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Service Manual - Genie Industries

1. BLK 422 BLK 26 WHT 23 9 Es 9 od BLK WHT 34 WHT 1 H P L 4 BRN TO GRD 2 TO 8 24 9 S BLU BLK 37 BLU 36 RED 10 H P L WHT BLK 31 WHT 30 eo WHT RED 32 BLK RED 35 GEN OPTION 45 GRN WHT 1 BLK 433 SPARE 44 GRN BLK 1 ds n HORN 43 GRN 1 BLU RED 13 ur SE SPARE 42 ORG RED 1 D PULSE PICKUP 41 LIMIT SWITCH 40 GRN 25 LP 39 BLU RED 1 GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 eee STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 O GLOW PLG OPT 34 BLK WHT 1 START 33 BLK 1 BRAKE 32 WHT RED 1 E D C 1 WHT BLK 1 E D C 30 WHT 1 2WD 4WD 29 RED WHT 1 28 O O AUX PWR 27 RED 1 PWR TO FS 26 BLK FS PWR START 25 RED FS M PWR CONT 24 WHT FS PWR FRM PLAT 23 WHT 2 RED Wy lS PWR TO PLAT 22
2. L K J H G F E D C B A SLAVE n 1 PLATFORM ROTATE PRIMARY 2 2 EU L Jez pud 9 1 Ke 4 E 0 025 e 3 SES posag EHEMH FUNCTION oto 118 non J MANIFOLD 290 PRESS OPTIONAL d FIER GENERATOR TEST EE a 2400 PSI 4 ze mg Do zu GPM i PSI 1 LL J PRESS im i 1 OPTIONAL esr dela GENERATOR 1 M MANIFOLD amp 2600 DRIVE PUMP ec 106 5 ZN T1 lt 2000 OPTIONAL PSI zo Be COOLER tA RESERVOIR AC BUMP pem Lt U A X 12 0 eeu si J 0 025 Mm STEER 7 MANIFOLD era m 7 Sar P P8 FT I T f LER avave 69 9 nii T3904 9 8 B VALVE BCYL poe STEE
3. M L K J H G F E D C B A SLAVE UT 1 I PLATFORM F E d SWING ROTATE m E i H Wi d PRIMARY 2 S 0 025 I p R A gt Tl sent Um Ev In rw P L 9T9 1 PSI HIGH S 92 Ie i W o 4 2200 290 M 751 d PRESS OPTIONAL Lif Ie LG f P IH ae GENERATOR I TEST E Poor E m a 2400 PSI 4 1 gt 3500 t LES psi 01 dl PRESS lz OPTIONAL Cee Rana GENERATOR i m Lt 1 10 GPM MANIFOLD B 2600 F i 9 M 9 XE aot W 60 1 Q e 1 34 DRIVE PUMP HE AL 1 p n EE oe old 1 press xL 3 Gem RZ 2000 57 3 SF mm SS J COOLER PSI PSI Si zza NC E RESERVOIR AUX PUMP 6 mm _ BL C MANIFOLD PEN aes m 7 I bo HER ie m TANK waj AVALVE le 09 CYL 4 097 B CYL 8 o B VALVE
4. NOTE CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION Service Manual Electrical Schematic Diesel Models Section 6 Schematics HIGH RPM ENGINE SPEED 8 x BLK RED 1 P 1 N FUNCTION ENABLE i HIGH RPM BLK RED Ga HIGH IDLE RELAY 8 20 2 2 SH HIGH IDLE CUTOUT 4 RELAY BEI HEDBEAEH 7 RPM SOLENOID o 59 e OFF r GENERATOR o LON E GRN WHT 1 GRN WHT 4 E H 7 GENERATOR A OPTION i st lt Ze 9 WHT a BLK 1 a fis 56 2 HOUR METER o s e ze aua p ENGINE START E aS ess EB gels 5 dt DE 5 Edd ES ER A NE SENDER ENGINE 3 EH ae WHT 24 E H 52 WATER TEMP START i m SENDER S E2 o a a a z WHT 21 E H bi BEKR pF FUEL SOLENOID GLOW Yo _ i PLUG SZ GLOW RJ PLUG BLK WHT 34 E H a 5 4 GLOW PLUG OPTION B LES xS BLK R1 E H al I u xz Eo c 52 T I STARTER MOTOR o i I o UD SAES EEA 1 g AUXILIARY amp m A AUXILIARY EUM
5. Service Manual Section 6 Schematics ju Z 3 2WD Hydraulic Schematic before serial number 1424 Non Oscillating Axle M L K J G F E D C B A SLAVE 1 L 1 PLATFORM iR i T d SWING ROTATE Mw I 2 Ws 4 PRIMARY H FQ oes Mi iz i Pena dup 290 Pw OPTIONAL AJ GENERATOR FILTER TEST a E a 2400 PSI 5 4 I DA pce EP osy i EH 4 CHAD MS GENERATOR LL 1 COM MANIFOLD 98 a800 L PSI PRESS DRIVE PUMP c Ac 1 W TANK 5 S 2000 a 36 s PSI PSI e COOLER PSI PSI 4 RESERVOIR AUX PUMP 11 6 IE IX L 7 1 Kp TENH 250 sa 6 psi TANK CP en 8 L 0 070 JG 8 N Mi STEERING sa See TRACTION Part No 52271 Genie S 40 Service Manual Section 6 Schematics M GW ZY ZJ 2WD Hydraulic Schematic before serial number
6. 210 RIGHT G REAR LEFT 5 E J STEERING TRACTION Part No 52271 Genie S 40 6 22 Service Manual Section 6 Schematics 2WD Hydraulic Schematic before serial number 1424 Oscillating Axle Service Manual Section 6 Schematics 2WD Hydraulic Schematic after serial number 1423 Oscillating Axle K J H G F E D C B A BOOM SLAVE UP DOWN PRIMARY 1 PLATFORM ROTATE TURNTABLE ROTATE l
7. 25 30 ft lbs 34 41 Nm 14 Relief valve 2200 psi 152 bar Fu Boom 25 30 ft lbs 34 41 Nm 15 Proportional solenoid valve uis unes Bie 10 12 ft Ibs 14 16 Nm 16 Flow regulator valve X Turntable rotate boom extend retract 10 12 ft Ibs 14 16 Nm 17 Normally closed poppet valve Platform 25 30 ft Ibs 34 41 Nm 18 Proportional solenoid valve 2 Turntable rotate boom extend retract 10 12 ft Ibs 14 16 Nm 19 Flow regulator valve M isses Platform 10 12 ft Ibs 14 16 Nm 20 Differential sensing valve AC AIL f nctioris gasi ertet 10 12 ft Ibs 14 16 Nm 21 Flow regulator valve U uu Platform rotate 10 12 ft Ibs 14 16 Nm 22 Flow regulator valve Witenes Differential sensing circuit 10 12 ft Ibs 14 16 Nm 23 Diagnostic fitting sseeeenneee Testing 24 Relief valve 2600 psi 179 bar System relief 35 40 ft lbs 47 54 Nm 25 Priority flow regulator valve T nius Steering ccr 10 12 ft Ibs 14 16 Nm 26 Check valve Platform rotate right differential sensing
8. 366 515 PG 220 298 300 406 569 9 30 433 430 583 827 350 474 470 637 908 8 480 650 640 867 1233 12 530 718 710 92 750 1016 990 1342 840 1139 1071 12 670 908 890 1206 1518 12 930 1260 1240 1681 6 212 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Size Class 4 6 Class 8 8 Class 10 9 Class 12 9 mm LUBED LUBED LUBED LUBED Nm inibs Nm in bs Nm in bs _Nm_ in Ibs Nm in bs Nm in tbs Nm 24 41 463 54 618 58 663 78 8 84 68 7 75 91 103 4 07 69 7 87 93 105 100 113 132 15 16 132 155 17 6 RY ftibs Nm ftibs ftibs Nm ftibs Nm ftibs Nm 394 83 1055 682 925 909 1233 i 1 8 05 12 5 6 Ala ajojo oo c w m N w E ols wole oO ho feo aim ole GE ol E A AJN a NINN S O EN o A EN ajojo A ko EN DOJ ERN DI kad bad baid ban x o o oo o 1 Q a N N B o o wl ES io o9 A o oe o wv co o 68 w
9. 5 53 24 Platform Rotate Right Function 5 55 25 Oscillate Function Inoperative esessesseeeneeeneeeenennenn 5 57 26 Steer Left Function Inoperative 0 2 4 5 58 viii Genie S 40 Part No 52271 Service Manual Second Edition Section Five Section Six TABLE OF CONTENTS Troubleshooting Flow Charts continued 27 Steer Right Function Inoperative sssssssssseeeeeeeeeeneennennn 5 60 28 All Drive Functions Inoperative All Other Functions Operate Normally 5 62 29 Drive Forward Or Reverse Function Inoperative 5 65 30 Traction Function Inoperative mmn 5 66 31 Machine Will Not Drive At Full 5 67 32 Machine Drives At Full Speed With Platform Raised or Extended 5 68 33 Drive Enable System Is 5 69 34 A Auxiliary Functions Inoperative 5 70 Schematics 6 1 Electrical Components 6 2 Electrical Symbols Legend enne nnne nennen 6 4 Abbreviation Legend ettet ete tee eet ES ote d ese 6 5 Electrical Schematic Gasoline LPG 6 7 Ground Control Box Legend Gasoline
10. 13038 Microswitch Control Inc ON TIST ient ie 1 TS6 7 14 15 16 17 Toggle switch DPDT 3 position momentary 16397 Microswitch Control Inc ON DIET iiis 6 TS3 TS11 Gas LPG Toggle switch DPST 2 position maintained 27378 Microswitch Control Inc ON TFS aee e 2 TS3 TS11 Diesel Toggle switch SPDT 3 position momentary 13037 Microswitch Control Inc INT 2 Vacuum switch 22278 Peterson Industrial ince 1 Part No 52271 Genie S 40 6 3 Section 6 Schematics Service Manual Second Edition Electrical Symbols Legend I HIa DHO Wire color with cable number TB20 Terminal TB Terminal base TP Terminal platform Us Quick disconnect terminal BLK 21 TB21 T circuits connect at terminal _ T circuits connect Connection no terminal Circuits crossing no connection Diode Battery 15AMP Circuit breaker Solenoid or relay coil TILT ALARM Horn nol Light U 07 Resistor AE Tilt sensor gt Spark plug Glow plug 181 NO Limit switch normally open held closed 17 an b ym
11. BRN 2 GROUND 2 5 E BLU RED 3 WHT 5 Be 1 BRN 5 E sz DRIVE ENABLE WHT 1 fo RED 5 BLKS LIMIT SWITCH LE 8 8 ig a Bow z g DRIVE ENABLE E BLU WHT 3 o 5 5 ex 1 n m WHT BLK 1 WHT BLK 31 E H U E a DRIVE EDC 2 3 e E WHT RED 1 4 WHT RED 32 E H 5 5 a a Z E BLU BLK 1 BLU BLK 37 E H d E STEER RIGHT BLU 1 BLU 36 E H rj STEER LEFT l ESEEMERS 1 8 EN B I I a z I E N a rak N Qi I a bue E N T w E E 5 TZ ORG 1 P WHT 6 BRN 6 BOOM UP z LIMIT SWITCH t eks u E WHT 7 T BRN 7 BOOM EXTEND A NENNEN a LIMIT SWITCH BSE 65565 Taam e E WHT RED 3 E WHT BLK 3 i WHT 3 M WHT x WHT 4 p E TURNTABLE ROTATE R RIGHT WHT BLK TURNTABLE ROTATE Mara 4 5 1 LLERT z TURNTABLE ROTATE L t 100 E WHT RED 4 TURNTABLE ROTATE 4 FLOW CONTROL RED m B BED PRIMARY BOOM UP UP RED BLK PRIMARY BOOM E ED BLK 4 p 5 EJ DOWN REDA PRIMARY BOOM DOWN B co RED WHT 4 n PRIMARY BOOM E 4 FLOW CONTROL RED 3 gt e RED BLK 3 N e p d RED WHT 3 a E BLK 3 EXTEND om RETRACT BLK WHT 3 m E 1 BLK 4 P BOOM EXTEND I EXTEND BOON BLK WHT 22 w RETRACT BLK WHT 4 5 EE BOOM RETRACT 1 eo E kea o m B B
12. NN 4 Pilot operated unloader valve 950 psi 65 OO 5 Shuttle valve 2 position way PP 6 irj m PEE Check valve Shuttle valve 2 position way RR Diagnostic fitting Function Torque Differential sensing circuit 10 12 ft Ibs 14 16 Nm 35 40 ft lbs 47 54 Nm Differential sensing Oscillate check left 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm Check valve circuit the piston is located between index numbers 3 and 7 35 40 ft lbs 47 54 Nm 35 40 ft lbs 47 54 Nm Oscillate check right Unloading Testing Plug Torque Specifications Description Hex size Torque SAE No 2 1 8 50 in Ibs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft Ibs 24 Nm 7 42 Genie S 40 PartNo 52271 Service Manual Second Edition Section 7 Repair Procedures 9 6 Valve Adjustments Oscillate Manifold How to Adjust the Oscillate Sequencing Valve Pressure When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Connect 0 to 2000 psi 0 to 138 bar pressure gauge to the test port located on the oscillate manifold Bodily injury hazard Spraying AWARNING
13. 7 44 Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures How to Set Up the Directional Valve Linkage Adjustment of the directional valve linkage is only necessary when the linkage or valve has been replaced 1 Lower the 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 Checkthe tire pressure in all four tires and add air if needed to meet specification 4 Remove the drive chassis cover from the non steer end 5 Disconnect the linkage clevis yoke from the drive chassis if not already disconnected 6 Place a bubble type level across the drive chassis non steer end Check to be sure the drive chassis is completely level 7 Tolevel the drive chassis start the engine and push up or pull down on the linkage adjustment rod until the machine is completely level 8 Verify that the ground and drive chassis are completely level 9 Adjust the length of the rod by turning the clevis yoke until the clevis yoke can be pinned to the drive chassis 10 Install the clevis yoke pin then the cotter pin Be sure to bend the cotter pin 11 Measure the distance between the drive chassis and the non steer axle on both sides from the inside of the drive chassis If the distan
14. ese now Ol 44 SPARE GRN HORN H 42 SPARE OGBKEH ORG BLKA 41 ORGEKISMIZ PULSE PICKUP WHTJRED 26A CABLE ORG 1 40 WHT 7 WHATS LIMIT SWITCH SIGNAL GRN GROUND 47 BLURED __ 39 BU RD R7 30 BU RD 8 LP j BUWT R6 30 BLUWHT1 38 BUWT S P GAS i BU BK E H BLU BLK 1 37 BUBK D B STEER LEFT i H BLU E H BLU 1 36 BLU D B STEER RIGHT 1 WHTIBLIC 25A BLKIRED1 25 BKIRD A4v86 BK RD S P RPM BLK 22A H BKWT EH BLKWHTA 84 GLOW PLUG WHT 23 _ START i 46 WTRDEH 32 WTIRD D BRAKE d WTIBK E H WHT BLK1__ EDC i d RED 5 WHT 1 30 ED C ONC SY RD WT EH RWA 29 2WD AWD i gt RD BK A H REDBLK1 28 TILT ALARM i NCC RED 27 REDISM 4 H RED S P AUX PWR 7 i CABLE WIIRD EH 26 WIIRD SR WATER TEMP SENDER B 45 WTIBKE H 25 WIJBK S P OIL PRESSURE SENDER H WnTisuet WHTEH 24 WARNING SENDER RED 27A WHT E H WHT 2 28 WHT S P KEYSWITCH POWER BLKIRED 9A BLensus BLK 2 22 BLK S P POWER TO PLATFORM S WHT R2487 WHTEH 21 WHT SP DB IGNITION POWER RED AH RED R17430 20 RED S P 12V BATT SUPPLY BLKTA d GeNWHTS 19 JIB VALVE RED IA GANBLKA GRNBUCS GRBKSP PLATFORM ROTATE RIGHT EDS A GRN 4 GRN 3 GRN S P PLATFORM ROTATE LEF
15. BLU RED 3 WHT 5 39 i 2 BRN 5 A WHT 1 RED 5 BLK 5 8 8 g Ig m EOS 2 NS DRIVE ENABLE BLU WHT 3 E 3 E E WHT BLK 1 WHT BLK 31 E H 0 BEBE 8 E WHT RED 1 WHT RED 32 E H 7 d E BLU BLK 1 B BLU BLK 37 E H n BLU 1 BLU 36 E H 7 r LEFEFEE 2 gres SN gi F 8j se I n o N E 5 49 ORG 1 E WHT6 BRN 6 Much C R WHT 7 BRN 7 NEN t uj Cm fa az ow w T lt 2 n E WHT RED 3 a WHT BLK 3 a WHT 3 i WHT M amp WHT 4 RIGHT WHT BLK TURNTABLE ROTATE LEFT WHT BLK 4 A s 100 WHT RED 4 m RED m L BU RED 4 D UP PRIMARY BOOM REDIBEK DOWN a aa RED BLK 4 n N QN m RED WHT 4 z 2 B gt RED 3 g RED BLK 3 m N a n E E RED WHT 3 N n BLK 3 EXTEND BOOM R RETRACT BLK WHT 3 R p BLK 4 9 2 EXTEND BLK WHT BOOM w RETRACT BLK WHT 4 B i BLK RED 4 n 2 a i BLK RED 3 Ru n i ORG 3 UP PLATFORM LEVEL DOWN ORG BLK 3 ORG i I za 2 E ORG 4 n i PLATFORM LEVEL g 4 coo DOWN ORGBLK4 p 2 2 1 m Jo e BLK 6 12 RED 6 ORG RED 3 f s m i I o M A E 59
16. Contact 29732 Telemecanique ZB2 BE102 4 Contact N O 45081 Telemecanique 2 2 101 1 PRI Relay 12V DC continuous 27155 SUANCOM 70 902 1 This list continues on the next page 6 2 Genie S 40 Part No 52271 Service Manual Second Edition Section 6 Schematics E J ELECTRICAL COMPONENTS Item Description Genie Part Manufacturer Manufacturer Qty Part Number Part Number B Resistor 1000 25 watt 27116 Dale RH25 100R 1 1 2 Resistor 100 25 27287 Dale ittis RH25 10R 1 1 TS1 TS9 Toggle switch DPST 2 position momentary 13480 Microswitch Control Inc PNT 8 wne oo 2 TS2 5 8 10 Toggle switch SPDT 3 position momentary 13037 Microswitch Control Inc INTI cist eee 6 TS20 Toggle switch DPST 2 position maintained 27378 Microswitch Control Inc ONT 128 iei 1 TS4 Toggle switch DPDT 3 position maintained
17. no continuity Please begin troubleshooting from beginning of chart OR consult Genie Industries Service Department Chart 33 Repair open in power supply circuit from TP24 The machine is operating correctly If machine does not operate consult Genie Industries Service Department Replace drive enable limit switch contact OR replace drive enable limit switch LS3 Part No 52271 Genie S 40 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 34 Auxiliary Functions Inoperative Be sure all other functions operate normally Be sure key switch is in the appropriate position and both Emergency Stop buttons are pulled out to the position Be sure engine is not running when using auxiliary power Note Operating auxiliary power with the engine running should immediately kill the engine Lift the red auxiliary motor pump switch cover hold operates auxiliary switch and listen for sound of auxiliary pump motor operating motor does not operate With the keyswitch turned to ground control and both Emergency Stop buttons pulled out lo the ON position activate the auxiliary pump toggle switch and check the voltage on the red cable on the auxiliary power unit 12V Continued on the next page Install a 0 to 5000 psi 0 to 345 bar pressure gauge into the pressure port of the auxili
18. 11 13 ft Ibs 15 18 Nm 27 Check valve H Platform rotate left differential sensing 11 13 ft Ibs 15 18 Nm 28 Check valve L Platform level differential sensing 11 13 ft Ibs 15 18 Nm 7 32 Genie 5 40 Part No 52271 Service Manual Second Edition January 2008 Section 7 Repair Procedures REVA MANIFOLDS OOO 2 9 Q 62 9 9 9 Genie S 40 7 33 Part No 52271 Section 7 Repair Procedures Service Manual Second Edition January 2008 MANIFOLDS 9 2 Function Manifold Components The function manifold is located on the tank side tra Index Schematic No Description Item 1 position 4 way DOS valve Aus 2 position 4 way DOS valve 3 position 4 way DOS valve Cau 4 Check valve pilot operated Du 5 Relief valve 1950 psi 134 bar E du 6 Relief valve 2200 psi 152 bar Fus 7 Flow regulator valve 1 5 5 7 L min G REVA after serial number 1423 y behind the ground control box Function Torque Turntable rotate left right 30 35 in Ibs 3 4 Nm Boom up down 30 35 in Ibs 3 4 Nm 30 35 in Ibs 3 4 Nm 11 13 ft lbs 15 18 Nm 25 30 ft Ibs 34 41 Nm 25 30 ft lbs 34
19. 218149 Sv C IH a 10 Olrzz o Sa GEN OPTION 45 GRN WHT 1 SPARE 44 GRN BLK 1 43 HORN GRN 1 a SPARE 42 ORG RED 1 41 a Ojo 40 zu LP 39 BLU RED 1 GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 CH STEER RIGHT 36 BLU 1 S z o RPM 35 BLK RED 1 0 GLOW PLUG 34 BLK WHT 1 a 55 START 38 BLK 1 lt 5 BRAKE 32 WHT RED 1 E D C 31 WHT BLK 1 E D C 30 WHT 1 2 2WD AWD 29 RED WHT 1 a 28 2 AUX PWR 27 RED 1 PWR TOFS 26 BLK FS PWR START 25 RED FS te PWR CONT 24 WHT H P L PWR FRMPLAT 23 WHT 2 PWR TO PLAT 22 BLK 2 5 OOO x 23 21 Flooo lt 20 JIB VALVE 19 GRN WHT 3 E PLAT ROT R 18 GRN BLK 3 Flooo SE PLAT ROT 1 17 GRN 3 PLAT LVL 16 ORG RED 3 PLAT LVL DN 15 ORG BLK 3 O 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 EXT RET F C 9 BLK RED 3 RETRACT 8 BLK WHT 3 a PE EXTEND 7 BLK 3 ul EO SWING 6 WHT RED 3 Ok at SWING RIGHT 5 WHT BLK 3 Al I 1xl R SWING LEFT 4 WHT 3 PRIMARY 3 RED WHT 3 PRIMARY DN 2 RED BLK 3 ry PRIMARY UP 1 RED 3 f DN mo m c R lt ui x zl E a X v ui 11221314156 8 910 a o n P 2 SENE O x Q I m RE
20. 5 19 7 Engine Low Idle Inoperative Gasoline LPG Models 5 22 8 Engine High Idle Inoperative Deutz Diesel Models 5 23 9 Engine Low Idle Inoperative Deutz Diesel Models 5 25 10 All Functions Inoperative Engine Starts and Runs 5 26 11 All Lift and Steer Functions Inoperative Drive Functions Operational 5 27 12 Ground Controls Inoperative Platform Controls Operate Normally 5 28 13 Platform Controls Inoperative Ground Controls Operate Normally 5 29 14 Boom Up Function Inoperative 2 2 5 30 15 Down Function Inoperative 5 33 16 Extend Function Inoperative 5 36 17 Retract Function 5 38 18 Turntable Rotate Left Function Inoperative 5 40 19 Turntable Rotate Right Function Inoperative 5 44 20 All Platform Leveling Functions Inoperative 5 48 21 Platform Level Up Function Inoperative 444 5 49 22 Platform Level Down Function Inoperative 5 51 23 Platform Rotate Left Function Inoperative
21. Do not inspect while the engine a engine pivot plate AWARNING is Mining Herode the bn b pivot plate retaining bolts secure from operation 2 All models Be sure that all nuts and bolts are ACAUTION Beware of hot engine tight components Contact with hot 3 Inspect all welds for cracks engine components may cause 4 Inspect for exhaust leaks i e carbon buildup severe burns around seams and joints Part No 52271 Genie S 40 4 15 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 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 Electrocution hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Batteries contain acid Avoid AWARNING spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 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 Checkthe battery acid level If needed replenish with distilled water to the bottom of the battery fi
22. 2 4 6 A 12 Test the Auxiliary Power Operation 2 4 6 A 13 Test the Tilt Sensor ssssssesssssseseseseeeeneeeeennen nennen nnne nnns nennen 4 7 A 14 Test the Limit Switches 4 8 A 15 Replace the Engine Oil and Filter Gasoline LPG Models 4 10 A 16 Drain the Fuel Filter Water Separator Deutz Diesel Models 4 11 A 17 Replace the Engine Air 2 4 12 B 1 Check the Engine 4 13 B 2 Check the Radiator Gasoline LPG 4 14 B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models 4 14 B 4 Check the Exhaust System 0 00 aaa aaa aaa 4 15 B 5 Check the Battery aaa sea R AAA AO OE 4 16 B 6 Check the Hydraulic Tank Filter Condition 4 16 B 7 Inspect the Electrical 0 4 17 B 8 Inspect the Tires and Wheels including lug nut torque Rev B 4 17 B 9 Confirm the Proper Brake Configuration sss 4 18 B 10 Check the Oil Level in the Torque 4 18 B 11 Check and Adjust the Engine Idle Mixture Gasoline LPG Models 4 19 B 12 Check and Adjust the Engine 02024200 0 1 0
23. How to Remove the flames and lighted tobacco Always have an approved fire extinguisher within easy reach Explosion hazard When transferring fuel connect a grounding wire between the machine and pump or container Turn the manual fuel shutoff valve to the CLOSED position Remove the tank side turntable cover See 4 1 How to Remove a Turntable Cover 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 Remove the retaining fasteners from the fuel Hydraulic Tank A CAUTION Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the fuel tank See 10 1 How to Remove the Fuel Tank tank hold down straps Remove the straps from the fuel tank 5 Supportthe fuel tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 6 Remove the fuel tank from the machine AWARNING Crushing hazard The fuel tank may become unbalanced and fall if itis not p
24. terminal 2 to 3 continuity zero Q terminal 2 to 4 5 amp 6 no continuity terminal 3 to 4 5 amp 6 no continuity terminal 4 to 5 amp 6 no continuity terminal 5 to 6 Center position continuity There are no terminal combinations that will produce continuity infinite Right position terminal 1 to 2 continuity zero Q terminal 1 to 3 4 5 amp 6 no continuity infinite terminal 2 to 3 4 5 amp 6 no continuity terminal 3 to 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 52271 Service Manual Second Edition Section 7 Repair Procedures Platform Components 2 1 Platform How to Remove the Platform 1 Separate the foot switch quick disconnect plug 2 Supportthe platform support weldment with a appropriate lifting device 3 Open the platform control box and remove the platform control box mounting fasteners Then lower the control box and set it aside If your machine is equipped with an airline to platform option the airline must be disconnected from the platform before removal 4 Remove the platform mounting fasteners and remove the platform from the machine Crushing hazard The platform AWARNING may become unstable and fall if it is not properly supported 2 2 Platform Leveling Slave Cylinder
25. Install a 0 to 3000 Check for mechanical 0 to 207 bar pressure psi restrictions keeping gauge at u pann asus the funcion manifold OR repair or replace and activate the platform platform rotator OR rotate right function replace platform rotator counterbalance valve manifold OR consult Genie Industries Service less than 2600 psi Department Exchange platform function rotate regulator valve operates Replace defective flow item EE with a like regulator valve valve item U and activate the platform rotate right function function inoperative Consult Genie Industries Service Department 5 56 Genie 5 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Oscillate Function Inoperative Be sure all other function operate normally Remove the chassis cover at the non steer end Check the linkage for damage or improper linkage adjustment See Repair section 10 6 How to Set Up the Directional Valve Linkage Install a O to 2000 psi 0 to 138 bar pressure gauge at the quick disconnect coupling on the oscillate manifold Disconnect the oscillate linkage from non steer axle Start the engine and manually activate the directional valve Check the pressure Consult Genie Industries Service Department Chart 25 Re adjust or replace linkage Adjust the sequence valve See Repair procedure 10 5 How to Adjust
26. SE S LEFT o PLATFORM ROTATE w RIGHT GRN BLK 3 GRN 2 7 GRN 4 a 7 7 x GRN BLK PLATFORM ROTATE RIGHT GRN BLK 4 7 p E i is EES pua i jaw o a n 6 14 GROUND DRIVE ENABLE LIMIT SWITCH Genie S 40 BRAKE STEER RIGHT STEER LEFT BOOM UP LIMIT SWITCH Part No 52271 BOOM EXTEND LIMIT SWITCH TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL BOOM EXTEND BOOM RETRACT EXTEND RETRACT FLOW CONTROL PLAT LEVEL UP PLAT LEVEL DOWN CE PLATFORM LEVEL DISABLE OPTION PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT Section 6 Schematics Service Manual Second Edition SSM Ground Control Box Legend Diesel Models STACKED CONTACTS GRNWHT 4_ GRNWHT 1 45 GEN OPTION i H GAN BLK 1 44 SPARE i d GRN GR5__ GRN 1 43 HORN i ORG RED 1 42
27. TABLE B PROCEDURES 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 not the 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 plattorm 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 B 16 Check the Directional Valve Linkage Perform this test only on models equipped with a oscillating axle Proper axle oscillation is essential to safe machine operation If the 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 nut is tight against yoke Yoke clevis pins are installed Cotter pins are installed through clevis pins Linkage is properly attached to directional valve a directional valve b clevis pin with cotter pin hidden c yoke d lock nut Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Sch
28. clo NJO joja oo BI B g _ alo o n 454 Io N Ojo RIA 65 8 co ko INS telka 1 o io ep R on um R ue x en R I e pa ol p co a B 2 R slal e R hdd 5 157 214 210 285 420 570 62 Part No 52271 Genie S 40 2 9 Section 2 Specifications Service Manual Second Edition mm ee This page intentionally left blank 2 10 Genie S 40 Part No 52271 Service Manual Second Edition Section 3 Scheduled Maintenance Inspections Scheduled Maintenance Inspections Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly 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 damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years MI Machines that have been out of service for a period longer than 3 mo
29. BLK 2 OOO OPTION WIRE 2 WHT BLK RED 9 M JIB VALVE 19 GRN WHT 3 2 PLAT ROT 18 GRN BLK 3 i evo PLAT ROT L 17 GRN 3 PLAT LVL 16 ORG RED 3 BLK WHT 8 PLAT LVL DN 15 ORG BLK 3 BLK 7 PLAT LVL UP 14 ORG 3 Q 1 ENA LT 13 BLU RED 3 DRV 12 BLU WHT 3 x GRN BLK 18 SEC BOOM DN 11 BLU BLK 3 B SEC BOOM UP 10 BLU 3 RED 1 EXT RET F C 9 BLK RED 3 RETRACT 8 BLK WHT 3 gt 7 BLK 3 fu RED WHT 3 d TURN ROT 6 WHT RED 3 Os s TURN ROT R 5 WHT BLK 3 o TR TURN ROT L 4 WHT 3 RED BLK 2 EET PRIMARY F C 3 RED WHT 3 EE PRIMARY DN 2 RED BLK 3 bol PRIMARY UP 1 RED 3 WHT BLK 5 ni m mo 5 WHT 4 z hr 2 x v x S 1 2 3 4 5 6 7 8 9 to m A N mE 9 WHT RED 6 Zo C J Y 96 a OF z ORG RED 16 o gt W RED BLK 1 2 a 5 M ORG 14 e ES SE ORG BLK 15 O GRN 43 6 18 Genie S 40 Part No 52271 Section 6 Schematics Service Manual Second Edition O Part No 52271 Genie S 40 6 19 Service Manual Second Edition Section 6 Schematics Hydraulic Symbols Legend 2 Pressure gauge a Filter Fixed displacement pump 3 Bi directional variable displacement pump d Bi directional motor 2 2 speed bi directional mot
30. M Abbreviation Legend LABEL DESCRIPTION BAT Battery BP Proportional controller OB PORTEM Circuit breaker Control relay DP pcm Drive proportional controller FD oss Flashing beacon FS ood Foot switch CRA Gauge Horn Alarm Hour meter KS E Keyswitch Lada LED E Limit switch Po coach Power switch PR tees nis Power relay Resistor Terminal base location jer Terminal platform location MP Toggle switch Vacuum switch Part No 52271 Genie S 40 6 5 Section 6 Schematics Service Manual Second Edition _ ZL L LA 6 6 Genie S 40 Part No 52271 BLK RED 1 o 2 TP35 HIGH RPM ENGINE SPEED FUNCTION ENABLE 4 7 I I HIGH RPM R BLK RED i 4 CR4 HIGH IDLE RELAY TB35 CR4 o lt BLK REDHR4 EH BEU BLICE H GOVERNOR ACTUATOR RED WHT R3 E H H I4 o z c u gt o 5 9 Le dites E CR3 8 FLASHING BEACONS PRECISION GOVERNOR S RELAY H FUEL RELAY d FUEL RELAY RED WHT 23 E H RED BLK R6 E H CR6 CR7 CR3 VACH OFF GENERATOR ON GRN WHT 1 GRN WHT 45 E H GENERATOR OPTION TP45 TS20 TB45 TP39 TB39 BLU RED 1 BLU RED amp R7 E H p LPG SOLENOI
31. Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 18 Turntable Rotate Left Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop ON position move the function enable switch to either side and hold the turntable rotate toggle switch TS17 on ground panel in the left direction and check voltage on wht red wire on turntable rotate left right proportional valve coil item S 12V or more Continued on the next page buttons pulled out to the 0V Move the function enable switch to either side and hold the turntable rotate toggle switch TS17 on ground panel in the left direction and check voltage at TB6 oV With keyswitch in platform position and both Emergency Stop buttons pulled out to the on position activate footswitch and turntable rotate left right proportional controller BP 1 on platform control panel in the left direction and check voltage at TP6 oV Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department Repair open in wht red wire circuit from TB6 to turntable rotate left right proportional valve coil item S OR repair open in brown ground wire circuit to valve coil 4 to 6V Repair open in wht r
32. injury Remove all rings watches and other jewelry extend retract proportional controller turntable rotate proportional controller 6 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller 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 terminal D2 directional output terminal A proportional output terminal ground a b d terminal positive e terminal R activates max out range f terminal D1 directional output g rate adjustable trimpot h lorange adjustable trimpot i threshold adjustable trimpot j hi range adjustable trimpot Set the preliminary ramp rate Turn the trimpot adjustment screw counterclockwise 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 appears Adjust the voltage to 3 5V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Genie S 40 Part No 52271 Service Manual
33. torque in sequence first step 14 to 19 19 to 26 second step 35 to 50 47 to 68 Flywheel to crankshaft 54 to 64 73 to 87 bolt M 10 Intake manifold to 15 to 22 20 to 30 cylinder head bolt or nut M 8 Oil pressure sending unit to block 8 to 18 11 to 24 Oil pan drain plug to pan M 14 15 to 25 20 to 34 Part No 52271 Genie S 40 2 5 Section 2 Specifications SPECIFICATIONS Deutz Engine F3L 1011F Displacement Number of cylinders Bore and stroke Horsepower Firing order Compression ratio Compression pressure Low idle High idle Governor Valve clearance cold 125 cu in 2 05 liters 3 3 58 x 4 13 inches 91 x 105 mm 36 3000 rpm 1 2 3 18 5 1 362 to 435 psi 25 to 30 bar 1300 rpm 2300 rpm centrifugal mechanical Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure 26 to 87 psi 1 8 to 6 0 bar Oil capacity 8 5 quarts including filter 8 liters 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 SG or CD SG grades Units ship with 10W 40 SG CC Injection system Injection pump make OMAP Service Manual Second Edition Injection pump pressure 4351 psi 300 bar Injector opening pressure 3626 psi 250 bar Fuel requirement diesel number
34. 3 Drive the machine until one plug is at the top Turntable Rotate Torque Hub and the other is at 90 degrees 1 Secure the turntable from rotating with the turntable rotation lock pin 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole unlocked locked Apply pipe thread sealant to the plugs and then 2 Remove the motor brake mounting bolts and install the plugs then remove the motor and brake from the 5 Repeat steps 1 through 4 for all the other drive torque hub and set them to the side torque hubs Component damage hazard ____ eee ACAUTION Hoses can be damaged if they are Oil capacity per hub 17 fl oz kinked or pinched 0 5 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 motor brake mounting bolt motor torque hub torque hub mounting bolt plug brake 3 Remove the torque hub mounting bolts and then use a lifting device to 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 4 32 Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 5 Install the torque hub Torque the hub mounting bolts to 180 foot pounds 244 Newton meters Install the brake and motor onto the torque hub 7 Fill the hub with oil from the side hole until the oil level is ev
35. 5 WT RD E H 26 WT RD S P WATER TEMP SENDER i WT BK E H 26 WT BK S P OIL PRESSURE SENDER i WHT ISMH10__ WHT EH 24 WARNING SENDER i WHT E H WHT 2 28 WHT S P KEYSWITCH PWR BLK R5 30 BLK 2 22 BLK S P PWR TO PLAT i WHT R2487 WHT EH 21 WHT SP DB IGNITION PWR RED CR17 20 RED S P 12V BATT SUPPLY GRNWHT 3_ 19 JIB VALVE i GRNIBLK 4 GRN BLK 3__ _18 GR BK D B GR BK S P PLAT ROT R i GRN 4 GRN 3 17 GRN D B GRN S P PLAT ROT L i CABLE ORGRED 3 16 OG AD D B OG RD S P PLAT LEVEL DIS 1 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 WHT 5 BLUREDS 13 DRV ENA LT i WHT EH BLUWHT 3__ 12 BLK 5 DRV ENA i BLU BLK 3 11 BU BK D B BU BK S P SEC BOOM DN i BLU 3 10 BLU D B BLU S P SEC BOOM UP i BLK RED 4 BLKREDS 9 BKIRD S P BOOM EXT RET FC BLKWHT 4 BLKWHT3 8 BKWT D B BKIWT S P BOOM RETRACT BLK 3 7 BLK D B BLK S P BOOM EXTEND c WIR 4 WHT RED 3_ 6 WT RD S P TURN ROT FC i ABLE wres wenmucs 5 wrBkoDa WTIRD S P TURN ROT L 2 WHT 4 WHT 3 WHT D B WHT S P TURN ROT R i R 4 REDIWHT 3 3 RD WT S P PRI BOOM FC i RED BLK 4 RED BLK3 2 RD BK D S RD BK S P PRI BOOM DOWN RED 4 RED 3 RED D B RED SP PRI BOOM UP i D c B A DIODE BLOCKS i CABLE 3 1 START RELAY IGN START O
36. 87 on CR4 to 2 speed solenoid Check linkage or replace solenoid 5 24 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Low Idle Inoperative Deutz Diesel Models Check if mechanical linkage from 2 speed solenoid to fuel injection system is binding or defective At the platform controls start the engine and move the rpm select switch TS4 to maintained low idle turtle symbol Check voltage at blk red wire on rpm select switch Check voltage at the blk red wire on the 2 speed solenoid Check if 2 speed solenoid moves in and out 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 moves freely Chart 9 Isolate the platform and ground rpm switches TS4 and TS12 check individually and replace defective switch Replace relay solenoid binds Check linkage or replace solenoid Part No 52271 Genie S 40 5 25 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 10 Functions Inoperative Engine Starts and Runs Check hydraulic Fill with Dexron fluid level equivalent hydraulic fluid Check pump suction line closed shutoff valves In the with valves closed it open position
37. 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 fastener from the rod end pivot pin of the steer cylinder Remove the pin 3 Remove the cotter pin from the barrel end clevis pin of the steer cylinder then remove the pin Always use a new cotter pin when installing a clevis pin 4 Remove the steering cylinder from the machine Part No 52271 Genie S 40 7 61 Section 7 Repair Procedures Service Manual Second Edition January 2008 2WD STEERING AXLE COMPONENTS 12 3 Tie Rod How to Remove the Tie Rod 1 Remove the cotter pins from the clevis pins at each end of the tie rod then remove the clevis pins 2 Remove 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 3 Center a lifting jack of ample capacity under the steering axle then raise the machine 4 Loosen the jam nut on the adjustable end of the tie rod 5 Remove the pin retaining fasteners then remove the pivot pin from the adjustable end of the tie rod REV B 6 Slide the tie rod off the yoke and adjust it by turning the end One half turn on the adjustable end
