Service Genie S60 4414

Service
Manual
Technical
Publications
Second Edition, First Printing
Part No. 48412 (Rev A1)
July 2008
S-60
S-65
G e n ie S -6 0 & G e n ie S -6 5 P a rt N o. 4 8 4 1 2
S e rvice M a n u a l - S e co n d E d itio n
ii
I n tro d u ctio n
C o p yrig h t 1 9 9 8 b y G e n ie I n d u strie s
S e co n d E d itio n : F irst P rin tin g , J u n e 1 9 9 8
" G e n ie " a n d " S " a re R e g iste re d T ra d e m a rks
o f G e n ie I n d u strie s in th e U S A a n d m a n y o th e r
co u n trie s.
T h e se m a ch in e s co m p ly with
A N S I /S I A 9 2 . 5 -1 9 9 2 .
P rin te d o n re cycle d p a p e r
P rin te d in U . S . A .
Genie North America
T e le p h o n e (4 2 5 ) 8 8 1 -1 8 0 0
T o ll F re e 8 0 0 5 3 6 -1 8 0 0 in U . S . A .
T o ll F re e 8 0 0 4 2 6 -8 0 8 9 in C a n a d a
F a x (4 2 5 ) 5 5 6 -8 6 4 9
Genie Europe
O ffice T e le p h o n e (4 4 ) 0 1 6 3 6 -6 0 5 0 3 0
O ffice F a xF a x (4 4 ) 0 1 6 3 6 -6 1 1 0 9 0
P a rts T e le p h o n e (4 4 ) 0 1 6 3 6 -6 0 5 0 0 2
P a rts F a x (4 4 ) 0 1 6 3 6 -6 1 1 0 9 1
Important
R e a d , u n d e rsta n d a n d o b e y th e sa fe ty ru le s a n d
o p e ra tin g in stru ctio n s in th e a p p ro p ria te
Genie S-60 & Genie S-65 Operator's Manual
b e fo re a tte m p tin g a n y m a in te n a n ce o r re p a ir
p ro ce d u re .
T h is se rvice m a n u a l co ve rs th e G e n ie S -6 0 a n d
G e n ie S -6 5 2 WD a n d 4 WD m o d e ls.
T h is m a n u a l p ro vid e s d e ta ile d sch e d u le d
m a in te n a n ce in fo rm a tio n fo r th e m a ch in e o wn e r
a n d u se r. I t a lso p ro vid e s tro u b le sh o o tin g a n d
re p a ir p ro ce d u re s fo r q u a lifie d se rvice
p ro fe ssio n a ls.
B a sic m e ch a n ica l, h yd ra u lic a n d e le ctrica l skills
a re re q u ire d to p e rfo rm m o st p ro ce d u re s.
H o we ve r, se ve ra l p ro ce d u re s re q u ire sp e cia lize d
skills, to o ls, liftin g e q u ip m e n t a n d a su ita b le
wo rksh o p . I n th e se in sta n ce s, we stro n g ly
re co m m e n d th a t m a in te n a n ce a n d re p a ir b e
p e rfo rm e d a t a G e n ie d e a le r se rvice ce n te r.
G e n ie I n d u strie s h a s e n d e a vo re d to d e live r th e
h ig h e st d e g re e o f a ccu ra cy p o ssib le . H o we ve r,
co n tin u o u s im p ro ve m e n t o f o u r p ro d u cts is a
G e n ie p o licy. T h e re fo re p ro d u ct sp e cifica tio n s a re
su b je ct to ch a n g e with o u t n o tice .
R e a d e rs a re e n co u ra g e d to n o tify G e n ie o f e rro rs
a n d se n d in su g g e stio n s fo r im p ro ve m e n t. A ll
co m m u n ica tio n s will b e ca re fu lly co n sid e re d fo r
fu tu re p rin tin g s o f th is a n d o th e r m a n u a ls. P le a se
write to th e te ch n ica l p u b lica tio n s te a m in ca re o f
G e n ie I n d u strie s, P O B o x 6 9 , R e d m o n d WA
9 8 0 7 3 -0 0 6 9 U . S . A .
I f yo u h a ve a n y q u e stio n s, p le a se ca ll G e n ie
I n d u strie s.
P a rt N o. 4 8 4 1 2 G e n ie S -6 0 & G e n ie S -6 5
iii
Safety Rules
S e ctio n 1 - S a fe ty R u le s
Danger
F a ilu re to o b e y th e in stru ctio n s a n d sa fe ty ru le s in
th is m a n u a l, a n d th e Genie S-60 & Genie S-65
Operator's Manual will re su lt in d e a th o r se rio u s
in ju ry.
M a n y o f th e h a za rd s id e n tifie d in th e o p e ra to r's
m a n u a l a re a lso sa fe ty h a za rd s wh e n
m a in te n a n ce a n d re p a ir p ro ce d u re s a re
p e rfo rm e d .
Do Not Perform Maintenance
Unless:
Y o u a re tra in e d a n d q u a lifie d to p e rfo rm
m a in te n a n ce o n th is m a ch in e .
Y o u re a d , u n d e rsta n d a n d o b e y:
- m a n u fa ctu re rs in stru ctio n s a n d sa fe ty ru le s
- e m p lo ye rs sa fe ty ru le s a n d wo rksite
re g u la tio n s
- a p p lica b le g o ve rn m e n ta l re g u la tio n s
Y o u h a ve th e a p p ro p ria te to o ls, liftin g
e q u ip m e n t a n d a su ita b le wo rksh o p .
S A F E T Y R U L E S
iv
S e ctio n 1 - S a fe ty R u le s
Workplace Safety
B e su re to ke e p sp a rks, fla m e s a n d
lig h te d to b a cco a wa y fro m fla m m a b le a n d
co m b u stib le m a te ria ls like b a tte ry g a se s
a n d e n g in e fu e ls. A lwa ys h a ve a n a p p ro ve d fire
e xtin g u ish e r with in e a sy re a ch .
B e su re th a t a ll to o ls a n d wo rkin g a re a s
a re p ro p e rly m a in ta in e d a n d re a d y fo r
u se . K e e p wo rk su rfa ce s cle a n a n d fre e
o f d e b ris th a t co u ld g e t in to m a ch in e co m p o n e n ts
a n d ca u se d a m a g e .
B e su re th a t yo u r wo rksh o p o r wo rk a re a
is p ro p e rly ve n tila te d a n d we ll lit.
B e su re a n y fo rklift, o ve rh e a d cra n e o r
o th e r liftin g o r su p p o rtin g d e vice is fu lly
ca p a b le o f su p p o rtin g a n d sta b ilizin g th e
we ig h t to b e lifte d . U se o n ly ch a in s o r stra p s th a t
a re in g o o d co n d itio n a n d o f a m p le ca p a city.
B e su re th a t fa ste n e rs in te n d e d fo r o n e
tim e u se (i. e . , co tte r p in s a n d se lf-lo ckin g
n u ts) a re n o t re u se d . T h e se co m p o n e n ts
m a y fa il if th e y a re u se d a se co n d tim e .
B e su re to p ro p e rly d isp o se o f o ld o il o r
o th e r flu id s. U se a n a p p ro ve d co n ta in e r.
P le a se b e e n viro n m e n ta lly sa fe .
Personal Safety
A n y p e rso n wo rkin g o n o r a ro u n d a m a ch in e m u st
b e a wa re o f a ll kn o wn sa fe ty h a za rd s. P e rso n a l
sa fe ty a n d th e co n tin u e d sa fe o p e ra tio n o f th e
m a ch in e sh o u ld b e yo u r to p p rio rity.
R e a d e a ch p ro ce d u re th o ro u g h ly. T h is
m a n u a l a n d th e d e ca ls, o n th e m a ch in e ,
u se sig n a l wo rd s to id e n tify th e fo llo win g :
I n d ica te s th e p re se n ce o f
a h a za rd th a t will ca u se
d e a th o r se rio u s in ju ry.
a h a za rd th a t may ca u se
d e a th o r se rio u s in ju ry.
a h a za rd th a t will o r may
ca u se se rio u s in ju ry o r
d a m a g e to th e m a ch in e .
I n d ica te s sp e cia l
o p e ra tio n o r m a in te n a n ce
in fo rm a tio n .
B e su re to we a r p ro te ctive e ye we a r a n d
o th e r p ro te ctive clo th in g if th e situ a tio n
wa rra n ts it.
B e a wa re o f p o te n tia l cru sh in g h a za rd s
su ch a s m o vin g p a rts, fre e swin g in g o r
u n se cu re d co m p o n e n ts, a n d liftin g o r
p la cin g lo a d s. A lwa ys we a r a p p ro ve d ste e l-to e d
sh o e s.
Table of Contents
v
Introduction
I m p o rta n t I n fo rm a tio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Section One Safety Rules
G e n e ra l S a fe ty R u le s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Section Two Specifications
M a ch in e S p e cifica tio n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
P e rfo rm a n ce S p e cifica tio n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
H yd ra u lic S p e cifica tio n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
F o rd L R G 4 2 3 E n g in e S p e cifica tio n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
D e u tz F 4 L 1 0 1 1 F E n g in e S p e cifica tio n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
H yd ra u lic H o se a n d F ittin g T o rq u e S p e cifica tio n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
B o lt T o rq u e S p e cifica tio n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
Section Three Scheduled Maintenance Inspections
I n tro d u ctio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
T a b le A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
T a b le B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
T a b le C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
T a b le D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
M a in te n a n ce I n sp e ctio n R e p o rt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7
Section Four Scheduled Maintenance Procedures
I n tro d u ctio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
A -1 I n sp e ct th e M a n u a ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
A -2 I n sp e ct th e D e ca ls a n d P la ca rd s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
A -3 I n sp e ct fo r D a m a g e , L o o se o r M issin g P a rts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
A -4 C h e ck th e E n g in e O il L e ve l. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
A -5 C h e ck th e E n g in e C o o la n t L e ve l - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
A -6 C h e ck fo r F u e l L e a ks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
A -7 C h e ck th e H yd ra u lic O il L e ve l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
A -8 C h e ck fo r H yd ra u lic L e a ks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
T A B L E O F C O N T E N T S
vi
Section Four Scheduled Maintenance Procedures, co n tin u e d
A -9 C h e ck th e T ire P re ssu re . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
A -1 0 T e st th e O scilla te A xle (if e q u ip p e d ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
A -1 1 T e st th e P la tfo rm a n d G ro u n d C o n tro ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
A -1 2 T e st th e A u xilia ry P o we r O p e ra tio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
A -1 3 T e st th e T ilt S e n so r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
A -1 4 T e st th e L im it S witch e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
A -1 5 R e p la ce th e E n g in e O il a n d F ilte r - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 0
A -1 6 D ra in th e F u e l F ilte r/Wa te r S e p a ra to r - D e u tz D ie se l M o d e ls . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 1
A -1 7 R e p la ce th e E n g in e A ir F ilte r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 2
B -1 C h e ck th e E n g in e B e lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 3
B -2 C h e ck th e R a d ia to r - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 4
B -3 C h e ck th e O il C o o le r a n d C o o lin g F in s - D e u tz D ie se l M o d e ls . . . . . . . . . . . . . . . . . . . . . 4 - 1 4
B -4 C h e ck th e E xh a u st S yste m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 5
B -5 C h e ck th e B a tte ry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 6
B -6 C h e ck th e H yd ra u lic T a n k F ilte r C o n d itio n I n d ica to r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 6
B -7 I n sp e ct th e E le ctrica l Wirin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 7
B -8 I n sp e ct th e T ire s a n d Wh e e ls (in clu d in g lu g n u t to rq u e ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 7
B -9 C o n firm th e P ro p e r B ra ke C o n fig u ra tio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 8
B -1 0 C h e ck th e O il L e ve l in th e T o rq u e H u b s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 8
B -1 1 C h e ck a n d A d ju st th e E n g in e I d le M ixtu re - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . 4 - 1 9
B -1 2 C h e ck a n d A d ju st th e E n g in e R P M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 9
B -1 3 T e st th e K e y S witch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 1
B -1 4 T e st th e E m e rg e n cy S to p B u tto n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 1
B -1 5 T e st th e G ro u n d C o n tro l O ve rrid e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 2
B -1 6 C h e ck th e D ire ctio n a l V a lve L in ka g e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 2
B -1 7 T e st th e P la tfo rm S e lf-le ve lin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 3
B -1 8 T e st th e H o rn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 3
B -1 9 T e st th e F o o t S witch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 3
B -2 0 T e st th e E n g in e I d le S e le ct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 4
B -2 1 T e st th e F u e l S e le ct O p e ra tio n - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 4
B -2 2 T e st th e D rive E n a b le S yste m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 5
vii
Section Four Scheduled Maintenance Procedures, co n tin u e d
B -2 3 T e st th e D rive B ra ke s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 5
B -2 4 T e st th e D rive S p e e d - S to we d P o sitio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 6
B -2 5 T e st th e A la rm P a cka g e - O p tio n a l E q u ip m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 7
B -2 6 P e rfo rm H yd ra u lic O il A n a lysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 7
B -2 7 R e p la ce th e E n g in e O il a n d F ilte r - D e u tz D ie se l M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 7
C -1 C h e ck th e B o o m We a r P a d s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 9
C -2 C h e ck th e T u rn ta b le R o ta tio n B e a rin g B o lts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 9
C -3 C h e ck th e F re e -wh e e l C o n fig u ra tio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 0
C -4 G re a se th e T u rn ta b le R o ta tio n B e a rin g a n d R o ta te G e a r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 1
C -5 R e p la ce th e T o rq u e H u b O il . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 1
C -6 R e p la ce th e H yd ra u lic T a n k F ilte r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 3
C -7 R e p la ce th e D rive L o o p H yd ra u lic F ilte r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 3
C -8 R e p la ce th e D ie se l F u e l F ilte r/Wa te r S e p a ra to r - D e u tz D ie se l M o d e ls . . . . . . . 4 - 3 4
C -9 R e p la ce th e G a so lin e F u e l F ilte r - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 4
C -1 0 R e p la ce th e P C V V a lve - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 6
C -1 1 R e p la ce th e S p a rk P lu g s - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 7
C -1 2 C h e ck a n d A d ju st th e A ir/L P G M ixtu re - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . 4 - 3 7
C -1 3 C h e ck a n d A d ju st th e I g n itio n T im in g - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . 4 - 3 8
C -1 4 C h e ck th e E n g in e V a lve C le a ra n ce s - D e u tz D ie se l M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 8
C -1 5 C h e ck th e T u rn ta b le R o ta tio n G e a r B a ckla sh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 8
D -1 T e st o r R e p la ce th e H yd ra u lic O il . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 9
D -2 C h a n g e o r R e co n d itio n th e E n g in e C o o la n t - G a so lin e /L P G M o d e ls . . . . . . . . . . . . 4 - 3 9
D -3 C h a n g e th e F u e l L in e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 1
D -4 C h e ck th e E n g in e V a lve C le a ra n ce - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 2
D -5 C h e ck th e E n g in e C ylin d e r C o m p re ssio n - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . 4 - 4 2
D -6 C le a n th e P C V H o se s a n d F ittin g s - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 2
D -7 C h e ck th e F u e l I n je ctio n P u m p s a n d I n je cto rs - D e u tz D ie se l M o d e ls . . . . . . . . . . 4 - 4 3
D -8 C h e ck th e T o o th e d B e lt - D e u tz D ie se l M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 3
D -9 R e p la ce th e T im in g B e lt - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 3
D -1 0 G re a se th e S te e r A xle Wh e e l B e a rin g s - 2 WD M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 4
viii
Section Five Troubleshooting Flow Charts
I n tro d u ctio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
1 E n g in e Will N o t C ra n k O ve r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
2 E n g in e C ra n ks O ve r B u t Will N o t S ta rt - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . 5 - 5
2 A E n g in e C ra n ks O ve r B u t Will N o t S ta rt O R E n g in e R u n s
Wh ile C ra n kin g T h e D ie s- G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8
2 B E n g in e R u n s Wh ile C ra n kin g T h e n D ie s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 1
3 E n g in e C ra n ks O ve r B u t Will N o t S ta rt - D e u tz D ie se l M o d e ls . . . . . . . . . . . . . . . . . . . . . 5 - 1 2
4 E n g in e Will N o t S ta rt O n L P G , B u t Will S ta rt O n G a so lin e
- G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 5
5 E n g in e Will N o t S ta rt O n G a so lin e , B u t Will S ta rt O n L P G
- G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 7
6 E n g in e H ig h I d le I n o p e ra tive - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 9
7 E n g in e L o w I d le I n o p e ra tive - G a so lin e /L P G M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 2
8 E n g in e H ig h I d le I n o p e ra tive - D e u tz D ie se l M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 3
9 E n g in e L o w I d le I n o p e ra tive - D e u tz D ie se l M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 5
1 0 A ll F u n ctio n s I n o p e ra tive , E n g in e S ta rts a n d R u n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 6
1 1 A ll L ift a n d S te e r F u n ctio n s I n o p e ra tive , D rive F u n ctio n s O p e ra tio n a l . . . . . . . . . . 5 - 2 7
1 2 G ro u n d C o n tro ls I n o p e ra tive , P la tfo rm C o n tro ls O p e ra te N o rm a lly . . . . . . . . . . . . . . 5 - 2 8
1 3 P la tfo rm C o n tro ls I n o p e ra tive , G ro u n d C o n tro ls O p e ra te N o rm a lly . . . . . . . . . . . . . . 5 - 2 9
1 4 B o o m U p F u n ctio n I n o p e ra tive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 0
1 5 B o o m D o wn F u n ctio n I n o p e ra tive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 3
1 6 B o o m E xte n d F u n ctio n I n o p e ra tive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 6
1 7 B o o m R e tra ct F u n ctio n I n o p e ra tive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 9
1 8 T u rn ta b le R o ta te L e ft F u n ctio n I n o p e ra tive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4 2
1 9 T u rn ta b le R o ta te R ig h t F u n ctio n I n o p e ra tive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4 6
2 0 A ll P la tfo rm L e ve lin g F u n ctio n s I n o p e ra tive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 0
2 1 P la tfo rm L e ve l U p F u n ctio n I n o p e ra tive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 1
2 2 P la tfo rm L e ve l D o wn F u n ctio n I n o p e ra tive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 3
2 3 P la tfo rm R o ta te L e ft F u n ctio n I n o p e ra tive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 5
2 4 P la tfo rm R o ta te R ig h t F u n ctio n I n o p e ra tive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 8
2 5 J ib B o o m U p I n o p e ra tive , S -6 5 M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6 1
2 6 J ib B o o m D o wn I n o p e ra tive , S -6 5 M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6 3
Part No. 48412 Genie S-60 & Genie S-65
Service Manual - Second Edition
TABLE OF CONTENTS
ix
Section Five Troubleshooting Flow Charts, continued
27 Oscillate Function Inoperative ....................................................................... 5 - 65
28 Steer Left Function Inoperative...................................................................... 5 - 66
29 Steer Right Function Inoperative ................................................................... 5 - 68
30 All Drive Functions Inoperative, All Other Functions Operate Normally.......... 5 - 70
31 Drive Forward Or Reverse Function Inoperative............................................. 5 - 73
32 Traction Function Inoperative ........................................................................ 5 - 74
33 Machine Will Not Drive At Full Speed ............................................................ 5 - 75
34 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 76
35 Drive Enable System Is Malfunctioning ......................................................... 5 - 77
36 Auxiliary Functions Inoperative...................................................................... 5 - 78
Section Six Schematics
Introduction ............................................................................................................... 6 - 1
Electrical Components .............................................................................................. 6 - 2
Electrical Symbols Legend........................................................................................ 6 - 4
Abbreviation Legend.................................................................................................. 6 - 5
Electrical Schematic - Gasoline/LPG Models (Rev B) ............................................... 6 - 7
Ground Control Box Legend - Gasoline/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 Models ............................................................ 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 Legend...................................................................................... 6 - 20
2WD Hydraulic Schematic - Non-oscillating axle ..................................................... 6 - 21
2WD Hydraulic Schematic - Oscillating axle ........................................................... 6 - 22
4WD Hydraulic Schematic - Non-oscillating axle ..................................................... 6 - 23
4WD Hydraulic Schematic - Oscillating axle ........................................................... 6 - 24
x
Section Seven Repair Procedures
I n tro d u ctio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
Platform Controls
1 -1 J o ystick C o n tro lle rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2
1 -2 H o rse p o we r L im ite r B o a rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
1 -3 F o o t S witch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8
1 -4 R e sisto rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9
1 -5 T o g g le S witch e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9
1 -6 C o n tro l R e la ys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 0
Platform Components
2 -1 P la tfo rm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 1
2 -2 P la tfo rm L e ve lin g S la ve C ylin d e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 1
2 -3 P la tfo rm R o ta to r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 2
Jib Boom Components, S-65 Models
3 -1 J ib B o o m , S -6 5 M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 5
3 -2 J ib B o o m L ift C ylin d e r, S -6 5 M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 6
3 -3 J ib B o o m / P la tfo rm R o ta te M a n ifo ld C o m p o n e n ts, S -6 5 M o d e ls . . . . . . . . . . . . . . . . . 7 - 1 7
Boom Components
4 -1 B o o m C a b le T ra ck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 8
4 -2 B o o m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 0
4 -3 B o o m L ift C ylin d e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 3
4 -4 E xte n sio n C ylin d e rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 4
4 -5 P la tfo rm L e ve lin g M a ste r C ylin d e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 5
Turntable Covers
5 -1 T u rn ta b le C o ve rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 6
Deutz Engine F4L 1011F
6 -1 R P M A d ju stm e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 7
6 -2 F le x P la te . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 7
6 -3 O il T e m p e ra tu re a n d O il P re ssu re G a u g e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 7
Ford LRG-423 Engine
7 -1 G o ve rn o r A ctu a to r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 8
7 -2 C h o ke A d ju stm e n ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 9
xi
Section Seven Repair Procedures, Ford LRG-423 Engine, co n tin u e d
7 -3 T im in g A d ju stm e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 0
7 -4 C a rb u re to r A d ju stm e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 0
7 -5 R P M A d ju stm e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 0
7 -6 F le x P la te . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 0
7 -7 Wa te r T e m p e ra tu re a n d O il P re ssu re G a u g e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 1
7 -8 V a cu u m S witch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 2
Ground Controls
8 -1 C o n tro l R e la ys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 3
8 -2 T o g g le S witch e s, S e e 1 -5 , Toggle Switches................................................... 7 - 9
8 -3 Wa g o
C o m p o n e n ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 3
8 -4 R e sisto rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 3
8 -5 P o we r R e la y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 4
Hydraulic Pumps
9 -1 L ift/S te e r P u m p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 5
9 -2 D rive P u m p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 5
Manifolds
1 0 -1 F u n ctio n M a n ifo ld C o m p o n e n ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 8
1 0 -2 V a lve A d ju stm e n ts - F u n ctio n M a n ifo ld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4 2
1 0 -3 T u rn ta b le R o ta tio n M a n ifo ld C o m p o n e n ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4 5
1 0 -4 O scilla te M a n ifo ld C o m p o n e n ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4 6
1 0 -5 V a lve A d ju stm e n ts - O scilla te M a n ifo ld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4 7
1 0 -6 D ire ctio n a l V a lve M a n ifo ld C o m p o n e n ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4 8
1 0 -7 S te e r M a n ifo ld C o m p o n e n ts, S -6 0 /6 5 O scilla tin g M o d e ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5 0
1 0 -8 2 WD D rive M a n ifo ld C o m p o n e n ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5 2
1 0 -9 V a lve A d ju stm e n ts, 2 WD D rive M a n ifo ld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5 4
1 0 -1 0 4 WD D rive M a n ifo ld C o m p o n e n ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5 6
1 0 -1 1 V a lve A d ju stm e n ts, 4 WD D rive M a n ifo ld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5 8
. Fuel and Hydraulic Tanks
1 1 -1 F u e l T a n k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5 9
1 1 -2 H yd ra u lic T a n k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5 9
xii
Section Seven Repair Procedures, co n tin u e d
Turntable Rotation Components
1 2 -1 R o ta tio n H yd ra u lic M o to r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6 2
2WD Steering Axle Components
1 3 -1 Y o ke a n d H u b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6 5
1 3 -2 S te e rin g C ylin d e rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6 6
1 3 -3 T ie R o d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6 7
1 4 -1 Y o ke a n d H u b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6 8
1 4 -2 S te e rin g C ylin d e rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6 9
1 4 -3 T ie R o d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6 9
Oscillating Axle Components
1 5 -1 O scilla tin g A xle L o ck-o u t C ylin d e rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 0
Non-steering Axle Components
1 6 -1 D rive M o to r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 1
1 6 -2 T o rq u e H u b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 1
P a rt N o. 4 8 4 1 2 G e n ie S -6 0 & G e n ie S -6 5 2 - 1
S e ctio n 2 - S p e cifica tio n s S e rvice M a n u a l - S e co n d E d itio n
Specifications
Machine Specifications
Stowed dimensions S-60 S-65
L e n g th 2 7 ft 2 in 3 0 ft 1 0 in
8 . 3 m 9 . 4 m
Wid th 8 ft 8 ft
2 . 4 3 m 2 . 4 3 m
H e ig h t 9 ft 9 ft
2 . 7 4 m 2 . 7 4 m
We ig h t 2 6 , 0 6 0 lb s 2 8 , 4 0 0 lb s
1 1 , 8 2 1 kg 1 2 , 8 8 2 kg
G ro u n d cle a ra n ce 1 2 in 1 2 in
3 0 cm 3 0 cm
Operational dimensions
M a xim u m p la tfo rm h e ig h t 6 0 ft 6 5 ft
1 8 . 3 m 1 9 . 8 m
M a xim u m h o rizo n ta l re a ch 5 1 ft 3 in 5 6 ft 4 in
1 5 . 6 m 1 7 . 2 m
M a xim u m tu rn ta b le ta ilswin g 3 ft 3
1
/2 in 3 ft 3
1
/2 in
1 0 0 cm 1 0 0 cm
Wh e e lb a se 9 ft 0 in 9 ft 0 in
2 . 7 m 2 . 7 m
M in im u m tu rn in g ra d iu s, 1 2 ft 1 in 1 2 ft 1 in
in sid e 3 . 7 m 3 . 7 m
M in im u m tu rn in g ra d iu s, 2 2 ft 2 in 2 2 ft 2 in
o u tsid e 6 . 7 6 m 6 . 7 6 m
T u rn ta b le ro ta tio n co n tin u o u s co n tin u o u s
P la tfo rm ro ta tio n 1 6 0 1 6 0
M a xim u m ca p a city 6 0 0 lb s 5 0 0 lb s
6 fo o t p la tfo rm 2 7 2 kg 2 2 7 kg
M a xim u m ca p a city 5 0 0 lb s 5 0 0 lb s
8 fo o t p la tfo rm 2 2 7 kg 2 2 7 kg
M a xim u m a llo wa b le
sid e fo rce (A N S I a n d C S A ) 1 5 0 lb s 1 5 0 lb s
6 8 kg 6 8 kg
Continuous improvement of our products is a
Genie policy. Product specifications are subject to
change without notice.
