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Service Manual - Genie Industries

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1. A B C D E F G H J K L M 1 EXTEND RETRACT CYL TURNTABLE mn 15 1 L min pria PLATFORM LEVEL So wEpuM 3 78 Umin P
2. L K J H G F E D C B A EXTEND RETRACT CYL TURNTABLE Lmin ROTATE PLATFORM LEVEL M N 3 2 sea 1 3
3. M L K J 46 LIMIT SWITCH POWER GR WH C6 89 GH WH C2B 7 45 GEN OPTION GR BK C2B 6 44 gt GR BK 2B SPARE GR C2B 5 43 GR CR5 85 HORN OR RD C2B 4 42 SPARE OR BK C5 2 OR BK C2B 3 41 PULSE PICKUP G1 G2 G3 OR C6 40 OR C2B 2 40 LIMIT SWITCH SIG BK WH C5 10 BL RD C2B i 39 BURD amp P LP S BL C533 BLWH C1B 12 38 BUWH ISMETO 6 CHECK ENGINE BR GROUND BL BK C6 37 BLBK C1B M 37 STEER LEFT BL C6 36 BL C1B 10 36 STEER RIGHT BK RD C5 9 BK RD C1B 9 35 BK RD amp P RPM 8 34 BK WH S P GLOW PLUG BK ISM 3 BK C1B 7 33 BK CR1
4. z x o 8 5 8 N HIGH RPM FS si 01 9 C35ESPD BK RD 5 QN z 4LowRPM N HIGH IDLE RELAY u FUNCTION 2 0 HIGH RPM pe BKIRD 2 19 x e 5 5 BRAD Se HIGH RPM SOLENOID z N 5 5 8 E C2 7 C45GEN GR WH C6 39 GR WH 45 i GENERATOR OPTION 2 1502 2 0 Eos ccce E g 2 C1 8 C34SA BK WH C5 22 1 SON GLOW 8 GLOW PLUG OPTION 5 FH GLOW l 4 em sls UG 000 Rz ABL uL Wu uL Eee a LLL Lu el 9 c3 WATER TEMP GAUGE 9 WH 24 WATER TEMP 58 SWITCH o gt E 65 19 2 OIL PRESSURE A SWITCH tua 1014 ado 2
5. C28TTA RD BK RD BK en C2 3 OR BK P26ESTP BK BK LS18 pa FS RD FS BK BKHFS 7 9 3 P25FSRD RD WH FS C9 2 P24FS WH WH V 9 9 g 2 i B SEE 2 79 5 5 5 P3 4181 2 pu 54 E m TB 134 IS WAGO TERMINAL BLOCK 42 9 g S A H HORN u TB 133 IS WAGO TERMINAL BLOCK 16 3 2 D gt v 5 TB 132 IS WAGO TERMINAL BLOCK 8 5 SQ Loi SEENOTE2 9 te 27 TB34 z s gt m 5 amp J EN a 2 gt 2 lt 2 h 3 CB2 TB134 m gt Pi BD 4 2 4 TB43 o o e lo Y 9 SAME Rp RD E i 3 d es 128 E TB22 js e 4 5 amp e pum PLAT i RD GRD 2 TS52 t 26 U33 9 g S 8 TS51 2 g Q TS55 9 3 g 9 B 3 vs 8 8 8
6. RD NOTE ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH OFF N N BR 2 GROUND C41RPM OR BK se C23 515 zo DRIVE SPEED 8 ae C14 lt 030500 5 21 C30EDC4 ___4 5 gt 8 4 DRIVE EDC FORWARD Tl c29ms RD WH gt 58 5 0 0 LED BURG STE TR4 C15 2 CatEDC WH BK zi 0 C31EDC WH BK I 4 DRIVE EDC REVERSE e i C632 B pDRE B Buek gt 37 TRAVEL ALARM OPTION DRIVE ENABLE 1 BL WH gt 56 Tg s 0796 C32BRK WH RD s C523 C32BRK 54 BRAKE RELEASE VALVE e 38 5 C5 24 Se 204 _ C13 C29MS RD WH C29MS RD WH lt lt 4S gt MOTOR STROKE 8 1 11 C6 37 Re BLIBK C37STCC
7. RD N e co N co BR2 GROUND M M CA1RPM OR BK lsz 23 75 DRIVE SPEED 5 21 A C14 c C30EDC4 C30EDC WH 4 DRIVE EDC FORWARD Tl c29Ms RD WH258 M cts C31EDC WH BK fe 05 20 C31EDC WH BK D 5 4 DRIVE EDC REVERSE DRE LED BURD 246 5 j E 6 32 5 4 TRAVEL ALARM OPTION gt 7 ere Tong A BLWH 6 Tace C6 lt lt C32BRK WH RD i 65 23 lt gt BRAKE RELEASE VALVE D 8 E SLM 204 C29MS RD WH E 5 24 C29MS omel y MOTOR STROKE N m e 0 re 7 BUBK g C6 37 C37STCC 1 STEER CCW ao AZ C36STC BL 65 36 C36STC X Al 4 STEER CW 1 g Q 8 amp RKOUTS lt
8. N EE e 3 35064 Jan WH C19JSV GR WH TS7 mae Jae C19JSV GR WH C4P 7 D seve BR JC3 E ad BK BR GND RD E STOP 25 RRE P134PWR 1 5 BR a CR13 86 GR WH 5 a m a 2 a 9 5 E P134PWR RD 5 6 8 e J GRWH RE gt RD 7 77 S P134PWR RD 700 RD H14 5 E 9 8 5 8 B 5 2 89 e i 4 27 P26ESTP BK E STOP R26ESTP BK C9P 1 6 c oy P23BAT WH 7 2 t P22BAT BK C7P 1 C19JSV GR WH C4P 7 C18JD GR BK 6 C17JU GR C4P 5 m C15PLD OR BK C4P 3 C14PLU OR C4P 2 C43HRN GR C2P 5 8 C8PBR BK WH C3P 8 1 C7PBE BK C3P 7 26 C9P 1 P25FS RD C9P 3 P24FS WH C9P 2 JDALARM GR BK 2 6 C45GEN GR WH C2P 2
9. GROUND STUD O RD H6 C32 1 uas BL WH 132D C32 3 BK 22C 32 4 RD C32 1 PLATFORM LOAD BKC7 1 032 5 RD 134B 71 m RD TS51 C32 6 GR BK L45 RD TS55 C32 7 GR BK 133 A GR BK 133B C32 8 BR GND 032 12 BR GROUND 48 SPARE GR WH C6 39 45 gt GR WH 35B GEN OPTION 44 gt GR BK2B GR BKS R JDALARM JIB 43 GR CR5 85 HORN 1844 om 34 5 1 RD H6 RD KSI 2 SP P134PWR OR BKC5 2 41 PULSE PICKUP WH BK 25A OR C6 40 40 LIMIT SWITCH SIG WH RD 26A BL RD C5 10 39 BURDSP L P BK 22A BL WH C1B 12 132 C132PLI BL BK C6 37 37 STEER CW P1 TS51 BL _C6 36 36 STEER CCW BK RD C5 9 35 GR WH 45B B BK RD amp R RPM RD CB2 5 E 34 BKWH S R GLOW PLUG D2 1349 a9 33 BKOR1 85 05 BKS P START B1 Ge WH RD C5 23 32 WH RD C6 32 BRAKE TRAVEL WH 23A WH BK C5 20 31 E D C R
10. Ford DSG 423 EFI Models ANSI 053 AS from serial number 16420 Electrical Schematic October 2013 a HIGH RPM FS 0 C35RPM BK RD 5 PER Ena 7 ENGSPEED HIGH RPM ple 2 a B 5 gt GENERATOR 8 8 GENERATOR C45GEN GR WH s 06 39 CA5GEN rn c _ adi 7 in vM Xa 7 7 7 WORKLIGHTS OPTION e 19 Sy 5 8 gt amp DRIVELIGHT 1 lt m 2 9 12 7 RO z 1 OPTION 8 3 a 1 2 3 5 15 5 25 4810 BD ST ja zz d C o N 5 2 VOLT METER R21IGN WH HOUR METER 0 C5 16 MN WH BK OIL PRESSURE GAUGE n AL evro o 1 B Gn 2 GASOLINE SENSOR 2 5 cl RD 28 8 2 D BK BE a NO Ag 21 C33STR BK nl 4 NE EI RD GR ra c LPG LOCKOUT ENGINE EO WHIBK e a 55 STAR wo 0 E TEMP GAUGE
11. N wo N BRN 2 A GROUND CA1RPM OR BK sz C2P 3 215 In e E 8 to s 5 4 C30EDC WH C5 21 C3OEDC WH A gt DRIVE EDC FORWARD 23 I DRELEDBURD 5 E 5 1 WH BK 5 C5 20 CS1EDO WHIBK_D n 5 gt DRIVE EDC REVERSE ot 8 I c6 32 i DREBBUBK E TRAVEL ALARM OPTION fa DREBBUBK 6 C32BRK WH RD C5 28 C32BRK WH RD a DREABUWH gt l TK e n 4 BRAKE RELEASE VALVE P lao C29MS RD WH C5 19 C29MS RD WH Al MOTOR STROKE m 1 11 071008086 C6 37 C37STCC BL BK iz 187 E 5 STEER RIGHT RKOUT EC BLW 5 YOUT 4 WH RD SS 4 1 10 C36STC BL 6 CS6SICIBE 4 steer LEFT l XOUT Z BL WI 5l 8 7 08 gt 13 E GNDIR BAN e lie C3P 6 C6TRF WH RD e hz 5 CS5TRR WH BK Ito 4 CATRL WH 8 C64 CATHL WH 4 TURNTABLE ROTATE LEFT C5TRR WH BK Re tRIGHT ia C65 TURNTABLE ROTATE RIGHT ni 8 g
12. BL WH 1 ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH OFF N e N co BR 2 1 GROUND C41RPM OR BK Ice C23 215 Ei 5 F DRIVE MODE P i De 5 _c29Ms RD WH gt gt 8 freee C14 e C30EDC 4 WH 5 2 C30EDC WU X f 53 4 DRIVE EDC FORWARD 5 5 C5 20 Biz xe TE C31EDC WH BK fe C31EDC WH BK DRIVE EDC REVERSE LED BURD 16 E i 0 oO Bp DRE B 81 86 57 66 32 TRAVEL ALARM OPTION zs DRIVE ENABLE R DRE BLWH gt gt 6 Re m C32BRK WH RD 8 Sy 65 23 C32BRK WH RD BRAKE RELEASE VALVE m N 38 C5 19 ug E13 4 C29MS RD WH e C29MS MOTOR STROKE B B 6 lt HB ChI gt C
13. Section 6 Schematics C DSG 423 EFI Models ANSI CSA AS from serial number 15663 to 16419 Electrical Schematic October 2013 86 5 Rx om 5 HIGHRPM FS 2 9 C35RPM BK RD 8 e ena e ENG SPEED HIGH RPM pe 28 2 oO fo v VENERATOR 8 GENERATOR x gt a C27 C45GEN GR WH G 6 39 gt OPTION 9 DLITE BK RD 1 2 g m RD DRIVE LIGHT s a a 2 12 gt lt gt OPTION 6 B CC
14. E m Pm 5 8 e 5 le o oe 5 MET i a m 5 gg SEG 8932 83 qr Sais i az o m w Der md i 0 Pv E i wi lt ug 9 HINHO i M i LA iq i p xl i I i i 5 i een i 6 EIS LUI 3 215 EN i a 5 a i ERE e Pg 2 d i Ki od ME il 1 E o ME d 21 me 5 x m x EE 5 T m m ig x x i 5 i 9 8 Pod 9 i r 3 1 m m a 1 bod IN i lo i EN CAAA AAA Ld aic DLE DOC MCI CM UI dE EDU C DN i a 1 T i i 5 2 z fo 96 3 E 8 E BE x uz zz i 6 63 53 226 mu
15. RD BUWH C132PLI2 BK Son RD BK OR BK 7 OR BK D89 P26ESTP BK 2 LS18A Fie BK U i 2 2200 J Lei bd ar RD FS C9 3 P25FSRD iss PBOX PB WH FS C9 2 P24FS WH 7 7 GND 088 WH Y 9 92 TS6 mejo o e S Q T 2 2 2 5 TS A 5 9 1817 2 5 g 3 gt m TS4 5 2 No 2 g 3 9m 5 5 2 z 4 30a 5 m 5g p E 5 g 3 x z o 5 3 E E va 8 3 3 39 TB132 IS WAGO TERMINAL BLOCK 36 lt E TB133 IS WAGO TERMINAL BLOCK 16 9 Q Q o GND 9 8 TB 134 15 WAGO TERMINAL BLOCK 42 3 t i 6 li CB2 m m von peces f Rp 8134 TB132 C28TTA RD BK 5 RDP mp i US els M RD Pee Mm 1 3 1 g a 2 RD 4 SPLAT i ES 2 8 8 8 8 91792 ig Tue 8 4 5 1856 5 GRD z d 8 2 Bele 5 re 9 5 m re m e 9 E 5 5 x v e sec Zlo 2 9 m 8 o 5 5 3 6 5 NO EIE g 3 LOAD 9 9 8 2 5 d 5 35 E EE E SENSE X 1 3 5 4 al E5 PBOX GND 253 5 MODULE 27 TB133 9 4 u34 eZ 5 ALOR TB45 gt 3 12 8 E i 2
16. RD N N BR2 GROUND C41RPM OR BK sz C23 515 8 5 DRIVE SPEED z fee 014 e C521 C30EDC WH lt gt 9 4 DRIVE EDC FORWARD C29MS RD WH58 5 1 5 C5 20 1EDC WH BK D gt DRIVE EDC REVERSE DRE LED BL RD SITE E CSIEDE WHIBK Ze Lp DRIVEEDEIREVERSE gt E 6 32 x D DREBBUBK 27 oe Ici DRIVE ENABLE Tonga BLWH 36 gee 616 6 WH RD 5 C525 C32BRK welly BRAKE RELEASE VALVE S oO N SIM 23 4 613 4 C29MS RD WH 624 C29MS MOTOR STROKE N m e 766 CM1 7 BUBK 6537 C37STCC ana Et STEER CCW 5 ae B lt Cr C36STC BL 60 96 C36STC STEER CW 9 6 lt 8 RKOUT5 BUWH YOUT 4 X wHRD 5 4 TE4 C36 x cerRF WH RD XOUT3 BUWH 55 5 Z 2 oA 035 05788 WH BK GND1 BRN SITA C34 C4TRL WH a s 4 C4TRL WH 4 TURNTABLE ROTATE CW 8 mt B 8 C6 5 C5TRR WH BK gt TURNTABLE ROTATE CCW e t C6 6 L5 TURNTABLE ROTATE
17. 1 RD BUWH RD BK OR BK OR BK 2 P26ESTP BK F18 Bk AV nem P2 FS1 TS48 2 RD FS 9 3 P25FSRD 1 C934BK BK FS Te FS 2 4 WH FS C92 P24FS WH WH RD lt 9 A 3 ROT TS TS6 mlo sjo g 2 5 4 5 E 1517 e lt m c d z m TS4 9 lt 5 3 5 3 8 0 3 8 5 oe o 5 16 P3 5 3 s Horn ups us 5 59 3 3 D39 d 5 o 5 3 3 fi whe 2 D 9 5 o e D40 gt s a TB132 IS WAGO TERMINAL BLOCK 36 R 5 NA 5 TB133 IS WAGO TERMINAL BLOCK 16 dm 9 o 2 g R TB 134 IS WAGO TERMINAL BLOCK 42 3 9 i re Rd E d RD ae 78132 7 C28TTA RD BK S 712 mp P 4 21 5 TB43 2 25 4 DNE 3 5 Q Q o 9 RD ar 7 5 9 8 Ki 8 TS51 TS52 9 7856 9 5 E TS55 8 5 2 8 E g c 5 5 5 E m GRD 9 g c d gt 2 gt 5 2 9 2 5 5 5 le 8 g 8 2 222 g 5 lt 5 ES 2 5 5 z ESS 5 2 gt B3 PBOX GND 232 E C32 4 TB133 amp 5 064 53 E CONN 5 217845 9 PLUG 5 m
18. M L K J F E D C B 1 EXTEND RETRACT CYLINDER UI 545 BOOM MEDIUM 1 4 gpm 15 1 L min PLATFORM LEVEL re 500 MEDIUM SUNE 71 2 gpm 7 5 L min CYLINDERS BRAKE 2 SPEED 35 bar PRESSURE Al A 2 MANIFOLD FILTER PRIMARY LIFT CYLINDER 2 025 8 11 3 L min vi 2 aa ms E EJ TEST 0 BRAKE 2SPEED RT I AUXILIARY ae jt PRI IMH PUMP d I Aux 0 PEST EXT Ret pn po t COOLER FUNCTION 2200 psi or TEST OPTION QE MANIFOLD aoe NE 3 2 amp zil 1950 psi T MANIFOLD _ u PRESS Sel 134 5 bar en s PLATFORM 3625 psi poc AS i e f i Ic h A i FUNCTION COUNTERBALANCE VALVE Did RATIO PRESS j PON i PM 6 i f A 3 1 1000 PSI Valve BD ch d Tr 7 5 Lmin 0 4 By 3 1 2000 PSI 1 7 bar NS serial number 16791 1 9 3 L min serial number 16791 3 1 3000 PSI
19. Ground Control Box Wiring Diagram Deutz F3L 1011F Models M L K J G F E C B A 1 C Sen M 3 DRIVE LIGHT OPTION RELAY 5 RD C23 1 U33 C23 BK 22C C23 4 RD 42B Dee PLATFORM LOAD BK C7 1 C23 5 H6 RD TS51 C23 6 GN BK L45 gt CR23 RD TS55 C23 7 GN BK 16A G1 G2 G3 BK RD 9B GN BK 16B C23 8 a BARDS _ BR GND C23 12 WH 21A RD 4 11 2 BR GROUND 46 LIMIT SWITCH POWER RD 04812 GR WH C6 39 GR WH C2B 7 45 GEN OPTION V BRN GND GR BK C2B 6 44 GR BK 2B GR BK S P JDALARM JIB GR C2B5 43 GR CR5486 HORN RD C6 23 OR RD C2B4 42 RD H6 RD KS1 2 S P C134PWR 5 2 OR BK C2B 3 41 OR BK ISM 2 PULSE PICKUP OR C6 40 OR C2B 2 40 LIMIT SWITCH SIG BK WH C5 10 BL RD C2B 1 9 BURD S P LP WH RD 26A BL WH C23 3 BL WH C1B 12 38 C132PLI BL BK C6 37 BUBK C1B 11 STEER LEFT BK 22A BL C6 36 BL C1B 10 36 STEER RIGHT KEY SWITCH 3 BK RD C1B 9 35 BK RD CR3 30 BK RD S P RPM P1 KS1 TS51 BK WH C5 22 BK WH C1B 8 34 BK WH S P GLOW PLUG RD CB2 B ca BK C1B 7 33 BK ISM 3 BK S P START
20. T components shown in the manifold illustrations Refer to the Repair Section A B C D E F G H J K L M 1 EXTEND RETRACT CYL TURNTABLE 161 Lmin m can zu PLATFORM LEVEL _ Bea re PRIMARY LIFT BRAKE MANIFOLD f PRESSURE Al Dy i 2 FILTER Nu ad er l ids t me t ROTATE ni CP 4 EN JL 5 2 Yo DA 1A 5 Al id 2 C 4 Al gt lt gt 1 mean BRAKE TEST 6 MD M n 030 1 ul o L 3 pes SUC GRA I Da AA gt ucc _ EIL AUX 2 5 sw swa P1 P2 J 11 PRI PR2 ee Pr el D COOLER FUNCTION ae ni d IN OPTION MANIFOLD se gt COUNTERBALANCE VALVE 3 o 1 1950 psi Er x 1 x x5 Tu T rosca aa p AZ ees 4 NE PRESS ous NS ANZ N Zi pisa m RATIO PRESS n _ UA AG Pt AH 1 E eG A 3 1 1000 PSI I 1 teks i cem 1 xx 4 2000 PSI e H 4 5 gpm ri 5 0 6 gpm
21. Ground Control Box Wiring Diagram Perkins 704 30 Models 1 2 G1 G2 G3 DRIVE LIGHT OPTION RELAY 2 WH 21A Zz RD CB3 SP BR GROUND i mo 4 5 eL BK RD 9B 1 RD C4B 12 WH BK 25A WH RD 26A BRN GND BK 22A KEY SWITCH 3 P1 EST TS51 RD CB2 LO NC o E 2 o m Gte WH 23A 4 2 RD 42A v HD 27A wv RD 623 6 DESCRIPTION LABEL RD H6 EMERGENCY STOP BUTTON P1 P1 4 OR RD H6 KEY SWITCH KS1 KS1 WEISE 7 AUXILIARY SWITCH 7551 42730 ENGINE START SWITCH TS52 7 HM BR GROUND 5 145 12 FUNCTION ENABLE TS55 13037 BLIWH C5 15 PLATFORM ROTATE SWITCH TS57 16397 BEEN TS61 PLATFORM LEVEL SWITCH TS59 13037 RD BK 2A BOOM EXTEND RETRACT SWITCH TS63 13037 RD 1A 6 6 PRIMARY BOOM UP DOWN SWITCH TS61 7 5 Do TURNTABLE ROTATE SWITCH TS62 16397 JIB BOOM UP DOWN SWITCH TS58 7 TR CIRCUIT BREAKER CONTROLS 15A 1 CB1 TS52 rae CIRCUIT BREAKER ENGINE 15A CB2 CB2 BK WH 34A CB3 CIRCUIT BREAKER OPTIONS 20A CB3 CB3 8 pay RESISTOR 5 OHM BOOM FUNCTION
22. 1 ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED N co N co BRN 2 GROUND C41RPM OR BK C2P 3 215 x P 8 r f y lise 1 4 C30EDC WH C52 C30EDO WH 58 DRIVE EDC FORWARD I DRELEDBURD su IR 5 C31EDC WHBK_ g C5 20 CS1EDO WHIBK D A C DRIVE EDC REVERSE 5 i 2 DREBBUBK 5 7 po TRAVEL ALARM OPTION 24 2 N 4 S BIWA rn 0196 C32BRKWHIRD 05 23 CSeBRI WH RD BRAKE RELEASE VALVE P C29MS RD WH C5 19 C29MS RD WH 1 MOTOR STROKE 5 8 B B 5 1 11 C37STCCBUBK C6 37 C37STCC BL BK K1 steer nient RKOUT EC BUWI se 5 YOUTZ WHIRDSS Hz C1P 10 C36STC BL z C6 36 CSTE BL 1 4 STEER LEFT l XOUT S BL WHESS 5 _ 8 PWR EOR 5 18 6 n 6 CGTRF WH RD 9 loz 5 WH BK n 4 CATRL F i C64 CaTRL WH 4 TURNTABLE ROTATE LEFT TT 5 WH BK Re git RIGHT 74 5 5 7 4 TURNTABLE ROTATE RIGHT 5 a 1 C66 C6TRF WH RD gt TURNTABLE ROTATE 8 FLOW CONTROL ly a P 8 5 uP ns 4 1 RD A PRIMARY BOOM UP IE vouT 4 RD WH 2 Sn 27 DOWN 2 C2PBD R
23. HYDRAULIC GENERATOR to serial number 16452 AUX FUNCTION T PT MANIFOLD FUNCTION C 1 50 psi 3 5 bar MEDIUM BRAKE 2 SPEED lt gt PRESSURE MANIFOLD 0 FILTER 2025 1 2 EJ 2 ot man EIN NE I BRAKE 12SPEED TEST 1 1 1 1 1 Mi S AUXILIARY PUMP 1 1 ti 3 TEST POE 1 1 315 psi 21 7 bar 1 1 3625 psi BE M Y amp 2499bar MEE a rd 1 1 aa FUNCTION SO PUMP 1 1 4 ec cs DRIVE PUMP eem ee 1 1 1 1 1 1 1 EN 3 psi 3 psi 0 20 0 20 RETURN 1 1 5 RESERVOIR 1 1 1 1 1 ENEE E E RET 1 1 SORT E 6 8 3 4 1 4 HYDRAULIC ROTARY COUPLER 1 1 6 1 gm amp c 1 8B dB 6C 3 787 m 1 NEE DEDE 26 a teme 1 E TEST A B 4B RIGHT 4 7 REAR TA 1 iH HD ee i 1 1 1 1 1 1 1 8 i 1 i
24. before serial number 7597 Electrical Schematic Ford LRG 425 EFI Models October 2013 z 5 5 m M a a 2 5 c oc T z z ii Oo 5 26 5 9 6 55 5 o 55 8 TS o ul gt 5 HIGH RPM FS 1 9 5 2 92 lt 7 5 2 Op p 4 20 5 an 5 i o 72 LOW RPM FUNCTION o 5 u HIGH RPM ENA BK RD ES 0 DE z 5 a 9 c2 7 C6 39 GR WH 45 GENERATOR A OPTION GENERATOR 5 13 C38ESL 658 PING 1 512 TSW FEH 458 PIN3 TEST C5 17 2 02116 306 PIN24 N 9 C5 10 C39LP BK WH FEH 72 PIN7 42 PIN PLUG RUN C5 9 C35RPM2 OR RD 307A PIN23 DIM 511 WH 16A 9 19 BL WH 787 PINS we 91 FUEL 58 GAS BR 570C PIN34 ar GT gt A FUEL PUMP gg WATER TEMP GAUGE 12 05 14 3 Bog 6 29 WH RD 24 _ WATER TEMP 2 SWITCH Er 265 5 15 WHIBK 24 OIL PRESSURE 9 C17 5554 g lo SWITCH e IO c lt lt 2 5 iD 6 T START ENGINE 8 ves z 5 16 F
25. a C45GEN GR WH C2P 7 8 TS48 WL1 RD C2P 12 8 TS48 WL2 RD C2P 11 C39LP BL RD C2P 1 DLITE GR BK C2P 6 P26BAT BK cerne WH RD car caP 10 C13DRE BL RD C4P 1 4 611680 BL BK CaP 11 P C40LS1 OR C2P 2 a 125 BL WH C3P 12 0 5 z C41RPM C2P 3 4 C30EDC 4 C1PBU RD C3P 1 catepe WH BK 5 2 gt C2PBD RD BK C3P 2 10 RD WH C3P 3 cssrcsuekctP ti 5 WH BK C3P 5 of C32BRK WHIRD 1 6 C4P BR C4TRL WH C3P 4 2 C29MS RD WH C1P 3 8 u C134PWR RD C2P 4 tn P GR lt _C35RPM BK RD C1P 9 C3P GR 0 C34SA 8 a 6 c1P 7 8 C27AUX RD 1 5 RD BK 4 6 C2P BK JC1 3 OR e JC2 4 RD JC1 2 BRN JC2 5 BK C1P GY JC2 3 OR JC1 5 YEL JC2 2 BRN JC3 5 BL ub a JC3 3 OR JC3 4 6 WH p JC3 2 BRN DRE ABLWH C28TTA RD BK C1P 2 a tL DRE B BL BK o C13LED BL RD m 5 4 C29MS RD WH 5 a 5 lt o 5 6 d D40 I RED BLK 28 z GN BK 148 4 o pote 1 J gt He RED TILT RED TILT a BRN u 88 a N Genie S 40 5 45 Part No 102521 6 14 October 2013 Section 6 Schematics
26. N LO N IGRouND C41RPM OR BK Er 2 gt 15 x zz 9 02908 he 1 4 C30EDC WH 5 21 C30EDC WH R58 ApRIVE EDC FORWARD S 5 _ onriEDBURD E 1 5 C31EDC WH BK C5 20 CS1EDC WHIBK 0 yC DRIVE EDC REVERSE a f C6 32 i 2 DRE B 81 86 Fr 1 TRAVEL ALARM OPTION 1 DRIVE ENABLE a ee fp a 2 DRE ABUWH gt Te a SSSR WEIRD 5 05 23 CSSBRICWHIRD 5 BRAKE RELEASE VALVE ly 7 C29MS RD WH B C29MS RD WH Sei 13 29 C5 19 29 S F W 5 2X JH 4MOTOR STROKE YOUTBE 4 ers SR 5 1 11 C37STCC BL BK c6 37 03700 SF reer RIGHT PWRBZ 0 58 H E 514 C1P 10 C36STC BL C6 36 C36STC BL x bi ner E 8 oO 1 he C3P 6 C6TRF WH RD C3P 5 WH BK 9 lt 4 CATRLWH CATRL WH 8 m 8 06 4 11 4 TURNTABLE ROTATE LEFT S ct TROTATE 3 R gi nacht 4 5 STAR gt 171 4 TURNTABLE ROTATE RIGHT E 8 o 5 7 1 C6 6 WH RD 5 02 TURNTABLE ROTATE 6 lt g 0 FLOW CONTROL lE YouTp BK 2 5 B E SE lt RD 1 ue C631 CAPBU RD PRIMARY BOOM UP 32 cd BOOM 8 5 amp 92 9 5 DOWN z C62 171 C2PBD RD BK ergo lz Rx e m 4 t C6 3 C3PBF RD WH p 4
27. a a c 5 HIGH RPM FS 1 9 casEsPD BK RD i HIGH IDLE RELAY SLOW RPM 5 FUNCTION ENA amp o a HIGH RPM BK RD 8 9 t o C5 BARD CSS HIGH RPM SOLENOID 9 Fs 2 2 o 2 7 C45GEN GR WH C6 39 GRWH 45 S GENERATOR GENERATOR OPTION 5 1 8 4 C3P 9 DLITE OR RD C2B 4 6 4 DRIVE LIGHT 9 RD DRIVE LIGHT 4 WR NA OPTION WORK LIGHT E 2 8 5 g 277 WORK LIGHTS w me 11 AA OPTION 2 Ox 11 52 c amp E i WH 4 BK ud 5 Ic cf er are e 4 re c p FUEL SOLENOID RELAY 8 BKWH 5 5 22 4 11 FON Glow T GLOW PLUG OPTION PLUG ON GLOW ol 000 4 5 2 22 BK gt y F WATER TEMP GAUGE 6 65 14 _ WH RD B Eu 58 z 2 58 zs WATER TEMP og T J144 4 SWITCH a C33STR BK gue 8 2 rame EU FSE EEEL po mas gt 4OIL PRESSURE 1 ENGINE 9 8 g SWITCH Filet bok eoe S 5 ENGINE elelelelelele clele Ss C5 16 WH BK 4 START i eT BK e Ww 2 8 0IL PRESSURE GAUGE 2 4 ul RPM FILTER Sx x 5 a 5 FUEL RELAY 5 n eg 8 VOLT METER a o 52 3 WH 21 8 8 ae HOUR METER E L P 6 Ble x EE
28. NOTE ALL SWITCHES AND CONTACTS ARE SHOWN WITH Electrical Schematic from serial number 14832 to 15662 Ford DSG 423 EFI Models October 2013 QN HIGH RPM FS C35RPM BK RD 9 a 427 SPEED HIGHRPM 5 8 m M m D GENERATOR g Et S GENERATOR C45GEN GR WH D C45GEN m il OPTION 1 DLITE BK RD 0 8 RD DRIVE LIGHT 5 al t 5 C4B 12 2277 45 OPTION WH x eu O 1 go 8 P 9 RD YS WORK LIGHTS C4B 10 q OPTION u cz 8 WH 13 P 5 e VOLT METER R21IGN WH HOUR METER gt 8 5 16 g 5 98 Whe 8 OIL PRESSURE GAUGE AL ew o 1 E en GWyI 9 GASOLINE SENSOR 8 8 RD 5 2 BK BL amp C B NO gt N c QN 9 C33STR BK e NE lt RD GR 2 2 di LPG LOCKOUT ENGINE WH BK STAR 0 5 TEMP GAUGE N 4 C26TSR WH RD PIN 39 e e a lt C127TSW GR 1 gt gt 65 17 s Co4GN WH PIN 16 9 C59 2 c gt C85RPM BK RD PIN 28 Te 4 C55 8 FORD 8 6 O58 gt mRoiuG
29. Part No 102521 Section 1 Safety Rules July 2007 M r This page intentionally left blank TEREX COMPANY S 40 5 45 102521 July 2007 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie S 40 and S 45 Operator s Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance andrepair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine Youread understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment anda suitable workshop TEREX COMPANY Part No 102521 5 40 5 45 Section 1 Safety Rules July 2007 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnelto potential personal injury hazards Obey
30. aNnouo gt oo oo 2 IE 65SLH0 O Pr VL Q CH 980200 z 8vo ideo 4 0 91 NMOG St Q G 9841280 06910 0 80 x8 HO 014910 0900680 131059 O Or G3MOIS WOOS 0 0 99 HO 2 929 seora to vel UMdbeld 08 99 UMd S1 97 90 08 i gz0 au 4o vi 90 uo mario 91 90 019910 z gt 0 91 28 80 0 ug lt a 9 z 8 8 5 5 0240 Co NMOG an AAR Ld 0 HO 1S1079 ug anis LIMIT SWITCHES METRIS 9 t E 2 a C20 1 C20 2 L R14PLU OR PLAT LEVEL UP x S Ci4PLU OR Dm R15PLD OR BK PLAT LEVEL DOWN 21 1 21 2 tr 5 91 C15PLD OR BK DA 1D e 2 a Ple N Genie S 40 3 45 Part No 102521 6 136 Section 6 Schematics February 2012 MTE Hydraulic Generator Option Wiring Diagram 6 138 6 137 Section 6 Schematics October 2013 MTE Hydraulic Generator Option Wiring Diagram
31. KN Non steer end drive motor circuit 55 60 ft lbs 74 81 Nm Genie 4 50 5 40 5 Part No 102521 October 2013 Section 4 Repair Procedures mnmmmm MANIFOLDS KA MO 2 KC 3 10 6 KD 4 aa 5 KF 6 ORS G Go KI KH KG 9 Genie Part No 102521 S 40 S 45 4 51 Section 4 Repair Procedures October 2013 MANIFOLDS 7 14 Valve Adjustments 4WD Drive Manifold How to Adjust the Hot Oil Shuttle Relief Valve Note The pressure differential between the charge pump relief valve located in the drive pump and the hot oil shuttle relief valve located in the drive manifold is necessary to return hot oil from the closed loop drive circuit to the hydraulic tank for cooling This pressure differential must be maintained at 40 psi 14 5 bar Note The following procedure will require two people 1 Open the engine side turntable cover and connect a 0 to 600 psi 0 to 41 bar pressure gauge to the diagnostic nipple on the drive pump 2 Start the engine from the platform controls and allow the engine to run at high idle Note the pressure reading on the pressure gauge 3 Turn the engine off and connect a 0 to 600 psi 0 to 41 bar pressure gauge to the diagnostic nipple located on the drive manifold 4 52 3
32. TURNTABLE 1 PLATFORM LEVEL 45 BOOM 030 orifice added after serial number 8445 removed at serial number 16791 4 gpm 15 1 L min ROTATE 3 27 2 gpm 7 5 L min CYLINDERS 21 A 8 gpm 11 3 L min d M ris __ _EXL_ __ swewe 2 2200 AED oA 1 m BH a ay 0 4 04 1 gt or 1 BF 116 cum 1 Hin x i 1 4 0 8 1 0 6 gpm in Qi me e X 3 L min 2 L min m 6 45 5 40 1 1 1 P TERES Valve AA changed to 0 4 gpm at serial number 16791 545 valve AA changed to 0 6 gpm at serial number 18302
33. FUSE 70A ee GLOW PLUG OPTION NO FUSE 70A WATER TEMP GAUGE IGN START e 2752 C33STR BK ENGINE ee START GROUND BATTERY _ MODULE TB33 4 5 6 te J144 4 4 C5 13 WH aH 5305714 RD Yo 22 26 1 2 1 4 OIL TEMPERATURE SWITCH OIL PRESSURE J144 6 I 5 2 lt 16 8 8 1 SWITCH OIL PRESSURE GAUGE TB41 P26ESTP P25FS RD P24FS WH C28TTA RD BK C9 3 C92 TS1 me C1 1 my R21IGN WH RPM FILTER DEUTZ ONLY amp FUEL SOLENOID CR2 1 E 4 IGNITION RELAY 5 VOLT METER TB21 HOUR METER NOTE 551 D4 Um 5 5 C27AUX RD FS1 C91 pk 21 2 TB24 CR1 NO START RELAY 4 STARTER MOTOR C6 27 hi EMISSION CONTROL AUXILIARY POWER 7 2 P23BAT WH Lag D40 Hil D39 4 23 C28TTA RD BK e C2 5 TB43
34. a senema T TS48 WL2 RD C2P C39LP BL RD Cap A wo T e x x m a m B more 5 8 i o 5 AI WH RD C3P 6 E 9 EN 0 010880 BL C3P 10 a BL RD C4P 1 011880 BL BK C3P 11 P24FS WH 01040151 OR C2P2 e 5 p SEA C12SBF BL WH C3P 12 P24FS Wi CA1RPM OR BK C2P 3 6 WP C30EDC WH C1P 4 o x BR C1PBU RD C3P 1 5 C31EDC WH BK C1P 5L G C2PBD RD BK C3P 2 036810 BL C1P 10 a 6 O4 C3PBF RD WH C3P 3 4 5 0878100 BL BK C1P 11 9 d CBTRR C3P 5 C4P BR z 8 C32BRK WH RD C1P 5 9 C4TRL WH 4 9 e x NL j C29MS RD WH C1P 3 e 2 5 P134PWR RD C2P 4 e C3P GR zn SS 8 C33STR BK C1P 7 C27AUX RD RD BK L4 C2P BK NX 22 5 5 o T JC1 2 OR JC2 3 WH RD JC1 1 BR P o C1P GY JC2 4 RD WH DNE JC2 2 OR JC1 4 WH BK JC2 1 BR JC3 4 WH RD y JC3 2 OR JC3 3 5 mi JC3 1 BR DRE A BL WH C28TTA RD BK 2 3 o 5 DRE B BL BK C13LED a C29MS MEC 5 S lt 8 5 lt l D40 4 2 z 039 RD BK 28 GR BK 148
35. 67 C7PBE BK 7 BOOM EXTEND 77 retract 200 8 8 t s268 C8PBR em SH BOOM RETRACT C37 2 G7RBE BI 7 e RETRACT 63 8 C8PBR BK WH 5 z 4 UP Cta C14PLU OR a pow PLATFORM LEVEL et 04 CISPLD OR BK 8 4 C14PLU OR IM PLAT LEVEL UP 4 E Aron LEVEL 1 C6 15 ei one lol 4 PLAT LEVEL DOWN X GR BK44 26 JDALARM GR BKis N Sis 8 rz C4 6 5 Dom C18JD GR BK 2 t UP 5 C17JU GR g 0 b gt 8 C6 18 B C18JD GR PLATFORM ROTATE CCW JIB DOWN _ M w Wi gt up JIB BOOM Gere C17JU GR PLATFORM ROTATE CW UP N io e CCW l et cw PLAT ROTATE ej PLAT ROTATE 5 E is C47 viti 19 5 GR WH B L_ z I gt 5 E 4 5 jit je 2 5 JIB VALVES xO T H 52 5 5 JIB VALVE ex 1 Bo c tr m I 5 P134PWR RD G 5 40 5 45 6 53 Part No 102521 October 2013 Section 6 Schematics Electrical Schematic Deutz F3L 201 1 Deutz D201 1L03i and Perkins 404 22 Models CE from serial number 16420 54 55 Section 6 Schematics October 2013 Ground Control Box Wiring Diagram Deutz F3L 201 1 Deutz D2011L03i and Perkins 404 22 Models before serial number 14832 October 2013 Section 6 Schematics Grou
36. M i 1 1 1 i 6 GENERATOR i 3 1 POTTER c6 39 GR WH 45 gt GENERATOR i H OPTION 1 i 1 e PPM ree ML Ir 1 eae Te ay scc nee a ee TII ne Zu nn 5 C3P 9 DLITE OR RD C2B 4 4 1 DRIVE LIGHT 2 1 1 3 4 1 i WH C4B 12 DRIVE LIGHT WORK LIGHT S 9 OPTION 1 lt 3 RD 3 4 5 1 2 BK C4B 10 u 89 WORKLIGHIS 5 757 g m OPTION oit a o 1 WH BK e a ER e Sw prb Get Sp nd 1 g 1 1 nad i bah ks a 1 5 2 m oa 5 1 8 C34SA BK WH C5 22 ME 3 GLOW PLUG OPTION a GLOW PLUG 4 uw 4 000 GLOW 5 a PLUG 2 2 3 WATER TEMP GAUGE d 05 14 WH RD a S 4 d F 5 s A 22 55 5 C5 13 WH OIL PRESSURE 3 C33STR BK J144 6 1 SWITCH E staat 2 sk 9 ENGINE 2 5 9 2 p P E m lt START ENGINE Sr SEIEWEIER gt t 4 2 J OIL PRESSURE GAUGE Be RPM FILTER 5 5 5
37. October 2013 Deutz F3L 201 1 Deutz D2011L03i and Perkins 404 22 Models ANSI CSA AS BL WH N LO N co BR 2 1 GROUND M c4 RPM OR BK C23 gt 15 g 5 rs 8 DRIVE MODE i 255 C29MS RD WH gt gt 8 freee 61 4 lt lt C30EDC WH C5 2 C30EDC WU X f 3 4 DRIVE EDC FORWARD 5 C1 5 C5 20 aC 16c C31EDC WH BK 4e C31EDC WH BK lt lt gt gt DRIVE EDC REVERSE LED 16 e x 2 p DRE B BL BK 5 7 x gt 5532 4 TRAVEL ALARM OPTION E DRIVE ENABLE DRE BLWH gt gt 6 Re 1 6 C32BRK WH RD 8 Sy C528 C32BRK WH RD BRAKE RELEASE VALVE C1 3 S 06 C13 x C29MS RD WH C519 C29MS RD WI MOTOR STROKE N B B 6
38. 5 6 gt NOI Kn a sow w N S gt 8 o a o E gt 5 gt 8 a 8 gt o c 00 m Jg B 8 2 erg gt m A 3 Part No 102521 5 40 5 45 2 15 October 2013 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly six months annually and every 2 years as specified on the Maintenance Inspection Report The frequency and extent of periodic examinations and tests may also depend on national regulations Failure to perform each procedure AWARNING as presented and scheduled may cause death serious injury or substantial damage M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than three months must complete the quarterly inspection Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a firm level s
39. en Pee ee i t C32BRK WH RD IP 6 SE e _Ca2BRK WHIRD 5 05 28 3 BRAKE RELEASE VALVE 8 A re A 1 3 C29MS RD WH 05 24 C29MS RD WH SM WH 202 2 A MOTOR STROKE iB BL 4 a n o 815 4 5 18 SITSTSC BEBK Sesr CSrSTUG BUBK gt STEER RIGHT 1 PWR SC OR 13 5 7 1 m GND 2C BRN 5 C1P 10 C36STC BL 0 C36STC BL 9 1 IX 8 STEER LEFT fi lt 5 8 Liz C3P 6 WH RD ER C3P 5 CSTRR WH BK C3P 4 CATRL WH m TURNTABLE ROTATE LEFT 1 ROTATE WH BK Sei g TRIGHT 605 51 TURNTABLE ROTATE RIGHT iD 8 i 4 g E T 7 C6 6 C6TRF WH RD EN TURNTABLE ROTATE ES ec 5 FLOW CONTROL 2 yours BK 2 7 52 1PBU RD RIP 1 5 mE PRIMARY BOOM UP 1 e PRIMARY BOOM B Ro 6 GND 2 BAN gt gt 12 5 DOWN 06 2 PRIMARY BOOM DOWN E ac t m 8 C3PBF RD WH 5 PRIMARY BOOM FLOW CONTROL 5n 6 lt 6801 C1PBURD 72 C3P2 C2PBD RD BK 8 lt 3 RDWH GEA9 RDIBIS DESCENT ALARM OPTION f 6 113 ce WH LS2 PRIMARY BOOM UP 12 DRIVE LIMIT SWITCH jo 44 BRN LS1 PRIMARY BOOM EXTEND gt DRIVE LIMIT SWITCH 5 E P24FS WH 9 lt t 5 C4P i CI3DREBURD 06 13 C13
40. oma i i ag gt Pw un v H8 QNO1Vg i i HWHO N3OSv2 HMO Ne ka 6 an een i po PN _ 9 fHIWHO N39SvO MET pecie i I 1 i i io f TE i pag 1 NE b ud et et i I A 3 8 E E 5 i 3 5 8 a gt x x i id 9 5 kod PS 5 ii a gt i i i i 1 Pd 2 Pod h 4110 LAA i I i ei rua 1 VENEREM N LO SCHEMATIC MTE HYDRUALIC GENERATOR OPTIONS o ge o 9 8 2 se 5558255 3 aare zg i aa o i 5 6 gt z i Im a 63 Pius 1 i co Km i BL lt lt GR WH 7 K i ij i gt 9 i S a i i E o cn CORO SOR TC ROC RETE a RZ ieee 1 i i E 8 E Fd 5 3 I 3 ij i 6 m m d i he
41. 3000 psi do Counterbalance valve with pressure and pilot ratio H H z 2 position 2 way solenoid valve z lt 4 Directional valve pilot operated 2 position 2 way Genie Part No 102521 Lib LAS Solenoid operated 3 position 4 way proportional directional valve gt 2 position 3 way shuttle valve Needle valve S 40 S 45 October2013 Section 6 Schematics Ford DSG 423 Engine Relay Layout Empty F2 5A 10 F4 15A F5 15A 4 F1 10A Starter Relay Power Relay a gt ES ac G S 40 S 45 Part No 102521 M L C1P DT06 12SA COLOR CKT PIN RD C27AUX 1 RD BK C28TTA 2 RD WH C29MS 3 WH C30EDC 4 WH BK C31EDC 5 WH RD C32BRK 6 BK C33STR 7 BK WH C34SA 8 BK RD C35RPM 9 BL C36STC 10 BL BK C37STCC 11 BL WH C132PLI 12 C2P DT06 12SB COLOR CKT PIN BL RD C39LP 1 OR C40LS1 2 OR BK C41RPM 3 OR RD C134PWR 4 GR C43HRN 5 GR BK JDALARM 6 GR WH C45GEN 7 PLUG 8 PLUG 9 PLUG 10 PLUG 11 PLUG 12 DT06 12SC COL
42. 3 36 C 3 Test the Platform Overload Mechanism if equipped 3 36 C 4 Replace the Engine Air Filter Deutz and Perkins Models 3 39 C 5 Replace the Inline Fuel 1 0 3 39 C 6 Perform Engine Maintenance Ford Models 3 40 Checklist D Procedures D 1 Check the Boom Wear 3 41 0 2 Check the Turntable Rotation Bearing Bolts 3 42 0 3 Free wheel Configuration ssesseeeenee 3 43 3 45 0 5 Perform Engine Maintenance Deutz 3 46 D 6 Replace the Hydraulic Filters 3 47 D 7 Inspectfor Turntable Bearing Wear 3 48 Checklist E Procedures E 1 Testor Replace the Hydraulic 3 50 E 2 Grease the Steer Axle Wheel Bearings 2WD Models 3 52 E 3 Perform Engine Maintenance Deutz and Perkins Models 3 53 E 4 Perform Engine Maintenance Ford Models 3 54 E 5 Perform Engine Maintenance Deutz and Perkins Models 3 54 Genie Part No 102521 5 40 5 45 ix October 2013 1 TABLE CONTENTS Section 3 Rev S
43. v 5 OR R40LS1 6 SPLICE R40LS1 TS4 5 HIGH LOW 9 e 30 P S RPM 3 TS2 TS3 START FUEL SELECT P2 DASHED LINES INDICATE RD EMERGENCY STOP OPTION WIRES 7 REMOVE FOR GENERATOR OPTION Genie PartNo 102521 S 40 S 45 6 75 October 2013 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram Ford LRG 425 EFI Models before serial number 7597 76 77 Section 6 Schematics October 2013 Electrical Schematic Ford LRG 425 EFI Models from serial number 7597 to 11066 78 BL WH Section 6 Schematics ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH OFF Electrical Schematic Ford LRG 425 EFI Models from serial number 7597 to 11066 October 2013
44. 0 4 24 5 3 FIEX Plate al cete enn eet ie dare e e P P Ee ERE Pe etta 4 24 5 4 Engine Fault Codes Ford Models 4 28 Genie S 40 5 45 Part No 102521 October 2013 TABLE OF CONTENTS Section 4 Rev Repair Procedures continued Hydraulic Pumps 6 1 Function Pump eiie te eL oe t e eot et v e e ec Egan 4 29 622 Drive Pump ne enia eeu S 4 30 Manifolds 7 1 Function Manifold Components 4 32 7 2 Valve Adjustments Function 4 36 7 3 Jib Select and Platform Rotate Manifold Components 4 37 7 4 Brake Manifold Components before 7569 2 2 4 4 38 7 5 Brake Two SpeedManifold Components after serialnumber 7568 4 39 7 6 Oscillate Directional Valve Manifold 4 40 7 7 Valve Adjustments Oscillate Relief Valve 4 42 7 8 Traction Manifold Components 2WD before serial number 7569 4 43 7 9 Traction Manifold Components 2WD after serial number 7568 4 44 7 10 Valve Adjustments 2WD Traction Manifold 4 45 7 11 Traction Manifold Components 4WD before serial number 7569 4 46 7 12 Traction Manifold Components 4WD from serial number 7568 to 1582
45. BL WH N N co BR 2 t GROUND C41RPM OR BK sce 623 4 gt 15 0 8 DRIVE MODE ne i Rep LB 1 29 RD WH gt J 8 15 4 lt WH C30EDC 5 gt DRIVE EDC FORWARD LED BL RD 16 pg mE C31EDC WH BK 1e C31EDC 9 DRIVE EDC REVERSE 7 em n C6 32 DREB BLIBK 7 p TRAVEL ALARM OPTION DRIVE ENABLE amp DRE A BUWH 6 Re CrS C32BRK WH RD mE C32BRK 4 BRAKE RELEASE VALVE 8 5 38 s C5 19 T 613 02908 RD WH E C29MS RD W MOTOR STROKE 5 N 8 P g g amp ga 017 cazsTCC BL BK f C637 C37STCC 0 4 STEER CCW RKOUTIBEBLIWH E gt vouta no 4 C110 C36STC E C636 C36STC BL STEER CW XOUT B BLIWH 75 5 2 PwrB2 OR 3 E GND gt 1 4 a 66 C9 WH RD e o 5 96 638 6 CSTRR WH BK 1102 C34 CATRL WH 8 i 6 4 C4TRL WH H TURNTABLE ROTATE CW rye 5 et C65 111 TURNTABLE ROTATE CCW E D m e gt 0 46 n TURNTABLE ROTATE E UT FLOW CONTROL 7 55 m N 5 6 C6 1 m 9 LUE fu CIPBU RD H PRIMARY BOOM UP vouTAA RD WH 22 2 tj amp Tr DOWN 5 olt 6 2 dl 8 C2PBD RD BK n PRIMAR
46. Proportional solenoid valve BB Counterbalance valve BC Needle Valve BD Counterbalance valve BE Solenoid valve 3 position 4 way BF Differential sensing valve 150 psi 10 3 BG Ghieck valVe REA BH Diagnostic nipple Function Blocks flow from auxiliary pump to function pump iS Steer left right Boom extend uis Turntable rotate left right u Platform level up Site Platform level circuit m Platform level down Platform rotate and jib boom up down S 45 S Differential sensing circuit meters flow to functions WI Differential sensing circuit platform rotate left and jib boom up S 45 RES Testing Genie October 2013 Torque 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 20 25 ft lbs 27 34 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 20 25 ft lbs 27 34 Nm 10 12 ft lbs 14 16 Nm 20 25 ft lbs 27 34
47. RD P1 E STOP OR BK 15A 5 8 BK 06 16 OR 14A x GR 17A GR WH 19A GR BK 18A 8 BK C6 25 RD CB3 SP GROUND STUD WIRING 5 unn BR HARNESS a 9 TO BASE 0 8 ALL BR WIRES 4 6 56 Part No 102521 12V TO PLAT 19 18 CABLES FUNCTIONS ENGINE GROUND STUD October 2013 Section 6 Schematics QO RD H6 C32 1 T BL WH 132D 3 c32 BK 22C 32 4 RD C32 1 PLATFORM LOAD BK C7 1 C32 5 gt RD TS51 C32 6 GR BK L45 H6
48. a a z x 5 a m c o HIGH RPM FS cre C35ESPD BK RD io e p LOW RPM FUNCTION ENA 5 HIGH RPM 6 e D e a IO rs In m 8 2 7 C45GEN GR WH C6 39 GR WH 45 4 GENERATOR GENERATOR OPTION 1 T To Tm 0 Tr N C29 DLITE BK RD 5 m 3 DRIVE LIGHT WH O OPTION 5 8 9 RD WORKLIGHTS i X BK 112 11 BIER OPTION 22 o o TE ee ee en m ee WH 0 BK E LPG LOCKOUT SOLENOID 3 Ec E S RD FEH 361A DGRN 242 VOLT METER une HOUR METER 9 TEMP GAUGE 1 5 14 WH RD o g E ES 2 8 05 16 WH BK cole e T 8 4 OIL PRESSURE GAUGE 0 p 8 2 om Let a ci C33STR BK r F zo t START ENGINE 8 ENGINE 65 PUMP AUXILIARY START N C5 12 C127TST GRPIN 18 BK SH C547 C21IGN WH PIN21 C543 C38ESL BLWH PIN 6 C2 1 E S 5 9 C35RPM BK RD PIN 23 34 8 Bo 5 PLP FUEL 52 GAS C55 R33STR BK PIN 15 Tx BR PIN34 FORD a Es 42 PIN PLUG o e 5 8 R21IGN WH PIN 24 m e C5 10 C39LP BL RD PIN 7 alz or 8 TE Fe n olal 5 esr e 8 t a VBATT RD PIN 9 E a e a 8 PIN 5 919 PIE TEE 55 FUEL PUMP 0 21 C5 11 VSW WH PIN 1 22 8 C33STR BK PIN 13 Bt 9 5 a r
49. 12 8 3 z GND TB27 Tes 3 014 5 CB1 gt UE TUS 5 RELAY TB20 E E i TB35 4 TB34 IGN START TBO TB28 TB24 SIGROUNTT MODUL 6 47 KEY PWA 12 CR2 ASS Ui m MERGE CRS TGNJFUEL ON 5 i ls d CR5 No jR qe ENG FAULT TB T 0 FUSE 10A x FUSE 70A 6 z BL WH WH cro Cok NO g g 8 U 9 o 5 8 g FUSE 70A Fa 8 5 5 o N g 3 m 2 1 CR23 cies PAM Tg 5 TB25 5 Di u lt gt E 63 NO E n aan 8 iz rat 7 ALTERNATOR g om E S A 7 8 IR g g NO 8 9 Zur 9 E pg 4 5 SUF a 18 8 i al PES o ZW BAT BAT 12V 2 0 Prat PR T i i Me Hp bang R 10A 7 8 3 ars 0 4 T Q 52 T a H2 ta 5 Pu Pe cok D TN NO L29 129 eo pr 7 c capo C4B H m 2 e 1 ao Do gt m 5 5 r as 2 oo oo r BRN 38 d 3 2 a ggg f 58 5 2 Rf 38 98 58 8 5 3 lt lt m ox 5 x o 5 m 5 2 d m c 22 2 8 59184 E CR 8 d 3 8 5 8 BD zn E RE 22 22 22 z
50. 2 8 Deutz F3L 201 1 Deutz D2011L03i Engine Specifications 2 9 Perkins 704 30 Engine Specifications ssssseeneeeene 2 10 Perkins 404 22 Engine Specifications 2 11 Machine Torque Specifications sese 2 12 Hydraulic Hose and Fitting Torque Specifications 2 3 SAE and Metric Fastener Torque Chart 2 2 22 4400 2 14 Scheduled Maintenance Procedures 3 1 Pre Delivery Preparation 3 3 Maintenance Inspection Report 3 5 Checklist A Procedures A 1 Inspect the Decals and Manuals 3 7 2 Perform Pre operation Inspection 3 8 A 3 Perform Function Tests 3 8 3 9 Genio PartNo 102521 5 40 S 45 i October 2013 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued 5 6 7 A 8 A 9 A 10 11 12 A 13 A 14 Inspect the Track Components TRAX option 3 9 Perform 30 Day Service enne 3 10 Perform Engine Maintenance Deutz and Ford Models 3 10 Replace the Drive Hub 3 11 Perf
51. BOOM 4 FLOW CONTROL 5n Bx CiPBU RD 7 lt C3P2 2 8 lt _ RD WH C6 19 HD BK DESCENT ALARM OPTION K lt a 1 c 12 LS2 PRIMARY BOOM UP lt 12 T m 1 9 DRIVE LIMIT SWITCH BRN 5 WH i LS1 PRIMARY BOOM EXTEND P24FS WH xz BK 11 9 DRIVE LIMIT SWITCH P24FS WH 5 tr 3 8 1 BL RD C6 13 b 3DRE BL RD Or P26ESTPBK 42 DRIVE ENABLE 5 SWITCH 2 5 C2P2 40151 OR C6 40 C40LS1 OR gt o o a E gt F I 6 2 8 8 B 1 E l aa 5 8 o o 5 o 2 46 8 8 5 4 See 2 E ul 8 S 967 C7PBE BOOM EXTEND 2 lt 6 g TE 1 RETRACT 200 cee e 5 t COPBR BKWH RETRACT 5 9 C3P 7 C7PBE BK 5 4 EZ BOOM ze tRETRACT C3P 8 C8PBR BK WH 2 D 229 E39 2 C14PLU OR er sur gt PLATFORM LEVEL DOWN CAP 3 C15PLD OR BK__ g 7 ai CIAFLUGR 7 PLAT LEVEL UP PLAT LEVEL ae o 2 P DOWN i 15PLD OR BK Al a aevi aid 1 GR BK44 C2P6 JDALARM GRIBK E C4P 6 C18JD GR BK 12a 8 C4P 5 C17JU GR E 8
52. If high idle rpm is correct disregard adjustment step 4 4 Loosen the yoke lock nut Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and re check the rpm Note Be sure the solenoid fully retracts when activating high idle Perkins Models 1 Connecta tachometer to the engine Start the engine from the ground controls Refer to Section 2 Specifications Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures Skip to step 3 if the low idle rpm is correct 2 Loosen the low idle lock nut Turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and confirm the rpm solenoid boot high idle adjustment nut clevis low idle lock nut and adjustment screw 3 Move the function enable toggle switch to the high idle rabbit symbol position Refer to Section 2 Specifications If high idle rpm is correct disregard adjustment step 4 4 Loosen the yoke lock nut Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and re check the rpm Note Be sure the solenoid fully retracts when activating high idle Part No 102521 Genie S 40 S 45 3 25 CHECKLIST B PROCEDURES B 12
53. amp 8 YOUTA WH RD 7 4 TEM lt lt C6TRF WH RD XOUT3 BUWH e25 5 PWR or Taxe 035 WH Bk GND1 lt 514 Ha C34 CATRL WH Bs i Ges C4TRL WH TURNTABLE ROTATE CW 9 87 5 C5TRR wekel y TURNTABLE ROTATE CCW Ei 5 m e C66 TURNTABLE amp WERD TU FLOW CONTROL 752 b ERMARY BOON g C6 1 RD P al 4 PRIMARY BOOM UP N rn e oe m e T y ip DOWN C6 2 C2PBD RD BK gt gt PRIMARY BOOM DOWN 8 lt 5 ex Eu PRIMARY BOOM 9 5K Ces lt lt 5 2 gt FLOW CONTROL YOUTAL 54 Jos 3 WH RD 251 18 Zi 6 PWR or 65 CIPBU RD 5 GND1 gt 2 7 lt C35 C2PBD RD BK Eel 8x C33 C3PBF RD WH N 3 4 C69 f DESCENT ALARM K lt o x INTE LS2 PRIMARY BOOM UP i lat x DRIVE LIMIT SWITCH LL 5 9 5 T is PRIMARY BOOM EXTEND 88 01 w g x DRIVE LIMIT SWITCH BK m P24FS WH 22 gt ee u tr 4824 8222 DRIVE ENABLE i 5 B P LIMIT SWITCH 5 26 23 Slax C 43DRE BLIRD fe 5 C913 C13DRE BURD TBK s ze E zo 3 C640 e E 4 e C 061 OR 40151 OR 25 5 5 wa lt oz C6 30 58
54. 51 2 en eu 0 0 4 WH BK dre e T Je VOLT METER R21IGN WH 5 E HOUR METER 1 8 05 16 WH BK mie 7 8 OILPRESSUREGAUGE 5 a E PA zo A GY RD 25 B GY YL 5 e 8 0 RD 5 8 o 9 E 9 BK BL z GASOLINE SENSOR E D ac tu m C17 C33STR BK ofr 89 as 2 95 RD GN oT Bo ee ENGINE 6 START wiak 2 ENGINE 9 LPG LOCKOUT E START 2 2 1 8 8 TEMP GAUGE 5 5 e 1 Eo C241 81 4 C26TSR WH RD PIN 39 Zu ar 8 8 C5 12 C127TSW GRPIN3 az amp GAS iom 05 17 C21IGN WHPIN 16 5 9 5 9 C35RPM BK RD PIN 23 f eLP alz Pe EL C5 5 R33STR BKPIN 15 GAS 6 5 x EL 8 R21IGN WHPIN 24 FORD 8 Exc 5 42 PIN PLUG C5 10 C39LP_ BURD PIN7 6 Ci35FP 5 5 AUXILIARY g 3 PUMP Bus g dies C135RET BLPIN18 4 5 81 d we 5 5 11 VSW 1 AUXILIARY 9 818 PUMP is gt 05 13 03869 PING E y IK 06 27 C27AUX RD AUXILIARY POWER RD RELAY 5 e a 5 AUXILIARY PUMP 1 1 C27AUX RD az 4 m n o x o al 8 C72 P23BAT WH lt eo ad E N D RD BK SA c12 C2STTARDEK C6 28 B wW Q5 C6 23 RD RD
55. C5 3 22 ALTERNATOR 4 RD 51 GRD RD SAMP 1 AMP 1 CB1 11 1 CB3 A 12 T TB20 18AMP 1 warn CB2 EE RD gt FUEL SOLENOID ADDED AT SERIAL NUMBER 15574 Part No 102521 p CB7 10A FUSE ADDED AT SERIAL NUMBER 15573 p 10A FUSE ADDED AT SERIAL NUMBER 15574 A TEREX 3 40 5 45 G 66 Section 6 Schematics Electrical Schematic from serial number 14832 to 15662 enie G 6 37 5 40 5 45 Deutz F3L 201 1 Deutz D201 1LO3i and Perkins 404 22 Models October 2013
56. 8 WATER TEMP GAUGE C5 14 WH RD 12 26 2 OIL TEMPERATURE J144 4 SWITCH WH IGN START 05 13 WH OIL PRESSURE ere J144 6 1 SWITCH C1 7 C33STR BK START ENGINE 9 2 4 START ENGINE BL WH TS52 C5 16 WH BK e BBATTERY MODULE BYPASS U1 9 START RELAY 2 ON 4 AUX ON 5 GHOUND TB25 T G2 1 OIL PRESSURE GAUGE WHEN C E OPTION IS NOT INSTALLED A JUMPER HARNESS CONNECTS PIN 4 TO PIN 5 AND PIN 6 TO PIN 7 1518 PLATFORM OVERLOAD SWITCH TB33 p C E OPTION ONLY 4 RPM FILTER DEUTZ ONLY TB41 3MF gt R21IGN WH A FUEL SOLENOID 4 P26ESTP BK Section 6 Schematics FUEL RELAY 9 5 VOLT METER WH 21 2 Iw CR2 CR2 jy P25FS RD P24FS WH 1 1 t HOUR METER 1 1 TB21 1 1 1 1 1 1 1 1 1 1 1 1 ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM 1 6 1 UMR 1 1 1 see NOTE C28TTA RD BK 9 3 9 2 8 PUMP AUXILIARY IGN START RELAY C5 5 33 RD FS WH FS
57. BRN B i LEVEL SENSOR X pea 4 C133PLA OR RD FEE 1 1 1 FLASHING BEACONS NL OPTION z e V OI n 1 5 g e 2 C25 C43HRN GR Sm 4 SERVICE HORN Ey i RELAY go P22BAT BK C74 65 C6 16 R43HRN BK S EWIEE HORN S 8 B ce S9 o MM L3 5625 6 HYDRAULICOIL TEMP SWITCH 6 34 Eo 3 02 8 C626 COOLING FAN ES OPTION C134PWR RD C24 1 OR BK 2 3 1 _ 2 42 PIN FORD CONNECTOR g 8 8 m m BLUE PINK FORDENGINEHARNESS 1 a PR2 STARTER RELAY peut ssec peor 1 E i lt ul l STARTER MOTOR 2 2 RM PR2 LIT 4 nae del ee dr o cuc 5 mpg 6 o 4 S a 4 i RD 12V DC 5 433 RESISTOR R3 REMOVED AT SERIAL NUMBER 13740 CHECK ENGINE LAMP L2 CHANGED TO INCANDESCENT Part No 102521 Genie 3 40 5 45 G 6 92 Section 6 Schematics October 2013 Electrical Schematic Ford DSG 423 EFI Models from serial number 12510 to 14831 BL WH
58. INJECTOR 1 INJECTOR 3 INJECTOR 4 INJECTOR 2 570 BK W 16 39 R W 18 151 LB BK 307 BK Y 18 14 25IVS 570 16 7 570 BK W 16 570 BK W 16 570 BICW 12 34 GROUND 16 R LG 18 16 R LG 18 MAP_CONN 38 EGR ANA IN 32 ANA AUX PD1 150 DG W 18 37 ANA AUX PU1 114 LB Y 18 12FPP2 00 41 EGR REC ee 33 ANA RTN 351 BR W 18 31 VREF THROTILE 32 R LB 16 FUEL PUMP STARTER RELAY 16 R LG 18 13 STARTER CONTROL SHD 355 GY 357 Y W 8 8 6 5 RELAY 151 LB BK 18 LB BK 18 4 317Gy 018 GY O 8 6 359GY R18 ss Bn w 18 1 SOTHLB 16 15 STARTER IN INTERUPT 359 GY R 18 E 351 BR W 18 3 32 6 351 BR W 18 F 359 GY R 18 2 55 39 STARTER IN AUTOCRANK 359 GY R 18 787A PK BK 16 5 FUEL PUMP 351 BR W 18 FUEL LOCKOFF 23 SABES 18 6 926A LB O 18 928ALB O 18 FUEL PUMP 32 Ll 5 RELAY CONTROL 15 RY 8 361 16 31 ae TPS2 anas OIL PRESSURE DBW 28 151 LB BK 8 DBW 29 317 GY O 18 BRAKE SWITCH 5 Sues M cR AL 50 818 4 mn 7 253 DGW 18 7779000 259 DG 18 C _ 8 11 18 11 18 T CH 11 TY 18 2 TACH a S58 PKLG 18 SEEPKIG TE
59. 40 C40LS1 OR 8 0 a x 5 T E C6 30 55 T lt 22 lt T So 80 z 5 5 25 ET E Zei a 8 6 7 2 3 65 LEXTEND D ce C7PBE BK 1 4 Boom EXTEND 2 1 3 99M B 28 t y C68 CBPBR BKWH BOOM RETRACT 5 5 C37 5 5 C7PBE Bu T e RETRACT T p a3 5 5 233 C8PBR BK WH 91 Cre C14PLU OR pown PLATFORM LEVEL et 04 C15PLD OR BK 8 gt gt 66 14 C14PLU OR 1 PLAT LEVEL UP TN DONRIATFORM LEVEL 1 c6 15 CIBPID onse fl 4 PLAT LEVEL DOWN X GR BK44 26 JDALARM GR BKis N 26 8 rz C4 6 7 Down sooli C18JD GR BK 7 t 2 5 p tup Ces C17JU GR g a 8 E 8 C6 18 8 C18JD GR H PLATFORM ROTATE CCW DOWN jun M WB BOW up JIB BOOM TUR 5206 17 C17JU GR 5 4 PLATFORM ROTATE CW JIB UP N io e CCW FIT Tem PLAT ROTATE ow PLAT ROTATE E 4 7 st C19JSV GR WH 5 L_ 3 T 5 E 6 5 jit je 5 JIB VALVES xO 7 8 52 5 5 8 JBVAVE t 2 5 1 gt omg EO tc m I 5 P134PWR RD 6 49 S 40 5 45 G Part No 102521 October 2013 Section 6 Schematics Electrical Schematic Deutz F3L 201 1 Deutz D201 1L03i and Perkins 404 22 Models ANSI CSA AS from serial number 16420 50 51 Secti
60. B gd wy D E p C5 11 vsw WH PIN 1 3 AUXILIARY 816 PUMP 59 24 1 C5 13 03858 BLWH PIN 6 QE 4 97 oI 5 n el u 0627 C27AUXRD 71 AUXILIARY POWER 2 RD N RELAY 5 AUXILIARY PUMP 1 1 C27AUX RD az m o x o B Seles C72 P23BAT WH FL Fl rue E M 8 5 1 i v 1 1 2 C28TTA RD BK C6 28 RD BK WH C6 23 RD RD BRN i LEVEL SENSOR ud Serene 1 C133PLA OR RD I 1 1 Yon 4 FLASHING BEACONS PS OPTION 9 D a a a pasen 2 C25 C43HRN GR o nl 4 SERVICE HORN 15 RELAY P22BAT BK C74 oz 06 16 R43HRN SESWIGEBORN S 8 Er c am 0625 9 HYDRAULICOIL 6 TEMP SWITCH C6 34 T G2 0633 0626 COOLING FAN g 7 E ae a Hr Ta ara Be Ti C134PWR RD C24 2 2 1 ___ 2 3 z cs CHEEMLOBEKRINZ 42 PIN FORD CONNECTOR 8008 8 am m E BLUE PINK FORD ENGINEHARNESS a 8 pose 1 6 6 PR2 STARTER RELAY gs pep Tem x cy 55 i joy 1 STARTER MOTOR 6 iz 5 PR2 ax 15 Ed 1 ISG 4 Sa Ce ed E a T pZ g 2 i 20 RD gt 28 N LO N co gt lt THIS W
61. BO EN 5 gt 5 g mx Y 85 a 9 5 gt 5 o gt E Do o x j 5 s Y a 2 Sog Ed 5 2 a w m 6 WH TS7 3 D E A N WH TS1 Q 2 5 0 9 25 Uu zL 1 86 gt S x 2 5 012 wou 2 amp WH RD C32BRK 5 SPLICE TO C32BRK S 4 o 1 CR30 TS9 TS7 E TS TS 0 1847 BOO 74 14 TS2 30 1 BONITO 5 GR us HIGH LOW BE d ET SAGE abo RPM TS3 O 7 86 GENERATOR 4 P2 HORN PLATFORM PLATFORM JIB SPEED OPTION p B ms ORRADEST P3 WH rie AUXILIARY EMERGENCY STOP LEVEL ROTATE anek pump HIGH LOW FUEL SELECT SPLICE TO R40LS1 i 1 7 7 7 7 Da7 NN mE CE SEE DETAIL A NOTE DASHED LINES INDICATE PP DRIVE WORK LIGHT OPTION CHANGED AT SERIAL NUMBER 16420 OPTION WIRES 8 Genie PartNo 102521 S 40 S 45 6 125 October 2013 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram Ford DSG 423 EFI Models from serial number 12510 6 125 6 126 Section 6 Schematics October 2013 Engine Wire Harness Ford LRG 425 EFI Models before serial number 11067 6 128 6 127 October 2013 Section 6 Schematics Engine Wire Harness Ford LRG 425 EFI Models before serial number 11067 A B 6 361R 16 INJ 7 555 T 16 INJ 1 INJ 8 557 BR Y 16 9 558 BR LB 16 4 10 556 W 16 INJ2 11 INJ5 12 6 31 AUX OUT 2 2
62. 14435 Perkins 404 22 Operation Manual Genie part number 94890 To access the engine Remove the engine tray retaining fasteners located under the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Section Scheduled Maintenance Procedures October2013 CHECKLIST E PROCEDURES E 4 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 2400 hours Required maintenance procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 or the Ford DSG 423 EFI Operator Handbook EDI part number 1060020 Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Genie S 40 5 45 5 Perform Engine Maintenance Deutz and Perkins Models Engine specifications require tha
63. I jojo ENGINE um Tee 9 le 9 OIL PRESSURE GAUGE e E N 5 az 5 FUEL RELAY E RD 3614 ug an nn Hr azul Toe No a DGRN FEH 242 925 a oz T ala to LPG LOCKOUT SOLENOID 88 a METER 4 WH 21 HOUR METER ee 8 i 4 IGN START RELAY cc N 055 0 ZA OZ 2 A d T STARTER MOTOR NI 5 cum PUMP AUXILIARY 6 27 RD 27 s AUXILIARY POWER x a o a 5 07 2 8 AUXILIARY PUMP 2x a gt lt a a l 8 Jd Sal 5 a _ p 402 6 28 RD BK28 WH 1 E e E 2 C6 23 RD P134 RD 5 419 BRN ever sensor T I 8 C44 p A FLASHING BEACONS Li D OPTION mE a nn SERVICE HORN a i RELAY co 8 08 16 BK49 SERVICE HORN P22BAT BK s uw o amp 5 de 9 M T a gt 5 15634 I 65 HYDRAULIC OIL TEMP SWITCH ce C6 26 C184PWR OR RD 52 59 COOLING FAN 24 g amp OPTION 5 my a C41RPM OR BK ps 05 2 af y ES 5 3 9 x 2 amp 8 Le eje ARE lt a s a s E Os s es RS a a e c i ale 4 2 o s e s 8 7 RD gt m N Part No 102521 eni
64. N 52 a RD WORK LIGHTS eu C4B 10 OPTION x WH Y x x Ass e 5 VOLT METER R21IGN WH E HOUR METER 1 E z 8 C5 16 6 95 ae WH BK 8 OIL PRESSURE GAUGE 8 3 4 C3 10 a ca A GY RB 8 Y o 1 B GYYL 58 GASOLINE SENSOR g 2 c RD 2 8 D BK BL at 8 C17 E 89 as B 4 C33STR BK 95 1 I di LPG LOCKOUT ENGINE 88 WH BK STAR 2 B E 4 TEMP GAUGE 5 Q C24 z I C9 14 gt gt 026788 WH RD PIN 39 N e e 5 p B N gt C127T8W GR PIN3 TU l gt 02110 WH PIN 16 P amp 2 2 2 4 5 33 gt gt gt casrpm BK RD 23 N GOE E 25 52 _ C95 s RsssTR BK PIN 15 nn g 5 R21IGN WH 24 C39LP BL RD C28TTA RD BK 9 8 a 2 3 BLWHPINS a a Sm z ges C135RET BLPIN 18 a ak s VSW WH PIN 1 i h e 8 8 1 1 5 1 C38ESL PING ji AUXILIARY POWER 5 RD E 0 RELAY e T os 5 ILIARY PUMP 95 ei Sr AUXILIARY a az fw E D tg 1 C27AUX RD 4 WORK LIGHT RELAY OPTION Cre P23BAT WH g m 5 C28TTA RD BK gt RD BK lt lt WH TILT ALARM N 5 8 1 BK gt gt BR LEVEL SENSOR C133PLA OR RD vey FLASHING BEACONS 8 AL OPTION 5 o SERVICE HORN C43HRN GR