38. Repair open in red wire terminal 30 on CR1 circuit from battery to CB1 to CR1 terminal 30 Hold the start switch to Check brown ground Repair open in brown either side and check wire to terminal 85 on ground wire circuit to voltage at terminal 87 CRI CRI on CR1 Replace CR1 relay Hold the start switch to Repair open in blk wire either side and check circuit from CR1 to voltage at the black wire starter solenoid on the starter solenoid Check voltage at starter cable Repair open in battery cable to starter Repair or replace starter or starter solenoid 5 4 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Cranks With the keyswiich os 1 turned to groun Over But Will OE ZA HV Not Start Emergency Stop buttons pulled out to the on Gasoline LPG position hold start switch to either side and Models check battery voltage while engine is cranking Be sure to check the engine oil level and fill as needed more than 11V Check if engine coolant temperature sending continuit Be sure to check fuel levels and engine coolant level unit signal post has continuity to ground Be sure the gasoline shut off valve is in the ON Or OPEN position Be sure that automatic choke is not sticking closed Perform following tests in gasoline mode only Be sure that the water temperature gauge does not show an
39. Second Edition pu SSS Se MANIFOLDS 9 13 Valve Adjustments 4WD Drive Manifold 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 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 charge pressure relief valve and remove the cap index 3 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 6 Restart the engine Drive the machine in either direction and recheck the valve pressure 7 Turn the engine off then remove the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 2 bar 7 54 Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures 10 1 Fuel and Hydraulic Tanks Fuel Tank How to Remove the Fuel Tank Explosion hazard Engine fuels are combustible Remove the fuel tank in an open well ventilated Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and deaerate the hydraulic fluid during operation It utilizes internal suction strainers for the pump supply lines and has an external return line filter with a filter condition indicator area away from heaters sparks
40. System Is Malfunctioning Be sure the boom is in the stowed position With keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position and the boom rotated between the non steer tires activate footswitch and drive controller in forward direction Will unit drive yes With keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position and the boom rotated between the steer end tires activate footswitch and drive controller in forward direction Will unit drive yes Check for continuity from TB30 to TB12 no continuity Repair open from TB30 through red wire to LS3 then from LS3 through blk wire to TB12 Section 5 Troubleshooting Flow Charts With keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and drive controller in forward direction and check voltage at terminal 2 on drive controller DP1 12V or more Repair open from terminal 4 on DP1 to center terminal on TS8 OR refer to Chart 28 OR consult Genie Industries Service Department Hold the drive enable switch TS8 to either side and activate the footswitch and drive forward function Will unit drive Repair open in blu wht wire from drive enable toggle switch TS8 to TP12 to TB12 OR replace drive enable toggle switch TS8 Activate limit switch by hand and check continuity from TB30 to TB12
41. attached to the correct spark plug Spark plug specifications Spark plug type Motorcraft AWSF 52C 0 042 to 0 046 inches 1 07 to 1 18 mm Spark plug gap Spark plug torque 5 to 10 foot pounds 7 to 14 Nm TABLE C PROCEDURES C 12 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 Engine fuels are combustible Perform this procedure an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach The engine rpm needs to be preset for 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 Part No 52271 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE C PROCEDURES 3 Load the system by activating the boom retract function then move the function enable toggle Switch to the high idle rabbit symbol position 4 Adjust the high idle adjustment screw to obtain an air to fuel mixture ratio o
42. blocks under the drive chassis for support 4 Remove the lug nuts then remove the tire and wheel assembly 5 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down O Result There should be no side to side or up and down movement Skip to step 10 if there is no movement 6 Remove the dust cap from the hub then remove the cotter pin from the castle nut 7 Tighten the castle nut to 35 foot pounds 47 Nm to seat the bearings 8 Loosen the castle nut then re tighten to 8 foot pounds 11 Nm 9 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down O Result If there is side to side or up and down movement proceed to step 10 to replace the wheel bearings with new ones When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced O Result If there is no side to side or up and down movement grease the wheel bearings 10 Remove the castle nut 11 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 12 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 13 Pack both bearings with clean fresh grease 14 Place the large inner bearing into the rear of the hub 15 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Always replac
43. damaged D 7 Check the Fuel Injection Pump and Injectors Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011F Workshop Manual Deutz number 0297 7195 Genie part number 52229 D 8 Check the Toothed Belt Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011F 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 LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 Part No 52271 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE D PROCEDURES D 10 Grease the Steer Axle Wheel Bearings 2WD Models Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Blockthe non steering wheels then center a lifting jack under the steer axle 3 Raise the machine 6 inches 15 cm and place
44. horsepower limiter board Electrocution hazard Contact AWARNING with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Platform control box a horsepower limiter board 3 Connect the black lead from a DC volt meter to the no 2 terminal and the red lead to the no 10 terminal L 12V DC or greater ground engine rpm sensor not used not used low drive speed limit switch not used not used not used output to drive controller 2 o 9 o o o o o o 0 R u a E E Horsepower limiter board a potentiometer maximum voltage output to 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 Switch activated high idle rabbit and foot switch symbol 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 10 5 to 11 5V DC 7 Move the engine idle control switch to low idle turtle symbol 8 Press down the foot switch and then adjust the C potentiometer to obtain a 0 01V DC to 0
45. 41 Nm Boom extend retract Boom extend retract circuit Boom extend Boom down Boom extend retract circuit prevents overflowing the proportional valve 10 12 ft Ibs 14 16 Nm 8 Flow regulator valve 1 5 5 7 L min H Boom up down circuit prevents overflowing the proportional valve 10 12 ft Ibs 14 16 Nm 9 Flow regulator valve 1 5 5 7 L min 1 Turntable rotate left right prevents overflowing the proportional valve 10 12 ft Ibs 14 16 Nm 10 Flow regulator valve 0 1 0 4 L min J Bleeds off differential sensing valve to tank 10 12 ft Ibs 14 16 Nm 11 Check Vale i 5 es Differential sensing circuit boom extend retract 11 13 ft Ibs 15 18 Nm 12 Orifice Plug 0 140 inch 3 6 mm Boom extend retract circuit 13 Solenoid valve N C Poppet M Boom extend retract 25 30 ft Ibs 34 41 Nm t4 Differential sensing circuit boom up down 11 13 ft Ibs 15 18 Nm Plug Torque Specifications Valve Coil Resistance Description Hex size Torque s Specifications SAE No 2 1 8 50 in Ibs 6 Nm 3 position 4 way directional valve 10V 2 to 50 SAE No 4 3 16 13 ft lbs 18 Nm schematic items
46. Also restricting air flow through the oil cooler will affect the performance of the cooling system Do not inspect while the engine AWARNING is running Remove the key to secure from operation ACAUTION Beware of hot engine components Contact with hot engine components may cause severe burns Oil Cooler 1 Remove the fasteners from the engine side cover then remove the cover 2 Inspect the oil cooler for leaks and physical damage Q N A t a cooler b cylinder head cooling fins c fan blower fins 3 Clean the oil cooler of debris and foreign material Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures TABLE B PROCEDURES Cooling and Fan Blower Fins 1 Deutz Diesel models Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access 5 Clean the fan blower fins of debris and foreign the exhaust system material 4 Inspect the fan blower fins for physical damage 6 Inspect the 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 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
47. BLU WHT 1 STEER LEFT 37 BLU BLK 1 BLUWHT 12 STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 O GLOW PLUG 34 BLK WHT 1 START 33 BLK 1 BRAKE 32 WHT RED 1 E D C 31 WHT BLK 1 E D C 30 WHT 1 2WD AWD 29 RED WHT 1 a O AUX PWR 27 RED 1 PWR TO FS 26 BLK FS PWR START 25 RED FS KE PWR CONT 24 WHT FS PWR FRM PLAT 23 WHT 2 REDHAT 5b PWR TO PLAT 22 BLK 2 000 21 20 fe BLK RED 9 gt gt JIB VALVE 19 GRN WHT 3 PLAT ROT R 18 GRN BLK 3 Ko PLAT ROT L 17 GRN 3 PLAT LVL 16 ORG RED 3 BLK WHT 8 PLAT LVL DN 15 ORG BLK 3 pues Rap PLAT LVL UP 14 ORG 3 DRV ENA LT 13 BLU RED 3 TE DRV ENA 12 BLU WHT 3 5 ES GRN BLK 18 SEC BOOM DN 11 BLU BLK 3 SEC BOOM UP 10 BLU 3 RED 1 EXT RET F C 9 BLK RED 3 fm RETRACT 8 BLK WHT 3 EXTEND 7 BLK 3 RED WHT 3 SWING F C 6 WHT RED 3 2x I SWING RIGHT 5 WHT BLK 3 o A X IR SWING LEFT WHT 3 BED BLK 42 T PRIMARY 3 RED WHT 3 uuu PRIMARY DN 2 RED BLK 3 ER 5 PRIMARY UP 1 RED 3 a WHT BLK 5 N hm n j 9 5 ZA WHT 4 P E y kEi e O 12 3 4 5 6 7 8 9 0 a w WHT RED 6 Y 9 5 ORG RED 16 o x RED BLK 1 X g a 0 ORG 14 9 Kz ORG BLK 15 RS O GRN 43 6 12 Genie S 40 Part No 52271
48. C 4 Grease rotation bearing C 5 Torque hub oil C 6 Hydraulic tank filter C 7 Drive loop hydraulic filter C 8 Fuel filter Deutz Diesel C 9 Fuel filter Gas LPG C 10 PCV valve Gas LPG C 11 Spark plugs Gas LPG C 12 Air LPG mixture C 13 Ignition timing Gas LPG C 14 Valves Deutz Diesel Checklist D YN R Refer to Table D D 1 Hydraulic oil D 2 Engine coolant Gas LPG D 3 Change fuel lines D 4 Valves Gas LPG D 5 Compression Gas LPG D 6 PCV hoses Gas LPG D 7 Fuel injection Diesel D 8 Toothed belt Diesel D 9 Timing belt Gas LPG D 10 Wheel bearings Part No 52271 Genie S 40 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition gt gt gt ZZL This page intentionally left blank 3 8 Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed 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 damaged or malfunctionin
49. Ford engine service manual for troubleshooting engine with weak spark OR consult Genie Industries Service Part No 52271 Genie S 40 5 7 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 2A Engine Cranks Over But Will Not Start Gasoline LPG Models or Engine Runs While Cranking Then Dies Perform these tests in gasoline mode only Hold the start switch to either side and check the voltage at the white wire on the choke while cranking the engine Check automatic choke for proper adjustment or internal damage good With keyswitch on and both Emergency Stop buttons pulled out to the ON position check voltage at red wht 23 wire on vacuum switch 12V Remove the blk wire with diode from terminal 86 CR3 hold the start switch to either side and crank the engine over for 15 seconds and check voltage at red blk wire on vacuum switch reconnect blk wire after test 12V With keyswitch on and both Emergency Stop buttons pulled out to the ON position disconnect wires from vacuum switch and connect the wires together Check the voltage at terminal 86 on CR6 12V Continued on the next page Repair open in white 21 wire circuit from the ignition coil plug to the automatic choke Adjust or replace automatic choke OR consult Genie Industries Service Department Repair open in red wht 23 wire circuit from TB23 to vacuum swi
50. Genie Industries Service Department Part No 52271 Genie S 40 5 65 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 30 Traction Any type of traction _ Function Ks Sona Inoperative AEP Be sure all other functions operate normally 5 66 Genie 5 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Machine Will Not Drive At Full Speed Be sure all other functions operate normally Be sure the machine is not raised above or extended beyond the drive limit switches Be sure the boom drive limit switch is clear of any debris and is not activated when the boom is in the stowed position Be sure that the boom extend drive limit switch arm is being activated when the boom is fully retracted Be sure the wiring to limit switches is intact and show no sign of damage or corrosion Be sure the free wheel valve is closed on the drive pump With the boom in the stowed position check continuity from TB40 to ground With the boom in the stowed position check terminal 6 on horsepower limiter board for continuity to ground Re adjust or replace horsepower limiter board OR check for misalignment of limit Switches LS1 and LS2 OR consult Genie Industries Service Department no continuity no continuity Chart 31 Repair short to ground in wht wires to limit switches LS1 and LS2 OR repair or replace b
51. Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures 7 2 Toggle Switches See 1 5 Toggle Switches 7 3 Wago Components How to Remove a Wago Component AWARNING Electrocution hazard 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 operator s manual storage box in the platform 1 Label the wiring from the component to be removed 2 Locate the removal tab on the bottom or top side of the component 3 Usea small narrow flat blade screwdriver to push in and release the wire from the component 4 Use the small narrow flat blade screwdriver to gently pry up on the tab of the component and remove it GROUND CONTROLS 7 4 Resistors How to Test the Resistor The resistor is used to maintain proper control of boom function speeds A 10 ohm resistor reduces voltage to all the boom function switches at the ground controls Refer to the schematic legends for resistor locations and values 1 Turn the key switch to the orr position 2 Disconnect either end of one of the wires connected to the resistor to be tested 3 Connectthe leads from an ohmmeter to each end or wiring of the resistor being tested 4 Compare the ohmmeter reading with the resistance rating printed on the res
52. Ground supression circuit 5 S LHM NC NO p LS3 s g Limit switch Ag NC 1 Limit switch normally closed held open VAC Vacuum switch O N 1590 Oil pressure switch normally closed Auxiliary pump 4 Water temperature switch normally open ON ISIM Foot switch PLAT KSI GRND Key switch HORN Horn button normally open P1 A Emergency Stop button normally closed Relay contact normally open Relay panel contactor CES RIES CDE EI Horsepower limiter board DP1 e oo Single axis drive controller LG LHM 3 Time delay relay TS3 am dz m Toggle switch SPDT 1 Naj Toggle switch DPDT JH9IH BP2 PWM X Single axis proportional controller O 1 START RELAY 2 TACHOMETER 3 START INPUT O 4 AUX ON O 5 GROUND 6 BATTERY KEY PWR 8 KEY BYPASS IGN FUEL ON 110 ENG FAULT Ignition start module BP1 pa ID A R 01 Dual axis Ramp up and down proportional controller Genie S 40 Part No 52271 Service Manual Second Edition Section 6 Schematics
53. LPG Models 6 9 Ground Control Box Wiring Diagram Gasoline LPG Models 6 10 Platform Control Box Legend Gasoline LPG Models 6 11 Platform Control Box Wiring Diagram Gasoline LPG Models 6 12 Electrical Schematic Deutz Diesel 0 6 13 Ground Control Box Legend Deutz Diesel Models 6 15 Ground Control Box Wiring Diagram Deutz Diesel Models 6 16 Platform Control Box Legend Deutz Diesel Models 6 17 Platform Control Box Wiring Diagram Deutz Diesel Models 6 18 Hydraulic Symbols 6 20 2WD Hydraulic Schematic Non oscillating axle 6 21 2WD Hydraulic Schematic Oscillating axle 6 22 4WD Hydraulic Schematic Oscillating 6 23 Part No 52271 Genie S 40 ix Service Manual Second Edition TABLE OF CONTENTS Section Seven Repair Procedures IniFOdUCIION EE 7 1 Platform Controls 1 1 Joystick 7 2 1 2 Horsepower Limiter emen 7 5 1 3 FOOL SWITH iieis Aenean tye einen Eye e yr iuge e poe dee 7 7 1 4 R
54. LT WHTEH BLUMHTS 12 DAV ENA BLU BLK 3 11 BU BKD B BUBKSP BOOM DN j TS17 i BLU S 10 BLU D B BLU S P SEC BOOM UP i TS11 TS10 H BLK RED 4_ BLK RED 3 9 BK RD S P BOOM EXT RET i i BLKWHT 4_ BLKWHT 3 8 BKWTD B BKWT S P BOOM RETRACT i eres BKSP BOOM EXTEND WRA WHT RED 3 6 WT RD S P TURN ROT FC i CABLE TS14 2 j wra wira 4 TURN ROT R RIW 4 RED WHT 3 3 RD WT S P PRI BOOM FC i TS12 CB1 CB2 7513 REDBLK4 RED BLK 3 2 RD BKD B RD BK S P PRI BOOM DOWN i RED 4 RED 3 1 RED D B RED S P PRI BOOM UP i uj UJ D C B A L7 DIODE i H BLOCKS i H CABLE i 3 i O 1 sTanrnEtay 2 TACHOMETER IGN START H START INPUT MODULE i i O 4 Aux on i m 5 GROUND i i 6 sarrenv i A i 7 KEY PWR i CABLE Q DISABLE 4 O KEY BYPASS LEVEI H O IGN FUELON i CR19 10 EnG LABEL DESCRIPTION i CR1 CR2 CR3 CR4 i P1 EMERGENCY STOP BUTTON i START FUEL RPM RPM i KS1 KEY SWITCH CR18 H RELAY RELAY CUTOUT RELAY i H RELAY i 759 AUXILIARY SWITCH cm i 7510 ENGINE START SWITCH DISABLE i i 7611 ENGINE GLOW PLUG OPTION H l i TS12 FUNCTION ENABLE H l i 7813 PLATFORM ROTATE SWITCH H 7814 PLATFORM LEVEL SWITCH i 7815 B
55. OR repair open in grn wire circuit from TS13 and TS5 to TB17 OR consult Genie Industries Service Department Part No 52271 Genie S 40 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 23 0 or infinite ohms Disconnect the wires from the platform rotate left directional valve coil Continued from the previous page item CC and test the resistance of the valve coil 610 7 ohms function Exchange platform operates rotate left and right directional valves items CC and DD and activate the platform rotate left function function inoperative function Exchange platform operates rotate left and right counterbalance valves at the counterbalance valve manifold and activate the platform rotate left function function inoperative Install a 0 to 3000 0 to 207 bar pressure gauge at the quick disconnect coupling on the function manifold and activate the platform rotate left function 2600 psi or more less than 2600 psi function Exchange platform operates rotate regulator valve item EE with a like valve item U and activate the platform rotate left function function inoperative Consult Genie Industries Service Department Replace the platform rotate left directional valve coil item CC Replace the defective directional valve Replace the defective counterbalance valve Check for mechanical restri
56. PSI Repair or replace the master cylinder 2000 PSI or more Repair or replace the slave cylinder 5 48 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Level Up Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the platform level toggle switch TS14 in the up direction and check the voltage at org wire on platform level up function directional valve item T 12V or more Continued on the next page With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the on position move the function enable switch to either side and activate the platform level toggle switch TS14 in the up direction and check the voltage at TB14 With the keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate the footswitch and the platform level toggle switch TS6 in the up direction and check the voltage at TB14 Troubleshoot platform level toggle switch TS14 on ground control panel OR repair open in red power wire circuit to TS14 OR repair open org wire circuit from TS14 to TB14 OR consult Genie Industries Service Department 12V or more C
57. Repair Procedures Service Manual Second Edition BOOM COMPONENTS 3 2 Boom How to Shim the Boom 1 Measure each upper and side wear pad Replace the pad if it is less than 9 16 inch 14 3 mm thick If the pad is more than 9 16 inch 14 3 mm thick perform the following procedure 2 Measure the bottom wear pad Replace the pad if it is less than 11 16 inch 17 5 mm thick If the pad is more than 11 16 inch 17 5 mm thick perform the following procedure 3 Extend the boom until the wear pads are accessible 4 Loosen the wear pad mounting fasteners Install the new shims under the wear pad to obtain zero clearance and zero drag 6 Tighten the mounting fasteners 7 Extend and retract the boom through an entire cycle Check for tight spots that may cause binding or scraping of the boom Always maintain squareness between the outer and inner boom tubes How to Remove the Boom AWARNING his procedure requires specific 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fittin
58. STARTINPUT MODULE O 4 5 GROUND BATTERY O key Pwr i KEY BYPASS i O 9 IGNFUEL i 10 ENG FAULT i CR1 CR2 CR3 CR4 i START IGNTION RPM RPM RELAY RELAY CUTOUT RELAY i RELAY i CR5 CR6 CR7 HORN FUEL FUEL i RELAY CUTOUT CUTOUT RELAY RELAY 52271 Genie 5 40 Section 6 Schematics Service Manual Second Edition S MM Ground Control Box Wiring Diagram Gasoline LPG Models STACKED CONTACTS O
59. TABLES Warm Cold Dealer engine engine service required required suggested C 1 Check the Boom Wear Pads C 2 Check the Turntable Rotation Bearing Bolts C 3 Check the Free wheel Configuration C 4 Grease the Turntable Rotation Bearing and Rotate Gear 5 Replace the Torque Hub Oil ov C 6 Replace the Hydraulic Tank Filter Is C 7 Replace the Drive Loop Hydraulic Filter C 8 Replace the Diesel Fuel Filter Water Separator Deutz Diesel Models C 9 Replace the Gasoline Fuel Filter Gasoline LPG Models ov C 10 Replace the PCV Valve Gasoline LPG Models C 11 Replace the Spark Plugs Gasoline LPG Models EEEEHEEHEE C 12 Check and Adjust the Air LPG Mixture Gasoline LPG Models C 13 and Adjust the Ignition Timing Gasoline LPG Models EJ C 14 Check the Engine Valve Clearances Deutz Diesel Models ra ra ra ra ra ra ra ra ra PA ra ra aad Part No 52271 Genie S 40 Section 3 Scheduled Maintenance Inspections Service Manual Second 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 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 Che
60. The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of boom motion It operates in a closed circuit hydraulic loop with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling Slave Cylinder Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Extend the boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the boom slightly and place blocks under the platform 3 Lower the boom until the platform is resting on the blocks just enough to support the platform Do not rest the entire weight of the boom on the blocks Part No 52271 Genie S 40 7 9 Section 7 Repair Procedures Service Manual Second Edition PLATFORM COMPONENTS 4 Tag disconnect and plug the hydraulic hoses from the slave cylinder at the union located near the platform rotate counterbalance valve manifold and connect them together using a connector Cap the fittings on the cylinder AWARNING Bodily injury hazard Spray
61. ana Rear turn the engine off Tire size 12 5 16 SL 12 16 5 NHS 5 Inspect the following areas for burnt chafed Pressure 45 psi 45 psi corroded pinched and loose wires 3 1 bar 3 1 bar Cable track on the boom Tire ply rating 12 8 Boom to platform cable harness Wheel luge 8 5 s 18 9 5 s 18 Inside of the platform control box Lug nut torque dry 170 ft Ibs 170 ft Ibs Boom cable cover 230 Nm 230 Nm Lug nut torque lubricated 130 ft Ibs 130 ft Ibs 176 Nm 176 Nm Part No 52271 Genie S 40 4 17 Section 4 Scheduled Maintenance Procedures Service Manual Second 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 j brake disengage position uj x mj p ES brake engage position 2 Besure the free wheel valve on the drive pump is closed clockwise The free wheel valve is located on the bottom of the drive pump a drive pump b free wheel valve c lift pump d screwdriver 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 machi
62. and then release it Move the drive control handle off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction B 26 Perform Hydraulic Oil Analysis See D 1 Test or Replace the Hyaraulic Oil 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 Beware of hot engine parts and oil ACAUTION Contact with hot engine oil and or engine parts may cause severe burns 1 Remove the oil filler cap located above the dipstick Part No 52271 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 2 Pullthe end of the drain hose out from under the engine 3 Remove the plug from the end of the drain hose and allow al
63. 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 crank the engine with the low oil pressure light on Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures 0 rn FORD LRG 423 ENGINE 6 8 Vacuum Switch How to Test the Vacuum Switch ohmmeter common terminal SOL vacuum switch normally open terminal ING 1 Connect the leads from an ohmmeter continuity tester to the common and normally open terminals Result There should be no continuity infinite Q 2 Apply mild suction to the vacuum port Result The switch should close and show full continuity zero Component damage hazard ACAUTION Do not short the vacuum switch terminals to ground Part No 52271 Genie S 40 7 25 Section 7 Repair Procedures Service Manual Second Edition Ground Controls 7 1 Control Relays Relays
64. at TP3 oV Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department Chart 15 Repair open in red wht wire circuit from TB3 to boom up down proportional valve coil item P OR repair open in brown ground wire circuit to valve coil Repair open in power supply circuit from TP24 to BP1 OR repair open Repair open in red wht wire from TP3 to TB3 in brown ground wire circuit from ground to Part 52271 Genie S 40 Section 5 Troubleshooting Flow Charts m CHART 15 Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom down toggle switch TS16 on ground panel in down direction and check voltage on red blk 42 wire on boom function directional valve coil item B 20V or more Continued on the next page Service Manual Second Edition Move the function enable switch to either side and hold the boom down toggle switch TS16 on ground panel in down direction and check voltage at TB2 With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and boom function controller BP1 on platform control panel in down
65. be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate Genie S 40 Operator s Manual Be sure that all necessary tools and parts are available and ready for use MI Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions MI 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 Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order General Repair Process Malfunction Identify Troubleshoot
66. circuit from battery to CB1 to CR1 to CR2 Hold the start switch to either side and check 12V voltage at terminal 9 on the ignition start module oV Check voltage at terminal 6 and 7 on ignition start module 12V Check continuity from ground to brown wire at continuity terminal 5 on ignition start module continuity Replace the ignition start module OR consult Genie Industries Service Department Repair open in brown ground wire circuit to CR2 CHART 3 Repair open in blk wire from terminal 86 on CR2 to terminal 9 on the ignition start module Repair open in power supply wires to terminal 6 and 7 on ignition start module Repair open in brown ground wire circuit to terminal 5 on ignition start module Part No 52271 Genie S 40 5 13 Section 5 Troubleshooting Flow Charts CHART 3 Crank engine and check gy voltage at terminal 2 on ignition start module Continued from the previous page 610 7V While cranking engine for 15 seconds check continuity to ground on yes terminal 10 on ignition start module Is continuity maintained no Check voltage at 12V terminal 4 on ignition start module oV Replace ignition start module OR consult Genie Industries Service Department Service Manual Second Edition 1 Crank engine and check ov voltage at org blk 41 wire on alternator 610 7V Repai
67. cover at the steer end Remove the cover Part No 52271 Genie S 40 7 65 Section 7 Repair Procedures Service Manual Second Edition January 2008 Non steering Axle Components 15 1 Drive Motor How to Remove a Drive Motor Component damage hazard ACAUTION Repairs to the motor should only be performed by an authorized Sundstrand Sauer dealer 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the fasteners from cover on the non steer axle Remove the cover 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor 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 REV B 3 Remove the drive motor mounting fasteners 4 Slide the drive motor shaft out of the brake and then remove the drive motor from the machine Torque specifications 75 ft Ibs 102 Nm Drive m
68. direction and check voltage TB2 Activate footswitch and boom function controller BP1 on platform control panel in down direction and check voltage TP2 oV Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more Repair open in red blk 2 wire circuit from TB2 to boom down function directional valve coil item B OR repair open in brown ground wire circuit to valve coil Troubleshoot boom down function toggle switch TS16 on ground control panel OR repair open in red blk 2 wire circuit from TS16 to TB2 OR consult Genie Industries Service Department Repair open in red blk wire from TP2 to TB2 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to 5 34 Genie 5 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Z Disconnect wires to 0 ar boom down directional infinite valve coil item B and ohms joe eel RM test the resistance of the te m B valve coil See Repair Section Continued from the previous page 2 5 to 3 5 ohms function Move function enable operates switch to either side and hold the boom down toggle switch at
69. directional valve gauge at the quick ae Exchange flow regulator function disconnect coupling more valve item with a like operates Replace defective flow the boom function valve item H Check regulator valve manifold and start the turntable rotate left engine Move the function function enable switch to either side and hold the T turntable rotate left function inoperative toggle switch at the ground controls in the Repair turntable rotation left direction and check motor OR function the pressure manifold may have an internal defect Consult Genie Industries Service Department less than 2600 PSI Continued on the next page 5 42 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts E CHART 18 Plumb a 0 to 5000 psi lessthan Function manifold could 0 to 345 bar pressure 250 psi have an internal defect gauge into the hose Consult Genie Industries from the function Service Department manifold to the turntable rotation brake Move the function enable switch to either side and activate the turntable rotate left function Continued from the previous page 250 psi or more Exchange turntable rotate left and right function counterbalance valves Operates items JJ and KK Activate turntable rotate left function Replace defective counterbalance valve function inoperative Check for mechanical
70. equals approximately 1 4 inch 6 4 mm change in the front and rear measurements 7 Slide the tie rod onto the yoke Install the pivot pin then install the retaining bolt 8 Tighten the jam nut against the tie rod 9 Lower the machine and recheck the front and back measurements step 2 If further adjustment is needed repeat steps 3 through 8 Toe in specification 0 1 8 inch 6 35 mm 7 62 Genie S 40 Part No 52271 Service Manual Second Edition January 2008 Section 7 Repair Procedures 4WD Steering Axle Components REV B 13 1 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittngs on the Yoke and Hub drive motor Bodily injury hazard Spraying How to Remove the Yoke AWARNING hydraulic oil can penetrate and and Hub burn skin Loosen hydraulic 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 3 Loosen the wheel lug nuts Do not When removing a hose assembly remove them or fitting the O ring on the fitting and or hose end must be replaced 4 Block the non steering wheels and then and then torqued to specification center a lifting jack of ample capacity under the during installation steering axle aa 19 22 Ex PORCJE 5 Raise the machine 6 inche
71. machine will travel Result The drive function should operate 5 Rotate the turntable to the left until the boom is past the left non steering wheel O Result The drive enable indicator light should come on 6 Repeat steps and 4 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 Be sure that the machine is not in AWARNING 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 Marka test line on the ground for reference 2 Startthe engine from the platform controls Part No 52271 Genie S 40 4 25 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 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 point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 5 Bring the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the ma
72. metal drift to remove the pin 6 Remove the turntable end cover BOOM COMPONENTS 7 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Remove the barrel end pivot pin retaining fasteners 9 Place a rod through the barrel end pivot pin and twist to remove the pin 10 Support and slide the extension cylinder out of the pivot end of the boom Crushing hazard The extension AWARNING cylinder will fall when it is removed from the extension boom if it is not properly supported Note the length of the cylinder after removal The cylinder must be at the same length for installation Part No 52271 Genie S 40 Section 7 Repair Procedures Service Manual Second Edition BOOM COMPONENTS 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 located at the base of the boom How to Remove the Platform Leveling Master Cylinder When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification d
73. mounting bolts dry 120 ft lbs 163 Nm lubricated 90 ft lbs 122 Nm Drive motor mounting bolts dry 75 ft lbs 102 Nm lubricated 56 ft lbs 76 Nm Part No 52271 Genie S 40 7 67 Distributed By E Genie North America 18340 NE 76th Street P O Box 97030 Redmond Washington 98073 9730 Genie Europe Brunel Drive Newark Nottinghamshire NG24 2EG England