Platform dimensions 6 ft 8 ft
(S ta n d a rd ) (O p tio n a l)
L e n g th 6 ft 8 ft
1 . 8 3 m 2 . 4 4 m
Wid th 3 0 in 3 6 in
7 6 . 2 cm 9 1 . 4 cm
Tires and wheels
T ire size 1 5 -1 9 . 5 N H S
T ire p ly ra tin g 1 2
T ire co n ta ct a re a 7 1 sq in
4 5 8 sq cm
O ve ra ll tire d ia m e te r 4 0 in
1 0 2 cm
T ire p re ssu re 8 5 p si
5 . 8 6 b a r
Wh e e l d ia m e te r 1 9
1
/2 in
4 9 . 5 cm
Wh e e l wid th 1 2
1
/4 in
3 1 cm
Wh e e l lu g s 1 0 @
3
/4 -1 6
L u g n u t to rq u e , d ry b o lts 4 2 0 ft-lb s
5 6 9 . 5 N m
L u g n u t to rq u e , lu b rica te d b o lts 3 2 0 ft-lb s
4 3 3 . 9 N m
Fluid capacities
F u e l ta n k 3 0 g a llo n s
1 1 4 lite rs
L P G ta n k 3 3 . 5 p o u n d s
1 5 . 2 kg
H yd ra u lic ta n k 4 5 g a llo n s
1 7 0 lite rs
H yd ra u lic syste m 5 5 g a llo n s
(in clu d in g ta n k) 2 0 8 lite rs
D rive to rq u e h u b s 4 4 fl o z
1 . 3 0 lite rs
T u rn ta b le ro ta tio n 1 7 fl o z
to rq u e h u b 0 . 5 1 lite rs
2 - 2 G e n ie S -6 0 & G e n ie S -6 5 P a rt N o. 4 8 4 1 2
S P E C I F I C A T I O N S
Boom function speeds, maximum
from platform controls
J ib b o o m u p 4 0 to 6 0 se co n d s
J ib b o o m d o wn 5 0 to 8 0 se co n d s
B o o m u p 5 5 to 8 5 se co n d s
B o o m d o wn 9 0 to 1 2 0 se co n d s
B o o m e xte n d 6 0 to 8 0 se co n d s
B o o m re tra ct 5 5 to 8 5 se co n d s
T u rn ta b le ro ta te - 3 6 0
b o o m fu lly sto we d 8 0 to 1 0 0 se co n d s
T u rn ta b le ro ta te - 3 6 0
b o o m e xte n d e d 1 3 0 to 1 6 0 se co n d s
P la tfo rm ro ta te - 1 6 0 1 0 to 2 0 se co n d s
P la tfo rm le ve l u p 3 5 to 6 5 se co n d s
P la tfo rm le ve l d o wn 2 5 to 5 5 se co n d s
Performance Specifications
Drive speeds, maximum 2WD 4WD
D rive sp e e d , sto we d 4 . 4 m p h 3 . 0 m p h
G a so lin e /L P G m o d e ls 7 . 1 km /h 4 . 8 km /h
4 0 ft/6 . 2 se c 4 0 ft/9 . 1 se c
1 2 . 2 m /6 . 2 se c 1 2 . 2 m /9 . 1 se c
D rive sp e e d , sto we d 4 . 0 m p h 2 . 8 m p h
D e u tz D ie se l m o d e ls 6 . 4 km /h 4 . 5 km /h
4 0 ft/6 . 8 se c 4 0 ft/9 . 7 se c
1 2 . 2 m /6 . 8 se c 1 2 . 2 m /9 . 7 se c
D rive sp e e d , 0 . 6 m p h 0 . 6 m p h
ra ise d o r e xte n d e d 1 . 0 km /h 1 . 0 km /h
- a ll m o d e ls 4 0 ft/4 0 se c 4 0 ft/4 0 se c
1 2 . 2 m /4 0 se c 1 2 . 2 m /4 0 se c
Gradeability (boom stowed) 2WD 4WD
R o u g h te rra in 2 8 % 4 0 %
Hydraulic Specifications
Hydraulic fluid D e xro n e q u iva le n t
Drive pump
T yp e : b i-d ire ctio n a l va ria b le d isp la ce m e n t p isto n p u m p
D isp la ce m e n t - 2 5 0 0 rp m 0 to 3 0 . 3 g a llo n s p e r m in u te
0 to 1 1 4 . 7 lite rs p e r m in u te
M a xim u m d rive p re ssu re 3 5 0 0 p si
2 4 1 . 3 b a r
C h a rg e p re ssu re
n e u tra l p o sitio n 2 9 0 p si 2 0 b a r
d rive p o sitio n 2 5 0 p si 1 7 b a r
M e d iu m p re ssu re filte r 3 m icro n
M e d iu m p re ssu re filte r 5 0 p si
b yp a ss p re ssu re 3 . 4 b a r
Drive manifold
B ra ke 2 5 0 p si
re lie f p re ssu re 1 7 . 2 b a r
Steer end drive motors 4WD models
D isp la ce m e n t 1 . 5 2 cu in
p e r re vo lu tio n 2 5 cc
Non-steer end drive motors
D isp la ce m e n t p e r re vo lu tio n , va ria b le 0 . 1 6 to 2 . 8 cu in
4 WD (2 sp e e d m o to r) 2 . 6 2 to 4 5 . 9 cc
D isp la ce m e n t p e r re vo lu tio n , va ria b le 1 . 1 2 to 2 . 8 cu in
2 WD 1 8 . 4 to 4 5 . 9 cc
Function pump
T yp e : p re ssu re b a la n ce d g e a r
D isp la ce m e n t - sta tic 1 . 1 4 cu in
1 9 cc
D isp la ce m e n t - 2 5 0 0 rp m 0 to 1 2 . 3 g a llo n s p e r m in u te
0 to 4 6 . 6 lite rs p e r m in u te
H yd ra u lic ta n k circu it 1 0 m icro n with 2 5 p si
re tu rn lin e filte r (1 . 7 b a r) b yp a ss
Function manifold
F u n ctio n re lie f va lve p re ssu re
S 6 0 2 6 0 0 p si 1 7 9 b a r
S 6 5 2 9 0 0 p si 2 0 0 b a r
B o o m d o wn 2 1 0 0 p si
re lie f va lve p re ssu re 1 4 5 b a r
B o o m e xte n d 2 5 0 0 p si
1 7 2 b a r
O scilla te a xle 9 5 0 p si
6 5 b a r
S te e r re g u la to r
O scilla te m o d e ls 5 g p m 1 8 . 9 lite rs/m in
N o n -o scilla te m o d e ls 3 . 5 g p m 1 3 . 2 lite rs/m in
Auxiliary pump
T yp e : fixe d d isp la ce m e n t g e a r p u m p
D isp la ce m e n t - sta tic 0 . 1 5 2 cu in
2 . 5 cc
D isp la ce m e n t 1 . 4 g a llo n s p e r m in u te
5 . 3 lite rs p e r m in u te
A u xilia ry p u m p 2 5 0 0 p si
re lie f p re ssu re 1 7 2 b a r
Ford Engine LRG-423
Displacement 1 4 0 cu in
2 . 3 lite rs
Number of cylinders 4
Bore & stroke 3 . 7 8 1 x 3 . 1 2 6 in ch e s
9 6 . 0 4 x 7 9 . 4 m m
Horsepower 6 3 @ 4 0 0 0 rp m
Firing order 1 - 3 - 4 - 2
Low idle - carburetor 9 0 0 rp m
Low idle - electronic governor 1 6 0 0 rp m
High idle 2 5 0 0 rp m
Governor e le ctro n ic
Compression ratio 9 . 4 : 1
Compression pressure (approx.)
P re ssu re (p si) o f lo we st cylin d e r m u st b e
a t le a st 7 5 % o f h ig h e st cylin d e r
Valve clearances - 0 . 0 3 5 to 0 . 0 5 5 in ch e s
collapsed tappet 0 . 8 8 9 to 1 . 3 9 7 m m
Lubrication system
O il p re ssu re 4 0 to 6 0 p si
(o p e ra tin g te m p . @ 2 0 0 0 rp m ) 2 . 7 5 to 4 . 1 b a r
O il ca p a city 5 q u a rts
(in clu d in g filte r) 4 . 7 lite rs
Oil viscosity requirements
T e m p e ra tu re b e lo w 6 0 F / 1 5 . 5 C 5 W-3 0
-1 0 F to 9 0 F / -2 3 C to 3 2 C 1 0 W-3 0
T e m p e ra tu re a b o ve 1 0 W-4 0 to 1 0 W-5 0
-1 0 F / -2 3 C
T e m p e ra tu re a b o ve 2 0 W-4 0 o r 2 0 W-5 0
2 0 F / -6 . 6 C
U se o ils m e e tin g A P I cla ssifica tio n S G (la b e le d S G /C C
o r S G /C D ) a s th e y o ffe r im p ro ve d we a r p ro te ctio n .
U n its sh ip with 1 0 W-4 0 S G /C C .
Starter motor
N o rm a l e n g in e cra n kin g sp e e d 2 0 0 to 2 5 0 rp m
C u rre n t d ra w, n o rm a l lo a d 1 7 0 A
C u rre n t d ra w, m a xim u m lo a d 2 0 0 A
C u rre n t d ra w, m in im u m 1 4 0 A
M a xim u m circu it vo lta g e d ro p 0 . 5 V D C
wh ile sta rtin g (n o rm a l te m p e ra tu re )
B ru sh le n g th , n e w 0 . 6 6 in
1 6 . 8 m m
B ru sh le n g th we a r lim it 0 . 2 5 in
6 . 3 5 m m
B ru sh sp rin g te n sio n 6 4 o u n ce s
1 8 N e wto n s
B o lt to rq u e 4 5 to 8 4 in ch -p o u n d s
th ro u g h b ru sh 5 . 0 8 to 9 . 5 N m
B ru sh m o u n tin g 1 5 to 2 0 fo o t-p o u n d s
b o lt to rq u e 2 0 to 2 7 N m
M a xim u m co m m u ta to r 0 . 0 0 5 in ch e s
ru n -o u t 0 . 1 2 7 m m
Battery
T yp e 1 2 V , G ro u p 3 1
Q u a n tity 1
C o ld cra n kin g a m p e re 1 0 0 0 A
R e se rve ca p a city @ 2 5 A ra te 2 0 0 m in u te s
Fuel pump
E le ctro n ic so le n o id 7 p si
0 . 4 8 b a r
Ignition System
S p a rk p lu g typ e M o to rcra ft A WS F -5 2 C
S p a rk p lu g g a p 0 . 0 4 2 to 0 . 0 4 6 in ch e s
1 . 0 7 to 1 . 1 8 m m
Engine coolant
C a p a city 1 1
1
/2 q u a rts
1 0 . 9 lite rs
Alternator
O u tp u t 9 5 A , 1 4 . 5 V
Bolt torque specifications
to rq u e to rq u e
B o lt d e scrip tio n (size ) ft-lb s N m
T im in g b e lt te n sio n e r 2 9 to 4 0 4 0 to 5 5
p ivo t b o lt (M -1 0 )
T im in g b e lt te n sio n e r 2 5 to 2 9 3 5 to 4 0
a d ju stin g b o lt (M -8 )
C a m sh a ft g e a r b o lt (M -1 2 ) 5 2 to 6 6 7 0 to 9 0
C a m sh a ft th ru st p la te b o lt (M -6 ) 6 to 9 8 to 1 2
C a rb u re to r to sp a ce r stu d (M -8 ) 7 . 5 to 1 5 1 0 to 2 0
C a rb u re to r sp a ce r to 1 0 to 1 4 1 4 to 1 9
m a n ifo ld b o lt (M -8 )
C ra n ksh a ft d a m p e r 9 2 to 1 2 2 1 2 5 to 1 6 5
b o lt (M -1 4 )
C ylin d e r h e a d b o lt (M -1 2 ): to rq u e in se q u e n ce
first ste p 5 0 to 6 0 6 8 to 8 1
se co n d ste p 8 0 to 9 0 1 0 8 to 1 2 2
Bolt torque specifications
to rq u e to rq u e
B o lt d e scrip tio n (size ) ft-lb s N m
E xh a u st m a n ifo ld to cylin d e r h e a d b o lt o r n u t (M -1 0 ):
to rq u e in se q u e n ce
first ste p 1 4 to 1 9 1 9 to 2 6
se co n d ste p 3 5 to 5 0 4 7 to 6 8
F lywh e e l to cra n ksh a ft 5 4 to 6 4 7 3 to 8 7
b o lt (M -1 0 )
I n ta ke m a n ifo ld to 1 5 to 2 2 2 0 to 3 0
cylin d e r h e a d b o lt o r n u t (M -8 )
O il p re ssu re se n d in g u n it to b lo ck 8 to 1 8 1 1 to 2 4
O il p a n d ra in p lu g to p a n (M -1 4 ) 1 5 to 2 5 2 0 to 3 4
O il p a n to b lo ck (M -6 ) 1 0 to 1 3 . 5 1 4 to 1 8
O il filte r in se rt to b lo ck 2 1 to 2 6 2 8 to 3 5
R o cke r a rm co ve r to 7 to 1 0 9 to 1 3
cylin d e r h e a d (M -6 )
S p a rk p lu g to cylin d e r 7 to 1 5 9 to 2 0
h e a d (M -1 4 )
T e m p e ra tu re se n d in g 8 to 1 8 1 1 to 2 4
u n it to b lo ck (M -1 4 )
Wa te r ja cke t d ra in p lu g to b lo ck 1 2 to 1 8 1 6 to 2 4
Wa te r p u m p to b lo ck b o lt (M -8 ) 1 5 to 2 2 2 0 to 3 0
Wa te r o u tle t co n n e ctio n 1 5 to 2 2 2 0 to 3 0
b o lt (M -8 )
C ylin d e r fro n t co ve r b o lt (M -6 ) 1 0 to 1 2 1 3 to 1 6
I n n e r tim in g b e lt co ve r 1 5 to 2 2 2 0 to 3 0
stu d (M -8 )
O u te r tim in g b e lt co ve r 6 to 9 8 to 1 2
b o lt (M -6 )
I n je ctio n p u m p p re ssu re 4 3 5 1 p si
3 0 0 b a r
I n je cto r o p e n in g p re ssu re 3 6 2 6 p si
2 5 0 b a r
F u e l re q u ire m e n t d ie se l n u m b e r 2 -D
Alternator output 5 5 A , 1 4 V
Starter motor
C u rre n t d ra w, n o lo a d 9 0 A
B ru sh le n g th , n e w 0 . 7 4 8 0 in
1 9 m m
B ru sh le n g th , m in im u m 0 . 5 in
1 2 . 7 m m
Battery
T yp e 1 2 V , G ro u p 3 1
Q u a n tity 1
C o ld cra n kin g a m p e re 1 0 0 0 A
R e se rve ca p a city @ 2 5 A ra te 2 0 0 m in u te s
Fan belt deflection
3
/8 to
1
/2 in ch
9 to 1 2 m m
Bolt tightening specifications
to rq u e to rq u e
B o lt d e scrip tio n (size , g ra d e ) ft-lb s N m
C a m sh a ft/th ru st b e a rin g b o lt 1 5 to 1 8 2 0 to 2 4
(M -8 x 3 5 , 8 . 8 )
R o cke r a rm b o lts 1 5 to 1 8 2 0 to 2 4
(M -8 x 4 5 , 8 . 8 )
R o cke r a rm se t scre w n u t 1 5 to 1 8 2 0 to 2 4
C ylin d e r h e a d co ve r 6 to 7 8 to 1 0
B lo we r ro to r n u t 3 3 to 4 1 4 5 to 5 5
(M -1 7 V a le o o r M -1 8 B o sch )
B lo we r ca rrie r b o lts 1 5 to 1 8 2 0 to 2 4
(M -8 x 5 0 T o rx, 8 . 8 )
V -b e lt p u lle y b o lts 2 8 to 3 4 3 8 to 4 6
(M -1 0 x 1 6 , 8 . 8 )
Displacement 1 6 6 . 7 cu in
2 . 7 3 2 lite rs
Number of cylinders 4
Bore and stroke 3 . 5 8 x 4 . 1 3 in ch e s
9 1 x 1 0 5 m m
Horsepower 5 6 @ 3 0 0 0 rp m
Firing order 1 - 3 - 4 - 2
Compression ratio 1 8 . 5 : 1
Compression pressure 3 6 2 to 4 3 5 p si
2 5 to 3 0 b a r
Low idle 1 3 0 0 rp m
High idle 2 3 0 0 rp m
Governor ce n trifu g a l m e ch a n ica l
Valve clearance, cold
I n ta ke 0 . 0 1 2 in
0 . 3 m m
E xh a u st 0 . 0 2 0 in
0 . 5 m m
Lubrication system
O il p re ssu re 2 6 to 8 7 p si
1 . 8 to 6 . 0 b a r
O il ca p a city 1 1 q u a rts
(in clu d in g filte r) 1 0 . 5 lite rs
T e m p e ra tu re b e lo w 6 0 F / 1 5 . 5 C (syn th e tic) 5 W-3 0
-1 0 F to 9 0 F / -2 3 C to 3 2 C 1 0 W-4 0
T e m p e ra tu re a b o ve -4 F / -3 4 C 1 5 W-4 0
E n g in e o il sh o u ld h a ve p ro p e rtie s o f A P I cla ssifica tio n
C C /S G o r C D /S G g ra d e s.
U n its sh ip with 1 0 W-4 0 S G /C C .
Injection system
I n je ctio n p u m p m a ke O M A P
Bolt tightening specifications, co n tin u e d
to rq u e to rq u e
B o lt d e scrip tio n (size , g ra d e ) ft-lb s N m
I d le r p u lle y/V -b e lt p u lle y b o lt 2 7 to 3 2 3 6 to 4 4
(M -1 0 x 2 5 , 8 . 8 )
I d le r p u lle y fo r to o th e d b e lt 3 0 to 3 6 4 1 to 4 9
(M -1 0 x 5 0 , 8 . 8 )
O il p u m p b o lts 1 5 to 1 8 2 0 to 2 4
(M -8 x 3 5 T o rx)
O il filte r b ra cke t b o lts 7 to 8 9 to 1 1
(M -8 x 2 0 T o rx, 8 . 8 )
O il in ta ke h o u sin g b o lts 1 5 to 1 8 2 0 to 2 4
(M -8 x 7 5 T o rx)
F u e l p u m p b o lts 1 5 to 1 8 2 0 to 2 4
I n je ctio n p u m p b o lts 1 5 to 1 8 2 0 to 2 4
I n je cto r ca p n u t 3 0 to 3 7 4 0 to 5 0
I n je cto r fa ste n in g b o lt 1 5 to 1 8 2 0 to 2 4
I n je ctio n lin e 1 0 to 1 2 1 3 . 5 to 1 6 . 5
A ir in ta ke m a n ifo ld b o lts 1 5 to 1 8 2 0 to 2 4
(M -8 x 3 0 , 8 . 8 )
A ir in ta ke m a n ifo ld , 3 -h o le 1 5 to 1 8 2 0 to 2 4
fla n g e b o lts (M -8 x 3 5 T o rx, 8 . 8 )
E xh a u st m a n ifo ld b o lts 2 7 to 3 2 3 6 to 4 4
(M -1 0 x 3 0 T o rx, 1 0 . 9 )
S ta rte r fa ste n in g b o lts 2 8 to 3 4 3 8 to 4 6
(M -1 0 x 2 8 , 8 . 8 )
S ta rte r ca rrie r b o lts 5 0 to 6 0 6 8 to 8 2
(M -1 2 x 2 8 , 8 . 8 )
O il p a n b o lts 1 5 to 1 8 2 0 to 2 4
(M -8 x 1 6 T o rx, 8 . 8 )
O il d ra in b o lts 3 7 to 4 4 5 0 to 6 0
to rq u e to rq u e
ft-lb s N m
O il th e rm o sta t h o u sin g scre w 3 7 to 4 4 5 0 to 6 0
p lu g (M -3 8 x 1 . 5 )
O il th e rm o sta t h o u sin g b o lts 5 . 5 to 7 7 . 5 to 9
(M -6 x 3 5 T o rx, 8 . 8 )
O il th e rm o sta t h o u sin g b o lts 5 . 5 to 7 7 . 5 to 9
(M -6 x 8 0 T o rx, 8 . 8 )
O il th e rm o sta t h o u sin g b o lts 1 4 to 1 6 1 9 to 2 2
(M -6 x 1 0 5 T o rx, 8 . 8 )
V a lve p lu n g e r h o u sin g b o lts 1 4 to 1 6 1 9 to 2 2
(M -8 x 3 0 T o rx, 8 . 8 )
A lte rn a to r n u ts (M -5 ) 3 4
F u e l b ra cke t b o lts (M -8 x 2 0 , 8 . 8 ) 1 5 2 0
A d a p te r h o u sin g b o lts 7 0 to 7 7 9 5 to 1 0 5
(M -1 2 x 3 5 , 1 0 . 9 o r M -1 2 x 7 5 , 1 0 . 9 )
first ste p se co n d ste p
tig h te n in g tig h te n in g
to rq u e a n g le s
ft-lb s N m 1 st 2 n d
M a in b e a rin g b o lts 3 7 5 0 6 0 4 5
B ig e n d b o lts 2 2 3 0 6 0 6 0
F lywh e e l b o lts 2 2 3 0 6 0 3 0
C ylin d e r h e a d ste p 1 2 2 3 0
stu d s ste p 2 5 9 8 0
ste p 3 1 1 8 1 6 0 1 2 0 N A
C a m sh a ft/ce n tra l b o lt 2 2 3 0 1 5 0 N A
C ra n ksh a ft/ce n tra l b o lt 9 6 1 3 0 2 1 0 N A
Hydraulic Hose and Fitting Torque Specifications
Y o u r m a ch in e is e q u ip p e d with P a rke r S e a l-L o k O -rin g fa ce se a l fittin g s a n d h o se e n d s. M a ch in e s th a t
u tilize P a rke r S e a l-L o k O -rin g fa ce se a l fittin g s a n d h o se e n d s re q u ire th a t th e fittin g s a n d h o se e n d s b e
to rq u e d to sp e cifica tio n wh e n th e y a re re m o ve d a n d in sta lle d o r wh e n n e w h o se s o r fittin g s a re in sta lle d .
Torque Procedure
1 R e p la ce th e O -rin g . T h e O -rin g m u st b e
re p la ce d a n ytim e th e se a l h a s b e e n b ro ke n .
T h e O -rin g ca n n o t b e re -u se d if th e fittin g o r
h o se e n d h a s b e e n tig h te n e d b e yo n d fin g e r
tig h t.
T h e O -rin g s u se d in th e P a rke r
S e a l L o k fittin g s a n d h o se e n d s
a re a cu sto m -size O -rin g . T h e y
a re n o t a sta n d a rd S A E size O -
rin g . T h e y a re a va ila b le in th e O -
rin g fie ld se rvice kit (G e n ie p n .
4 9 6 1 2 ).
2 L u b rica te th e O -rin g b e fo re in sta lla tio n .
3 B e su re th a t th e fa ce se a l O -rin g is se a te d a n d
re ta in e d p ro p e rly.
4 P o sitio n th e tu b e a n d n u t sq u a re ly o n th e fa ce
se a l e n d o f th e fittin g a n d tig h te n th e n u t fin g e r
tig h t.
5 T ig h te n th e n u t o r fittin g to th e a p p ro p ria te
to rq u e p e r g ive n size a s sh o wn in th e ta b le
a b o ve .
6 O p e ra te a ll m a ch in e fu n ctio n s a n d in sp e ct th e
h o se s a n d fittin g s a n d re la te d co m p o n e n ts to
b e su re th a t th e re a re n o le a ks.
Hydraulic Hose and Fitting Torque Specifications
SAE O-ri ng Boss Port - tube fitting Seal -Lok - hose end
SAE Dash
Size
Installing
into... ft. lbs. Nm
SAE Dash
Size ft. lbs. Nm
-4 Aluminum 11 14.9 -4 18 24.4
Steel 16 21.7 -6 27 36.6
-6 Aluminum 23 31.2 -8 40 54.2
Steel 35 47.5 -10 63 85.4
-8 Aluminum 40 54.2 -12 90 122
Steel 60 81.3 -16 120 162.7
-10 Aluminum 69 93.6 -20 140 190
Steel 105 142.4 -24 165 223.7
-12 Aluminum 93 126.1
Steel 140 190
-16 Aluminum 139 188.5
Steel 210 284.7
-20 Aluminum 172 233.2
Steel 260 352.5
-24 Aluminum 208 282
Steel 315 427.1
2 4
3 2
2 0
2 8
1 8
2 4
1 6
2 4
1 4
2 0
1 3
2 0
1 2
1 8
1 1
1 8
1 0
1 6
9
1 4
8
1 2
T o rq u e - D ry
in ch -p o u n d s
T o rq u e - D ry
fo o t-p o u n d s
T o rq u e - D ry
N e wto n m e te rs
T o rq u e - D ry
in ch -p o u n d s
T o rq u e - D ry
fo o t-p o u n d s
T o rq u e - D ry
N e wto n m e te rs
4 3
4 9
9 6
1 2 0
1 7
1 9
3 0
3 5
5 0
5 5
7 5
9 0
1 1 0
1 2 0
1 5 0
1 7 0
2 6 0
3 0 0
4 3 0
4 7 0
6 4 0
7 0 0
5
6
1 1
1 4
2 3
2 8
4 1
4 8
6 8
7 5
1 0 2
1 2 2
1 4 9
1 6 3
2 0 4
2 3 1
3 5 3
4 0 7
5 8 3
6 3 7
8 6 8
9 4 9
6 0
6 8
1 4 4
1 6 8
2 5
2 5
4 5
5 0
7 0
8 0
1 1 0
1 2 0
1 5 0
1 7 0
2 2 0
2 4 0
3 8 0
4 2 0
6 0 0
6 6 0
9 0 0
1 0 0 0
7
8
1 6
1 9
3 4
3 4
6 1
6 8
9 5
1 0 9
1 4 9
1 6 3
2 0 4
2 3 1
2 9 8
3 2 6
5 1 5
5 7 0
8 1 4
8 9 5
1 2 2 1
1 3 5 6
Size Threads SAE Grade 5 Bolts SAE Grade 8 Bolts
Bolt Torque Specifications
N o . 1 0
1
/4 in ch
5
/1 6 in ch
3
/8 in ch
7
/1 6 in ch
1
/2 in ch
9
/1 6 in ch
5
/8 in ch
3
/4 in ch
7
/8 in ch
1 in ch
T o rq u e sp e cifica tio n s fo r lu b rica te d b o lts a re 2 5 % le ss th a n d ry to rq u e sp e cifica tio n s fo r e a ch b o lt size .
T h e se b o lt to rq u e sp e cifica tio n s a re fo r g e n e ra l u se o n ly. S p e cifica tio n m a y va ry d e p e n d in g o n a p p lica tio n o f b o lt.
2 - 1 0 G e n ie S -6 0 & G e n ie S -6 5 P a rt N o. 4 8 4 1 2
T h is p a g e in te n tio n a lly le ft b la n k.
P a rt N o . 4 8 4 1 2 G e n ie S -6 0 & G e n ie S -6 5 3 - 1
S e ctio n 3 - S ch e d u le d M a in te n a n ce I n sp e ctio n s S e rvice M a n u a l - S e co n d E d itio n
T o o ls a re
re q u ire d
N e w p a rts
re q u ire d
Wa rm
e n g in e
re q u ire d
C o ld
e n g in e
re q u ire d
D e a le r
se rvice
su g g e ste d
Scheduled Maintenance Inspections
Observe and Obey:
M a in te n a n ce in sp e ctio n s sh a ll b e co m p le te d b y
a p e rso n tra in e d a n d q u a lifie d o n th e
m a in te n a n ce o f th is m a ch in e .
S ch e d u le d m a in te n a n ce in sp e ctio n s sh a ll b e
co m p le te d d a ily, q u a rte rly, a n n u a lly a n d e ve ry
2 ye a rs a s sp e cifie d o n th e Maintenance
Inspection Report.
F a ilu re to p ro p e rly co m p le te e a ch
in sp e ctio n wh e n re q u ire d m a y
ca u se d e a th , se rio u s in ju ry o r
su b sta n tia l d a m a g e .
I m m e d ia te ly ta g a n d re m o ve fro m se rvice a
d a m a g e d o r m a lfu n ctio n in g m a ch in e .
R e p a ir a n y m a ch in e d a m a g e o r m a lfu n ctio n
b e fo re o p e ra tin g m a ch in e .
K e e p re co rd s o n a ll in sp e ctio n s fo r th re e ye a rs.
M a ch in e s th a t h a ve b e e n o u t o f se rvice fo r a
p e rio d lo n g e r th a n 3 m o n th s m u st co m p le te th e
q u a rte rly in sp e ctio n .
About This Section
The Schedule
T h e re a re fo u r typ e s o f m a in te n a n ce in sp e ctio n s
th a t m u st b e p e rfo rm e d a cco rd in g to a sch e d u le
d a ily, q u a rte rly, a n n u a l, two ye a r. T o a cco u n t fo r
re p e a te d p ro ce d u re s, th e Maintenance Tables a n d
th e Maintenance Inspection Report h a ve b e e n
d ivid e d in to fo u r su b se ctio n sA , B , C , D . U se th e
fo llo win g ch a rt to d e te rm in e wh ich g ro u p (s) o f
p ro ce d u re s a re re q u ire d to p e rfo rm a sch e d u le d
in sp e ctio n .
Inspection Table or Checklist
D a ily A
Q u a rte rly A +B
A n n u a l A +B +C
T wo ye a r A +B +C +D
Maintenance Tables
T h e m a in te n a n ce ta b le s co n ta in e d in th is se ctio n
p ro vid e su m m a ry in fo rm a tio n o n th e sp e cific
p h ysica l re q u ire m e n ts fo r e a ch in sp e ctio n .
C o m p le te ste p -b y-ste p in stru ctio n s fo r e a ch
sch e d u le d m a in te n a n ce p ro ce d u re a re p ro vid e d in
se ctio n 4 , Scheduled Maintenance Procedures.
Maintenance Inspection Report
T h e m a in te n a n ce in sp e ctio n re p o rt co n ta in s
ch e cklists fo r e a ch typ e o f sch e d u le d in sp e ctio n .
M a ke co p ie s o f th e Maintenance Inspection
Report to u se fo r e a ch in sp e ctio n . S to re
co m p le te d fo rm s fo r th re e ye a rs.
3 - 2 G e n ie S -6 0 & G e n ie S -6 5 P a rt N o . 4 8 4 1 2
T o o ls a re
re q u ire d
N e w p a rts
re q u ire d
Wa rm
e n g in e
re q u ire d
C o ld
e n g in e
re q u ire d
D e a le r
se rvice
su g g e ste d
Table A
A -1 I n sp e ct th e M a n u a ls
A -2 I n sp e ct th e D e ca ls a n d P la ca rd s
A -3 I n sp e ct fo r D a m a g e , L o o se o r M issin g P a rts
A -4 C h e ck th e E n g in e O il L e ve l
A -5 C h e ck th e E n g in e C o o la n t L e ve l -
G a so lin e /L P G M o d e ls
A -6 C h e ck fo r F u e l L e a ks
A -7 C h e ck th e H yd ra u lic O il L e ve l
A -8 C h e ck fo r H yd ra u lic L e a ks
A -9 C h e ck th e T ire P re ssu re
A -1 0 T e st th e O scilla te A xle (if e q u ip p e d )
A -1 1 T e st th e P la tfo rm a n d G ro u n d C o n tro ls
A -1 2 T e st th e A u xilia ry P o we r O p e ra tio n
A -1 3 T e st th e T ilt S e n so r
A -1 4 T e st th e L im it S witch e s
Every 100 hours, perform the following three engine
maintenance procedures.
