to the turntablerotation brake. Hold thefunction enable switch toeither side and move theturntable rotate toggleswitch TS17 in the LEFTdirection. Check thepressure.

lessthan250 psi

250 psi or more

Exchange turntablerotate left and rightcounterbalance valves(items JJ and KK).Activate turntable rotateleft function.



counterbalance valve.

Function manifold couldhave an internal fault.Consult Genie IndustriesService Department.



REV B

5 - 42 S-40 • S-45 Part No. 72136

Chart 19

TurntableRotate RightFunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theturntable rotate toggleswitch TS17 in the RIGHTdirection. Check voltageon wht/red wire onturntable rotateproportional valve coil(item S).

0V

12V or more

Hold the function enableswitch to either side andmove the turntablerotate toggle switch inthe RIGHT direction.Check voltage at TB6.

4 to 6V

Repair open in wht/red-4wire circuit from TB6 toturntable rotateproportional valve coilOR repair open in brnground wire circuit tovalve coil.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove turntable rotatecontroller in the RIGHTdirection. Check voltageat TP6.


Repair open in wht/red-3wire from TP6 to TB6.

0V


12V or more



4 to 6V


REV B

Part No. 72136 S-40 • S-45 5 - 43

CHART 19

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theturntable rotate toggleswitch TS17 in the RIGHTdirection. Check voltageon wht-4 wire onturntable rotate rightdirectional valve coil(item A).

0V

12V or more

Hold the function enableswitch to either side andmove the turntablerotate left/right toggleswitch in the RIGHTdirection. Check voltageat TB4.

12V ormore

Repair open in wht-4wire circuit from TB4 toturntable rotate rightdirectional valve coil ORrepair open in brnground wire circuit tovalve coil.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove the turntablerotate controller in theRIGHT direction. Checkvoltage at TB4.

12V ormore

0V

Press down the footswitch and move theturntable rotatecontroller in the RIGHTdirection. Check voltageat TP4.


Troubleshoot turntablerotate controller ORrepair open in wht-3 wirecircuit from boomcontroller to TB4 ORconsult Genie IndustriesService Department.


12V ormore Repair open in wht-3


0V


12V or more




REV B

5 - 44 S-40 • S-45 Part No. 72136

CHART 19

Disconnect wires onturntable 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.

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and start theengine. Hold thefunction enable switch toeither side and move theturntable rotate toggleswitch in the RIGHT


Hold function enableswitch to either side andmove the turntablerotate toggle switch inthe RIGHT direction.Manually override thedirectional valve bypushing in on the end ofthe valve spool.



directional valve.

Exchange flow regulatorvalve (item I) with boomup/down flow regulatorvalve (item H). Checkturntable rotate rightfunction.

functionoperates




Repair turntable rotationmotor OR functionmanifold may have aninternal fault. ConsultGenie Industries ServiceDepartment.

*See Note 2

*SeeNote 1




REV B

Part No. 72136 S-40 • S-45 5 - 45

CHART 19

Check for mechanicalrestrictions keepingturntable rotate rightfunction from operatingOR replace shuttle valve(item II) OR consultGenie Industries ServiceDepartment.

Plumb a 0 to 5000 psi(345 bar) pressuregauge into the hosefrom the functionmanifold to the turntablerotation brake. Hold thefunction enable switch toeither side and move theturntable rotate toggleswitch in the RIGHTdirection .

lessthan250 psi

250 psi or more

Exchange turntablerotate right and leftcounterbalance valves(items JJ and KK).Activate turntable rotateright function.



counterbalance valve.

Function manifold couldhave an internal fault.Consult Genie IndustriesService Department.



REV B

5 - 46 S-40 • S-45 Part No. 72136

Chart 20

All PlatformLevelingFunctionsInoperativeBe sure all otherfunctions operatenormally.

Remove both hydraulichoses from the manifold(ports PL1 & PL2). Plugthe hoses and cap themanifold fittings.Activate the boom upfunction. Check to see ifplatform levels.

no

Plumb a 0 to 5000 psi(345 bar) pressuregauge into mastercylinder rod-endhydraulic hose (hoseconnected to port PL2)using a tee fitting.Activate boom upfunction and check thepressure.

Install a 0 to 5000psi(345 bar) pressuregauge into the barrel-end hydraulic hose fromthe master cylinder andraise the boom one inch(2.5 cm) at a time.Continually monitor thepressure gauge duringboom up. Do not allowthe pressure to exceed2600/2900 PSI.

Repair or replace theslave cylinder.

Replace the platformlevel counterbalancevalves (items FF & GG).

yes

Check for mechanicalrestrictions OR replacethe slave cylindercounterbalance valves.

Repair or replace themaster cylinder.

*See Note 2

*SeeNote 3



*SeeNote 1

*SeeNote 2

*Note 3S-40: 2600 psiS-45: 2900 psi


REV B

Part No. 72136 S-40 • S-45 5 - 47

Chart 21

Platform LevelUp FunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theplatform level toggleswitch TS14 in the UPdirection. Check voltageat org-4 wire on platformlevel up directional valve(item T).

0V

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theplatform level toggleswitch in the UPdirection. Check voltageat TB14.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove the platform leveltoggle switch in the UPdirection. Check voltageat TB14.

Repair open in org-4wire from TB14 toplatform level updirectional valve coil ORrepair open in brnground wire circuit tovalve coil.

12V ormore

0V

Troubleshoot platformlevel toggle switchesTS14 and TS6 ORrepair open in red powerwire circuit to TS14 andTS6 OR repair open inorg-4 wire circuit fromTS14 and TS6 to TB14OR consult GenieIndustries ServiceDepartment.

12V or more

Troubleshoot platformlevel toggle switch TS14OR repair open in redpower wire circuit toTS14 OR repair open inorg-4 wire circuit fromTS14 to TB14 ORconsult Genie IndustriesService Department.

12V or more



REV B

5 - 48 S-40 • S-45 Part No. 72136

CHART 21

Disconnect the wiresfrom platform level updirectional valve coil(item T) and test theresistance of the valvecoil.

0 orinfiniteohms Replace the platform

level up directional valvecoil.

6 to 7 ohms


Exchange platform leveldirectional valves (itemsT and V) and activatethe platform level upfunction.


functionoperates

Replace the faultydirectional valve.

Exchange platform levelcounterbalance valves(items FF and GG) andactivate the platformlevel up function.


functionoperates

Replace the faultycounterbalance valve.

Install a 0 to 3000 (207bar) pressure gauge atthe quick disconnectcoupling on the functionmanifold and activatethe platform level upfunction.

Check for mechanicalrestrictions keepingplatform level upfunction from operatingOR replace slavecylinder OR replaceslave cylindercounterbalance valvesOR consult GenieIndustries ServiceDepartment.

Test master cylinder(see Chart 20) ORrepair or replace slavecylinder or slave cylindercounterbalance valvesOR function manifoldmay have an internalfault. Consult GenieIndustries ServiceDepartment.

Exchange platform levelflow regulator valve(item U) with the jibboom flow regulatorvalve (item EE) andactivate the platformlevel up function.


functionoperates




*See Note 2

*SeeNote 1


REV B

Part No. 72136 S-40 • S-45 5 - 49

Chart 22

Platform LevelDown FunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theplatform level toggleswitch TS14 in theDOWN direction. Checkvoltage at org/blk-4 wireon platform level downdirectional valve(item V).

0V

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theplatform level toggleswitch in the DOWNdirection. Check voltageat TB15.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove the platform leveltoggle switch TS6 in theDOWN direction. Checkvoltage at TB15.

Repair open in org/blk-4wire from TB15 toplatform level downdirectional valve coil ORrepair open in brnground wire circuit tovalve coil.

12V ormore

0V

Troubleshoot platformlevel toggle switchesTS14 and TS6 ORrepair open in red powerwire circuit to TS14 andTS6 OR repair open inorg/blk wire circuit fromTS14 and TS6 to TB15OR consult GenieIndustries ServiceDepartment.

12V or more

Troubleshoot platformlevel toggle switch TS14OR repair open in redpower wire circuit toTS14 OR repair open inorg/blk wire circuit fromTS14 to TB15 ORconsult Genie IndustriesService Department.

12V or more



REV B

5 - 50 S-40 • S-45 Part No. 72136

CHART 22

Disconnect the wiresfrom the platform leveldown directional valvecoil (item V) and test theresistance of the valvecoil.


level down directionalvalve coil.

6 to 7 ohms


Exchange platform leveldown and up directionalvalves (items V and T)and activate the platformlevel down function.


functionoperates


Exchange platform leveldown and upcounterbalance valves(items GG and FF) andactivate the platformlevel down function.


functionoperates


Install a 0 to 3000 (207bar) pressure gauge atthe quick disconnectcoupling on the functionmanifold and activatethe platform level downfunction.

*See Note 2

*SeeNote 1

Check for mechanicalrestrictions keepingplatform level down fromoperating OR replaceslave cylinder ORreplace slave cylindercounterbalance valvesOR consult GenieIndustries ServiceDepartment.

Test master cylinder(see Chart 20) ORrepair or replace slavecylinder or slave cylindercounterbalance valvesOR function manifoldmay have an internalfault. Consult GenieIndustries ServiceDepartment.

Exchange platform levelflow regulator valve(item U) with jib boomflow regulator valve(item EE) and activatethe platform level downfunction.


functionoperates





REV B

Part No. 72136 S-40 • S-45 5 - 51

Chart 23

Platform RotateLeft FunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theplatform rotate toggleswitch TS13 in the LEFTdirection. Check voltageat grn wire on platformrotate left directionalvalve (item CC).

0V

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theplatform rotate toggleswitch in the LEFTdirection. Check voltageat TB17.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove the platform rotatetoggle switch in the LEFTdirection. Check voltageat TB17.

Repair open in grn-4wire from TB17 toplatform rotate leftdirectional valve coil(item CC) OR repairopen in brn ground wirecircuit to valve coil.

12V ormore

0V

Troubleshoot platformrotate toggle switchesTS13 and TS5 ORrepair open in red powerwire circuit to TS13 andTS5 OR repair open ingrn wire circuit fromTS13 and TS5 to TB17OR consult GenieIndustries ServiceDepartment.

12V or more

Troubleshoot platformrotate toggle switchTS13 OR repair open inred power wire circuit toTS13 OR repair open ingrn wire circuit fromTS13 to TB17 ORconsult Genie IndustriesService Department.

12V or more



REV B

5 - 52 S-40 • S-45 Part No. 72136

CHART 23

Disconnect the wiresfrom the platform rotateleft directional valve coil(item CC) and test theresistance of the valvecoil.


rotate left directionalvalve coil (item CC).

6 to 7 ohms


Exchange platformrotate left and rightdirectional valves (itemsCC and DD) andactivate the platformrotate left function.


functionoperates


Exchange platformrotate left and rightcounterbalance valvesat the counterbalancevalve manifold andactivate the platformrotate left function.


functionoperates


Install a 0 to 3000 (207bar) pressure gauge atthe quick disconnectcoupling on the functionmanifold and activatethe platform rotate leftfunction.

Check for mechanicalrestrictions keepingplatform rotate leftfunction from operatingOR repair or replaceplatform rotator ORreplace platform rotatorcounterbalance valvemanifold OR consultGenie Industries ServiceDepartment.


Exchange platformrotate flow regulatorvalve (item EE) with theplatform leveling flowregulator valve (item U)and activate the platformrotate left function.


functionoperates


*See Note 2

*SeeNote 1




REV B

Part No. 72136 S-40 • S-45 5 - 53

Chart 24

Platform RotateRight FunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theplatform rotate toggleswitch TS13 in the RIGHTdirection. Check voltageat grn/blk-4 wire onplatform rotate rightdirectional valve(item DD).

0V

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, hold thefunction enable switch toeither side and move theplatform rotate toggleswitch in the RIGHTdirection. Check voltageat TB18.

0V

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove the platform rotatetoggle switch in theRIGHT direction. Checkvoltage at TB18.

Repair open in grn/blk-4wire from TB18 toplatform rotate rightdirectional valve coil ORrepair open in brnground wire circuit tovalve coil.

12V ormore

0V

Troubleshoot platformrotate toggle switchesTS13 and TS5 ORrepair open in red powerwire circuit to TS13 andTS5 OR repair open ingrn/blk wire circuit fromTS13 and TS5 to TB18OR consult GenieIndustries ServiceDepartment.

12V or more

Troubleshoot platformrotate toggle switchTS13 OR repair open inred power wire circuit toTS13 OR repair open ingrn/blk wire circuit fromTS13 to TB18 ORconsult Genie IndustriesService Department.

12V or more



REV B

5 - 54 S-40 • S-45 Part No. 72136

CHART 24

Disconnect the wiresfrom the platform rotateright directional valvecoil (item DD) and testthe resistance of thevalve coil.


rotate right directionalvalve coil (item DD).

6 to 7 ohms


Exchange platformrotate right and leftdirectional valves (itemsDD and CC) andactivate the platformrotate right function.


functionoperates


Exchange platformrotate right and leftcounterbalance valvesat the counterbalancevalve manifold andactivate the platformrotate right function.


functionoperates


Install a 0 to 3000 (207bar) pressure gauge atthe quick disconnectcoupling on the functionmanifold and activatethe platform rotate rightfunction.

Check for mechanicalrestrictions keepingplatform rotate rightfunction from operatingOR repair or replaceplatform rotator ORreplace platform rotatorcounterbalance valvemanifold OR consultGenie Industries ServiceDepartment.


Exchange platformrotate flow regulatorvalve (item EE) withplatform level flowregulator valve (item U)and activate the platformrotate right function.


functionoperates


*See Note 2

*SeeNote 1




REV B

Part No. 72136 S-40 • S-45 5 - 55

Chart 25

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(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.

less than950 psi

Adjust the sequencevalve. See Repairprocedure 10-5, How toAdjust the OscillateSequencing ValvePressure OR consultGenie Industries ServiceDepartment.

950 psi



REV B

5 - 56 S-40 • S-45 Part No. 72136

Chart 26

Jib Boom UpFunctionInoperativeBe sure all otherfunctions operatenormally.

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, hold thefunction enable switch toeither side and move thejib boom toggle switchTS19 in the UP direction.Check voltage at the grnwire on the jib boom updirectional valve(item CC).

0V

12V

Hold the function enableswitch to either side andmove the jib boomtoggle switch in the UPdirection and checkvoltage at TB17.

12V

0V

Repair open in grn-4wire from TB17 to jibboom up directionalvalve OR repair open inbrn ground wire circuit todirectional valve.

Repair open in redpower wire circuit fromkey switch to TS19 ORreplace TS19.

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, press down thefoot switch and movethe jib boom toggleswitch TS24 in the UPdirection. Check voltageat TB17.

12V

0VPress down the footswitch and move the jibboom toggle switch inthe UP direction. Checkvoltage at TP17.

Repair open in grn-3wire from TP17 to TB17.

12V

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, press down thefoot switch and checkvoltage on the centerterminal of the jib boomtoggle switch.


0V

12V Repair open in grn wirefrom TS24 to TP17 ORreplace TS24.

