Ford LSG to LRG Engine Conversion Supplement
Contents
1. LO GRN 2 D BLU RED 3 B 29 GRN 5 R a WHT 1 P REDS BLK 5 Q 56 N ui P 2 R I DRIVE ENABLE R BLU WHT 3 8 Y WHT BLK 1 WHT BLK 31 E H gt 8 T E WHT RED 1 WHT RED 32 E H n 5 8 an BLU BLK 1 B BLU BLK 37 E H BLU 1 BLU 36 E H 8 Se Qi 5 m n Poo 7 9 Z ORG 1 WHT 6 GRN 6 MIR hi E WHT 7 BLK 7 ERN 2 32 este 0026 a 5 WHT RED 3 E WHT BLK 3 A WHT 3 WHT M m j a WHT 4 RIGHT WHT BLK 5 TURNTABLE ROTATE 4 LEFT 14 WHT BLK 4 gt sj ii EC S Z o EH T 8 a a 100 x WHT RED 4 E a 4 gt RED 1 T T wr 27 RED 4 t Ca UP RED BLK PRLBOOM 9 4 DOWN H RED BLK 4 rj a 1 D d Lo LLL AL o a E RED WHT 4 4 gt RED 3 RED BLK 3 N is a f gt RED WHT 3 N n BLK 3 EXTEND BOOM RETRACT BLK WHT 3 M a BLK 4 P EXTEND BLK WHT BOOM 4 o RETRACT BLK WHT 4 7 P 8 e Mm m gt hu n ORG 3 UP PLATFORM LEVEL g DOWN R ORG BLK 3 ORG F 22. 0 0 45 GRNWHT 1 GR WT 4 SPARE GR BK AH 44 SPARE 48 GRN 1 SPARE 42 ORG RED 1 PULSE PICKUP ORG BLK ISMY2__ 41 ORG BLK LIMIT SWITCH SIG 40 ORG 1 WHT 40 E H LP BU RD SP BU RD R7 30 99 BLU RED 1 GAS BU WT S P BU WT R6 30 383 BLU WHT 1 STEER LEFT BL BK D B 37 BLU BLK 1 BU BK E H STEER RIGHT BLU D B 36 BLU 1 BLU E H N RPM BK RD S P BLK RD R4 86 35 BLK RED 1 GLOW PLUG 34 BLK WHT 1 BK WT E H START BLK S P BLK ISM 3 33 BLK 1 BLK R3486 R A BRAKE WT RD D B 32 WHT RED 1 WT RD EH ED C 31 WHT BLK 1 WT BK E H E D C 30 WHT 1 RED430 E H 2WD 4WD RD WT TR146_ 29 R W 1 RDWTEH TILT ALARM 28 REDIBLK 1 RD BK EH AUX PWR RED S P amp RED ISMi4 27 RED 1 RED E H WATER TEMP SENDER WT RD S P 26 WT RD E H OIL PRESSURE SENDER WT BK S P 25 WT BK E H WARNING SENDER WHT ISM 10 De 24 WHT E H KEYSWITCH PWR WHT S P 23 WHT2 RD WT EH u PWR TO PLAT BLK S P BLK R5 30 22 BLK 2 dy IGNITION PWR WHT S P WHT D B 21 WHT E H WHT R2487 5 12V BATT SUPPLY RED S P 20 RED A H JIB VALVE 19 GRN WHT 3 PLAT ROT GR BK S P GR BK DB 18 GRN BLK 3 GRN BLK 4 PLAT ROT 1 GRN S P GRN D B 17 GRN 3 GRN 4 PLAT LEVEL FC OG RD S P OG RD D B
3. P2 NC NC STOP TS3 DP1 7 6 5 4 3 2 1 FUEL SELECT TS4 ARE HIGH R P M GEN OPTION _ 45 GRN WHT 1 SPARE 44 GRN BLK 1 SPARE 43 GRN 1 SPARE 42 ORG RED 1 S 40 LP 39 BLU RED 1 LED START GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 1520 STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 H GLOW PLUG 34 BLK WHT 1 TS8 START 33 BLK 1 fo GENERATOR BRAKE 32 WHT RED 1 E D C 31 WHT BLK 1 O E D C 30 WHT 1 2WD 4WD 29 RED WHT 1 DRIVE ENABLE a O AUX PWR 27 RED 1 PWR TOFS _ 26 BLK FS PWR START 25 GREEN FS hd PWR CONT 24 WHT H P L Tsi PWR FRM PLAT 28 WHT 2 PWR PLAT 22 BLK 2 000 a TS7 20 A JIB VALVE 19 GRN WHT 3 a s AUX PLAT ROT R 18 GRN BLK 3 KA PLAT ROT L 17 GRN 3 a PLAT LVL FC 16 ORG RED 3 EXTEND PLAT LVL DN 15 ORG BLK 3 RETRACT PLAT LVL UP 14 ORG 3 Q DRV ENA LT 13 BLU RED 3 a DRY ENA 12 BLUWHT 3 SS SEC BOOM DN 11 BLU BLK 3 10 BLU 3 TS5 HORN 9 BLK RED 3 RETRACT BLK WHT 3 O EXTEND 7 BLK 3 A a E SWING F C 6 WHT RED 3 az J SWING RIGHT 5 WHT BLK 3 ala x Ir PLATFORM SWING LEFT 4 WHT 3 j ROTAT
4. GRWT4 GRN WHT 1 45 GEN OPTION RED 6 44 GRIBK AH SPARE RED 7 GANA 48 SPARE A m BLK 7 ORG RED 1 42 BLK 6 SPARE CABLE OGIBK EH ORG BLK 1 41 ORGIBLKISME PULSE PICKUP 7 ORG 1 40 WHT 7 WHT 6 LIMIT SWITCH SIG BLU RED 1 39 BU AD R7 30 BU RD S P LP BU WT R6430 BLU WHT 38 BUWTSP GAS BU BK E H BLUIBLK1 37 BL BK D B STEER LEFT BLU EH BLU 1 36 BLU D B STEER RIGHT BLK RED 1 35 BLK RD R4 86 BKIRD S CABLE BKWT EH BLKIWHT 1 34 GLOW PLUG GEJ BLK ISM 3 38 BLK R3486 BLK S P START WTIRD E H WHT RED 1 32 WT RD D B BRAKE WT BK EH WHTIBLK 1 31 EDC s WHT 1 30 RED 5 E D C A ROWT EH 29 2WD 4WD RD BKAH RED BLK 28 TILT ALARM CABLE RED EH RED 1 27 RED ISM 4 gt RED S P AUX PWR 2 WT RD E H 26 WT RD SP TEMP SENDER WI BK EH 25 WT BK S P OIL PRESSURE SENDER WHT ISM 10 WHT E H 24 WARNING SENDER WHTEH WHT2 28 WHT S P KEYSWITCH PWR BLK R5 30 BLK 2 22 BLK S P PWR TO PLAT WHT R2487 21 WHT D B WHT S P IGNITION PWR 20 RED S P 12V BATT SUPPLY GRNWHT 3 19 JIB VALVE GRN BLK 4 GRN BLK 3 18 GR BK D B GR BK SP PLAT R GRN 4 GRN 3 17 GRN D B GRN S P PLAT ROT L CABLE ORG RED 4 ORG RED 3 16 OG RD D B OG RD S PLAT LEVEL FC 1 ORGBLK4 ORG B
5. LO N HIGH IDLE RELAY FLASHING BEACONS PRECISION GOVERNOR RELAY FUEL RELAY FUEL RELAY GENERATOR OPTION LPG SOLENOID ANTI DIESEL VALVE FUEL PUMP WATER TEMP SENDER OIL PRESSURE SENDER HOUR METER AUTOMATIC CHOKE IGNITION SYSTEM PULSE GENERATOR STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN HYDRAULIC OIL TEMP SWITCH COOLING FAN OPTION Part No 35023 Genie Industries 28 Service Manual Supplement Gasoline LPG Models Z 60 34 Electrical Schematic TP41 e Lo GRN 2 5 5 E BLURED3 WHT 5 BS GRN 5 o a WHT 1 REDS BLK 5 Hu o A ui el NE 2 Ps DRIVE ENABLE A BLUMHT 3 E E o M E WHT BLK 1 g WHT BLK 31 E H N Ry A 8 E WHT RED 1 WHT RED 32 E H n P 5 BLU BLK 1 BLU BLK 37 E H BLU 1 BLU 36 E H 8
6. Part No 35023 Service Manual Supplement mg Z 60 34 Electrical Schematic Gasoline LPG Models Service Manual Supplement Ej Z 60 34 Ground Control Box Legend Gasoline LPG Models R O U GRWT 4___ GRNWHT 1 45 GEN OPTION 0 6 RED 6 44 GRIBRAF SPARE SU RED 7 GRN 1 43 SPARE ao G IN BLK 7 ORG RED 1 42 BLES SPARE CABLE OGBK EH ORGIBLK 1 41 ORG BLK ISM PULSE PICKUP 7 ORG 1 40 WHT 7 WHT 6 LIMIT SWITCH SIG 959 NEJ BLU RED 1 39 BU RD R7430 BURD SP LP BUMWT R6430 BLUWHT 1 38 BUWTSP GAS BU BK E H BLU BLK 1 37 BL BK D B STEER LEFT IN BLUEH BLUM 36 BLU D B STEER RIGHT BLK RED 1 35 BLK RD R4 86 BK RD S P RPM CABLE BKWT EH BLKWHT 34 GLOW PLUG Pi GEJ BLK ISM 3 BLK 1 33 BLK R3 86 BLK S P START m WI RD EH WHT RED 1 22 WT RD D B BRAKE ONCO WTIBK E H WHT BLK 1 31 EDC NO NO WHT 1 30 RED 5 EDC ONGO RDWTEH 29 2WD AWD RD BK A H RED BLK 1 28 TILT ALARM CABLE RED EH RED 1 27 RED ISM 4 gt RED S P AUX PWR 5 WT RD E H 26 WTJRD S P TEMP SENDER WT BK E H 25 WT BK S P OIL PRESSURE SENDER WHT ISM 10 WHTEH 24 WARNING SENDER WHTE H __ WHT 2 28 WHT S P KEYSWITCH PWR BLK R5 30_ BLK 2 22 BLK S P PWR TO PLAT WHT R2487 WHTEH 21 WHT D B WHT S
7. O ews eect 35 7 6 Flex Plate N 35 7 7 Water Temperature and Oil Pressure 36 7 8 Vacuum 4 36 35023 Genie Supplement First Edition N Ee Genie Supplement Part No 35023 First Edition Service Manual Supplement Specifications Ford Engine LRG 423 Displacement 140 cu in 2 3 liters Number of cylinders 4 3 781 x 3 126 inches 96 04 x 79 4 mm Bore amp stroke Horsepower 63 4000 rpm Firing order 1 3 4 2 S 40 RPM Specifications Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm S 80 85 RPM Specifications Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm Z 45 22 RPM Specifications Low idle carburetor 900 rpm Low idle electronic governor 1400 rpm High idle 2150 rpm Z 60 34 RPM Specifications Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm Governor electronic Compression ratio 9 4 1 Compression pressure approx Pressure psi of lowest cylinder must be at least 75 of highest cylinder 0 035 to 0 055 inches 0 889 to 1 397 mm Valve clearances collapsed tappet Oil viscosity requirements Temperature below 60 F 15 590 5W 30 10 F to