74. on the horsepower limiter circuit board 12V or more Activate the footswitch and hold the drive joystick in the full forward position and check the voltage at terminal 10 on the horsepower limiter board 9to 12V Continued on the next page Check continuity of Repair open in power brown ground wire from continuity supply circuit from TP24 terminal 3 on DP1 to to terminal 2 on drive ground joystick DP1 no continuity Repair open in brown ground wire circuit from ground to DP1 Check continuity of brown ground wire from terminal 2 on the horsepower limiter circui board to ground Repair open in power supply circuit from TP24 continuit to terminal 1 on the horsepower limiter circuit board no continuity Repair open in brown ground wire circuit from ground to terminal 2 on the horsepower limiter circuit board Activate the footswitch 7 to 8V Replace horsepower and check the voltage at limiter board terminal 3 on the horsepower limiter board Activate the footswitch and check the voltage on the org blk 4 1wire on the alterator Repair open in org blk 7108V 41 wire from alternator to TB41 to TP41 to terminal 3 on horsepower limiter board oV Repair or replace alternator 5 62 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Activate the footswitch and hold the dr
75. 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 cLosED position 2 Remove the fuel filter with a filter wrench oil filter fuel filter water separator Prime the fuel pump 3 Fill the new filter Genie part no 29560 with fresh diesel fuel and apply a thin layer of oil or diesel fuel to the new fuel filter gasket 4 Install the new filter 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 oPEN position 6 Startthe engine from the ground controls then inspect the fuel filter for leaks If a fuel leak is discovered keep ADANGER any additional personnel 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 that the filter be replaced more often Engine fuels are combustible ADANGER Replace the fuel filter in an open well ventilated area aw
76. overheated condition no continuity good spark Remove 1 spark plug and ground spark plug body Crank engine and observe spark weak or no spark 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 radiator and or hot engine block feels excessively hot not hot Remove wht wire from temperature sending unit check continuity to ground on temperature sending unit no continuity Remove wht wire from TB24 and check continuity to ground no continuity Repair short in wht wire circuit from terminal 10 on ignition start module to TB24 OR consult Genie Industries Service Department Go to Chart 2A continuit continuit Chart 2 Check engine coolant level OR check radiator fins for clogging OR check engine fan belts OR see Ford service manual for troubleshooting an overheating engine Replace temperature switch sender Repair short in wht wire circuit from TB24 to temperature sender Part No 52271 Genie S 40 Section 5 Troubleshooting Flow Charts E CHART 2 Continued from the previous page Disable starter by removing blk wire atthe 12V starter solenoid hold the start switch to either side and check voltage at the white wire on the ignition coil plug less than 12V Hold the start switch to 12V either sid
77. red wht wire on electronic governor 12V Check voltage at terminal 1 red wht wire on governor actuator 12V Check continuity fom terminal 6 on precision continuit governor to blu blk terminal 42 on governor actuator full continuity Continued on the next page Repair open in wht wire circuit from CR2 terminal 487 to CR3 30 Repair open in rd blk R6 wire circuit from vacuum switch to CR6 to CR7 to terminal 86 on CR3 Repair open in ground wire to terminal 85 on CR3 Replace relay Repair open in red wht wire circuit from terminal 87 CR3 to terminal 1 on electronic governor Repair open in red wht wire circuit from electronic governor terminal 5 to governor actuator terminal 1 Repair open in blu blk wire circuit from governor actuator to electronic governor 5 20 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts E CHART 6 Check voltage on red Repair open in red wht wht wire on governor wire from governor actuator controller to governor actuator Continued from the previous page Turn machine off 0 or remove both wires infinite from governor actuator ohms and check resistance across governor actuator terminals Replace governor actuator 210 3 ohms Reconnect governor Repair open in brown wires and restart engine OV wir
78. rotation specifications PLATFORM CONTROLS 1 2 Horsepower Limiter Board The horsepower 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 Threshold 3 5V DC du drive resistance rough terrain or incline and Turntable rotation decreases voltage to the drive controller which in hi range boom retracted 5 BV DC turn decreases voltage to the drive pump thereby Cycle time 80 to 100 seconds reducing pump output to maintain optimum engine lo range boom extended 4 5V DC rpm and horsepower Three adjustments are Cycle time 130 to 160 seconds required for optimum performance Ramp rate 5seconds How to Adjust the Horsepower Limiter Board The engine rpm 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 Part No 52271 Genie S 40 7 5 Section 7 Repair Procedures Service Manual Second Edition PLATFORM CONTROLS 2 Open the control box lid and locate the 5 Move the engine idle control switch to foot
79. side and hold the boom up toggle switch at the ground controls in the up direction and check the pressure less than 2500 PSI Exchange flow regulator function valve item H with a like operates valve item G Check boom up function Replace defective flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal defect Consult Genie Industries Service Department 5 32 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Boom Down Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom down toggle switch TS16 on ground panel in down direction and check voltage on red wht wire on boom up down proportional valve coil item P 20V or more Continued on the next page Move the function enable switch to either side and hold the boom down toggle switch AA TS16 on ground panel in the down direction and check voltage at TB3 With the keyswitch in 610 7V the platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and boom function controller BP 1 on platform control panel in down direction and check voltage
80. t8Hom Refer to Table A B 19 Foot switch A 1 Manuals B 20 Engine idle select A 2 Decals and placards B 21 Fuel select Gas LPG A 3 Damage loose or missing parts A 4 Engine oil level A 5 Engine coolant Gas LPG A 6 Fuel leaks 7 Hydraulic oil level A 8 Hydraulic leaks A 9 Tire pressure A 10 Oscillate axle A 11 Platform and ground controls A 12 Auxiliary power A 13 Tilt sensor A 14 Limit switches Perform every 100 hours A 15 Replace engine oil and filter Gas LPG Models A 16 Drain filter separator Deutz Diesel A 17 Replace air filter Checklist B Refer to Table B B 1 Engine belt B 2 Engine radiator Gas LP B 3 Oil cooler and fins Diesel B 4 Exhaust system B 5 Battery B 6 Hydraulic tank filter B 7 Electrical wiring B 8 Tires and wheels B 9 Brake configuration B 10 Torque hub oil level B 11 Idle mixture Gas LPG B 12 Engine RPM B 13 Key switch B 14 Emergency Stop B 15 Ground control override B 16 Directional valve B 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 someone engine oil someone filter Deutz Diesel Checklist C Y NR Refer to Table C C 1 Boom wear pads C 2 Turntable bearing bolts C 3 Free wheel configuration
81. the plugs Turntable rotate torque hub Capacity 8 fluid ounces 0 24 liters 2 Remove the motor brake mounting bolts and then remove the motor and brake from the Type SAE 90 multipurpose hypoid gear oil API service classification GL5 torque hub and set them to the side Component damage hazard ACAUTION Hoses can be damaged if they are kinked or pinched motor brake mounting bolt motor torque hub torque hub mounting bolt plug brake 3 Remove the torque hub mounting bolts and then use a lifting device to remove the torque hub from the machine Part No 52271 Genie S 40 Section 7 Repair Procedures Service Manual Second Edition January 2008 2WD Steering Axle Components 12 1 Yoke and Hub How to Remove the Yoke and Hub 1 Remove pin retaining fastener from the steering cylinder rod end pivot pin and remove the cotter pin from the tie rod clevis pin Remove the pins Always use a new cotter pin when installing a clevis pin tie rod axle yoke pivot pin yoke hub pivot pin g steering cylinder 2 Loosen the wheel lug nuts Do not remove them Block the non steering wheels and then center a lifting jack of ample capacity under the steering axle 4 Raise the machine 6 inches 15 cm and place REV B blocks under the chassis for support 5 Remove the lug nuts Then remove the tire and wheel asse
82. the valve may have damaged one handles should be or both pumps Please parallel with hose contact the Genie Industries Service Department Do the pumps feel If engine has been run excessively hot Open valves and start the engine Check all machine functions for correct operation Disconnect ignition coil Troubleshoot connector plug from inoperative boom ignition coils On Deutz functions and diesel models hold inoperative drive manual fuel shutoff lever functions separately to the closed position clockwise 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 15 defective OR main pump is defective Consult Genie Industries Service Department 5 26 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts 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 Install a 0 to 5000 PSI 345 bar pressure gauge on the function manifold Start engine move the function enable toggle switch to either side and hold the boom retract function t
83. to check LPG fuel level Disconnect LPG supply line from LPG tank and bleed pressure from line With keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the ON position crank engine and check voltage at LPG side blu red wire of fuel select switch TS11 12V With keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the ON position crank engine and check voltage at TB39 12V With keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the on position crank engine and check voltage at terminal 30 on CH7 12V Crank engine for 15 seconds and check voltage at terminal 86 on CR7 12V Check continuity from bad ground to brown wire on terminal 485 on CR7 good Continued on the next page Chart 4 Replace fuel select switch Repair open in blu red wire circuit from fuel select switch 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 brown ground wire circuit to terminal 85 on CR7 Part No 52271 Genie S 40 5 15 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 4 Hold the start switch to either side and check voltage at terminal 87 on CR7 Continued from the Replace CR7 relay previous page Hol
84. when it is removed from the boom tube if it is not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 6 Remove the external snap rings from the extension cylinder rod end pivot pin at the platform end of the extension tube Use a soft metal drift to remove the pin Part No 52271 Genie S 40 Section 7 Repair Procedures Service Manual Second Edition BOOM COMPONENTS 7 Support and slide the extension cylinder out of the base end of the extension tube Place the extension cylinder on blocks for support Crushing hazard The extension AWARNING cylinder may become unbalanced and fall when it is removed from the number 3 boom tube if it is not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 8 Remove and label the wear pads from the extension cylinder 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and the
85. 0 ft 7 8 sec 40 9 1 sec fully stowed 70 to 110 seconds 12 2 m 7 8 sec12 2 m 9 1 sec Platform rotate 160 8 to 20 seconds Drive speed 0 6 mph 0 6 mph raised or extended 1 km h 1km h Platform level up 25 to 50 seconds all models 40 ft 40 sec 40 ft 40 sec 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 S 40 Part No 52271 Service Manual Second Edition Section 2 Specifications Hydraulic Specifications Hydraulic fluid Dexron equivalent Drive pump Type bi directional variable displacement piston pump Displacement 2500 rpm 0 to 31 6 gallons per minute 0 to 119 6 liters per minute Maximum drive pressure 3500 psi 241 3 bar Charge pressure neutral position 290 psi 20 bar drive position 250 psi 17 bar Medium pressure filter 3 micron Medium pressure filter 50 psi bypass pressure 3 4 bar Drive manifold Brake 250 psi relief pressure 17 2 bar Steer end drive motors 4WD models 4WD front motor flow regulators 2 5 to 8 gallons per minute 9 4 to 30 2 liters per minute 4WD rear motor flow regulators 5 to 15 gallons per minute 18 9 to 56 7 liters per minute 2WD rear motor 8 to 22 gallons per minute SPECIFICATIONS Function pump Type pressure balanced gear 1 14 cu in 19 cc Displacement static Displacement 2500 rpm 0 to 12 3 gallons per minute to
86. 000 4 19 B 13 Test the Key 04 4 21 B 14 Test the Emergency Stop Switches 2 4 21 B 15 Test the Ground Control 4 22 B 16 Check the Directional Valve 4 22 B 17 Test the Platform Self leveling aaa aaa 4 23 B 18 Test the 0 4 23 B 19 Test the Foot Switch 04 22 21 000 nennen nennen 4 23 B 20 Test the Engine Idle aaa aaa anawa aan 4 24 B 21 Test the Fuel Select Operation Gasoline LPG Models 4 24 B 22 Test the Drive Enable 4 25 vi Genie S 40 Part No 52271 Service Manual Second Edition Section Four TABLE OF CONTENTS Scheduled Maintenance Procedures continued B 23 Test the Drive Brakes nnne 4 25 B 24 Test the Drive Speed Stowed 4 26 B 25 Test the Alarm Package Optional 4 27 B 26 Perform Hydraulic Oil Analysis 4 27 B 27 Replace the Engine Oil and Filter Deutz Diesel Models 4 27 C 1 Check the Boom Wear 4 29 C 2 Check the Turntable Rotation Bearing B
87. 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 position 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 horizontal 14 Drive the machine for 40 feet 12 m and record the elapsed time Repeat this step in the opposite drive direction Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures mnmmm I PLATFORM CONTROLS 15 Adjust the B potentiometer to obtain the 2 Do not press down the foot switch Connect the correct raised drive speed of 1 foot per second leads from an ohmmeter or continuity tester to 0 31 m per second Turn the B each wire combination listed below and check potentiometer counterclockwise to increase for continuity volt r clockwise t r volt S
88. 0789 VDO ineat 392 502 x4 etii anat 1 Gauge Oil Pressure 30786 VDO ER 950 5190 entere 1 GS iius Gauge Water Temp 30787 VDO 910 502 ix 1 TAA Alarm Warble tone 19270 Floyd Bell Inc MW 09 616 Q 1 H2 scite Horn 12V DC 130 dB 19145 Sparton Engineered Prod 7431 24823 5 1 Alarm intermittent 18963 Floyd Bell Inc XB 09 630 Q 1 unes Alarm chime tone 45462 Floyd Bell Inc CH 09 525 Q 1 19506 ENM Corporation T40A4508 1 K91 Contact Keyswitch N O 45081 Telemecanique ZB2 BE101 2 LED Red 12V DC 32335 Arctolectric Corp LE177C39007 1 LS1 2 3 Contact Limit switch NCH O S 19491 Telemecanique XESP2051 3 Level sensor Level sensor 4 5 44586 Power Comp of Midwest LS36 1 P1 P2
89. 1 Close the manual fuel shutoff valve located next to the fuel tank 2 Remove and replace the fuel line hoses and clamps according to the following illustrations Fuel may be expelled under ADANGER pressure Wrap cloth around fuel hoses to absorb leaking fuel before disconnecting them TABLE D PROCEDURES 1 CG li 3 zl 2 ELA ZA 2 Q Fil O 9 Deutz Diesel models 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 X 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 52271 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE D PROCEDURES 3 Clean up any fuel that may have spilled during Gasoline LPG a carburetor b fuel filter c hose from the fuel filter to the fuel pump d hose from the fuel pump to the fuel tank not shown this procedure 4 Start the engine from the ground controls then inspect the fuel filter and hoses for leaks ADANGER If a fuel leak is discovered keep 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
90. 1424 Non Oscillating Axle REAR RIGHT REAR LEFT Service Manual Section 6 Schematics BE Eccc 2WD Hydraulic Schematic after serial number 1423 Non Oscillating Axle K J G F E D C B A BOOM SLAVE UP DOWN PRIMARY ET je 4 1 TURNTABLE ROTATE icc AD ANNUS VU eL pomme EL a 90 Ted irn jog 5 1 0030 lt 02 EN Ecce OF Eie d MASTER sz J PLATFORM TURNTABLE 0 025 LEVEL ROTATE OOM BOOM ES RR P si eileen EXTEND __ RETRACT ee RW OPTIONAL FUNCTION 2 9 s 7 gt Eur 4 Psi I i RM MOTOR GEN MANIFOLD d
91. 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 25 rate 200 minutes Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Bolt tightening specifications torque torque Bolt description size grade ft lbs Nm Camshaft thrust bearing bolt 15 to 18 20 to 24 M 8 x 35 8 8 Rocker arm bolts 15 to 18 20 to 24 M 8 x 45 8 8 Rocker arm set screw nut 15 to 18 20 to 24 Cylinder head cover 6 to 7 8 to 10 Blower rotor nut 33 to 41 45 to 55 M 17 Valeo or M 18 Bosch Blower carrier bolts 15 to 18 20 to 24 M 8 x 50 Torx 8 8 V belt pulley bolts 28 to 34 38 to 46 M 10 x 16 8 8 Genie S 40 Part No 52271 Service Manual Second Edition Section 2 Specifications T SPECIFICATIONS Bolt tightening specifications continued torque torque ft lbs Nm torque torque Bolt description size grade ft lbs Nm Oil thermostat housing screw 371044 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 41to4g M 6x35 Torx 8 8 M 10 x 50 8 8 Oil thermostat housing bolts 5 5 to 7 7 5 to 9 O
92. 3 H1 TP28 TB28 1 i RED BLK 1 RED BLK 28 E H LEVEL SENSOR I I WHT 2 RED WHT 23 E H L 1 TP23 x TB23 CR5 GRN 1 GRN n SERVICE HORN J RELAY TB22 TB43 CR5 NO BLK 2 BLK R5 E H TP22 Service Manual SERVICE HORN OTS1 o WHT Z WHT R17 E H n HYDRAULIC OIL J TEMP SWITCH R LL Eg KS1 PLAT GRND COOLING FAN I OPTION RED WHT 21 E H RED E H P1 500 _ TB41 ORG BLK 1 ORG BLK 41 E H Electrical Schematic Gasoline LPG Models Section 6 Schematics CB2 FUSE 25 AMP ALTERNATOR RED o a RED RED 20 E H Part No 52271 Genie S 40 6 7 Section 6 Schematics Electrical Schematic Gasoline LPG Models Service Manual CN LO N
93. 3 5 ohms function Move function enable operates switch to either side and hold the boom extend toggle switch at the ground controls in the extend direction Manually override the directional valve by pushing in on the end of the valve spool Replace defective directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick boom from extending disconnect coupling on OR repair cylinder or the boom function cylinder counterbalance manifold and start the valves OR consult engine Move the Genie Industries Service function enable switch to Department either side and hold the boom extend toggle switch at the ground controls in the extend direction and check the pressure less than 1700 PSI function Exchange flow regulator operates valve item G with a like valve item H Check boom extend function Replace defective flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department CHART 16 Part No 52271 Genie S 40 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 17 Boom Retract Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Sto
94. 4 1 Oscillating Axle Lock out Cylinders Rev 7 65 Non steering Axle Components 15 1 Drive Motor Rev 48 7 66 15 2 Torque Hub Rev 4 1 7 66 Xii Genie S 40 Part No 52271 Service Manual Second Edition January 2008 Section 2 Specifications REV B Specifications Machine Specifications Maximum capacity 500 Ibs 500 Ibs 227 kg 227 kg Stowed dimensions 2WD RT 4WD RT Maximum allowable Length 23 ft 11 in 23 ft 11 in side force ANSI and CSA 150 Ibs 150 Ibs 7 01 7 01 m 68 kg 68 kg Width 7 ft 6 in 7ft6in Tires and wheels 2WD 2 3m 2 3m 2WD Front 4WD Front Tires Only and Rear Height 8 ft 2 in 8 ft 2 in ILE 25m 25m Tire size 12 5L 16SL 12 16 5 NHS Weight 11 650 Ibs 11 650 Ibs 1 Ply rating 12 5284 kg 5284 kg Tire contact area 88 sq in 57 sq in 568 sq cm 368 sq cm Ground clearance 12 1 2 in 12 1 2 in 31 8 cm 31 8 cm Overall tire diameter 33 7 in 33 2 in 85 6 cm 84 3 cm Operational dimensions 7 Tire pressure 45 psi 45 psi Maximum platform height 40 ft 40 ft 3 1 bar 3 1 bar 122m laem Wheel diameter 16 in 161 2 in Maximum horizontal reach 31 ft 8 in 31 ft 8 in 40 6 cm 41 9 cm 9 65 m 9 65 m wheel width 10 in 9 3 4 in Maximum turntable tailswing 34 in 34 in RY EZ 86 4 cm 86 4 cm Wheel
95. 46 6 liters per minute Hydraulic tank circuit return line filter 10 micron with 25 psi 1 7 bar bypass Function manifold Function relief valve pressure S 60 2600 psi 179 bar S 65 2900 psi 200 bar Boom down 2100 psi relief valve pressure 145 bar Boom extend 2500 psi 172 bar Oscillate axle 950 psi 65 bar Steer regulator 3 5 gallons per minute 13 2 liters per minute Auxiliary pump Type fixed displacement gear pump flow regulators 30 2 to 83 2 liters per minute Displacement static A Front drive motors 4WD models f Displacement 1 4 gallons per minute Displacement 5 3 liters per minute er revolution 1 52 cu in 25 cc s Auxiliary pump 2500 psi Non steer end drive motors relief pressure 172 bar Displacement per revolution 2 13 cu in 35 cc Part No 52271 Genie S 40 2 3 Section 2 Specifications SPECIFICATIONS Ford Engine LRG 423 Displacement 140 cu in 2 3 liters Number of cylinders 4 3 781 x 3 126 inches 96 04 x 79 4 mm Bore amp stroke Horsepower 63 Q 4000 rpm Firing order 1 3 4 2 Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm Governor electronic Compression ratio 9 4 1 Compression pressure approx Pressure psi of lowest cylinder must be at least 75 of highest cylinder 0 035 to 0 055 inches 0 889 to 1 397 mm Valve clearances collapsed tappet Lubrication system Oil pressure ope
96. 5 30 ft Ibs 34 41 Nm 31 Flow regulator valve 0 6 gpm 2 27 l min EE Platform rotate 10 12 ft Ibs 14 16 Nm 32 Counterbalance valve FF Platform level up 35 40 ft lbs 47 54 Nm 33 Counterbalance valve GG Platform level down 35 40 ft lbs 47 54 Nm 34 Check valve 2 2 HH Boom extend retract circuit 11 13 ft Ibs 15 18 Nm Plug Torque Specifications 3 g q P Valve Coil Resistance Description Hex size Torque Specifications SAE No 2 8 50 in Ibs 6 Nm Proportional solenoid valve 12V 4 7 to 6 50 schematic items P and S SAE No 4 3 16 13 ft lbs 18 Nm Normally open poppet valve 4 to 70 SAE No 6 1 4 18ft lbs 24 Nm schematic item T V CC and DD 7 36 Genie 5 40 Part No 52271 Service Manual Second Edition January 2008 Section 7 Repair Procedures REV A MANIFOLDS amp amp amp 6 8 K AA zt Ch L 2 5 9 Y UE We A NZ S Part No 52271 Genie S 40 7 37 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 9 3 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this procedure with the boom in the st
97. 6 wire circuit that runs from TB36 to steer left directional valve coil on steer manifold OR repair open in brown ground wire circuit to steer left valve coil Replace steer left directional valve coil item TT OR repair open in brown ground wire circuit to steer left valve coil Repair open in blu 36 wire circuit from drive controller DP1 to TP36 then to TB36 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts N CHART 26 Install a 0 to 5000 PSI Check for mechanical 0 to 345 bar pressure restrictions keeping gauge at the quick steer left function from disconnect coupling on operating OR repair or the boom function replace steer cylinder manifold and activate OR replace flow the steer left function regulator valve item WW OR consult Genie Industries Service less than 2600 PSI Department Continued from the previous page Repair or replace steer cylinder OR steer manifold could have an internal defect Consult Genie Industries Service Department Part No 52271 Genie S 40 5 59 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 27 Steer Right Function Inoperative Be sure all other functions operate normally With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in
98. 8 to TP30 to TB30 through drive enable limit switch LS3 to TB12 to wht 12 wire on EDC quick disconnect plug Repair open in blu wht wire from TS9 to TP12 to TB12 Repair open in wire from terminal 4 from drive joystick DP1 to drive enable toggle switch TS8 OR replace drive joystick controller OR consult Genie Industries Service Department 5 64 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Chart 29 Drive Forward Disconnect Mu sets i voltage readings different WA ie Pf wire connector from the rive controller drive pump start H engine move the drive Fu nction controller to full forward inoperative position and note the voltage across the wht 12 and the wht blk 31 Be surg all other wire terminals on the functions operate EDC Reverse the volt i i meter leads and move normaly meuding the drive controller to full drive in opposite reverse position and direction of note the voltage malfunction voltage readings the same 0 infinite ohms Check the resistance of the Replace the EDC m C 20 to 24 ohms Adjust the drive pum Defective Sundstrand null neutral Consult no improvement drive pump contact Genie Industries Service Sundstrand authorized Department repair facility symptoms improve Re adjust drive joystick controller OR if problem still persists consult
99. A B and C SAE No 6 1 4 18 ft lbs 24 Nm Proportional solenoid valve 10V 7 5 to 10 50 schematic item M 7 34 Genie S 40 Part No 52271 Service Manual Second Edition January 2008 Section 7 Repair Procedures REV A MANIFOLDS ORGS i CGE gt 9 D VR 9 Part No 52271 Genie S 40 7 35 Section 7 Repair Procedures Service Manual Second Edition January 2008 MANIFOLDS REVA Function Manifold Components continued Index Schematic No Description Item Function Torque 15 Check ValVe eee rete WE Qu Differential sensing circuit turntable rotate left right 11 13 ft Ibs 15 18 Nm 16 Proportional solenoid valve Pius Boom up down 10 12 ft Ibs 14 16 Nm AZ Check Differential sensing circuit platform level 11 13 ft Ibs 15 18 Nm 18 Check valve dese Rai Differential sensing circuit platform level down 11 13 ft Ibs 15 18 Nm 19 Proportional solenoid valve Sas Turntable rotate left right 10 12 ft lbs 14 16 Nm 20 Solenoid valve Poppet Nes Platform level up 25 30 ft lbs 34 41 Nm 21 Flow regulator valve 0 6 gpm 2 3 L min
100. BLU RED 3 za DRV ENA 12 BLU WHT 3 Ec SEC BOOM DN 11 BLU BLK 3 SEC BOOM UP 10 BLU 3 EXT RET F C 9 BLK RED 3 RETRACT 8 BLK WHT 3 EXTEND 7 BLK 3 ul SWING FC 6 WHT RED 3 Ok SWING RIGHT 5 WHT BLK 3 SWING LEFT 4 WHT 3 PRIMARY 3 RED WHT 3 PRIMARY DN 2 RED BLK 3 PRIMARY UP 1 RED 3 ao o z ui 121314 51678 910 a o ol 50 E 8 2 5 RED BLK S ep O On 2 TILT ALARM P2 5 DP1 TS3 GLOW PLUG OPTION BP1 L1 LED TS2 START TS8 TS7 TS4 HIGH R P M 5 z 00 55 u F ooojz5 m olg o SE O O D 5 Floooj lt za W ge CE z 4 lt Se a R o LL gt E n v o z e z tc Part No 52271 Genie S 40 6 17 Service Manual Second Edition Section 6 Schematics Platform Control Box Wiring Diagram Diesel Models
101. Be sure that both bearings are packed with clean fresh 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 Component damage Do not ACAUTION 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 to seat the bearing 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 2WD STEERING AXLE COMPONENTS 12 2 Steering Cylinders 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin
102. D TS3 LP FUEL GAS NO BLU WHT 1 BLU WHT R6 E H m ANTI DIESEL VALVE CR6 CR7 NO TP38 TB38 BLU WHT R6 E H p LP FUEL PUMP FUEL GAS TS11 IGN START MODULE TP33 BLK 1 TS2 ENGINE WATER TEMP NOTE CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION RED RED TP25 RED gt WHT WHT FS BLK BLK BLK a START 8 KEY BYPASS 9 IGN FUEL ON e gt SENDER 5 OIL PRESSURE SENDER TS10 5 GROUND ro ENG FAULT TB24 WHT 24 1 START RELAY 2 3 START INPUT ENGINE START BLK p NC WHT 3 HOUR METER TB33 CR2 HI ca TB21 No i 1 i AUTOMATIC CR2 gt gt 21 IGNITION SYSTEM gt WATER TEMP SENDER 2 PULSE Ut GENERATOR DNE IGNITION MODULE CR1 BLK R1 E H i i I 21 gt Lu 0 i STARTER MOTOR UXILIARY AUXILIARY PUMP RED CR1 NO TB27 PR1 RED 27 E H AUXILIARY POWER RELAY 1 T f 2 AUXILIARY PUMP 35 EE RED TP24 TP27 TP21 PRI NO I I I
103. D BLK 1 2 GP l8 amp o d go ES 22 x Part No 52271 Genie S 40 6 11 Service Manual Second Edition Platform Control Box Wiring Diagram Gasoline LPG Models Section 6 Schematics BLK 22 BLK 4 26 WHT 23 BLU RED 39 BLU WHT 38 WHT 1 BRN TO GRD BLU BLK 37 BLU 36 RED 10 H P L WHT BLK 31 WHT 30 WHT RED 32 BLK RED 35 GEN OPTION 45 GRN WHT 1 BLK 33 SPARE 44 GRN BLK 1 HORN 43 GRN 1 BLU RED 13 SPARE 42 ORG RED 1 PULSE PICKUP 41 D LIMIT SWITCH 40 GRN 25 L P 39 BLU RED 1 GAS 38
104. Deutz Diesel models Hold the manual fuel shutoff valve clockwise to the cLosep position 3 Tagand disconnect and plug the hydraulic hoses from the drive and lift steer pumps Cap the fittings on the pumps 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 a manual fuel shutoff valve 3 Crankthe engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the 5 Carefully pull the drive pump out until the pump pressure reaches 320 psi 22 bar coupler separates from the flex plate 4 Supportthe pump with a lifting device and remove the two drive pump mounting fasteners 4 Gasoline LPG models Connect the ignition 6 Remove the drive pump from the machine coil wiring and start the engine from the ground ACAUTION Component damage hazard controls Check for hydraulic leaks Be sure to open the two hydraulic tank valves and prime the pump after installing the pump 7 90 Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures eee This page intentionally left blank Part No 52271 Genie S 40 7 31 Section 7 Repair Procedures Service Manual Second Edition January 2008 Manifolds REVA 9 1 Function Manifold Components before serial number 1424 Index Sche
105. ER OPTION RELAYS Service Manual Second Edition CABLE BLE 6 CABLE CABLE l HARNESS GR WT 4 GRN WHT 1 45 GENERATOR OPTION 44 GREKAN SPARE GRNRS6 GANA 4 HORN BUG ORGREDA 42 SPARE OGBKEH _ ORGBLK1 41 ORGBKISMAZ PULSE PICKUP ORG 40 wHT 7 WHS LIMIT SWITCH SIGNAL BLURED 39 BURD SP LP BLUWHTA 35 BUWT SP GAS BUBKEH BLUBLK1 37 STEER LEFT BLU 1 36 STEER RIGHT BLKRED 35 4 86 _ EKRDSP RPM BRWIE _ BLKWHT1 34 BKWI S P GLOW PLUG OPTION BLKISMEG BLK 1 BLES START WIRDEH WHURED 32 WTRD D BRAKE weken WHTELKA 51 EDC REDS WHT 30 EDC RDWTEH awa 29 2WD AWD _ REDBLK1 28 TILT ALARM RED E H RED 1 27 RED ISM84__ RED S P AUXILIARY POWER WIRDEN 26 WT RD S P WATER TEMP SENDER WIIBKE R 25 WIBKS P OIL PRESSURE SENDER 0 WHTEH 24 WARNING SENDER WHTE H wHr2 23 WHTISMAT KEVSWITCH POWER BUch
106. ESISTORS 2 2 O ASA KAB ee ode eti a ee e RE 7 8 1 56 LOGGIE SWitChes a eerte retenir ba ER ERR RE UE da Fe REM AA ERES RENS 7 8 Platform Components 251 Uum 7 9 2 2 Platform Leveling Slave Cylinder sssseeenmnn 7 9 2 3 Platform 7 10 Boom Components 3 1 Boom Cable Track o a repetere a rte AAA 7 12 3 2 BOOM A ith ea tete tte le ettet etate atte 7 14 3 3 Lift Cylinder 4 0000 60000 nennen nnne nnne 7 16 3 4 Extension Cylinder 7 17 3 5 Platform Leveling Master 7 18 Turntable Covers 4 1 Turntable Covers nnne nns 7 19 Deutz Engine F3L 1011F 5 4 2 2 2 O AJ rene e dee 7 20 522 Flex Plate unsere tee IRI te o t A e ce S 7 20 5 3 Oil Temperature and Oil Pressure 7 20 Ford LRG 423 Engine 6 1 Governor 7 21 6 2 Choke Adjustments cule ies en es e E eed ened 7 22 6 3 Timing Adjustment 0 cece eect cece e aaa aaa aaa aaa 7 23 6 4 Carburetor Adjustment eeeeeeeeee eee aaa aaa aaa aaa nennen nennen 7 23 6 5 2 ec ha
107. Genie Industries Technical Publications Genie 5 40 _____ Service Manual from serial number 832 to 1789 Second Edition First Printing Part No 52271 Rev A1 January 2008 Introduction Service Manual Second Edition Genie 40 Important Read understand and obey the safety rules and operating instructions in the appropriate 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 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 technic
108. LK RED 4 EXTEND RETRACT FLOW CONTROL BLK RED 3 n a ORG 3 UP f PLATFORM LEVEL o DOWN ORG BLK 3 R ORG puse 1 F ia X ORG 4 i E b rus g PLAT LEVEL UP PLATFORM LEVEL L 2 3 DOWN PLAT LEVEL DN I o o B a z 2 m 1 OO I BLK 6 T c REDS PLAT LEVEL E ORG RED 3 5 CE PLATFORM LEVEL DISABLE OPTION M a amp E GRN 3 LEFT PLATFORM ROTATE A RIGHT GRN BLK 3 GRN 0 zj m e x i GANS 4 PLATFORM ROTATE LEFT z H LEFT PLATFORM ROTATE RIGHT ea GRN BLK 4 7 PLATFORM ROTATE RIGHT p SEREM x qum DOE PE 1206 sanden 2 Service Manual Second Edition Section 6 Schematics STACKED CONTACTS G1 P1 KS1 ONCO ojo NO NO ONCO olo HM TS11 TS10 O 9 TS12 CB1 CB2 d a 1 LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH 159 AUXILIARY SWITCH TS10 ENGINE START SWITCH TS ENGINE FUEL SELECT SWITCH TS12 FUNCTION ENABLE TS13 PLATFORM ROTATE SWITCH TS14 PLATFORM LEVEL SWITCH TS15 BOOM EXTEND RETRACT SWITCH TS16 PRIMARY 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 FUNCTIO
109. M o 0 0 1 HIGH i LY a Yi I 360 PSI 7E vx 5 PS L 1O r PRESS m RL T pi p di O 4 0 4 1 0 ANI 39 LiT TEST NI amp ad B F3 Fi za 6 fa BAL Ec ex TAS en TX E a fo rat 9 4 41 YE gif i press ME PT iba M I ft gt Lig aee i i f 2 1 1 1 ja au 1111 FUNCTION effen Oo GO DEZ eo EVOO Pump NM uM UE e ELLO 4 GPM T s quas COTRA 84G l eee ee FEE IE DRIVE PUMP XX 9X gt us C 4 4 SEM 4 4 OPTIONAL be ta OIL COOLER 3 8 PSI SEE i PSI PSI zu RESERVOIR AUXILIARY PUMP TEDA CTCTO gt 250 PSI m TANK Dos Uo STEERING TRACTION Part No 52271 Genie S 40 6 21 Service Manual Section 6 Schematics 2WD Hydraulic Schematic after serial number 1423 Non Oscillating Axle Service Manual Section 6 Schematics ju 3 2WD Hydraulic Schematic before serial number 1424 Oscillating Axle
110. Manual Second Edition Section 4 Scheduled Maintenance Procedures Lift the red auxiliary power switch cover 3 Simultaneously hold the auxiliary power switch and activate each boom function toggle switch To conserve battery power test each function through a partial cycle Result All boom functions should operate 4 Turn the key switch to platform control 5 Pull out the Emergency Stop button to the oN position at the platform controls then press down the foot switch 6 Liftthe red auxiliary power switch cover 7 Simultaneously hold the auxiliary power switch and activate each function control handle or toggle switch To conserve battery power test each function through a partial cycle Result All boom and steer functions should operate Drive functions should not operate with auxiliary power TABLE A PROCEDURES A 13 Test the Tilt Sensor The tilt sensor sounds an alarm located in the platform when the incline of the turntable exceeds the rating on the serial plate Select a level test area The tilt alarm should not be sounding prior to the test 1 Startthe engine from the platform controls 2 Openthe tank side turntable cover and press down on one side of the tilt sensor O Result After a 1 5 second delay the alarm in the platform should sound Tip over hazard The alarm should AWARNING be audible at the ground controls If the alarm is not audible at