A -1 5 R e p la ce th e E n g in e O il a n d F ilte r
Maintenance Tables
T o o ls a re
re q u ire d
N e w p a rts
re q u ire d
Wa rm
e n g in e
re q u ire d
C o ld
e n g in e
re q u ire d
D e a le r
se rvice
su g g e ste d
M A I N T E N A N C E T A B L E S
Table A, co n tin u e d
A -1 6 D ra in th e F u e l F ilte r/Wa te r S e p a ra to r -
D e u tz D ie se l M o d e ls
A -1 7 R e p la ce th e E n g in e A ir F ilte r
Table B
B -1 C h e ck th e E n g in e B e lt
B -2 C h e ck th e R a d ia to r -
B -3 C h e ck th e O il C o o le r a n d C o o lin g F in s -
B -4 C h e ck th e E xh a u st S yste m
B -5 C h e ck th e B a tte ry
B -6 C h e ck th e H yd ra u lic T a n k
F ilte r C o n d itio n I n d ica to r
B -7 I n sp e ct th e E le ctrica l Wirin g
B -8 I n sp e ct th e T ire s a n d Wh e e ls
(in clu d in g lu g n u t to rq u e )
B -9 C o n firm th e P ro p e r B ra ke C o n fig u ra tio n
B -1 0 C h e ck th e O il L e ve l in th e T o rq u e H u b s
B -1 1 C h e ck a n d A d ju st th e E n g in e I d le M ixtu re -
B -1 2 C h e ck a n d A d ju st th e E n g in e R P M
T o o ls a re
re q u ire d
N e w p a rts
re q u ire d
Wa rm
e n g in e
re q u ire d
C o ld
e n g in e
re q u ire d
D e a le r
se rvice
su g g e ste d
Table B, co n tin u e d
B -1 3 T e st th e K e y S witch
B -1 4 T e st th e E m e rg e n cy S to p B u tto n s
B -1 5 T e st th e G ro u n d C o n tro l O ve rrid e
B -1 6 C h e ck th e D ire ctio n a l V a lve L in ka g e
B -1 7 T e st th e P la tfo rm S e lf-le ve lin g
B -1 8 T e st th e H o rn
B -1 9 T e st th e F o o t S witch
B -2 0 T e st th e E n g in e I d le S e le ct
B -2 1 T e st th e F u e l S e le ct O p e ra tio n -
B -2 2 T e st th e D rive E n a b le S yste m
B -2 3 T e st th e D rive B ra ke s
B -2 4 T e st th e D rive S p e e d -
S to we d P o sitio n
B -2 5 T e st th e A la rm P a cka g e -
O p tio n a l E q u ip m e n t
B -2 6 P e rfo rm H yd ra u lic O il A n a ysis
S e e D -1 Test or Replace the Hydraulic Oil
Every 500 hours, perform the following engine
maintenance procedure.
B -2 7 R e p la ce th e E n g in e O il a n d F ilte r -
T o o ls a re
re q u ire d
N e w p a rts
re q u ire d
Wa rm
e n g in e
re q u ire d
C o ld
e n g in e
re q u ire d
D e a le r
se rvice
su g g e ste d
Table C
C -1 C h e ck th e B o o m We a r P a d s
C -2 C h e ck th e T u rn ta b le R o ta tio n B e a rin g B o lts
C -3 C h e ck th e F re e -wh e e l C o n fig u ra tio n
C -4 G re a se th e T u rn ta b le R o ta tio n B e a rin g
a n d R o ta te G e a r
C -5 R e p la ce th e T o rq u e H u b O il
C -6 R e p la ce th e H yd ra u lic T a n k F ilte r
C -7 R e p la ce th e D rive L o o p H yd ra u lic F ilte r
C -8 R e p la ce th e D ie se l F u e l F ilte r/Wa te r S e p a ra to r
C -9 R e p la ce th e G a so lin e F u e l F ilte r -
C -1 0 R e p la ce th e P C V V a lve -
C -1 1 R e p la ce th e S p a rk P lu g s -
C -1 2 C h e ck a n d A d ju st th e A ir/L P G M ixtu re -
C -1 3 C h e ck a n d A d ju st th e I g n itio n T im in g -
C -1 4 C h e ck th e E n g in e V a lve C le a ra n ce s -
C -1 5 C h e ck th e T u rn ta b le R o ta tio n G e a r B a ckla sh
T o o ls a re
re q u ire d
N e w p a rts
re q u ire d
Wa rm
e n g in e
re q u ire d
C o ld
e n g in e
re q u ire d
D e a le r
se rvice
su g g e ste d
Table D
D -1 T e st o r R e p la ce th e H yd ra u lic O il
D -2 C h a n g e o r R e co n d itio n th e E n g in e C o o la n t -
D -3 C h a n g e th e F u e l L in e s
D -4 C h e ck th e E n g in e V a lve C le a ra n ce -
D -5 C h e ck th e E n g in e C ylin d e r C o m p re ssio n -
D -6 C le a n th e P C V H o se s a n d F ittin g s -
D -7 C h e ck th e F u e l I n je ctio n P u m p s a n d I n je cto rs
- D e u tz D ie se l M o d e ls
D -8 C h e ck th e T o o th e d B e lt -
D -9 R e p la ce th e T im in g B e lt -
D -1 0 G re a se th e S te e r A xle Wh e e l B e a rin g s -
2 WD M o d e ls
T o o ls a re
re q u ire d
N e w p a rts
re q u ire d
Wa rm
e n g in e
re q u ire d
C o ld
e n g in e
re q u ire d
D e a le r
se rvice
su g g e ste d
B -1 8 H o rn
B -1 9 F o o t switch
B -2 0 E n g in e id le se le ct
B -2 1 F u e l se le ct-G a s/L P G
B -2 2 D rive e n a b le syste m
B -2 3 D rive b ra ke s
B -2 4 D rive sp e e d -sto we d
B -2 5 A la rm p a cka g e
B -2 6 H yd ra u lic o il a n a lysis
Perform every 500 hours:
B -2 7 R e p la ce e n g in e o il
a n d filte r-D e u tz D ie se l
Checklist C Y N R
R e fe r to T a b le C
C -1 B o o m we a r p a d s
C -2 T u rn ta b le b e a rin g b o lts
C -3 F re e -wh e e l co n fig u ra tio n
C -4 G re a se ro ta tio n b e a rin g
C -5 T o rq u e h u b o il
C -6 H yd ra u lic ta n k filte r
C -7 D rive lo o p h yd ra u lic filte r
C -8 F u e l filte r-D e u tz D ie se l
C -9 F u e l filte r-G a s/L P G
C -1 0 P C V va lve -G a s/L P G
C -1 1 S p a rk p lu g s-G a s/L P G
C -1 2 A ir/L P G m ixtu re
C -1 3 I g n itio n tim in g -G a s/L P G
C -1 4 V a lve s-D e u tz D ie se l
C -1 5 T u rn ta b le b a ckla sh
Checklist D Y N R
R e fe r to T a b le D
D -1 H yd ra u lic o il
D -2 E n g in e co o la n t-G a s/L P G
D -3 C h a n g e fu e l lin e s
D -4 V a lve s-G a s/L P G
D -5 C o m p re ssio n -G a s/L P G
D -6 P C V h o se s-G a s/L P G
D -7 F u e l in je ctio n -D ie se l
D -8 T o o th e d b e lt-D ie se l
D -9 T im in g b e lt-G a s/L P G
D -1 0 Wh e e l b e a rin g s
Checklist A Y N R
R e fe r to T a b le A
A -1 M a n u a ls
A -2 D e ca ls a n d p la ca rd s
A -3 D a m a g e , lo o se o r
m issin g p a rts
A -4 E n g in e o il le ve l
A -5 E n g in e co o la n t-G a s/L P G
A -6 F u e l le a ks
A -7 H yd ra u lic o il le ve l
A -8 H yd ra u lic le a ks
A -9 T ire p re ssu re
A -1 0 O scilla te a xle
A -1 1 P la tfo rm a n d
g ro u n d co n tro ls
A -1 2 A u xilia ry p o we r
A -1 3 T ilt se n so r
A -1 4 L im it switch e s
Perform every 100 hours:
A -1 5 R e p la ce e n g in e o il
a n d filte r-G a s/L P G M o d e ls
A -1 6 D ra in filte r/se p a ra to r
D e u tz D ie se l
A -1 7 R e p la ce a ir filte r
Checklist B Y N R
R e fe r to T a b le B
B -1 E n g in e b e lt
B -2 E n g in e ra d ia to r-G a s/L P G
B -3 O il co o le r a n d fin s-D ie se l
B -4 E xh a u st syste m
B -5 B a tte ry
B -6 H yd ra u lic ta n k filte r
B -7 E le ctrica l wirin g
B -8 T ire s a n d wh e e ls
B -9 B ra ke co n fig u ra tio n
B -1 0 T o rq u e h u b o il le ve l
B -1 1 I d le m ixtu re -G a s/L P G
B -1 2 E n g in e R P M
B -1 3 K e y switch
B -1 4 E m e rg e n cy S to p
B -1 5 G ro u n d co n tro l o ve rrid e
B -1 6 D ire ctio n a l va lve
B -1 7 P la tfo rm le ve lin g
Instructions
M a ke co p ie s o f th is p a g e to u se fo r
e a ch in sp e ctio n .
S e le ct th e a p p ro p ria te ch e cklist(s) fo r
th e typ e o f in sp e ctio n to b e p e rfo rm e d .
Daily Inspection: A
Quarterly Inspection: A+B
Annual Inspection: A+B+C
2 Year Inspection: A+B+C+D
P la ce a ch e ck in th e a p p ro p ria te b o x
a fte r e a ch in sp e ctio n p ro ce d u re is
co m p le te d .
U se th e m a in te n a n ce ta b le s in th is
se ctio n a n d th e ste p -b y-ste p
p ro ce d u re s in se ctio n 4 to le a rn h o w to
p e rfo rm th e se in sp e ctio n s.
I f a n y in sp e ctio n re ce ive s a n N , ta g
a n d re m o ve th e m a ch in e fro m se rvice ,
re p a ir a n d re -in sp e ct it. A fte r re p a ir,
p la ce a ch e ck in th e R b o x.
Legend
Y = ye s, a cce p ta b le
N = n o , re m o ve fro m se rvice
R = re p a ire d
Comments
Maintenance Inspection Report
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
T o o ls a re
re q u ire d
N e w p a rts
re q u ire d
Wa rm
e n g in e
re q u ire d
C o ld
e n g in e
re q u ire d
D e a le r
se rvice
su g g e ste d
S e rvice M a n u a l - S e co n d E d itio n S e ctio n 4 - S ch e d u le d M a in te n a n ce P ro ce d u re s
Scheduled Maintenance Procedures
Observe and Obey:
M a in te n a n ce in sp e ctio n s sh a ll b e co m p le te d b y
a p e rso n tra in e d a n d q u a lifie d o n th e
m a in te n a n ce o f th is m a ch in e .
S ch e d u le d m a in te n a n ce in sp e ctio n s sh a ll b e
co m p le te d d a ily, q u a rte rly, a n n u a lly a n d e ve ry 2
ye a rs a s sp e cifie d o n th e Maintenance
Inspection Report.
F a ilu re to p e rfo rm e a ch p ro ce d u re
a s p re se n te d a n d sch e d u le d m a y
ca u se d e a th , se rio u s in ju ry o r
su b sta n tia l d a m a g e .
b e fo re o p e ra tin g m a ch in e .
K e e p re co rd s o n a ll in sp e ctio n s fo r th re e ye a rs.
U n le ss o th e rwise sp e cifie d , p e rfo rm e a ch
m a in te n a n ce p ro ce d u re with th e m a ch in e in th e
fo llo win g co n fig u ra tio n :
M a ch in e p a rke d o n a fla t, le ve l su rfa ce
B o o m in sto we d p o sitio n
T u rn ta b le ro ta te d with th e b o o m b e twe e n
th e n o n -ste e rin g wh e e ls
T u rn ta b le se cu re d with th e tu rn ta b le
ro ta tio n lo ck p in
K e y switch in th e O F F p o sitio n with th e
ke y re m o ve d
Wh e e ls ch o cke d
About This Section
T h is se ctio n co n ta in s d e ta ile d p ro ce d u re s fo r e a ch
sch e d u le d m a in te n a n ce in sp e ctio n .
E a ch p ro ce d u re in clu d e s a d e scrip tio n , sa fe ty
in fo rm a tio n a n d ste p -b y-ste p in stru ctio n s.
Symbols Legend
I n d ica te s th e p re se n ce o f a h a za rd
th a t will ca u se d e a th o r se rio u s
in ju ry.
th a t may ca u se d e a th o r se rio u s
in ju ry.
th a t will o r may ca u se se rio u s
in ju ry o r d a m a g e to th e m a ch in e .
I n d ica te s sp e cia l o p e ra tio n o r
m a in te n a n ce in fo rm a tio n .
I n d ica te s th a t a sp e cific re su lt is e xp e cte d a fte r
p e rfo rm in g a ste p .
A-1
Inspect the Manuals
M a in ta in in g th e o p e ra to rs a n d sa fe ty m a n u a ls in
g o o d co n d itio n is e sse n tia l to sa fe m a ch in e
o p e ra tio n . M a n u a ls a re in clu d e d with e a ch
m a ch in e a n d sh o u ld b e sto re d in th e co n ta in e r
p ro vid e d in th e p la tfo rm . A n ille g ib le o r m issin g
m a n u a l will n o t p ro vid e sa fe ty a n d o p e ra tio n a l
in fo rm a tio n n e ce ssa ry fo r a sa fe o p e ra tin g
co n d itio n .
1 C h e ck to b e su re th a t th e sto ra g e co n ta in e r is
p re se n t a n d in g o o d co n d itio n .
2 C h e ck to m a ke su re th a t th e o p e ra to r's,
re sp o n sib ilitie s a n d sa fe ty m a n u a l a re p re se n t
a n d co m p le te in th e sto ra g e co n ta in e r in th e
p la tfo rm .
3 E xa m in e th e p a g e s o f e a ch m a n u a l to b e su re
th a t th e y a re le g ib le a n d in g o o d co n d itio n .
4 A lwa ys re tu rn th e m a n u a ls to th e sto ra g e
co n ta in e r a fte r u se .
C o n ta ct yo u r a u th o rize d G e n ie
d istrib u to r o r G e n ie I n d u strie s if
re p la ce m e n t m a n u a ls a re n e e d e d .
A-2
Inspect the
Decals and Placards
M a in ta in in g a ll o f th e sa fe ty a n d in stru ctio n a l
d e ca ls a n d p la ca rd s in g o o d co n d itio n is
m a n d a to ry fo r sa fe m a ch in e o p e ra tio n . D e ca ls
a le rt o p e ra to rs a n d p e rso n n e l to th e m a n y p o ssib le
h a za rd s a sso cia te d with u sin g th is m a ch in e . T h e y
a lso p ro vid e u se rs with o p e ra tio n a n d m a in te n a n ce
in fo rm a tio n . A n ille g ib le d e ca l will fa il to a le rt
p e rso n n e l o f a p ro ce d u re o r h a za rd a n d co u ld
re su lt in u n sa fe o p e ra tin g co n d itio n s.
1 R e fe r to th e Decals se ctio n in th e
Genie S-60 & Genie S-65 Operator's Manual
a n d u se th e d e ca l list a n d illu stra tio n s to
d e te rm in e th a t a ll d e ca ls a n d p la ca rd s a re in
p la ce .
Table A Procedures
2 I n sp e ct a ll d e ca ls fo r le g ib ility a n d d a m a g e .
R e p la ce a n y d a m a g e d o r ille g ib le d e ca l
im m e d ia te ly.
C o n ta ct yo u r a u th o rize d G e n ie
d istrib u to r o r G e n ie I n d u strie s if
re p la ce m e n t d e ca ls a re n e e d e d .
A-3
Inspect for Damage, Loose or
Missing Parts
D a ily m a ch in e co n d itio n in sp e ctio n s a re e sse n tia l
to sa fe m a ch in e o p e ra tio n a n d g o o d m a ch in e
p e rfo rm a n ce . F a ilu re to lo ca te a n d re p a ir d a m a g e ,
a n d d isco ve r lo o se o r m issin g p a rts m a y re su lt in
a n u n sa fe o p e ra tin g co n d itio n .
1 I n sp e ct th e e n tire m a ch in e fo r d a m a g e a n d
im p ro p e rly in sta lle d o r m issin g p a rts in clu d in g :
E le ctrica l co m p o n e n ts, wirin g a n d e le ctrica l
ca b le s
H yd ra u lic h o se s, fittin g s, cylin d e rs a n d
m a n ifo ld s
F u e l a n d h yd ra u lic ta n ks
D rive a n d tu rn ta b le ro ta tio n m o to rs a n d
to rq u e h u b s
A xle co m p o n e n ts
B o o m co m p o n e n ts a n d we a r p a d s
D e n ts o r d a m a g e to m a ch in e
T ire s a n d wh e e ls
E n g in e a n d re la te d co m p o n e n ts
L im it switch e s
A la rm s, h o rn a n d b e a co n (if e q u ip p e d )
N u ts, b o lts a n d o th e r fa ste n e rs
P la tfo rm e n try m id -ra il o r g a te
C ra cks in we ld s o r stru ctu ra l co m p o n e n ts
C o m p a rtm e n t co ve rs a n d la tch e s
T A B L E A P R O C E D U R E S
A-4
Check the Engine Oil Level
M a in ta in in g th e p ro p e r e n g in e o il le ve l is e sse n tia l
to g o o d e n g in e p e rfo rm a n ce a n d se rvice life .
O p e ra tin g th e m a ch in e with a n im p ro p e r o il le ve l
ca n d a m a g e e n g in e co m p o n e n ts.
C h e ck th e o il le ve l with th e
e n g in e o ff.
1 C h e ck th e o il d ip stick. A d d o il a s n e e d e d .
R e su lt: T h e o il le ve l sh o u ld b e in th e " sa fe "
zo n e .
Ford LRG-423 Engine 5 q u a rts
Oil capacity (including filter) 4 . 7 lite rs
Ford LRG-423 Engine
b e lo w 6 0 F / 1 5 . 5 C 5 W-3 0
-1 0 to 9 0 F / -2 3 to 3 2 C 1 0 W-3 0
a b o ve -1 0 F / -2 3 C 1 0 W-4 0 o r 1 0 W-5 0
a b o ve 2 5 F / -4 C 2 0 W-4 0 o r 2 0 W-5 0
U se o ils m e e tin g A P I cla ssifica tio n S F (la b e le d S F /C C
o r S F /C D ) a s th e y o ffe r im p ro ve d we a r p ro te ctio n .
Deutz Engine F4L 1011F 1 1 q u a rts
Oil capacity (including filter) 1 0 . 5 lite rs
Deutz Engine F4L 1011F Oil viscosity requirements
b e lo w 6 0 F / 1 5 . 5 C (syn th e tic) 5 W-3 0
-1 0 F to 9 0 F / -2 3 C to 3 2 C 1 0 W-4 0
a b o ve -4 F / -3 4 C 1 5 W-4 0
C C /S E , C D /S E , S F /C C o r S F /C D g ra d e s.
A-5
Check the Engine Coolant Level
- Gasoline/LPG Models
M a in ta in in g th e e n g in e co o la n t a t th e p ro p e r le ve l
is e sse n tia l to e n g in e se rvice life . I m p ro p e r co o la n t
le ve l will a ffe ct th e e n g in e 's co o lin g ca p a b ility a n d
d a m a g e e n g in e co m p o n e n ts. D a ily ch e cks will
a llo w th e in sp e cto r to id e n tify ch a n g e s in co o la n t
le ve l th a t m ig h t in d ica te co o lin g syste m p ro b le m s.
1 C h e ck th e flu id le ve l in th e co o la n t re co ve ry
ta n k. A d d flu id a s n e e d e d .
R e su lt: T h e flu id le ve l sh o u ld b e in th e
N O R M A L ra n g e .
F lu id s in th e ra d ia to r a re u n d e r
p re ssu re a n d e xtre m e ly h o t. U se
ca u tio n wh e n re m o vin g ca p a n d
a d d in g flu id s.
A-6
Check for Fuel Leaks
F a ilu re to d e te ct a n d co rre ct fu e l le a ks will re su lt in
a n u n sa fe co n d itio n . A n e xp lo sio n o r fu e l fire m a y
ca u se d e a th o r se rio u s in ju ry.
E n g in e fu e ls a re co m b u stib le .
I n sp e ct th e m a ch in e in a n o p e n ,
we ll-ve n tila te d a re a a wa y fro m
h e a te rs, sp a rks, fla m e s a n d
lig h te d to b a cco . A lwa ys h a ve a n
a p p ro ve d fire e xtin g u ish e r with in
e a sy re a ch .
1 O p e n th e sh u to ff va lve o n th e liq u id p e tro le u m
g a s (L P G ) ta n k b y tu rn in g it co u n te rclo ckwise .
2 P e rfo rm a visu a l in sp e ctio n a ro u n d th e fo llo win g
a re a s. (A n L P G d e te cto r m a y b e n e ce ssa ry to
lo ca te L P G le a ks. )
Gasoline/LPG models:
L P G ta n k, h o se s a n d fittin g s, so le n o id sh u to ff
va lve , L P G re g u la to r a n d ca rb u re to r
G a so lin e ta n k, m a n u a l sh u to ff va lve , fu e l
p u m p so le n o id sh u to ff va lve , h o se s a n d
fittin g s a n d ca rb u re to r
Deutz Diesel models:
F u e l ta n k, sh u to ff va lve , h o se s a n d fittin g s,
fu e l p u m p , fu e l filte r, fu e l in je ctio n p u m p s a n d
fu e l in je cto rs
I f a fu e l le a k is d isco ve re d , ke e p
a n y a d d itio n a l p e rso n n e l fro m
e n te rin g th e a re a a n d d o n o t
o p e ra te th e m a ch in e . R e p a ir th e
le a k im m e d ia te ly.
A-7
Check the Hydraulic Oil Level
M a in ta in in g th e h yd ra u lic o il a t th e p ro p e r le ve l is
e sse n tia l to m a ch in e o p e ra tio n . I m p ro p e r h yd ra u lic
o il le ve ls ca n d a m a g e h yd ra u lic co m p o n e n ts. D a ily
ch e cks a llo w th e in sp e cto r to id e n tify ch a n g e s in o il
le ve l th a t m ig h t in d ica te th e p re se n ce o f h yd ra u lic
syste m p ro b le m s.
1 B e su re th a t th e b o o m is in th e sto we d p o sitio n ,
th e n visu a lly in sp e ct th e sig h t g a u g e lo ca te d o n
th e sid e o f th e h yd ra u lic o il ta n k.
R e su lt: T h e h yd ra u lic o il le ve l sh o u ld b e with in
th e to p 2 in ch e s (5 cm ) o f th e sig h t g a u g e .
Hydraulic oil specifications
H yd ra u lic o il typ e D e xro n e q u iva le n t
T a n k ca p a city 4 5 g a llo n s
1 7 0 lite rs
(in clu d in g ta n k) 2 0 8 lite rs
A-8
Check for Hydraulic Leaks
D e te ctin g h yd ra u lic flu id le a ks is e sse n tia l to
o p e ra tio n a l sa fe ty a n d g o o d m a ch in e p e rfo rm a n ce .
U n d isco ve re d le a ks ca n d e ve lo p in to h a za rd o u s
situ a tio n s, im p a ir m a ch in e fu n ctio n s a n d d a m a g e
m a ch in e co m p o n e n ts.
1 I n sp e ct fo r h yd ra u lic o il p u d d le s, d rip p in g o r
re sid u e o n o r a ro u n d th e fo llo win g a re a s:
H yd ra u lic ta n kfilte r, fittin g s, h o se s, a u xilia ry
p o we r u n it a n d tu rn ta b le su rfa ce
E n g in e co m p a rtm e n tfittin g s, h o se s,
p u m p s, filte r a n d tu rn ta b le su rfa ce
A ll h yd ra u lic cylin d e rs
A ll h yd ra u lic m a n ifo ld s
B o o m (s)
T h e u n d e rsid e o f th e tu rn ta b le
T h e u n d e rsid e o f th e d rive ch a ssis
G ro u n d a re a u n d e r th e m a ch in e
A-9
Check the Tire Pressure
T h is p ro ce d u re d o e s n o t n e e d
to b e p e rfo rm e d o n m a ch in e s
e q u ip p e d with th e fo a m -fille d
tire o p tio n .
A n o ve r-in fla te d tire ca n e xp lo d e
a n d m a y ca u se d e a th o r se rio u s
in ju ry.
T o sa fe g u a rd m a xim u m sta b ility, a ch ie ve
o p tim u m m a ch in e h a n d lin g a n d m in im ize tire
we a r, it is e sse n tia l to m a in ta in p ro p e r p re ssu re
in a ll a ir-fille d tire s.
1 C h e ck e a ch tire with a n a ir p re ssu re g a u g e a n d
a d d a ir a s n e e d e d .
Tire specifications
T ire size 1 5 -1 9 . 5 N H S
P re ssu re 8 5 p si
5 . 8 6 b a r
A-10
Test the Oscillate Axle
(if equipped)
P ro p e r a xle o scilla tio n is e sse n tia l to sa fe m a ch in e
o p e ra tio n . I f th e a xle o scilla tio n syste m is n o t
o p e ra tin g co rre ctly, th e sta b ility o f th e m a ch in e is
co m p ro m ise d a n d it m a y tip o ve r.
1 S ta rt th e e n g in e fro m th e p la tfo rm co n tro ls.
2 D rive th e rig h t ste e r tire u p o n to a 6 in ch
(1 5 . 2 cm ) b lo ck o r cu rb .
R e su lt: T h e th re e re m a in in g tire s sh o u ld sta y in
firm co n ta ct with th e g ro u n d a n d th e ch a ssis
sh o u ld re m a in le ve l a t a ll tim e s.
3 D rive th e le ft ste e r tire u p o n to a 6 in ch
(1 5 . 2 cm ) b lo ck o r cu rb .
R e su lt: T h e th re e re m a in in g tire s sh o u ld sta y in
firm co n ta ct with th e g ro u n d a n d th e ch a ssis
sh o u ld re m a in le ve l a t a ll tim e s.
4 D rive b o th ste e r tire s u p o n to a 6 in ch
(1 5 . 2 cm ) b lo ck o r cu rb .
R e su lt: T h e n o n -ste e r tire s sh o u ld sta y in firm
co n ta ct with th e g ro u n d .
I f th e ch a ssis d o e s n o t re m a in
le ve l d u rin g te st, se e R e p a ir
P ro ce d u re 1 0 -6 , How to Set Up
the Directional Valve Linkage O R
se e R e p a ir P ro ce d u re 1 0 -5 , How
to Adjust the Sequence Valve
Pressure.
A-11
Test the Platform and
Ground Controls
T e stin g th e m a ch in e fu n ctio n s a n d th e E m e rg e n cy
S to p b u tto n s fo r m a lfu n ctio n s is e sse n tia l fo r sa fe
m a ch in e o p e ra tio n . A n u n sa fe wo rkin g co n d itio n
e xists if a n y fu n ctio n fa ils to o p e ra te p ro p e rly o r
e ith e r E m e rg e n cy S to p b u tto n fa ils to sto p a ll th e
m a ch in e fu n ctio n s a n d sh u t o ff th e e n g in e . E a ch
fu n ctio n sh o u ld a ctiva te , o p e ra te sm o o th ly a n d b e
fre e o f h e sita tio n , je rkin g a n d u n u su a l n o ise .
1 P u ll o u t th e E m e rg e n cy S to p b u tto n a t th e
g ro u n d co n tro ls to th e O N p o sitio n .
2 S ta rt th e e n g in e fro m th e g ro u n d co n tro ls.
3 D o n o t h o ld th e fu n ctio n e n a b le switch to e ith e r
sid e . A tte m p t to a ctiva te e a ch b o o m a n d
p la tfo rm fu n ctio n to g g le switch .
R e su lt: A ll b o o m a n d p la tfo rm fu n ctio n s sh o u ld
not o p e ra te .
4 H o ld th e fu n ctio n e n a b le switch to e ith e r sid e
a n d a ctiva te e a ch b o o m a n d p la tfo rm fu n ctio n
to g g le switch .
R e su lt: A ll b o o m a n d p la tfo rm fu n ctio n s sh o u ld
o p e ra te th ro u g h a fu ll cycle . D e sce n t a la rm (if
e q u ip p e d ) sh o u ld so u n d wh ile th e b o o m is
lo we rin g .
5 P u sh in th e E m e rg e n cy S to p b u tto n to th e O F F
p o sitio n .
R e su lt: N o fu n ctio n sh o u ld o p e ra te , th e e n g in e
sh o u ld sto p .
M a ch in e s e q u ip p e d with P la tfo rm
L e ve l C o n tro l D isa b le F u n ctio n :
T h e p la tfo rm le ve l fu n ctio n will n o t
o p e ra te wh e n th e b o o m is ra ise d
o r e xte n d e d p a st th e d rive sp e e d
lim it switch e s.
