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Service Manual - Genie Industries

1. E QM H MASTER TES e PLATFORM PR1 PR2 PL LEVEL PL2 TURNTABLE s2 EXTEND RETRACT R1 R2 1 BOOM OPTIONAL MOTOR GEN HIGH ECH E 34 PRESS FILTER A a PX PRESS Ai FUNCTION 52606 6 PUMP 2600 6 4 GPM o DRIVE PUMP XX L i 2500 PSI RE SEC REG e Q D RESERVOIR AUX PUMP mitt ML DA a TANK 5 EISA Sree 4 z REAR e T RIGHT uH ES uz Eh Ut BRP Bese I REAR LEFT NK B STEERING DRIVE MANIFOLD 250 PS PartNo 32222 Genie S 40 6 13 Service Manual Section 6
2. SLAVE TURNTABLE x BOOM BOOM PLATFORM EXTENSION UP DOWN ROTATE MASTER NE b DS L PLATFORM LEVEL TURNTABLE BOOM ums PR1 PR2 PL PL2 51 EXTEND RETRACT R1 R2 P1 2 OPTIONAL 2500 FUNCTION pn PSI I ici ER 7 MANIFOLD O 360 T he PSI U PRESS SE FT FILTER ES Lo 3 5 5 3500 ZIEM PRESS A FUNCTION EJOO Pume 6 4 GPM L I kt H rn EU EZ E PRESST DRIVE PUMP 2 p 5e wht ov l 2500 1 i 1 ac PSI SEC REG PS PSI 7 foto Din q RESERVOIR AUX PUMP OSCILLATE ITE m Em M 24 a TANK amp H Q Rys A dk acie T E 5 I STEER MANIFOLD w x SZ IA REAR b BS ES Us FRONT RIGHT SE AL 4 RIGHT M5 M6 OSCILLATE DIRECTIONAL VALVE O
3. TB18 he GRN 2 o x 2 m BLU RED 3 WHT 5 p 4 GRN S WHT 1 F RED 5 BLK 5 S gt a 0 FA aoa p ui EFR S DRIVE ENABLE BLU WHT 3 I E 8 5 WHT BLK 1 WHT BLK431 E H Y DRIVE EDC R 4 E E 4 WHT RED 1 E WHT RED 32 E H n M BLU BLK 1 E BLU BLK 37 E H n g BLU 1 B BLUs36 E H n A 8 E i E a a S ORG 1 a 49 WHT 6 GRN 6 Eg wo a Eemer 49 5255 WHT 7 12 BLK 7 Ica WHT RED 3 wo E WHT BLK 3 A e WHT 3 WHT WHT 4 r1 RIGHT WHT BLK TURNTABLE ROTATE 8 ME LEFT be WHT BLK 4 o p UT mn 2 E fo i 7 1 WHT RED 4 n Ye g RED m RED 4 e UP aan PRIMARY BOOM HEDIBLK EEREETE o 7 DOWN Pak RED BLK 4 m b 4 o m E RED WHT 4 n n RED 3 p gt A RED BLK 3 RED WHT 3 e M E BLK 3 1 EXTEND gt BOOM R p BLK WHT 3 0 d got BL
4. RESERVOIR PUMP OSCILLATE LS DA A m hi 1 5 X I A L a TANK 5 H 471 7 STEER MANIFOLD M4 REAR TO RIGHT E T OSCILLATE DIRECTIONAL VALVE WE OSCILLATE MANIFOLD Pa EE ad TLT Pa 1 dam 2 28 E M3 5 4 i REAR 1 T LEFT a DOSES pd A VALVE ACYL l ry ___ F OX B VALVE Ki x BCYL STEERING Part No 32222 Genie S 40 6 14 Service Manual Section 6 Schematics oz ZZ ZLA LAO 4WD Hydraulic Schematic Service Manual Section 6 Schematics 4WD Hydraulic Schematic
5. P2 FS1 TP25 22 TP26 88 LK BLK BLK WHT lt TB24 i TS1 Ts2 rsa 5 2 A 2 z P3 5 2 a 4 TP23 z z S H HORN amp z EJ x TN w CB2 KS1 19 27 TP33 5 P1 15AMP a PLAT p RED RED GRND u s E 2 2 D ES 2 m 5 a 8 13 9 m 9 a o z a 2 R TS9 4 TS10 TS12 g 8 2 3 3 8 9 2 b Y x t ki aj TB19 TERP 8 TB23 TB33 TB9 4 5 TB35 1 START RELAY E pest 2 TACHOMETER IGN START CB1 3 START INPUT MODULE 5 S9 m 4 AUX ON o 5 GROUND 41820 S RED 6 BATTERY 7 KEY PWR m O 8 KEY BYPASS g 9 IGN FUEL Of CR1 10 ENG FAULT 9 CR1 CR2 1 CR2 m NO NO P e u TB21 5 cej n o 2 i 1 9 m m E m th CR4 CR4 Z g lt 9 NO 3 E 5 i N m 4 7824 p 590 E n m m 8 E 2 z I E 9 3 i 9 m 3 PRI Ry R 5 NO 4 m 1 E A 4 E ALTERNATOR a i 4 EXCT CR5 CR5 ie 4 NO cp m BAT Ge t LL E g EJ sra t Nm ca STARTER wrist lt 1 AUX PUMP NO UREGULATOR H 195 T opsi NA NC a g
6. O r1 Section Four TABLE OF CONTENTS Scheduled Maintenance Procedures continued 22 Testthe Drive Enable System 4 23 B 23 Testthe Drive Brakes nnne 4 24 B 24 Testthe Drive Speed Stowed Position 4 24 B 25 Testthe Alarm Package Optional Equipment 4 25 B 26 Perform Hydraulic Oil Analysis 4 25 B 27 Replace the Engine Oil and Filter Deutz Diesel Models 4 26 C 1 Check the Boom 5 eem 4 27 C 2 Check the Turntable Rotation Bearing Bolts 4 27 C 3 Check the Free wheel Configuration 4 28 C 4 Grease the Turntable Rotation Bearing and Rotate Gear 4 29 C 5 Replace the Torque Hub Oil eee mmn 4 29 C 6 Replace the Hydraulic Tank Filter 0 0 eee m 4 31 C 7 Replace the Drive Loop Hydraulic Filter s se 4 31 C 8 Replace the Diesel Fuel Filter Deutz Diesel Models 4 32 C 9 Replace the Gasoline Fuel Filter Gasoline LP G Models 4 32 C 10 Replace the PCV Valve Gasoline LP G Models 4 34 C 11 Clean or Replace the Distributor Cap and Rotor Gasoline LP G Models 4 34 C 12 Replace the Spark Plugs
7. Boom 10 12 ft lbs 14 16 Nm 13 Relief valve 1950 psi 134 bar Dudas Boom 25 30 ft lbs 34 41 Nm 14 Relief valve 2200 psi 152 bar Boom down 2 25 30 ft lbs 34 41 Nm 15 Proportional solenoid valve NA BOOM farce O e 10 12 ft lbs 14 16 Nm 16 Flow regulator valve Turntable rotate boom extend retract 10 12 ft lbs 14 16 Nm 17 Normally closed poppet valve JEM Platform 25 30 ft lbs 34 41 Nm 18 Proportional solenoid valve Zu Turntable rotate boom extend retract 10 12 ft lbs 14 16 Nm 19 Flow regulator valve M esten Platform 10 12 ft lbs 14 16 Nm 20 Differential sensing valve AC All 5 222 2 0 10 12 ft lbs 14 16 Nm 21 Flow regulator valve Platform 10 12 ft lbs 14 16 Nm 22 Flow regulator valve W ais Differential sensing circuit 10 12 ft lbs 14 16 Nm 23 Diagnostic fitting 1 2 Testing 24 Relief valve
8. A 15 Replace the Engine Oil and Filter Gasoline LPG Models A 16 Replace the Engine Air Filter 1 Check the Engine Belt s B 2 Check the Radiator Gasoline LPG Models B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models B 4 Check the Exhaust System B 5 Check the Battery B 6 Check the Hydraulic Tank Filter Condition Indicator B 7 Inspect the Electrical Wiring B 8 Inspect the Tires and Wheels 4 including lug nut torque B 9 Confirm the Proper Brake Configuration B 10 Check the Oil Level in the Torque Hubs B 11 Check and Adjust the Engine Idle Mixture Gasoline LP G Models B 12 Check and Adjust the Engine RPM Part No 32222 Genie S 40 Section 3 Scheduled Maintenance Inspections Service Manual First Edition nh MAINTENANCE TABLES Table B continued Warm d Dealer Tools are New parts engine engine service required required required required suggested B 13 Test the Key Switch B 14 Test the Emergency Stop Buttons B 15 Test the Ground Control Override B 16 Check the Directional Valve Linkage B 17 Testthe Platform Self leveling B 18 Test the Service Horn B 19 Test the Foot Switch B 20 Testthe Engine Idle Select B 21 Test the Fuel Select Operation Gasoline LPG Models B 22 Testthe Drive Enable System B 23 Test the Drive Brakes B 24 Drive Speed Stowed Position ra ra B 25 Testthe Al
9. Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform Service repair problem solved Part No 32222 Genie 5 40 6 1 Section 6 Schematics Service Manual First Edition Electrical Symbols Legend SN Circuit breaker Bij ib E Water temperature Starter motor Wire color switch relay with cable d normally closed number Solenoid or Ground Ft ney relay coil supression Buk circuit Terminal Foot switch TILT TP29 ALARM LS4 NC Horn M PLAT Quick disconnect o Limit switch terminal SERA GRND BLK 21 TB2t Key switch T circuits connect no at terminal e Light Limit switch J normally open held closed T circuits Toggle switch SPDI connect Horn button 3 normally open Resistor Ph Connection Limit switch a no terminal normally closed Toggle switch DPDT held open Emergency Stop Pm button BP normally closed gt PIM Circuits crossing Tilt sensor connection 3 Single axis proportional Vacuum switch sonwoler 1 Relay contact Diode Spark plug normally open 5 I Oil pressure switch Relay panel Dual axis Glow plug normally closed contactor proportional Battery controller 6 2 Genie S 40 Par
10. Part 32222 Genie 5 40 3 5 Section 3 Scheduled Maintenance Inspections Service Manual First Edition MAINTENANCE TABLES Warm Cold Dealer Table D Tools are New parts engine engine service required required required required suggested D 1 Test or Replace the Hydraulic Oil a u D 2 Change or Recondition the Engine Coolant Gasoline LPG Models D 3 Change the Fuel Lines D 4 Check the Engine Valve Clearance Gasoline LPG Models D 5 Check the Engine Cylinder Compression Gasoline LPG Models D 6 Clean the PCV Hoses and Fittings Gasoline LPG Models D 7 Check the Fuel Injection Pumps and Injectors n Deutz Diesel Models D 8 Check the Toothed Belt Deutz Diesel Models D 9 Replace the Timing Belt Gasoline LPG Models EE Genie 5 40 Part No 32222 Service Manual First Edition Section 3 Scheduled Maintenance Inspections Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Comments Checklist A YN R B 18 Service horn B 19 Foot switch B 20 Engine idle select A 2 Decals and placards B 21 Fuel select gasoline A 3 Damage loose or missing parts A 4 Engine oil level A 5 Engine coolant gasoline A 6 Fuel leaks A 7 Hydraulic oil level A 8 Hydraulic leaks A 9 Tire pressure
11. s 5 5 gt Qus Gasoline LP G idle adjustment a low idle adjustment b high idle adjustment 10 Re assemble the governor and recheck low and high idle Gasoline LPG models Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm Deutz Diesel models 1 Connectan rpm gauge to the engine and then start the engine from the ground controls Result Low idle should be 1300 rpm Skip to step 3 if the low idle rpm is correct Genie 5 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures TABLE B PROCEDURES 2 Loosenthe lock nut then turn the adjustment B 13 screw clockwise to increase the rom or counterclockwise to decrease the rpm Tighten Test the Key Switch the lock nut and recheck the rpm 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 ofthe key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pull outthe 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 turn the key switch to platform control a solenoid boot 3 Checkany machine function from the ground b high
12. gu 0 E e 2 S p 9 WHT y BLK 1 HOUR METER BZ BO ENGINE JB 924408 START 2 ere 2 OIL PRESSURE 22 D S N rol m a o lo ler ele im SENDER 3 WHT 24 E H START 2 WATER TEMP SENDER N t f o jf e AUTOMATIC 7 2 od ES pur zo SEZ gt WHT 21 E H RED L 5 54 E e E e cu b IGNITION 5 gt 4 SYSTEM 5 ola fo o gt 5 oz R sii w NUTS o BLK R1 E H Tint o 52 are STARTER MOTOR 8 1 i 0 E c 5 1 RED 27 E H a gt a AUXILIARY POWER 1 RED 1 RELAY lt AUXILIARY PUMP t gt Eg M o E m WHT GRN WHT 3 GRN WHT 19 E H e 5 WHT E WHT 2 E RED WHT 23 E H LEVEL SENSOR gt o e BLK RED 3 p BLK RED n Ys SERVICE HORN N a RELAY a BLK 2 Os BLK 6 kz SERVICE HORN zs 8 o xja 6 Ly je a E a N N N N m BRN BLK E H ORG BLK 41 E H 4 2 8 c 5 5 z i WHT 21 E H a S c H a E RED E H 9 5 0 alec S 4 Oe p 3 35 gt o E RED RED 20 E H 1 Y o m Section 6 Schematics Service Manual Electrical Schematic Gasoline LPG Models TP41
13. function inoperative Check the resistance of function the directional valve Hold toggle switch and operates coil manually override extend directional valve push in button on end of valve spool Note overriding the valve will RUE two people If helper is not available interchange the valve item S with a like valve item 4 to 5 ohms Replace the valve function inoperative Continued on the next page 0 or infinite ohms Chart 16 Replace the defective valve coil PartNo 32222 Genie 5 40 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 16 Install a 0 to 3000 PSI pressure gauge at the quick disconnect coupling on the function manifold and hold the function switch Continued from the previous page Adjust the boom extend relief valve item D in one tum clockwise Then with pressure gauge still attached Counting the turns adjust the boom extend relief valve item D in all the way Then operate the extend function Check for mechanical restrictions and or the less than 1200 psi cylinder has internal defects Please consult Genie Industries Service Department With boom fully extended hold the extend function switch Adjust the relief valve to function inoperative operate the function read 1200 psi less th an 1200 psi Remove the extend 0 function pressure lin
14. RR flow control in forward 4 Flow regulator valve Fs LR flow contol in reverse 5 Flow regulator valve Japani LR flow control in forward 6 Flow control b anis RR flow regulator in reverse 7 Flow control E igi LR flow regulator in reverse 8 Flow control ln RR flow regulator in forward 9 Flow control lus LR flow regulator in forward 10 Shuttle valve Bus Charge pressure circuit Plug Torque Specifications Description Hex size Torque Description Torque 15 18 ft lbs 20 24 Nm 15 18 ft lbs 20 24 Nm 15 18 ft lbs 20 24 Nm 15 18 ft lbs 20 24 Nm 15 18 ft lbs 20 24 Nm 15 18 ft lbs 20 24 Nm 15 18 ft lbs 20 24 Nm 15 18 ft lbs 20 24 Nm 15 18 ft lbs 20 24 Nm 15 18 ft lbs 20 24 Nm Hex size Torque SAE No 2 1 8 50 in Ibs 6Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 4 3 16 13 ftlbs 18 Nm SAE No 10 he 55 ft lbs 75 Nm SAE No 6 1 4 18 ftlbs 24 Nm SAE No 12 5 8 75 ft lbs 102 Nm 7 52 Genie S 40 PartNo 32222 Section 7 Repair Procedures Service Manual First Edition 2WD DRIVE MANIFOLD 53 Genie S 40 Pa
15. 6 1 Governor Actuator How to Set Up the Governor Actuator and Linkage Adjustment of the governor actuator is only necessary when the governor actuator or the linkage has been replaced 1 Connect the linkage rod to the throttle plate shaft then tighten the lock nut 2 Fasten the lock nut and clevis yoke to the linkage rod Do not tighten the lock nut against the clevis yoke 3 Loosen the fastener on the actuator arm Rotate the actuator arm until itis ata 110 degree angle to the linkage rod Ford LSG 423 Engine Governor actuator and linkage clevis yoke linkage rod carburetor throttle plate shaft governoractuator actuator shaft actuatorarm ow Position the linkage rod so that the throttle is in the idle position Then adjust the clevis yoke on the linkage rod to obtain the proper length Install the yoke onto the actuator arm and tighten the lock nut With the throttle in the idle position and the actuator arm ata 110 degree angle to the linkage rotate the actuator shaft slightly counterclockwise to pre load the spring Tighten the fastener on the actuator arm without releasing the shaft Part No 32222 Genie S 40 7 19 Section 7 Repair Procedures Service Manual First Edition FORD LSG 423 ENGINE 6 Manually pull the actuator arm through a full cycle to be sure that the linkage moves freely Be sure that the linkage activates the throttle shaft to approximately half throt
16. PartNo 32222 Genie S 40 4 1 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table A Procedures A 1 Inspect the Manuals 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 1 Check to be sure thatthe storage container is present and in good condition 2 Check to make sure thatthe operator s responsibilities and safety manual are present and complete in the storage container in the platform 3 Examine the pages of each manual to be sure thatthey are legible and in good condition 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed A 2 Inspect the Decals and Placards Maintaining all ofthe safety and instructional decals and placards 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 Referto the De
17. lift cylinder Part No 32222 Genie S 40 4 7 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES 3 Remove the turntable end cover to access the 9 Lowerthe boom to the stowed position then limit switch mounted inside the boom extend the boom 1 foot 30 cm 4 Visually inspect the drive limit switch located in 10 Slowly move the drive control handle off center the pivot end of the boom Inspect for the Result The machine should move ata reduced following drive speed broken or missing actuator arm missing fasteners Drive speed maximum raised or extended loose wiring All models 1 foot per second 0 3 meter per second Drive Enable Limit Switch 1 With the engine off and the boom in the stowed position visually inspectthe drive enable limit switch for the following broken or missing rollers or arms missing fasteners loose wiring a drive limit switch b C extension boom tube d extension cylinder 5 Lowerthe boom to the stowed position 6 Startthe engine from the platform controls Then slowly move the drive control handle off center Result The machine should move at normal drive speeds a turntable S b drive enable limit switch 7 Raise the boom above the drive limit switch c turntable rotation bearing 8 Slowly move the drive control handle off center Result The machine should m
18. wow ay ow etc Ld e 0 69 Plug Torque Specifications Torque 10 12 ft lbs 14 16 Nm 35 40 ftlbs 47 54 Nm 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm 35 40 ft lbs 47 54 Nm 35 40 ft lbs 47 54 Nm Description Hex size Torque Description Hex size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 4 3 16 13 ftlbs 18 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 12 5 8 75 ft lbs 102 Nm PartNo 32222 Genie S 40 7 45 Section 7 Repair Procedures Service Manual First Edition pu J r STEER AND OSCILLATE MANIFOLDS 15 2 Valve Adjustments How to Adjust the Sequencing Valve Pressure 1 Connecta 0 to 600 psi 0 to 41 bar pressure gauge to the test port located on the oscillate manifold Bodily injury hazard S praying ACAUTION 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 2 Disconnect the directional valve linkage by removing the clevis yoke from the drive chassis 3 Startthe engine from the platform controls 4 With the engine running manually activate the valve and observe the pressure reading on the pressure gauge 5 Tum the engine off Hold the valve and remove the cap index 4 6 Adjustthe internal hex socke
19. 6 6 Flex Plate The flex plate acts as a coupler between the engine and the pump Itis bolted to the engine flywheel and has a splined center to drive the pump FORD LSG 423 ENGINE Flex Plate Removal 1 Disconnect and remove the hose between the carburetor venturi and the air cleaner 2 Disconnect the linkage from the governor then remove the governor linkage from the carburetor Do not alter the length of the linkage 3 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 4 Remove the mounting fasteners from the regulator mounting bracket then pull the bracket up past the bell housing Secure the bracket before continuing 5 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 6 Carefully pull the pump away from the engine and secure it from moving 7 Remove the flex plate mounting fasteners then remove the flex plate from the engine How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline against the flywheel Torque the flex plate mounting bolts to 34 ft lbs 46 Nm 2 Install the coupler onto the pump shaft with the set screw towards the pump Leave a heinch 4 7 mm gap between the coupler and pump end plate 3 Apply Loctite removable thread sealant to the coupler set screw Torque the set screw to 45 ft lbs 61 Nm Component
20. Troubleshooting Flow Charts Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair ofthis machine M Immediately tag and remove from service a damaged or malfunctioning machine M 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 flat level surface boom in stowed position turntable rotated with the boom between the non steering wheels turntable secured with the turntable rotation lock pin key switch in the orr position with the key removed wheels chocked Before Troubleshooting M Read understand and obey the safety rules and operating instructions printed in the Genie S 40 Operator s Manual M Be sure thatall necessary tools and test equipment are available and ready for use M Read each appropiate flow chart thoroughly Attempting shortcuts may produce hazardous conditions M Be aware of the following hazards and follow generally accepted safe workshop practices Ty Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement Electrocution hazard Contact LLS with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily inju
21. 1 Connecta 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Startthe engine from the ground controls 3 Hold the extend switch with the boom fully extended and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the relief valve and remove the cap item 13 function manifold 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap E A Tip over hazard Do not adjust AWARNING the relief valves higher than recommended 6 Restartthe engine Hold the extend switch with the boom fully extended and recheck the valve pressure Boom extend relief valve specifications Pressure 1950 psi 134 bar FUNCTION MANIFOLD How to Override a Valve A hydraulic valve may need to be manually overridden to troubleshoot a malfunction The proportional boom functions boom up down and turntable rotate use a variable position proportional valve and a three position directional valve Example one position for boom up one position for neutral and one position for boom down The platform rotate function uses a three position valve The platform level uses a three position and a two position valve The three position valves and the proportional valves can be manually overridden To identify the manifold valves see 9 1 Function Manifold in th
22. CR1 to terminal 30 on CR8 Hold start switch and Repair open in blk wire check voltage at i terminal 86 of CR8 Re Check ole to Repair open in ground terminal 85 on CR8 wire to CR8 If weak spark still exists contact Genie Industries Service Department Part No 32222 Genie S 40 5 7 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 2A Engine Cranks engine and check Repair open in M voltage at automatic 421 wire circuit from Over But Will choke ILU NT ignition module to Not Start automatic choke 12V Gasoline LPG Models Check automatic choke pa Adjust or replace for proper adjustment or H automatic choke OR or internal damage consult Genie Industries Service Department good Engine Runs While Cranking With keyswitch on and Repair open in red wht both mushroom oV 36 wire circuit from Then Dies switches pulled out YY TB36 to vacuum switch check voltage at red wht Continuation of good FOO Wire onvacuum Switch spark fault path Perform these tests in 12V gasaline mode Ony Remove the blk wire N y Turn machine off See Bad Replace vacuum switch with diode from terminal Repair section for 86 on CR6 crank the vacuum switch check engine over for 15 seconds and check ok voltage at On Wire bad on vac
23. 23 WHT S P kEvswiTCH PWR BLK 2 22 BLK CR5_ BLK S P PWR TO PLAT WHT EH GR2 21 WHT S P IGNITION PWR RED E H 20 RED S P 12V BATT SUPPLY GRN WHT 4 GRN WHT 3 19 TILT ALARM GRN BLK 4 GRN BLK 3 18 GR BK D B GR BK S P PLAT ROT R GRN 4 GRN 3 17 GRN D B GRN S P PLAT ROT L CABLE ORG RED 4 ORG RED 3 16 OG RD D B OG RD S P PLAT LEVEL 41 ORG BLK 4 ORG BLK 3 15 OG BK D B s P PLAT LEVEL DN ORG 4 ORG 3 14onG D B ORG S P PLAT LEVEL UP BLU RED 3 18 WHT 5 DRV ENA LT WHT E H _ BLU WHT 3 12 BLK 5 DRV ENA BLU BLK 4 BLU BLK 3 11 BU BK D B BU BK S P BLU 4 BLU 3 D B BLU BLK RED 3 BK RD HORN BLK WHT 4 BLK WHT 3 8 BK WT D B BK WT S P BOOM RETRACT BLK 4 BLK 3 7 BLK D B BLK S P BOOM EXTEND W R 4 WHT RED 3 6 WT RD S P TURN ROT CABLE WHT BLK 3 5 wT BK D B WT BK S P TURN ROT L 2 WHT 4 WHT 3 WHTD B WHT S P TURN ROT R RIW 4 RED WHT 3 L3 RD WT S P BOOM RED BLK 4 RED BLK 3 2 RD BK D B S P BOOM DOWN RED 4 RED 3 i RED D B RED S P BOOM UP D c B A DIODE O BLOCKS CABLE 3 1 START RELAY 2 TACHOMETER IGN STAR 3 START INPUT MODULE Q 4 AUX ON 5 GROUND BATTERY 7 KEY pwr CABLE KEYBYPAss 9 IGN FUEL ON 10 ENG FAULT CR1 CR2 CR3 START IGNITION RPM RPM RELAY RELAY CUTOUT REL
24. Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures 8 Disconnect and plug the boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying ACAUTION 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 9 Remove the mounting fasteners from the lift cylinder mounting bracket 10 With the lift cylinder being supported by the overhead crane pull the cylinder toward the platform until itis out Component damage hazard The ACAUTION cables and hydraulic hoses can be damaged if the lift cylinder is pulled across them 3 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 may cause death or serious injury and significant component damage Dealer service is strongly recommended 1 Raise the boom to a horizontal position 2 Extend the boom until the extension cylinder rod end mounting pins are accessible BOOM COMPONENTS 3 Remove the snap rings from the extension cy
25. Quantity 1 Oil viscosity requirements Cold cranking 1000A Temperature below 60 F 15 5 C 5W 30 3 Reserve capacity 25A rate 200 minutes 10 F to 90 F 23 C to 32 C 10W 30 Fuel pump Temperature above 10W 40 to 10W 50 10 F 23 C Static pressure 5 to 7 psi Temperature above 20W 40 or 20W 50 0 34 to 0 48 bar 25 F 4 C Minimum volume flow 1 pint in 25 seconds 473 cc Use oils meeting API classification SF labeled SF CC or SF CD as they offer improved wear protection Part No 32222 Genie S 40 2 5 Section 2 Specifications Service Manual First Edition 4 FORD ENGINE 156 423 SPECIFICATIONS Ignition System Bolt torque specifications torque torque Ignition spark advance 10 BTDC Bolt description size ftlbs Nm Ignition coil primary 1 13 to 1 259 Distributor clamp bolt M 10 14 21 19 to 28 resistance 75 F 24 C Distributor vacuum tube 5 to 8 7 to 11 Ignition coil secondary 7700 to 93000 to manifold adaptor resistance 75 F 24 C Exhaust manifold to cylinder head bolt or nut M 10 Spark plug type Motorcraft AWSF 52 torque in sequence first step 14 to 19 19 to 26 Spark plug gap 0 042 to 0 046 inches 1 07 to 1 18 mm second step 20 to 30 27 to 41 Flywheel to crankshaft 56 to 64 76 to 87 Engine coolant bolt M 10 Capacity ola Fuel pu
26. Schematics 2WD Hydraulic Schematic Oscilating Axle Service Manual Section 6 Schematics gt 2WD Hydraulic Schematic Oscilating Axle SLAVE TURNTABLE BOOM BOOM EXTENSION UP DOWN PLATFORM 7 ROTATE oo MASTER 4 H 3j Rg 025 PLATFORM e LEVEL TURNTABLE BOOM PR1 PR2 PL1 PL2 51 s2 EXTEND RETRACT RI R2 P1 P2 OPTIONAL FUNCTION MOTOR GEN MANIFOLD 0 70 LS EL HIGH ae o 1950 Pal PRESS PSI a FILTER l x E TM NE H LS s M EE py PSL eee 1 x PRESS s Wi Ha X d Pied X d FUNCTION Li i COO 6 4 GPM i g AZ a PRESS f i ANM CO D wid DRIVE PUMP gt L 4 4 4 i 4 4 i m m SEC REG RZA
27. 0 or Remove both wires from infinite valve coil and check ohms Replace the coil resistance across the coil terminals 4 to 5 ohms function operates Replace the platform leveling directional Hold toggle switch and manually override the level up directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not avallable interchange the valve item O with a like valve item N valve function inoperative Interchange check valve es Replace defective item L with like valve check valve item K Interchange the level up and down function inoperative Install 2400 nstall a pressure gauge psi at the quick disconnect more coupling on the function manifold and hold the function switch 2400 psi or counterbalance valves MOE items B amp C function operates Replace defective counterbalance valve less than 2400 psi Replace the directional valve OR the manifold has internal defects OR one of the previous tests was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department Chart 22 Disconnecting hydraulic lines or adjusting the cylinder counterbalance valves in this situation can be very dangerous Please consult Genie Industries Service Department PartNo 32222 Genie S 40 Section 5 Troubleshooting Flow Charts Service Manu
28. 15 16 9 Bolt torque sequence Part No 32222 Genie S 40 4 27 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES C 3 Check the Free wheel Configuration Proper use of the free wheel configuration is essential to safe 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 Collision hazard Selecta work AWARNING site that is firm and level Non steering wheels All models 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 15 000 1bs 6 804 kg under the drive chassis between the non steering wheels 3 Liftthe wheels off the ground and then place jack stands under the drive chassis for support 4 Disengage the torque hubs by turning over the torque hub disconnect caps on each non steering wheel hub disengage position arf mj h engage position 5 Manually rotate each non steering wheel Result Each non steering wheel should rotate with minimum effort 6 Re engage the torque hubs by turning over the hub disconnect caps Carefully remove the jack stands lower the machine and remove the jack AWARNING Collision hazard Failure to re engage the torque hubs may cause death or serious injury and property damage Steer wheels 4WD mo
29. 2600 psi 179 bar AB System relief ee 35 40 ft lbs 47 54 Nm 25 Priority flow regulator valve Tae 10 12 ft lbs 14 16 Nm 26 Check Platform rotate right differential sensing eee 11 13 ft lbs 15 18 Nm 27 Check valve see Platform rotate left differential sensing aaa 11 13 ft lbs 15 18 Nm 28 Check valve sese Let Platform level differential sensing 11 13 ft lbs 15 18 Nm 7 30 Genie 5 40 Part 32222 Service Manual First Edition Section 7 Repair Procedures FUNCTION MANIFOLD GG SE 5659 9 9 PartNo 32222 Genie 5 40 7 31 Section 7 Repair Procedures Service Manual First Edition FUNCTION MANIFOLD 9 2 Valve Adjustments Function Manifold How to Adjust the Main Relief Valve Parfarm_this nrocedure with the boom in the stowed position 1 Connecta 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Startthe engine from the ground controls 3 Hold the retract switch with the boom fully retracted and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the relief valve and remove the cap item 24 function manifold 5 Adjustthe internal hex socket Turn it clockw
30. 3 Engine Cranks Over But Will Not Start Deutz Diesel Models 5 12 4 Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LP G 5 15 5 Engine Will Not Start On Gasoline But Will Start On LPG Gasoline LPG 5 17 6 Engine High Idle Inoperative Gasoline LP G Models 5 19 7 Engine Low Idle Inoperative Gasoline LP G Models 5 21 8 Engine High Idle Inoperative Deutz Diesel Models 5 22 9 Engine Low Idle Inoperative Deutz Diesel Models 5 24 10 AllFunctions Inoperative Engine Starts and Runs 5 25 11 AllLiftand Steer Functions Inoperative Drive Functions Operational 5 26 12 Ground Controls Inoperative Platform Controls Operate Normally 5 27 13 Platform Controls Inoperative Ground Controls Operate Normally 5 28 14 Boom Up Function cece memes 5 29 15 Down Function Inoperative memes 5 31 16 Boom Extend Function Inoperative eem 5 33 17 BoomhRetractFunction Inoperative 0 5 35 18 Turntable Rotate Function Inoperative
31. A 10 Platform and ground controls Refer to Table A A 1 Manuals B 22 Drive enable system B 23 Drive brakes B 24 Drive speed stowed B 25 Alarm package B 26 Hydraulic oil analysis Perform every 500 hours B 27 Replace engine oil and filter Deutz Instructions Checklist C Y N R copies of this page to use for A 11 Auxiliary power Refer to Table C NA UL A 12 Tilt sensor C 1 Boom wear pads Select the appropriate checklist s for A 13 Limit switches i the type of inspection to be i C 2 Turntable bearing bolts rmed A 14 Oscillate Axle C 3 Free wheel configuration Perform every 100 hours C 4 Grease rotation bearing Daily Inspection A A 15 Replace engine oil CH Torque hub oil Quarterly Inspection A B and filter gasoline 3 Annual Inspection A B C A 16 Replace air filter oe avait tarik ET 2 Year Inspection A B C D C 7 Drive loop hydraulic filter Z ME C 8 Fuel filter diesel Place a check in the appropriate box Checklist B C 9 Fuel filter gasoline after each inspection procedure is Refer to Table B mE 7 completed B 1 Engine belt s ER Vegaso Use the maintenance tables in this B 2 Engine radiator C 11 Distibutor cap gasoline section and the step by step C 12 Spark plugs gasoline procedures in section 4 to le