111. N 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connection at the electronic displacement controller EDC located on the drive pump Part No 52271 Genie S 40 Section 7 Repair Procedures Service Manual Second Edition HYDRAULIC PUMPS 2 Close the two hydraulic tank valves located at How to Prime the Pump the hydraulic tank 1 Connect a O to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump 2 Gasoline LPG models Disconnect the L_9 electrical connector at the ignition coils The m ignition coils are located above the alternator AWARNING Electrocution hazard Contact with electrically charged ii id circuits may cause death or ACAUTION Component damage hazard The serious injury Hemove all rings engine must not be started with watches and other jewelry 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
112. NS G1 VOLT METER GAGE G2 OIL PRESSURE GAGE G3 WATER TEMP GAGE IZ TS14 Ground Control Box Legend Gasoline LPG Models TS9 Qo TS16 DISABLE LEVEL PLAT CR19 CR18 PLAT LEVEL DISABLE CR17 COOLING FAN RELAY SECTION A A GR WT 4 GRN WHT 1_ 45 GEN OPTION i 44 GRIBKAH SPARE GRN R5Y86 _ GRN 1 48 HORN i BLK 7 ORGIRED 42 SPARE CABLE ORGBLK1 41 ORG BLK ISM 2 PULSE PICKUP i 47 ORG 1 40 WHT 7 WHT 6 LIMIT SWITCH SIG BLUREDA BU RD A7 30 BURD SP LP _ BLU WHT 38 BUWT S P GAS i BU BK E H BLU BLK 1 37 BL BK D B STEER LEFT BLU EH BLU 1 36 BLU D B STEER RIGHT i BLKIRED 1 35 BLK RD R4t86 BK RD S P RPM CABLE Bewren BLKWHTA 34 GLOW PLUG i 6 BLK ISM 3 BLK 1 BLK R3486 9 BLI S P START i WT RD E H WHT RED 1 32 WT RD D B BRAKE i WTIBK E H WHT BLK 1 31 E D C i RED 5 WHT 1 30 ED C i RW 29 2WD AWD i RD BK A H REDBLKA 28 TILT ALARM CABLE RED E H RED 1 27 RED ISMK4__ RED S P AUX PWR i
113. O Result High idle should be 2500 rpm 7 Turn the engine off If low and high idle rpm s are correct disregard adjustment steps 8 and 9 8 Remove the mounting fasteners from 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 trimpot screw clockwise to increase the rpm or counterclockwise to decrease the rpm Do not adjust any trimpot other than specified in this procedure um um om o eo 1 Qe Us a low idle adjustment b high idle adjustment 10 Apply a drop of silicone to the top of the trimpot screw Apply a bead of silicone to the surface of the back panel prior to re assembly 11 Re assemble the governor and recheck low and high idle Gasoline LPG models Deutz Diesel models 1 Connect an rpm gauge to the engine and then start the engine from the ground controls O Result Low idle should be 1300 rpm Skip to step 3 if the low idle rpm is correct 2 Loosen the low idle lock nut then turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and recheck the rpm solenoid boot high idle adjustment nut yoke lock nut yoke low idle adjustment screw low idle lock nut 3 Move the function enable toggle switch to the high idle rabbit symbol position at the ground contro
114. OOM EXTEND RETRACT SWITCH 7816 PRIMARY BOOM UP DOWN SWITCH d i 7817 TURNTABLE ROTATE SWITCH CR5 i CIRCUIT BREAKER CONTROLS 15A CRI7 HORN i CB2 CIRCUIT BREAKER ENGINE 15A RELAY i HM HOUR METER NUNG R2 RESISTOR 10 OHM BOOM FUNCTIONS RELAY i G1 VOLT METER GAGE i G2 OIL PRESSURE GAGE H i G3 WATER TEMP GAGE H i SECTION A A 52271 Genie S 40 6 15 Section 6 Schematics Ground Control Box Wiring Diagram Diesel Models STACKED CONTACTS eee WHTIRED 26A GRN GROUND WHTZIA WHTIBLK 25A BLIC22A gt WHT 23 JO NC AJ z NO NO D e RED 27A BLKIRED 9A BLTWHT 9A BUSTA P HM 2 ed Z JA WHTIBLK SA O v R2 WHT 4A WHT RED 6A BLK 33A BLKIRED 35A BLKIWHT 34A ORG TB14 RED 20A ORGIBLK TB15 78 RED 6 gt RED TB20C we FUSE hz SECTION A A RED A1430 PLATFORM LEVEL DISABLE 8 HYD OIL COOL
115. P1 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more CHART 18 Repair open in wht blk wire circuit from TB5 to turntable rotate left function directional valve coil item A OR repair open in brown ground wire circuit to valve coil Troubleshoot turntable rotate left right function toggle switch TS17 on ground control panel OR repair open in wht blk wire circuit from TS17 to TB5 OR consult Genie Industries Service Department Repair open in wht blk wire from TP5 to TBS Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to Part No 52271 Genie S 40 5 41 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 18 0 or infinite ohms Disconnect wires to turntable rotate left directional valve coil Continued from the previous page item A and test the resistance of the valve coil See Repair Section 2 5 to 3 5 ohms Move function enable switch to either side and hold the turntable rotate left right toggle switch at the ground controls in the left direction Manually override the directional valve by pushing in on the end of the valve spool function inoperative Install a 0 to 5000 PSI 345 bar pressure function Operates Replace turntable rotate left directional valve coil item A Replace defective
116. RED 27 E H n AUXILIARY POWER t Q gE PUMP a REDS RED RELAY R t Li ENEA AUXILIARY PUMP Li gt rog 8 WHT E RED BLK 1 RED BLK 28 E H Q WHT gt WHT 2 REDIWEITH2S EM LEVEL SENSOR x g 5 m gt B amp x m z 3 9 n tr LE GRN GRN 1 GRN B 7 SERVICE HORN TD e RELAY 4 y 9 D A 52 a BLK 2 Es SERVICE HORN N I 5 c 9 WHT lt WHT R17 E H 7 O HYDRAULIC OIL Z gt TEMP SWITCH q Yu o p TO mU a 62 ORGMITEH zy COOLING FAN u OPTION tt PEL amp x ORG BLK 1 g ORG BLK 41 E H Q Q Q w raj oc ae i d a L aL g 405 5 BC 1516 3 OY ped QT ul ty a Ho N RED RED 20 E H Part No 52271 Genie S 40 6 13 Section 6 Schematics Service Manual Electrical Schematic Diesel Models N t LO c N BRN 2 m
117. RING Part No 52271 Genie S 40 6 23 Service Manual Section 6 Schematics 4WD Hydraulic Schematic before serial number 1424 Oscillating Axle REAR RIGHT REAR LEFT Service Manual Section 6 Schematics 4WD Hydraulic Schematic after serial number 1423 Oscillating Axle K J H G F E D C B A BOOM SLAVE UP DOWN PRIMARY 1 bd PLATFORM ROTATE m gt TURNTABLE 63 ROTATE Lex 3 LJ L Fd 1 9 etol hes Teo ESO RSEN tte DD OM TE Toad 6 1 2 0 030 Sh F MASTER Up pM v0 SAR U 0 025 P BUS TU
118. RNTABLE 2222222 mma pu EE foe ROTATE BOOM e _EXTEND __ RETRACT a OPTIONAL FUNCTION T i tal MOTOR GEN MANIFOLD E tPs e 3 360 PSI HIGH mi t j A WE o PSI lt PRESSURE 3 GE 2200 1950 t I FILTER a Q eund PSI i fT m c 0 4 0 4 P S Ik Hec PNE NEL 1 AL sz RZE a J el ES Ao XA a Y HAX AARE I LL ndr I I CH i 1 alt 1 3500 e H io o ee 3 pz 34 Ez recs MEE press WSIE MITIS 4 17 EN Pa EE pe ane BLUE ISBN S zm vg GL 6 4 2900 4 4 t et press DRIVE PUMP XX pud T Pr d a al 4 ut GPM i ls M 2000 L OPTIONAL PSI m imc a cdd R SS SS SS SS SS SS SS SS RK 5 OIL COOLER s 3 PSI L PSI PSI ER Hi poo RESERVOIR AUXILIARY PUMP ES 6 FH OSCILLATE MANIFOLD 1 r MANIFOLD pee ppp R0 7 oet Hide DEI ore RIGHT 4 7 T 4 EE n ee eel 8 FRONT 1 LEFT STEERING TRACTION Part No 52271 Genie S 40 6 23 Service Manual Section 6 Schematics 4WD Hydraulic Schematic after serial number 1423 Oscillating Axle Service Manual Second Edition Section 7 Repair Procedures Observe and Obey Repair procedures shall
119. Repair Process Malfunction Identify Troubleshoot discovered symptoms problem Still exists Retum to Perform Service problem repair Solved Part No 52271 Genie S 40 6 1 Section 6 Schematics Service Manual Second Edition Electrical Components Item Description Genie Part Manufacturer Manufacturer Qty Part Number Part Number BAT Battery 1000 CCA 12V DC 30143 Trojan eese 2 1 BP1 Joystick controller Dual axis 24493 OEM Controls EJS5M6881 1 CB1 CB2 Circuit breaker 24018 45 700 IG1 P10 2 CRithrough CR7 17 18 TO niit Relay SPDT 12V DC 34052 Potter Brumfield VF4 15F11 CO5 10 Diode Diode 6 amp 200 PIV 45782 Motorola uictis MOTMR752 36 DPI ie Joystick controller Drive 20424 OEM Controls MCH1159AD1386 1 EB hs Flashing beacon 20189 ECCO Electronic Controls 6400X 2 FS1 Footswitch 13482 Linemaster Switch Corp 632 9 1 Gi iso Gauge Voltage 3
120. SPARE i G1 G2 G3 H CABLE OG BK E H _ ORG BLK 1 41 5 2 PULSE PICKUP i m H 7 ORG 1 40 WHT 7 WHT 6 LIMIT SWITCH i m BLU RED T 39 BU RDCR7 BU RD S P LP i H BLUWHT 1 BuwrCRe BUWTS P GAS i H BU BK BLU BLK 1 37 BL BK D B STEER LEFT i BLUEH BLU 1 36 BLU D B STEER RIGHT BLK RED 1 35 BK RD S P RPM 1 BLK WHT 1 34 GLOW PLUG P1 KS1 6 BLK ISM 3_ BLK 1 33 BLK S P START 1 TS9 H WTIRD EH WHT RED 1 32 WT RD D B BRAKE i ONCO o o i WT BK EH WHTIBLK 1 31 EDC i NO NO H RED 5 WHT 1 30 E D C ONCO o O i RWA 29 2WD AWD i ojo H RED BLK 1 28 TILT ALARM i o 0 CABLE REDE H _ RED 1 27 REDD B RED SP AUX PWR f 5 WT RD 26 WT RD S P TEMP SENDER WIIBKEH 25 WIBKSP OLPRESSURESENDER WHTEH 24 WHT S P WARNING SENDER i i WHTEH 2 28 WHT S P KEYSWITCH PWR i BLK 2 22 BLKCR5 BLKSP PWR TO PLAT i WHTGRZ WHTEH 21 WHTSP DB IGNITION PWR RED EH RED CR17 20 RED S P 12V BATT SUPPLY i 19 JIB VALVE i HM H GRNBLK4 GRN BLK 3 18 GR BKD B GRIBK S P PLAT ROT i TS15 TS16 i GRN 4 GRN 3 17 GRND B GRN S P PLAT ROT L i H CABLE Bike ORG RED 3 16 OG RD D B OG RD S P PLAT LEVEL DIS i o9 1 onces 15 OGBKDB OGEKSP PLAT LEVEL DN ORG 4 ORG 3 14 ORG D B ORG S P PLAT LEVEL UP i WHT 5 BLU RED 3 13 DRV ENA
121. Second Edition Section 7 Repair Procedures 7 Setthe hi range Press down the foot switch then move the control handle all the way to the uP position Adjust the voltage to 8 5V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 8 Setthe lo range Press down the foot switch then move the control handle all the way to the DOWN position Adjust the voltage to 6 2V 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 55 to 85 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 90 to 120 second cycle time If the function cycle time is not achievable check the relief valve pressure See 10 2 Valve Adjustments Function Manifold 12 Turn the engine off and re connect the volt meter 13 Pull out the Emergency Stop button to the position 14 Press down the foot switch and then move the control handle all the way to the up position Record the maximum voltag
122. Second Edition Section 5 Troubleshooting Flow Charts Chart 2B Engine Runs Hold start switch to Wh i Cran ki ng either side and check voltage at terminal 42 on Then Dies ignition start module Crank engine and check py Check alternator wiring OR repair or replace alternator OR contact voltage at org blk 41 wire on alternator Genie Industries Service Department 610 7V Repair open in org blk 41 wire circuit from alternator to TB41 to terminal 42 on ignition start module 6 to 7V While cranking engine Disconnect wht 24 wire Check oil level OR for 15 seconds check from oil pressure sender replace oil pressure continuity to ground on yes and check continuity to yes sending unit OR refer to Ford service manual for troubleshooting low oil pressure ground on signal post of terminal 10 ignition sender while cranking start module Is continuity maintained the engine Is continuity maintained Check coolant level OR replace water temperature sending unit OR refer to Ford service manual for troubleshooting a overheated engine Disconnect wht 24 wire from water temperature sender and check continuity to ground on signal post of sender while cranking the engine Is continuity maintained yes no no Repair short to ground in wht 24 wire from sending units to TB24 to terminal 10 on ignition start module Replace ignition start from terminal 4 on 12
123. Start the engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 11 Check the oil filter and the oil pan drain plug for leaks 12 Swing the engine pivot plate back to its original position and replace the two pivot plate retaining bolts 13 Check the engine oil level dipstick Add oil if needed Ford LRG 423 Engine 5 quarts Cil capacity including filter 4 7 liters Ford LRG 423 Engine Cil viscosity requirements below 60 F 15 5 C 5W 30 10 to 90 F 23 to 32 C 10W 30 above 10 F 23 C 10W 40 or 10W 50 above 25 F 4 C 20W 40 or 20W 50 Use oils meeting API classification SF labeled SF CC or SF CD as they offer improved wear protection TABLE A PROCEDURES A 16 Drain the Fuel Filter Water Separator Deutz Diesel Models Engine specifications require that this procedure be performed every 500 hours Poor fuel quality or very wet conditions may necessitate performing this procedure more often Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and component damage Engine fuels are combustible ADANGER Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco A
124. T p ee H BLK G ORGIRED 3 16 OG AD D B OG RD S P PLATFORM LEVEL DISABLE RED WHT 3A Eu CABLE ORGBIK4 _ ORGALKG 15 OGBKDA _ OGBKS PLATFORM LEVEL DOWN 3 ODO O 1 ORG 4 ORG 3 14 ORG S P PLATFORM LEVEL UP WHT EH BLU WHT 3 12 BLK 5 DRIVE ENABLE i es _ n BU BK S P SEC BOOM DOWN WHTIBLK SA d BLU 3 10 BLU S P SEC BOOM UP WHT 4A BLK RED 4 BLK RED 3 9 BK RD S P BOOM EXT RET FC 1 L Y BLKIWHT 4 BLKIWHT3 8 BK WT D B BKWT S P BOOM RETRACT ge H 7 BLKD B BOOM EXTEND j ORG waraka _ WHTELKS 5 WNEKDB WURDSP TURNTABLE ROTATE LEFT H CABLE WHT 4 WHT 3 WHTD B WHT S P TURNTABLE ROTATE RIGHT j GBN 17A H 2 REDWHT 3 3 RD WT S P PRIMARY BOOM F C RED BLK 4 REDBLKs 2 RD BK D B RD BI S P PRIMARY BOOM DOWN i GRN BLK 18A i d RED 4 RED 3 1 RED D B RED SP PRIMARY BOOM UP i 81 m d D B A i ORG BLK 158 T ORG RED 16B 7 QRG 14B FEM GRN 17B i Co v ORG BLK 15A H 4 P BLK R1 87 O BLK WHT 8B H ORG 14A d BRN GROUND gf ORGIRED 16A BLK7B EJ 21 H CABLE WHTIBLKCSB HE BLU 36B i WHT AB BLU BLK 378 J RED BLK 2B WHTIRED 32B L i RED 1B 10 BRN GROUND ALEI smarneay BLK 33A H ORGIBLK 418 LE 2 IGN START BLK RED 35A EC s sta
125. U Platform level circuit 10 12 ft Ibs 14 16 Nm 22 Solenoid valve Poppet Mss Platform level down 25 30 ft Ibs 34 41 Nm 23 Differential sensing valve W Pilot to close flow directional valve 10 12 ft lbs 14 16 Nm 24 Relief valve 2600 psi 180 bar 5 40 System 35 40 ft lbs 47 54 Nm 24 Relief valve 2900 psi 200 bar 5 45 System 35 40 ft Ibs 47 54 Nm 25 Diagnostic Testing 26 Check SEE Differential sensing circuit Platform rotate left 11 13 ft Ibs 15 18 Nm 27 Check AA Differential sensing circuit Platform rotate right 11 13 ft Ibs 15 18 Nm 28 Priority flow regulator valve 10 12 ft Ibs 14 16 Nm 3 5 gpm 13 25 L min oscillate models 2 0 gpm 7 6 L min non oscillate models 29 Solenoid valve Poppet CC Platform rotate left 25 30 ft lbs 34 41 Nm 30 Solenoid valve Poppet DD Platform rotate right 2
126. V module OR consult ignition start module and check voltage at terminal 4 Check voltage at 12V Disconnect red wire terminal 4 on ignition Genie Industries Service Department start module oV oV Test auxiliary power toggle switches TS1 and Replace ignition start TS9 See Repair module OR consult Section Genie Industries Service Department Part No 52271 Genie S 40 5 11 Section 5 Troubleshooting Flow Charts Service Manual Second 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 fuel shut off valve is in the on position Be sure that the battery is fully charged Hold the start switch to 55 either side and check 11V battery voltage while engine is cranking 11V or more Check if engine over temperature sending signal post has continuity to ground no continuity Disable the starter by removing the blk wire at sy the starter solenoid Hold the start switch to either side and check the voltage at positive terminal on fuel solenoid Continued on the next page continuit 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 temperatu
127. ach a lifting strap from an overhead crane to the cable track 12 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom 13 Remove the cable track mounting fasteners that attach the lower cable track to the boom Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures 0 rn BOOM COMPONENTS 14 Remove the cable track from the machine and place it on a structure capable of supporting it 5 Lift up the hoses and cables and carefully remove the damaged 4 link section of cable AWARNING Crushing hazard The cable track hack may become unbalanced and fall if it is not properly attached to the overhead crane Component damage hazard ACAUTION Hoses and cables can be damaged if they are kinked or pinched ACAUTION Component damage hazard Cables and hoses can be 6 Remove the upper rollers from the replacement damaged if they are kinked or section of cable track pinched 7 Lift up the hoses and cables and carefully insert How to Repair the Boom the new 4 link section of cable track Cable Track Component damage hazard ACAUTION The boom cable track can be damaged if it is twisted Component damage hazard ACAUTION Hoses and cables can be damaged if they are kinked or pinched 8 Connect the ends of the replacement cable track section to the existing cable track using the fasteners provided in the kit Do not overtighten the fa
128. al publications team in care of Genie Industries PO Box 97030 Redmond WA 98073 97030 U S A If you have any questions please call Genie Industries Genie North America Telephone 425 881 1800 Toll Free 800 536 1800 in U S A Toll Free 800 426 8089 in Canada Fax 425 556 8649 Genie Europe Office Telephone 44 01636 605030 Office FaxFax 44 01636 611090 Parts Telephone 44 01636 605002 Parts Fax 44 01636 611091 Genie Industries Copyright 1998 by Genie Industries Second Edition First Printing August 1998 Genie and S are Registered Trademarks of Genie Industries in the USA and many other countries These machines comply with ANSI SIA 92 5 1992 oy _ 2 Printed on recycled paper Printed in U S A ii Genie S 40 Part No 52271 Service Manual Second Edition Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Genie S 40 Operator s Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You are trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You
129. ard Spraying hydraulic oil can Hydraulic Motor 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to 3 Remove the motor brake mounting fasteners Section Two Hydraulic Hose and then remove the motor from the brake Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin z mmm Unlocked position motor brake mounting bolts motor brake torque hub mounting bolts torque hub plug Locked position 7 58 Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures How to Remove the Turntable 4 Rotation Brake or Torque Hub 1 Secure the turntable from rotating with the turntable rotation lock pin unlocked locked TURNTABLE ROTATION COMPONENTS Remove the plug from the side of the torque hub Then drain the oil from the hub Install the torque hub Torque the hub mounting bolts to 180 foot pounds 244 Newton meters Install the brake and motor onto the torque hub 7 Fillthe hub with oil from the side hole until the oil level is even with the bottom of the hole Apply pipe thread sealant to the plugs and then install
130. ary 2000 psi pump and hold the auxiliary power toggle switch and note the pressure less than 2000 psi Check for a positive connection between good electric motor and the pump by removing the pump from the motor but leave all the hoses connected Visually check coupling connection bad Replace the auxiliary power unit Test PR1 See Repair bad Procedure 8 5 good Activate the auxiliary 12V or pump toggle switch and more check the voltage at TB27 oV Activate the auxiliary pump toggle switch and check the voltage at the center terminal of TS9 Reconnect pressure line and check battery condition There is possibly not enough battery capacity to operate both aux pump and function valves Repair or replace pump OR replace relief valve Consult Genie Industries Service Department Replace PR1 Repair open from TB27 to PR1 OR repair open in brown ground wire circuit to PR1 OR replace PR Repair open in red power supply wire from keyswitch KS1 to auxiliary toggle switch TS9 12V or more Repair open in red 27 wire from TS9 to TB27 OR replace TS9 5 70 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 34 Check continuity from Replace negative cable negative terminal on from auxiliary pump to auxiliary power unit to ground ground Continued from the previous page R
131. ated high idle rabbit and foot switch symbol O Result The engine should not change to high idle 8 Press down the foot switch Result The engine should change to high idle 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 of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation 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 it to run at low idle 3 Press down the foot switch to allow the engine to run at high idle O Result The engine should start promptly and operate smoothly in low and high idle 4 Release the foot switch and shut the engine off by pushing the Emergency Stop button in to the OFF position 5 Move the fuel select switch to LPG Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 6 Restart the engine and allo
132. ative Install a 0 to 5000 PSI 345 bar pressure function operates Replace turntable rotate right directional valve coil item A Replace defective directional valve gauge at the quick ae Exchange flow regulator function disconnect coupling more valve item with a like operates Replace defective flow the boom function valve item H Check regulator valve manifold and start the turntable rotate right engine Move the function function enable switch to either side and hold the TS x turntable rotate right function inoperative toggle switch at the ground controls in the Repair turntable rotation right direction and check motor OR function the pressure manifold may have an internal defect Consult Genie Industries Service Department less than 2600 PSI Continued on the next page 5 46 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts E CHART 19 Plumb a 0 to 5000 psi lessthan Function manifold could 0 to 345 bar pressure 250 psi have an internal defect gauge into the hose Consult Genie Industries from the function Service Department manifold to the turntable rotation brake Move the function enable switch to either side and activate the turntable rotate right function Continued from the previous page 250 psi or more Exchange turntable rotate right and left function counterbalance valves
133. ay from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 4 34 Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 1 Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the fuel filter located near the carburetor a pivot plate retaining bolts b engine pivot plate 2 Disconnect the fuel hose from the filter then remove the filter from the fitting a fuel filter b hose from the fuel pump to the fuel filter TABLE C PROCEDURES 3 Install the new fuel filter Genie part no 33971 into the fitting on the carburetor 4 Connect the fuel hose to the filter 5 Clean up any fuel that may have spilled during the installation procedure 6 Start the machine from the ground controls then inspect the fuel filter and hose for leaks If a fuel leak is discovered keep A DANGER any additional personnel from entering the area and do not operate the machine Repair the leak immediately 7 Swing the engine pivot plate back to its original position and replace the two retaining bolts Part No 52271 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE C PROCEDURES C 10 Replace the PCV Valve Gasoline LPG Models Yearly replacement of
134. between the drive chassis and the oscillating axle The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure The valves are not or spray adjustable 4 Remove the pin retaining fasteners from the How to Remove an Oscillating rod end pivot pin Use a soft metal drift to Axle Cylinder remove the pin This procedure requires specific 5 Attach a lifting strap from an overhead crane to AWARNING robal skilsand the barrel end of the oscillating cylinder workshop Attempting this 6 Remove the pin retaining fasteners from the procedure without these skills barrel end pivot pin Use a soft metal drift to and tools may result in death or remove the pin serious injury and significant component damage Dealer AWARNING Crushing hazard The oscillate cylinder may become unbalanced and fall when it is removed from Perform this procedure on a firm the machine if it is not properly level surface with the boom in attached to the overhead crane the stowed position service is strongly recommended 7 Remove the cylinder from the machine When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Rotate the boom until the boom is between the steer tires 2 Remove the fasteners from drive chassis
135. c 12 2 m 6 8 sec 12 2 m 7 8 sec 40 fU7 8 sec 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 52271 Service Manual Second 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 running or not running 1 Turn the key switch to ground control and pull out the Emergency Stop button to the oN position at both the ground and platform controls Result The flashing beacon should on and flashing 2 Move the function enable switch to either side and activate the boom toggle switch in the Down position hold for a moment and then release it Result The descent alarm should sound when the switch is held down 3 Turn the key switch to platform control Result The flashing beacon should be on and flashing 4 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 TABLE B PROCEDURES 5 Press down the foot switch Move the drive control handle off center hold for a moment
136. ce is not equal and the adjustment to the linkage was completed with the ground and drive chassis level consult Genie Industries Service Department MANIFOLDS Part No 52271 Genie S 40 Section 7 Repair Procedures Service Manual Second Edition 0 rn MANIFOLDS 9 8 Steer Manifold Components Oscillating Models The steer manifold is mounted underneath the function manifold Index Schematic No Description Item Function Torque 1 3 position 4 way solenoid valve SS Steer 30 35 in lbs 3 4 Nm 2 Check valve qu eese Priority flow regulator circuit 10 12 ft Ibs 14 16 Nm 3 Orifice plug 0 025 inch 0 635 mm UU Priority flow regulator circuit 4 Priority flow regulator valve 2 gpm 7 57 l min VV Regulates flow to oscillate manifold 10 12 ft Ibs 14 16 Nm SS 9 7 46 Genie 5 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS 9 9 Steer Manifold Components Non oscillating Models The steer manifold is underneath the function manifold Index Schematic No Description Item Function 1 position 4 way 003 valve SS Steer left right L 0 Part No 52271 Genie S 40 7 47 Section 7 Repair Procedures Service Ma
137. chine crosses the test line 6 Measure the distance between the test line and your machine reference point Braking paved surface 2WD 4WD Stopping distance 2 to 4 ft 2 to 4 ft 0 6 to 1 2 m 0 6 to 1 2 m The brakes must be able to hold the machine on any slope it is 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 point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 5 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 6 Continue at full speed and note the time when the machine reference point crosses the finish line Drive speed stowed position 2WD 4WD Gasoline LPG models 40 ft 6 8 sec 40 ft 7 8 se
138. chine functions should not operate TABLE B PROCEDURES 6 Turn the key switch to the orr position O Result The engine should stop and no functions should operate Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds 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 operating the ground controls will override the platform controls including the Emergency Stop button 1 Startthe 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 Start the engine from the platform controls 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 Part No 52271 Genie S 40 4 21 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition
139. ck is available through Genie part no 33484 2 Be sure that each turntable mounting bolt is torqued in sequence to 210 foot pounds 285 Newton meters Bolt torque sequence Upper and side wear pads 9 16 inch 14 3 mm Bottom wear pads 11 16 inch 17 5 mm Part No 52271 Genie S 40 4 29 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE C PROCEDURES 3 Lower the boom to the stowed position 4 Checkto ensure that each bearing mounting bolt under the drive chassis is torqued in sequence to 210 foot pounds 285 Newton meters 1 10 15 Bolt torque sequence 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 Select a 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 20 000 1 5 9072 kg under the drive chassis between the non steer tires 3 Liftthe wheels off the ground and then place jack stands under the drive chassis for support 4 Disengage the torque hubs by turning over the torque hub disconnect caps on each non steering wheel hub 5 Manually rotate each non stee
140. ck the Engine Cylinder Compression Gasoline LPG Models D 6 Clean the PCV Hoses and Fittings Gasoline LPG Models D 7 Check the Fuel Injection Pumps and Injectors Deutz Diesel Models D 8 Check the Toothed Belt Deutz Diesel Models D 9 Replace the Timing Belt Gasoline LPG Models D 10 Grease the Steer Axle Wheel Bearings 2WD Models ra ra ra ra ra 3 6 Genie S 40 Part No 52271 Service Manual Second 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 Instructions copies of this page to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily Inspection A Quarterly Inspection A B Annual Inspection A B C 2 Year Inspection A B C D Place a check in the appropriate box after each inspection procedure is completed Use the maintenance tables in this section and the step by step procedures in section 4 to learn how to perform these inspections If any inspection receives an tag and remove the machine from Service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired Comments B 17 Platform leveling ChecklistA gt YNR B
141. ctions keeping platform rotate left function from operating OR repair or replace platform rotator OR replace platform rotator counterbalance valve manifold OR consult Genie Industries Service Department Replace defective flow regulator valve Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Rotate Right Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the platform rotate toggle switch TS13 in the right direction and check the voltage at grn blk wire on platform rotate right function directional valve item DD Continued on the next page 12V or more With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the on position move the function enable switch to either side and activate the platform rotate toggle switch TS13 in the right direction and check the voltage at TB18 With the keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate the footswitch and the platform rotate toggle Switch TS5 in the right direction and check the voltage at TB18 Troubleshoot platform rotate toggle switch TS13 on ground control panel OR repair open in red power w
142. d Ed 7 23 6 6 Plex Plate eto d e n emet tate ads 7 23 X Genie S 40 Part No 52271 Service Manual Second Edition January 2008 Section Seven TABLE OF CONTENTS Repair Procedures Ford LRG 423 Engine continued 6 7 Water Temperature and Oil Pressure Gauges 7 24 6 8 VACUUM SWITCH rq nr 7 25 Ground Controls 7 1 Control Relays une ihre eden Pee adr d de Po Aaa 7 26 7 2 Toggle Switches See 1 5 Toggle Switches 222 7 8 7 3 Wago Components 7 27 1 4 R SIStOTS ide EG ne RR a e ee ee aS 7 27 7 5 Power Relay aine bi renean tbid ens 7 28 Hydraulic Pumps 8 1 Lift Steer PUMP aaa nad teet nep adeb Deed ie ets 7 29 8 2 Drive 7 29 Manifolds 9 1 Function Manifold Components before serial number 1424 Rev A 7 32 9 2 Function Manifold Components after serial number 1423 Rev 7 34 9 3 Valve Adjustments Function 7 38 9 4 Turntable Rotation Manifold Components 7 41 9 5 Oscillate Manifold 7 42 9 6 Valve Adjustments Oscillate 7 43 9 7 Directional Valve Manifold 7 44 9 8 Steer Mani
143. d LRG 423 Engine 5 quarts Cil capacity including filter 4 7 liters Ford LRG 423 Engine Cil viscosity requirements below 60 F 15 5 C 5W 30 10 to 90 F 23 to 32 C 10W 30 above 10 F 23 C 10W 40 or 10W 50 above 25 F 4 C 20W 40 or 20W 50 Use oils meeting API classification SF labeled SF CC or SF CD as they offer improved wear protection Deutz Engine F3L 1011F Oil capacity including filter 8 5 quarts 8 liters Deuiz Engine F3L 1011F Oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE CD SE SF CC or SF CD 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 O Result The fluid level should be in the NORMAL range Fluids in the radiator are under AWARNING pressure and extremely hot Use caution when removing cap and adding fluids A 6 Check for Fuel Leaks Failure to detect and correct fuel leaks will result in a
144. d stop immediately The engine will shut off after 2 to 3 seconds Start the engine from the platform controls Do not press down on the footswitch Attempt to operate all machine functions O U Result All machine functions should not operate 9 Press down on the footswitch and activate each machine function Result All machine functions should operate through a full cycle 10 Push in the Emergency Stop button to the position at the platform controls O 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 switch Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds A 12 Test the Auxiliary Power Operation Detection of auxiliary power system malfunctions is essential for safe machine operation An unsafe working condition exists if the auxiliary powered functions do not operate in the event of a main power loss When operating the machine on engine power selecting auxiliary power will stop the engine immediately Auxiliary power is designed for short term use only and excessive use will result in battery drain and component damage 1 Turn the key switch to ground control and pull out the Emergency Stop button to the oN position at the ground controls 4 6 Genie S 40 Part No 52271 Service
145. d the start switch to Repair open in blu red either side and check wire circuit from CR7 voltage at blu red wire terminal 487 to LPG on LPG solenoid solenoid 12V 0 or infinite ohms Check resistance of LPG solenoid Replace LPG solenoid 910 10 ohms Reconnect LPG tank and starter then see Maintenance section for LPG adjustments OR consult Genie Industries Service Department 5 16 Genie S 40 Part No 52271 Service Manual Second 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 Chart 5 With keyswitch turned to OV Replace fuel select ground controls and switch both Emergency Stop buttons pulled out to the ON position crank engine and check voltage at gasoline side blu wht wire of fuel select switch TS11 12V With keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the ON position crank engine and check voltage at TB38 12V With keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the on position crank engine and check voltage at terminal 30 on CR6 12V Crank engine for 15 seconds and check voltage at terminal 86 on CR6 12V no Check continui