D e u tz D ie se l m o d e ls:
A ll fu n ctio n s sh o u ld sto p
im m e d ia te ly. T h e e n g in e will
sh u t o ff a fte r 2 to 3 se co n d s.
7 D o n o t p re ss d o wn o n th e fo o tswitch .
8 A tte m p t to o p e ra te a ll m a ch in e fu n ctio n s.
R e su lt: A ll m a ch in e fu n ctio n s sh o u ld not
o p e ra te .
9 P re ss d o wn o n th e fo o tswitch a n d a ctiva te e a ch
m a ch in e fu n ctio n .
R e su lt: A ll m a ch in e fu n ctio n s sh o u ld o p e ra te
th ro u g h a fu ll cycle .
1 0 P u sh in th e E m e rg e n cy S to p b u tto n to th e O F F
p o sitio n a t th e p la tfo rm co n tro ls.
R e su lt: N o fu n ctio n sh o u ld o p e ra te , th e e n g in e
sh o u ld sto p .
A s a sa fe ty fe a tu re , se le ctin g
a n d o p e ra tin g th e g ro u n d
co n tro ls will o ve rrid e th e
p la tfo rm co n tro ls, in clu d in g
th e E m e rg e n cy S to p switch .
D e u tz D ie se l m o d e ls:
A ll fu n ctio n s sh o u ld sto p
im m e d ia te ly. T h e e n g in e will
sh u t o ff a fte r 2 to 3 se co n d s.
A-12
Test the Auxiliary Power
Operation
D e te ctio n o f a u xilia ry p o we r syste m m a lfu n ctio n s is
e sse n tia l fo r sa fe m a ch in e o p e ra tio n . A n u n sa fe
wo rkin g co n d itio n e xists if th e a u xilia ry p o we re d
fu n ctio n s d o n o t o p e ra te in th e e ve n t o f a m a in
p o we r lo ss. Wh e n o p e ra tin g th e m a ch in e o n
e n g in e p o we r, se le ctin g a u xilia ry p o we r will sto p
th e e n g in e im m e d ia te ly. A u xilia ry p o we r is
d e sig n e d fo r sh o rt te rm e m e rg e n cy u se o n ly,
a n d e xce ssive u se will re su lt in b a tte ry d ra in
a n d co m p o n e n t d a m a g e .
1 T u rn th e ke y switch to g ro u n d co n tro l a n d p u ll
o u t th e E m e rg e n cy S to p b u tto n to th e O N
p o sitio n a t th e g ro u n d co n tro ls.
2 L ift th e re d a u xilia ry p o we r switch co ve r.
3 S im u lta n e o u sly h o ld th e a u xilia ry p o we r switch
O N a n d a ctiva te e a ch b o o m fu n ctio n to g g le
switch .
T o co n se rve b a tte ry p o we r, te st
e a ch fu n ctio n th ro u g h a p a rtia l
cycle .
R e su lt: A ll b o o m fu n ctio n s sh o u ld o p e ra te .
4 T u rn th e ke y switch to p la tfo rm co n tro l.
5 P u ll o u t th e E m e rg e n cy S to p switch to th e O N
p o sitio n a t th e p la tfo rm co n tro ls, th e n p re ss
d o wn th e fo o t switch .
6 L ift th e re d a u xilia ry p o we r switch co ve r.
7 S im u lta n e o u sly h o ld th e a u xilia ry p o we r switch
O N a n d a ctiva te e a ch fu n ctio n co n tro l h a n d le o r
to g g le switch
T o co n se rve b a tte ry p o we r, te st
e a ch fu n ctio n th ro u g h a p a rtia l
cycle .
R e su lt: A ll b o o m a n d ste e r fu n ctio n s sh o u ld
o p e ra te . D rive fu n ctio n s sh o u ld n o t o p e ra te with
a u xilia ry p o we r.
A-13
Test the Tilt Sensor
T h e tilt se n so r so u n d s a n a la rm lo ca te d in th e
p la tfo rm wh e n th e in clin e o f th e tu rn ta b le e xce e d s
4 . 5 d e g re e s.
S e le ct a le ve l te st a re a . T h e tilt
a la rm sh o u ld n o t b e so u n d in g p rio r
to th e te st.
2 O p e n th e ta n k sid e tu rn ta b le co ve r a n d p re ss
d o wn o n o n e sid e o f th e tilt se n so r.
R e su lt: A fte r a 1 . 5 se co n d d e la y, th e a la rm in
th e p la tfo rm sh o u ld so u n d .
T ip -o ve r h a za rd . T h e a la rm sh o u ld
b e a u d ib le a t th e g ro u n d co n tro ls.
I f th e a la rm is n o t a u d ib le a t th e
g ro u n d co n tro ls, re p la ce th e
a la rm .
a fu e l ta n k
b tilt se n so r
c g ro u n d co n tro l b o x
c b a
a
A-14
Test the Limit Switches
Drive Limit Switches
D e te ctin g lim it switch m a lfu n ctio n s is e sse n tia l to
sa fe m a ch in e o p e ra tio n . T h e d rive lim it switch e s
a re u se d to re strict d rive sp e e d wh e n th e b o o m is
ra ise d o r e xte n d e d . A n im p ro p e rly fu n ctio n in g d rive
lim it switch will a llo w th e m a ch in e to o p e ra te a t a n
u n sa fe d rive sp e e d .
1 R e m o ve th e co ve r fro m th e re a r o f th e tu rn ta b le
to a cce ss th e d rive lim it switch .
2 V isu a lly in sp e ct th e d rive lim it switch m o u n te d
to th e tu rn ta b le sid e p la te a t th e p ivo t e n d o f th e
b o o m . I n sp e ct fo r th e fo llo win g :
B ro ke n o r m issin g ro lle r o r ro lle r h e a d
M issin g fa ste n e rs
L o o se wirin g
a tu rn ta b le rise r
b b o o m
c b o o m d rive lim it switch
3 V isu a lly in sp e ct th e b o o m e xte n d d rive lim it
switch lo ca te d o n th e e n d o f th e ca b le tra ck o n
th e b o o m . I n sp e ct fo r th e fo llo win g :
B ro ke n o r m issin g ro lle r o r a rm
L o o se wirin g
a b o o m e xte n d d rive lim it switch
b ca b le tra ck
5 E xte n d th e b o o m a p p ro xim a te ly 3 fe e t (0 . 9 m ).
6 M a n u a lly a ctiva te th e b o o m e xte n d d rive lim it
switch .
R e su lt: T h e b o o m e xte n d d rive lim it switch a rm
sh o u ld m o ve fre e ly a n d sp rin g re tu rn to ce n te r.
A d istin ct click sh o u ld b e fe lt a n d h e a rd .
7 T u rn th e ke yswitch to p la tfo rm co n tro l.
8 F u lly re tra ct th e b o o m .
9 S lo wly m o ve th e d rive co n tro l h a n d le
o ff ce n te r.
R e su lt: T h e m a ch in e sh o u ld m o ve a t n o rm a l
d rive sp e e d s.
1 0 R a ise th e b o o m to ju st a b o ve h o rizo n ta l.
1 1 S lo wly m o ve th e d rive co n tro l h a n d le o ff ce n te r.
R e su lt: T h e m a ch in e sh o u ld m o ve a t a re d u ce d
d rive sp e e d .
b a
b
c
a
b c
1 2 L o we r th e b o o m to th e sto we d p o sitio n , th e n
e xte n d th e b o o m 3 fe e t (9 1 cm ).
1 3 S lo wly m o ve th e d rive co n tro l h a n d le o ff ce n te r.
R e su lt: T h e m a ch in e sh o u ld m o ve a t a re d u ce d
d rive sp e e d .
Drive speed, maximum,
raised or extended
A ll m o d e ls 1 fo o t p e r se co n d
0 . 3 1 m e te r p e r se co n d
Drive Enable Limit Switch
1 With th e e n g in e o ff a n d th e b o o m in b e twe e n
th e ste e r a n d n o n -ste e r tire s, visu a lly in sp e ct
th e d rive e n a b le lim it switch fo r th e fo llo win g :
B ro ke n o r m issin g ro lle r o r a rm
L o o se wirin g
a tu rn ta b le
b d rive e n a b le lim it switch
c tu rn ta b le ro ta tio n b e a rin g
2 M a n u a lly a ctiva te th e d rive e n a b le lim it switch .
R e su lt: T h e d rive e n a b le lim it switch ro lle r
sh o u ld m o ve fre e ly a n d sp rin g re tu rn to ce n te r.
A d istin ct click sh o u ld b e fe lt a n d h e a rd .
3 S ta rt th e e n g in e fro m th e p la tfo rm co n tro ls a n d
ro ta te th e tu rn ta b le so th e b o o m is b e twe e n th e
n o n -ste e r tire s.
4 R o ta te th e tu rn ta b le to th e le ft u n til th e b o o m is
p a st th e le ft n o n -ste e r wh e e l.
R e su lt: T h e d rive e n a b le in d ica to r lig h t sh o u ld
b e o n . D rive fu n ctio n sh o u ld n o t o p e ra te u n til
th e d rive e n a b le to g g le switch is a ctiva te d .
5 R o ta te th e tu rn ta b le to th e rig h t u n til th e b o o m is
p a st th e rig h t n o n -ste e r wh e e l.
b e o n . D rive fu n ctio n sh o u ld n o t o p e ra te u n til
th e d rive e n a b le to g g le switch is a ctiva te d .
4 - 1 0 G e n ie S -6 0 & G e n ie S -6 5 P a rt N o . 4 8 4 1 2
A-15
Replace the Engine Oil and
Filter - Gasoline/LPG Models
F o rd e n g in e sp e cifica tio n s re q u ire
th a t th is p ro ce d u re b e p e rfo rm e d
e ve ry 1 0 0 h o u rs. P e rfo rm th is
p ro ce d u re m o re o fte n if d u sty
co n d itio n s e xist o r th e m a ch in e is
su b je cte d to e xte n d e d lo w id le
o p e ra tio n .
P e rio d ic re p la ce m e n t o f th e e n g in e o il a n d filte r
is e sse n tia l to g o o d e n g in e p e rfo rm a n ce . O p e ra tin g
th e m a ch in e with a n im p ro p e r o il le ve l o r
n e g le ctin g p e rio d ic o il a n d filte r ch a n g e s ca n
d a m a g e e n g in e co m p o n e n ts. A d a ily ch e ck o f
e la p se d m a ch in e h o u rs a g a in st th e h o u rs n o te d
o n th e o il filte r will a llo w th e in sp e cto r to a n ticip a te
a n d p e rfo rm o il a n d filte r ch a n g e s a t th e 1 0 0 h o u r
in te rva l.
P e rfo rm th is p ro ce d u re a fte r
wa rm in g th e e n g in e to n o rm a l
o p e ra tin g te m p e ra tu re .
B e wa re o f h o t e n g in e p a rts a n d o il.
C o n ta ct with h o t e n g in e o il a n d /o r
e n g in e p a rts m a y ca u se se ve re
b u rn s.
1 R e m o ve th e o il fille r ca p lo ca te d o n th e
va lve co ve r.
2 P la ce a su ita b le co n ta in e r u n d e r th e e n g in e
p ivo t p la te d ire ctly b e lo w th e o il p a n d ra in p lu g .
a e n g in e p ivo t p la te
b p ivo t p la te re ta in in g b o lts
c o il d ra in h o se
3 R e m o ve th e p lu g fro m th e o il p a n a n d a llo w a ll
o f th e o il fro m th e e n g in e to d ra in in to a su ita b le
co n ta in e r. S e e ca p a city sp e cifica tio n s b e lo w.
4 I n sta ll th e p lu g in to th e o il p a n .
5 R e m o ve th e 2 e n g in e p ivo t p la te re ta in in g b o lts
fro m u n d e r th e e n g in e p ivo t p la te . S win g th e
e n g in e p ivo t p la te a wa y fro m th e m a ch in e to
a cce ss th e o il filte r.
6 U se a n o il filte r wre n ch a n d re m o ve th e filte r.
7 A p p ly a th in la ye r o f o il to th e n e w o il filte r
g a ske t (G e n ie p a rt n o . 2 8 6 5 6 ). T h e n in sta ll th e
filte r a n d tig h te n it se cu re ly b y h a n d .
8 U se a p e rm a n e n t in k m a rke r to write th e d a te
a n d n u m b e r o f h o u rs fro m th e h o u r m e te r o n
th e o il filte r.
9 F ill th e e n g in e with n e w o il p e r sp e cifica tio n s
a n d in sta ll th e fille r ca p . S e e ca p a city
sp e cifica tio n s b e lo w.
1 0 S ta rt th e e n g in e fro m th e g ro u n d co n tro ls.
A llo w th e e n g in e to ru n fo r 3 0 se co n d s, th e n
tu rn th e e n g in e o ff.
a b c b
P a rt N o . 4 8 4 1 2 G e n ie S -6 0 & G e n ie S -6 5 4 - 1 1
1 1 C h e ck th e o il filte r a n d th e o il p a n d ra in p lu g fo r
le a ks.
1 2 S win g th e e n g in e p ivo t p la te b a ck to its o rig in a l
p o sitio n a n d re p la ce th e two p ivo t p la te
re ta in in g b o lts.
1 3 C h e ck th e e n g in e o il le ve l d ip stick. A d d o il
if n e e d e d .
Ford LRG-423 Engine 5 q u a rts
Oil capacity (including filter) 4 . 7 lite rs
Ford LRG-423 Engine
b e lo w 6 0 F / 1 5 . 5 C 5 W-3 0
-1 0 to 9 0 F / -2 3 to 3 2 C 1 0 W-3 0
a b o ve -1 0 F / -2 3 C 1 0 W-4 0 o r 1 0 W-5 0
a b o ve 2 5 F / -4 C 2 0 W-4 0 o r 2 0 W-5 0
U se o ils m e e tin g A P I cla ssifica tio n S F (la b e le d S F /C C
o r S F /C D ) a s th e y o ffe r im p ro ve d we a r p ro te ctio n .
A-16
Drain the Fuel Filter/ Water
Separator - Deutz Diesel Models
E n g in e sp e cifica tio n s re q u ire th a t
th is p ro ce d u re b e p e rfo rm e d e ve ry
1 0 0 h o u rs. P o o r fu e l q u a lity o r
ve ry we t co n d itio n s m a y
n e ce ssita te p e rfo rm in g th is
p ro ce d u re m o re o fte n .
P ro p e r m a in te n a n ce o f th e fu e l filte r/wa te r
se p a ra to r is e sse n tia l fo r g o o d e n g in e
p e rfo rm a n ce . F a ilu re to p e rfo rm th is p ro ce d u re ca n
le a d to p o o r e n g in e p e rfo rm a n ce a n d co m p o n e n t
d a m a g e .
P e rfo rm th is p ro ce d u re in a n o p e n ,
e a sy re a ch .
P e rfo rm th is p ro ce d u re with th e
e n g in e o ff.
1 L o o se n th e d ra in p lu g lo ca te d a t th e b o tto m o f
th e filte r. A llo w th e wa te r to d ra in in to a su ita b le
co n ta in e r u n til fu e l sta rts to co m e o u t.
I m m e d ia te ly tig h te n th e d ra in p lu g .
a fu e l filte r
b d ra in p lu g
b
a
2 C le a n u p a n y fu e l th a t m a y h a ve sp ille d .
I f th e fu e l filte r is co m p le te ly
d ra in e d , yo u m u st p rim e th e fu e l
filte r/wa te r se p a ra to r b e fo re
sta rtin g th e e n g in e . R e fe r to C -8 in
th is se ctio n , Replace The Diesel
Fuel Filter/Water Separator, fo r
in stru ctio n s o n h o w to p rim e th e
fu e l filte r/wa te r se p a ra to r.
3 S ta rt th e e n g in e fro m th e g ro u n d co n tro ls a n d
ch e ck th e fu e l filte r/wa te r se p a ra to r fo r le a ks.
A-17
Replace the Engine Air Filter
E n g in e sp e cifica tio n s re q u ire th a t
th is p ro ce d u re b e p e rfo rm e d e ve ry
1 0 0 h o u rs. P e rfo rm th is p ro ce d u re
m o re o fte n if d u sty co n d itio n s
e xist.
M a in ta in in g th e e n g in e a ir filte r in g o o d co n d itio n is
e sse n tia l to g o o d e n g in e p e rfo rm a n ce a n d se rvice
life . F a ilu re to p e rfo rm th is p ro ce d u re ca n le a d to
p o o r e n g in e p e rfo rm a n ce a n d co m p o n e n t d a m a g e .
e n g in e o ff.
1 R e m o ve th e re ta in in g rin g fro m th e e n d ca p o f
th e a ir filte r ca n iste r.
2 R e m o ve th e e n d ca p fro m th e a ir cle a n e r
ca n iste r.
3 R e m o ve th e a ir filte r re ta in in g fa ste n e r, th e n
re m o ve th e filte r.
4 C le a n th e in sid e o f th e ca n iste r a n d th e g a ske t
with a d a m p clo th .
5 I n se rt th e n e w filte r a n d re p la ce th e m o u n tin g
fa ste n e r.
6 R e p la ce th e e n d ca p o n th e ca n iste r, th e n
re p la ce th e re ta in in g rin g .
Air filters - Genie part numbers
F o rd L R G -4 2 3 E n g in e 2 7 9 1 6
D e u tz F 4 L 1 0 1 1 F E n g in e 2 7 9 1 6
B-1
Check the Engine Belt
M a in ta in in g th e e n g in e b e lt(s) is e sse n tia l to g o o d
e n g in e p e rfo rm a n ce a n d se rvice life . T h e m a ch in e
will n o t o p e ra te p ro p e rly with a lo o se o r d e fe ctive
b e lt a n d co n tin u e d u se m a y ca u se co m p o n e n t
d a m a g e .
D o n o t in sp e ct wh ile th e e n g in e
is ru n n in g . R e m o ve th e ke y to
se cu re fro m o p e ra tio n .
B e wa re o f h o t e n g in e
co m p o n e n ts. C o n ta ct with h o t
e n g in e co m p o n e n ts m a y ca u se
se ve re b u rn s.
1 Deutz Diesel models: R e m o ve th e 2 b o lts fro m
u n d e r th e e n g in e p ivo t p la te . S win g th e e n g in e
p ivo t p la te a wa y fro m th e m a ch in e to a cce ss
th e fro n t e n g in e a cce ss co ve r m o u n tin g
fa ste n e rs.
2 R e m o ve th e fro n t e n g in e a cce ss co ve r
m o u n tin g fa ste n e rs.
3 All models: I n sp e ct th e e n g in e b e lt fo r:
C ra ckin g
G la zin g
S e p a ra tio n
B re a ks
4 R e p la ce b e lt if a n y d a m a g e is fo u n d .
Table B Procedures
D e u tz D ie se l e n g in e
5 C h e ck th e e n g in e b e lt fo r p ro p e r te n sio n .
F o rd L R G -4 2 3 e n g in e s a re
e q u ip p e d with a se rp e n tin e b e lt
a n d in co rp o ra te a se lf a d ju stin g
p u lle y te n sio n e r. N o a d ju stm e n t is
re q u ire d .
Belt deflection -
3
/8 in ch to
1
/2 in ch
Deutz Diesel models 9 m m to 1 2 m m
T A B L E B P R O C E D U R E S
a c b
B-2
Check the Radiator
M a in ta in in g th e ra d ia to r in g o o d co n d itio n is
e sse n tia l fo r g o o d e n g in e p e rfo rm a n ce . O p e ra tin g
a m a ch in e with a d a m a g e d o r le a kin g ra d ia to r m a y
re su lt in e n g in e d a m a g e . A lso , re strictin g a ir flo w
th ro u g h th e ra d ia to r (i. e . , d irt o r d e b ris) will a ffe ct
th e p e rfo rm a n ce o f th e co o lin g syste m . A fre q u e n t
ch e ck a llo ws th e in sp e cto r to id e n tify ch a n g e s in
th e co n d itio n o f th e ra d ia to r th a t m ig h t in d ica te
co o lin g syste m p ro b le m s.
B e wa re o f h o t e n g in e p a rts a n d
co o la n t. C o n ta ct with h o t e n g in e
p a rts a n d /o r co o la n t m a y ca u se
se ve re b u rn s.
a cce ss th e ra d ia to r.
2 I n sp e ct th e ra d ia to r fo r le a ks a n d p h ysica l
d a m a g e .
3 C le a n th e ra d ia to r fin s o f d e b ris a n d fo re ig n
m a te ria ls.
B-3
Check the Oil Cooler and Cooling
Fins - Deutz Diesel Models
M a in ta in in g th e o il co o le r in g o o d co n d itio n is
e sse n tia l fo r g o o d e n g in e p e rfo rm a n ce . O p e ra tin g
a m a ch in e with a d a m a g e d o il co o le r m a y re su lt in
e n g in e d a m a g e . A lso , re strictin g a ir flo w th ro u g h
th e o il co o le r will a ffe ct th e p e rfo rm a n ce o f th e
co o lin g syste m .
se ve re b u rn s.
Oil Cooler
1 R e m o ve th e fa ste n e rs fro m th e e n g in e sid e
co ve r, th e n re m o ve th e co ve r.
2 I n sp e ct th e o il co o le r fo r le a ks a n d p h ysica l
d a m a g e .
a o il co o le r
b cylin d e r h e a d co o lin g fin s
c fa n b lo we r fin s
3 C le a n th e o il co o le r o f d e b ris a n d fo re ig n
m a te ria l.
Cooling and Fan Blower Fins
4 I n sp e ct th e fa n b lo we r fin s fo r p h ysica l d a m a g e .
5 C le a n th e fa n b lo we r fin s o f d e b ris a n d fo re ig n
m a te ria l.
6 I n sp e ct th e h e a d co o lin g p a ssa g e s a n d fin s fo r
p h ysica l d a m a g e o r fo re ig n m a te ria l, u sin g a
fla sh lig h t.
7 C le a n th e cylin d e r h e a d co o lin g p a ssa g e s o f
d e b ris a n d fo re ig n m a te ria l.
B-4
Check the Exhaust System
M a in ta in in g th e e xh a u st syste m is e sse n tia l to
g o o d e n g in e p e rfo rm a n ce a n d se rvice life . R u n n in g
th e e n g in e with a d a m a g e d o r le a kin g e xh a u st
syste m ca n ca u se co m p o n e n t d a m a g e a n d u n sa fe
o p e ra tin g co n d itio n s.
se ve re b u rn s.
1 Deutz Diesel models: R e m o ve th e 2 b o lts fro m
u n d e r th e e n g in e p ivo t p la te . S win g th e e n g in e
p ivo t p la te a wa y fro m th e m a ch in e to a cce ss
th e e xh a u st syste m .
a e n g in e p ivo t p la te
b p ivo t p la te re ta in in g b o lts
2 All models: B e su re th a t a ll n u ts a n d b o lts a re
tig h t.
3 I n sp e ct a ll we ld s fo r cra cks.
4 I n sp e ct fo r e xh a u st le a ks; i. e . , ca rb o n b u ild u p
a ro u n d se a m s a n d jo in ts.
a b b
B-5
Check the Battery
P ro p e r b a tte ry co n d itio n is e sse n tia l to g o o d
e n g in e p e rfo rm a n ce a n d o p e ra tio n a l sa fe ty.
I m p ro p e r flu id le ve ls o r d a m a g e d ca b le s a n d
co n n e ctio n s ca n re su lt in e n g in e co m p o n e n t
d a m a g e a n d h a za rd o u s co n d itio n s.
E le ctro cu tio n h a za rd . C o n ta ct with
h o t o r live circu its m a y re su lt in
d e a th o r se rio u s in ju ry. R e m o ve a ll
rin g s, wa tch e s a n d o th e r je we lry.
B a tte rie s co n ta in a cid . A vo id
sp illin g o r co n ta ctin g b a tte ry a cid .
N e u tra lize b a tte ry a cid sp ills with
b a kin g so d a a n d wa te r.
1 P u t o n p ro te ctive clo th in g a n d e ye we a r.
2 B e su re th a t th e b a tte ry ca b le co n n e ctio n s a re
fre e o f co rro sio n .
3 B e su re th a t th e b a tte ry h o ld d o wn s a n d ca b le
co n n e ctio n s a re tig h t.
4 R e m o ve th e b a tte ry ve n t ca p s a n d ch e ck th e
sp e cific g ra vity with a h yd ro m e te r.
5 C h e ck th e b a tte ry a cid le ve l. I f n e e d e d ,
re p le n ish with d istille d wa te r to th e b o tto m o f
th e b a tte ry fill tu b e . D o n o t o ve rfill.
6 I n sta ll th e ve n t ca p s.
A d d in g te rm in a l p ro te cto rs a n d a
co rro sio n p re ve n ta tive se a la n t will
h e lp e lim in a te co rro sio n o n th e
b a tte ry te rm in a ls a n d ca b le s.
B-6
Check the Hydraulic Tank Filter
Condition Indicator
M a in ta in in g th e h yd ra u lic ta n k filte r in g o o d
co n d itio n is e sse n tia l to g o o d syste m p e rfo rm a n ce
a n d sa fe m a ch in e o p e ra tio n . T h e filte r co n d itio n
in d ica to r will sh o w wh e n th e h yd ra u lic flo w is
b yp a ssin g a clo g g e d filte r. I f th e filte r is n o t
fre q u e n tly ch e cke d a n d re p la ce d , im p u ritie s
will re m a in in th e h yd ra u lic syste m a n d ca u se
co m p o n e n t d a m a g e .
2 M o ve th e e n g in e sp e e d co n tro l switch to h ig h
id le (ra b b it sym b o l).
3 I n sp e ct th e filte r co n d itio n in d ica to r.
a filte r co n d itio n in d ica to r
b filte r
c h yd ra u lic ta n k
R e su lt: T h e filte r sh o u ld b e o p e ra tin g with th e
p lu n g e r in th e g re e n a re a . I f th e d isp la y sh o ws
th e p lu n g e r in th e re d a re a , th is in d ica te s th a t
th e h yd ra u lic filte r is b e in g b yp a sse d a n d th e
filte r sh o u ld b e re p la ce d . S e e C -6 , Replace the
Hydraulic Tank Filter.
a
b
c
B-7
Inspect the Electrical Wiring
M a in ta in in g e le ctrica l wirin g in g o o d co n d itio n is
e sse n tia l to sa fe o p e ra tio n a n d g o o d m a ch in e
p e rfo rm a n ce . F a ilu re to fin d a n d re p la ce b u rn t,
ch a fe d , co rro d e d o r p in ch e d wire s co u ld re su lt in
u n sa fe o p e ra tin g co n d itio n s a n d m a y ca u se
co m p o n e n t d a m a g e .
h o t o r live circu its m a y re su lt in
d e a th o r se rio u s in ju ry. R e m o ve a ll
rin g s, wa tch e s a n d o th e r je we lry.
1 I n sp e ct th e fo llo win g a re a s fo r b u rn t, ch a fe d ,
co rro d e d a n d lo o se wire s:
E n g in e co m p a rtm e n t e le ctrica l p a n e l
(G a so lin e /L P G m o d e ls)
E n g in e wirin g h a rn e ss
I n sid e o f th e g ro u n d co n tro l b o x
T u rn ta b le m a n ifo ld wirin g
ra ise th e b o o m a b o ve th e tu rn ta b le co ve rs.
3 I n sp e ct th e tu rn ta b le a re a fo r b u rn t, ch a fe d a n d
p in ch e d ca b le s.
4 L o we r th e b o o m in to th e sto we d p o sitio n a n d
tu rn th e e n g in e o ff.
5 I n sp e ct th e fo llo win g a re a s fo r b u rn t, ch a fe d ,
co rro d e d , p in ch e d a n d lo o se wire s:
C a b le tra ck o n th e b o o m
B o o m to p la tfo rm ca b le h a rn e ss
I n sid e o f th e p la tfo rm co n tro l b o x
J ib b o o m ca b le co ve r (S -6 5 m o d e ls)
B-8
Inspect the Tires and Wheels
(including lug nut torque)
M a in ta in in g th e tire s a n d wh e e ls in g o o d
co n d itio n is e sse n tia l to sa fe o p e ra tio n a n d g o o d
p e rfo rm a n ce . T ire a n d /o r wh e e l fa ilu re co u ld re su lt
in a m a ch in e tip -o ve r. C o m p o n e n t d a m a g e m a y
a lso re su lt if p ro b le m s a re n o t d isco ve re d a n d
re p a ire d in a tim e ly fa sh io n .
A n o ve r-in fla te d tire ca n
e xp lo d e a n d m a y ca u se d e a th
o r se rio u s in ju ry.
T ip -o ve r h a za rd . D o n o t u se
te m p o ra ry fla t tire re p a ir p ro d u cts.
1 C h e ck a ll tire tre a d s a n d sid e wa lls fo r cu ts,
cra cks, p u n ctu re s a n d u n u su a l we a r.
2 C h e ck e a ch wh e e l fo r d a m a g e , b e n d s a n d
cra cke d we ld s.
3 C h e ck e a ch lu g n u t fo r p ro p e r to rq u e .
4 C h e ck th e p re ssu re in e a ch a ir-fille d tire .
Tires and wheels
T ire size 1 5 -1 9 . 5 N H S
T ire p ly ra tin g 1 2
T ire p re ssu re 8 5 p si
5 . 8 6 b a r
Wh e e l lu g s 1 0 @
3
/4 -1 6
L u g n u t to rq u e , d ry 4 2 0 ft-lb s
5 6 9 . 5 N m
L u g n u t to rq u e , lu b rica te d 3 2 0 ft-lb s
4 3 3 . 9 N m
B-9
Confirm the Proper
Brake Configuration
P ro p e r b ra ke co n fig u ra tio n is e sse n tia l to sa fe
o p e ra tio n a n d g o o d m a ch in e p e rfo rm a n ce .