65. me C5 3 Sle gl lms 328 4 gt 818 1 ot 555 g 259 5 E 5 8 ug sist gist zi zs ols lt lt 5 7 T zzz olge ols Ed tet 555 Dl 1 SS g a Ee 8 5 ala 999 EE ET 4 4 4 hb dup I zzz Se zo L ana m agb mam FRE N e t LO N 1 ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH OFF 2 THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION G 5 40 5 45 Part No 102521 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 1011F Models before serial number 7544 N st N
66. 7 l FORDENGINE Eg a 8 go a n Sg 252 PR i STARTER RELAY Bo m leo a ay 5 oje g g STARTER MOTOR o 8 Tu NI Ir x 8 15AMP P20BAT RD gt x N ES0433K NOTE ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH OFF gt DIODE BETWEEN TB35 AND TB45 ADDED AT SERIAL NUMBER 16453 Part No 102521 Te Y 0 e 0 G 6 108 Section 6 Schematics October 2013 Electrical Schematic Ford 056 423 EFI Models ANSI 5 AS from serial number 16420 RD NOTE ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH OFF N co N BR 2 GROUND C41RPM OR BK se 2 3 15
67. B I e gt 5 EE gt E 9 5 s 2 EE 3 E 9 5 12 8 lt 9 S T o 2 2 z 8 8 zt 7 B 3 o 2 5 a o 2 5 I o 4 AE TB27 TB33i i gt H6 77 145 TB23 START RELAY TB45 _ 5 1 e 2 Msc M TB133 e 3 START INPUT TB20 TB28 4 TSAMP RD e 4 AUX ON IGN START 78358 4 TB24 e 5 GROUND MODULE L5 5 5 6 0855 L 1le 7 KEY PWR 9 ET NS v cm O 8 KEY BYPASS 5 9 s i 3 5 1 u No g OTS g 19 g G TB25 TB26 L NO 5 2 8 8 a G Y 8 v1 159 8 J 9 5 8 5 7983 E m 6 ALTERNATOR 2 2 8 I 48 i 25521 g N N 8 Z L CR4 E 5 PRI 253 E 3 5 CR17 2 s PR a la 6 NO o cr o 12V pk E g D 7 CR17 5 c 7 9 af d 5 5 D 5 m STA lA 5 8 9 H2 x S 2 To Zu AUX P RS co L UMP starten REGULATOR CAN ops ors 2 2 IND E 7 E E gt 1 d 18 TN 3 o hd BRN I T 58 3 888 92 z g 5 858 4 ge ge e 82 38 5
68. BRN 2 GROUND C41RPM OR BK 5 C2P 3 4 gt 15 58 15 4 030506 WH C5 21 C30EDC WH A B DRIVE EDC FORWARD 3 9 PS DRE LED BL RD 18 16 05 C31EDC WH BK C5 20 C31EDC WH BK D 0 DRIVE EDC REVERSE m 8 VELUM 9 2 DREBBUBK fo L TRAVEL ALARM OPTION d Hd Rb ilr D 5 f DREABUWH 6 19 CS C32BRK WH RD NE C5 23 C32BRK WH RD I BRAKE RELEASE VALVE e 9 ix 120 RKOUT 6 WH 5 W oO alt yout 5E BL 4 m 5 4 5 C37STCC BLBK C6 37 C37STCC BUBK STEER RIGHT PWR 3 OR 313 enD BRN 1 10 C36STC BL 5 C6 36 C36STC BL nl STEER LEFT MET a CSP 6 WH RD C3P 5 C5TRR WH BK 9 lt C3P 4 C4TRL WH MR 4 C6 4 C4TRL WH n oe TURNTABLE ROTATE LEFT e n CSTAR WIEK ROTATE RIGHT E lz 7 E ce C6TRF WH RD 5 TURNTABLE ROTATE eo 4 FLOW CONTROL alE YOUT 5C BK 2 17 50 m m 0 ee ln 4 PRIMARY BOOM UP 5 PWR SCOR 11 PRIMARY co P 5 2 gt 12 amp BOOM 062 4 PRIMARY BOOM DOWN BE 48 C3PBF RD WH 5 PRIMARY BOOM FLOW CONTROL C3P 1 Y e lt C1PBU RD p e C2PBD RD BK L C3P 3 8 lt lt RD WH 0619 RDIEK DESCENT ALARM
69. CR27 GND STUD WH TS1 SPLICE TO C32BRK OR R40LS1 CR30 SPLICE TO R40LS1 Part No 102521 Genie S 40 S 45 October 2013 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram Perkins 704 30 Models 26 27 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 201 1 Deutz D201 1L03i from serial number 7544 to 12509 Perkins 404 22 Models from serial number 7472 to 12509 28 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 201 1 Deutz D201 1LO3i from serial number 7544 to 12509 Perkins 404 22 Models from serial number 7472 to 12509 BL WH RD BK OR BK C2 3 TB41
70. 0617 gt 1914 PLATFORM ROTATE LEFT JIB UP a wo o RICHT AT ROTATE LEFT 8 1 C19JSV GRWH JIB VALVES 5 5 3 o L JIB VALVE 25 SS 8258 gg G S 40 5 45 6 33 Part No 102521 October 2013 Section 6 Schematics Electrical Schematic Deutz F3L 201 1 Deutz 20111 03 and Perkins 404 22 Models from serial number 12510 to 14831 34 35 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 201 1 Deutz D201 1LO3i and Perkins 404 22 Models from serial number 14832 to 15662 BL WH RD BK OR BK 2 3 BK WH RD RD BRN HIGH RPM FS C19 casEsPD BK RD HIGH IDLE RELAY TS55 LOW RPM FUNCTION ENA HiGH RPM cR3 cok TS4 BK RD NO HIGH RPM SOLENOID C6 39 GR WH 45 29 52 o m F4 m 5 2 2 7 C45GEN GR WH OPTION C3P 9 DLITEORRD C2B 4 4 DRIVE LIGHT 1 1 1 1 1 RD d DRIVE LIGHT i WH capa OPTION L 1 1 1 1 1 TS48 N L29 WORK LIGHT RD WORK LIGHTS OPTION 1 5 WH BK 1 O ET 1 BK FUSE 10A PBOX GND F18 2 gt te SECOND GLOW PLUG OPTION DEUTZ ONLY 5 4 PR NO 8 458 GLOW PLUG OPTION gt Mg
71. 4 OR S P PLAT LEVEL UP BURD C6 13 BURD C4B i 13 DRV ENA LT BL WH C3B 12 12 BUBK C3B 11 11 BR GND STUD BL C3B 10 10 m coa BK RD C3B 9 9 B RD CR23887 DRIVE LIGHT OPTION N 1 2235 8 BK WH C3B 8 8 BKWH SP BOOM RETRACT 2 WH 23C BK C6 7 BK C3B 7 7 BK S P BOOM EXTEND WH RD 06 6 WH RD C3B 6 6 WH RD amp P TURN ROT WHIBK C6 5 WH BK C3B 5 5 WH BK SP TURN ROT L WH C6 4 WH C3B 4 4 WH S P TURN m RD WH C6 3 RD WH C3B 3 RD WH amp P PRI BOOM F C 5 RD BK C6 2 RD BK C3B 2 2 44B RD BK C6 19 RD BK S P PRI BOOM DOWN RD C6 1 RD C3B 1 1 RD S P PRI BOOM UP m D 0 8 A BK CR1886 SIT START RELAY m SRB 2 TACHOMETER IGN START RD 27 B 3 START INPUT MODULE RD 27B__ AUX ON en BR GND _ I5 GROUND T RD CR2 30 BATTERY 258 216 238 217 KEY PWR KEY BYPASS WH CR2 86 9 IGN FUEL ON ENG FAULT BK 22B amp ae RD CB3 SP 9 an RD 24B BK C6 25 or F 15 1 5 5 OR C6 33 8 BR GND c6 26 7 GROUND STUD BR ALL BR WIRES BK RD C5 9
72. 5 ES FUNCTION 1 Hmm Dno LU E E 2 3 L min A 81 3000 PSI y 1 1 pen L ng NS hae T T je T AN 31 3300 PSI m ERE rum RETURN H peau LUI 22555 Pudens ee i ixi ie 4 DRIVE PUMP RETUR corte i 31 3500 PSI Lothar 1 0 4 Lmin 51 3500 51 4 1 1 au pm E Fi 1 0 bar NI CREME nen AUX lt gt T2 STi ST2 LS TEST FUNCTION MANIFOLD RESERVOIR 5 PRESS Ite OPTIONAL GENERATOR lt 8 6 3 1 2 4 5 2 MANIFOED gt ee CAE en Seer ee EE TON ile NP SY 2400 psi n HYDRAULIC ROTARY COUPLER 165 5 bars 7 e o 6 Rk fo 1 8A 8B 8 6B 60 8 8 1 2A 2C 2B 7 4 5 FUNCTION PUMP REAR wp 77 ipee 12 7 bar FRR FLB FLR on TO HYD ROTARY COUPLER 7 EN aw d 1 RIGHT STEERING LEFT 1 50 210 psi 1 a 1 14 5 bar Y par oy 07 ae X ES p Lim 1 e ma 8 N 11 Note alpha callouts refer to E Sas REAR 185 psi M2 LEFT 12 7 bar RELEASE ea MANIFOLD Genie 6 142 S 40 S 45 PartNo 102521 October 2013 Section 6 Schematics 2WD Non Oscillating Hydraulic Schematic
73. 5 gu 5 a START RELAY PUMP AUXILIARY 4 E 5 E RD 5 STARTER MOTOR x E m oa o C27AUX RD coz f AUXILIARY POWER 8 TERI H 33 AUXILIARY PUMP C72 P23BAT WH 8 ie zg 48 Eg O sl Pi a al lt 4 2 g C1 2 C6 28 i gt C28TTA RD BK 5 RD BK 28 WH H TILT ALARM g x 6 23 RD 134 RD BK BRN LEVEL SENSOR 5 0 x C133PLA OR RD el yoy 4 FLASHING BEACONS z ju OPTION etr 9 2 x LK ee 5 o 1 C25 _CASHRN GR SERVICE HORN x ee 0 RELAY P22BAT BK C74 c 9 KS SERVICE HORN a 2 M mE He m l H a 5 oes 07 HYDRAULIC OIL z TEMP SWITCH C134PWR RD C24 ce 1 58 ces 0628 COOLING FAN GHS M OPTION e oe m a C41RPM ORIBK s OR BK PIN2 42 PIN FORD CONNECTOR n ae EN gt 5 3 9 5 a rata QW c o x 8 XP 510 OHM E 5 z i 5 BI 2 get 5 on E i i li ui Eo o al 4 4 4 6 B 3 Sc 5 1 0 RD 3 e Part No 102521 THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION REFER TO E0375 FOR FORD HARNSS gt gt 3 40 5 45 G 6 78 Section 6 Schematics Electrical Schema
74. 5 A C2 1 5 14 1 m oj __ 5 14 5 cosrSR WH RD PIN 39 5 8 12 p g L E s c127T9W GR PINS o gt qu C517 gt gt C211GN WH PIN 16 elig C59 5 6 4 gt 035800 BK RD PIN 23 NO y o 52 5 695 R33STR BKPIN 15 3 I ov T a 25a Te 658 gt oti WH PIN 24 az C5 10 E 5 19 C39LP BL RDPIN7 09 i x oor E 5 3 C135FP BLWHPIN5 n p amp p CI35RETBLPIN 8 zi EN po n m 8 RD e C511 vswwHpN1 8 68 OR 038686 BLWH PIN 6 N M J N a A WORK LIGHTS RELAY OPTION 8 52 AUXILIARY POWER C27AUX RD t 88 ES S AUXILIARY PUMP P23BAT WH x d Eg i a gt g z pu PI o boo C28TTA RD BK ie WH TILT ALARM o 8 Si 5 9 BR LEVEL SENSOR z 8 FLASHING BEACONS B C133PLA OR RD D OPTION l z o L E EN tr go E 5 SERVICE HORN C43HRN GR RELAY 5 C6 16 22 8 R43HRN SERVICE HORN y B I lt T Q T g 5 0625 1 16 HYDRAULIC OIL l 5 TEMP SWITCH C182PLI1 fe 2 EO at 9 oe 0933 m 108 28 COOLING FAN 4 0 23 gt 50 NE RJ PST cs C41RPM OR BK D CA1RPM OR BK PIN 2 42 FORD CONNECTOR GND BR 2 5
75. C133PLA OR RD C43HRN GR H HORN C7 1 TB28 PR1 RELAY CR45 PR 1 AU ve fip 02 CR45 NO AUXILIARY PUMP C6 28 WH C6 23 RD WORK LIGHTS RELAY OPTION TILT ALARM LEVEL SENSOR P22BAT BK RD lt C132PLI1 1 12 e TB132 TB13 5 7 8 C2 4 P134PWR RD TB134 C32 CONN PLUG GR BK FLASHING BEACON 1 OPTION SERVICE HORN RELAY SERVICE HORN HYDRAULIC OIL C6 26 1 TEMP SWITCH 4 COOLING FAN o FAN M1 en OPTION RD C41RPM OR BK a eo 022 EXCT IND GBOX GND A CB1 15 CB3 20AMP TB20 REGULATOR J ALTERNATOR RD IN THE STOWED POSITION AND KEYSWITCH OFF gt DIODE BETWEEN TB35 AND TB45 ADDED AT SERIAL NUMBER 16453 1 ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM Part No 102521 G 3 40 5 45 6 8 Section 6 Schematics Electrical Schematic from serial number 16420
76. C1P C28TTA RD BK C1P 2 C2P C3P C3P GR C2P BK C1P GY 19 18 CONTROL CABLE GR BK C4P 4 BATGND C7P 3 D40 RED TILT RED TILT e RD BK 28 I D39 e TILT ALALRM AAA EEA 2 6 NN NN SS NN NN NN NN SN NA NNNN G 3 40 5 45 Part No 102521 6 60 Section 6 Schematics from serial number 14832 Deutz D201 1L03i and Perkins 404 22 Models LOAD SENSE OPTION Platform Control Box Wiring Diagram ALC 500 October 2013 N 5 C19JSV GR WH TS7 me C19JSV GR WH C4P 7 BR JC3 Ex re BR GND RD E STOP GEB RD P134PWR 1 5 BR CR13 86 GR WH 5 a O 0 55 gt 5 Pd EN 5 5 a 8 E f 9 sl P134PWRRD 20 e a 2 2 GR WH 2 gt RD P134PWR RD ul gt RD H1 Be 5 E
77. DESCRIPTION LABEL PART EMERGENCY STOP BUTTON P1 P1 KEY SWITCH KS1 KS1 AUXILIARY SWITCH TS51 42730 ENGINE START SWITCH TS52 13037 STARTER AID TS56 13037 FUNCTION ENABLE SWITCH TS55 13037 PLATFORM ROTATE SWITCH TS57 16397 PLATFORM LEVEL SWITCH TS59 13037 BOOM EXTEND RETRACT SWITCH TS63 13037 PRIMARY BOOM UP DOWN SWITCH TS61 16397 TURNTABLE ROTATE SWITCH TS62 16397 JIB BOOM UP DOWN SWITCH TS58 13037 CIRCUIT BREAKER CONTROLS 15A CB1 CB1 CIRCUIT BREAKER ENGINE 15A CB2 CB2 CIRCUIT BREAKER OPTIONS 20A CB3 CB3 RESISTOR 5 OHM BOOM FUNCTION Ri R1 RESISTOR 7 5 OHM TURNTABLE FUNCT R2 R2 VOLT METER GAGE G1 Gt OIL PRESSURE GAGE G2 G2 OIL TEMP GAGE G3 G3 HOUR METER HM HM IGN START RELAY CR1 CR1 IGN POWER RELAY CR2 CR2 HIGH IDLE RPM CUTOUT RELAY CR3 RPM RELAY CR4 CR4 COOLING FAN RELAY CR17 CR17 PLATFORM OVERLOAD ALARM H6 PLAT OVERLOAD MODULE U33 PLAT OVERLOAD LED L45 c32 RD H6 C32 1 BL WH 38D C32 3 22 32 4 gt eu PLATFORM LOAD _ BK C7 1 C32 5 d RD TS51 C32 6 GRIBK LAS gt RD TS55 C32 7 GREEN GR BK 16B C32 8 Gi G2 63 GND C32 12 WH 21A 2 8 SPARE 3 gt GR WH C6 39 GR WH C2B 7 45 GEN OPTION BR GROUND 2 GR BK C2B 6 44 GR BK 2B GRIBK S P GR C2B 5 GR CR5 85 HORN RD C6 23 OR RD C2B 4 42 RD H6 RD KS1 2 S P C134PWR OR BK C5 2 OR BK C2B 8 41 OR BK ISM 2 BR 3MF CAP PULSE PIC
78. E 1 a 51 5 2 JIB VALVES x gt o Hiie 5 JIBVALVE Ki T hh 5 amp 4l x enie G S 40 S 45 6 113 Part No 102521 October 2013 Section 6 Schematics Electrical Schematic Ford DSG 423 EFI Models CE from serial number 16420 6 113 6 114 Section 6 Schematics October 2013 Ground Control Box Wiring Diagram Ford DSG 423 EFI Models before serial number 14832 6 116 6 115 October 2013 Section 6 Schematics Ground Control Box Wiring Diagra Ford DSG 423 EFI Models before serial number 14832 A B C m 46 SPARE GR WH C6 39 GR IWH C2B 7 45 GEN OPTION GR BK C2B 6 44 gt GR BK 2B GR BK S P JDALARM JIB GR C28 5 23 GR CR5 85 HORN RD C2B 4 42 RD KSI2SP Ci34PWR OR BK C5 2 OR BK C2B 3 4 PULSE PICKUP OR C6 40 OR C2B 2 40 LIMIT SWITCH SIG BL RD C5 10 BL RD C2B 1 39 BURD S P LP 2 BLWH C1B 12 38 C132PLI BL BK C6 37 BUBK C1B 11 37 STEER LEFT BL C6 36 BL C1B 10 36 STEER
79. Ford MSG 425 EFI Operator Handbook Genie part number 215322 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Genie Part No 102521 S 40 5 45 3 57 Section 3 Scheduled Maintenance Procedures October 2013 CHECKLIST E PROCEDURES This page intentionally left blank Genio 3 58 3 40 8 45 PartNo 102521 October 2013 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the Genie S 40 and Genie S 45 Operator s Manualon your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specifie
80. P25FS RD C9P 3 P24FS WH C9P 2 JDALARM GR BK C2P 6 DRIVE LT BK RD C3P 9 a C45GEN GRMWH C2P 7 8 TS48 WL1 RD C2P 12 TS48 WL2 RD C2P 11 C39LP BL RD C2P 1 DLITE GR BK C2P 6 P26BAT BK cerne WHIRD 6 C10SBU BL C3P 10 C13DRE 81 80 C4P 1 E CrisBb BUBK C3P 11 x C40LS1 OR 2 2 e C12SBF BUWH C3P 12 0 a P24FS WH 9 C41RPM OR BK C2P 3 T 4 C30EDC 4 C1PBU RD C3P 1 m WHIBK 5 5 m 9 C2PBD RD BK C3P 2 e 6365100 1 10 RD WH C3P 3 cszsrcBUEKCIP Ii 5 o C5TRR WH BK 5 of 2 a 32 WH RD 6 C4P BR 0 E C4TRL WH C3P 4 6 2 g C29MS RD WH C1P 3 8 C134PWR RD C2P 4 P GR lt 35 BK RD 1 9 CSP GR 0 C348A BKWH C1P 8 E 6 casstr amp C27AUX RD C1P 1 RD BK L4 C2P BK 5 clo 5 JC1 3 OR le 9 JC2 4 RD A JC1 2 BRN TE e o C1P GY JC2 3 OR JC1 5 YEL JC2 2 BRN JC3 5 BL JC3 8 OR JC3 4 6 WH JC3 2 DRE A BLWH C28TTA RD BK C1P 2 a a DRE B o 0 C13LED BL R
81. Platform Control Box Switch Panel Wiring Diagram Deutz F3L 1011F Models N M L K J F E D C B A 1 HARNESS PBOX WIRING 7 7 COMPONENT INDEX PART NUMBER 2 TS48 TS49 BOOM PROPORTIONAL JOYSTICK 6 WORK DRIVE LITE 6 PRIMARY UP DN TURNTABLE ROTATE 62390 5 515 i 5 163 DRIVE PROPORTIONAL JOYSTICK 75565 9 DRV ENA GENERATOR L1 DRIVE ENABLE LED 56298 3 ope OPTION 4 SWITCH 56813 68816 p AUXILIARY SWITCH 42730 3 T 3 TS2_ START ENGINE SWITCH 13037 2 1513 gr 2 TS4 RPM SWITCH 27378 3 PRIMARY 756 GLOW PLUG OPTION 56298 JC2 BOOM JC3 757 PLATFORM ROTATE SWITCH 16397 1 1 TS8 JIB UP DOWN SWITCH 13037 EXTEND TS9 PLATFORM LEVEL SWITCH 13037 RETRACT 5 TS13 PRIMARY BOOM EXTEND RETRACT SWITCH 13037 TS15 DRIVE ENABLE SWITCH 13037 TS47 GENERATOR SWITCH OPTION 27378 5 TS48 9 WORK DRIVE LIGHT OPTION 2737
82. Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST D PROCEDURES 5 Remove the drive hub mounting bolts Carefully remove the turntable rotate drive hub assembly from the machine AWARNING Crushing hazard The turntable rotate drive hub assembly could become unbalanced and fall if not properly supported by the lifting device 6 Remove the plug from the side of the drive hub Drain the oil from the hub into a suitable container 7 Install the drive hub assembly onto the machine Torque the drive hub mounting bolts to specification Refer to Section 2 Specifications 8 Fill the drive hub with oil from the side hole until the oil level is even with the bottom of the hole Apply pipe thread sealant to the plug Install the plug Genie S 40 S 45 D 5 Perform Engine Maintenance Deutz and Perkins Models Engine specifications require that this procedure be performed every 1000 hours Deutz models Required maintenance procedures and additional engine information are available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0312 3547 Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 139320 Perkins models Required maintenance procedures and additional engine information are available in the Perkins 404 22 Operation Manual Perkins part number
83. T m 2 3 5 5 3 EE a EMT ET ACA ems Q 9 8N C U36 a 4 1 9 1N O amp 2 COM CR66 3GND sswINPUT OMRON RELAY i rm v 0 9 e N 5 2 5 TIME DELAY MODULE e P g e 124 4SECOND 5 S JA j Mn 5 099 W a I e TB35 2 T s rim Pe 3 TB29 ai UM tn TB41 124 ohms A1 BATTERY d POR Te 2 4 6 a a A2 SENSOR POWER 5 VDC S S 1 BATTERY el 1240005 OE Oa B1 VALVE 0 FWD COIL VISIRG GR B2 VALVE 1 NC g 9 Q 9 9 Sepe V150HG GR BK B3 DIGITAL OUTPUT BYPASS D S T 5 N 1 3 2 4 8 BK 16 2 A gt gt RS232TxD 4 C1 TxD YLW crso 4 4 J129 RS232RxD C2 RxD GRN 5 L C57 m 5 5 OMRON CC c C3 BOOT g RELAY PEN 4 B 3 7 a Y75 w E D1 ANALOG 0 JOYSTICK 5 5 E EA EE 7 D2 ANALOG 1 NC 2 9 7 7 D3 DIG IN 3 NC ze 5 AIO Pa Et NOT USED cad MES E 3 v E2 NOT USED MS gt 2m 5 7 PS4 E a S 5 15 3 NOT USED a 8 SS F1 DIGINO E NG Sm F2 DIG IN 1 GENERATOR ON 8 UC a 2 F3 DIG IN 2 SX Controller i T 5 Y75 2 PILOT PRESSURE SIGNAL m m FROM GENERATOR MANIFOLD m m BR2 8 8 02 H m DIVERTER MANIFOL
84. brake disengaged position E af arf brake engaged position Illustration 1 Part No 102521 5 40 5 4 59 Section 4 Repair Procedures October2013 half sprocket idler wheel tensioner bogey wheel assembly Illustration 2 8 Install the new track onto the undercarriage Note Be sure the idler and bogey wheels are aligned with the inside surface of the track 9 Using a suitable lifting device lift up on the rubber track and rotate the half sprocket until one of the sprocket teeth is engaging the track 10 Continue rotating the half sprocket until it is fully engaging the track Genie S 40 S 45 11 Install the other sprocket half removed in step 4 12 Install the lug nuts onto the wheel hub and torque to specification Refer to Section 2 Specifications 13 Adjust the track tension Tighten the tensioner nut on both sides of the idler wheel until there is about 0 75 1 0 inch 19 25 mm of droop between the inside of the rubber track and the bottom surface of the bogey wheels Note Make sure that both sides of the track have the same amount of clearance between the rollers and the track 14 Tighten the jam nuts and idler axle bolts on both tensioner assemblies Part No 102521 October 2013 Section 4 Repair Procedures 11 1 Hydraulic Generator How to Adjust the Generator Voltage AWARNING Bodily injury hazard Spraying hydrauli
85. 23 2 7 KEY PWR WH 4A 8 Mt 8 KEY BYPAS 9 IGN FUEL ON 2 IS In ENG FAULT pid m RD ISM 6 BK RD 35B U TS57 WH ISM 9 8 4 RD 24B 1 RD C32 7 am gene 55791 D13 BK ISM 1 F BK RD 35A RD 20A 5 5 WH2IB RD 24A BK RD C5 9 RD 20B RD P1 E STOP 8 1 BK C6 16 OR C6 33 OR BK 15A OR 14A GR 17A CES H GR WH 19A H 1 GR BK 18A CR5 GR 43D CR17 BK BK22B RD CB3 SP WIRING GROUND STUD HARNESS BR TO BASE ALL BR WIRES C2 pP DIODE BETWEEN TB35 AND TB45 ADDED AT SERIAL NUMBER 16453 Ground Control Box Wiring Diagram Deutz 020111 03 and Perkins 404 22 Models from serial number 14832 D LOAD SENSE OPTION TIMER RELAY B WH CR2 86 WH ISM 9 RD TB134 A C BR GND 3 U34 BK C3B 10 REPLACE WIRE WITH THIS WIRING DIAGRAM DRIVE LIGHT OPTION RELAY RD 24C CR23 0 8 BN GND RD C4B 10 RD C4B 12 WH 21B WORK LIGHT OPTION RELAY RD 20C CR45 30 BR GND 87 WH W L CABLE WH 21C DESCRIPTION LABEL EMERGENCY STOP BUTTON P1 KEY SWITCH AUXILIARY SWITCH TS51 ENGINE START SWITCH 7852 STARTER AID TS56 FUNCTION ENABLE TS55 PLATFORM ROTATE SWITCH 1857
86. 5 Support the engine with an overhead crane or other suitable lifting device Do not lift it 6 Remove the engine mounting plate to bell housing fasteners 7 Raise the engine slightly using the overhead crane and place a block of wood under the oil pan for support 8 Support the drive pump assembly with an overhead crane or other suitable lifting device Do not apply any lifting pressure Section 4 Repair Procedures ENGINES 9 Remove all of the engine bell housing retaining fasteners 10 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 11 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Perkins models 1 Remove the fuel filter water separator mounting fasteners Remove the fuel filter water separator and lay it to the side Do not disconnect the hoses Support the drive pump assembly with an appropriate lifting device Remove all of the engine bell housing fasteners 5 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched Remove the flex plate mounting fasteners Remove the flex plate from the flywheel How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised
87. 8 E 5 EB 5005 8 8 gt 8 2 2 5 9 5 2 5 8 m S 8 m m 5 5 SQ 9 E o 5 5 5 5 o 5 3 gt 2 lt 9 2 8 E E 2 x 2 5 6 i 5 8 5 T 5 2 5 5 od m NOTE 9 N 1 ALLSWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH OFF Genie A TEREX 6 4 5 40 5 45 Part No 102521 Section 6 Schematics Electrical Schematic from serial number 15663to 16419 Deutz F3L 201 1 Deutz D201 1L O3i and Perkins 404 22 Models CE October 2013 BL WH N LO N co BR 2 GROUND p carp OR BK lsz C23 gt 15 Ut 8 5 DRIVE MODE m E ioe 8 T C29MS RD WH2 8 T5 7 lt lt C30EDC WH C30EDC
88. C19JSV GR WH m m 5 P Ta JIB VALVES E ar55g 8 z gt z a 5 f BELLE 8 5 JIB VALVE TOO CO 9 Fe X e e gt a m Ja 258 gg d 5 S 40 5 45 Part No 102521 October 2013 Section 6 Schematics Electrical Schematic Deutz F3L 1011F Models before serial number 7544 10 ENGINE FUNCTIONS 19 8 CABLES 12V TO PLAT GROUND STUD October 2013 Section 6 Schematics
89. Gasoline LPG models before serial number 13740 and Diesel models all Note Perform this procedure with the engine off Note Gasoline LPG models use a pressurized cap beginning with serial number 13740 1 Remove the cap from the fuel tank Genie S 40 S 45 2 Checkfor proper venting Note When checking for positive fuel tank cap venting air should pass freely through the cap O Result Air should pass through the fuel tank cap Proceed to step 4 Result Air is not passing through the fuel tank cap Clean or replace the cap Proceed to step 3 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 2 4 Install the fuel tank cap onto the fuel tank All models 5 Remove the breather cap from the hydraulic tank 6 Check for proper venting Result Air should pass through the breather cap Proceed to step 8 W Result If air does not pass through the breather cap clean or replace the cap Proceed to step 7 Note When checking for positive tank cap venting air should pass freely through the cap 7 Using 8 mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 6 8 Install the breather cap onto the hydraulic tank Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures B 23 Check the Tra
90. Horsepower gross intermittent 50 6 2800 rpm continuous 41 6 2800 rpm gross intermittent 37 3 kW Q 2800 rpm continuous 31 kW 6 2800 rpm Firing order 1 3 4 2 Low idle rpm 1300 rpm Frequency 200 5 Hz Low Idle rpm with generator option 1500 rpm Frequency 231 3 Hz High idle rpm 2500 rpm Frequency 385 5 Hz Compression ratio 22 4 1 Compression pressure 426 psi 29 4 bar Pressure psi of lowest cylinder must be within 50 psi 3 45 bar of highest cylinder Governor centrifugal mechanical Valve clearance cold Intake 0 008 in 0 2 mm Exhaust 0 008 in 0 2 mm Lubrication system Oil pressure hot 40 to 60 psi at 2000 rpm 2 8 to 4 1 bar Oil capacity including filter 9 4 quarts to 11 2 quarts 8 9 liters to 10 6 liters Genie S 40 S 45 Cil viscosity requirements Unit ships with 15 W40 oil Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the engine Operator s Manual on your machine Oil pressure sending unit Torque 8 18 ft lbs 11 24 Nm Oil pressure switch point 14 2 psi 1 bar Coolant temperature sending unit Torque 8 18 ft lbs 11 24 Nm Temperature switch point 221 105 Fuel injection system Injection pump make Zexel Injection pressure 2133 psi 147 bar Fuel requirement For fuel requirement refer to the engine Operator s Manual on your machine Battery Type 12V Group
91. How to Adjust the Joystick Max out Setting The max out setting of a joystick controls the maximum speed of a joystick controlled machine function Whenever a hydraulic cylinder drive motor or hydraulic pump is replaced the max out setting should be adjusted to maintain optimum performance The max out settings on the joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Note Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Pushin the platform controls red Emergency Stop button to the off position 4 Do not press down the foot switch 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position 6 When the alarm sounds release the drive enable toggle switch Genie 4 4 S 40 S 45 7 Momentarily activate the drive enable toggle switch in the right direction 4 times Result There should be a pause and the alarm should sound 4 times indicating that the machine is in max out calibration mode W Result The alarm does not sound Repeat steps 3through 7 8 Startthe engine from the platform controls and press down the foot switch 9 Startatimer and activate the machine function that needs to be adjust
92. Low idle rpm 1600 rpm Frequency 246 7 Hz High idle rpm 2200 rpm Frequency 339 2 Hz Governor centrifugal mechanical Valve clearance cold SPECIFICATIONS Cil viscosity requirements 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 classification CC SE API classification CD SE or CCMC D4 can be used but is not recommended during the first 50 hours nor 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 For fuel requirement refer to the engine Operator s Manual on your machine Enginecoolant Capacity 111 2 quarts Intake 0 014 in 10 9 liters 0 35 mm Alternator output 65A 12V Exhaust 0 014 in 0 35 mm Battery Lubrication system Type 12V Group 31 Oil pressure 41 psi Quantity 1 at 2600 rpm 2 8 bar Cold cranking ampere 1000A Oil capacity 7 3 quarts including filter 8 3 liters Reserve capacity 6 25A rate 200 minutes Fan belt deflection 3 8 in 10 mm Genio Part No 102521 5 40 5 2 11 Section 2 Specifications October 2013 SPECIFICATIONS Perkins 404 22 Engine Displacement 134 cu in 2 2 liters Number of cylinders 4 3 31 x 3 94 inches 84 x 100 mm Bore and stroke
93. RD TB27 STARTER MOTOR Ble p PUMP AUXILIARY E SAO T EINER 1 1 C27AUX RD 1 EMISSION CONTROL e RELAY IN THE STOWED POSITION AND KEYSWITCH OFF p SECOND GLOW PLUG OPTION ADDED AT SERIAL NUMBER 15151 RD 27 AUXILIARY POWER T 1 1 1 1 gie 7 x a x a 8 7 2 P23BAT WH AUXILIARY PUMP TM 5 5 gt gt 1 2 C28TTA RD BK Ns TB23 28 7 WH TILT ALARM i 1 1 x RD 134 RD 1 1 1 x 1 1 1 C133PLA OR RD i 4 9 1 o i dccem 4 A 4 ge o 1 C25 C43HRN GR P22BAT BK C74 g e TB28 S7 IBK BRN LEVEL SENSOR FLASHING BEACONS OPTION TB133 CR5 SERVICE HORN RELAY TB43 e BK 43 n 1318 NO 4 SERVICE HORN RD TEMP SWITCH 4 RD IBR COOLING FAN OPTION C132PLI BL WH C1 12 4 WH T 6 5 HYDRAULIC OIL 132 C134PWR OR RD C2 4 TB42 C41RPM OR BK 5 2 OR BK 41 Electrical Schematic Deutz F3L 201 1 Deutz D201 1L03i and Perkins 404 22 Models from serial number 14832 to serial 15662 October 2013
94. WH RD C amp 23 _ WH RD C1B 6 32 WH RD C6 32 BRAKE TRAVEL ALARM WE wp E DESCRIPTION LABEL PART WH BK C5 20 WH BK C1B 5 31 E D C NC WH C5 21 WH C1B 4 30 EDC WH 23A It EMERGENCY STOP BUTTON P1 P1 RD WH C1B 3 29 SPARE RD 42A v KEY SWITCH 1 1 RD BK C6 28 RD BK C1B 2 28 TILT ALARM RD 27A RD C6 27 RD C1B 1 27 RD ISM 4 gt D6 RD SP AUX PWR RD C23 6 AUXILIARY SWITCH TS51 42730 WH RD C5 14 26 WH RD S P WATER TEMP SENDER WH BK C5 16 25 WH BK S P OIL PRESSURE SENDER ENGINE START SWITCH TS52 13037 RD C5 1 2 RED CR1 30 RD S P ENGINE POWER RD H6 WH C7B 2 RD C5 19 WH ISM 7 WH S P KEYSWITCH PWR FB OR RD H6 BL WH C6 30 Con d 22 BKCASHSO PWR us PLAT FUNCTION ENABLE TS55 13037 4 WH C5 3 C5 11 WH C6 34 21 WH CR2 87 WH S P IGNITION PWR RD 12VOLT CB3 SP 20 CB2 SP CB1 SP 12 VOLT BATTERY POWER WH 21A N 1327 18397 GR WH C4B 7 19 GR WH SP JIB VALVE GR BK C6 18 GR BK C4B 6 18 GR BK S P PLAT ROT R HM Fan cas 9 15 CRSP BR GROUND E L L45 BOOM EXTEND RETRACT SWITCH TS63 13037 OBBICCOWE San ies 15 GN BK C23 8 SNEKES an L2 2 PRIMARY UP DOWN SWITCH TS61 16397 6 BK C4B 3 S P E 5 2 OR C6 14 080482 14 OR S P PLAT LEVEL UP WE MIO T TURNTABLE ROTATE SWITCH TS62 16397 xS BURD C6 13 BLHD CAST 13 DRUSENASETS RD WH 3A TS61 JIB BOOM UP DOWN SWITCH TS58 13037 1T CIRCUIT BREAKER CONTROLS 15A 1 CB
95. gt C27 C45GEN GRWH C6 39 GR WH A OPTION ep ge Ue E 7 5 C3 9 DLITE BK RD Sm 3 ig RD lt DRIVELIGHT m C4B 12 AA OPTION e o 1 1 3 9 4 WORK LIGHTS way x BK l x g 9 C4B 11 1 1 ay PM 1 WH N BK PS 5 MEN ne RE ES NE amp VOLT METER R21lGN WH HOUR METER 1 8 05 16 WH BK 6 mie ji Ne OILPRESSURE GAUGE 5 a AL GY RD Zy 6 GY YL 20 5 5 RD Tr Q 6 of 3 E 9 BK BL GASOLINE SENSOR a D 1 7 C33STR BK Sa Na 4 t 95 RD GN Oc m o e ENGINE START WHBK E LL ENGINE 52 LPG LOCKOUT 5 lt lt START 57 5 5 2 5 3 C107AF WH E E 5005 TO ALTERNATOR FIELD amp a wa gt 8 TEMP GAUGE 5 8 a E C24 3 i 0514 C26TSR WH RD PIN 39 5 or 24 9 2 C5 12 CI27TSW GRPIN3 du yt a amp GAS sp 5 17 C21IGN WH PIN 16 aZ 9 05 9 C35RPM BK RD PIN 23 iP 5 FUEL 05 5 R33STR BKPIN 15 213 x GAS of a x 5 8 R21IGN PIN 4 a we g E IN PLUG a C5 10 _ C39LP BURDPIN7 9 8 013565 BLWHPIN 5 AUXILIARY g PUMP m a gan C135RET 18 m
96. lo P26ESTPBK X 11 25 DRIVEENABLE BRI Q LIMIT SWITCH m E NNI 0202 40151 OR C6 40 C40LS1 OR lt gt a E n I z z 8 8 5 T I l 14 5 u No o pee he 8 22 n e 5 8 SIEBEBS 4 EXTEND 9 lt 0150 4 EXTEND E E retract 200 SIR 55 t ESEDRIBIANH BOOM RETRACT E 9 7 C7PBE a S EXTEND 2 p EL BOOM 5 5 RETRACT 8 C8PBR BK WH zE 2 wad C4P 2 C14PLU OR UP EL BR PLATFORM LEVEL x DOWN CIBPLDOR BK 5 S 55 0814 C14PLU OR 1 PLAT LEVEL mM 8 2 DOWN 5 B 15PED ORIBK VJ 5 PLAT LEVEL DOWN 5 I GR BK44 6 JDALARM GR BK 20 C4P 6 C18JD GR BK 54 DOWN LO 5 sup P BOOM caps C17JU GR 2 C6 18 C18JD GR BK Sm wo o n 2 to owt meni JJ4 4 PLATFORM ROTATE RIGHT JIB DOWN 6 17 E 10 DIJO 4PLATFORM ROTATE LEFT JIB UP io RIGHT 9 RIGHT 4 e PLATROTATE n PLAT ROTATE 2 LEFT 5 t Cap C19J5V GR WH o o I JIB VALVES 2 5 o 5 B JIB VALVE alc gt z sz gg 8 6 29 5 40 5 45 G Part No 102521 October 2013 Section 6 Schematics Electrical Schematic Deut
97. sepas iw 10 pss Dav 18 1 258 0G 18 1 7 5 7101618 77 7101518 d u exe L ZYK zac 2 our ILES a meyn et ee ners pick GOV SELECT 2 307 BK Y 18 307 BK Y 18 307 BK Y 18 23 GOV SELECT 2 11 16 6 BK 18 169 LG BK 18 169 LG BK 18 ROAD SPEED 35 ROADSPEED 12 17218918 17208818 ROAD SPEED 2 36 ROADSPEED 77 DB Y 18 33 349A DB 18 0 349A DB 18 S ADS 18 OVERSPEED 30 OVERSPEED Cu 18 662 DG P 18 662 DG P 18 662 06 218 p 19 45901518 EEE c z_ IS 458 06 18 45901618 Jj can 8 20 64206048 5206018 64206018 usas 461018 Od 451018 481018 ans 48s 34 eegpG wis 669 DG W 18 D 1 0406 0180 2 20 00 77 DG W 18 1 669 DG W 18 20 RS 232 E TT T 458 O BK 18 Nard 35 458 O BK 18 1 458 O BK 18 SURG is TWR SHD 570 BK W 16 TRIM VALVE 8 A PLUG GROUND Al 77 DB Y 18 8 8 PLUG RELAY POWER PLUG CAN B 361A R 16 361A R 16 662 DG P 18 D PLUG CAN WPTWR2_GY MTRTWR4 MTRSHD4 6 128 Part No 102521 ENGINE ECM CONNECTOR SPK SPK_COILIB SPARK_COIL2A COLL2B SPK COLLA SPK_COILSB UEGOS uEGoc UEGOP UEGPR AUX ANAPDI FRP AUX ANA PD2 CANT CANI CAN2 AUX ANA PDS SVEXTI SV RTN EGO EGO MAP AUX ANA PUDS CR
98. 20 On og 55 or 115 ba 26 H 65 6 lo 2 8 C67 Sri 43 5 G C7PBE BK BOOM EXTEND 25 t Sago E 4 EXTEND BOOM g o lt 9 55 8 8 RETRACT 1 068 C8PBR 8004 gt BOOM RETRACT SH C37 C7PBE BK Fer FER m C8PBR 2 C42 C14PLU OR UP PLATFORM LEVEL 2 e e 2 045 0150 OR BK ib By C614 C14PLU OR lt A gt PLAT LEVEL UP 2 UP PLATFORM LEVE E DOWN 68 15 C15PLD OR BK gt gt PLAT LEVEL DOWN m C2 6 E GR BK 44 JDALARM GR BK Is e 20 027 65 gt crs C18JD GR BK DOWN 5 2 UP JIB BOOM C4 5 C17JU GR g E 2 Sow 00219 C18JD GR BK lt gt PLATFORM ROTATE CCW JIB DOWN N 5 pues soon SEA C17JU GR 4 PLATFORM ROTATE CW JIB N PLAT ROTATE 5 cow t PLAT ROTATE ce C19J5V GR WH 5 47 Le VALVES im Oi Eo A 52 5 D JIBVALVE 2 2 Ui a E mi 5 1 i om 6 97 5 40 5 45 Part No 102521 October 2013 Electrical Schematic Ford DSG 423 EFI Models from serial number 14832 to 15662 Section 6 Schematics 98 99 Section 6 Schematics October 2013 Electrical Schematic Ford DSG 423 EFI Models ANSI CSA AS from serial number 15663 to 16419 6 100 RD
99. 5 1 ee g 5 H je lt Re i 5 Xm 4 El 8 S o o 9 8 3 lo 8 8 9 o E gp 5 N 8 5 3 T o e gt lt E A gt o lt 6 c I ES 2 o lt o 5 5 n 3 2 2 5 2 5 2 amp 2 Q 6 5 gt WH _ TS7 TS8 N Gh TS14 ec _ WH 5 a DRIVE PLATFORM WH PLATFORM JIB AUXILIARY 7 mE _ PUMP CE SEE DETAIL A Genie A TEREX BAND 3 40 5 45 6 124 Part No 102521 GENERATOR OPTION Sc ad ZySL HM LH S au a TO HM HIGH LOW RPM TS4 JC3 HO 9 17 HM 66 08 au e FUEL SELECT REMOVE FOR GENERATOR OPTION t a S L HM v o R IR N u 8 EI 5 5 2 13 Do gt EMERGENCY STOP P2 HARNESS PBOX WIRING COMPONENT INDEX PART NUMBER Jc2 BOOM PROPORTIONAL JOYSTICK 62390 PRIMARY UP DN TURNTABLE ROTATE JC3 DRIVE PROPORTIONAL JOYSTICK 75565 L1 DRIVE ENABLE LED 56298
100. 89 ha 2 ugl 5 8 22 4 0 e m Sr whieh 8 5 67 oe gt LH BOOM EXTEND 6556 P SEXTEND poom 3 m a see E RETRACT C8PBR BKWH S 5 BOO BETBRCT C3P 7 C7PBE BK PLATFORM LEVEL C3P 8 C8PBR BK WH C4P 2 C14PLU OR tDOWN PEAIFORMEEVEL C4P 3 C15PLD OR BK Q E gt C6 14 C14PLU OR 2 PLATFORMLEVEL o PEAT LEVELUP 6 t DOWN C6 15 C15PLD OR BK PLAT LEVEL DOWN wo 5 1 i ec GR BK 4 JDALARM GR BK gt 6 C18JD GR BK DOWN 5 C17JU GR 2 z 8 6 18 C18 D GR BK 2 Bi 2 toowh PLATFORM ROTATE RIGHT JIB DOWN t P JIB BOOM C617 C17JU GR tu 5 PLATFORM ROTATE LEFT UP M m rs 5 oa RIGHT SRIGHT lel se LEFT PLAT ROTATE terr PLAT ROTATE lt B e 100r 9 5 5 5 19 5 GRWH 8 E 2 5 JIB VALVES ac 5 5 amp H 22001 5 02 lt lt 5 2 E 5 5 cccccc 5 JIB VALVE S o 5 888 JE 8 5 6 79 Genie S 40 5 45 Part No 102521 POSITION EXCEPT AS NOTED October 2013 Electrical Schematic Ford LRG 425 EFI Models from serial number 7597 to 110
101. A 83 RD TILT RD TILT COMPONENT INDEX TILT ALARM JIB DELAY RELAY JIB TIME DELAY LOAD SENSE TIME DELAY RELAY 30A H1 CR14 C1 U35 E _ G 5 40 3 45 6 121 Part No 102521 October 2013 Section 6 Schematics Platform Control Box Wiring Diagram Ford DSG 423 EFI Models from serial number 14832 6 121 6 122 Section 6 Schematics October 2013 Platform Control Box Switch Panel Wiring Diagram Ford DSG 423 EFI Models from serial number 11067 to 12509 6 124 6 123 October 2013 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram Ford DSG 423 EFI Models from serial number 11067 to 12509 A B C D E F 10 AMP FUSE 1 N TS49 EN DRVENA TS15 P i 3 isi PRIMARY BOOM E EXTEND RETRACT 8 JC2 TS13 4 CR13 i i gt NU ig E sl le g N 5 5 3 IN Y 15 2 1 E pu Blo m 15 S i 5 20 sm
102. BooM EXTEND su if 1 BOOM E ces C8PBR BK WH 2 2 1 RETRACT BOOM RETRACT OS C7PBE BK lt 4EXTEND BOOM 5 8 C8PBR BK WH E D 2 2 2 C14PLU OR Er PLAT AR 5 5 g 1DOWN LEVEL C4P 3 C15PLDOR BK 5 5 E 2 C6 14 C14PLU OR ps 5 L gt H PLAT LEVEL UP XE PLD OR BK e grown LEVEL 1 C6 15 GISELD ORB PLATLEVELDOWN e i 3 GR BK44 C2P 6 JDALARM GR BK 220 5 e C4P 6 C18JD GR BK DOWN JIB sup Eal 5 C17JU GR o 9 C6 18 C18JD GR BK L 8 Hone 4 11 PLATFORM ROTATE RIGHT DOWN BOOM tLEFT 5 06 17 mE 1 PLATFORM ROTATE LEFT JIB UP N 8 in RIGHT PLAT RIGHT PLAT m LEFT ROTATE LEFT ROTATE 4 7 19 5 GR WH 6 Re s lt o IL e I n e m 5 5 m JIB VALVES e 8 5 5 III 3 5 26533 8 xu JIB VALVE BENE 9 F ti 2 aaaaaa 5 2 2 5 8 8 6 69 5 40 5 45 Part No 102521 October 2013 Electrical Schematic Ford LRG 425 EFI Models before serial number 7597 Section 6 Schematics 70 ENGINE FUNCTIONS 19 18 CABLES 12V TO PLAT GROUND STUD
103. Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Section 2 Specifications October 2013 SPECIFICATIONS Auxiliary pump Type fixed displacement gear pump Displacement static 0 151 cu in 2 47 cc Displacement Function manifold 1 75 gallons per minute 6 62 liters per minute Function relief valve pressure S 40 2600 psi 179 bar Steer end drive motors 4WD before serial number 7569 Displacement per revolution 1 52 cu in 25 cc Non steer end drive motors 2WD and 4WD before serial number 7569 Displacement per revolution 2 13 cu in 35 cc Two speed drive motors 2WD and 4WD after serial number 7568 Displacement per revolution 0 99 cu in 16 3 cc S 45 2900 psi 200 bar low speed Boom down 2200 psi Displacement per revolution 1 83 cu in 30 cc relief valve pressure 152 bar high speed Boom extend 1950 psi Hydraulic Filters 134 bar Medium pressure filter Beta 3 lt 0 Oscillate axle 950 psi 66 bar Medium pressure filter 51 psi bypass pressure 3 5 bar Steer regulator All models 2 gallons per minute 7 6 liters per minute Traction manifold 2WD and 4WD before serial number 7569 Hot oil relief pressure 210 psi 14 5 bar Traction manifold 2WD and 4WD after serial number 7568 Hot oil relief pressure 280 psi 19 3 bar Continuous improve
104. DRIVE LIMIT SWITCH a a 1 2218 LS1 PRIMARY BOOM EXTEND 1 GNDIER aU 26 sew g DRIVE LIMIT SWITCH P24FS WHO eo o 519 4 P24FS WH 4 5 Es 2 LIN 2241 DRIVE ENABLE it PA6ESTPBKCO3 3 lt C CI3DRE BURD 6 13 C13DRE BURD UF LIMIT SWITCH x z 8 az C __c4oLsi OR Costo C40LS1 OR 8 2 i 8 z z Eu C6 30 2 9 56 5 5 5 2 gt 6 o 5 M o z pie 5 T e N t waren 9 C67 PBE BK A 2 0300 P EXTEND 4 C7PB W BOOM EXTEND lt a 71 5 retract 2007 5 8 88 2 668 C8PBR emi BOOM RETRACT 5 5 LEXTEND m C7PBE BK 522 BOOM t RETRACT 2 m C8PBR BK WH z E 2 a m C4 C14PLU OR 1 a pown PLATFORM LEVEL Pt 04 C15PLD OR BK 9 pop 4 C14PLU on gl 4 PLAT LEVEL UP PLATFORM LEVEL PRONN i C6 15 CiSPLDORIBK Il PLAT LEVEL DOWN p m C26 GR BK44 JDALARM GR BKIs Be 8 C4 6 C18JD GR BK B Ces C17JU GR g gt Bt iecur C18JD GRIBK H 4 PLATFORM ROTATE CCW JIB DOWN te zur E C17JU GR gt M PLATFORM ROTATE CW JIB UP N 5 e CCW 4 gw PLAT ROTATE lt cw PLAT ROTATE r N p t 210 EH C19JSV GRIWH amp i B 5 5 5 5 JIB VALVES E 5 5 158 gt 5 5 JIB VALVE 3 m a 8 1 5 a
105. GENERATOR SWITCH OPTION 27378 WORK DRIVE LIGHT OPTION 27378 WH TS7 WH RD C32BRK DETAIL A LIFT DRIVE OPTION REPLACE WIRE WITH THIS WIRING DIAGRAM BRN BATGND GND STUD WH TS1 SPLICE TO C32BRK OR R40LS1 SPLICE TO R40LS1 NOTE 1 DASHED LINES INDICATE OPTION WIRES SEE DETAIL A 10 AMP FUSE WORK DRIVE LITE po E PRIMARY BOOM TS48 E UP DOWN gt 6 5 DRIVE ENABLE 615 0 6 gt f TURNTABLE ROTATE PRIMARY BOOM EXTEND gt o RETRACT 9 5 5 fo 1 TS13 8 N i 86 87A r 5 c m Clee 7 1 5 5 5 2 85 5 P3 z 9 5 3 23833 5 9 8 3 2 o m 85565 4 2 TEE 85656 9 ME 9 5 92 ka S5 1 o o o 9 9 2 9 g 8 9 9 s9 5923 N 2 SI 5 sg 2 E 5 5888 5 k 2 9 S E 5 2 gt 9 z 8 E 5 9 o z E 5 22 3 9 2 z i s g D amp m WH as TS14 TS6 2 e GR DRIVE 5 5 SPEED OOO P
106. GND BR e wit BLUE PINK FORDENGINE Q 2 m e Sc o o STARTER RELAY 5 3 ei STARTER MOTOR Is Be Sc N a e 15AMP A Fe 4 P20BAT RD 8g N LO co N Part No 102521 3 40 5 45 6 112 Section 6 Schematics October 2013 Electrical Schematic Ford DSG 423 EFI Models CE from serial number 16420 RD BL WH N LO N co BR2 t GROUND C41RPM OR BK Is C23 515 gu 8 DRIVE SPEED 1 4 e 5 21 B zt TR Et lt lt C30EDC WH C30EDC WH gt gt 8 DRIVE EDC FORWARD C29MS RD WH gt SE DRE LED BURD SH ee 9 WH BK 8 05 20 9 gt gt _ D
107. Genie A TEREX BRAND Serial Number Range from S40 7001 to 6 40 54012 17231 8 45 102521 October 2013 Introduction October2013 Important Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting fault codes andrepair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Compliance Machine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie 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
108. Mineral based Part No 102521 October 2013 Section 2 Specifications Continued use of Chevron Aviation A hydraulic oil when ambient temperatures are consistently above 32 F 0 may result in component damage Note Use Chevron Aviation A hydraulic oil when ambient temperatures are consistently below 0 F 18 C Note Use Shell Tellus S2 V 46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use Part No 102521 Genie S 40 5 45 2 3 SPECIFICATIONS Hydraulic Component Specifications Drive pump bi directional variable displacement piston pump Type Displacement per revolution variable 4WD models 0 to 2 8 cu in 0 to 46 cc Flow rate 2500 rpm 0 to 28 gpm 106 L min Drive pressure maximum 3625 psi 250 bar Charge pump Type gerotor pump Displacement 0 85 cu in 13 9 cc Flow rate 2500 rpm 9 gpm 34 1 L min Charge pressure 6 2500 rpm 310 psi Neutral position 21 4 bar Function pump Type gear pressure balanced Displacement 1 04 cu in 17 cc Flow rate amp 2500 rpm 10 69 gpm 40 5 L min Oscillation pump Type gear fixed displacement Displacement 0 37 cu in 6 cc Flow rate amp 2500 rpm 2 8 gallons per minute 10 6 liters per minute
109. amp 5 WHRD T R FLOW CONTROL 75 5 y PRIMARY BOOM 6 1 Sei TDP eho C6 C1PBU RD 4 PRIMARY BOOM UP Ne y 51 DOWN 2 A C2PBD RD Bk lt lt HH gt gt 4 PRIMARY BOOM DOWN AL 8 O 8 E PRIMARY BOOM 5 5 lt C3PBF lt lt 5 2 FLOW CONTROL IF YOUT4 RD WH gt 4 Ba E xouraL SwH RD 221 8 5 Pwaalz en amp C33 C1PBU RD 5 GND1 gt gt 32 7 gt C2PBD RD BK EL EK cag C3PBF RD WH x gt 4 C619 RD BK DESCENT ALARM 8 Tc Te Spee 27 Lsz PRIMARY BOOM UP lat x DRIVE LIMIT SWITCH Qus 5 a 5 1 25 2 LS1 PRIMARY BOOM EXTEND 88 21 5 wi xi DRIVE LIMIT SWITCH P24FS WH 22 eS e P24F 2 rizgeg 2458 WH gt gt 4 E T 5727A DRIVE ENABLE 5 WH PR6ESTPBKCO3 0 C41 cigpRE BLIRD C13DRE BURD IE LIST EMIESWILOH x9 EI g zo C caoist OR 4 C640 C40LS1 OR 25 9 E 2 2a 9 ox lt 2 06 30 5 lt 50 On 2 55 E 5 32 e N i 8 2 C67 C7PBE 35 P EXTEND m 6 m N nim RETRACT 1 068 7 5 gt 4 BOOM RETRACT C37 C7PBE RETRACT C3 8 5 t 08088 BK WH C42 14P UP PLATFORM LEVEL DOWN
110. g m i WH y c aad WH gt ode 9 5 Wa TS7 H 8 TS14 TS6 PLATFORM JIB TS1 HIGH LOW GLOW PLUG ROTATE AUXILIARY PUMP DRIVE 4 SPEED Genie CE SEE DETAIL A A TEREX 3 40 5 45 Part No 102521 JC3 RD LH 49 48 REMOVE FOR GENERATOR OPTION ve HM S Qu ig ORO ve HM L TS4 NIC HIGH LOW RPM St HWH9 TS47 GENERATOR OPTION 2 z 5 92 vizizi2 5 Be Ba 8 x 5 jel o A A N ak 5 nogo P2 EMERGENCY STOP HARNESS PBOX WIRING COMPONENT INDEX PART NUMBER BOOM PROPORTIONAL JOYSTICK PRIMARY UP DN TURNTABLE ROTATE 62390 CHASSIS TILT LED 56298 DRIVE PROPORTIONAL JOYSTICK 75565 DRIVE ENABLE LED 56298 EMERGENCY STOP BUTTON 66812 95406 HORN SWITCH 66813 66815 AUXILIARY SWITCH 42730 START ENGINE SWITCH 13037 CE PLATFORM LED 56298 HI LO RPM SWITCH 56457 GLOW PLUG OPTION 13037 PLATFORM ROTATE SWITCH 16397 JIB UP DOWN SWITCH 13037 PLATFORM LEVEL SWITCH 13037 PRIMARY BOOM EXTEND RETRACT SWITCH 13037 DRIVE SPEED SWITCH 56457 DRIVE ENABLE SWITCH 13037
111. t 210 DOE te C19JSV GRIWH k L _ B 5 gt c E 5 5 JIB VALVES B 5 58 gt m JIB VALVE 3 m 8 5 5 5 a LEE 5 1 3 P134PWR RD 6 41 G S 40 5 45 Part No 102521 October 2013 Section 6 Schematics Electrical Schematic Deutz F3L 201 1 Deutz 20111 03 and Perkins 404 22 Models ANSI CSA 5 from serial number 15663 to 16419 6 41 42 43 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 201 1 Deutz D201 1L03i and Perkins 404 22 Models CE from serial number 15663to 16419 6 44 October 2013 Section 6 Schematics Electrical Schematic Deutz F3L 201 1 Deutz D201 1L03i and Perkins 404 22 Models CE from serial number 15663 to 16419 A B C D E F G H J K L M N
112. 14435 Perkins 404 22 Operation Manual Genie part number 94890 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures D 6 Replace the Hydraulic Filter Elements Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Perform this procedure more often if dusty conditions exist Replacement of the hydraulic filters is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filters be replaced more often Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Note Perform this procedure with the engine off Hydraulic return filter 1 Open the ground controls side turntable cover and locate the hydraulic return filter housing on top of the hydraulic tank 2 Remove the cap from the filter housing 3 Liftthe handle on the filter element and rotate the element coun
113. 3 455 6814 PLAT LEVEL UP E o lt PLAT LEVEL DOWN 1 C6 15 CISPLDORIBK 7 4 PLAT LEVEL DOWN wo 4 im GR BK44 6 JDALARM E mee 20 Eg 6 C18JD GR BK Dow 5 5 5 C17JU GR a B JIBBOOM 8 tco gt C618 GREK 1 PLATFORM ROTATE RIGHT JIB DOWN up are Egon gt 1914 PLATFORM ROTATE LEFT JIB UP wo o M RIGHT ROTATE LEFT 8 mE 1 C19JSV GRWH b JIB VALVES 5 5 gt t E o JIB VALVE 4 Sg x ao 258 G S 40 5 45 6 93 Part No 102521 October 2013 Electrical Schematic Ford DSG 423 EFI Models from serial number 12510 to 14831 Section 6 Schematics 94 95 Section 6 Schematics October 2013 Electrical Schematic Ford DSG 423 EFI Models from serial number 14832 to 15662 6 96 BL WH RD BK OR BK BK RD R RD BR Section 6 Schematics
114. 32 2 WH RD C32TA WH RD R146HYD OR 34 R21IGN WH 35 36 C36STC BL C36STC BL 37 0 BL BK C37STCC BL BK 38 39 C45GEN GR WH C45GEN GR WH 40 40151 OR C40LS1 OR October 2013 Section 6 Schematics C5 GBOX PIN CKT COLOR 1 2 C41RPM OR BK 3 C107AF WH 4 5 6 7 8 9 10 C39LP BL RD 11 TB23 WH 12 18 C38ESL BL WH 14 15 16 17 C21IGN WH 18 19 20 C31EDC WH BK 21 C30EDC WH 22 C34SA BK WH 23 C32BRK WH RD 24 C29MS RD WH C9 C9 FS DT04 4P COLOR CKT PIN BK P22ESTOP 1 WH P24FS 2 RD P25BAT 3 N C 4 Connector Pin Legend B A 1 2 C5 ENGINE HARNESS PIN COLOR CKT 1 2 OR BK C41RPM 3 WH C107AF 4 5 BK R33STR 3 6 RD R27AUX 7 8 WH R21IGN 9 BK RD C35RPM 10 BURD C39LP WH 12 vsw 12 GR C127TST 18 BLWH C38ESL 14 WH RD C26TSR 15 16 WH BK C25PSR 4 17 WH C21IGN 18 19 20 WH BK C31EDC 21 WH C30EDC 22 23 WH RD C32BRK 24 RD WH C29MS 5 6 7 8 2 Genie Part No 102521 5 40 5 45 6 5 October 2013 Connector Pin Legend Section 6 Schematics Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 1011F Models before serial number 7544 6 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 1011F Models before serial number 7544 RD BK
115. 52 5 xt x 5 E 5 m 5 5 zo sz i 88 52 lt 5 52 ex 2 a d 5 5 az om E O2 o zz Ez gt gt m 3 a Gn 5 5 2 2 2 5 c m m z o 5 gt m m m U 2 20 SF mg 2 2 2 2 m n m zt I I z lt lt 5 4 9 c Ec m 6 m o eo gt o o m T 2 m 5 lt c c E o mo 5 8 2 2 Go J c 9 2 2 2 5 5 1 9 m gt 2 5 2 5 5 m m 5 in x o m 2 8 d z 2 o 7 1 NOTE m 1 ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH OFF 2 THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION Genie 6 18 S 40 S 45 PartNo 102521 Section 6 Schematics October 2013 Electrical Schematic Perkins 704 30 Models before serial number 7472 C BL WH
116. 59 8 E DRIVE SPEED a B zt ae C14 lt 030500 WH te C5 21 C30EDC wH ve f 8 4 DRIVE EDC FORWARD T 29 RD WH gt gt 8 5 5 C5 20 Biz amp 9615 C31EDC WH BK DRIVE EDC REVERSE 2 DRE LED BL RD SITE 16 amp C31EDC WH BK 5 wa gt C6 32 8 pDRE 8 8 557 TRAVEL ALARM OPTION DRIVE ENABLE Tong A 1 6 C5 23 e 56 Tae CTS 4 WHIRD C32BRK wurd Inl s 4 BRAKE RELEASE VALVE e N 1 3 C524 Jp 204 1 9 29 RD WH E C29MS RD WH lt lt 4S gt MOTOR STROKE e Tre 07776 0878700 BUBK ie 6637 C37STCC Bus lt gt STEER CCW 8 C1 10 ii C6 36 En es TZ C36STC BL C36STC BL _ lt lt HH gt gt STEER CW H RKOUTS BUwH YOUTA wHo pya ree C9 cerRF WH RD XOUT3 BUWH amp 55 5 PWR2 OR S8 Sz 35 _ csrmR WH BK gt gt 10 c34 C4TRL WH g i 6 4 C4TRL 6 TURNTABLE ROTATE CW a d St s ces C5TRR weke hly TURNTABLE ROTATE CCW 2 m 0 C6 6 TURNTABLE amp WH RD TED FLOW CONTROL 7 5 m PRIMARY BOOM 1 SIM s C6 C1PBU RD A PRIMARY BOOM UP a ie Di EF T Es Bt OWN 5 2 C2PBD 4 PRIMARY BOOM DOWN i E 1 8 x ry C63 E PRIMARY BOOM E 5 lt RDWH TU FLOW
117. 7597 4 Move and hold the run test toggle switch to the test position O Result The check engine light should turn on The check engine light should begin to blink Genie S 40 S 45 5 Continue to hold the run test toggle switch in the test position and count the blinks Note If any fault codes are present the ECM will use the check engine light to blink a three digit code It will blink the first digit of a three digit code pause blink the second digit pause and then blink the third digit For example the check engine light blinks 5 consecutive times blinks 3 times and then 1 time That would indicate code 531 There will be alonger pause between codes 6 Referto Section 5 Fault Codes for definition of engine fault codes Note Once a fault code has been retrieved and the repair has been completed the ECM memory must be reset to clear the fault code from the ECM See How to Clear Engine Fault Codes from the ECM How to Clear Engine Fault Codes from the ECM Note Perform this procedure with the engine off and the key switch in the off position 1 Openthe engine side turntable cover and locate the battery 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches andother jewelry 3 Connectthe negative battery cable to the ba
118. 76 PRIMARYLIFT A A CYLINDERS D PRESSURE rex FILTER NUM oux 1 afl al A vel DT aad MASTER o e ol l UN i 477 I Lr E lac uvm 1 swi sw2 P1 P2 Jj JIB SELECT PUMP HYDRAULIC FUNCTION dea Ao N Le ad AoA 1 p COOLER r 151 7 Ll PLATFORM 4299 4 OPTION x S p 1 x 275 ROTATE gt 134 5 et 277 4 D m ENIMS Cini 2 we _ _3625 Sr i A 1 177 a A 1 t pum 1 T i Ia gu Enc A AR 4 5 gpm 1 1 m 1 770 1 1 1 oum jr 4 Tem fiaim AMD T 5 4 COUNTERBALANCE VALVE 1 tis ey DRIVE PUMP RETURN d T 1 5 RATIO PRESS 5 XX 0 1 gpm 1000 PSI 25 PSI 0 3 U min 2 A 1 i 1 1 1 3 1 2000 PSI 3 psi si A 3000 PSI 0 2 bar 2 ES ee un an ER CE 24 y 81 330029 3 1 3500 PSI nem 51 3500 PSI 151 3000 PSI AUX 1 FUNCTION 4 i HYDRAULIC ROTARY COUPLER MANIFOLD zl EL at an 8B 8C 6B
119. 9 QU HM gt t Hwa gt s gt 21 lt lt Nug eh 66 80 S2 hmd 66 04 is LN IT lt 2 Cuwau JOYSTICK CONTROL CARD Note Production changed from 7 pin to 6 pin Joysticks at Serial Number 12510 TURNTABLE ROTATE Deutsch 6 Pin Connector 1 60 ZOP QH HM 1 16 e 2 1 607 5 o 2 m 1 17 6 07 1 17 Or 9 17 7 9 607 9 17 Pin1 Pin 1 GND Pin2 Pin2 PWR Pin 3 Pin 3 XOUT Pin 4 Pin 4 YOUT Pin 5 Pin 5 RKOUT Pin 6 Pin 6 Pin 7 Joystick Adaptor Harness e o Genie Joystick Connector Diagram Part No 102521 S 40 3 45 6 133 October 2013 Section 6 Schematics Joystick Connector Diagram 6 133 6 134 Section 6 Schematics October 2013 CTE Option Wiring Diagram 6 136 6 135 Section 6 Schematics February 2012 CTE Option Wiring Diagram NCTION P