32. EDC wires on drive pump move drive Raise boom off drive limit switch turn machine off and check continuity between ground and terminal 6 controller to full forward on horsepower limiter position and check board voltage between terminals 4 and 5 on drive controller no continuity Replace horsepower limiter board full Repair open in org wire circuit from TB40 to horsepower limiter board terminal 6 Check continui between groun and TB40 no continuity Repair limit switch wiring OR replace boom lift drive limit switch OR replace boom extend drive limit switch Defective Sundstrand drive pump Replace or repair at authorized Sundstrand repair facility Genie S 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 34 Drive Enable DO not hold the drive will holding the drive Troubleshoot enable switch and enable switch allow orsepower limit board System Is wi Gy drive in controller 1 i i rive in the stowe stowed position over rive pump See chart Malfunctioning position with boom over non steer wheels 30 non steer wheels Repair or replace drive enable limit switch Do not hold the drive enable switch and check if machine will drive in the stowed position with boom over the steer wheels Repair or replace drive enable limit switch Will holding the drive enable switch
33. Operate boom up function and check if platform levels Check for mechanical restrictions OR replace the slave cylinder counterbalance valves Plumb a pressure gauge into the master cylinder barrel end hydraulic hose using a tee fitting Operate boom up function and read the pressure less than 2400 psi Deadhead the pressure gauge into the barrel end hydraulic hose from the master cylinder and raise the boom one inch ata time Continually monitor the pressure gauge during boom up Do notallow the pressure to exceed 2500 psi i Repair or replace the master cylinder 2400 psi or more Repair or replace the slave cylinder Genie 5 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Platform Level Up Function Inoperative Be sure all other functions operate normally If platform level up function operates normally from the ground controls but not from the platform controls troubleshoot the platform control toggle switch See Repair section If platform level up function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check voltage at org Repair open in org wire circuit from TB14 to directional valve wire on platform level up function directional valve 12V
34. WHT 7 12 BLK 7 Ica WHT RED 3 E WHT BLK 3 WHT 3 gt WHT ES WHT 4 RIGHT WHT BLK g URNTABLE ROTATE LE BLK 4 m be WHTA E FII B f 7 4 WHT RED 4 p 2 4 g RED m RED 4 a 4 UP PRIMARY BOOM HED BLK EEREETE o 7 DOWN PGA RED BLK 4 m b 4 o m T E RED WHT 4 n 4 RED 3 RED BLK 3 o N n E E RED WHT 3 e M n e BLK 3 1 EXTEND gt BOOM R p RETRACT BLK WHT 3 0 r E BLK 4 7 100 EXTEND BLK WHT t BOOM mE w RETRACT BLK WHT 4 a 0 d 4 E B 150 BLK RED 4 a 2 ORG 3 l UP PLATFORM LEVEL DOWN g ORG BLK 3 ORG 4 F E 2 ORG 4 o UP PLATFORM LEVEL x ORG BLK p lt DOWN ORG BLK 4 7 Iu 2 m gt t p ORG RED 4 i E ORG RED 3 M a 3 GRN 3 LEFT PLATFORM ROTATE w p RIGHT GRN BLK 3 GRN X GRN 4 E E EFT NT PLATFORM ROTATE CANEL se p GRN BLK 4 n 6 9 Genie S 40 GROUND Part No 32222 DRIVE ENABLE LIMIT SWITCH BRAKE STEER RIGHT STEER LEFT BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH TURNTABLE ROTATER TURNTABLE ROTATE L TURNTABLE ROTATE amp EXTEND RETRACT FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL BOOM EXTEND BOOM RETRACT PLAT LEVEL UP PLAT LEVEL DN PLAT LEVEL PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT Service M
35. 0bar 8 35 8 8 Oil capacity 8 5 quarts Rocker arm bolts 15 to 18 20 to 24 including filter 8 liters 8 x 45 8 8 Oil viscosity requirements Rocker arm set screw nut 15 to 18 20 to 24 Temperature below 60 F 15 5 synthetic 5w 30 Cylinder head cover 6 to 7 8 to 10 10 F to 90 F 23 C to 32 C 10W 40 Blower rotor nut 33 to 41 45 to 55 M 17 Valeo or M 18 Bosch Temperature above 4 F 34 C 15W 40 5 Blower carrier bolts 15 to 18 20 to 24 Engine oil should have properties of API classification M 8 x 50 Torx 8 8 CC SE CD SE CC SF or CD SF grades GU V belt pulley bolts 281034 38046 Injection system M 10 x 16 8 8 Injection pump make OMAP Part No 32222 Genie S 40 2 7 Section 2 Specifications DEUTZ ENGINE F3L 1011 SPECIFICATIONS Service Manual First Edition RH w e Bolt tightening specifications continued pir airs torque torque Awe Bolt description size grade ft lbs Nm thermostat housing screw 37 to 44 50 to 60 Idler pulley V belt pulley bolt 27 to 32 36 to 44 Plug M 38 x 1 5 M 10 x 25 8 8 Oil thermostat housing bolts 5 5 to 7 7 5 to 9 Idler pulley for toothed belt 30 to 36 41to49 M 6x 35 Torx 8 8 M 10 x 50 8 8 Oil thermostat housing bolts 5 5 to 7 7 5 to 9 Oil pump bolts 15 to 18 20 to 24 M 6 x 80 Torx 8 8 M 8 x 35 Torx Oil thermostat housing bolts 14 to 16 19 to 22 O
36. 12 B 4 Check the Exhaust System 20 1 enne eene 4 13 B Check the Battery eet a De er t APO 4 14 B 6 Check the Hydraulic Tank Filter Condition 4 14 B 7 Inspect the Electrical 4 15 B 8 Inspect the Tires and 4 15 B 9 Confirm the Proper Brake Configuration 4 16 B 10 Check the Oil Level in Torque lt cca 4 16 B 11 Check and Adjust the Engine Idle Mixture Gasoline LP G Models 4 17 B 12 Check and Adjust the Engine 4 17 13 Test the Key WIEC irre eme OE t ieee A E 4 19 B 14 Testthe Emergency Stop Buttons 2 eee 4 20 B 15 Testthe Ground Control Override sss 4 20 B 16 Check the Directional Valve Linkage 2 4 21 B 17 Testthe Platform Self leveling 2022 22 mes 4 21 18 Testthe Service Horn uuu aaa aaa aaa aaa nnns 4 21 19 Testthe Foot Switch oo eer eene 4 22 B 20 Testthe Engine Idle Select 0 44 4 22 21 Testthe Fuel Select Operation Gasoline LP G Models 4 23 vi Genie S 40 Part No 32222 Service Manual First Edition EE
37. 5 36 19 Turntable Rotate Left Function Inoperative 5 38 20 Turntable Rotate Right Function Inoperative 5 39 21 AllPlatform Leveling Functions Inoperative 5 40 22 Platform Level Up Function Inoperative 5 41 23 Platform Level Down Function 5 42 viii Genie 5 40 PartNo 32222 Service Manual First Edition Section Five TABLE OF CONTENTS Troubleshooting Flow Charts continued 24 Platform Rotate Left Function Inoperative 5 43 25 Platform Rotate Right Function 5 44 26 Oscillate Function memes 5 45 27 SteerLeftFunction Inoperative sssssseee eee 5 46 28 SteerRightFunction 1 2 5 47 29 AllDrive Functions Inoperative All Other Functions Operate Normally 5 48 30 Drive Forward Or Reverse Function Inoperative 5 51 31 Traction Function Inoperative eee ue 5 52 32 Machine Will Not Drive At Full Speed sm 5 53 33 Machine Drives At Full Speed With Platform
38. 83 2 liters per minute Oscillate cylinder pressure 900 psi 62 bar Front drive motors 4WD models Auxiliary pump Displacement 1 52 cu in per revolution 25 cc Type fixed displacement gear pump Rear drive motors Displacement static 0 152 cu in 2 5 Displacement per revolution 2 13 cu in 35 cc Displacement 1 4 gallons per minute 5 3 liters per minute Auxiliary pump 2500 psi relief pressure 176 bar PartNo 32222 Genie S 40 2 3 Section 2 Specifications Service Manual First Edition BOLT TORQUE SPECIFICATIONS Bolt Torque Specifications Size Threads SAE Grade 5 Bolts lt gt SAE Grade 8 Bolts Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry inch pounds foot pounds Newton meters inch pounds foot pounds Newton meters No 10 24 43 5 60 7 32 49 6 68 8 Ya inch 20 96 11 144 16 28 120 14 168 19 5 16 inch 18 17 23 25 34 24 19 28 25 34 3 inch 16 30 41 45 61 24 35 48 50 68 The inch 14 50 68 70 95 20 55 75 80 109 12 inch 13 75 102 110 149 20 90 122 120 163 9 16 inch 12 110 149 150 204 18 120 163 170 231 5 s inch 11 150 204 220 298 18 170 231 240 326 3 4 inch 10 260 353 380 515 16 300 407 420 570 ls inch 9 430 583 600 814 14 470 637 660 895 1 inch 8 640 868 900 1221 12 700 949 1000 1356 Torque specification for lubricated bolts is 25 less than dry torque specification for bolt size 2 4 Geni
39. BLK WHT 1 z START 33 BLK 1 lt BRAKE 32 WHT RED 1 8 E D C 31 WHT BLK 1 E D C 30 WHT 1 gt 2WD 4WD 29 RED WHT 1 SPARE 28 RED BLK 1 gt O AUX PWR 27 RED 1 PWR TO FS 26 BLK ES PWR START 25 GREEN PWR 24 WHT H P L PWR FRM PLAT 23 WHT 2 PWR PLAT 22 BLK 2 000 x 21 g 20 cools TILTALARM 19 GRN WHT 3 5 ooo jg PLAT ROT R 18 GRN BLK 3 PLAT ROT L 17 GRN 3 ug PLAT LVL 16 ORG RED 3 PLAT LVL DN 15 ORG BLK 3 PLAT LVL UP 14 3 DRV ENA LT 13 BLU RED 3 o DRV ENA 12 BLU WHT 3 SEC BOOM DN 11 BLU BLK 3 SEC BOOM 10 BLU 3 gt HORN 9 BLK RED 3 of o5 RETRACT 8 BLK WHT 3 94 EXTEND 7 BLK 3 AN 18 EG ROTATE EC 6 WHT RED 3 Ir ROTATE RIGHT 5 WHT BLK 3 ROTATELEFT 4 WHT 3 3 RED WHT 3 BOOM DN 2 RED BLK 3 5 x BOOMUP 1 RED 3 As glooo Qu an E EG u mu ooojqH E 7 Nu s a R X A 1 2 3 4 5 6 7 8 919 9 do rs 5 2 IZ 9 E Q g m 63 5E 55 Fa PartNo 32222 Genie S 40 6 7 Service Manual Section 6 Schematics ET Electrical Schematic Diesel Models Section 6 Schematics Electrical Schematic Diesel Models Service Manual
40. Genie S 40 5 17 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 5 E Hold start switch and Repair open in blu wht PO Tom the check voltage at blu wht wire circuit from CR6 p page wire on gasoline to fuel solenoid solenoid at fuel tank Replace gasoline solenoid Repair ground wire Replace anti diesel valve 0 or infinite ohms Check resistance of gasoline solenoid 18 to 19 ohms Check ground wire to gas solenoid infinite ohms Check resistance of anti diesel valve 24 to 25 ohms Reconnect starter check anti diesel and fuel valve for defects OR see Ford service manual for carburetor troubleshooting 5 18 Genie S 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine High Idle Inoperative Gasoline LPG Models If high idle operates on LPG but not on gasoline see Ford service manual for carburetor troubleshooting If high idle operates on gasoline but not on LPG see Repair section for LPG regulator adjustments Be sure throttle linkage from governor to carburetor is not binding see Repair section Be sure high idle can be achieved by grasping the governor actuator arm and momentarily pulling to throttle the carburetor Start engine and switch rpm select to high idle rabbit symbol for following checks Check voltage at blk
41. Hex size Torque Description Hex size Torque SAE No 2 1 50in lbs 6 Nm No 8 5 16 50 ft lbs 68 Nm SAE No 4 316 13 ftlbs 18 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 6 14 18 ft lbs 24 Nm SAE No 12 5 8 75 ft lbs 102 Nm PartNo 32222 Genie 5 40 7 49 Section 7 Repair Procedures Service Manual First Edition Non steering Axle Components 16 1 Drive Motor Component damage hazard ACAUTION Repairs to the motor should only be performed by an authorized Sundstrand S auer dealer How to Remove a Drive Motor A drive motor can only be removed from the inside of the chassis Component damage hazard The ACAUTION 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 1 Disconnect the hydraulic hoses from the drive motor and plug them Bodily injury hazard Spraying ACAUTION 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 2 Remove the drive motor mounting bolts 3 Slide the drive motor shaft out of the brake and 16 2 Torque Hub How to Remove a Drive Torque Hub 1 Remove the drive motor See 16 1 How to Remove a Drive Motor 2 Disconnectthe hydraulic hose from the brake and plug it Then remove the hydraulic
42. Horsepower Limiter 2 7 5 1 3 EOOESWIECIY reet iid edd ee eee a ted Ada 7 7 MEI 7 7 1 5 Toggle S witches o reete petro era tei ease tee eda feo nca AO alos 7 8 Platform Components 2 1 PlatfoFmo cnt etc ei ce e PRU Dr nee 7 9 2 2 Platform Leveling Slave m 7 9 2 3 Platform Rotator iiio ooi c te e en aa Dedi o daa 7 10 Boom Components 3 L Plastic C ables ee 7 12 3225 BOOM O wd a oko E 7 12 3 3 BoomiLift C ylinder acce ih ea Een eden epe me porte pasa 7 14 3 4 Extension Cylinder eire e op p e a Red 7 15 3 5 Platform Leveling Master Cylinder mm 7 16 Turntable Covers 4 1 Turntable COV6ers nz ote dete pde tended eed baee de cetera be 7 17 Deutz Engine F3L 1011 5 1 jiRPM Adjustmenb e e re t D tete ee n a 7 18 5 2 FleX Plates tei de dte ie tee edet e e ur rangs 7 18 5 3 Oil Temperature and Oil Pressure Gauges 7 18 Ford LSG 423 Engine 6 1 Governor Actuator rd OSA edv dre 7 19 6 2 Choke Adjustments 0 00 ee eect eee 7 20 6 3 TIMING AdjUStMENE maz ae di a ttd meta da e ERR BUR ERR ME Lee AE 7 21 6 4 Carburetor Adjustment t eee ee Oe ne Ra deer 7 21 0 5 RPM Adj stmebt et rere etr e ite Pepe Pede Des 7 21 6 6 Flex tre pae Pare tete pant 7 2
43. How to Remove a Steering Cylinder There are two identical steering cylinders that work in parallel They are part of the same hydraulic circuit but move in opposite directions The tie rod maintains equal movement of the tires Bushings are used at both ends of each steering cylinder clevis 1 Disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings Bodily injury hazard Spraying ACAUTION 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 2 Remove the pin retaining fasteners Then remove the pivot pin from each end of the steering cylinder 3 Remove the steering cylinder 7 40 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures 12 3 Tie Rod How to Remove the Tie Rod 1 Remove the pin retaining fasteners then remove the pivot pin from each end of the tie rod 2 Remove the tie rod How to Perform the Toe in Adjustment Perform this procedure on a firm level surface Block the non steering tires and be sure that the machine is in the stowed position 1 Straighten the steer wheels 2 Measure the steer tires front to front and back to back using a measuring fixture Toe in specification 2WD STEERING AXLE COMPONENTS Centera lifting jack under the steering axle then raise the machine Loosen the ja
44. ROTATE SWITCH CB1 CIRCUIT BREAKER CONTROLS 15A CB2 CIRCUIT BREAKER ENGINE 15A HM HOUR METER R2 RESISTOR 10 OHM BOOM FUNCTIONS G1 VOLT METER GAGE G2 OIL PRESSURE GAGE G3 WATER TEMP GAGE TS9 RE TS15 TS16 TS17 4 o ooo WS Eg TS13 B Service Manual Section 6 Schematics 2 Ground Control Box Legend Gasoline LPG Models GRN WHT 1 45 SPARE GRN BLK 1 aal SPARE GRN 1 43 SPARE ORG RED 1 az SPARE CABLE OG BK E H ORG BLK 1 41 PULSE PICKUP ET ORG 1 40 WHT 7 WHT 6 LIMIT SWITCH BLU RED 1 39 BU RD CR7 SP L P IBLU WHT 1 38 BU WT CR6 BU WT S P GAS BU BK E H BLU BLK 1 37 STEER LEFT BLU E H _ BLU 1 36 STEER PIGHT BLK RED 1 35 BK RD S P RPM CABLE BLK WHT 1 34 GLOW PLUG BLK 1 BLK S P START WT RD E H WHT RED 1 32 WT RD D B BRAKE WT BK E H WHT BLK 1 31 E D C WHT 1 30 RED 5 E D C R W 1 29 2WD AWD RED BLK 1 28 SPARE CABLE RED RED 1 27 RED D B RED S P AUX PWR z 5 WT RD 26 WT RD S P TEMP SENDER WT BK 25 WT BK S P OIL PRESSURE SENDER WHT E H 24 WHT S P WARNING SENDER WHT EH WHT 2
45. Raised or Extended 5 54 34 Drive Enable System Is 1 5 55 35 A Auxiliary Functions Inoperative 3 22 memes 5 56 Section Six Schematics Introd gctioh tei He eu ale d pM d ad Padwa 6 1 Electrical Symbols Legend eee eee ce mpi ne tha 6 2 Electrical Schematic Gasoline LP G Models sem 6 3 Ground Control Box Legend Gasoline LP G Models 6 5 Relay Panel Legend Gasoline LP G Models meme 6 6 Platform Control Box Legend Gasoline LP G Models 6 7 Electrical Schematic Diesel emm 6 8 Ground Control Box Legend Diesel 6 10 Platform Control Box Legend Diesel Models sss 6 11 Hydraulic Symbols Legend teet p tede a he Re ctae 6 12 2WD Hydraulic Schematic Non Oscillating 6 13 2WD Hydraulic Schematic Oscillating Axle s 6 14 AWD Hydraulic 5 6 15 32222 Genie 5 40 ix Service Manual First Edition TABLE OF CONTENTS Section Seven Repair Procedures Introductionis di eR E E Met acs Mis i aa ale 7 1 Platform Controls 1 1 Joystick Controllers ec seen 7 2 1 2
46. Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steering wheels and place a lifting jack under the steering axle 3 Raise the machine and place blocks under the chassis for support 4 Remove the lug nuts Then remove the tire and wheel assembly 5 Remove the dust cap cotter pin and slotted nut 6 Pull the hub off the spindle The washer and outer bearing should fall loose from the hub 7 Place the hub on a flat surface and gently pry the bearing seal out ofthe hub Remove the rear bearing How to Install the Hub and Bearings When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with grease 2 Place the large inner bearing into the rear of the hub 3 Press the bearing seal evenly into the hub until it is flush 4 Slide the hub onto the yoke spindle ACAUTION Component damage Do not apply excessive force or damage to the lip of the seal may occur 5 Place the outer bearing into the hub 6 Install the washer and slotted nut 7 Tighten the slotted nut to 35 foot pounds 47 Nm 8 Loosen the slotted nut then re tighten to 8 foot pounds 11 Nm 9 Install a new cotter pin Bend the cotter pin to lock it in 10 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 125 foot pounds 169 5 Nm 12 2 Steering Cylinders
47. Toggle switches used for single function switching are single pole double throw SPDT switches Dual function switching requires a double pole double throw DPDT switch How to Test a Toggle Switch Continuity is the equivalent of 0 to 3 ohms A simple continuity tester may not accurately test the switch This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches 1 Turn the key switch to the orr position Tag and disconnect all wiring from the toggle switch to be tested 2 Connect the leads of an ohmmeter to the switch terminals in the following combinations listed below y AR for continuity Center Right dowie trow CAA 21212 p 21012 RIA SPDT Double pole double throw DPDT Service Manual First E dition p Test Left position Desired result terminal 1 to 2 3 4 5 amp 6 no continuity infinite Q terminal 2 to 3 continuity zero Q terminal 2 to 4 5 amp 6 no continuity terminal 3to 4 5 amp 6 no continuity terminal 4 to 5 amp 6 no continuity terminal 5 to 6 continuity Center position There are no terminal combinations that will produce continuity infinite Q Right position terminal 1 to 2 continuity zero Q terminal 1 to 3 4 5 amp 6 no continuity infinite Q terminal
48. be completed by a person trained and qualified on the maintenance ofthis machine M Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required may cause death serious injury or substantial damage M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating machine M Keep records on all inspections for three years M Machines that have been out of service fora period longer than 3 months must complete the quarterly inspection About This Section The Schedule There are four types of maintenance inspections that must be performed according to a schedule daily quarterly annual two year To account for repeated procedures the Maintenance Tables and the Maintenance Inspection Report have been divided into four subsections A B C D Use the following chartto determine which group s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily A Quarterly A B Annual A B C Two year A B C D Maintenance Tables The maintenance tables contained in this section provide summary information on the specific physical requirements for each inspection Complete step by step instructions for each scheduled maintenance procedure are provided in sect
49. check the over temperature engine block feels level OR check radiator 4 sending signal post has excessively hot fins for clogging OR engine oil level and fill continuity to ground check engine fan belts as needed OR see Ford service manual for not hot troubleshooting an Be sure to check fuel c overheating engine levels and engine coolant level Remove wht wire from temperature sending Replace temperature Be sure the gasoline unit check continuity to continuity switch sender shut off valve is in the ground on position no continuity Be sure that automatic choke is not sticking closed no continuity Repair short in wht wire continuity circuit from TB24 to temperature sender Remove wht wire from c N Perform following tests in gasoline mode only no continuity Repair short in wht wire circuit from terminal 10 start lock out module to TB24 OR consult Genie Industries Service Department Remove 1 spark plug Go to Chart 2A and ground spark plug page 5 8 4 body Crank engine and i observe spark weak or no spark Disable starter by See Ford service removing blk wire at the manual for starter solenoid hold troubleshooting ignition start switch and check System voltage at positive terminal on ignition coil less than 12V Continued on the next page Part No 32222 Genie S 40 5 5 Section 5 Troubleshooting Flow Charts Service
50. 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 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures HYDRAULIC PUMPS 3 Disconnect the hydraulic hoses from the pumps and cap them Bodily injury hazard Spraying ACAUTION 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 4 Support the pump and remove the two drive pump mounting bolts Carefully remove the pump Component damage hazard ACAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the pump How to Prime the Pump 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump 2 Gasoline LPG models Remove the high tension lead from the center of the ignition coil Electrocution hazard AWARNING Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry Deutz Diesel models Hold the manual fuel shutoff valve counterclockwise to the CLOSED position 3 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 PartNo 32222 Genie 5 40 7 29 Section 7
51. cylinder rod from damage 4 Remove the cover hinge bolts that fasten the hinge support bracket to the bulkhead 5 Carefully lift and remove the cover from the machine If a turntable cover must be AWARNING replaced be sure that all appropriate safety and instructional decals are applied to the new cover Alignment adjustments may be necessary when a new cover is installed Part No 32222 Genie S 40 7 17 Section 7 Repair Procedures Service Manual First Edition Deutz Engine F3L 1011 5 1 RPM Adjustment Refer to Maintenance Procedures B 12 Check and Adjust the Engine RPM 5 2 Flex Plate The flex plate acts as a coupler between the engine and the pump Itis bolted to the engine flywheel and has a Splined center to drive the pump How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it from moving 4 Remove the flex plate mounting fasteners then remove the flex plate from the engine How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the flat side of the spline against the flywheel Torque the flex plate mounting bolts to 34 105 46 Nm 2 Install the coupler onto the pump shaft with t
52. from under the engine 3 Remove the plug from the end of the drain hose and allow all of the oil from the engine to drain into a suitable container 4 Install the plug into the drain hose 5 Use wrench and remove the oil filter a engine oil level dipstick b oil filter c fuel filter 6 Apply a thin layer of oil to the new filter gasket filter part no 29561 Then install the filter and tighten it securely by hand 7 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 8 Fill the engine with new oil per specifications and replace the oil filler cap 9 Start the engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off 10 Check the oil filter and oil pan for leaks 11 Check the engine oil level dipstick Add oil if needed Deutz Engine F3L 1011 Oil capacity including filter 8 5 quarts 8 liters Deutz Engine F3L 1011 Oil viscosity requirements Temperature below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 Temperature above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE CD SE CC SF or CD SF grades Genie S 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures C 1 Check the Boom Wear Pads Maintaining the boom wear pads in good condition is essential to safe machine
53. ft lbs 68 Nm SAE No 10 She 55 ft lbs 75 Nm SAE No 12 5 s 75 ft lbs 102 Nm Torque 10 13 ft lbs 14 18 Nm 35 40 ft lbs 47 54 Nm 35 40 ft lbs 47 54 Nm 7 38 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures 2WD Steering Axle Components 12 1 Yoke and Hub How to Remove the Yoke and Hub 1 Remove the retaining bolt then the pivot pin from both the steering cylinder and the tie rod tie rod axle king pin retaining bolt yoke hub pivotpin retaining bolt steering cylinder 2 Loosen the wheel lug nuts Do not remove them 3 Block the non steering wheels and then center a lifting jack under the steering axle 4 Raise the machine 6 inches 15 cm and place blocks under the chassis for support 5 Remove the lug nuts then the tire and wheel assembly 6 Remove the retaining bolt from the king pin 7 Attach a strap from a lifting device to the yoke hub assembly for support 8 Usea slide hammer to remove the upper king pin then use a soft metal drift to drive the lower king pin down and out Crushing hazard The yoke hub AWARNING assembly will fall when the king pins are removed if itis not properly supported Torque specifications 125 ft lbs 169 5 Nm Lug nut Part No 32222 Genie S 40 7 39 Section 7 Repair Procedures Service Manual First Edition 2WD STEERING AXLE COMPONENTS How to
54. hoses Cap the fittings Bodily injury hazard S praying A CAUTION 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 Component damage hazard ACAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the pump 8 2 Drive Hydraulic Pump The drive hydraulic pump is a bi directional variable displacement piston pump The pump output is controlled by the electronic displacement controller EDC 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 Sundstrand S auer service center How to Remove the Drive Hydraulic Pump Component damage hazard The ACAUTION 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 1 Disconnect the electrical connection at the electronic displacement controller EDC located on the drive pump 2 Close the two hydraulic tank valves located at the hydraulic tank open closed Component damage hazard The ACAUTION engine must not be started with the hydraulic tank shutoff valves in the cLosep position or
55. inform personnel of the condition 2 Remove the drain plug from the hydraulic tank 3 Completely drain the tank into a suitable container See capacity specifications listed below 4 Disconnectand cap the two suction hoses that are attached to the hydraulic tank shutoff valves 5 Remove the strainer assemblies from the tank 6 Carefully clean any foreign material from the strainers Clean the strainers from the inside out 7 Apply pipe thread sealantto the strainer mounting threads and then install them 8 Apply pipe thread sealantto the drain plug and then install it in the tank 9 Install the two suction hoses 10 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 11 Clean up any oil that may have spilled and open the hydraulic tank valves 12 Prime the pump by doing the following Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump Gasoline LPG models Remove the high tension lead from the center of the ignition coil Electrocution hazard Contact with AWARNING electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry Genie 5 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Deutz Diesel models Hold the manual fuel shutoff valve counterclockwise to the cLosep position a manual f
56. is possibly not enough battery capacity to operate both aux pump and function valves Replace defective auxiliary power toggle switch Repair open in red wire circuit from TB27 to PR1 Replace PR1 relay Genie S 40 Part No 32222 Service Manual First Edition Section 6 Schematics Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Before Troubleshooting M Read understand and obey the safety rules and operating instructions printed in the Genie 5 40 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Electrocution hazard Contact AWARNING with electrically charged circuits may 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
57. limiter board is responsible for governing drive pump output It senses engine rpm from the alternator The horsepower limiter board senses drops in rpm normally due to increased drive resistance rough terrain or incline and decreases voltage to the drive controller which in turn decreases voltage to the drive pump thereby reducing pump output to maintain optimum engine rpm and horsepower Three adjustments are required for optimum performance How to Adjust the Horsepower Limiter Board The engine rom must be correct before performing this procedure See Maintenance Procedure B 12 Check and Adjust the Engine RPM Do not adjust the horsepower limiter board unless the static battery voltage is above 12V DC and the alternator is operating properly with 12 5 to 14 5V DC output Gasoline LPG models Perform this procedure in gasoline mode 1 Remove the fasteners from the platform control box lid 2 Open the control box lid and locate the horsepower limiter board AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry PLATFORM CONTROLS EEEE rearea Sumera or mmr rrite ee Platform control box a horsepowerlimiterboard 3 Connectthe black lead from a DC volt meter to the no 2 terminal and the red lead to the no 10 terminal 12V DC or greater ground engi
58. oon ow Boom Up Down Controller Adjustments Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 12 5 to 14 5V DC output Electrocution hazard Contact AWARNING with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller 2 Turn the key switch to platform control and pull out the Emergency Stop button to the oN position at both the ground and platform controls Do not start the engine Open the platform control box lid and locate the boom up down controller ramp rate adjustable trimpot dual lo range adjustable trimpot terminal R activates max outrange terminalunused terminal X auxiliary terminal ground terminal battery positive terminal A proportional output threshold adjustable trimpot max outadjustable trimpot 0 Setthe preliminary ramp rate Turn the trimpot adjustment screw clockwise 15 turns or until you hear a repeated click Connect the red lead from a volt meter to the A terminal on the controller printed circuit board Connect the black lead to ground Set the threshold Press down the foot switch then slowly move the control handle off center until the moment a voltage reading appear
59. operate normally including turntable rotate right function Ifturntable rotate right function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If turntable rotate right function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control ov function switch and check volts at wht wire on rotate function directional valve 0 or Remove both wires from infinite rotate right valve coil ohms and check resistance across the coil terminals 4 to 5 ohms Hold toggle switch right and manually override rotate right directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not avallable interchange the valve item with a like valve item S function inoperative 2400 Install a pressure gauge psi atthe quick disconnect coupling on the function manifold and hold the function switch less than 2400 psi Remove the rotate right function pressure line from the manifold and cap the port 51 2400 Then with pressure ps gauge still attached operate the function less than 2400 psi Replace the directional valve OR the manifold has internal defects function operates Chart 20 Repair open in wht wire