H yd ro sta tic b ra ke s a n d h yd ra u lica lly-re le a se d ,
sp rin g -a p p lie d in d ivid u a l wh e e l b ra ke s ca n a p p e a r
to o p e ra te n o rm a lly wh e n th e y a re a ctu a lly n o t fu lly
o p e ra tio n a l.
1 C h e ck e a ch to rq u e h u b d isco n n e ct ca p to b e
su re it is in th e e n g a g e d p o sitio n .
2 B e su re th e fre e -wh e e l va lve o n th e d rive p u m p
is clo se d (clo ckwise ).
T h e fre e -wh e e l va lve is lo ca te d o n
th e b o tto m o f th e d rive p u m p .
a d rive p u m p
b fre e -wh e e l va lve
c lift p u m p
d scre wd rive r
T h e fre e -wh e e l va lve sh o u ld
a lwa ys re m a in clo se d .
B-10
Check the Oil Level
in the Torque Hubs
F a ilu re to m a in ta in p ro p e r to rq u e h u b o il le ve ls
m a y ca u se th e m a ch in e to p e rfo rm p o o rly a n d
co n tin u e d u se m a y ca u se co m p o n e n t d a m a g e .
Drive Torque Hubs
1 D rive th e m a ch in e to ro ta te th e h u b u n til th e
p lu g s a re lo ca te d o n e o n to p a n d th e o th e r a t
9 0 d e g re e s.
2 R e m o ve th e p lu g lo ca te d a t 9 0 d e g re e s a n d
ch e ck th e o il le ve l.
R e su lt: T h e o il le ve l sh o u ld b e e ve n with th e
b o tto m o f th e p lu g h o le .
3 I f n e ce ssa ry, re m o ve th e to p p lu g a n d a d d o il
u n til th e o il le ve l is e ve n with th e b o tto m o f th e
sid e p lu g h o le .
4 A p p ly p ip e th re a d se a la n t to th e p lu g , a n d th e n
in sta ll it in th e to rq u e h u b .
5 R e p e a t th is p ro ce d u re fo r e a ch d rive to rq u e
h u b .
Drive torque hub oil
C a p a city 4 4 fl o z
1 . 3 0 lite rs
T yp e : S A E 9 0 m u ltip u rp o se h yp o id g e a r o il - A P I se rvice
cla ssifica tio n G L 5
b ra ke d ise n g a g e p o sitio n
b ra ke e n g a g e p o sitio n
a
b
c
d
Turntable Rotate Torque Hub
1 R e m o ve th e p lu g lo ca te d o n th e sid e o f th e h u b
a n d ch e ck th e o il le ve l.
R e su lt: T h e o il le ve l sh o u ld b e e ve n with th e
b o tto m o f th e p lu g h o le .
a to rq u e h u b
b p lu g
2 I f n e ce ssa ry, a d d o il u n til th e o il le ve l is e ve n
with th e b o tto m o f th e sid e p lu g h o le .
3 A p p ly p ip e th re a d se a la n t to th e p lu g , a n d th e n
in sta ll it in th e to rq u e h u b .
Turntable rotate torque hub oil
C a p a city 1 7 flu id o u n ce s
0 . 5 1 lite rs
T yp e S A E 9 0 m u ltip u rp o se h yp o id g e a r o il - A P I se rvice
cla ssifica tio n G L 5
B-11
Check and Adjust the Engine Idle
Mixture - Gasoline/LPG Models
C o m p le te in fo rm a tio n to p e rfo rm th is p ro ce d u re is
a va ila b le in th e Ford LRG-423 2.3 Liter Industrial
Engine Service Manual (F o rd n u m b e r: P P D -1 9 4 -
2 8 7 ). G e n ie p a rt n u m b e r 3 3 9 0 7 .
B-12
Check and Adjust the
Engine RPM
M a in ta in in g th e e n g in e rp m a t th e p ro p e r se ttin g fo r
b o th lo w a n d h ig h id le is e sse n tia l to g o o d e n g in e
p e rfo rm a n ce a n d se rvice life . T h e m a ch in e will n o t
o p e ra te p ro p e rly if th e rp m is in co rre ct a n d
Gasoline/LPG Models:
P e rfo rm th is p ro ce d u re in g a so lin e
m o d e with th e e n g in e a t n o rm a l
1 D isco n n e ct th e b lu e /b la ck wire fro m th e
g o ve rn o r a ctu a to r.
2 C o n n e ct a n rp m g a u g e to th e e n g in e , th e n sta rt
th e e n g in e fro m th e g ro u n d co n tro ls.
R e su lt: C a rb u re to r lo w id le sh o u ld b e 9 0 0 rp m .
Skip to step 4 if the low idle rpm is correct.
3 T u rn th e id le a d ju stm e n t scre w o n th e
ca rb u re to r clo ckwise to in cre a se rp m o r
co u n te rclo ckwise to d e cre a se rp m .
a ca rb u re to r
b a d ju stm e n t scre w
4 T u rn th e e n g in e o ff a n d re co n n e ct th e
b lu e /b la ck wire to th e g o ve rn o r a ctu a to r.
R e su lt: E le ctro n ic g o ve rn o r lo w id le sh o u ld
b e 1 6 0 0 rp m .
b
a
b
a
6 M o ve th e fu n ctio n e n a b le to g g le switch to th e
h ig h id le (ra b b it sym b o l) a t th e g ro u n d co n tro ls.
R e su lt: H ig h id le sh o u ld b e 2 5 0 0 rp m .
7 T u rn th e e n g in e o ff.
If low and high idle rpms are correct,
disregard adjustment steps 8 and 9.
8 R e m o ve th e m o u n tin g fa ste n e rs fro m th e
e le ctro n ic g o ve rn o r lo ca te d o n th e e n g in e
sid e b u lkh e a d , th e n re m o ve th e b a ck p a n e l
fro m th e g o ve rn o r.
9 R e sta rt th e e n g in e , tu rn th e lo w o r h ig h sp e e d
trim p o t scre w clo ckwise to in cre a se th e rp m o r
co u n te rclo ckwise to d e cre a se th e rp m .
D o n o t a d ju st a n y trim p o t o th e r
th a n sp e cifie d in th is p ro ce d u re .
a lo w id le a d ju stm e n t
b h ig h id le a d ju stm e n t
1 0 A p p ly a d ro p o f silico n e to th e to p o f th e trim p o t
scre w. A p p ly a b e a d o f silico n e to th e su rfa ce o f
th e b a ck p a n e l p rio r to re -a sse m b ly.
1 1 R e -a sse m b le th e g o ve rn o r a n d re ch e ck lo w a n d
h ig h id le .
Gasoline/LPG models
L o w id le - ca rb u re to r 9 0 0 rp m
L o w id le - e le ctro n ic g o ve rn o r 1 6 0 0 rp m
H ig h id le 2 5 0 0 rp m
Deutz Diesel models:
1 C o n n e ct a n rp m g a u g e to th e e n g in e , a n d th e n
sta rt th e e n g in e fro m th e g ro u n d co n tro ls.
R e su lt: L o w id le sh o u ld b e 1 3 0 0 rp m .
Skip to step 3 if the low idle rpm is correct.
2 L o o se n th e lo w id le lo ck n u t, th e n tu rn th e lo w
id le a d ju stm e n t scre w clo ckwise to in cre a se th e
rp m o r co u n te rclo ckwise to d e cre a se th e rp m .
T ig h te n th e lo w id le lo ck n u t a n d re ch e ck th e
rp m .
a so le n o id b o o t
b h ig h id le a d ju stm e n t n u t
c yo ke lo ck n u t
d yo ke
e lo w id le a d ju stm e n t scre w
f lo w id le lo ck n u t
3 M o ve th e fu n ctio n e n a b le to g g le switch to th e
h ig h id le (ra b b it sym b o l) p o sitio n a t th e g ro u n d
co n tro ls.
R e su lt: H ig h id le sh o u ld b e 2 3 0 0 rp m .
If high idle rpm is correct, disregard
adjustment step 4.
b
a
f
e
c d b a
4 L o o se n th e yo ke lo ck n u t, th e n tu rn th e h ig h id le
a d ju stm e n t n u t a n d so le n o id b o o t
co u n te rclo ckwise to in cre a se th e rp m o r
clo ckwise to d e cre a se th e rp m . T ig h te n th e
yo ke lo ck n u t a n d re ch e ck th e rp m .
B e su re th e so le n o id fu lly re tra cts
wh e n a ctiva tin g h ig h id le .
Deutz Diesel models
L o w id le 1 3 0 0 rp m
H ig h id le 2 3 0 0 rp m
B-13
Test the Key Switch
P ro p e r ke y switch a ctio n a n d re sp o n se is e sse n tia l
to sa fe m a ch in e o p e ra tio n . T h e m a ch in e ca n b e
o p e ra te d fro m th e g ro u n d o r p la tfo rm co n tro ls a n d
th e a ctiva tio n o f o n e o r th e o th e r is a cco m p lish e d
with th e ke y switch . F a ilu re o f th e ke y switch to
a ctiva te th e a p p ro p ria te co n tro l p a n e l co u ld ca u se
a h a za rd o u s o p e ra tin g situ a tio n .
1 P u ll o u t th e E m e rg e n cy S to p b u tto n to th e O N
p o sitio n a t b o th th e g ro u n d a n d p la tfo rm
co n tro ls.
2 T u rn th e ke y switch to g ro u n d co n tro l, sta rt th e
e n g in e a n d th e n tu rn th e ke y switch to platform
control.
3 C h e ck a n y m a ch in e fu n ctio n fro m th e ground
controls.
R e su lt: T h e m a ch in e fu n ctio n s sh o u ld not
o p e ra te .
4 T u rn th e ke y switch to g ro u n d co n tro l.
5 C h e ck a n y m a ch in e fu n ctio n fro m th e platform
controls.
o p e ra te .
6 T u rn th e ke y switch to th e O F F p o sitio n .
R e su lt: T h e e n g in e sh o u ld sto p a n d n o
fu n ctio n s sh o u ld o p e ra te .
D e u tz D ie se l m o d e ls: A ll fu n ctio n s
sh o u ld sto p im m e d ia te ly. T h e
e n g in e will sh u t o ff a fte r 2 to 3
se co n d s.
B-14
Test the Emergency
Stop Buttons
P ro p e rly fu n ctio n in g E m e rg e n cy S to p b u tto n s
a re e sse n tia l fo r sa fe m a ch in e o p e ra tio n . A n
im p ro p e rly o p e ra tin g E m e rg e n cy S to p b u tto n
will fa il to sh u t o ff p o we r a n d sto p a ll m a ch in e
fu n ctio n s, re su ltin g in a h a za rd o u s situ a tio n fo r
g ro u n d a n d p la tfo rm p e rso n n e l.
A s a sa fe ty fe a tu re , se le ctin g
a n d o p e ra tin g th e g ro u n d co n tro ls
will o ve rrid e th e p la tfo rm co n tro ls,
in clu d in g th e E m e rg e n cy S to p
b u tto n .
2 P u sh d o wn th e E m e rg e n cy S to p b u tto n to th e
O F F p o sitio n .
R e su lt: T h e e n g in e sh o u ld sh u t o ff a n d n o
m a ch in e fu n ctio n s sh o u ld o p e ra te .
Deutz Diesel models: A ll
fu n ctio n s sh o u ld sto p im m e d ia te ly.
T h e e n g in e will sh u t o ff a fte r 2 to 3
se co n d s.
4 P u sh d o wn th e E m e rg e n cy S to p b u tto n to th e
O F F p o sitio n .
R e su lt: T h e e n g in e sh o u ld sh u t o ff a n d n o
m a ch in e fu n ctio n s sh o u ld o p e ra te .
T h e g ro u n d E m e rg e n cy S to p
b u tto n will sto p a ll m a ch in e
o p e ra tio n , e ve n if th e ke y switch
is switch e d to p la tfo rm co n tro l.
B-15
Test the Ground Control Override
A p ro p e rly fu n ctio n in g g ro u n d co n tro l o ve rrid e is
e sse n tia l to sa fe m a ch in e o p e ra tio n . T h e g ro u n d
co n tro l o ve rrid e fu n ctio n is in te n d e d to a llo w
g ro u n d p e rso n n e l to o p e ra te th e m a ch in e fro m th e
g ro u n d co n tro ls wh e th e r o r n o t th e E m e rg e n cy
S to p b u tto n o n th e p la tfo rm co n tro ls is in th e O N o r
O F F p o sitio n . T h is fu n ctio n is p a rticu la rly u se fu l if
th e o p e ra to r a t th e p la tfo rm co n tro ls ca n n o t re tu rn
th e b o o m to th e sto we d p o sitio n .
1 P u sh in th e p la tfo rm E m e rg e n cy S to p b u tto n
to th e O F F p o sitio n .
3 O p e ra te e a ch b o o m fu n ctio n th ro u g h a
p a rtia l cycle .
R e su lt: A ll b o o m fu n ctio n s sh o u ld o p e ra te .
B-16
Check the Directional Valve
Linkage
P e rfo rm th is te st o n ly o n m o d e ls
e q u ip p e d with a o scilla tin g a xle .
P ro p e r a xle o scilla tio n is e sse n tia l to sa fe m a ch in e
o p e ra tio n . I f th e d ire ctio n a l va lve lin ka g e is n o t
o p e ra tin g co rre ctly, th e sta b ility o f th e m a ch in e is
co m p ro m ise d a n d it m a y tip o ve r.
1 R e m o ve th e d rive ch a ssis co ve r fro m th e
n o n -ste e r e n d .
2 I n sp e ct th e lin ka g e fo r th e fo llo win g :
L o ck n u t is tig h t a g a in st yo ke
Y o ke cle vis p in s a re in sta lle d
C o tte r p in s a re in sta lle d th ro u g h cle vis p in s
L in ka g e is p ro p e rly a tta ch e d to
d ire ctio n a l va lve
a d ire ctio n a l va lve
b cle vis p in with co tte r p in (h id d e n )
c yo ke
d lo ck n u t
a
b
c
d
B-17
Test the Platform Self-leveling
A u to m a tic p la tfo rm se lf-le ve lin g th ro u g h o u t
th e fu ll cycle o f b o o m ra isin g a n d lo we rin g is
e sse n tia l fo r sa fe m a ch in e o p e ra tio n . T h e
p la tfo rm is m a in ta in e d a t le ve l b y th e p la tfo rm
le ve lin g sla ve cylin d e r wh ich o p e ra te s in a clo se d
lo o p h yd ra u lic circu it with th e m a ste r cylin d e r
lo ca te d a t th e b a se o f th e b o o m . A p la tfo rm se lf-
le ve lin g fa ilu re cre a te s a n u n sa fe wo rkin g co n d itio n
fo r p la tfo rm a n d g ro u n d p e rso n n e l.
lo we r th e b o o m in to th e sto we d p o sitio n .
2 H o ld th e fu n ctio n e n a b le to g g le switch to e ith e r
sid e a n d a d ju st th e p la tfo rm to a le ve l p o sitio n
u sin g th e p la tfo rm le ve l to g g le switch .
3 R a ise a n d lo we r th e b o o m th ro u g h
a fu ll cycle .
R e su lt: T h e p la tfo rm sh o u ld re m a in le ve l a t
a ll tim e s to with in 5 d e g re e s.
B-18
Test the Horn
A fu n ctio n a l h o rn is e sse n tia l to sa fe m a ch in e
o p e ra tio n . T h e h o rn is a ctiva te d a t th e p la tfo rm
co n tro ls a n d so u n d s a t th e g ro u n d a s a wa rn in g to
g ro u n d p e rso n n e l. A n im p ro p e rly fu n ctio n in g h o rn
will p re ve n t th e o p e ra to r fro m a le rtin g g ro u n d
p e rso n n e l o f h a za rd s o r u n sa fe co n d itio n s.
1 T u rn th e ke y switch to p la tfo rm co n tro l a n d
p u ll o u t th e E m e rg e n cy S to p b u tto n to th e
O N p o sitio n a t b o th th e g ro u n d a n d
p la tfo rm co n tro ls.
2 P u sh d o wn th e h o rn b u tto n a t th e p la tfo rm
co n tro ls.
R e su lt: T h e h o rn sh o u ld so u n d .
I f n e ce ssa ry, th e h o rn ca n b e
a d ju ste d to o b ta in th e lo u d e st
vo lu m e b y tu rn in g th e a d ju stm e n t
scre w n e a r th e wire te rm in a ls o n
th e h o rn .
B-19
Test the Foot Switch
A p ro p e rly fu n ctio n in g fo o t switch is e sse n tia l to
sa fe m a ch in e o p e ra tio n . M a ch in e fu n ctio n s sh o u ld
a ctiva te a n d o p e ra te sm o o th ly a s lo n g a s th e fo o t
switch is p re sse d d o wn , a n d p ro m p tly sto p wh e n
th e fo o t switch is re le a se d . T h e fo o t switch will a lso
sh ift th e e n g in e in to h ig h id le if th e id le se le ct is
switch e d to th e ra b b it a n d fo o t switch sym b o l. A n
im p ro p e rly fu n ctio n in g fo o t switch ca n ca u se a n
u n sa fe wo rkin g co n d itio n a n d e n d a n g e r p la tfo rm
a n d g ro u n d p e rso n n e l.
T h e e n g in e sh o u ld n o t sta rt if th e
fo o t switch is p re sse d d o wn .
1 T u rn th e ke yswitch to p la tfo rm co n tro ls a n d p u ll
co n tro ls.
2 P re ss d o wn th e fo o tswitch a n d a tte m p t to sta rt
th e e n g in e b y m o vin g th e sta rt to g g le switch to
e ith e r sid e .
R e su lt: T h e e n g in e sh o u ld not sta rt.
3 D o n o t p re ss d o wn th e fo o tswitch a n d sta rt th e
e n g in e .
4 D o n o t p re ss d o wn th e fo o tswitch . C h e ck th e
m a ch in e fu n ctio n s.
o p e ra te .
5 P re ss d o wn th e fo o t switch a n d o p e ra te th e
m a ch in e fu n ctio n s.
R e su lt: T h e m a ch in e fu n ctio n s sh o u ld o p e ra te .
B-20
Test the Engine Idle Select
A p ro p e rly o p e ra tin g e n g in e id le se le ct switch
is e sse n tia l to g o o d e n g in e p e rfo rm a n ce a n d sa fe
m a ch in e o p e ra tio n . T h e re a re th re e se ttin g s.
Low idle (tu rtle sym b o l) a llo ws th e o p e ra to r to
co n tro l in d ivid u a l b o o m fu n ctio n s o n ly. D rive
fu n ctio n s d o n o t o p e ra te a t lo w id le .
High idle (ra b b it sym b o l) a llo ws th e o p e ra to r
to co n tro l m u ltip le b o o m a n d /o r d rive fu n ctio n s
sim u lta n e o u sly. T h is se ttin g m a in ta in s a
co n siste n t h ig h id le a n d is u su a lly se le cte d o n ly
wh e n th e g e n e ra to r o p tio n is b e in g u se d .
Foot switch activated high idle (ra b b it a n d fo o t
switch sym b o ls) sh o u ld b e u se d fo r n o rm a l
m a ch in e o p e ra tio n . T h is se le ctio n a ctiva te s h ig h
id le o n ly wh e n th e fo o t switch is p re sse d d o wn .
1 P u ll o u t th e E m e rg e n cy S to p b u tto n to th e
O N p o sitio n a t b o th th e g ro u n d a n d p la tfo rm
co n tro ls.
2 S ta rt th e e n g in e fro m th e g ro u n d co n tro ls. T h e n
m o ve th e fu n ctio n e n a b le to g g le switch to th e
h ig h id le (ra b b it sym b o l) p o sitio n a n d h o ld in th e
O N p o sitio n .
R e su lt: T h e e n g in e sh o u ld ch a n g e to h ig h id le .
3 R e le a se th e fu n ctio n e n a b le to g g le switch .
R e su lt: T h e e n g in e sh o u ld re tu rn to lo w id le .
4 T u rn th e ke y switch to p la tfo rm co n tro ls.
5 A t th e p la tfo rm co n tro ls, m o ve th e e n g in e id le
co n tro l switch to h ig h id le (ra b b it sym b o l).
6 M o ve th e e n g in e id le co n tro l switch to lo w id le
(tu rtle sym b o l).
R e su lt: T h e e n g in e sh o u ld ch a n g e to lo w id le .
7 M o ve th e e n g in e id le co n tro l switch to fo o t
switch a ctiva te d h ig h id le (ra b b it a n d fo o t switch
sym b o l).
R e su lt: T h e e n g in e sh o u ld not ch a n g e to
h ig h id le .
8 P re ss d o wn th e fo o t switch .
B-21
Test the Fuel Select Operation
T h e a b ility to se le ct a n d switch b e twe e n
g a so lin e a n d L P G fu e ls a s n e e d e d is e sse n tia l to
sa fe m a ch in e o p e ra tio n . A fu e l se le ctio n ca n b e
m a d e wh e n th e e n g in e is ru n n in g o r n o t.
S witch in g m a lfu n ctio n s a n d /o r th e fa ilu re o f th e
e n g in e to sta rt a n d ru n p ro p e rly in b o th fu e l
m o d e s a n d th ro u g h a ll id le sp e e d s ca n in d ica te
fu e l syste m p ro b le m s th a t co u ld d e ve lo p in to a
h a za rd o u s situ a tio n .
P e rfo rm th is te st a fte r ch e ckin g
th e g a so lin e a n d L P G fu e l le ve ls,
a n d wa rm in g th e e n g in e to n o rm a l
1 M o ve th e fu e l se le ct switch to g a so lin e a n d th e n
m o ve th e e n g in e id le co n tro l switch to fo o t
sym b o l).
2 S ta rt th e e n g in e fro m th e p la tfo rm co n tro ls a n d
a llo w it to ru n a t lo w id le .
3 P re ss d o wn th e fo o t switch to a llo w th e e n g in e
to ru n a t h ig h id le .
R e su lt: T h e e n g in e sh o u ld sta rt p ro m p tly a n d
o p e ra te sm o o th ly in lo w a n d h ig h id le .
4 R e le a se th e fo o t switch a n d sh u t th e e n g in e o ff
b y p u sh in g th e E m e rg e n cy S to p b u tto n in to th e
O F F p o sitio n .
5 M o ve th e fu e l se le ct switch to L P G .
6 R e sta rt th e e n g in e a n d a llo w it to ru n a t
lo w id le .
7 P re ss d o wn th e fo o t switch to a llo w th e e n g in e
to ru n a t h ig h id le .
R e su lt: T h e e n g in e sh o u ld sta rt p ro m p tly a n d
o p e ra te sm o o th ly in lo w a n d h ig h id le .
T h e e n g in e m a y h e sita te
m o m e n ta rily a n d th e n co n tin u e
to ru n o n th e se le cte d fu e l if th e
fu e l so u rce is switch e d wh ile
th e e n g in e is ru n n in g .
B-22
Test the Drive Enable System
P ro p e r d rive e n a b le syste m o p e ra tio n is
e sse n tia l to sa fe m a ch in e o p e ra tio n . Wh e n th e
b o o m is p a st th e n o n -ste e rin g wh e e ls, d rive
m o ve m e n t is sto p p e d a n d th e in d ica to r lig h t tu rn s
o n . T h e d rive e n a b le switch m u st b e to e ith e r sid e
to re a ctiva te th e d rive fu n ctio n a n d sh o u ld in fo rm
th e o p e ra to r th a t th e m a ch in e will m o ve in th e
o p p o site d ire ctio n th a t th e d rive a n d ste e r co n tro ls
a re m o ve d . A n im p ro p e rly fu n ctio n in g d rive e n a b le
syste m m a y a llo w th e m a ch in e to b e m o ve d in to
a n u n sa fe p o sitio n .
2 R o ta te th e tu rn ta b le to th e rig h t u n til th e b o o m is
p a st th e rig h t n o n -ste e rin g wh e e l.
tu rn o n .
3 S lo wly m o ve th e d rive co n tro l h a n d le o ff ce n te r.
R e su lt: T h e d rive fu n ctio n sh o u ld not o p e ra te .
4 H o ld th e d rive e n a b le to g g le switch to e ith e r
sid e a n d slo wly m o ve th e d rive co n tro l h a n d le
o ff ce n te r.
A lwa ys u se th e co lo r-co d e d
d ire ctio n a rro ws o n th e
p la tfo rm co n tro l p a n e l a n d th e
d rive ch a ssis to id e n tify wh ich
d ire ctio n th e m a ch in e will tra ve l.
R e su lt: T h e d rive fu n ctio n sh o u ld o p e ra te .
5 R o ta te th e tu rn ta b le to th e le ft u n til th e b o o m is
p a st th e le ft n o n -ste e rin g wh e e l.
co m e o n .
6 R e p e a t ste p s 3 a n d 4 .
B-23
Test the Drive Brakes
P ro p e r b ra ke a ctio n is e sse n tia l to sa fe m a ch in e
o p e ra tio n . T h e d rive b ra ke fu n ctio n sh o u ld o p e ra te
sm o o th ly, fre e o f h e sita tio n , je rkin g a n d u n u su a l
n o ise . H yd ro sta tic b ra ke s a n d h yd ra u lica lly-
re le a se d in d ivid u a l wh e e l b ra ke s ca n a p p e a r to
o p e ra te n o rm a lly wh e n th e y a re a ctu a lly n o t fu lly
o p e ra tio n a l.
B e su re th a t th e m a ch in e is n o t in
fre e -wh e e l o r p a rtia l fre e -wh e e l
co n fig u ra tio n . R e fe r to B -9 in th is
se ctio n , Confirm the Proper Brake
Configuration.
S e le ct a te st a re a th a t is firm , le ve l
a n d fre e o f o b stru ctio n s.
1 M a rk a te st lin e o n th e g ro u n d fo r re fe re n ce .
3 M o ve th e e n g in e id le co n tro l switch to
fo o t switch a ctiva te d h ig h id le (ra b b it a n d
fo o t switch ), th e n lo we r th e b o o m in to th e
sto we d p o sitio n .
4 C h o o se a p o in t o n th e m a ch in e ; i. e . , co n ta ct
p a tch o f a tire , a s a visu a l re fe re n ce fo r u se
wh e n cro ssin g th e te st lin e .
5 B rin g th e m a ch in e to to p d rive sp e e d b e fo re
re a ch in g th e te st lin e . R e le a se th e d rive jo ystick
wh e n yo u r re fe re n ce p o in t o n th e m a ch in e
cro sse s th e te st lin e .
6 M e a su re th e d ista n ce b e twe e n th e te st lin e a n d
yo u r m a ch in e re fe re n ce p o in t.
Braking:
paved surface 2WD 4WD
S to p p in g d ista n ce 3 to 5 ft 3 to 5 ft
0 . 9 to 1 . 5 m 0 . 9 to 1 . 5 m
T h e b ra ke s m u st b e a b le to h o ld
th e m a ch in e o n a n y slo p e it is a b le
to clim b .
B-24
Test the Drive Speed
- Stowed Position
P ro p e r d rive fu n ctio n m o ve m e n t is e sse n tia l to
sa fe m a ch in e o p e ra tio n . T h e d rive fu n ctio n sh o u ld
re sp o n d q u ickly a n d sm o o th ly to o p e ra to r co n tro l.
D rive p e rfo rm a n ce sh o u ld a lso b e fre e o f
h e sita tio n , je rkin g a n d u n u su a l n o ise o ve r th e
e n tire p ro p o rtio n a lly co n tro lle d sp e e d ra n g e .
S e le ct a te st a re a th a t is firm , le ve l
a n d fre e o f o b stru ctio n s.
1 C re a te sta rt a n d fin ish lin e s b y m a rkin g two
lin e s o n th e g ro u n d 4 0 fe e t (1 2 . 2 m ) a p a rt.
3 M o ve th e e n g in e id le co n tro l switch to
fo o t switch a ctiva te d h ig h id le (ra b b it a n d fo o t
switch ), th e n lo we r th e b o o m in to th e sto we d
p o sitio n .
4 C h o o se a p o in t o n th e m a ch in e ; i. e . , co n ta ct
p a tch o f a tire , a s a visu a l re fe re n ce fo r u se
wh e n cro ssin g th e sta rt a n d fin ish lin e s.
5 B rin g th e m a ch in e to to p d rive sp e e d b e fo re
re a ch in g th e sta rt lin e . B e g in tim in g wh e n yo u r
re fe re n ce p o in t o n th e m a ch in e cro sse s th e
sta rt lin e .
6 C o n tin u e a t fu ll sp e e d a n d n o te th e tim e wh e n
th e m a ch in e re fe re n ce p o in t cro sse s th e fin ish
lin e .