8. 16 ORG RED 3 ORG RED 4 PLAT LEVEL DN OG BK S P OG BK D B 15 ORG BLK 3 ORG BLK 4 PLAT LEVEL UP ORG S P ORG D B 14 ORG 3 ORG 4 DRV ENA LT 13 BLU RED 3 WHTFISEH WHT 12 E H 12 BLUWHT 3 BLK 12 E H SEC BOOM DN BU BK S P BUBK DB 11 BLU BLK 3 BLU BLK 4 SEC BOOM UP BLU S P BLU D B 10 BLU 3 BLU 4 ABEL DESCRIPTION HORN BK RD R5 86_ 9 BLK RED 3 CABLE P1 EMERGENCY STOP BUTTON BOOM RETRACT BK WT S P BK WT D B 8 BLK WHT 3 BLK WHT 4 2 KS1 KEY SWITCH BOOM EXTEND BLK S P BLK D B 7 TS9 AUXILIARY SWITCH TURN ROT WT RD S P S WHT RED 3 WIR 4 TS10 ENGINE START SWITCH TURN ROT L WT RD S P WT BK D B 5 WHT BLK 3 WHT BLK 4 EE ie TURN ROT WHT S P WHT D B 4 WHT 3 WHT 4 PRI BOOM RD WT S P REDWHT 3 RIW 4 1512 ENONEREMEWIIEH PRI BOOM DOWN RD BK S P RD BK D B 2 RED BLK 3 RED BLK 4 1813 PLATFORM ROTATE SWITCH PRI BOOM UP RED SP BED DB 1 RED 3 RED 4 TS14 PLATFORM LEVEL SWITCH id 5 TS15 BOOM EXTEND RETRACT SWITCH TS16 PRIMARY BOOM UP DOWN SWITCH O 1517 TURNTABLE ROTATE SWITCH ach IGN START TS18 SECONDARY BOOM UP DOWN SWITCH 2 TACHOMETER nd CABLE 3 CB1 CIRCUIT BREAKER CONTROLS 15A CIRCUIT BREAKER ENGINE 15A 4 aux on HM HOUR METER O 5 GROUND R3 RESISTOR 10 OHM BOOM FUNCTIONS BATTERY O 7 KEY PWR 8 KEYBYPASS TS15 TS17 TS13 O 9
9. NC NC STOP TS3 DP1 o O FUEL SELECT TS4 HIGH R P M GEN OPTION 45 GRN WHT 1 SPARE 44 GRN BLK 1 gt SPARE 43 GRN 1 SPARE 42 ORG RED 1 L1 4 40 L P 39 BLU RED 1 LED ABY GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 1329 STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 m GLOW PLUG 34 BLK WHT 1 TS8 OD START 33 BLK 1 o GENERATOR BRAKE 32 WHT RED 1 O OPTION E D C 31 WHT BLK 1 O E D C 30 WHT 1 2WD AWD 29 RED WHT 1 DRIVE ENABLE 28 AUX PWR 27 RED 1 PWR TOFS 26 BLK FS PWR START 25 GREEN F S g PWR CONT 24 WHT H P L NS PWR FRMPLAT 3 WHT 2 PWR TO PLAT 22 BLK 2 a TS7 JIB VALVE 19 GRN WHT 3 fa PLAT ROT R 18 GRN BLK 3 NS 2 PLAT ROT L 17 GRN 3 PLAT LVL F C 16 ORG RED 3 EXTEND PLAT LVL DN 15 ORG BLK 3 RETRACT PLAT LVL UP 14 ORG 3 DRV ENA LT 13 BLU RED 3 3 si DRV ENA 12 BLU WHT 3 SS SEC BOOM DN 11 BLU BLK 3 E SEC BOOM UP 10 BLU 3 TS5 HORN 9 BLK RED 3 fo RETRACT 8 BLK WHT 3 5 EXTEND 7 BLK 8 n 5 SWING 6 WHT RED 3 ak
10. SWING RIGHT 5 WHT BLK 3 5 PLATFORM SWING LEFT 4 WHT 3 ROTATE PRIMARY 3 RED WHT 3 TS6 PRIMARY DN 2 RED BLK 8 _ aaa ac PRIMARY UP 1 RED 3 ON w BP1 a 2 2 PLATFORM LEVEL HORSE POWER LIMITER R 12 3 4 5 6 7 8 9 10 EN P3 NO Y dac m x o 8 z RED BLK 1 6 GRD 7 TLT HORN STUD ALARM Part No 35023 Genie Industries 32 First Edition Service Manual Supplement Ford LRG 423 Engine 9 5 Governor actuator and linkage Genie S 40 models This section a clevis yoke replaces Section 6 b linkage rod carburetor Genie S 80 85 models This d throttle plate shaft section replaces Section 7 e governor actuator f actuator shaft Genie Z 45 22 models This g actuator arm section replaces Section 7 Genie Z 60 34 models This section replaces Section 8 7 1 Governor Actuator How to Set Up the Governor Actuator and Linkage 2 Fasten the lock nut and clevis yoke to the Adjustment of the governor linkage rod Do not tighten the lock nut actuator is only necessary when against the clevis yoke the governor actuator or the 3 Loosen the fastener on the actuator arm linkage has been replaced Rotate the actuator arm until it is at a 1 Connect the linkage rod to the throttle plate 110 degree angle to the linkage rod Then shaft then tighten the lock nut tighten the actuator arm fastener Part No 35023 Genie Industr
11. This supplement is an addition to the service Product Machines after manuals listed below The serial numbers listed 5 40 271 below mark the first affected machine Only 5 80 amp 5 85 132 following changes are documented in this Z 45 22 2134 supplement Z 60 34 481 Replacement of the Ford LSG 423 engine with the Ford LRG 423 engine If you have any questions about what this supplements covers or how it fits in to your existing documentation please call the Genie Industries Service Department Service Manual There are four sections to the service manual supplement The Specifications section contains only the specifications for Ford LRG 423 Engine The maintenance section contains only those maintenance procedures that are different for the Ford LRG engine Please note the procedure number for your machine indentified at the beginning of each procedure in this supplement The schematic section contains complete updated electrical schematics for the Gasoline LPG machines The schematics are arranged by product The repair section contains the complete Ford LRG engine section Please note the section number for your machine Service Manuals Product Part Number S 40 32222 S 80 amp 5 85 34032 Z 45 22 32960 Z 60 34 30105 Part No 35023 Genie Supplement iii First Edition Table of Contents Section One Specifications Ford ERG 423 ARE OE ORE EA EE RE S 1 Section Two Scheduled Maintenance Pro
12. 4 Aux ON 5 GROUND 6 BATTERY 7 KEY Pwr O 8 KEY BYPASS 9 IGN FUELON O 10 ENG FAULT CRI CR2 CR3 CRA ISTART IGNITION RPM RPM RELAY RELAY CUTOUT RELAY RELAY CRS CR6 HORN FUEL RELAY CUTOUT RELAY 7 FUEL CUTOUT RELAY O Part No 35023 Genie Industries 20 Service Manual Supplement rc ZO Z P S 80 85 Relay Panel Legend Gasoline LPG Models IGNITION MODULE VAC GOVERNOR 21 Genie Industries Part No 35023 Service Manual Supplement E S 80 85 Platform Control Box Legend Gasoline LPG Models C ed P2 NC NC STOP DP1 o o O O 7 6 5 4 3 2 1 TTE SELECT TS4 f R PM GEN OPTION 45 GRN WHT 1 SPARE 44 GRN BLK 1 SPARE 43 GRN 1 o SPARE 42 ORG RED 1 Li 4 ao START LP 39 BLU RED 1 LED GAS BLU WHT 1 Bar STEER LEFT 37 BLU BLK 1 STEER RIGHT 36 BLU 1 OOO RPM 35
13. BOOM RETRACT PLAT LEVEL UP PLAT LEVEL DN PLAT LEVEL F C PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT 14 Genie Industries Part No 35023 Service Manual Supplement OJ S 40 Electrical Schematic Gasoline LPG Models 9 KS1 ONCO ONCO olo TS11 TS10 r 000 000 Ts12 CB1 CB2 S 9 x LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KST KEY SWITCH TS9 AUXILIARY SWITCH TS10 ENGINE START SWITCH TS11 ENGINE FUEL SELECT SWITCH TS12 ENGINE RPM SWITCH TS13 PLATFORM ROTATE SWITCH 7514 PLATFORM LEVEL SWITCH 7515 BOOM EXTEND RETRACT SWITCH TS16 PRIMARY BOOM UP DOWN SWITCH 1517 TURNTABLE ROTATE SWITCH CB1 CIRCUIT BREAKER CONTROLS 15A 2 CIRCUIT BREAKER ENGINE 15A HM HOUR METER 82 RESISTOR 10 OHM BOOM FUNCTIONS Gi VOLT METER GAGE G2 _ OIL PRESSURE GAGE G3 WATER TEMP GAGE NEA s PON TS15 ooo 000 N TS14 V x 2 TS16 1817 000 000 NZ 513 Service Manual Supplement IZ CL ZL ZZO S 40 Ground Control Box Legend Gasoline LPG Models
14. CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION R BLK RED 1 HIGH RPM A a ENGINE SPEED 8 5 n x ENGINE SPEED E HIGH RPM BLK RED p 8 RED WHT E H e05 m x is 120 59 HLUBLKEH ES BLK RED R4 E H et 43E zc EE 9 nad 8 3 RED WHTYRG E H Ti slee 5 4 L 148 c MIR ean M x VL ig FIN a oru dl RED WHT 23 E H RED BLK R6 E H Sr e 9 gt OFF 9 GENERATOR ON GRN WHT 1 GRN WHT 45 E H 7 8 e e n m m BLU RED 1 BLU RED R7 E H p e M e Loy FUEL 59 GAS BLU WHT 1 9 BLUWHT RE E H p 8 59 n T BLU WHTHRE E H a gt FUEL GAS GE 28 SE g n BLK 1 KE o s2 ENGINE 1 START 5 b 5 m 5 5 add AA II E WHT 24 82 ENGINE 9909900 START BLK 2 a
15. 448 1B TE 4 a 8 16 o x B 262 gt RED RED 20 E H 2 RA SSS ay N LO HIGH IDLE RELAY FLASHING BEACONS PRECISION GOVERNOR RELAY FUEL RELAY FUEL RELAY GENERATOR OPTION LPG SOLENOID ANTI DIESEL VALVE FUEL PUMP WATER TEMP SENDER OIL PRESSURE SENDER HOUR METER AUTOMATIC CHOKE IGNITION SYSTEM PULSE GENERATOR STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN HYDRAULIC OIL TEMP SWITCH COOLING FAN OPTION Part No 35023 Genie Industries 13 Service Manual Supplement S 40 Electrical Schematic Gasoline LPG Models N S GRN 2 5 2 BLU RED 3 B WHT 5 BS 212 GRN S WHT 1 RED 5 BLK 5 e I eo oo SA uj e amp a z E EE hid DRIVE ENABLE s BLU WHT 3 e e gt WHT BLK 1 WHT BLK 31 E H NY E WHT RED 1 WHT RED 32 E H di BLU BLK 1 BLU BLK 37 E H 7 B