60. pin 21 Remove the boom pivot pin with a soft metal drift then carefully remove the boom from the machine Crushing hazard If the overhead AWARNING crane is not properly attached the boom may become unbalanced and fall when it is removed from the machine How to Disassemble the Boom Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced The extension cylinder can be removed without completely disassembling of the boom See 3 4 How to Hemove the Extension Cylinder 1 Remove the boom See 3 2 How to Remove the Boom 2 Place blocks under the extension cylinder for support Part No 32222 Genie S 40 7 13 Section 7 Repair Procedures Service Manual First Edition BOOM COMPONENTS 3 Remove the retaining fastener from the extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin 4 Remove and label the wear pads from the platform end of the boom Pay careful attention to the location and amount of shims used with each wear pad 5 Support and slide the extension tube out of the platform end of the boom ACAUTION Crushing hazard The extension tube will fall when itis removed from the boom if is not properly supported 6 Remove the snap rings from the extension cylinder rod end pins Use a soft metal drift to remove the pins 7 Supportand slide the extension cylinder out of the platform end of the extension boom 8 R
61. to 60 68 to 81 bolt M 6 second step 80 to 90 108 to 122 2 6 Genie S 40 PartNo 32222 Service Manual First Edition Deutz Engine F3L 1011 Displacement 125 02 cu in 2 049 liters Number of cylinders 3 Bore and stroke 3 58 x 4 13 inches 91 x 105 mm Horsepower 36 2300 rpm Firing order 1 2 3 Compression ratio 18 5 1 Compression pressure 362 to 435 psi 25 to 30 bar Pressure psi of lowest cylinder must be at least 8596 of highest cylinder Low idle 1300 rpm High idle 2300 rpm Governor centrifugal mechanical Valve clearance cold Section 2 Specifications r s t DEUTZ ENGINE F3L 1011 SPECIFICATIONS Injection pump pressure 4351 psi 300 bar Injector opening pressure 3626 psi 250 bar Fuel requirement diesel number 2 D Alternator output 55A 14V Starter motor Current draw no load 90A Brush length new 0 7480 in 19 mm Brush length minimum 0 5 in 12 7 mm Battery Type 12V Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Intake 0 012 in Fan belt deflection 3 8 to 1 2 inch 0 3 mm 9 to 12 mm Exhaust prod I Bolt tightening specifications amm torque torque Lubrication system Bolt description size grade ft lbs Nm Oil pressure 26 to 87 psi Camshaft thrust bearing bolt 15 to 18 20 to 24 1 8t06
62. valve OR manifold has internal defect consult Genie Industries Service Department 5 30 Genie 5 40 PartNo 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Boom Down Function Inoperative Be sure all other functions operate normally including boom up function If boom down function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If boom down function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check volts at red blk wire on boom function directional valve 12V Hold toggle switch down function and manually override operates the down directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item R with a like valve item S function inoperative Install a 0 to 3000 PSI pressure gauge at the 1800 quick disconnect ps coupling on the function manifold and hold the function switch less than 1800 psi Continued on the next page Chart 15 Repair open in red blk wire circuit from TB2 to directional valve 0 or infinite ohms Replace the coil Check the resistance of the down directional
63. valve coil 4 to 5 ohms Replace the valve Counting the turns adjust the boom down relief valve item F in all the way Then operate the function down With boom fully lowered hold the function down switch Adjust the relief valve to read 1800 PSI function and replace the cylinder counterbalance valve function inoperative Check for mechanical restrictions and or a condition exists in which the cylinder counterbalance valve is not allowing the cylinder to retract or the cylinder has internal defects Disconnecting hydraulic lines or adjusting the cylinder counterbalance valve in this situation can be very dangerous Please consult Genie Industries Service Department Part No 32222 Genie S 40 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 15 Continued from the previous page Adjust the boom down With boom fully lower relief valve item F hold the function down in one tum clockwise switch Adjust the relief Then with pressure valve to read 1800 psi gauge still attached operate the function down less than 1800 psi Remove the boom down Repair the boom lift high pressure line from cylinder the manifold and cap the port Hold down function and recheck pressure less than 1800 psi Internal defect in manifold OR one ofthe previous tests involving the pump or manifold components was possibly overlooked or diagnosed in
64. voltage or counterclockwise to decrease the voltage 9 Start the engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol be at normal operating temperature 10 Start a timer and record how long it takes the turntable to rotate through a complete circle Adjust the max out trimpot to achieve a 70 to 110 second cycle time 11 Turn the engine off and re connect the volt meter 12 Pull outthe Emergency Stop button to the on position 13 Press down the foot switch and then move the control handle all the way to the left or right Record the maximum voltage reading 14 Start the engine 15 Start a timer and simultaneously move the control handle all the way to the left or right Note how long it takes to reach the maximum voltage recorded in step 13 This is the ramp rate 16 Setthe ramp rate Turn the trimpot to obtain a 3to 4 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Turntable rotation specifications Threshold 2 5V DC Turntable rotation Max out 5 5V DC adjustment screw clockwise 15 turns or until Cycle time 70to 110 seconds you hear a click This is the only dual range adjustment for this controller Ramp 3 to 4 seconds 7 4 Genie S 40 Part 32222 Service Manual First Edition Section 7 Repair Procedures 1 2 Horsepower Limiter Board The horsepower
65. 00 hours 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 F ailure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off 1 Remove the end cap from the air cleaner canister 2 Remove the mounting fastener from the air filter then remove the filter 3 Clean the inside of the canister and the gasket with a dry cloth 4 Insertthe new filter and replace the mounting fastener 5 Replace the end cap on the canister Air filters Genie part numbers Ford LSG 423 Engine 27916 Use oils meeting API classification SF labeled SF CC Deutz F3L 1011 29553 or SF CD as they offer improved wear protection Part No 32222 Genie S 40 4 11 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table B Procedures B 1 Check the Engine Belt s Maintaining the engine belt s is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt and continued use may cause component damage ANAFA Do not inspect while the engine AWARNING is running Remove the key to secure from operation AFRIITIARI Beware of hot engine ACAUTION components Contact with hot engine components may cause severe burns 1 Deutz Diesel models R emove front engi
66. 1 X Genie 5 40 PartNo 32222 Service Manual First Edition 22220ZZZZ ZZL OOO Section Seven TABLE OF CONTENTS Repair Procedures Ford LSG 423 Engine continued 6 7 Water Temperature and Oil Pressure 7 22 0 8 Vacuum S With cett terr Ehe p E ERE RE dL E EAA 7 22 Ground Controls 7 1 Control Relays x eee bb e A e Cdi el 7 23 7 2 Toggle Switches See 1 5 Toggle Switches 7 8 7 3 Wago Component wad dy dE pw 7 25 7 4 RESISIOT nia wd i na Sis ab d ipe deeds 7 26 7 5 Power Relay ole vein e ende 7 26 Hydraulic Pumps 8 1 Lift Steer Pump 7 27 8 2 Drive Hydraulic meme 7 28 Function Manifold 9 1 Function Manifold 7 30 9 2 Valve Adjustments Function Manifold sss 7 32 Fuel and Hydraulic Tanks 10 1 Hydraulic Tank creas uie ede eee oed red ecce bo ped on 7 35 10 2 Fuel Fa k wince nA 7 36 Turntable Rotation Components 11 1 Rotation Hydraulic eee eee aaa emen 7 37 11 2 Turntable Rotation Manifold Components sss 7 38 2WD Steering Axle Components 12 1 Y ke and HUD s ted e eec epe ee pedet een 7 39 12 2 Steering Cylinders sssssseeeeenneeneeenn
67. 2 to 3 4 5 amp 6 no continuity terminal 3to 4 5 amp 6 no continuity terminal 4 to 5 continuity terminal 4 to 6 no continuity terminal 5 to 6 no continuity 7 8 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures Platform Components 2 1 Platform How to Remove the Platform 1 Remove the cable harness from the cable clamp located on the platform mounting bracket and separate the foot switch quick disconnect plug 2 Remove the platform control box mounting bolts then lower the control box and set it aside 3 Remove the platform mounting bolts and lift the platform off the mount 2 2 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 ina 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 Slave Cylinder Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop 1 Remove the platform See 2 1 How to Remove the Platform 2 Extend the boom until the slave cylinder barrel end pivot pin is accessible 3 Support the platform rotator but do not apply any lifting pressure 4 Remove the pin retainer fa
68. 3 5 o Ground Controls Test Desired result terminal 13 to 14 160 01700 terminal 8 to 5 4 1 12 amp 9 no continuity infinite Q terminal 5 to 4 1 12 amp 9 no continuity terminal 4 to 1 amp 9 no continuity terminal 1 to 12 no continuity terminal 4 to 12 continuity zero Q terminal 1 to 9 continuity 4 Connect 12V DC to terminal 14 and a ground wire to terminal 13 then test the following terminal combinations Test Desired result terminal 8 to 1 5 9 amp 4 no continuity infinite Q terminal 5 to 1 4 amp 12 no continuity terminal 4 to 1 9 amp 12 no continuity terminal 1 to 9 amp 12 no continuity terminal 8 to 12 continuity zero Q terminal 5 to 9 continuity zero Q Part No 32222 Genie S 40 Section 7 Repair Procedures Service Manual First Edition GROUND CONTROLS How to Test a Single Pole Double Throw Relay This procedure covers fundamental relay testing and does not specifically apply to all varieties of relays Socket Connection Relay 1 Turn the key switch to the orr position and remove the key 2 Label and then disconnect all the wiring from the relay to be tested 3 Connectthe leads from an ohmmeteror continuity tester to each terminal combination and check for continuity Terminals 13 and 14 represent the coil and should not be tested in any other combination Que terminal no 5 terminal no 1
69. 586 C 15 Check the Engine Valve Clearances Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011 Workshop Manual Deutz Number 02611642 Genie part number 29789 PartNo 32222 Genie S 40 4 37 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table D Procedures D 1 Test or Replace the Hydraulic Oil 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 The machine uses Dexron II equivalent hydraulic oil 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 quarterly testing B 26 thereafter should be completed Perform this procedure with the boom in the stowed position 1 Close the two hydraulic shutoff valves located at the hydraulic tank closed Component damage hazard The ACAUTION engine must not be started with the hydraulic tank shutoff valves in the cLosep position or component damage will occur Ifthe tank valves are closed remove the key from the key switch and tag the machine to
70. AY RELAY CRS CR6 CR8 HORN FUEL FUEL BALLAST RELAY CUTOUT CUTOUT BYPASS RELAY RELAY RELAY ENGINE HARNESS Part No 32222 Genie S 40 Section 6 Schematics Service Manual CO G MM Relay Panel Legend Gasoline LPG Models IGNITION COIL VOLTAGE REG IGNITION MODULE PUR RED WHT GOVERNOR 6 Genie S 40 PartNo 32222 Service Manual Section 6 Schematics gt gt gt Y Platform Control Box Legend Gasoline LPG Models O ja RU a gt n kK O O m ou Oj 0 a 8 7 6 5 4 3 2 1 O gt Plo ojaa oJ c SPARE 45 GRN WHT 1 SPARE 44 GRN BLK 1 SPARE 43 GRN 1 olt SPARE 42 ORG RED 1 B lt PULSE PICKUP 41 ORG BLK 1 LIMIT SWITCH 40 ORG 1 z u L P 39 BLU RED 1 GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 O GLOW PLUG 34
71. 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 Indicates the presence of A DANGER a hazard that will cause death or serious injury AWARNING Indicates the presence of a hazard that may cause death or serious injury ACAUTION 74 1 5 the presence of a hazard that will or may cause serious injury or damage to the machine NOTICE special operation or maintenance information Be sure to wear protective eye wear and other protective clothing if the situation warrants it such as moving parts free swinging or unsecured components and lifting or placing loads Always wear approved steel toed shoes 3j Be aware of potential crushing hazards zl 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 Be sure thatall tools and working areas x are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure that your workshop or work area is properly ventilated and well lit other lifting or suppo
72. Gasoline LPG Models 4 35 C 13 Check and Adjust the Air LP G Mixture Gasoline LP G Models 4 36 C 14 Check and Adjust the Ignition Timing Gasoline LP G Models 4 37 C 15 Check the Engine Valve Clearances Deutz Diesel Models 4 37 D 1 Testor Replace the Hydraulic Oil eee 4 38 D 2 Change or Recondition the Engine Coolant Gasoline LP G Models 4 39 D 3 Change the Fuel LINES sza ee e teh e ee pd eee pad 4 41 D 4 Check the Engine Valve Clearance Gasoline LP G Models 4 42 D 5 Check the Engine Cylinder Compression Gasoline LP G Models 4 42 D 6 Cleanthe PCV Hoses and Fittings Gasoline LP G Models 4 43 D 7 Check the Fuel Injection Pumps and Injectors Deutz Diesel Models 4 44 D 8 Check the Toothed Belt Deutz Diesel Models 4 44 D 9 Replace the Timing Belt Gasoline LP G Models 4 44 PartNo 32222 Genie 5 40 vii Service Manual First Edition TABLE OF CONTENTS Section Five Troubleshooting Flow Charts droni a o e 5 1 1 Engine Will Not Crank meme enne 5 3 2 Engine Cranks Over But Will Not Start Gasoline LP G Models 5 5
73. Genie Industries Technical Publications RZE KZ Genie 40 ODD ED eee Service Manual First Edition First Printing Part No 32222 Introduction Service Manual First Edition Genie 9 40 Important Read understand and obey the safety rules and operating instructions in the Genie S 40 Operator s Manual before attempting any maintenance or repair procedure This service manual covers the Genie 5 40 2WD and 4WD models introduced in 1994 This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair 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 a Genie dealer service center Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and other manuals Please write to the technical publications team in care of Genie
74. I lockout module good Consult Genie Industries Service Department Continued on the next page Part No 32222 Genie 5 40 5 3 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 1 Continued from the previous page Hold start switch and check voltage at terminal 85 on Repair open in blk wire from terminal 1 on start lockout module to CR1 OV n Check voltage at terminal 30 on CR 1 0 Repair red wire circuit from battery to CB1 to CR1 terminal 430 Hold start switch and check voltage at terminal 487 on CR1 ov Check ground to bad Repair open in ground terminal 86 on CR1 to CR1 i d Check voltage at solenoid Check repair or solenoid initiate terminal starter replace starter or starter good Replace CR1 relay Repair open in blk wire circuit from CR1 to starter solenoid Genie 5 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 2 Engine Cranks Hold start switch and Check battery condition check battery voltage OR check alternator OR Over But Will is REZ cranking OR check battery Not Start cables OR replace the Gasoline LPG more than 11V battery M odels Check if engine coolant continuity Check if radiator and or Check engine coolant Be sure to
75. ING Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry A small screwdriver is provided and should be used when removing a Wago component This screwdriver is located in the operators manual storage box in the platform 1 Label the wiring from the component to be removed 2 Use the provided screwdriver to push in and release the wire from the component 3 Locate the removal tab on the bottom or top side of the component 4 Use the provided screwdriver to gently pry up on the tab of the component and remove it terminal 87 to 87a amp 30 no continuity infinite Q terminal 87 to 30 continuity zero Q Part No 32222 Genie S 40 7 25 Section 7 Repair Procedures Service Manual First Edition p d m GROUND CONTROLS 7 A 2 Connect 12V DC to one of the small posts and Resi a ground wire to the other small post then test esistors the following terminal combination How to Test the Resistor Test Desired result The resistor is used to maintain proper control of 2 large posts continuity zero Q boom function speeds A 10 ohm resistor reduces voltage to all the boom function switches Turn the key switch to the off position and remove the key 1 Disconnect either end of one of the wires connected to the resistor to be tested 2 Connectthe leads from an ohmmeter to each end or wirin
76. Industries PO Box 69 Redmond WA 98073 0069 U S A If you have any questions call Genie Industries Genie North America Telephone 206 881 1800 Toll Free 800 536 1800 Fax 206 883 3475 Genie Europe Telephone 44 0636 813943 Fax 44 0636 815270 Genie Industries Copyright 1994 by Genie Industries FirstEdition First Printing February 1994 Genie is a registered trademark of Genie Industries Registered 2009987 These machines comply with ANSI SIA 92 5 1992 Printed on recycled paper Patents Pending Printed in U S A ii Genie 5 40 PartNo 32222 Service Manual First Edition Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie S 40 Operator s Manual will result in death or serious injury Many ofthe hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M Youare trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Part No 32222 Genie S 40 iii Section 1 Safety Rules Service Manual First Edition SAFETY RULES Personal Safety
77. K 4 4 100 EXTEND B BLK WHT BOOM m RETRACT BLK WHT 4 g 8 1 150 BLK RED 4 a E ORG 3 e l up PLATFORM LEVEL DOWN ORG BLK 3 ORG x ORG 4 5 5 UP PLATFORM LEVEL 5 ORG BLK DOWN ORG BLK 4 7 A 2 m 3 e 2 t ORG RED 4 4 E ORG RED 3 e M a a GRN 3 e LEFT PLATFORM ROTATE RIGI a 5 GRN BLK 3 GRN 2 GRN 4 i 5 J LEFT GRN BLK PLATFORM ROTATE ie RIGHT 1 GRN BLK 4 7 6 4 Genie S 40 GROUND Part No 32222 DRIVE ENABLE LIMIT SWITCH BRAKE STEER RIGHT STEER LEFT BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH TURNTABLE ROTATE R TURNTABLE ROTATE L TURNTABLE ROTATE amp EXTEND RETRACT FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL BOOM EXTEND BOOM RETRACT PLAT LEVEL UP PLAT LEVEL DN PLAT LEVEL F C PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT 0 G1 G2 P1 KS1 olo TS11 TS10 O eld U TS12 CB1 CB2 LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH TS9 AUXILIARY SWITCH TS10 ENGINE START SWITCH TS11 ENGINE FUEL SELECT SWITCH TS12 ENGINE RPM SWITCH TS13 PLATFORM ROTATE SWITCH TS14 PLATFORM LEVEL SWITCH TS15 BOOM EXTEND RETRACT SWITCH TS16 BOOM UP DOWN SWITCH TS17 TURNTABLE
78. LU E H _ BLU 1 36 STEER PIGHT BLK RED 1 35 BK RD S P RPM CABLE BLK WHT 1 34 GLOW PLUG BLKCRi__ BLK 1 33 BLK S P START WT RD E H WHT RED 1 32 WT RD D B BRAKE WT BK WHT BLK 1 31 E D C WHT 1 30 RED 5 E D C R W 1 29 2WD 4WD RED BLK 1 28 SPARE CABLE RED E H RED 1 27 RED D B RED S P AUX PWR S WT RD 26 WT RD S P TEMP SENDER WT BK 25 WT BK S P PRESSURE SENDER WHT E H za WHT S P WARNING SENDER WHT E H WHT 2 23 WHT S P KEYSWITCH PWR BLK 2 22 BLK CR5_ BLK S P PWR TO PLAT WHTE H _ WHT CR2 21 WHT S P IGNITION PWR RED E H 20 RED S P 12V BATT SUPPLY GRN WHT 4 GRN WHT 3 19 TILT ALARM GRN BLK 4 GRN BLK 3 18 GR BK D B GR BK S P PLAT ROT R GRN 4 GRN 3 17 GRN D B GRN S P PLAT ROT L CABLE ORG RED 4 ORG RED 3 16 OG RD D B OG RD S P PLAT LEVEL F C ORG BLK 4 ORG BLK 3 15 OG BK D B OG BK S P PLAT LEVEL DN ORG 4 ORG 3 14 ORG D B ORG S P PLAT LEVEL UP BLU RED 3 13 WHT 5 DRV ENA LT WHT E H BLU WHT 3 12 BLK 5 DRV ENA BLU BLK 4 BLU BLK 3 11 BU BK D B S P BLU 4 BLU 3 10 BLU D B _ BLU S P BLK RED 3 BK RD HORN BLK WHT 4 BLK WHT 3 8 D B BK WT s P BOOM RETRACT BLK 4 BLK 3 7 BLK D B BLK S P BOOM EXTEND W R 4 WHT RED 3 6 WT RD S P TURN ROT CABLE WHTBLK 4 WHT BLK 3 5 wr BK D B S P TURN ROT L 2 j WHT4 WHT 3 4 WHT D B WHT S P TURN ROT R R W 4
79. LVL F C 16 ORG RED 3 DP1 o a N O TS8 DRIVE ENABLE EXTEND RETRACT 5 LED al 2 5 0 1 gt n o O z5 Es A o 5 090 x a opa H OIRS a Blo oo lEz oplag WZ ZA 2 eo 5 iE 0 PLAT LVL DN 15 ORG BLK 8 PLAT LVL UP 14 ORG 3 DRV ENA LT 13 BLU RED 3 DRV ENA 12 BLU WHT 3 SEC BOOM DN 11 BLU BLK 3 SEC BOOM UP 10 BLU 3 HORN 9 BLK RED 3 RETRACT 8 BLK WHT 3 EXTEND 7 BLK 3 a ROTATE 6 WHT RED 3 Bx ROTATE RIGHT 5 WHT BLK 3 o R ROTATE LEFT 4 WHT 3 BOOM FC 3 RED WHT 3 BOOM DN 2 RED BLK 3 BOOM UP 1 RED 3 aX E EEN 5 NS 5 O E tr R X A 8 12 3 456 7 8 910 y a a 2 2 e o 9 53 tg 615 Fo o lt 6 11 Genie S 40 PartNo 32222 Service Manual Section 6 Schematics 2WD Hydraulic Schematic Non Oscilating Axle Service Manual First Edition Section 6 Schematics Pressure gauge O Filter Fixed displacement pump ki Bi directional variable displacement pump d Bi directional motor
80. Manual First Edition CHART 2 Hold start switch and check voltage at wht 21 on terminal 487 of CR2 Repair open in wht 21 wire to ignition coil Continued from the previous page Check voltage at red Repair open in red wire wire on terminal 30 of circuit from battery to CR2 CB1 to CR1 to CR2 Hold start switch and check voltage at terminal 49 on start lockout module Hold start switch and check voltage at terminal 86 of CR2 Check voltage at terminal 6 and 7 on start lockout module 12V Check ground wire terminal 45 on start lockout module Repair open in blk wire from terminal 86 on CR2 to terminal 49 on start lockout module Repair open in power supply wires to terminal 6 and 7 on start lockout module Repair open in ground circuit to start lockout module good the start lockout module OR consult Genie Industries Service Department Check ground to no good Repair open in ground terminal 85 on CR2 wire to CR2 good Continued on the next page 5 6 Genie S 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 2 Hold start switch and from the check voltage at wht on previous page terminal 87 of CR8 Repair open in brn 4R8 wire to ignition coil Check voltage at wht Repair open in wht wire wire on terminal 30 of circuit from terminal 87 R8
81. NTS 3 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion The master cylinder is attached to the lift cylinder and is located atthe base ofthe boom How to Remove the Platform Leveling Master Cylinder 1 Raise the boom to a horizontal position 2 Remove the turntable end cover to access the master cylinder 3 Disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying ACAUTION 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 4 Remove the pin retaining fasteners from both master cylinder pins 5 Use a soft metal drift to remove the pins 7 16 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures Turntable Covers 4 1 Turntable Covers How to Remove a Turntable Cover 1 Raise the turntable cover Support the open cover with an overhead crane or forklift Do not lift it Crushing hazard Due to its heavy ACAUTION weight do not attempt to support the cover by hand 2 Remove the upper and lower retaining clips from the gas strut 3 Gently pry the strut pivot sockets off of the ball studs and remove the strut Protect the strut
82. PE ACAUTION Always use the color coded direction arrows on the platform control panel and the drive chassis to identify which direction the machine will travel Result The drive function should operate 5 Rotate the turntable to the left until the boom is pastthe left non steering wheel Result The drive enable indicator light should come on 6 Repeatsteps 3 and 4 Part No 32222 Genie S 40 4 23 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 23 Test the Drive Brakes 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 Be sure that the machine is not in free wheel or partial free wheel configuration Refer to B 9 in this section Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions 1 Mark a testline 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 then lower the boom into the stowed position 4 Choose a pointon the machine i e contact patch of a tire as a visual reference for use when crossing the test lin
83. RED WHT 3 3 RD wTS P BOOM RED BLK 4 RED BLK 3 2 RD BK D B RD BK S P BOOM DOWN RED 4 RED 3 RED D B RED S P BOOM UP D DIODE O BLOCKS CABLE 1 START RELAY 2 TACHOMETER IGN START START INPUT MODULE O 4 aux on 5 GROUND BATTERY 7 key pwr key Bypass 4 9 IGN FUEL ON O 10 ENG FAULT CR1 CR2 CR3 START FUEL RPM RPM RELAY RELAY CUTOUT RELAY RELAY CRS HORN RELAY ENGINE HARNEss Part No 32222 Genie 5 40 6 10 Section 6 Schematics E d Platform Control Box Legend Diesel Models Service Manual SPARE 45 GRN WHT 1 SPARE 44 GRN BLK 1 SPARE 43 GRN 1 SPARE 42 ORG RED 1 PULSE PICKUP 41 ORG BLK 1 LIMIT SWITCH 40 ORG 1 L P 39 BLU RED 1 GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 GLOW PLUG 34 BLK WHT 1 START 33 1 BRAKE 32 WHT RED 1 E D C 31 WHT BLK 1 E D C S0 wHT 1 2WD 4WD 29 RED WHT 1 SPARE 28 RED BLK 1 AUX PWR 27 RED 1 PWR TO FS 26 BLK FS PWR START 25 GREEN PWR CONT 24 WHT H P L PWR FRM PLAT 23 WHT 2 PWR TO PLAT 22 BLK 2 21 20 TILT ALARM 19 GRN WHT 3 PLAT 18 GRN BLK 3 PLAT ROT L 17 GRN 3 PLAT
84. Repair Procedures Service Manual First Edition Function Manifold 9 1 Function Manifold Components Index Schematic No Description Item Function Torque 1 3 position 4 way D03 valve Platform 30 35 in Ibs 3 4 Nm 2 Counterbalance valve ZERA Platform level 35 40 ft lbs 47 54 Nm 3 Sandwich valve manifold Platform level 4 3 position 4 way D03 valve Qe Platform 30 35 in Ibs 3 4 Nm 5 3 position 4 D03 valve Bruno Turntable rotate 30 35 in Ibs 3 4 Nm 6 Cover plate ONENOTE Pero bv d d d 30 35 in lbs 3 4 Nm 7 3 position 4 way D03 valve Roses Boom up down 30 35 in Ibs 3 4 Nm 8 3 position 4 way DO3 valve S csset Boom 30 35 in lbs 3 4 Nm 9 Counterbalance valve Platform level down 35 40 ft lbs 47 54 Nm 10 Check valve eene Katie Turntable rotate differential sensing 11 13 ft lbs 15 18 Nm 11 Check valve ess Me assises Boom up down differential sensing 11 13 ft lbs 15 18 Nm 12 Flow regulator valve
85. SCILLATE MANIFOLD LH s GH 41 4 P P8 M4 REAR FRONT LEFT M2 LEFT A VALVE ACYL B VALVE BCYL STEERING MANIFOLD zl 250 PSI Part No 32222 Genie S 40 6 15 Service Manual First Edition Section 7 Repair Procedures Observe and Obey M 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 M Repair any machine damage or malfunction before operating the machine Before Repairs Start M Read understand and obey the safety rules and operating instructions in the Genie S 40 Operator s Manual Be sure that all necessary tools and parts are available and ready for use M Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions M Unless otherwise specified perform each repair procedure with the machine in the following configuration machine parked on a flat level surface boom in stowed position turntable rotated with the boom between the non steering wheels turntable secured with the tumtable rotation lock pin key switch in the orr position with the key removed wheels chocked 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 repa
86. T 2 speed bi directional motor Pump prime mover engine or motor Cylinder MAVA Accumulator TT 0 035 Orifice with size at Variable orifice or shut off valve gt Check valve a Ia Relief valve Priority flow divider Solenoid operated dump valve Hydraulic Symbols Legend LT EW al Differenti sensing valve Solenoid operated proportional valve CX z F Flow regulator valve 47 Solenoid operated 2 pos 3 way directional valve t 4 EA Counterbalance valve Y Pilot operated flow control valve M Solenoid operated 2 pos 4 way directional valve S EDO Solenoid operated 3 pos 4 way directional valve DO1 gt 2 pos 3 way shuttle valve 1 d LE NER 3 pos 4 way directional valve Unloader valve EM M 9 Pressure compensating valve PartNo 32222 Genie 5 40 Service Manual Section 6 Schematics 2WD Hydraulic Schematic Non Oscilating Axle TURNTABLE BOOM BOOM EXTENSION UP DOWN PLATFORM 1 ROTATE Ts
87. V stop button to TP23 i L 22 Repair open in blk wire circuit from TP23 to foot switch OR replace foot switch 5 28 Genie 5 40 Part 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Boom Up Function Inoperative Be sure all other functions operate normally If boom up function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If boom up function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch up and check volts at red wht wire on boom function proportional valve 3 to 6V Chart 14 Repair open in red wht wire circuit with diode from TB3 to proportional valve Remove both wires from Replace coil valve coil and check resistance across the coil terminals 4 5 to 5 5 Hold toggle switch u and manually override ohms function operates Replace R EA proportional valve proportional valve push In button on end of valve spool Note Overriding the valve wil KIE two people If a helper is not available interchange the valve item AA with a like valve item Z function inoperative Hold ground control function switch up Check volts at red wire on boom function directional valve Repair open circu
88. al First Edition Chart 23 Platform Level Down Function Inoperative Be sure all other functions operate normally If platform level down function operates normally from the ground controls but not from the platform controls troubleshoot the platform control toggle switch See Repair section If platform level down function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check voltage at org blk Repair open in org blk wire circuit from TB 15 to directional valve wire on platform level down function directional valve 12V 0 or Remove both wires from e valve coil and check ohms 5 resistance across the Replace the coil coil terminals 4to 5 ohms function operates Replace the platform leveling directional Hold toggle switch and manually override the level down directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not avallable interchange the valve item O with a like valve item N valve function inoperative Interchange check valve EE Replace defective check valve item L with like valve item K function inoperative Install 2400 nstall a pressure gauge psi or at the quick disconnect more coupling on the function manifold