120. AUX ANA PU2 IVS AUX ANA BRAKE AUX DIG 3 GOV2 AUX DIG 4 TACH vsw AUX ANA PUD2 AUX PUD1 51 TPS2 FUELSELECT AUX 0161 AUX DIG 2 KNOCK KNOCK FPP24VS PCTX PCRX KNOCK 2 KNOCK 2 VBAT PROT VBAT EGOH2 EGOH 1 INJHS INA LS INJ2LS INJSLS INJALS INS LS GROUND INJ6 LS AUX PWM8 STARTER RELAY MIL UEGOH AUX PWM7 LOCKOFF AUX PWMG VBAT DBW GROUND DBW AUX PWMS REC AUX PWMS AUX PW AUX PWM4 FPP2 FUEL PUMP AUX PWM2 AUX PWM4 REC FPREC AUXPWM3 REC Levarzuve 0 C IGNITION COILS 25 2 GRIS XIRD 18 avas 18 ess yeK 18 DGfP18 Re 1 WIPK 18 DB O 18 BKILB 18 2 Y RD18 B 3 16 GY R 18 GYN 18 4 ep 4 t 5 CYL 4 CYL 1 cE vn is 748 GASOLINE LGW 16 ei INTERFACE 7 Daos WAG i8 12 wacis 18 TIT Dapp 18 TV FORD gt oncs Mn 42 PIN 15 16 ie 18 CONN
121. BK RD C5 9 BK RD C1B 9 35 BK RD S P RPM BKWH CiB 8 4 BK WH S P GLOW PLUG BK C1B 7 33 BK CR1485 D5 BK SP START WH RD C5 23 WH RD C1B 6 32 WH RD C6 32 BRAKE TRAVEL ALARM WH BK C5 20 WH BK C1B 5 31 E D C WH BK 25A WH 5 21 WH C1B 4 30 E D C WERD 26A RD WH C5 24 RD WH C1B 3 29 MOTOR SPEED De RD BK C6 28 RD BK C1B 2 28 TILT ALARM KS1 RD C6 27 RD C1B 1 27 RD CR39 85 RD SP AUX PWR P1 KEY SWITCH WH RD C5 14 26 WH RD S P WATER TEMP SENDER WH BK C5 16 25 WH BK S P OIL PRESSURE SENDER 24 RED CR1830 RD S P ENGINE POWER RD C6 23 WH C7B 2 23 CR39 30 WH S P KEYSWITCH PWR FB BL AWH C6 30 BK C7B 1 22 BK CR5430 BK S P PWR TO PLAT WH C5 34C5 8 6 34 21 WH CR2 87 WH S P IGNITION PWR v RD 12 VOLT RD S P CB3 20 RD S P CB2 RD S P CB1 12V BATTERY SUPPLY BURD S9 GR WH C4B 7 19 GR WH SP JIB VALVE GR BK C6 18 GR BK C4B 6 18 GR BK S P _ PLAT ROT GR C6 17 GR C4B 5 17 GR S P PLAT ROT L OR RD C4B 4 16 GR BK C23 8 GR BK H6 C133PLT OR BK C6 15 OR BK C4B 3 15 OR BK S P PLAT LEVEL DN OR C6 14 OR C4B 2 14 OR S P PLAT LEVEL UP WH 21A BURD C6 13 BURD C4B 1 13 DRV ENA LT 7 T BLWH C3B 12 12 HM 1853 BUBK C3B 11_ 11 L2 BL C3B 10 10 BR GROUND o5 BK RD C3B 9 9 BK RD CR23 86 DRIVE LIGHT OPTION BK WH C6 8 BK WH C3B 8 8 BK WH S P BOOM RETRACT BEWH eS 4 7 BK C3B 7 7 BK S P BOOM EXTEND WH RD C6 6 WH RD C3B 6 6 WH RD S
122. C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 C36STCC BL C1P 10 C3PBF RD WH C3P 3 75 BL BK C1P 11 N o GH 5 WH BK C3P 5 C4P BR B C32BRK WH RD C1P 5 9 m C4TRL WH C3P 4 e lt C29MS RDWH C1P 3 0 a lt o P134PWR RD C2P 4 C3P GR BK RDCIP9 6 C34SA BKWH 1 8 o 5 o C33STR BK C1P 7 9 C27AUX RD C1P 1 Cc RD BK 148 C2P BK a ke P 5 5 l JC1 2 OR 2 3 WH RD JC1 1 BR C1P GY I JC2 4 RD WH JC2 2 OR L JC1 4 WH BK JC2 1 BR JC3 4 WH RD ua JC3 2 OR I JC3 3 5 JC3 1 BR DRE BL WH C28TTA RD BK C1P 2 8 5 2 B BL BK x 013150 0 lt m C29MS 9 n lt 2 5 5 8 gt o a D40 r 5 39 28 GRIBKLA i 83 RD TILT 6 61 G S 40 5 45 Part No 102521 LOAD SENSE TIME DELAY RELAY 30A JIB TIME DELAY JIB DELAY RELAY COMPONENT INDEX TILT ALARM H1 C1 CR14 U35 October 2013 Section 6 Schematics Platform Control Box Wiring Diagram ALC 500 Deutz 020111 03 and Perkins 404 22 Models from serial num
123. EGR 18 O Y 18 2 19 198 DG O 18 AUX ANA PD1 MAP 358 LG BK 18 15 151 LB BK 18 FPP 1 IAT 27 743 GY 18 28 354 LG R 18 ECT 7 1 5 AUX ANA PU1 a 150 DG W 8 FPP2 1141 18 EGR PWM gt aaa s 352 BR LG 18 EGR RECIRC 5 29 0080000000 1 570 BK W 16 POWER GROUND 3 2 570 BK W 16 POWER GROUND 13 359 GY R 18 21 ANA RTN 14 351 BR W 18 5 VOLT REF 3 16 R LG 18 _ VSW CRANK CRANK CAM CAM VBAT VBAT 350 GY 18 349 DB 18 452 GY R 18 282 DB O 18 4 361R 16 KNK J1 BLACK 30 8 5 361816 361814 392 R LG 18 25 EGO2 4 24 74 GY LB 18 26 EBOS 02 SENSOR 361AR 16 570 BK W 16 74 GY LB 18 5 J2 GREY 570 BK W 16 850 Y BK 18 SPK PWR GROUND 13 COIL 4 COIL5 COIL6 STARTER LOCKOUT 24 25 22 342 LG P 18 4 COIL 1 1 Lj 307 BK Y 18 354 LG R 18 361 16 555 T 16 557 BR Y 16 558 BR LB 16 556 W 16 743 GY 18 359 GY R 18 151 LB BK 570 BK W 16 570 BK W 16 570 BK W 16 351 BR W 18 16 R LG 18 351 BR W 18 TWR c ETT eo esee 198 DG O 18 198 06 0 18 150 DG W 18 114 LB Y 18 352 BR LG 18 360 BR PK 18 361 R 14 151 LB BK 18 342 LG P 18 669 DG W 18 458 O BK 18 K L M N 361 R 16 361 R 16 361 16 359 GY R 18 FORD 42 PIN CONNECTOR 16 WATER TEMP
124. Engine specifications require that this procedure be performed after the first 50 hours of operation Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Deutz models Required maintenance procedures and additional engine information are available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0312 3547 Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 139320 Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures Ford models Required maintenance procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 orthe Ford DSG 423 EFI Operator Handbook EDI part number 1060020 orthe Ford MSG 425 EFI Operator Handbook Ford part number 1020010 Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG 425 EFI Operator Handbook Genie part number 215322 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray
125. L GBOX 2 m 5 GND 4 55 ter lt I 4 TB23 4 TB33 014 CB1 6 5 Teo S 6 T834 Teas gt IGN START 9 e 1 TB28 TB24 0 gt MODULE 7 12 u m CRI CR2 5 20am S LL I ISO E CRS ent 2 Fa LNO Loos 8 TB NO fi 5 La FUSE 10A FUSE 70A 5 BUWH WH 55 g a g o E i ors 8 9 FUSE 70A Eu g 5 9 N CR23 0 1 No 2 6 TB2 7 CR23 S i S z 62 5 63 NO 5 y 022 g z J 2 No o I ALTERNATOR 9 8 5 4 cias Q Q cree ter 0817 17 gt 8 6 NO 8 5 BE Mook amp pm P 9 WEL amp 8 io the i 7 2 12V BAT BAT PR2 ES PR7 3E VU PR2 D52 5 S if No Zer E 8 i 8 6 z 10A Ls STA ge A 29 8 7 ml s2 3 REGULATOR Hal H IND aN Si 5 129 cok od NC 9 NO e w 2 45 1 bd hd 1 T BAN e mo eo 5 lt e r WHO Hu be LHP f PPP 51 5 3 cuc oH 1 B d 49 53 5 0 Ho 2c 8B 3 n 5 5 2 ox 3 dd m 9 9 om om 5 I 9 oF 8 R 221 gk 3 3 g z 8 85 5 BP p SE E 3 02 5 3 5 z 5 gt lt 2 5 m 4 m m Lr o o B 35 5 E 3 5 8 8 2 3 d 5 9
126. Lsz PRIMARY BOOM UP DRIVE LIMIT SWITCH r EE z Ls1 Primany BOOM EXTEND 5 HE 8 gem y 2 DRIVE LIMIT SWITCH PMFSWH D2 2 BEES 2 pp Pears wea B ua 120 DRIVE ENABLE 6 26 23 I 047 oispREBL RD ie C613 C13DRE BRD Bk x EIMIESWITCH x 3 zo m C 40131 OR 6 40 C40LS1 OR z E 7 E 52 ge S IU u a lt C6 30 lt EQ 509 Oa 2 lt 6 or FR 8 5 5 8 7 z 1 D EXTEND gt es C7PBE BK BOOM EXTEND 85 e BOOM 8 9 lt O N i RETRACT C68 C8PBR BK WH 7 gt gt BOOM RETRACT C37 C7PBE BK te nemor POM 5t C8PBR BK WH 2 C42 UP PLATFORM LEVEL e DOWN C4 3 2 C15PLD OR B 5 3 e 0914 C14PLU OR S PLAT LEVEL UP PLATFORM LEVEI 5 5 2 DOWN 6815 C15PLD ORIBK 5 4 PLAT LEVEL DOWN x GR BK44 26 JDALARM GR BK E 2 o D27 rz C4 6 5 gt C18JD GR BK p DOWN lt UP JIB BOOM j 2 Bt C45 C17JU GR g m 2 8 p C618 C18JD GRBK 5 4 PLATFORM ROTATE CCW JIB DOWN e 4 M i UP JIB Boom 5 t cele C17JU GR gt 4 PLATFORM ROTATE CW JIB UP PLAT ROTATE 5 CCW cw 7 PLAT ROTATE NN e ee eo s Cre C19JSV GR WH f o 5
127. P2 EMERGENCY STOP BUTTON 66812 95406 P3 HORN SWITCH 66813 66816 TS1 AUXILIARY SWITCH 42730 TS2 START ENGINE SWITCH 13037 3 FUEL SELECT SWITCH FORD EFI ONLY 56457 TS4 HI LO RPM SWITCH 56457 14 CHASSIS TILT LED 56298 TS7 PLATFORM ROTATE SWITCH 16397 TS8 JIB UP DOWN SWITCH 13037 TS9 PLATFORM LEVEL SWITCH 13037 TS13 PRIMARY BOOM EXTEND RETRACT SWITCH 13037 TS14 DRIVE SPEED SWITCH 56457 TS15 DRIVE ENABLE SWITCH 13037 TS47 GENERATOR SWITCH OPTION 27378 TS49 WORK DRIVE LIGHT OPTION 27378 DETAIL A LIFT DRIVE OPTION REPLACE WIRE WITH THIS WIRING DIAGRAM BRN BATGND GND STUD ICR27 WH TS7 eT N WH TS1 WH RD C32BRK SPLICE TO C32BRK ICR30 H OR R40LS1 SPLICE TO R40LS1 NOTE DASHED LINES INDICATE OPTION WIRES October 2013 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram Ford DSG 423 EFI Models from serial number 12510 1 10 AMP FUSE eec LA jum WIRING 1 WORK DRIVE LITE N PRI BOOM TS49 ES UP DOWN gt DRIVE STEER Q 2 DRIVE ENABLE COMPONENT IND
128. PLATFORM LEVEL p a CYLINDERS Safar MEDIUM A SUAVE LAY BRAKE MANIFOLD S PRESSURE rh A Lor 1 205 us JEN I e iso CP L Wt 1 MON 1 oo acl fal petty EEL tT fl aor MASTER 4 NIE o OW sy 71 AUXILIARY El 7 PUMP 0 4 E AUX 65 PTEST EXT RET SWi SW2 P2 7 PR1 ead 5 Ert a a FUNCTION O 27 L CD HER TEST XD COOLER lo IFUNCTION p N Ac Ke E PLATFORM 3 _ p 315 psi OPTION MANIFOLD Far ANE 5 ROTATE BRENT n gt 15 91 my PRESS TNT d r3 8 M a 7 oe i aN n 2 4 249 9 bar 8 POTES Er lg 4 1 0 1 5 al FUNCTION X Xi mo x4 0620 X EPA PUMP NR 1 1 En RETURN im qb zer al 4 DRIVE PUMP 20gpm 25 psi 7 6 L min X 0 1 1 7 gt XN AT 1 0 38 L min BE e 1 e 3 psi AUX 02b 4 0
129. PRI BOOM UP gt D B A BR GND STUD 8 22 S wH 2s0 amp mos 8 6 mom 8 5 8 4 8 5 as og WH C5 11 OR C6 33 7 2 2 8 2 6 25 GR C5 12 RD CB3 SP H o o a 8 GROUND STUD BR 5 2 mmi 2 S ALL BR WIRES WIRING HARNESS TO BASE BR GROUND WH BK 25A WH RD 26A BK 22A RD CB2 WH 23A RD 42A KEY SWITCH KS1 RD 27A BL RD 39A WH 21A BR GROUND BL WH C5 13 RD WH 3A RD BK 2A RD 1A BK WH 8A BK 7A GR BK 44A BK 33A RD 20C CB3 DAS TS52 J RD CR17 CR23 30 WH BK 5A OO GC WH RD 6A WH 4A CB1 BK RD 35A RD 20A RD 24A RD 20B RD P1 E STOP OR BK 15A OR 14A GR 17A GR WH 19A GR BK 18A TS57 KEY SWITCH TEN 3 5 03 1 B1 4 2 gt Check Engine Light after serial number 13739 Note Removed resistor R3 and changed L2 to incandescent 6 116 Part No 102521 RD CB3 S P CR23 p BK RD 9B RD C4B 11 RD C4B
130. R1 RD 206 n RESISTOR 7 5 OHM TURNTABLE FUNCTION R2 R2 RD CR17 30 TS58 6 WH 4 E VOLTMETERGAGE 1 G1 WHER OIL PRESSURE GAGE G2 G2 2 OILTEMP GAGE G3 G3 R2 n STARTER AID 128 56298 H D14 1 CB2 o A HOUR METER HM HM gao D j Jw al i TS57 IGN START RELAY 1 CRI RD C297 25 0 IGN POWER RELAY CR2 CR2 3 TS59 HIGH IDLE RPM CUTOUT RELAY 7 RPM RELAY CR4 4 RD 20A COOLING FAN RELAY CR17 7 nn PLATFORM OVERLOAD ALARM H6 RD PI PLAT OVERLOAD MODULE U33 OR BK 15A PLATOVERLOADLED L45 OR 14A GR 17A GR WH 19A GR BK 18A 8 WIRING HARNESS TO BASE C Genie Part No 102521 5 40 5 45 6 21 October 2013 Ground Control Box Wiring Diagram Perkins 704 30 Models Section 6 Schematics 22 23 Section 6 Schematics October 2013 Platform Control Box Wiring Diagram Perkins 704 30 Models 24 Section 6 Schematics October 2013 Platform Control Box Wiring Diagram Perkins 704 30 Models PART NUMBER 45383 89353 COMPONENT INDEX TILT ALARM ALC 500 H1 HARNESS PBOX WIRING RD P2 RDH1 C132PLI BK C1P 12 P23SWBAT WH C7P 2 P22BAT BK C7P 1 C19JSV GR WH JIB C19JSV GR WH C4P 7 AND TS8 C18JD GR BK C4P 6 C17JU GR C4P 5 C15PLD OR BK C4P 3 C14PLU 2 C43 HRN GR C2P 5 C8PBR BK WH C3P 8 C7PBE BK C3P 7 P26BAT BK C9P 1 BRN
131. RD TS55 C32 7 GR BK 133A gt GR BK 133B 032 8 BR GND 2 181 s E 46 SPARE WH 21 GRWHCe3S GRWHOOB 45 P gt GEN OPTION AR C GR BK C2B 6 44 gt GR BK 2B GR BKS R JDALARM JIB GR C2B 5 43 GR CR5 85 HORN RD U34 2 194A e f 1E EE RD C6 28 OR RD C2B 4 19b RD H RD KS1 2 S P P134PWR OR BK C5 2 OR BK C2B 3 41 OR BKISM 2 BR 3MF CAP PULSE PICKUP DEUTZ ONLY 8 OR C6 40 OR C2B 2 40 LIMIT SWITCH SIG BK WH C5 10 BL RD C2B 1 39 BL RD S P LR BL WH C32 3 BL WH C1B 12 132 C132PLI BL BK C6 37 BUBK C1B 11 37 STEER CCW BL C6 36 BL C1B 10 36 STEER CW BK22A BK RD C1B 9 35 BK RD CR3 30 GR WH458 BK RD S P RPM j KEY SWITCH BK WH C5 22 BK WH C1B 8 34 BK WH S P GLOW PLUG Pi 7 33 BKISM 3 BKS P START WH RD C5 23 WH RD C1B 6 32 WH RD C6 32 BRAKE TRAVEL ALARM D m 5 20 WH BK C1B 5 81 E D C RIERS gt NCC WH C5 21 WH C1B 4 30 E D C S NCC RD WH C5 24 RD WH C1B 3 29 MOTOR SPEED asd RD BK C6 28 RD BK C1B 2 28 TILT ALARM WH 23A RD C6 27 RD C1B 1 27 RD ISM 4 gt D6 RD amp R AUX PWR RD 134A 26 WH RD S P WATER TEMP SENDER RD 27A 25 WH BK S P OIL PRESSURE SENDER RD C32 6 RD C5 1 RD CR23 30 24 RED CR1 30 RD S P ENGINE POWER WH C7B 2 23 WH ISM 7 WH S R KEYSWITCH PWR FB BL WH C6 30 BK C32 4 22 BK CR5 30 BK S P PWR TO PLAT RD WH C5 3 C5 11 _ C634 amp CR45 86 21 WH CR2 87 amp CR
132. RD WH C6 3 RD WH C3B 3 3 RD WH S P PRI BOOM F C RD 1A at RD BK C6 2 RD BK C3B 2 2 44B RD BK C6 19 RD BK S P PRI BOOM DOWN gt RD C6 1 RD C3B 1 1 RD S P PRI BOOM UP p 9 po D C B A 563 BK 7A 3 BR GND STUD BK CR1 86 em TS62 t 6 1 START RELAY TS 5 BK 33B 2 TACHOMETER T952 CB3 9 2 WH 23C 3 START INPUT GN START bd ann 4 AUX ON MODULE 95 Gy Y BR GND 5 GROUND m RD CR2 30 6 BATTERY AD 200 TS58 WH TS22 6 RD CR17 30 2 5 7 KEY PWR GR 17A 2 WH CR2 86 8 KEY BYPASS e BK WH 38B 9 10 ENG FAULT 1 mh m RD ISM 6 22 WH ISM 9 eae 214 CB2 m 11857 RD 24B BK C6 25 2 Q m 2 17 CRS E BK ISM 1 1 TS59 M 86055 WH 21B OR C6 33 WH TS22 4 BR GNDsC6 26 BK C6 16 RD 20A RD 24A o CHECK ENGINE TOGGLE SWITCH RD 208 RD P1 E STOP BR R1 O36 OR BK 15A 25388 BKIRD C5 12 2 14 WH CR2 87 WH C5 17 GR 17A TS22 LM GR WH 19A 8 GR BK 18A WIRING HARNESS TO BASE GROUND STUD BR ALL BR WIRES October 2013 Section 6 Schematics Ground Control Box Wiring Diagram Ford LRG 425 EFI Models before serial number 7597 E D C B A 1 2 3 4 DESCRIPTION LABEL PART EMERGENCY STOP BUTTON P1 P1 KEY SWITCH KS1 KS1
133. Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped 6 Using a suitable lifting device place an additional 50 Ibs 23 kg of weight onto the platform Result The alarm should sound and the engine should shut off The platform overload indicator lights should be flashing at both the ground and platform controls Result The alarm does not sound the engine does not shut off and the platform overload indicator lights are not flashing Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash the alarm sounds and the engine shuts off Part No 102521 Genie S 40 S 45 CHECKLIST C PROCEDURES 7 Usinga suitable lifting device remove the test weights restart the engine and carefully move the test weights to each remaining location on the platform Refer to Illustration 1 O Result The alarm should sound the engine should shut off and the platform overload indicator lights should be flashing at both the ground and platform controls W Re
134. S 45 Models before serial number 7569 M L K J G F E D C B A 1 EXTEND RETRACT CYL TURNTABLE ee 18 1 Lmin ROTATE
135. S rr Rt S a dt T2 ST ST2 a 9 LS TEST FUNCTION MANIFOLD 5 RESERVOIR Ti PRESS OPTIONAL COUNTERBALANCE VALVE GENERATOR SA ENT NEA EN 2 2 4 15 RATIO PRESS MANIFOLD ini i HYDRAULIC ROTARY COUPLER A 10008 6 34 2000 PSI 8A ac 2A 2 2B 7 4 5 AA jm m AN 3 1 3300 PSI PUMP x Ig 31 3500 PSI 5 REAR CITT mm 51 8500PSI RIGHT M 7 OPTIONAL RELEASE FRR E pi GENERATOR TO HYD ROTARY COUPLER 5 1 RIGHT STEERING 50 X 070 4 2 1 X m 50 2 Note alpha callouts refer to 8 4 components shown in the manifold illustrations 25 Refer to the Repair Section REAR 185 psi 2 T LEFT 12 7 bar RELEASE TRACTION MANIFOLD Genie Part No 102521 S 40 5 45 6 143 October 2013 Section 6 Schematics 2WD Non Oscillating Hydraulic Schematic S 45 Models before serial number 7569 6 143 6 144 Section 6 Schematics October 2013 4WD Oscillating Hydraulic Schematic S 40 Models before serial number 7569 6 146 6 145 October 2013 Section 6 Schematics 4WD Oscillating Hydraulic Schematic S 40 Models before serial number 7569
136. Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Part No 102521 Genie S 40 S 45 CHECKLIST A PROCEDURES A 8 Replace the Drive Hub Oil Manufacturer drive hub specifications require that this one time procedure be performed after the first 150 hours Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the torque hub oil after the first 50 hours of use may cause the machine to perform poorly and continued use may cause component damage 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Refer to Section 2 Specifications 5 Install the plugs Use pipe thread sealant on units with pipe plugs 6 Repeat steps 1 through 5 for all the other drive hubs models with pipe plugs a drive hub plugs Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST A PROCEDURES A 9 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed e
137. Testing This list continues Please turn the page Genie 4 32 5 40 5 45 Part No 102521 MANIFOLDS Section 4 Repair Procedures October 2013 Sx 7 SNN LN 69 Gr ES 5 40 5 Genie 62 GD 69 69 IF gi 2 EM 5 Q 7 7 0 AG L Et A 0 CL 0 RR 2 2 EN lt lt Y lt lt lt COO 9G BH BF Part No 102521 Section 4 Repair Procedures sari MANIFOLDS Function Manifold Components continued Index No 18 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Schematic Description Item Relief valve 2900 psi 200 AQ Relief valve 2600 psi 179 AQ Flow regulator valve 4 5 gpm 17 03 AR Check valve AS Solenoid valve 3 position 4 way AT Solenoid valve 2 position 3 way AU Solenoid valve 2 position 3 way AV Proportional solenoid valve AW Solenoid valve 2 position 3 way AX Solenoid valve 2 position 3 way AY Solenoid valve 3 position 4 way AZ Check valve
138. Threshold Setting The threshold setting of a joystick is the minimum output at which a function proportional valve can open and allow the function to operate Note Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Pushin the red Emergency Stop button to the off position at the platform controls 4 Do not press down the foot switch 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position 6 When the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle Switch in the right direction 8 times Result There should be a pause and the alarm should sound 8 times indicating that the machine is in threshold calibration mode Result The alarm does not sound Repeat steps 3 through 7 PartNo 102521 Genie S 40 S 45 4 7 PLATFORM CONTROLS 8 Start the engine from the platform controls and press down the foot switch 9 Select a boom function joystick to set the threshold 10 Slowly move the joystick off center in either direction just until the function begins to move 11 Slowly move the joystick back to the neutral position Just before the function stops moving move the drive enable toggle switch to e
139. gt BR LEVEL SENSOR hooo L C133PLA OR RD 3 4 4 FLASHING BEACONS Es D OPTION om SERVICE HORN C43HRN GR 2 BELAY 52 86 T SERVICE HORN o e i I e P22BAT BK 7 1 8 1 Q m 4 8 3 9 p45 amp 8 a 2 HYDRAULIC OIL 8 8 E MMe TEMP SWITCH C1 12 e 6 34 gt C132PLI1 BL WH D wa 05 C633 0656 COOLING FAN _ ogg e 4 C24 568 NEZ OPTION lt P134PWR RD C24 5 558 182 LE e ig C23 C52 LL C41RPM OR BK CA1RPM PIN 2 42 PIN FORD CONNECTOR 9 GND BR 4 8 m Fi wi pl BLUE PINK FORDENGINE BLOG E 8 PR2 52 8 ara STARTER RELAY 5 5 6 E gy zy STARTER MOTOR g o PR2 CIE me m lt 0 99 8 2 t e c zo g G y elel 15 a D P20BAT RD Pal 58 N LO co N NOTE ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH OFF gt STARTER RELAY PR8 ADDED AT SERIAL NUMBER 15703 Part No 102521 A TEREX 3 40 5 45 G 6 100 Section 6 Schematics October 2013 Electrical Schematic Ford 056 423 EFI Models ANSI 5 AS from serial number 15663 to 16419
140. hose at the return filter Cap the fitting on the filter housing 7 Remove the ground controls side turntable cover Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures 8 Supportthe hydraulic tank with an appropriate lifting device 9 Remove the hydraulic tank mounting fasteners 10 Remove the hydraulic tank from the machine AWARNING Crushing hazard The hydraulic tank could become unbalanced and fall if not properly supported when removed from the machine 11 Remove the hydraulic return filter housing mounting fasteners Remove the hydraulic return filter housing from the hydraulic tank 12 Remove the suction strainers from the tank and clean them using a mild solvent 13 Rinse out the inside of the tank using a mild solvent 14 Install the suction strainers using a thread sealant on the threads 15 Install the drain plug using a thread sealant on the threads 16 Install the hydraulic return filter housing onto the hydraulic tank 17 Install the hydraulic tank onto the machine 18 Install the two suction hoses to the suction strainers 19 Install the supply hose for the auxiliary power unit and the return filter hose Part No 102521 Genie S 40 S 45 CHECKLIST E PROCEDURES 20 Models with hydraulic tank shut off valves Open the two hydraulic tank valves at the hydraulic tank 21 Fill the tank with hydraulic oil until the level is within the top 2 inches 5
141. i C6 6 WH RD gt p TURNTABLE ROTATE FLOW CONTROL P lk H P 5 6 E C6 1 C1PBU RD 4 PRIMARY BOOM UP IE amp PRIBOOM 552 EYOUTACRDWHS 2 gy gt DOWN 2 C2PBD RD BK 7 Hl PRIMARY BOOM DOWN ZXOUT WH RDSS T gt 2 0 IQ PWR X l 8 C3PBF RD WH p 5 GND t He FLOW CONTROL d 4 I N 8 EE CiPBURD 7 C3P 2 RD BK BX C3P 3 C3PBF RDWH 4 0619 RD BK 4 DESCENTALARM L3 WH 5 ES 9 LS2 PRIMARY UP I 7 5 DRIVE LIMIT SWITCH S A 5 LS1 PRIMARY BOOM EXTEND R 867 DRIVE LIMIT SWITCH P24FS WH B 0451 CISDREBLRD C6 13 C13DRE BL RD lt w lo P26ESTP BK ER e 2 DRIVE ENABLE gt 53 5 9 uMiT SWITCH m 5 C2P2 40151 OR C6 40 040151 OR E 5 8 2 E gt o C6 30 m T E gt 5 17 5 5 gt 9 9 2 22 5 wee 8 667 C7PBE SH ii lt 0 5 BOOM EXTEND rk Lee PP EXTEND Boom 8 ou FS N RETRACT 068 C8PBR BK WH A BOOM RETRACT g N C3P7 C7PBE BK EE EXTEND Books zo 5 C3P 8 C8PBR BK WH E lt 2 0402 CIA4PLU OR 1 3 PLAT LEVEL Down C4P3 CISPLDORIBK 2 E gt
142. i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 10 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 11 Continue at top speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications Genie 3 30 S 40 S 45 B 20 Perform Hydraulic Oil Analysis Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures B 21 Test the Alarm Package if equipped and the Descent Alarm Genie specifications require that this procedure be performed every 250
143. lt lt 5 DRIVE EDC FORWARD 5 5 m 5 C31EDC WH BK 5 C5 20 C31EDC WH BK D 1 5 4 DRIVE EDC REVERSE gt LED BL RD 16 4 fsa E C6 32 x l DRE B BL BK 7 Fa 4 TRAVEL ALARM OPTION DRIVE ENABLE DRE BLWH 86 TR crs C32BRK WH RD C32BRK WHIRb Al BRAKE RELEASE VALVE e N m N C13 C5 19 9 ng C13 4 C29MS RD WH C29MS RD WI MOTOR STROKE MN B B g g amp Fre 07700 cazsTOC C637 C37STCC STEER CCW EE RKOUT BZBL WH 2 g no 4 AZ C1 10 C36STC C6 36 BSTC BE 4 STEER cw 358 15555 8 PWRBZ OR gt 13 GND 1 lt BR gt gt 14 2 ie BEL 8 C35 e get OSS 4 05788 WH BK e 102 C4TRL WH Eu i 4 C4TRL WH Sf TURNTABLE ROTATE CW git 8 C6 5 gt estar WH BK 14 TURNTABLE ROTATE CCW E 8 0 osse ome weno A N ur Bal 5 IX 5 C6 1 E u C1PBU RD PRIMARY BOOM UP m N YOUTACRD WH222 w 21 DOWN C62 5 gt PBD RD B PRIMARY BOOM DOWN 2 XOUTSEWHRDOL1 P Tus an a Q 2 OR 8 5 d 0 C63 PRIMARY BOOM 5 BR 12 z FLOW CONTROL m 8 8 8 6 lt CIPBU Rb 7 lt cag C2PBD RD BK EK Cg C3PBF RD WH C679 DESCENT ALARM OPTION T TA 18 a Eu m x WEE 18202 Ls2 PRIMARY BOOM UP 1 SH
144. 1 Extend the primary boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the primary boom slightly and place blocks under the platform for support 3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks 4 Protectthe slave cylinder rod from damage Genie 4 8 S 40 S 45 S 40 Models 5 Tag disconnect and plug the hydraulic hoses from the slave cylinder at the union located near the platform rotate counterbalance valve manifold and connect them together using a connector Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray S 45 Models 6 Tag disconnect and plug the slave cylinder hoses at the union 7 Pullthe slave cylinder hoses through the platform rotator 8 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Do not remove the pin 9 Remove the external retaining fastener from the barrel end pivot pin 10 Use a soft metal drift to drive the rod end pivot pin out 11 Use a soft metal drift and drive the barrel end pin out 12 Carefully pull the cylinder out of the boom Component damage hazard Hoses can be damaged if they are kinked orpinched
145. 12 45 95 P 9 RD WORK LIGHTS 4 10 OPTION i c2 8 WH vant BK AS VOLT METER R21IGN 2 4 HOUR METER E E 9s 8 1 C916 4 N OIL PRESSURE GAUGE 8 a Og C3 10 5 4 5 GYRB 1 amp E B 58 GASOLINE SENSOR 2 2 CI RD 28 8 2 o 1 7 5 88 C33STR BKde ax ot 2 RD GR EI d LPG LOCKOUT ENGINE WH BK cv e STAR 3 E JU _ TEMP GAUGE m a 8 2 1 5 S C5 14 z 2 4 C514 _ 8 026 WH RD PIN 39 3 8 8 0 12 8 1 5 E B E gt 012719 GR PINS ors C517 Co4GN WH PIN 16 e amp 5 ld 659 gt cssRPM BK RD PIN 23 e go E a 65 g L 65 RsssTRBKPIN 15 5 8 E a nn 8 ee C58 ReiuGNWHPIN24 NN e X C510 C39LP BL RDPIN7 ge C28TTA RD BK ale 8 a E P 2 E C135FP BL WH PINS a a mij 5 5 0195887 18 o fy g eg P z C511 vSwwH PINT e 5 8 8 1 59 5 C5 13 P gt lt PING t 6 27 A RD uit C27AUX RD i p AU POWER o N tr 8 a 5 lt Ss 98 eb 1532 AUXILIARY PUMP Q az 9 wu 5 SETAUXRD WORK LIGHT RELAY OPTION IR 5 72 P23BAT WH 8 N E C6 28 C28TTA RD BK f RD BK 4WH L TILT ALARM Ed 8 C623 NI 5 BK gt
146. 2WD from serial number 7569 6 150 Hydraulic Schematic 4WD from serial number 7569 6 151 Generator Hydraulic Schematic welder option 6 153 Genie S 40 5 45 Part No 102521 October 2013 Section 2 Specifications Machine Specifications S 40 and S 45 Models Tires and wheels Tire size 2WD front tires only 12 5L 16SL rear tires only 12 16 5 NHS Tire size 2WDRT amp 4WD front 8 rear 12 16 5 NHS Tire weight new foam filled minimum 300 Ibs Rough terrain 136 kg Tire ply rating 12 8 Tire contact area 88 sq in 57 sq in 568 sq cm 368 sq cm Overall tire diameter 33 7 in 33 2 in 85 6 cm 84 3 cm Tire pressure 45 psi 45 psi Rough terrain 3 1 bar 3 1 bar Tire pressure 60 psi 60 psi Rough terrain 4 1 bar 4 1 bar Wheel diameter 16 in 161 2 in 40 6 cm 41 9 cm Wheel width 10 in 9 3 4 in 25 4 cm 24 8 cm Wheel lugs 86 5 8 18 9 5 8 18 Lug nut torque Drive and 9 bolt non drive hubs Specifications Track Components TRAX option Track material Rubber Weight assembly each 480 Ibs 218 kg Fluid capacities Fuel tank 20 gallons 75 7 liters Fuel tank Option 30 gallons 114 liters LPG tank 33 5 pounds 15 2 kg Hydraulic tank 45 gallons 170 liters Hydraulic system 55 gallons including tank 208 liters Drive
147. 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Starter motor Current draw normal load 140 200A Alternator output 65A 13 8V DC 3 8 to 1 in 9to12mm Fan belt deflection PartNo 102521 October 2013 Section 2 Specifications Machine Torque Specifications Platform rotator SPECIFICATIONS TRAX Torque Specifications Hub to drive sprocket fasteners 1 8 center bolt Gr 5 dry 640 ft lbs Lug nut dry 230 ft lbs 868 Nm 312 Nm 1 8 center bolt Gr 5 lubricated 480 ft lbs Lug nut lubricated 170 ft lbs 651 Nm 230 Nm 3 8 16 bolts Gr 8 lubricated 35 ft Ibs Idler and bogey wheel fasteners use blue thread locking compound 47 5 Nm 3 4 10 bolts GR 8 dry 375 ft lbs Turntable rotator 508 Nm Drive hub mounting bolts dry 210 ft lbs 3 4 10 bolts GR 8 lubricated 281 ft Ibs 284 Nm 381 N Drive hub mounting bolts lubricated 160 ft Ibs use blue thread locking compound 217 Nm Drive motor and hubs Drive hub mounting bolts dry 210 ft lbs 284 Nm Drive hub mounting bolts lubricated 160 ft Ibs use blue thread locking compound 217 Nm Drive motor mounting bolts dry 49 ft Ibs 66 4 Nm Drive motor mounting bolts lubricated 37 ft lbs 50 Nm Turntable bearing Turntable bearing mounting bolts lubricated 180 ft lbs 244 Nm Genie PartNo 102521 5 40 5 45 2 13 Section 2 Specifications October 2013 SPECIFICATIONS Hydraulic H
148. 40 5 45 Genie Start the engine from the platform controls and drive the machine slowly in the forward direction Note the pressure reading on the pressure gauge Turn the engine off and remove the hot oil shuttle relief valve cap item HH Adjust the internal hex socket clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap before serial no 7569 Turn the engine off and remove the hot oil shuttle relief valve cap item JA Adjust the internal hex socket clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap from serial no 7569 to 15822 Turn the engine off and remove the hot oil shuttle relief valve cap item KA Adjust the internal hex socket clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap from serial no 15823 Repeat steps 4 and 5 until the pressure reading on the guage is 40 psi 2 8 bar less than the pressure reading at the pump Part No 102521 October 2013 Section 4 Repair Procedures 7 15 Valve Coils How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification
149. 5 2 5 D 2 21 P26ESTP BK E STOP R26ESTP BK C9P 1 7 BR GND 8 Y 2 WH C7P 2 P22BAT BK C7P 1 C19JSV GR WH C4P 7 Pu N C18JD GR BK C4P 6 C17JU GR C4P 5 C15PLD OR BK C4P 3 5 C14PLU OR 2 C43HRN GR C2P 5 C8PBR BK WH 8 C7PBE BK C3P 7 P26ESTP BK C9P 1 P25FS RD C9P 3 P24FS WH C9P 2 90 0 0 00 00000 JDALARM GR BK C2P 6 C45GEN GR WH C2P 7 e TS48WL1RDC2P42 8 9 TS48 WL2 RD C2P 11 e C39LP BL RD C2P 1 N o a og o8 P26ESTP 8 co 5 9 e E C6TRF WH RD C3P 6 o 6 E Q 9 6 S 010880 BL C3P 10 2 C13DRE BL RD C4P 1 C11SBD BL BK C3P 11 ii P24FS WH G 0401 51 OR C2P 2 9 5 C12SBF BL WH 12 P24FS WH C41RPM OR BK C2P 3 C30EDC WH C1P 4 e 4 BR C1PBU RD C3P 1 5
150. 5 AUXILIARY SWITCH TS51 42730 ENGINE START SWITCH TS52 13037 LP GAS SWITCH TS53 56457 FUNCTION ENABLE TS55 13037 PLATFORM ROTATE SWITCH TS57 16397 PLATFORM LEVEL SWITCH TS59 13037 BOOM EXTEND RETRACT SWITCH TS63 13037 PRIMARY BOOM UP DOWN SWITCH TS61 16397 CR23 TURNTABLE ROTATE SWITCH TS62 16397 6 GHBK JIB BOOM UP DOWN SWITCH TS58 13037 er CHECK ENGINE SWITCH TS22 42730 RDIGAB CIRCUIT BREAKER CONTROLS 15A CB1 CB1 RD C4B 12 CIRCUIT BREAKER ENGINE 15A CB2 2 BRN CIRCUIT BREAKER OPTIONS 20A CB3 CB3 RESISTOR 5 OHM BOOM FUNCTION R1 R1 DRIVE PORTO RTONRECAY RESISTOR 7 5 OHM TURNTABLE FUNCT R2 R2 VOLT METER GAGE 1 G1 7 OIL PRESSURE GAGE G2 G2 WATER TEMP GAGE G3 G3 CHECK ENGINE 12 56298 HOUR METER HM HM 8 Genie Part No 102521 S 40 S 45 6 71 October 2013 Ground Control Box Wiring Diagram Ford LRG 425 EFI Models before serial number 7597 Section 6 Schematics 72 78 Section 6 Schematics October 2013 Platform Control Box Wiring Diagram Ford LRG 425 EFI Models before serial number 7597 74 Section 6 Schematics October 2013 Platform Control Box Wiring Diagram Ford LRG 425 EFI Models before serial number 7597 PART NUMBER 45383 89353 COMPONENT INDEX TILT ALARM ALC 500 HARNESS PBOX WIRING RD P2 H1 RD H1 C132PLI BK C1P 12 NN 63 OPT P23SWBAT WH C7P 2 P22B
151. 5 4 BELAY 5 B s R43HRN 4 SERVICE HORN o N GN BK 6 P22BAT BK C21 8 2 1 S i 1 HYDRAULIC OIL D e 8 8 5 MEM 1 l E TEMP SWITCH 1 12 ug gt C132PLI1 53 62 C633 E C626 COOLING FAN C24 5208 amp OPTION P134PWR RD C24 Sug 98 Ie 2 ad C23 C41RPM OR BK C41RPM OR BK PIN 2 42 PIN FORD CONNECTOR 5 GND BR m m E BLUE PINK FORDENGINE B 8 A PR2 o ar STARTER RELAY 5 ay ay 2 STARTER MOTOR 9 pa IS iC SG N S ISAM 9 gt 8 42 PIN PLUG FORD THE BOOM IN THE STOWED POSITION AND KEYSWITCH OFF NOTE ALL SWITCHES AND CONTACTS ARE SHOWN WITH gt STARTER RELAY PR8 ADDED AT SERIAL NUMBER 15703 Part No 102521 Ts Y 0 e 0 G 6 104 Section 6 Schematics October 2013 Electrical Schematic Ford DSG 423 EFI Models CE from serial number 15663 to 16419
152. 500 Board 16 Test all machine functions from the platform controls O Result All platform control functions should operate Note If the platform overload system is not operating properly Referto Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped 17 Push in the red Emergency stop button at the platform to shut off engine Illustration 3 18 Using a suitable lifting device remove all test 22 Step on the footswitch at the platform weights from the platform Result The Valve Power LED should not 19 Pull out the red Emergency stop button to the on ME illuminate position at the platform controls W Result The Valve Power LED is illuminated Remove the machine from service and contact the Genie Service Department 20 Remove the fasteners securing the lid to the platform controls Using Illustration 2 as a guide locate the timer relay inside the platform control box Tag and disconnect the red wire 23 Securely install the red wire disconnected in from terminal 5 on the timer relay step 20 onto terminal 5 of the relay timer 24 Step on the footswitch at the platform Result The Valve Power LED should illuminate W Result The Valve Power LED is not illuminated Remove the machine from service and contact the Genie Service Department 25 Using a suitable lifting device place a test weight equal to that of the available capacity at the center location shown in Illu
153. 6 85 Electrical Schematic Ford 059 423 EFI Models from serial number 11067 to 12509 6 88 Electrical Schematic Ford 059 423 EFI Models from serial number 125101014831 sss 6 92 Electrical Schematic Ford 059 423 EFI Models from serial number 12510 to 15662 6 96 Electrical Schematic Ford DSG 423 EFI Models ANSA CSA AS from serial number 15663 to 16419 6 100 Electrical Schematic Ford DSG 423 EFI Models CE from serial number 15663 to 16419 6 104 Electrical Schematic Ford DSG 423 EFI Models ANSA CSA AS from serial number 16420 6 108 Electrical Schematic Ford DSG 423 EFI Models CE from serial number 16420 22400440 00 00 000 6 112 Ground Control Box Wiring Diagram Ford DSG 423 EFI Models before serial number 14832 6 116 Ground Control Box Wiring Diagram Ford DSG 423 EFI Models from serial number 14832 6 117 Platform Control Box Wiring Diagram Ford DSG 423 EFI Models before serial number 14832 6 120 Platform Control Box Wiring Diagram Ford DSG 423 EFI Models from serial number 14832 6 121 Platform Control Box Switch Panel Wiring Diagram
154. 6C 6A 3 1 ows 1 OPTIONAL 7 GENERATOR e 5 2 _ MANIFOLD gt 1 2 amm 1 FRONT LE i LEFT 5 FRB FLB FLA a i 1 at je RIGHT 1 FUNCTION ee 2 145 bar fex awe PUMP t TEST 71 ul 1 EM T2 IN CERA 1 out iri 1 OPTIONAL 1 950 psi me le ne mI GENERATOR TO HYD ROTARY COUPLER 1 65 5 ber RIGHT L 3 7 Note alpha callouts refer to 1 components shown in the OSCILLATE EE manifold illustrations A Refer to the Repair Section TRACTION MANIFOLD ren 21 OSCILLATE CYLINDER Genie Part No 102521 S 40 5 45 October 2013 Section 6 Schematics 4WD Oscillating Hydraulic Schematic S 45 Models before serial number 7569 6 148 Section 6 Schematics October 2013 2WD Hydraulic Schematic from serial number 7569 6 150 6 149 October 2013 2WD Hydraulic Schematic from serial number 7569 Section 6 Schematics EXTEND RETRACT CYLINDER G
155. 8 C67 Sri 6556 5 C7PBE 7 BOOM EXTEND P L EXTEND Loon 8 gt m RETRACT Fs 068 C8PBR BK WH BOOM RETRACT C37 F EXTEND soon C7PBE BK e e TRACT cas C8PBR BK WH 2 C42 C14PLU OR PLATFORM LEVEL T gt Di E g DOWN S43 CISPLD ORBK ib 8 2 6 14 C14PLU OR lt gt PLAT LEVEL UP 2 SUP PLATFORM LEVEL 9 z DOWN 6 15 C15PLD OR BK lt lt gt PLAT LEVEL DOWN x GR BK44 lt 26 JDALARM 2 o D27 46 05 C18JD GR BK DOWN i UP JIB BOOM C4 5 pud C17JU GR in E 5 D28 2 6 18 C18JD GRBK gt PLATFORM ROTATE CCW DOWN N Boom zur Coua C17JU GR M PLATFORM ROTATE CW JIB UP Nn PLAT ROTATE 5 CCW PLAT ROTATE ol Cer 019080 GR WH Ts E 16 2i Ba 5 I 5 JIB VALVES pH Eo z 5 1 1 A 52 JIB VALVE d e 8 mi 5g 5 u TEN SEN stes 5 sy i m c om z G S 40 3 45 6 101 Part No 102521 October 2013 Section 6 Schematics Electrical Schematic Ford 056 423 EFI Models ANSI CSA AS from serial number 15663 to 16419 6 101 6 102 Section 6 Schematics October 2013 Electrical Schematic Ford DSG 423 EFI Models CE from serial number 15663 to 16419 6 104 6 103 BL W
156. 9 z b C1 7 C33STR BK 5 5 16 WHIBK ENGINE a OC uz START e to c om x 2 MESES Ne 4 OIL PRESSURE GAUGE ele lelelelelelolele START ENGINE fo i e 8 a x alz E EE 5 FUEL RELAY o w F a 9 4 e als VOLT METER E 8 oz _ eo 88 AZ 4 HOUR METER pt 6 x om IGN START RELAY Tiz 8 t gt Pon a C55 AUXILARY ad 33 i 2 a 2 p Los AUXILIARY 8 Eg 6 N 6 a o X STARTER MOTOR x Lo A _ eta C27AUX RD 0627 RD27 AUXILIARY POWER x 2 7 RELAY 7 A 1 s 4 AUXILIARY PUMP P23BAT WH g ES 52 1 8 az C28TTA RD BK F 0628 RD BK 28 e 3 8 C6 23 RD 134 RD 5 BRN EVEL SENSOR 2 C133PLA OR RD a e 8 3 a 4 FLASHING BEACONS z rm L wy OPTION a tc 24 e SS 2 5 _ GR 4 SERVICE HORN ib e m RELAY AB 52 C6 16 83 P22BAT BK 7 1 i 4 SERVICE HORN lt 35 N z 05 5 5 M 5 C634 7 HYDRAULIC OIL T m 1 M je TEMP SWITCH C132PLI BUWH N 5 ko CODE 8 oz C939 COOLING FAN C134PWROR RD 4 5 OPTION gt c t lt EH m 8 C41RPM OR BK EE 052 41 a u o
157. C6 18 gt 8 toow ie C180 GIVBK PLATFORM ROTATE RIGHT JIB DOWN BOOM C617 z ur PLATFORM ROTATE LEFT JIB UP io RIGHT 9 RIGHT n ___ PLAT ROTATE 4 PLAT ROTATE Mele fo gt LEFT _ 0M 9 aS tcccccc 8 if C19JSV GR WH GG 0 5 o gt I i x JIB VALVES 2 5 E 5 5 S 9 550 2 2200 g 2 Oax a A JIB VALVE 1 acarana 9 en c ac X C o 858 olg 000 8 2 9 9 G 5 40 5 45 6 9 Part No 102521 October 2013 Section 6 Schematics Electrical Schematic Perkins 704 30 Models before serial number 7472 19 20 19 18 CABLES 12V TO PLAT FUNCTIONS ENGINE GROUND STUD October 2013 Section 6 Schematics RD H6 C23 1 U33 c23 BL WH 38D C23 3 PLATFORM BK 22C C23 4 RD C23 1 BK C7 1 C23 5 RD 42B gt LOAD RD TS51 23 6 GN BK L45 RD TS55 023 7 GN BK 16A GN BK 16B C23 8 BR GND C23 12 46 LIMIT SWITCH POWER GRAWH C6 39 GRAWH C2B 7 45 GE
158. Deutz and Perkins models Perform every 5000 hours E 6 Engine maintenance Deutz models Perform every 6000 hours E 7 Engine maintenance Deutz and Perkins models Perform every 12 000 hours E 8 Engine maintenance Deutz models Perform every 4 years Comments Genie E 9 Engine maintenance Ford models S 40 S 45 Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures Checklist A Procedures A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed daily Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the
159. Differential sensing circuit boom up down 10 12 ft Ibs 14 16 Nm 7 Differential sensing valve 150 psi 10 3 AG Turntable rotate circuit 30 35 ft lbs 41 47 Nm 8 Differential sensing valve 150 psi 10 3 Boom up down circuit 30 35 ft lbs 41 47 Nm 9 Relief valve 2200 psi 152 bar 1 Boom down 1 20 25 ft lbs 27 34 Nm 10 Flow regulator valve 0 1 0 38 U min Bleeds off differential sensing valves to 20 25 ft lbs 27 34 Nm 11 Check valve motto AK Differential sensing circuit boom up down 10 12 ft Ibs 14 16 Nm 12 Relief valve 1950 psi 134 bar Extend cylinder relief 20 25 ft lbs 27 34 Nm 13 GCheck valV6e nes AM Differential sensing circuit boom extend retract 10 12 ft Ibs 14 16 Nm 14 Flow regulator valve 2 0 7 6 L min Steer left right circuit 30 35 ft lbs 41 47 Nm 15 Check valve AQ sth Platform level up 14 ft lbs 19 Nm 16 Diagnostic nipple
160. Fuel Select Operation Ford Models 3 26 Test the Ground Control Override 1 000 3 27 Check the Directional Valve Linkeage 3 27 Test the Platform Self leveling sseseeeeeeenn 3 28 Genie viii S 40 5 45 Part No 102521 October 2013 m er TABLE OF CONTENTS Section3 Rev Scheduled Maintenance Procedures continued B 17 Test the Drive Brakes 3 28 B 18 Test the Drive Speed Stowed Position 3 29 B 19 Test the Drive Speed Raised or Extended Position 3 29 B 20 Perform Hydraulic Oil 3 30 B 21 Testthe Alarm Package if equipped and the Descent Alarm 3 31 B 22 Inspect the Fuel and Hydraulic Tank Cap Venting System 3 32 B 23 Check the Track Tension and Fastener Torque TRAX Option 3 33 B 24 Perform Engine Maintenance Ford Models 3 34 Checklist C Procedures 0 1 Perform Engine Maintenance Deutz and Perkins Models 3 35 0 2 Grease the Platform Overload Mechanism if equipped
161. HB Ce C378TCC BLIBK Te C6 37 C37STCC BL BK STEER CCW r RKOUTIS lt BL WH x pe YOUT gt 4 C36STC BL 8 C36STC BL STEER CW XOUTBZBLIWH gt 55 3 PWRE OR 718 GND 1 gt 4 a HIC 636 6 _ cgTRF WH RD 8 C3 5 face C35 4 05788 WH BK m 102 C4TRL WH 4 CATRL WH TURNTABLE ROTATE CW m N 51 gt C65 5 ipl TURNTABLE ROTATE CCW 5 0 m e 2 x 0 C6 6 TURNTABLE ROTATE amp WH RD 131 HOW CONTROL 5 754 s B S E 6c E C6 1 C1PBU RD IS PRIMARY BOOM UP E 5C UP Ug 2 4 YOUTAE RDWH gt gt 2 21 DOWN C62 C2PBD RD BK PRIMARY BOOM DOWN KOUTBEWHRD IT t 4 Q PWR 2 OR 511 8 5 C63 PRIMARY BOOM 2 GNDI BR gt gt 12 RD WH Y FLOW CONTROL a n B 8 9 6 lt C34 CIPBU RD 8 7 C32 C2PBD RD BK 8 Cag C3PBF RD WH 6619 RDBk 4 DESCENT ALARM OPTION K lt o BERG m eee wi 51272 LS2 PRIMARY BOOM UP DRIVE LIMIT SWITCH 1 51 2 5 8998 LS1 PRIMARY BOOM EXTEND 8 w levy x DRIVE LIMIT SWITCH PMFSWH 22 I BR e 4 24 5 WH 5 4 a cla 272 DRIVE ENABLE lt P26ESTP BK gt gt 8 8 sz C BURD C6 13 C13DRE BL RD gy LIMIT SWITCH x C OR
162. LEE 5 1 3 P134PWR RD 6 5 5 40 5 45 G Part No 102521 October 2013 Section 6 Schematics Electrical Schematic Deutz F3L 201 1 Deutz D201 1LOSi and Perkins 404 22 Models CE from serial number 15663 to 16419 46 47 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 201 1 Deutz D2011L03i and Perkins 404 22 Models ANSI CSA AS from serial number 16420 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 201 1 Deutz D2011L03i and Perkins 404 22 Models ANSI CSA AS from serial number 16420 RD BL WH RD BK BK OR BK HIGH RPM FS oeo 4 ENG SPEED C35RPM BK RD LOW RPM 1555 HIGH RPM FUNCTION ENA D14 013 BR BK RD HIGH IDLE RELAY 55 HIGH RPM SOLENOID 4 TB35 eder Arcs CR4 N D C27 GENERATOR C45GEN GR WH gt TB45 C6 39 Y29 GENERATOR C45GEN GR WI OPTION C2 3 WORK LIGHTS BR OPTION 8 CR23 C4B 12 N gt 0 lt TE OPTION DRIVE LIGHT FUSE 10A 27 NO Q T 5 NA CR23 C4B 9 C4B C1 8 TS6 TB34 LIGHTS PACKAGE C5 22 SECOND GLOW PLUG OPTION 4 DEUTZ ONLY
163. LG 18 cam eae INTERFACE it c 2 was 18 miene e 13 Wi 8 DG is Dar 18 FORD Sonat 42 PIN ae id en m CONNECTOR e E LG Ri8 B UE GROUND arie 6 ub 1 GAB 18 Lu suns COE nore m 8 ET gt Lem 18 36 ROADSPEED 24 GOV SELECT 1 Len DGWIS ayia var Leere 14 gt WIRE u 080018 F2 41 WLB 18 BAG 18 BAG 18 BAG 18 12 BR 18 gt A Ur 5A vsw 44 mon 45 DB 18 4g PAB 18 AL SYM EET S Y R 18 BK 18 23GOV SELECT2 DGP 18 orce TEES 28 DG Deo 18 DGIO 18 att eee 8 12 FPP2 an ae 61 BKB 18 Gym t8 Gy 8 AA fo EKAGIS BAW 18 SAME 3 4 s BAVIS BOSCH THROTTLE HHH m me LB DG 18 LB DG 18 5 18 BRW 18 4 1 PKLG 18 gt Wek 18 a ATTS a0 180618 BKW 16 OIL PRESSURE YO 18 snc HH ETEN 16 AUX PWM 4 T GN 18 18 26 OIL PRES TW 18 2 TACH 18 1 BERE 18 FUEL PUMP 39 AUX OUT 16 16 H Y DB 18 7 FUELSELECT 10 AUX TON 18 27 AUX OUT 2 pied 0618 H RS 232 Hide INJECTOR CYL 2 BN LB 16 16 19 START IN AUTOCRANK PKIBK 16 5 FUELPUMP 1 ma wie 18
164. Nm 30 35 ft lbs 41 47 Nm 20 25 ft lbs 27 34 Nm 30 35 ft lbs 41 47 Nm 20 25 ft lbs 27 34 Nm 30 35 ft lbs 41 47 Nm 10 12 ft lbs 14 16 Nm 3 40 5 45 Part No 102521 Section 4 Repair Procedures October 2013 MANIFOLDS BA G3 Genie KY 2 f 3 X V V BE B 82 AVO D 2 0 7 0 Le 69 0 0 Qe BG BF 5 5 40 5 45 Part No 102521 Section 4 Repair Procedures October 2013 mnmmmm I MANIFOLDS 7 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connecta 0 to 5000 psi 0 to 350 bar pressure gauge to the PTEST port on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable rpm select toggle Switch to the high idle position Activate and hold the boom retract toggle switch with the boom fully retracted 4 Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the engine off Use a wrench to hold the relief valve and remove the cap item AQ 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install t
165. OPTION X c EK 2 lt WH 9 LS2 PRIMARY BOOM UP 2 DRIVE LIMIT SWITCH a BRN LS1 PRIMARY BOOM EXTEND passw gt d e DRIVE LIMIT SWITCH OPE fa P24FS WH s ciaDREBURD F gt 4 2 sc C4P 1 6 13 C13DRE BL RD 9 DRIVE ENABLE 26 8 5 LIMIT SWITCH 2 Sas 8 2 2 C40LS1 OR C6 40 C40LS1 OR 3 lt lt 5 HH 5 5 e 5 E ge 5 2 ge 5 I 5 T ta z 9 5 5380 2 z C7PBE BK 11 EXTEND 55 2 Czulr amp gp 8 52 0 6 RETRACT z c6 8 C8PBR BK WH RETRACT 2 7 C7PBE BK 5 222 EXTEND BooM 5 5 RETRACT C3P 8 C8PBR BK WH 2 gt gt 2 C4P 2 C14PLU OR 25 X PLATFORM ms LEVEL O8 2 DOWN C4P 3 C15PLD OR BK am C6 14 C14PLU OR SUP PLATFORM LEVEL UP m 5 DOWN LEVEL B C6 15 SISPLD OR ER PLAT LEVEL DOWN i s GR BK 44 C2P 6 JDALARM GR BK 21 2 4 6 C18JD GR BK o DOWN jig E 8 BOOM C4P 5 C17JU GR m x 5 tooth ae C18JD GR BK L PLATFORM ROTATE RIGHT JIB DOWN as 9617 omnes PLATFORM ROTATE LEFT JIB UP m RIGHT pi aT 5 N LEFT ROTATE an M Jo LE 2 lt H CAR
166. P TURN ROT F C WH BK C6 5 WH BK C3B 5 5 WH BK S P TURN ROT L TS61 WH 6 4 WH C3B 4 4 WH SP TURN ROT R RD WH C6 3 RD WH C3B 3 3 RD WH S P PRI BOOM EE RD BK C6 2 RD BK C3B 2 2 44B RD BK C6 19 RD BK S P PRI BOOM DOWN gt RD C6 1 RD C3B 1 1 RD S P PRI BOOM UP 25 9 D C B A KNEA 563 BK 7A GR BK 44A BR GND STUD GREK TS62 6 1952 Mm CB3 2 WH 23C Nes p v RD 20C m RD CR17 30 TS58 WHIBK 5A 2 WH RD 6A en WH 4A 8 R2 y a D14 8 CB1 CB2 2 1987 6 0 an 21 T J 3 TS59 RD 24A o RD 208 RD Pi E STOP OR BK 15A 6 25 OR 14A GR C5 12 RD CB3 SP GR WH 19A 8 GR BK 18A WIRING HARNESS TO BASE GROUND STUD BR nn ALL BR WIRES October 2013 Section 6 Schematics Ground Control Box Wiring Diagram Ford LRG 425 EFI Models from serial number 7597 to 11066 E D C B A DESCRIPTION LABEL PART EMERGENCY STOP BUTTON P1 P1 KEY SWITCH KS1 KS1 AUXILIARY SWITCH TS51 13480 ENGINE START SWITCH TS52 13037 LP GAS SWITCH TS53 56457 FUNCTION ENABLE TS55 13037 PLATFORM ROTATE SWITCH TS57 16397 PLATFORM LEVEL SWITCH TS59 13037 BOOM EXTEND RETRACT SWITCH TS63 13037 cxPD GBSISE PRIMARY BOOM UP DOWN SWITCH TS61 16397 TURNTABLE SWITCH TS62 16397 JI
167. Procedures mnmmmmm n MANIFOLDS 7 16 Drive Oil Diverter Manifold Components welder option The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment Index Schematic No Description Item Function Torque 1 Directional Valve Y oss Diverter 80 90 ft lbs 108 122 Nm 2 Orifice disc Delays shift to drive 35 40 ft lbs 47 54 Nm 3 Solenoid valve GV u Pilot valve to diverter 35 40 ft lbs 47 54 Nm 4 Relief valve Charge pressure circuit 35 40 ft lbs 47 54 Nm 5 Check QU iui Prevents oil to generator 35 40 ft lbs 47 54 Nm 2 102521 S 40 S 45 4 55 Section 4 Repair Procedures October 2013 Turntable Rotation Components 8 1 2 Tag disconnect and plug the hydraulic hoses from the motor brake and manifold Cap the Turntable Rotation Assembly fittings on the motor brake and manifold How to Remove the Turntable AWARNING Bolly injury hazard Spraying hydraulic oil can penetrate and Rotation Assembly burn skin Loosen hydraulic connections very slo
168. RD WH C619 DESCENT ALARM OPTION X Ta 18 a x WEE 18242 Ls2 PRIMARY BOOM UP 1 O DRIVE LIMIT SWITCH 12 3 a 5 1 527 2 Lst PRIMARY BOOM EXTEND 1 2 ew g 3j 2 DRIVE LIMIT SWITCH P24FS WHO e SES eo o 55 9 PRS WH al Es L WJg 2 DRIVE ENABLE PA6ESTPBKC23 3 lt 0471 cigpREBURD is C6 13 CIBDREBURD ewe La LIMIT SWITCH x S az C 4051 OR C640 C40LS1 OR 8 2 a 9 T z Eu C6 30 2 9 55 ZE 2 gt 6 o Tos 8 5 5 9 9 5 QE 7 9 e 8 6 7 E 2 5 6 55 5 amp C7PBE nl BOOM EXTEND 8 P EXTEND poom g in gt m N q RETRACT Fs 068 caper BKWH Boom RETRACT 5 5 oor C7PBE BK au BOOM 5 RETRACT 2 c38 C8PBR BK WH g z E 2 C4 C14PLU OR 1 powy PLATFORM LEVEL S gt 04 CISPLD OR BK 9 5 8 Lus 4 C14PLU OR PLAT LEVEL UP i Ln PLATFORM LEVEL tow C6 15 cisPLDORIBK 14 PLAT LEVEL DOWN p m C26 GR BK44 JDALARM 0 8 2 6 xo C4 6 52 vom o C18JD GR BK _ B Oro C17JU GR g gt 5 8 P C18JD GR B x PLATFORM ROTATE CCW JIB DOWN gt yp JIB BOOM E C17JU ea PLATFORM ROTATE CW UP 5 e CCW 4 e cw PLAT ROTATE ef cw PLAT ROTATE r N
169. RD s 05 23 CS2BRICWHRD gt RELEASE VALVE lt C29MS RD WH i C5 19 C29MS RD WH RKOUTIGZ W 5 24 5 A MOTOR STROKE voursz 4 iae de SIE 4 5 1 11 3700 86 C6 37 C37STCC ED rag PWRBZOR 3 gt T E 514 1 10 C36STC BL C6 36 C36STC BL Si la ae 1 8 HR C3P 6 C6TRF WH RD C3P 5 WH BK 94 4 WH 0 C4TRL WH 8 6 4 TURNTABLE ROTATE LEFT LEFT TRISTE 5 WH BK 8 3 RIGHT C6 5 S 1 1 TURNTABLE ROTATE RIGHT E 8 5 7 D i C6 6 C6TRF WH RD 5 p TURNTABLE ROTATE amp g 52 4 FLOW CONTROL lE 5 lt BK 2 5 8 OS xourac E ES C61 CIPBU RD E H1 b primany Boom uP PWRBC OR 11 e BOOM fo 2 GNDRZBAN SZ 9 5 DOWN 6 2 z C2PBDIRD BK 2 LH 4 PRIMARY BOOM DOWN E R F 8 S C6 3 C3PBF RD WH 5 0 PRIMARY BOOM E 4 FLOW CONTROL 6 lt C3P i CIPBURD 7X C3P 2 C2PBD RD BK EK 035 C3PBF RD WH uc ee ee C6 19 BD BK DESCENT ALARM OPTION lt lt 1 a 119 Ls2 PRIMARY BOOM UP lt 12 11 5 DRIVE LIMIT SWITCH 5 ce BK 72 BRN E WH mui g 3 lt lt 2 LSt PRIMARY BOOM EXTEND PMFSWH BR 31 9 DRIVE LIMIT SWITCH e 24 WH 5 L gt 4 Ly 4 1__ BL RD C6 13 18DRE BL RD