0V

12V

Repair open in red wirefrom boom controller toCR13 OR repair open inbrn ground wire circuit toCR13.

Check the voltage atterminal #87a on CR13.

12V

0V Replace CR13.

Repair open in red wirefrom terminal#87a onCR13 to TS8 ORconsult Genie IndustriesService Department.



REV B

Part No. 72136 S-40 • S-45 5 - 57

CHART 26


Press down the footswitch and move the jibboom toggle switch inthe UP direction. Checkvoltage on the red andblack wires at thejib/boom platform rotatedirectional valves (itemsAC).

0V

12VReplace CR13.

Exchange jibboom/platform rotatedirectional valves (item

Press down thefoot switch and activatethe jib boom up function.

AC).

Install a 0 to 5000 psi(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifoldand activate the jibboom up function.

functionoperates


Replace faulty valve.

Check for mechanicalrestrictions keeping jibboom up function fromoperating OR repair orreplace jib boomcylinder OR replacecounterbalance valveOR 0.030" orifice (itemAE) may be plugged ORjib boom/platform rotateselect manifold has aninternal fault OR consultGenie Industries ServiceDepartment.

Exchange jib boomcounterbalance valvesand activate jib boom upfunction.

functionoperates


Replace faultycounterbalance valve.


*See Note 2

*SeeNote 1




REV B

5 - 58 S-40 • S-45 Part No. 72136

Chart 27

Jib Boom DownFunctionInoperativeBe sure all otherfunctions operatenormally.

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, hold thefunction enable switch toeither side and move thejib boom toggle switchTS19 in the DOWNdirection. Check voltageat the grn/blk-4 wire onthe jib boom downdirectional valve(item DD).

0V

12V

Hold the function enableswitch to either side andmove the jib boomtoggle switch in theDOWN direction. Checkvoltage at TB18.

12V

0V

Repair open in grn/blk-4wire from TB18 to jibboom down directionalvalve OR repair open inbrn ground wire circuit todirectional valve.

Repair open in redpower wire circuit fromkey switch to TS12 toTS19 OR replace TS19.

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, press down thefoot switch and movethe jib boom toggleswitch TS24 in theDOWN direction. Checkvoltage at TB18.

12V

0VPress down the footswitch and move the jibboom toggle switch inthe DOWN direction.Check voltage at TP18.

Repair open in grn/blk-3wire from TP18 to TB18.

12V

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, press down thefoot switch and checkvoltage on the centerterminal of the jib boomtoggle switch.

Check the voltage atterminal #30 on CR13.

0V

12V Repair open in grn/blkwire from TS24 to TP18OR replace TS24.

0V

12V

Repair open in red wirefrom boom controller toCR13 OR repair open inbrn ground wire circuit toCR13.

Check the voltage atterminal #87a on CR13.

12V

0V Replace CR13.

Repair open in red wirefrom terminal#87a onCR13 to TS8 ORconsult Genie IndustriesService Department.



REV B

Part No. 72136 S-40 • S-45 5 - 59

CHART 27


Press down the footswitch and move the jibboom toggle switch TS6in the DOWN direction.Check voltage on thered and black wires atthe jib/platform rotateselect valves (item AC).

0V

12VReplace CR13.

Exchange jibboom/platform rotatedirectional valves (itemAC). Press down thefoot switch and activatethe jib boom downfunction.

Install a 0 to 5000 psi(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifoldand activate the jibboom down function.

functionoperates


Replace faulty valve.

Check for mechanicalrestrictions keeping jibboom down functionfrom operating ORrepair or replace jibboom cylinder ORreplace counterbalancevalve OR 0.030" orifice(item AE) may beplugged OR jibboom/platform rotateselect manifold has aninternal fault OR consultGenie Industries ServiceDepartment.

Exchange jib boomcounterbalance valvesand activate jib boomdown function.

functionoperates


Replace faultycounterbalance valve.


*See Note 2

*SeeNote 1




REV B

5 - 60 S-40 • S-45 Part No. 72136

Steer LeftFunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 28

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch and holdthe steer rocker switchon drive controller in theLEFT direction. Checkvoltage on TB36.

0V

12V or more

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch and holdthe steer rocker switchon drive controller in theLEFT direction. Checkvoltage at the controllerterminal with the bluwire attached.

12V ormore

Repair open in blu wirecircuit from drivecontroller to TP36 thenblu-1 wire circuit toTB36.

0V

Repair or replace steermicroswitch on drivecontroller. ConsultGenie Industries ServiceDepartment.


With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch and holdthe steer rocker switchon drive controller in theLEFT direction. Checkvoltage on blu #36 wireon steer left directionalvalve coil (item TT) onsteer manifold.

12V or more

0V

Repair open in blu #36wire circuit from TB36 tosteer left directionalvalve coil on steermanifold OR repairopen in brn ground wirecircuit to steer leftdirectional valve coil.

Disconnect wires tosteer left directionalvalve coil on steermanifold and test theresistance of the valvecoil.

0 orinfiniteohms

Replace steer leftdirectional valve coil ORrepair open in brnground wire circuit tosteer left valve coil.

5 to 6 ohms


REV B

Part No. 72136 S-40 • S-45 5 - 61

CHART 28


Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and activatethe steer left function.

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 replace flowregulator valve (itemWW) OR consult GenieIndustries ServiceDepartment.

*See Note 2

*SeeNote 1




REV B

5 - 62 S-40 • S-45 Part No. 72136

Chart 29

Steer RightFunctionInoperativeBe sure all otherfunctions operatenormally.

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch and holdthe steer rocker switchon drive controller in theRIGHT direction. Checkvoltage on TB37.

0V

12V or more

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch and holdthe steer rocker switchon drive controller in theRIGHT direction. Checkvoltage at the controllerterminal with the blu/blkwire attached.

12V ormore

Repair open in blu/blkwire circuit from drivecontroller to TP37 thenblu/blk-1 to TB37.

0V

Repair or replace steermicroswitch on drivecontroller. ConsultGenie Industries ServiceDepartment.


With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch and holdthe steer rocker switchon drive controller in theRIGHT direction. Checkvoltage on blu/blk #37wire on steer rightdirectional valve coil(item TT) on steermanifold.

12V or more

0V

Repair open in blu/blk#37 wire circuit that runsfrom TB37 to steer rightdirectional valve coil onsteer manifold ORrepair open in brnground wire circuit tosteer right valve coil.

Disconnect wires tosteer right directionalvalve coil on steermanifold and test theresistance of the valvecoil.

0 orinfiniteohms

Replace steer rightdirectional valve coil ORrepair open in brnground wire circuit tosteer right valve coil.

5 to 6 ohms


REV B

Part No. 72136 S-40 • S-45 5 - 63

CHART 29


Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe boom functionmanifold and activatethe steer right function.

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 replace flowregulator valve (itemWW) OR consult GenieIndustries ServiceDepartment.

*See Note 2

*SeeNote 1




REV B

5 - 64 S-40 • S-45 Part No. 72136

Chart 30

All DriveFunctionsInoperative,All OtherFunctionsOperateNormallyBe sure the rpmselect switch is inthe foot switchactivated high idleposition.

Be sure thehyydraulic tank shutoff valves are in theOPEN position.

Be sure machine isnot in the free wheelconfiguration.

Press down the footswitch and check thevoltage at terminal #10on the horsepowerlimiter board.

0V

9 to 12V


With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andcheck voltage atterminal #2 on drivecontroller.

lessthan12V

Repair open in powersupply circuit from TP24to terminal #2 on drivecontroller.

12V or more

Check continuity of brnground wire fromterminal #3 on drivecontroller to ground.

continuity

no continuity

Repair open in brnground wire circuit fromground to drivecontroller.

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andcheck voltage atterminal #1 on thehorsepower limiterboard.

12V or more

lessthan12V

Repair open in powersupply circuit from TP24to terminal #1 on thehorsepower limiterboard.

Check continuity of brnground wire fromterminal #2 on thehorsepower limiterboard to ground.

continuity

no continuity

Repair open in brnground wire circuit fromground to terminal #2 onthe horsepower limiterboard.

Adjust the "A" trimpot.See repair procedure1-2, How to Adjust theHorspower LimiterBoard OR replacehorsepower limiterboard.

Press down the footswitch and checkvoltage at terminal #3 onthe horsepower limiterboard.

7 to 8V

0V

Press down the footswitch and checkvoltage on the org/blk#41wire on the alterator.

7 to 8V

0V

Repair or replacealternator.

Repair open in org/blk#41 wire from alternatorto TB41 and org/blk-1wire from TP41 toterminal #3 onhorsepower limiterboard.


REV B

Part No. 72136 S-40 • S-45 5 - 65

CHART 30


Repair open in wire fromterminal #10 onhorsepower limiterboard to terminal #6 onthe drive controller.

Press down the footswitch and hold thedrive controller in the fullforward position. Checkvoltage at terminal #6 onthe drive controller.

9 to 12V

Connect the positvelead from a voltmeter toterminal #4 on the drivecontroller and thenegative lead to terminal#5 on the drivecontroller. Press downthe foot switch and holdthe drive controller in thefull forward position.Check voltage acrossthe #4 and #5 terminalson the drive controller.

0V

2V

Replace drive controllerOR consult GenieIndustries ServiceDepartment.

0V

nocontinuity

continuity

Check continuity fromterminal #3 on drivecontroller to ground.

Repair open in brnground wire circuit fromterminal #3 on drivecontroller to ground.

Connect the positvelead from a voltmeter toterminal #5 on the drivecontroller and thenegative lead to terminal#4 on the drivecontroller. Press downthe foot switch and holdthe drive controller in thefull reverse position.Check voltage acrossthe terminals #5 and #4on the drive controller.

0V

Replace drive controllerOR consult GenieIndustries ServiceDepartment.

nocontinuity

continuity

Check continuity fromterminal #3 on drivecontroller to ground.

Repair open in brnground wire circuit fromterminal #3 on drivecontroller to ground.

2V



REV B

5 - 66 S-40 • S-45 Part No. 72136


Press down the footswitch and hold thedrive controller in the fullforward position andcheck voltage acrossthe wht #12 wire and thewht/blk #31 wire onEDC.

0V

2V

Repair open in blu/whtwire from TS9 to TP12to TB12.

Press down the footswitch and hold thedrive controller in the fullforward position. Holdthe drive enable toggleswitch TS8 to either sideand check the voltageacross the wht #12 wireand the wht/blk #31 onEDC.

2V

0V

Repair open in wht wirefrom terminal #4 ondrive controller to TS8 toTP30 to TB30 throughdrive enable limit switch(LS3) to TB12 to wht#12 wire on EDC quickdisconnect plug.

Connect the positvelead from a voltmeter toterminal #5 on the drivecontroller and thenegative lead from thevoltmeter to theblu/wht wire on TS8.Press down the footswitch and move thedrive controller in the fullforward position. Holdthe drive enable toggleswitch to either side.and check voltage.

2V

0V

Replace drive enabletoggle switch TS8.

0V

2V

Repair open in wire fromterminal #4 from drivecontroller to drive enabletoggle switch ORreplace drive controllerOR consult GenieIndustries ServiceDepartment.

Troubleshoot driveforward and drivereverse functionsseparately OR replacepump OR consult GenieIndustries ServiceDepartment.

Connect the positvelead from a voltmeter toterminal #5 on the drivecontroller and thenegative lead of thevoltmeter on the centerterminal of the driveenable toggle switch.Press down the footswitch and move thedrive controller in the fullforward position. Holdthe drive enable switchto either side and checkvoltage.

CHART 30


REV B

Part No. 72136 S-40 • S-45 5 - 67

Chart 31

Disconnect the EDCwire connector from thedrive pump, start theengine, move the drivecontroller to full forwardposition and note thevoltage across the wht#12 and the wht/blk #31wire terminals on theEDC. Reverse the voltmeter leads and movethe drive 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 improvement Faulty drive pump,contact authorizedrepair facility.

symptoms improve

Re-adjust horsepowerlimiter board OR ifproblem persists,consult Genie IndustriesService Department.

Check the resistance ofthe EDC.

0 orinfiniteohms Replace the EDC.

20 to 24 ohms

Drive Forwordor ReverseFunctionInoperativeBe sure all otherfunctions operatenormally includingdrive in oppositedirection ofmanfunction.


REV B

5 - 68 S-40 • S-45 Part No. 72136

Chart 32

Any type of tractionproblem, consult GenieIndustries ServiceDepartment.

TractionFunctionInoperativeBe sure that all otherfunctions operatenormally.


REV B

Part No. 72136 S-40 • S-45 5 - 69

Chart 33

With the boom in thestowed position, checkcontinuity from TB40 toground.

continuityRepair short to groundin wht wires to limitswitches (LS1 and LS2)OR repair or replaceboom lift 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 fromTB40 to TP40 toterminal #6 onhorsepower limiterboard.

no continuity

Re-adjust or replacehorsepower limiterboard OR check formisalignment of limitswitches (LS1 and LS2)OR consult GenieIndustries ServiceDepartment.

Machine WillNot Drive AtFull SpeedBe sure all otherfunctions operatenormally.

Be sure the machine isnot raised above orextended beyond thedrive limit switches.

Be sure the drive limitswitches are clear ofany debris and are notactivated when theboom is in the stowedposition.

Be sure the wiring tolimit switches is intactand show no signs ofdamage or corrosion.

Be sure the free-wheelvalve is closed on thedrive pump.


REV B

5 - 70 S-40 • S-45 Part No. 72136

Chart 34

Extend the boom pastthe limit switch (LS1)and check continuityfrom ground to terminal#6 on the horsepowerlimiter board.

continuity

no continuity

Check continuity fromground to TB40.

continuity Repair open in org wirecircuit from TB40 toTP40 to terminal #6 onhorsepower limiterboard.

no continuity

Repair open from whtwires at TB40 to drivelimit switches (LS1 andLS2), then from brnground wires to ground.

bad

good

Test limit switches. Seeprocedure A-14 in theMaintenance Section.

Replace faulty limitswitch contact ORreplace limit switch.

Replace horsepowerlimiter board OR re-adjust horsepowerlimiter board OR consultGenie Industries ServiceDepartment.

Machine DrivesAt Full SpeedWith PlatformRaised orExtendedBe sure boom up drivelimit switch is beingactivated by the cam onthe boom when theboom is raised.

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 signs ofdamage or corrosion.


REV B

Part No. 72136 S-40 • S-45 5 - 71

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, and theboom rotated betweenthe non-steer tires,press down the footswitch and move drivecontroller in the forwarddirection. Does machinedrive?

no

yes

no continuity

continuity

0V

Repair open fromterminal #4 on drivecontroller to centerterminal on TS8 ORrefer to Chart 28 ORconsult Genie IndustriesService Department.

12V or more

Repair open in powersupply circuit fromTP24.

yes

Repair open in blu/whtwire from drive enabletoggle switch to TP12 toTB12 OR replace driveenable toggle switchTS8.

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove the drive controllerin forward direction.Check voltage atterminal #2 on drivecontroller.