146. d tighten the nut finger tight Tighten the nut or fitting to the appropriate torque per given size as shown in the table above Operate all machine functions and inspect the hoses and fittings and related components to be sure that there are no leaks 2 8 Genie S 40 Part No 52271 Service Manual Second Edition January 2008 Section 2 Specifications REVA SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual THREAD Grades 2 Grade 8 LUBED LUBED LUBED in ibs_ __Nm__ __in lbs_ __Nm__ __in lbs_ __Nm__ __in lbs_ __Nm__ ____in lbs___ ____Nm____ vq 20 80 9 10 113 10 124 140 158 159 147 28 90 101 120 135 120 135 160 18 140 158 5 LUBED DRY LUBED LUBED ftibs Nm ftibs ftibs Nm ftibs Nm Nm 516 8 18 176 17 233 18 24 25 339 2 284 2 4 109 149 257 20 271 27 366 325 ee RPM aa ee _ 5 113 2 35 474 37 501 49 664 43 58 3 a6 7 A P RECHT 0 1 58 Sr T MT 20 41 555 55 745 6o 813 80 1082 68 921 ou ee H UH 1016 92 1084 110 149 93 123 _ 2 64 867 85 115 90 122 120 162 105 142 ons ep 149 18 90 122 120 162 Pe ep 203 18 1 30 176 170 230
147. d use may cause component damage Extremely dirty conditions may require that the filter be replaced more often ACAUTION Beware of hot oil Contact with 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 Remove the filter housing by using a wrench on the nut provided on the bottom of 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 Genie 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 sure that there are no leaks 8 Clean up any oil that may have spilled Part No 52271 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE C PROCEDURES C 8 Replace the Diesel Fuel Filter Water Separator 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 Engine fuels are combustible ADANGER Replace the fuel filter in an
148. defective switch Repair open in wht wire circuit from terminal 87 on CR2 to CR4 terminal 30 Replace CR4 relay Repair open in blk red wire circuit from CR4 terminal 487A to electronic governor terminal 7 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 5 22 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine High Idle Inoperative Deutz Diesel Models Be sure mechanical linkage is not binding or defective Be sure 2 speed solenoid grounding wires are free of corrosion and have full continuity to ground Start engine switch rpm select switch to high idle rabbit symbol and solenoid pulls in check if 2 speed solenoid pulls in solenoid does not pull in Check voltage at blk red gy wire on rpm select switch 54 and TS12 12V Check voltage at TB35 W 12V Check voltage at oV terminal 430 on CR3 12V Check voltage to oV terminal 486 on CR3 12V no continuit Check continuity from ground to brown wire at terminal 485 on CR3 continuity Check voltage to oV terminal 87 on CR3 12V Continued on the next page Chart 8 Check high idle adjustment see Maintenance section OR
149. discovered symptoms problem Still exists Return to Perform service repair problem Solved 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 personal injury or damage to the machine Indicates special operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 52271 Genie S 40 7 1 Section 7 Repair Procedures Service Manual Second 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 Platform control box horsepower limiter board terminals drive proportional controller boom proportional controller 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 13 6 to 14 5V DC output AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious
150. draulic 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 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 Inspect for 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 pumps filter and turntable surface All hydraulic cylinders All hydraulic manifolds Boom The underside of the turntable The underside of the drive chassis Ground area under the machine Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures A 9 Check the Tire Pressure This procedure does not need to be performed on machines equipped with the foam filled tire option An over inflated tire can explode AWARNING and may cause death or serious injury To safeguard
151. drive manifold 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 charge pressure relief valve and remove the cap item 1 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 6 Restart the engine Drive the machine in either direction and recheck the valve pressure 7 Turn the engine off then remove the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 2 bar 7 50 Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures mnmmmm MANIFOLDS This page intentionally left blank Part No 52271 Genie S 40 7 51 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 9 12 4WD Drive Manifold Components The drive manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Flow divider combiner valve AB Controls flow to flow divider combiner valves 4 and 5 25 30 ft Ibs 34 41 Nm 2 Relief valve 250 psi 17 2 bar AG Charge pressure circuit 10 12 ft Ibs 14 16 Nm Orifice plu
152. e 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Tag disconnect and plug the hydraulic hoses from the platform rotator Cap the fittings on the rotator Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures 3 Supportthe 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 Crushing hazard The platform AWARNING mounting weldment may become unbalanced and fall if it is not properly supported 5 Supportthe platform rotator Do not apply any lifting pressure 6 Supportthe rod end of the platform leveling slave cylinder 7 Remove the pin retainer from t
153. e Industries Service Department Part No 52271 Genie S 40 5 63 Section 5 Troubleshooting Flow Charts CHART 28 Continued from the previous page Activate the footswitch and hold the drive joystick in the full forward position and check the voltage across the wht 12 wire and the wht blk 431 wire on EDC Troubleshoot drive forward and drive reverse functions separately OR replace pump OR consult Genie Industries Service Department Service Manual Second Edition With the footswitch activated and the drive joystick in the full forward position move the drive enable toggle switch TS9 to either side and check the voltage across the wht 1H2 wire and the wht blk 310n EDC Connect the positve lead from a voltmeter to terminal 5 on the joystick and with the footswitch activated and the drive joystick in the full forward position move the drive enable toggle switch TS8 to either side and hold the negative lead from the voltmeter onto the blu wht wire on TS8 and check the voltage Connect the positve lead from a voltmeter to terminal 5 on the joystick and with the footswitch activated and the drive joystick in the full forward position hold the negative lead of the voltmeter onto the center terminal of the drive enable toggle switch TS8 and check the voltage 2V Replace drive enable toggle switch TS9 Repair open in wht wire from terminal 4 on drive joystick to TS
154. e and check voltage at wht 21 on terminal 87 of CR2 oV Check voltage at red wire on terminal 30 of CR2 12V Hold the start switch to either side and check voltage at terminal 86 of CR2 12V Continued on the next page Service Manual Second Edition See Ford service manual for troubleshooting ignition system Repair open in wht 21 wire from CR2 to ignition coil Repair open in red wire circuit from battery to TB20 to CB1 to CR1 to CR2 Hold start switch and check voltage at 12V terminal 9 on ignition start module oV Check voltage at terminal 6 on ignition start module 12V Check continuity from ground wire at terminal 5 on ignition start module to ground continuity Consult Genie Industries Service Department Repair open in blk wire from terminal 86 on CR2 to terminal 9 on ignition start module Repair open in power supply wires from CB1 to CR1 to CR2 to terminal 6 on ignition start module Repair open in brown ground wire to ignition start module Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 2 Check continuity f gt Repai in b eck continuity from continui epair open in brown Continued from the ground to terminal 85 y ground wire circuit to previous page on CR2 CR2 continuity If weak spark still exists consult
155. e check voltage at terminal on BP1 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to 12V or more BP1 Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department Continued on the next page 5 44 Genie S 40 Part No 52271 Service Manual Second Edition Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the turntable rotate left right toggle switch TS17 on ground panel in the right direction and check voltage on wht wire on boom function directional valve coil item A 12V or more Continued on the next page Section 5 Troubleshooting Flow Charts N Move the function enable switch to either side and hold the turntable rotate left right toggle switch TS17 on ground panel in the right direction and check voltage at TB4 With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and turntable rotate left right proportional controller BP1 on platform control panel in the right direction and check voltage TB4 oV Activate footswitch and turntable rotate left right proportional controller BP1 on platform control panel in the right directio
156. e circuit from ignition and check voltage at coil plug to electronic electronic governor governor terminal 3 and 4 brown wires See Maintenance section for governor adjustments OR replace electronic governor Part No 52271 Genie S 40 5 21 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 7 Engine Low Idle inoperative Gasoline LPG Models If low idle operates on LPG but not on 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 86 blk rd wire on Check voltage at OV terminal 30 on M 12V Check voltage at terminal 87A on CR4 lt 12V Check voltage at terminal 7 on electronic governor 12V Check voltage at electronic governor terminal 3 and 4 brown wires 12V Turn machine off remove blu blk wire from terminal 46 on electronic governor and restart engine engine goes to low idle Recheck electronic governor adjustments OR replace electronic governor engine goes to high idle Isolate the ground and platform rpm toggle Switches TS4 and TS12 check individually and replace
157. e 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 rate 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 3 5V DC 8 5V DC 55 to 85 seconds Boom up hi range Cycle time 6 2V DC 90 to 120 seconds Boom down 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 13 6 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 position at both the ground and platform controls Do not start the engine Part No 52271 Genie S 40 7 3 Section 7 Repair Procedures PLATFORM CONTROLS 3 Open the platform control box lid and locate the turntable rotati
158. e the bearing grease seal when removing the hub 16 Slide the hub onto the yoke spindle Component damage Do not ACAUTION apply excessive force or damage to the lip of the seal may occur 17 Place the outer bearing into the hub 18 Install the washer and slotted nut 19 Tighten the slotted nut to 35 foot pounds 47 Nm to seat the bearings 20 Loosen the slotted nut then re tighten to 8 foot pounds 11 Nm 21 Install a new cotter pin Bend the cotter pin to lock it in 22 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 125 foot pounds 169 5 Nm Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a 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 Troubleshoo
159. ed wire from TP6 to TB6 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to 5 40 Genie 5 40 Part No 52271 Service Manual Second Edition Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the turntable rotate left right toggle switch TS17 on ground panel in the left direction and check voltage on wht blk wire on boom function directional valve coil item A 12V or more Continued on the next page Section 5 Troubleshooting Flow Charts N Move the function enable switch to either side and hold the turntable rotate left right toggle switch TS17 on ground panel in the left direction and check voltage at TB5 With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and turntable rotate left right proportional controller BP1 on platform control panel in the left direction and check voltage TB5 oV Activate footswitch and turntable rotate left right proportional controller BP1 on platform control panel in the left direction and check voltage TP5 oV Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller B
160. eduled Maintenance 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 operates in a closed loop hydraulic circuit with the master cylinder located at the base of the boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Start the engine from the ground controls and lower the boom into the stowed position 2 Hold the function enable toggle switch to either side and adjust the platform to a level position using the platform level toggle switch 3 Raise and lower the boom through a full cycle Result The platform should remain level at all times to within 5 degrees B 18 Test the Horn A functional horn is essential to safe machine operation The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 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 TABLE B PROCEDURES 2 Push down the horn button at the platform controls Result The horn should sound If necessary the horn can be adjus
161. eduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURES A 11 Test the Platform and Ground Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machine functions and shut off the engine Each function should activate operate smoothly and be free of hesitation jerking and unusual noise 1 Pull out the Emergency Stop button at the ground controls to the position 2 Startthe engine from the ground controls 3 Do not hold the function enable switch to either side Attempt to activate each boom and platform function toggle switch O Result All boom and platform functions should not operate 4 Hold the function enable switch to either side and activate each boom and platform function toggle switch O Result All boom and platform functions should operate through a full cycle Descent alarm if equipped should sound while the boom is lowering 5 Pushin the Emergency Stop button to the position O Result No function should operate the engine should stop Machines equipped with Platform Level Control Disable Function The platform level function will not operate when the boom is raised or extended past the drive speed limit switches Deutz Diesel models All functions shoul
162. en with the bottom of the hole Apply pipe thread sealant to the plugs and then install the plugs Turntable rotate torque hub 8 fluid ounces 0 24 liters Oil capacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 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 this procedure with the engine off 1 Remove the filter with an oil filter wrench 2 Applyathin layer of oil to the new oil filter gasket 3 Install the new filter genie part no 46014 and tighten it securely by hand Clean up any oil that may have spilled during the installation procedure 4 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter TABLE C PROCEDURES 5 Startthe engine from the ground controls 6 Inspect the filter and related components to be sure that there are no leaks 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 continue
163. eplace auxiliary pump motor Part No 52271 Genie S 40 5 71 Section 5 Troubleshooting Flow Charts Service Manual Second Edition 0 This page intentionally left blank 5 72 Genie S 40 Part No 52271 Service Manual Second Edition Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the appropriate Genie S 40 Operator s Manual MI 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 AWARNING Electrocution hazard Contact 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
164. er AWARNING may become unbalanced and fall if itis not properly supported Component damage hazard The ACAUTION cables and hydraulic hoses can be damaged if the lift cylinder is pulled across them Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Extend the boom until the extension cylinder rod end pivot pin is accessible in the extension tube 2 Remove the platform See 2 1 How to Remove the Platform 3 Remove the master cylinder See 3 5 How to Remove the Master Cylinder 4 Raise the boom to a horizontal position 5 Remove the external snap rings from the extension cylinder rod end pin at the platform end Use a soft
165. er from the boom lift cylinder rod end pin Use a soft metal drift to remove the pin Crushing hazard The boom lift AWARNING cylinder will fall unless it is properly supported 13 Lower the rod end of the lift cylinder onto support blocks Protect the cylinder rod from damage 14 Remove the pin retaining fastener from the boom pivot pin 15 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 BOOM COMPONENTS 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 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 3 Remove the pin retaining fastener from the extension cylinder barrel end pivot pin at the pivot end of the boom 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 boom tube Crushing hazard The extension AWARNING tube may become unbalanced and fall
166. es to 0 2 boom extend directional infinite valve coil item C and ohms kos m AO test the resistance of the it be C al valve valve coil See Repair 5 Section Continued from the previous page 2 5 to 3 5 ohms function Move function enable operates switch to either side and hold the boom retract toggle switch at the ground controls in the extend direction Manually override the directional valve by pushing in on the end of the valve spool Replace defective directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick boom from retracting disconnect coupling on OR repair cylinder or the boom function cylinder counterbalance manifold and start the valves OR consult engine Move the Genie Industries Service function enable switch to Department either side and hold the boom retract toggle switch at the ground controls in the retract direction and check the pressure less than 1700 PSI function Exchange flow regulator operates valve item G with a like valve item H Check boom retract function Replace defective flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department CHART 17 Part No 52271 Genie S 40
167. essure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 6 Repeat steps 2 through 5 and recheck relief valve pressure Boom down relief valve specifications Pressure 2200 psi 152 bar Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures How to Adjust the Boom Extend Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 207 bar pressure gauge to the test port item 23 on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to either side and activate and hold the extend switch with the boom fully extended Observe the pressure reading on the pressure gauge 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 5 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 6 Repeat steps 2 through 5 and recheck relief valve pressure Boom extend relief valve specifications Pressure 1950 psi 134 bar MANIFOLDS How to Override a Valve A hydraulic valve may need to be manually overridden to troubleshoo
168. f 13 0 1 to 13 2 1 using an exhaust gas analyzer Preliminary setting is 1 4 inch of threads showing Measure from top of lock nut to top of adjustment screw If an exhaust gas analyzer is not available adjust to obtain peak or optimum rpm 5 Hold the adjustment screw and tighten the lock nut 6 Return the function enable toggle switch to the center position 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 Preliminary setting turn low idle adjustment screw clockwise all the way in Turn low idle adjustment screw counterclockwise 2 3 4 turns C 13 Check and Adjust the Ignition Timing Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 C 14 Check the Engine Valve Clearances Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011F Workshop Manual Deutz Number 0297 7195 Genie part number 52229 Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance 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 u
169. fold Components Oscillating Models 7 46 9 9 Steer Manifold Components Non oscillating Models 7 47 9 10 2WD Drive Manifold 7 48 9 11 Valve Adjustments 2WD Drive 7 50 9 12 AWD Drive Manifold Components 2 2 4440 7 52 9 13 Valve Adjustments 4WD Drive 000001 7 54 Fuel and Hydraulic Tanks 10 1 Fuel Tanks edet eet ette 7 55 10 2 Hydraulic Tank iiiter eh en REP 7 55 Part No 52271 Genie S 40 xi Service Manual Second Edition January 2008 n TABLE OF CONTENTS Section Seven Repair Procedures continued Turntable Rotation Components 11 1 Rotation Hydraulic enne 7 58 2WD Steering Axle Components 1221 YOke a d HUB s szeroko Gi ai oi O E Ghee ete 7 60 12 2 Steering 2 0 242 1 1 11 10 eene nennen enne 7 61 12 3 Die R J den eo O 7 62 4WD Steering Axle Components 13 1 Yoke and Hub Rev 7 63 13 2 Steering Cylinders See 12 2 Steering Cylinders Rev B 7 64 13 3 Tie Rod See 12 3 Tie Rod Rev B 7 64 Oscillating Axle Components 1
170. free wheel valve is located on the bottom of the drive pump a drive pump b free wheel valve c lift pump d screwdriver The free wheel valve should always remain closed TABLE C PROCEDURES C 4 Grease the Turntable Rotation Bearing and Rotate Gear Yearly application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Locate the grease fitting on the platform 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 at a 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 Grease type Multipurpose grease C 5 Replace the Torque Hub Oil Replacing the torque hub oil is essential for good machine performance and service life Failure to replace the torque hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage Drive Torque Hubs 1 Select the 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 Part No 52271 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE C PROCEDURES
171. g 0 052 inch 1 32 mm AD Front drive motor circuit 4 Flow divider combiner valve gt Controls flow to steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 5 Flow divider combiner valve Controls flow to non steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 6 Orifice 0 070 in 1 78 mm AG Rear drive motor circuit Orifice 0 070 in 1 78 mm nu Equalizes pressure on both sides of flow divider combiner valve Index no 1 8 Shuttle valve 3 position way npe Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift 15 18 ft lbs 20 24 Nm 9 Diagnostic fitting Testing Plug Torque Specifications Description Hex size Torque SAE No 8 5 16 50 ft lbs 68 Nm SAE No 2 1 8 50 in Ibs 6 Nm SAE No 10 9 16 55 ft Ibs 75 Nm SAE No 4 3 16 13 ft Ibs 18 Nm SAE No 12 5 8 75 ft lbs 102 Nm SAE No 6 1 4 18 ft lbs 24 Nm 7 52 Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS O f i AG Part No 52271 Genie S 40 7 53 Section 7 Repair Procedures Service Manual
172. g Torque Specifications 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 Tag disconnect and plug the lift steer pump hydraulic hoses Cap the fittings on the pump 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 Hydraulic Pumps 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 Pump The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electronic displacement controller EDO 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 Sauer service center Call Genie Industries Service Department to locate your local authorized service center How to Remove the Drive Pump Component damage hazard The ACAUTIO
173. g Torque Specifications Remove the platform See 2 1 How to Remove the Platform Remove the platform rotator and leveling slave cylinder See 2 3 How to Remove the Platform Rotator Remove the cable track See 3 1 How to Remove the Boom Cable Track Raise the boom to a horizontal position Remove the turntable end cover Remove the retaining fastener from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin Pull the cylinder back and secure it out of the way ACAUTION Component damage hazard When pulling the master cylinder back be sure not to damage the master cylinder hoses or fittings 7 Remove the fasteners from the drive speed limit switch mounted to the turntable riser at the pivot end of the boom Do not disconnect the wiring Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures 8 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Attach an overhead 5 ton 4536 kg crane to the center point of the boom 10 Attach a similar lifting device to the lift cylinder 11 Place support blocks under the lift cylinder across the turntable 12 Remove the pin retaining fasten
174. g machine Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years M Unless otherwise specified perform each maintenance 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 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 ADANGER 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 O Indicates that a specific result is expected after performing a step Part No 52271 Genie S 40 4 1 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition Table A Procedures A 1 Inspect the Manuals Maintaining the operators and safety manuals in good condition is essential to safe machine operation Manuals are included with eac
175. h 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 Checkto be sure that the storage container is present and in good condition 2 Check to make sure that the 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 that they 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 of the 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 Decals section in the appropriate Genie S 40 Operator s Manual and use the decal list and illustrations to determine that all decals and placards are in place 2 Inspect all decals for legibility and damage Replace any damaged or illegible decal immediately Contact your authorized Genie distribu
176. h a serpentine belt and incorporate a self adjusting pulley tensioner No adjustment is required 3 8 inch to 1 2 inch Part No 52271 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 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 of the cooling system A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems AWARNING Do not inspect while the engine is running Remove the key to secure from operation Beware of hot engine parts and ACAUTION coolant Contact with hot engine parts and or coolant may cause severe burns 1 Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the radiator 2 Inspect the radiator for leaks and physical damage 3 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
177. hart 21 Repair open in org wire from TB14 to platform level up directional valve coil item T OR repair open in brown ground wire circuit to valve coil Troubleshoot platform level toggle switches TS14 and TS6 on ground and platform control panels OR repair open in red power wire circuit to TS14 and TS6 OR repair open in org wire circuit from TS14 and TS6 to TB14 OR consult Genie Industries Service Department Part No 52271 Genie S 40 5 49 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 21 0 or infinite ohms Disconnect the wires from the platform level up directional valve coil Continued from the previous page item T and test the resistance of the valve coil 610 7 ohms function Exchange platform level operates up and down directional valves items T and V and activate the platform level up function function inoperative function Exchange platform level operates up and down counterbalance valves items FF and GG and activate the platform level up function function inoperative Install a 0 to 3000 0 to 207 bar pressure gauge at the quick disconnect coupling on the function manifold and activate the platform level up function 2600 psi or more less than 2600 psi function Exchange platform level operates flow regulator valve item U with a like valve item EE and activate the platform level up func
178. have the appropriate tools lifting equipment and a suitable workshop Part No 52271 Genie S 40 iii Section 1 Safety Rules Service Manual Second Edition SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Indicates the presence of a hazard that will cause death or serious injury AWARNING Indicates the presence of a hazard that may cause death or serious injury Indicates the presence of ACAUTION p a hazard that will or may cause serious injury or damage to the machine ADANGER Indicates special operation or maintenance information other protective clothing if the situation G Be sure to wear protective eye wear and 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 gl Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris
179. he voltage to 4 5V DC Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 9 Startthe engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Engine should be at normal operating temperature 10 Fully retract the boom then 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 80 to 100 second cycle time 11 Extend the boom then start a timer and record how long it takes the turntable to rotate through a complete circle Adjust the lo range trimpot to achieve a 130 to 160 second cycle time 12 Turn the engine off and re connect the volt meter 13 Pull out the Emergency Stop button to the position 14 Press down the foot switch and then move the control handle all the way to the left or right Record the maximum voltage reading 15 Start the engine 16 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 14 This is the ramp rate 7 4 Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures 17 Set the ramp rate Turn the trimpot to obtain a 5 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Turntable
180. he slave cylinder rod end pivot pin and the rotator pivot pin 8 Use a soft metal drift to drive both pins out then remove the platform rotator from the machine Crushing hazard The platform AWARNING rotator may become unbalanced and fall if it is not properly supported How to Bleed the Platform Rotator Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Move the function enable toggle switch to either side and activate 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 Connect a 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 top bleed valve b bottom bleed valve c container d clear hose 4 Move the function enable toggle switch to either side and activate and hold the platform rotate switch to the Lert 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 AWARNING the platform during rotation 5 Connect the clear hose to the bottom bleed valve and open the valve Do not remove the bleed valve 6 Move the function enable toggle
181. he torque hub Remove the yoke weldment from the torque hub Replace the thrust washer when installing the yoke torque hub assembly onto the axle Torque specifications Lug nut REV B 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 dry 170 ft Ibs 230Nm 13 3 lubricated 130 ft lbs 176 Nm Tie Rod Torque hub mounting bolts dry 120 ft lbs 163Nm How to Remove the Tie Rod lubricated 90 ft lbs 122 Nm This procedure is the same as the 2WD procedure Drive motor mounting bolts See Repair Procedure 12 3 dry 75 ft lbs 102 Nm How to Remove the Tie Rod lubricated 56 ft lbs 76 Nm 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 7 64 Genie S 40 Part No 52271 Service Manual Second Edition January 2008 Section 7 Repair Procedures Oscillating Axle Components REV B 14 1 3 Tag disconnect and plug the oscillating axle Oscillating Axle cylinder hydraulic hoses Cap the fittings on the oscillate cylinder Lock out Cylinders AWARNING odily 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 The oscillating axle cylinders extend and retract
182. heck in wht wire circuit from Inope rative voltage at TP24 foot switch to TP24 Ground 12V Controls no Operate Repair open in wht wire circuit from TP24 to Normal ly function toggle switches and function controllers Be sure all cables from chassis omma Woe EE T eck voltage a epair open in red wire through the cable circuit from key switch to track are in good condition with no kinks or abrasions 12V ov Check voltage at TP22 12V Check voltage at blk wire on input side of platform Emergency Stop button contact P2 12V With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the on TB22 OR Replace the platform controls contact at the key switch Repair open in blk 2 wire circuit from TB22 TP22 Repair open in blk wire from TP22 to Emergency Stop button P2 Check if Emergency Stop button internal cam yes is activating the contact Replace contact on Emergency Stop button P2 position check the voltage on the output side of the platform Replace the platform Emergency Stop button Emergency Stop button contact 12V oy Repair open in wht wire with diode from 12V Emergency Stop button to TP23 Repair open in blk wire circuit from platform Emergency Stop button to TP26 to foot switch OR replace foot switch OR consult Genie Industries Service Department Part No 52271 Genie S 40 5 29 Section 5 Troubles
183. hooting Flow Charts Service Manual Second Edition Chart 14 Boom Up Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom up toggle switch TS16 on ground panel in up direction and check voltage on red wht wire on boom up down proportional valve coil item P 20V or more Continued on the next page Move the function enable switch to either side and hold the boom up toggle switch TS16 on ground panel in the up direction and check voltage at TB3 With the keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and boom function controller BP 1 on platform control panel in up direction and check voltage at TP3 oV Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department Repair open in red wht wire circuit from TB3 to boom up down SOW proportional valve coil item P OR repair open in brown ground wire circui to valve coil Repair open in power supply circuit from TP24 to BP1 OR repair open 8 to 9V Repair open in red wht wire from TP3 to TB3 in brown ground wire circuit from grou
184. 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 Turn the engine off Hold the unloader valve and remove the cap item 4 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap Tip over hazard Do not adjust the AWARNING relief valve higher than specified MANIFOLDS 7 Repeatsteps 3 through 6 and 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 Sequencing valve specifications Pressure 950 psi 65 bar Part No 52271 Genie S 40 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 9 7 Directional Valve Manifold Components The directional valve manifold is mounted inside the drive chassis at the non steer end Index No Description Function Torque 1 M HM 1 20 25 ft lbs 27 33Nm 2 Spool valV6 22 iren eere Directional control