170. Section 2 install the plug in the drive hub Specifications 4 Check the torque of the turntable drive hub mounting fasteners Refer to Section 2 Specifications Install the plug s in the drive hub Use pipe thread sealant on units with pipe plugs Check the torque of the drive hub mounting fasteners Refer to Section 2 Specifications Repeat this procedure for each drive hub models with pipe plugs a drive hub plugs Genie 3 22 S 40 5 45 PartNo 102521 October 2013 Section 3 Scheduled Maintenance Procedures B 10 Confirm the Proper Brake Configuration Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake configuration is essential to safe operation and good machine performance Hydrostatic brakes and hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each drive hub disconnect cap to be sure it is in the engaged position Ho brake disengaged position i brake engaged position Part No 102521 Genie S 40 S 45 CHECKLIST B PROCEDURES 2 sure the free wheel valve on the drive pump is closed clockwise Note The free wheel valve is located on the bottom of the drive pump a drive pump b screwdriver pump d free wheel valve Note The free wheel valve should always remain c
171. T 1 4 TRACTION MANIFOLD B M3 LEFT REAR d Genie 6 150 S 40 S 45 Part No 102521 PUMP FLB FLR STEERING LERT LEFT X e deor lll 1 4 sl PRESS ont 7 gt 4 1 2 TO HYD ROTARY COUPLER Note alpha callouts refer to components shown in the manifold illustrations Refer to the Repair Section TEE MTS a Ly p 5_1 fess 97 amp 1 e Eti JB SELECT Fe A wwe boy PLATFORM ROTATE COUNTERBALANCE VALVE RATIO PRESS 3 1 1000 PSI 31 2000 PSi A 34 3000 PSI A S1 3800 PSi A 31 3500 Psi A 51 3500PSI amp 181 3000 PSI MTE HYDRAULIC GENERATOR OPTION from serial number 16453 FUNCTION PUMP HYDRAULIC GENERATOR OPTION PORT ON RELIEF VALVE SIDE OF MOTOR SET 69 2700 PSI NONEM m 1 P z CD PORTON TOP OF MOTOR PMP Bye FUNCTION TO OC OIL MANIFOLD COOLER ENS October 2013 Section 6 Schematics 4WD Hydraulic Schematic f
172. Tag disconnect and plug the hydraulic hoses from the jib boom lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Remove the hose cover hoses and cables from the side of the jib boom and set them aside Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 7 Place blocks under the platform leveling cylinder for support Protect the cylinder rod from damage Remove the pin retaining fasteners from the jib boom lift cylinder barrel end pivot pin Do not remove the pin 9 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder 10 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin 11 Use a soft metal drift to remove the jib boom lift cylinder barrel end pivot pin then remove the jib boom cylinder AWARNING Crushing hazard The jib boom lift cylinder could become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane 12 Remove the pin retaining fasteners from the jib boom pivot pin Use a soft metal drift to remove the pin then remove the jib boom from the bellcrank AWARNING Crushing hazard The jib boom could become unbalanc
173. battery is fully charged Proceed to step 11 Result One or more battery cells display specific gravity of 1 217 or below Proceed to step 8 7 Perform an equalizing charge OR fully charge the batteries and allow the batteries to rest at least 6 hours 8 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 9 Checkthe ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 5 5 C above 80 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 26 7 C O Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 11 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 217 Replace the battery 10 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 not overfill 11 Install the vent caps and neutralize any electrolyte that may have spilled with baking soda Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures B 2 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 250 hours or quarterly whicheve
174. cm of the sight gauge Do not overfill 22 Clean up any oil that may have spilled 23 Prime the pump Refer to Repair Procedure 6 2 How to Prime the Pump Note Always use pipe thread sealant when installing the suction hose fittings and the drain plug Section Scheduled Maintenance Procedures October2013 CHECKLIST E PROCEDURES E 2 Grease the Steer Axle Wheel Bearings 2WD Models Genie specifications require that this procedure be performed every 2000 hours or 2 years whichever comes first Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steering wheels Center a lifting jack under the steer axle 3 Raise the machine 6 inches 15 cm Place blocks under the drive chassis for support 4 Remove the lug nuts Remove the tire and wheel assembly 5 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down O Result There should be no side to side or up and down movement Skip to step 10 if there is no movement Genie S 40 S 45 6 Remove
175. cycle Result The platform should remain level at all times to within 5 degrees Genie S 40 S 45 B 17 Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydrostatic brakes and hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational AWARNING Collision hazard Be sure that the machine is not in free wheel or partial free wheel configuration See B 10 Confirm the Proper Brake Configuration Note Select a test area that is firm level and free of obstructions 1 Mark a test line on the ground for reference 2 Startthe engine from the platform controls 3 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol then lower the boom into the stowed position 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 5 Bring the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications No
176. cylinder must be at least 75 of highest cylinder Lubrication system Section 2 Specifications eer Electronic fuel pump SPECIFICATIONS Fuel pressure static 64 psi 4 4 bar Fuel flow rate 0 43 gpm 1 6 L min Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Ignition system Spark plug type Motorcraft AGSF 32 FEC Spark plug gap Engine coolant 0 049 to 0 053 inches 1 244 to 1 346 mm Capacity 10 quarts 9 5 liters Cylinder head temperature sending unit Fault code set temperature 280 F 138 C Engine shut down temperature 300 F 149 C Oil pressure 29 to 39 psi Starter motor at operating temperature 2500 rpm 2 to 2 7 bar Normal engine cranking speed 200 to 250 rpm Oil capacity 4 quarts including filter 3 8 liters Current draw normal load 140 200A Oil viscosity requirements Current draw maximum load 800A Unit ships with 5 W20 oil Alternator Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Output 95A 13 8V DC engine Operator s Manual on your machine Battery Type 12V DC Group 31 Quantity 1 Cold cranking ampere 09 1000A Reserve capacity 25A rate 200 minutes Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 1
177. f TS59 BK C6 16 WH C5 11 OR C6 33 BK RD 35A RD 20A m RD 24A tl RD 20B ergo CRi7 RD P1 E STOP GR 43B RD 27B BKC625 OR BK 15A BK22B OR 14A GR C5 12 RD CB3 SP WH23B GR 17A GR WH 19A WIRING GR BK 18A HARNESS TO BASE GROUND STUD p gt DIODE ADDED AT SERIAL NUMBER 16453 ALL BR WIRES S Ground Control Box Wiring Diagram Ford DSG 423 EFI Models from serial number 14832 LOAD SENSE OPTION TIMER RELAY WH CR2 86 28 WH ISM 9 9 RD TB134 A C 2 BR GND 3 5 c U34 BK C3B 10 REPLACE WIRE WITH THIS WIRING DIAGRAM DRIVE LIGHT OPTION RELAY RD 24C CR23130 a BN GND 87 RD C4B 10 RD C4B 12 WH 21B WORK LIGHT OPTION RELAY RD 20C 45130 he ail BR GND 87 WH W L CABLE WH 21C DESCRIPTION LABEL EMERGENCY STOP BUTTON P1 KEY SWITCH KS1 AUXILIARY SWITCH TS51 ENGINE START SWITCH TS52 LP GAS SWITCH TS53 FUNCTION ENABLE TS55 PLATFORM ROTATE SWITCH TS57 PLATFORM LEVEL SWITCH TS59 BOOM EXTEND RETRACT SWITCH TS63 PRIMARY BOOM UP DOWN SWITCH TS61 TURNTABLE ROTATE SWITCH TS62 JIB BOOM UP DOWN SWITCH TS58 CHECK ENGINE SWITCH TS22 CIRCUIT BREAKER CONTROLS 15A CB1 CIRCUIT BREAKER ENGINE 15A CB2 CIRCUIT BREAKER OPTIONS 20A CB3 RESISTOR 5 OHM BOOM FUNCTION R1 RESISTOR 7 5 OHM TURNTABL
178. for future printings of this and all other manuals Contact Us http www genielift com e mail awp techpub terex com Genio 4 S 40 S 45 Serial Number Information Genie offers the following Service Manuals for these models Title Part No S 40 and S 45 Service Manual before serial number 3804 32222 S 40 and S 45 Service Manual from serial number 3804 to 4728 52271 S 40 and S 45 Service Manual from serial number 4729 to 7000 72136 Copyright O 2011 by Terex Industries 102521 Rev E October 2013 Fourth Edition Fifth Printing Genie and S are registered trademarks of Terex South Dakota Inc in the USA and many other countries 8 Printed on recycled paper Printed in U S A PartNo 102521 October 2013 Revision History Revision Date Section Procedure Schematic Page Description 22012 int 3 1 3 3 3 9 to 3 15 3 17 3 35 to 3 38 3 54 i 4 4 4 5 4 6 4 7 4 48 4 49 4 50 4 51 4 60 6 4 6 5 6 32 to 6 64 6 92 to 6 125 6 138 6 139 6 150 6 151 6 153 D1 10 1012 21 2 int 3 9 3 33 to 3 34 i 4 59 to 4 60 D2 10 2013 i 6 29 6 33 6 93 2 1_Section 2_Specifications Page Electronic Version 3 3 Section3 Maintenance Procedure Page 4 48 Section4 Repair Procedure Page Click on any procedure or page number Fault Codes Section 5 highlighted in blue to view the update 6
179. from serial number 7472 to 12509 6 64 Platform Control Box Switch Panel Wiring Diagram Deutz F3L 201 1 Deutz D2011L03i Models Perkins 404 22 Models from serial number 12510 6 65 Electrical Schematic Ford LRG 425 EFI Models before serial number 7597 6 68 Ground Control Box Wiring Diagram Ford LRG 425 EFI Models before serial number 7597 6 71 Platform Control Box Wiring Diagram Ford LRG 425 EFI Models before serial number 7597 6 74 Platform Control Box Switch Panel Wiring Diagram Ford LRG 425 EFI Models before serial number 7597 6 75 Electrical Schematic Ford LRG 425 EFI Models from serial number 7597 1 11066 6 78 Ground Control Box Wiring Diagram Ford LRG 425 EFI Models from serial number 7597 to 11066 seen 6 81 Platform Control Box Wiring Diagram Ford LRG 425 EFI Models from serial number 7597 to 11066 6 84 Genie xiv S 40 5 45 Part No 102521 October 2013 TABLE OF CONTENTS Section6 Rev Schematics continued Platform Control Box Switch Panel Wiring Diagram Ford LRG 425 EFI Models from serial number 7597 to 11066
180. gt HIGH LOW jos PLATFORM PLATFORM JIB AUXILIARY PUMP LEVEL 4 ROTATE anek D27 Sc aH 2 010 Md HLSEED TS2 October 2013 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram Deutz D2011L03i and Perkins 404 22 Models from serial number 12510 F E D C B A HARNESS PBOX WIRING COMPONENT INDEX JC2 BOOM PROPORTIONAL JOYSTICK DRIVE STEER PRIMARY UP DN TURNTABLE ROTATE JC3 DRIVE PROPORTIONAL JOYSTICK L48 CHASSIS TILT LED L1 DRIVE ENABLE LED P2 EMERGENCY STOP BUTTON P3 HORN SWITCH TS1 AUXILIARY SWITCH 3 TS2 START ENGINE SWITCH TS3 FUEL SELECT SWITCH FORD EFI ONLY TS4 HI LO RPM SWITCH 14 CE PLATFORM LED TS7 PLATFORM ROTATE SWITCH TS8 JIB UP DOWN SWITCH PLATFORM LEVEL SWITCH TS13 PRIMARY BOOM EXTEND RETRACT SWITCH 7514 DRIVE SPEED SWITCH TS15 DRIVE ENABLE SWITCH TS47 GENERATOR SWITCH OPTION TS49 WORK DRIVE LIGHT OPTION 4 gt 648 REMOVED FROM PLATFORM BOX SERIAL NUMBER 16420 AN RD 4 DETAIL A LIFT DRIVE OPTION c c 5 5 REPLACE WIRE WITH THIS WIRING DIAGRAM G D z Na 5 2 So 8 E WH RD C32B
181. hours or quarterly whichever comes first The alarm package includes Travel alarm e Flashing beacons Alarms and beacons are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable rear cover Beacons are installed on both turntable covers Note The alarms and beacons will operate with the engine running or not running Note The descent alarm is standard equipment beginning with serial number 12602 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls Result Both flashing beacons should be on and flashing 2 Hold the function enable switch to either side and activate the boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the toggle switch is held down Part No 102521 CHECKLIST B PROCEDURES Move the function enable rpm select toggle Switch to either side and activate the jib boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the toggle switch is held down Turn the key switch to platform controls Result The flashing beacons should be on and flashing Press down the foot switch Move the boom controller to the down position hold for a moment and then release it Result The de
182. hub 17 fl oz before serial number 7569 0 5 liters Drive hub 24 fl oz from serial number 7569 to 15677 0 71 liters Drive hub 20 fl oz from serial number 15678 0 6 liters Turntable rotation 8 fl oz drive hub 0 24 liters Drive hub oil type SAE 90 multipurpose hypoid gear oil API service classification GL5 Lug nut dry 230 ft lbs PT 312 Nm For operational specifications referto the Operator s Manual Lug nut lubricated 170 ft Ibs 230 Nm Lug nut torque 8 bolt non drive spindles Lug nut dry 170 ft Ibs 230 Nm Lug nut lubricated 130 ft Ibs 176 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 102521 5 40 5 2 1 Section 2 Specifications October 2013 SPECIFICATIONS Performance Specifications All Models Drive speeds 2WD and 4WD 40 ft 5 2 5 9 sec 12 2 5 2 sec Drive speed stowed 40 ft 40 45 sec 12 2 m 40 45 sec Drive speed raised or extended Drive speed TRAX option 40 ft 11 sec 12 2 m 11 sec Drive speed stowed 40 ft 40 sec 12 2 m 40 sec Drive speed raised or extended Gradeability See Operator s Manual Boom function speeds maximum from platform controls Boom up 50 to 60 seconds Boom down 45 to 60 seconds Boom extend 30 to 60 seconds Boom retract 15 to 35 seconds Hydraulic Oil Specifications Hydraulic Oil Specificatio
183. meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired Checklist A YNR A 1 Inspect the Decals Checklist B Y N R A 2 Pre operation B 1 Battery inspection A 3 Functions tests A 4 Engine maintenance all models A 5 Inspect tracks TRAX option Perform after 40 hours A 6 30 Day Service Perform after first 50 hours B 2 Electrical wiring B 3 Air filter element B 4 Key switch B 5 Engine maintenance Deutz and Perkins models B 6 Exhaust system B 7 Oil cooler and fins Deutz models A 7 Engine maintenance Deutz and Ford model B 8 Tires wheels and lug n
184. minimum 0 5 in 12 7 mm Battery Type 12V Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice S 40 S 45 Part No 102521 October 2013 Section 2 Specifications Deutz F3L 2011 Engine Deutz D2011L03i Engine Displacement Number of cylinders Bore and stroke Horsepower Net intermittent Net continuous Net intermittent Net continuous 142 cu in 2 33 liters 3 3 7 x 4 4 inches 94 x 112 mm 48 7 Q 2800 rpm 46 2 2800 rpm 36 kW 6 2800 rpm 34 5 kW 2800 rpm SPECIFICATIONS Lubrication system Oil pressure hot 2000 rpm 40 60 psi 2 8 to 4 1 bar Oil capacity 8 5 quarts including filter 8 liters Deutz F3L2011 Engine Oil capacity 9 5 quarts including filter 9 liters Deutz D2011L03i Engine Cil viscosity requirements Unit ships with 15 W40 oil Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Firing order 1 2 3 engine Operator s Manual on your machine Low idle rpm 1500 rpm Oil temperature switch Frequency 313 Hz Torque 8 18 ft lbs High idle rpm 2500 rpm 11 24 Nm 7 Temperature switch point 220 Compression ratio 19 1 104 C Compression pressure 362 to 43
185. output when moved out of the neutral position The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Note Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls Genie PLATFORM CONTROLS 2 Turn the key switch to platform control Do not start the engine 3 Pushin the platform controls red Emergency Stop button to the off position 4 Do not press down the foot switch 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position 6 When the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle switch in the right direction 6 times O Result There should be a pause and the alarm should sound 6 times indicating that the machine is in ramp rate calibration mode Result The alarm does not sound Repeat steps 3through 7 8 Startthe engine from the platform controls and press down the foot switch 9 Start a timer and simultaneously move the joystick in either direction full stroke Note how long it takes the function to reach maximum speed This is the ramp rate 10 Compare the function ramp rate time with the table below and determine whether the ramp rate time needs to increase or decrease 11 Release
186. platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced Part No 102521 Genie S 40 S 45 3 7 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST A PROCEDURES A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed daily Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to e
187. property damage Steer Wheels 4WD Models 7 Chock the non steer wheels to prevent the machine from rolling 8 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the steer tires 9 Liftthe wheels off the ground and then place jack stands under the drive chassis for support 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort 12 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Raise the machine and remove the jack stands AWARNING Collision hazard Failure to re engage the drive hubs may cause death or serious injury and property damage Note The free wheel valve should always remain closed drive pump screwdriver lift pump free wheel valve Genie 3 44 S 40 S 45 Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures D 4 Replace the Drive Hub Oil Genie specifications requires that this procedure be performed every 1000 hours or annually whichever comes first Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the torque hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage 1 Se
188. seal may occur Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged Part No 102521 Genie S 40 S 45 4 27 ENGINES Ford LRG 425 models after serial number 7596 Ford LRG 425 models before serial number 7597 6 1 i NN SS PN 8 FT 1 tie Jona NN XN lt 26 275 559 Perkins models after serial number 7471 Perkins models before serial number 7472 Deutz 1011 models before serial number 7544 Deutz 2011 models after serial number 7543 Section 4 Repair Procedures October2013 ENGINES 5 4 Engine Fault Codes Ford Models How to Retrieve Engine Fault Codes When an engine malfunction is detected by the Electronic Control Module ECM a fault code is recorded and the check engine light will turn on at the ground controls Special equipment is required to retrieve fault codes stored within the ECM Contact Genie Industries Service Department for assistance in retrieving fault codes Note Perform this procedure with the key switch in the off position 1 Openthe ground controls side cover and locate the run test toggle switch on the side of the ground control box 2 Pullout the red Emergency Stop button to the on position at both the ground and platform controls 3 Quickly activate and release the start toggle switch button Do not start the engine before serial no
189. spline towards the pump Apply Loctite removable thread sealant to the screws Torque the flex plate in a star pattern using the following values Ford models Before serial number 13740 Torque the flex plate mounting bolts in sequence to 24 ft lbs 32 Nm October2013 After serial number 13739 Torque the flex plate mounting bolts in sequence to 20 ft Ibs 27 Nm Deutz models Torque the flex plate mounting bolts in sequence to 28 ft lbs 38 Nm Perkins models Before serial number 7472 Torque the flex plate mounting bolts in sequence to 28 ft Ibs 38 Nm From serial number 7472 to 13773 Torque the flex plate mounting bolts in sequence to 49 ft lbs 66 Nm After serial number 13773 Torque the flex plate mounting bolts in sequence to 14 ft lbs 19 1 Nm Install the pump coupler onto the pump shaft with the set screw toward the pump Leave the appropriate gap between coupler and pump end plate for your engine pump pump shaft pump coupler flex plate with raised spline engine flywheel 0 18 inch 4 6 mm gap Deutz Models 0 070 inch 1 8 mm gap Perkins Models 0 0625 inch 1 6 mm gap Ford LRG 425 0 080 inch 2 mm gap Ford DSG 423 20 7 4 Apply Loctite removable thread sealant to the pump coupler set screw Torque the set screw to 61 ft Ibs 83 Nm 5 Install the pump and bell housing assembly Genie S 40 S 45 Part No 102521 October 20
190. tensioner jam nut and idler axle bolts on both sides of the tensioner wheel and tighten the tensioner nut until there is between 0 75 1 inch 1 9 2 5 cm of gap between the bogey wheels and the inside surface of the track Component damage hazard Do not over tighten the track Overtightening the track will cause the machine to lose power during operation 7 Tighten the jam nut 8 Checkthe torque of the track assembly fasteners Refer to Section 2 Specifications 9 Raise the machine remove the jack stands and lower the machine 10 Repeat this procedure for each track assembly Genie S 40 S 45 B 24 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 400 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 orthe FFord DSG 423 EFI Operator Handbook EDI part number 1060020 orthe Ford MSG 425 EFI Operator Handbook Ford part number 1020010 Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG 425 EFI Operator Han
191. the coil Resistor 100 Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 3 Setamultimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA Genie S 40 S 45 COIL AMMETER 100 9v BATTERY RESISTOR Be EMI MOM 1 AAA o 6 4 a oM rd qb 74 el multimeter 9V DC battery 100 resistor coil ao oo Note Dotted lines in illustration indicate a reversed connection as specified in step 6 4 Connect the negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 At the battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced Part No 102521 October 2013 Section 4 Repair
192. the extension cylinder rod end pivot pin at the platform end of the secondary boom tube Use a soft metal drift to remove the pin 11 Support and slide the extension cylinder out of the base end of the secondary boom tube Place the extension cylinder on blocks for suppport AWARNING Crushing hazard The extension cylinder may become unbalanced and fall when removed from the secondary boom tube if not properly supported Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing 12 Remove the label the wear pads from the extension cylinder Note Pay careful attention to the location of each wear pad Part No 102521 October 2013 Section 4 Repair Procedures mnmmmmm BOOM COMPONENTS 4 3 5 Tag disconnect and plug the boom lift cylinder hydraulic hoses Cap the fitti th linder Boom Lift Cylinder PE u Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray The boom lift cylinder raises and lowers the boom The boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Boom Lift Cylinder AWARNING injury hazard Th
193. the dust cap from the hub Remove the cotter pin from the castle nut 7 Tighten the castle nut to 158 ft lbs 214 Nm to seat the bearings Note Rotate the hub by hand while torqueing the castle nut to make sure the bearings seat properly 8 Loosen the castle nut one full turn and then torque to 35 ft lbs 47 Nm 9 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down O Result If there is no side to side or up and down movement continue to step 11 and grease the wheel bearings W Result If there is side to side or up and down movement continue to step 11 and replace the wheel bearings with new ones Note 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 the cotter pin from the castle nut 11 Remove the castle nut 12 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 13 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures 14 Pack both bearings with clean fresh grease 15 Place the large inner bearing into the rear of the hub 16 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Note Always replace the bearing grease seal
194. the foot switch Part No 102521 5 40 5 45 4 5 Section 4 Repair Procedures October2013 PLATFORM CONTROLS 12 While the joystick is activated set the ramp rate Momentarily move the drive enable toggle switch in the right direction to increase the time or momentarily move the drive enable toggle switch in the left direction to decrease the time Note Each time the drive enable toggle switch is momentarily moved the time will change in 5 increments 13 Repeat steps 9 through 11 for each joystick controlled machine function 14 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved O Result The alarm should sound indicating that the settings have been saved in memory Note Do not operate any machine function during the 10 second waiting time 15 Cycle the red Emergency Stop button off then back on Genie 4 6 S 40 S 45 Ramp rate factory settings Boomup down accelerate 3 second decelerate 1 seconds Turntable rotate accelerate 2 seconds decelerate 1 second Drive accelerate 2 seconds decelerate to neutral 0 5 second decelerate change of direction 0 5 second decelerate coasting 0 75 second decelerate braking 1 second decelerate shift from low to high speed 1 second decelerate shift from high to low speed 3 seconds Part No 102521 October 2013 Section 4 Repair Procedures How to Adjust the Joystick
195. to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove the pin 5 Support the jib boom lift cylinder with a lifting device 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pin and let the cylinder hang down Crushing hazard The platform AWARNING and jib boom could become unbalanced and fall when the jib boom barrel end pivot pin is removed if not properly supported 7 Attacha lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder 8 Use a soft metal drift to remove the jib boom lift cylinder rod end pin Remove the cylinder from the machine AWARNING Crushing hazard The jib boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Section 4 Repair Procedures October2013 Boom Components 4 1 Cable Track The primary boom cable track guides the cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom How to Remove the Cable Track Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specific
196. troubleshoot or repair faulty engine sensor OR replace ECM Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM PartNo 102521 S 40 S 45 Section 5 Fault Codes October2013 FAULT CODES Ford DSG 423 EFI Engine How to Retrieve Ford Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light Note Perform this procedure with the key switch in the off position 1 Openthe ground controls side cover and locate the run test toggle switch on the side of the ground control box 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Quickly activate and release the start toggle switch button Do not start the engine 4 Move and hold the run test toggle switch to the test position O Result The check engine light should turn on The check engine light should begin to b
197. when removing the hub 17 Slide the hub onto the yoke spindle Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur 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 to seat the bearings 21 Loosen the castle nut one full turn and then torque to 35 ft lbs 47 Nm 22 Install a new cotter pin Bend the cotter pin to lock it in 23 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Section 2 Specifications Part No 102521 Genie S 40 S 45 CHECKLIST E PROCEDURES E 3 Perform Engine Maintenance Deutz and Perkins Models Engine specifications require that this procedure be performed every 2000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Deutz 1011F models Required maintenance procedures and additional engine information is available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 Deutz 1011F Operation Manual Genie part number 52883 Perkins models Required maintenance procedures and additional engine information are available in the Perkins 404 22 Operation Manual Perkins part number
198. 02521 S 40 5 45 2 7 Section 2 Specifications October 2013 SPECIFICATIONS Deutz F3L 1011F Engine Displacement Number of cylinders Bore and stroke Horsepower Firing order Compression ratio Compression pressure Low idle rpm Frequency High idle rpm Frequency Governor Valve clearance cold 125 cu in 2 05 liters 3 3 58 x 4 13 inches 91 x 105 mm 36 Q 3000 rpm 26 8 kW 3000 rpm 1 2 3 18 5 1 362 to 435 psi 25 to 30 bar 1500 rpm 313 Hz 2300 rpm 479 9 Hz centrifugal mechanical Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure 26 to 87 psi 1 8 to 6 0 bar Oil capacity 8 5 quarts including filter 8 liters Cil viscosity requirements Temperature below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 Temperature above 4 F 34 C 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the engine Operator s Manual on your machine Genie Injection system Injection pump make OMAP Injection pump pressure 4351 psi 300 bar Injector opening pressure 3626 psi 250 bar Fuel requirement For fuel requirement refer to the engine Operator s Manual on your machine Alternator output 55A 14V Starter motor Current draw no load 90A Brush length new 0 7480 in 19 mm Brush length
199. 04 22 Models from serial number 15663 to 16419 6 40 Electrical Schematic Deutz F3L 201 1 Deutz D2011L03i Models CE Perkins 404 22 Models from serial number 15663 to 16419 6 44 Electrical Schematic Deutz F3L 201 1 Deutz D2011L03i Models ANSI CSA AS Perkins 404 22 Models from serial number 16420 6 48 Electrical Schematic Deutz F3L 201 1 Deutz D2011L03i Models CE Perkins 404 22 Models from serial number 16420 6 52 Ground Control Box Wiring Diagram Deutz F3L 201 1 Deutz D2011L03i Models Perkins 404 22 Models before serial number 14832 6 56 Ground Control Box Wiring Diagram Deutz F3L 201 1 Deutz D2011L03i Models Perkins 404 22 Models from serial number 14832 6 57 Genie Part No 102521 5 40 5 45 xiii October 2013 Section 6 TABLE OF CONTENTS Rev Schematics continued Platform Control Box Wiring Diagram Deutz F3L 201 1 Deutz D2011L03i Models Perkins 404 22 Models before serial number 14832 6 60 Platform Control Box Wiring Diagram Deutz F3L 201 1 Deutz D2011L03i Models Perkins 404 22 Models from serial number 14832 6 61 Platform Control Box Switch Panel Wiring Diagram Deutz F3L 201 1 Deutz D2011L03i Models from serial number 7544 to 12509 Perkins 404 22 Models
200. 1 BL C3B 10 10 m BK C23 5 BK RD C3B 9 9 BK RD CR23 87 DRIVE LIGHT OPTION p MAS CIRCUIT BREAKER ENGINE 15 2 CB2 5 J wu esc BK WH C6 8 BK WH C3B 8 8 BK WH S P BOOM RETRACT 4 o G CIRCUIT BREAKER OPTIONS 20A CB3 2 BK C6 7 BK C3B 7 7 BK S P BOOM EXTEND BKSA TS63 WH RD C6 6 WH RD C3B 6 5 WERD SP TURN BOT EC BICTA RESISTOR 5 OHM BOOM FUNCTION R1 R1 WH BK C6 5 WH BK CSB 5 WH BK S P TURN ROT L WH C6 4 WHcaB4 14 WH SE TURN ROT R GR BK 44A 1862 RESISTOR 7 5 OHM TURNTABLE FUNCTION R2 R2 RD WH C6 3 RD WH CSB 3 3 BDWHS P BOOM PO 2 TS52 CB3 Z c VOLT METER GAGE G1 G1 RD BK C6 2 RD BK C3B 2 2 44B RD BK C6 19 RD BK S P i RD C6 1 RD C3B 1 1 RD S P PRI BOOM UP 46 W D 6 4 OIL PRESSURE GAGE G2 G2 B A TS56 6 OILTEMP GAGE G3 G3 RD 20C o BK CR1486 1T START RELAY RD CH17830 TS58 STARTER AID L28 56298 em ORBK 41B 5 2 TACHOMETER IGN START E 2 HOUR METER HM HM 6 SK SSD 9 START INPUT RD 27B TAT AUX ON WHIBK 5 IGN START RELAY 1 CR1 a BRAND 6 5 GROUND 1 m IGN POWER RELAY CR2 CR2 WH 23B Ie 7 KEY PWR HIGH IDLE RPM CUTOUT RELAY CR3 CR3 6 18 KEY BYPASS CB e 5 RPMRELAY CR4 CR4 BUWHA2 12 9 IGN FUEL ON JX TS57 1010 ENG FAULT 23 7 COOLING FAN RELAY CR17 BK 22B RD CB3 SP D13 TS59 L PLATFORM OVERLOAD ALA
201. 11 Operation Manual Deutz part number 0312 3547 Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 139320 Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures Perkins models Required maintenance procedures and additional engine information are available in the Perkins 404 22 Operation Manual Perkins part number TPD 14435 Perkins 404 22 Operation Manual Genie part number 94890 Ford models Required maintenance procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 or the Ford DSG 423 EFI Operator Handbook EDI part number 1060020 orthe Ford MSG 425 EFI Operator Handbook Ford part number 1020010 Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG 425 EFI Operator Handbook Genie part number 215322 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Part No 102521 Genie S 40 S 45 CHECKLIST A PROCEDURES A 5 Inspect the T
202. 12 BRN GND DRIVE LIGHT OPTION RELAY DESCRIPTION LABEL PART EMERGENCY STOP BUTTON P1 P1 KEY SWITCH KS1 KS1 AUXILIARY SWITCH TS51 13480 ENGINE START SWITCH TS52 13037 LP GAS SWITCH TS53 56457 FUNCTION ENABLE TS55 13037 PLATFORM ROTATE SWITCH TS57 16397 PLATFORM LEVEL SWITCH TS59 13037 BOOM EXTEND RETRACT SWITCH TS63 13037 PRIMARY BOOM UP DOWN SWITCH TS61 16397 TURNTABLE ROTATE SWITCH 2 16397 JIB BOOM UP DOWN SWITCH TS58 13037 CHECK ENGINE SWITCH TS22 42730 CIRCUIT BREAKER CONTROLS 15A CB1 CB1 CIRCUIT BREAKER ENGINE 15A CB2 CB2 CIRCUIT BREAKER OPTIONS 20A CB3 CB3 RESISTOR 5 OHM BOOM FUNCTION R1 R1 RESISTOR 7 5 OHM TURNTABLE FUNCT R2 R2 VOLT METER GAGE Gi G1 OIL PRESSURE GAGE G2 G2 WATER TEMP GAGE G3 G3 CHECK ENGINE before serial number 13740 L2 110395 CHECK ENGINE after serial number 13739 L2 119870 HOUR METER HM HM RESISTOR 1K OHM 2W CHECK ENGINE R3 104333 ESO433 October 2013 12V 12V TO PLAT C7B C4B BR C3B GR 19 18 CABLES C2B C1B GY FUNCTIONS C6 ENGINE C5
203. 13 CHECKLIST B PROCEDURES B 13 Test the Fuel Select Operation Ford Models Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made when the engine is running or not Switching malfunctions and or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation Note Perform this test after checking the gasoline and LPG fuel levels and warming the engine to normal operating temperature 1 Move the fuel select switch to gasoline and then move the engine idle control switch to foot Switch activated high idle rabbit and foot switch symbol Genie S 40 S 45 2 Startthe engine from the platform controls and allow it to run at low idle Press down the foot switch to allow the engine to run at high idle O Result The engine should start promptly and operate smoothly in low and high idle 3 Release the foot switch and shut the engine off by pushing the red Emergency Stop button in to the off position 4 Move the fuel select switch to LPG 5 Start the engine and allow it to run at low idle Press down the foot switch to allow the engine to run at high idle O Result The engine should start promptly
204. 13 Section 4 Repair Procedures Ford LRG 425 models Before serial number 7597 Torque the bell housing mounting bolts in sequence to 23 ft lbs 31 Nm After serial number 7596 Torque the bell housing mounting bolts labeled C in sequence to 47 ft Ibs 63 Nm Torque the bell housing mounting bolts labeled B in sequence to 61 ft lbs 83 Nm Ford DSG 423 models Torque the bell housing mounting bolts labeled A and B in sequence to 28 ft Ibs 38 Nm and the mounting bolts labeled C to 49 ft Ibs 66 Nm Then torque the bell housing mounting bolts labeled A and B in sequence to 40 ft Ibs 54 Nm and the mounting bolts labeled C to 70 ft lbs 95 Nm Deutz models Before serial number 7544 Torque the bell housing mounting bolts in sequence to 28 ft Ibs 38 Nm After serial number 7543 Torque the bell housing mounting bolts in sequence to 47 ft Ibs 63 Nm Perkins models Before serial number 7472 Torque the bell housing mounting bolts in sequence to 28 ft Ibs 38 Nm After serial number 7471 Torque the bell housing mounting bolts labeled B in sequence to 28 ft lbs 38 Nm and the mounting bolts labeled to 49 ft lbs 66 Nm Then torque the bell housing mounting bolts labeled B in sequence to 40 ft lbs 54 Nm and the mounting bolts labeled A to 70 ft Ibs 95 Nm Component damage hazard When installing the pump do not force the pump coupler into the flexplate or damage to the pump shaft
205. 2 4 48 7 13 Traction Manifold Components 4WD from serial number 15823 4 50 7 14 Valve Adjustments 4WD Traction Manifold 4 52 7 15 4 53 7 16 Drive Oil Diverter Manifold Components welder option 4 55 Turntable Rotation Components 8 1 Turntable Rotation 4 56 Axle Components 9 1 Oscillate Axle Cylinders 22 4 58 Track Components 10 1 Track Assembly TRAX Option sse 4 59 Generators 10 1 Hydraulic enne nennen nnns 4 61 Genie PartNo 102521 5 40 S 45 October 2013 TABLE OF CONTENTS Section 5 Rev Fault Codes Introduction trece Fault Codes Control System Fault Codes Ford LRG 425 Fault Codes Ford 503 423 EFI Engine Section 6 Rev Schematics Introduction ee Electrical Symbols Legend Hydraulic Symbols Legend Ford DSG 423 Engine Relay Connector Pin 2 240000 4 Electrical Schematic Deutz F3L 1011 Models before serialnumber 7544 Ground Contr
206. 2 5 to 5 cm 1 to 2 inches Allow the platform to settle Result The overload indicator lights are off and the alarm does not sound Proceed to step 8 Result The overload indicator lights are flashing atthe platform and ground controls the alarm is sounding and the engine stops Repeat this procedure beginning with step 5 Note There may be a 2 second delay before the platform overload indicator light and alarm responds 8 Addan additional 10 Ib 4 5 kg test weight to the platform O Result The overload indicator light is flashing at both the ground and platform controls the alarm is sounding and the engine stops Proceed to step 9 Result The overload indicator light is off at both the ground and platform controls and the alarm does not sound Remove the additional 10 Ib 4 5 kg test weight Repeat this procedure beginning with step 6 Note There may be a 2 second delay before the overload indicator lights and alarm turn off 9 Testall machine functions from the platform controls Result All platform control functions should not operate 10 Turn the key switch to ground control Part No 102521 October 2013 Section 4 Repair Procedures mnmmmmm PLATFORM COMPONENTS 11 Test all machine functions from the ground controls O Result All ground control functions utilizing engine power should not operate Only limited ground control
207. 20 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852569 Genie Singapore Phone 65 67533544 Fax 65 67533544 Genie Japan Phone 81 3 6436 0 Fax 81 3 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 44 1476 584333 Fax 44 1476 584334 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Service Manual S 40 S 45 from serial number S40 7001 Part No 102521 Rev E rx DRAKA ATEN
208. 23 86 WH S R IGNITION PWR GR BK H6 RD 12VOLT CB3 SP 20 CB2 SP 1 12 VOLT BATTERY POWER xc GRWH C4B7 19 GR WH SP JIB VALVE WH2IA N GR BK C6 18 GR BK C4B 6 18 GR BK S R PLAT ROT CCW CHECK ENG d di GR C6 17 GR C4B 5 17 GR S P PLAT ROT CW LEDL2 OR RD C4B 4 138GR BK C32 8 GR BK H6 C133PLA BR GROUND OR BK C6 15 OR BK C4B 3 15 OR BKS R PLAT LEVEL DN m OR C6 14 OR C4B 2 14 OR S R PLAT LEVEL UP Wi gt BL RD C6 13 BL RD C4B 1 13 DRV ENA LT 5 13 BL WH C3B 12 12 BL BK C3B 11 11 BUWH ISM 10 BL C3B 10 10 TS61 9 SPARE RD WH SA 3 8RSNDSTUD BK WH Co 8 BK WH C3B 8 8 BK WH S P BOOM RETRACT RD BK2A D 5 BK C6 7 BK C3B 7 7 BKS R BOOM EXTEND RD 1A lt 2 wh 230 WH RD C6 6 WH RD C3B 6 6 WH RD S P TURN ROT OBG gt C WH BK C6 5 WH BK C3B 5 5 WH BK S P TURN ROT CCW WH C6 4 WH C3B 4 4 WH S P TURN ROT CW 16 2 RD WH C6 3 RD WH C3B 3 3 RD WH S R PRI BOOM FC BK WH 8A RD BK C6 2 RD BK C3B 2 2 44B RD BKC6 19 RD BKS P PRI BOOM DOWN BK 7A 9 RD C6 1 RD C3B 1 1 RD SP PRI BOOM UP GR BK 44A D 0 8 BK 33A TS52 CBS DQ D64 gt oDe a BKCRI 86 1 START RELAY BKWH34A 9 0 5 OR BK4lB 2 2 ness 99 86988 1513 5 S m RD27B 9 4 AUX ON IGN START RD 20C TS58 BR GND 54 MODULE RD CR17 30 GROUND WH BK 5A RD CR2 30__ 6 BATTERY WH RD 6A
209. 3 EFI Operator Handbook EDI part number 1060020 orthe Ford MSG 425 EFI Operator Handbook Ford part number 1020010 Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG 425 EFI Operator Handbook Genie part number 215322 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST A PROCEDURES A 12 Grease the Turntable Rotation Bearing and Rotate Gear Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Raise the boom enugh to access the turntable gearing 2 Locate the grease fitting on the platform end of the engine side bulkhead 3 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 i
210. 4IGN START RELAY 5 c PUMP AUXILIARY p 5 8 RD N B al a 52 8 zi PUMP AUXILIARY 5 4STARTER MOTOR x E A EMISSION CONTROL C27AUX RD Geer RD 27 AUXILIARY POWER RELAY a 8 557 1 AUXILIARY PUMP C72 P23BAT WH g gt ln a gt 8 E 5 3 m 4 gt 1 2 C28TTA RD BK r C6 28 RD BK 28 WH 07 F a x C6 23 RD 134 RD BK TILT ALARM ri 1 E C44 C133PLA 2 LEVEL SENSOR FE E 5 m FLASHING BEACONS OPTION 9 A e 8 gt T ces E C43HRN GR 14 SERVICE HORN T us a RELAY 2 22 C7 1 9 41 Z 1 BK 43 E 4 al SERVICE HORN Ll zd tpe C132PLI BLWH 1 12 2 ra l C6 34 T C625 HYDRAULIC OIL 8 z TEMP SWITCH 5 C134PWR RD C24 co pP 4 52 6 33 Gy gt COOLING FAN ARER el Oo 012015 ero 3 Bd 2 C41RPM OR BK ixi C5 2 41 JE gt C5 8 9 5 1 Teg ze iie x 558g 5 g 925 6 L Le eje 5 ium 999 s3 T 8 ann a olf T zd c nz gt d t T lt lt 5 5 x 222 ECT E gt gt gt L __ coo T a FRE g 5 8 959 01 lt lt lt g 555 OB i 59 t ma FRE N LO co N 1 ALL SWITCHES AND CONTAC
211. 5 DRIVE MODE A E me Ar T C29MS RD WH2 8 T5 lt lt C30EDC WH C30EDC WH lt lt gt gt DRIVE EDC FORWARD 5 1 5 C5 20 Di peace by B gt DRIVE EDC REVERSE S LED BL RD 516 ec C31EDC WH BK zt C31EDC ES e E C6 32 I DRE B BUBK 5 7 TRAVEL ALARM OPTION DRIVE ENABLE DRE A BLWH 86 TR cre C32BRK WH RD 92 woop ul 4 BRAKE RELEASE VALVE e N m N 38 Is C5 19 e aoe 4 C29MS RD WH C29MS RD WI MOTOR STROKE 5 a e 6 gt g amp Fre 077 4 037STCC BL BK te C6 37 C37STCC P STEER CCW EE RKOUT BZBL WH x g YOUT wo 4 qx C1 10 C36STC C6 36 CSBSTC B STEER OW 358 5555 8 PWRBZ OR 73 GND 1 lt BR gt 4 ie 055 gt cerRE WH RD 8 C35 et OSS 4 WH BK e 1102 cus C4TRL WH i 4 C4TRL TURNTABLE CW B 8 p et eS 5 WH B TURNTABLE ROTATE CCW E 8 o jo ose 0 RE N 7 5 5 6 lt 6 1 PRIMARY BOOM UB 2 E D H zi JARY BOO YOUT A RD WHZ 2 e DOWN C62 gt 6 PBD RD B PRIMARY BOOM DOWN 2 XOUTSEWHRD2L1 P T a WnZe On PRIMARY BOOM 5 BR 12 z FLOW CONTROL x 8 8 6 lt Cg CIPBU RD 72 cag C2PBD RD BK EK cag
212. 5 Section 5 Fault Codes October 2013 A e This page intentionally left blank Genie 5 16 S 40 S 45 PartNo 102521 October 2013 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine BeforeTroubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie S 40 amp Genie S 45 Operator s Manual Be sure that all necessary tools and test Schematics About This Section There are two groups of schematics in this section Anillustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process equipment are available and ready for use M
213. 5 13 g BL RD C6 13 BL RD C4B 1 18 DRV ENA LT BL WH C3B i2 12 BL WH ISM 10 PRIMARY BOOM BLIBK C3B 11 71 UP DOWN BL C3B 10 10 RD WH 3A 861 IBR GND STUD BK RD C3B 9 9 BK RD CR23 86 DRIVE LIGHT OPTION RD BK 2A i 5 BK WH C6 8 BKWH C3B 8 8 BK WH S P BOOM RETRACT RD 1A z 5 5 560925 Bk Ce 7 BK C3B 7 7 BK S P BOOM EXTEND 9 a S wH 23C WH RD C6 6 WH RD C3B 8 6 WHIRD S P TURN ROT F C sean df 2 WH BK C6 5 WH BK C3B 5 5 WH BK S P TURN ROT L EXTEND RETRACT 5 WH C6 4 WH C3B 4 4 WH S P TURN ROT R BK WH SA 7569 T RD WH C6 3 RD WH C3B 3 3 RDWH S P PRI BOOM F C RD BK C6 2 RD BK C3B 2 2 gt 44B RD BK C6 19 RD BK S P PRI BOOM DOWN GRIBK 44A TURNTABLE RD C6 1 RD C3B 1 1 RD S P PRI BOOM UP BK 33A ROTATE e TS52 I 9 BK WH 34A 6 i pn e m BK CR1 86 START RELAY STARTER AID v 8 o OR BK 41B ENGINE TS58 PT C 2 TACHOMETER RD 20C TS56 START IGN START 2 RD 27B po 2 START INPUT RD CR17430 UPIDOWN S 6 8 CO 4 AUX MODULE WH BK 5A 5 5 GROUND WH RD 6A RD CR2 30 516 BATTERY WH 4A 8 WH ZaB FO 7 KEY PWR O 8 KEY BYPASS WH CR2 86 IGN FUELON 4 v WH L2 DIODE LO ENG FAULT FUNCTION pis CB1 ENABLE RD ISM 6 BK RD 35B TS57 5 WH ISM 9 RD C32 7 9 09 5 RD 24B 0 W 7559 PLATFORM 9 PLATFORM ROTATE 7 5 BK ISM 1 BK RD 35A LEVEL RD 20A RD 24A RD 208 BK RD C5 9
214. 5 Section 6 Schematic Page Genie Part No 102521 S 40 5 45 October 2013 REVISIONHISTORY CONTINUED A Procedure Schematic Page Description 2 1 Section 2 Specifications Page Electronic Version 3 3 Section3 Maintenance Procedure Page 4 48 Section 4 Repair Procedure Page Click on any procedure or page number Fault Codes Section 5 highlighted in blue to view the update 6 5 Section 6 Schematic Page Genie S 40 5 45 Part No 102521 October 2013 Section 1 Safety Rules Serial Number Legend Genie A TEREX COMPANY Model S 40 Serial number S4006 12345 Model year 2006 Manufacture date 01 05 06 Electrical schematic number 50274 Machine unladen weight Rated work load including occupants 500 Ib 227 kg Maximum number of platfrm occupants 2 Maximum allowable side force 150 Ib 670 Maximum allowable inclination of the chassis 0 deg S40 06 1 2345 Maximum wind speed 28 mph 12 5 m s Maximum platform height 60 ft 6 in 18 3 m 112 271 Model Sequence Maximum platform reach 34 ft 3 in 10 4 m number Gradeability N A Country of manufacture USA This machine complies with ANSI A92 5 CAN B 354 4 Model year Genie Industries 18340 NE 76th Street Redmond WA 98052 USA Sequence number Serial label stamped on chassis located under cover PN 77055
215. 5 psi Oil pressure switch EL Torque 8 18 ft lbs Governor centrifugal mechanical 11 24 Nm Valve clearance cold Oil pressure switch point 7 psi Deutz F3L2011 Engine 5 bar Intake 0 012 in 0 3 mm Oil pressure switch point 22 psi Deutz D2011L03i Engine 1 5 bar Exhaust 0 020 in 0 5 mm Genie Part No 102521 S 40 5 45 2 9 Section 2 Specifications SPECIFICATIONS Fuel injection system Injection pump make Bosch Injection pump pressure maximum 15000 psi 1034 bar Injector opening pressure 3046 psi 210 bar Fuel requirement For fuel requirement refer to the engine Operator s Manual on your machine Starter motor Current draw normal load 140 200A Brush length new 0 72 in 18 5 mm Brush length minimum 0 27 in 7 mm Battery Type 12V Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 6 25 rate 200 minutes Alternator output 60A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm October 2013 1 Genie S 40 S 45 Part No 102521 October 2013 Section 2 Specifications Perkins 704 30 Engine Displacement 183 cu in 2 9 liters Number of cylinders 4 Bore and stroke 3 82 x 3 94 inches 97 x 100 mm Horsepower 63 2600 rpm 47 kW Q 2600 rpm Firing order 1 3 4 2 Compression ratio 17 5 1 Compression pressure 300 to 500 psi 20 7 to 34 5 bar Pressure psi of lowest cylinder must be within 50 psi 3 45 bar of highest cylinder
216. 6 37 C37STCC BL BK If STEER CCW r RKOUTIS lt BL WH x YOUT mo 4 AZ 1 10 C36STC BL 20 20 C36STC BL jis STEER CW XOUT B BL WH 55 8 3 PWRBZ OR gt 13 s GND 1 lt 214 IE cg TRF WH RD n 2 faze 635 WH BK 102 css C4TRL WH i C4TRL WH TURNTABLE ROTATE CW et gi C6 5 estar WHIBK ML TURNTABLE ROTATE CCW 5 5 a 22 0 6 n TURNTABLE ROTATE 2 COTREWFURD t FLOW CONTROL 5 7 54 a N 5 6 E C6 1 2 Pup 3 CIPBU RD p PRIMARY BOOM UP YOUTACRD WH222 21 DOWN 02 m 5 8 C2PBD RD BK PRIMARY BOOM DOWN B 22 5 PRIMARY ONDE 12 RD WH Yi FLOW CONTROL a E 8 8 9 6 cgr C1PBU RD 8 7 _ C2PBD RD BK 6 Cgg C3PBF RD WH C69 ABK DESCENT ALARM OPTION T K lt o Imc wi NT LS2 PRIMARY BOOM UP Ta DRIVE LIMIT SWITCH icu 4 GNDBR 1 8 5 rae LS1 PRIMARY BOOM EXTEND 8 7 wi x DRIVE LIMIT SWITCH PRAFSWH 22 S s o e P24FS WH 5 4 5 E T WS j DRIVE ENABLE x 8 it P26ESTPBK gt gt 3 IR 641 1 BURD 8 Costa C13DRE BRD LAT LIMIT SWITCH x e mac C22 S1 OR z C6 40 C40LS1 ui 2 I C6 30 T 58 NO Lago z M LPS 29 46 05 54 uber 9 5 ft 6
217. 66 Section 6 Schematics 80 ENGINE FUNCTIONS 19 18 CABLES 12V TO PLAT GROUND STUD M L K J 46 SPARE C GR WH 06 39 GR WH C2B 7 45 GEN OPTION GR BK C2B 6 44 gt GR BK 2B GR BK SP JDALARM JIB GR C2B 5 43 GR CR5 85 HORN OR RD C2B 4 42 RD H6 RD KS1 2 S P C134PWR 5 2 2 3 41 PULSE PICKUP G1 G2 G3 OR C6 40 OR C2B 2 40 LIMIT SWITCH SIG BL RD C5 10 BL RD C2B i 39 BURD SP LP BL WH C23 3 BL WH C1B 12 38 C132PLI BR GROUND Y BL BK C6 37 BL BK C1B M 37 STEER LEFT BL C6 36 BL C1B 10 36 STEER RIGHT