16. 5 A 2 1 o a m m E BLU RED 1 r BLU RED R7 E H 3 N N M FUEL tr 9 GAS BLUMHT 1 9 BLUWHT R6 E H s _ 8 fo B amp B BLU WHT4R6 E H n 2 LP EE FUEL 1GAS amp E 2 ao zo g f BLK 1 3 P 9345 ENGINE OES START 5 b 5 m Po WHT 424 E H 59 ENGINE o gt START Y 8 R WHT p o x A a i i 52 P I gt a gt lt zak WHT 21 E H 100 r 00 T EEEE p zu gt lt L bi 163 8 zn 129 WATER TEMP ble SENDER 619 2 IG oO i Hej 5 i WIE er qom 4 BLK R1 E H oz s P A s M Fl p AUXILIARY x eere EHEN SEN J 5 x PUMP RED RED 27 E H A AUXILIARY A u PUMP E RED 1 T To 9 tz o z A RED RED BLK 1 RED BLK 28 E H m i WHT 2 RED WHT 23 E H i m N dIE EN E S mii gt e ad a F BLK RED 3 BLK RED ia E N 2 co S BLK 2 m 02 BLK RS E H E a 55 2 5 e a HO WHT WHT R17 E H 95 n a e cro amp SZ ORG RIT EH WHTH2I EH oo _ RED EH lt a ORG BLK 1 E ORG BLK 41 E H a a E I 5 18 lt Ga amp GI Je TYE _ c EIE NE EE u x RED RED 20 E H Ka AR L n T 2
17. BLK RED 1 GLOW PLUG BLKIWHT 1 TS8 START 38 BLK 1 GENERATOR BRAKE 32 WHT RED 1 O OPTION E D C 31 WHT BLK 1 E D C 30 WHT 1 2WD AWD 29 RED WHT 1 DRIVE ENABLE 28 Q AUX PWR 27 RED 1 PWR TO FS 26 BLK FS f N PWR START _ 25 GREEN 5 8 PWR 24 WHT H P L A EZ si PWR FRM PLAT 23 WHT 2 PWR PLAT 22 BLK 2 5 OO 21 TS7 000 20 FTN JIB VALVE 19 GRN WHT 3 e AUX PLAT ROT R 18 GRN BLK 3 NS PLAT ROT L 17 GRN 3 PLAT LVL 16 ORG RED 3 EXTEND PLAT LVL DN 15 ORG BLK 3 RETRACT O PLAT LVL UP 14 ORG 3 DRV LT 13 BLU RED 3 DRV ENA 12 BLUMHT 3 5 SEC BOOM DN 11 BLU BLK 3 SEC BOOMUP 10 BLU 3 TS5 HORN 9 BLK RED 3 RETRACT 8 BLKWHT 3 6 EXTEND 7 BLK 3 UN O SWING 6_ WHT RED 3 ar SWING RIGHT 5 WHT BLK 3 5 all xl In PLATFORM SWING LEFT 4 WHT 3 ROTATE PRIMARY FC 3 RED WHT 3 TS6 PRIMARY DN 2 RED BLK 3 z PRIMARY UP 1 RED 3 BPI 990 89 lt 5 PLATFORM LEVEL HORSE POWER LIMITER x 1 2 3 4 5 6 7 8 9 ho P3 NO z m 5 5 E RED BLK 1 GAD TILT HORN A STUD ALARM O Part No 35023 Genie Industries 22 Service Manual Supplement mg Z 45 22 Electrical Schematic Gasoline LPG Models Service Manual Supplement Z 45 22 Electrical Schematic Gasoline LPG Models NOTE
18. Legend Gasoline LPG Models 17 S 80 85 Electrical Schematics Electrical Schematic Gasoline LPG Models 18 Ground Control Box Legend Gasoline LPG Models 20 Relay Panel Legend Gasoline LPG Models 21 Platform Control Box Legend Gasoline LPG Models 22 Z 45 22 Electrical Schematics Electrical Schematic Gasoline LPG Models 23 Ground Control Box Legend Gasoline LPG Models 25 Relay Panel Legend Gasoline LPG 26 Platform Control Box Legend Gasoline LPG Models 27 Genie Supplement Part No 35023 First Edition Section Three continued Section Four Z 60 34 Electrical Schematics Electrical Schematic Gasoline LPG Models 28 Ground Control Box Legend Gasoline LPG Models 30 Relay Panel Legend Gasoline LPG Models 31 Platform Control Box Legend Gasoline LPG Models 32 Repair Procedures FeAl Governot Ge MERE 33 7 2 Choke Adjustments is oie redu einer Re zla 34 1 8 TIMING Adjustmerit ua ete cr terere tex ee 35 7 4 Carburetor Re Re ee ee ee Re ee enne 35 7 5 RPM Adjusiment OR EO
19. ORG 4 7 UP ORG BLK PLATFORM LEVEL DOWN ORG BLK 4 4i 9 oe ORG RED 4 j ORG RED 3 R GRN 3 LEFT PLATFORM ROTATE w RIGHT GRN BLK 3 GRN ki m S gt GRN 4 E e LEFT GRN BLK PLATFORM ROTATE 4 LRIGHT GRN BLK 4 TB18 GROUND DRIVE ENABLE LIMIT SWITCH DRIVE EDC BRAKE STEER RIGHT STEER LEFT BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH TURNTABLE ROTATE R TURNTABLE ROTATE L TURNTABLE ROTATE amp EXTEND RETRACT FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL BOOM EXTEND BOOM RETRACT PLAT LEVEL UP PLAT LEVEL DN PLAT LEVEL F C PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT 19 Genie Industries Part No 35023 Service Manual Supplement ZIZI ZL S 80 85 Electrical Schematic Gasoline LPG Models kJ ON Gi P1 Onc O 010 NO NO Onc O olo HM 7 TSH 510 E CN U 000 7812 CB2 000 Th 1 C 77 k em OP LABEL DESCRIPTION Pt EMERGENCY STOP BUTTON KS1 KEY SWITCH TS9 AUXILIARY SWITCH TS10 ENGINE START SWITCH TS11 ENGINE FUEL SELECT SWITCH 1512 ENGINE RPM SWITCH 1513 PLATFORM ROTATE SWITCH 1514 PLATFORM LEVEL SWITCH 1515 BOOM EXTEND RETRACT SWITCH TS16 PRIMARY BOOM UP DOWN SWITCH TS17 TURNTABLE R
20. P IGNITION PWR __ RED A H 20 RED S P 12V BATT SUPPLY GRNWHT 3 19 JIB VALVE GRNBLK4 GRNBLK3 18 GR BK D B GRIBKSP PLAT ROT R HM TS16 N GRN 4 GRN 3 17 GRN D B GRN SP PLAT ROT L gm CABLE ORG RED 4 ORG RED 3 16 OG RD D E OG RD S PLAT LEVEL F C NEJ ORG BLK4 ORGIBLK 3 15 OG BK DB OGBKSP PLAT LEVEL DN 088 4 ORG 3 14 ORG D B ORG S P PLAT LEVEL UP 00 BLU RED 3 13 WHTS DRV ENA LT WHT EH BLUWHT3 12 DPV BLUBLK4 BLUBLK3 11 BUIBK D B BUBBK SP SEC BOOM DN T 7517 BLU 4 BLU 3 10 BLU D B BLU S P SEC BOOM UP TS10 BKIRD R5 86 BLKIRED 3 9 HORN N 000 000 BLKWHT4 BLKWHT3 8 BK WT D B BK WT S P BOOM RETRACT U 000 a BLK 4 BLK 3 7 BLK D B BLK S P BOOM EXTEND 000 000 WR 4 WHT RED 3 6 WT RD S PR TURN ROT CABLE WHTIBLK lt 4_ WHTIBLK 3 5 WIIBKD B WTRD SF TURN ROT L 2 j wars WHT 3 WHT D B WHTSP TURN ROT R RW REDWHT 3 8 RDAWT amp P BOOM F C TS12 CB1 CB2 TS13 RED BLK4 RED BLK 3 2 RD BK D B RD BK SP PRI BOOM DOWN RED 4 RED 3 1 RED D B RED S P PRI BOOM UP 000 fi 000 Ug 7 DIODE BLOCKS CABLE LABEL DESCRIPTION 1 START RELA Br EMERGENCY STOP BUTTON O2 Tacnomeren _ IGN START MODULE TS9 AUXILIARY SWITCH 3 STARTINPUT TS10 ENGINE START SWITCH 4 AUX ON TS11 ENGINE FUEL SELECT SWITCH O 5 GROUND 1512 ENGINE RPM SWITCH lt 6 BATTERY T
21. RELAY AUXILIARY PUMP LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN HYDRAULIC OIL TEMP SWITCH COOLING FAN OPTION Part No 35023 Genie Industries 23 Service Manual Supplement Z 45 22 Electrical Schematic Gasoline LPG Models TP41 N e LO GRN 2 2 gt 5 BLU RED 3 5 29 GRN 5 o 8 WHT 1 P RED 5 BLK 5 e e I 2 ui 2 E Jm 3k DRIVE ENABLE BLU WHT 3 a E WHT BLK 1 WHT BLK 31 E H N 5 8 E WHT RED 1 B WHT RED 32 E H 8 BLU BLK 1 BLU BLK 37 E H w BLU 1 BLU 36 E H ri EN Re 9 U i c De i o 5 42 ORG 1 WHT 6 GRN 6 T a WHT 7 BLK 7 S o 42 E 5 5 WHT RED 3 WHT BLK 3 A gt WHT 3 WHT i 2 WHT 4 n RIGHT WHT BLK E TURNTABLE ROTATE 4 s LEFT 14 WHT BLK 4 T BER gt IE E p pA p WHT RED 4
22. This procedure replaces C 12 Periodic replacement of the spark plugs is essential to good engine performance and service life Worn loose or corroded spark plugs will cause the engine to perform poorly and may result in component damage Perform this procedure with the engine off 1 Label then disconnect the plug wires from the spark plugs by grasping the molded boot Do not pull on the plug wire Blow out any debris around spark plugs Remove all the spark plugs from the engine Adjust the gap on each new spark plug a R I Install the new spark plugs then connect the wires Be sure that each spark plug wire is attached to the correct spark plug Spark plug specifications Spark plug type Motorcraft AWSF 52C 0 042 to 0 046 inches 1 07 to 1 18 mm Spark plug gap C 4 Check and Adjust the Air LPG Mixture Gasoline LPG Models Genie S 40 models This procedure replaces C 13 Genie S 80 85 models This procedure replaces C 14 Genie Z 45 22 models This procedure replaces C 13 Genie Z 60 34 models This procedure replaces C 13 Maintaining the proper air to fuel mixture during LPG operation is essential to good engine performance Engine fuels are combustible A DANGER Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach The engine rpm needs to be preset for g