185. il pump bolts 15 to 18 20to24 6 80 Torx 8 8 M 8 x 35 Torx Oil thermostat housing bolts 14 to 16 19 to 22 Oil filter bracket bolts 7108 9 to 11 6 105 8 8 8 20 8 8 Valve plunger housing bolts 14 to 16 19 to 22 Oil intake housing bolts 15 to 18 201024 M 8x 30 Torx 8 8 M 8 x 75 Torx Alternator nuts M 5 3 4 Fuel pump bolts 15 to 18 20024 Fuel bracket bolts M 8 x 20 8 8 15 20 Injection pump bolts 15 to 18 201024 Adapter housing bolts 701077 9510105 Injector cap nut 30 to 37 40to50 M 12 x35 10 9 or M 12 x 75 10 9 Injector fastening bolt 15 to 18 20 to 24 second step tightening tightening Injection line 10to12 13 5 to 16 5 torque angles m ft Ibs Nm 1st 2nd Air intake manifold bolts 15 to 18 20 to 24 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 30 609 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 Part No 52271 Genie S 40 2 7 Section 2 Specifications Service Manual Second Edition 0 r
186. ilage ceDeluuisg lo uecieasevohage Do not use the color of the 16 Close the platform control box lid and install connector as a guide for these the fasteners tests Use the actual wire color to identify which wire to use for Drive speed specifications testing Stowed position distance 40 ft 12 m Test Desired result 2WD 4WD mE Gasoline LPG models 40 6 8 sec 40 7 8 ed to black continuity 12 2 m 6 8 sec 12 2 m 7 8 sec zero Deutz Diesel models 40 ft 7 8 sec 40 ft 9 1 sec red to white no continuity 12 2 m 7 8 sec 12 2 m 9 1 sec infinite Q Boom raised or distance 40 ft 12 m black to white no continuity extended 1 foot per second All models 30 5 cm per second Do not use the color of the connector as a guide for these tests Use the actual wire color to identify which wire to use for 1 3 testing Foot Switch 3 Press down the foot switch Connect the leads from an ohmmeter or continuity tester to each How to Test the Foot Switch wire combination listed below and check for continuity 1 Turn the key switch to the orr position and separate the wiring quick disconnect plug from Test Desired result the platform toe board red to black no continuity infinite red to white no continuity black to white continuity zero Q Part No 52271 Genie S 40 7 7 Section 7 Repair Procedures Service Manual Second Edition PLATFORM CONTROLS 1 4 Resist
187. ing 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 5 Pull the slave cylinder hoses through the platform rotator 6 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Do not remove the pin 7 Remove the external retaining ring from the barrel end pivot pin 8 Use a soft metal drift to drive the rod end pivot pin out 9 Use a soft metal drift and drive the barrel end pin out 10 Carefully pull the cylinder out of the boom Component damage hazard ACAUTION Hoses can be damaged if they are kinked or pinched How to Bleed the Slave Cylinder Do not start 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 on the rotator flange as it was before removal If a new rotator is installed or th
188. ing bracket then pull the bracket up past the bell housing Secure the bracket before continuing Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts Carefully pull the pump away from the engine and secure it from moving Remove the flex plate mounting fasteners then remove the flex plate from the fly wheel Part No 52271 Genie S 40 7 23 Section 7 Repair Procedures Service Manual Second Edition FORD LRG 423 ENGINE How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline towards the pump Torque the flex plate mounting bolts to 34 ft Ibs 46 Nm 2 Install the coupler onto the pump shaft with the set screw towards the pump Leave 1 4 inch 6 35 mm gap between the coupler and pump end plate 3 Apply Loctite removable thread sealant to the coupler set screw Torque the set screw to 45 ft Ibs 61 Nm Component damage hazard Do ACAUTION not force the drive pump during installation or the flex plate teeth may become damaged 4 Install the pump and torque the pump mounting plate fasteners to 34 ft lbs 46 Nm 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
189. ining fastener then remove the filter 4 Clean the inside of the canister and the gasket with a damp cloth 5 Insert the new filter and replace the mounting fastener 6 Replace the end cap on the canister then replace the retaining ring Air filters Genie part numbers Ford LRG 423 Engine Deutz F3L 1011F Engine 27916 27916 Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures Table B Procedures B 1 5 Checkthe engine belt for proper tension Check the Engine Belt Maintaining the engine belt s is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt and continued use may cause component damage AWARNING Do not inspect while the engine is running Remove the key to secure from operation ACAUTION Beware of hot engine components Contact with hot engine components may cause severe burns 1 Deutz Diesel models Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the front engine access cover mounting fasteners 2 Remove the front engine access cover mounting fasteners 3 All models Inspect the engine belt for Cracking Glazing Separation Breaks 4 Replace belt if any damage is found Belt deflection Deutz Diesel models 9 mm to 12 mm Deutz Diesel engine Ford LRG 423 engines are equipped wit
190. ire circuit to TS13 OR repair open in grn blk wire circuit from 151310 TB18 OR consult Genie Industries Service Department 12V or more Chart 24 Repair open in grn blk wire from TB18 to platform rotate right directional valve coil item DD OR repair open in brown ground wire circuit to valve coil Troubleshoot platform rotate toggle switches 513 and TS5 on ground and platform control panels OR repair open in red power wire circuit to TS13 and TS5 OR repair open in grn blk wire circuit from TS13 and TS5 to TB18 OR consult Genie Industries Service Department Part No 52271 Genie S 40 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 24 Disconnect the wires 0 or from the platform rotate infinite right directional valve ohms coil item DD and test the resistance of the valve coil Continued from the previous page Replace the platform rotate right directional valve coil item DD 610 7 ohms Exchange platform function rotate right and left operates Replace the defective directional valves items directional valve DD and CC and activate the platform rotate right function function inoperative Exchange platform function rotate right and left operates Replace the defective counterbalance valves counterbalance valve at the counterbalance valve manifold and activate the platform rotate right function function inoperative
191. ire on the input side of the ground controls contact of the key switch KS1 the red wire checked should originate from the Emergency Stop button 12 With the keyswitch turned to ground controls and both Emergency Stop buttons are pulled out to theon position check voltage at red wire at the output side of the ground controls contact on the key switch 12V Repair open in red wire circuit from key switch to function enable toggle Switch to each function toggle switch Start the engine from the ground controls Move the function enable toggle switch to either side and check the voltage on the center terminal of the platform rotate toggle switch TS13 Repair open in red wire circuit from key switch to function enable toggle switch to each function toggle switch 12V Troubleshoot each function individually Repair open in red wire circuit from emergency stop button to the key switch Check if key switch internal cam is activating Replace key switch contact for ground ground contact controls no Replace key switch 1 2 5 28 Genie S 40 Part No 52271 Section 5 Troubleshooting Flow Charts Chart 13 Service Manual Second Edition Platform Does engine start from yes 2 W pe Test or replace foot the platform controls platform controls then switch see Repair Controls press down the foot Section OR repair open i switch and c
192. istor Part No 52271 Genie S 40 7 27 Section 7 Repair Procedures Service Manual Second Edition GROUND CONTROLS 7 5 Power Relay Electrocution hazard Contact with AWARNING electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry The power relay is mounted on the backside of the ground control box 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 1210160 no continuity infinite 2 large posts no continuity infinite Q Any small post to any large post 2 Connect 12V DC to one of the small posts and a ground wire to the other small post then test the following terminal combination Test Desired result 2 large posts continuity zero Q a high amp power contact terminal large post b solenoid activate coil terminal small post Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures 8 1 Lift Steer Pump How to Remove the Lift Steer Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fittin
193. ith raised spline flywheel 1 2 inch gap How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Supportthe 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 flywheel How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline towards the pump Torque the flex plate mounting bolts to 34 ft lbs 46 Nm 2 Install the coupler onto the pump shaft with the set screw toward the pump Leave a 2 inch 12 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 Install the pump and torque the pump mounting plate fasteners to 34 ft Ibs 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 3009 F 1479 C When the contacts close the engine will shut off to prevent damage and will not start until the tem
194. ive joystick in the full Continued from the previous page forward position and check the voltage at terminal 6 on the drive joystick controller 9 to 12V Connect the positve lead from a voltmeter to terminal 4 on the joystick and the negative lead to terminal 5 on the joystick Activate the footswitch and hold the drive joystick in the full forward position and check the voltage across the 4 and 5 terminals on the drive joystick controller Connect the positve lead from a voltmeter to terminal 5 on the joystick and the negative lead to terminal 4 on the joystick Activate the footswitch and hold the drive joystick in the full reverse position and check the voltage across the 5 and 4 terminals on the drive joystick controller 2V Continued on the next page CHART 28 Repair open in wire from terminal 10 on horsepower limiter board to terminal 6 on the drive joystick no Check continuity from nuity terminal 3 on drive joystick to ground Repair open in brown ground wire circuit from terminal 3 on drive joystick to ground continuity Replace drive joystick controller OR consult Genie Industries Service Department no Check continuity from terminal 3 on drive joystick to ground Repair open in brown ground wire circuit from terminal 3 on drive joystick to ground continuity Replace drive joystick controller OR consult Geni
195. iveur MODULE LO 4 aux s enouvo LO e LO 7 kev ewe s kevevrass LC 9 on veren LO 10 ENG FAUT RED 6 ISM WHT 9 ISM BLK RED R4 E H BLK RED 35B RED CB1 aa A T 2 3 4 BLKit1 ISM E 1 IWHT 21D BLK D B BLK R5 A H 5 LE F BLK 22D GRN 43D 6 16 Genie S 40 Part No 52271 Section 6 Schematics Service Manual Second Edition Platform Control Box Legend Diesel Models GEN OPTION 45 GRN WHT 1 SPARE 44 GRN BLK 1 HORN 43 GRN 1 SPARE 42 ORG RED 1 41 40 LE 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 BLK 1 BRAKE 32 WHT RED 1 E D C 31 WHT BLK 1 E D C 30 WHT 1 2WD 4WD 29 RED WHT 1 28 AUX PWR 27 RED 1 PWR TO FS 26 BLK ES PWR START 25 RED FS 2 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 2 PLAT ROT R 18 GRN BLK 3 e PLAT ROT L 17 GRN 3 PLAT LVL FC 16 ORG RED 3 PLAT LVL DN 15 ORG BLK 3 PLAT LVL UP 14 ORG 3 DRV ENA LT 13
196. l of the oil from the engine to drain into a suitable container See capacity specifications to the right 4 Install the plug into the drain hose Use an oil wrench and remove the oil filter a engine oil level dipstick b fuel filter c filter 6 Apply a thin layer of oil to the new filter gasket genie part no 49924 Then install the filter and tighten it securely by hand 7 Usea 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 install the oil filler cap 9 Startthe 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 drain hose for leaks 11 Check the engine oil level dipstick Add oil if needed Deutz Engine F3L 1011F Cil capacity including filter 8 5 quarts 8 liters Deutz Engine F3L 1011F Oil viscosity requirements Temperature below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 Temperature above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE CD SE CC SF or CD SF grades Genie S 40 Part No 52271 Service Manual Second 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 operation Wear pads are placed on boom tube
197. level down function function inoperative function Exchange platform level operates down and up counterbalance valves items GG and FF and activate the platform level down function function inoperative Install a 0 to 3000 0 to 207 bar pressure gauge at the quick disconnect coupling on the function manifold and activate the platform level down function 2600 psi or more less than 2600 psi function Exchange platform level operates flow regulator valve item U with a like valve item EE and activate the platform level down function function inoperative Test master cylinder see Chart 20 OR repair or replace slave cylinder or slave cylinder counterbalance valves OR function manifold may have an internal defect Consult Genie Industries Service Department Replace the platform level down directional valve coil item V Check for mechanical restrictions keeping platform level down function from operating OR replace slave cylinder OR replace Replace the defective directional valve Replace the defective counterbalance valve slave cylinder counterbalance valves OR consult Genie Industries Service Department Replace defective flow regulator valve Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Rotate Left Function Inoperative Be sure all other functions operate nor
198. lic Hose and Fitting Torque 2 8 Bolt Torque Specifications Rev B 2 9 Scheduled Maintenance Inspections Introduction c a d e D De ades 3 1 NE EE 3 2 Table eee ieee ees eoe 3 3 C O NCAA 3 5 REID EAR 3 6 Maintenance Inspection 3 7 Scheduled Maintenance Procedures ich ei RE Ee Tt 4 1 A 1 Inspectthe Manuals 4 2 2 Inspect the Decals and 4 2 Inspect for Damage Loose or Missing 4 2 A 4 Check the Engine Oil 1 4 3 A 5 Check the Engine Coolant Level Gasoline LPG Models 4 3 A 6 Check for Fuel 1 20 0 4 3 A 7 Check the Hydraulic 4 4 A 8 Check for Hydraulic 4 4 Part No 52271 Genie S 40 V Service Manual Second Edition January 2008 TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued A 9 Check the Tire Pressure 4 5 A 10 Test the Oscillate Axle if 4 5 A 11 Testthe Platform and Ground
199. line LPG Models Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 TABLE B PROCEDURES B 12 Check and Adjust the Engine RPM Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Gasoline LPG Models Perform this procedure in gasoline mode with the engine at normal operating temperature 1 Disconnect the blue black wire from the governor actuator 2 Connectan rpm gauge to the engine then start the engine from the ground controls O 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 a carburetor b adjustment screw 4 Turn the engine off and reconnect the blue black wire to the governor actuator 5 Startthe engine from the ground controls O Result Electronic governor low idle should be 1600 rpm Part No 52271 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 6 Move the function enable toggle switch to the high idle rabbit symbol position at the ground controls
200. ll tube Do not overfill 6 Install the vent caps Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 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 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 Startthe engine from the platform controls 2 Move the engine speed control switch to high idle rabbit symbol 3 Inspectthe filter condition indicator a filter condition indicator b filter c hydraulic tank O Result The filter should be operating with the plunger in the green area If the 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 Hyaraulic Tank Filter Genie S 40 Part No 52271 Service Manual Second Edition January 2008 Section 4 Scheduled Maintenance Procedures Rev B 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 un
201. ls O Result High idle should be 2300 rpm If high idle rpm is correct disregard adjustment step 4 Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm 4 20 Genie 5 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 4 Loosen the yoke lock nut then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle Deutz Diesel models Low idle 1300 rpm High idle 2300 rpm B 13 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pull out the Emergency Stop button to the 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 3 Check any machine function from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Check any machine function from the platform controls Result The ma
202. lugs 80 5 8 18 9Q 5 8 18 Wheelbase 7 ft 3 in 7ft3in Lug nut torque 2 21 m 2 21 m Dry 170 ft lbs 230 Nm Lubricated 130 ft lbs 176 Nm Minimum turning radius 7 ft 10 in 7 ft 10 in outside 24m 24m Fluid capacities Minimum turning radius 3 ft 4 in 3 ft 4 in Ryeltank n Gallons 114 liters inside 1m 1m LPG tank 33 5 pounds Turntable rotation continuous X continuous 15 2 kg Platform rotation 160 160 Hydraulic tank 45 gallons 170 liters Platform dimensions 6 ft 8 ft Standard Optional Hydraulic system 50 gallons including tank 189 liters Length 6 ft 8 ft 183m 244m Drive torque hubs 17 fl oz 0 5 liters Width 30 in 36 in 76 2 cm 91 4 cm Turntable rotation 8floz torque hub 0 24 liters Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 52271 Genie S 40 2 1 Section 2 Specifications Service Manual Second Edition p H ES eG SPECIFICATIONS Performance Specifications Boom function speeds maximum from platform controls Drive speeds maximum 2WD 4WD E Boom up 40 to 60 seconds Drive speed stowed 4 mph 3 5 mph Gasoline LPG models 6 4 km h 5 6 km h Boom down 50 to 80 seconds 40 f 6 8 sec 40 1 7 8 Boom extend 35 to 65 seconds 12 2 m 6 8 sec 12 2 m 7 8 sec Drive speed stowed 3 5 mph 3 mph Boom retract 40 to 70 seconds Deutz Diesel models 5 6 km h 4 8 km h Turntable rotate 360 4
203. lways have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Loosen the drain plug located at the bottom of the filter Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug a fuel filter b drain plug Part No 52271 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURES 2 Clean up any fuel that may have spilled If the fuel filter is completely drained you must prime the fuel filter water separator before starting the engine Refer to C 8 in this section Replace The Diesel Fuel Filter Water Separator for instructions on how to prime the fuel filter water separator 3 Startthe engine from the ground controls and check the fuel filter water separator for leaks A 17 Replace the Engine Air Filter Engine specifications require that this procedure be performed every 100 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 Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off 1 Remove the retaining ring from the end cap of the air filter canister 2 Remove the end cap from the air cleaner canister 3 Remove the air filter reta
204. mally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the platform rotate toggle switch TS13 in the left direction and check the voltage at grn wire on platform rotate left function directional valve item CC Continued on the next page 12V or more With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the on position move the function enable switch to either side and activate the platform rotate toggle switch TS13 in the left direction and check the voltage at TB17 With the keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate the footswitch and the platform rotate toggle switch TS5 in the left direction and check the voltage at TB17 Troubleshoot platform rotate toggle switch 513 on ground control panel OR repair open in red power wire circuit to TS13 OR repair open in grn wire circuit from 151310 TB17 OR consult Genie Industries Service Department 12V or more Chart 23 Repair open in grn wire from TB17 to platform rotate left directional valve coil item CC OR repair open in brown ground wire circuit to valve coil Troubleshoot platform rotate toggle switches 513 and TS5 on ground and platform control panels OR repair open in red power wire circuit to TS13 and TS5
205. matic No Description Item Function Torque 1 position 4 way DOS valve Platform rotate 30 35 in lbs 3 4 Nm 2 Counterbalance valve Bins Platform level up 35 40 ft lbs 47 54 Nm 3 Sandwich valve manifold Platform level 4 position 4 way DOS valve Platform level 30 35 in lbs 3 4 Nm 5 position 4 way DOS valve Pee Turntable rotate 30 35 in Ibs 3 4 Nm 6 Cover ON O reer Mee TH 30 35 in Ibs 3 4 Nm 7 position 4 way DOS valve FU siis Boom up down 30 35 in Ibs 3 4 Nm 8 position 4 way DOS valve Boom extend retract 30 35 in lbs 3 4 Nm 9 Counterbalance valve Ozi Platform level down 35 40 ft lbs 47 54 Nm 10 Check valve K Turntable rotate differential sensing 11 13 ft Ibs 15 18 Nm 11 Check valve M Boom up down differential sensing 11 13 ft Ibs 15 18 Nm 12 Flow regulator valve Boom up down 10 12 ft Ibs 14 16 Nm 13 Relief valve 1950 psi 134 bar Dus Boom extend
206. maximum stability achieve optimum machine handling and minimize tire wear it is essential to maintain proper pressure in all air filled tires 1 Check each tire with an air pressure gauge and add air as needed Tire specifications TABLE A PROCEDURES A 10 Test the Oscillate Axle if equipped 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 Startthe engine from the platform controls 2 Drive the right steer tire up onto a 6 inch 15 2 cm block or curb O Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 3 Drive the left steer tire up onto a 6 inch 15 2 cm block or curb O Result The three remaining tires should stay in firm contact with the ground and the chassis Bye tires only 12 5 16 SL should remain level at all times 2WD and 4WD front and rear tires 12 16 5 NHS 4 Drive both steer tires up onto a 6 inch 15 2 cm block or curb Pressure 45 psi 3 1 bar Result The non steer tires should stay in firm contact with the ground If the chassis does not remain level during test see Repair Procedure 9 6 How to Set Up the Directional Valve Linkage OR see Repair Procedure 9 5 How to Adjust the Oscillate Sequencing Valve Pressure Part No 52271 Genie S 40 4 5 Section 4 Sch
207. mbly 6 Remove the pin retaining fasteners from the yoke pivot pins 7 Support the yoke hub assembly with a lifting jack 8 Usea slide hammer to remove the upper yoke pivot pin then use a soft metal drift to drive the lower yoke pivot pin down and out Crushing hazard The yoke hub AWARNING assembly may become unbalanced and fall when the yoke pivot pins are removed if it is not properly secured and supported by the lifting jack Torque specifications Lug nut torque dry 170 ft Ibs 230 Nm Lug nut torque lubricated 130 ft Ibs 176 Nm How to 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 of ample capacity under the steering axle 3 Raise the machine 6 inches 15 cm 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 60 Genie S 40 Part No 52271 Service Manual Second Edition January 2008 Section 7 Repair Procedures REV B 7 Place the hub on a flat surface and gently pry the bearing seal out of the 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
208. meter 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 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Will Not Crank Over Be sure the key switch is in the appropriate position Be sure that both Emergency Stop buttons are pulled out to the position Be sure the circuit breakers are not tripped Be sure the battery is fully charged Check battery voltage 12V or more With the keyswitch turned to ground controls and both Emergency Stop buttons are pulled out to the ON position check the voltage at the center terminal on the start toggle switch TS10 12V Hold the start toggle Switch to either side and check the voltage at either side terminal on start switch 12V Hold the start switch to either side and check voltage at
209. mpt to support the cover by hand Component damage hazard ACAUTION Protect the cover from damage byusing carpet or padding on the crane or fork lift forks 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 cylinder rod from damage Mark the locationof the hinge support bracket on the bulkhead to ensure proper cover alignment during installation 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 Crushing hazard The turntable AWARNING cover may become unbalanced and fall if it is not properly supported and secured to a appropriate lifting device AWARNING If a turntable cover must be 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 52271 Genie S 40 7 19 Section 7 Repair Procedures Service Manual Second Edition Deutz Engine F3L 1011F 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 It is bolted to the engine flywheel and has a splined center to drive the pump 9 OO pump pump shaft coupler flex plate w
210. n SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Loke O ring face seal fittings and hose ends Machines that utilize Parker Seal Lok O ring face seal hoses and fittings require that the fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed Hydraulic Hose and Fitting Torque Specifications SAE O ring Boss Port tube fitting Seal Lok hose end SAE Dash Installing SAE Dash sea e 27 27 399 6 lAummm 8 8 40 52 es 45 9 es 64 _ 8 Aumnm 40 842 gt o 12 tea 60 83 9 197 90 Alummm 6 amp 9 se sed os 4 1 2397 126 1 190 188 5 2847 2332 852 5 282 2271 LL 3 Torque Procedure 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight The O rings used in the Parker Seal Lok fittings and hose ends are a custom size O ring They are not a standard SAE size O ring They are available in the O ring field service kit Genie part no 49612 2 Lubricate the O ring before installation Be sure that the face seal O ring is seated and retained properly Position the tube and nut squarely on the face seal end of the fitting an
211. n 4 way directional valve 10V 3 20 schematic items A B and C Normally open poppet valve 6 40 schematic item T V CC and DD 7 40 Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures Z D SS i 9 4 MANIFOLDS Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor on the tank side of the turntable Index No Schematic Description Item Function Torque Shuttle valve 2 position 3 way Turntable rotation brake release 10 13 ft Ibs 14 18 Nm Counterbalance valve JJ Turntable rotate right 35 40 ft lbs 47 54 Nm Counterbalance valve KK Turntable rotate 35 40 ft lbs 47 54 Nm Plug Torque Specifications Description Hex size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm Part No 52271 Genie S 40 7 41 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 9 5 Oscillate Manifold Components The oscillate manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item 1 Orifice plug 0 052 inch 1 32 mm LL 2 Differential sensing valve MM 3 Check
212. n Section 5 Troubleshooting Flow Charts m CHART 27 Install a 0 to 5000 PSI Check for mechanical 0 to 345 bar pressure restrictions keeping gauge at the quick steer right function from disconnect coupling on operating OR repair or the boom function replace steer cylinder manifold and activate OR replace flow the steer right function regulator valve item WW OR consult Genie Industries Service less than 2600 PSI Department Continued from the previous page Repair or replace steer cylinder OR steer manifold could have an internal defect Consult Genie Industries Service Department Part No 52271 Genie S 40 5 61 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 28 All Drive Functions Inoperative All Other Functions Operate Normally Be sure the rpm toggle switch is in the footswitch activated high idle position Be sure the hydraulic tank shut off valves are in the oPEN position Be sure machine is not in the free wheel configuration With the keyswitch less turned to platform than control and both 12V Emergency Stop buttons pulled out to the ON position activate the footswitch and check the voltage at terminal 2 on the drive joystick DP1 12V or more With the keyswitch turned to platform 12V control and both Emergency Stop buttons pulled out to theon position activate the footswitch and check the voltage at terminal 1
213. n and check voltage TP4 oV Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more CHART 19 Repair open in wht wire circuit from TB4 to turntable rotate right function directional valve coil item A OR repair open in brown ground wire circuit to valve coil Troubleshoot turntable rotate left right function toggle switch TS17 on ground control panel OR repair open in wht wire circuit from TS17 to TB4 OR consult Genie Industries Service Department Repair open in wht blk wire from TP4 to 4 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to Part No 52271 Genie S 40 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 19 0 infinite ohms Disconnect wires to turntable rotate right directional valve coil Continued from the previous page item A and test the resistance of the valve coil See Repair Section 2 5 to 3 5 ohms Move function enable switch to either side and hold the turntable rotate left right toggle switch at the ground controls in the right direction Manually override the directional valve by pushing in on the end of the valve spool function inoper
214. n torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom until the boom is horizontal 2 Place support blocks under the cylinder across the turntable 3 Attach an overhead 5 ton 4536 kg crane to the boom Do not lift the boom 4 Support the rod end 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 it is disconnected from the machine 5 Tag disconnect and plug the boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Remove the pin retaining fastener from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin then lower the lift cylinder onto the blocks Protect the cylinder rod from damage Crushing hazard The lift cylinder AWARNING may become unbalanced and fall if itis not properly supported 7 Remove the four mounting fasteners from the barrel end cylinder pin mounting plate 8 With the lift cylinder being supported by the overhead crane pull the cylinder toward the platform until it is out Crushing hazard The lift cylind
215. n unsafe condition An explosion or fuel fire may cause death or serious injury Engine fuels are combustible Inspect the machine in 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 2 Perform a visual inspection around the following areas An LPG detector may be necessary to locate LPG leaks Part No 52271 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURES Gasoline LPG models LPG tank hoses and fittings solenoid shutoff valve LPG regulator and carburetor Gasoline tank manual shutoff valve fuel pump solenoid shutoff valve hoses and fittings and carburetor Deutz Diesel models Fuel tank shutoff valve hoses and fittings fuel pump fuel filter fuel injection pumps and fuel injectors ADANGER If a fuel leak is discovered keep 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 hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hy
216. nd Placards A 3 Inspect for Damage Loose or Missing Parts A 4 Check the Engine Oil Level A 5 Check the Engine Coolant Level Gasoline LPG Models o AN A 6 Check for Fuel Leaks A 7 Check the Hydraulic Oil Level A 8 Check for Hydraulic Leaks A 9 Check the Tire Pressure A 10 Test the Oscillate Axle if equipped A 11 Test the Platform and Ground Controls A 12 Test the Auxiliary Power Operation A 13 Test the Tilt Sensor A 14 Test the Limit Switches Genie S 40 Part No 52271 Service Manual Second Edition Table A continued Section 3 Scheduled Maintenance Inspections n OMEN Tools are required New parts required MAINTENANCE TABLES Warm Cold Dealer engine engine service required required suggested Every 100 hours perform the following three engine maintenance procedures Gasoline LPG Models A 15 Replace the Engine Oil and Filter Gasoline LPG Models A 16 Drain the Fuel Filter Water Separator Deutz Diesel Models A 17 Replace the Engine Air Filter 1 Check the Engine Belt B 2 Check the Radiator 52 Gasoline LPG Models B 3 Check the Oil Cooler and Cooling Fins u Deutz Diesel Models 221 4 Check the Exhaust System B 5 Check the Battery 6 Check the Hydraulic Tank Filter Condition Indicator B 7 Inspect the Electrical Wiring B 8 I
217. nd to Genie 5 40 Part No 52271 Service Manual Second Edition Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom up toggle switch TS16 on ground panel in up direction and check voltage on red 1 wire on boom up down directional valve coil item B 20V or more Continued on the next page Section 5 Troubleshooting Flow Charts Wo Z MH Move the function enable switch to either side and hold the boom up toggle switch TS16 on ground panel in up direction and check voltage at TB1 With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and boom function controller BP1 on platform control panel in up direction and check voltage TB1 Activate footswitch and boom function controller BP1 on platform control panel in up direction and check voltage TP1 oV Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more CHART 14 Repair open in red 1 wire circuit from TB1 to boom up function directional valve coil item B OR repair
218. ne 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 If necessary 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 sealant to the plug and then install it in the torque hub 5 Repeatthis procedure for each drive torque hub Drive torque hub oil 17 fl oz 0 5 liters Capacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures Turntable Rotate Torque Hub 1 Remove the plug located on the side of the hub and check the oil level Result The oil level should be even with the bottom of the plug hole a torque hub b plug 2 If necessary add oil until the oil level is even with the bottom of the side plug hole 3 Apply pipe thread sealant to the plug and then install it in the torque hub Turntable rotate torque hub oil 8 fluid ounces 0 24 liters Capacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 B 11 Check and Adjust the Engine Idle Mixture Gaso