89. allow boom to drive in stowed position over steer wheels Repair or replace drive enable toggle switch Part No 32222 Genie S 40 5 55 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 35 Auxiliary Functions Inoperative Be sure all other functions operate normally Be sure key switch is in the appropriate position and the emergency stop buttons are pulled up into the on position Be sure engine is notrunning when using auxiliary power Note Operating auxiliary power with the engine running should immediately kill the engine With A notrunning pump lift switch cover hold runs auxiliary switch and listen for sound of auxiliary pump running pump does not run Hold the auxiliary power switch and check the voltage at terminal TB27 12V Hold the auxiliary power switch and check the voltage at initiate terminal red wire on PR1 motor start solenoid 12V Hold the auxiliary power Switch and check the voltage at positive power cable on auxiliary power unit 12V Check auxiliary power unit grounding cable OR repair or replace electric motor Deadhead a pressure 1 5 than Hold auxiliary switch gauge into the pressure 2000 psi and adjust pump relief Ine of the auxiliary and hold the auxiliary power switch valve or replace pump 2000 psi Reconnect pressure line and check battery condition There
90. and hold the function switch Interchange the level up 2400 and down psi or counterbalance valves more items B amp C function operates Replace defective counterbalance valve less than 2400 psi Replace the directional valve OR the manifold has internal defects OR one ofthe previous tests was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department Disconnecting hydraulic lines or adjusting the cylinder counterbalance valves in this situation can be very dangerous Please consult Genie Industries Service Department Genie S 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 24 Platform Rotate Hold ground control function switch and check voltage at grn blk Repair open in grn blk Left Fu nction wire circuit from TB 18 to directional valve Inoperative Be sure all other functions operate normally If platform rotate left function operates normally from the ground controls but not from the platform controls troubleshoot the platform control toggle switch See Repair section If platform rotate left function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section wire on platform rotate left function directinal valve 12V Remove both wires from 0 ar infinite o
91. and then between the steer tires center a lifting jack under the steering axle 2 Remove the pin retaining fasteners then 6 Raisethe machine 15 inches 38 cm and place remove the pivot pin from both the steering blocks under the chassis for support cylinder and the tie rod 7 Remove the lug nuts then remove the tire and wheel assembly 8 Remove the hydraulic hose mounting bracket from the top of the yoke 9 Remove the roll pin from the upper king pin 10 Remove the retaining bolts from the upper and lower king pins 11 Remove the drive motor mounting fasteners 12 Slide the drive motor shaft out of the brake and then remove it 13 Attach a strap from a lifting device to the yoke torque hub assembly for support oscillate cylinder king pin torque hub yoke pivotpin steer cylinder tie rod 3 Disconnect and plug the hydraulic hoses 7 42 Genie 5 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures 14 Use a slide hammer to remove the upper king pin then use a soft metal drift to drive the lower king pin down and out Crushing hazard The yoke torque AWARNING ub assembly will fall when the lower king pin is removed if it is not properly supported 15 Place the yoke torque hub assembly on a flat surface with the torque hub down Remove the bolts that secure the yoke to the torque hub Torque specifications Lug nut 125 ft lbs 169 5 Nm Tor
92. anual Section 6 Schematics gne Ground Control Box Legend 22 1 KS1 Ts9 OncO OncO olo R HM TS15 TS16 Go TS17 TS10 817 S 9 TS14 TS12 CB1 CB2 TS13 coo NSA U 1 LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH Ts9 AUXILIARY SWITCH TS10 ENGINE START SWITCH TS12 ENGINE RPM SWITCH TS13 PLATFORM ROTATE SWITCH TS14 PLATFORM LEVEL SWITCH TS15 BOOM EXTEND RETRACT SWITCH TS16 BOOM UP DOWN SWITCH TS17 TURNTABLE ROTATE SWITCH CB1 CIRCUIT BREAKER CONTROLS 15A CB2 CIRCUIT BREAKER ENGINE 15A HM HOUR METER R2 RESISTOR 10 OHM BOOM FUNCTIONS G1 VOLT METER GAGE G2 OIL PRESSURE GAGE G3 WATER TEMP GAGE Diesel Models GRN WHT 1 45 SPARE GRN BLK 1 44 SPARE GRN 1 43 SPARE ORG RED 1 a2 SPARE CABLE OG BK E H ORG BLK 1 41 PULSE PICKUP gt ORG 1 40 wHT 7 WHT 6 LIMIT SWITCH BLU RED 1 39 BU RD CR7 BU RD L P IBLU WHT 1 38 BU WT CRG BU WT S P GAS BU BK BLU BLK 1 37 STEER LEFT B
93. arm Package Optional Equipment B 26 Perform Hydraulic Oil Anaysis See D 1 Test or Replace the Hydraulic Oil 5 Every 500 hours perform the following engine maintenance procedure B 27 Replace the Engine Oil and Filter Deutz Diesel Models 3 4 Genie 5 40 PartNo 32222 Service Manual First Edition Section 3 Scheduled Maintenance Inspections MAINTENANCE TABLES New parts engine engine service required required required suggested C 1 Check the Boom WearPads C 2 Check the Turntable Rotation Bearing Bolts C 3 Check the Free wheel Configuration C 4 Grease the Turntable Rotation Bearing and Rotate Gear 5 Replace the Torque Hub Oil s C 6 Replace the Hydraulic Tank Filter 7 Replace the Drive Loop Hydraulic Filter o C 8 Replace the Diesel Fuel Filter Deutz Diesel Models C 9 Replace the Gasoline Fuel Filter Gasoline LPG Models C 10 Replace the PCV Valve Gasoline LP G Models C 11 Clean or Replace the Distributor Cap and Rotor Gasoline LP G Models o C 12 Replace the Spark Plugs Gasoline LP G Models oY E E E E eee C 13 Check and Adjust the Air LPG Mixture Gasoline LPG Models C 14 Check and Adjust the Ignition Timing Gasoline LPG Models Ej C 15 Check the Engine Valve Clearances Deutz Diesel Models ra ra ra rz ra ra ra ra eee ra ee EB EB BB BB Be
94. arn how B 3 Oil cooler and fins Deutz CIS ALP G mikire B t Exhaust system C 14 Ignition timing gasoline If any inspection receives N tag B 5 Battery C 15 Valves Deut and remove the machine from service B 6 Hydraulic tank filter repair and re inspect it After repair place a check in the R box B 7 Electrical wiring Checklist D Y NR Legend B 8 Tires and wheels Refer to Table D Y yes acceptable B 9 Brake configuration D 1 Hydraulic oil N no remove from service B 10 Torque hub oil level D 2 Engine coolant gasoline R repaired B 11 Idle mixture gasoline D 3 Change fuel lines B 12 Engine RPM D 4 Valves gasoline B 13 Key Switch D 5 Compression gasoline B 14 Emergency Stop D 6 PCV hoses gasoline B 15 Ground control override D 7 Fuel injection Deutz B 16 Valve linkage D 8 Toothed belt Deutz B 17 Platform leveling D 9 Timing belt Ford PartNo 32222 Genie 5 40 3 7 Section 3 Scheduled Maintenance Inspections Service Manual First Edition n This page intentionally left blank 3 8 Genie S 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey M Maintenance inspections shall be completed by a person trained and qualified on the maintenance ofthis machine M Scheduled maintenance inspections shall be co
95. atform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check voltage at grn directional valve wire on platform rotate right function directional valve 12V Remove both wires from 0 or infinite ohms valve coil and check reisitance across coil terminals 4 to 5 ohms Hold toggle switch right function operates and manually override rotate left directional valve push in button on end of valve spool Note overriding valve will require two people If a helper is not available interchange the valve item N with a like valve item O function inoperative Install a pressure gauge 2400 psi or more at quick disconnect coupling on rotate function manifold and hold function switch 2400 psi Interchange check valve function operates item 1 with like valve item L function inoperative Replace directional valve OR manifold has internal defects OR consult Genie Industries Service Department Repair open in grn wire circuit from TB17 to Replace the coil Replace platform rotate directional valve Check for mechanical restrictions OR hydraulic rotator or function manifold has internal defect Consult Genie Industries Service Department Replace defective check valve Genie S 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooti
96. cals section in the Genie S 40 Operator s Manual and use the decal list and illustrations to determine that all decals and placards are in place 2 Inspectall decals for legibility and damage Replace any damaged or illegible decal immediately Contact your authorized Genie distributor or Genie Industries if replacement decals are needed A 3 Inspect for Damage Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage and discover loose or missing parts may result in an unsafe operating condition 1 Inspectthe entire machine for damage and improperly installed or missing parts including electrical components wiring and electrical cables hydraulic hoses fittings cylinders and manifolds fuel and hydraulic tanks drive and turntable rotation motors and torque hubs boom components and wear pads dents or damage to machine tires and wheels engine and related components limit switches alarms horn and beacon nuts bolts and other fasteners platform entry mid rail or gate cracks in welds or structural components compartment covers and latches 4 2 Genie S 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures A 4 Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and s
97. ce and zero drag 4 Use a round punch to align the shim to the wear pad Install the mounting fasteners 5 Extend and retract the boom through an entire cycle Check for tight spots that could cause scraping or binding Always maintain squareness between the outer and inner boom tubes How to Remove the Boom This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may cause death or serious injury and significant component damage Dealer service is strongly recommended Perform this procedure with the boom in the stowed position 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 7 12 Genie 5 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures 3 Remove the mounting fasteners from the counterbalance valve manifold on the end of the boom Then remove the manifold and setit aside 4 Supportthe cable track with an overhead crane 5 Remove the hose cable cover from the pivot end ofthe boom 6 Remove the cable track mounting bolts atthe platform end of the boom 7 Remove the side panel from the cable track to access the cable track mounting bolts 8 Remove the cable track mounting fasteners then remove the cable track from the boom and lay it off to the side Comp
98. ch Check voltage at red Check if key switch Replace key switch wire at ground controls internal cam is contact for ground contact on the key activating ground controls switch contact Replace key switch Repair open in red wire circuit from key switch to function switches PartNo 32222 Genie 5 40 5 27 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 13 Platform Controls Inoperative Ground Controls Operate Normally Be sure all cables are in good Does engine startfrom yes the platform controls no 0v Start engine from the OV platform then press down the foot switch and check voltage at TP 24 Test and replace foot Switch OR repair open in wht wire circuit from foot switch to TP 24 Repair open wht wire circuit from TP 24 to function controllers y Check voltage atTB22 Check for open red wire circuit from key condition with no switch to TB22 OR 12V Replace the key switch kinks or abrasions platform contacts Check voltage 22 _ Repair open in blk 2 wire circuit from TB22 22 12V a LLL LL Check voltage at blk OV Replace contact on wire on platform gt emergency stop button emergency stop button 12V poser Check voltage at TP23 Repair open in blk wire erl circuit from emergency 12
99. circuit from TB4 to directional valve Interchange the rotate right and left counterbalance valves Replace the valve coil Replace the rotate directional valve pud Replace defective counterbalance valve item M and item N on turntable rotation motor function inoperative Check for mechanical restrictions keeping turntable from rotating right OR replace directional valve OR repair rotation motor Repair rotation motor Consult Genie Industries Service Department Part No 32222 Genie S 40 5 39 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 21 All Platform Leveling Functions Inoperative Be sure all other functions operate normally Be sure both automatic and manual platform leveling do not operate If automatic leveling operates but manual leveling does not troubleshoot Platform Leveling Up Function Inoperative Repair org red wire circuit from TB 16 to flow control valve Hold ground control function switch and check voltage at org red wire on platform level flow control valve 0 or infinite Remove both wires from gh ohms valve coil and check resistance across coil terminals Replace the coil 4 to 8 ohms Remove both hydraulic Replace the hoses from the manifold counterbalance valves ports PL1 amp PL2 Plug items B amp C or valve e hoses and cap the block A manifold fittings
100. controls and check the engine for proper operation TABLE C PROCEDURES C 12 Replace the Spark Plugs Gasoline LPG Models Periodic replacement of the spark plugs is essential to good engine performance and service life Worn loose or corroded spark plugs will cause the engine to perform poorly and may resultin component damage Perform this procedure with the engine off 1 Label then disconnectthe plug wires from the spark plugs by grasping the molded boot Do not pull on the plug wire Blow out any debris around spark plugs Remove all the spark plugs from the engine Adjustthe gap on each new spark plug Install the new spark plugs then connectthe wires Be sure that each spark plug wire is attached to the correct spark plug Spark plug specifications Spark plug type Motorcraft AWSF 42 0 042 to 0 046 inches 1 07 to 1 18 mm Spark plug gap Spark plug torque 5 to 10 foot pounds 7to 14 Nm Part No 32222 Genie S 40 4 35 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES C 13 Check and Adjust the Air LPG Mixture Gasoline LPG Models Maintaining the proper air to fuel mixture during LPG operation is essential to good engine performance SER Engine fuels are combustible ul Perform this procedure an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approve
101. correctly Recheck and or consult Genie Industries Service Department Genie 5 40 PartNo 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Boom Extend Function Inoperative Be sure all other functions operate normally If boom extend function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If boom extend function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Repair open in wht red wire circuit from TB6 to proportional valve Hold ground control 0 function switch and check volts at wht red wire on proportional Jos 0 or RERO peth menm valve coil and chec ohms resistance across the Replace coil coil terminals E to 5 5 ohms Hold toggle switch in function 1 Replace the defective extend position and operates proportional valve manually override proportional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item Z with a like valve item AA inoperative function operates Interchange flow regulator valve item X with a like valve item Y Replace defective flow regulator valve
102. d fire extinguisher within easy reach The engine rpm needs to be preset for gasoline fuel operation before adjusting the LPG idle mixture Refer to B 12 Check and Adjust the Engine RPM The engine should be warmed to normal operating temperature before performing this procedure 1 Move the fuel select switch to LPG fuel and start the engine from the ground controls 2 Loosen the high idle mixture adjustment lock nut a high idle mixture adjustment screw 3 Load the system by pressing the boom retract switch then move the engine idle control switch to high idle rabbit symbol 4 Adjustthe high idle adjustment screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 using an exhaust gas analyzer If an exhaust gas analyzer is not available adjustto obtain peak or optimum rpm Genie S 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 5 Hold the adjustment screw and tighten the lock nut 6 Move the engine idle control switch to low idle turtle symbol and adjust the low idle screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 a low idle mixture adjustment screw TABLE C PROCEDURES C 14 Check and Adjust the Ignition Timing Gasoline LPG Models Complete information to perform this procedure is available in the Ford LSG 423 2 3 Liter Industrial Engine Service Manual F ord number 194 216 Genie part number 29
103. damage hazard Do ACAUTION not force the drive pump during installation or the flex plate teeth may become damaged 4 Assemble the engine and torque the pumpmountint plate to 34 ft lbs 46 Nm Part No 32222 Genie S 40 7 21 Section 7 Repair Procedures Service Manual First Edition FORD LSG 423 ENGINE 6 7 Water Temperature and Oil Pressure Gauges The water temperature gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 230 F 109 C When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Temperature will be indicated when the key is on and the Emergency Stop Button is pulled out to the on position Component damage hazard ACAUTION Do not crank the engine with the over temperature light on The oil pressure gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 8 psi 0 55 bar When the contacts close the engine will shut off to prevent damage Oil pressure will be indicated when the engine is running Component damage hazard ACAUTION Do not continue to run the engine with the low oil pressure light on 6 8 Vacuum Switch How to Test the Vacuum Switch ohmmeter common terminal SOL vacuum switch normally open terminal ING O w 1 Connectthe leads from an ohmmeter
104. dels 7 Chock the non steering wheels to prevent the machine from rolling 8 Position the lifting jack under the steering axle and center it between the steering wheels 9 Lift the wheels off the ground and then place jack stands under the drive chassis for support 10 Disengage the torque hubs by turning over the torque hub disconnect caps on each steer wheel hub disengage position engage position 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort 12 Re engage the torque hubs by turning over the hub disconnect caps Carefully remove the jack stands lower the machine and remove the jack Collision hazard Failure to AWARNING re engage the torque hubs may cause death or serious injury and property damage Genie 5 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures All models 13 Be sure the free wheel valve on the drive pump is closed clockwise a drive pump b free wheel valve C screwdriver d liftpump The free wheel valve should always remain closed TABLE C PROCEDURES C 4 Grease the Turntable Rotation Bearing and Rotate Gear Y early 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 component damage 1 Locate the grease fitting on the p
105. dex Schematic No Description Item Function Torque 1 Flow regulator valve S cases RF flow control in forward 15 18 ft lbs 20 24 Nm 2 Flow regulator valve RR flow control in forward 15 18 ft lbs 20 24 Nm 3 Flow regulator valve RF flow control in reverse 15 18 ft lbs 20 24 Nm 4 Flow regulator valve RR flow control in reverse 15 18 ft Ibs 20 24 Nm 5 Flow regulator valve LF flow control in forward 15 18 ft lbs 20 24 Nm 6 Flow regulator valve Jussi LR flow control in forward 15 18 ft lbs 20 24 Nm 7 Flow regulator valve Gato LF flow control in reverse 15 18 ft lbs 20 24 Nm 8 Flow regulator valve Es LR flow contol in reverse 15 18 ft lbs 20 24 Nm 9 Flow control Quse RR flow regulator in forward 15 18 ft lbs 20 24 Nm 10 Flow control RR flow regulator in reverse 15 18 ft lbs 20 24 Nm 11 Flow control LR flow regulator in forward 15 18 ft lbs 20 24 Nm 12 Flow control E usus LR flow regulator in reve
106. dle soe adjustment see rabbit symbol and pus Maintenance section or check if IAR see Deutz workshop solenoid pulls in manual to troubleshoot Ea fuel injection system solenoid does not pull in Check voltage at blk red gy Check voltage on center wire on rpm select terminal of rpm select switch switch 12 Replace toggle switch Check voltage at TB35 R Repair open in blk red wire circuit from toggle switch to TP 35 to 7835 Check voltage at OV Repair open in blk red terminal 30 on CR3 Check voltage to terminal 86 on CR3 wire circuit from TB35 to terminal 30 on CR3 Repair open in wht 21 wire circuit from TB21 to terminal 86 on CR3 Check ground wire to terminal 85 on CR3 Repair open in ground wire to terminal 85 on O 22 w Check voltage to terminal 487 on CR3 Replace CR3 relay Check voltage at initiate terminal 86 on CR4 Repair open in blk red wire circuit from CR3 to CR4 Continued on the next page Repair open in circuit supplying 12V to center terminal of switch Genie 5 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts previous page Continued from the Check ground wire to terminal 85 on CR4 Repair ground wire to terminal 85 on CR4 Check voltage to Repair open i
107. dustries Service Department Genie 5 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Will Not Start On Gasoline But Will Start On LPG Gasoline LPG Models Be sure fuel select switch is switched to gasoline Be sure to check gasoline fuel level Be sure that engine choke is operating properly With keyswitch on and both mushroom switches pulled out check voltage at gasoline side blu wht wire of fuel select switch 12V With keyswitch on and both mushroom switches pulled out check voltage at TB38 12V With keyswitch on and both mushroom switches pulled out check voltage at terminal 430 on CR6 12V Crank engine for 15 seconds and check voltage at terminal 86 on CR6 12 Check gouna wire to bad terminal 85 on CR6 good Hold start switch and check voltage at blu wht wire on anti diesel valve on carburetor 12V Continued on the next page Chart 5 Replace fuel select switch Repair open in blu wht wire circuit from fuel select switch to TP 38 to TB38 Repair open in blu wht wire circuit from TB 38 to terminal 30 on CR6 Repair open in red blk wire circuit from vacuum switch to CR6 Repair open in ground wire to terminal 85 on 22 D Repair open in blu wht wire circuit from CR 6 terminal 87 to anti diesel valve OR replace CR6 Part No 32222
108. e 5 Bring the machine to top drive speed before reaching the testline 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 Braking paved surface Stopping distance 2 to 4 ft 0 60 to 1 21 m The brakes must be able to hold the machine on any slope itis able to climb B 24 Test the Drive Speed Stowed Position 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 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 then lower the boom into the stowed position 4 Choose a pointon the machine i e contact patch ofa 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 th
109. e from the manifold and cap the port Then with pressure gauge still attached operate the function Repair the cylinder and or replace cylinder counterbalance valves less than 1200 psi Internal defect in manifold OR one of the previous tests involving the pump or manifold components was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department With boom full extended hold the extend function switch Adjust the relief valve to read 1200 PSI and replace the cylinder counterbalance valve 5 34 Genie S 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Boom Retract Function Inoperative Be sure all other functions operate normally including boom extend function If boom retract function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If boom retract function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Repair open in blk wht wire circuit from TB8 to directional valve Hold ground control function switch and check volts at blk wht wire on extend retract function valve function operates Check the resistance of the retract directional valve coil Hold toggle switch down and manual
110. e 5 40 Part No 32222 Service Manual First Edition Ford Engine LSG 423 Displacement 140 cu in 2 3 liters Number of cylinders 4 Bore 8 stroke 3 780 x 3 126 inches 96 x 79 4 mm Horsepower 63 4000 rpm Firing order 1 3 4 2 Low idle 1600 rpm High idle 2500 rpm Governor electronic Compression ratio 9 5 1 Compression pressure approx 150 to 175 psi 10 to 12 bar Pressure psi of lowest cylinder must be at least 75 of highest cylinder Valve clearances 0 040 to 0 050 inches Section 2 Specifications r MG FORD ENGINE LSG 423 Starter motor SPECIFICATIONS Normal engine cranking speed 110 rpm Current draw normal load 150A Current draw maximum load 460A Current draw no load 70A Maximum circuit voltage drop 0 5V DC while starting normal temperature Brush length new 0 50 in 12 7 mm Brush length wear limit 0 25 in 6 35 mm Brush spring tension 40 ounces 11 Newtons Bolt torque through brush 55 to 75 inch pounds 6 to 8 5 Nm Brush mounting 15 to 20 foot pounds 1 0 to 1 3 mm bolt torque 20to 27 Nm Lubrication system Maximum commutator 0 005 inches run out 0 127 mm Oil pressure 40 to 60 psi operating temp 2600 rpm 2 75 to 4 1 bar Battery Oil capacity 5 quarts Type 12V Group 31 including filter 4 7 liters
111. e engine to drain into a suitable container 4 Install the plug into the drain hose 5 Remove the 2 bolts from the engine pivot plate S wing the engine pivot plate away from the machine to access the oil filter Use an oil filter wrench and remove the filter Apply a thin layer of oil to the new oil filter gasket filter part no 28656 Then install the filter and tighten it securely by hand Genie 5 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 8 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 9 Fill the engine with new oil per specifications and install the filler cap 10 Start the engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off 11 Check the oil filter and the oil drain hose for leaks 12 Swing the engine pivot plate back to its original position and replace the two retaining bolts 13 Check the engine oil level dipstick Add oil ifneeded Ford Engine LSG 423 Oil capacity including filter 5 quarts 4 7 liters Ford Engine LSG 423 Oil viscosity requirements below 60F 15 5C 5W 30 10 to 90F 23 to 32C 10W 30 above 10F 23C 10W 40 or 10W 50 above 25F 4C 20W 40 or 20W 50 TABLE A PROCEDURES A 16 Replace the Engine Air Filter Engine specifications require that this procedure be performed every 1
112. e finish line Drive speed stowed position 2WD 4WD Gasoline LP G models 40ft 6 8sec 40 ft 7 8 sec 12 2 m 6 8 sec 12 2 m 7 8 sec 40 7 8 40 ft 9 1 sec 12 2 m 7 8 sec 12 2 m 9 1 sec Deutz Diesel models Genie S 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 25 Test the Alarm Package Optional Equipment The alarm package includes travel alarm descent alarm flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable covers The alarms and beacon will operate with the engine TABLE B PROCEDURES Press down the foot switch Move the boom control handle to the pown position hold for a moment and then release it Result The descent alarm should sound when the control handle is held down Press down the foot switch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite direction hold for a momentand then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction running or not running Atthe ground controls pull outthe Emergency Stop button to the on position and turn the key switch to ground control Result The flashing beacon should be on and flashing Move the bo
113. eennneenen nennen nennen ns 7 40 12 3 THE Rode edere e tec tco rte rc Tugel bc WS 7 41 4WD Steering Axle Components 13 1 Yoke and HUD ewa a Z AE er etr Hr HO EE e bugie 7 42 13 2 Steering C ylinders ott de ra e etd a i a ee 7 43 13 3 RET RE eta Re Ur ed e RS 7 43 PartNo 32222 5 40 Service Manual First Edition 5 TABLE OF CONTENTS Section Seven Repair Procedures continued Oscillating Axle Components 14 1 Oscillating Axle 32 eee 7 44 Steer and Oscillate Manifolds 15 1 Oscillate Manifold 32 memes 7 45 15 2 Valve Adjustmerits tec eet ere vean ER das 7 46 15 3 Directional Valve Manifold 7 47 15 4 Steer Manifold 3 emen 7 49 Non steering Axle Components 16 1 Drive be edu eee A ees 7 50 16 2 Torque H b eere rete e ee Ja at ni 7 50 2WD Drive Manifold 17 1 2WD Drive Manifold 7 52 17 2 Valve Adjustrmriente sormeni reet A so OWE 7 54 4WD Drive Manifold 18 1 4WD Drive Manifold 2 emen 7 56 18 2 Valve AdjuStMeNtS awa i e Ee ee Lo qp eet p ts 7 58 xii Genie 5 40 PartNo 32222 Service Manual First Edition Section 2 Specifications Machine Spec
114. el should be in the NORMAL range A 6 Check for Fuel Leaks Failure to detect and correct fuel leaks will result in an unsafe condition An explosion or fuel fire may cause death or serious injury we yrr Engine fuels are combustible i Inspect the machine in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach 1 Open the shutoff valve on the liquid petroleum gas LPG tank by turning it counterclockwise Part No 32222 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES 2 Perform a visual inspection around the following areas An LPG detector may be necessary to locate LPG leaks Gasoline LPG models LPG tank hoses and fittings solenoid shutoff valve LPG regulator and carburetor gasoline tank shutoff valve solenoid shutoff valve hoses and fittings fuel pump and carburetor Deutz Diesel models fuel tank shutoff valve hoses and fittings fuel pump fuel filter fuel injection pumps and fuel injectors If a fuel leak is discovered keep A DANGER any additional personnel from entering the area and do not operate the machine Repair the leak immediately A 7 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hyd
115. els then center a lifting jack between the steering wheels under the axle pivot pin 2 Raise the machine 6 inches 15 cm and place blocks under the drive chassis 3 Disconnect and plug the oscillating axle cylinder hydraulic hoses and cap the cylinder fittings ACAUTION 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 Remove the pin retaining fasteners from both pivot pins Attach a strap from a lifting device to the cylinder for support Use a soft metal drift to remove the pins Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures Steer and Oscillate Manifolds 15 1 Oscillate Manifold Components Index Schematic No Description Item Function 1 Diagnostic fitting seen Testing 2 Differential sensing valve enses Differential sensing 3 Check valve Oscillate check left 4 Pilot operated unloader valve 1200 psi 82 7 Sequencing sesser 5 Shuttle valve 2 position 3 way nsn 6 G uses Check valve circuit 7 Check valve sse Eoo Oscillate check right 8 Shuttle valve 2 position 3 way Fuss