23. to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 12 Genie Industries Part No 35023 Service Manual Supplement S 40 Electrical Schematic Gasoline LPG Models NOTE CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION BLK RED 1 HIGH RPM a ENGINE SPEED N He x ENGINE SPEED a HIGH RPM BLK RED gt 7 9 deo 3 RED WHT EH p 12 52 LUBLK EH Se BLK RED R4 E H S 111 ED nn 0 gt lt 100 r 150 Os RED WHT R3 E H Tee 5 4 148 oz EE Hd ET poe NT N 2 ora RED WHT 23 E H RED BLK R6 E H Sr ot OFF 2 GENERATOR 5 ON E GRN WHT 1 GRN WHT 45 E H 7
24. 0000000 f NS GOVERNOR 16 Genie Industries Part No 35023 Service Manual Supplement wIm ZA S 40 Platform Control Box Legend Gasoline LPG Models P2 NC NC STOP DP1 876543211 SELECT TS4 i HIGH R PM GEN OPTION 45 GRN WHT 1 ES SPARE 44 GRN BLK 1 SPARE 43 GRN 1 SPARE 42 ORG RED 1 4 O 40 m L P 39 BLU RED 1 SMART GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 1520 STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 GLOW PLUG 34 BLK WHT 1 TS8 START 33 BLK 1 GENERATOR BRAKE 32 WHT RED 1 OPTION E D C 31 WHT BLK 1 O E D C 30 WHT 1 2WD 4WD 29 RED WHT 1 DRIVE ENABLE AN 28 k O AUX PWR 27 RED 1 PWR TO 5 26 BLK 5 PWR START 25 GREEN 5 8 PWR CONT 24 WHT H P L NEJ 351 PWR FRM PLAT 23 WHT 2 PWR TOPLAT 22 BLK 2 2 TS7 20 E e JIB VALVE 19 GRN WHT 3 g AUX PLAT ROT R 18 GRN BLK 3 NU 000 PLAT ROT L 17 GRN 3 PLAT LVL 16 ORG RED 3 EXTEND P
25. 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the radiator drain valve Ji VM A 5 CA dz a _ pivot plate retaining bolts b engine pivot plate Open the drain valve on the radiator and allow all the coolant to drain into a suitable container After all the coolant has drained close the drain valve Connect the coolant return hose to the radiator Open the drain valve on the engine block and allow the coolant to drain into a container After the fluid is drained close the drain valve Replace all coolant hoses and clamps Pour the proper coolant mixture anti freeze and water for your climate into the radiator until it is full 8 Genie Industries Part No 35023 First Edition Service Manual Supplement SCHEDULED MAINTENANCE PROCEDURES 10 Disconnect the upper hose at the top and hold D 2 it until coolant starts to pour out of the open hose Then immediately reconnect the hose Change the Fuel Lines Genie S 40 models This procedure replaces D 3 Genie S 80 85 models This procedure replaces D 3 Genie Z 45 22 models This procedure replaces D 3 Genie Z 60 34 models This procedure replaces D 3 Maintaining the fuel lines in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or leaking fuel line may cause an unsafe operating condition Engine fuels are comb
26. 90 F 23 C to 32 C 10W 30 Temperature above 10 F 23 C 10W 40 to 10W 50 Temperature above 20 F 6 6 C 20W 40 or 20W 50 Use oils meeting API classification SG labeled SG CC or SG CD as they offer improved wear protection Units ship with 10W 40 SG CC Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 170A Current draw maximum load 200A Current draw minimum 140A Maximum circuit voltage drop 0 5V DC while starting normal temperature Brush length new 0 66 in 16 8 mm Brush length wear limit 0 25 in 6 35 mm Brush spring tension 64 ounces 18 Newtons Bolt torque through brush 45 to 84 inch pounds 5 08 to 9 5 Nm Brush mounting 15 to 20 foot pounds bolt torque 20 to 27 Nm Maximum commutator 0 005 inches run out 0 127 mm Battery Type 12V Group 31 Quantity 1 Lubrication system Cold cranking ampere 1000A Oil pressure 40 to 60 psi Reserve capacity 25A rate 200 minutes operating temp amp 2000 rpm 2 75 to 4 1 bar Fuel pump Oil capacity 5 guarts Electronic solenoid 7 psi including filter 4 7 liters 0 48 bar Part No 35023 Genie Industries 1 Service Manual Supplement First Edition Scheduled Maintenance Procedures B 1 Check the Engine Belt s morra Genie 5 40 models This procedure replaces B 1 Genie S 80 85 models This procedure replaces B 1 Genie Z 45 22 models Th
27. E PRIMARY F C 3 REDWHT 3 TS6 un Joka m BP1 a 9 QOO NC PLATFORM LEVEL HORSE POWER LIMITER R 1123145 67189 10 P3 2 J NO 5 z RED BLK 1 GRD TILT HORN STUD ALARM VI Part No 35023 Genie Industries Service Manual Supplement Z 60 34 Electrical Schematic Gasoline LPG Models NOTE CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION BLK RED 1 HIGH RPM m a ENGINE SPEED 5 x E x ENGINE SPEED S HIGH RPM BLK RED n a i 39 a 9 3 ice Z BLK RED R4 E H Bull SP Sc 100 Pe 159 0 lt RED WHT R3 E H ML 5 gt Lcd dl 1 a a a sm di RED WHT 23 E H RED BLK R6 E H AE rand t gt E OFF GENERATOR o LON E GRN WHT 1 GRN WHT 45 E H 7 8
28. EN E r ORG 1 P WHT6 GRN 6 9 T hi E WHT 7 BLK 7 HO 22 WHT RED 3 E WHTIBLK 3 A WHT 3 WHT ARE x 4 a E WHT 4 RIGHT WHTIBLK z TURNTABLE ROTATE TP N LEFT _ SK iX Ce m 100 Mon WHT RED 4 5 LI o m Y RED i Bon RED 4 5 MEN UP RED BLK s PRI BOOM 4 ERE DOWN E RED BLK 4 DL E e 0 p 8 RED WHT 4 a U gt RED 3 RED BLK 3 N o ft fob RED WHT 3 N n BLK 3 EXTEND BOOM x RETRACT BLK WHT 3 N 5 amp 4 a BLK 4 EXTEND BLK WHT BOOM 4 Y RETRACT RR id BLKWHT 4 4 2 59 m a x n gt ORG 3 UP PLATFORM LEVEL x o DOWN ORG BLK 3 X ORG a a 2 ORG 4 j UP ORG BLK PLATFORM LEVEL 4 DOWN ORG BLK 4 7 2 eg n ORG RED 4 E ORG RED 3 N E GRN 3 LEFT PLATFORM ROTATE o RIGHT GRN BLK 3 K GRN n 0 2 GRN 4 E LEFT GRN BLK PLATFORM ROTATE RIGHT GRN BLK 4 7 m m GROUND DRIVE ENABLE LIMIT SWITCH DRIVE EDC BRAKE STEER RIGHT STEER LEFT BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH TURNTABLE ROTATE R TURNTABLE ROTATE L TURNTABLE ROTATE amp EXTEND RETRACT FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL BOOM EXTEND BOOM RETRACT PLAT LEVEL UP PLAT LEVEL DN PLAT LEVEL F C PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT 29 Genie Industries
29. ENGINE SPEED 5 z ENGINE SPEED LHIGH RPM BLK RED 7 di a 8 ses DE 4 im 129 H Ee 2 BLK RED R4 E H GN BS Z 10G EE 169 o6 RED WHT R3 E H 59 5 H EE gt A ZN amp ay ortu NE RED WHT 23 E H RED BLK R6 E H E P OFF g GENERATOR o LON E GRN WHT 1 GRN WHT 45 E H 4 B 1 e n m s BLU RED 1 BLU RED R7 E H p lt FUEL 9 GAS BLUMHT 1 9 BLU WHTERG E H o e co a m Dz B BLU WHT R6 E H ZE FUEL 1GAS 2 20 oz 8 gt L E BLK 1 kk KB 5 In EO DH ENGINE 3 START 5 DERE N ERPS PEEP WHT 24 EH z ENGINE LSTART BLK 8 a WHT A E k o V 1 A i Lo oz ees gt N a gt 112222211 I WHT 21 E H Lae 2 T ae Fm I gt lt LL or e gt 154 gi 159 WATER TEMP 73 SENDER n i xi 8 WS x tt BLK R1 E H EO 8 1 E M E 2 AUXILIARY amp x Bean 4 5 PUMP RED RED 27 E H amp AUXILIARY u PUMP E RED 1 dis Tak tr a z o BY A 5 RED RED BLK 1 RED BLK 28 E H m WHT 2 RED WHT 23 E H gt m 9 A E A x z
30. Genie Industries Technical Publications Genie Supplement 1 9 Service Manual For the following products 2 First Edition Third Printing 7 60 34 Part No 35023 First Edition Genie Supplement Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and other manuals Please write or fax to the Technical Publications team Genie Industries PO Box 69 Redmond WA 98073 6900 USA Fax Number 206 556 8528 If you have any questions call Genie Industries Genie Industries Copyright O 1995 by Genie Industries First Edition First Printing February 1995 Second Printing March 1995 Third Printing June 1995 Genie is a registered trademark of Genie Industries Registered 2009987 Patents pending 6 Printed on recycled paper Printed in U S A Genie North America Telephone 206 881 1800 Toll Free in U S A 800 536 1800 Toll Free in Canada 800 426 8089 Fax 206 883 3475 Genie Europe Telephone 44 01636 605030 Fax 44 01636 611090 ii Genie Supplement Part No 35023 First Edition How To Use This Supplement Serial Number Breaks