219. nspect the Tires and Wheels a including lug nut torque N 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 Part No 52271 Genie S 40 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition MAINTENANCE TABLES Table B continued Tools are New parts mash required required required Cold Dealer engine service required suggested B 12 Check and Adjust the Engine RPM B 13 Test the Key Switch B 14 Test the Emergency Stop Switches B 15 Test the Ground Control Override B 16 Check the Directional Valve Linkage B 17 Test the Platform Self leveling B 18 Test the Horn B 19 Test the Foot Switch B 20 Test the Engine Idle Select B 21 Test the Fuel Select Operation Gasoline LPG Models Yt B 22 Test the Drive Enable System B 23 Test the Drive Brakes B 24 Test the Drive Speed Stowed Position ra B 25 Test the Alarm Package Optional Equipment B 26 Perform Hydraulic Oil Anaysis See D 1 Test or Replace the Hydraulic Oil Every 500 hours perform the following engine maintenance procedure B 27 Replace the Engine Oil and Filter Deutz Diesel Models 3 4 Genie S 40 Part No 52271 Service Manual Second Edition Section 3 Scheduled Maintenance Inspections Table C Tools are required New parts required MAINTENANCE
220. nt weur MODULE H RED 27B i feos aux H T 5 GROUND i BED 0A d CABLE RED R2 30 i H 4 1 6 BATTERY BLUMHTSSA 7 KEY PWR RED R1 30 d 8 KEY BYPASS B wih ergs LQ s IGN FUELON emen LO 5 ene mur PLATFORM LEVEL DISABLE amp HYD OIL COOLER d BLK RED R4 E H i OPTION RELAYS REDHGJSM BLK RED 35B WHT 2 ISM RED WHT R3 E H OnG TBi4 RED CB1 BLK 38B zai s H 1 2 3 E i BLK 1 ISM i d _ pem d BLK R1 E H WHT 21D j BLK D B BLU WHTFRG A i H BLK R5 A H BLU WHT R BLU RED R7 E H H ORGIBLK i FUSE f 5 6 Em INLINE i EW a d E H HARNESS h h rl i wrazen i H BLK 22D BLU WHT 38D i ORGAI EH GRN 43D RED BLK R6 E H i BLU RED 39B O SECTION i 6 10 Genie S 40 Part No 52271 Section 6 Schematics Service Manual Second Edition 1N Platform Control Box Legend Gasoline LPG Models o a a z 5 e 2 7 a Olao Blo o uu 2 O
221. nths 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 chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily A Quarterly A B Annual 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 section 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 52271 Genie S 40 3 1 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition Maintenance Tables Warm Cold Dealer Table A Tools are New parts engine engine service required required required required suggested A 1 Inspect the Manuals A 2 Inspect the Decals a
222. nual Second Edition pu MANIFOLDS 9 10 2WD Drive Manifold Components The drive manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Relief valve 250 psi 17 2 bar WW Charge pressure circuit 10 12 ft Ibs 14 16 Nm 4 Flow divider combiner valve XX Controls flow to drive motors in forward and reverse 25 30 ft lbs 34 41 Nm Orifice 0 070 in 1 78 mm Y Y as ates Drive circuit 2 Shuttle valve 3 position way ZZ Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift gp 15 18 ft lbs 20 24 Nm 5 Diagnostic fitting Testing Plug Torque Specifications Description Hex size Torque SAE No 8 5 16 50 ft lbs 68 Nm SAE No 2 1 8 50 in Ibs 6 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 12 5 8 75 ft lbs 102 Nm SAE No 6 1 4 18 ft lbs 24 Nm 7 48 Genie S 40 Part No 52271 Section 7 Repair Procedures Service Manual Second Edition pu SSS Se MANIFOLDS 9 11 Valve Adjustments 2WD Drive Manifold 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
223. o 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 52271 Service Manual Second Edition Section 7 Repair Procedures 6 3 Timing Adjustment Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 6 4 Carburetor Adjustment Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 6 5 RPM Adjustment Refer to Maintenance Procedures B 12 Check and Adjust the Engine RPM FORD LRG 423 ENGINE 6 6 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump OO pump pump shaft coupler flex plate with raised spline flywheel 1 4 inch gap Flex Plate Removal 1 Disconnect and remove the hose between the carburetor venturi and the air cleaner Disconnect the linkage from the governor then remove the governor linkage from the carburetor Do not alter the length of the linkage Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump Remove the mounting fasteners from the regulator mount
224. o om 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 With the throttle in the idle position and the actuator arm at a 110 degree angle to the linkage rotate the clevis yoke on the linkage rod two turns counterclockwise to pre load the spring Tighten the lock nut on the linkage rod Part No 52271 Genie S 40 7 21 Section 7 Repair Procedures Service Manual Second Edition FORD LRG 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 throttle ACAUTION Component damage hazard If the throttle linkage is improperly adjusted and allowed to reach full throttle the engine will over rev and cause component damage The linkage must be free of friction and obstruction Do not let it rub against the engine brackets or hoses 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 t
225. oggle switch and check the hydraulic pressure less than 2600 psi Adjust the function manifold system relief valve item X all the way in clockwise counting the number of turns Move the function enable switch to either side and hold the boom retract toggle switch and recheck the pressure Check steer functions Check the function pump see Repair section Replace the function pump steering inoperative Chart 11 Troubleshoot each function individually or consult Genie Industries Service Department Move the function enable switch to either side and hold the boom retract switch and readjust the relief pressure to 2600 psi for S 60 or 2900 psi for 5 65 Repair or replace differential sensing valve item W OR repair or replace flow regulator valve item BB OR manifold has an internal defect consult Genie Industries Service Department Replace the relief valve item X OR manifold has an internal defect Consult the Genie Industries Service Department Part No 52271 Genie S 40 5 27 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 12 Ground Controls Inoperative Platform Controls Operate Normally ne Does the engine start from the ground controls Be sure all other functions operate normally including the platform controls With both Emergency Stop buttons pulled out to the ON position check voltage at red w
226. olts 4 29 C 3 Check the Free wheel Configuration 4 30 C 4 Grease the Turntable Rotation Bearing and Rotate Gear 4 31 C 5 Replace the Torque Hub 4 31 C 6 Replace the Hydraulic Tank Filter essen 4 33 C 7 Replace the Drive Loop Hydraulic 4 33 C 8 Replace the Diesel Fuel Filter Water Separator Deutz Diesel Models 4 34 C 9 Replace the Gasoline Fuel Filter Gasoline LPG Models 4 34 C 10 Replace the PCV Valve Gasoline LPG Models 4 36 C 11 Replace the Spark Plugs Gasoline LPG Models 4 37 C 12 Check and Adjust the Air LPG Mixture Gasoline LPG Models 4 37 C 13 Check and Adjust the Ignition Timing Gasoline LPG Models 4 38 C 14 Check the Engine Valve Clearances Deutz Diesel Models 4 38 D 1 Testor Replace the Hydraulic Oil 4 39 D 2 Change or Recondition the Engine Coolant Gasoline LPG Models 4 39 D 3 Change the Fuel Lines 0 4 nennen nnne 4 41 D 4 Check the Engine Valve Clearance Gasoline LPG Models 4 42 D 5 Check the Engine Cylinder C
227. ompression Gasoline LPG Models 4 42 D 6 Clean the PCV Hoses and Fittings Gasoline LPG Models 4 42 D 7 Check the Fuel Injection Pumps and Injectors Deutz Diesel Models 4 43 D 8 Check the Toothed Belt Deutz Diesel Models 4 43 D 9 Replace the Timing Belt Gasoline LPG Models 4 43 0 10 Grease the Steer Axle Wheel Bearings 2WD Models 4 44 Part No 52271 Genie S 40 vii Service Manual Second Edition TABLE OF CONTENTS Section Five Troubleshooting Flow Charts troduction T 5 1 1 Engine Will Not Crank 5 3 2 Engine Cranks Over But Will Not Start Gasoline LPG Models 5 5 2A Engine Cranks Over But Will Not Start OR Engine Runs While Cranking the Dies Gasoline LPG 5 8 2B Engine Runs While Cranking Then 2 5 11 Engine Cranks Over But Will Not Start Deutz Diesel Models 5 12 Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LPG Models 5 15 5 Engine Will Not Start On Gasoline But Will Start On LPG Gasoline LPG Models renn rinna aa eneee nnne 5 17 6 Engine High Idle Inoperative Gasoline LPG
228. on Section 2 Specifications p sy SPECIFICATIONS Engine coolant Oil pan to block M 6 10 to 13 5 14 to 18 Capacity 111 2 quarts Oil filter insert to block 21 to 26 28 to 35 10 9 liters Rocker arm cover to 7 to 10 9 to 13 Alternator cylinder head M 6 Output 95A 14 5V Spark plug to cylinder 7 to 15 9 to 20 head M 14 Bolt torque specifications torque torque Temperature sending 8 to 18 11 to 24 Bolt description size ft lbs Nm unit to block M 14 Timing belt tensioner 29 to 40 40 to 55 Water jacket drain plug to block 12 to 18 16 to 24 pivot bolt M 10 Water pump to block bolt M 8 15 to 22 20 to 30 Timing belt tensioner 25 to 29 35 to 40 adjusting bolt M 8 Water outlet connection 15 to 22 20 to 30 bolt M 8 Camshaft gear bolt M 12 52 to 66 70 to 90 Cylinder front cover bolt M 6 10 to 12 13 to 16 Camshaft thrust plate bolt M 6 6 to 9 8 to 12 Inner timing belt cover 15 to 22 20 to 30 Carburetor to spacer stud M 8 7 5 to 15 10 to 20 stud M 8 Carburetor spacer to 10 to 14 14 to 19 Outer timing belt cover 6 to 9 8 to 12 manifold bolt M 8 bolt M 6 Crankshaft damper 92 to 122 125 to 165 bolt M 14 Cylinder head bolt M 12 torque in sequence first step 50 to 60 68 to 81 second step 80 to 90 108 to 122 Bolt torque specifications torque torque Bolt description size ft lbs Nm Exhaust manifold to cylinder head bolt or nut M 10
229. on controller Refer to the platform control box illustration page 7 2 US terminal D2 directional output terminal A proportional output terminal ground terminal positive terminal D1 directional output ramp rate adjustable trimpot lo range adjustable trimpot threshold adjustable trimpot hi range adjustable trimpot SQ 4 Set the preliminary ramp rate Turn the trimpot adjustment screw counterclockwise 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 Setthe 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 3 5V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage terminal R activates max out range Service Manual Second Edition 7 Setthe hi range Press down the foot switch fully retract the boom 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 voltage or counterclockwise to decrease the voltage 8 Setthe lo range Press down the foot switch extend the boom 3 feet then move the control handle all the way to the left or right Adjust t
230. oolant to be changed more frequently Beware of hot engine parts and ACAUTION coolant Contact with hot engine parts and or coolant will cause severe burns Perform this procedure with the engine off and cooled 1 Puton protective clothing and eye wear 2 Disconnect the coolant return hose at the radiator and drain the coolant return tank into a suitable container 3 Slowly remove the radiator cap from the radiator Bodily injury hazard Allow any ACAUTION pressure to dissipate gradually before removing the radiator cap Part No 52271 Genie S 40 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE D PROCEDURES 4 Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the radiator drain valve wa 24 A a pivot plate retaining bolts b engine pivot plate 5 Open the drain valve on the radiator and allow all the coolant to drain into a suitable container 6 After all the coolant has drained close the drain valve Connect the coolant return hose to the radiator 7 Openthe drain valve on the engine block and allow the coolant to drain into a container After the fluid is drained close the drain valve 8 Replace all coolant hoses and clamps 9 Pour the proper coolant mixture anti freeze and water for your climate into the radiator until it is full 10 Disconnec
231. oom lift drive limit switch or boom extend limit switch Repair short to ground in orange wire from TB40 to TP40 to terminal 6 on horsepower limiter circuit board Part No 52271 Genie S 40 5 67 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 32 Machine Drives At Full Speed With Platform Raised or Extended Be sure boom drive limit switch is being activated by the cam on the boom when the boom is raised Be sure that the boom extend drive limit switch is not being held down or being activated when the boom is extended Be sure the wiring to limit switches is intact and show no sign of damage or corrosion Extend the boom past Replace horsepower the drive limit switch and limiter board OR re check continuity from adjust horsepower ground to terminal 6 on limiter board OR consult the horsepower limiter Genie Industries Service board Department no continuity Check continuity from ground to TB40 Repair open in org wire circuit from TB40 to TP40 to terminal 6 on horsepower limiter circuit board no continuity Test limit switches See Replace defective limit procedure A 14 in the switch contact OR Maintenance Section replace limit switch Repair open from wht wires at TB40 to drive limit switches LS1 and LS2 then from brown ground wires to ground Genie S 40 Part No 52271 Service Manual Second Edition Drive Enable
232. open in brown ground wire circuit to valve coil Troubleshoot boom up function toggle switch TS16 on ground control panel OR repair open in red 1 wire circuit from TS16 to TB1 OR consult Genie Industries Service Department Repair open in red wire from TP1 to TB1 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to Part No 52271 Genie S 40 5 31 Section 5 Troubleshooting Flow Charts Service Manual Second Edition gt X LL OO Z ZZ CHART 14 Disconnect wires to 0 2 boom up directional infinite valve coil item B and ohms UTE d test the resistance of the item B valve coil See Repair Section Continued from the previous page 2 5 to 3 5 ohms 3 function Move function enable operates switch to either side and hold the boom up toggle switch at the ground controls in the up direction Manually override the directional valve by pushing in on the end of the valve spool Replace defective directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick boom from moving OR disconnect coupling on repair cylinder or the boom function cylinder counterbalance manifold and start the valve OR consult Genie engine Move the Industries Service function enable switch to Department either
233. operates items JJ and KK Activate turntable rotate left function Replace defective counterbalance valve function inoperative Check for mechanical restrictions keeping turntable rotate right function from operating OR replace shuttle valve item Il OR consult enie Industries Service Department Part No 52271 Genie S 40 5 47 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 20 All Platform Leveling Functions Inoperative Be sure all other functions operate normally Remove both hydraulic Replace the hoses from the manifold yes counterbalance valves ports PL1 amp PL2 Plug on function manifold the hoses and cap the items FF amp GG manifold fittings Move the function enable Switch to either side and activate the boom up function and check to see if platform levels Plumb a 0 to 5000 psi Check for mechanical 0 to 345 bar pressure restrictions OR replace gauge into master the slave cylinder cylinder rod end counterbalance valves hydraulic hose hose connected to port PL2 using a tee fitting Activate boom up function and check the pressure less than 2000 PSI Install a O to 5000 psi 0 to 345 bar pressure gauge into the barrel end hydraulic hose from the master cylinder and raise the primary boom one inch at a time Continually monitor the pressure gauge during boom up Do not allow the pressure to exceed 2500
234. 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 functions do not operate at low idle High idle rabbit symbol allows the operator to control multiple boom and or drive functions simultaneously This setting maintains a consistent high idle and is usually selected only when the generator option is being used 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 Startthe engine from the ground controls Then move the function enable toggle switch to the high idle rabbit symbol position and hold in the ON position Result The engine should change to high idle Release the function enable toggle switch Result The engine should return to low idle Turn the key switch to platform controls nA w At the 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 O Result The engine should change to low idle 7 Move the engine idle control switch to foot Switch activ
235. or Om Pump prime mover engine or motor Cylinder wv Accumulator Sat 0 035 Orifice with size A Variable orifice or shut off valve n x Check valve A Relief valve Priority flow divider olf Wy ul Solenoid operated dump valve L ares Differential sensing valve Solenoid operated proportional valve Solenoid operated 2 pos 3 way directional valve 9 M duo E Pilot operated flow control valve XI Solenoid operated 2 pos 4 way directional valve Solenoid operated 3 pos 4 way directional valve DO1 d 2 pos 3 way shuttle valve mU E 3 pos 4 way directional valve Sequencing valve ril gt 1 Unloader valve Pressure compensating valve Genie S 40 Part No 52271 REAR RIGHT REAR LEFT
236. orm level toggle switch TS14 in the down direction and check the voltage at TB15 Repair open in org blk wire from TB15 to platform level down directional valve coil item V OR repair open in brown ground wire circuit to valve coil With the keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate the footswitch and the platform level toggle Switch TS6 in the down direction and check the voltage at TB15 Troubleshoot platform level toggle switches TS14 and TS6 on ground and platform control panels OR repair open in red power wire circuit to TS14 and TS6 OR repair open in org blk wire circuit from TS14 and TS6 to 15 OR consult Genie Industries Service Department 12V or more Troubleshoot platform level toggle switch TS14 on ground control panel OR repair open in red power wire circuit to TS14 OR repair open org blk wire circuit from TS14 to TB15 OR consult Genie Industries Service Department Part No 52271 Genie S 40 5 51 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 22 0 or infinite ohms Disconnect the wires from the platform level down directional valve Continued from the previous page coil item V and test the resistance of the valve coil 610 7 ohms function Exchange platform level operates down and up directional valves items V and T and activate the platform
237. ors The resistors are used on 4WD machines to maintain low range drive speed The resistors are 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 Disconnect either end of one of the wires connected to the resistor to be tested 3 Connect the leads from an ohmmeter to each end or wiring of the resistor being tested 4 Compare the ohmmeter reading with the resistance rating printed on the resistor 1 5 Toggle Switches 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 to check for continuity Left Single pole double throw SPDT 62 Double pole double throw DPDT Test Left position Center Right Desired result terminal 1 to 2 3 4 5 amp 6 no continuity infinite
238. otor mounting bolts 15 2 Torque Hub How to Remove a Drive Torque Hub When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the drive motor See 16 1 How to Remove a Drive Motor 2 Tag disconnect and plug the hydraulic hose from the brake Then remove the hydraulic fitting and the bleed valve 3 Loosen the wheel lug nuts Do not remove them 4 Center a lifting jack of ample capacity under the non steering axle Raise the machine and place blocks under the drive chassis for support 5 Remove the wheel lug nuts then the tire and wheel assembly 6 Place a second lifting jack under the torque hub for support and secure the torque hub to the lifting jack Genie S 40 Part No 52271 Service Manual Second Edition January 2008 mnmmm 1 REV B 7 Remove the torque hub mounting bolts that attach the torque hub to the chassis Remove the torque hub Crushing hazard The torque AWARNING hub may become unbalanced and fall if it is not properly supported and secured to the lifting jack Torque specifications Section 7 Repair Procedures NON STEERING AXLE COMPONENTS Lug nut dry 170 ft lbs 230 Nm lubricated 130 ft lbs 176 Nm Torque hub
239. ove the rpm select to high idle rabbit symbol for switch TS4 and TS12 the following checks Check voltage at blk red 12V wire on rpm select switch TS4 and TS12 Replace rpm select toggle switch 12V Check voltage at TB35 x Repair open in blk red wire circuit from toggle switch to TP35 to TB35 12V Check voltage at terminal 86 blk red on CR4 Repair open in blk red wire circuit from TB35 to CR4 12V no Check continuity from continuit ground to the brown wire on terminal 85 of 4 Repair open in brown ground wire circuit to terminal 485 continuity Check voltage at ov Repair open in white terminal 30 on CR4 21 power wire from terminal 87 on CR2 to CR3 to CR4 12V Check voltage at 12V terminal 87A on CR4 Replace CR4 relay Repair short in blk red Check voltage at 12V wire to terminal 7 terminal 7 on electronic governor on precision governor Continued on the next page Part No 52271 Genie S 40 5 19 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 6 Continued from the previous page Check voltage at ov terminal 30 on CR3 12V Check voltage at oV terminal 486 on CR3 12V no continuit Check continuity from ground to brown wire on terminal 485 of CR3 continuity Check voltage to ov terminal 87 on CR3 12V Check voltage at terminal 1
240. owed position 1 Connect a 0 to 5000 psi 0 to 345 bar pressure gauge to the test port item 23 on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to either side and activate and hold the retract switch with the boom fully retracted Observe the pressure reading on the pressure gauge 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 23 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 6 Repeat steps 2 through 5 and recheck relief valve pressure System relief valve specifications Pressure 2900 psi 200 bar How to Adjust the Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect O to 5000 psi 0 to 345 bar pressure gauge to the test port item 23 on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to either side and activate and hold the boom down switch with the boom fully lowered Observe the pressure reading on the pressure gauge 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 6 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pr
241. p buttons pulled out to the ON position move the function enable switch to either side and hold the boom retract toggle switch TS15 on ground panel in the retract direction and check voltage on blk red wire on boom extend retract proportional valve coil item G 12V or more Continued on the next page Move the function enable switch to either retract toggle switch TS15 on ground panel in the extend direction and check voltage at TB9 oV With keyswitch in 9 to 10V platform position and both Emergency Stop buttons pulled out to the on position activate footswitch and boom extend retract toggle switch TS7 on platform control panel in the retract direction and check voltage at TP9 oV Activate footswitch and check voltage at center terminal of TS7 12V or more Test toggle switch see bad Repair Section good Repair open in blk red wire circuit from TS7 to TP9 side and hold the boom 9 to 10V Repair open in blk red wire circuit from TB9 to boom extend retract proportional valve coil item G OR repair open in brown ground wire circuit to valve coil Repair open in power supply circuit from TP24 Repair open in blk red wire from TP9 to TB9 to TS7 Replace extend retract toggle switch TS7 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Z Disconnect wir
242. perature 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 crank the engine with the low oil pressure light on Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures 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 Connectthe 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 it is at a 110 degree angle to the linkage rod Then tighten the actuator arm fastener Ford LRG 423 Engine Governor actuator and linkage clevis yoke linkage rod carburetor throttle plate shaft governor actuator actuator shaft actuator arm oroan
243. procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 D 5 Check the Engine Cylinder Compression Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 D 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 Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 1 Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the PCV hoses a pivot plate retaining bolts b engine pivot plate 2 Disconnect the hose from the PCV valve then disconnect the hose from the engine a carburetor to valve cover hose b PCV valve c PCV valve to carburetor hose 3 Disconnect the hose from the carburetor then disconnect the hose from the valve cover 4 Clean the hoses with a mild cleaning solvent TABLE D PROCEDURES 5 Dry both hoses and inspect them for cracks and damage Replace the hoses if they are
244. pump The 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 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 Disconnect the electrical connector at the ignition coils The ignition coils are located above the alternator AWARNING Electrocution hazard Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry FUEL AND HYDRAULIC TANKS Deutz Diesel models Hold the manual fuel shutoff valve clockwise to the cLosep position Ao HOW cuum kw Nic a manual fuel shutoff valve 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 4 Connect the wiring and start the engine from the ground controls Check for hydraulic leaks Part No 52271 Genie S 40 Section 7 Repair Procedures Service Manual Second Edition Turntable Rotation Components 11 1 2 Tag disconnect and plug the hydraulic hoses from the motor brake and manifold Cap the Rotation Hyd raulic Motor fittings on the motor brake and manifold How to Remove the Rotation AWARNING injury haz
245. r 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 oil ACAUTION 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 Place a suitable container under the engine pivot plate directly below the oil pan drain plug a engine pivot plate b pivot plate retaining bolts C oildrain hose 3 Remove the plug from the oil pan and allow all of the oil from the engine to drain into a suitable container See capacity specifications below 4 Install the plug into the oil pan 5 Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the oil filter 6 Use an oil filter wrench and remove the filter 7 Applyathin layer of oil to the new oil filter gasket Genie part no 28656 Then install the filter and tighten it securely by hand 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 See capacity specifications below 10
246. r open in org blk 141 wire circuit from alternator to TB41 to terminal 2 on ignition start module Disconnect wht 424 wire from oil pressure sender and check continuity o yes ground on signal post of sender while cranking the engine Is continuity maintained Disconnect wht 424 wire from engine temperature sender and check continuity to ground on signal post of sender while cranking the engine Is continuity maintained yes no Repair short to ground in wht 24 wire from sending units to TB24 to terminal 10 on ignition start module Disconnect red wire from terminal 4 on 12V ignition start module and check voltage at terminal 4 oV Test auxiliary power toggle switches TS1 and TS9 See Repair Section 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 Check oil level OR replace engine temperature sending unit OR refer to Deutz service manual for troubleshooting a overheated engine Replace ignition start module OR consult Genie Industries Service Department Genie S 40 Part No 52271 Service Manual Second 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
247. rating temp 2000 rpm 40 to 60 psi 2 75 to 4 1 bar Oil capacity 5 quarts including filter 4 7 liters Oil viscosity requirements Temperature below 60 F 15 5 C 5W 30 10 F to 90 F 23 C to 32 10W 30 Temperature above 10W 40 to 10W 50 10 F 23 C Temperature above 20W 40 or 20W 50 20 F 6 6 C Use oils meeting API classification SG labeled SG CC or SG CD as they offer improved wear protection Units ship with 10W 40 SG CC Service Manual Second Edition Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 170A Current draw maximum load 200A Current draw minimum 140A Maximum circuit voltage drop 0 5V DC while starting normal temperature Brush length new 0 66 in 16 8 mm Brush length wear limit 0 25 in 6 35 mm Brush spring tension 64 ounces 18 Newtons Bolt torque through brush 45 to 84 inch pounds 5 08 to 9 5 Nm Brush mounting 15 to 20 foot pounds bolt torque 20 to 27 Nm Maximum commutator 0 005 inches run out 0 127 mm Battery Type 12V Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Fuel pump Electronic solenoid 7 psi 0 48 bar Ignition System Spark plug type Motorcraft AWSF 52C Spark plug gap 0 042 to 0 046 inches 1 07 to 1 18 mm Genie S 40 Part No 52271 Service Manual Second Editi
248. rbalance valve manifold located near the platform rotator Cap the fittings on the manifold 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 4 Tag disconnect and plug the hydraulic hoses from the platform leveling cylinder at the union and connect the hoses from the cylinder together using a connector 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 5 Raise the boom to a horizontal position 6 Remove the fasteners from the drive speed limit switch mounted on the side of the cable track at the pivot end of the boom Do not disconnect the wiring 7 Remove the fasteners from the side panel on the lower cable track then remove the panel Pull all of the cables out of the channel 8 Remove the cable cover on the side of the boom 9 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and AWARNING lower cable tracks are not properly secured together the cable track may become unbalanced and fall when it is removed from the machine 10 Remove the hose and cable clamp at the platform end of the cable track 11 Att
249. re sending unit check continuity to ground on sending unit no continuity Remove wht wire from TB24 no continuity Repair short in wht wire circuit from ignition start module to TB24 OR consult Genie Industries Service Department Turn the machine off and isolate the fuel solenoid Check the resistance of the solenoid 3 50 ohms See Deutz service manual for troubleshooting fuel system hot 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 continuity Replace temperature switch sending unit continuity Repair short in wht wire circuit from TB24 to temperature sender infinite Replace the fuel ohms solenoid 5 12 Genie S 40 Part No 52271 Continued from the Service Manual Second Edition nm Hn en Hold start switch and check voltage at wht 21 wire on terminal 87 of CR2 Check voltage at red wire on terminal 30 of CR2 Hold the start switch to either side and check voltage at terminal 86 of CR2 12V Check continuity from ground to terminal 85 on CR2 good Continued on the next page Section 5 Troubleshooting Flow Charts Repair open wht 21 wire from CR2 to fuel solenoid Repair open in red wire
250. restrictions keeping turntable rotate left function from operating OR replace shuttle valve item Il OR consult enie Industries Service Department Part No 52271 Genie S 40 5 43 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 19 Turntable With key switch in Move the function Repair open in wht red i ground position and enable switch to either wire circuit from TB6 to Rotate Rig ht both Emergency Stop side and hold the 4to 6v turntable rotate left right Function buttons pulled out to the OV turntable rotate toggle proportional valve coil ON position move the i function enable switch to Inoperative either side and hold the B Il oth turntable rotate toggle e sure all other switch TS17 on ground functions operate panel in the right normally switch TS17 on ground panel in the right direction and check voltage at TB6 item S OR repair open in brown ground wire circuit to valve coil direction and check voltage on wht red wire on turntable rotate left right proportional valve oV coil item S With keyswitch in 4 to 6V Repair open in wht red platform position and wire from TP6 to TB6 both Emergency Stop buttons pulled out to the on position activate footswitch and turntable rotate left right proportional controller 1 on platform control panel in the right direction and check voltage at TP6 oV Activate footswitch and 12V or mor
251. retract proportional valve coil item G 12V or more Continued on the next page Move the function enable switch to either extend toggle switch TS15 on ground panel in the extend direction and check voltage at TB9 oV With keyswitch in 9 to 10V platform position and both Emergency Stop buttons pulled out to the on position activate footswitch and boom extend retract toggle switch TS7 on platform control panel in extend direction and check voltage at TP9 oV Activate footswitch and check voltage at center terminal of TS7 12V or more Test toggle switch see bad Repair Section good Repair open in blk red wire circuit from TS7 to TP9 side and hold the boom 910 10V Repair open in blk red wire circuit from TB9 to boom extend retract proportional valve coil item G OR repair open in brown ground wire circuit to valve coil Repair open in blk red wire from TP9 to TB9 Repair open in power supply circuit from TP24 to TS7 Replace extend retract toggle switch TS7 Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Wo Z MH Z Disconnect wires to 0 2 boom extend directional infinite valve coil tem C and ohms oka A test the resistance of the it he C valve coil See Repair 5 Section Continued from the previous page 2 5 to