218. 7 Check the Oil Cooler and Cooling Fins Deutz Models Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the oil cooler in good condition is essential for good engine performance Operating a machine with a damaged oil cooler may result in engine damage Also restricting air flow through the oil cooler will affect the performance of the cooling system AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation A CAUTION Burn hazard Beware of hot engine components Contact with hot engine components may result in severe burns Oil cooler 1 Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury 2 Remove the fasteners from the engine side cover and remove the cover 3 Inspect the oil cooler for leaks and physical damage 4 Clean the oil cooler of debris and foreign material Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures a oilcooler b cylinder head cooling fins c fan blower fins Cooling and fan blower fins 5 Inspect the fan blower fins for ph
219. 8 CR13 TE NU L1 DETAIL A LIFT DRIVE OPTION 8 REPLACE WIRE WITH THIS WIRING DIAGRAM gt m 5 E og E Bl E BRN BATGND g 3 5 3g z GND STUD 5 2 o 2 Ba zz TS7 WHTSA 3 S WH RD C32BRK F 5 5 5 gt 5 EO SPLICE TO C32BRK EN lt lt Ilo 2 ls a E 2 amp m m 2 5 5 S 9 E 9 E 3 9 2 6 v E a 4 8 4 OR R40LS1 5 6 fot lad SPLICE TO R40LS1 2 0 RD 896 FORES 9 7 T REP Geo HIGH LOW 0 En 7 P3 Tsg TS8 TS1 Uns TEE P 2 HORN 9 GLOW PLUG START TS7 WB AUSIEARTF DIE REMOVE FOR GENERATOR OPTION EMERGENCY STOP PLATFORM ROTATE CE SEE DETAILA NOTE 1 DASHED LINES INDICATE OPTION WIRES 8 Genie PartNo 102521 S 40 5 45 6 15 October 2013 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram Deutz F3L 1011F Models 15 16 17 Section 6 Schematics October 2013 Electrical Schematic Perkins 704 30 Models before serial number 7472 18 October 2013 Section 6 Schematics Electrical Schematic Perkins 704 30 Models before serial number 7472 A B C D E F G H K L M N
220. 85 gt 05 BK S P START WH RD C5 23 WH RD C1B 6 32 gt WH RD C6 32 BRAKE TRAVEL ALARM WH BK C5 20 WH BK C1B 5 31 E D C WH BK 25A WH 5 21 WH C1B 4 30 E D C RD WH C1B 3 29 SPARE BK 22A RD BK C6 28 RD BK C1B 2 28 TILT ALARM KS1 RD C6 27 RD C1B 1 27 RD ISM 4 gt D6 RD S P AUX PWR P1 KEY SWITCH WH RD C5 14 26 WH RD S P WATER TEMP SENDER WH BK C5 16 25 WH BK S P OIL PRESSURE SENDER PO NC RD C5 1 24 RED CR1830 RD S P ENGINE POWER I RD C6 23 WH C7B 23 WH TS22 5 WH S P KEYSWITCH PWR FB 9 NC 6 30_ BK C7B 22 BK CR5 30 BK S P PWR TO PLAT EA WH C5 3 C6 84 5 11 21 WH CR2 87 WH S P IGNITION PWR EA 20 BL RD 39A GRIWH C4B 7 19 GR WH SP JIB VALVE RD C23 6 GR BK C6 18 GR BK C4B 6 18 GR BK S P PLAT ROT R GR C6 17 GR C4B 5 17 GR SP PLAT ROT L OR RD H6 OR RD C4B 4 16 OR BK C6 15 _ 4 3 15 OR BK S P _ PLAT LEVEL DN OR C6 14 OR C4B 2 14 OR S P PLAT LEVEL UP WH 21A BL RD C6313 BU RD C4B 1 13 DRV ENA LT 7 T BL WH C3B 12 12 A TS53 PN BL BK C3B 1 11 BR GROUND 12 BL C3B 10 10 RU 99 BK RD C3B 9 9 145 BK WH C6 8 BK WH C3B 8 8 BK WH S P BOOM RETRACT PLWH 05 13 a 7 BK C3B 7 7 BK S P BOOM EXTEND BLWHISMITO WHIRD C6 6 WH RD C3B 6 6 WH RD S P TURN ROT FC WH BK C6 5 WH BK C3B 5 5 WH BK S P TURN ROT L RD WH 3A TS61 WH C6 4 WH C3B 4 4 WH S P TURN ROT R RD BK 2A
221. 86 lt gt STEER CCW e e Az E C36STC BL lt C6 36 C36STC STEER CW i 1 RKOUTS BL WH YOUT4 wo 2 pee 63 6 WH RD D XOUT3 BUWH amp 55 5 M 5 C3 5 PWR2 13 9 lt lt L C5TRR WH BK gt 10 68 4 CATRL WH de i 25 4 C4TRL WH 217 TURNTABLE ROTATE CW 9 nc 87 ces weeh TURNTABLE ROTATE CCW 24 E E C6 6 Eu TURNTABLE ROTATE a WH RD TUI FLOW CONTROL e 7 5 ne BOOM s Cet RD 4 PRIMARY BOOM UP cgi a 5 eD 1 y luc S 5 T DOWN 5 82 C2PBD RD BK lt lt gt _ PRIMARY BOOM DOWN i i Fi 7 e E m 6L lt PRIMARY BOOM 5 5 lt RD WH lt lt gt gt _ FLOW CONTROL E youral RDWHS gt n Z 251 18 5 PwRe Lz on gt 66 C34 RD 5 GND 1 lt BAn a2 7 C2PBD RD BK EL Cgg RD WH 9 C6 19 RD BK 4 DESCENT ALARM 1 amp o et 1 ila 5 8 5 FLE LS1 PRIMARY BOOM EXTEND lt 1 1 DRIVE LIMIT SWITCH m PAAFSWH 2O2 5 9 PAAFS WH D 5 5 DRIVE ENABLE _ a P26ESTPBK gt gt 3 I C 13DRE BURD ie 06 13 C13DRE BURD 87 UMIT SMITEN E ate 22 OR E 5820 C40LS1 OR 5 5 C6 30 Hage HAES wee
222. 9 2 2 2 2 2 3 r m 9 9 m 5 5 8 5 35 w 5 s a m m 2 3 m 5 29 g m 8 2 2 891 3 s 38 8 a amp g 8 8 39 a 7 8 a o S 3 g 5 5 gt I 5 5 E 5 g 5 20 5 L o D ol m NOTE 9 N ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM 8 e Genie IN THE STOWED POSITION AND KEYSWITCH OFF 6 40 A TEREX S 40 S 45 Part No 102521 Section 6 Schematics Electrical Schematic from serial number 15663to 16419 October 2013 Deutz F3L 201 1 Deutz D2011L03i and Perkins 404 22 Models ANSI CSA AS BL WH N N co BR 2 GROUND M C41RPM OR BK Lsze C23 gt 15 Ut g
223. ALALRM G 3 40 5 45 Part No 102521 6 84 October 2013 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram Ford LRG 425 EFI Models from serial number 75971011066 N M L K J G F E D C B A 1 10 AMP FUSE HARNESS ae PBOX WIRING 1548 TS49 BOOM Tone WORK DRIVE LITE JC PRIMARY UP DN TURNTABLE ROTATE 62390 2 TS15 DRV ENA 7 JC3 DRIVE PROPORTIONAL JOYSTICK 75565 LO 9 Li DRIVE ENABLE LED 56298 6 6 P2 EMERGENCY STOP BUTTON 66812 94506 P3 HORN SWITCH 66813 66816 AUXILIARY SWITCH 42730 5 5 TS2 START ENGINE SWITCH 13037 TS13 TS3 FUEL SELECT SWITCH FORD EFI ONLY 56457 TS4 HI LO RPM SWITCH 56457 4 2 PRIMARY 4 14 CHASSIS TILT LED 56298 3 o BOOM TS7 PLATFORM ROTATE SWITCH 16397 3 EXTEND 3 TS8 JIB UP DOWN SWITCH 13037 RETRACT 2 TS9 PLATFORM LEVEL SWITCH 13037 o TS13 PRIMARY BOOM EXTEND RETRACT SWITCH 13037 2 5 2 TS14 DRIVE SPEED
224. ANK CRANK CAM CAM SPEED SPEED svEXT2 8V RTN2 PULSE IN Gov OIL PRESS ECT AUX PU1 LPTEMP AUX ANA PU2 IVS AUX ANA BRAKE AUX DIG 3 GOV2 AUX DIG 4 TACH AUX ANA PUD2 AUX ANA PUD1 TP52 FUELSELECT AUX DIG1 AUXDIG2 KNOCK KNOCK 1 FPP2HVS PCRX KNOCK 2 KNOCK 2 VBAT PROT VBAT EGOH2 EGOH 1 INJ HS INI LS INiLS INiSLS NILS INISLS GROUND 1461 AUX PWM STARTER RELAY ML UEGOH AUX PWM7 LOCKOFF FUELPUMP AUXPWMG VBAT DEW GROUND DBW AUX PWMS REC AUX PWMS AUX PWM AUX AUX PWM2 AUX PWM4 REC FPREC AUXPWM3 REC PUMP AUX PWM3 October 2013 Section 6 Schematics Engine Wire Harness Ford DSG 423 EFI Models from serial number 11067 to 11784 IGNITION COILS 25 1 16 HO2S 2 vekis WIPK 18 EHO Y ES Eo YiRD 18 GYLB18 MA es Fe me DB O 18 BK LB 18 evi gt CYL 2 CYL 3 cvs TR GASOLINE
225. AT BK C7P 1 C19JSV GR WH JIB C19JSV GR WH C4P 7 AND 8 C18JD GR BK C4P 6 C17JU GR C4P 5 C15PLD OR BK C4P 3 C14PLU OR C4P 2 C43 HRN GR C2P 5 C8PBR BK WH C3P 8 C7PBE BK C3P 7 P26BAT BK C9P 1 BRN P25FS RD C9P 3 P24FS WH C9P 2 JDALARM GR BK C2P 6 DRIVE LT BK RD C3P 9 C45GEN GR WH C2P 7 TS48 WL1 RD C2P 12 TS48 WL2 RD C2P 11 C39LP BL RD C2P 1 DLITE GR BK C2P 6 WH RD 6 C3P C10SBU BL 10 C13DRE BL RD C4P 1 C11SBD BL BK C3P 11 C40LS1 OR C2P 2 C12SBF BL WH C3P 12 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C1PBU RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 C36STCC BL 10 C3PBF RD WH C3P 3 C37STC BL BK C1P 11 5 WH BK 5 C32BRK WH RD C1P 6 C4TRL WH C3P 4 ALC 500 J2 E C29MS RD WH C134PWR RD C2P 4 C35RPM BK RD C1P 9 C34SA BK WH C1P 8 C33STR BK C1P 7 C27AUX RD C1P 1 RD BK L4 J1 JC1 3 OR JC2 4 RD JC1 2 BRN JC2 5 BK JC2 3 OR JC1 5 YEL JC2 2 BRN JC3 5 BL JC3 3 OR JC3 4 6 WH JC3 2 BRN DRE A BL WH C28TTA RD BK C1P 2 DRE B BL BK C13LED BL RD 06909 Ne C29MS RD WH GR BK L48 C28TTA
226. ATE CE SEE DETAIL A REMOVE FOR GENERATOR OPTION 8 Genie PartNo 102521 S 40 S 45 6 85 October 2013 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram Ford LRG 425 EFI Models from serial number 7597 to 11066 86 87 Section 6 Schematics October 2013 Electrical Schematic Ford DSG 423 EFI Models from serial number 11067 to 12509 Section 6 Schematics October 2013 Electrical Schematic Ford DSG 423 EFI Models from serial number 11067 to 12509 BL WH z Ex 8 8 a 6 HIGH RPM FS 1 019 casESPD BK RD V EP 3 5 P QLOWRPM FUNCTION ENA i HIGH RPM p 8 m pe uim a 5o 2 gt amp GENERATOR
227. B BOOM UP DOWN SWITCH TS58 13037 CHECK ENGINE SWITCH TS22 42730 T 11 CIRCUIT BREAKER CONTROLS 15 CB1 CB1 RD C4B 12 CIRCUIT BREAKER ENGINE 15A CB2 CB2 BRN GND CIRCUIT BREAKER OPTIONS 20A RESISTOR 5 BOOM FUNCTION R1 R1 DRIVE NIGHTOPTONRELAY RESISTOR 7 5 OHM TURNTABLE FUNCT R2 R2 VOLT METER GAGE G1 G1 OIL PRESSURE GAGE G2 G2 WATER TEMP GAGE G3 G3 CHECK ENGINE L2 56298 HOUR METER HM HM Genie PartNo 102521 3 40 5 45 October 2013 Ground Control Box Wiring Diagram Ford LRG 425 EFI Models from serial number 7597 to 11066 Section 6 Schematics 82 83 Section 6 Schematics October 2013 Platform Control Box Wiring Diagram Ford LRG 425 EFI Models from serial number 7597 to 11066 6 84 Section 6 Schematics October 2013 Platform Control Box Wiring Diagram Ford LRG 425 EFI Models from serial number 7597 to 11066 PART NUMBER COMPONENT INDEX 8 5 2 lt 5 3 lt RD P2 RD H1 r C132PLI BK C1P 12 P23SWBAT WH C7P 2 P22BAT BK C7P 1 C19JSV GR WH JIB 9 2 C19JSV GR WH C4P 7 AND 8 Jl C18JD GR BK C4P 6 C17JU GR 5 C15PLD OR BK C4P 3 C14PLU OR C4P 2 C43 HRN GR C2P 5 C8PBR BK WH 8 C7PBE BK C3P 7 P26BAT BK C9P 1 BRN P25FS RD C9P 3 P24FS WH C9P 2 JDALARM GR BK C2
228. Box Switch Panel Wiring Diagram Ford LRG 425 EFI Models before serial number 7597 1 HARNESS PBOX WIRING COMPONENT INDEX PART NUMBER BOOM PROPORTIONAL JOYSTICK JC2 PRIMARY UP DN TURNTABLE ROTATE 62390 7 2 203 DRIVE PROPORTIONAL JOYSTICK 75565 L1 DRIVE ENABLE LED 56298 6 P2 EMERGENCY STOP BUTTON 66812 73805 P3 HORN SWITCH 66813 66816 AUXILIARY SWITCH 42730 5 TS2 START ENGINE SWITCH 13037 753 FUEL SELECT SWITCH FORD EFI ONLY 56457 4 TS4 HI LO RPM SWITCH 56457 13 CHECK ENGINE LIGHT 56298 TS7 PLATFORM ROTATE SWITCH 16397 3 TS8 JIB UP DOWN SWITCH 13037 TS9 PLATFORM LEVEL SWITCH 13037 3 TS13 PRIMARY BOOM EXTEND RETRACT SWITCH 13037 2 1515 DRIVE ENABLE SWITCH 13037 JC3 T547 GENERATOR SWITCH OPTION 27378 1 TS48 9 WORK DRIVE LIGHT OPTION 27378 Lu L4 4 DETAIL A LIFT DRIVE OPTION REPLACE WIRE WITH THIS WIRING DIAGRAM BRN BATGND 9 2750 GND STUD 9 55 5 g 05 eR WHS TS1 5 a A B T sl 3 2 2 3 Bg ola WH RD C32BRK ao 14 o 5 lt SPLICE TO C32BRK EM eo N a je 2 Ig Q 9
229. Box Switch Panel Wiring Diagram Perkins 704 30 Models HARNESS PBOX WIRING JC3 G TS47 GENERATOR OPTION Qe T d ve HM S aun a NS TS4 HIGH LOW RPM RD 71 17 851 1 d69 g9Zd 1 20 1V8ccd PRE see RD REMOVE FOR GENERATOR OPTION 1 DASHED LINES INDICATE OPTION WIRES P2 EMERGENCY STOP COMPONENT INDEX PART NUMBER JC2 BOOM PROPORTIONAL JOYSTICK PRIMARY UP DN TURNTABLE ROTATE 62390 DRIVE PROPORTIONAL JOYSTICK 75565 DRIVE ENABLE LED 56298 EMERGENCY STOP BUTTON 66812 73805 HORN SWITCH 66813 66816 AUXILIARY SWITCH 42730 TS2 START ENGINE SWITCH 13037 TS4 HI LO RPM SWITCH 27378 L24 GLOW PLUG INDICATOR 56298 TS7 PLATFORM ROTATE SWITCH 16397 TS8 JIB UP DOWN SWITCH 13037 TS9 PLATFORM LEVEL SWITCH 13037 TS13 PRIMARY BOOM EXTEND RETRACT SWITCH 13037 TS15 DRIVE ENABLE SWITCH 13037 TS47 GENERATOR SWITCH OPTION 27378 TS48 9 WORK DRIVE LIGHT OPTION 27378 DETAIL A LIFT DRIVE OPTION REPLACE WIRE WITH THIS WIRING DIAGRAM WH TS7 WH RD C32BRK BRN BATGND
230. CONTROL E YouTAL amp RD WH2 5 Ei xouraLSwuiRD 251 18 5 PwRe Lz on 66 C33 CIPBU RD 5 2 7 lt C32 C2PBD RD BkK z i Bcc Cg RD WH 8 C6 19 5 RD BK 4 DESCENT ALARM TAC 9 8 a0 x WIZ E Lsz PRIMARY BOOM UP 1 MERE DRIVE LIMIT SWITCH Lt 5 7 2 5 F 808942 Lst PRIMARY BOOM EXTEND 2 DRIVE LIMIT SWITCH P24FS WH 22 d wenn gt e 9 fr E E 177821 prive ENABLE 5 WH i P26ESTP 86 g Be C oi3pRE BURD C6 13 C13DRE BL RD tW UAT LIMIT SWITCH x E re C OR E C640 040181 OR 5 i 5 C6 30 N e NO gt cz B 8 8 gt 1 wars 2 2 5 C67 C7PBE BK gt M BOOM EXTEND EXTEND tf cr BOOM 8 8 2 068 C8PBR BK WH S BOOM RETRACT C37 SEXTEND oom G7PBE TRACT T 2 gt C8PBR BKWH C42 C14PLU OR UP PLATFORM LEVEL e DOWN C4 3 E C15PLD OR B 5 5 E 8 4 C14PLU OR 5 4 PLAT LEVEL UP 4 PLATFORM LEVE 5 DOWN C6 15 C15PLD OR BK SA 4 PLAT LEVEL DOWN i GR BK44 6 JDALARM 2 o D27 r2 C4 6 C18JD GR BK DOWN 0 7 1 UP JIB BOOM 2 UP JIB BOO C4 5 C17JU GR g E 2 pow 5 8 C18JD GRBK gt PLATFORM ROTATE CCW DOWN i N 1 up Boom N zur Cond C17JU GR gt 5 PLA
231. D x sx C29MS RD WH 5 1 T 8 SSS SS 6 m to lt 8 6 D40 hd r RED BLK 28 z GN BK L48 i D39 2 RED TILT RED TILT lt BRN Genie 3 40 5 45 Part No 102521 6 24 JC2 91 9 7548 7549 WORK DRIVE LITE IN 01 0 5 E TS13 PRIMARY BOOM EXTEND RETRACT 1 ZIM QU 1 CR13 HORN J 21 17 NH8 LL LP HO WH 9 49 49 80 6 4 48 8 aif HWH9 5 6 AST6LO 5 H9 9 920 vv 8 89 Wuv var WH N om TS9 PLATFORM LEVEL GR BK TS8 TS7 JB PLATFORM ROTATE 2 lt 5 5 5 5 T w e 5 2 P Q N 5 gt m gt 2 o E WH TS1 AUXILIARY PUMP CE SEE DETAIL TS15 DRV ENA 29 amp 2 17 9 17 L33 HW 18 0 8 ve HM 8 d LO 5 EA L24 GLOW PLUG gend NOTE October 2013 Section 6 Schematics Platform Control
232. D Genie Part No 102521 S 40 5 45 6 139 October 2013 Section 6 Schematics Hydraulic Generator Wiring Diagram Welder Option 6 139 6 140 Section 6 Schematics October 2013 2WD Non Oscillating Hydraulic Schematic S 40 Models before serial number 7569 6 142 6 141 October 2013 Section 6 Schematics 2WD Non Oscillating Hydraulic Schematic S 40 Models before serial number 7569
233. D 42A WH 5 21 30 E D C RD 27A v RD WH C5 24 29 MOTOR SPEED BURD 39A D4 RD BK C6 28 28 TILT ALARM RD C6 27 27 RD CR39 85 RD S R AUX PWR WH RD C5 14 28 WH RD S P WATER TEMP SENDER WH BK C5 16 25 WH BKS P OIL PRESSURE SENDER 24 RED CR1 30 RD S P ENGINE POWER Pm RD C6 23 23 CR39 30 WH S P KEYSWITCH PWR FB WH 21A BL WH C6 30 22 BK CR5 30 BKS R PWR TO PLAT TS 5 3 5 8 C6 34 amp CR45786 21 2 8 002386 WH S P IGNITION PWR HM RD 12 VOLT 20 RD S P CB2 RD S P CB1 12V BATTERY SUPPLY 19 GR WH SP JIB VALVE BR GROUND GR BK C6 18 18 GR BKS R PLAT ROT CCW M GR 7 7 GR S P PLAT ROT CW BL WH C5 13 183 C133PLA OR BK C6 15 15 OR BKS R PLAT LEVEL DN OR C6 14 14 OR S P PLAT LEVEL UP TS61 BL RD C6 13 13 DRV ENA LT RD WH 3A BL WH C3B 12 12 RD BK 2A 11 RD 1A 10 6 9 SPARE 5 BK WH C6 8 8 BK WH S P BOOM RETRACT u 86 7 7 BK S R BOOM EXTEND BK WH 8A WH RD C6 6 6 WH RD S P TURN ROT 7 3 BR GND STUD WH BK C6 5 5 WH BKS P TURN ROT CCW GR BK 44A TS62 1LBK22C WH C64 4 WH S P TURN ROT CW b o RD WH C6 3 3 RD WH amp P PRI BOOM 5 WH236 2 2 44B RD BKC6 19 RD BKS PR PRI BOOM DOWN 852 QO RD C6 1 1 RD S P PRI BOOM UP D B RD 20C RD CR17 CR23 30 2 WH BK 5A wages by d RE BK 33B Y D28 EN 2 4TS57 55 BK C5 5 WH 21B WH C5 17 6
234. D BK pieni E E 8 gt Al PRIMARY BOOM DOWN 18 PWR ZX 1 m a cea C3PBF RD WH OM PRIMARY BOOM 12 GND ig BRN 5 12 z FLOW CONTROL la 1 a Y 8 Bx C3P CiPBURD 7 C3P2 C2PBD RD BK 8 lt C3P3 C3PBF RD WH 4 C6 19 IRD BK 4 DESCENTALARM TC T WH 1119 LS2 PRIMARY BOOM UP lt 12 DRIVE LIMIT SWITCH 2 WH LS1 PRIMARY BOOM EXTEND 1 5 DRIVE LIMIT SWITCH P24FS WH lt 54 1 1 BL RD MINE U c6 13 C13DRE BL RD SWH g E ss x LIMIT SWITCH 5 Er EM C2P 2 40151 OR C6 40 40151 OR gt lt I C6 30 f N 3 z 382 Hag 4 2 z 2 ES ta 0 56 a gt BOOM EXTEND E E e BOOM m 8 4 RETRACT gt C68 CBEBRIBIIWH 71 BOOM RETRACT 7 C7PBE EXTEND 5 nErRAcr BOOM 8 C8PBR BK WH P o z CAP2 CI4PLU OR PLATLEVEL 9 DOWN C4P3 _ CiSPLDOR BK X o gt B ur gt gt 06 14 SIAPLU OR 4 PLAT LEVEL UP PLAT LEVEL 2 DOWN d C6 15 CISPLDON BK N 4 PLATLEVEL DOWN wo i NO De E GR BK44 C2P6 JDALARM GRB l 20 EQ 6 C18JD GR BK Down B 5 C17JU GR 2 S m JIB BOOM B rcg ar gt gt 06 18 7 PLATFORM ROTATE RIGHT JIB DOWN eis up
235. DRE BURD lt WH o P26ESTP BK 3 5 A 5 een BK gt BK 41 2 Slave C2P 2 40181 C6 40 C40LS1 OR lt 2 8 5 I e 5 2 E C6 30 9 gd 5 2 2 2 1 9 i cz cz o 5 o 5 u 5 8 C67 C7PBE BK sr E 5 oo 7 b EXTEND 5 5 BOOM 8 0 RETRACT ss 068 C8PBR BK WH IBGORMRETRAET 3 5 lt 7 C7PBE 2 EXTEND p e BOOM lt RETRACT C3P 8 C8PBR BK WH 2 2 C14PLU OR UP 1 po FORM LEVEL DOWN 3 C15PLD OR BK d C14PLU OR 8 Bi 8 C6 14 gt 11 57 a PLAT LEVELUP lt PLATFORM LEVEL 2 DOWN c6 15 C15PLD OR BK A 4 PLAT LEVEL DOWN i GR BK44 __ C2P 6 JDALARM GR BK 2 E 9 gt 4 6 C18JD GR BK DOWN 4 e JiB BOOM 2 tu 5 C17JU GR 2 B ue C6 18 C18JD GR BK oes B town A 4 PLATFORM ROTATE RIGHT JIB DOWN HH JIB BOOM tue Cate SIG any PLATFORM ROTATE LEFT JIB UP 5 B 5 8 RIGHT PS RIGHT PLATROTATE PLAT ROTATE LEFT LEFT N C4P 7 19 2 gt JIB VALVES 5 H 5 E 9 JIB VALVE B z al a 258 October 2013 Section 6 Schematics Electrical Schematic Ford DSG 423 EFI Models from serial number 11067 to 12509 90 91 Secti
236. Dez 2 Genie Part No 102521 S 40 S 45 6 151 October 2013 Section 6 Schematics 4WD Hydraulic Schematic from serial number 7569 6 151 6 152 Note alpha callouts refer to components shown in the manifold illustrations Refer to the Repair Section October 2013 Section 6 Schematics Generator Hydraulic Schematic Welder Option F E D C B A 1 HYDRAULIC WELDER OPTION 2 s OL 8 5 GPM DRIVE COOLER ME D A P Toce ees ues j 3 PMP B CLR PMP A WELDER MANIFOLD AJJ AK AL Ha 4 MEIN NO PRESS SW 200 PSI 0 031 5 A LE IN 270 PSI b 3 5 GPM 61 1 z MTRB Be 6 e e I TANK 5 a 7 QE a i 21CC 588 G2 G1 a 12 5 KW GENERATOR 8 Genie Part No 102521 5 40 5 45 6 153 October 2013 Section 6 Schematics Generator Hydraulic Schematic Welder Option 6 153 6 154 Genie Scandinavia Phone 46 31 57 51 00 Fax 46 31 57 04 Genie France Phone 33 2 37 26 99 Fax 33 2 37 09 98 Genie Iberica Phone 34 93 572 5090 Fax 34 93 572 5091 Genie Germany Phone 0800 180 9017 Phone 49 4221 491 810 Fax 49 4221 491 8
237. E g 613 C15PLD OR BK Seh 8 5 0814 C14PLU OR 2 4 PLAT LEVEL UP E UP PLATFORM LEVEI o T DOWN C6 15 E C15PLD lt 4 PLAT LEVEL DOWN x ge GR BK44 C26 JDALARM GR BK IS D27 EQ C46 5 Som C18JD GR BK 2 i 8 UP JIB BOOM C4 5 C17JU GR 275 8 D28 t C6 18 5 kom 9 C18JD GR BK lt gt PLATFORM ROTATE CCW DOWN i e e p JIB Boom _ E eU gt m C17JU GR 4 PLATFORM ROTATE CW JIB UP 1 N PLAT ROTATE 9 CCW er cw PLAT ROTATE I Ej 4 Cer C19JSV GR WH 5 B E 1 1 8 c er i 5 i JIB VALVES 5 5 HM e 5 a JIBVALVE i Z 5 mi 5R 5 m TM iain seman i om 5 enie G Teran wo S 40 S 45 6 105 Part No 102521 October 2013 Section 6 Schematics Electrical Schematic Ford DSG 423 EFI Models CE from serial number 15663 to 16419 10 6 106 Section 6 Schematics October 2013 Electrical Schematic Ford 056 423 EFI Models ANSI CSA AS from serial number 16420 6 108 6 107 RD BL WH RD BK OR BK BK wi RI RD BR P26ESTP BK Section 6 Schematics
238. E FUNCT R2 VOLT METER GAGE G1 OIL PRESSURE GAGE G2 WATER TEMP GAGE G3 CHECK ENGINE 12 HOUR METER HM LOAD SENSE TIME DELAY RELAY 10A U34 Genie Part No 102521 Section 6 Schematics S 40 3 45 October 2013 Section 6 Schematics Ground Control Box Wiring Diagram Ford DSG 423 EFI Models from serial number 14832 6 117 6 118 Section 6 Schematics October 2013 Platform Control Box Wiring Diagram Ford DSG 423 EFI Models before serial number 14832 6 120 6 119 Section 6 Schematics October 2013 Platform Control Box Wiring Diagram Ford DSG 423 EFI Models before serial number 14832 HARNESS PBOX WIRING RD P2 RDH1 C132PLI BK C1P 12 LS18 P23SWBAT WH C7P 2 P22BAT BK C7P 1 a C19JSV GRWH en C19JSV GRIWH JIB 7 158 5 C18JD GR BK 4 6 BRN C17JU GR C4P 5 C15PLD OR BK C4P 3 C14PLU OR C4P 2 C43 HRN GR C2P 5 C8PBR BKIWH C3P 8 C7PBE BK C3P 7 P26BAT BK C9P 1 P25FS RD C9P 3 P24FS WH C9P 2 JDALARM GR BK C2P 6 DRIVE
239. ECTOR s IM Gum t GROUND pnis arte 8 21 GYLB 18 1 S uns OB sew a LGIBK 18 RING avis GYA 1E CHT 5 4 20 p ERIE 36 ROADSPEED 19 TAB 18 24 GOV SELECT 1 BK 16 BKW 16 18 LBIBK 158018 F2 BAG 18 RIG 18 RAG i8 om 5A VSW BK 18 23 GOV SELECT 2 ona 18 28 DGIO 18 32 ANA AUX PDI TE I 12 FPP2 GYR 18 33 RTN 18 31 VREF sa BKWW16 IBIDG 18 Lama BRW 18 BRIW 18 18 18 Lop 18 ALTERNATOR a PXLG 18 BKR 16 Lop 18 180018 RIS 16 FIT LBIDG 18 ern BBK 18 sade CE BW 18 RWS 16 AUX PWM 4 18 BKO 18 25 is RW 18 18 Daw 18 18 26 OILPRES Hs BREITE L H BR 16 true ONG i8 OLG 18 39 AUX OUT R16 wie Y DB 18 YDB 18 7 FUEL SELECT Piste PAD 18 PLB 18 10 AUX ANA PD1B TIGEN 18 TIGN 18 wise visa DG18 Picnic INJECTOR CYL 2 DM FUEL PUMP BNLB16 z WIPK36 19 START IN AUTOCRANK 18 PKIBK 16 Sse a PKfek 16 5 FUELPUMP 1 FUEL PUMP RELAY STARTE
240. EED FUNCTION ENA AD 1 5 n P H GH RPM ET BK RD 11 2 0 4 lt B 5 8 nF 5 So De e 5 8 4 HIGH RPM SOLENOID i T 2 M A D F H c27 C639 GENERATOR C45GEN GR WH C45GEN GRWH 4 OPTION GENERATOR Ses WORK LIGHTS WH Ox BK BR OPTION 8 z zt ig VV be DRIVE LIGHT 4 WH Ox 5 2 RD IT option 8 5 m 2 E ud 4 8 5 25 10 NA uo DE Se ee c wr E E Er E SECOND 4 GLOW PLUG OPTION 900 DEUTZ ONLY ET 5 az e a B p 8 1 8 03484 BK WH C5 22 3 4 h 5 GLOW PLUG OPTION 8 5 lt g 27 t tk te E ow 2 3 u N E 4 8 COOLANT TEMP GAUGE amp Ql 2 1 WH RD o Eu 5 5 amp 3 OIL TEMPERATURE 28 21442 pets 1 SWITCH 8 9 C5 18 OIL PRESSURE i H r e 8 1 Ot C33STR BK 5522 w 446 lt lt SWITCH cc H 2 e ioter pol a 5 ENGINE 8 1010000100000 T ul z 5 C5 16 5 gis WH BK x 5 z E n C21IGN WH 6 OIL PRESSURE GAUGE 5 5 2 zr 4 4RPMFLTER DEUTZONL 0 8 8 8 NE 2 ex B x Ae amp R21l1GN WH lt lt lt FUEL SOLENOID 9220 m ee Sx 5 5 zi os 5 5 5 8 e 4 z 4 IGNITION RELAY oF g 8 E a 2 0 2 Sa 9 VOL
241. EX N a 1915 Ki JC2 BOOM PROPORTIONAL JOYSTICK P t Q T lt 2 PRIMARY UP DN TURNTABLE ROTATE gt gt Jc2 1 e a Je JC3 DRIVE PROPORTIONAL JOYSTICK d 54914 1 44 3 Li DRIVE ENABLE LED P2 EMERGENCY STOP BUTTON ig P3 HORN SWITCH 8 TS AUXILIARY SWITCH TT ROTATE E PRIMARY 5 TS2 START ENGINE SWITCH a 15 TS3 FUEL SELECT SWITCH FORD EFI ONLY EXTEND 5 TS4 HI LO RPM SWITCH RETRACT 5 14 CHASSIS TILT LED TS7 PLATFORM ROTATE SWITCH o TOME TS8 JIBUP DOWN SWITCH 4 TS9 PLATFORM LEVEL SWITCH 148 TS13 PRIMARY EXTEND RETRACT SWITCH TS13 TS14 DRIVE SPEED SWITCH z 83 1815 DRIVE ENABLE SWITCH 85 TS47 GENERATOR SWITCH OPTION 5 87 14 1949 WORK DRIVE LIGHT OPTION 30 E EL E ido Eg m i m w uu II o 1 86 Ez u zs i 2s ig 5 5 5 2 ES 2 I 90 91 225 2 9 m o 2 o 5 Qe m m 6 6 5 5 5 5 DETAIL A LIFT DRIVE OPTION 5 0 31 E e a 5 A 29 0920 m i 1p gt 5 T 7 S 2 x REPLACE WIRE WITH THIS WIRING DIAGRAM B S g o N BR BATGND 6 5 2 5 Q fos a 2 0 ee mm Pe i POI SN sg 5 9 A 52 5
242. FUEL PUMP RELAY INJECTOR CYL 4 RUG 18 5 iB dS STARTER STARTER RELAY CAN LPG SOLENOID ieee TERMINATION BRN 16 LOCKOFF qnc n CONNECTOR 7 weke SENSOR DIAGNOSTIC CONNECTOR RING wis 3 RELAY 5 H OMRON Lop ig 85 LP FPP Er 18 5 GROUND PKK 16 16 o unusen R16 INJECTOR CYL 1 8 2 0 B Junuseo RIT18 ag 7 RELAYED POWER ES0400A F1 ate rns 16 FAB 16 POWER RELAY e mvis 10A EPR EPR I Ri a oh CONNECTOR Genie Part No 102521 S 40 3 45 6 129 October 2013 Section 6 Schematics Engine Wire Harness Ford DSG 423 EFI Models from serial number 11101 to 11784 6 129 6 130 Section 6 Schematics October 2013 Engine Wire Harness Ford DSG 423 EFI Models from serial number 11785 6 132 6 131 October 2013 Section 6 Schematics Engine Wire Harness Ford DSG 423 EFI Models from serial number 11785 A ENGINE ECM CONNECTOR SPK COILIB SPARK COIL2A SPK GND SPK_COIL2B SPK_COIL3A SPK COILSB UEGOS UEGOP UEGPR AUX ANAPD1 AUX ANA PD2 CAN2 AUX ANA PD3 SVEXT1 SV RTN EGO EGO2 MAP AUX ANA PUD3 CRANK CRANK CAM CAM SPEED SPEED SVEXT2 5V RTN2 PULSE IN Govt PRESS IAT ECT AUX ANA PU LPTEMP
243. Ford DSG 423 EFI Models from serial number 11067 to 12509 6 124 Platform Control Box Switch Panel Wiring Diagram Ford DSG 423 EFI Models from serial number 12510 6 125 Genio Part No 102521 5 40 5 45 October 2013 41 TABLE OF CONTENTS Section6 Rev Schematics continued Engine Harness Ford LRG 425 EFI Models before serialnumber 11067 6 128 Engine Harness Ford 056 423 EFI Models from serial number 11067 011782 6 129 Engine Harness Ford DSG 423 EFI Models from serialnumber 11785 7 6 132 Joystick Connector Diagram 6 133 CTE Option Wiring Diagram ennemis 6 136 MTE Hydraulic Generator Option Wiring Diagram 6 138 Hydraulic Generator Wiring Diagram Welder option 6 139 Hydraulic Schematic 2WD Non oscillating 5 40 Models 12 6 09 7 Hydraulic Schematic 2WD Non oscillating S 45 Models before serial number 7569 6 143 Hydraulic Schematic 4WD Oscillating 5 40 5 before 7569 22 20 222 0 6 146 Hydraulic Schematic 4WD Oscillating 5 45 Models before serial number 7569 6 147 Hydraulic Schematic
244. H RD Section 6 Schematics C Electrical Schematic Ford DSG 423 EFI Models CE from serial number 15663 to 16419 October 2013 T 8 c t HicHRPM FS 1 9 C35RPM BK RD 9 TORO ena 45 gt ENG SPEED HIGH RPM NR 9 2 a fo lo GENERATOR 9 ps m CES S GENERATOR e C45GEN GR WH C45GEN GRWH it 4 OPTION 1 059 DLITE BK RD 5 gt 8 a VG DRIVE LIGHT 5 e 3 2 d 5 C4B 12 Ox 255 OPTION Ile s
245. HT PWR SC OR gt 13 gt GND ZZ 5574 C36STC BL E C6 36 C36STC BL IA 4 STEER LEFT m L C3P 6 CeTRFWH RD 5 S 5 C5TRR WH BK 5 C3P 4 C4TRL WH foc c 9P 1 5 56 4 Zu l TURNTABLE ROTATE LEFT 8 7 TROTATE 5 ener t 65 CSTAR WHER TURNTABLE ROTATE RIGHT m LE C66 C6TRF WH RD gt TURNTABLE ROTATE 5 0 FLOW CONTROL a E 30075 8 al C1PBU RD Bi gt 21 C61 PRIMARY BOOM UP 8 won oom UP primary 9 bi 5 312 Y ip TPOWN Boom mE 062 C2PBD eee PRIMARY BOOM DOWN 1 p 2 0 a EJ P E cs CaPBF PRIMARY BOOM 0 FLOW CONTROL 5 1 EX CIPBU RD 7 C2PBD RD BK cl SS SS SS SS SS SS Sy C3PBF RD WH C6 19 RD BK 6 19 RD 2 DESCENT ALARM OPTION I 1 O LS2 PRIMARY BOOM UP T ze 9 DRIVE LIMIT SWITCH T WH BAN 8 aM 4 V um LS1 PRIMARY BOOM EXTEND PMFSWH gt 2 51 0 DRIVE LIMIT SWITCH AES Wis oz P24FS WH Ss c1sore BL RD lt a 742 Oye C4P1 C13DRE BURD 2 06 13 w o a P26ESTP gt gt 5 Tn OTE o C40LS1 OR 2 2 z C2P 2 C40LS1 OR C6 40 lt 7 MET Ns 5 i X 5 Y za P EXTEND 55 5 BK
246. How to Bleed the Slave Cylinder Note Do not start the engine Use auxiliary power forthis procedure 1 Raise the primary boom to a horizontal position 2 Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system Part No 102521 October 2013 Section 4 Repair Procedures 2 2 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees How to Remove the Platform Rotator Component damage hazard Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal If a new rotator is installed or the rotator is disassembled proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Removethe platform and platform support Part No 102521 Genie S 40 S 45 4 9 PLATFORM COMPONENTS S 40 Models 2 Tag disconnect and plug the hydraulic hoses from the platform rot
247. I BK C1P 12 P23SWBAT WH C7P 2 P22BAT BK C7P 1 FW C19JSV GR WH JIB C19JSV GR WH 4 C4P 7 AND TS8 IB C18JD GR BK C4P 6 BRN C17JU GR C4P 5 C15PLD OR BK C4P 3 C14PLU OR C4P 2 C43 HRN GR C2P 5 C8PBR BK WH C3P 8 C7PBE BK C3P 7 P26BAT BK C9P 1 P25FS RD C9P 3 P24FS WH C9P 2 JDALARM GR BK C2P 6 DRIVE LT BK RD C3P 9 C45GEN GR WH C2P 7 TS48 WL1 RD C2P 12 TS48 WL2 RD C2P 11 C39LP BL RD C2P 1 P26BAT BK C6TRF WH RD C3P 6 C3P C9P C10SBU BL C3P 10 C13DRE BL RD C4P 1 C11SBD BL BK C3P 11 C40LS1 OR C2P 2 C12SBF BL WH C3P 12 C7P C41RPM C2P 3 C30EDC WH C1P 4 C1PBU RD C3P 1 031506 WH BK C1P 5 C2PBD RD BK C3P 2 C7P 0365100 BL C1P 10 C3PBF RD WH C3P 3 F S 12V BATT C37STC BL BK C1P 11 C5TRR WH BK C3P 5 C4P BR C32BRK WH RD C1P 6 C4TRL WH C3P 4 ALC 500 C29MS RD WH C1P 3 J2 E C134PWR RD C2P 4 C35RPM BK RD C1P 9 C34SA BK WH C1P 8 C33STR BK C1P 7 C27AUX RD C1P 1 RD BK L48 J1 JC1 3 OR JC2 4 RD JC1 2 BRN JC2 5 BK JC2 3 OR JC1 5 YEL 402 JC3 5 BL 63 3 OR JC3 4 6 WH 2 BRN DRE ABL WH C28TTA RD BK C1P 2 m B BL BK 2 BURD C29MS RD WH GR BK L4
248. IRE FOR UNITS WITHOUT GENERATOR OPTION ESO433B 3 gt RESISTOR R4 REMOVED AT SERIAL NUMBER 11785 enie G A TEREX S 40 S 45 Part No 102521 6 88 Section 6 Schematics Electrical Schematic Ford DSG 423 EFI Models from serial number 11067 to 12509 C October 2013 BL WH 6 89 enie G S 40 S 45 Part No 102521 N N co GROUND C41RPM ER C2P 3 515 3 8 5 e DRIVESPEED C30EDC WH ae 150 CIE CSUEDEEWH mE x 5 DRIVE EDC FORWARD C29MS RD WH DRE LED BURO 5 1 5 C31EDC WH BK ges C5 20 C31EDC WH BK Dic 559 DRIVE REVERSE C6 32 i DREBBUBK gt TRAVELALARMOPTION cr ee
249. Jector OR replace battery OR repair running charging system OR replace the MegaJector MegaJector Voltage Supply Low Genie PartNo 102521 S 40 S 45 5 9 Section 5 Fault Codes October2013 FAULT CODES Code MegaJector Internal Circuitry Fault Detection MegaJector Internal Communication Fault Detection Coil Driver 1 Open Coil Driver 2 Open TPS1 Signal Voltage High TPS1 Signal Voltage Low TPS2 Signal Voltage High TPS2 Signal Voltage Low TPS1 Higher than TPS2 TPS1 Lower than TPS2 Throttle Unable to Open Throttle Unable to Close Governor Interlock Failure The Megavector detects an internal communications failure Open or short in power ground or CAN circuits Open wiring and or connections to ignition coil 1 OR ignition coil 1 is faulty Open wiring and or connections to ignition coil 2 OR ignition coil 2 is faulty qms Wiring and or connections to ignition coil 1 shorted OR ignition coil 1 is faulty psi Wiring and or connections to ignition coil 2 shorted OR ignition coil 2 is faulty The 1 throttle position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR throttle position sensor 1 is faulty The 2 throttle position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR throttle position sensor 2 is faulty The throttle position sensor wiring and or conn
250. KRD PIN 23 509 8 a i hae C55 g wv 5 62 95 gt R33STR BKPIN 15 3 9 C58 86 5 5 R21IGN WH PIN 24 1 oz T C5 10 lt 5 gt gt 0391 7 BL RD PIN7 56 C28TTA RD BK 2 5 C135FP BL WH PINS 5 5 5 zz 5 C135RET BLPIN 18 1 z i 22 5 T cs zB a T 5 sz VSW WH PIN 1 X e 8 41 59 9 p N C5 13 4 C38ESL BL WH PIN 6 A m 5 C6 27 a AUXILIARY POWER C27AUX 1 RELAY tr 8 a BK 35 os 4 5 AUXILIARY PUMP 28 9 ES lt gt 5 C27AUX RD WORK LIGHT RELAY OPTION m a i5 C72 P23BAT WH 55 g 5 e C6 28 C28TTA RD BK 8 RD BK lt amp WH TILT ALARM 8 6623 RD gt gt BR 9 LEVEL SENSOR C4 4 _ Yan FLASHING BEACONS GR BKC tx C138PLA OR RD 8 D N SERVICE HORN C43HRN GR RELAY go 4 2 oz C6 16 S o R43HRN 4 SERVICE HORN a 8 Ed 8 GN BK P22BAT Bk 1 8 ER 8 P e Alli 52 5 9 M 8 825 u9 HYDRAULIC OIL g g E 2 M gt TEMP SWITCH a o C6 34 gt gt C132PLI1 ouis 7 62 0898 0656 COOLING FAN 2 4 228 1 5 t OPTION z P134PWR RD C23 gt lt l 1192 vL LE e gt c23 5 2 C41RPM OR BK ie C41RPM OR BK PIN2 42 PIN FORD CONNECTOR 4
251. KUP A OR C6 40 OR C2B 2 40 LIMIT SWITCH SIG 4 BK WH C5 10 BL RD C2B 1 39 BL RD S P ER BL WH C23 3 1 12 8 C132PLI WH BK 25A BL BK C6 37 BLIBK C1B M 7 STEER LEFT WH RD 26A BL C6 36 BL C1B 10 36 STEER RIGHT GND BK 22A BK RD C1B 9 35 BK RD 30 BK RD S P RPM BK WH C5 22 BK WH C1B 8 34 BK WH S P GLOW PLUG KEY SWITCH AUXILIARY 3 BK C1B 7 BK ISM 3 BK S P START P1 WH RD C5 23 WH RD C1B 6 32 WH RD C6 32 BRAKE TRAVEL ALARM RD CB2 WH BK C5 20 5 31 E D C sand 8 1 WH C5 21 WH C1B 4 30 E D C RD WH C5 24 RD WH C1B 3 29 MOTOR SPEED Bi RD BK C6 28 RD BK C1B 2 28 TILT ALARM NESSUN 1 2 RD C6 27 RD C1B 1 27 RD ISM 4 3 D6 RD S P AUX PWR DA Y 26 WHIRD S P WATER TEMP SENDER 6 25 WH BK S P OIL PRESSURE SENDER RD C5 1 24 RED CR1 30 RD S P ENGINE POWER WH C7B 2 23 WH ISM 7 WH S P KEYSWITCH PWR FB RD BL WH C6 30 BK C32 4 22 BK CR5 30 BK S P PWR TO PLAT Bi WH C5 3 C5 11 WH C6 34 21 WH CR2 87 WH S P IGNITION PWR 4 RD 12VOLT CB3 SP 20 CB2 SP CB1 SP 12 VOLT BATTERY POWER Wasik GR WH CAB 7 19 GR WH SP JIB VALVE GR BK C6 18 GR BK C4B 6 18 GR BK S P PLAT ROT R GR C6 17 GR C4B 5 7 GR S P PLAT ROT L BR GROUND IT OR RD C4B 4 16 GR BK C32 8 GR BK H6 C133PLA T OR BK C6 15 OR BK C4B 3 15 OR BK S P PLAT LEVEL DN OR C6 14 OR C4B 2 14 OR S P PLAT LEVEL UP WH C
252. LT BK RD C3P 9 n C45GEN C2P 7 8 a TS48 WL1 RD C2P 12 8 TS48 WL2 RD C2P 11 d E d C39LP BURD C2P 1 DLITE BK RD C3P 9 P26BAT BK al S ox 0 C6TRF WH RD 6 7 105 10 1 E C13DRE BURD C4P 1 011880 11 P24 S WH 6 C40LS1 OR C2P 2 C12SBF C3P 12 5 E P24 S WH o CA1RPM OR BK C2P 3 lt C30EDC WH C1P 4 5 BRN B C1PBU RD C3P 1 C31EDC WH BK C1P 5 5 6 C2PBD RD BK C3P 2 C36STC BL 10 o RD WH C3P 3 C37STCC C1P 11 a 9955 C5TRR WH BK C3P 5 B G e C32BRK WH RD C1P 6 C4P BR 6 CATRLWH C3P 4 2 N C29MS RD WH C1P 3 a 5 C134PWR RD C2P 4 C3P GR BK RD C1P 9 C34SA 1 8 C33STR BK 7 8 C27AUX RD RD BK L4 C2P BK lt M 5 al 3 5 JC1 30R 5 JC2 4 RD P 8 JC1 2 BRN 1P GY 5 JC2 5 BK A C1P GY JC2 3 OR JC1 5 YEL JP JC2 2 BRN JC3 5 BL 9 JC3 3 OR JC3 4 6 WH P JC3 2 BRN DRE ABLWH 2 C28TTA RD BK C1P 2 DRE BUBK q C13LED BURD 5 29 6 RD WH 3 x 9 5 al 5 o 8 5 2 5 amp 8 68 D40 _ 0 RED BLK 28 D39 GR BK 148 ag RED TILT RED TILT 2 BRN co N ESO433 3 40 5 45 Part No 102521 6 120 Section 6 Schematics October 2013 Platform Control Box Wiring Diagram Ford DSG 423 EFI Models from serial number 14832
253. N OPTION GR BK C2B 6 44 GR BK 2B GR BK SP JDALARM JIB GR C2B5 43 GR CR5 86 HORN RD C6 23 OR RD C2B 4 42 6 RD KS1 2S P C134PWR OR BK C5 2 OR BK C2B 8 41 OR BK ISM 2 PULSE PICKUP OR C6 40 OR C2B2 40 LIMIT SWITCH SIG BK WH C5 10 BL RD C2B i 39 BURD S P LP BLIWH C23 3 BLWH CIB 12 8 C132PLI BL BK C6 37 _ BLIBK C1B 11 37 STEER LEFT BL C6 36 BL C1B 10 36 STEER RIGHT BK RD C1B 9 35 BK RD CR3 30 BK RD S P RPM BK WH C5 22 BKWH C1B 8 34 BKWH SP GLOW PLUG BK ISM 3 BK C1B 7 33 BK ISM 3 BK S P START WH RD C5 28 WH RD C1B 6 32 WH RD C6 32 BRAKE TRAVEL ALARM 5 20 WH BK C1B 5 31 E D C WH C5 21 40184 30 EDC RD WH C1B 3 29 SPARE RD BK C6 28 RD BK C1B 2 28 TILT ALARM RD C6 27 RD C1B 1 27 RDISM 4 06 AD SP AUX PWR WHIRD C5 14 26 WH RD S P WATER TEMP SENDER WH BK C5 16 25 WH BK amp P OIL PRESSURE SENDER RD C5 1 24 RED CR1 30 RD S P ENGINE POWER WH C7B 2 RD C5 19 23 WH SP WH46A KEYSWITCH PWR FB BLUWH C6 30 23 4 22 BK CR5 30 BK S P PWR TO PLAT WH C5 C5 M WH C6 34 21 WH CR2 87 WH S P IGNITION PWR RD 12VOLT CB3 SP 20 CB2 SP CBi SP 12 VOLT BATTERY POWER GRIWH C4B 7 19 GAWH SP JIB VALVE GRIBK C6 18 GRIBK C4B 6 18 GRIBK S P PLAT ROT R GR C6 17 GR C4B 5 17 GR SP PLAT ROT L OR RD C4B 4 16 GR BK C23 8 GR BK H6 C133PLA gt ORIBK C6 15 OR BK C4B 3 15 ORIBK S P PLAT LEVEL DN OR C6 14 OR C4B2
254. NG Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 17 Attach an overhead 5 ton 4500 kg crane to the center point of the boom Part No 102521 Genie 5 40 5 45 18 Attach similar lifting device to the boom lift cylinder 19 Use the overhead crane to lift the boom to a horizontal position 20 Place support blocks under the boom lift cylinder across the turntable 21 Remove the pin retaining fastener from the boom lift cylinder rod end pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The boom lift cylinder will fall if not properly supported 22 Lower the rod end of the lift cylinder onto support blocks Protect the cylinder rod from damage 23 Remove the pin retaining fastener from the boom pivot pin 24 Use a soft metal drift to remove the boom pivot pin then carefully remove the boom from the machine Crushing hazard The primary AWARNING boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Section 4 Repair Procedures October2013 How to Disassemble the Boom Note Complete disassembly of the boom is only necessary if the secondary boom tube must be replaced The extension cylinder can be removed without completely disassembling the boom See 4 4 H
255. NWHPIN24 nn 5 5 10 C39LP BLRDPIN7 ERE 8 a gt 3 C135FP 5 a E m 88 1 18 2 um d EU 0 C511 PIN 1 8 8 Ve 5519 03869 BLIWH PIN 6 N mI RD amp C6 27 C27AUX RD 5 1 AUXILIARY POWER N a N s a 33 AUXILIARY PUMP 1 1 C27AUX RD tz e N P23BAT WH Sut IG NE 8 5 C28TTA RD BK WH TILT ALARM 8 RD gt RD eer BK gt gt BR LEVEL SENSOR r 1 yay FLASHING AL OPTION 2 L l a VY c25 Sm SERVICE HORN n C43HRN GR RELAY go P22BAT BK C7 is R43HRN BK 4 SERVICE HORN o N 6 5 55625 18 HYDRAULIC OIL TEMP SWITCH 6 34 Eo E 4 P134PWR RD E i CA1RPM OR BK 23 gt C41RPM OR BK PIN 2 42 PIN FORD CONNECTOR em E BLUE PINK FORD ENGINE 5 8 g PR2 STARTER RELAY 5 a STARTER MOTOR ha 5 pr2 sc S 0 S 8 5 fo D P20BAT RD 8g N co Part No 102521 THE BOOM IN THE STOWED POSITION AND KEYSWITCH OFF 3 40 5 45 G 6 96 Section 6 Schematics Electrical Schematic Ford DSG 423 EFI Models from serial number 14832 to 15662 October 2013
256. OMPONENTS How to Repair the Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A cable track repair kit is available through the Genie Industries Service Parts Department part no 81007 The kit includes a 4 link section of cable track 1 Visually inspect the cable track and determine which 4 link section needs to be replaced 2 Remove the snap on cable track spacers 3 Carefully remove the external snap rings from the pivot pins at each end of the 4 link section to be removed 4 Liftup the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 5 Remove the snap on spacers from the replacement section of the cable track 6 Lift up the hoses and cables and carefully insert the new 4 link section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 7 Connect the ends of the replacement cable track section to the existing cable track using the pivot pins and external snap rings Note Be sure the pivot pins are installed from the inside out so the external snap rings are on the outside of the cable track 8 Operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track Section 4 Repair Procedures October2013 BOOM COMPONENTS 4 2 B
257. OR CKT PIN RD C1PBU 1 RD BK C2PBD 2 RD WH C3PBF 3 WH C4TRL 4 WH BK C5TRR 5 WH RD C6TRF 6 BK C7PBE 7 BK WH C8PBR 8 GR BK JALARM 9 BL C10SBU 10 BL BK C11SBD 11 BL WH C12SBF 12 C4P DT06 12SD COLOR CKT PIN BL RD C13DRE 1 OR C14PLU 2 OR BK C15PLD 3 GR BK C133PLA 4 GR C17JU 5 GR BK C18JD 6 GR WH C19JSV 7 PLUG 8 PLUG 9 PLUG 10 PLUG 11 PLUG 12 C1 C2 C3 C4 C1 GRAY 2 BLACK C3 GREEN C4 BROWN C7 4 COLOR CKT PIN s BK P22BAT 1 WH P23BAT 2 BRN BATGND 3 N A PLUG 4 C7 NOTE WIRE ONLY IN C7B CONNECTOR 1 C6 C6 GBOX C6 FUNCTION HARNESS CIRCUIT COLOR CIRCUIT COLOR 1 C1PBU RD C1PBU RD 2 C2PBD RD BK C2PBD RD BK 3 C3PBF RD WH C3PBF RD WH 4 C4TRL WH C4TRL WH 5 C5TRR WH BK C5TRR WH BK 6 C6TRF WH RD C6TRF WH RD 7 C7PBE BK C7PBE BK 8 C8PBR BK WH C8PBR BK WH 9 10 11 12 13 C13DRE BL RD C13DRE BL RD 14 C14PLU OR C14PLU OR 15 C15PLD OR BK C15PLD OR BK 16 R43HRN BK R43HRN BK 17 C17JU GR C17JU GR 18 C18JD GR BK C18JD GR BK 19 C2DA RD BK C2DA RD BK 20 21 22 23 C134PWR RD C23BAT RD 24 25 C116HYD BK 26 GND BR 27 C27AUX RD C27AUX RD 28 C28TTA RD BK C28TTA RD BK 29 30 P46PWR BL WH P46PWR BLIWH 31
258. OR low side short to ground 4 TPS1 throttle position sensor high voltage TPS1 throttle position sensor low voltage TPS2 throttle position sensor high voltage TPS2 throttle position sensor low voltage TPS1 throttle position sensor higher than TPS2 TPS1 throttle position sensor lower than TPS2 537 Unable to reach higher TPS throttle position sensor Unable to reach lower TPS throttle position sensor TPS 1 2 simultaneous voltages AUX analog PU1 high AUX analog PU1 low AUX analog PU2 high AUX analog PU2 low Max govern speed override Fuel rev limit sss Fen 66 ez ann e m 615 mee Genie S 40 5 45 Part No 102521 October 2013 Section 5 Fault Codes Code 648 11 13 menses 14 15 meme 21 22 semen 23 1 o A N N N N N N G CO O1 OIN gt N A FAULT CODES 44 62 n 1629 1630 For further engine fault code troubleshooting and diagnostic information refer to the Ford DSG 423 EFI Service Manual EDI part number 1060040 Genie part number 119494 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Genie PartNo 102521 5 40 5 4
259. P 6 DRIVE LT BK RD C3P 9 C45GEN GR WH C2P 7 TS48 WL1 RD C2P 12 TS48 WL2 RD C2P 11 C39LP BL RD C2P 1 DLITE BK RD C3P 9 C6TRF WH RD C3P 6 C3P C10SBU BL C3P 10 C13DRE BL RD C4P 1 C11SBD BL BK C3P 11 C40LS1 OR C2P 2 C12SBF BL WH C3P 12 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C1PBU RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 C36STC BL 10 RD WH 3 C37STCC C1P 11 5 WH BK C3P 5 C32BRK WH RD C1P 6 C4TRL WH 4 ALC 500 C29MS RD WH C1P 3 J2 A C134PWR RD C2P 4 C35RPM BK RD C1P 9 C34SA BK WH C1P 8 C33STR BK C1P 7 C27AUX RD C1P 1 RD BK L4 J1 JC1 3 OR JC2 4 RD JC1 2 BRN JC2 5 BK JC2 3 OR JC1 5 YEL JC2 2 BRN JC3 5 BL JC3 3 OR JC3 4 6 WH JC3 2 BRN DRE A BL WH C28TTA RD BK C1P 2 DRE B BL BK C13LED BL RD C29MS RD WH GR BK L48 C28TTA RD BK C1P 2 C2P _ 040 C7P GR BK 4 BATGND C7P 3 FS C9P C7P F S 12V BATT C4P BR C3P GR C2P BK C1P GY 19 18 CONTROL CABLE RED BLK 28 D39 RED TILT RED TILT BRN H1 TILT
260. PLATFORM LEVEL SWITCH T859 BOOM EXTEND RETRACT SWITCH TS63 PRIMARY BOOM UP DOWN SWITCH TS61 TURNTABLE ROTATE SWITCH 62 JIB BOOM UP DOWN SWITCH 8 CIRCUIT BREAKER CONTROLS 15A CIRCUIT BREAKER ENGINE 15A CIRCUIT BREAKER OPTIONS 20A RESISTOR 5 FUNCTION Ri RESISTOR 7 5 OHM TURNTABLE FUNCT R2 VOLT METER GAGE G1 OIL PRESSURE GAGE G2 OIL TEMP GAGE G3 CHECK ENG LED L2 HOUR METER HM IGN START RELAY IGN POWER RELAY CR2 HIGH IDLE RPM CUTOUT RELAY CR3 RPM RELAY CR4 HORN RELAY CR5 COOLING FAN RELAY CR17 PLATFORM OVERLOAD ALARM H6 PLAT OVERLOAD MODULE LOAD SENSE TIME DELAY RELAY 10A PLAT OVERLOAD LED L45 Genie Part No 102521 5 40 5 45 6 57 October 2013 Section 6 Schematics Ground Control Box Wiring Diagram Deutz D201 11 03 and Perkins 404 22 Models from serial number 14832 58 59 Section 6 Schematics October 2013 Platform Control Box Wiring Diagram Deutz F3L 201 1 Deutz D2011L03i and Perkins 404 22 Models before serial number 14832 Section 6 Schematics October 2013 Platform Control Box Wiring Diagram ALC 500 Deutz F3L 201 1 Deutz D201 1L03i and Perkins 404 22 Models before serial number 14832 PART NUMBER 45383 94771 COMPONENT INDEX TILT ALARM ALC 500 H1 A NN HARNESS PBOX WIRING RD P2 RD H1 C132PL
261. PM Adjustment Perkins Models Refer to Maintenance Procedure B 11 Check and Adjust the Engine RPM Genie S 40 S 45 5 3 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 pump pump shaft pump coupler flex plate with raised spline engine flywheel 0 18 inch 4 6 mm gap Deutz Models 0 070 inch 1 8 mm gap Perkins Models 0 0625 inch 1 6 mm gap Ford LRG 425 0 080 inch 2 mm gap Ford DSG 423 20 oT M How to Remove the Flex Plate Deutz models 1 Removethe tailpipe bracket mounting fasteners from the engine bell housing 2 Supportthe drive pump assembly with an appropriate lifting device 3 Remove all of the engine bell housing fasteners 4 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 5 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Part No 102521 October 2013 Section 4 Repair Procedures Ford LRG 425 EFI models 1 Disconnect the electrical connector for the oxygen sensor at the tailpipe Do not remove the oxygen sensor 2 Remove the engine oil dipstick fasteners from the muffler bracket Remove the dipstick from the engine 3 Remove the muffler retaining fasteners from the exhaust pip
262. Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions AWARNING Electrocution burn hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery hold downs and cable connections are tight 4 Fully charge the batteries and allow the batteries to rest at least 6 hours 5 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 6 Checkthe ambient air temperature and adjust the specific gravity reading for each cell as follows Genie S 40 S 45 Add 0 004 to the reading of each cell for every 10 5 5 C above 80 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 26 7 C O Result All battery cells display an adjusted specific gravity of 1 277 or higher The
263. R STARTER RELAY CAN INJECTOR CYL 4 LPG SOLENOID PPM TERMINATION 0 Ris 6 LOCKOFF KNOCK OLG18 0 feee o CONNECTOR EE mans 8 weke SENSOR DIAGNOSTIC CONNECTOR RING wie 99 l wie 2 BAG i6 macis s x RELAY Lb OMRON 4 Lop 1g 85 INJECTOR CYL 3 FPP 1 mis PKIBK 16 PKIBK 16 2 Fi np 16 RIB 16 1 POWER RELAY Jos EPR 1 INJECTOR CYL LI an m ie nm JA CONNECTOR a Ri6 RELAYED POWER ES0400A Genie 6 132 A TEREX 3 40 5 45 Part No 102521 October 2013 Section 6 Schematics PRI UP DN amp TT ROTATE DRIVE amp STEERING M L K J F E D PRIMARY BOOM UP DOWN DRIVE STEER JC3 JC2 JC3 PRI UP DN amp TT ROTATE DRIVE amp STEERING lt A 9 2 0 2 2 2 6 5 5 5 8 55 m Joo m foo gt om e xt TURNTABLE ROTATE oo m g 985 2 S 5 UNT Sum J1 J1 JOYSTICK CONTROL CARD do 5 xe zoo AMP 7 Pin Connector PRIMARY BOOM UP DOWN DRIVE STEER ate Jc2 JC3 Be 1 9 v 29 gt L
264. RD BK C1P 2 C2P _C3P D40 C7P GR BK 4 BATGND C7P 3 FS C9P C7P F S 12V BATT C4P BR C3P GR C2P BK C1P GY 19 18 CONTROL CABLE RED BLK 28 D39 RED TILT RED TILT BRN TILT ALALRM G 3 40 5 45 Part No 102521 6 74 JC2 r H9 91 M L K J 7948 9 WORK DRIVE LITE TS13 PRIMARY 6 5 1 RETRACT 2 5 5 5 3 9 5 9 9 zt de JE EIE Size a 2l 9 PLATFORM LEVEL c 9 9 gt I c gt o 0 eim lt lt 20 x J 2 D 2210 w 2 9 P 5 gt Q N 0 WH o 2 GR WH ed O WH TS8 TS1 JIB AUXILIARY TS7 PUMP PLATFORM ROTATE CE SEE DETAIL A TS15 DRV ENA 2 17 eaqaouu 1a cog 9 1 E 08 91 17 St HWH9 5 TS47 GENERATOR October 2013 Section 6 Schematics Platform Control
265. RIGHT BK RD C5 9 BK RD C1B 9 35 BK RD S P RPM BK WH C1E 8 34 BK WH S P GLOW PLUG BK C1B 7 33 BK CR1485 gt 05 BK S P START WH RD C5 23 WH RD C1B 6 32 WH RD C6 32 BRAKE TRAVEL ALARM WHIBK C5 20 WH BK C1B 5 31 ED C WH C521 WH C1B 4 30 E D C RD WH C5 24 RD WH CiB 3 29 MOTOR SPEED RD BK C6 28 RD BK C1B 2 28 TILT ALARM RD 06 27 RD C1B 1 27 RD CR39 85 AUX PWR 3 WHIRD C5 14 26 WATER TEMP SENDER WHIBK C5 16 25 OIL PRESSURE SENDER 24 RED CR1 30 ENGINE POWER RD C6 23 WH C7B 2 23 cR39 30 KEYSWITCH PWR FB BLANH C6 30 BK C7B 1 22 BK CR5 30 PWR TO PLAT WH C5 3 05 8 WH C6 34 21 WH CR2 87 IGNITION PWR RD 12 VOLT RD S P CB3 20 RD S P CB2 12V BATTERY SUPPLY GR WH C4B 7 19 GRWH SP JIB VALVE GR BK C6 18 GR BK C4B 6 18 GRIBK S P PLAT ROT GR 6 17 GR C4B 5 17 GR S P PLAT ROT L OR RD C4B 4 16 C133PLT OR BK C6 15 OR BK C4B 3 15 OR BK S P PLAT LEVEL DN OR C6 14 OR C4B 2 14 OR S P PLAT LEVEL UP 4 BL RD C6 13 BL RD C4B 1 18 DRV ENA LT BLWH C3B I2 12 BUBK C3B 11 11 BL C3B 10 10 BK RD C3B 9 9 BK RD CR23 86 DRIVE LIGHT OPTION BK WH C6 8 BK WH C3B 8 8 BK WH S P BOOM RETRACT 6 7 BK C3B 7 7 BK S P BOOM EXTEND WH RD C6 6 WH RD C3B 6 6 WH RD S P TURN ROT F C WHIBK C6 5 WH BK C3B 5 5 WHIBK S P TURN ROT R WH C64 WH C3B 4 4 WH S P TURN ROT L RD WH C6 3 RD WH C3B 3 3 RD WH S P PRI BOOM FC RD BK C6 2 RD BK C3B 2 2 gt 44 RD BK C6 19 RD BK S P PRI BOOM DOWN 5 RD 6 1 RD C3B 1 1 RD S P
266. RIMARY LIFT A CYLINDERS BRAKE MANIFOLD a PRESSURE fh 0 7 A rz FILTER I mf mm T ee M m J We EE i NI E 5 6 6 DS TW c qe MASTER 4 1 2 PATE leo TES EG M i Om ES PN LL byes 1 L ear v2 Vi L 1 2 ee BUXTEGBM Jen ppm AUX pd PTEST EXT RET SW1 swe P1 _ ROTATE MHI HYDRAULIC FUNCTION 4 a XE I pump COOLER ng E 2 COUNTERBALANCE VALVE r lp MES 217 bar 1950 psi Tor ES RATIO PRESS QD 4 i 1 AZ AX Lt 3 i press I SIME NIST AN 3 1 1000 PSI 5 1 I 4 4 icc 31 2000 4 5 gpm 1 ape eut Lo ul oe aon 4 3 1 3000 PSI Fune Ei pm 2 A 3300 PSI gt e RETOBNT 4 i o d A 3 1 3500 PSI DRIVE PUMP FILTER 7212 0 gpm es a A 51 3500 Ps 25 psi CP 7 6 L min 1 0 1 gpm 4 1 7 bar J 0 Ei CTS 0 38 L min A 1 5 1 3000 PSI TANK P 179 3 bar i ZS 1 4 o 1 l 4 un im m 7 Ten 0 FUNCTION RESERVOIR MANIFOLD 5 Press OA OPTIONAL GENERATOR 8
267. RIVE EDC REVERSE gt n s x E 6 32 i5 X TRAVEL ALARM OPTION E 2 t 646 C5 28 AS DRE A BL WH 8 mgee 618 lt lt 03288 WH RD C32BRK WH RD 17 gt gt BRAKE RELEASE VALVE 3 5 24 Sr 244 C29MS RD WH C29MS RDIWH lt HH gt gt MOTOR STROKE 1 11 C6 37 re OH e 0978700 C37STCC 6511 STEER CCW e e TR 00 C36STC BL 5 C6 36 C36STC 4 STEER CW S 8 E RKOUTS BUWH YOUTAL warn 7 4 636 WH RD V XOUT3 555 gt 5 PWR2 0R 2513 638 gt csrRR WH BK EE 10 094 CATRL WH Re 8 i m C4TRL WH 217 TURNTABLE ROTATE CW o 9 Ein ot C65 C5TRR os 4 TURNTABLE ROTATE CCW 2 e 0 C6 6 TURNTABLE ROTATE amp C6TRF WH RD TU gt gt FLOW CONTROL e 7 5n ne BOOM Fe C61 C1PBU RD 4 PRIMARY BOOM UP a 51 DOWN E E ur 1 S 2 it 2 C2PBD Roekel PRIMARY BOOM DOWN E 8 8 C6 3 5 PRIMARY 5 lt lt lt 2 gt FLOW CONTROL youral RDWHS gt 5 los o XOUT3 SWH RD gt 21 9 zi 5 pwrete on gt EX CIPBU RD 5 gt 272 7 lt 2 C2PBD RD BK E EK Cgg RDWH S C6 19 DESCENT ALARM TKK 48 x WP 518
268. RK BRN BATGND 5 2 a 6 5 5 5 SPLICE TO C32BRK GND STUD 6 699 9 I 9 9 oc v CR27 d 86 T eh WH TS1 T 85 5 Noc 282 2380 5 2 3 2 S 8 5 653 9 5 CR30 i g S i Fi um 0 P T T dec X 40151 SPLICE R40LS1 o5 8 Mm TS4 EMERGENCYSTOP 0 ee P2 TS17 7 HIGH LOW RPM NOTE GENERATOR 1 DASHED LINES INDICATE OPTION WIRES LEE OPTION Genie Part No 102521 5 40 5 45 6 65 October 2013 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram Deutz D201 11 03 and Perkins 404 22 Models from serial number 12510 66 67 Section 6 Schematics October 2013 Electrical Schematic Ford LRG 425 EFI Models before serial number 7597 6 68 RD BK OR BK C2 3 C28TTA RD BK TB41 Section 6 Schematics