31. IGN FUELON o O o O O 10 ENG FAULT o sm Ts9 Oo 2 g 4 000 EXT R TURNTABLE PLAT 5 8 ROTATE ROTATE TS TS16 TS14 DIODE FEES BLOCKS o AUXILIARY o0 U oo O d 5 B U FUELSELECT PRI BOOM RAL TS18 LEVEL crt CR3 cra L3 START IGNITION RPM RPM O noO RELAY RELAY CUTOUT RELAY RELAY NO OW WATER see soon 1 1 021121121 TS10 CRG P1 O HORN FUEL FUEL ojo SURE RELAY CUTOUT CUTOUT Y Na ine RELAY RELA a a1 5 TS12 x lt B IS TEI 5 O A HOUR METER p TRI TRACTION CRY DELAY TIMER OSCILLATE OSCILLATE OSCILLATE RELAY LOCKOUT LOCKOUT GRD i RELAY RELAY 1 1 1 1 Part No 35023 Genie Industries 25 Service Manual Supplement PPI TOO ZOO Z 45 22 Relay Panel Legend Gasoline LPG Models i IGNITION MODULE eeceecccccccnc S VAC GOVERNOR 26 Genie Industries Part No 35023 Service Manual Supplement Z 45 22 Platform Control Box Legend Gasoline LPG Models
32. LAT LVL DN 15 ORG BLK 3 RETRACT O PLAT LVL UP 14 ORG 3 5 Ae DRV ENA LT 13 BLU RED 3 a zm DRV ENA 12 BLUWHT 3 57 SEC BOOM DN 11 BLU BLK 3 SEC BOOMUP 10 BLU 3 TS5 HORN 9 BLK RED 3 RETRACT 8 BLK WHT 3 5 EXTEND 7 BLK 3 w N SWING 6 WHT RED 3 ak SWING RIGHT 5_ WHT BLK 3 NS J n PLATFORM SWING LEFT 4 WHT 3 ROTATE PRIMARY F C 3 RED WHT 3 PRIMARY DN 2 RED BLK 3 PRIMARY UP 1 RED 3 d PLATFORM LEVEL HORSE POWER LIMITER R 1 2 5 6 7 8 9 10 NO 5 6 RED BLK 1 GRD gt TILT HORN srub ALARM 35023 Genie Industries 17 Service Manual Supplement S 80 85 Electrical Schematic Gasoline LPG Models NOTE CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION BLK RED 1 HIGH RPM ia a
33. LK 3 15 OG BK D OG BK S P PLAT LEVEL DN ORG 4 ORG 3 14 ORG D B ORG S P PLAT LEVEL UP BLU RED 3 13 WHT 5 DRV ENA LT WHTEH BLUWHT3 12 BLK 5 BLUIBLK 4 BLU BLK 3 11 BU BK D B BU BK SP SEC BOOM DN BLU 4 BLU 3 10 BLU D B BLU S P SEC BOOM UP BK RD R5 86 BLK RED 3 9 HORN BLKWHT4 BLK WHT 3 8 BKIWT D B BKWT SP BOOM RETRACT N BLK 4 BLK 3 7 BLK D B BLK S P BOOM EXTEND CABLE MR WHT RED 3 6 WT RD S TURN ROT FC WHTIBLK 4 WHT BLK 3 5 WT BK D B WT RD amp P TURN ROT L WHT 4 WHT 3 4 WHT D B WHT S P TURN ROT R RED WHT 3 3 RD WI SP BOOM RED BLK 4 RED BLK 3 2 RD BK D B RD BK S P PRI BOOM DOWN RED 4 RED 3 1 RED D B RED S P PRI BOOM UP D B A DIODE a BLOCKS CABLE 3 O 1 START RELA 2 IGN START O 3 START INPUT MODULE 4 AUX ON lt 5 GROUND 6 BATTERY N A A 7 KEY Pwr LEJ O 8 KEY BYPASS Es 9 IGNJFUEL ON Y cu 10 ENG FAULT COOLING FAN RELAY CR1 CR2 CR3 CR4 ISTART IGNITION REM RPM RELAY RELAY CUTOUT RELAY RELAY LI N A CR5 CR6 CR7 HORN FUEL FUEL RELAY Er CUTOUT RE RELAY HARNES Part No 35023 Genie Industries 15 Service Manual Supplement Og S 40 Relay Panel Legend Gasoline LPG Models 2 IGNITION MODULE 0000
34. LU 1 BLU 36 E H n B E EN E B 5 MEAE li 5 9 m AI ORG 1 WHT 6 GRN 6 a 1 RUE UN i E WHT 7 BLK 7 1 1 ese cll she 22 0530 5 WHT RED 3 2 WHT BLK 3 x WHT 3 4 5 WHT z d WHT 4 RIGHT WHT BLK TURNTABLE ROTATE 4 LEFT WHT BLK 4 D u 100 WHT RED 4 n p di m RED 5 Bara RED 4 5 UP RED BLK PRI BOOM E DOWN E JEZ RED BLK 4 E 5 p amp B RED WHT 4 RED 3 RED BLK 3 N e RED WHT 3 n BLK 3 EXTEND BOOM RETRACT BLK WHT 3 e m 0 m H BLK 4 rj EXTEND BLK WHT BOOM Bes w RETRACT jee BLK WHT 4 g wn E 8 b x a Em ORG 3 UP PLATFORM LEVEL A DOWN ORG BLK 3 ES ORG 2 ORG 4 p lup ORG BLK PLATFORM LEVEL 4 DOWN ORG BLK 4 n a o E l Be ORG RED 4 p ORG RED 3 2 rs ED GRN 3 LEFT PLATFORM ROTATE 5 RIGHT GRN BLK 3 GRN 2 m 2 5 GRN 4 7 GRN BLK PLATFORM ROTATE 4 RIGHT L GRN BLK 4 7 TB18 GROUND DRIVE ENABLE LIMIT SWITCH DRIVE EDC BRAKE STEER RIGHT STEER LEFT BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH TURNTABLE ROTATE R TURNTABLE ROTATE L TURNTABLE ROTATE 8 EXTEND RETRACT FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL BOOM EXTEND
35. O a a aq BK F BLK RED 3 BLK RED Sp sa a a A A o a m 5 gt A BLK 2 BLK RS E H LI a r z M ola WHT 0 WHT R17 E H 95 a E a SZ ORG R17 E H 6 WHT 21 E H com _ RED E H m 3 ORG BLK 1 E ORG BLK 41 E H a a Fa 2 EE SE amp m 371 E 5 4 IE 5 m BIE a amp 21 5 1 15 2 lt gt a s I 2150 a Sc LA E a et AN aa 4 a 2 79 c o x 2 25 lt TREE RED RED 20 E H d a a EN 1 N LO HIGH IDLE RELAY FLASHING BEACONS PRECISION GOVERNOR RELAY FUEL RELAY FUEL RELAY GENERATOR OPTION LPG SOLENOID ANTI DIESEL VALVE FUEL PUMP WATER TEMP SENDER OIL PRESSURE SENDER HOUR METER AUTOMATIC CHOKE IGNITION SYSTEM PULSE GENERATOR STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN HYDRAULIC OIL TEMP SWITCH COOLING FAN OPTION Part No 35023 Genie Industries 18 Service Manual Supplement S 80 85 Electrical Schematic Gasoline LPG Models
36. OTATE SWITCH CB CIRCUIT BREAKER CONTROLS 15A CB2 CIRCUIT BREAKER ENGINE 15 HM HOUR METER R2 RESISTOR 10 OHM BOOM FUNCTIONS Gi VOLT METER GAGE G2 OIL PRESSURE GAGE 63 WATER TEMP GAGE Me Ts9 T515 TS16 000 00 000 J 1517 In O 000 000 514 7513 000 LETT NEO ome EXTJRET CUTOUT RELAY IT Service Manual Supplement S 80 85 Ground Control Box Legend Gasoline LPG Models N SECTION lt lt CD CRIT LAF COOLING FAN RELAY in 4 GRIWI4__ GRNWHT 1 45 GEN OPTION GRN BLK E H RED 6 44 GRN RDIBK 2 DUMP VALVES RED 7 GAN 1 43 RED 27 WHTt21 LS POWER BLK7 ORG RED i 42 BKWT 8 BLK 6 TURNTABLE ROT HIGH OGIBKEH ORGBLK 41 OG BK 2ISM PULSE PICKUP WHT 6 ORG 1 40 WHT 7 LIMIT SWITCH BLU RED 1 39 BURD CRZ BURDS P LP BUWTCR6__ BLUWHT1 38 BUWTSP GAS BU BK BLU BLK 1 37 BL BK D B STEER LEFT BLU EH BLU 1 36 BLU D B STEER RIGHT BLKIRED 1 35 BKIRD SP RPM BLKWHTA _ 34 GLOW PLUG BK 31SM BLK 1 33 BLKCR8 BLKSP START WT RD WHT RED t 32 WT RD D B BRAKE WT BKE H WHTBLKi 31 EDC RED 5 WHT 1 30 E D C RDW
37. S13 PLATFORM ROTATE SWITCH 7814 PLATFORM LEVEL 5 ______ caste 07 KY Pn 7515 BOOM EXTEND RETRACT SWITCH J 4 8 KEY BYPASS TS16 PRIMARY BOOM UP DOWN SWITCH 018 16x FUELON 7517 TURNTABLE ROTATE SWITCH CR17 10 ENG FAULT CBi CIRCUIT BREAKER CONTROLS 15A COOLING O Td ev rau BREAKER ENGINE 154 RELAY cat cre CR3 TART IGNITION RPM RPM R2 RESISTOR 10 OHM BOOM FUNCTIONS RZY ENT RELAY Gi VOLT METER GAGE G2 OIL PRESSURE GAGE TX NN 03 WATER TEMP GAGE IN 1 1 T T LA A SECTION A A CR5 CR6 CR7 IHORN FUEL FUEL RELAY CUTOUT CUTOUT RELAY RELAY ENGINE HARNESS CO Part No 35023 Genie Industries Service Manual Supplement ZZ Z 60 34 Relay Panel Legend Gasoline LPG Models IGNITION MODULE g 9000000000000 A 2 7 e SN 2 Y GOVERNOR 31 Genie Industries Part No 35023 Service Manual Supplement r Z 60 34 Ground Control Box Legend Gasoline LPG Models A P2