Drive speed:
stowed position 2WD 4WD
G a so lin e /L P G m o d e ls 4 0 ft/6 . 2 se c 4 0 ft/9 . 1 se c
1 2 . 2 m /6 . 2 se c 1 2 . 2 m /9 . 1 se c
D e u tz D ie se l m o d e ls 4 0 ft/6 . 8 se c 4 0 ft/9 . 1 se c
1 2 . 2 m /6 . 8 se c 1 2 . 2 m /9 . 1 se c
B-25
Test the Alarm Package
- Optional Equipment
T h e a la rm p a cka g e in clu d e s:
T ra ve l a la rm
D e sce n t a la rm
F la sh in g b e a co n
A la rm s a n d a b e a co n a re in sta lle d to a le rt
o p e ra to rs a n d g ro u n d p e rso n n e l o f m a ch in e
p ro xim ity a n d m o tio n . T h e a la rm p a cka g e is
in sta lle d o n th e tu rn ta b le co ve rs.
T h e a la rm s a n d b e a co n will
o p e ra te with th e e n g in e
ru n n in g o r n o t ru n n in g .
1 T u rn th e ke y switch to g ro u n d co n tro l a n d p u ll
co n tro ls.
R e su lt: T h e fla sh in g b e a co n sh o u ld b e o n a n d
fla sh in g .
2 M o ve th e fu n ctio n e n a b le to g g le switch to e ith e r
sid e a n d a ctiva te th e b o o m to g g le switch in th e
D O WN p o sitio n , h o ld fo r a m o m e n t a n d th e n
re le a se it.
R e su lt: T h e d e sce n t a la rm sh o u ld so u n d wh e n
th e switch is h e ld d o wn .
3 T u rn th e ke y switch to p la tfo rm co n tro l.
R e su lt: T h e fla sh in g b e a co n sh o u ld b e o n
a n d fla sh in g .
4 P re ss d o wn th e fo o t switch . M o ve th e b o o m
co n tro l h a n d le to th e D O WN p o sitio n , h o ld fo r a
m o m e n t a n d th e n re le a se it.
R e su lt: T h e d e sce n t a la rm sh o u ld so u n d wh e n
th e co n tro l h a n d le is h e ld d o wn .
5 P re ss d o wn th e fo o t switch . M o ve th e d rive
co n tro l h a n d le o ff ce n te r, h o ld fo r a m o m e n t
a n d th e n re le a se it. M o ve th e d rive co n tro l
h a n d le o ff ce n te r in th e o p p o site d ire ctio n , h o ld
fo r a m o m e n t a n d th e n re le a se it.
R e su lt: T h e tra ve l a la rm sh o u ld so u n d wh e n th e
d rive co n tro l h a n d le is m o ve d o ff ce n te r in
e ith e r d ire ctio n .
B-26
Perform Hydraulic Oil Analysis
S e e D -1 , Test or Replace the Hydraulic Oil.
B-27
Replace the Engine Oil and
Filter - Deutz Diesel Models
E n g in e sp e cifica tio n s re q u ire
th a t th is p ro ce d u re b e p e rfo rm e d
e ve ry 5 0 0 h o u rs. P e rfo rm th is
p ro ce d u re m o re o fte n if d u sty
co n d itio n s e xist.
P e rio d ic re p la ce m e n t o f th e e n g in e o il a n d
filte r is e sse n tia l to g o o d e n g in e p e rfo rm a n ce .
O p e ra tin g th e m a ch in e with a n im p ro p e r o il le ve l o r
n e g le ctin g p e rio d ic o il a n d filte r ch a n g e s ca n
d a m a g e e n g in e co m p o n e n ts. A fre q u e n t ch e ck
o f e la p se d m a ch in e h o u rs a g a in st th e h o u rs
n o te d o n th e o il filte r will a llo w th e in sp e cto r to
a n ticip a te a n d p e rfo rm o il a n d filte r ch a n g e s a t
th e 5 0 0 h o u r in te rva l.
P e rfo rm th is p ro ce d u re a fte r
wa rm in g th e e n g in e to n o rm a l
B e wa re o f h o t e n g in e p a rts a n d o il.
C o n ta ct with h o t e n g in e o il a n d /o r
e n g in e p a rts m a y ca u se se ve re
b u rn s.
1 R e m o ve th e o il fille r ca p lo ca te d a b o ve th e
d ip stick.
2 P u ll th e e n d o f th e d ra in h o se o u t fro m u n d e r
th e e n g in e .
3 R e m o ve th e p lu g fro m th e e n d o f th e d ra in h o se
a n d a llo w a ll o f th e o il fro m th e e n g in e to d ra in
in to a su ita b le co n ta in e r. S e e ca p a city
sp e cifica tio n s b e lo w.
4 I n sta ll th e p lu g in to th e d ra in h o se .
5 U se a n o il wre n ch a n d re m o ve th e o il filte r.
a e n g in e o il le ve l d ip stick
b fu e l filte r
c o il filte r
6 A p p ly a th in la ye r o f o il to th e n e w filte r g a ske t
(G e n ie p a rt n o . 4 9 9 2 4 ). T h e n in sta ll th e filte r
a n d tig h te n it se cu re ly b y h a n d .
th e o il filte r.
8 F ill th e e n g in e with n e w o il p e r sp e cifica tio n s
a n d in sta ll th e o il fille r ca p .
9 S ta rt th e e n g in e fro m th e g ro u n d co n tro ls. A llo w
th e e n g in e to ru n fo r 3 0 se co n d s th e n tu rn th e
e n g in e o ff.
1 0 C h e ck th e o il filte r a n d o il d ra in h o se fo r le a ks.
1 1 C h e ck th e e n g in e o il le ve l d ip stick. A d d o il if
n e e d e d .
Deutz Engine F4L 1011F 1 1 q u a rts
Oil capacity (including filter) 1 0 . 5 lite rs
Deutz Engine F4L 1011F Oil viscosity requirements
T e m p e ra tu re b e lo w 6 0 F / 1 5 . 5 C (syn th e tic) 5 W-3 0
-1 0 F to 9 0 F / -2 3 C to 3 2 C 1 0 W-4 0
T e m p e ra tu re a b o ve -4 F / -3 4 C 1 5 W-4 0
C C /S E , C D /S E , C C /S F o r C D /S F g ra d e s.
2 C le a n u p a n y fu e l th a t m a y h a ve sp ille d .
a
b
c
C-1
Check the Boom
Wear Pads
M a in ta in in g th e b o o m we a r p a d s in g o o d co n d itio n
is e sse n tia l to sa fe m a ch in e o p e ra tio n . We a r p a d s
a re p la ce d o n b o o m tu b e su rfa ce s to p ro vid e a lo w
frictio n , re p la ce a b le we a r p a d b e twe e n m o vin g
p a rts. I m p ro p e rly sh im m e d we a r p a d s o r co n tin u e d
u se o f wo rn o u t we a r p a d s m a y re su lt in
co m p o n e n t d a m a g e a n d u n sa fe o p e ra tin g
co n d itio n s.
I f th e we a r p a d s a re n o t wo rn
b e lo w sp e cifica tio n b u t a re still
with in sp e cifica tio n , se e R e p a ir
P ro ce d u re 4 -2 , How to Shim the
Boom.
2 R a ise th e e n d o f th e b o o m to a co m fo rta b le
wo rkin g h e ig h t (ch e st h ig h ), th e n e xte n d th e
b o o m 1 fo o t (3 0 cm ).
3 M e a su re e a ch we a r p a d . R e p la ce th e we a r p a d
if it is le ss th a n sp e cifica tio n . I f th e we a r p a d is
n o t le ss th a n sp e cifica tio n , sh im a s n e ce ssa ry
to o b ta in ze ro cle a ra n ce a n d ze ro d ra g .
4 E xte n d a n d re tra ct th e b o o m th ro u g h th e e n tire
ra n g e o f m o tio n to ch e ck fo r tig h t sp o ts th a t
m a y ca u se b in d in g o r scra p in g o f th e b o o m .
A lwa ys m a in ta in sq u a re n e ss
b e twe e n th e b o o m o u te r a n d in n e r
tu b e s.
Wear pad specifications
U p p e r we a r p a d s
9
/1 6 in ch 1 4 . 3 m m
B o tto m a n d sid e we a r p a d s
1 1
/1 6 in ch 1 7 . 5 m m
Table C Procedures
1
2
3
4
5
6
7
8
9
10
11
12
13
14 15
16
17
18
22
26
30
19
23
27
20
24
28
21
25
29
C-2
Check the Turntable Rotation
Bearing Bolts
M a in ta in in g p ro p e r to rq u e o n th e tu rn ta b le b e a rin g
b o lts is e sse n tia l to sa fe m a ch in e o p e ra tio n .
I m p ro p e r b o lt to rq u e co u ld re su lt in a n u n sa fe
o p e ra tin g co n d itio n a n d co m p o n e n t d a m a g e .
1 R a ise th e b o o m a n d p la ce a sa fe ty ch o ck o n
th e lift cylin d e r ro d . C a re fu lly lo we r th e b o o m
o n to th e lift cylin d e r sa fe ty ch o ck.
C ru sh in g h a za rd . K e e p h a n d s
a wa y fro m cylin d e r a n d a ll m o vin g
p a rts wh e n lo we rin g th e b o o m .
T h e lift cylin d e r sa fe ty ch o ck is
a va ila b le th ro u g h G e n ie
(p a rt n o . 3 3 4 8 4 ).
2 B e su re th a t e a ch tu rn ta b le m o u n tin g b o lt is
to rq u e d in se q u e n ce to 2 1 0 fo o t-p o u n d s
(2 8 5 N e wto n m e te rs).
B o lt to rq u e se q u e n ce
T A B L E C P R O C E D U R E S
1
15
7
12
4
17
5
14
9
2
16
8
11
3
18
6
13
10
d ise n g a g e p o sitio n
e n g a g e p o sitio n
d ise n g a g e p o sitio n
e n g a g e p o sitio n
3 L o we r th e b o o m to th e sto we d p o sitio n .
4 C h e ck to e n su re th a t e a ch b e a rin g m o u n tin g
b o lt u n d e r th e d rive ch a ssis is to rq u e d in
se q u e n ce to 2 1 0 fo o t-p o u n d s
(2 8 5 N e wto n m e te rs).
B o lt to rq u e se q u e n ce
C-3
Check the Free-wheel
Configuration
P ro p e r u se o f th e fre e -wh e e l co n fig u ra tio n is
e sse n tia l to sa fe m a ch in e o p e ra tio n . T h e
fre e -wh e e l co n fig u ra tio n is u se d p rim a rily fo r
to win g . A m a ch in e co n fig u re d to fre e -wh e e l with o u t
o p e ra to r kn o wle d g e m a y ca u se d e a th o r se rio u s
in ju ry a n d p ro p e rty d a m a g e .
C o llisio n h a za rd . S e le ct a wo rk
site th a t is firm a n d le ve l.
Non-steering wheels: All models
1 C h o ck th e ste e r wh e e ls to p re ve n t th e m a ch in e
fro m ro llin g .
2 C e n te r a liftin g ja ck o f a m p le ca p a city
(2 0 , 0 0 0 lb s/9 0 7 2 kg ) u n d e r th e d rive ch a ssis
b e twe e n th e n o n -ste e r tire s.
3 L ift th e wh e e ls o ff th e g ro u n d a n d th e n p la ce
ja ck sta n d s u n d e r th e d rive ch a ssis fo r su p p o rt.
4 D ise n g a g e th e to rq u e h u b s b y tu rn in g o ve r th e
to rq u e h u b d isco n n e ct ca p s o n e a ch
n o n -ste e rin g wh e e l h u b .
5 M a n u a lly ro ta te e a ch n o n -ste e rin g wh e e l.
R e su lt: E a ch n o n -ste e rin g wh e e l sh o u ld ro ta te
with m in im u m e ffo rt.
6 R e -e n g a g e th e to rq u e h u b s b y tu rn in g o ve r
th e h u b d isco n n e ct ca p s. R o ta te e a ch wh e e l to
ch e ck fo r e n g a g e m e n t. L ift th e m a ch in e a n d
re m o ve th e ja ck sta n d s.
C o llisio n h a za rd . F a ilu re to
re -e n g a g e th e to rq u e h u b s m a y
ca u se d e a th o r se rio u s in ju ry a n d
p ro p e rty d a m a g e .
Steer wheels: 4WD models
7 C h o ck th e n o n -ste e rin g wh e e ls to p re ve n t th e
m a ch in e fro m ro llin g .
8 C e n te r a liftin g ja ck o f a m p le ca p a city
(2 0 , 0 0 0 lb s/9 0 7 2 kg ) u n d e r th e d rive ch a ssis
b e twe e n th e n o n -ste e r tire s.
9 L ift th e wh e e ls o ff th e g ro u n d a n d th e n p la ce
ja ck sta n d s u n d e r th e d rive ch a ssis fo r su p p o rt.
1 0 D ise n g a g e th e to rq u e h u b s b y tu rn in g o ve r th e
to rq u e h u b d isco n n e ct ca p s o n e a ch
ste e r wh e e l h u b .
1 1 M a n u a lly ro ta te e a ch ste e r wh e e l.
R e su lt: E a ch ste e r wh e e l sh o u ld ro ta te with
m in im u m e ffo rt.
1 2 R e -e n g a g e th e to rq u e h u b s b y tu rn in g o ve r
th e h u b d isco n n e ct ca p s. R o ta te e a ch wh e e l to
ch e ck fo r e n g a g e m e n t. L ift th e m a ch in e a n d
re m o ve th e ja ck sta n d s.
C o llisio n h a za rd . F a ilu re to
re -e n g a g e th e to rq u e h u b s m a y
ca u se d e a th o r se rio u s in ju ry a n d
p ro p e rty d a m a g e .
All models:
1 3 B e su re th e fre e -wh e e l va lve o n th e d rive p u m p
is clo se d (clo ckwise ).
T h e fre e -wh e e l va lve is lo ca te d o n
th e b o tto m o f th e d rive p u m p .
a d rive p u m p
b fre e -wh e e l va lve
c lift p u m p
d scre wd rive r
T h e fre e -wh e e l va lve sh o u ld
a lwa ys re m a in clo se d .
C-4
Grease the Turntable Rotation
Bearing and Rotate Gear
Y e a rly a p p lica tio n o f lu b rica tio n to th e tu rn ta b le
b e a rin g a n d ro ta te g e a r is e sse n tia l to g o o d
m a ch in e p e rfo rm a n ce a n d se rvice life . C o n tin u e d
u se o f a n im p ro p e rly g re a se d b e a rin g a n d g e a r will
re su lt in co m p o n e n t d a m a g e .
1 L o ca te th e g re a se fittin g o n th e p la tfo rm e n d o f
th e ta n k sid e b u lkh e a d .
2 P u m p g re a se in to th e tu rn ta b le ro ta tio n b e a rin g .
R o ta te th e tu rn ta b le in in cre m e n ts
o f 4 to 5 in ch e s (1 0 to 1 3 cm ) a t a tim e a n d
re p e a t th is ste p u n til th e e n tire b e a rin g h a s
b e e n g re a se d .
3 A p p ly g re a se to e a ch to o th o f th e d rive g e a r,
lo ca te d u n d e r th e tu rn ta b le .
Grease type M u ltip u rp o se g re a se
C-5
Replace the Torque Hub Oil
R e p la cin g th e to rq u e h u b o il is e sse n tia l fo r g o o d
m a ch in e p e rfo rm a n ce a n d se rvice life . F a ilu re to
re p la ce th e to rq u e h u b o il a t ye a rly in te rva ls m a y
ca u se th e m a ch in e to p e rfo rm p o o rly a n d
Drive Torque Hubs:
1 S e le ct th e to rq u e h u b to b e se rvice d . T h e n d rive
th e m a ch in e u n til o n e o f th e two p lu g s is a t th e
lo we st p o in t.
2 R e m o ve b o th p lu g s a n d d ra in th e o il.
a
b
c
d
3 D rive th e m a ch in e u n til o n e p lu g is a t th e to p
a n d th e o th e r is a t 9 0 d e g re e s.
4 F ill th e h u b with o il fro m th e to p h o le u n til th e o il
le ve l is e ve n with th e b o tto m o f th e sid e h o le .
A p p ly p ip e th re a d se a la n t to th e p lu g s, a n d th e n
in sta ll th e p lu g s.
5 R e p e a t ste p s 1 th ro u g h 4 fo r a ll th e o th e r d rive
to rq u e h u b s.
Oil capacity per hub 4 4 fl o z
1 . 3 0 lite rs
T yp e : S A E 9 0 m u ltip u rp o se h yp o id g e a r o il - A P I
se rvice cla ssifica tio n G L 5
Turntable Rotate Torque Hub:
1 S e cu re th e tu rn ta b le fro m ro ta tin g with th e
tu rn ta b le ro ta tio n lo ck p in .
u n lo cke d lo cke d
2 R e m o ve th e m o to r/b ra ke m o u n tin g b o lts, a n d
th e n re m o ve th e m o to r a n d b ra ke fro m th e
to rq u e h u b a n d se t th e m to th e sid e .
C o m p o n e n t d a m a g e h a za rd .
H o se s ca n b e d a m a g e d if th e y a re
kin ke d o r p in ch e d .
a m o to r/b ra ke m o u n tin g b o lt
b m o to r
c to rq u e h u b
d to rq u e h u b m o u n tin g b o lt
e p lu g
f b ra ke
3 R e m o ve th e to rq u e h u b m o u n tin g b o lts, a n d
th e n u se a liftin g d e vice to re m o ve th e to rq u e
h u b fro m th e m a ch in e .
b
c
d
e
f
a
4 R e m o ve th e p lu g fro m th e sid e o f th e to rq u e
h u b . T h e n d ra in th e o il fro m th e h u b .
5 I n sta ll th e to rq u e h u b . T o rq u e th e h u b m o u n tin g
b o lts to 1 8 0 fo o t-p o u n d s (2 4 4 N e wto n m e te rs).
6 I n sta ll th e b ra ke a n d m o to r o n to th e to rq u e h u b .
7 F ill th e h u b with o il fro m th e sid e h o le u n til th e
o il le ve l is e ve n with th e b o tto m o f th e h o le .
8 A d ju st tu rn ta b le ro ta tio n g e a r b a ckla sh . S e e
R e p a ir P ro ce d u re 1 2 -1 , How to Adjust the
Turntable Rotation Gear Backlash.
Turntable rotate torque hub
O il ca p a city 1 7 flu id o u n ce s
0 . 5 1 lite rs
C-6
Replace the Hydraulic Tank Filter
R e p la ce m e n t o f th e h yd ra u lic ta n k filte r is
e sse n tia l fo r g o o d m a ch in e p e rfo rm a n ce a n d
se rvice life . A d irty o r clo g g e d filte r m a y ca u se th e
m a ch in e to p e rfo rm p o o rly a n d co n tin u e d u se m a y
ca u se co m p o n e n t d a m a g e . E xtre m e ly d irty
co n d itio n s m a y re q u ire th a t th e filte r b e re p la ce d
m o re o fte n .
B e wa re o f h o t o il. C o n ta ct with
h o t o il m a y ca u se se ve re b u rn s.
e n g in e o ff.
1 R e m o ve th e filte r with a n o il filte r wre n ch .
2 A p p ly a th in la ye r o f o il to th e n e w o il filte r
g a ske t.
3 I n sta ll th e n e w filte r (G e n ie p a rt n o . 4 6 0 1 4 ) a n d
tig h te n it se cu re ly b y h a n d . C le a n u p a n y o il
th a t m a y h a ve sp ille d d u rin g th e in sta lla tio n
p ro ce d u re .
th e o il filte r.
6 I n sp e ct th e filte r a n d re la te d co m p o n e n ts to
b e su re th a t th e re a re n o le a ks.
C-7
Replace the Drive Loop
Hydraulic Filter
R e p la cin g th e d rive lo o p h yd ra u lic filte r is e sse n tia l
to g o o d m a ch in e p e rfo rm a n ce a n d se rvice life . A
d irty o r clo g g e d filte r m a y ca u se th e m a ch in e to
p e rfo rm p o o rly a n d co n tin u e d u se m a y ca u se
co m p o n e n t d a m a g e . E xtre m e ly d irty co n d itio n s
m a y re q u ire th a t th e filte r b e re p la ce d m o re o fte n .
B e wa re o f h o t o il. C o n ta ct with
h o t o il m a y ca u se se ve re b u rn s.
e n g in e o ff.
1 O p e n th e e n g in e sid e tu rn ta b le co ve r a n d lo ca te
th e d rive lo o p h yd ra u lic filte r m o u n te d o n th e
e n g in e n e a r th e m a in p u m p .
2 R e m o ve th e filte r h o u sin g b y u sin g a wre n ch o n
th e n u t p ro vid e d o n th e b o tto m o f th e h o u sin g .
3 R e m o ve th e filte r e le m e n t fro m th e h o u sin g .
4 I n sp e ct th e h o u sin g se a l a n d re p la ce it if
n e ce ssa ry.
5 I n sta ll th e n e w filte r (G e n ie p a rt n o . 2 0 8 8 0 ) a n d
h a n d tig h te n th e h o u sin g o n to th e filte r h e a d .
C le a n u p a n y o il th a t m a y h a ve sp ille d d u rin g
th e in sta lla tio n p ro ce d u re .
7 I n sp e ct th e filte r a sse m b ly to b e su re th a t th e re
a re n o le a ks.
8 C le a n u p a n y o il th a t m a y h a ve sp ille d .
a
b
C-8
Replace the Diesel Fuel
Filter/Water Separator - Deutz
Diesel Models
R e p la cin g th e d ie se l fu e l filte r is e sse n tia l to g o o d
e n g in e p e rfo rm a n ce a n d se rvice life . A d irty o r
clo g g e d filte r m a y ca u se th e e n g in e to p e rfo rm
p o o rly a n d co n tin u e d u se m a y ca u se co m p o n e n t
d a m a g e . E xtre m e ly d irty co n d itio n s m a y re q u ire
th a t th e filte r b e re p la ce d m o re o fte n .
R e p la ce th e fu e l filte r in a n o p e n ,
e a sy re a ch .
e n g in e o ff.
1 T u rn th e m a n u a l fu e l sh u to ff va lve , lo ca te d a t
th e fu e l ta n k, to th e C L O S E D p o sitio n .
2 R e m o ve th e fu e l filte r with a filte r wre n ch .
a o il filte r
b fu e l filte r/wa te r se p a ra to r
3 F ill th e n e w filte r (G e n ie p a rt n o . 2 9 5 6 0 ) with
fre sh d ie se l fu e l a n d a p p ly a th in la ye r o f o il o r
d ie se l fu e l to th e n e w fu e l filte r g a ske t.
4 I n sta ll th e n e w filte r a n d tig h te n it se cu re ly b y
h a n d . C le a n u p a n y d ie se l fu e l th a t m ig h t h a ve
sp ille d d u rin g th e p ro ce d u re .
5 T u rn th e m a n u a l fu e l sh u to ff va lve , lo ca te d a t
th e fu e l ta n k, to th e O P E N p o sitio n .
6 S ta rt th e e n g in e fro m th e g ro u n d co n tro ls, th e n
in sp e ct th e fu e l filte r fo r le a ks.
o p e ra te th e m a ch in e . R e p a ir
th e le a k im m e d ia te ly.
C-9
Replace the Gasoline Fuel
Filter - Gasoline/LPG Models
R e p la cin g th e g a so lin e fu e l filte r is e sse n tia l to
g o o d e n g in e p e rfo rm a n ce a n d se rvice life . A d irty
o r clo g g e d filte r m a y ca u se th e e n g in e to p e rfo rm
p o o rly a n d co n tin u e d u se m a y ca u se co m p o n e n t
d a m a g e . E xtre m e ly d irty co n d itio n s m a y re q u ire
th a t th e filte r b e re p la ce d m o re o fte n .
R e p la ce th e fu e l filte r in a n o p e n ,
e a sy re a ch .
e n g in e o ff.
1 R e m o ve th e 2 b o lts fro m u n d e r th e e n g in e p ivo t
p la te . S win g th e e n g in e p ivo t p la te a wa y fro m
th e m a ch in e to a cce ss th e fu e l filte r, lo ca te d
n e a r th e ca rb u re to r.
a p ivo t p la te re ta in in g b o lts
b e n g in e p ivo t p la te
2 D isco n n e ct th e fu e l h o se fro m th e filte r, th e n
re m o ve th e filte r fro m th e fittin g .
a fu e l filte r
b h o se fro m th e fu e l p u m p to
th e fu e l filte r
3 I n sta ll th e n e w fu e l filte r (G e n ie p a rt n o . 3 3 9 7 1 )
in to th e fittin g o n th e ca rb u re to r.
4 C o n n e ct th e fu e l h o se to th e filte r.
5 C le a n u p a n y fu e l th a t m a y h a ve sp ille d d u rin g
th e in sta lla tio n p ro ce d u re .
6 S ta rt th e m a ch in e fro m th e g ro u n d co n tro ls,
th e n in sp e ct th e fu e l filte r a n d h o se fo r le a ks.
7 S win g th e e n g in e p ivo t p la te b a ck to its o rig in a l
p o sitio n a n d re p la ce th e two re ta in in g b o lts.
a b
b a a
C-10
Replace the PCV Valve
Y e a rly re p la ce m e n t o f th e P C V va lve is e sse n tia l to
g o o d e n g in e p e rfo rm a n ce . A m a lfu n ctio n in g P C V
va lve ca n im p a ir cra n kca se ve n tila tio n a n d m a y
ca u se e n g in e d a m a g e .
e n g in e o ff.
a cce ss th e P C V va lve .
2 R e m o ve th e h o se fro m th e P C V va lve , th e n
re m o ve th e va lve .
a P C V va lve
3 I n sta ll th e n e w P C V va lve . C o n n e ct th e h o se s.
4 S win g th e e n g in e p ivo t p la te b a ck to its o rig in a l
p o sitio n a n d re p la ce th e two re ta in in g b o lts.
b a a
a
C-11
Replace the Spark Plugs
P e rio d ic re p la ce m e n t o f th e sp a rk p lu g s is
e sse n tia l to g o o d e n g in e p e rfo rm a n ce a n d
se rvice life . Wo rn , lo o se o r co rro d e d sp a rk p lu g s
will ca u se th e e n g in e to p e rfo rm p o o rly a n d m a y
re su lt in co m p o n e n t d a m a g e .
e n g in e o ff.
1 L a b e l, th e n d isco n n e ct th e p lu g wire s fro m th e
sp a rk p lu g s b y g ra sp in g th e m o ld e d b o o t. D o
n o t p u ll o n th e p lu g wire .
2 B lo w o u t a n y d e b ris a ro u n d sp a rk p lu g s.
3 R e m o ve a ll th e sp a rk p lu g s fro m th e e n g in e .
4 A d ju st th e g a p o n e a ch n e w sp a rk p lu g .
5 I n sta ll th e n e w sp a rk p lu g s, th e n co n n e ct th e
wire s. B e su re th a t e a ch sp a rk p lu g wire is
a tta ch e d to th e co rre ct sp a rk p lu g .
Spark plug specifications
S p a rk p lu g typ e M o to rcra ft A WS F -5 2 C
S p a rk p lu g g a p 0 . 0 4 2 to 0 . 0 4 6 in ch e s
1 . 0 7 to 1 . 1 8 m m
S p a rk p lu g to rq u e 5 to 1 0 fo o t-p o u n d s
7 to 1 4 N m
C-12
Check and Adjust the Air/LPG
Mixture - Gasoline/LPG Models
M a in ta in in g th e p ro p e r a ir-to -fu e l m ixtu re d u rin g
L P G o p e ra tio n is e sse n tia l to g o o d e n g in e
p e rfo rm a n ce .
P e rfo rm th is p ro ce d u re in a n o p e n ,
e a sy re a ch .
T h e e n g in e rp m n e e d s to b e
p re se t fo r g a so lin e fu e l o p e ra tio n
b e fo re a d ju stin g th e L P G id le
m ixtu re . R e fe r to B -1 2 , Check and
Adjust the Engine RPM.
T h e e n g in e sh o u ld b e wa rm e d to
n o rm a l o p e ra tin g te m p e ra tu re
b e fo re p e rfo rm in g th is p ro ce d u re .
1 M o ve th e fu e l se le ct switch to L P G fu e l a n d
sta rt th e e n g in e fro m th e g ro u n d co n tro ls.
2 L o o se n th e h ig h id le m ixtu re a d ju stm e n t
lo ck n u t.
a h ig h id le m ixtu re
a d ju stm e n t scre w
a
a
3 L o a d th e syste m b y a ctiva tin g th e b o o m re tra ct
fu n ctio n , th e n m o ve th e fu n ctio n e n a b le to g g le
switch to th e h ig h id le (ra b b it sym b o l) p o sitio n .
4 A d ju st th e h ig h id le a d ju stm e n t scre w to o b ta in
a n a ir-to -fu e l m ixtu re ra tio o f 1 3 . 0 : 1 to 1 3 . 2 : 1 ,
u sin g a n e xh a u st g a s a n a lyze r.
P re lim in a ry se ttin g is
1
/4 in ch o f
th re a d s sh o win g . M e a su re fro m
to p o f lo ck n u t to to p o f a d ju stm e n t
scre w.
I f a n e xh a u st g a s a n a lyze r is n o t
a va ila b le , a d ju st to o b ta in p e a k o r
o p tim u m rp m .
5 H o ld th e a d ju stm e n t scre w a n d tig h te n th e
lo ck n u t.