269. RM H6 o WIN BK C6 25 PLAT OVERLOAD MODULE U33 7 CR1 qu 17 045 PLAT OVERLOAD LED L45 BK ISM 1 c RD 24A RD 20B BK C5 5 RD P1 E STOP WH 21B OR C6 33 Sane OR BKABA BR GND C6 26 o OR 14A GR 17A M GR WH 19A 1 GR BK 18A 8 BK RI ROUND STUD WIRING G nn EM HARNESS TO BASE ALL BR WIRES O Genie Part No 102521 S 40 S 45 6 11 October 2013 Ground Control Box Wiring Diagram Deutz F3L 1011F Models Section 6 Schematics 12 13 Section 6 Schematics October 2013 Platform Control Box Wiring Diagram ALC 500 Deutz F3L 1011F Models Section 6 Schematics October 2013 Platform Control Box Wiring Diagram Deutz F3L 1011F Models PART NUMBER 45383 89353 COMPONENT INDEX TILT ALARM ALC 500 H1 HARNESS PBOX WIRING RD P2 RD 1 C132PLI BK C1P 12 P23SWBAT WH C7P 2 P22BAT BK C7P 1 C19JSV GR WH JIB C19JSV GR WH C4P 7 AND TS8 C18JD GR BK C4P 6 C17JU GR C4P 5 C15PLD OR BK C4P 3 C14PLU OR C4P 2 C43 HRN GR C2P 5 C8PBR BK WH C3P 8 C7PBE BK C3P 7 P26BAT BK C9P 1 BRN P25FS RD C9P 3 P24FS WH C9P 2 JDALARM GR BK C2P 6 DRIVE LT BK RD C3P 9
270. SSS See 1 ko 1 et A i 2JL Dp SS C41RPM OR BK E C52 ORIBK 41 8 a Plea cx xx a Sc r 9 222 Le aon x r j a3 Baus if EEE 18 5 5 5 8184 222 LANE E A Ts zzz la Bs s Qo 15 1 917 Bere 1 RD e Lo N co gt 70A FUSE ADDED AT SERIAL NUMBER 12978 ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH OFF gt THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION 1 WHEN OPTION IS NOT INSTALLED A JUMPER HARNESS CONNECTS PIN 4 TO PIN 5 AND PIN 6 TO PIN 7 LS18 PLATFORM OVERLOAD SWITCH gt OPTION ONLY enie G A TEREX S 40 S 45 Part No 102521 6 32 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 201 1 Deutz D201 1LO3i and Perkins 404 22 Models from serial number 12510to 14831 BL WH
271. ST B PROCEDURES B 19 Test the Drive Speed Raised or Extended Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Startthe engine from the platform controls 3 Move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol 4 Raise the boom above horizontal 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST B PROCEDURES 6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications 8 Lower the boom to the stowed position and extend the boom 1 foot 30 cm 9 Choose a point on the machine
272. SWITCH 56457 S TS15 DRIVE ENABLE SWITCH 13037 JC2 JC3 TS47 GENERATOR SWITCH OPTION 27378 1 1 548 9 WORK DRIVE LIGHT OPTION 27378 Vd 14 CR13 P r Bt 4 5 m 2 L1 14 5 DETAIL A LIFT DRIVE OPTION m u REPLACE WIRE WITH THIS WIRING DIAGRAM gm 5 D 5 2 I I 1 gt U BRN BATGND 29 ym x e m m o 2 3 GND STUD 22 29 5 5 5 2 5 9 25 6 T A I A 55 c 2 2 210 TIN I ar rn 5 N JaN N zZ o R A o ICR27 LUE Hl WH TS1 D 5 e mio v 2 2 6 9 9 2 2225 9 dr BS 8 39 6 5 Cle 2525 RE gig 3 5 3 S WH RD C32BRK gt oio gt CIR als oo o OR e gt lt SPLICE C32BRK EN o gt gt mu x I v 5 co 4g z 2 9 5 8 5 I m 0 o 2 9 S CR30 E IE Pos J H 6 5 8 N Q T N OR R40LS1 h SPLICE TO R40LS1 WH Do A i gt 05 6 6 54 WH oor 922 HIGH LOW O 000 5 220 RPN TS14 TS2 TS3 mn NOTE TS9 WH TS8 TS1 DRIVE 797 START FUEL SELECT i 7 HORN P2 DASHED LINES INDICATE PLATFORM 4 JIB AUXILIARY SPEED GENERATOR EMERGENCY STOP OPTION WIRES LEVEL HIGH LOW __ PLATFORM ROT
273. T METER md aa NS IE 5 mou E 8 52 5 C3 10 e u 5 HOUR METER E gt C28TTA RD BK Z 5 7 A START RELAY a ab i Spl C5 5 5 POT om 5 4 C27AUX RD 3T STARTER MOTOR 8 BK os zo x E EMISSION CONTROL 5 2 C627 AUXILIARY POWER E g li 2 RELAY 0 S af 88 m OE ME AUXILIARY PUMP 5 2 e a E P23BAT WH m D C28TTA 80 86 1 5 3g o 8 WH TILT ALARM C133PLA OR RD4 00 29 RD 4 LEVEL SENSOR FLASHING BEACON C43HRN GR e 5 GR BK n g SERVICE HORN B 4 9 go 2 5 94 C6 16 1 SERVICE HORN e N e e 5 97 5 C1 12 ug Po 5 4 C132PLI1 BL WH wa 8 6 5 2 i 9 922 1219540 0025 HYDRAULIC OIL o 5 P134PWR RD gt 582 E TEMP SWITCH 118 DW 8 C633 7 1 C6 26 an COOLING FAN 1 OPTION m Q 4 ae C52 C41RPM OR BK Wt C5 3 _ at 2 Fea z 5 ce B 15 3 15 i 8 5 5 58 85 85 S ISS 8 g B 4 I Nx t C ale RD N LO co N Part No 102521 3 40 5 45 6 52 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 201 1 Deutz D201 11 O3i and Perkins 404 22 Models CE from serial number 16420
274. TFORM ROTATE CW UP PLAT ROTATE 5 CCW CCW e cw PLAT ROTATE s cen C19JSV GR WH x 2 E i oi m 5 I JIB VALVES i pH Eo 5 5 i IT 5 ar si t mi 5g 2 e 5 Ll EN 5 5 fy i m c om 5 G S 40 3 45 6 109 Part No 102521 October 2013 Section 6 Schematics Electrical Schematic Ford 056 423 EFI Models ANSI CSA AS from serial number 16420 6 109 6 110 Section 6 Schematics October 2013 Electrical Schematic Ford DSG 423 EFI Models CE from serial number 16420 6 112 6 111 BL WH RD Section 6 Schematics Fo
275. TS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH OFF gt THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION G 3 40 5 45 Part No 102521 6 8 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 201 1 Deutz D201 1L03i from serial number 7544 to 12509 Perkins 404 22 Models from serial number 7472 to 12509 BL WH N N BRN 2 crounD C41RPM OR BK sc C2P 3 515 x zn g 5 lH 8 ME C29MS 8 4 C30EDC WH 5 C521 C30EDC WH DRELEDBURD 5 7 ME 5 C5 20 CS1EDC WHIBK 0 50 DRIVE EDC REVERSE amp ae ee e a jj ORE B BLIBK gt 2 TRAVEL ALARM OPTION gt DRIVE ENABLE SS SS 1 N DREABUWH gt TIe cikg C32BRK WH
276. Test the Engine Idle Select Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly operating engine idle select switch is essential to good engine performance and safe machine operation There are two settings Foot switch activated low idle turtle symbol allows the operator to control individual boom functions Foot switch activated high idle rabbit symbol should be used for normal machine operation This selection activates high idle only when the foot Switch is pressed down 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Startthe engine from the ground controls then move and hold the function enable rpm select toggle switch to the high idle rabbit symbol Result The engine should change to high idle 3 Release the function enable rpm select toggle Switch O Result The engine should return to low idle 4 Turn the key switch to platform controls 5 Move the engine idle control switch to foot Switch activated high idle rabbit and foot switch symbol O Result The engine should not change to high idle 6 Press down the foot switch Result The engine should change to high idle 7 Move the engine idle control switch to foot Switch activated low idle turtle symbol O Result The engine should change to low idle Section 3 Scheduled Maintenance Procedures October20
277. W JIB DOWN up JIB BOOM x m C17JU GR PLATFORM ROTATE CW UP io e CCW cow e PLAT ROTATE PLAT ROTATE I 71 cw cw z 5 si CISUSV GR WH 2 o R 5 5 JIB VALVES 5 0 5 5 JIB VALVE 55 zd d c aq m P134PWR RD Part No 102521 October 2013 Section 6 Schematics Electrical Schematic Deutz F3L 201 1 Deutz D201 1LOSi and Perkins 404 22 Models from serial number 14832 to 15662 38 39 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 201 1 Deutz D2011L03i and Perkins 404 22 Models ANSI CSA AS from serial number 15663to 16419 6 40 October 2013 Section 6 Schematics Electrical Schematic Deutz F3L 201 1 Deutz 20111 03 and Perkins 404 22 Models ANSI CSA AS from serial number 15663 to 16419 A B
278. X X 2900 psi 2600 psi m ce i 200 bar 179 bar i i 545 valve changed to 3 1 3300 PSI TANK 6 45 i 110 6 gpm at serial number 18302 A 3 1 3500 PSI 3 psi 3 psi 7 5 7 0 20 pel Ll 0 20 bar RETURN d 51 3500 PSI FILTER o T2 sm Terz amp 151 3000 PSI RESERVOIR AUX HYDRAULIC GENERATOR FUNCTION 71 MTE HYDRAULIC GENERATOR OPTION OPTION MANIFOLD 2 from serial number 16453 to serial number 16452 _ FUNCTION PRESS ont PUMP 2400 psi HYDRAULIC GENERATOR OPTION OPTIONAL 165 4 bar A 6 MANIFOLD gt PORT ON 2400 psi gt RELIEF VALVE SIDE OF MOTOR 1654 bar Pd SET 2700 PSI 2 pex T 9 7 1 i i i FUNCTION 0 i i i i ne a PUMP i ie fy i i RIGHT FRR FRB FLB FLR L FRONT ilia LEFT Pj STEERING BE LH i i i dic OPTIONAL SS SS eer ee HYD ROTARY COUPLER er Led CD PORTON 7 2 040 TOP OF MOTOR 7 PMP 8 ees FUNCTION TO OC OIL TT tert RIGHT MANIFOLD COOLER v IE ke gt Note alpha callouts refer to c components shown the 4 4 M2 LEFT manifold illustrations 6 A a m Refer to the Repair Section L
279. Y BOOM DOWN a Se Om am E C6 3 5 p PRIMARY BOOM 5 2 RD WH l FLOW CONTROL Qa n 8 3 9 ez CIPBU RD 7 lt C32 C2PBD RD BK EK cag RD WH 4 0619 pig DESCENT ALARM OPTION T ag S x we NIZ IZ Ls2 PRIMARY BOOM UP ELA DRIVE LIMIT SWITCH 12 2 5 1 8 2 Lst PRIMARY BOOM EXTEND GND BR gt 21 8 a DRIVE LIMIT SWITCH gt 9 T PRaFS WH 18 8912 DRIVE ENABLE d PReESTPBIC2S 9 137 041 GigpREBURD ie 6 13 crore FM Ls 2 LIMIT SWITCH 5 z 9 az 22 015108 C6 40 C40LS1 OR 8 2 d ai 9 z m C6 30 X T 2 gt 6 o x Fo oz 2 o z BQ g9 ud 8 8 2 8 t 9 dum g E e 28 pst 9 5 C67 C7PBE BK BOOM EXTEND 5 poom 8 m oeo _ gt gt 068 caper 7 Boom RETRACT 5 E E E C7PBE 8 RETRACT 800 B 5 Ss C8PBR BK WH g iz C42 __crapLuoR 2 4 pown PLATFORM LEVEL 97 C43 C15PLD ORIBK 5 8 2 LUE 155 C6 14 C14PLU OR I i PLAT LEVEL UP ig 5 PLATFORM LEVEL 2 DOWN 6 15 CiSPLDIOR BK Al PLAT LEVEL DOWN GR BK44 26 JDALARM GR BKEe N Zo 8 Eg C46 Dom C18JD GR BK 5 UP JIB C4 5 C17JU GR 2 8 C6 18 LI P toowk C18JD PLATFORM ROTATE CC
280. ach work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the Operator s Manual on your machine A 3 Perform Function Tests Genie specifications require that this procedure be performed daily Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the Operator s Manual on your machine Genie 3 8 S 40 5 A 4 Perform Engine Maintenance Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Deutz models Required maintenance procedures and additional engine information are available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 20
281. ad is still within specification shim as necessary to obtain minimum clearance with zero binding Note The minimum shim clearance for primary boom wear pads is 0 070 inch 1 8 mm and the maximum allowable shim clearance is 0 188 inch 4 8 mm Part No 102521 Genie S 40 S 45 Wear pad specifications Minimum all wear pads 9 16 inch 14 3 mm 4 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Note Always maintain squareness between the outer and inner boom tubes Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST D PROCEDURES D 2 Check the Turntable Rotation Bearing Bolts Genie specifications requires that this procedure be performed every 1000 hours or annually whichever comes first Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the primary boom and place safety chocks on the lift cylinders rods Carefully lower the boom onto the lift cylinders safety chocks AWARNING Crushing hazard Keep hands away from cylinders and all moving parts when lowering the boom Note The lift cylinder safety chock is available through Genie Genie part number 75097 2 Turn the engine off 3 Remove the engine tray retaining fasteners located under t
282. afe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and property damage AWARNING Collision hazard Select a work site that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h Non steer Wheels All Models 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of sufficient capacity 20 000 Ibs 10 000 kg under the drive chassis between the non steer tires 3 Liftthe wheels off the ground and then place jack stands under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steer wheel hub ho disengaged position _ engaged position Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST D PROCEDURES 5 Manually rotate each non steer wheel All Models Result Each non steer wheel should rotate with 13 Be sure the free wheel valve on the drive pump minimum effort is closed clockwise 6 Re engage the drive hubs by turning over Note The free wheel valve is located on the the hub disconnect caps Rotate each wheel to bottom of the drive pump check for engagement Lift the machine and remove the jack stands AWARNING Collision hazard Failure to re engage the drive hubs may cause death or serious injury and
283. alfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform Service problem repair solved Genie Part No 102521 S 40 S 45 6 1 Section 6 Schematics October 2013 Electrical Symbols Legend Quick disconnect terminal TB21 WHT 21 5 T circuits connect at terminal T circuits connect Connection no terminal Circuits crossing no connection Diode Battery CBI 15 Circuit breaker with amperage Coil solenoid or relay H1 Horn or alarm 4 Flashing beacon L3 f LED F1 BCE 25A Fuse with amperage Starting aid glow plug or flame ignitor 153 N C H O Limit switch KS1 7 7 GROUND Key switch before number 22051 PRI E Power relay 6 g Toggle switch SPDT BAJI WHOd1V 1d Toggle switch DPDT Control relay contact normally open HR Horn button normally open LE OTS2 0 Oil temperature switch normally open 2 CTS NO Coolant temperature Switch normally open OPS1 N C Oil pressure switch normally closed Gauge sending unit PULL IN Ka HOLD Fuel or RPM solenoid Coil 1 BLK Foot switch P1 T Q Emergenc
284. all safety messages that follow this symbol to avoid possible injury or death A Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Used to indicate the presence of a AWARNING potentially hazardous situation which if not avoided could result in death or serious injury Used to indicate the presence of a ACAUTION potentially hazardous situation which if not avoided may result in minor or moderate injury Used to indicate the presence of a potentially hazardous situation Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards Bl such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage 8 Be sure that all tools and working areas other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forkli
285. amp from the pivot end of the boom 8 Remove the hose cable clamp at the platform end of the cable track 9 Remove the fasteners from the large cable track guide at the platform end of the cable track Remove the guide 10 Remove the cotter pin from the clevis pin at the platform end of the cable track Remove the clevis pin Note Always replace the cotter pin with a new one when removing a clevis pin 11 Remove the fasteners from the side panel on the cable track to access the cable track mounting fasteners Part No 102521 October 2013 Section 4 Repair Procedures 12 Remove the cable track mounting fasteners then remove the cable track from the boom and lay it off to the side Component damage hazard The boom cable track can be damaged if it is twisted Component damage hazard Hoses can be damaged if they are kinked or pinched 13 Remove the turntable end cover 14 Remove the retaining fastener from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin Pull the cylinder back and secure it from moving Component damage hazard When pulling the master cylinder back be sure not to damage the master cylinder hoses or fittings 15 Remove the fasteners from the limit switch mounted to the turntable riser at the pivot end of the boom Do not disconnect the wiring 16 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNI
286. an penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the pin retaining fasteners from the rod end pivot pin Use a soft metal drift to remove the pin 5 Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder 6 Remove the pin retaining fasteners from the barrel end pivot pin Use a soft metal drift to remove the pin 7 Remove the cylinder from the machine Crushing hazard The oscillate AWARNING cylinder could become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane Part No 102521 October 2013 Section 4 Repair Procedures 10 1 Track Assembly TRAX option How to Remove a Track Assembly Note Perform this procedure on a firm level surface with the boom in the stowed position 1 Chock the tracks at the opposite end of the machine to prevent the machine from rolling 2 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the tracks 3 Liftthe machine until the tracks are off the ground and then place jack stands under the drive chassis for support 4 Remove the lug nut bolts holding each half sprocket on the drive hub Rotate the sprockets until only one sprocket is contacting the track Remove the lower half sprocket from the track assembly 5 Ro
287. and operate smoothly in low and high idle Note The engine may hesitate momentarily and then continue to run on the selected fuel if switched while running Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures B 14 Test the Ground Control Override Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the red Emergency Stop button on the platform controls is in the on or off position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Pushin the platform red Emergency Stop button to the off position 2 Startthe engine from the ground controls 3 Atthe ground controls operate each boom function through a partial cycle Result All boom functions should operate Part No 102521 Genie S 40 S 45 CHECKLIST B PROCEDURES B 15 Check the Directional Valve Linkage Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Note Perform this test only on models equipped with a oscillating axle Proper axle oscillation is essential to safe machine operation If th
288. ankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Crankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace sensor Genie S 40 3 45 Part No 102521 October2013 Section 5 Fault Codes FAULT CODES oe Camshaft position sensor wiring and or Be sure system ground connections are in place Camshaft Sensor Noise connections open or shorted OR there is a poor and secure OR repair wiring and or connections system ground connection OR sensor is faulty to sensor OR replace sensor Knock Sensor Open Knock sensor wiring and or connections open or Repair wiring and or connections to knock sensor p shorted OR sensor is faulty OR replace knock sensor Knock sensor wiring and or connections open or Check for excessive engine vibration OR repair Excessive Knock Signal shorted OR there is excessive engine vibration wiring and or connections to knock sensor OR OR sensor is faulty replace knock sensor Injector Driver 1 Open Open wiring and or connections to fuel injector 1 OR fuel injector 1 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 1 Wiring and or connections to fuel injector 1 is OR replace fue
289. art number 139320 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Genie S 40 S 45 Toaccessthe engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures CHECKLIST E PROCEDURES E 9 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 4 years Required maintenance procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 or the Ford DSG 423 EFI Operator Handbook EDI part number 1060020 orthe Ford MSG 425 EFI Operator Handbook Ford part number 1020010 Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488
290. ation during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom to a horizontal position 2 Locate the cables from the cable track to the platform control box Number each cable and its entry location at the platform control box 3 Disconnect the cables from the platform control box 4 Remove the electrical outlet box bracket mounting fasteners Remove the outlet box and lay it to the side 5 Remove the hose and cable clamp from the platform support Genie S 40 S 45 6 Tag disconnect and plug the hydraulic hoses from the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Tag disconnect and plug the hydraulic hoses from the platform leveling cylinder at the union and connect the hoses from the cylinder together using a connector AWARNING aa injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Locate all electrical cables that enter the cable track 9 Tag and disconnect the electrical connectors for all cables that enter the cable track 10 Remove the
291. ator Cap the fittings on the rotator Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray S 45 Models 3 Tag and disconnect the hydraulic hoses from the V1 and V2 ports on the counterbalance valve manifold located on the platform rotator and connect them together using a connector Cap the fittings on the manifold 4 Support the platform leveling arms and platform mounting weldment with an appropriate lifting device but do not apply any lifting pressure All Models 5 Remove the six mounting bolts from the platform mounting weldment Remove the center bolt and slide the platform mounting weldment off of the platform rotator Crushing hazard The platform AWARNING mounting weldment could become unbalanced and fall if it is not properly supported 6 Supportthe platform rotator with an appropriate lifting device Do not apply any lifting pressure Section 4 Repair Procedures October2013 PLATFORM COMPONENTS 7 Supportthe platform leveling slave cylinder Protect the cylinder rod from damage 8 Remove the pin retaining fasteners from both the slave cylinder rod end pivot pin and the rotator pivot pin 9 Use a soft metal drift to drive both pins out then remove the platform rotator from the machine Crushing hazard The platform AWARNING r
292. be indicating fault corrected Part No 102521 as Continued on next page Genie S 40 5 45 5 3 Section 5 Fault Codes October 2013 FAULT CODES Error Source Error Type Condition Solution ID Name ID Name 33 Boom 2 flow Valve is operating Cycle power off control valve 12 Value too high outside of operational then on and 15 Value too low limits Alarm sounds problem should be indicating fault corrected Normal function except threshold for Calibrate valve 17 Not calibrated one or both directions thresholds is zero 41 Turntable rotate 11 Value at 5V Joystick is operating Cycle power off joystick 12 Value too high outside of operational then on and 15 Value too low limits Alarm sounds problem should be 16 Value at OV indicating fault corrected Function is inoperative 17 Not calibrated until joystick is Calibrate joystick calibrated 42 Turntable rotate Valve is operating Cycle power off directional valves 21 Fault outside of operational then on and limits Alarm sounds problem should be indicating fault corrected 43 Turntable rotate Valve is operating Cycle power off flow control valve 12 Value too high outside of operational then on and 15 Value too low limits Alarm sounds problem should be indicating fault corrected Normal function except threshold for Calibrate valve TE Nobealibrates or both directions t
293. ber 14832 62 63 Section 6 Schematics October 2013 Platform Control Box Switch Panel Wiring Diagram Deutz F3L 201 1 Deutz 020111031 from serial number 7544 to 12509 Perkins 404 22 Models from serial number 7472 to 12509 6 64 October 2013 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram Deutz F3L 201 1 Deutz D201 1L03i from serial number 7544 to 12509 Perkins 404 22 Models from serial number 7472 to 12509 A C TS48 WORK DRIVE LITE JC2 D E 10 AMP FUSE 2t e 57 39 91 9 5 P3 GT HORN TS9 PLATFORM LEVEL TS15 DRV ENA 9 PRIMARY BOOM EXTEND RETRACT o z sad 513 Q t E 5 CR13 CD EE L1 2 o 2 gt 5 m gc c E 2 5 9 8 m om 23 gg 5 5 z Pe f 5 D Om m mI 2 o gt 0 c 0 0 0 220 BP gz 2 SED S 2 a c gt SS S o lt lt 2 x D m SD E o m 5 2 a iv gt J R o 5 E 2 3 g I 2 je fe 5 9 e
294. bi FUEL RELAY 8 7 VOLT METER x or 05 o x pm E g g 5 WH 21 S 8 Sx a Er HOUR METER aya gt Bu 1 amp E 0 2 818 5 a pl IGN START RELAY a 1 gt PUMP AUXILIARY 60 SEE x 1 C5 5 BK 33 alz S i 6 amp E zo z RD N 52 m et STARTER MOTOR 4 PUMP AUXILIARY B Ct4 C27AUX RD 2 EMISSION CONTROL RD 27 M 2 AUXILIARY POWER E RELAY 8 d m T 1 1 8 C72 P23BAT WH H 1 GY 1 AUXILIARY PUMP l 1 5 7 B s 5 3 N S RD BK 28 gcc Dp 1 gt 1 2 28 RD BK s WH m SIUPADAEM e 1 8 1BK LeveL SENSOR all 1 5 8 1 22450222222202222222222222222222222 8 aor C133PLA OR RD 2 9 1 i 4 FLASHING BEACONS INE c 4 8 A 1 E OPTION A z A 5 p 2 EI C2 5 p Bi SERVICE HORN 218 ues 5 i RELAY of BK 43 SERVICE HORN P22BAT BK C74 a d 1 5 9 1 a 8i i 1 WH O HYDRAULIC OIL t 0 1 TEMP SWITCH 1 1 1 C132PLI 1 12 Im i 1 1 1 8 l 95 RD i y IBR COOLING FAN C134PWR OR RD C24 I 1 Pel OPTION 122 4 1 1 cr a SSS
295. c No Description Item Function Torque 1 Flow divider combiner valve Controls flow to steer end drive motors in forward reverse 90 100 ft Ibs 122 136 Nm 2 Flow divider combiner valve HB Controls flow to non steer end drive motors in forward reverse 90 100 ft Ibs 122 136 Nm 3 Orifice 0 070 inch 1 778 mm Rear drive motor circuit 4 Orifice 0 070 inch 1 778 mm HD Equalizes pressure on both sides of flow divider combiner valve 7 5 Shuttle valve 3 position way Charge pressure hot oil shuttle 50 55 ft lbs 68 75 Nm 6 Diagnostic nipple HE Testing 7 Flow divider combiner valve Controls flow to flow divider combiner valves 2 ttes 90 100 ft Ibs 122 136 Nm 8 Relief valve 210 psi 14 5 bar HH Charge pressure circuit 30 35 ft lbs 41 47 Nm 9 Orifice 0 052 inch 1 32 mm HI Front drive motor circuit Genio 4 46 S 40 5 45 Part No 102521 October 2013 Section 4 Repair Procedures mnmmmmm MANIFOLDS HF Genie Part No 102521 S 40 S 45 4 47 Section 4 Repair Procedures Octobe
296. c oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Be sure that the hydraulic oil level is within the top 2 inches 5 cm of the sight gauge Note Perform this procedure with the machine on a firm level surface 1 2 3 4 Disconnect all electrical tools from the machine Start the engine from the platform controls Press the generator select switch Connect an electrical tool which does not draw more than 15 to the electrical outlet at the platform controls and run the tool at full speed Connect the positive and negative leads from a multimeter of sufficient capacity to the electrical Part No 102521 Genie Generators outlet at the generator Result The reading on the multimeter should be 112 to 118V AC Result If the reading on the multimeter is not 112 to 118V AC proceed to step 6 Turn the key switch to the off position Use a wrench to hold the generator flow regulator valve item AM and remove the cap a flow regulator Adjust the internal hex socket Turn it clockwise to increase the AC voltage or counterclockwise to decrease the AC voltage Install the flow regulator valve cap Component dama
297. can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches andother jewelry Note If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tagand disconnect the wiring from the coil to be tested 2 Testthe coil resistance using a multimeter set to resistance Q Refer to the Valve Coil Resistance Specification table W Result If the resistance is not within the adjusted specification plus or minus 1096 replace the coil Part No 102521 Genie 5 40 5 45 MANIFOLDS Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 10 C that your air temperature increases or decreases from 68 F 20 C Description Specification Solenoid valve 2 position 3 way 10V DC 6 3 Q schematic it
298. cated at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Part No 102521 Genie S 40 S 45 CHECKLIST E PROCEDURES E 6 Perform Engine Maintenance Deutz and Perkins Models Engine specifications require that this procedure be performed every 5000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0312 3547 Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 139320 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Section Scheduled Maintenanc
299. charge ESD can damage printed circuit board components If the circuit board does need to be handled maintain firm contact with a metal part of the machine that is grounded at all times when handling the printed circuit board OR use a grounded wrist strap Genie 5 2 S 40 S 45 3 Determine the error source The red LED indicates the error source and will flash two separate codes The first code will indicate the first digit of the two digit code flashing once per second It will then pause for 1 5 seconds and flash the second digit once per 0 5 second Note When the red LED is flashing the code the yellow LED will be on solid 4 Determine the error type The yellow LED indidates the error type and will flash two separate codes The first code will indicate the first digit of the two digit code flashing once per second It will then pause for 1 5 seconds and flash the second digit once per 0 5 second Note When the yellow LED is flashing the code the red LED will be on solid 5 Use the fault code table on the following pages to aid in troubleshooting the machine by pinpointing the area or component affected Part No 102521 October2013 Section 5 Fault Codes FAULT CODES Error Source Error Type Condition Solution ID Name ID Name 21 Boom 1 Joystick 11 Value at 5V Function is inoperative Cycle power off pri
300. cheduled Maintenance Procedures continued E 6 Perform Engine Maintenance Deutz and Perkins Models 3 55 E 7 Perform Engine Maintenance Deutz 3 56 E 8 Perform Engine Maintenance Deutz 3 56 E 9 Perform Engine Maintenance Ford Models 3 57 Section4 Rev RepairProcedures NTPOCU CHO tete len HET eet 4 1 Platform Controls 1 1 ALC 500 Circuit Board nnns 4 2 1 2 Joysticks een ea 4 3 Platform Components 2 1 Platform Leveling Slave 2 2 24440 00 4 8 2 2 Platform Rotator ee en ee eee m ens 4 9 2 3 Platform Overload System sssssssssssseeeneeeenneeennnne nnns 4 11 Jib Boom Components 1 JID BOOM Mis 2 AAG RE PERLE I ER E ER ERR IU Aas 4 14 3 2 Jib Boom Lift nennen enn nnne 4 15 Boom Components 24 Cable Track Be Ha ein 4 16 4 22 BOOM isotopes ERE 4 18 4 3 Boom Lift Cylinder nennen tnnt nnns 4 19 4 4 Boom Extension Cylinder 4 00 4 20 4 5 Platform Leveling Master 2 4 21 Engines 5 1 RPM Adjustment Deutz Models 4 24 5 2 RPM Adjustment Perkins
301. ck 11 Value at 5V Joystick is operating Cycle power off 12 Value too high outside of operational then on and 15 Value too low limits Alarm sounds problem should be 16 Value at OV indicating fault corrected Function is inoperative 17 Notcalibrated until joystick is Calibrate Joystick calibrated 62 Steer directional Valve is operating Cycle power off valves 21 Fault outside of operational then on and limits Alarm sounds problem should be indicating fault corrected Genie Part No 102521 S 40 5 45 5 5 Section 5 Fault Codes October2013 FAULT CODES Ford LRG 425 EFI Engine How to Retrieve Ford Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light Note Perform this procedure with the key switch in the off position 1 Openthe ground controls side cover and locate the run test toggle switch on the side of the ground control box 2 Pull out the red Emerg
302. ck Tension and Fastener Torque TRAX option Note Manufacturer specifications require that this procedure be performed every 250 hours or quarterly Maintaining proper track tension and properly torqued fasteners is essential to good machine performance and service life The machine will not operate properly with a track that is incorrectly tensioned Continued use of a machine with incorrectly tensioned tracks may cause component damage 1 Thoroughly clean the track assembly of any dirt rocks clay etc 2 Chockthe tracks at one end of the machine to prevent the machine from rolling 3 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the tracks at the other end of the machine 4 Liftthe machine until the tracks are off the ground and then place jack stands under the drive chassis for support Part No 102521 Genie S 40 S 45 CHECKLIST B PROCEDURES 5 Visually inspect the section of track under the bogey wheels O Result There should be between 0 75 1 inch 1 9 2 5 cm of gap between the bogey wheels and the inside surface of the track Proceed to step 7 Result There is 1 inch 2 5 cm or more of gap between the bogey wheels and the inside surface of the track Proceed to step 6 half sprocket idler wheel tensioner bogey wheel assembly Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST B PROCEDURES 6 Loosen the
303. connect the negative battery cable from the battery for a minimum of 5 minutes AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Connect the negative battery cable to the battery Part No 102521 October2013 Section 5 Fault Codes Code Closed Loop Multiplier High LPG HO2S Open Inactive Bank 1 HO2S Open Inactive Bank 2 Post cat oxygen sensor open Closed Loop Multiplier High Gasoline Closed Loop Multiplier Low Gasoline Closed Loop Multiplier Low LPG Gasoline cat monitor LPG cat monitor NG cat monitor Adaptive Lean Fault High Limit Gasoline Adaptive Rich Fault Low Limit Gasoline Adaptive Learn High LPG Adaptive Learn Low LPG Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty The post cat Heated Oxygen Sensor wiring and or connections are open or shorted OR sensor is cold non responsive or inactive for 60 seconds or longer Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel pressure is low OR the fuel injectors nee
304. cription Item Function Torque 1 Solenoid valve 2 position 3 way DA Brake release 20 25 ft lbs 27 34 Nm 2 Orifice 0 025 inch 0 635 mm Turntable rotation brake release Genie 4 38 5 40 5 45 PartNo 102521 October 2013 Section 4 Repair Procedures 1 7 5 MANIFOLDS Brake Two Speed Manifold Components after serial number 7568 Index No A OU N Schematic Description Item Function Torque Orifice 0 025 inch 0 63 mm EA Turntable rotation brake release Solenoid valve 2 position way EB Brake release 20 25 ft lbs 27 34 Nm Solenoid valve 2 position way EC Two speed motor shift 20 25 ft lbs 27 34 Nm Check 5 Brake release circuit 20 25 ft lbs 27 34 Nm EA EB EC Genie Part No 102521 5 40 5 45 4 39 Section 4 Repair Procedures October 2013 mnmmm MANIFOLDS 7 6 Oscillate Directional Valve Components The oscillate directional valve is mounted inside the drive chassis at the non steer end Index No Description Function Torque 1 er Breather 2 2 20 25 ft lbs 27 33 Nm 2 Spool valve sse Directi
305. d perform each repair procedure with the machine in the following 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 All external AC power supply disconnected from the machine Part No 102521 Genie S 40 S 45 4 1 Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed To re assemble perform the disassembly steps in reverse order Symbols Legend A Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION With safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause min
306. d OR sensor is faulty OR engine intake air temperature is too cold IAT sensor wiring and or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too hot Air intake temperature is greater than 200 F with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty Air intake temperature is greater than 210 F with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty Faulty oil pressure sensor OR sensor wiring and or connections open or shorted OR engine oil level too low Engine cooling system is malfunctioning OR sensor wires and or connections open or shorted OR sensor is faulty Engine cooling system is malfunctioning and overheating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant level is low Coolant temperature at the cylinder head is 240 F Engine cooling system is malfunctioning and overheating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant level is low Coolant temperature at the cylinder head is 250 F Engine cooling system is malfunctioning and overheating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant level is low System Voltage Low Battery is faulty OR alternator is not charging OR Replace battery OR repair alternator OR repair y 9 battery supply wiring to ECM is open o
307. d cleaning or replacing MAP IAT or ECT sensors not in correct position OR wiring and or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck open OR there is electro magnetic interference from a faulty crankshaft and or camshaft position sensor Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR fuel quality is poor OR fuel system components may be faulty There are exhaust leaks OR the catalyst system efficiency is below the acceptable level Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum or exhaust leaks OR one or more fuel injectors faulty or stuck closed OR fuel quality is poor OR fuel pressure is too low MAP IAT or ECT sensors not in correct position OR wiring and or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck closed OR there is electro magnetic interference from a faulty crankshaft and or camshaft position sensor Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel quality is poor OR fuel system components may be faulty Engine wire harness may have an intermittent short to 5V DC or 12V DC OR fuel system components may be faulty Genie PartNo 102521 FAULT CODES Repair wiring and or connections OR replace senso
308. d controls 19 Inspect the filter housings and related components to be sure that there are no leaks Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST D PROCEDURES D 7 Inspect for Turntable Bearing Wear Genie specifications requires that this procedure be performed every 1000 hours or annually whichever comes first Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Note Perform this procedure with the machine on a firm level surface and the boom in the stowed position 3 Start the machine from the ground controls and raise the boom to full height Do not extend the boom 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing Note To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from the turntable rotation bearing Genie S 40 S 45 turntable dial indicator drive chassis turntable rotation bearing ao oo 5 At the dial indicator adjust it to zero the indicator 6 Fully extend the boom and lower to a horizontal pos
309. d if the lift cylinder is pulled across them 9 Using auxiliary power activate the boom down Support and secure both ends of the boom lift cylinder to a second overhead crane or similar lifting device Part No 102521 function so the cylinder will retract Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the boom Turn the machine off Genie 5 40 5 45 Section 4 Repair Procedures October2013 BOOM COMPONENTS 4 4 Extension Cylinder The extension cylinder extends and retracts the boom extension tube The extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Extension Cylinder This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could cause death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Extend the boom until the extension cylinder rod end pivot pins are accessible in the extension tube 2 Remove the master cylinder See 4 5 How to Remove the Master Cylinder 3 Raise the boom to a
310. dbook Genie part number 215322 Toaccessthe engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures Checklist C Procedures C 1 Perform Engine Maintenance Deutz and Perkins Models Engine specifications require that this procedure be performed every 500 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Deutz models Required maintenance procedures and additional engine information are available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0312 3547 Deutz 1011F Operation Manual Perkins models Required maintenance procedures and additional engine information are available in the Perkins 404 22 Operation Manual Perkins part number 14435 Perkins 404 22 Operation Manual Genie part number 94890 To access the engine Remove t
311. diesel fuel strainer is essential for good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Explosion and fire hazard Engine fuels are combustible 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 Note Perform this procedure with the engine off 1 Put on protective clothing and eye wear 2 Locate the inline strainer above the throttle actuator solenoid 4 Place a suitable container under the filter Loosen the clamp holding the strainer to the engine mount Loosen the clamps securing the fuel lines to the strainer Remove and replace Genie S 40 S 45 C 6 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 800 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 OR the Ford DSG 423 EFI Operator Handbook EDI part number 1060020 orthe Ford MSG 425 EFI Operator Handbook Ford part
312. e 4 Supportthe muffler and bracket assembly with an overhead crane or other suitable lifting device 5 Remove the muffler bracket mounting fasteners Carefully remove the muffler and bracket assembly from the engine 6 Supportthe engine with a suitable lifting device Do not lift it 7 Removethe engine plate to vibration isolator fasteners 8 Remove the engine mounting plate to bell housing fasteners 9 Raise the engine slightly to take the weight off of the engine mounting plate 10 Slide the engine mounting plate towards the pump as far as it will go 11 Support the drive pump assembly with an appropriate lifting device Part No 102521 Genie 5 40 5 45 ENGINES 12 Remove all of the engine bell housing fasteners 13 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 14 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Ford DSG 423 EFI models 1 Disconnect the electrical connectors from both oxygen sensors at the tailpipe and exhaust manifold Do not remove the oxygen sensors 2 Remove the exhaust pipe fasteners at the muffler 3 Support the muffler and bracket assembly with a suitable lifting device 4 Remove the muffler bracket mounting fasteners from the bell housing Carefully remove the muffler and bracket assembly from the engine
313. e G S 40 S 45 6 68 Section 6 Schematics Electrical Schematic Ford LRG 425 EFI Models before serial number 7597 October 2013 N e st N co BRN 2 GROUND C41RPM OR BK 215 F ig 1 4 C30EDC WH 5 21 COE DG WH SP B DRIVE EDC FORWARD u 6 5 NS ADRE LED BURD ig Hec CTP 5 C31EDC WHBK w 05 20 C31EDC WHBKD 5 DRIVE EDC REVERSE gt ee ce zc 9 2 DREBBUBK ar gt C632 I TRAVEL ALARM OPTION e WM o Moo Se a a i e B C1P 6 BRK WH RD E quae WH RD 4 ores 1 1 BRAKE RELEASE VALVE m E Le 20 7 62 WH 5 85 BL 4 C37STCC BUBK Bi 5 4 5 EX 11 0375100 BL BK C6 37 A STEER RIG
314. e Procedures October2013 CHECKLIST E PROCEDURES E 7 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 6000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0312 3547 Deutz 1011F Operation Manual E 8 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 12 000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0312 3547 Deutz 1011F Operation Manual Genie part number 52883 Genie part number 52883 Deutz 2011 Operation Manual Deutz 2011 Operation Manual Genie part number 139320 Genie p
315. e Service Department 31 Turn off the multimeter and remove the leads from the machine Securely connect the wires disconnected in step 27 32 Close the platform control box Install and securely tighten the fasteners Do not overtighten Part No 102521 Genie S 40 S 45 CHECKLIST C PROCEDURES C 4 Replace the Engine Air Filter Element Deutz and Perkins Models Genie specifications requires that this procedure be performed every 500 hours or 6 months whichever comes first Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage 1 Open the evacuator valve located on the air cleaner cap by squeezing the sides together with your fingers 2 Disconnect the latches on the air cleaner cap Remove the end cap from the air cleaner canister Remove the filter element 4 Clean the inside of the canister and the gasket with a damp cloth 5 Install the new filter element 6 Install the end cap on the canister and re connect the latches Note Be sure the evacuator valve is pointing down Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST C PROCEDURES C 5 Replace the In line Fuel Strainer Deutz Models Engine specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Replacing the
316. e directional valve linkage is not operating correctly the stability of the machine is compromised and it may tip over 1 Remove the drive chassis cover and the axle covers from the non steer end of the drive chassis 2 Locate the directional valve inside of the non steer axle and inspect the linkage for the following e Lock nut is tight against yoke Yoke clevis pins are installed Cotter pins are installed through clevis pins Linkage is properly attached to directional valve Section Scheduled Maintenance Procedures October2013 CHECKLIST B PROCEDURES B 16 Test the Platform Self leveling Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Automatic platform self leveling throughout the full cycle of primary boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located at the base of the boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Start the engine from the ground controls and lower the boom to the stowed position 2 Hold the function enable toggle switch to either side and adjust the platform to a level position using the platform level toggle switch 3 Raise and lower the primary boom through a full
317. e engine harness wiring and connections are in place and secure OR repair wiring and or connections to one or both TPS sensors OR replace one or both TPS sensors Repair wiring and or connections to governor actuator OR replace the governor actuator Repair wiring and or connections in engine harness OR replace the ECM Genie S 40 5 45 Part No 102521 October 2013 Section 5 Fault Codes FAULT CODES Ge S9 8 Max Governor Speed Override ECM needs to be re programmed OR throttle is 552 FPP1 Low Voltage sticking open OR there are air leaks between the throttle body and cylinder head 553 FPP1 Higher than IVS Limit 611 COP Failure 612 Invalid Interrupt 613 aois O Loose wire connections to ECM OR ECM is faulty 614 RTI 1 Loss 615 Flash Checksum Invalid 616 RAM Failure External 5V DC Ref Lower than Expected Engine harness wiring and or connections open or shorted to ground OR there is a faulty engine External 5V DC Ref sensor OR ECM is faulty Higher than Expected 655 RTI2 Loss Loose wire connections to ECM OR ECM is faulty 656 RTI3 Loss Genie Re program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM Locate and repair any engine harness wiring damage or shorts OR locate and
318. ections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty Governor actuator is stuck closed OR wiring and or connections open or shorted OR governor actuator is faulty Governor actuator is stuck open OR wiring and or connections open or shorted OR governor actuator is faulty Engine harness wiring and or connections open or shorted OR there is a poor system ground connection OR ECM is faulty MegaJector Internal The MegaJector detects an internal fault Open or Actuator Fault Detection short in power ground or CAN circuits The MegaJector detects an internal circuitry failure Open or short in power ground or CAN circuits Check Power Ground and CAN circuits at Megavector and all connections and repair as necessary OR MegaJector has an internal fault Contact Ford Power Products for assistance Repair wiring and or connections to ignition coil 1 OR replace ignition coil 1 Repair wiring and or connections to ignition coil 42 OR replace ignition coil 2 If this fault appears on your machine contact the Genie Industries Service Department Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 1 Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 2 Be sur