38. TEH RWA 29 2WD AWD RD BK E H RED BLK 1 28 TILT ALARM __ 27 RD 4 ISM 3 REDSP AUX PWR WTIRD 26 WI RDS P WATER TEMP SENDER WT BK 25 WT BKS P OIL PRESSURE SENDER WT 101SM 24 WARNING SENDER RDWT E H WHT2 28 WHTSP KEYSWITCH PWR BLKCR5 BLK2 22 BLKSP PWR TO PLAT WHT CR2 WHT E H 21 WHT D B WHT S P IGNITION PWR RED E H 20 RED S P 12V BATT SUPPLY GRN WHT 3 19 S P JIB VALVE GRNBLK4 GRNBLKS 18 GR BKD B GRIBKSP PLAT ROT GRN4 GRN 3 17 GRND B _ GRNS P PLAT ROT L ORG RED4 ORG RED 16 OG RDD B OG RDS P PLAT LEVEL FC ORGBLK4 _ ORG BLK 3 15 OGIBKD B OG BKS P PLAT LEVEL DN ORG 4 ORG 3 14 ORG D B ORG S P PLAT LEVEL UP WHT 5 BLURED3 13 LT WHT E H BLU WHT 3 12 BLK 5 DRV ENA BLUBLK4 BLUBLK3 11 BU BKD B BU BKS R SEC BOOM DN BLU 4 BLU 3 10 BLUDB BLUSP SEC BOOMUP BK RD CR5__ BLK RED 3 9 HORN BLKWHT4 __ 8 BKWTD B BKIWTS P BOOM RETRACT BLK 4 BLK 3 7 BLKD B BLK S P BOOM EXTEND WIR A WHTRED3 6 WI RDSP TURN ROT FC WHT BLK 4 WHT BLK 3 5 WT BK D B WT BK S P TURN ROT L WHT 4 WHT 3 WHTD B WHTSP TURN ROT R R W 4 RED WHT 3 3 RD WTS P PRI BOOM RED BLK 4 RED BLK 3 2 RD BK D B RD BK S P PRI BOOM DOWN RED 4 RED 3 1 RED D B RED S P PRI BOOM UP D B A DIODE BLOCKS O 1 START RELAY 2 TACHOMETER IGNJSTART O a START INPUT MODULE
39. WHT B n o 2 gt gt a sd 1 T I WHT 21 E H QO x Box I REN 17 el 19 I on I 163 EZ Z 129 91 WATER TEMP SENDER 51 gt amm MEME 5 ZEE BLK R1 E H 7 5 E 5 z AUXILIARY c hee E 1 5 R PUMP RED RED427 E H AUXILIARY amp ER PUMP RED 1 a SIF z a 9 tz co 5 a Bl wd 2 we RED RED BLK 1 RED BLK 28 E H a WHT 2 RED WHT 23 E H E z g 5 c za m z g g AG BK F BLK RED 3 BLK RED SY d a 2 8 N BLK 2 SZ BLK RS E H E a 55 2 5 M 9 i 5 WHT O7 WHT R17 E H 3n 8 T a n oz q WHT 21 EH _ RED EH 5 ORG BLK 1 ORG BLK 41 E H a a EN HE 20 u u lo halo NE 3 5 EN r E Ma o i 1 a 2 la Iq W 1 HIN 1905 th SEG algo 1298 5i la rg Qe Ld Ed MN a S z a en LX o 2 a 295 RED RED420 E H EH N LO HIGH IDLE RELAY FLASHING BEACONS PRECISION GOVERNOR RELAY FUEL RELAY FUEL RELAY GENERATOR OPTION LPG SOLENOID ANTI DIESEL VALVE FUEL PUMP WATER TEMP SENDER OIL PRESSURE SENDER HOUR METER AUTOMATIC CHOKE IGNITION SYSTEM PULSE GENERATOR STARTER MOTOR AUXILIARY POWER
40. and the poppet valve will provide a flow path during LPG fueled operation 34 Genie Industries Part No 35023 First Edition Service Manual Supplement 7 3 Timing Adjustment Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 7 4 Carburetor Adjustment Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 7 5 RPM Adjustment Refer to Maintenance Procedures B 3 Check and Adjust the Engine RPM 7 6 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump 9 OO pump pump shaft coupler flex plate with raised spline flywheel 1 4 inch gap a b f FORD LRG 423 ENGINE Flex Plate Removal 1 Disconnect and remove the hose between the carburetor venturi and the air cleaner 2 Disconnect the linkage from the governor then remove the governor linkage from the carburetor Do not alter the length of the linkage 3 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 4 Remove the mounting fasteners from the regulator mounting bracket then pull the bracket up past the bell
41. area and do not operate the machine Repair the leak immediately 8 Swing the engine pivot plate back to its original position and replace the two retaining bolts C 2 Replace the PCV Valve Gasoline LPG Models Genie S 40 models This procedure replaces C 10 Genie S 80 85 models This procedure replaces C 11 Genie Z 45 22 models This procedure replaces C 10 Genie Z 60 34 models This procedure replaces C 10 Yearly replacement of the PCV valve is essential to good engine performance A malfunctioning valve can impair crankcase ventilation and may cause engine damage Perform this procedure with the engine off SCHEDULED MAINTENANCE PROCEDURES 1 Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the PCV valve a _ pivot plate retaining bolts b engine pivot plate 2 Remove the hose from the PCV valve then remove the valve a PCV valve 3 Install the new PCV valve Connect the hoses 4 Swing the engine pivot plate back to its original position and replace the two retaining bolts Part No 35023 Genie Industries 5 Service Manual Supplement First Edition SCHEDULED MAINTENANCE PROCEDURES C 3 Replace the Spark Plugs Gasoline LPG Models Genie S 40 models This procedure replaces C 12 Genie S 80 85 models This procedure replaces C 13 Genie Z 45 22 models This procedure replaces C 12 Genie Z 60 34 models
42. asoline fuel operation before adjusting the LPG idle mixture Refer to B 3 Check and Adjust the Engine RPM ra The engine should be warmed to normal operating temperature before performing this procedure 1 Move the fuel select switch to LPG fuel and start the engine from the ground controls Spark plug torque 5 to 10 foot pounds 7 to 14 Nm 6 Genie Industries Part No 35023 First Edition Service Manual Supplement SCHEDULED MAINTENANCE PROCEDURES 2 Loosen the high idle mixture adjustment 6 Move the engine idle control switch to low idle lock nut turtle symbol and adjust the low idle screw to a obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 adjustment screw 3 Load the system by pressing the boom retract switch then move the engine idle control switch to high idle rabbit symbol 4 Adjust the high idle adjustment screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 using an exhaust gas analyzer a low idle mixture adjustment screw Preliminary setting is 1 4 inch of threads showing Measure from Preliminary setting turn low idle top of lock nut to top of adjustment adjustment screw clockwise all the Screw way in Turn low idle adjustment screw counterclockwise 2 3 4 If an exhaust gas analyzer is not turns available adjust to obtain peak or optimum rpm 5 Hold the adjustment screw and tighten the lock nut Part No 35023 Genie Industries 7 Service Manual Sup
43. cedures B 1 Check the Engine 5 nn rn 2 B 2 Check and Adjust the Engine Idle Mixture Gasoline LPG Models 2 B 3 Check and Adjust the Engine RPM nennen nnne 2 C 1 Replace the Gasoline Fuel Filter Gasoline LPG Models 4 C 2 Replace the PCV Valve Gasoline LPG Models ee RR ee RR ee 5 C 3 Replace the Spark Plugs Gasoline LPG 5 6 C 4 Check and Adjust the Air LPG Mixture Gasoline LPG Models 6 C 5 Check and Adjust the Ignition Timing Gasoline LPG Models 8 D 1 Change or Recondition the Engine Coolant Gasoline LPG Models 8 D 2 Change the Fuel Lines iic odere niet RE ER N PSE 9 D 3 Check the Engine Valve Clearance Gasoline LPG Models 10 D 4 Check the Engine Cylinder Compression Gasoline LPG Models 10 D 5 Clean the PCV Hoses and Fittings Gasoline LPG Models 11 D 6 Replace the Timing Belt Gasoline LPG Models 2 12 Section Three 5 40 Electrical Schematics Electrical Schematic Gasoline LPG Models 13 Ground Control Box Legend Gasoline LPG Models 15 Relay Panel Legend Gasoline LPG 16 Platform Control Box
44. he proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Perform this procedure in gasoline mode with the engine at normal operating temperature 1 Disconnect the blue black wire from the governor actuator Genie Industries Part No 35023 First Edition Service Manual Supplement 2 Connect an rpm gauge to the engine then start the engine from the ground controls Result Refer to the RPM Specification chart for the correct rpm setting Skip to step 4 if the low idle rpm is correct 3 Turn idle adjustment screw on the carburetor clockwise to increase rpm or counterclockwise to decrease rpm Gasoline LPG low idle adjustment a carburetor b adjustment screw 4 Turn the engine off and reconnect the blue black wire to the governor actuator 5 Start the engine from the ground controls O Result Refer to the RPM Specification chart for the correct rpm setting 6 Move the engine idle control switch to high idle rabbit symbol from the ground controls O Result Refer to the RPM Specification chart for the correct rpm setting 7 Turn the engine off If low and high idle rpm s are correct disregard adjustment steps 8 and 9 8 Remove the mounting fasteners from the electronic governor located on the engine side bulkhead then remove the back pane