116. emove and label the wear pads from the extension boom Pay careful attention to the location and amount of shims used with each wear pad 3 3 Boom Lift Cylinder How to Remove the Boom Lift Cylinder This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Raise the boom until the boom lift cylinder rod end pin is above the turntable covers 2 Place blocks under the cylinder for support 3 Supportthe boom with an overhead crane Do not lift the boom 4 Supportthe balance point of the boom lift cylinder with an overhead crane or similar lifting device Crushing hazard If the overhead AWARNING crane is not properly attached the lift cylinder may become unbalanced and fall when itis disconnected from the machine 5 Remove the pin retaining fastener from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin then allow the lift cylinder to rest on the blocks Protect the cylinder rod from damage Crushing hazard The lift ACAUTION cylinder will fall unless it is properly supported 6 Use the crane to lift the boom to a horizontal position 7 Remove the turntable end cover to access the lift cylinder mounting bracket label and disconnect alarm wiring if equipped
117. engine pivot plate away from the machine to access the PCV hoses Ay i A a pivot plate retaining bolts b engine pivot plate TABLE D PROCEDURES 2 Disconnectthe hoses from the P CV valve then disconnectthe hoses from the engine Shown with distributor cap removed a PCV valve b hose PCV valve to carburetor C hose PCV valve to crankcase 3 Clean the hoses with a mild cleaning solvent 4 Dry both hoses and inspect them for cracks and damage Replace the hoses if they are damaged Part No 32222 Genie S 40 4 43 Section 4 Scheduled Maintenance Procedures Service Manual First Edition punc o R TABLE D PROCEDURES D 7 Check the Fuel Injection Pumps and Injectors Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011 Workshop Manual Deutz number 0291 1942 Genie part number 29789 D 8 Check the Toothed Belt Deutz Diesel Models Complete information to perform this procedure is available in Deutz FL 1011 Operation Manual Deutz number 0297 4706 EN Genie part number 29790 D 9 Replace the Timing Belt Gasoline LPG Models Complete information to perform this procedure is available in the Ford LSG 423 2 3 Liter Industrial Engine Service Manual F ord number 194 216 Genie partnumber 29586 4 44 Genie 5 40 PartNo 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts
118. enie 5 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 10 All Functions Inoperative Engine Starts and Runs Check hydraulic fluid level Fill with Dexron II equivalent hydraulic fluid ok Check pump suction Open valves If engine line shutoff valves has been run with Valve handles should valves closed it may be parallel with hose have damaged one or both pumps Disconnect center coil Troubleshoot wire from distributor cap inoperative boom and isolate from functions and grounding Deutz inoperative drive models hold manual functions separately fuel shutoff lever counterclockwise Remove function pump from main pump but leave all hoses connected Hold start switch and crank engine over while observing Spline drive at rear of main pump Spline does not turn Engine to pump flex plate coupling Is defective See Repair section Part No 32222 Genie S 40 5 25 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 11 All Lift and Steer Functions Inoperative Drive Functions Operational Be sure the hydraulic suction line shutoff valve for the lift steer pump is in the open position Be sure all grounding wires for the hydraulic manifold valves are free of corrosion and have full continuity to ground Troubleshoot each function individually or consult Genie Industries Service Department In
119. ervice life Operating the machine with an improperoil level can damage engine components Check the oil level with the engine off 1 Checkthe oil level dipstick Add oil as needed Result The oil level should be in the safe zone Ford Engine LSG 423 Oil capacity including filter 5 quarts 4 7 liters Ford Engine LSG 423 Oil viscosity requirements below 60F 15 5C 5W 30 10 to 90F 23 to 32C 10W 30 above 10F 23C 10W 40 or 10W 50 above 25F 4C 20W 40 or 20W 50 Use oils meeting API classification SF labeled SF CC or SF CD as they offer improved wear protection Deutz Engine F3L 1011 Oil capacity including filter 8 5 quarts 8 liters Deuiz Engine F3L 1011 Oil viscosity requirements below 60 F 15 5 synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 34 15W 40 Engine oil should have properties of API classification CC SE CD SE CC SF or CD SF grades TABLE A PROCEDURES A 5 Check the Engine Coolant Level Gasoline LPG Models Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems 1 Check the fluid level in the coolant recovery tank Add fluid as needed Result The fluid lev
120. esistance across coil valve coil terminals 4 to 8 ohms Replace steer valve OR consult Genie Industries Service Department 5 46 Genie S 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Steer Right Function Inoperative Be sure all other functions operate normally Start the engine from the platform press down foot switch hold the steer switch right and check voltage at terminal 7 on the drive controller blu blk wire Hold the steer switch right and check voltage at TB37 Hold the steer switch right and check voltage at blu blk wire on steer valve Remove both wires from infinite Steer right coil and check resistance across coil terminals Replace steer valve OR 4 to 8 ohms Chart 28 Repair or replace the steer microswitch in controller handle Repair open in blu blk wire circuit from steer switch to TP37 to TB37 Repair open in blu blk wire circuit from TB37 to steer valve 0 or ohms Replace steer right valve coil consult Genie Industries Service Department Part No 32222 Genie S 40 5 47 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 29 All Drive ENAR 7 machine does not move hee the Functions Standing clear of the i tires momentarily move Inoperative pump control override All Other lever in each direction Functions machine moves Operate Mo
121. eyswitch on and both mushroom switches pulled out check voltage at LPG side blu red wire of fuel select switch 12V With keyswitch on and both mushroom switches pulled out check voltage at TB39 12V With keyswitch on and both mushroom switches pulled out check voltage at terminal 30 on CR7 12V Crank engine for 15 seconds and check voltage at terminal 86 on CR7 12V Check ground wire to terminal 485 on CR7 good Continued on the next page bad Replace fuel select switch Repair open in blu red wire circuit from fuel select switch to TP39 to TB39 Repair open in blu red wire circuit from TB39 to terminal 30 on CR7 Repair open in red blk wire circuit from vacuum Switch to CR6 to CR7 Repair open in ground to terminal 485 on CR7 Chart 4 Part No 32222 Genie S 40 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 4 Continued from the previous page Hold start switch and check voltage at terminal 487 on CR7 Replace CR7 relay Hold start switch and Repair open in blu red check voltage at blu red wire circuit from CR7 wire on LPG solenoid terminal 487 to LPG solenoid 0 or infinite ohms Check resistance of LPG solenoid Replace LPG solenoid 9 to 10 ohms Reconnect LPG tank and starter then see Maintenance section for LPG adjustments OR consult Genie In
122. ff and re connect the volt meter 13 Pull out the Emergency Stop button to the on position 14 Press down the foot switch and then move the control handle all the way to the up position Record the maximum voltage reading 15 Start the engine PLATFORM CONTROLS 16 Start a timer and simultaneously move the control handle all the way to the up position Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp speed 17 Set the ramp rate turn the trimpot to obtain a 3 to 4 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Boom up down specifications Threshold 2 58V DC 5 9V DC 40 to 60 seconds Boom up Max out Cycle time 5 9V DC 50 to 80 seconds Boom down Dual lo range Cycle time Ramp rate 3 to 4 seconds Turntable Rotation Controller Adjustments Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 12 5 to 14 5V DC output AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller 2 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both t
123. fitting and the bleed valve 3 Loosen the wheel lug nuts Do not remove them 4 Centera lifting jack under the non steering axle Raise the machine and place blocks under the drive chassis to support it 5 Remove the wheel lug nuts then the tire and wheel assembly 6 Place a second lifting jack under the torque hub for support 7 Remove the bolts that attach the torque hub to the chassis then remove the torque hub Crushing hazard The torque ACAUTION hub will fall if itis not properly supported when the mounting bolts are removed Torque specifications Lug nut 125 ft lbs then remove it 169 5 Nm Torque specifications Drive torque hub mounting bolts 120 ftlbs 163 Nm Drive motor mounting bolts 75 ft lbs 102 Nm Drive motor mounting bolts 75 165 102 Nm 7 50 Genie S 40 Part 32222 Service Manual First Edition Section 7 Repair Procedures p M M H M d This page intentionally left blank Part No 32222 Genie S 40 7 51 Section 7 Repair Procedures Service Manual First Edition 2WD Drive Manifold 17 1 2WD Drive Manifold Components Index Schematic No Description Item Function 1 Relief valve 250 psi 17 bar A oi Charge pressure 2 Flow regulator valve RR flow control in reverse 3 Flow regulator valve
124. function proportional valve Repair open in wht red wire circuit from TB6 to proportional valve 4 to 7V 0 or Remove both wires infinite from valve coil and ohms check resistance across Replace the the coil terminals 4 5 to 5 5 ohms Hold toggle switch and function Replace defective manually override operates proportional valve proportional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item Z with a like valve item AA function inoperative Interchange rotation function function flow regulator operates Replace defective flow regulator valve valve item X with a like valve item Y function inoperative 0 or Replace the defective onms valve coil s Hold toggle switch to function Check the resistance left and manually operates of the directional override rotate left valve coils directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item with a like valve item 5 4 to 5 ohms Replace the valve function inoperative Continued on the next page Genie S 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts function Interchange check valve operates item K w
125. g of the resistor being tested 3 Compare the ohmmeter reading with the resistance rating printed on the resistor 7 5 Power Relay a high amp powercontactterminal i j large post AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry small post How to Test the Power Relay Electrocution hazard Disconnect AWARNING the ground cable from the battery before performing this procedure 1 Connect the leads from an ohmmeter to each terminal combination and check for continuity Test Desired result 2 small posts 13 to 170 2 large posts no continuity infinite Q Any small post to no continuity any large post infinite Q 7 26 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures Hydraulic Pumps 8 1 5 Deutz Diesel models Hold the manual fuel shutoff valve counterclockwise to the Lift Steer Pump CLOSED position models Observe the pressure gauge How to Test the Lift Steer Pump while cranking the engine Immediately stop cranking if the pressure reaches or exceeds 1 Disconnect and plug the high pressure 3000 psi 206 bar hydraulic hose from the lift steer pump NE Component damage hazard Bodily injury hazard Spraying ACAUTION ACAUTION hydraulic oil can penetrate and ek cee burn skin Loosen hydraulic SOOM periodo AI WI cau
126. gauge SAE No 4 3 16 13 ftlbs 18 Nm Relief valve specifications SAE No 6 1 4 18 ft lbs 24 Nm Pressure 250 psi 17 bar SAE No 8 5 16 50 ft lbs 68 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 12 5 8 75 ft lbs 102 Nm 18 2 Valve Adjustments How to Adjust the Charge Pressure Relief Valve 1 Connecta 0 to 600 psi 0 to 41 bar pressure gauge to the test port located on the drive manifold ACAUTION 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 2 Start the engine from the platform controls 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the relief valve and remove the cap index 13 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 7 58 Genie S 40 Part No 32222 Distributed By E Genie North America 18340 NE 76th Street P O Box 97030 Redmond Washington 98073 9730 E Genie Europe Brunel Drive Newark Nottinghamshire NG24 2EG England
127. ge Loose or Missing Parts A 4 Check the Engine meme A 5 Check the Engine Coolant Level Gasoline LPG Models As6 Check for Fuel Leaks es aaa di e en eere dede RO A 7 Check the Hydraulic Oil Level oo eee eee 8 Check for Hydraulic Leaks oo eee eee 1 1 1 1 1 1 A W N 1 1 1 1 1 1 O Ul W DN BR BE W W W DND n PartNo 32222 Genie 5 40 Service Manual First Edition Ool TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued A 9 Check the Tire Pressure si asa A te eels 4 5 A 10 Test the Platform and Ground 5 3322 4 5 A 11 Test the Auxiliary Power emn 4 6 A 12 Testthe 5 canine a Sadi aig Gaia e es 4 7 A 13 Testthe EiIMIESWIICHES rer A ertet ete exte A Ee ee iets 4 7 A 14 Testthe Oscillate AXle iccirco Red nda 4 9 A 15 Replace the Engine Oil and Filter Gasoline LP G Models 4 10 A 16 Replace the Engine Air Filter sseee mmm 4 11 B l Checkthe Engine Belt s nA a taka 4 12 B 2 Check the Radiator Gasoline LP G 4 12 B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models 4
128. he machine to access the radiator petcock L AT Z j Y a pivot plate retaining bolts b engine pivot plate 5 Open the petcock on the radiator and allow all the coolantto drain into a container 6 After all the coolant has drained close the petcock Connect the coolant return hose to the radiator 7 Openthe petcock on the engine block and allow the coolantto drain into a container After the fluid is drained close the petcock 8 Replace all coolanthoses and clamps 9 Pourthe proper coolant mixture anti freeze and water for your climate into the radiator until itis full 10 Disconnect hose A from hard line and hold until coolant starts to pour out of the open hose Then immediately reconnectthe hose a hose A b hard line B 11 Fill the radiator and then fill the coolant recovery tank to the NoRMAL range 12 Clean up any coolantspilled during this procedure 13 Startthe engine from the ground controls run it for 30 seconds and then turn it off 14 Inspect for leaks and then check the fluid level in the coolant recovery tank Add water if needed 15 Start the engine from the ground controls and run it until reaching normal operating temperature 16 Allow engine to cool and check the fluid level in the coolant recovery tank Add water if needed Ford Engine LSG 423 Coolant capacity 11 5 quarts 10 9 liters 4 40 Genie 5 40 Part No 32222 Service Manual First Edition Secti
129. he set screw toward the pump Leave a 3 16 inch 4 7 mm gap between the coupler and pump end plate 3 Apply Loctite removable thread sealant to the coupler set screw Torque the set screw to 45 ft lbs 61 Nm Component damage hazard Do ACAUTION not force the drive pump during installation or the flex plate teeth may become damaged 4 Assemble the engine and torque the pump mountint plate to 34 ft lbs 46 Nm 5 3 Oil Temperature and Pressure Gauges The oil temperature gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 300 F 147 When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Temperature will be indicated when the key is on and the Emergency Stop Button is pulled out to the on position Component damage hazard ACAUTION Do not crank the engine with the over temperature light on The oil pressure gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 7 psi 0 48 bar When the contacts close the engine will shut off to prevent damage Oil pressure will be indicated when the engine is running Component damage hazard ACAUTION Do not continue to run the engine with the low oil pressure light on Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures
130. he ground and platform controls Do not start the engine Part No 32222 Genie S 40 7 3 Section 7 Repair Procedures Service Manual First Edition PLATFORM CONTROLS 3 Open the platform control box lid and locate the turntable rotation controller Refer to the platform control box illustration page 7 2 ramp rate adjustable trimpot dual lo range adjustable trimpot terminal R activates max out range terminalunused terminal X auxiliary terminal ground terminal battery positive terminal A proportional output threshold adjustable trimpot max outadjustable trimpot so p 4 Setthe preliminary ramp rate Turn the trimpot adjustment screw clockwise 15 turns or until you hear a repeated click 5 Connect the red lead from a volt meter to the A terminal on the controller printed circuit board Connect the black lead to ground 6 Set the threshold Press down the foot switch then slowly move the control handle off center until the moment a voltage reading appears Adjust the voltage to 2 5V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 Set the dual lo range Turn the trimpot 8 Setthe max out Press down the foot switch then move the control handle all the way to the left or right Adjust the voltage to 5 5V DC Turn the max out trimpot adjustment screw clockwise to increase the
131. his procedure with the engine off 1 Remove the filter with an oil filter wrench 2 Apply a thin layer of oil to the new oil filter gasket 3 Install the new filter part no 20293 and tighten it securely by hand Clean up any oil that may have spilled during the installation procedure 4 Start the engine from the ground controls 5 Inspect the filter and related components to be sure that there are no leaks TABLE C PROCEDURES C 7 Replace the Drive Loop Hydraulic Filter Replacing the drive loop hydraulic filter is essential to 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 filter be replaced more often Beware of hot oil Contact with ACAUTION hot oil may cause severe burns Perform this procedure with the engine off 1 Open the engine side turntable cover and locate the drive loop hydraulic filter mounted on the engine near the main pump 2 Rotate the filter housing counterclockwise and remove the housing 3 Remove the filter element from the housing 4 Inspect the housing seal and replace it if necessary 5 Install the new filter part no 20880 and hand tighten the housing onto the filter head Clean up any oil that may have spilled during the installation procedure 6 Startthe engine from the ground controls 7 Inspect the filter assembly to be
132. hms valve coil and check reisitance across coil terminals 4 to 5 ohms Hold toggle switch left and manually override rotate left directional valve push in button on end of valve spool Note overriding valve will require two people If a helper is not available interchange the valve item N with a like valve item O function inoperative Install a pressure gauge at quick disconnect coupling on rotate function manifold and hold function switch 2400 psi or more 2400 psi Interchange check valve function operates item H with like valve item L function inoperative Replace directional valve OR manifold has internal defects OR consult Genie Industries Service Department Replace the coil Replace platform rotate directional valve Check for mechanical restrictions OR hydraulic rotator or function manifold has internal defect Consult Genie Industries Service Department Replace defective check valve Part No 32222 Genie S 40 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 25 Platform Rotate Right Function Inoperative Be sure all other functions operate normally If platform rotate right function operates normally from the ground controls but not from the platform controls troubleshoot the platform control toggle switch See Repair section If platform rotate right function operates normally from the pl
133. hub 5 Repeatthis procedure for each drive torque hub Drive torque hub oil 17 fluid ounces 0 51 liters Capacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Genie S 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Turntable Rotate Torque Hub 1 Removethe plug located on the side ofthe hub and check the oil level Result The oil level should be even with the bottom ofthe plug hole a torque hub b plug 2 Ifnecessary add oil until the oil level is even with the bottom ofthe side plug hole 3 Apply pipe thread sealantto the plug and then install itin the torque hub Turntable rotate torque hub oil Capacity 8 fluid ounces 0 24 liters TypeSAE 90 multipurpose hypoid gear oil API service classification GL5 TABLE B PROCEDURES B 11 Check and Adjust the Engine Idle Mixture Gasoline LPG Models Complete information to perform this procedure is available in the Ford LSG 423 2 3 Liter Industrial Engine Service Manual Ford number 194 216 Genie partnumber 29586 B 12 Check and Adjust the Engine RPM Maintaining the engine rpm atthe 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 Gasoline LPG Models Perform this procedure in gas
134. ial to safe machine operation The service horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will preventthe operator from alerting ground personnel of hazards or unsafe conditions 1 Tum the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls 2 Push down the service horn button at the platform controls Result The service horn should sound Part No 32222 Genie S 40 4 21 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 19 Test the Foot Switch A properly functioning foot switch is essential to safe machine operation Machine functions should activate and operate smoothly as long as the foot switch is pressed down and promptly stop when the foot switch is released The foot switch will also shift the engine into high idle if the idle select is switched to the rabbit and foot switch symbol An improperly functioning foot switch can cause an unsafe working condition and endanger platform and ground personnel The engine should not start if the foot switch is pressed down 1 Start the engine from the platform controls 2 Without pressing down the foot switch check the machine functions Result The machine functions should not operate 3 Press down the foot switch and operate the machine functi
135. idle adjustment nut controls C lock nut d yoke O Result The machine functions should not e low idle adjustment screw operate f lock nut 4 Turn the k itch t trol 3 Move the engine idle control switch to high idle rabbit symbol from the ground controls 5 Check any machine function from the platform Is Result High idle should be 2300 rpm controls If high idle rpm is correct disregard adjustment step 4 Result The machine functions should not operate 6 Turn the key switch to the orr position 4 Loosen the yoke lock nut then turn the adjustment nut and solenoid boot Result The engine should stop and no counterclockwise to increase the rpm or functions should operate clockwise to decrease the rpm Tighten the Deutz Diesel models All functions yoke lock nut and recheck the rpm should stop immediately The engine will shut off after 2 to 3 Deutz Diesel models seconds Low idle 1300 rpm High idle 2300 rpm PartNo 32222 Genie 5 40 4 19 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 14 Test the Emergency Stop Buttons Properly functioning Emergency Stop buttons are essential for safe machine operation An improperly operating Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation for ground and platform personnel As a Safety feature selecting and operati
136. ifications Specifications Stowed dimensions 2WD RT 4WD RT Tires and wheels 2WD Rear 2WD Front 4WD Front Length 23 ft 11 in 23 ft 11 in Tires Only amp Rear 7 28 7 28 Tire size 12 5L 16SL 12 16 5 NHS Width 7 ft 6 in 7 ft 6 in 2 29m 2 29m Tire ply rating 12 8 Height 8 ft 2 in 8 ft 2 in Tire contact area 88 sq in 57 sqin 2 48 m 2 48 m 568 sq cm 368 sq cm Weight 11 650 165 11 650 165 Overall tire diameter 33 7 in 33 2 in 5 284 kg 5 284 kg 85 6 cm 84 3 cm Ground clearance 12 1 2 in 12 1 2 in Tire pressure 45 psi 45 psi 31 8 cm 31 8 cm 3 10 bar 3 10 bar Operational dimensions Wheel diameter 16 in 16 1 2 in 40 6 41 9 Maximum platform height 40 ft 40ft 12 2m 12 2m Wheel width 10 in 9 75 in 25 4 cm 247 Maximum horizontal reach 31 ft 8 in 31 ft 8 in 9 64 m 9 64 m Wheel lugs 8 5 8 18 9 5 8 18 Maximum turntable tailswing 34 in 34 in Lug nut torque 125 ftlbs 125 ftlbs 86 4 cm 86 4 cm 169 5 Nm 169 5 Nm Wheelbase 7 ft3 in 7 ft3 in Fluid capacities 2 2m 2 2m Fuel tank 30 gallons 114 liters Minimum turning circle 15 ft8 in 15 ft8 in outside 4 77 m 477 m LPG tank 33 5 pounds 15 2 kg Minimum turning circle 6 ft8 in 6ft8in Hydraulic tank 45 gallons 170 liters PM RM Hydraulic system 50 gallons 189 liters Turntable rotation continuous continuous including tank Platform rotation 160 160 torque hub 17 fl
137. il filter bracket bolts 7 to 8 9to 11 6 105 8 8 M 8 x 20 Torx 8 8 Valve plunger housing bolts 14 to 16 19 to 22 Oil intake housing bolts 15 to 18 20to24 M 8 30 Torx 8 8 M 8 x 75 Torx Alternator nuts M 5 3 4 Fuel pump bels 151018 2004 Fuel bracket bolts M 8 x 20 8 8 15 20 Injection pump bolts 15 to 18 20024 Adapter housing bolts 70 to 77 95 to 105 Injector cap nut 30 to 37 40 to 50 M 12 x 35 10 9 or M 12 x 75 10 9 Injector fastening bolt 15 to 18 20 to 24 first step second step tightening tightening Injection line 10012 13 5 to 16 5 torque angles ft N Ist 2 Air intake manifold bolts 15 to 18 20 to 24 gt M ue M 8 x 30 8 8 Main bearing bolts 37 50 60 45 Air intake manifold 3 hole 15 to 18 20 to 24 Big end bolts 22 30 60 60 flange bolts M 8 x 35 Torx 8 8 Flywheel bolts 22 30 60 30 Exhaust manifold bolts 27 to 32 36 to 44 M 10 x 30 Torx 10 9 Cylinder head step 1 22 30 studs step 2 59 80 Starter fastening bolts 28 to 34 38 to 46 step 3 118 160 120 NA M 10 x 28 8 8 Camshaft central bolt 22 30 150 NA Starter carrier bolts 50 to 60 68 to 82 M 12 x 28 8 8 Crankshaft central bolt 96 130 210 NA Oil pan bolts 15 to 18 20 to 24 M 8 x 16 Torx 8 8 Oil drain bolts 37 to 44 50 to 60 2 8 Genie 5 40 PartNo 32222 Service Manual First Edition Section 3 Scheduled Maintenance Inspections Scheduled Maintenance Inspections Observe and Obey M Maintenance inspections shall
138. ine Check voltage at terminal 4 on electronic governor 12V Turn machine off remove both wires from governor actuator and check resistance across governor actuator terminals 2 to 3 ohms Reconnect governor wires and restart engine and check voltage at electronic governor terminal 3 brown wire 6 to 7V See Maintenance section for governor adjustments OR replace electronic governor Replace CR4 relay Repair open in red wht wire circuit from TB23 to electronic governor Repair open in red wht wire circuit from electronic governor to governor actuator Repair open in blu blk wire circuit from governor actuator to electronic governor OR check and or replace governor actuator Replace governor actuator Repair open in brown wire circuit from ignition module to electronic governor Genie S 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Low Idle Inoperative Gasoline LPG Models If low idle operates on LPG butnoton gasoline see Ford service manual for carburetor troubleshooting If low idle operates on gasoline but not on LPG see Repair section for LPG regulator adjustments Be sure throttle linkage from governor to carburetor is not binding see Repair section Start engine and switch rpm select to low idle 12V turtle symbol Check voltage at terminal 30 blk wire on CR3 0
139. ion 4 Scheduled Maintenance Procedures 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 Store completed forms for three years Part No 32222 Genie S 40 3 1 Section 3 Scheduled Maintenance Inspections Service Manual First Edition Maintenance Tables Table A took endhe senis required required required required suggested A 1 Inspect the Manuals A 2 Inspectthe Decals and Placards A 3 Inspect for Damage Loose or Missing P arts A 4 Check the Engine Oil Level A 5 Check the Engine Coolant Level Gasoline LPG Models A 6 Check for Fuel Leaks A 7 Check the Hydraulic Oil Level A 8 Check for Hydraulic Leaks A 9 Check the Tire Pressure A 10 Platform and Ground Controls A 11 Test the Auxiliary Power Operation A 12 Testthe Tilt Sensor A 13 Testthe Limit Switches A 14 Testthe Oscillate Axle oscillating axle equipped models Genie S 40 Part No 32222 Service Manual First Edition Table A continued Section 3 Scheduled Maintenance Inspections Tools are required New parts required MAINTENANCE TABLES Warm engine required Cold Dealer engine service required suggested Every 100 hours perform the following two engine maintenance procedures
140. ion indicator How to Remove the Hydraulic Tank Component damage hazard ACAUTION 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 1 Remove the fuel tank See 10 2 How to Remove the Fuel Tank 2 Close the two hydraulic tank valves located at the hydraulic tank T open closed 3 Completely drain the oil from the tank by removing the drain plug located in the bottom of the tank ACAUTION Burn hazard Contact with hot oil may cause severe burns 4 Disconnectthe hydraulic hoses from the tank 5 Remove the mounting fasteners from the bottom of the tank 6 Use an appropriate lifting device to remove the tank from the machine Always use pipe thread sealant when installing the drain plug Use only Dexron II equivalent hydraulic fluid Component damage hazard ACAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the hydraulic tank How to Prime the Pump 1 Connecta 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump 2 Gasoline LPG models Remove the high tension lead from the center of the ignition coil Electrocution hazard AWARNING Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry Deutz Diesel models Hold the manual fuel shutoff valve counterclockwise to the cLosEp po
141. ions very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Remove the pin retainer from the slave cylinder rod end pivot pin and the rotator pivot pin 11 Use a soft metal drift to drive both pins out then remove the platform rotator from the machine How to Bleed the Platform Rotator Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Move the platform rotate 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 PLATFORM COMPONENTS 3 Open the top bleed valve on the rotator but do not remove it a topbleed valve b X bottom bleed valve c clearhose d container 4 Hold the platform rotate switch to the LEFT position until the platform is fully rotated Continue holding the switch until air stops coming out of the bleed valve Then close the bleed valve Crushing hazard Keep clear of ACAUTION the platform during rotation 5 Connectthe clear hose to the bottom bleed valve and open the valve Do not remove the bleed valve 6 Hold the platform rotate switch to the RIGHT position until the platform is fully rotated Continue holding the switch until air stops comi
142. ir procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem Still exists Return to Perform problem repair solved Symbols Legend faj esence of a hazard that will cause AASS death or serious injury REM RENT NZOZ AWARNING resence of a hazard that may cause death or serious injury awiu a esence of a hazard that will or ACAUTION may cause serious personal injury or damage to the machine Uuncient es 5 2 3 operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 32222 Genie S 40 7 1 Section 7 Repair Procedures Service Manual First Edition Platform Controls 1 1 Joystick Controllers Maintaining joystick controllers at the proper settings is essential to safe machine operation Every joystick controller should operate smoothly and provide proportional speed control over its entire range of motion p gt c Platform control box horsepower limiter board quick disconnectterminal strip drive proportional controller boom proportional controller turntable rotate proportional controller