With key switch turnedto platform controls andboth Emergency Stopbuttons pulled out to theON position, and theboom rotated betweenthe steer tires, pressdown the foot switch andmove the drive controllerin forward direction.Does the machinedrive?

yes

no

Hold the drive enabletoggle switch TS8 toeither side and pressdown the foot switch.Move the drive controllerin the forward direction.Does the machinedrive?

The machine isoperating properly. 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-5 wire toLS3 then from LS3through blk-5 wire toTB12.

Please begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.

Drive EnableSystem IsMalfunctioningBe sure the boom is inthe stowed position.

Chart 35


REV B

5 - 72 S-40 • S-45 Part No. 72136

Lift the red auxiliarypump switch cover,move the auxiliarypower toggle switch TS9to either side and listenfor sound of auxiliarypump motor operating.

motoroperates

Install a 0 to 5000 psi(345 bar) pressuregauge into the pressureport of the auxiliarypump and move theauxiliary power toggleswitch to either side andnote the pressure.

2000 psi

Repair or replace pumpOR replace relief valve.Consult Genie IndustriesService Department.

less than2000 psi

Reconnect pressurehose and check batterycondition. There maynot be enough batterycapacity to operate bothauxiliary pump anddirectional valves.

motor doesnot operate

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, move theauxiliary pump toggleswitch to either side andcheck the voltage on thered cable on theauxiliary power unit.

goodCheck for a positiveconnection betweenelectric motor and thepump by removing thepump from the motor.Leave all the hosesconnected and visuallycheck couplingconnection.

bad

Replace the auxiliarypower unit.

12V

0V Test PR1. See RepairProcedure 8-5.

bad Replace PR1.

good

Move the auxiliary pumptoggle switch to eitherside and check voltageat TB27.

12V ormore

0V

Repair open from TB27to PR1 OR repair openin brn ground wire circuitto PR1 OR replace PR1.

Move the auxiliary pumptoggle switch to eitherside and check thevoltage at the centerterminal of TS9.

0VRepair open in redpower supply wire fromkey switch to auxiliarypump toggle switch.

12V or more

Repair open in red #27wire from TS9 to TB27OR replace TS9.


AuxiliaryFunctionsInoperativeBe sure all otherfunctions operatenormally.

Be sure key switchis in the appropriateposition and bothEmergency Stopbuttons are pulledout to the ON

position.

Be sure engine isnot running whenusing auxiliarypower.

Note: Operatingauxiliary power withthe engine runningshould immediatelystop the engine.

Chart 36


REV B

Part No. 72136 S-40 • S-45 5 - 73

Check continuity fromnegative terminal onauxiliary pump motor toground.


good

bad Replace negative cablefrom auxiliary pumpmotor to ground.

Replace auxiliary pumpmotor.

CHART 36


REV B

5 - 74 S-40 • S-45 Part No. 72136


Part No. 72136 S-40 • S-45 6 - 1

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-40 and S-45 Operator's Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in thissection. An illustration legend precedes eachgroup of drawings.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

March 2008 Section 6 • Schematics

Item Description Genie Part Manufacturer Manufacturer QtyPart Number Part Number

BAT ................ Battery, 1000 CCA, 12V DC .. 30143 ........... Trojan .................................. C31XH-2 ........................ 1

BP1 ................ Joystick controller, Dual axis . 53073 ........... OEM Controls ...................... EJS5M1197 ................... 1

CB1, CB2 ....... Circuit breaker ....................... 24018 ........... ETA ...................................... 45-700-IG1-P10 ............. 2

CR1throughCR7, 17, 18,19 ................... Relay, SPDT, 12V DC ........... 34052 ........... Potter-Brumfield .................. VF4-15F11-CO5 .......... 10

Diode .............. Diode, 6 amp, 200 PIV .......... 45782 ........... Motorola ............................... MOTMR752 ................. 36

DP1 ................ Joystick controller-Drive ........ 20424 ........... OEM Controls ...................... EMS4M11664 ................ 1

FB .................. Flashing beacon .................... 20189 ........... ECCO Electronic Controls ... 6400A-GEN ................... 2

FS1 ................ Footswitch .............................. 13482 ........... Linemaster Switch Corp. ..... 632-S ............................. 1

G1 .................. Gauge - Voltage .................... 53761 ........... VDO ..................................... 332-030001C ................. 1

G2 .................. Gauge - Oil Pressure ............. 53758 ........... VDO ..................................... 350-030021C ................. 1

G3 .................. Gauge - Water Temp. ........... 53759 ........... VDO ..................................... 310-030023C ................. 1

H1 .................. Alarm, Warble tone ................ 45383 ........... Floyd Bell Inc. ...................... MW09-530-Q ................. 1

H2 .................. Horn, 12V DC ........................ 81578 ........... Wesco. ................................. HELLA 95346 ................ 1

H3 .................. Alarm, intermittent ................. 18963 ........... Floyd Bell Inc. ...................... XB-09-630-Q(S) ............. 1

H4 .................. Alarm, chime tone ................. 45462 ........... Floyd Bell Inc. ...................... CH-09-525-Q ................. 1

HM ................. Hourmeter ............................. 19506 ........... ENM Corporation ................ T40A4508 ...................... 1

KS1 ................ Contact - Key switch, N.O. .... 128497 .......... Laughlin .............................. ZB5AGO ......................... 2

L1 ................... LED - Red, 12V DC ............... 56298 ........... Laughlin. .............................. 30XX-4-11-37610.0001 1

LS1, 2, 3 ......... Contact - Limit switch,N.C.H.O. ................................ 19491 ........... Telemecanique .................... XESP2151 ..................... 3

Level sensor .. Level sensor, 4.5° .................. 44586 ........... Power Comp. of Midwest .... LS36-04.5L1-501 ........... 1

P1, P2 ............ Contact, N.C. ........................ 128499 .......... Laughlin .............................. ZB5AT4 .......................... 4

P3 ................... Contact, N.O. ......................... 45081 ........... Telemecanique ................... ZB2-BE101 .................... 1

PR1 ................ Relay, 12V DC continuous .... 27155 ........... Stancor ................................ 70-902 ........................... 1

This list continues on the next page.

March 2008Section 6 • Schematics

Electrical Components

- 2 S-40 • S-45 Part No. 72136

ELECTRICAL COMPONENTS

Item Description Genie Part Manufacturer Manufacturer QtyPart Number Part Number

R2 .................. Resistor, 10Ω 25 watt ............ 27287 ........... Dale ..................................... 825F10R ........................ 1

TS1, TS9 ........ Toggle switch, DPST2 position momentary ............ 13480 ........... Microswitch Control Inc. ...... 2NT1-8 ........................... 2

TS2, 5, 8, 10,12, 13 ............. Toggle switch, SPDT

3 position momentary ............ 13037 ........... Microswitch Control Inc. ...... 1NT1-7 ........................... 6

TS20 .............. Toggle switch, DPDT2 position maintained ............ 27378 ........... Microswitch Control Inc. ...... 2NT1-3 ........................... 1

TS4 ................ Toggle switch, DPDT3 position maintained ............ 13038 ........... Microswitch Control Inc. ...... 2NT1-1 ........................... 1

TS6,7,14,15,16,17 .............. Toggle switch, DPDT


TS3, TS11(Gas/LPG) ...... Toggle switch, DPDT

2 position maintained ............ 27378 ........... Microswitch Control Inc. ...... 2NT1-3 ........................... 2

TS3, TS11(Diesel) ........... Toggle switch, SPDT



Part No. 72136 S-40 • S-45 - 3

6 - 4 S-40 • S-45 Part No. 72136


Electrical Symbols Legend

Part No. 72136 S-40 • S-45 6 - 5

LABEL DESCRIPTION

BAT ............. Battery

BP ............... Boom proportional controller

C1................Capacitor

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 .................. Emergency Stop Button

PR ............... Power relay

R.................. Resistor

TB................Terminal base location

TP................Terminal platform location

TS................Toggle switch


Abbreviation Legend

6 - 6 S-40 • S-45 Part No. 72136

Hydraulic Symbols Legend



1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A

Part No. 72136 S-40 • S-45 6 - 7

Ford LRG-425 EFIEngine Wire Harness

REV A


6 - 8

Ford LRG-425 EFIEngine Wire Harness

6 - 7


6 - 9 6 - 10

Electrical Schematic-Gasoline/LPG Models

Section 6 • SchematicsMarch 2008


1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N

6 - 10 S-40 • S-45 Part No. 72136

REV A



1

2

3

4

5

6

7

8


REV A

Part No. 72136 S-40 • S-45 6 - 11

TB1

RE

D-4

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

EX

TE

ND

RE

TR

AC

TB

OO

M

TP16

TB16

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

LIF

T/D

RIV

ES

EL

EC

TO

RO

PT

ION

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

GR

N-4

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

TB17

GR

N/B

LK

-4

GR

N

TB18

GR

N/B

LK

GR

N/B

LK

-3

GR

N/W

HT

GR

N/W

HT

-3

RE

D

RE

D

BL

KR

ED

/BL

K

JIB

VA

LV

ES

TS13

UP

DO

WN

JIB

BO

OM

TS19

TB19

TP17

TP19

OR

G/R

ED

-3

GR

N-3

TP18

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

BO

OM

RE

TR

AC

T

TP14

OR

G/B

LK

-4

TB15

OR

G/B

LK

TB14

OR

G-4

OR

G

TP15

TS14

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

OR

G-3

OR

G/B

LK

-3

BL

K/W

HT

-4

TB8

TS15

10

R2

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

TP3

TP2

BL

K-4

BL

K

BL

K/W

HT

BL

K/W

HT

-3

TP8

BL

K-3

RE

D/W

HT

-3

TP7

TB3

RE

D/W

HT

-4

RE

D/B

LK

-4

TB2

RE

D/B

LK

RE

D/B

LK

-3

RE

D-3

TP1

UP

DO

WN PR

IMA

RY

BO

OM

TS16

X

R

CR13N.C.

TS6

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

TS5C1

CR14

+

TS7

PWM

A+-

6 DR

IVE

EN

AB

LE

BL

U/R

ED

-3

LS3

TB40

RE

D

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

LIM

ITS

WIT

CH

LIM

ITS

WIT

CH

BO

OM

EX

TE

ND

BO

OM

UP

WH

T-7

BR

N-7

LS1

WH

T-6

BR

N-6

LS2N.C.H.O

RIG

HT

LE

FT T

UR

NTA

BL

E R

OTA

TE

TB5W

HT

/RE

D-4

TB6

WH

T/B

LK

-4

WH

T-4

WH

T/B

LK

TB4

WH

T

TS17

R

X

WH

T-3

TP4

WH

T/B

LK

-3

WH

T/R

ED

-3

TP5 TP6

OR

G-1

87

109

ST

EE

R L

EF

T

ST

EE

R R

IGH

T

WHT#12-E.H.

DR

IVE

ED

C

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

TB12

TP37

TB37

TB36

BL

U#

36

-E.H

.

BL

U/B

LK

#3

7-E

.H.

RED

BL

U-1

BL

U/B

LK

-1

TP36

WH

T/B

LK

#3

1-E

.H.

TB31

BR

N-5

RE

D-5

BL

K-5

TB30

BL

U/W

HT

-3

WH

T/B

LK

-1

TP31

WH

T-1

TP12

TS8

TP30

L1

GR

OU

ND

WH

T-5

TB13

BR

N-2

BRN-2TS23

WHT

TP13

-+A

PWM

BP1

1

3

54

2

DP1

BR

AK

E

N.C.H.O.N.O.H.C.

HORSEPOWERLIMITERBOARD

LIFT/DRIVE SELECT OPTION

JIB BOOM OPTIONLS2N.C.

BL

K-6

CR18A

RE

D-6

PL

AT

FO

RM

LE

VE

LD

ISA

BL

E(C

E O

PT

ION

)

BL

K/R

ED

-3

TP9

BL

K/R

ED

-4

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

T

TB9

N.O.

N.O.86

86

86

85

85

85

87

87

87

30

30

30

CR18B

5678

2

43

1

ORG/BLK-1

RED

RED

RED

BRN

WHT

UP

DO

WN

JIB

BO

OM

TS24

DE

SC

EN

TA

LA

RM

(OP

TIO

N)

TP32

TB32

WH

T/R

ED

#3

2-E

.H.

WH

T/R

ED

-1

TR

AV

EL

AL

AR

M(O

PT

ION

)

N.C.H.O


6 - 12


6 - 11


6 - 13

Ground Control Box Wiring Diagram-Gasoline/LPG Models

6 - 14


Ground Control Box Wiring Diagram-Gasoline/LPG Models

1

2

3

4

5

6

7

8


REV A

6 - 14 S-40 • S-45 Part No. 72136


Platform Control Box Wiring Diagram-Gasoline/LPG Models

1

2

3

4

5

6

7

8


REV A

Part No. 72136 S-40 • S-45 6 - 15


6 - 16

Platform Control Box Wiring Diagram-Gasoline/LPG Models

6 - 15


6 - 17 6 - 18

Electrical Schematic-Deutz Diesel Models



1

2

3

4

5

6

7

8


REV A

6 - 18 S-40 • S-45 Part No. 72136



1

2

3

4

5

6

7

8


REV A

Part No. 72136 S-40 • S-45 6 - 19

TB1

RE

D-4

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

EX

TE

ND

RE

TR

AC

TB

OO

M

TP16

TB16

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

LIF

T/D

RIV

ES

EL

EC

TO

RO

PT

ION

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

GR

N-4

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

TB17

GR

N/B

LK

-4

GR

N

TB18

GR

N/B

LK

GR

N/B

LK

-3

GR

N/W

HT

GR

N/W

HT

-3

RE

D

RE

D

BL

KR

ED

/BL

K

JIB

VA

LV

ES

TS13

UP

DO

WN

JIB

BO

OM

TS19

TB19

TP17

TP19

OR

G/R

ED

-3

GR

N-3

TP18

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

BO

OM

RE

TR

AC

T

TP14

OR

G/B

LK

-4

TB15

OR

G/B

LK

TB14

OR

G-4

OR

G

TP15

TS14

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

OR

G-3

OR

G/B

LK

-3

BL

K/W

HT

-4

TB8

TS15

10

R2

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

TP3

TP2

BL

K-4

BL

K

BL

K/W

HT

BL

K/W

HT

-3

TP8

BL

K-3

RE

D/W

HT

-3

TP7

TB3

RE

D/W

HT

-4

RE

D/B

LK

-4

TB2

RE

D/B

LK

RE

D/B

LK

-3

RE

D-3

TP1

UP

DO

WN PR

IMA

RY

BO

OM

TS16

X

R

CR13N.C.

TS6

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

TS5C1

CR14

+

TS7

PWM

A+-

6 DR

IVE

EN

AB

LE

BL

U/R

ED

-3

LS3

TB40

RE

D

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

LIM

ITS

WIT

CH

LIM

ITS

WIT

CH

BO

OM

EX

TE

ND

BO

OM

UP

WH

T-7

BR

N-7

LS1

WH

T-6

BR

N-6

LS2N.C.H.O

RIG

HT

LE

FT T

UR

NTA

BL

E R

OTA

TE

TB5W

HT

/RE

D-4

TB6

WH

T/B

LK

-4

WH

T-4

WH

T/B

LK

TB4

WH

T

TS17

R

X

WH

T-3

TP4

WH

T/B

LK

-3

WH

T/R

ED

-3

TP5 TP6

OR

G-1

87

109

ST

EE

R L

EF

T

ST

EE

R R

IGH

T

WHT#12-E.H.