45. housing Secure the bracket before continuing 5 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 6 Carefully pull the pump away from the engine and secure it from moving 7 Remove the flex plate mounting fasteners then remove the flex plate from the fly wheel How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline towards the pump Torque the flex plate mounting bolts to 34 ft Ibs 46 Nm 2 Install the coupler onto the pump shaft with the set screw towards the pump Leave a 1 4 inch 6 35 mm gap between the coupler and pump end plate 3 Apply Loctite removable thread sealant to the coupler set screw Torque the set screw to 45 ft lbs 61 Nm Component damage hazard Do ACAUTION not force the drive pump during installation or the flex plate teeth may become damaged 4 Install the pump and torque the pump mounting plate fasteners to 34 ft Ibs 46 Nm Part No 35023 Genie Industries 35 Service Manual Supplement First Edition FORD LRG 423 ENGINE 7 7 Water Temperature and Oil Pressure Gauges The water temperature gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 230 F 109 C When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact poi
46. i LS T o 5 m RED 5 r i T RED 4 n td UP RED BLK PRI BOOM A 4 TE DOWN B a RED BLK 4 s b 4 8 RED WHT 4 n a n RED 3 b e RED BLK 3 N Qa ER tc RED WHT 3 A N a FL BLK 3 EXTEND BOOM LRETRACT BLK WHT 3 5 m 4 E BLK 4 7 EXTEND BLK WHT BOOM Y RETRACT Ed BLK WHT 4 7 o b m m gt a EA ORG 3 UP PLATFORM LEVEL DOWN ORG BLK 3 S ORG 0 i p pe 5 ORG 4 p 10 ORG BLK PLATFORM LEVEL 4 DOWN ORG BLK 4 5 E ORG RED 4 5 R ORG RED 3 N R GRN 3 LEFT PLATFORM ROTATE RIGHT GRN BLK 3 GRN 0 m gt GRN 4 a 5 N GRN BLK PLATFORM ROTATE RIGHT EE sus GRN BLK 4 7 TB18 GROUND DRIVE ENABLE LIMIT SWITCH DRIVE EDC BRAKE STEER RIGHT STEER LEFT BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH TURNTABLE ROTATE R TURNTABLE ROTATE L TURNTABLE ROTATE amp EXTEND RETRACT FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL BOOM EXTEND BOOM RETRACT PLAT LEVEL UP PLAT LEVEL DN PLAT LEVEL F C PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT 24 Genie Industries Part No 35023 Service Manual Supplement a Z 45 22 Ground Control Box Legend Gasoline LPG Models
47. ies 33 Service Manual Supplement First Edition FORD LRG 423 ENGINE 4 Position the linkage rod so that the throttle is in the idle position Then adjust the clevis yoke on the linkage rod to obtain the proper length Install the yoke onto the actuator arm 5 With the throttle in the idle position and the actuator arm at a 110 degree angle to the linkage rotate the clevis yoke on the linkage rod two turns counterclockwise to pre load the spring Tighten the lock nut on the linkage rod 6 Manually pull the actuator arm through a full cycle to be sure that the linkage moves freely Be sure that the linkage activates the throttle shaft to approximately half throttle The linkage must be free of friction and obstruction Do not let it rub against the engine brackets or hoses Component damage hazard ACAUTION If the throttle linkage is improperly adjusted and allowed to reach full throttle the engine will over rev and cause component damage 7 2 Choke Adjustments This engine is equipped with an electrically heated automatic choke The choke has a poppet valve to enhance cold starting ability on LPG fuel Choke adjustments are affected by climate Richer adjustment will be necessary in colder climates leaner adjustment in warmer climates Automatic Choke with Poppet Valve The choke functions in both gasoline and LPG mode The choke butterfly may be adjusted to a fully closed rich position for colder climates
48. io 5 B o e a a m BLU RED 1 BLU RED R7 E H p 2 d E M o FUEL 59 GAS BLU WHT 1 BLU WHT R6 E H p _ 8 fo S a B 22 BLUWHT R6 EH n 0 P 4 FUEL GAS EH SE 20 oz 8 gt BLK 1 D E o 9 se ENGINE 3 START 2 EKGNROGREGE m RO E E WHT 24 E H gt ENGINE START__ BLK 8 WHT F m i 5 Iw N p 59 4 IEEE x gt 4 N m gt 1122 2241 WHT 21 E H N i rm _00 NOZE NSE a gt 4 LL di 1 e 54 8 Eg 4 59 9 WATER TEMP e gie SENDER Eie Sy NE 5905 NES 5 pepe 1 led BLK R1 E H EO a I N 2 E p AUXILIARY A x be EE d N PUMP REDF RED 27 E H AUXILIARY 215 PUMP RED 1 SIE T S a z A N n a RED E RED BLK 1 RED BLK 28 E H m 4 WHT 2 RED WHT 23 E H m 9 A E gt E 89 m gt 5 5 e ag AE BLK RED 3 BLK RED n d a X B A BLK 2 OZ BLK R5 E H E a 55 2 5 9 x WHT WHT R17 E H On R a a oz q WHT 21 E H mm _ RED E H 3 ORG BLK 1 E ORG BLK 41 E H 2 e g Ese a o c paspas I amp Ed A E 1 1 ii a sj ES KDE I A sad i20 E N gt 8184 8841015
49. is procedure replaces B 1 Genie Z 60 34 models This procedure replaces B 1 Maintaining the engine belt s is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt and continued use may cause component damage AWARNING Do not inspect while the engine is running Remove the key to secure from operation ACAUTION Beware of hot engine components Contact with hot engine components may cause severe burns 1 Inspect the engine belt for cracking glazing Separation breaks Ford LRG 423 engines are equipped with a serpentine belt and incorporate a self adjusting pulley tensioner No adjustment is required B 2 Check and Adjust the Engine Idle Mixture Gasoline LPG Models Genie S 40 models This procedure replaces B 11 Genie S 80 85 models This procedure replaces B 11 Genie Z 45 22 models This procedure replaces B 11 Genie Z 60 34 models This procedure replaces B 11 Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 B 3 Check and Adjust the Engine RPM Genie S 40 models This procedure replaces B 12 Genie S 80 85 models This procedure replaces B 12 Genie Z 45 22 models This procedure replaces B 12 Genie Z 60 34 models This procedure replaces B 12 Maintaining the engine rpm at t
50. l from the governor SCHEDULED MAINTENANCE PROCEDURES 9 Restart the engine turn the low or high speed set screw clockwise to increase the rpm or counterclockwise to decrease the rpm Do not adjust any trimpot other than specified in this procedure Gasoline LPG idle adjustment a lowidle adjustment b high idle adjustment 10 Apply a drop of silicone to the top of the trimpot screw Apply a bead of silicone to the surface of the back panel prior to re assembly 11 Re assemble the governor and recheck low and high idle S 40 RPM Specifications Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm S 80 85 RPM Specifications Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm Z 45 22 RPM Specifications Low idle carburetor 900 rpm Low idle electronic governor 1400 rpm High idle 2150 rpm Z 60 34 RPM Specifications Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm Part No 35023 Genie Industries 3 Service Manual Supplement First Edition SCHEDULED MAINTENANCE PROCEDURES C 1 Replace the Gasoline Fuel Filter Gasoline LPG Models Genie 5 40 models This Ak A 2 procedure replaces 9 7 Hi Y Genie S 80 85 models This procedure replaces C 10 Genie Z 45 22 models This procedure replaces C 9 Genie Z 60 34 models This procedure replace