143. is section 1 Push the button on the end of the valve in 14 inch 6 mm 2 Move the ground control function switch for the function being overridden to operate function AWARNING Collision hazard Impact with moving boom components may cause death or serious injury Use extreme caution when overriding a machine function Identify the direction of machine movement before overriding a valve Part No 32222 Genie S 40 7 33 Section 7 Repair Procedures Service Manual First Edition pu J H Z FUNCTION MANIFOLD How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and disconnect the wires from the valve coil to be tested 2 Connectthe leads from an ohmmeter to the valve coil terminals Valve coil specifications Proportional solenoid valve 50 3 position 4 way directional valve 4 50 Normally closed poppet valve 70 7 34 Genie 5 40 Part 32222 Service Manual First Edition Section 7 Repair Procedures Fuel and Hydraulic Tanks 10 1 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and deaerate the hydraulic fluid during operation This tank has a 45 gallon 170 liter capacity and an oil level gauge with a temperature indicator It utilizes internal suction strainers for the pump supply suction lines and has an external return line filter with a condit
144. isconnected 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 push up or pull down on the linkage adjustment rod until the machine is completely level 7 Verify that the ground and drive chassis are completely level 8 Adjustthe length of the rod by turning the clevis yoke until the clevis yoke can be pinned to the drive chassis 9 Install the clevis yoke pin then the cotter pin Be sure to bend the cotter pin 10 Measure the distance between the drive chassis and the non steer axle on both sides from the inside of the drive chassis If the distance is not equal and the adjustment to the linkage was completed with the ground and drive chassis level consult Genie Industries Service Department 7 48 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures nmmm STEER AND OSCILLATE MANIFOLDS 15 4 Steer Manifold Components Index Schematic No Description Item Function Torque 1 3 position 4 way valve zur T Tire etic ects cheers Ad PARA 30 35 in Ibs 3 4 Nm 2 Priority flow regulator valve B uses ie 10 12 ft lbs 14 16 Nm W 9 Plug Torque Specifications Description
145. ise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valves higher than How to Adjust the Boom Down Relief Valve cedure with the boom in the stowed position 1 Connecta 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Startthe engine from the ground controls 3 Hold the boom down switch with the boom fully lowered and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the relief valve and remove the cap item 14 function manifold 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap A TAFA DANTAI a Tip over hazard Do not adjust AWARNING the relief valves higher than recommended 6 Restart the engine Hold the boom down switch with the boom fully lowered and recheck the valve pressure recommended Boom down relief valve specifications 6 Restart the engine Hold the retract switch with Pressure 2200 psi the boom fully retracted and recheck the valve 152 bar pressure Main relief valve specifications Pressure 2600 psi 179 bar 7 32 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures How to Adjust the Boom Extend Relief Valve n cedure with the boom in the stowed position
146. it in red wire from TB1 to boom function directional valve Remove both wires from valve coil Check resistance across coil terminals 0 or infinite ohms Replace coil 4 to 5 ohms Interchange flow regulator valve item Y with a like valve item X function operates Replace defective flow regulator valve function inoperative Continued on the next page PartNo 32222 Genie 5 40 5 29 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 14 Hold toggle switch up function Check the resistance Me and manually override operates of the directional 5 directional valve push valve coils ooms in button on end of valve spool Note Overriding the valve will require two people If a helper is not available interchange the valve item R with a like valve item S M the Replace the defective valve coil s 4 to 5 ohms Replace the valve function inoperative Interchange check valve function operates item M with a like valve item Replace defective shuttle valve function inoperative Install a 0 to 3000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect boom from moving coupling on the function OR te manifold and hold the OR cylinder function switch counterbalance valve less than 2400 psi Repair cylinder OR replace cylinder counterbalance
147. ith a like valve item M Continued from the previous page Replace defective check valve Install a 0 to 3000 psi Check for mechanical pressure gauge at the restrictions keeping quick disconnect turntable from rotating coupling on the function OR check rotation motor manifold and hold the OR check rotation brake function switch OR check rotation torque hub function inoperative less than 2400 psi Repair rotation motor OR manifold has internal defect consult Genie Industries Service Department CHART 18 Part No 32222 Genie 5 40 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 19 Turntable Rotate Left Function Inoperative Be sure all other functions operate normally including turntable rotate right function If turntable rotate left function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If turntable rotate left function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control Repair open in wht blk function switch and wire circuit from TBS to check volts at wht blk directional valve wire on rotate function directional valve 0 or Remove both wires from infinite rotate left valve oh ohms check resi
148. ition then drive the machine and observe how the engine rpm reacts to drive control handle movement If the engine surges or hunts adjust the C potentiometer counterclockwise until surging is minimized Under an extreme load an excessive counterclockwise adjustment to the C potentiometer will cause the engine to stall The C potentiometer adjustment is a compromise between engine stability surging and engine rpm droop 12 Disconnect the volt meter 13 Raise the boom above the drive limit switch a drive limit switch b boomliftcylinder 14 Drive the machine for 40 feet 12 m and record the elapsed time Repeat this step in the opposite drive direction 15 Adjust the B potentiometer to obtain the correct raised drive speed of 1 foot per second 30 5 cm per second Turn the B potentiometer counterclockwise to increase voltage or clockwise to decrease voltage 16 Close the platform control box lid and install the fasteners Drive speed specifications Stowed position distance 40 ft 12 m 2WD 4WD Gasoline LP G models 40 ft 6 8 sec 40 ft 7 8 sec 12 2 m 6 8 sec 12 2 m 7 8 sec Deutz Diesel models 40 ft 7 8 40 ft 9 1 sec 12 2 m 7 8 sec 12 2 m 9 1 sec distance 40 ft 12 m 1 foot per second 30 5 cm per second Boom raised or extended All models 7 6 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures 1 3 Foot Switch How to Te
149. l First Edition Section 5 Troubleshooting Flow Charts Engine Will Not Crank Over Be sure the key switch is in the appropriate position Be sure the emergency stop buttons are pulled up into the on position Be sure the circuit breaker s are not tripped Check battery voltage 12V or more y Check voltage at center terminal on start switch 12V y Hold start switch and check voltage at either side terminal on start switch 12V Hold start switch and check voltage at terminal TB33 m Hold start switch and check voltage at terminal 3 on start lockout module 12V Hold start switch and less than 12V L from start switch to gt from TB33 to start Check battery condition OR check alternator OR check battery cables OR replace the battery Trace circuit back through the key switch emergency stop button and CB2 repair open Replace start toggle switch Repair blk wire circuit TB33 Repair blk wire circuit lockout module terminal 13 Check repair open in Chart 1 check voltage at OV power supply wire to terminal 6 and 7 at terminal and 7 on Start lockout module Start lockout module 12V Hold start switch and Check ground wire to check voltage at ov terminal 45 on start Repair open in ground terminal 1 on start lockout module W
150. l 4 on start lockout module Replace start lockout module OR consult Genie Industries Service Department Crank engine and check gy Crank engine and check voltage at org blk 41 wire on alternator 6 to 7V Repair open in org blk 41 wire circuit from alternator to TB41 to terminal 2 on start lockout module Disconnect wht 424 wire from oil pressure sender and check continuity to ground on signal post of sender while cranking the engine Is continuity maintained Repair short to aj in wht 424 wire from sender to TB24 to start lockout module terminal 10 Disconnect red wire from terminal 4 on start lockout module and check voltage at terminal 4 Repair short to power in red wire circuit from 27 Chart 2B Repair or replace alternator OR contact Genie Industries Service Department Check oil level OR replace oil pressure sending unit OR refer to Ford service manual for troubleshooting low oil pressure Replace start lockout module OR consult Genie Industries Service Department PartNo 32222 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 3 Engine Cranks Over But Will Not Start Deutz Diesel Models Be sure to check the engine oil level and fill as needed Be sure to check fuel level Be sure the diesel shut off valve is in the on position Hold start switch and less check battery voltage than while engine is cra
151. latform end of the tank side bulkhead 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm ata time and repeat this step until the entire bearing has been greased 3 Apply grease to each tooth of the drive gear located under the turntable Oil type Multipurpose grease C 5 Replace the Torque Hub Oil Replacing the torque hub oil is essential for good machine performance and service life F ailure to replace the torque hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage Drive Torque Hubs 1 Select the drive torque hub to be serviced Then drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil PartNo 32222 Genie S 40 4 29 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES 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 Apply pipe thread sealant to the plugs and then install the plugs 5 Repeatsteps 1 through 4 for all the other drive torque hubs Oil capacity per hub 17 fluid ounces 0 51 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Turntable Rotate Torque Hub 1 Secure the turntable from r
152. linder rod end pins Use a soft metal drift to remove the pins 4 Remove the turntable end cover label and disconnect the alarm wiring if equipped 5 Disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying ACAUTION 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 pin retaining fasteners from both master cylinder pins 7 Use a soft metal drift to remove the pins Then remove the master cylinder from the machine 8 Disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying ACAUTION 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 9 Place a small block under the cylinder for Support 10 Remove the pin retaining fastener from the extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin 11 Support and slide the extension cylinder out of the extension boom Crushing hazard The extension ACAUTION cylinder will fall when itis removed from the extension boom if it is not properly supported Part No 32222 Genie S 40 7 15 Section 7 Repair Procedures Service Manual First Edition BOOM COMPONE
153. ly override the retract directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item S with a like valve item P 4 to 5 ohms Replace the valve function inoperative Check for mechanical restrictions keeping boom from retracting OR repair cylinder OR replace cylinder counterbalance valve Install a 0 to 3000 psi pressure gauge at quick disconnect coupling on the function manifold and hold the function switch less than 2400 psi Repair cylinder OR replace cylinder counterbalance valve OR manifold has internal defect consult Genie Industries Service Department Chart 17 0 or infinite ohms Replace the coil PartNo 32222 Genie 5 40 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 18 Turntable Rotate Function Inoperative Be sure all other functions operate normally If turntable rotate function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If turntable rotate function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check volts at wht red wire on turntable rotate
154. m nuton the adjustable end of the tie rod Remove the pin retaining fasteners then remove the pivot pin from the adjustable end of the tie rod Slide the tie rod off the yoke and adjust it by turning the end One turn on the adjustable end equals approximately 1 8 inch 3 2 mm change in the front and rear measurements Slide the tie rod onto the yoke Install the pivot pin then install the retaining bolt Tighten the jam nut against the tie rod Lower the machine and recheck the front and back measurements step 2 If further adjustment is needed repeat steps 3 through 8 0 1 s inch 6 35 mm PartNo 32222 Genie S 40 7 41 Section 7 Repair Procedures Service Manual First Edition 4WD Steering Axle Components 13 1 from the wheel motor Cap the wheel motor hydraulic fittings Yoke and Hub i v ___ _ _ __ Bodily injury hazard Spraying ACAUTION RA hydraulic oil can penetrate and How to Remove the Yoke burn skin Loosen hydraulic and Hub connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray The yoke installation utilizes bushings and a thrust washer that may require periodic replacement The yoke must be removed before the torque hub can be removed 4 Loosen the wheel lug nuts Do not remove them 1 Startthe engine from the ground controls Rotate the turntable until the platform is 5 Block the non steering wheels
155. mp to cylinder 14 to 21 19 to 28 block M 8 Alternator Intake manifold to 14 to 21 19 to 28 Output 35A 14 5V cylinder head bolt or nut M 8 Fan belt deflection pressure sending unit to block 8 to 18 11 to 24 ZARZ Gil pan drain plug to pan M 14 15 to 25 20 to 34 Bolt torque specifications Oil pan to block M 6 10 to 13 5 14 to 18 torque torque Bolt description size ft lbs Nm OQilfilter insert to block 20 to 35 27 to 47 Auxiliary shaft gear bolt M 10 28 to 40 38 to 54 Rocker arm cover to 5 to 8 7to 11 Auxiliary shaft thrust 6 to 9 ped Cv inderheagiM s plate bolt M 6 Spark plug to cylinder 5 to 10 7 to 14 Timing belt tensioner 28 to 40 38 to 54 Pead M 14 pivot bolt M 10 Temperature sending 8 to 18 11 to 24 Timing belt tensioner 14 to 21 19 to 28 Unite DOG M 14 adjusting bolt M 8 Water jacket drain plug to block 23 to 28 31 to 38 Camshaft gear bolt M 12 50 to 71 681096 Water pump to block bolt M 8 14 to 21 19 to 28 Camshaft thrust plate bolt M 6 609 8 to 12 Auxiliary shaft cover bolt M 6 6 to 9 8 to 12 Carburetor to spacer stud M 8 7 5 to 15 10 to 20 Water outlet connection 14 to 21 19 to 28 Carburetor spacer to 10 to 14 14 to 19 bolt M 8 manifold bolt M 8 Cylinder front cover bolt M 6 6 to 9 8 to 12 Crankshaft damper 1030133 1400180 Inner timing belt cover 14 to 21 19 to 28 bolt M 14 stud M 8 Cylinder head bolt M 12 torque in sequence Outer timing belt cover 6 to 9 8 to 12 first step 50
156. mpleted daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report 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 M Repair any machine damage or malfunction before operating machine M Keep records on all inspections for three years Unless otherwise specified perform each repair procedure with the machine in the following configuration machine parked on a flat level surface in stowed position turntable rotated with the boom between the non steering wheels turntable secured with the turntable rotation lock pin key switch in the orr position with the key removed wheels chocked 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 Indicates the presence of a hazard that will cause death or serious injury Indicates the presence of a hazard AWARNING that may cause death or serious injury Indicates the presence of a hazard ACAUTION that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information Indicates that a specific resultis expected after performing a step
157. n Section 2 Specifications Hydraulic Specifications Hydraulic fluid Dexron II equivalent Drive pump HYDRAULIC SPECIFICATIONS Function pump Type pressure balanced gear Type bi directional variable displacement piston pump Displacement 2500rpm Oto 31 6 gallons per minute 0 to 119 6 liters per minute 0 98 cu in 16 cc Displacement static 10 8 gallons per minute 0 to 40 8 liters per minute Displacement 2550 rpm Maximum drive pressure 3500 psi 241 3 bar Hydraulic tank circuit 10 micron with 25 psi return line filter 1 7 bar bypass Charge pressure neutral position 360 psi 25 bar Function manifold drive position 250 psi 17 bar Function relief 2600 psi Medium pressure filter 3 micron valve pressure 179 bar Medium pressure filter 50 psi Boom down 2200 psi bypass pressure 3 4 bar relief valve pressure 152 bar Drive manifold Boom extend 1950 psi 134 bar Brake 250 psi relief pressure 17 2 bar Steer oscillate 3 5 gallons per minute 4WD front motor flow regulators 2 5 to 8 gallons per minute 9 4 to 30 2 liters per minute 4WD rear motor 5 to 15 gallons per minute flow regulator 13 2 liters per minute Steer regulator 2 gallons per minute 7 6 liters per minute flow regulators 18 9 to 56 7 liters per minute Boom retract pressure 2600 psi 179 bar 2WD rear motor 8 to 22 gallons per minute flow regulators 30 2 to
158. n 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 1 Remove the platform See 2 1 How to Remove the Platform 2 Disconnect and plug the hydraulic hoses from the platform rotator Bodily injury hazard Spraying ACAUTION 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 Support the platform mounting weldment but do not apply any lifting pressure 4 Remove the six mounting bolts from the platform mounting weldment then remove the center bolt and slide the platform mounting weldment off of the platform rotator 5 Support the platform rotator Do not apply any lifting pressure 7 10 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures 6 Support the platform leveling slave cylinder 7 Remove the pin retainer from the slave cylinder barrel end pivot pin 8 Use a soft metal drift to remove the barrel end pin 9 Disconnect and plug the hydraulic hoses from the slave cylinder Pull the hoses up through the platform rotator Bodily injury hazard S praying ACAUTION hydraulic oil can penetrate and burn skin Loosen hydraulic connect
159. n wht 21 terminal 30 on CR4 wire circuit from TB21 to CR3 to CR4 Check voltage at the Replace CR4 relay blk red wire on the OR repair open in 2 speed solenoid blk red wire circuit from terminal 87 on CR4 to 2 speed solenoid Check if 2 speed eee Check linkage or solenoid moves in and replace solenoid out freely moves freely Replace 2 speed solenoid Note resistance across solenoid terminals should be approximately 0 3 ohms CHART 8 PartNo 32222 Genie S 40 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 9 Engine Low Idle Inoperative Deutz Diesel Models Check if mechanical linkage from 2 speed solenoid to fuel injection system is binding or defective At platform controls start engine and switch rpm select switch to maintained low idle Isolate the platform and ground rpm switches check individually and replace defective turtle symbol Check switch volts at blk red wire on rpm select switch Check voltage atthe red wire on the 2 speed solenoid Replace CR4 relay solenoid binds Check if 2 speed solenoid moves in and out freely Check linkage or replace solenoid moves freely Check adjustment of linkage and fuel injection system low idle See Maintenance section See Deutz workshop manual to troubleshoot fuel injection system OR consult Genie Industries Service Department G
160. ne cover to access belt 2 All models Inspect the engine belt s for cracking glazing separation breaks 3 Check the engine belt s for proper tension Ford engine Deutz Diesel engine 3 8 inch to 1 2 inch 9 mm to 12 mm Belt deflection all models B 2 Check the Radiator Gasoline LPG Models Maintaining the radiator in good condition is essential for good engine performance Operating a machine with a damaged or leaking radiator may result in engine damage Also restricting air flow through the radiator i e dirt or debris will affect the performance ofthe cooling system A frequent check allows the inspector to identify changes in the condition ofthe radiator that might indicate cooling system problems DAHMA Do not inspect while the engine AWARNING is running Remove the key to secure from operation ATTTI I Beware of hot engine ACAUTION components Contact with hot engine components may cause severe burns 1 Inspect the radiator for leaks and physical damage 2 Clean the radiator fins of debris and foreign materials B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models 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 Do not inspect
161. ne rpm sensor not used not used low drive speed limit switch not used not used not used output to drive controller o o o o o 2 o o o w a a E E 5 Horsepowerlimiter board a A potentiometer maximum voltage outputto the controller in the stowed position b B potentiometer maximum voltage output to the drive controller in the boom raised position c C potentiometer reaction rate or how fast the voltage output reacts to the change in engine rpm 4 Startthe engine from the platform controls 5 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Part No 32222 Genie S 40 7 5 Section 7 Repair Procedures Service Manual First Edition PLATFORM CONTROLS 6 Press down the foot switch and adjust the A potentiometer counterclockwise to increase voltage or clockwise to decrease voltage A potentiometer specifications all models Voltage setting 9 5V DC 7 Move the engine idle control switch to low idle turtle symbol 8 Press down the foot switch and then adjust the C potentiometer to obtain a 0 01V DC to 0 03V DC voltage reading 9 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 10 Press down the foot switch and re adjust the A potentiometer to the previous voltage setting in step 6 11 Be sure that the boom is in the stowed pos
162. need Ground Controls to be performed on machines equipped with the foam filled Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition AWARNING An over inflated tire can explode exists if any function fails to operate properly or and may cause death or serious either Emergency Stop button fails to stop all the injury machine functions and shut off the engine Each function should activate operate smoothly and be To safeguard maximum stability achieve free of hesitation jerking and unusual noise optimum machine handling and minimize tire wear itis essential to maintain proper pressure 1 Startthe engine from the ground controls and in all air filled tires then operate each machine function through a a full cycle 1 Checkeach tire with an air pressure gauge and add air as needed Result All machine functions should operate smoothly Tire specifications 2WD front 2WD rear 2 Push in the Emergency Stop button to the orr AWD front iH position amp rear Result No function should operate the engine Tire size 12 5L 16SL 12 16 5NHS should stop Pressure 45 psi 45 psi Deutz Diesel models 3 10 bar 3 10 bar All functions should stop immediately The engine will shut off after 2 to 3 seconds 3 Start the engine from the platform controls and then operate each machine function through a full cycle Re
163. ng 2 Start the engine from the ground controls then TABLE B PROCEDURES B 8 Inspect the Tires and Wheels including lug nut torque Maintaining the tires and wheels in good condition 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 An over inflated tire can explode and may cause death or serious injury 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque 4 Check the pressure in each air filled tire 5 Tires and 2WD front 2WD rear raise the boom above the turntable covers wheels 4WD front 3 Inspect the turntable area for burnt chafed and amp rear pinched cables Tire size 12 5L 16SL 12 16 5 5 4 Lower the boom into the stowed position and turn the engine off Tire ply rating 12 8 5 Inspect the following areas for burnt chafed corroded pinched and loose wires Overall tire diameter 33 7 in 33 2 in 85 6 cm 84 3 cm cable track on the boom Tire pressure 45 psi 45 psi boom to platform cable harness 3 10 bar 3 10 bar inside of the platform control box Wheel diameter 16 in 16 5 in 40 6 cm 41 9 cm Wheel width 10 in 9 75 in 25 4 cm 24 7 cm Wheel lugs 8 5 18 9 9 5 8 18 Lug n
164. ng Flow Charts Oscillate Function Inoperative Be sure all other function operate normally Check for linkage damage or improper linkage set up See Repair section 15 2 How to Set Up the Directional Valve Linkage Install a pressure gauge at the quick disconnect coupling on the oscillate manifold Disconnect linkage from drive chassis and manually activate directional valve while engine is running Check the pressure Consult Genie Industries Service Department Chart 26 Re adjust or replace linkage sequence valve See Repair procedure 15 2 How to Adjust the Oscillate Sequence Valve Pressure OR consult Genie Industries Service Department PartNo 32222 Genie 5 40 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 27 Steer Left dd engine from Repair or enee the 1 e platform press steer microswitch in Function oath hold controller handle i e steer switch left and Inoperative check voltage at terminal 8 on the drive Be sure all other controller blu wire functions operate normally Hold the steer switch Repair open in blu wire left and check voltage circuit from steer switch at TB36 to TP36 to TB36 Hold the steer switch Repair open in blu wire left and check ia at circuit from TB36 to blu wire on steer valve steer valve 0 or Remove both wires from infinite steer left coil and check ohms Replace steer left r
165. ng out of the bleed valve Then close the bleed valve Crushing hazard Keep clear of ACAUTION 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 full right then left and inspect the bleed valves for leaks Part No 32222 Genie S 40 7 11 Section 7 Repair Procedures Service Manual First Edition Boom Components 3 1 Plastic Cable Track The boom cable track guides 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 boom cable track is only necessary when performing major repairs that involve removing the boom How to Repair the Plastic Cable Track Component damage hazard ACAUTION The boom cable track can be damaged if it is twisted a ___ link separation point b lowerclip 1 Use a screwdriver to pry down on the lower clip 2 Repeatstep 1 for each link 3 To remove a single link open the lower clip and then use a screwdriver to pry the link to the side 3 2 Boom How to Shim the Boom Measure each wear pad Replace the pad if it is less than 7 16 inch 11 mm thick Ifthe pad is more than 7 16 inch 11 mm thick perform the following procedure 1 Extend the boom 10 inches 25 cm 2 Remove the wear pad mounting fasteners 3 Install the new shims under the wear pad to obtain zero clearan
166. ng the ground controls will override the platform controls including the Emergency Stop button 1 Start the engine from the ground controls 2 Push down the Emergency Stop button to the OFF position Result The engine should shut off and no machine functions should operate Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds 3 Startthe engine from the platform controls 4 Push down the Emergency Stop button to the OFF position Result The engine should shut off and no machine functions should operate The ground Emergency Stop button will stop all machine operation even if the key switch is switched to platform control B 15 Test the Ground Control Override 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 notthe Emergency Stop button on the platform controls is in the oN or orr 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 Emergency Stop button to the orr position 2 Startthe engine from the ground controls 3 Operate each boom function through a partial cycle Result All boom functions should operate Genie S 40 Part No 32222 Service Manual First Edi
167. nking 11V more than 11V Check if engine coolant over temperature sending signal post has continuity to ground continuity no continuity Disable starter by removing blk wire at the starter solenoid hold start switch and check voltage at positive terminal on fuel solenoid Continued on the next page Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery Check if oil cooler and or engine block feels excessively hot not hot Remove wht wire from temperature sending unit check continuity to ground on wire no continuity Remove wht wire from TB24 continuity circuit from TB24 to temperature sender no continuity Repair short in wht wire circuit from start lock out module to TB24 OR consult Genie Industries Service Department 0 or infinite ohms Turn machine off and isolate the fuel solenoid Check the resistance of the solenoid 3 50 ohms See Deutz service manual for troubleshooting fuel System Check engine oil level OR oil cooler fins for clogging OR check engine fan belts OR see Deutz service manual for troubleshooting an overheating engine _ Replace temperature continuity switch sender Repair short in wht wire Replace the fuel solenoid Genie S 40 Part No 32222 Service Manual First Edition Hold start switch and Continued from the check v
168. o high idle Gasoline LPG models functions do not operate at low idle OOM High idle rabbit symbol allows the operator High idle 2500 rpm to control multiple boom and or drive functions simultaneously This setting maintains a Deutz Diesel models consistent high idle and is usually selected only when the generator option is being used Eon Idle PAM High idle 2300 rpm 4 22 Genie S 40 PartNo 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 21 Test the Fuel Select Operation Gasoline LPG Models 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 ofthe 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 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 2 Startthe engine from the platform controls and allow itto run atlow idle 3 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smo