DR

IVE

ED

C

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

TB12

TP37

TB37

TB36

BL

U#

36

-E.H

.

BL

U/B

LK

#3

7-E

.H.

RED

BL

U-1

BL

U/B

LK

-1

TP36

WH

T/B

LK

#3

1-E

.H.

TB31

BR

N-5

RE

D-5

BL

K-5

TB30

BL

U/W

HT

-3

WH

T/B

LK

-1

TP31

WH

T-1

TP12

TS8

TP30

L1

GR

OU

ND

WH

T-5

TB13

BR

N-2

BRN-2TS23

WHT

TP13

-+A

PWM

BP1

1

3

54

2

DP1

BR

AK

E

N.C.H.O.N.O.H.C.




BL

K-6

CR18A

RE

D-6

PL

AT

FO

RM

LE

VE

LD

ISA

BL

E(C

E O

PT

ION

)

BL

K/R

ED

-3

TP9

BL

K/R

ED

-4

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

T

TB9

N.O.

N.O.86

86

86

85

85

85

87

87

87

30

30

30

CR18B

5678

2

43

1

ORG/BLK-1

RED

RED

RED

BRN

WHT

UP

DO

WN

JIB

BO

OM

TS24

DE

SC

EN

TA

LA

RM

(OP

TIO

N)

TP32

TB32

WH

T/R

ED

#3

2-E

.H.

WH

T/R

ED

-1

TR

AV

EL

AL

AR

M(O

PT

ION

)

N.C.H.O


6 - 20


6 - 19


6 - 21

Ground Control Box Wiring Diagram-Deutz Diesel Models

6 - 22

March 2008

Ground Control Box Wiring Diagram-Deutz Diesel Models

1

2

3

4

5

6

7

8


REV A

6 - 22 S-40 • S-45 Part No. 72136

Section 6 • Schematics


Platform Control Box Wiring Diagram-Deutz Diesel Models

1

2

3

4

5

6

7

8


REV A

Part No. 72136 S-40 • S-45 6 - 23


6 - 24

Platform Control Box Wiring Diagram-Deutz Diesel Models

6 - 23


6 - 25 6 - 26

Electrical Schematic-Perkins Diesel Models

March 2008


1

2

3

4

5

6

7

8


REV A

6 - 26 S-40 • S-45 Part No. 72136




1

2

3

4

5

6

7

8


REV A

Part No. 72136 S-40 • S-45 6 - 27

TB1

RE

D-4

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

EX

TE

ND

RE

TR

AC

TB

OO

M

TP16

TB16

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

LIF

T/D

RIV

ES

EL

EC

TO

RO

PT

ION

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

GR

N-4

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

TB17

GR

N/B

LK

-4

GR

N

TB18

GR

N/B

LK

GR

N/B

LK

-3

GR

N/W

HT

GR

N/W

HT

-3

RE

D

RE

D

BL

KR

ED

/BL

K

JIB

VA

LV

ES

TS13

UP

DO

WN

JIB

BO

OM

TS19

TB19

TP17

TP19

OR

G/R

ED

-3

GR

N-3

TP18

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

BO

OM

RE

TR

AC

T

TP14

OR

G/B

LK

-4

TB15

OR

G/B

LK

TB14

OR

G-4

OR

G

TP15

TS14

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

OR

G-3

OR

G/B

LK

-3

BL

K/W

HT

-4

TB8

TS15

10

R2

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

TP3

TP2

BL

K-4

BL

K

BL

K/W

HT

BL

K/W

HT

-3

TP8

BL

K-3

RE

D/W

HT

-3

TP7

TB3

RE

D/W

HT

-4

RE

D/B

LK

-4

TB2

RE

D/B

LK

RE

D/B

LK

-3

RE

D-3

TP1

UP

DO

WN PR

IMA

RY

BO

OM

TS16

X

R

CR13N.C.

TS6

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

TS5C1

CR14

+

TS7

PWM

A+-

6 DR

IVE

EN

AB

LE

BL

U/R

ED

-3

LS3

TB40

RE

D

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

LIM

ITS

WIT

CH

LIM

ITS

WIT

CH

BO

OM

EX

TE

ND

BO

OM

UP

WH

T-7

BR

N-7

LS1

WH

T-6

BR

N-6

LS2N.C.H.O

RIG

HT

LE

FT T

UR

NTA

BL

E R

OTA

TE

TB5W

HT

/RE

D-4

TB6

WH

T/B

LK

-4

WH

T-4

WH

T/B

LK

TB4

WH

T

TS17

R

X

WH

T-3

TP4

WH

T/B

LK

-3

WH

T/R

ED

-3

TP5 TP6

OR

G-1

87

109

ST

EE

R L

EF

T

ST

EE

R R

IGH

T

WHT#12-E.H.

DR

IVE

ED

C

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

TB12

TP37

TB37

TB36

BL

U#

36

-E.H

.

BL

U/B

LK

#3

7-E

.H.

RED

BL

U-1

BL

U/B

LK

-1

TP36

WH

T/B

LK

#3

1-E

.H.

TB31

BR

N-5

RE

D-5

BL

K-5

TB30

BL

U/W

HT

-3

WH

T/B

LK

-1

TP31

WH

T-1

TP12

TS8

TP30

L1

GR

OU

ND

WH

T-5

TB13

BR

N-2

BRN-2TS23

WHT

TP13

-+A

PWM

BP1

1

3

54

2

DP1

BR

AK

E

N.C.H.O.N.O.H.C.




BL

K-6

CR18A

RE

D-6

PL

AT

FO

RM

LE

VE

LD

ISA

BL

E(C

E O

PT

ION

)

BL

K/R

ED

-3

TP9

BL

K/R

ED

-4

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

T

TB9

N.O.

N.O.86

86

86

85

85

85

87

87

87

30

30

30

CR18B

5678

2

43

1

ORG/BLK-1

RED

RED

RED

BRN

WHT

UP

DO

WN

JIB

BO

OM

TS24

DE

SC

EN

TA

LA

RM

(OP

TIO

N)

TP32

TB32

WH

T/R

ED

#3

2-E

.H.

WH

T/R

ED

-1

TR

AV

EL

AL

AR

M(O

PT

ION

)

N.C.H.O


6 - 28


6 - 27


6 - 29

Ground Control Box Wiring Diagram-Perkins Diesel Models

6 - 30

March 2008

Ground Control Box Wiring Diagram-Perkins Diesel Models

1

2

3

4

5

6

7

8


REV A

6 - 30 S-40 • S-45 Part No. 72136



Platform Control Box Wiring Diagram-Perkins Diesel Models

1

2

3

4

5

6

7

8


REV A

Part No. 72136 S-40 • S-45 6 - 31


Platform Control Box Wiring Diagram-Perkins Diesel Models

6 - 326 - 31

1

2

3

4

5

6

7

8



S-40/45 2WD Hydraulic SchematicNon-Oscillating Axle

REV A

TT

Y

S

I

H

PM

G L

XXYY

ZZ

AB

10 GPM

PRESS.

FILTER

HIGH

FUNCTION

RESERVOIR

DRIVE PUMP

3500PSI

290

PSI

3PSI

3PSI

E

25PSI

PUMP

50PSI

STEERING

AUX. PUMP

2000PSI

0.025

REAR

LEFT

M1

M3

TRACTION

M4

RIGHT

REAR

M2PSI

250

AB

CP

0.070

OIL

COOLER

OPTIONAL

TURNTABLE

TEST

T1

PRESSURE

RQAAZ

SEC

S40- 2600 PSIS45- 2900 PSI

X

REG

W

BB2GPM

CC

EE GPM0.6

DD

JGPM0.1

0.6GPM

V

U

T

O

A

PR2PR1

MANIFOLD

FUNCTION

PLATFORM

LEVEL

2500 PSI- (before serial no. 1865)3500 PSI- (after serial no. 1864)

FF

PL1

GG

PL2

MASTER

SLAVE

BA

RETRACT

PSI1950

N

B

K

F

C

S2S1BOOM

P1

C

EXTEND

2200PSI

P2

HH

D

E

TURNTABLE

ROTATE

PRESS.

TANK

PRIMARYUP/DOWN

BOOM

.030

0.14

GENERATOR

OPTIONAL

2400 PSI

GENERATOR

MANIFOLD

OPTIONAL

PLATFORM ROTATE

M

X

X

X

FF

TANK

S-45 JIB BOOM

F F

S-45 JIB SELECT MANIFOLD(BEFORE SERIAL NO. 5593)

0.035 0.030

0.030

J2 J1

R1

R2

V1V2

TO PR1

R1

S-45 JIB SELECT MANIFOLD(AFTER SERIAL NO. 5592)

J1J2

0.035

S-45 JIB BOOM

V2

R2

PLATFORM ROTATE

F F

FF

TO PR2

V1

Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.

Part No. 72136 S-40 • S-45 6 - 33


S-40/45 2WD Hydraulic SchematicNon-Oscillating Axle

6 - 346 - 33

1

2

3

4

5

6

7

8



S-40/45 2WD Hydraulic SchematicOscillating Axle

REV A

Y

S

I

H

PM

G L

NNMM

PPOOSS

QQ

RR

XXYY

ZZ

AB

TT

WW

UUVV

10 GPM

PRESS.

FILTER

HIGH

FUNCTION

RESERVOIR

DRIVE PUMP

3500PSI

290

PSI

3PSI

3PSI

E

25PSI

PUMP

50PSI

STEERING

AUX. PUMP

2000PSI

0.025

950PSI

X

XP8P

A CYL

B CYL

A VALVE

B VALVE

REAR

LEFT

M1

M3

TRACTION

M4

RIGHT

REAR

M2PSI

250

AB

CP

0.070

OIL

COOLER

OPTIONAL

TURNTABLE

TEST

T1

PRESSURE

RQAAZ

SEC

S40- 2600 PSIS45- 2900 PSI

X

REG

W

BB3.5GPM

CC

EE GPM0.6

DD

JGPM0.1

0.6GPM

V

U

T

O

A

PR2PR1

MANIFOLD

FUNCTION

PLATFORM

LEVEL


FF

PL1

GG

PL2

MASTER

SLAVE

BA

RETRACT

PSI1950

N

B

K

F

C

S2S1BOOM

P1

C

EXTEND

2200PSI

P2

HH

D

E

TURNTABLE

ROTATE

PRESS.

TANK

PRIMARYUP/DOWN

BOOM

.030

0.14

0.025

STEER

MANIFOLD

2.0GPM

GENERATOR

OPTIONAL

2400 PSI

GENERATOR

MANIFOLD

OPTIONAL

PLATFORM ROTATE

M

X

X

X

FF

TANK

TO PR1

R1


J1J2

0.035

S-45 JIB BOOM

V2

R2

PLATFORM ROTATE

F F

FF

TO PR2

V1

S-45 JIB BOOM

F F


0.035 0.030

0.030

J2 J1

R1

R2

V1V2


Part No. 72136 S-40 • S-45 6 - 35



6 - 366 - 35

1

2

3

4

5

6

7

8




REV A

Y

S

I

H

PM

G L

NNMM

PPOOSS

QQ

RR

ADAJ

AH

AGAC

AI

AF

AE

TT

WW

UUVV

10 GPM

PRESS.

FILTER

HIGH

FUNCTION

RESERVOIR

DRIVE PUMP

3500PSI

290

PSI

3PSI

3PSI

E

25PSI

PUMP

50PSI

STEERING

AUX. PUMP

2000PSI

0.025

950PSI

X

XP8P

A CYL

B CYL

A VALVE

B VALVE

REAR

LEFT

M1

M3

TRACTION

M7

RIGHT

REAR

M5

FRONT

LEFT

M2

M4

M8

RIGHT

FRONT

M6PSI

250

AB

TANKCP

0.070

67% 33%

0.070 0.052

OIL

COOLER

OPTIONAL

TURNTABLE

TEST

T1

PRESSURE

RQAAZ

SEC

S40- 2600 PSIS45- 2900 PSI

X

REG

W

BB3.5GPM

CC

EE GPM0.6

DD

JGPM0.1

0.6GPM

V

U

T

O

A

PR2PR1

MANIFOLD

FUNCTION

PLATFORM

LEVEL


FF

PL1

GG

PL2

MASTER

SLAVE

BA

RETRACT

PSI1950

N

B

K

F

C

S2S1BOOM

P1

C

EXTEND

2200PSI

P2

HH

D

E

TURNTABLE

ROTATE

PRESS.

TANK

PRIMARYUP/DOWN

BOOM

.030

0.14

0.025

STEER

MANIFOLD

2.0GPM

GENERATOR

OPTIONAL

2400 PSI

GENERATOR

MANIFOLD

OPTIONAL

S-45 JIB BOOM

PLATFORM ROTATE

M

X

X

X

F F

FF


0.035 0.030

0.030

J2 J1

R1

R2

V1V2

TO PR1

R1


J1J2

0.035

S-45 JIB BOOM

V2

R2

PLATFORM ROTATE

F F

FF

TO PR2

V1


Part No. 72136 S-40 • S-45 6 - 37



6 - 386 - 37

March 2008 Section 7 • Repair Procedures

REV A

Part No. 72136 S-40 • S-45 7 - 1

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






Green—used to indicate operationor maintenance information.

Indicates that a specific result is expected afterperforming 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 the Genie S-40 &Genie S-45 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

· Boom in the stowed position

· 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

March 2008Section 7 • Repair Procedures

REV A

7 - 2 S-40 • S-45 Part No. 72136

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 controllerd extend/retract controllere boom controllerf turntable rotate controller

Boom Up/Down ControllerAdjustments


Do not adjust the controllersunless the static battery voltage isabove 12V DC and the alternatoris operating properly with13.6 to 14.5V DC output.

Individual trim potentiometers(trimpots) are used to adjustvarious output signals from thedrive and boom functioncontrollers. The trimpots will beidentified as the following:

• Max out trim potentiometer (max out trimpot)

• High range trim potentiometer (max out trimpot)

• Lo range trim potentiometer (lo range trimpot)

• Dual range trim potentiometer (lo range trimpot)

• Threshold trim potentiometer (threshold trimpot)

• Ramp rate trim potentiometer (ramp rate trimpot)

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 red Emergency Stop button to theon position at both the ground and platformcontrols. Do not start the engine.

Platform Controls

b

c

a

def


REV A

Part No. 72136 S-40 • S-45 7 - 3

3 Open the platform control box lid and locatethe boom up/down controller.

a ramp rate trimpotb lo range trimpotc terminal "R" activates max out ranged (not used)e terminal "X" (not used)f terminal "-" groundg terminal "+" positiveh terminal "A" proportional outputi threshold trimpotj max out trimpot

4 Set the preliminary ramp rate: Turn the ramprate trimpot adjustment screw counterclockwise15 turns or until 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.

7 Set the max out: Press down the foot switch,then move the control handle all the way tothe UP position. Adjust the voltage to 6.5V 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 4.8V DC. Turn the lo 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 the max outtrimpot to achieve a 40 to 44 second cycle time.Turn the max out trimpot adjustment screwclockwise to increase the speed orcounterclockwise to decrease the speed.