51. nt Temperature will be indicated when the key is on and the Emergency Stop Button is pulled out to the position Component damage hazard ACAUTION Do not crank the engine with the over temperature light on The oil pressure gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 8 psi 0 55 bar When the contacts close the engine will shut off to prevent damage Oil pressure will be indicated when the engine is running Component damage hazard ACAUTION Do not crank the engine with the low oil pressure light on 7 8 Vacuum Switch How to Test the Vacuum Switch ohmmeter common terminal SOL vacuum switch normally open terminal ING 1 Connect the leads from an ohmmeter or continuity tester to the common and normally open terminals Result There should be no continuity infinite Q 2 Apply mild suction to the vacuum port Result The switch should close and show full continuity zero Component damage hazard ACAUTION Do not short the vacuum switch terminals to ground 36 Genie Industries Part No 35023 U S A 18340 NE 76th Street P O Box 69 Redmond Washington 98073 0069 Europe Brunel Drive Newark Nottinghamshire NG24 2EG England
52. plement First Edition SCHEDULED MAINTENANCE PROCEDURES C 5 Check and Adjust the Ignition Timing Gasoline LPG Models Genie S 40 models This procedure replaces C 14 Genie S 80 85 models This procedure replaces C 15 Genie Z 45 22 models This procedure replaces C 14 Genie Z 60 34 models This procedure replaces C 14 Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 D 1 Change or Recondition the Engine Coolant Gasoline LPG Models Genie S 40 models This procedure replaces D 2 Genie S 80 85 models This procedure replaces D 2 Genie Z 45 22 models This procedure replaces D 2 Genie Z 60 34 models This procedure replaces D 2 Replacing or reconditioning the engine coolant is essential to good engine performance and service life Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage Extremely dirty conditions may require coolant to be changed more frequently Beware of hot engine parts and ACAUTION coolant Contact with hot engine parts and or coolant will cause severe burns Perform this procedure with the engine off and cooled Put on protective clothing and eye wear Disconnect the coolant return hose at the radiator and drain the coolant return tank Remove the radiator cap from the radiator Remove the
53. s C 9 mil a Replacing the gasoline fuel filter is essential to good engine performance and service life A dirty or clogged filter may cause the engine to perform a _ pivot plate retaining bolts poorly and continued use may cause component b engine pivot plate damage Extremely dirty conditions may require that the filter be replaced more often 2 Disconnect the fuel hose from the filter then remove the fitting from the filter Engine fuels are combustible ADANGER Dee the fuel filter in an open 3 Remove the filter from the carburetor well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the fuel filter located near the carburetor a fuelfilter b hose from the fuel pump to the fuel filter 4 Install the fitting into the new fuel filter then install the fiter into the carburetor 4 Genie Industries Part No 35023 First Edition Service Manual Supplement 5 Connect the fuel hose to the filter 6 Clean up any fuel that may have spilled during the installation procedure 7 Start the machine from the ground controls then inspect the fuel filter and hose for leaks If a fuel leak is discovered keep A DANGER any additional personnel from entering the
54. ure replaces D 6 Genie Z 45 22 models This procedure replaces D 6 Genie Z 60 34 models This procedure replaces D 6 Maintaining PCV hoses is essential to good engine performance Improperly functioning PCV hoses will fail to ventilate the crankcase and continued use of neglected hoses could result in component damage Perform this procedure with the engine off 1 Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the PCV hoses D TT EE a pivot plate retaining bolts b engine pivot plate SCHEDULED MAINTENANCE PROCEDURES 2 Disconnect the hose from the PCV valve then disconnect the hose from the engine a hose carburetor to valve cover b PCV valve hose PCV valve to carburetor 3 Disconnect the hose from the carburetor then disconnect the hose from the valve cover 4 Clean the hoses with a mild cleaning solvent 5 Dry both hoses and inspect them for cracks and damage Replace the hoses if they are damaged Part No 35023 Genie Industries 11 Service Manual Supplement First Edition SCHEDULED MAINTENANCE PROCEDURES D 6 Replace the Timing Belt Gasoline LPG Models Genie S 40 models This procedure replaces D 9 Genie 5 80 85 models This procedure replaces D 9 Genie Z 45 22 models This procedure replaces D 9 Genie Z 60 34 models This procedure replaces D 9 Complete information
55. ustible ADANGER 2 Replace the fuel lines in an open a upper hose b lower hose well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within 12 Clean up any coolant spilled during this easy reach procedure 11 Fill the radiator and then fill the coolant recovery tank to the NORMAL range r Perform this procedure with the 13 Start the engine from the ground controls engine off run it for 30 seconds and then turn it off 1 Close the manual fuel shutoff valve located 14 Inspect for leaks and then check the fluid next to the fuel tank level in the coolant recovery tank Add water if needed 15 Start the engine from the ground controls and run it until reaching normal operating temperature 16 Allow engine to cool and check the fluid level in the coolant recovery tank Add water if needed Ford Engine 11 5 quarts Coolant capacity 10 9 liters Part No 35023 Genie Industries 9 Service Manual Supplement First Edition SCHEDULED MAINTENANCE PROCEDURES 2 Remove and replace the fuel line hoses and clamps according to the following illustrations Fuel may be expelled under A DANGER pressure Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them Ue a carburetor b fuelfilter c hose from the fuel filter to the fuel pump d hose from the fuel pump to the fuel tank not shown 3 Clean up an
56. y fuel that may have spilled during this procedure 4 Start the engine from the ground controls then inspect the fuel filter and hoses for leaks If a fuel leak is discovered keep A DANGER any additional personnel from entering the area and do not operate the machine Repair the leak immediately D 3 Check the Engine Valve Clearance Gasoline LPG Models Genie S 40 models This procedure replaces D 4 Genie S 80 85 models This procedure replaces D 4 Genie Z 45 22 models This procedure replaces D 4 Genie Z 60 34 models This procedure replaces D 4 Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 D 4 Check the Engine Cylinder Compression Gasoline LPG Models Genie S 40 models This procedure replaces D 5 Genie S 80 85 models This procedure replaces D 5 Genie Z 45 22 models This procedure replaces D 5 Genie Z 60 34 models This procedure replaces D 5 Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 10 Genie Industries Part No 35023 First Edition Service Manual Supplement D 5 Clean the PCV Hoses and Fittings Gasoline LPG Models Genie S 40 models This procedure replaces D 6 Genie S 80 85 models This proced
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