252. right direction and check voltage on TB37 12V or more With key switch in platform position and both Emergency Stop buttons pulled out to the OV ON position activate footswitch and steer rocker switch on drive controller DP1 in the right direction and check voltage on blu blk 437 wire on steer right directional valve coil item TT on steer manifold 12V or more Disconnect wires to 0 or steer right directional infinite valve coil item TT on ohms steer manifold and test the resistance of the valve coil 5 to 6 ohms Continued on the next page With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in the right direction and check voltage at the controller terminal with the blu blk wire attached Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department Repair open in blu blk 37 wire circuit that runs from TB37 to steer right directional valve coil on steer manifold OR repair open in brown ground wire circuit to steer right valve coil Replace steer right directional valve coil item TT OR repair open in brown ground wire circuit to steer right valve coil Repair open in blu blk 37 wire circuit from drive controller DP1 to TP37 then to TB37 Genie S 40 Part No 52271 Service Manual Second Editio
253. ring wheel disengage position engage position O Result Each non steering wheel should rotate with minimum effort 6 Re engage the torque hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the jack stands AWARNING Collision hazard Failure to re engage the torque hubs may cause death or serious injury and property damage Steer wheels 4WD models 7 Chockthe non steering wheels to prevent the machine from rolling 8 Center a lifting jack of ample capacity 20 000 1 5 9072 kg under the drive chassis between the non steer tires 9 Liftthe 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 11 Manually rotate each steer wheel disengage position engage position Result Each steer wheel should rotate with minimum effort Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 12 Re engage the torque hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the jack stands AWARNING Collision hazard Failure to re engage the torque hubs may cause death or serious injury and property damage All models 13 Be sure the free wheel valve on the drive pump is closed clockwise The
254. roperly supported and secured to the overhead crane Clean the fuel tank and inspect for rust and corrosion before installing Part No 52271 Genie S 40 Section 7 Repair Procedures Service Manual Second Edition FUEL AND HYDRAULIC TANKS 2 Close the two hydraulic shutoff 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 Remove the drain plug from the hydraulic tank 4 Completely drain the tank into a suitable container See capacity specifications 5 Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves 6 Disconnect and plug the T fitting located at the return filter with the 2 hoses connected to it Cap the fitting on the return filter housing 7 Disconnect and plug the supply hose for the auxiliary power unit Cap the fitting on the hydraulic tank 8 Remove the retaining fasteners from the hydraulic tank hold down straps Remove the straps from the hydraulic tank 9 Support the hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 10 Remove the hydraulic tank from the machine Cru
255. s 15 2 cm and place blocks under the chassis for support Specifications 6 Remove the lug nuts then remove the tire and 1 Remove the pin retaining fasteners from both wheel assembly the steering cylinder and the tie rod pivot pins Remove the pins 7 Remove the hydraulic hose clamp retaining fastener from the top of the yoke 8 Remove the drive motor mounting fasteners 9 Slide the drive motor shaft out of the torque hub and then remove the drive motor from the machine 10 Remove the pin retaining fasteners from the upper and lower yoke pivot pins 11 Support the yoke torque hub assembly with a lifting jack Secure the yoke torque hub assembly to the lifting jack 12 Use a slide hammer to remove the upper yoke pivot pin then use a soft metal drift to drive the lower yoke pivot pin down and out steer cylinder tie rod PUR cylinder Crushing hazard The yoke hub b yoke pivot pin AWARNING b b y c torque hub assembly may become d yoke unbalanced and fall when the yoke pivot pin pivot pins are removed if it is not 9 properly secured supported by the lifting jack Part No 52271 Genie S 40 7 63 Section 7 Repair Procedures Service Manual Second Edition January 2008 4WD STEERING AXLE COMPONENTS 13 Place the yoke torque hub assembly on a flat surface with the torque hub facing down 14 Remove the torque hub mounting fasteners that attach the yoke to t
256. s than Service Manual Second Edition 1 Check continuity from no ground to brown wire at fuel pump continuity Repair open in blu wht wire from anti diesel solenoid to fuel pump OR replace fuel pump no Check continuity from continuity ground to brown wire at gasoline solenoid continuity Repair open in blu wht wire from fuel pump to gasoline solenoid OR replace gasoline solenoid Replace gasoline solenoid Replace anti diesel valve Replace fuel pump OR check anti diesel and fuel valve for defects continuity Repair open in brown ground wire circuit to the fuel pump Repair open in brown ground wire circuit to the gasoline solenoid Genie S 40 Part No 52271 Service Manual Second 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 Be sure high idle can be achieved by grasping the governor actuator arm and momentarily pulling to throttle the carburetor Chart 6 Check voltage at center terminal on rpm select Repair open in power supply circuit to center terminal of switch Start engine and m
257. sHO _ BiK2 22 BLKS P POWER TO PLATFORM WHT Rets7 WHTEH 21 WHT SP DB IGNITION POWER RED A H RED R17 30 20 RED S P 12V BATTERY SUPPLY GRNWHT3 19 JIB VALVE GANBIK4 omweLks 1 GRBKDB__ GRGKSP PLATFORM ROTATE RIGHT GRN 4 GRN 3 17 GAN Da GANS PLATFORM ROTATE LEFT BIKE ORGmED3 15 oemp bs OGRD SP PLATFORM LEVEL DISABLE ORGBLKA 15 OGBKDA _ 5 PLATFORM LEVEL DOWN ORG 4 ORG 3 14 ORG S P PLATFORM LEVEL UP WHT 5 BLUREDS 13 DRIVE ENABLE LIGHT WHT EH BLUWHT3 12 BLES DRIVE ENABLE BLUBLKA BUBKSP SEC BOOM DOWN BLU 10 BLu Da BLU SP SEC BOOM UP BLK RED 4 BLK RED 3 9 BK RD S P BOOM EXT RET BLK WHT 4 BLK WHT 3 8 BK WT D B BK WT S P BOOM RETRACT BLA BLK S 7 BLK S BOOM EXTEND WRA WHTREDS 6 WTJRD S P TURNTABLE ROTATE WHTBLK4 WHTBLKS 5 WIBKDB wreks TURNTABLE ROTATE LEFT WHT 3 4 WHT S P TURNTABLE ROTATE RIGHT RMA REDMNTS 3 ROMT S P PRIMARY BOOM REDBLK4 REDBLKS 2 RDBKOB RDIBICS P PRIMARY BOOM DOWN RED 4 RED 3 1 RED D B RED S P PRIMARY BOOM UP D B A ORG ELK15B ORGIRED 168 ORG 14B KE GRN 178 GRNBLI 18B RE BLK ALH87 10 BRN GROUND poz BLK 7B Bie GI WHT 21A WHTIBLK SB KIE BLU 368 WHT 48 BLU BLK 378 RED BLK28 WHTIRED 828 RED 18 19 BRN GROUND SS stant revay onama saHOMETER IGN START acan LC s smer
258. safe operating conditions and may cause component damage Electrocution hazard Contact with AWARNING 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 Gasoline LPG models Engine wiring harness Inside of the ground control box Turntable manifold wiring 2 Startthe engine from the ground controls and raise the boom above the turntable covers 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 AWARNING Tip over hazard Do not use temporary flat tire repair products 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque 4 Checkthe pressure in each air filled tire 3 Inspect the turntable area for burnt chafed and Tires and wheels 2WD Front 2WD Rear pinched cables 4WD Front 4 Lower the boom into the stowed position and
259. se may cause component damage Extremely dirty conditions may require oil changes to be performed more often The machine uses Dexron 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 test the oil quarterly Replace the oil when it fails the test Perform this procedure with the boom in the stowed position 1 Remove the hydraulic tank See Repair Procedure 10 2 How to Remove the Hyaraulic Tank The pump needs to primed before starting the engine See Repair Procedure 10 2 How to Remove the Hydraulic Tank Component damage hazard Be ACAUTION sure that the hydraulic tank shutoff valves are in the position before priming the pump The 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 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 c
260. see Deutz workshop manual to troubleshoot fuel injection system Check voltage on red wire at center terminal o rpm select switch Repair open in circuit supplying 12V to center f oV terminal of switch 12V Replace toggle switch Repair open in blk red wire circuit from toggle switch to TB35 Repair open in blk red wire circuit from TB35 to terminal 30 on CR3 Repair open in wht wire circuit from terminal 87 on CR2 to terminal 86 on CR3 Repair open in brown ground wire circuit to terminal 85 on CR3 Replace CR3 relay Part No 52271 Genie S 40 5 23 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 8 Continued from the previous page Check voltage at oV terminal 86 on CR4 12V Check continuity from bad ground to brown wire at terminal 85 on CR4 good Check voltage to oV terminal 30 on CR4 12V Check voltage at the blk red wire on the 2 speed solenoid 12V solenoid moves in and out freely moves freely Replace 2 speed solenoid Note resistance across solenoid terminals should be approximately 0 3 ohms solenoid Check if 2 speed binds Repair open in blk red wire circuit from CR3 to CR4 Repair open in brown ground wire circuit to terminal 85 on CR4 Repair open in wht wire circuit from CR2 to CR3 to CR4 Replace CR4 relay OR repair open in blk red wire circuit from terminal
261. select toggle switch TS11 Replace toggle switch Repair open in blu wht wire circuit from toggle TS11 toggle switch to TB38 Repair open in blu wht wire circuit from TB38 to terminal 430 on CR6 Check brown ground Repair open in brown wire on terminal 85 of ground wire circuit to CRG no goo CRG good Replace CR6 Part No 52271 Genie S 40 5 9 Section 5 Troubleshooting Flow Charts Service Manual Second Edition pu CHART 2A Continued from the previous page Hold the start switch to Repair open in blu wht either side and check 38 wire circuit from voltage at blu wht wire CR6 to anti diesel valve on anti diesel valve on engine carburetor Hold the start switch to Check continuity from Repair open in brown either side and check brown ground wire on ground wire circuit to voltage at blu wht 38 fuel pump to ground fuel pump wire on fuel pump continuity Repair open in blu wht 38 wire circuit from anti diesel valve to fuel pump Hold the start switch to Reconnect the two wires either side does engine to vacuum switch and start check for fuel line blockage OR replace anti diesel valve OR see Ford service manual for troubleshooting fuel pump and or carburetor OR Consult Genie Industries Service Go to chart 2B Department 5 10 Genie S 40 Part No 52271 Service Manual
262. shing hazard The hydraulic AWARNING may become unbalanced and fall if itis not properly supported and secured to the overhead crane 11 Remove the suction strainers from the tank and clean them using a mild solvent 12 Rinse out the inside of the tank using a mild solvent 13 Install the suction strainers using a thread sealant on the threads 14 Install the drain plug using a thread sealant on the threads 15 Install the hydraulic tank onto the machine 16 Install the two suction hoses and the supply hose for the auxiliary power unit 17 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 18 Clean up any oil that may have spilled and open the hydraulic tank valves Component damage hazard ACAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the hydraulic tank Always use pipe thread sealant when installing the drain plug Use only Dexron II equivalent hydraulic fluid Hydraulic system Hydraulic tank capacity 45 gallons 170 liters Hydraulic system 55 gallons capacity including tank 208 liters Hydraulic fluid Dexron equivalent Genie S 40 Part No 52271 Service Manual Second Edition Section 7 Repair Procedures How to Prime the Pump Component damage hazard Be ACAUTION sure that the hydraulic tank shutoff valves in the position before priming the
263. steners A cable track repair kit is available through the Genie Industries Service Parts Department part no 46677 The kit includes a 4 link section of cable track fasteners other miscellaneous parts and detailed instructions Component damage hazard ACAUTION Over tightening the fasteners will result in the cable track not rotating and may bind during 1 Remove the boom cable track See 4 1 How to operation Remove the Boom Cable Track Be sure that the fasteners are installed from the inside out so the nuts are on the outside of the 2 Visually inspect the cable track and determine which 4 link section needs to be replaced 3 Drill out the 4 spot welds on each side of the cable track cable track using a 17 64 drill bit Repeat this 9 Install the black rollers onto the new section of step for the other end of the 4 link section of cable track cable track 10 Install cable track onto the machine and operate ACAUTION Component damage hazard Cables and hoses can be damaged if the drill bit comes in contact with them Protect the hoses and cables with a block of wood to prevent drilling into the hoses and cables 4 Remove the retaining fasteners from upper black rollers from the 4 link section of cable track to be replaced Remove the rollers the boom extend retract function throught a full cycle to ensure smooth operation of the new section of cable track Part No 52271 Genie S 40 Section 7
264. 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 If the wear pads are not worn below specification but are still within specification see Repair Procedure 3 2 How to Shim the Boom 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 specification If the wear pad is not less than specification 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 may cause binding or scraping of the boom Always maintain squareness between the outer and inner boom tubes Wear pad specifications 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 and place a safety chock on the lift cylinder rod Carefully lower the boom onto the lift cylinder safety chock Crushing hazard Keep hands AWARNING away from cylinder and all moving parts when lowering the boom The lift cylinder safety cho
265. switch to either side and activate and hold the platform rotate switch to the RIGHT position until the platform is fully rotated Continue holding the switch until air stops coming out of the bleed valve Then closethe bleed valve Crushing hazard Keep clear of AWARNING 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 52271 Genie S 40 Section 7 Repair Procedures Service Manual Second Edition Boom Components 3 1 Boom 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 necessary when performing major repairs that involve removing the boom How to Remove the Boom Cable Track When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Open the platform control box and remove the platform control box mounting fasteners 2 Separate the footswitch quick disconnect then lower the platform control box and lay it off to the side 3 Tag disconnect and plug the hydraulic hoses from the V1 and V2 ports on the counte
266. t a malfunction The proportional boom functions boom up down extend retract 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 10 1 Function Manifold in this section 1 Push the button on the end of the valve in inch 6 mm 2 Hold the function enable switch to either side and 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 52271 Genie S 40 Section 7 Repair Procedures Service Manual Second Edition pu SSS Se MANIFOLDS 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 Connect the leads from an ohmmeter to the valve coil terminals Valve coil specifications Proportional solenoid valve 12V 8 60 schematic items M P and S 3 positio
267. t the hose coupler at the fan end from the tube that is connected to the water pump and hold it until coolant starts to come out of the open hose Then immediately reconnect the hose a tube connected to water pump b hose coupler 11 Fill the radiator and then fill the coolant recovery tank to the NORMAL range 12 Clean up any coolant spilled during this procedure 13 Start the engine from the ground controls run it for 30 seconds and then turn it off 14 Inspect for leaks and then check the 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 Coolant capacity 11 5 quarts 10 9 liters Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures D 3 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 leaking fuel line may cause an unsafe operating condition Engine fuels are combustible ADANGER 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 Perform this procedure with the engine off
268. table b drive enable limit switch LS3 c turntable rotation bearing TABLE A PROCEDURES 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 Result The drive enable indicator light should be on Rotate the turntable so the boom is between the non steer tires 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 toggle 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 toggle switch is activated Part No 52271 Genie S 40 4 9 Section 4 Scheduled Maintenance Procedures Service Manual Second 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 o
269. tch Turn machine off See bad Repair section for how the test the vacuum switch ok bad Check vacuum line for restrictions or damage ok See Ford service manual to troubleshoot low manifold vacuum Repair open in red blk wire circuit from vacuum Switch to CR6 Replace vacuum switch Replace vacuum line Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts With keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the ON position crank the Continued from the previous page engine and check voltage at center terminal on fuel select switch TS11 in ground control box 12V With keyswitch on and both Emergency Stop buttons pulled out to the ON position crank engine and check voltage on gasoline side bluAwht wire of fuel select switch 12V With keyswitch on and both Emergency Stop buttons pulled out to the on position crank engine and check voltage at terminal TB38 12V With keyswitch on and both Emergency Stop buttons pulled out to the ON position crank engine and check voltage at blu wht wire at terminal 30 on CR6 12V With keyswitch on and both Emergency Stop buttons pulled out to the ON position crank the engine and check voltage at terminal 87 on CR6 12V Continued on the next page CHART 2A Repair open in red power wire circuit with diode to fuel
270. ted to obtain the loudest volume by turning the adjustment Screw near the wire terminals on the horn 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 Turn the keyswitch to platform controls and pull out the Emergency Stop button to the oN position at both the ground and platform controls 2 Press down the footswitch and attempt to start the engine by moving the start toggle switch to either side Result The engine should not start 3 Do not press down the footswitch and start the engine 4 Do not press down the footswitch Check the machine functions Result The machine functions should not operate 5 Press down the foot switch and operate the machine functions Result The machine functions should operate Part No 52271 Genie S 40 4 23 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES B 20 Test the Engine Idle Select A properly
271. ter A distinct click should be felt and heard 7 Turn the keyswitch to platform control Fully retract the boom 9 Slowly move the drive control handle off center Result The machine should move at normal drive speeds 10 Raise the boom to just above horizontal 11 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed 12 Lower the boom to the stowed position then extend the boom 3 feet 91 cm Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 13 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed Drive speed maximum raised or extended All models 1 foot per second 0 31 meter per second Drive Enable Limit Switch A properly functioning drive enable limit switch is essential for safe machine operation and workplace safety The drive enable limit switch stops the drive function when the boom is rotated past a non steer tire and alerts the operator that the machine may drive in the opposite direction that the drive and steer control handle is moved 1 Atthe ground controls start the engine and rotate the boom between the steer and non steer tires Turn the engine off 2 Visually inspect the drive enable limit switch for the following Broken or missing roller or arm Missing fasteners Loose wiring a turn
272. terminal TB33 12V Hold the start switch to either side and check voltage at terminal 3 on ignition start module 12V Hold the start switch to either side and check voltage at terminal 6 on the ignition start module Continued on the next page less than 12V Chart 1 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 Repair open in jumper wire from one side of the switch to the other OR replace start toggle switch TS10 Repair blk wire circuit from start switch TS10 to TB33 Repair blk wire circuit from TB33 to terminal 3 on ignition start module Repair open in red power supply wire circuit from CB1 to CR1 to CR2 then to terminal 6 to on ignition start module Part No 52271 Genie S 40 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 1 Hold the start switch to Check ground wire to either side and check terminal 5 on ignition voltage at terminal 1 on start module ignition start module Repair open in ground wire Continued from the previous page Consult Genie Industries Service Department Hold the start switch to Repair open in blk wire either side and check from terminal 1 on voltage at terminal 86 ignition start module to on CR1 CRI Check voltage at
273. that could get into machine components and cause damage NN Be sure that all tools and working areas Be sure that your workshop or work area is properly ventilated and well lit Be sure any forklift overhead crane or d other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity ZN Be sure that fasteners 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 A Be sure to properly dispose of old oil or ue other fluids Use an approved container Please be environmentally safe iv Genie S 40 Part No 52271 Service Manual Second Edition January 2008 Introduction Section One Section Two Section Three Section Four Table of Contents Important eoe ccce eed nce Eee de D Eee aur Le Re li Safety Rules General Safety iii Specifications Machine Specifications Rev 2 1 Performance Specifications enne 2 2 Hydraulic Specifications rror aan aaee aeaa a Ea anaa Ea r enne enne 2 3 Ford LRG 423 Engine Specifications 2 4 Deutz 1011F Engine Specifications 4004000 00 2 6 Hydrau
274. the ground controls in the down direction Manually override the directional valve by pushing in on the end of the valve spool Replace defective directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick boom from moving OR disconnect coupling on repair cylinder or the boom function cylinder counterbalance manifold and start the valve OR consult Genie engine Move the Industries Service function enable switch to Department either side and hold the boom down toggle switch at the ground controls in the down direction and check the pressure less than 2100 PSI Reset boom down relief valve item F pressure see Repair Section OR replace boom down relief valve OR repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department CHART 15 Part No 52271 Genie S 40 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 16 Boom Extend Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom extend toggle switch 7515 on ground panel in extend direction and check voltage on blk red wire on boom extend
275. the ground controls replace the alarm fuel tank tilt sensor c ground control box o mv Part No 52271 Genie S 40 4 7 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURES A 14 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 at an unsafe drive speed 1 Remove the cover from the rear of the turntable to access the drive limit switch 2 Visually inspect the drive limit switch mounted to the turntable side plate at the pivot end of the boom Inspect for the following Broken or missing roller or roller head Missing fasteners Loose wiring a turntable riser b boom c boom drive limit switch LS2 3 Visually inspect the boom extend drive limit Switch located on the end of the cable track on the boom Inspect for the following Broken or missing roller or arm Missing fasteners Loose wiring a extend drive limit switch LS1 b cable track 4 Startthe engine from the ground controls Extend the boom approximately 3 feet 0 9 m 6 Manually activate the boom extend drive limit Switch Result The boom extend drive limit switch arm should move freely and spring return to cen
276. the Oscillate Sequencing Valve Pressure OR consult Genie Industries Service Department Part No 52271 Genie S 40 5 57 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 26 Steer Left Function Inoperative Be sure all other functions operate normally With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in left direction and check voltage on TB36 12V or more With key switch in platform position and both Emergency Stop buttons pulled out to the OV ON position activate footswitch and steer rocker switch on drive controller DP1 in left direction and check voltage on blu 36 wire on steer left directional valve coil item TT on steer manifold 12V or more Disconnect wires to 0 or steer left directional infinite valve coil item TT on ohms steer manifold and test the resistance of the valve coil 5 to 6 ohms Continued on the next page With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in left direction and check voltage at the controller terminal with the blu wire attached Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department Repair open in blu 3
277. the PCV valve is essential to good engine performance A malfunctioning PCV valve can impair crankcase ventilation and may cause engine damage 1 Perform this procedure with the engine off Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the PCV valve DAN CNN MET D um i a pivot plate retaining bolts b engine pivot plate 2 Remove the hose from the PCV valve then remove the valve a PCV valve 3 Install the new PCV valve Connect the hoses 4 Swing the engine pivot plate back to its original position and replace the two retaining bolts Genie S 40 Part No 52271 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures C 11 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 result in component damage Perform this procedure with the engine off 1 Label then disconnect the plug wires from the spark plugs by grasping the molded boot Do not pull on the plug wire Blow out any debris around spark plugs Remove all the spark plugs from the engine Adjust the gap on each new spark plug a R Install the new spark plugs then connect the wires Be sure that each spark plug wire is
278. ting Read understand and obey the safety rules and operating instructions printed in the appropriate Genie S 40 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate flow chart thoroughly Attempting shortcuts may produce hazardous conditions MI Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 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 Perform all troubleshooting on a firm level surface Two persons will be required to safely perform some troubleshooting procedures Part No 52271 Genie S 40 5 1 Section 5 Troubleshooting Flow Charts Service Manual Second 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 ohm
279. tion function inoperative Test master cylinder see Chart 20 OR repair or replace slave cylinder or slave cylinder counterbalance valves OR function manifold may have an internal defect Consult Genie Industries Service Department Replace the platform level up directional valve coil item T Replace the defective directional valve Replace the defective counterbalance valve Check for mechanical restrictions keeping platform level up function from operating OR replace slave cylinder OR replace slave cylinder counterbalance valves OR consult Genie Industries Service Department Replace defective flow regulator valve Genie S 40 Part No 52271 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Level Down Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the platform level toggle switch TS14 in the down direction and check the voltage at org blk wire on platform level down function directional valve item V Continued on the next page 12V or more Chart 22 With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the on position move the function enable switch to either side and activate the platf
280. tor 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 Inspect the 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 Axle components Boom components and wear pads Dents or damage to machine Tires and wheels Engine and related components Limit switches Alarms horn and beacon if equipped Nuts bolts and other fasteners Platform entry mid rail or gate Cracks in welds or structural components Compartment covers and latches 4 2 Genie S 40 Part No 52271 Service Manual Second 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 service life Operating the machine with an improper oil level can damage engine components Check the oil level with the engine off 1 Checkthe oil dipstick Add oil as needed Result The oil level should be in the safe zone For
281. ty from opnti nuty ground to brown wire on terminal 85 on CR6 continuity Hold the start switch to either side and check voltage at blu wht wire on anti diesel valve on carburetor 12V Continued on the next page Repair open in blu wht wire circuit from fuel select switch to TB38 Repair open in blu red wire circuit from TB38 to terminal 30 on CR6 Repair open in red blk wire circuit from vacuum Switch to CR6 Repair open in brown ground wire circuit to terminal 85 on CR6 Repair open in blu wht wire circuit from CR6 terminal 487 to anti diesel valve OR replace CR6 Part No 52271 Genie S 40 5 17 Section 5 Troubleshooting Flow Charts CHART 5 Hold the start switch to either side and check Continued from the previous page voltage at blu wht wire on the fuel pump 12V Hold the start switch to either side and check voltage at blu wht wire on gasoline solenoid at fuel tank 12V 0 infinite Check resistance of ohms gasoline solenoid 1810 19 ohms 0 infinite Check resistance of ohms anti diesel valve 24 to 25 ohms Install a pressure gauge to the fuel pump Hold 7 psi start switch to either side and observe the pressure on the gauge more than 7 psi Reconnect starter and see Ford service manual for carburetor troubleshooting OR consult Genie Industries Service Department les
282. uring installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom until the master cylinder rod end pivot pin is accessible 2 Remove the turntable end cover to access the master cylinder 3 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Attach a lifting strap from an overhead crane to the lug on the rod end of the cylinder 5 Remove the pin retaining fasteners from the master cylinder barrel end pivot pin 6 Place a rod through the barrel end pivot pin and twist to remove the pin 7 Remove the pin retaining fastener from the rod end pivot pin 8 Use a soft metal drift to remove the pin 9 Remove the master cylinder from the machine Crushing hazard The master AWARNING cylinder may become unbalanced and fall if it is not properly attached to the overhead crane Genie S 40 Part No 52271 Service Manual Second 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 AWARNING weight do not atte
283. used for single function switching are single pole double throw SPDT relays How to Test a Single Pole Double Throw Relay AWARNING Electrocution hazard Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry 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 Test Desired result terminal 85 to 86 without resistor 85 to 950 terminal 85 to 86 with resistor 75 to 850 terminal 87 to 87a 8 30 no continuity infinite Q terminal 87a to 30 continuity zero Q 87 86 9 8 30 terminal no 87a N C terminal no 85 ground terminal no 30 common terminal no 86 coil terminal no 87 N O Control Relay Schematic without resistor O 85 87 87a E O 86 30 Control Relay Schematic with resistor 3 Connect 12V DC to terminal 85 and a ground 85 87 87a wire to terminal 86 then test the following iR terminal combinations Test Desired result terminal 87 to 87a amp 30 no continuity 86 30 infinite Q terminal 87 to 30 continuity zero Q 7 26
284. w it to run at low idle 7 Press down the foot switch to allow the engine to run at high idle O Result The engine should start promptly and operate smoothly in low and high idle 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 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 to either side 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 Startthe engine from the platform controls 2 Rotate the turntable to the right until the boom is past the right non steering wheel O Result The drive enable indicator light should turn on 3 Slowly move the drive control handle off center O Result The drive function should not operate TABLE B PROCEDURES 4 Hold the drive enable toggle switch to either side and slowly move the drive control handle off center LLL Always use the color coded ACAUTION direction arrows on the platform control panel and the drive chassis to identify which direction the
285. y 8 I or 1 tot 2 MASTER PLATFORM TURNTABLE LEVEL ROTATE OM Lm PRZ _PLI pig sls __ EXTEND RETRACT OFTIONAL FUNCTION R d MOTOR GEN MANIFOLD 3 EHH _ m RL ald de eT i SE E TEST 1 IKA SDD sx s 8 I rd mu 1 ae PRESS i tr 4 m EE ts LE i O Pd ee BE mi exu 64GPM A 2900 LOREM ej press DRIVEPUMP XX am OWSA OGAR desees GAR i 1 D 2000 L i t OPTIONAL z Wes fl E N E CUm 5 OIL COOLER a 2 SEC REG PSI PSI d RESERVOIR AUXILIARY PUMP 1 6 TT OSCILLATE OSCILLATE CYLINDERS MANIFOLD B MANIFOLD 5 1 7 REAR Ho RIGHT A EINE aed n TANK 1 spa 8 REAR LEFT STEERING TRACTION Part No 52271 Genie S 40 6 22 Service Manual Section 6 Schematics 2WD Hydraulic Schematic after serial number 1423 Oscillating Axle Service Manual Section 6 Schematics ju ZZ 3 4WD Hydraulic Schematic before serial number 1424 Oscillating Axle

Service Manual - Genie Industries

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