11 Start a timer and record how long it takes forthe boom to fully lower. Adjust the lo rangetrimpot to achieve an 50 to 60 second cycletime. Turn the lo range trimpot adjustmentscrew clockwise to increase the speed orcounterclockwise to decrease the speed.

If the function cycle time is notachievable, check the relief valvepressure. See 11-2, ValveAdjustments - Function Manifold.

PLATFORM CONTROLS

a b c d e f g h i j


REV A

7 - 4 S-40 • S-45 Part No. 72136

PLATFORM CONTROLS

Turntable Rotation ControllerAdjustments


Do not adjust the controllersunless the static battery voltage isabove 12V 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 red Emergency Stop button tothe ON position at both the ground andplatform controls. Do not start the engine.

3 Open the platform control box lid and locatethe turntable rotation controller. Refer to theplatform control box illustration, page 7-2.

12 Turn the engine off.

13 Pull out the red 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.

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 ramp rate trimpot toobtain a 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 - Max outCycle time 40 to 44 seconds

Boom down - Lo rangeCycle time 50 to 60 seconds

Ramp rate 3 to 4 seconds


REV A

Part No. 72136 S-40 • S-45 7 - 5

a ramp rate trimpotb lo range trimpotc terminal "R" activates max out ranged (not used)e terminal "X" (not used)f terminal "-" groundg terminal "+" positiveh terminal "A" proportional outputi threshold trimpotj hi range trimpot

4 Set the preliminary ramp rate: Turn the ramprate trimpot adjustment screw counterclockwise15 turns or until you hear a repeated click.

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.

PLATFORM CONTROLS

7 Set the max out: Press down the foot switch,fully retract the boom, then move the controlhandle all the way to the left or right. Adjust thevoltage to 5.7V DC. Turn the max out trimpotadjustment screw clockwise to increase thevoltage or counterclockwise to decrease thevoltage.

Engine should be at normaloperating temperature.

8 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 78 to 83 second cycle time.Turn the max out trimpot adjustment screwclockwise to increase the speed orcounterclockwise to decrease the speed.

If the function cycle time is notachievable, check the relief valvepressure. See 11-2, ValveAdjustments - Function Manifold.

9 Turn the engine off.

10 Pull out the Emergency Stop button tothe on position.

11 Press down the foot switch and then move thecontrol handle all the way to the left or right.Record the maximum voltage reading.

12 Start the engine.

a b c d e f g h i j


REV A

7 - 6 S-40 • S-45 Part No. 72136

PLATFORM CONTROLS

13 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.

14 Set the ramp rate: Turn the ramp rate trimpot toobtain a 5 second ramp speed. Turn the ramprate trimpot clockwise to increase the time orcounterclockwise to decrease the time.

Turntable rotation specifications

Threshold 3.5V DC

Turntable rotation -Max outCycle time 78 to 83 seconds

Ramp rate 5 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.


REV A

Part No. 72136 S-40 • S-45 7 - 7

How to Adjust the HorsepowerLimiter Board

The engine rpm must becorrect before performing thisprocedure. See MaintenanceProcedure B-11, 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.

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 number 2 terminal, and the red(+) lead tothe number 10 terminal.

Horsepower limiter board

a "A" potentiometer maximum voltageoutput to the drive controller in thestowed position

b "B" potentiometer maximum voltageoutput to the drive controller in theboom raised or extended position

c "C" potentiometer reaction rate orhow fast the voltage output reacts tothe change in engine rpm

PLATFORM CONTROLS

a

12V DC or greatergroundengine rpm sensornot usednot usedlow drive speed limit switchnot usednot usednot usedoutput to drive controller

b

a

c


REV A

7 - 8 S-40 • S-45 Part No. 72136


5 Move the engine idle control toggle switch tofoot switch activated high idle (rabbit and footswitch symbol).

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 toggle switch tolow idle (turtle symbol).

8 Press down the foot switch and adjustthe "C" potentiometer to obtain the correctDC voltage reading.

Diesel Models: 0.1V DC

Gasoline/LPG Models: 3.5V DC

9 Move the engine idle control toggle switch tofoot switch activated high idle (rabbit and footswitch symbol).

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 drop.

12 Disconnect the volt meter.

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 of1 foot per second / 30.5 cm per second. Turnthe "B" potentiometer clockwise to increasevoltage or counterclockwise to decreasevoltage.

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/6.8 sec 40 ft/7.8 sec

12.2 m/6.8 sec12.2 m/7.8 sec

Diesel models 40 ft/7.8 sec 40 ft/9.1 sec12.2 m/7.8 sec 12.2 m/9.1 sec

Boom raised or distance: 40ft / 12 mextended 1 foot per secondAll models 30.5 cm per second

PLATFORM CONTROLS


REV A

Part No. 72136 S-40 • S-45 7 - 9

6 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(infinite Ω)

black to white continuity(zero Ω)

1-3Foot Switch

How to Test the Foot SwitchPerform this procedure with thekey switch in the off position.

1 Remove the foot switch cover plate fastenersfrom the platform.

2 Remove the foot switch guard mountingfasteners from the platform.

3 Remove the foot switch mounting fasteners thatattach the foot switch to the foot switch guard.

4 Remove the cover plate from the bottom of thefoot switch to access the foot switch wireterminals.

5 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(infinite Ω)

PLATFORM CONTROLS


REV A

7 - 10 S-40 • S-45 Part No. 72136

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(infinite )


terminal 4 to 5 & 6 no continuity(infinite )


Center position There are no terminal combinationsthat will produce continuity

(infinite )

Right position


terminal 1 to 3, 4, 5 & 6 no continuity(infinite )

terminal 2 to 3, 4, 5 & 6 no continuity(infinite )



terminal 4 to 6 no continuity(infinite )

terminal 5 to 6 no continuity(infinite )

1-4Toggle 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 listed toon right to check for continuity.

PLATFORM CONTROLS

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)


REV A

Part No. 72136 S-40 • S-45 7 - 11

Platform Components

2-1Platform

How to Remove the Platform1 Open the platform control box.

2 Disconnect the foot switch wiring from theterminal strip inside the platform control box.Remove the cable from the machine.

3 Remove the platform control box mountingfasteners. Lower the control box and set itaside.

If your machine is equipped withan airline to platform option, theairline must be disconnected fromthe platform before removal.

4 Raise the boom and place saw horses of amplecapacity under the platform mountingweldment. Lower the boom until the platform isresting on the saw horses just enough tosupport the platform.

Do not rest the entire weight of theboom on the saw horses.

5 Remove the platform mounting fasteners andremove the platform from the machine.

Crushing hazard. The platformcould 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 movementin the event of a hydraulic line failure.

How to Remove theSlave Cylinder

Before cylinder removal isconsidered to correct amalfunction, bleed the slavecylinder to be sure there is noair in the closed loophydraulic circuit.

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 Adjust the platform to a level position.

2 Extend the boom until the slave cylinderbarrel-end pivot pin is accessible.


REV A

7 - 12 S-40 • S-45 Part No. 72136

PLATFORM COMPONENTS

3 Raise the boom slightly and place saw horsesof ample capacity under the platform mountingweldment. Lower the boom until the platform isresting on the saw horses just enough tosupport the platform.

Do not rest the entire weight of theboom on the saw horses.

4 Protect the slave cylinder rod from damage.

S-40 Models:

5 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.


S-45 Models:

6 Tag, disconnect and plug the slave cylinderhoses at the union.

7 Pull the slave cylinder hoses through theplatform rotator.

8 Remove the pin retaining fastener fromthe slave cylinder rod-end pivot pin. Do notremove the pin.

9 Remove the external retaining fastener from thebarrel-end pivot pin.

10 Use a soft metal drift to drive the rod-end pivotpin out.

11 Use a soft metal drift and drive the barrel-endpin out.

12 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 toggle switch up anddown through two platform leveling cycles toremove any air that might be in the system.


REV A

Part No. 72136 S-40 • S-45 7 - 13

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.

S-40 Models:

2 Tag, disconnect and plug the hydraulic hosesfrom the platform rotator. Cap the fittings on therotator.


S-45 Models:

3 Tag and disconnect the hydraulic hoses fromthe "V1" and "V2" ports on the counterbalancevalve manifold located on the platform rotatorand connect them together using a connector.Cap the fittings on the manifold.

4 Support the platform leveling arms and platformmounting weldment with an appropriate liftingdevice, but do not apply any lifting pressure.

All Models:

5 Remove the six mounting bolts from theplatform mounting weldment. Remove thecenter bolt and slide the platform mountingweldment off of the platform rotator.

Crushing hazard. The platformmounting weldment could becomeunbalanced and fall if it is notproperly supported.

6 Support the platform rotator with an appropriatelifting device. Do not apply any lifting pressure.

PLATFORM COMPONENTS


REV A

7 - 14 S-40 • S-45 Part No. 72136

PLATFORM COMPONENTS

7 Support the platform leveling slave cylinder.Protect the cylinder rod from damage.

8 Remove the pin retaining fasteners from boththe slave cylinder rod-end pivot pin, and therotator pivot pin.

9 Use a soft metal drift to drive both pins out, thenremove the platform rotator from the machine.

Crushing hazard. The platformrotator could 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 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.

a top bleed valveb bottom bleed valvec containerd clear hose

2 Move the platform rotate toggle switch to the leftand then to the right through two platformrotation cycles, continue holding the switch tothe right until the platform is fully rotated to theright.

3 Open the top bleed valve, but do not remove it.

4 Move the platform rotate toggle switch to the leftuntil the platform is fully rotated to the left.Continue holding the switch until air stopscoming out of the bleed valve. Close the bleedvalve.

Crushing hazard. Keep clear ofthe platform during rotation.

5 Connect the clear hose to the bottom bleedvalve. Open the bottom bleed valve, but do notremove it.

6 Hold the platform rotate toggle switch to theright until the platform is fully rotated to theright. Continue holding the switch until air stopscoming out of the bleed valve. Close the bleedvalve.

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 full left andinspect the bleed valves for leaks.


REV A

Part No. 72136 S-40 • S-45 7 - 15

3-1Jib Boom

How to Remove the Jib BoomBegin this procedure with theboom in the stowed position.



2 Remove the platform mounting weldment,and the platform rotator. See 2-3, How toRemove the Platform Rotator.

3 From the ground controls, raise the jib boom toa horizontal position.

4 Support the jib boom with a strap from anoverhead crane.

5 Tag, disconnect and plug the hydraulic hosesfrom the jib boom lift cylinder. Cap the fittingson the cylinder.


6 Remove the hose cover, hoses and cables fromthe side of the jib boom and set them aside.

Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.

7 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

8 Remove the pin retaining fasteners from the jibboom lift cylinder barrel-end pivot pin. Do notremove the pin.

9 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

10 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin.

11 Use a soft metal drift to remove the jib boom liftcylinder barrel-end pivot pin, then remove thejib boom cylinder.

Crushing hazard. The jib boomlift cylinder could becomeunbalanced and fall when it isremoved from the machine if it isnot properly attached to theoverhead crane.

12 Remove the pin retaining fasteners from the jibboom pivot pin. Use a soft metal drift to removethe pin, then remove the jib boom from thebellcrank.

Crushing hazard. The jib boomcould become unbalanced and fallwhen it is removed from themachine if it is not properlyattached to the overhead crane.

Jib Boom Components,S-45 Models


REV A

7 - 16 S-40 • S-45 Part No. 72136

3-2Jib Boom Lift Cylinder,S-45 Models

How to Remove the Jib BoomLift Cylinder



1 Raise the jib boom slightly and place blocksunder the platform mounting weldment forsupport. Then lower the jib boom until theplatform is resting on the blocks.

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.


2 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

3 Use a soft metal drift to tap the jib boom liftcylinder rod-end pivot pin half way out. Lowerone of the leveling arms to the ground. Tap thepin the opposite direction and lower the secondleveling arm. Do not remove the pin.

4 Attach a strap from an overhead crane to the jibboom lift cylinder.

5 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the pin.

6 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 could become unbalancedand fall when it is removed fromthe machine if it is not properlysupported.

JIB BOOM COMPONENTS, S-45 MODELS


REV A

Part No. 72136 S-40 • S-45 7 - 17

4-1Cable 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 Cable TrackWhen 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 Open the platform control box and remove theplatform control box mounting fasteners.

2 Disconnect the foot switch wiring from theterminal strip inside the platform control box.Remove the cable from the machine.

Boom Components

S-45 Models:

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.


4 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling cylinder at the unionand connect the hoses from the cylindertogether using a connector.



6 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.

7 Remove the fasteners from the side panel onthe lower cable track, then remove the panel.Pull all of the cables out of the channel.


REV A

7 - 18 S-40 • S-45 Part No. 72136

BOOM COMPONENTS

8 Remove the cable cover on the side of theboom.

9 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 trackcould become unbalanced and fallwhen it is removed from themachine.

10 Remove the hose and cable clamp at theplatform end of the cable track.

11 Attach a lifting strap from an overhead crane tothe cable track.

12 Remove the mounting fasteners from the uppercable track at the platform end of the extensionboom.

13 Remove the cable track mounting fasteners thatattach the lower cable track to the boom.

14 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackcould become unbalanced and fallif it is not properly attached to theoverhead crane.


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 inch drill bit. Repeatthis step for the other end of the 4 link sectionof cable 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.


REV A

Part No. 72136 S-40 • S-45 7 - 19

BOOM COMPONENTS

5 Lift up the hoses and cables and carefullyremove the damaged 4 link section of cabletrack.


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.


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 it may bind duringoperation.

Be sure that the fasteners areinstalled from the inside out so thenuts are on the outside of thecable track.

9 Install the black rollers onto the new section ofcable track.

10 Install cable track onto the machine and operatethe boom extend/retract function through a fullcycle to ensure smooth operation of the newsection of cable track.

4-2Boom

How to Shim the Boom1 Measure each upper and side wear pad.

Replace the pad if it is less than9/16 inch / 14.3 mm thick. If thepad is more than9/16 inch / 14.3 mm thick, performthe following procedure.

2 Measure the bottom wear pad.

Replace the pad if it is less than11/16 inch / 17.5 mm thick (S-40) or9/16 inch / 14.3 mm thick (S-45). Ifthe pad is more than11/16 inch / 17.5 mm thick (S-40) or9/16 inch / 14.3 mm thick (S-45),perform the following 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 could causebinding or scraping.

Always maintain squarenessbetween the outer and inner boomtubes.


REV A

7 - 20 S-40 • S-45 Part No. 72136

BOOM COMPONENTS

How to Remove the BoomBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.


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.


2 Remove the platform rotator and leveling slavecylinder. See 2-3, How to Remove the PlatformRotator.

S-45 Models:

3 Remove the jib boom. See 3-1, How toRemove the Jib Boom.

4 Remove the cable track. See 3-1, How toRemove the Boom Cable Track.


6 Remove the turntable end cover.

7 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 out of the way.

Component damage hazard.When pulling the master cylinderback, be sure not to damage themaster cylinder hoses or fittings.