(tu rtle sym b o l) a n d a d ju st th e lo w id le scre w to
o b ta in a n a ir-to -fu e l m ixtu re ra tio
o f 1 3 . 0 : 1 to 1 3 . 2 : 1 .
a lo w id le m ixtu re a d ju stm e n t scre w
P re lim in a ry se ttin g : tu rn lo w id le
a d ju stm e n t scre w clo ckwise a ll th e
wa y in . T u rn lo w id le a d ju stm e n t
scre w co u n te rclo ckwise 2
3
/4
tu rn s.
C-13
Check and Adjust the Ignition
Timing - Gasoline/LPG Models
C-14
Check the Engine Valve
Clearances - Deutz Diesel Models
C o m p le te in fo rm a tio n to p e rfo rm th is p ro ce d u re
is a va ila b le in th e Deutz FL 1011F Workshop
Manual (D e u tz N u m b e r 0 2 9 7 7 1 9 5 ).
G e n ie p a rt n u m b e r 5 2 2 2 9 .
C-15
Check the Turntable Rotation
Gear Backlash
T h e tu rn ta b le ro ta tio n to rq u e h u b is m o u n te d o n a n
a d ju sta b le p la te th a t co n tro ls th e g a p b e twe e n th e
ro ta tio n m o to r g e a r a n d th e tu rn ta b le b e a rin g .
M a in ta in in g p ro p e r b a ckla sh o f th e tu rn ta b le
b e a rin g is e sse n tia l to sa fe m a ch in e o p e ra tio n .
I m p ro p e r b a ckla sh co u ld re su lt in a n u n sa fe
o p e ra tin g co n d itio n a n d co m p o n e n t d a m a g e .
S e e 1 2 -1 , How to Adjust the
D-2
Change or Recondition the
Engine Coolant
R e p la cin g o r re co n d itio n in g th e e n g in e co o la n t is
e sse n tia l to g o o d e n g in e p e rfo rm a n ce a n d se rvice
life . O ld o r d irty co o la n t m a y ca u se th e e n g in e to
p e rfo rm p o o rly a n d co n tin u e d u se m a y ca u se
e n g in e d a m a g e . E xtre m e ly d irty co n d itio n s m a y
re q u ire co o la n t to b e ch a n g e d m o re fre q u e n tly.
B e wa re o f h o t e n g in e p a rts a n d
co o la n t. C o n ta ct with h o t e n g in e
p a rts a n d /o r co o la n t will ca u se
se ve re b u rn s.
e n g in e o ff a n d co o le d .
1 P u t o n p ro te ctive clo th in g a n d e ye we a r.
2 D isco n n e ct th e co o la n t re tu rn h o se a t th e
ra d ia to r a n d d ra in th e co o la n t re tu rn ta n k in to a
su ita b le co n ta in e r.
3 S lo wly re m o ve th e ra d ia to r ca p fro m th e
ra d ia to r.
B o d ily in ju ry h a za rd . A llo w a n y
p re ssu re to d issip a te g ra d u a lly
b e fo re re m o vin g th e ra d ia to r ca p .
D-1
Test or Replace the Hydraulic Oil
R e p la ce m e n t o r te stin g o f th e h yd ra u lic o il is
e sse n tia l fo r g o o d m a ch in e p e rfo rm a n ce a n d
se rvice life . D irty o il a n d su ctio n stra in e rs m a y
ca u se th e m a ch in e to p e rfo rm p o o rly a n d
E xtre m e ly d irty co n d itio n s m a y re q u ire o il ch a n g e s
to b e p e rfo rm e d m o re o fte n .
T h e m a ch in e u se s D e xro n
e q u iva le n t h yd ra u lic o il. B e fo re
re p la cin g th e h yd ra u lic o il, th e o il
m a y b e te ste d b y a n o il d istrib u to r
fo r sp e cific le ve ls o f co n ta m in a tio n
to ve rify th a t ch a n g in g th e o il is
n e ce ssa ry. If the hydraulic oil is
not replaced at the two year
inspection, test the oil quarterly.
Replace the oil when it fails the
test.
b o o m in th e sto we d p o sitio n .
1 R e m o ve th e h yd ra u lic ta n k. S e e R e p a ir
P ro ce d u re 1 1 -2 , How to Remove the Hydraulic
Tank.
T h e p u m p n e e d s to p rim e d b e fo re
sta rtin g th e e n g in e . S e e R e p a ir
P ro ce d u re 1 1 -2 , How to Remove
the Hydraulic Tank.
C o m p o n e n t d a m a g e h a za rd . B e
su re th a t th e h yd ra u lic ta n k sh u to ff
va lve s a re in th e O P E N p o sitio n
b e fo re p rim in g th e p u m p . T h e
e n g in e m u st n o t b e sta rte d with
th e h yd ra u lic ta n k sh u to ff va lve s in
th e C L O S E D p o sitio n o r co m p o n e n t
d a m a g e will o ccu r. I f th e ta n k
va lve s a re clo se d , re m o ve th e ke y
fro m th e ke y switch a n d ta g th e
m a ch in e to in fo rm p e rso n n e l o f th e
co n d itio n .
Table D Procedures
a cce ss th e ra d ia to r d ra in va lve .
5 O p e n th e d ra in va lve o n th e ra d ia to r a n d a llo w
a ll th e co o la n t to d ra in in to a su ita b le co n ta in e r.
6 A fte r a ll th e co o la n t h a s d ra in e d , clo se th e d ra in
va lve . C o n n e ct th e co o la n t re tu rn h o se to
th e ra d ia to r.
7 O p e n th e d ra in va lve o n th e e n g in e b lo ck a n d
a llo w th e co o la n t to d ra in in to a co n ta in e r.
A fte r th e flu id is d ra in e d , clo se th e d ra in va lve .
8 R e p la ce a ll co o la n t h o se s a n d cla m p s.
9 P o u r th e p ro p e r co o la n t m ixtu re (a n ti-fre e ze a n d
wa te r) fo r yo u r clim a te in to th e ra d ia to r u n til it is
fu ll.
T A B L E D P R O C E D U R E S
1 0 D isco n n e ct th e h o se co u p le r a t th e fa n e n d fro m
th e tu b e th a t is co n n e cte d to th e wa te r p u m p
a n d h o ld it u n til co o la n t sta rts to co m e o u t o f th e
o p e n h o se . T h e n im m e d ia te ly re co n n e ct th e
h o se .
a tu b e co n n e cte d to wa te r p u m p
b h o se co u p le r
1 1 F ill th e ra d ia to r a n d th e n fill th e co o la n t re co ve ry
ta n k to th e N O R M A L ra n g e .
1 2 C le a n u p a n y co o la n t sp ille d d u rin g th is
p ro ce d u re .
1 3 S ta rt th e e n g in e fro m th e g ro u n d co n tro ls,
ru n it fo r 3 0 se co n d s, a n d th e n tu rn it o ff.
1 4 I n sp e ct fo r le a ks a n d th e n ch e ck th e flu id
le ve l in th e co o la n t re co ve ry ta n k. A d d
wa te r if n e e d e d .
1 5 S ta rt th e e n g in e fro m th e g ro u n d co n tro ls
a n d ru n it u n til re a ch in g n o rm a l o p e ra tin g
te m p e ra tu re .
1 6 A llo w e n g in e to co o l a n d ch e ck th e flu id le ve l in
th e co o la n t re co ve ry ta n k. A d d wa te r if n e e d e d .
Ford Engine 1 1 . 5 q u a rts
Coolant capacity 1 0 . 9 lite rs
a
b
b a a
D-3
Change the Fuel Lines
M a in ta in in g th e fu e l lin e s in g o o d co n d itio n is
e sse n tia l to sa fe o p e ra tio n a n d g o o d e n g in e
p e rfo rm a n ce . F a ilu re to d e te ct a wo rn , cra cke d o r
le a kin g fu e l lin e m a y ca u se a n u n sa fe o p e ra tin g
co n d itio n .
R e p la ce th e fu e l lin e s in a n o p e n ,
e a sy re a ch .
e n g in e o ff.
1 C lo se th e m a n u a l fu e l sh u to ff va lve , lo ca te d
n e xt to th e fu e l ta n k.
2 R e m o ve a n d re p la ce th e fu e l lin e h o se s a n d
cla m p s a cco rd in g to th e fo llo win g illu stra tio n s:
F u e l m a y b e e xp e lle d u n d e r
p re ssu re . Wra p a clo th a ro u n d fu e l
h o se s to a b so rb le a kin g fu e l
b e fo re d isco n n e ctin g th e m .
Deutz Diesel models
a h o se fro m th e in je cto r to
th e fu e l ta n k
b h o se s co n n e ctin g in je cto rs
c h o se fro m th e fu e l sh u to ff va lve
to th e fu e l p u m p
d h o se fro m th e fu e l p u m p to
th e fu e l filte r
e h o se fro m th e fu e l filte r to th e
in je ctio n p u m p
f h o se fro m th e in je ctio n p u m p
to th e in je cto rs
b b b b b b
e d c f
b a
Gasoline/LPG
a ca rb u re to r
b fu e l filte r
c h o se fro m th e fu e l filte r to
th e fu e l p u m p
d h o se fro m th e fu e l p u m p
to th e fu e l ta n k (n o t sh o wn )
3 C le a n u p a n y fu e l th a t m a y h a ve sp ille d d u rin g
th is p ro ce d u re .
4 S ta rt th e e n g in e fro m th e g ro u n d co n tro ls, th e n
in sp e ct th e fu e l filte r a n d h o se s fo r le a ks.
D-4
Check the Engine Valve
Clearance - Gasoline/LPG Models
D-5
Check the Engine Cylinder
Compression
D-6
Clean the PCV Hoses and
Fittings - Gasoline/LPG Models
M a in ta in in g P C V h o se s is e sse n tia l to g o o d e n g in e
p e rfo rm a n ce . I m p ro p e rly fu n ctio n in g P C V h o se s
will fa il to ve n tila te th e cra n kca se a n d co n tin u e d
u se o f n e g le cte d h o se s co u ld re su lt in co m p o n e n t
d a m a g e .
e n g in e o ff.
a b c
d
a cce ss th e P C V h o se s.
2 D isco n n e ct th e h o se fro m th e P C V va lve , th e n
d isco n n e ct th e h o se fro m th e e n g in e .
a ca rb u re to r to va lve co ve r h o se
b P C V va lve
c P C V va lve to ca rb u re to r h o se
3 D isco n n e ct th e h o se fro m th e ca rb u re to r, th e n
d isco n n e ct th e h o se fro m th e va lve co ve r.
4 C le a n th e h o se s with a m ild cle a n in g so lve n t.
b a a
5 D ry b o th h o se s a n d in sp e ct th e m fo r cra cks a n d
d a m a g e . R e p la ce th e h o se s if th e y a re
d a m a g e d .
D-7
Check the Fuel Injection Pump
and Injectors - Deutz Diesel
Models
a va ila b le in th e Deutz FL 1011F Workshop Manual
(D e u tz n u m b e r: 0 2 9 7 7 1 9 5 ).
D-8
Check the Toothed Belt
- Deutz Diesel Models
a va ila b le in th e Deutz FL 1011 Operation Manual
(D e u tz n u m b e r: 0 2 9 7 4 7 0 6 E N ).
D-9
Replace the Timing Belt
c
b
a
D-10
Grease the Steer Axle
Wheel Bearings - 2WD Models
M a in ta in in g th e ste e r a xle wh e e l b e a rin g s is
e sse n tia l fo r sa fe m a ch in e o p e ra tio n a n d se rvice
life . O p e ra tin g th e m a ch in e with lo o se o r wo rn
wh e e l b e a rin g s m a y ca u se a n u n sa fe o p e ra tin g
co n d itio n a n d co n tin u e d u se m a y re su lt in
co m p o n e n t d a m a g e . E xtre m e ly we t o r d irty
co n d itio n s o r re g u la r ste a m cle a n in g a n d p re ssu re
wa sh in g o f th e m a ch in e m a y re q u ire th a t th is
p ro ce d u re b e p e rfo rm e d m o re o fte n .
1 L o o se n th e wh e e l lu g n u ts. D o n o t re m o ve
th e m .
2 B lo ck th e n o n -ste e rin g wh e e ls, th e n ce n te r a
liftin g ja ck u n d e r th e ste e r a xle .
3 R a ise th e m a ch in e 6 in ch e s (1 5 cm ) a n d p la ce
b lo cks u n d e r th e d rive ch a ssis fo r su p p o rt.
4 R e m o ve th e lu g n u ts, th e n re m o ve th e tire a n d
wh e e l a sse m b ly.
5 C h e ck fo r wh e e l b e a rin g we a r b y a tte m p tin g to
m o ve th e wh e e l h u b sid e to sid e , th e n u p a n d
d o wn .
R e su lt: T h e re sh o u ld n o t b e a n y sid e to sid e o r
u p a n d d o wn m o ve m e n t.
Skip to step 10 if there is no movement.
6 R e m o ve th e d u st ca p fro m th e h u b , th e n
re m o ve th e co tte r p in fro m th e ca stle n u t.
7 T ig h te n th e ca stle n u t to 3 5 fo o t-p o u n d s
(4 7 N m ) to se a t th e b e a rin g s.
8 L o o se n th e ca stle n u t, th e n re -tig h te n to
8 fo o t-p o u n d s (1 1 N m ).
9 C h e ck fo r wh e e l b e a rin g we a r b y a tte m p tin g to
m o ve th e wh e e l h u b sid e to sid e , th e n u p a n d
d o wn .
R e su lt: I f th e re is sid e to sid e o r u p a n d d o wn
m o ve m e n t, p ro ce e d to ste p 1 0 to re p la ce th e
wh e e l b e a rin g s with n e w o n e s.
Wh e n re p la cin g a wh e e l b e a rin g ,
b o th th e in n e r a n d o u te r b e a rin g s,
in clu d in g th e p re sse d -in ra ce s,
m u st b e re p la ce d .
R e su lt: I f th e re is n o sid e to sid e o r u p a n d
d o wn m o ve m e n t, g re a se th e wh e e l b e a rin g s.
1 0 R e m o ve th e ca stle n u t.
1 1 P u ll th e h u b o ff o f th e sp in d le . T h e wa sh e r a n d
o u te r b e a rin g sh o u ld fa ll lo o se fro m th e h u b .
1 2 P la ce th e h u b o n a fla t su rfa ce a n d g e n tly p ry
th e b e a rin g se a l o u t o f th e h u b . R e m o ve th e
re a r b e a rin g .
1 3 P a ck b o th b e a rin g s with cle a n , fre sh g re a se .
1 4 P la ce th e la rg e in n e r b e a rin g in to th e re a r o f th e
h u b .
1 5 I n sta ll a n e w b e a rin g g re a se se a l in to th e h u b
b y p re ssin g it e ve n ly in to th e h u b u n til it is flu sh .
A lwa ys re p la ce th e b e a rin g g re a se
se a l wh e n re m o vin g th e h u b .
1 6 S lid e th e h u b o n to th e yo ke sp in d le .
C o m p o n e n t d a m a g e . D o n o t
a p p ly e xce ssive fo rce o r d a m a g e
to th e lip o f th e se a l m a y o ccu r.
1 7 P la ce th e o u te r b e a rin g in to th e h u b .
1 8 I n sta ll th e wa sh e r a n d slo tte d n u t.
1 9 T ig h te n th e slo tte d n u t to 3 5 fo o t-p o u n d s
(4 7 N m ) to se a t th e b e a rin g s.
2 0 L o o se n th e slo tte d n u t, th e n re -tig h te n to
8 fo o t-p o u n d s (1 1 N m ).
2 1 I n sta ll a n e w co tte r p in . B e n d th e co tte r p in
to lo ck it in .
2 2 I n sta ll th e d u st ca p , th e n th e tire a n d wh e e l
a sse m b ly. T o rq u e th e wh e e l lu g n u ts to
4 2 0 fo o t-p o u n d s (5 6 9 . 5 N m ).
S e rvice M a n u a l - S e co n d E d itio n S e ctio n 5 - T ro u b le sh o o tin g F lo w C h a rts
Before Troubleshooting:
R e a d , u n d e rsta n d a n d o b e y th e sa fe ty ru le s
a n d o p e ra tin g in stru ctio n s p rin te d in th e
Genie S-60 & Genie S-65 Operators Manual.
B e su re th a t a ll n e ce ssa ry to o ls a n d te st
e q u ip m e n t a re a va ila b le a n d re a d y fo r u se .
R e a d e a ch a p p ro p ia te flo w ch a rt th o ro u g h ly.
A tte m p tin g sh o rtcu ts m a y p ro d u ce h a za rd o u s
co n d itio n s.
B e a wa re o f th e fo llo win g h a za rd s a n d fo llo w
g e n e ra lly a cce p te d sa fe wo rksh o p p ra ctice s.
C ru sh in g h a za rd . Wh e n te stin g
o r re p la cin g a n y h yd ra u lic
co m p o n e n t, a lwa ys su p p o rt
th e stru ctu re a n d se cu re it
fro m m o ve m e n t.
E le ctro cu tio n h a za rd . C o n ta ct
with e le ctrica lly ch a rg e d circu its
m a y re su lt in d e a th o r se rio u s
in ju ry. R e m o ve a ll rin g s, wa tch e s
a n d o th e r je we lry.
B o d ily in ju ry h a za rd . S p ra yin g
h yd ra u lic o il ca n p e n e tra te a n d
b u rn skin . L o o se n h yd ra u lic
co n n e ctio n s ve ry slo wly to a llo w
th e o il p re ssu re to d issip a te
g ra d u a lly. D o n o t a llo w o il to
sq u irt o r sp ra y.
P e rfo rm a ll tro u b le sh o o tin g o n a
firm le ve l su rfa ce .
T wo p e rso n s will b e re q u ire d to
sa fe ly p e rfo rm so m e
tro u b le sh o o tin g p ro ce d u re s.
Troubleshooting Flow Charts
Observe and Obey:
T ro u b le sh o o tin g a n d re p a ir p ro ce d u re s sh a ll b e
co m p le te d b y a p e rso n tra in e d a n d q u a lifie d o n
th e re p a ir o f th is m a ch in e .
b e fo re o p e ra tin g th e m a ch in e .
re p a ir p ro ce d u re with th e m a ch in e in th e
M a ch in e p a rke d o n a fla t le ve l su rfa ce
ke y re m o ve d
General Repair Process
T R O U B L E S H O O T I N G F L O W C H A R T S
About This Section
Wh e n a m a lfu n ctio n is d isco ve re d , th e flo w ch a rts
in th is se ctio n will h e lp a se rvice p ro fe ssio n a l
p in p o in t th e ca u se o f th e p ro b le m . T o u se th is
se ctio n , b a sic h a n d to o ls a n d ce rta in p ie ce s o f te st
e q u ip m e n t a re re q u ire d vo ltm e te r, o h m m e te r,
p re ssu re g a u g e s.
T h e lo ca tio n o f te rm in a ls m e n tio n e d in th is se ctio n
ca n b e fo u n d o n th e a p p ro p ria te e le ctrica l o r
h yd ra u lic sch e m a tics p ro vid e d in S e ctio n 6 ,
Schematics.
S in ce va rio u s d e g re e s o f a p a rticu la r fu n ctio n
lo ss m a y o ccu r, se le ctin g th e a p p ro p ria te flo w
ch a rt m a y b e tro u b le so m e . Wh e n a fu n ctio n will n o t
o p e ra te with th e sa m e sp e e d o r p o we r a s a
m a ch in e in g o o d wo rkin g co n d itio n , re fe r to th e
flo w ch a rt wh ich m o st clo se ly d e scrib e s th e
p ro b le m .
Malfunction
discovered
Identify
symptoms
Troubleshoot
Perform
repair
Return to
service
problem
solved
problem
still exists
Inspect
and test
Engine Will Not
Crank Over
B e su re th e ke y switch
is in th e a p p ro p ria te
p o sitio n .
B e su re th a t b o th
E m e rg e n cy S to p
b u tto n s a re p u lle d o u t to
th e O N p o sitio n .
B e su re th e circu it
b re a ke rs a re n o t
trip p e d .
B e su re th e b a tte ry is
fu lly ch a rg e d .
Chart 1
Check battery voltage.
Check battery condition
OR check alternator
OR check battery cables
OR replace the battery.
less than
12V
12V or more
0V
Trace circuit back
through the key switch,
emergency stop button
and CB2, repair open.
12V
Hold the start toggle
switch to either side and
check the voltage at
either side terminal on
start switch.
0V
Repair open in jumper
wire fromone side of the
switch to the other OR
replace start toggle
switch TS11.
12V
Hold the start switch to
either side and check
voltage at terminal
TB33.
0V
Repair blk wire circuit
fromstart switch TS11
to TB33.
12V
voltage at terminal #3 on
ignition/start module.
0V
Repair blk wire circuit
fromTB33 to terminal
#3 on ignition/start
module.
Continued on the next
page.
12V
the ignition/start module.
0V
Repair open in red
power supply wire circuit
fromCB1 to CR1 to CR2
then to terminal #6 to
on ignition/start module.
12V
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 TS11.
C H A R T 1
Continued fromthe
previous page.
voltage at the black wire
on the starter solenoid.
0V
Repair open in blk wire
circuit fromCR1 to
starter solenoid.
12V
Repair or replace starter
or starter solenoid.
Check voltage at
terminal #30 on CR1.
0V Repair open in red wire
circuit frombattery to
CB1 to CR1 terminal
#30.
12V
voltage at terminal #87
on CR1.
0V
Replace CR1 relay.
12V
on CR1.
0V
fromterminal #1 on
ignition/start module to
CR1.
12V
Check brown ground
wire to terminal #85 on
CR1.
good
bad
Repair open in brown
ground wire circuit to
CR1.
12V
0V
Check ground wire to
terminal #5 on start
lockout module.
bad Repair open in ground
wire.
good
Consult Genie Industries
Service Department.
Check voltage at starter
cable.
Repair open in battery
cable to starter.
0V
12V
Chart 2
Engine Cranks
Over But Will
Not Start -
Gasoline/LPG
Models
B e su re to ch e ck th e
e n g in e o il le ve l a n d fill
a s n e e d e d .
B e su re to ch e ck fu e l
le ve ls a n d e n g in e
co o la n t le ve l.
B e su re th e g a so lin e
sh u t-o ff va lve is in th e
O N o r O P E N p o sitio n .
B e su re th a t a u to m a tic
ch o ke is n o t stickin g
clo se d .
P e rfo rm fo llo win g te sts
in g a so lin e m o d e o n ly.
B e su re th a t th e wa te r
te m p e ra tu re g a u g e
d o e s n o t sh o w a n
o ve rh e a te d co n d itio n .
With the keyswitch
turned to ground
controls and both
pulled out to the on
position, hold start
check battery voltage
while engine is cranking.
less
than
11V
OR check alternator OR
check for short circuits
more than 11V
Check if engine coolant
temperature sending
unit signal post has
continuity to ground.
continuity
Check if radiator and/or
engine block feels
excessively hot.
hot
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. not hot
Remove wht wire from
temperature sending
unit, check continuity to
ground on temperature
sending unit.
continuity Replace temperature
switch sender.
no continuity
TB24 and check
continuity
Repair short in wht wire
circuit fromTB24 to
temperature sender.
no continuity
circuit fromterminal #10
on ignition/start module
to TB24 OR consult
Genie Industries Service
Department.
no continuity
Remove #1 spark plug
and ground spark plug
body. Crank engine and
observe spark.
good
spark
Go to Chart 2A.
weak or no spark
page.
C H A R T 2
Continued fromthe
previous page.
voltage at wht #21 on
terminal #87 of CR2.
12V
Repair open in wht #21
wire fromCR2 to ignition
coil.
0V
Check voltage at red
wire on terminal #30 of
CR2.
0V
Repair open in red wire
TB20 to CB1 to CR1 to
CR2.
12V
of CR2.
0V
fromterminal #86 on
CR2 to terminal #9 on
12V
Hold start switch and
check voltage at
terminal #9 on ignition/
start module.
12V
Service Department.
0V
Check voltage at
start module.
12V
0V
Repair open in power
supply wires fromCB1
to CR1 to CR2 to
start module.
Check continuity from
ground wire at terminal
#5 on start lockout
module to ground.
continuity
no
continuity
ground wire to start
lockout module.
Disable starter by
removing blk wire at the
starter solenoid, hold the
start switch to either
side and check voltage
at the white wire on the
ignition coil plug.
See Ford service
manual for
troubleshooting ignition
system.
less than 12V
12V
page.
C H A R T 2
ground to terminal #85
on CR2.
no
continuity
CR2.
continuity
If weak spark still exists,
consult Ford engine
service manual for
troubleshooting engine
with weak spark OR
consult Genie Industries
Service.
Continued fromthe
previous page.
Chart 2A
Engine Cranks
Over But Will
Not Start -
Gasoline/LPG
Models
or
Engine Runs
While Cranking
Then Dies
P e rfo rm th e se te sts in
g a so lin e m o d e o n ly.
With keyswitch on and
both Emergency Stop
buttons pulled out to the
ON position, check
voltage at red/wht #23
wire on vacuumswitch.
0V
Repair open in red/wht
#23 wire circuit from
TB23 to vacuumswitch.
12V
Remove the blk wire
with diode fromterminal
#86 on CR3, hold the
side and crank the
engine over for 15
seconds and check
voltage at red/blk wire
on vacuumswitch
(reconnect blk wire after
test).
0V
Turn machine off. See
Repair section for how
the test the vacuum
switch.
bad
Replace vacuumswitch.
ok
Check vacuumline for
restrictions or damage.
bad
Replace vacuumline.
ok
See Ford service
manual to troubleshoot
lowmanifold vacuum.
12V
both Emergency Stop
ON position, disconnect
wires fromvacuum
switch and connect the
wires together. Check
the voltage at terminal
#86 on CR6.
0V
Repair open in red/blk
wire circuit fromvacuum
switch to CR6.
12V
page.
Check automatic choke
for proper adjustment or
internal damage.
bad
Adjust or replace
automatic choke OR
Service Department.
the voltage at the white
wire on the choke while
cranking the engine.
12V
0V
Repair open in white
#21 wire circuit fromthe
ignition coil plug to the
automatic choke.
good
C H A R T 2 A
Continued fromthe
previous page.
both Emergency Stop
ON position, crank the
engine and check
on CR6.
0V
Check brown ground
CR6.
good
no good
CR6.
Replace CR6.
both Emergency Stop
ON position, crank
engine and check
voltage at center
terminal on fuel select
switch TS3 in platform
control box.
0V
Repair open in red
power wire circuit with
diode to fuel select
toggle switch TS3.
12V
both Emergency Stop
ON position, crank
engine and check
voltage on gasoline side
(blu/wht wire) of fuel
select switch.
0V
Replace toggle switch.
12V
both Emergency Stop
on position, crank
engine and check
voltage at terminal
TB38.
0V
Repair open in blu/wht
wire circuit fromtoggle
TS3 toggle switch to
TP38 to TB38.
12V
both Emergency Stop
ON position, crank
engine and check
voltage at blu/wht wire
at terminal #30 on CR6.
wire circuit fromTB38 to
12V
0V
page.
12V
C H A R T 2 A
on anti-diesel valve (on
engine carburetor).
0V
#38 wire circuit CR6 to
anti-diesel valve.
12V
voltage at blu/wht #38
wire on gasoline
solenoid (at gasoline
tank).
0V
#38 wire circuit fromfuel
pump to gasoline
solenoid.
Reconnect the two wires
to vacuumswitch and
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
Department.
Continued fromthe
previous page.
12V
either side, does engine
start?
no
yes
Go to chart 2B.
voltage at blu/wht #38
wire on fuel pump.
0V
anti-diesel valve to fuel
pump.
12V
brown ground wire on
fuel pump to ground.
continuity
no
continuity
fuel pump.
Chart 2B
Engine Runs
While Cranking
Then Dies
Hold start switch to
start lockout module.
0V
Crank engine and check
voltage at org/blk #41
wire on alternator.
0V
Check alternator wiring
OR repair or replace
alternator OR contact
Department.
6 to 7V
Repair open in org/blk
alternator to TB41 to
lockout module.
6 to 7V
While cranking engine
for 15 seconds, check
continuity to ground on
terminal #10 start
lockout module. Is
continuity maintained?
yes
Disconnect wht #24 wire
fromoil pressure sender
and check continuity to
ground on signal post of
sender, while cranking
the engine. Is continuity
maintained?
yes
Check oil level OR
replace oil pressure
sending unit OR refer to
Ford service manual for
troubleshooting lowoil
pressure.
no
Repair short to ground
in wht #24 wire from
sending units to TB24 to
start module.
no
Check voltage at
start module.
12V
Disconnect red wire
fromterminal #4 on
ignition/start module and
check voltage at
terminal #4.
12V
Replace ignition/start
module OR consult
Department.
0V 0V
Replace start lockout
module OR consult
Department.
fromwater temperature
sender and check
signal post of sender,
while cranking the
engine. Is continuity
maintained?
yes
Check coolant level OR
replace water
temperature sending
unit OR refer to Ford
service manual for
troubleshooting a
overheated engine.
no
Test auxiliary power
toggle switches TS1 and
TS10. See Repair
Section.
Engine Cranks
Over But Will
Not Start -
Deutz Diesel
Models
B e su re to ch e ck th e
e n g in e o il le ve l a n d fill
a s n e e d e d .
B e su re to ch e ck
fu e l le ve l.
B e su re th e d ie se l fu e l
sh u t-o ff va lve is in
th e o n p o sitio n .
B e su re th a t th e b a tte ry
is fu lly ch a rg e d .