319. ed Record the time it takes for that function to complete a full cycle ie boom up 10 Compare the machine function time with the function times listed in Section 2 Specifications Determine whether the function time needs to increase or decrease 11 While the joystick is activated adjust the max out setting to achieve the proper function cycle time Momentarily move the drive enable toggle switch in the right direction to increase the function speed or momentarily move the drive enable toggle switch in the left direction to decrease the function speed Note Each time the drive enable toggle switch is momentarily moved the function speed will change in 296 increments 12 Repeat steps 9 through 11 for each joystick controlled machine function Part No 102521 October 2013 Section 4 Repair Procedures 13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved O Result The alarm should sound indicating that the settings have been saved in memory W Result The alarm does not sound minimum or maximum adjustment has been obtained No changes can be saved Note Do not operate any machine function during the 10 second waiting time 14 Cycle the red Emergency Stop button off then back on How to Adjust the Joystick Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum
320. ed and fall when it is removed from the machine if it is not properly attached to the overhead crane Genie 4 14 5 40 5 45 PartNo 102521 October 2013 Section 4 Repair Procedures 3 2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Then lower the jib boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin Part No 102521 Genie 5 40 5 45 JIB BOOM COMPONENTS 5 45 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out Then lower one of the leveling arms
321. ems AC and AE Solenoid valve 3 position 4 way 10V DC 6 3 Q schematic item AT and AZ Solenoid valve 2 position 3 way 10V DC 6 3 Q schematic items AU AV AX and AY Solenoid valve 3 position 4 way 10V DC 6 3 Q schematic items AZ and BF Proportional solenoid valve 12V DC 90 schematic items AW Solenoid valve 2 position 3 way 10V DC 6 8 Q schematic item CC Solenoid valve 2 position 3 way 10V DC 330 schematic items DA Solenoid valve 2 position 3 way 12V DC 480 schematic items Section 4 Repair Procedures October 2013 MANIFOLDS How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its directional valve coils except proportional valves and those coils with a metal case Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Test the coil for resistance See How to Test a Coil 2 Connecta 10Q resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on
322. ency Stop button to the on position at both the ground and platform controls 3 Quickly activate and release the start toggle switch button Do not start the engine 4 Move and hold the run test toggle switch to the test position O Result The check engine light should turn on The check engine light should begin to blink 5 Continue to hold the run test toggle switch in the test position and count the blinks Note Before the fault codes are displayed the check engine light will blink a code 123 three times After the fault codes the check engine light will blink a code 123 three times again indicating the end of the stored codes Genie 5 6 S 40 S 45 Note If any fault codes are present the ECM will blink a three digit code three times for each code stored in memory It will blink the first digit of a three digit code pause blink the second digit pause and then blink the third digit For example the check engine light blinks 5 consecutive times blinks 3 times and then 1 time That would indicate code 531 Note Once a fault code has been retrieved and the repair has been completed the ECM memory must be reset to clear the fault code from the ECM See How to Clear Engine Fault Codes from the ECM How to Clear Engine Fault Codes from the ECM Note Perform this procedure with the engine off and the key switch in the off position 1 Open the engine side turntable cover and locate the battery 2 Dis
323. fect technology for proportional control If a joystick is disconnected or replaced it must be calibrated before that particular machine function will operate Note The joystick must be calibrated before the threshold max out or ramping can be set Note Perform this procedure with the engine off 1 Openthe platform control box Part No 102521 Genie S 40 S 45 4 3 PLATFORM CONTROLS 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Turn the key switch to platform control Do not start the engine 4 Select a joystick to calibrate 5 Disconnectthe wire harness connector from the joystick for approximately 10 seconds or until the alarm sounds Connect the wire harness connector to the joystick 6 Move the joystick full stroke in either direction and hold for 5 seconds 7 Return the joystick to the neutral position pause for a moment then move the joystick full stroke in the opposite direction Hold for 5 seconds O Result The alarm should sound indicating successful joystick calibration Result The alarm does not sound Check the electrical connections or replace the joystick 8 Repeatthis procedure for each joystick controlled machine function including the thumb rocker steer switch Note No machine fuction should operate while performing the joystick calibration procedure Section 4 Repair Procedures October2013 PLATFORM CONTROLS
324. ff valves Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Models without hydraulic tank shut off valves Component damage hazard Be sure to fill the hydraulic tank to specification and prime the pump after installing the pump How to Prime the Pump 1 Connecta 0 to 600 psi 0 to 50 bar pressure gauge to the test port on the drive pump 2 Remove the safety pin if equipped from the engine pivot plate latch Note The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine Part No 102521 Genie HYDRAULIC PUMPS Ford models Close the valve on the LPG tank then disconnect the hose from the tank Move the fuel select switch to the LPG position Perkins models Disconnect the engine wiring harness from the fuel solenoid at the injector pump Deutz models Hold the manual fuel shutoff valve clockwise to the closed position c 247 wee TNT ie Rr 8 manual fuel shutoff valve Have another person crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 320 psi 22 bar Ford models Connect the LPG hose to the LPG tank and open the valve on the
325. fore serial number 4546 Motorcraft AWSF 52 C Spark plug type after serial number 4545 Motorcraft AGSF 32 FM Spark plug gap 0 042 to 0 046 inches Oil pressure 40 to 60 psi operating temp 2000 rpm 2 75 to 4 1 bar 1 07 to 1 17 mm Oil capacity 4 5 quarts Spark plug torque 5 10 ft lbs including filter 4 3 liters 7 14 Nm Oil viscosity requirements Engine coolant Unit ships with 5W 30 oil Capacity 11 5 quarts Extreme operating temperatures may require the use of 10 9 liters alternative engine oils For oil requirements refer to the Coolant temperature switch engine Operator s Manual on your machine PUT Torque 8 18 ft Ibs Cil pressure switch specifications 11 24 Nm Torque 8 18 ft Ibs Temperature switch point 230 F 11 24 Nm 112 C Oil pressure switch point 3 5 psi Alternator 0 21 0 34 bar Genie 2 6 S 40 S 45 Part No 102521 October 2013 Ford DSG 423 EFI Engine Displacement 140 4 cu in 2 3 liters Number of cylinders 4 3 44 x 3 7 inches 87 5 x 94 mm Bore amp stroke Horsepower Continuous horsepower Peak horsepower Continuous horsepower Peak horsepower 59 2500 rpm 69 Q 2500 rpm 44 kW 6 2500 rpm 51 kW 6 2500 rpm Firing order 1 3 4 2 Low function idle computer controlled 1600 rpm Frequency 53 3 Hz High function idle computer controlled 2500 rpm Frequency 83 3 Hz Compression ratio 9 7 1 Compression pressure approx Pressure psi or bar of lowest
326. ft overhead crane or Be sure ries fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time which if not avoided may result in Be sure to properly dispose of old oil or property damage 2 other fluids Use an approved container Please be environmentally safe Be sure that your workshop or work area 5 1 is properly ventilated and well lit Genie A TEREX S 40 5 45 Part No 102521 October 2013 Introduction Section 1 Section 2 Rev Section 3 Rev Table of Contents Important Information ete Deep Ri E LE ni D EUR ne 0 eak aaae ae aaa ea eie iadaa aaas iv Safety Rules General Safety 400 0 00 Specifications Machine 2 1 Hydraulic Oil Specifications 444220 0 00 2 2 Manifold Component Specifications sssssseseeeeeeeeeeenenne 2 5 Valve Coil Resistance 2 5 Ford LRG 425 EFI Engine 2 6 Ford DSG 423 EFI Engine Specifications 2 7 Deutz F3L 1011F Engine Specifications
327. functions utilizing APU power shouldfunction 12 Using a suitable lifting device lift the test weight off the platform floor O Result The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound Note There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Start the engine from the ground controls 14 Test all machine functions from the ground controls O Result All ground control functions should operate normally 15 Turn the key switch to platform control 16 Test all machine functions from the platform controls Result All platform control functions should operate normally Genio Part No 102521 S 40 8 45 4 18 Section 4 Repair Procedures October2013 Jib Boom Components S 45 3 1 Jib Boom How to Remove the Jib Boom Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Removethe platform 2 Remove the platform mounting weldment and the platform rotator See 2 2 How to Remove the Platform Rotator 3 From the ground controls raise the jib boom to a horizontal position 4 Supportthe jib boom with a strap from an overhead crane 5
328. ge Repeat the procedure beginning with step 2 Genie 4 62 S 40 5 45 Part No 102521 October2013 Section 5 Fault Codes Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boom in stowed position Turntable rotated with the boom between the non steer wheels Turntable secured with the turntable rotation lock Key switch in the off position with the key removed Wheels chocked All external AC power disconnected from the machine Part No 102521 Genie S 40 S 45 5 1 Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie S 40 and S 45 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate fault code thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic compone
329. ge hazard Failure to adjust the generator as instructed may result in damage to the generator or other electrical equipment Do not adjust the generator to other than specified Repeat steps 2 through 5 to confirm the generator AC voltage 3 40 5 45 Section 4 Repair Procedures October 2013 GENERATORS How to Purge the Hydraulic Line on the MTE Generator AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note This procedure should be performed if the hydaulic line to the generator has been removed Note Perform this procedure with the machine on a firm level surface 1 Locate the blue purge wire with the male spade connector from the MTE generator harness 2 Connecta jumper wire of sufficient length from the positive battery terminal to the spade connector on the purge wire 3 Startthe engine and turn on the generator Allow the generator to run for three minutes 4 Turn off the generator and turn off the engine Remove the jumper wire from the positive battery terminal and disconnect from the purge wire 6 Startthe engine and turn on the generator Using a digital multimeter check the voltage at the outlet Result The generator produces a voltage 10 of rated output The generator is ready for use W Result The generator output voltage is outside the 10 voltage ran
330. he O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the turntable end cover to access the master cylinder 2 Raise the boom until the master cylinder rod end pivot pin is accessible Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 102521 Genie 5 40 5 45 4 23 COMPONENTS 4 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder 5 Remove the pin retaining fasteners from the master cylinder barrel end pivot pin 6 Place a rod through the barrel end pivot pin and twist 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 master AWARNING cylinder could become unbalanced and fall if it is not properly attached to the overhead crane Section 4 Repair Procedures October 2013 Engines 5 1 RPM Adjustment Deutz Models Refer to Maintenance Procedure B 11 Check and Adjust the Engine RPM 5 2 R
331. he engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Bolt torque sequence Be sure that each turntable mounting bolt is torqued in sequence to specifications Refer to Section 2 Specifications Start the engine form the ground controls Raise the secondary boom and remove the safety chock Lower the boom to the stowed position Remove drive chassis covers from both the steer end and the non steer end of the machine Genie 3 42 S 40 S 45 Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures 9 Checkto ensure that each lower bearing mounting bolt under the drive chassis is torqued in sequence to specifications Refer to Section 2 Specifications 10 15 Bolt torque sequence 10 Swing the engine back to its original position and install the engine pivot plate retaining fasteners AWARNING Crushing hazard Failure to install the fasteners into the engine tray to secure it from moving could result in death or serious injury Part No 102521 Genie S 40 S 45 CHECKLIST D PROCEDURES D 3 Check the Free wheel Configuration Genie specifications requires that this procedure be performed every 1000 hours or annually whichever comes first Proper use of the free wheel configuration is essential to s
332. he engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Genie part number 52883 Deutz 2011 Operation Manual Genie part number 139320 Genie Part No 102521 5 40 5 45 3 35 Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST C PROCEDURES C 2 Grease the Platform Overload Mechanism if equipped Genie specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting using a multi purpose grease Grease type Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Genie S 40 S 45 C 3 Test the Platform Overload System if equipped Genie specifications require that this procedure be
333. he relief valve cap Tip over hazard Do not adjust AWARNING the relief valve higher than specified 7 Repeat steps 2 through 5 and recheck relief valve pressure 8 Remove the pressure gauge Genie 4 36 S 40 S 45 Part No 102521 October 2013 Section 4 Repair Procedures 1 MANIFOLDS 7 3 Jib Select Platform Rotate and Generator Manifold Components Index Schematic No Description Item Function Torque 1 Counterbalance valve ums Platform rotate right 30 35 ft lbs 41 47 Nm 2 Counterbalance valve CB Platform rotate left 30 35 ft lbs 41 47 Nm 3 Relief valve 2 CD Generator overload relief 30 35 ft lbs 41 47 Nm 4 Solenoid valve Controls generator on off 50 55 ft lbs 68 75 Nm 5 Solenoid valve 2 position 3 way CC Platform rotate jib boom select 18 20 ft lbs 25 27 Nm O Jib Select Manifold An oO C Platform Rotate Manifold Generator Manifold 28 5 Genie Part No 102521 5 40 5 45 4 37 Section 4 Repair Procedures October 2013 mnmmmm T MANIFOLDS 7 4 Brake Manifold Components before serial number 7569 Index Schematic No Des
334. hi 2 Ale MANIFOLD SS E ee E m 746 oem m HYDRAULIC ROTARY COUPLER 1 4 He tae Balder A a at ce 5 x DEREN 1 ae 6 8A 8B 8C 6B 6C 6A 3 1 12A 2c 2B 7 4 5 1 4 1 2 771 1 REAR M7 _ i TE Hd OPTIONAL FRR FRB FLB GENERATOR TO HYD ROTARY COUPLER 01004 lt 7 msl ve Se RIGHT LEFT me STEERING 14 5 0 zu 67 33 X MA 5 H 070 X x i 2 B joe eE 1 M8 1 psi 8 RIGHT FRONT c 65 5 en zb EFT pes T 1 ma i gt Note alpha y alpha callouts refer to OSCILLATE VALVE A components shown in the M6 manifold illustrations 252 A Refer to the Repair Section TRACTION MANIFOLD E E cn OSCILLATE CYLINDER Genie 6 146 S 40 S 45 Part No 102521 BRAKE MANIFOLD October 2013 Section 6 Schematics 4WD Oscillating Hydraulic Schematic S 45 Models before serial number 7569
335. hine Note When the engine is shut off in an overloaded condition it will not be possible to re start the engine until the overloaded condition is corrected Part No 102521 Genie 5 40 5 45 PLATFORM COMPONENTS How to Calibrate the Platform Overload System if equipped Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine and level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from the platform Note Failure to remove all weight tools and accessories from the platform will result in an incorrect calibration 4 Using a suitable lifting device place a test weight equal to the maximum platform capacity at the center of the platform floor Section 4 Repair Procedures October2013 PLATFORM COMPONENTS 5 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle O Result The overload indicator lights are off and the alarm does not sound Proceed to step 6 Result The overload indicat
336. horizontal position Genie S 40 S 45 4 Remove the external snap rings from the extension cylinder rod end pins at the platform end Use a soft metal drift to remove the pins 5 Removethe turntable end cover 6 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the barrel end pivot pin retaining fasteners 8 Place a rod through the barrel end pivot pin and twist to remove the pin 9 Support and slide the extension cylinder out of the pivot end of the boom Crushing hazard The extension AWARNING cylinder will fall when it is removed from the extension boom if it is not properly supported Note Note the length of the cylinder after removal The cylinder must be at the same length for installation Part No 102521 October 2013 Section 4 Repair Procedures 4 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It is part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion The master cylinder is located at the base of the boom How to Remove the Platform Leveling Master Cylinder Note When removing a hose assembly or fitting t
337. hresholds is zero 44 Drive enable Drive enable function Cycle power off toggle switch 24 Fault is inoperative then on and problem should be corrected Genie S 40 S 45 Part No 102521 October2013 Section 5 Fault Codes FAULT CODES Error Source Error Type Condition Solution ID Name ID Name 51 Drive joystick 11 Value at 5V Joystick is operating Cycle power off 12 Value too high outside of operational then on and 15 Value too low limits Alarm sounds problem should be 16 Value at OV indicating fault corrected Function is inoperative 17 Notcalibrated until joystick is Calibrate joystick calibrated 53 Drive flow valve Valve is operating Cycle power off EDC 12 Value too high outside of operational then on and 15 Value too low limits Alarm sounds problem should be indicating fault corrected Normal function except threshold for Calibrate valve 17 Notcalibrated one or both directions thresholds is zero 54 Drive brake valve Valve is operating Cycle power off 24 Fault outside of operational then on and limits Alarm sounds problem should be indicating fault corrected 55 High speed drive Motor speed frozen in Cycle power off motor Valve 24 Fault the low state Alarm then on and sounds indicating problem should be fault corrected 61 Steer joysti
338. il may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note Perform this procedure with the boom in the stowed position 1 Ford models Turn the valve on the LPG tank clockwise to the off position if equipped Then slowly disconnect the hose from the LPG tank 2 Ford models Open the clamps from the LPG tank straps and remove the LPG tank from the machine if equipped Genie S 40 S 45 3 Models with hydraulic tank shut off valves Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable Close the valves open closed Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition 4 Remove the drain plug and completely drain the tank into a suitable container Refer to Section 2 Specifications 5 Tag disconnect and plug the two suction hoses and supply hose for the auxiliary pump from the hydraulic tank Cap the fittings on the tank Note The hoses can be accessed through the access hole under the turntable 6 Disconnect and plug the return filter hydraulic
339. is procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 6 Remove the pin retaining fastener from the boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Lower the lift cylinder onto the blocks Protect the cylinder rod from damage Crushing hazard The lift cylinder AWARNING could become unbalanced and fall if itis not properly supported 7 Remove the four mounting fasteners from the lift cylinder barrel end pivot pin mounting plate Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 8 With the lift cylinder being supported by the overhead crane pull the cylinder toward the platform to remove it from the machine Crushing hazard The lift cylinder AWARNING could become unbalanced and fall 1 Raise the boom to a horizontal position if it is not properly supported 2 Place support blocks across the turntable under the boom lift cylinder 3 Attach a 5 ton 5000 kg overhead crane to the boom at the platform end for support Do not lift the boom Component damage hazard The cables and hydraulic hoses can be damage
340. ither side to set the threshold Result The alarm should sound indicating a successful calibration 12 Repeat steps 9 through 11 for each boom joystick controlled machine function up down boom extend retract and turntable rotate 13 Return the joystick to the neutral position and wait for approximately 10 seconds Result The alarm should sound indicating that the settings have been saved in memory Note Do not operate any machine function during the 10 second waiting time 14 Cycle the red Emergency Stop button off then back on Section 4 Repair Procedures October2013 Platform Components 2 1 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of boom motion It operates in a closed circuit hydraulic loop with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling Slave Cylinder Note Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications
341. ition 7 Note the reading on the dial indicator Result The measurement is less than 0 063 inch 1 6 mm The bearing is good Ww Result The measurement is more than 0 063 inch 1 6 mm The bearing is worn and needs to be replaced 8 Fully retract the boom and raise the boom to full height Visually inspect the the dial indicator to be sure the needle returns to the zero position Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures CHECKLIST D PROCEDURES 9 Remove the dial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the boom to the stowed position and turn the machine off 12 Remove the dial indicator from the machine Genie Part No 102521 S 40 5 45 3 49 Section 3 Scheduled Maintenance Procedures October2013 Checklist E Procedures E 1 Test or Replace the Hydraulic Oil Genie specifications require that this procedure be performed every 2000 hours or 2 years whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Note Before replacing the hydraulic oil the o
342. l 1 1 9 3 i i P N Pod i 9 1 Do MN EN M d e e 1 1 ho i i x 5 El E 9 i 1 5 I 3 ioi a a Iz i 4 x i LA S E E 5 J j 1 8 j gt 3 gt S ME p d io hc ig N CAAA CAAA bc i N 3 40 5 45 A TER Part No 102521 6 138 October 2013 Section 6 Schematics Hydraulic Generator Wiring Diagram Welder Option K J G F E D C B A 1 FOOTSWITCH P2 __ 2 gt P25FS AD P22PWR BK P24FS WH ALC 500 TS4 Y z eje RPM TS47 2 SELECT GENERATOR ON 2 5 5 I 9 0 C32BRK WH RD 2 2 9 9 gt S a T U E LA es 3 e e e 5 5 9 m a W 0 9 9 5 3 EZ E 8
343. l injector 1 OR replace the ECM Injector Driver 1 Shorted shorted OR fuel injector 1 is faulty OR ECM is faulty Injector Driver 2 Open Open wiring and or connections to fuel injector 2 OR fuel injector 2 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 2 Wiring and or connections to fuel injector 2 is OR replace fuel injector 2 OR replace the ECM Injector Driver 2 Shorted shorted OR fuel injector 2 is faulty OR ECM is faulty i Open wiring and or connections to fuel injector 3 Injector Driver 3 Open m OR fuel injector 3 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 3 Wiring and or connections to fuel injector 43 is OR replace fuel injector 3 OR replace the ECM Injector Driver 3 Shorted shorted OR fuel injector 3 is faulty OR ECM is faulty Open wiring and or connections to fuel injector 4 Injector Driver 4 Open irector Driver 4 Open OR fuel injector 4 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 4 Wiring and or connections to fuel injector 4 is OR replace fuel injector 4 OR replace the ECM Injector Driver 4 Shorted shorted OR fuel injector 4 is faulty OR ECM is faulty Open wiring and or connections to fuel pump OR fuel pump power shorted to ground OR fuel pump is faulty Repair wiring and or connections to fuel pump OR Fuel Pump High Side Wiring and or connections to fue
344. l pump shorted to replace fuel pump Shorted to Power power OR fuel pump is faulty Fuel pressure too high OR LPG lockoff not opening Megavector Delivery completely OR the line between the MegaJector Pressure Higher Than and carburetor is kinked or restricted or is leaking Expected OR engine cooling system is not operating properly Check fuel pressure OR repair LPG lockoff OR OR MegaJector is faulty repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace the MegaJector Fuel Pump Loop Open or High Side Short to Ground Fuel pressure too low OR LPG lockoff not opening Megavector Delivery completely OR the line between the MegaJector Pressure Lower Than and carburetor is kinked or restricted or is leaking Expected OR engine cooling system is not operating properly OR Megauector is faulty The ECM doesn t get any response from the Check CAN circuits for continuity and shorts to MegaJector or an incorrect response for 500ms power or ground and for continuity and repair as period or longer necessary OR replace the MegaJector MegaJector Communication Lost The Megavector detects voltage greater than 18 volts for 5 seconds anytime the engine is cranking or running MegaJector Voltage Supply High Repair charging system OR replace the Megavector The Megavector detects voltage less than 9 5 volts Repair VBAT power or ground circuit to ECM and for 5 seconds anytime the engine is cranking or Mega
345. le covers 8 Inspect the turntable area for burnt chafed and pinched cables 9 Lower the boom to the stowed position and turn the 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 boom Platform rotate manifold Inside of the platform control box 11 Inspect for a liberal coating of dielectric grease in all connections between the ECM and the platform controls 12 Swing the engine back to its original position and install the engine pivot plate retaining fasteners AWARNING Crushing hazard Failure to install the fasteners into the engine tray to secure it from moving could result in death or serious injury Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST B PROCEDURES B 3 Inspect the Air Filter Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Note Perform this procedure with the engine off 1 Open the engine side cover Empty the dust discharge valve by pressing together the sides of the discharge slot Clean the discharge slo
346. lect the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Refer to Section 2 Specifications 5 Install the plugs Use pipe thread sealant on units with pipe plugs 6 Repeat steps 1 through 5 for all the other drive hubs drive hub plugs models with pipe plugs a Part No 102521 Genie S 40 S 45 CHECKLIST D PROCEDURES Turntable Rotate Drive Hub Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the secondary boom until the platform end of the lower secondary boom arm is approximately 8 feet 2 4 m off the ground 2 Secure the turntable from rotating with the turntable rotation lock pin 3 Tag disconnect and plug the hydraulic hoses from the turntable rotate drive motor Cap the fittings on the drive motor turntable drive hub a plug 4 Attach a suitable lifting device to the lifting eyes located near the drive motor
347. link 5 Continue to hold the run test toggle switch in the test position and count the blinks Note Before the fault codes are displayed the check engine light will blink a code 123 three times After the fault codes the check engine light will blink a code 123 three times again indicating the end of the stored codes Note If any fault codes are present the ECM will blink a three digit code three times for each code stored in memory It will blink the first digit of a three digit code pause blink the second digit pause and then blink the third digit For example the check engine light blinks 5 consecutive times blinks 3 times and then 1 time That would indicate code 531 Note Once a fault code has been retrieved and the repair has been completed the ECM memory must be reset to clear the fault code from the ECM See How to Clear Engine Fault Codes from the ECM How to Clear Engine Fault Codes from the ECM Note Perform this procedure with the engine off and the key switch in the off position 1 Openthe engine side turntable cover and locate the battery 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Connectthe negative battery cable to the battery Genie 5 12 S 40 S 45 Part No 102521 Oct
348. losed Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST B PROCEDURES B 11 Check and Adjust the Engine RPM Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the engine rpm at the 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 Note This procedure will require two people Ford Models Note The engine rpm is controlled by the ECM and can only be adjusted by re programming the ECM If rpm adjustment or service is required please contact Genie Industries Service Department OR your local Ford dealer Deutz Models 1 Connect a tachometer to the engine Start the engine from the ground controls Refer to Section 2 Specifications Skip to step 3 if the low idle rpm is correct 2 Loosen the low idle lock nut and turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and re check the rpm 3 Move the function enable rpm select toggle Switch to the high idle rabbit symbol position at the ground controls Refer to Section 2 Specifications Genie S 40 S 45 solenoid boot high idle adjustment nut yoke lock nut yoke low idle adjustment screw low idle lock nut
349. lve 12V DC 90 schematic items AW Solenoid valve 2 position 3 way 10V DC 680 schematic item CC Solenoid valve 2 position 3 way 10V DC 330 schematic items DA Solenoid valve 2 position 3 way 12V DC 4 8 Q schematic items CE 5 40 5 45 2 5 Section 2 Specifications October 2013 SPECIFICATIONS Ford LRG 425 EFI Engine Displacement Number of cylinders Bore amp stroke Horsepower Gross intermittent Continuous Gross intermittent Continuous Firing order Low idle rpm Frequency High idle rpm Frequency Compression ratio 153 cu in 2 5 liters 4 3 78 x 3 4 in 96 01 x 86 36 mm 70 Q 2500 rpm 60 2500 rpm 52 kW 6 2500 rpm 44 7 kW 2500 rpm 1 3 4 2 1600 rpm 396 8 Hz 2500 rpm 620 Hz 9 4 1 Compression pressure approx Pressure psi of lowest cylinder must be at least 75 of highest cylinder Valve clearances collapsed tappet Lubrication system 0 035 to 0 055 in 0 889 to 1 397 mm Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 140 200A Current draw maximum load 800A Current draw no load 70A Battery Type 12V DC Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 6 25 rate 200 minutes Electronic fuel pump Fuel pressure static 64 psi 4 4 bar Fuel flow rate 0 58 gpm 2 18 L min Ignition System Spark plug type be
350. m 11 Check valve ierit JK Steer end drive motor circuit 35 40 ft Ibs 48 54 Nm 12 Shuttle valve 3 position way JL ss Charge pressure circuit that directs hot oil out of low pressure side of drive pump 80 90 ft lbs 108 122 Nm 13 Flow divider combiner valve Controls flow to steer end drive motors in forward and reverse 80 90 ft Ibs 108 122 Nm 14 Check valve JN Non steer end drive motor circuit 35 40 ft lbs 48 54 Nm Genie 4 48 5 40 5 45 Part No 102521 October 2013 Section 4 Repair Procedures mnmmmm MANIFOLDS Om 13M 2 Oo Osa Jl JH JG 9 8 D Genie PartNo 102521 5 40 5 45 4 49 Section 4 Repair Procedures October 2013 MANIFOLDS 7 13 Traction Manifold Components 4WD from serial number 15823 The traction manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Relief valve 280 psi 19 3 bar gt Charge pressure circuit 55 60 ft lbs 74 81 Nm 2 Flow divider combiner valve KB Controls flow to non steer end drive motors in fo
351. m moving could result in death or serious injury Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST B PROCEDURES B 6 Check the Exhaust System Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation A CAUTION Burn hazard Beware of hot engine components Contact with hot engine components may result in severe burns 1 Remove the engine tray retaining fasteners located under the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Be sure that all nuts and bolts are tight Inspect all welds for cracks Inspect for exhaust leaks i e carbon buildup around seams and joints 5 Swing the engine back to its original position and install the engine pivot plate retaining fasteners AWARNING Crushing hazard Failure to install the fasteners into the engine tray to secure it from moving could result in death or serious injury Genie S 40 S 45 B
352. m 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 Note Perform this procedure with the engine off 1 Loosen the drain plug located at the bottom of the filter Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures a fuel filter b drain plug 2 Clean up any fuel that may have spilled 3 Startthe engine from the ground controls and check the fuel filter water separator for leaks Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Part No 102521 Genie S 40 S 45 CHECKLIST A PROCEDURES A 11 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 100 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 orthe Ford DSG 42
353. mary boom up 12 until joystick is down 15 calibrated Alarm hem onang 16 Value too low sounds indicating problem should be Value at OV fault corrected Function is inoperative 17 Not calibrated until joystick is Calibrate joystick calibrated 22 Boom 1 directional Valve is operating Cycle power off valves 21 Fault outside of operational then on and limits Alarm sounds problem should be indicating fault corrected 23 Boom 1 flow Valve is operating control valve nn Cycle power off 12 Value too high indicating fault then on and 15 Value too low i problem should be corrected Normal function except Calibrate valve 17 Not calibrated threshold for one or both thresholds directions is zero 24 Boom 1 angle 11 Value at 5V Reduced speed Cycle power off sensor 12 Value too high then on and 15 Value too low problem should be 16 Value at OV corrected Initiate 1 second beep Calibrate angle a Invalid setup of alarm sensor 31 Boom 2 Joystick Trane Joystick is operating Cycle power off poom Mans bs je outside of operational then on and vier boom 16 Value at OV limits Alarm sounds problem should be y indicating fault corrected extend retract Function is inoperative 17 Not calibrated until joystick is Calibrate joystick calibrated 32 Boom 2 directional Valve is operating Cycle power off valves 21 Fault outside of operational then on and limits Alarm sounds problem should
354. ment of our products is a Genie policy Product specifications are subject to change without notice 2 4 Genie Hydraulic tank circuit return line filter 10 micron with 25 psi 1 7 bar bypass S 40 S 45 Part No 102521 October 2013 Section 2 Specifications Manifold Component Specifications Plugtorque SAE No 2 36 in Ibs 4 1 Nm SAE No 4 10 ft lbs 13 6 Nm SAE No 6 14 ft lbs 19 Nm SAE No 8 38 ft Ibs 51 5 Nm SAE No 10 41 ft Ibs 55 6 Nm SAE No 12 56 ft Ibs 75 9 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 102521 Genie SPECIFICATIONS Valve Coil Resistance Specifications Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 20 C that your air temperature increases or decreases from 68 F 20 C Description Specification Solenoid valve 2 position 3 way 10V DC 6 3 Q schematic items AC and AE Solenoid valve 3 position 4 way 10V DC 6 3 Q schematic item AT and AZ Solenoid valve 2 position 3 way 10V DC 6 3 Q schematic items AU AV AX and AY Solenoid valve 3 position 4 way 10V DC 6 3 Q schematic items AZ and BF Proportional solenoid va
355. n the drive pump Genie S 40 S 45 2 Models with hydraulic tank shut off valves Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable Close the valves open closed Componentdamage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition Models without hydraulic tank shut off valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container See capacity specifications 3 Tagand disconnect and plug the hydraulic hoses from the drive and function pumps Cap the fittings on the pumps AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 102521 October 2013 Section 4 Repair Procedures 4 Supportthe pump with a lifting device and remove the two drive pump mounting fasteners 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate 6 Remove the drive pump from the machine Component damage hazard The hydraulic pump may become unbalanced and fall if not properly supported Models with hydraulic tank shut o
356. n the key switch to platform control 3 Check all machine function from the ground controls Result All machine functions should not operate 4 Turn the key switch to ground control 5 Check all machine function from the platform controls Result All machine functions should not operate 6 Turn the key switch to the off position O Result The engine should stop and no functions should operate Part No 102521 Genie S 40 S 45 CHECKLIST B PROCEDURES B 5 Perform Engine Maintenance Deutz and Perkins Models Engine specifications require that this procedure be performed quarterly or every 250 hours whichever comes first Deutz models Required maintenance procedures and additional engine information are available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 Deutz 1011F Operation Manual Genie part number 52883 Perkins models Required maintenance procedures and additional engine information are available in the Perkins 404 22 Operation Manual Perkins part number 14435 Perkins 404 22 Operation Manual Genie part number 94890 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate fro
357. nches 10 to 18 cm at a time and repeat this step until the entire bearing has been greased 4 Apply grease to each tooth of the drive gear located under the turntable Grease specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Genie S 40 S 45 A 13 Perform Engine Maintenance Deutz 1011F Models Engine specifications require that this procedure be performed after the first 125 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 Deutz 1011F Operation Manual Genie part number 52883 To access the engine 1 Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures A 14 Perform Engine Maintenance Ford Models Engine specifications require that this
358. nd Control Box Wiring Diagram Deutz F3L 201 1 Deutz 20111 03 and Perkins 404 22 Models before serial number 14832 A B DRIVE LIGHT OPTION RELAY RD CB3 SP CR23 BK RD 9B RD 11 RD C4B 12 BRN GND
359. ng fasteners to 160 ft Ibs 217 Nm Genio Part No 102521 S 40 8 45 4 57 Section 4 Repair Procedures October2013 Axle Components 9 1 Oscillate Cylinders The oscillating axle cylinders extend and retract between the drive chassis and the axle to maintain a level chassis while driving over uneven terrain The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic hose failure How to Remove an Oscillating Axle Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Perform this procedure on a firm level surface with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Rotate the turntable until the boom is between the steer tires Genie S 40 S 45 2 Remove the fasteners from drive chassis cover at the steer end Remove the cover 3 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the oscillate cylinder Bodily injury hazard Spraying AWARNING hydraulic oil c
360. ngine side turntable cover and connect a 0 to 600 psi 0 to 41 bar pressure gauge to the diagnostic nipple on the drive pump 2 Startthe engine from the platform controls and allow the engine to run at high idle Note the pressure reading on the pressure gauge 3 Turn the engine off and connect a 0 to 600 psi 0 to 41 bar pressure gauge to the diagnostic nipple located on the drive manifold Part No 102521 Genie MANIFOLDS Start the engine from the platform controls and drive the machine slowly in the forward direction Note the pressure reading on the pressure gauge Turn the engine off and remove the hot oil shuttle relief valve cap item FA Adjust the internal hex socket clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap before serial no 7569 Turn the engine off and remove the hot oil shuttle relief valve cap item GA Adjust the internal hex socket clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap after serial no 7568 Repeat steps 4 and 5 until the pressure reading on the guage is 40 psi 2 8 bar less than the pressure reading at the pump 3 40 5 45 4 45 Section 4 Repair Procedures October 2013 MANIFOLDS 7 11 Traction Manifold Components 4WD before serial number 7569 The traction manifold is mounted inside the drive chassis at the non steer end Index Schemati
361. ns Hydraulic oil type Viscosity grade Chevron Rando HD MV equivalent Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rando HD MV oil is fully compatible and mixable with Shell Donax TG Dexron III oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optionalfluids Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Turntable rotate 360 boom fully stowed 70 to 100 seconds Turntable rotate 360 boom fully extended 120 to 140 seconds Platform level 10 range of motion ANSI CE Austrailia 3 to 5 seconds 20 to 22 seconds Jib boom up S 45 models 35 to 45 seconds Jib boom down S 45 models 20 to 30 seconds Braking distance maximum 3 to 4 ft 0 9 to 1 2 m High range on paved surface Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice 2 2 Genie S 40 S 45 Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron Aviation A Eni Arnica 32
362. nt always support the structure and secure it from movement AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Note Perform all troubleshooting on a firm level surface Note Two persons will be required to safely perform some troubleshooting procedures Section 5 Fault Codes October2013 FAULT CODES Fault Code Chart Control System How to Retrieve Control System Fault Codes Note At least one fault code is present when the alarm at the platform controls produces two short beeps every 30 seconds for 10 minutes Note Perform this procedure with the engine off the key switch turned to platform controls and the red Emergency Stop button pulled out to the on position at both the ground and platform controls 1 Openthe platform control box lid AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches andother jewelry 2 Locate the red and yellow fault LEDs on the ALC 500 circuit board inside the platform control box Do not touch the circuit board Component damage hazard Electrostatic dis
363. ntham Lincolnshire NG31 6BH England 44 1476 584333 Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown SD 57201 6150 605 882 4000 Copyright 2011 Terex Corporation GenieG is a registered trademark of Terex South Dakota Inc 133192 RevD Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and reinspect it After repair place a check in the R box Legend Y yes completed N 2 no unable to complete repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section 3 Scheduled Maintenance Procedures October 2013 m M a 1 Pn This page intentionally left blank Genie 3 4 S 40 5 45 Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour
364. number 1020010 Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG 425 EFI Operator Handbook Genie part number 215322 Toaccessthe engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures Checklist D Procedures D 1 Check the Boom Wear Pads Genie specifications requires that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions 1 Start the engine from the ground controls 2 Raise the end of the primary boom to a comfortable working height chest high then extend the boom 1 foot 30 cm 3 Measure each wear pad Replace the wear pad once it reaches the minimum allowable thickness If the wear p
365. ober 2013 Section 5 Fault Codes Code 167 ya ree 3 or 4 __ N N Part 102521 Genie S 40 S 45 FAULT CODES 212 IAT intake air temperature low voltage 213 IAT intake air temperature higher than expected 1 214 IAT intake air temperature higher than expected 2 215 o 221 ECT CHT engine cylinder head temp high voltage 222 ECT CHT engine cylinder head temp low voltage 228 224 ommeweencus 225 226 231 MAP manifold absolute pressure high pressure 232 MAP manifold absolute pressure low pressure 284 er prononcon 235 EP cremene reao ovo _ 240 248 za CS 248 266 cmm CS 288 errar 254 wwe mani Section 5 Fault Codes October2013 FAULT CODES F P fuel pressure high voltage P fuel pressure low voltage N 1 1 T fuel temperature gasoline high voltage 272 T fuel temperature gasoline low voltage 273 FT fuel temperature gaseous fuel high voltage 274 FT fuel temperature gaseous fuel low voltage 5 jector loop open low side short to ground 1 njector coil shorted 1 njector loop open OR low side short to ground 2 njector coil shorted 2 njector loop open OR low side short to ground 3 njector coil shorted 3 njector loop open
366. ol Box Wiring Diagram Deutz F3L 1011F Models Platform Control Box Wiring Diagram Deutz F3L 1011F Models Platform Control Box Switch Panel Wiring Diagram Deutz F3L 1011F Models Electrical Schematic Perkins 704 30 Models before serialnumber 7472 Ground Control Box Wiring Diagram Perkins 704 30 Models Platform Control Box Wiring Diagram Perkins 704 30 Models Platform Control Box Switch Panel Wiring Diagram Perkins 704 30 Models Genie id S 40 5 45 Part No 102521 October 2013 1 TABLE OF CONTENTS Section 6 Rev Schematics continued Electrical Schematic Deutz F3L 201 1 Deutz D2011L03i Models from serial number 7544 to 12509 Perkins 404 22 Models from serial number7472to 12509 6 28 Electrical Schematic Deutz F3L 201 1 Deutz D2011L03i Models Perkins 404 22 Models from serial number 12510 to 14831 6 32 Electrical Schematic Deutz F3L 201 1 Deutz D2011L03i Models Perkins 404 22 Models from serial number 14832 to 15662 6 36 Electrical Schematic Deutz F3L 201 1 Deutz D2011L03i Models ANSI CSA AS Perkins 4
367. on 6 Schematics October 2013 Electrical Schematic Deutz F3L 201 1 Deutz D201 1L03i and Perkins 404 22 Models CE from serial number 16420 6 52 RD BL WH Section 6 Schematics Deutz F3L 201 1 Deutz 20111 O3i and Perkins 404 22 Models CE Electrical Schematic from serial number 16420 October 2013 x a 5 58 EI 5 c HIGH RPM FS 0 9 C35RPM BK RD 8 2 HIGH IDLE RELAY JLOWRPM S l o Xo FNG SP
368. on 6 Schematics February 2012 Electrical Schematic Ford DSG 423 EFI Models from serial number 12510 to 14831 6 92 BL WH gt THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION E Section 6 Schematics Electrical Schematic Ford DSG 423 EFI Models from serial number 12510 to 14831 October 2013 z E a 44 gg 5 a 6 HIGH RPM FS 979 casEsPD BK RD i 5 2 JIOWRPM mte FUNCTION ENA HIGH RPM 8 8 wo GENERATOR 3 5 g e C27 C45GEN GRWH C6 39 GRWH m T OPTION Ge gt E C3 9 DLITE BK RD 4 i DRIVELIGHT 8 N 6 3 4 WH RD a 8 C4B 12 MM I 2 WORKLIGHT 8 9 RD 4 WORK LIGHTS i C4B 11 BK g 9 OPTION