8 Remove the fasteners from the drive speed limitswitch mounted to the turntable riser at thepivot end of the boom. Do not disconnect thewiring.

9 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


10 Attach an overhead 5 ton / 5,000 kg crane tothe center point of the boom.

11 Attach a similar lifting device to the boom liftcylinder.

12 Place support blocks across the turntableunder the lift cylinder.


REV A

Part No. 72136 S-40 • S-45 7 - 21

13 Remove the pin retaining fastener from theboom lift cylinder rod-end pivot pin. Use a softmetal drift to remove the pin.

Crushing hazard. The boom liftcylinder will fall unless it isproperly supported.

14 Lower the rod end of the boom lift cylinder ontosupport blocks. Protect the cylinder rod fromdamage.

15 Remove the pin retaining fastener from theboom pivot pin.

16 Remove the boom pivot pin with a soft metaldrift. 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 Removethe Boom.

2 Place blocks under the extension cylinder forsupport.

3 Remove the pin retaining fastener from theextension cylinder barrel-end pivot pin at thepivot end of the boom. Use a soft metal drift toremove the pin.

4 Remove and label the wear pads from theplatform end of the boom.

Pay careful attention to thelocation and amount of shimsused with each wear pad.

BOOM COMPONENTS


REV A

7 - 22 S-40 • S-45 Part No. 72136

BOOM COMPONENTS

5 Support and slide the extension tube andextension cylinder out of the boom tube.

Crushing hazard. The extensiontube could become unbalancedand fall when it is removed fromthe primary boom tube if it is notproperly supported.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.

6 Remove the external snap rings from theextension cylinder rod-end pivot pins at theplatform end of the extension tube. Use a softmetal drift to remove the pin.

7 Support and slide the extension cylinder out ofthe base end of the extension tube.

Crushing hazard. The extensioncylinder could become unbalancedand fall when it is removed fromthe boom tube if it is not properlysupported.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.

8 Remove and label the wear pads from theextension cylinder.

Pay careful attention to thelocation and amount of shimsused with each wear pad.

4-3Boom Lift Cylinder

How to Remove the BoomLift Cylinder

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could 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 across the turntableunder the boom lift cylinder.

3 Attach an overhead 5 ton / 5,000 kg crane tothe boom. Do not lift the boom.

4 Support the rod end of the boom lift cylinderwith an appropriate lifting device.


REV A

Part No. 72136 S-40 • S-45 7 - 23

5 Tag, disconnect and plug the boom lift cylinderhydraulic hoses. Cap the fittings on thecylinder.


6 Remove the pin retaining fastener from theboom lift cylinder rod-end pivot pin. Use a softmetal drift to remove the pin. Lower the liftcylinder onto the blocks. Protect the cylinderrod from damage.

Crushing hazard. The lift cylindercould become unbalanced and fallif it is not properly supported.

7 Remove the four mounting fasteners from thelift cylinder barrel-end pivot pin mounting plate.

8 With the lift cylinder being supported by theoverhead crane, pull the cylinder toward theplatform to remove it from the machine.

Crushing hazard. The lift cylindercould 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 Cylinder

The extension cylinder extends and retracts theboom extension tube. The extension cylinder isequipped with counterbalance valves to preventmovement in the event of a hydraulic line failure.

How to Remove theExtension Cylinder

This procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools could cause death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.


1 Extend the boom until the extension cylinderrod-end pivot pins are accessible in theextension tube.

2 Remove the master cylinder. See 4-5, How toRemove the Platform Leveling Master Cylinder.

BOOM COMPONENTS


REV A

7 - 24 S-40 • S-45 Part No. 72136

BOOM COMPONENTS


4 Remove the external snap rings from theextension cylinder rod-end pins (at the platformend). Use a soft metal drift to remove the pins.

5 Remove the turntable end cover.

6 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


7 Remove the barrel-end pivot pin retainingfasteners.

8 Place a rod through the barrel-end pivot pin andtwist to remove the pin.

9 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.


REV A

Part No. 72136 S-40 • S-45 7 - 25

4-5Platform LevelingMaster Cylinder

The master cylinder acts as a pump for the slavecylinder. It is part of the closed circuit hydraulicloop that keeps the platform level through theentire range of boom motion. The master cylinderis located at the base of the boom.

How to Remove the PlatformLeveling Master Cylinder


1 Remove the turntable end cover to access themaster cylinder.

2 Raise the boom until the master cylinderrod-end pivot pin is accessible.

3 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on thecylinder.


4 Attach a lifting strap from an overhead crane tothe lug on the rod end of the master cylinder.

5 Remove the pin retaining fasteners from themaster cylinder barrel-end pivot pin.

6 Place a rod through the barrel-end pivot pin andtwist to remove the pin.

7 Remove the pin retaining fastener from the rod-end pivot pin.

8 Use a soft metal drift to remove the pin.

9 Remove the master cylinder from the machine.

Crushing hazard. The mastercylinder could become unbalancedand fall if it is not properly attachedto the overhead crane.

BOOM COMPONENTS


REV A

7 - 26 S-40 • S-45 Part No. 72136

5-1Turntable Covers

How to Remove aTurntable Cover1 Raise the turntable cover. Support and secure

the open cover with an overhead crane orforklift. 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 fork lift forks.

2 Remove the upper retaining clip from the gasstrut.

3 Gently pry the strut pivot socket off of the ballstud and lower 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.

Turntable Covers

5 Carefully lift and remove the cover fromthe machine.

Bodily injury hazard. Safety decalsare essential to safe machineoperation. Failure to replace allsafety and instructional decalscould result in death or seriousinjury. If a turntable cover must bereplaced, be sure that allappropriate safety andinstructional decals are applied tothe new cover.

Crushing hazard. The turntablecover could become unbalancedand fall if it is not properlysupported and secured to anappropriate lifting device.

Alignment adjustments may benecessary when a new coveris installed.


REV A

Part No. 72136 S-40 • S-45 7 - 27

6-1RPM Adjustment

Refer to Maintenance Procedures, B-11,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 3/8 inch / 9.5 mm gap

Deutz F3L 1011F Engine

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 engineflywheel.

How to Install the Flex Plate1 Install the flex plate onto the engine flywheel

with the raised spline towards the pump.Torque the flex plate mounting bolts to34 ft-lbs / 46 Nm.

2 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave a3/8 inch / 9.5 mm gap between the pumpcoupler and pump end plate.

3 Apply removable thread locking material to thepump coupler set screw. Torque the set screwto 45 ft-lbs / 61 Nm.

4 Install the pump and torque the pump mountingplate fasteners to 34 ft-lbs / 46 Nm.

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

a b c d e

f


REV A

7 - 28 S-40 • S-45 Part No. 72136

6-3Oil Temperature and Oil PressureGauges

The engine oil temperature gauge is an electricalgauge. The engine oil temperature sending unithas limit contacts that are factory set. The contactswill close at approximately 300o F / 149o C. Whenthe contacts close, the engine will shut off toprevent damage and will not start until thetemperature drops below the contact point. Engineoil temperature will be indicated on the gaugewhen the key is ON and the Emergency Stop Buttonis pulled out to the on position.

The engine oil pressure gauge is an electricalgauge. The engine oil pressure sending unit haslimit contacts that are factory set. The contacts willclose at approximately 7 psi / 0.48 bar. When thecontacts close, the engine will shut off to preventdamage. Engine oil pressure will be indicated onthe gauge when the engine is running.

DEUTZ F3L 1011F ENGINE

How to Remove the OilTemperature and Oil PressureGauge Sending Units


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

2 Tag and disconnect the wiring from the desiredsending unit. Remove the sending unit from theengine block.

3 Install the new sending unit. Do not over tighten.

4 Connect the wires to the new sending unit.

Burn hazard. Contact with hotengine fluids or components maycause severe burns

Always use pipe thread sealantwhen installing a sending unit.

Oil temperature sending unit specifications

Torque 8-10 ft-lbs11-14 Nm

Hex size 13/16 inch

Temperature switch point 300° F /149° C

Oil pressure sending unit specifications


Hex size 11/16 inch

Oil pressure switch point 7 psi0.48 bar


REV A

Part No. 72136 S-40 • S-45 7 - 29

7-1RPM Adjustment

Refer to Maintenance Procedures, B-11,Check and Adjust the Engine RPM.

7-2Flex Plate


a pumpb pump shaftc couplerd flex plate with raised splinee flywheelf 1/4 inch / 6.4 mm gap

How to Remove the Flex Plate1 Disconnect the wiring plug at the electronic



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 engineflywheel.



2 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave a1/4 inch / 6.4 mm gap between the pumpcoupler and pump end plate.




a b c d e

f

Perkins 704-30 Engine


REV A

7 - 30 S-40 • S-45 Part No. 72136

7-3Coolant Temperature and OilPressure Gauges

The engine coolant temperature gauge is anelectrical gauge. The engine coolant temperaturesending unit has limit contacts that are factory set.The contacts will close at approximately221o F / 105o C. When the contacts close, theengine will shut off to prevent damage and will notstart until the temperature drops below the contactpoint. Engine coolant temperature will be indicatedon the gauge when the key is on and theEmergency Stop Button is pulled out to the ON

position.

The engine oil pressure gauge is an electricalgauge. The engine oil presure sending unit haslimit contacts that are factory set. The contacts willclose at approximately 4.2 psi / 0.3 bar. When thecontacts close, the engine will shut off to preventdamage. Engine oil pressure will be indicated onthe gauge when the engine is running.

How to Remove the CoolantTemperature and Oil PressureGauge Sending Units







Coolant temperature sending unit specifications


Hex size 7/8 inch

Temperature switch point 221° F / 105° C



Hex size 7/8 inch

Oil pressure switch point 4.2 psi0.3 bar

PERKINS 704-30 ENGINE


REV A

Part No. 72136 S-40 • S-45 7 - 31

Ford LRG-425 EFI Engine

8-1Timing Adjustment

The ignition timing is controlled bythe ECM and can only be adjustedby re-programming the ECM. Iftiming adjustment or service isrequired, please contact GenieIndustries Service Department ORyour local Ford dealer.

8-2Flex Plate


a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 1/16 inch / 1.6mm gap

Flex Plate Removal1 Disconnect the wiring plug at the electronic



3 Carefully pull the pump away from theengine and secure it from moving.


4 Remove the flex plate mounting fasteners,then remove the flex plate from the engine flywheel.



2 Install the pump coupler onto the pump shaftwith the set screw towards the pump. Leave a1/16

inch / 1.59 mm gap between the pump

coupler and pump end plate.




a b c d e

f


REV A

7 - 32 S-40 • S-45 Part No. 72136

8-3Coolant Temperature and OilPressure Gauges

The coolant temperature gauge is an electricalgauge. The coolant temperture sending unit haslimit contacts that are factory set. The contacts willclose at pproximately 230° F / 112° C. When thecontacts close, the engine will shut off to preventdamage and will not start until the temperaturedrops below the contact point. Engine coolanttemperature will be indicated on the gauge whenthe key switch is ON and the Emergency Stopbutton is pulled out to the on position.

The oil pressure gauge is an electrical gauge. Theoil pressure sending unit has limit contacts thatare factory set. The contacts will close atapproximately 8 psi / 0.55 bar. When the contactsclose, the engine will shut off to prevent damage.Engine oil pressure will be indicated on the gaugewhen the engine is running.

How to Remove the CoolantTemperature and Oil PressureGauge Sending Units



2 Remove the 2 engine pivot plate retaining bolts.Swing the engine pivot plate away from themachine to access the water temperature andoil pressure sending units.

FORD LRG-425 EFI ENGINE

3 Locate the oil pressure and coolant temperaturesending units.

a oil pressure sending unitb coolant temperature sending unit

(hidded from view)






Coolant temperature sending unit specifications


Hex size 13/16 inch

Temperature switch point 230° F / 112° C



Hex size 11/16 inch

Oil pressure switch point 8 psi0.55 bar

b

a


REV A

Part No. 72136 S-40 • S-45 7 - 33

Ground Controls

9-1Control 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 could result in death orserious injury. Remove all rings,watches and other jewelry.

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)

a terminal no. 87a - N.C.b terminal no. 85 - coil negative (-)c terminal no. 30 - commond terminal no. 86 - coil positive (+)e terminal no. 87 - N.O.

Control Relay Schematic - without resistor

Control Relay Schematic - with resistor


REV A

7 - 34 S-40 • S-45 Part No. 72136

GROUND CONTROLS

9-2Toggle Switches

See 1-5, Toggle Switches.

9-3Wago® Components

How to Remove a Wago®

ComponentElectrocution hazard. Contact withelectrically charged circuits couldcause death or serious injury.Remove all rings, watches andother jewelry.

Wago® tools are available fromthe Genie Service PartsDepartment (Genie part number33996).

1 Label the wiring from the component to beremoved.

2 Use a small screwdriver to push in and releasethe wire from the component.

3 Locate the removal tab on the bottom or topof the component.

4 Use a small screwdriver to gently pry up on thetab of the component and remove it.

9-4Engine Fault Codes -Gasoline/LPG Models

How to Retrieve Engine FaultCodesWhen a engine malfunction is detected by theElectronic Control Module (ECM), a fault code isrecorded and the check engine light will turn ON atthe ground and platform controls. Use the followingprocedure to retrieve the engine fault code todetermine the engine malfunction.

Perform this procedure with thekey switch in the off position.

1 Open the ground controls side turntable cover.

2 Open the ground control box and locate the run/test toggle switch inside of the ground controlbox.

3 Pull out the ground controls red EmergencyStop button to the on position.

4 Hold the run/test toggle switch to the testposition and turn the key switch to the groundcontrols position.

Result: The check engine light should turn on.The check engine light should begin to blink.


REV A

Part No. 72136 S-40 • S-45 7 - 35

5 Continue to hold the run/test toggle switch in thetest position and count the blinks.

Fault codes are two digits. Thecheck engine light will blink thefirst digit of a two digit code thenwill pause for 1.2 seconds andthen blink the second digit. Forexample: the check engine lightblinks 5 consecutive times thenpauses for 1.2 seconds and thenblinks 1 time. That would indicatecode 51. The ECM is able to storeup to six individual fault codes.There will be a 2.4 second pausebetween codes.

6 Refer to the Troubleshooting Section fordefinition of engine fault codes.

Once a fault code has beenretrieved and the repair has beencompleted, the ECM memory mustbe reset to clear the fault codefrom the ECM. See 9-4, How toClear Engine Fault Codes.

How to Clear Engine Fault Codesfrom the ECM

Perform this procedure with theengine off and the key switch inthe off position.

1 Open the engine side turntable cover and locatethe battery.

2 Disconnect the negative battery cable from thebattery for a minimum of 20 minutes.

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

3 Connect the negative battery cable to thebattery.

GROUND CONTROLS


REV A

7 - 36 S-40 • S-45 Part No. 72136

Hydraulic Pumps

10-1Lift/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.See 10-2, How to Prime thePump.

open closed


REV A

Part No. 72136 S-40 • S-45 7 - 37

HYDRAULIC PUMPS

10-2Drive 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

2 Close the two hydraulic tank valves located atthe hydraulic tank.


3 Tag and disconnect and plug the hydraulichoses from the drive and lift/steer pumps. Capthe fittings on the pumps.


4 Support the pumps with a suitable lifting deviceand remove the two drive pump mountingfasteners.


REV A

7 - 38 S-40 • S-45 Part No. 72136

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.