169. od Repair open in ground both mushroom terminal 85 of CRO wire switches pulled out Crank engine and check aod voltage at terminal 87 9 CR6 Replace CR6 12V Continued on the next page DNA PartNo 32222 Genie 5 40 5 9 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 2A Hold start switch and oV Repair open in blu wht from the check voltage at blu wht 436 wire circuit CR6 to previous page wire on anti diesel valve anti diesel valve on engine carburetor Hold start switch and 0 Repair open in blu wht check voltage at blu wht 436 wire circuit from 438 wire on gasoline anti diesel valve to PS at gasoline gasoline solenoid nk Hold start switch does Reconnect the two engine fire wires to vacuum switch and check for fuel line blockage OR replace anti diesel valve OR see Ford service manual for Go to chart 2B troubleshooting fuel page 5 11 pump and or carburetor OR Consult Genie Industries Service Department 5 10 Genie 5 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Runs While Cranking Then Dies voltage at terminal 2 on start lockout module While cranking engine for 15 seconds check continuity to ground on terminal 10 start lockout module Is continuity maintained Check voltage at termina
170. odule Replace start lockout module OR consult Genie Industries Service Department Service Manual First Edition eee Crank engine and check ov voltage at org blk 41 wire on alternator 6 to 7V Repair open in org blk 41 wire circuit from alternator to TB41 to terminal 2 on start lockout module Disconnect wht 24 wire from oil pressure sender and check continuity to yes ground on signal post of sender while cranking the engine Is continuity maintained no Repair short to ground wht 24 wire from sender to TB24 to start terminal 10 on lockout module Disconnect red wire from terminal 4 on start DV lockout module and check voltage at terminal 4 Repair positive short in red wire circuit from TB27 Repair or replace alternator OR contact Genie Industries Service Department Check oil level OR replace oil pressure sending unit OR refer to Deutz service manual for troubleshooting low oil pressure Replace start lockout module OR consult Genie Industries Service Department 5 14 Genie S 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LPG Models Be sure fuel select switch is switched to LPG Be sure to check LPG fuel level Disconnect LPG supply line from LPG tank and bleed pressure from line With k
171. oline mode with the engine at normal operating temperature 1 Disconnectthe blue black wire from the governor actuator Part No 32222 Genie S 40 4 17 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES 2 Connectan rpm gauge to the engine then start the engine from the ground controls Result Carburetor low idle should be 900 rpm Skip to step 4 if the low idle rpm is correct 3 Turn the idle adjustment screw on the carburetor clockwise to increase rpm or counterclockwise to decrease rpm Gasoline LP low idle adjustment a carburetor b adjustment screw R Tum the engine off and reconnect the blue black wire to the governor actuator ul Start the engine from the ground controls Result Electronic governor low idle should be 1600 rpm 6 Move the engine idle control switch to high idle rabbit symbol from the ground controls Result High idle should be 2500 rpm Turn the engine off If low and high idle rpm s are correct disregard adjustment steps 8 and 9 8 Remove the mounting fasteners from the electronic governor located on the engine side bulkhead then remove the back panel from the governor 9 Restart the engine turn the low or high speed set screw clockwise to increase the rpm or counterclockwise to decrease the rpm m 1 ny trimpot other than specified in this procedure lt gt CJ
172. oltage at wht previous page of CR2 Check voltage at red wire on terminal 30 of CR2 Hold start switch and check voltage at terminal 86 of CR2 Check to terminal 485 on CR2 good Continued on the next page 21 wire on terminal 487 Section 5 Troubleshooting Flow Charts E Repair open in wht 21 wire from CR2 to fuel solenoid Repair open in red wire circuit from battery to CB1 to CR1 to CR2 Hold start switch and check voltage at terminal 49 on start lockout module Check voltage at terminal 6 and 7 on start lockout module Check gema wire terminal on start lockout module good Replace the start lockout module OR consult Genie Industries Service Department Repair open in ground wire to CR2 CHART 3 Repair open in blk wire from terminal 486 on CR2 to terminal 49 on start lockout module Repair open in power supply wires to terminal 6 and 7 on start lockout module Repair open in ground circuit to terminal 5 on start lockout module PartNo 32222 Genie 5 40 Section 5 Troubleshooting Flow Charts CHART 3 Crank engine and check py voltage at terminal 2 on start lockout module Continued from the previous page 6 to 7V While cranking engine for 15 seconds check yes continuity to ground on terminal 10 on start lockout module 15 continuity maintained no Check voltage at 12V terminal 4 on start lockout m
173. om switch to the pown position hold for a moment and then release it Result The descent alarm should sound when the switch is held down Turn the key switch to platform control Atthe platform controls pull outthe Emergency Stop button to the ow position Result The flashing beacon should be on and flashing B 26 Perform Hydraulic Oil Analysis See D 1 Test or Heplace the Hyaraulic Oil Part No 32222 Genie S 40 4 25 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 27 Replace the Engine Oil and Filter Deutz Diesel Models Engine specifications require that this procedure be performed every 500 hours Perform this procedure more often if dusty conditions exist Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A frequent check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 500 hour interval Perform this procedure after warming the engine to normal operating temperature ACAUTION Beware of hot engine parts and oil Contact with hot engine oil and or engine parts may cause severe burns 1 Remove the oil filler cap located on the valve cover 2 Pull the end of the drain hose out
174. on 4 Scheduled Maintenance Procedures TABLE D PROCEDURES D 3 0 GG 0 W W 9 Change the Fuel Lines Maintaining the fuel lines in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or SRRI gh 9 leaking fuel line may cause an unsafe operating 4 SS condition NO NK Engine fuels are combustible Replace the fuel lines in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach al 2 Perform this procedure with the engine off 1 Close the manual fuel shutoff valve located next to the fuel tank JJ d 2 Remove and replace the fuel line hoses and S lt clamps according to the following illustrations Fuel may be expelled under e 4 c R pressure Wrap a cloth around fuel hoses to absorb leaking fuel Deutz Diesel models before disconnecting them a hose from the injector to the fuel tank b hoses connecting injectors c hose from the fuel shutoff valve to the fuel pump d hose from the fuel pump to the fuel filter e hose from the fuel filter to the injection pump f hose from the injection pump to the injectors Part No 32222 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE D PROCEDURES Gasoline LPG models a fil
175. onent damage hazard ACAUTION The boom cable track can be damaged if itis twisted 9 Carefully raise the boom enough to access the master cylinder rod end pivot pin 10 Remove the turntable end cover 11 Remove the retaining bolt 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 12 Remove the drive speed limit switch mounted on the inside of the pivot end of the boom Do not disconnect the wiring 13 Disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard S praying ACAUTION 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 14 Attach an overhead crane to the center point ofthe boom BOOM COMPONENTS 15 Attach a similar lifting device to the lift cylinder 16 Place support blocks under the cylinder across the turntable 17 Remove the pin retaining fastener from the boom lift cylinder rod end pin Use a soft metal drift to remove the pin Crushing hazard The boom lift ACAUTION cylinder will fall unless it is properly supported 18 Lower the rod end of the lift cylinder onto support blocks Protect the cylinder rod from damage 19 Use the crane to lift the boom to a horizontal position 20 Remove the pin retaining fastener from the boom pivot
176. ons Result The machine functions should operate B 20 Test the Engine Idle Select A properly operating engine idle select switch is essential to good engine performance and safe machine operation There are three settings Low idle turtle symbol allows the operator to control individual boom functions only Drive Foot switch activated high idle rabbit and foot switch symbols should be used for normal machine operation This selection activates high idle only when the foot switch is pressed down 1 Pull out the Emergency Stop button to the oN position at both the ground and platform controls 2 engine from the ground controls Then move the engine idle control switch to high idle rabbit symbol and hold in the on position Result The engine should change to high idle Release the engine idle control switch Result The engine should return to low idle Turn the key switch to platform controls u R w Atthe platform controls move the engine idle control switch to high idle rabbit symbol Result The engine should change to high idle 6 Move the engine idle control switch to low idle turtle symbol Result The engine should change to low idle 7 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Result The engine should not change to high idle 8 Press down the foot switch Result The engine should change t
177. 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 worn out 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 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 if itis less than 7 16 inch 11 mm thick If the wear pad is more than 7 16 inch 11 mm thick shim as necessary to obtain zero clearance and zero drag 4 Extend and retract the boom through the entire range of motion to check for tight spots that could cause binding or scraping Always maintain squareness between the boom outer and inner tubes Table C Procedures C 2 Check the Turntable Rotation Bearing Bolts 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 boom approximately 7 to 8 feet 2 1 to 2 4 m 2 Be sure that each turntable mounting bolt is torqued in sequence to 210 foot pounds 285 Newton meters Bolt torque sequence Lower the boom to the stowed position 4 Check to ensure that each bearing mounting bolt under the drive chassis is torqued in sequence to 210 foot pounds 285 Newton meters 10
178. or continuity tester to the common and normally open terminals Result There should be no continuity infinite 2 2 Apply mild suction to the vacuum port Q Result The switch should close and show full continuity zero Q Component damage hazard ACAUTION Do not short the vacuum switch terminals to ground Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures 7 1 Control Relays Relays used for single function switching are single pole double throw SPDT relays There are two types of single pole double throw relays used for ground controls Dual function switching requires a double pole double throw DPDT relay How to Test a Double Pole Double Throw Relay Electrocution hazard AWARNING Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry This procedure covers fundamental relay testing and does not specifically apply to all varieties of relays 1 Turn the key switch to the orr position and remove the key 2 Label and then disconnect all the wiring from the relay to be tested 3 Connect the leads from an ohmmeter to each terminal combination and check for continuity Terminals 13 and 14 represent the coil and should not be tested in any other combination terminal no 13 inal no 9 terminal no 12 terminal no 14 terminal no 4 terminal no 8 50 0o0n0cono 8 5
179. otating with the turntable rotation lock pin unlocked locked 2 Remove the motor brake mounting bolts and then remove the motor and brake from the torque hub and set them to the side motor brake mounting bolt motor torque hub torque hub mounting bolt plug brake 0M 3 Remove the torque hub mounting bolts and then remove the torque hub from the machine 4 Remove the plug from the side of the torque hub Then drain the oil from the hub 5 Install the torque hub Torque the hub mounting bolts to 180 foot pounds 244 Newton meters 6 Install the brake and motor onto the torque hub 7 Fill the hub with oil from the side hole until the oil level is even with the bottom ofthe hole Apply pipe thread sealant to the plugs and then install the plugs Capacity 8 fluid ounces 0 24 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 4 30 Genie S 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures C 6 Replace the Hydraulic Tank Filter Replacement of the hydraulic tank filter 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 filter be replaced more often Beware of hot oil Contact with ACAUTION hot oil may cause severe burns Perform t
180. otation Hydraulic Motor 1 Secure the turntable from rotating with the turntable rotation lock pin mI I Unlocked position 2 Disconnectthe hydraulic hoses from the motor and manifold and cap them ACAUTION 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 motor mounting bolts then remove the motor from the brake motor brake mounting bolts motor brake torque hub mounting bolts plug torque hub ow Locked position How to Remove the Turntable Rotation Brake or Torque Hub Refer to Maintenance Procedures C 5 How to Replace the Torque Hub Oil Part No 32222 Genie S 40 7 37 Section 7 Repair Procedures Service Manual First Edition TURNTABLE ROTATION COMPONENTS 11 2 Turntable Rotation Manifold Components Index Schematic No Description Item Function 1 Shuttle valve 2 position 3 way rasis Turntable rotation brake release 2 Counterbalance valve B sess Turntable rotate right 3 Counterbalance valve B inen Turntable rotate left Plug Torque Specifications Description Hex size SAE No 2 108 50 in lbs 6 Nm SAE No 4 3 16 13 ftlbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 8 5 16 50
181. othly in low and high idle 4 Release the foot switch and stop the engine 5 Move the fuel select switch to LPG 6 Restartthe engine and allow it to run at low idle 7 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running TABLE B PROCEDURES B 22 Test the Drive Enable System Proper drive enable system operation is essential to safe machine operation When the boom is past the non steering wheels drive movement is stopped and the indicator light turns on The drive enable switch must be used to reactivate the drive function and should inform the operator that the machine will move in the opposite direction that the drive and steer controls are moved An improperly functioning drive enable system may allow the machine to be moved into an unsafe position 1 Start the engine from the platform controls 2 Rotate the turntable to the right until the boom is past the right non steering wheel Result The drive enable indicator light should turn on 3 Slowly move the drive control handle off center Result The drive function should not operate 4 Hold the drive enable toggle switch to either side and slowly move the drive control handle off center LILII I
182. ough a partial cycle boom up down extend and retract turntable rotate right left Result Each function should operate smoothly 3 Turn the key switch to platform control 4 6 Genie 5 40 PartNo 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures A 12 Test the Tilt Sensor The tilt sensor sounds an alarm in the platform when the incline of the drive chassis exceeds 5 degrees Selecta level testarea The tilt alarm should not be sounding prior to test 1 Start the engine from the platform controls 2 Open the tank side cover and press down on one side of the tilt sensor Result After a 1 second delay the alarm in the platform should sound a tank b tilt sensor c ground control box TABLE A PROCEDURES A 13 Test the Limit Switches Drive Limit Switches Detecting limit switch malfunctions is essential to safe machine operation The drive limit switches are used to restrict drive speed when the boom is raised or extended An improperly functioning drive limit switch will allow the machine to operate inan unsafe position 1 Startthe engine from the ground controls Raise the boom 10 ft 3 m off the ground Turn the engine off 2 Visually inspect the drive limit switch located next to the boom lift cylinder for the following broken or missing actuator arm missing fasteners loose wiring a drive limit switch b
183. ove at a reduced drive speed 4 8 Genie S 40 Part No 32222 Service Manual First Edition Manually activate the drive enable limit switch Result The drive enable limit switch roller should move freely and spring return to center A distinct click should be felt and heard Start the engine from the platform controls Rotate the turntable to the left until the boom is past the left non steer wheel Result The drive enable indicator light should be on Drive function should not operate until the drive enable switch is activated Rotate the turntable to the right until the boom is past the right non steer wheel Result The drive enable indicator light should be on Drive function should not operate until the drive enable switch is activated Section 4 Scheduled Maintenance Procedures TABLE A PROCEDURES A 14 Test the Oscillate Axle oscillating axle equipped models Proper axle oscillation is essential to safe machine operation If the axle oscillation system is not operating correctly the stability of the machine is compromised and it may tip over 1 2 Start the engine from the platform controls Drive the right steer tire up onto a 6 inch 15 2 cm block or curb Result The three remaining tires should stay in firm contact with the ground Drive the left steer tire up onto a 6 inch 15 2 cm block or curb Result The three remaining tires should stay in firm contact with the gro
184. oz 0 51 liters Platform dimensions 6 ft Turntable rotation 8 fl oz 0 24 liters Standard Optional torque hub Length 6 ft Continuous improvement of our products is a Genie 1 83m 244m policy Product specifications are subject to change without notice Width 30 in 36 in 76 2 cm 91 4 cm Maximum capacity 500 lbs 500 lbs 227 kg 227 kg PartNo 32222 Genie S 40 2 1 Section 2 Specifications Service Manual First Edition gt gt m PERFORMANCE SPECIFICATIONS Performance Specifications Drive speeds maximum 2WD 4WD Boom function speeds maximum from platform controls Boom stowed 4 0 mph 3 5 mph Gasoline LP G models 6 4 km h 5 6 km h Boom up 40 to 60 seconds 40ft 6 8sec 40 ft 7 8 sec 12 2 m 6 8 sec12 2 m 7 8 sec Boom down 50 to 80 seconds Boom stowed 3 5 mph 3mph extend 35 to 65 seconds Deutz diesel models 5 6 km h 4 8 km h 40 fU7 8 sec 40 ft 9 1 sec Boom retract 40 to 70 seconds 12 2 m 7 8 12 2 9 1 sec Turntable rotate 360 70 to 110 seconds Boom raised or extended 0 68 mph 0 68 mph Platform rotate 160 8 to 20 seconds All models 1 1 km h 1 1 km h 40 40 sec 40 ft 40 sec Platform level up 25 to 50 seconds 12 2 m 40 sec 12 2 m 40 sec Platform level down 15 to 35 seconds Gradeability boom stowed 2WD 4wD Rough terrain 30 40 2 2 Genie 5 40 Part No 32222 Service Manual First Editio
185. que hub mounting bolts 120 ft lbs 163 Nm Drive motor mounting bolts 75 ft lbs 102 Nm 13 2 Steering Cylinders How to Remove a Steering Cylinder This procedure is the same as the 2WD procedure See repair procedure 12 2 How to Remove a Steering Cylinder 4WD STEERING AXLE COMPONENTS 13 3 Tie Rod How to Remove the Tie Rod This procedure is the same as the 2WD procedure See Repair Procedure 12 3 How to Remove the Tie Rod How to Perform the Toe in Adjustment This procedure is the same as the 2WD procedure See Repair Procedure 12 3 How to Perform the Toe in Adjustment Part No 32222 Genie S 40 7 43 Section 7 Repair Procedures Service Manual First Edition Oscillating Axle Components 14 1 Oscillating Axle Lock out Cylinders The oscillating axle cylinders extend and retract between the drive chassis and the oscillating axle The cylinders are equipped with counterbalance valves to prevent movement in the eventofa hydraulic line failure The valves are not adjustable How to Remove an Oscillating Axle Cylinder AWARNING This procedure requires specific repair skills and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended Perform this procedure on a firm level surface with the boom in the stowed position 1 Block the non steering whe
186. r or replace drive controller Repair open in either wht or wht blk wire circuit from drive controller to TP 30 and TP31 respectively Repair open in either wht or wht blk wire circuit from TB30 and TB31 respectively Repair open in wht blk wire circuit from TB31 to EDC quick disconnect OR repair open in wht wire circuit from TB30 to EDC quick disconnect Genie 5 40 PartNo 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Drive Forward Or Reverse Function Inoperative Be sure all other functions operate normally including drive in opposite direction of malfunction Chart 30 Disconnect the EDC voltage readings different wire connector from the drive pump start engine move the drive controller to full forward position and note the voltage across terminals TB30 and TB31 Reverse the volt meter leads and move the drive controller to full reverse position and note the voltage Repair or replace the drive controller voltage readings the same Adjust the drive pump Defective Sundstrand null neutral See no improvement drive pump contact Sundstrand Series 40 Sundstrand authorized Service Manual repair facility symptoms improve Check all drive speeds and monitor for recurring symptoms Possible contamination in hydraulic system Part No 32222 Genie S 40 5 51 Section 5 Troubleshooting Flow Charts Service Manual First Edition Cha
187. raulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure that the boom is in the stowed position then visually inspect the sight gauge located on the side of the hydraulic oil tank Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge Hydraulic oil specifications Hydraulic oil type Dexron Il equivalent Tank capacity 45 gallons 170 liters Hydraulic system 50 gallons including tank 189 liters A 8 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develop into hazardous situations impair machine functions and damage machine components 1 Inspectfor hydraulic oil puddles dripping or residue on or around the following areas hydraulic tank filter fittings hoses auxiliary power unit and turntable surface engine compartment fittings hoses main pump filter and turntable surface all hydraulic cylinders all hydraulic manifolds boom the underside of the turntable underside of the drive chassis ground area under the machine 4 4 Genie S 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures TABLE A PROCEDURES A 9 A 10 Check the Tire Pressure Test the Platform and This procedure does not
188. rcuit from TB41 to horsepower limiter switch and check terminal 3 voltage at terminal 3 on horsepower limiter Check voltage at 6to7v Repair open in org blk org blk wire on engine wire circuit from alternator alternator to TB41 6 to 7V ov Repair or replace alternator Press down foot switch and check voltage at Replace horsepower terminal 10 on limiter board horsepower limiter 9 to 12V Press down foot switch Repair open in red wire and check voltage at circuit from horse power terminal 6 on drive limiter board to drive controller control terminal 6 9 to 12V Continued on the next page Part No 32222 Genie S 40 5 49 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 29 Continued from the previous page Disconnect drive pump EDC wires ig down foot switch hold drive controller in full forward position and check voltage across terminals 4 and 5 on drive controller Press down foot switch hold drive controller in full forward position and check voltage across terminals TP 30 and 31 Press down foot switch hold drive controller in full forward position and check voltage across terminals TB30 and TB31 Press down foot switch hold drive controller in full forward position and check voltage across the two wires at EDC quick disconnect Replace drive pump EDC OR consult Genie Industries Service Department Repai
189. red wire on rpm switch 12V Check voltage at TB35 oY 12V Check voltage at OV terminal 30 on CR3 12V Check voltage at OV terminal 86 on CR3 12V Check ground wire to bad terminal 85 on CR3 good Check voltage to 0v terminal 487 on CR3 12V Check voltage at ov terminal 86 blk red of CR4 12V Check ground wire to bad terminal 85 on CR4 a good Continued on the next page Chart 6 Check voltage at center terminal on rpm select switch Repair open in circuit supplying 12V to center terminal of switch 12V Replace rpm select toggle switch Repair open in blk red wire circuit from toggle switch to TP35 to TB35 Repair open in blk red wire circuit from TB35 to CR3 Repair open in wht 21 wire circuit from TB21 to terminal 86 on CR3 Repair open in ground wire to terminal 85 on CR3 Replace CR3 relay Repair open in blk red wire circuit from CR3 to CR4 Repair open in ground wire to terminal 85 on PartNo 32222 Genie S 40 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 6 Continued from the previous page Check voltage at terminal 5 on electronic governor 0v Check voltage at terminal 1 red wht wire on electronic governor 12V Check voltage at terminal 1 red wht wire on governor actuator 12V Turn engine off then turn machine on but do not start eng
190. relay terminal no 13 terminal no 9 terminal no 14 Test Desired result terminal 13 to 14 190 to 2000 terminal 5 to 1 amp 9 no continuity infinite Q terminal 1 to 9 continuity zero Q 4 Connect 12V DC to terminal 14 and a ground wire to terminal 13 then test the following terminal combinations Test Desired result terminal 1 to 5 amp 9 no continuity infinite Q terminal 5 to 9 continuity zero Q 7 24 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures Direct Connection Relay 1 Label and then disconnect all the wiring from the relay to be tested 2 Connectthe leads from an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other combination 5 o Fic terminal no 87a b terminalno 85 C terminal no 30 d terminal no 86 e terminal no 87 Test Desired result terminal 85 to 86 85 to 950 terminal 87 to 87a amp 30 no continuity infinite Q terminal 87a to 30 continuity zero Q 3 Connect 12V DC to terminal 85 and a ground wire to terminal 86 then test the following terminal combinations Test Desired result GROUND CONTROLS 7 2 Toggle Switches See 1 5 Toggle Switches 7 3 Wago Components How to Remove a Wago Component Electrocution hazard AWARN
191. rse 15 18 ft Ibs 20 24 Nm 13 Relief valve 250 psi 17 bar wasi Charge pressure 15 18 ft lbs 20 24 Nm 14 Shuttle valve 3 position 3 way Bess Charge pressure circuit 15 18 ft lbs 20 24 Nm 15 Flow control LF flow regulator in reverse 15 18 ft lbs 20 24 Nm 16 Flow control lE sss LF flow regulator in forward 15 18 ft lbs 20 24 Nm 17 Flow control Buh RF flow regulator in reverse 15 18 ft lbs 20 24 Nm 18 Flow control Wodza RF flow regulator in forward 15 18 ft lbs 20 24 Nm 7 56 Genie S 40 Part No 32222 Section 7 Repair Procedures Service Manual First Edition 4WD DRIVE MANIFOLD 9 9 000 OH 49 9 6909 57 Genie 5 40 PartNo 32222 Section 7 Repair Procedures Service Manual First Edition pu i 4WD DRIVE MANIFOLD Plug Torque Specifications 6 Restartthe engine Drive the machine in either direction and recheck the valve pressure Description Hex size Torque 7 Turn the engine off then remove the SAE No 2 1 8 50 in lbs 6 Nm pressure
192. rt 31 Traction Apy of Ea A roblem consult Genie Function industries Service Inoperative penalise Be sure all other functions operate normally 5 52 Genie S 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 32 Machine Will With boom stowed inti Ri para replace chec or continuity lift drive limit switch or Not Drive At continuity to ground boom extend limit Full Speed MIEM no continuity Be sure all other functions operate With boom fully stowed normally ie Med 6 orange wire circuit from TB40 to horsepower for continuity to ground limiter board Be sure the free wheel valve is closed on the no continui drive pump y Re adjust or replace horsepower limiter board See Repair Section OR consult Genie Industries Service Department Part No 32222 Genie S 40 5 53 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 33 Machine Drives At Full Speed With Platform Raised or Extended Remove machine from service immediately Be sure boom lift drive limit switch or boom extend drive limit switch is not being held down or up Be sure wiring to limit switches is intact and shows no sign of tampering Be sure orange wire cable 1 is properly attached to horsepower limiter Disconnect electronic continuity displacement controller
193. rt No 32222 Section 7 Repair Procedures Service Manual First Edition pu M Ml 2WD DRIVE MANIFOLD 17 2 Valve Adjustments How to Adjust the Charge Pressure Relief Valve 1 Connecta 0 to 600 psi 0 to 41 bar pressure gauge to the test port located on the drive manifold ACAUTION Bodily injury hazard S praying 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 2 Startthe engine from the platform controls 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the relief valve and remove the cap index 1 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 6 Restartthe engine Drive the machine in either direction and recheck the valve pressure 7 Turn the engine off then remove the pressure gauge Relief valve specifications Pressure 250 psi 17 bar 7 54 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures nh This page intentionally left blank Part No 32222 Genie S 40 7 55 Section 7 Repair Procedures Service Manual First Edition 4WD Drive Manifold 18 1 4WD Drive Manifold Components In
194. rting 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 forklift overhead crane or sure thatfasteners intended for one Q time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time 4 gt Be sure to properly dispose of old oil or c other fluids Use an approved container Please be environmentally safe iv Genie 5 40 PartNo 32222 Service Manual First Edition Introduction Section One Section Two Section Three Section Four Important Information aw ev ah dE a i Se Safety Rules General Safety Rules ee eee seed be AAA a add a ete a teda Specifications Machine Specifications Performance Specifications Hydraulic Specifications Bolt Torque Specifications Ford LSG 423 Engine Specifications Deutz Engine Specifications Scheduled Maintenance Inspections Introduction aaa Table A tae Va des Table B ES Scheduled Maintenance Procedures Table of Contents INtTOGUCHON ed e tr iets A eet E eerte Eee KA A l Inspectthe Manuals nae ee e e n RR ERR Ra De ci ERE RE a ee 2 Inspectthe Decals and A 3 Inspect for Dama