369. onal control 2 Relief e eter Rs Pressure adjustment Genie 4 40 5 40 5 45 PartNo 102521 October 2013 Section 4 Repair Procedures How to Set Up the Oscillate Directional Valve Note Adjustment of the oscillate directional valve linkage is only necessary when the linkage or valve has been replaced 1 Lowerthe boom to the stowed position 2 Use a bubble type level to be sure the floor is completely level AWARNING Tip over hazard Failure to perform this procedure on a level floor could compromise the stability of the machine resulting in the machine tipping over 3 Check the tire pressure in all four tires and add air if needed to meet specification Note The tires on some machines are foam filled and do not need air added to them 4 Remove the drive chassis cover and the non steer axle covers 5 Place a bubble type level across the drive chassis non steer end Check to be sure the drive chassis is completely level 6 To level the drive chassis start the engine and loosen the lock nuts on both sides of the urethane cushions Part No 102521 Genie S 40 S 45 MANIFOLDS 7 Push up or pull down on the threaded rod until the machine is completely level 8 Verify that the ground and drive chassis are completely level 9 Tighten the nuts on both sides of the urethane cushions until they are snug Tighten the locknuts 10 Verify that the ground and drive chassi
370. oom How to Remove the Boom Consult the Genie Industries Service Department for instructions on how to safely remove the boom assembly from the machine Failure to read and follow the warnings listed below could result in death or serious injury AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Genie S 40 S 45 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the platform rotator and leveling slave cylinder See 2 3 How to Remove the Platform Rotator 3 S 45 Models Remove the jib boom See 3 1 How to Remove the Jib Boom 4 Remove the mounting fasteners from the jib boom platform rotate valve manifold on the end of the boom Remove the manifold and set it aside 5 Remove the fasteners from the limit switch mounted on the side of the cable track Do not disconnect the wiring 6 Supportthe cable track with an overhead crane 7 Remove the hose cable cl
371. or lights are flashing at the platform and ground controls the alarm is sounding and the engine stops Slowly tighten the load spring adjustment nut in a clockwise direction in 10 increments until the overload indicator light turns off and the alarm does not sound Proceed to step 8 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator light and alarm responds 6 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle O Result The overload indicator lights are off at the platform and ground controls and the alarm does not sound Slowly loosen the load spring adjustment nut in a counterclockwise direction in 10 increments until the overload indicator light flashes at both the platform and ground controls the alarm sounds and the engine stops Proceed to step 7 Result The overload indicator lights are flashing at the platform and ground controls the alarm is sounding and the engine stops Repeat this procedure beginning with step 5 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator light and alarm responds Genie S 40 S 45 7 Move the platform up and down by hand so it bounces approximately
372. or or moderate injury Used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures October 2013 Platform Controls The platform control box contains one printed 1 1 circuit board The ALC 500 circuit board inside the platform control box controls all proportional ALC 500 Circuit Board machine functions from the platform The joystick Sa ee ne E controllers at the platform controls utilize Hall AWARNING Electrocution hazard Contact Effect technology and require no adjustment The with electrically charged circuits operating parameters of the joysticks are stored in could result in death or serious memory at the ECM circuit board at the platform injury Remove all rings watches controls If a joystick error occurs or if a joystick is and other jewelry replaced it will need to be calibrated before that Note When the ALC 500 circuit board is replaced particular machine function will operate See 1 2 the joystick controllers will need to be calibrated How to Calibrate a Joystick See 1 2 How to Calibrate a Joystick Each joystick controller should operate smoothly and provide proportional speed control over its How to Remove the ALC 500 enti
373. orm Engine Maintenance Perkins Models 3 12 Inspect the Fuel Filter Water Separator Diesel Models 3 12 Perform Engine Maintenance Ford Models 3 13 Grease the Turntable Rotation Bearing and Rotate Gear 3 14 Perform Engine Maintenance Deutz 1011F Models 3 14 Perform Engine Maintenance Ford Models 3 15 Checklist B Procedures B 1 B 2 B 3 B 4 B 5 B 6 B 7 B 8 B 9 B 10 B 11 B 12 B 13 B 14 B 15 B 16 Inspect the 3 16 Inspect the Electrical 3 17 Inspect the Air Filter ee BR ann 3 18 Test the Key Switch 3 19 Perform Engine Maintenance Deutz and Perkins Models 3 19 Check the Exhaust System ssssssssssssseeeeeeeeneeeennnnnnnn 3 20 Check the Oil Cooler and Cooling Fins Deutz Models 3 20 Inspect the Tires Wheels and Lug Nut Torque 3 21 Check the Drive Hub Oil Level and Fastener Torque 3 22 Confirm the Proper Brake Configuration 3 23 Check and Adjust the Engine RPM sss 3 24 Test the Engine Idle Select 3 25 Test the
374. ose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed 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 Ibs 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 Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight Note The O rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O 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 and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm tha
375. otator could become unbalanced and fall if it is not properly supported How to Bleed the Platform Rotator Note This procedure will require two people Do not start the engine Use auxiliary power for this procedure 1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right then the left through two platform rotation cycles then hold the switch to the right position until the platform is fully rotated to the right 2 Connecta clear hose to the top bleed valve Place the other end of the hose in a container to collect any drainage Secure the container to the boom Genie S 40 S 45 3 Open the top bleed valve on the rotator but do not remove it a top bleed valve b bottom bleed valve 0 container d clear hose 4 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left Continue holding the toggle switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Crushing hazard Keep clear of the platform during rotation 5 Connect the clear hose to the bottom bleed valve and open the valve Do not remove the bleed valve 6 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right Continue holding the toggle swi
376. ow to Remove the Extension Cylinder 1 Remove the boom See 4 2 How to Remove the Boom 2 Place blocks under the extension cylinder for support 3 Remove the external snap rings from the extension cylinder barrel end pivot pin at the pivot end of the primary boom tube Use a soft metal drift to remove the pin 4 Remove and label the wear pads from the top side of the primary boom tube at the platform end of the boom Note Pay careful attention to the location and amount of shims used with each wear pad 5 Attach a lifting strap from an overhead crane to the secondary boom tube at the platform end of the boom for support 6 Supportand slide the secondary boom tube out of the primary boom tube Place the secondary boom tube on blocks for support AWARNING Crushing hazard The secondary boom tube could become unbalanced and fall when removed from the primary boom tube if not properly supported Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing 7 Remove and label the wear pads from the top side of the secondary boom tube at the platform end of the boom Genie S 40 S 45 8 Removethe trunnion pin retaining fasteners at the base end of the secondary boom tube Use a slide hammer to remove the trunnion pins 9 Carefully rotate the base end of the extension cylinder until the pin mounting bore is in a vertical position 10 Remove the external snap rings from
377. per 126 142 176 Re SIRES SS AIO IN Jo oo gt 1260 1681 1510 2010 1700 1950 3213 3160 3620 2190 3620 3560 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Size Class 4 6 Class 8 8 Class 10 9 Class 12 9 LUBED LUBED LUBED Nm in Ibs Nm in bs Nm in ibs Nm in lbs Nm in bs Nm in Ibs Nm 24 41 463 54 618 58 663 78 8 84 68 7 75 91 103 407 69 7 87 93 105 100 113 132 15 116 132 155 17 6 Nm ftibs Nm ftibs Nm ftibs Nm ftibs Nm ft lbs Nm ft lbs Nm 1 1055 682 925 909 1233 mm aR U m di Dla 6 Ala ajojo aj 1 T m gt za c A gt A co un eoo zu oO ala alo QIN A olmnm 2 2 o co 1 2 lt 00 4 60 60 O Ico Alo a o ola gt e o o O o eJ c5 s I gt gt o a gt Klo ajo ENTS alo S io a AYA R col eoo o AI ed CID o Qo g g ofalolnj Ixe 6 gt lt gt 6 gt Del Rea NIOJN ioo The Ice s 4 mI
378. performed every 500 hours or six months whichever comes first Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stablity could be compromised resulting in the machine tipping over Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine and level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from the platform Note Failure to remove all weight tools and accessories from the platform will result in an inaccurate test 4 Using a suitable lifting device place a test weight equal to that of the available capacity at one of the locations shown Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound W Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped PartNo 102521 October 2013 Section 3 Scheduled Maintenance Procedures Illustration 1 5 Carefully move the test weight to each remaining location
379. procedure be performed every 200 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 or the Ford DSG 423 EFI Operator Handbook EDI part number 1060020 orthe Ford MSG 425 EFI Operator Handbook Ford part number 1020010 Ford LRG 425 EFI Operation Manual CHECKLIST A PROCEDURES To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG 425 EFI Operator Handbook Genie part number 215322 Genie Part No 102521 5 40 5 45 3 15 Section 3 Scheduled Maintenance Procedures October2013 Checklist B Procedures B 1 Inspect the Battery Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first
380. punctures and unusual wear 2 Check each wheel for damage bends and cracks 3 Check each lug nut for proper torque Refer to Section 2 Specifications Models with air filled tires 4 Check pressure in each air filled tire Add air as necessary Refer to Section 2 Specifications Section Scheduled Maintenance Procedures October2013 CHECKLIST B PROCEDURES B 9 Turntable rotate drive hub Check the Drive Hub Oil Level 1 Remove the plug located on the side of the hub and Fastener Torq ue and check the oil level Result The oil level should be even with the bottom of the plug hole Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees Remove the plug located at 90 degrees and check the oil level turntable drive hub Result The oil level should be even with the a plug bottom of the side plug hole 2 If necessary add oil until the oil level is even If necessary remove the top plug and add oil with the bottom of the plug hole until the oil level is even with the bottom of the 3 Apply pipe thread sealant to the plug and side plug hole Refer to
381. r comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage AWARNING Electrocution burn hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Open the engine side turntable cover 2 Remove the engine tray retaining fasteners located under the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Inspect the following areas for burnt chafed corroded and loose wires Engine wiring harness Hydraulic manifold wiring Part No 102521 Genie S 40 S 45 CHECKLIST B PROCEDURES 4 Inspect for a liberal coating of dielectric grease in the following locations Between the ground and platform controls Between the ground and drive controls All harness connectors Level sensor 5 Open the turntable cover at the ground control side of the machine 6 Inspect the following areas for burnt chafed corroded and loose wires Inside of the ground control box Hydraulic manifold wiring 7 Startthe engine from the ground controls and raise the boom above the turntab
382. r 2013 E MANIFOLDS 7 12 Traction Manifold Components 4WD from serial number 7568 to 15822 The traction manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Relief valve 280 psi 19 3 bar JA Charge pressure circuit 35 40 ft lbs 48 54 Nm 2 Flow divider combiner valve Controls flow to non steer end drive motors in forward and reverse 80 90 ft Ibs 108 122 Nm 3 Gheck valve oett het JG sega Steer end drive motor circuit 35 40 ft Ibs 48 54 Nm 4 Check Valve eek JD Non steer end drive motor circuit 35 40 ft lbs 48 54 Nm 5 Flow divider combiner valve JE 252 Controls flow to flow divider combiner valves 2 80 90 ft lbs 108 122 Nm 6 Check JE secs Non steer end drive motor circuit 60 70 ft lbs 81 95 Nm 7 Orifice 0 040 inch 1 mm JG Equalizes pressure on both sides of flow divider combiner valve 5 8 Orifice 0 040 inch 1 mm JH Equalizes pressure on both sides of flow divider combiner valve 2 9 Orifice 0 040 inch 1 mm Jl sins Equalizes pressure on both sides of flow divider combiner valve 13 10 Check valve JJa Steer end drive motor circuit 60 70 ft lbs 81 95 N
383. r OR repair vacuum and exhaust leaks Repair wiring and or connections OR replace sensor Repair wiring and or connections OR replace the post cat oxygen sensor Repair wiring and or connections OR replace sensor OR repair any vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors Adjust or replace sensors OR clean or repair fuel injectors Repair wiring and or connections OR replace sensor OR replace fuel OR test and repair the fuel system components Repair exhaust leaks OR there is an emissions compliance issue Contact Ford Power Products for assistance Repair heated oxygen sensor wiring and or connections OR replace sensor OR repair vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors Adjust or replace sensors OR clean or repair fuel injectors Repair wiring and or connections OR replace sensor OR repair any vacuum and exhaust leaks OR replace fuel OR test and repair the fuel system components Repair short in engine wire harness OR test and repair the fuel system components 5 40 5 45 Section 5 Fault Codes October2013 FAULT CODES IAT High Voltage IAT Low Voltage IAT Higher Than Expected 1 IAT Higher Than Expected 2 Oil Pressure Low CHT ECT High Voltage CHT ECT Low Voltage CHT Higher Than Expected 1 CHT Higher Than Expected 2 IAT sensor wiring and or connections are open or shorte
384. r shorted battery supply wiring to ECM Alternator is overcharging the battery when System Voltage High engine RPM is greater than 1500 rpm Repair or replace the alternator Repair wiring and or connections OR replace sensor OR direct warmer air into air intake Repair wiring and or connections OR replace sensor OR direct cooler air into air intake Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor Replace oil pressure sensor OR repair sensor wiring and or connections OR fill engine oil level to specification Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification MAP High Pressure Open or shorted wiring and or connections to MAP sensor OR sensor is faulty MAP Low Voltage Open or shorted wiring and or connections to MAP sensor OR sensor is faulty BP High Pressure MAP sensor is faulty OR ECM is faulty BP Low Pressure MAP sensor is faulty OR ECM is faulty Repair wiring and or connections to sensor OR replace MAP sensor Replace MAP sensor OR replace the ECM Crank Sync Noise Never Crank Synced At Start Camshaft Sensor Loss Crankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Cr
385. rack Components TRAX option Note Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Maintaining tracks and track assembly components is essential to safe operation and good performance A track assembly failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion 1 Thoroughly clean the track assembly of any dirt rocks clay etc 2 Inspectthe following areas for damaged cracked loose or missing parts and fasteners e Track Idlerwheels Drive sprocket and hub Bogeywheels Undercarriage e Kingpin and steering linkage bushings Section 3 Scheduled Maintenance Procedures October2013 CHECKLIST A PROCEDURES A 6 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage whichever comes first After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures A 10 Grease the Turntable Bearing and Rotate Gear B 8 Inspect the Tires Wheels and Lug Nut Torque 2 9 Check the Drive Hub Oil Level and Fastener Torque e 0 2 Check the Turnable Rotation Bearing Bolts D 6 Replace the Hydraulic Filter Elements Genie S 40 S 45 A 7 Perform Engine Maintenance Deutz and Ford Models
386. rd DSG 423 EFI Models CE from serial number 16420 Electrical Schematic October 2013 5 5 8 55 a c m l PM FS Cr9 y C35RPM BK RD ILS 9 EXE e ENG SPEED HIGH RPM Te De 2 518 M D GENERATOR amp et E E bas GENERATOR 7 C45GEN GR WH s C45GEN eaw OPTION V WORK LIGHTS WH lt lt Bk BR 1 OPTION o v g Wi amp N DRIVE LIGHT I ps u lt CaB lt OPTION e Qn 22 3 224 5 R 5 5 Tt 2 C4B 10 BER NO 6 5 g 5 VOLT METER R21IGN WH S HOUR METER 1 II 0 8 C5 16 5 als WH BK 4 2 54 0 OIL PRESSURE GAUGE u gt 900 8 C3 10 5 al GYRB a o 1 E B GYY 59 GASOLINE SENSOR o 8 RD gt e z BK BE Qc D 17 C33STR BK isi E 5 0 4 Pa RD GR di LPG LOCKOUT WH BK 52 3 zog 4 TEMP GAUGE 3 m a z 5 9 C5 14 E C914 _ 026788 WH RD PIN 39 S g C5 12 95 8 5 p a Hy 01271900 08 8 ay 5 5 17 C21IGN WH PIN 16 Es 8 T oz a x lg 089 cssRPM B
387. re range of motion Circuit Board 1 Pushin the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining N fasteners Open the control box lid 3 Locate the ALC 500 circuit board mounted to the inside of the platform control box IET EN EI I C 8 e 5 98 699 ess 59 lt C 59 8 559 ALC 500 circuit board drive steer joystick controller secondary boom up down joystick controller d primary boom up down and turntable rotate left right joystick controller Genie 4 2 40 5 45 PartNo 102521 October 2013 Section 4 Repair Procedures 4 Attach a grounded wrist strap to the ground screw inside the platform control box Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 5 Carefully disconnect the wire connectors from the circuit board 6 Remove the ALC 500 circuit board mounting fasteners 7 Carefully remove the ALC 500 circuit board from the platform control box 1 2 Joysticks How to Calibrate a Joystick The joysticks on this machine utilize digital Hall Ef
388. retaining fasteners from the electrical connector receptacles for the cables that enter the cable track 11 Remove the fasteners from the drive speed limit switch mounted on the side of the cable track at the pivot end of the boom Do not disconnect the wiring Part No 102521 October 2013 Section 4 Repair Procedures 12 Remove the fasteners from the side panel on the lower cable track then remove the panel Pull all of the cables out of the channel 13 Remove the cable cover on the side of the boom 14 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and AWARNING lower cable tracks are not properly secured together the cable track could become unbalanced and fall when it is removed from the machine 15 Attach a lifting strap from an overhead crane to the cable track 16 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom 17 Remove the cable track mounting fasteners that attach the lower cable track to the boom 18 Remove the cable track from the machine and place it on a structure capable of supporting it Crushing hazard The cable track AWARNING could become unbalanced and fall if itis not properly attached to the overheadcrane Component damage hazard Hoses and cables can be damaged if they are kinked or pinched Part No 102521 Genie 5 40 5 45 BOOM C
389. ries of steps Section 3 Scheduled Maintenance Procedures October2013 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold motor pump or engine will be required to perform this procedure Indicates that a warm motor or pump will be required to perform this procedure Ti Indicates that dealer service is required to perform this procedure Genie 3 2 S 40 S 45 Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation Heportto use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly every six months annual and two years The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perfo
390. ription Item Function Torque 1 Relief valve 280 psi 19 3 bar QA usus Charge pressure circuit 30 35 ft lbs 41 47 Nm 2 Flow divider combiner valve GB Controls flow to drive motors in forward and reverse 90 100 ft Ibs 122 136 Nm Check valve GC Drive circuit 444 2 22 30 35 ft Ibs 41 47 Nm Check valve GD Drive circuit 44 2 22222 30 35 ft Ibs 41 47 Nm 5 Flow divider combiner valve Controls flow to drive motors in forward and reverse 50 55 ft lbs 68 75 Nm 6 Orifice 0 070 inch 1 78 mm GP s Equalizes flow across flow divider combiner valve item GB NUR Genie 4 44 S 40 5 45 Part No 102521 October 2013 Section 4 Repair Procedures 7 10 Valve Adjustments 2WD Drive Manifold How to Adjust the Hot Oil Shuttle Relief Valve Note The pressure differential between the charge pump relief valve located in the drive pump and the hot oil shuttle relief valve located in the drive manifold is necessary to return hot oil from the closed loop drive circuit to the hydraulic tank for cooling This pressure differential must be maintained at 40 psi 14 5 bar Note The following procedure will require two people 1 Openthe e
391. rm a scheduled inspection Inspection 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 years or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with employer jobsite and govermental regulations and requirements PartNo 102521 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Genie UK The Maltings Wharf Road Gra
392. rom serial number 7569
393. rward and reverse 80 90 ft Ibs 108 122 Nm 3 Gheck valV6 KG uuu Steer end drive motor circuit 55 60 ft lbs 74 81 Nm 4 Check valVe KD Non steer end drive motor circuit 55 60 ft lbs 74 81 Nm 5 Check ien Non steer end drive motor circuit 70 75 ft lbs 95 100 Nm 6 Flow divider combiner valve Controls flow to flow divider combiner valves PANG 80 90 ft lbs 108 122 Nm 7 Orifice 0 040 inch 1 mm KG Equalizes pressure on both sides of flow divider combiner valve 5 8 Orifice 0 040 inch 1 mm KH Equalizes pressure on both sides of flow divider combiner valve 2 9 Orifice 0 040 inch 1 mm Kass Equalizes pressure on both sides of flow divider combiner valve 13 11 Shuttle valve position way KJ Charge pressure circuit that directs hot oil out of low pressure side of drive pump 35 40 ft lbs 48 54 Nm 10 Check Valve Ree KK Steer end drive motor circuit 55 60 ft lbs 95 100 Nm 12 Check valye 5 nete Steer end drive motor circuit 70 75 ft lbs 95 100 Nm 13 Flow divider combiner valve KM Controls flow to steer end drive motors in forward and reverse 80 90 ft Ibs 108 122 Nm 14 Check
394. s are completely level 11 Measure the distance between the drive chassis and the non steer axle on both sides from the inside of the drive chassis Note If the distance is not equal and the adjustment to the linkage was completed with the ground and drive chassis level repeat steps 6 through 11 OR consult Genie Industries Service Department Section 4 Repair Procedures October2013 MANIFOLDS 7 7 Valve Adjustments Oscillate Relief Valve How to Adjust the Oscillate Relief Valve Pressure 1 Remove the drive chassis cover from the non steer end of the machine 2 Connect a 0 to 2000 psi 0 to 150 bar pressure gauge to the diagnostic nipple located near the oscillate directional valve 3 Disconnect the directional valve linkage by removing the heim joint and retaining fastener from the axle 4 Startthe engine from the platform controls 5 With the engine running manually activate the valve and observe the pressure reading on the pressure gauge Oscillate relief valve specification Pressure 950 psi 65 5 bar 6 Turn the engine off 7 Locate the relief valve on the directional valve and remove the cap Genie S 40 S 45 8 Adjust the internal screw Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 9 Repeat steps 4 through 7 and manuall
395. scent alarm should sound when the controller is held down Press down the foot switch Move the jib boom toggle switch to the down position hold for a moment and then release it Result The descent alarm should sound when the controller is held down Press down the foot switch Move the drive controller off center hold for a moment and then release it Move the drive controller off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive controller is moved off center in either direction Genie S 40 S 45 4291 Section Scheduled Maintenance Procedures October2013 CHECKLIST B PROCEDURES B 22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie specifications require that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist A free breathing fuel and hydraulic tank cap is essential for good machine performance and service life A dirty or clogged cap may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the cap be inspected more often Explosion and fire hazard Engine fuels are combustible 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
396. stration 1 Illustration 2 Genie 3 38 S 40 S 45 Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures 26 Using a suitable lifting device place an additional 50 Ibs 23 kg of weight onto the platform O Result The alarm should sound and the Valve Power LED should not light The platform overload indicator lights should be flashing at both the ground and platform controls 27 Working from outside the platform and standing next to the platform rotator locate the orange wire which enters into the base of the platform control box from the load sense switch and locate the wire terminal at the end of the wire Tag and disconnect the connectors Refer to Illustration 2 28 Using a multimeter set to read resistance ohms securely install a lead from the multimeter to the connector on the orange wire and securely connect the other multimeter lead to a ground point in the control box Result The readout on the multimeter should indicate zero resistance Result The readout on the multimeter shows resistance Remove the machine from service and contact the Genie Service Department 29 Using a suitable lifting device remove all weight from the platform Note the result on the multimeter Result The readout on the multimeter should indicate infinite resistance W Result The readout on the multimeter shows zero resistance Remove the machine from service and contact the Geni
397. sult The alarm does not sound and the platform overload indicator lights are not flashing Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash the alarm sounds and the engine shuts off 8 Testall machine functions from the platform controls Result All platform control functions should not operate 9 Turn the key switch to ground control 10 Test all machine functions from the ground controls O Result All ground control functions should not operate 11 Activate the auxiliary power toggle switch 12 Using auxiliary power test all machine functions from the ground controls O Result All ground control functions should operate 13 Using a suitable lifting device lift the additional test weight from the platform Result The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound Section 3 Scheduled Maintenance Procedures October2013 _ CHECKLIST C PROCEDURES 14 Start the engine and test all machine functions 21 Using Illustration 3 as a guide locate D31 Valve from the ground controls Power LED on the ALC500 printed circuit board O Result All ground control functions should operate normally Valve Power LED 15 Turn the key switch to platform control ALC
398. t as needed 2 Inspect the dust discharge valve If the valve shows any signs of damage replace the valve clamp canister end cap c dust discharge valve 3 Disconnect the latches and remove the end of the air cleaner canister Genie 4 Remove the filter element 5 Clean the inside of the canister and the gasket with a damp cloth 6 Clean the filter using dry compressed air Blow out from inside to outside Check filter gasket for damage 7 Re install the filter element or if there are any signs of loss of filtration replace the element 8 Install the end cap onto the canister Secure the clamps Note Be sure the dust discharge valve is pointing down 3 18 5 40 5 45 PartNo 102521 October 2013 Section 3 Scheduled Maintenance Procedures B 4 Test the Key Switch Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to ground control start the engine and then tur
399. t there are no leaks Seal Loke Fittings ORFS tube fitting installed into Steel hose end SAE Dash size Torque SAE Dash size Torque 4 15 ft lbs 20 3 Nm 4 18 ft lbs 24 4 Nm 6 35 ft lbs 47 5 Nm 6 30 ft lbs 40 7 Nm 8 60 ft lbs 81 3 Nm 8 40 ft Ibs 54 2 Nm 10 100 ft Ibs 135 6 Nm 10 60 ft Ibs 81 3 Nm 12 135 ft lbs 183 Nm 12 85 ft lbs 115 Nm 16 200 ft lbs 271 Nm 16 110 ft lbs 149 Nm 20 250 ft lbs 334 Nm 20 140 ft Ibs 190 Nm 24 305 ft lbs 414 Nm 24 180 ft lbs 244 Nm Genie 2 14 S 40 5 45 Part No 102521 October 2013 Section 2 Specifications SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual 74 High Strength Grade 5 2 Grade 8 65 Aor gr Black Oxide Bolts LUBED LUBED in bs 12 4 15 8 LUBED Nm indbs 9 18 LUBED DRY Nm Nm f ribs Nm fbs 13 33 9 14 20 271 gt 366 24 i6 p 2 32 3 42 p 3 447 44 596 38 26 352 35 474 50 678 70 947 7 813 80 1084 57 80 1084 110 149 93 867 90 122 120 162 105 1084 203 130 122 230 140 110 284 200 271 200 271 7270 366 14 770 1044 718 710 96 750 1016 990 840 1139 800 970 1315 1290 1749 1090 1477 908 19 1220 1654 2467 1530 2074 2304 2 lt La
400. t this procedure be performed every 3000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0312 3547 Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 139320 Toaccessthe engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures Perkins models Required maintenance procedures and additional engine information are available in the Perkins 404 22 Operation Manual Perkins part number 14435 Perkins 404 22 Operation Manual Genie part number 94890 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener lo
401. tank Move the fuel select switch to the gasoline position Perkins models Connect the engine wiring harness to the fuel solenoid Deutz models Release the manual fuel shutoff valve Start the engine from the ground controls and check for hydraulic leaks 3 40 5 45 4 31 Section 4 Repair Procedures October 2013 Manifolds 7 1 Function Manifold Components The function manifold is located underneath the ground controls side turntable cover Index Schematic No Description Item Function Torque 1 Flow regulator valve 0 8 3 03 L MIN AA aa platform rotate and jib boom 5 45 20 25 ft lbs 27 34 Nm 1 Flow regulator valve 0 6 2 27 L MIN platform rotate 5 40 20 25 ft lbs 27 34 Nm 2 Check valve te Differential sensing circuit platform rotate right and jib boom down S 45 10 12 ft Ibs 14 16 Nm 3 Solenoid valve 2 position 3 way AC Platform level up down 20 25 ft lbs 27 34 Nm 4 Check valve Differential sensing circuit platform level up 10 12 ft Ibs 14 16 Nm Solenoid valve 2 position 3 way AE Platform level up down 20 25 ft lbs 27 34 Nm Check valve Abus
402. tate the remaining half sprocket 180 so that it is free of the track 6 Attach a lifting strap from an overhead crane to the center point of the track assembly above the sprocket 7 Remove the fasteners holding the TRAX mounting pin located underneath the axle Remove the pin supporting the TRAX assembly 8 Carefully remove the track assembly from the drive hub and set aside Crushing hazard The track ACAUTION assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Genie Track Components How to Replace the Track Note The sprocket is comprised of two halves 1 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the tracks 2 Referto illustration 1 and place the drive hub disconnect cap in the brake disengaged position 3 Liftthe machine until the tracks are off the ground and then place jack stands under the drive chassis for support 4 Loosen the idler axle bolt tensioner jam nut and tension nut on both sides of the assembly to allow maximum play in the tensioner wheel 5 Remove the lug nut bolts holding each half sprocket on the drive hub Rotate the sprockets until only one sprocket is contacting the track Remove the lower half sprocket from the track assembly 6 Rotate the remaining half sprocket 180 so that it is free of the track 7 Carefully remove the track from the undercarriage
403. tch until air stops coming out of the bleed valve Close the bleed valve AWARNING Cushing hazard Keep clear of the platform during rotation 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled 8 Rotate the platform fully in both directions and inspect the bleed valves for leaks Part No 102521 October 2013 Section 4 Repair Procedures 2 3 Platform Overload System The platform overload system is designed to prevent the machine from continuing to operate when the load in the platform exceeds maximum rated capacity Refer to the machine serial label for maximum capacity information If maximum platform capacity is exceeded the alarm will sound at the platform controls and the platform overload indicator lights will flash at both the ground and platform controls The ground and platform controls will become disabled and the engine will stop Before normal machine operation can continue the excess load will need to be removed from the platform If the excess load cannot be removed or if the operator at the platform controls is unable to correct the overloaded condition another person at the ground controls can operate the machine using auxiliary power There will be limited control of boom functions from the ground controls when using auxiliary power Auxiliary power can be used to correct the overloaded platform condition in order to resume normal safe operation of the mac
404. te The brakes must be able to hold the machine on any slope it is able to climb Part No 102521 October 2013 Section 3 Scheduled Maintenance Procedures B 18 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Startthe engine from the platform controls 3 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol then lower the boom into the stowed position 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 5 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 6 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications Part No 102521 Genie S 40 S 45 CHECKLI
405. terclockwise to release the element from the housing 4 Remove the filter element from the filter housing 5 Install the new filter element into the filter housing 6 Push the filter element down to be sure the o ring on the element is fully seated into the housing Part No 102521 Genie S 40 S 45 CHECKLIST D PROCEDURES 7 Rotate the filter element clockwise to lock it in place 8 Install the filter housing cap 9 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housing Medium and high pressure filter Note The medium pressure filter is for the charge pump and the high pressure filter if equipped is for all machine functions except the drive circuit and oscillating axle circuit 10 Open the engine side turntable cover and locate the medium pressure filter mounted to the engine tray 11 Place a suitable container under each filter 12 Remove the filter housings by using a wrench on the nut provided on the bottom of the housings 13 Remove the filter elements from the housings 14 Inspect the housing seals and replace them if necessary 15 Install the new filter elements into the housings and tighten them securely 16 Clean up any oil that may have spilled during the installation procedure 17 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housings 18 Start the engine from the groun
406. terly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections f any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired Checklist C Y NR October 2013 Checklist E Y NR C 1 Engine maintenance Deutz and Perkins models C 2 Platform overload if equipped C 3 Platform overload if equipped C 4 Air filter element Deutz and Perkins models C 5 Fuelinline strainer Deutz models Perform every 800 hours C 6 maintenance Ford Checklist D D 1 Boom wear pads D 2 Turntable bearing bolts D 3 Free wheel D 4 Drive hub oil configuration D 5 Engine maintenance Deutz and Perkins models D 6 Hydraulic filters D 7 Turntable bearing wear E 1 Hydraulic oil E 2 Steer axle wheel bearings 2WD models Perform every 2000 hours E 3 Engine maintenance Deutz and Perkins models Perform every 2400 hours E 4 Engine maintenance Ford models Perform every 3000 hours E 5 Engine maintenance
407. th hydraulic tank shut off valves Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Models without hydraulic tank shut off valves Component damage hazard Be sure to fill the hydraulic tank to specification and prime the pump after installing the pump 3 40 5 45 4 29 Section 4 Repair Procedures October2013 HYDRAULIC PUMPS 6 2 Drive Pump The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electro proportional controller located on the pump The only adjustment that can be made to the pump is the neutral or null adjustment Any internal service to the pump should only be performed at an authorized Eaton Hydraulics center Call Genie Industries Service Department to locate your local authorized service center How to Remove the Drive Pump Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connection at the electro proportional controller located o
408. tic Ford LRG 425 EFI Models from serial number 7597 to 11066 October 2013 BL WH N N co BAN 2 GROUND C41RPM OR BK C2P 3 gt 15 Fy 8 m 2 P 5 c1p 4 C30EDC WH 5 6521 Coenor WH DRIVE EDC FORWARD 5 1 5 C31EDC WH BK C5 20 C31EDC WH BK D n 0 LED BURD 16 16 de DRIVE EDC REVERSE 0 8 C6 32 2 DREBBUBK gt TRAVEL ALARM OPTION Ee Bi mu qm mem a mam mun amd l g DREABUWH 6 19 6 C32BRK WH RD C5 23 C32BRK WH RD A 4 BRAKE RELEASE VALVE 2 E 5 o 7 lt 202 CIP 3 C29MS RD WH Fog 5 19 C29MS RD WH ua 4 MOTOR STROKE RKouT e lt WH 5 alt YOUTB lt BL 3 4 g B Q 2 4 5 18 11 C37STCC BL BK e C6 37 C37STCC BUBK A 4 STEER RIGHT PWRBZ oR 5513
409. ttery Part No 102521 October 2013 Section 4 Repair Procedures 6 1 Function Pump How to Remove the Function Pump Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Models with hydraulic tank shut off valves Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable Close the valves open closed Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition Part No 102521 Hydraulic Pumps Models without hydraulic tank shut off valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container See capacity specifications 2 Tag disconnect and plug the function pump hydraulic hoses Cap the fittings on the pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pump mounting bolts Carefully remove the pump Models wi
410. urface Boom in the stowed position Turntable rotated with the boom between the non steer wheels Turntable secured with the turntable rotation lock Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine Part No 102521 Genie S 40 S 45 Bed About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety information and step by step instructions Symbols Legend A Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION With safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a se
411. ut torque A 8 Drive Hub Oil Perform every 50 hours B 9 Drive hub maintenance B 10 Brake configuration A 9 Engine maintenance Perkins models Perform every 100 hours A 10 Fuel filter water separator Deutz models A 11 Engine maintenance Ford models A 12 Rotation bearing Perform after first 125 hours A 13 Engine maintenance Deutz 1011F models Perform every 200 hours Ford models A 14 Engine maintenance Comments Genie Part No 102521 B 11 Engine RPM B 12 Engine idle select B 13 Fuel select Ford models B 14 Ground control B 15 Directional valve linkage B 16 Platform self leveling B 17 Drive brakes B 18 Drive speed stowed position B 19 Drive speed raised position B 20 Hydraulic oil analysis B 21 Alarm package B 22 Fuel and hydraulic cap venting systems B 23 Check track tension TRAX option Perform every 400 hours B 24 Engine maintenance Ford models S 40 S 45 Section 3 Scheduled Maintenance Procedures MAINTENANCE INSPECTION REPORT Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of both pages to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quar
412. very 50 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Perkins models Required maintenance procedures and additional engine information are available in the Perkins 404 22 Operation Manual Perkins part number TPD 1443S Perkins 404 22 Operation Manual Genie part number 94890 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving AWARNING Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury Genie S 40 S 45 A 10 Inspect the Fuel Filter Water Separator Deutz Models Genie specifications require that this procedure be performed every 100 hours or monthly whichever comes first Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and or hard starting and continued use may result in component damge Extremely dirty conditions may require this procedure be performed more often Explosion and fire hazard Engine fuels are combustible Perfor
413. wly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting 3 Attach a suitable lifting device to the turntable Torque Specifications rotator assembly Note Perform this procedure with the machine on a firm and level surface 1 Securethe turntable from rotating with the D 59 9 turntable rotation lock pin i 0 5 9 brake assembly drive hub backlash plate mounting bolts backlash plate manifold motor 09 Genie 4 56 S 40 S 45 Part No 102521 October 2013 Section 4 Repair Procedures TURNTABLE ROTATION COMPONENTS 4 Removethe turntable rotation assembly mounting fasteners 5 Carefully remove the turntable rotation assembly from the machine AWARNING Crushing hazard The turntable could rotate unexpectedly when the rotation drive hub assembly is removed if the turntable is not secured with the turntable rotation lock pin AWARNING Crushing hazard The turntable rotation drive hub assembly could become unbalanced and fall when removed from the machine if not properly supported When installing the drive hub assembly 6 Install the drive hub Apply Loctite removable thread sealant and torque the backlash plate mounti
414. x gt gt 14 TZ C1P 10 C36STC BL C6 36 C36STC BL 4 STEER LEFT a H 8 L F E B TZ C3P 6 6 WH RD EE 5 5 C3P 4 C4TRLWH 8 m gt 4 TURNTABLE ROTATE LEFT e LEFT TROTATE x amp p gt RIGHT 065 CSTRRWHEK TURNTABLE ROTATE RIGHT 9 e dx E 7 6 di C6 6 C6TRF WHRD TURNTABLE ROTATE o 6 lt 0 FLOW CONTROL al E 706 2 75 B ES 9 BASED 1 s GIPBURD PRIMARY BOOM UP E PWR 3Z 5 11 le PRIMARY a a ae 5 DOWN 5 6 2 C2PBD RD BK gt PRIMARY BOOM DOWN amp E E 8 a E 063 C3PBF RD WH 5 PRIMARY BOOM t 0 1 FLOW CONTROL 51 a 16 C3P 1 C1PBU RD E 7 C3P2 2 RD BK e 8 lt lt 3 3 RD WH 19 RD BK Q sem DESCENT ALARM OPTION 6 x lt 5 LS2 PRIMARY BOOM UP gt M DRIVE LIMIT SWITCH 5 BK BRN 5 WH a 8 4 2 LS1 PRIMARY BOOM EXTEND 5 P24FS WH 52 2 4 9 DRIVE LIMIT SWITCH 5 P24FS WH 5 lt gt 4 3 1 C13DRE BL RD C6 13 C13DRE BURD WH z P26ESTP BK 3 31 5 DRIVE BK 3 g 8 A C2P 2 C40LS1 OR 5 c6 40 C40LS1 OR lt 3 E E 2 5 C6 30 5 2 5 E z mm Gum E d R 2
415. y Stop button normally closed Hydraulic oil cooling fan Auxiliary pump 510 Q Resistor with ohm value Key switch after serial number 22050 Genie S 40 S 45 Part No 102521 October 2013 25 psi e 9 1 7 bar Filter with bypass valve relief setting fixed displacement U c 3 2 ae bi directional variable displacement o bi directional amp 2 speed bi directional E Pump prime mover engine or motor Double acting cylinder NY P eit 035 0 89 mm Orifice with size aca Check valve r 1 200 psi 13 8 bar Relief valve with pressure setting Directional valve mechanically activated 5096 50 Flow divider combiner valve with pressure balancing orifice and flow percentages ai as Pilot operated 3 position 3 way shuttle valve dd m Differential sensing valve Xu Solenoid operated proportional valve Section 6 Schematics Hydraulic Symbols Legend Solenoid operated 3 position 4 Way directional valve Priority flow regulator valve y Solenoid operated 2 position 3 way directional valve
416. y activate the valve to confirm the valve pressure 10 Turn the engine off remove the pressure gauge and assemble the directional valve linkage 11 Install the cover on the non steer end of the drive chassis Part No 102521 October 2013 Section 4 Repair Procedures 1 MANIFOLDS 8 Traction Manifold Components 2WD before serial number 7569 The traction manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Relief valve 210 psi 14 5 bar FA Charge pressure circuit 30 35 ft lbs 41 47 Nm 2 Flow divider combiner valve EB Controls flow to drive motors in forward and reverse 90 100 ft Ibs 122 136 Nm 3 Orifice 0 070 inch 1 78 mm Equalizes flow across flow divider combiner valve item FB 4 Shuttle valve 3 position way FD Charge pressure hot oil shuttle 50 55 ft lbs 68 75 Nm 5 Diagnostic nipple EE Testing Fe 2WD 5 Genie Part No 102521 5 40 5 45 4 43 Section 4 Repair Procedures October 2013 mnmmm MANIFOLDS 7 9 Traction Manifold Components 2WD after serial number 7568 The traction manifold is mounted inside the drive chassis at the non steer end Index Schematic No Desc
417. ysical damage 6 Clean the fan blower fins of debris and foreign material 7 Inspect the head cooling passages and fins for physical damage or foreign material using a flashlight 8 Clean the cylinder head cooling passages of debris and foreign material 9 Install the engine side cover 10 Swing the engine back to its original position and install the engine pivot plate retaining fasteners Tighten the pivot fastener AWARNING Crushing hazard Failure to install the fasteners into the engine tray to secure it from moving could result in death or serious injury Part No 102521 Genie S 40 S 45 3 21 CHECKLIST B PROCEDURES B 8 Inspect the Tires Wheels and Lug Nut Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion AWARNING Bodily injury hazard An over inflated tire can explode and could cause death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products Note The tires on some machines are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks
418. z F3L 201 1 Deutz D201 1L03i from serial number 7544 to 12509 Perkins 404 22 Models from serial number 7472 to 12509 30 31 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 201 1 Deutz D201 1L03i and Perkins 404 22 Models from serial number 12510 to 14831 32 Section 6 Schematics October 2013 Electrical Schematic Deutz F3L 201 1 Deutz D201 11 03 and Perkins 404 22 Models from serial number 12510 to 14831 x E Bg 5 e 6 A HIGH RPM FS C casESPD J 8 HIGH IDLE RELAY due P LOWRPM E FUNCTION ENA 5 5 HIGH RPM BK RD 2 8 BK RD C5 8 A HIGH RPM SOLENOID 2 r

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