Before installing the pump, verifyproper pump coupler spacing.Refer to the appropriate flex plateinstallation instructions for yourengine.

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.

1 Connect a 0 to 600 psi / 0 to 41 bar pressuregauge to the test port on the drive pump.

2 Gasoline/LPG models: Close the valve on theLPG tank, then disconnect the hose from thetank. Move the fuel select toggle switch to theLPG position.

Deutz Diesel models: Hold the manual fuelshutoff valve clockwise to the closed position.

a

HYDRAULIC PUMPS

a manual fuel shutoff valve

Perkins Diesel models:Disconnect the engine wiring harness from thefuel solenoid at the injector pump.

3 Crank the engine with the starter motor for15 seconds, wait 15 seconds, then crank theengine an additional 15 seconds or until thepressure reaches 250 psi / 17.2 bar.

4 Gasoline/LPG models:Connect the LPG hose to the LPG tank andopen the valve on the tank.Perkins Diesel models:Connect the engine wiring harness to the fuelsolenoid.

5 Deutz Diesel Models:Release the manual fuel shut off valve.

6 Start the engine from the ground controls andcheck for hydraulic leaks.


REV A

Part No. 72136 S-40 • S-45 7 - 39


12345678901234567123456789012345671234567890123456712345678901234567123456789012345671234567890123456712345678901234567


REV B

7 - 40 S-40 • S-45 Part No. 72136

11-1Function 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 DO3 valve ........................ A ....... Turntable rotate left/right .......................30-35 in-lbs / 3-4 Nm

2 3 position 4 way DO3 valve ........................ B ....... Boom up/down ......................................30-35 in-lbs / 3-4 Nm

3 3 position 4 way DO3 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, 1950 psi / 134 bar .................. E ....... Boom extend ..................................... 25-30 ft-lbs / 34-41 Nm

6 Relief valve, 2200 psi / 152 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 overflowingthe 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 overflowingthe 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 overflowingthe proportional valve) ...................... 10-12 ft-lbs / 14-16 Nm

10 Flow regulator valve, 0.1 gpm / 0.4 L/min ... J ....... Bleeds off differentialsensing valve 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 Orifice - Plug, 0.140 inch / 3.6 mm ............. L ....... Boom extend/retract circuit

13 Solenoid valve - N.C. Poppet ..................... M....... Boom extend/retract .......................... 25-30 ft-lbs / 34-41 Nm

14 Check valve ................................................ N ....... Differential sensing circuit,boom up/down .................................. 11-13 ft-lbs / 15-18 Nm

This list continues. Please turn the page

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

SAE No. 6 1/4 18 ft-lbs / 24 Nm

SAE No. 8 5/16 50 ft-lbs / 68 Nm

Valve Coil ResistanceSpecifications

3 position 4 way directional valve, 10V 2 to 5Ω(schematic items A, B and C)

Proportional solenoid valve, 10V 7.5 to 10.5Ω(schematic item M)

Manifolds


REV B

Part No. 72136 S-40 • S-45 7 - 41

MANIFOLDS


REV B

7 - 42 S-40 • S-45 Part No. 72136

MANIFOLDS

Function Manifold Components, continued


15 Check valve ................................................. O ..... Differential sensing circuit,turntable rotate left/right .................... 11-13 ft-lbs / 15-18 Nm

16 Proportional solenoid valve ......................... P ...... Boom up/down .................................. 10-12 ft-lbs / 14-16 Nm

17 Check valve ................................................. Q ..... Differential sensing circuit,platform level up ............................... 11-13 ft-lbs / 15-18 Nm

18 Check valve ................................................. R ..... Differential sensing circuit,platform level down ........................... 11-13 ft-lbs / 15-18 Nm

19 Proportional solenoid valve ......................... S ...... Turntable rotate left/right ................... 10-12 ft-lbs / 14-16 Nm

20 Solenoid valve - N.O. Poppet ...................... T ...... Platform level up ............................... 25-30 ft-lbs / 34-41 Nm

21 Flow regulator valve, 0.6 gpm / 2.3 L/min .... U ..... Platform level circuit .......................... 10-12 ft-lbs / 14-16 Nm

22 Solenoid valve - N.O. Poppet ...................... V ...... Platform level down .......................... 25-30 ft-lbs / 34-41 Nm

23 Differential sensing valve ............................. W ..... Pilot to close, flow directional valve .. 10-12 ft-lbs / 14-16 Nm

24 Relief valve, 2600 psi / 180 bar (S-40) ........ X ...... System relief ..................................... 35-40 ft-lbs / 47-54 Nm24 Relief valve, 2900 psi / 200 bar (S-45) ........ X ...... System relief ..................................... 35-40 ft-lbs / 47-54 Nm

25 Diagnostic nipple ......................................... Y ...... Testing

26 Check valve ................................................. Z ...... Differential sensing circuitPlatform rotate left ............................. 11-13 ft-lbs / 15-18 Nm

27 Check valve ................................................. AA ... Differential sensing circuitPlatform rotate right .......................... 11-13 ft-lbs / 15-18 Nm

28 Priority flow regulator valve, ......................... BB ... Steering ............................................. 10-12 ft-lbs / 14-16 Nm3.5 gpm / 13.25 L/min, oscillate models2.0 gpm / 7.6 L/min, non-oscillate models

29 Solenoid valve - N.O. Poppet ..................... CC ... Platform rotate left ............................. 25-30 ft-lbs / 34-41 Nm

30 Solenoid valve - N.O. Poppet ..................... DD ... Platform rotate right .......................... 25-30 ft-lbs / 34-41 Nm

31 Flow regulator valve, 0.6 gpm / 2.27 l/min ... EE ... Platform rotate .................................. 10-12 ft-lbs / 14-16 Nm

32 Counterbalance valve .................................. FF .... Platform level up ............................... 35-40 ft-lbs / 47-54 Nm

33 Counterbalance valve .................................. GG .. Platform level down .......................... 35-40 ft-lbs / 47-54 Nm

34 Check valve ................................................. HH ... Boom extend/retract circuit ............... 11-13 ft-lbs / 15-18 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


Proportional solenoid valve, 12V 4.7 to 6.5Ω(schematic items P and S)

Normally open poppet valve 4 to 7Ω(schematic item T, V, CC and DD)


REV B

Part No. 72136 S-40 • S-45 7 - 43

MANIFOLDS


REV B

7 - 44 S-40 • S-45 Part No. 72136

MANIFOLDS

11-2Valve 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 (index 25) 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.

System relief valve specifications

PressureS-40 2600 psi

179 barS-45 2900 psi

200 bar

4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap(index 24, function manifold).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.

Tip-over hazard. Do not adjustthe relief valves higher thanspecified.

6 Repeat steps 2 through 5 and check the reliefvalve pressure.

How to Adjust the Boom DownRelief Valve




3 Hold the function enable switch to the high rpm(rabbit symbol) side and activate and hold theboom down toggle switch with the boom fullylowered. Observe the pressure reading on thepressure gauge.

Boom down relief valve specifications

Pressure 2200 psi152 bar


5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then install the reliefvalve cap.


6 Repeat steps 2 through 5 and check the reliefvalve pressure.


REV B

Part No. 72136 S-40 • S-45 7 - 45

How to Adjust the Boom ExtendRelief Valve




3 Hold the function enable switch to the high rpm(rabbit symbol) side and activate and hold theextend switch with the boom fully extended.Observe the pressure reading on the pressuregauge.

Boom extend relief valve specifications



5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then install the reliefvalve cap.


6 Repeat steps 2 through 5 to confirm relief valvepressure.

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 11-1, 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 couldresult in death or serious injury.Use extreme caution whenoverriding a machine function.Identify the direction of machinemovement before overriding avalve.

MANIFOLDS


REV B

7 - 46 S-40 • S-45 Part No. 72136

MANIFOLDS

11-3Turntable 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 .......... II ........... Turntable rotation brake release ....... 10-13 ft-lbs / 14-18 Nm

2 Counterbalance valve ........................ JJ .......... Turntable rotate right ........................ 35-40 ft-lbs / 47-54 Nm

3 Counterbalance valve ........................ KK ......... Turntable rotate left ........................... 35-40 ft-lbs / 47-54 Nm

4 Orifice plug, 0.030 inch / 0.76 mm ..... LL ......... Brake circuit




SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

I I

JJ

KK

LL


REV B

Part No. 72136 S-40 • S-45 7 - 47


123456789012345678901234567890123456789012345678901234567890123456789012345678901234567890123456789012345678901234567890123456789012345678901234567890123456789012345678901234567890


REV B

7 - 48 S-40 • S-45 Part No. 72136

MANIFOLDS

11-4Oscillate 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 ..... MM ....... Differential sensing circuit

2 Differential sensing valve .................. NN ........ Differential sensing ........................... 10-12 ft-lbs / 14-16 Nm

3 Check valve ....................................... OO ........ Oscillate check - left .......................... 35-40 ft-lbs / 47-54 Nm

4 Pilot operated unloader valve,950 psi / 65 bar .................................. PP ......... Sequencing ....................................... 10-12 ft-lbs / 14-16 Nm

5 Shuttle valve, 2 position 3 way ......... QQ ........ Pilot ................................................... 10-12 ft-lbs / 14-16 Nm

6 Check valve ....................................... RR ........ Oscillate check - right ....................... 35-40 ft-lbs / 47-54 Nm

7 Piston ................................................................ Check valve circuit(the piston is located between index numbers 3 and 6)

8 Shuttle valve, 2 position 3 way .......... SS ......... Unloading .......................................... 35-40 ft-lbs / 47-54 Nm

9 Diagnostic nipple .............................................. Testing




SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm


REV B

Part No. 72136 S-40 • S-45 7 - 49

11-5Valve Adjustments -Oscillate Manifold

How to Adjust the OscillateSequencing Valve Pressure


1 Connect a 0 to 2000 psi / 0 to 138 bar pressuregauge to the diagnostic nipple (index 9) locatedon the oscillate manifold.


2 Remove the chassis cover from the non-steerend of the drive chassis.

3 Disconnect the directional valve linkage, byremoving the clevis yoke from the drivechassis.


5 With the engine running, manually activate thevalve and observe the pressure reading on thepressure gauge.

Sequencing valve specifications


6 Turn the engine off. Hold the unloader valvewith a wrench and remove the cap (index 4).

7 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwiseto decrease the pressure. Install the valve cap.

Tip-over hazard. Do not adjust therelief valve higher than specified.

8 Repeat steps 3 through 6 and manually activatethe valve to confirm the valve pressure.

9 Turn the engine off, remove thepressure gauge and assemble the directionalvalve linkage.

10 Install the cover on the non-steer end of thedrive chassis.

MANIFOLDS


REV B

7 - 50 S-40 • S-45 Part No. 72136

MANIFOLDS

11-6Directional 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


REV B

Part No. 72136 S-40 • S-45 7 - 51

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.

Tip-over hazard. Failure toperform this procedure on a levelfloor will compromise the stabilityof the machine and could result inthe machine tipping over.

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 side plates at the non-steer end. Checkto be sure the drive 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


REV B

7 - 52 S-40 • S-45 Part No. 72136

MANIFOLDS

11-7Steer Manifold Components, Oscillating Models

The steer manifold is mounted underneath the function manifold.


1 Solenoid valve, 3 position 4 way ....... TT ......... Steer left/right ........................................30-35 in-lbs / 3-4 Nm

2 Check valve ....................................... UU ........ Priority flow regulator circuit .............. 10-12 ft-lbs / 14-16 Nm

3 Orifice plug, 0.025 inch / 0.64 mm ..... VV ......... Priority flow regulator circuit

4 Priority flow regulator valve,2 gpm / 7.6 L/min ............................... WW....... Regulates flow to oscillate manifold... 10-12 ft-lbs / 14-16 Nm


Description Measurement

Solenoid valve, 3 position 4 way, 10V 4.5 to 7.5Ω(schematic item TT)

TT

UU

VV

WW


REV B

Part No. 72136 S-40 • S-45 7 - 53

11-8Steer Manifold Components, Non-oscillating Models

The steer manifold is located underneath the function manifold.

Index SchematicNo. Description Item Function

1 3 position 4 way DO3 valve ............... TT ......... Steer left/right ........................................30-35 in-lbs / 3-4 Nm

TT

MANIFOLDS


REV B

7 - 54 S-40 • S-45 Part No. 72136

MANIFOLDS



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

11-92WD Drive Manifold Components

The drive manifold is mounted inside the drive chassis at the non-steer end.


1 Relief valve, 250 psi / 17 bar ............. XX ......... Charge pressure circuit .....................10-12 ft-lbs / 14-16 Nm

2 Shuttle valve, 3 position 3 way .......... YY ......... 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

3 Orifice plug, 0.070 in / 1.8 mm .......... ZZ ......... Drive circuit

4 Flow divider/combiner valve .............. AB ......... Controls flow to drive motorsin forward and reverse ......................25-30 ft-lbs / 34-41 Nm



REV B

Part No. 72136 S-40 • S-45 7 - 55

11-10Valve Adjustments, 2WDDrive Manifold

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi / 0 to 40 bar pressure

gauge to the diagnostic nipple (index 5) locatedon the drive manifold.


3 Drive the machine slowly in either direction andobserve the pressure reading on the pressuregauge.

Charge Pressure Relief valve specifications


4 Turn the engine off. Hold the charge pressurerelief valve with a wrench and remove thecap (index 1).


6 Start the engine from the platform controls.Drive the machine in either direction andrecheck the valve pressure.

7 Turn the engine off. Remove thepressure gauge.

MANIFOLDS


REV B

7 - 56 S-40 • S-45 Part No. 72136

MANIFOLDS

11-114WD Drive Manifold Components

The drive manifold is mounted inside the drive chassis at the non-steer end.


1 Flow divider/combiner valve .............. AC ........ Controls flow to flowdivider/combiner valves 4 and 5 ....... 25-30 ft-lbs / 34-41 Nm

2 Relief valve, 250 psi / 17 bar ............. AD ........ Charge pressure circuit ..................... 10-12 ft-lbs / 14-16 Nm

3 Orifice plug, 0.052 inch / 1.32 mm ..... AE ......... Front drive motor circuit

4 Flow divider/combiner valve .............. AF ......... Controls flow to steer enddrive motors in forwardand reverse ....................................... 25-30 ft-lbs / 34-41 Nm

5 Flow divider/combiner valve .............. AG ........ Controls flow to non-steer enddrive motors in forwardand reverse ....................................... 25-30 ft-lbs / 34-41 Nm

6 Orifice plug, 0.070 in / 1.8 mm .......... AH ........ Rear drive motor circuit

7 Orifice plug, 0.070 in / 1.8 mm .......... AI .......... Equalizes pressure on both sidesof flow divider combiner valveIndex no. 1

8 Shuttle valve, 3 position 3 way .......... AJ ......... 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




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


REV B

Part No. 72136 S-40 • S-45 7 - 57

MANIFOLDS


REV B

7 - 58 S-40 • S-45 Part No. 72136

MANIFOLDS

11-12Valve Adjustments, 4WDDrive Manifold

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi / 0 to 41 bar pressure

gauge to the diagnostic nipple (index 9) locatedon the drive manifold.