195. ry hazard S praying 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 Perform all troubleshooting on a firm level surface Two persons will be required to safely perform some troubleshooting procedures Part No 32222 Genie S 40 5 1 Section 5 Troubleshooting Flow Charts Service Manual First Edition TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform service repair problem solved 5 2 Genie S 40 Part No 32222 Service Manua
196. s Adjust the voltage to 2 5V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 2 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures 7 Setthe max out Press down the foot switch then move the control handle all the way to the up position Adjust the voltage to 5 9V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 8 Set the dual lo range Press down the foot switch then move the control handle all the way to the pown position Adjust the voltage to 5 9V DC Turn the dual range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 9 Start the engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Lower the boom to the stowed position Engine should be at normal operating temperature 10 Start a timer and record how long it takes for the boom to fully raise Adjust the max out trimpot to achieve a 40 to 60 second cycle time 11 Start a timer and record how long it takes for the boom to fully lower Adjust the dual range trimpot to achieve an 50 to 80 second cycle time If the function cycle time is not achievable check the relief valve pressure See 9 2 Valve Adjustments Function Manifold 12 Turn the engine o
197. se 3 y damage to the machine connections very slowly to allow the oil pressure to dissipate Result If the pressure gauge reads gradually Do not allow oil to 3000 psi 206 bar immediately stop squirt or spray cranking the engine The pump is good 2 Connecta 0 to 5000 psi 0 to 350 bar pressure Result If the pressure fails to reach 3000 psi gauge to the high pressure port 206 bar the pump is bad and will need to be 3 Gasoline LPG models Remove the high tension lead from the center of the ignition coil 6 Gasoline LPG models Reconnect the high tension lead to the ignition coil Electrocution hazard Contact with AWARNING electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry 4 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position Part No 32222 Genie S 40 7 21 Section 7 Repair Procedures Service Manual First Edition HYDRAULIC PUMPS How to Remove the Lift Steer Pump 1 Close the two hydraulic tank valves located at the hydraulic tank open closed Component damage hazard The ACAUTION engine must not be started with the hydraulic tank shutoff valves in the cLosep 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 2 Disconnect and plug the lift steer pump hydraulic
198. sition 3 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 Part No 32222 Genie S 40 7 35 Section 7 Repair Procedures Service Manual First Edition pu J d l FUEL AND HYDRAULIC TANKS 10 2 Fuel Tank How to Remove the Fuel Tank r z Explosion hazard Engine fuels A DANGER are combustible Remove the fuel tank in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach y Explosion hazard When Bea transferring fuel connect a grounding wire between the machine and pump or container 1 Turn the manual fuel shutoff valve to the CLOSED position 2 Gasoline LPG models Disconnect drain and plug the fuel hose Deutz Diesel models Disconnect drain and plug the supply and return fuel lines Cap the fuel return fitting on the fuel tank 3 Remove the mounting fasteners from the bottom of the tank 4 Use an appropriate lifting device to remove the tank from the machine Clean the fuel tank and inspect for rust and corrosion before installing 7 36 Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures Turntable Rotation Components 11 1 Rotation Hydraulic Motor How to Remove the R
199. sition and replace the two retaining bolts C 11 Clean or Replace the Distributor Cap and Rotor Gasoline LPG Models A distributor cap and rotor that are clean and free of damage wear and corrosion are essential to good engine performance and service life A dirty or worn cap and rotor may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require thatthe cap and rotor be replaced more often Perform this procedure with the engine off Genie S 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 1 Removethe 2 bolts from the engine pivot plate Swing the engine pivot plate away from the machine to access the distributor an XE AY a pivot plate retaining bolts b engine pivot plate 2 Labeland disconnectthe coil and spark plug wires from the distributor cap 3 Remove the cap and rotor from the distributor 4 Cleanthe cap and rotor using electrical contact cleaner or a damp cloth 5 Completely dry the cap and rotor Moisture in the distributor cap will cause the engine to run poorly 6 Inspectthe cap and rotor for corrosion cracks and abrasion Replace the cap and rotor if they are damaged 7 Install the rotor and cap then connectthe coil and spark plug wires 8 Swing the engine pivot plate back to its original position and replace the two retaining bolts 9 Startthe engine from the ground
200. sonnel from entering the area and do not operate the machine Repair the leak immediately C 9 Replace the Gasoline Fuel Filter Gasoline LPG Models Replacing the gasoline fuel filter is essential to good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require thatthe filter be replaced more often ye yrr Engine fuels are combustible ADANGER Replace the fuel filter in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 4 32 Genie 5 40 Part 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures TABLE C PROCEDURES 1 Removethe 2 bolts from the engine pivot plate Swing the engine pivot plate away from the machine to access the fuel filter located near the carburetor Gasoline LPG models a filter b X hose from the fuel filter to a pivot plate retaining bolts the carburetor b engine pivot plate C hose from the fuel pump to the fuel filter 2 Loosen the filter bracket mounting bolt d hose from the fuel shutoff Disconnectthe fuel hoses from the filter then valve to the fuel pump slide the filter out of the bracket 3 Install the new fuel filter in the bracket with the flow direction arrow on the fil
201. st the Foot Switch 1 Turn the key switch to the orr position and separate the wiring quick disconnect plug from the platform toe board 2 Do not press down the foot switch Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for continuity Test Desired result green to black continuity zero Q green to white no continuity infinite Q black to white no continuity Do not use the color of the connector as a guide for these tests Use the actual wire color to identify which connector to use for testing 3 Press down the foot switch Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for continuity PLATFORM CONTROLS 1 4 Resistors The resistor is used to maintain proper control of boom extend retract The resistor is located in the platform control box Refer to the schematic legends for resistor locations and values How to Test the Resistors 1 Turn the key switch to the orr position 2 Connect the leads from an ohmmeter to each end of the resistor being tested 3 Compare the ohmmeter reading with the resistance rating printed on the resistor Test Desired result green to black no continuity infinite Q green to white no continuity black to white continuity zero Q Part 32222 Genie S 40 7 7 Section 7 Repair Procedures PLATFORM CONTROLS 1 5 Toggle Switches
202. stall a 0 to 3000 PSI pressure gauge on the function manifold Start engine hold the boom retract function and check the hydraulic pressure less than 2400 psi a Hold the boom retract manifold relief valve more Switch and readjust item AB all the way in the relief pressure to clockwise counting 2400 psi the number of turns Hold the boom retract switch and recheck the pressure Adjust the function less than 2400 psi Check the function Replace the relief valve pump see Repair OR manifold has section internal defects consult Genie Industries Service Department Replace the pump Genie 5 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Ground Controls Inoperative Platform Controls Operate Normally Be sure all other functions operate normally including platform controls Chart 12 Does the engine start Start the engine from from the ground the ground controls and controls check the voltage on the center pole red wire of the platform level switch Repair open in red wire circuit from key switch to function switches Troubleshoot the functions individually Check voltage at red wire on ground controls contact of the key switch the red wire checked should originate at the emergency stop button Repair open in red wire circuit from emergency Stop button to the key swit
203. stance across the coil terminals Replace the valve coil to 5 ohms function operates Hold toggle switch left and manually override rotate left directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item P with a like valve item S Replace the rotate directional valve tt inoperative Install a pressure gauge a at the quick disconnect coupling on the function manifold and hold the function switch Interchange the rotate left and right counterbalance valves item M and item N on turntable rotation motor Replace defective counterbalance valve function inoperative less than 2400 psi Check for mechanical restrictions keeping turntable from rotating leftOR directional valve OR repair rotation motor Remove the rotate left function pressure line from the manifold and cap the port S2 Then with pressure gauge still attached operate the function Repair rotation motor less than 2400 psi Replace the directional valve OR the manifold has internal defects OR Consult Genie Industries Service Department Genie S 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Turntable Rotate Right Function Inoperative Be sure all other functions
204. stener from both the barrel and rod end pins 5 Drive the rod end pin out using a soft metal drift 6 Manually pivot the rotator up and secure it to the boom 7 Use a soft metal drift and drive the barrel end pin out 8 Carefully pull the cylinder out of the boom 9 Disconnect the hydraulic hoses from the Slave cylinder and connect them together with a connector Cap the fittings on the cylinder Bodily injury hazard Spraying ACAUTION 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 32222 Genie 5 40 7 9 Section 7 Repair Procedures Service Manual First Edition PLATFORM COMPONENTS How to Bleed the Slave Cylinder Do notstart the engine Use auxiliary power for all machine functions in this procedure 1 Raise the boom to a horizontal position 2 Move the platform level switch up and down through two platform leveling cycles to remove any air that might be in the system 2 3 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 ACAUTION 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 o
205. sult All machine functions should operate smoothly 4 Push in the Emergency Stop button to the orr position Result No function should operate the engine should stop As a Safety feature selecting and operating the ground controls will override the platform controls including the Emergency Stop button PartNo 32222 Genie S 40 4 5 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 11 4 Atthe platform controls pull outthe Emergency AT Stop button to the oN position then press down Test the Auxiliary Power Operation 5 Simultaneously hold the auxiliary power switch Detection of auxiliary power system malfunctions is on while activating the following functions essential for safe machine operation An unsafe through a partial cycle working condition exists if the auxiliary powered boom up down functions do not operate in the event of a main power loss When operating the machine on extend and retract engine power selecting auxiliary power will stop the engine immediately Auxiliary power is designed for short term emergency use only steer right left and excessive use will result in battery drain and component damage turntable rotate right left 1 Turn the key switch to ground control and pull out the Emergency Stop button to the on position 2 Simultaneously hold the auxiliary power switch on while activating the following functions thr
206. sure that there are no leaks Part No 32222 Genie S 40 4 31 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES C 8 Replace the Diesel Fuel Filter Deutz Diesel Models Replacing the diesel fuel filter is essential to 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 Extremely dirty conditions may require that the filter be replaced more often yrr ry Engine fuels are combustible ADANGER Replace the fuel filter in an open well ventilated area away from heaters Sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Turn the manual fuel shutoff valve located at the fuel tank to the cLosep position 2 Remove the fuel filter with a filter wrench Ly A fuel filter b oil filter w 3 Apply a thin layer of oil or diesel fuel to the new fuel filter gasket 4 Install the new filter part no 29560 and tighten it securely by hand Clean up any diesel fuel that might have spilled during the procedure 5 Turn the manual fuel shutoff valve located at the fuel tank to the position 6 Startthe engine from the ground controls then inspectthe fuel filter for leaks f a fuel leak is discovered keep ADANGER any additional per
207. t 32222 Service Manual Section 6 Schematics N Electrical Schematic Gasoline LPG Models HIGH RPM Service Manual Electrical Schematic Gasoline LPG Models Section 6 Schematics 19 ENGINE SPEED 9 3 I s BLK RED 1 N 0 1 gt ENGINE SPEED os fo mr THIGH RPM BLK RED 02 0 2 z de HIGH IDLE RELAY E o HIGH IDLE CUTOUT RELAY al tr M RED WHT E H s5 gg BLU BLK E H 4 1 BLK RED R4 E H ge 9 9 89 zu BLU RED 1 REDWHT 23 E H 99 8 E ug TNEPEJ mim uo pes BLU WHT 1 d BLU RED4R7 E H o 3 ees Ye LPG SOLENOID v p gt a oz p GAS BLU WHT R6 E H S ANTI DIESEL VALVE 8 29 BLU WHT RE E H B Ye GASOLINE SOLENOID FLASHING BEACONS Z N REDWHT 23 E H RED BLK R6 E H 6 5 FUEL RELAY o b
208. t D gt v z m xc m mm m m d c m QF 2 2 Bo BE Z 5 m gt zi i 8 48 gt lt 5 B g 52 g 8 lt 5 5 m m 2 2 3 el 3 m 5 x T 2 lt z 2 o m o o o 3 o 2 2 d 2 o o u 5 5 c R z z 2 9 d u m D 3 5 2 Genie S 40 Part No 32222 Section 6 Schematics Service Manual Electrical Schematic Diesel Models TP41 TB18 he GRN 2 m e a m BLU RED 3 WHT 5 n e 4 GRN S WHT 1 RED 5 BLK 5 gt a E i rs EN EJ u E DRIVE ENABLE BLU WHT 3 8 m F WHT BLK 1 SN WHT BLK 31 E H AY DRIVE EDC o 2 8 E WHT RED 1 E WHT RED 32 E H n M hd ks BLU BLK 1 BLU BLK 37 E H n J g BLU 1 2 BLUs36 E H n M g 4 a E a N S a 49 ORG 1 WHT 6 GRN 6 E o p ZuEQ Seine 5255
209. t Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 7 Restartthe engine manually activate the valve and recheck the valve pressure 8 Turn the engine off then remove the pressure gauge and assemble the directional valve linkage Unloader valve specifications Pressure 1200 psi 82 7 bar 7 46 Genie 5 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures nh STEER AND OSCILLATE MANIFOLDS 15 3 Directional Valve Manifold Components Index Schematic No Description Item Function Torque 1 a Breather 2 20 25 ft lbs 27 33 Nm S POO valve a AA A eec tes Directional control S Part No 32222 Genie S 40 7 47 Section 7 Repair Procedures Service Manual First Edition STEER AND OSCILLATE MANIFOLDS How to Set Up the Directional Valve Linkage Adjustment of the directional valve S 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 Failure to perform this procedure AWARNING on a level floor will compromise the stability of the machine and may result in the machine tipping over 3 Remove the drive chassis cover from the non steer end 4 Disconnect the linkage clevis yoke from the drive chassis if not already d
210. ter b hose from the fuel filter to the carburetor c hose from the fuel pump to the fuel filter d hose from the fuel shutoff valve to the fuel pump 3 Clean up any fuel that may have spilled during this procedure 4 Startthe engine from the ground controls then inspect the fuel filter and hoses for leaks y If a fuel leak is discovered keep 2149313 any additional personnel from entering the area and do not operate the machine Repair the leak immediately D 4 Check the Engine Valve Clearance Gasoline LPG Models Complete information to perform this procedure is available in the Ford LSG 423 2 3 Liter Industrial Engine Service Manual F ord number 194 216 Genie part number 29586 D 5 Check the Engine Cylinder Compression Gasoline LPG Models Complete information to perform this procedure is available in the Ford LSG 423 2 3 Liter Industrial Engine Service Manual F ord number 194 216 Genie part number 29586 Genie S 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures D 6 Clean the PCV Hoses and Fittings Gasoline LPG Models Maintaining PCV hoses is essential to good engine performance Improperly functioning PCV hoses will fail to ventilate the crankcase and continued use of neglected hoses could result in component damage Perform this procedure with the engine off 1 Remove the 2 bolts from the engine pivot plate Swing the
211. ter pointing toward the carburetor Tighten the bracket mounting bolt then connectthe fuel hoses to the filter 4 Clean up any fuel that may have spilled during the installation procedure 5 Startthe machine from the ground controls then inspectthe fuel filter and hoses for leaks fa fuel leak is discovered keep A DANGER any additional personnel from entering the area and do not operate the machine Repair the leak immediately 6 Swing the engine pivot plate back to its original position and replace the two retaining bolts PartNo 32222 Genie 5 40 4 33 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES C 10 Replace the PCV Valve Gasoline LPG Models Y early replacement of the PCV valve is essential to good engine performance A malfunctioning valve can impair crankcase ventilation and may cause engine damage NOTICE Perform this procedure with the engine off 1 Remove the 2 bolts from the engine pivot plate Swing the engine pivot plate away from the machine to access the PCV valve Kee a pivot plate retaining bolts b engine pivot plate 2 Remove the hoses from the PCV valve then remove the valve Shown with distributor cap removed a PCV valve b hose PCV valve to carburetor C hose PCV valve to crankcase 3 Install the new PCV valve Connectthe hoses 4 Swing the engine pivot plate back to its original po
212. tion Section 4 Scheduled Maintenance Procedures B 16 Check the Directional Valve Linkage Proper axle oscillation is essential to safe machine operation Ifthe 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 from the non steer end 2 Inspect the linkage for the following lock nuts are tight against yokes yoke clevis pins are installed cotter pins are installed through clevis pins linkage is properly attached to directional valve a directional valve b lock nut c yoke d clevis pin with cotter pin TABLE B PROCEDURES B 17 Test the Platform Self leveling Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which is controlled by the master cylinder located atthe base of the boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Startthe engine from the ground controls then lower the boom into the stowed position 2 Adjustthe platform to a level position using the platform leveling switch 3 Raise and lower the boom through a full cycle Result The platform should remain level at all times to within 5 degrees B 18 Test the Service Horn A functional service horn is essent
213. tle The linkage must be free of friction and obstruction Do not let it rub against the engine brackets or hoses Component damage hazard ACAUTION If the throttle linkage is improperly adjusted and allowed to reach full throttle the engine will over rev and cause component damage 6 2 Choke Adjustments This engine is equipped with an electrically heated automatic choke The choke has a poppet valve to enhance cold starting ability on LPG fuel Choke adjustments are affected by climate Richer adjustment will be necessary in colder climates leaner adjustment in warmer climates Automatic Choke with Poppet Valve The choke functions in both gasoline and LPG mode The choke butterfly may be adjusted to a fully closed rich position for colder climates and the poppet valve will provide a flow path during LPG fueled operation Genie S 40 Part No 32222 Service Manual First Edition Section 7 Repair Procedures 6 3 Timing Adjustment Complete information to perform this procedure is available in the Ford LSG 423 2 3 Liter Industrial Engine Service Manual Ford number 194 216 Genie part number 29586 6 4 Carburetor Adjustment Complete information to perform this procedure is available in the Ford LSG 423 2 3 Liter Industrial Engine Service Manual Ford number 194 216 Genie part number 29586 6 5 RPM Adjustment Refer to Maintenance Procedures B 12 Check and Adjust the Engine RPM
214. uel shutoff valve All models 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 13 Connectthe wiring and startthe engine from the ground controls Check the hydraulic tank for leaks Hydraulic system Hydraulic tank capacity 45 gallons 170 liters Hydraulic system 50 gallons capacity including tank 189 liters Hydraulic fluid Dexron II equivalent TABLE D PROCEDURES D 2 Change or Recondition the Engine Coolant Gasoline LPG Models Replacing or reconditioning the engine coolant is essential to good engine performance and service life Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage Extremely dirty conditions may require coolantto be changed more frequently Beware of hot engine parts and ACAUTION coolant Contact with hot engine parts and or coolant will cause severe burns Perform this procedure with the engine off and cooled 1 Puton protective clothing and eye wear Disconnectthe coolant return hose atthe radiator and drain the coolant return tank 3 Remove the radiator cap from the radiator Part No 32222 Genie S 40 4 39 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE D PROCEDURES 4 Remove the 2 bolts from the engine pivot plate Swing the engine pivot plate away from t
215. und Drive both steer tires up onto a 6 inch 15 2 cm block or curb Result The non steer tires should stay in firm contact with the ground PartNo 32222 Genie S 40 4 9 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 15 Replace the Engine Oil and Filter Gasoline LPG Models Ford engine specifications require that this procedure be performed every 100 hours Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A daily check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 100 hour interval Perform this procedure after warming the engine to normal operating temperature Beware of hot engine parts and ACAUTION oil Contact with hot engine oil and or engine parts may cause severe burns 1 Remove the filler cap located on the valve cover 2 Pull the end ofthe oil drain hose out from under the engine X 4 U a engine pivot plate b pivot plate retaining bolts c oildrain hose 3 Remove the plug from the end of the drain hose and allow all of the oil from th
216. ut torque 125 ft lbs 125 ftlbs 169 5 Nm 169 5 Nm Part No 32222 Genie S 40 4 15 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 9 Confirm the Proper Brake Configuration 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 torque hub disconnect cap to be sure it is in the engaged position 2 Be sure the free wheel valve on the drive pump is closed clockwise brake disengage position brake engage position a drive pump b free wheel valve C screwdriver d lift pump The free wheel valve should always remain closed B 10 Check the Oil Level in the Torque Hubs Failure to maintain proper torque hub oil levels may cause the machine to perform poorly and continued use may cause component damage Drive Torque Hubs 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the plug hole 3 Ifnecessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole 4 Apply pipe thread sealantto the plug and then install itin the torque
217. uum switc a reconnect blk wire after Check vacuum line for Replace vacuum line test restrictions 12V See Ford service manual to troubleshoot low manifold vacuum With keyswitch on and both mushroom switches pulled out disconnect wires from Repair open in red blk vacuum switch and H wire circuit from vacuum connect the wires switch to CR6 together Check the voltage at terminal 86 onCR6 Continued on the next page 5 8 Genie S 40 PartNo 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 2A With keyswitch on and Repair open in red Continued from the both mushroom y power wire circuit with previous page switches pulled out diode check voltage at center terminal on fuel select switch in platform control box 12V OV With keyswitch on and Replace toggle switch both mushroom switches pulled out check voltage on gasoline side blu wht wire of fuel select switch 12V With keyswitch on and ov Repair open in blu wht both mushroom wire circuit from to gle switches pulled out switch to TP 38 to 1838 check at terminal TB38 12V With keyswitch onand OV Repair open in blu wht both mushroom wire circuit from TB 38 to switches pulled out terminal 30 on CR6 check voltage at blu wht wire at terminal 30 on CR6 12V With keyswitch on and OV Check ground wire on no go
218. v 12V 12V Check voltage at 0v terminal 430 on CR4 Check voltage at 0v terminal 487A on Check voltage at terminal 45 on electronic governor 12V Check voltage at oV electronic governor terminal 3 brown wire 6 to 7V Turn machine off remove blu blk wire from terminal 4 on electronic governor and restart engine engine goes to low idle Recheck electronic governor adjustments OR replace electronic governor engine goes to high idle Chart 7 Isolate the ground and platform rpm switches check individually and replace defective switch Repair open in wht 21 wire circuit from TB21 to to CR4 Replace CR4 relay Repair open in blk red wire circuit from CR4 to electronic governor Repair open in brown wire circuit from ignition module to electronic governor Recheck throttle linkage see Repair section OR check and or replace governor actuator OR see Ford service manual for carburetor troubleshooting PartNo 32222 Genie S 40 5 21 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 8 Engine High Idle Inoperative Deutz Diesel Models Be sure mechanical linkage is not binding or defective Be sure PR2 relay and 2 speed solenoid grounding wires are free of corrosion and have full continuity to ground Start engine switch rom Check high idle select switch to high i
219. ve to platform machine Place a jumper wire Normally n down footswitch drives between TB30 and no drive Repair open in old drive enable TB12 and test drive wht wire circuit from TP30 to TB30 without holding drive Be sure the hydraulic switch to either side enable switch suction line valve is in and try to drive the open position machine drives Be sure machine is f Replace drive enable notin the free wheel imt switch OR repair configuration no drive open in wire circuits from terminal TB30 to limit switch and from limit switch to TB12 Disconnect drive pump por electronic displacement infinite controller EDC wires ohms Check resistance Replace EDC across both wires on EDC side of quick disconnect 20 to 24 ohms Press down foot switch Correct insufficient and check voltage at less than 12V voltage supply alternator or battery horsepower limiter board terminal 1 OR repair open in wht wire circuit supplying 12V to terminal 1 12V or more Continued on the next page 5 48 Genie S 40 Part No 32222 Service Manual First Edition Section 5 Troubleshooting Flow Charts Continued from the previous page Switch rpm select switch to rabbit with foot switch press down foot 0v Check voltage at TB41 g 6 to 7V CHART 29 Repair open in org blk wire ci
220. while the engine is running Remove the key to secure from operation Beware of hot engine components Contact with hot engine components may cause severe burns ACAUTION Genie S 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Oil Cooler 1 Remove the cover from the side of the engine then remove the oil cooler top cover 2 Inspect the oil cooler for leaks and physical damage a oil cooler b cylinder head cooling fins C blower fins 3 Clean the oil cooler of debris and foreign material Cooling and Blower Fins 4 Inspectthe blower fins for physical damage 5 Clean the blower fins of debris and foreign material 6 Inspectthe head cooling passages and fins for physical damage or foreign material using a flashlight 7 Clean the cylinder head cooling passages of debris and foreign material TABLE B PROCEDURES B 4 Check the Exhaust System 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 Do not inspect while the engine AWARNING is running Remove the key to secure from operation Beware of hot engine ACAUTION components Contact with hot engine components may cause severe burns 1 Deutz Diesel models Remove the 2 bolts from the engine pivot plate S
221. will show when the hydraulic flow is bypassing a clogged filter If the filter is not frequently checked and replaced impurities will remain in the hydraulic system and cause component damage 1 Start the engine from the platform controls 2 Move the engine speed control switch to high idle rabbit symbol 3 Inspect the filter condition indicator filter condition indicator filter c hydraulic tank Result The filter should be operating with the plunger in the green area Ifthe display shows the plunger in the red area this indicates that the hydraulic filter is being bypassed and the filter should be replaced See C 6 Replace the Hydraulic Tank Filter 4 14 Genie 5 40 Part No 32222 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 7 Inspect the Electrical Wiring 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 hazard Contact with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires engine compartment electrical panel engine wiring harness inside of the ground control box turntable manifold wiri
222. wing the engine pivot plate away from the machine to access the exhaust system A E a pivot plate retaining bolts b engine pivot plate Part No 32222 Genie S 40 4 13 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES 2 Be sure that all nuts and bolts are tight 3 Inspectall welds for cracks 4 Inspect for exhaust leaks i e carbon buildup around seams and joints B 5 Check the Battery 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 P unta marne in acid Avoid spilling or contacting AWARNING 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 3 Be sure that the battery hold downs and cable connections are tight 4 Remove the battery vent caps and check the specific gravity with a hydrometer 5 Check the battery acid level If needed replenish with water to the bottom of the battery fill tube Do not overfill 6 Install the vent caps B 6 Check the Hydraulic Tank Filter Condition Indicator Maintaining the hydraulic tank filter in good condition is essential to good system performance and safe machine operation The filter condition indicator

Service Manual - Genie Industries

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