3 Drive the machine slowly in either direction andobserve the pressure reading on the pressuregauge.

Charge Pressure Relief valve specifications

Pressure 250 psi17.2 bar

4 Turn the engine off. Hold the charge pressurerelief valve with a wrench and remove thecap (index 2).


6 Start the engine from the platform controls.Drive the machine in either direction andrecheck the valve pressure.

7 Turn the engine off. Remove thepressure gauge.


REV B

Part No. 72136 S-40 • S-45 7 - 59

11-13Jib Boom / Platform Rotate Manifold Components, S-45 Models

(before serial number 5593)

The jib boom/platform rotate manifold is mounted on the platform end of the boom.


1 2 position 3 way valve ....................... AM ........ Platform rotate select .......................... 8-10 ft-lbs / 11-14 Nm

2 Orifice Disc, 0.030 / 0.762 mm .......... AN ........ Platform rotate select .............................................................

AN

AN

AM

AM

1

2

1 2

123456789012345678901234567890121234567890123451234567890123456789012345678901212345678901234512345678901234567890123456789012123456789012345

Valve Coil ResistanceSpecification

3 position 4 way solenoid valve, 12V 4.5 to 7.5Ω(schematic item AM)


REV B

7 - 60 S-40 • S-45 Part No. 72136

11-14Jib Boom / Platform Rotate Manifold Components, S-45 Models(after serial number 5592)

The jib boom/platform rotate manifold is mounted on the platform end of the boom.


1 2 position 3 way valve ....................... AC ........ Platform rotate select .......................... 8-10 ft-lbs / 11-14 Nm

1 1

AC

AC

Valve Coil ResistanceSpecification

2 position 3 way solenoid valve, 12V 4.5 to 7.5Ω(schematic item AC)

MANIFOLDS


REV B

Part No. 72136 S-40 • S-45 7 - 61

123456789012345678123456789012345678123456789012345678123456789012345678123456789012345678123456789012345678123456789012345678123456789012345678123456789012345678123456789012345678



REV A

7 - 62 S-40 • S-45 Part No. 72136

Fuel and Hydraulic Tanks

12-1Fuel Tank

How to Remove the Fuel TankExplosion and fire hazard. Enginefuels are combustible. Remove thefuel tank in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Explosion and fire 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.

Diesel models: Disconnect, drain and plug thesupply and return fuel hoses. Cap the fuelreturn fitting on the fuel tank.

Steel tank:

4 Remove the retaining fasteners from the fueltank hold down straps. Remove the straps fromthe fuel tank.

Plastic tanks:

5 Remove the fuel tank mounting fasteners

6 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.

7 Remove the fuel tank from the machine.

Crushing hazard. The fuel tankcould become unbalanced and fallif it is not properly supported andsecured to the overhead crane.

Clean the fuel tank and inspectfor rust and corrosion beforeinstalling.


REV A

Part No. 72136 S-40 • S-45 7 - 63

FUEL AND HYDRAULIC TANKS

12-2Hydraulic 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 hoses and has an external returnfilter equipped 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 12-1, How toRemove the Fuel Tank.

2 Close the two hydraulic shutoff valves locatedat the hydraulic tank.


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 thehold down straps from the hydraulic tank.

open closed


REV A

7 - 64 S-40 • S-45 Part No. 72136


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 hydraulictank could become unbalancedand fall if it is not properlysupported and secured to theoverhead 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 pipe threadsealant on the threads.

14 Install the drain plug using pipe thread sealanton the 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.


19 Open the hydraulic tank shutoff valves.

Component damage hazard.Be sure to open the two hydraulictank shutoff valves and prime thepump after installing the hydraulictank.

Always use pipe thread sealantwhen installing the drain plug andstrainers.

Use only Rykon MV equivalenthydraulic fluid.

Hydraulic system

Hydraulic tank capacity 45 gallons170 liters

Hydraulic system 55 gallonscapacity (including tank) 208 liters

Hydraulic fluid Rykon MV equivalent


REV A

Part No. 72136 S-40 • S-45 7 - 65

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.

1 Connect a 0 to 600 psi / 0 to 41 bar pressuregauge to the diagnostic nipple on the drivepump.

2 Gasoline/LPG models: Close the valve on theLPG tank, then disconnect the hose from thetank. Move the fuel select toggle switch to theLPG position.

Deutz Diesel models: Hold the manual fuelshutoff valve clockwise to the closed position.

a manual fuel shutoff valve

Perkins Diesel models:Disconnect the engine wiring harness from thefuel solenoid at the injector pump.

3 Crank the engine with the starter motor for15 seconds, wait 15 seconds, then crank theengine an additional 15 seconds or until thepressure reaches 250 psi / 17.2 bar.

4 Gasoline/LPG models:Connect the LPG hose to the LPG tank andopen the valve on the tank.Perkins Diesel models:Connect the engine wiring harness to the fuelsolenoid.

5 Deutz Diesel Models:Release the manual fuel shut off valve.

6 Start the engine from the ground controls andcheck for hydraulic leaks.

a



REV A

7 - 66 S-40 • S-45 Part No. 72136

13-1Rotation Hydraulic Motor

How to Remove the RotationHydraulic Motor


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

Unlocked position

Locked position

Turntable Rotation Components

2 Tag, disconnect and plug the hydraulic hosesfrom the motor, brake and manifold. Cap thefittings on the motor, brake and manifold.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. 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 drive hub mounting boltse drive hub

ba

d

e

c


REV A

Part No. 72136 S-40 • S-45 7 - 67

How to Remove the TurntableRotation Brake or Drive Hub1 Secure the turntable from rotating with the

turntable rotation lock pin.

unlocked locked

2 Remove the motor, See 13-1, How to Removethe Rotation Hydraulic Motor.


a motor/brake mounting boltsb motorc braked drive hub mounting boltse drive hub

3 Remove the drive hub mounting bolts, and thenuse an appropriate lifting device to remove thedrive hub from the machine.

Crushing hazard. The turntablerotate torque hub could becomeunbalanced and fall when it isremoved from the machine if it isnot properly supported.

4 Install the drive hub. Torque the drive hubmounting bolts to 180 ft-lbs / 244 Nm.

5 Install the brake, then motor onto the drive hub.Torque the brake/motor mounting bolts to75 ft-lbs / 102 Nm.

Turntable rotate drive hub

Capacity 8 fluid ounces0.24 liters


TURNTABLE ROTATION COMPONENTS

ba

d

e

c


REV B

7 - 68 S-40 • S-45 Part No. 72136

2 Loosen the wheel lug nuts. Do notremove them.

3 Block the non-steering wheels, and center alifting jack of ample capacity under the steeringaxle.

4 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.

5 Remove the lug nuts. Remove the tire andwheel assembly.

6 Remove the pin retaining fasteners from theyoke pivot pins.

7 Support and secure the yoke/hub assembly to alifting jack.

8 Use a slide hammer to remove the upper yokepivot pin.

9 Use a soft metal drift to drive the lower yokepivot pin down and out.

Crushing hazard. The yoke/hubassembly may becomeunbalanced and fall when the yokepivot pins are removed if it is notproperly supported and secured tothe lifting jack.

Torque specifications

Lug nut torque, dry 170 ft-lbs230 Nm

Lug nut torque, lubricated 130 ft-lbs176 Nm






2WD Steering Axle Components

14-1Yoke and Hub

How to Remove the Yokeand Hub1 Remove the pin retaining fasteners from the

steering cylinder and tie rod clevis pins.Remove the pins.

Always use a new cotter pin wheninstalling a clevis pin.

a tie rodb axlec yoke pivot pind yokee hubf pivot ping steering cylinder

a b

e

d

fg

c

f


REV B

Part No. 72136 S-40 • S-45 7 - 69

2WD STEERING AXLE COMPONENTS

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 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 158 ft-lbs / 214 Nm toseat the bearing.

8 Loosen the slotted nut, then re-tighten to35 ft-lbs / 47 Nm.

9 Install a new cotter pin. Bend the cotter pinto lock it.


10 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts.









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 approximately6 inches/ 15 cm and place blocks under thechassis 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.

Always install a new bearing sealwhen removing a hub.


REV A

7 - 70 S-40 • S-45 Part No. 72136


14-2Steering 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 from thesteering cylinder clevis pins.

3 Remove the clevis pins from the steer cylinder.


4 Remove the steering cylinder from the machine.


REV A

Part No. 72136 S-40 • S-45 7 - 71

14-3Tie Rod

How to Remove the Tie Rod1 Remove the cotter pins from the clevis pins at

each end of the tie rod, then remove the clevispins.


2 Remove the tie rod.

How to Perform the Toe-inAdjustment(before serial number 3536)

Perform this procedure on afirm, level surface. Block thenon-steering tires and be surethat the machine is in thestowed position.

Machines manufactured afterserial number 3535 have non-adjustable tie-rods.

1 Straighten the steer wheels.

2 Measure the steer tires, front to front and backto back, using a measuring fixture.



5 Loosen the jam nut on the adjustable endof the tie rod.

6 Remove the pin retaining fasteners, thenremove the pivot pin from the adjustable end ofthe tie rod.

7 Slide the tie rod off the yoke and adjust it byturning the end.

One half turn on the adjustableend equals approximately1/8 inch / 6.4 mm change in thefront and rear measurements.

8 Slide the tie rod onto the yoke. Install thepivot pin, then install the retaining fasteners.

9 Tighten the jam nut against the tie rod.

10 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



REV B

7 - 72 S-40 • S-45 Part No. 72136

2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on thedrive motor.


3 Loosen the wheel lug nuts. Do notremove them.



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 drive huband then remove the drive motor from themachine.

10 Remove the pin retaining fasteners from theupper and lower yoke pivot pins.

11 Support and secure the yoke/drive hubassembly to a lifting jack.

12 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.

4WD Steering Axle Components

15-1Yoke 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 drive hub can beremoved.


1 Remove the pin retaining fasteners from boththe steering cylinder and the tie rod clevis pins.Remove the pins.


a oscillate cylinderb yoke pivot pinc drive hubd yokee pivot pinf steer cylinderg tie rod

a

b

c

defg


REV B

Part No. 72136 S-40 • S-45 7 - 73


13 Place the yoke/drive hub assembly on a flatsurface with the drive hub facing down.

14 Remove the drive hub mounting fasteners thatattach the yoke to the drive hub. Remove theyoke weldment from the drive hub.

Replace the thrust washer wheninstalling the yoke/drive hubassembly onto the axle.














15-2Steering Cylinders

How to Remove aSteering CylinderThis procedure is the same as the 2WD procedure.See 14-2,How to Remove a Steering Cylinder.

15-3Tie Rod

How to Remove the Tie RodThis procedure is the same as the 2WD procedure.See 14-3,How to Remove the Tie Rod.

How to Perform the Toe-inAdjustment(before serial number 3536)This procedure is the same as the 2WD procedure.See 14-3,How to Perform the Toe-in Adjustment.


REV B

7 - 74 S-40 • S-45 Part No. 72136

16-1Oscillating 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 hose failure.

How to Remove an OscillatingAxle Cylinder

Bodily injury hazard. Thisprocedure requires specific repairskills and a suitable workshop.Attempting this procedure withoutthese skills and tools could resultin death or serious injury andsignificant component damage.Dealer service is stronglyrecommended.

Perform this procedure on a firm,level surface with the boom inthe stowed position.


1 Rotate the turntable until the boom is betweenthe steer tires.

Oscillating Axle Components

2 Remove the fasteners from drive chassis coverat the steer end. Remove the cover.

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.

7 Remove the cylinder from the machine.

Crushing hazard. The oscillatecylinder could become unbalancedand fall when it is removed fromthe machine if it is not properlyattached to the overhead crane.

123456789012123456789012123456789012123456789012123456789012REV A


REV B

Part No. 72136 S-40 • S-45 7 - 75

17-1Drive 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 the cover on thenon-steer axle. Remove the cover.

Non-steering Axle Components

2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on thedrive motor.


3 Remove the drive motor mounting fasteners.

4 Slide the drive motor shaft out of the brake andremove the drive motor from the machine.


Drive motor mounting bolts, dry 75 ft-lbs 102 Nm



REV B

7 - 76 S-40 • S-45 Part No. 72136

NON-STEERING AXLE COMPONENTS

17-2Drive Hub

How to Remove aDrive Hub


1 Remove the drive motor. See 17-1, How toRemove a Drive Motor.

2 Tag, disconnect and plug the hydraulic hosefrom the brake.

3 Loosen the wheel lug nuts. Do not removethem.

3 Block the steering wheels, and center a liftingjack of ample capacity under the non-steeringaxle.


5 Remove the wheel lug nuts, then the tire andwheel assembly.

6 Place a second lifting jack under the drive hubfor support and secure the drive hub to thelifting jack.

7 Remove the drive hub mounting bolts thatattach the drive hub to the chassis. Remove thedrive hub.

Crushing hazard. The drive hubmay become unbalanced and fallif it is not properly supported andsecured to the lifting jack.















REV B

Part No. 72136 S-40 • S-45 7 - 77

17-3Wheel Brake

How to Remove aWheel Brake


1 Remove the drive motor. See 17-1, How toRemove a Drive Motor.

2 Tag, disconnect and plug the hydraulic hosefrom the brake.


3 Remove the brake from the machine.

NON-STEERING AXLE COMPONENTS

Dis

trib

ute

d B

y:

California Proposition 65

WARNINGThe exhaust from this product contains chemicals

known to the State of California to cause cancer,

birth defects or other reproductive harm.

Genie North America

Genie Australia Pty Ltd.

Genie China

Genie Malaysia

Genie Japan

Genie Korea

Genie Brasil

Genie Holland

Phone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Phone +61 7 3375 1660

Fax +61 7 3375 1002

Phone +86 21 53852570

Fax +86 21 53852569

Phone +65 98 480 775

Fax +65 67 533 544

Phone +81 3 3453 6082

Fax +81 3 3453 6083

Phone +82 25 587 267

Fax +82 25 583 910

Phone +55 11 41 665 755

Fax +55 11 41 665 754

Phone +31 183 581 102

Fax +31 183 581 566

Genie Scandinavia

Genie France

Genie Iberica

Genie Germany

Genie U.K.

Genie Mexico City

Phone +46 31 575100

Fax +

Phone +33 (0)2 37 26 09 99

Fax +33 (0)2 37 26 09 98

Phone +34 93 579 5042

Fax +34 93 579 5059

Phone 0800 180 9017

Fax +49 422 149 1820

Phone +44 (0)1476 584333

Fax +44 (0)1476 584334

Phone +52 55 5666 5242

Fax +52 55 5666 3241

46 31 579020

Phone +49 422 149 1818

Service Manual - Manuals - Geniemanuals.gogenielift.com/Parts And Service...

Documents

Transcript of Service Manual - Manuals - Geniemanuals.gogenielift.com/Parts And Service...