Chart 3
battery voltage while
engine is cranking.
less
than
11V
OR check alternator OR
check for short circuits
11V or more
Check if engine over-
temperature sending
signal post has
continuity
Check if oil cooler
and/or engine block
feels excessively hot.
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.
not hot
temperature sending
unit, check continuity to
ground (on sending
unit).
continuity Replace temperature
switch sending unit.
no continuity
TB24.
continuity
circuit fromTB24 to
temperature sender.
no continuity
circuit fromignition/start
module to TB24 OR
Service Department.
no continuity
Disable the starter by
removing the blk wire at
the starter solenoid.
the voltage at positive
terminal on fuel
solenoid.
12V
See Deutz service
manual for
troubleshooting fuel
system.
0V
page.
Turn the machine off
and isolate the fuel
solenoid. Check the
resistance of the
solenoid.
3.50 ohms
0 or
infinite
ohms
Replace the fuel
solenoid.
C H A R T 3
Continued fromthe
previous page.
Hold start switch and
check voltage at wht
#21 wire on terminal #87
of CR2.
12V
Repair open in wht #21
wire fromCR2 to fuel
solenoid.
0V
Check voltage at red
CR2.
0V
CB1 to CR1 to CR2.
12V
of CR2.
0V
fromterminal #86 on
CR2 to terminal #9 on
12V
ground to terminal #85
on CR2.
no
continuity
CR2.
good
12V
Replace the ignition/
start module OR consult
Department.
0V
Check voltage at
terminal #6 and 7 on
12V
0V
supply wires to terminal
#6 and 7 on ignition/start
module.
ground to brown wire at
start module.
continuity
no
continuity
start module.
page.
C H A R T 3
start lockout module.
0V
voltage at org/blk #41
wire on alternator.
0V
Repair or replace
alternator OR contact
Department.
6 to 7V
alternator to TB41 to
lockout module.
6 to 7V
While cranking engine
for 15 seconds, check
lockout module. Is
continuity maintained?
yes
fromoil pressure sender
and check continuity to
ground on signal post of
sender, while cranking
the engine. Is continuity
maintained?
yes
Check oil level OR
replace oil pressure
sending unit OR refer to
Deutz service manual
for troubleshooting low
oil pressure.
no
no
Check voltage at
start module.
12V
Disconnect red wire
fromterminal #4 on
ignition/start module and
check voltage at
terminal #4.
12V
module OR consult
Department.
0V
Test auxiliary power
toggle switches TS1 and
TS10. See Repair
Section.
0V
module OR consult
Department.
Continued fromthe
previous page.
in wht #24 wire from
sending units to TB24 to
start module.
fromengine temperature
sender and check
signal post of sender,
while cranking the
engine. Is continuity
maintained?
yes
Check oil level OR
replace engine
temperature sending
unit OR refer to Deutz
service manual for
troubleshooting a
overheated engine.
no
Engine Will Not
Start On LPG,
But Will Start
On Gasoline -
Gasoline/LPG
Models
B e su re fu e l se le ct
switch is switch e d
to L P G .
L P G fu e l le ve l.
Chart 4
Disconnect LPG supply
line fromLPG tank and
bleed pressure from
line.
both Emergency Stop
ON position, check
voltage at LPG side
(blu/red wire) of fuel
select switch.
0V Replace fuel select
switch.
12V
both Emergency Stop
ON position, check
voltage at TB39.
0V
Repair open in blu/red
wire circuit fromfuel
select switch to TP39 to
TB39.
12V
both Emergency Stop
ON position, check
on CR7.
0V
12V
Crank engine for 15
seconds and check
on CR7.
0V
switch to CR6 to CR7.
12V
ground to brown wire on
bad
good
page.
C H A R T 4
Continued fromthe
previous page.
on CR7.
0V
Replace CR7 relay.
voltage at blu/red wire
on LPG solenoid.
0V
wire circuit fromCR7
terminal #87 to LPG
solenoid.
12V
Check resistance of
LPG solenoid.
0 or
infinite
ohms
Replace LPG solenoid.
9 to 10 ohms
Reconnect LPG tank
and starter then see
Maintenance section for
LPG adjustments OR
Service Department.
12V
Chart 5
Engine Will
Not Start On
Gasoline,
But Will Start
On LPG -
Gasoline/LPG
Models
B e su re fu e l se le ct
switch is switch e d
to g a so lin e .
g a so lin e fu e l le ve l.
B e su re th a t e n g in e
ch o ke is o p e ra tin g
p ro p e rly.
both Emergency Stop
switches pulled out to
the ON position, check
voltage at gasoline side
(blu/wht wire) of fuel
select switch.
0V Replace fuel select
switch.
12V
both Emergency Stop
ON position, check
voltage at TB38.
0V
wire circuit fromfuel
select switch to
TP38 to TB38.
12V
on anti-diesel valve (on
carburetor).
0V
terminal #87
to anti-diesel valve OR
replace CR6.
12V
both Emergency Stop
ON position, check
on CR6.
0V
12V
Crank engine for 15
seconds and check
on CR6 while cranking.
0V
switch to CR6.
12V
no
continuity
continuity
page.
C H A R T 5
on the fuel pump.
0V
12V
Check resistance of
gasoline solenoid.
0 or
infinite
ohms Replace gasoline
solenoid.
18 to 19 ohms
Check resistance of
anti-diesel valve.
0 or
infinite
ohms Replace anti-diesel
valve.
24 to 25 ohms
Reconnect starter and
see Ford service manual
for carburetor
troubleshooting OR
Service Department.
Continued fromthe
previous page.
Install a pressure gauge
to the fuel pump. Hold
side and observe the
pressure on the gauge.
less than
7 psi
Replace fuel pump OR
check anti-diesel and
fuel valve for defects
more than 7 psi
on gasoline solenoid (at
fuel tank).
0V
12V
fuel pump.
no
continuity
ground wire circuit to the
fuel pump.
continuity
wire fromanti-diesel
solenoid to fuel pump
OR replace fuel pump.
gasoline solenoid.
no
continuity
ground wire circuit to the
gasoline solenoid.
continuity
wire fromfuel pump to
gasoline solenoid OR
replace gasoline
solenoid.
Chart 6
Engine
High Idle
Inoperative -
Gasoline/LPG
Models
I f h ig h id le o p e ra te s
o n L P G b u t n o t o n
g a so lin e , se e F o rd
se rvice m a n u a l fo r
ca rb u re to r
tro u b le sh o o tin g .
I f h ig h id le o p e ra te s
o n g a so lin e b u t n o t
o n L P G , se e R e p a ir
se ctio n fo r L P G
re g u la to r a d ju stm e n ts.
B e su re th ro ttle
lin ka g e fro m g o ve rn o r
to ca rb u re to r is n o t
b in d in g .
B e su re h ig h id le ca n
b e a ch ie ve d b y g ra sp in g
th e g o ve rn o r a ctu a to r
a rm a n d m o m e n ta rily
p u llin g to th ro ttle th e
ca rb u re to r.
Start engine and move
the rpmselect to high
idle (rabbit symbol) for
following checks. Check
voltage at blk/red wire
on rpmselect switch
TS4 and TS13.
0V
Check voltage at center
terminal on rpmselect
switch TS4 and TS13.
0V
supply circuit to center
terminal of switch.
12V
Replace rpmselect
toggle switch.
12V
Check voltage at TB35.
0V
Repair open in blk/red
switch to TP35 to TB35.
12V
Check voltage at
terminal #85 (blk/red) on
CR4.
0V
wire circuit from
TB35 to CR4.
12V
page.
ground to the brown
CR4.
no
continuity
continuity
Check voltage at
0V Repair open in white
#21 power wire from
terminal 87 on CR2 to
CR3 to CR4.
12V
Check voltage at
terminal 87A on CR4.
12V
Replace CR4 relay.
0V
Check voltage at
terminal 7 on electronic
governor.
12V
Repair short in blk/red
#R4 wire to terminal #7
on precision governor.
0V
C H A R T 6
Continued fromthe
previous page.
wire circuit fromterminal
#87 on CR3 to terminal
#1 on electronic
governor.
Check voltage at
terminal 1 (red/wht wire)
on electronic governor.
0V
12V
Check voltage at
terminal 1 (red/wht wire)
on governor actuator.
0V
wire circuit from
electronic governor
terminal #5 to governor
actuator terminal #1.
12V
terminal #6 on precision
governor to blu/blk
terminal #2 on governor
actuator.
no
continuity
Repair open in blu/blk
wire circuit from
governor actuator to
electronic governor.
full continuity
Check voltage at
0V Repair open in rd/blk
#R6 wire circuit from
vacuumn switch to CR6
to CR7 to terminal #86
on CR3.
12V
ground to brown wire on
terminal #85 of CR3.
no
continuity
Repair open in ground
wire to terminal #85 on
CR3.
continuity
Check voltage to
0V
Replace CR3 relay.
12V
Check voltage at
Repair open in wht wire
circuit fromCR2
terminal #87 to CR3
#30.
12V
0V
page.
C H A R T 6
Continued fromthe
previous page.
Turn machine off,
remove both wires
fromgovernor actuator
and check resistance
across governor
actuator terminals.
0 or
infinite
ohms Replace governor
actuator.
2 to 3 ohms
Reconnect governor
wires and restart engine
and check voltage at
electronic governor
terminal 3 and 4 (brown
wires).
0V
wire circuit fromignition
coil plug to electronic
governor.
12V
See Maintenance
section for governor
adjustments OR replace
Check voltage on red/
wht wire on governor
actuator.
0V
12V
wire fromgovernor
controller to governor
actuator.
Engine Low Idle
Inoperative -
Gasoline/LPG
Models
I f lo w id le o p e ra te s
o n L P G b u t n o t o n
g a so lin e , se e F o rd
se rvice m a n u a l fo r
ca rb u re to r
tro u b le sh o o tin g .
I f lo w id le o p e ra te s
o n g a so lin e b u t n o t
o n L P G , se e R e p a ir
se ctio n fo r L P G
re g u la to r a d ju stm e n ts.
B e su re th ro ttle
lin ka g e fro m g o ve rn o r
to ca rb u re to r is n o t
b in d in g , se e R e p a ir
se ctio n .
Chart 7
Start engine and switch
rpmselect to lowidle
(turtle symbol). Check
(blk/rd wire) on CR4.
12V
Isolate the ground and
platformrpmtoggle
switches TS4 and TS13,
check individually and
replace defective switch.
0V
Check voltage at
terminal #7 on
0V
terminal #87A to
electronic governor
terminal #7.
12V
Check voltage at
electronic governor
terminal 3 and 4 (brown
wires).
0V
wire circuit fromignition
module to electronic
governor.
12V
Turn machine off,
remove blu/blk wire from
terminal #6 on electronic
governor and restart
engine.
engine goes to high idle
Recheck throttle linkage
(see Repair section) OR
check and/or replace
governor actuator OR
see Ford service manual
for carburetor
troubleshooting.
engine goes to lowidle
Recheck electronic
governor adjustments
OR replace electronic
governor.
Check voltage at
0V Repair open in wht wire
on CR2 to CR4 terminal
#30.
12V
Check voltage at
terminal #87A on CR4.
0V
Replace CR4 relay.
12V
Chart 8
Engine
High Idle
Inoperative -
Deutz Diesel
Models
B e su re m e ch a n ica l
lin ka g e is n o t b in d in g
o r d e fe ctive .
B e su re 2 -sp e e d
so le n o id g ro u n d in g
wire s a re fre e o f
co rro sio n a n d h a ve fu ll
co n tin u ity to g ro u n d .
Start engine, switch rpm
select switch to high idle
(rabbit symbol) and
check if 2-speed
solenoid pulls in.
solenoid
pulls in
Check high idle
adjustment (see
Maintenance section) or
see Deutz workshop
fuel injection system.
solenoid does
not pull in
Check voltage at blk/red
wire on rpmselect
switch TS4 and TS13.
0V
Check voltage on red
wire at center terminal of
rpmselect switch.
0V
Repair open in circuit
supplying 12V to center
terminal of switch.
12V
Replace toggle switch 12V
0V
switch to TP35 to TB35.
12V
Check voltage at
0V Repair open in blk/red
12V
Check voltage to
12V
on CR2 to terminal #86
on CR3.
no
continuity
continuity
Check voltage to
0V
Replace CR3 relay.
12V
page.
C H A R T 8
Check voltage at the
blk/red wire on the
2-speed solenoid.
0V
Replace CR4 relay
OR repair open in
blk/red wire circuit from
terminal #87 on CR4 to
2-speed solenoid.
12V
Check if 2-speed
solenoid moves in and
out freely.
solenoid
binds Check linkage or
replace solenoid.
moves freely
Replace 2-speed
solenoid. Note:
resistance across
solenoid terminals
should be approximately
0.3 ohms.
Continued fromthe
previous page.
bad
good
Check voltage to
circuit fromCR2 to CR3
to CR4.
12V
Check voltage at
0V Repair open in blk/red
wire circuit from
CR3 to CR4.
12V
Chart 9
Engine
Low Idle
Inoperative -
Deutz Diesel
Models
C h e ck if
m e ch a n ica l lin ka g e
fro m 2 -sp e e d
so le n o id to fu e l
in je ctio n syste m is
b in d in g o r d e fe ctive .
At platformcontrols,
start engine and switch
rpmselect switch TS4 to
maintained lowidle
(turtle symbol). Check
voltage at blk/red wire
on rpmselect switch.
12V
Isolate the platformand
ground rpmswitches,
check individually and
replace defective switch.
0V
Check voltage at the
red wire on the
2-speed solenoid.
12V
Replace CR4 relay.
0V
Check if 2-speed
solenoid moves in and
out freely.
solenoid
binds Check linkage or
replace solenoid.
moves freely
Check adjustment of
linkage and fuel injection
systemlowidle. See
Maintenance section.
ok
See Deutz workshop
fuel injection systemOR
Service Department.
Chart 10
All Functions
Inoperative,
Engine Starts
and Runs
Check hydraulic
fluid level.
low Fill with Dexron
equivalent hydraulic
fluid.
ok
Check pump suction line
shutoff valves. In the
open position, the valve
handles should be
parallel with hose.
closed
Open valves and start
the engine. Check all
machine functions for
correct operation.
open
Disconnect ignition coil
connector plug from
ignition coils. On Deutz
diesel models, hold
manual fuel shutoff lever
to the closed position
(clockwise).
Remove function pump
frommain pump but
leave all hoses
connected. Hold start
switch and crank engine
over while observing
spline drive at rear of
main pump.
spline
turns
Troubleshoot
inoperative boom
functions and
inoperative drive
functions separately.
spline does not turn
Engine to pump flex
plate coupling is
defective OR main
pump is defective.
Service Department.
Do the pumps feel
excessively hot?
no
yes If engine has been run
with valves closed, it
may have damaged one
or both pumps. Please
contact the Genie
Industries Service
Department.
Chart 11
All Lift and
Steer Functions
Inoperative,
Drive Functions
Operational
B e su re th e h yd ra u lic
su ctio n lin e sh u to ff
va lve fo r th e lift/ste e r
p u m p is in th e o p e n
p o sitio n .
B e su re a ll g ro u n d in g
wire s fo r th e h yd ra u lic
m a n ifo ld va lve s a re fre e
o f co rro sio n a n d h a ve
fu ll co n tin u ity to g ro u n d .
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
boomretract function
and check the hydraulic
pressure.
2600
psi or
more
Troubleshoot each
function individually or
Service Department.
less than
2600 psi
Adjust the function
manifold systemrelief
valve (itemW) all the
way in (clockwise)
counting the number of
turns. Move the function
enable switch to either
side and hold the boom
retract switch and
recheck the pressure.
2600
psi or
more
Move the function
retract switch and
readjust the relief
pressure to 2600 psi for
S-60 or 2900 psi for
S-65 .
less than
2600 psi
Check the function
pump, see Repair
section.
ok
Replace the relief valve
(itemW) OR manifold
has an internal defect.
Consult the Genie
Industries Service
Department.
bad
Replace the function
pump.
Check steer functions.
steering
operates
Repair or replace
differential sensing valve
(itemV) OR repair or
replace flowregulator
valve (itemAA) OR
manifold has an internal
defect, consult Genie
Industries Service
Department.
steering inoperative
Chart 12
Ground
Controls
Inoperative,
Platform
Controls
Operate
Normally
B e su re a ll o th e r
fu n ctio n s o p e ra te
n o rm a lly, in clu d in g
th e p la tfo rm
co n tro ls.
Does the engine start
fromthe ground
controls?
yes
Start the engine from
the ground controls.
Move the function
enable toggle switch to
the voltage on the
center terminal of the
platformlevel toggle
switch TS16.
0V
circuit fromkey switch to
function enable toggle
switch to each function
toggle switch.
12V
Troubleshoot each
function individually.
no
With both Emergency
Stop buttons pulled out
to the ON position, check
voltage at red wire 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).
0V
circuit fromemergency
stop button to the
key switch.
12V
With the keyswitch
turned to ground
controls and both
are pulled out to the ON
position, check voltage
at red wire at the output
side of the ground
controls contact on the
key switch.
0V
Check if key switch
internal camis activating
ground contact.
yes
Replace key switch
contact for ground
controls.
no
Replace key switch
KS1.
12V
function enable toggle
switch to each function
toggle switch.
Chart 13
Platform
Controls
Inoperative,
Ground
Controls
Operate
Normally
B e su re a ll
ca b le s fro m ch a ssis
th ro u g h th e ca b le
tra ck a re in g o o d
co n d itio n with n o
kin ks o r a b ra sio n s.
Does engine start from
the platformcontrols?
yes Start engine fromthe
platformcontrols, then
press down the foot
switch and check
voltage at TP24.
0V
Test or replace foot
switch (see Repair
Section) OR repair open
in wht wire circuit from
foot switch to TP24.
12V
circuit fromTP24 to
function toggle switches
and function controllers.
no
0V
TB22 OR Replace the
platformcontrols contact
at the key switch.
12V
Check voltage at TP22.
0V
Repair open in blk-2
wire circuit fromTB22
TP22.
12V
Check voltage at blk
wire on input side of
platformEmergency
Stop button contact P2.
0V
With the key switch
turned to platform
controls and both
position, check the
voltage on the output
side of the platform
Emergency Stop button
contact.
12V
Check voltage at TP23.
0V
with diode from
to TP23.
12V
circuit fromplatform
to TP26 to foot switch
OR replace foot switch
OR consult Genie
Industries Service
Department.
Replace contact on
P2.
0V
12V
fromTP22 to
P2.
Check if Emergency
Stop switch the contact.
no
Replace the platform
Emergency Stop button.
yes
Chart 14
Boom Up
Function
Inoperative
n o rm a lly.
With key switch in
ground position and
both Emergency Stop
ON position, move the
function enable switch to
boomup toggle switch
(TS17) on ground panel
in up direction and
check voltage on red/
wht wire on boomup/
down proportional valve
coil (itemO).
0V
20V or more
Move the function
up toggle switch (TS17)
on ground panel in the
up direction and check
voltage at TB3.
8 to 9V
boomup/down
proportional valve coil
(itemO) OR repair open
in brown ground wire
circuit to valve coil.
0V
With the keyswitch in
platformposition and
both Emergency Stop
ON position, activate
footswitch and boom
function controller (BP1)
on platformcontrol
panel in up direction and
check voltage at TP3.
page.
8 to 9V Repair open in red/wht
wire fromTP3 to TB3.
0V
Activate footswitch and
check voltage at "+"
terminal on BP1.
12V or more
0V
supply circuit fromTP24
to BP1 OR repair open
circuit fromground to
BP1.
Re-adjust controller (see
Repair Section) OR
replace controller BP1
OR consult Genie
Industries Service
Department.
C H A R T 1 4
With key switch in
ground position and
both Emergency Stop
in up direction and
check voltage on red #1
wire on boomup/down
directional valve coil
(itemB).
0V
20V or more
Move the function
up toggle switch (TS17)
on ground panel in up
direction and check
voltage at TB1.
12V or
more
Repair open in red #1
boomup function
(itemB) OR repair open
0V
With key switch in
both Emergency Stop
footswitch and boom
on platformcontrol
panel in up direction and
check voltage TB1.
12V or
more
0V
boomfunction controller
(BP1) on platform
control panel in up
direction and check
voltage TP1.
page.
Troubleshoot boomup
function toggle switch
(TS17) on ground
control panel OR repair
open in red #1 wire
circuit fromTS17 to TB1
OR consult Genie
Industries Service
Department.
Continued fromthe
previous page.
12V or
more Repair open in red wire
fromTP1 to TB1.
0V
terminal on BP1.
12V or more
0V
BP1.
Repair Section) OR
OR consult Genie
Industries Service
Department.
C H A R T 1 4
Disconnect wires to
boomup directional
valve coil (itemB) and
test the resistance of the
valve coil. See Repair
Section.
Continued fromthe
previous page.
0 or
infinite
ohms
2.5 to 3.5 ohms
Replace boomup
(itemB).
(345 bar) pressure
gauge at the quick
disconnect coupling on
the boomfunction
manifold and start the
engine. Move the
at the ground controls in
the up direction and
check the pressure.
2500
PSI or
more
less than 2500 PSI
Repair cylinder or
cylinder counterbalance
valve OR boomfunction
manifold could have an
internal defect. Consult
Department.
Check for mechanical
restrictions keeping
boomfrommoving OR
repair cylinder or
valve OR consult Genie
Industries Service
Department.
Move function enable
hold the boomup 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.
function inoperative
function
operates
Replace defective
directional valve.
Exchange flowregulator
valve (itemH) with a like
valve (itemG). Check
boomup function.
function
operates Replace defective flow
regulator valve.
Boom Down
Function
Inoperative
n o rm a lly.
Chart 15
With key switch in
ground position and
both Emergency Stop
boomdown toggle
switch (TS17) on ground
panel in down direction
and check voltage on
red/wht wire on boom
up/down proportional
valve coil (itemO).
0V
20V or more
Move the function
down toggle switch
in the down direction
TB3.
6 to 7V
boomup/down
(itemO) OR repair open
0V
With the keyswitch in
the platformposition and
both Emergency Stop
footswitch and boom
on platformcontrol
TP3.
page.
6 to 7V Repair open in red/wht
0V
terminal on BP1.
12V or more
0V
BP1.
Repair Section) OR
OR consult Genie
Industries Service
Department.
C H A R T 1 5
With key switch in
ground position and
both Emergency Stop
boomdown toggle
red/blk #2 wire on boom
function directional valve
coil (itemB).
0V
20V or more
Move the function
down toggle switch
in down direction and
check voltage at TB2.
12V or
more
#2 wire circuit fromTB2
to boomdown function
(itemB) OR repair open
0V
With key switch in
both Emergency Stop
footswitch and boom
on platformcontrol
and check voltage TB2.
12V or
more
0V
boomfunction controller
(BP1) on platform
control panel in down
direction and check
voltage TP2.
page.
Troubleshoot boom
down function toggle
control panel OR repair
open in red/blk #2 wire
OR consult Genie
Industries Service
Department.
Continued fromthe
previous page.
12V or
more Repair open in red/blk
0V
terminal on BP1.
12V or more
0V
BP1.
Repair Section) OR
OR consult Genie
Industries Service
Department.
C H A R T 1 5
Disconnect wires to
boomdown directional
valve coil (itemB) and
Section.
Continued fromthe
previous page.
0 or
infinite
ohms
2.5 to 3.5 ohms
Replace boomdown
(itemB).
(345 bar) pressure
gauge at the quick
the boomfunction
engine. Move the
boomdown toggle
controls in the down
direction and check the
pressure.
2100
PSI
less than 2100 PSI
Reset boomdown relief
valve (itemF) pressure
(see Repair Section) OR
replace boomdown
relief valve OR repair
cylinder or cylinder
counterbalance valve
OR function manifold
could have an internal
defect. Consult Genie
Industries Service
Department.
boomfrommoving OR
repair cylinder or
valve OR consult Genie
Industries Service
Department.
hold the boomdown
toggle switch at the
ground controls in the
down direction.
Manually override the
directional valve by
pushing in on the end of
the valve spool.
function
operates
Replace defective
directional valve.
Chart 16
Boom Extend
Function
Inoperative
n o rm a lly.
With key switch in
ground position and
both Emergency Stop
boomextend toggle
panel in extend direction
blk/red wire on boom
extend/retract
(itemM).
0V
20V or more
Move the function
extend toggle switch
in the extend direction
TB9.
9 to 10V
boomextend/retract
(itemM) OR repair open
0V
With keyswitch in
both Emergency Stop
on position, activate
footswitch and boom
extend/retract
proportional controller
(BP2) on platform
control panel in extend
direction and check
voltage at TP9.
page.
9 to 10V Repair open in blk/red
0V
terminal on BP2.
12V or more
0V
to BP1 to BP2 OR repair
open in brown ground
wire circuit fromground
to BP2.
Repair Section) OR
OR consult Genie
Industries Service
Department.
C H A R T 1 6
With key switch in
ground position and
both Emergency Stop
boomextend/retract
toggle switch (TS19) on
ground panel in the
extend direction and
check voltage on blk
wire on boomfunction
(itemC).
0V
20V or more
Move the function
extend toggle switch
in the extend direction
TB7.
12V or
more
circuit fromTB7 to boom
extend function
(itemC) OR repair open
0V
With key switch in
both Emergency Stop
footswitch and boom
extend/retract
(BP2) on platform
direction and check
voltage TB7.
12V or
more
0V
boomextend/retract
(BP2) on platform
direction and check
voltage TP7.
page.
Troubleshoot boom
extend/retract function
ground control panel OR
repair open in blk wire
OR consult Genie
Industries Service
Department.
Continued fromthe
previous page.
12V or
more Repair open in blk wire
fromTP7 to TB7.
0V
terminal on BP2.
12V or more
0V
to BP2.
Repair Section) OR
OR consult Genie
Industries Service
Department.
C H A R T 1 6
Disconnect wires to
boomextend directional
valve coil (itemC) and
Section.
Continued fromthe
previous page.
0 or
infinite
ohms
2.5 to 3.5 ohms
Replace boomextend
(itemC).
(345 bar) pressure
gauge at the quick
the boomfunction
engine. Move the
boomextend toggle
controls in the extend
pressure.
2500
PSI or
more
less than 2500 PSI
Repair cylinder or
valve OR function
Department.
boomfromextending
OR repair cylinder or
valves OR consult
Department.
hold the boomextend
extend direction.
the valve spool.
function
operates
Replace defective
directional valve.
valve (itemH) with a like
valve (itemG). Check
boomextend function.
function
regulator valve.
Chart 17
Boom Retract
Function
Inoperative
n o rm a lly.
With key switch in
ground position and
both Emergency Stop
boomretract toggle
panel in the retract
direction and check
voltage on blk/red wire
on boomextend/retract
(itemM).
0V
20V or more
Move the function
retract toggle switch
in the retract direction
TB9.
9 to 9.5V
boomextend/retract
(itemM) OR repair open
0V
With keyswitch in
both Emergency Stop
footswitch and boom
extend/retract
(BP2) on platform
control panel in the
retract direction and
page.
0V
terminal on BP2.
12V or more
0V
to BP2.
Repair Section) OR
OR consult Genie
Industries Service
Department.
9 to 9.5V
C H A R T 1 7
With key switch in
ground position and
both Emergency Stop
the ON position, move
the function enable
hold the boomextend/
blk/wht wire on boom
coil (itemC).
0V
20V or more
Move the function
TB8.
12V or
more
Repair open in blk/wht
boomretract function
(itemC) OR repair open
0V
With key switch in
both Emergency Stop
the ON position, activate
footswitch and boom
extend/retract
(BP2) on platform
check voltage TB8.
12V or
more
0V
boomextend/retract
(BP2) on platform
check voltage TP8.
page.
Troubleshoot boom
extend/retract function
repair open in blk/wht
wire circuit fromTS19 to
TB8 OR consult Genie
Industries Service
Department.
Continued fromthe
previous page.
12V or
more Repair open in blk/wht
0V
terminal on BP2.
12V or more
0V
to BP2.
Repair Section) OR
OR consult Genie
Industries Service
Department.
C H A R T 1 7
Disconnect wires to
boomretract directional
valve coil (itemC) and
Section.
Continued fromthe
previous page.
0 or
infinite
ohms
2.5 to 3.5 ohms
Replace boomretract
(itemC).
(345 bar) pressure
gauge at the quick
the boomfunction
engine. Move the
boomretract toggle
controls in the retract
pressure.
2500
PSI or
more
less than 2500 PSI
Repair cylinder or
valve OR function
Department.
boomfromretracting
OR repair cylinder or
valves OR consult
Department.
hold the boomretract
retract direction.
the valve spool.
function
operates
Replace defective
directional valve.
valve (itemG) with a like
valve (itemH). Check
boomretract function.
function
regulator valve.
Chart 18
Turntable
Rotate Left
Function
Inoperative
n o rm a lly.
With key switch in
ground position and
both Emergency Stop
turntable rotate toggle
panel in the left direction
wht/red wire on turntable
rotate left/right
(itemR).
0V
20V or more
Move the function
side and hold the
panel in the left direction
TB6.
4 to 6V
Repair open in wht/red
turntable rotate left/right
(itemR) OR repair open
0V
With keyswitch in
both Emergency Stop
footswitch and turntable
rotate left/right
(BP1) on platform
control panel in the left
direction and check
voltage at TP6.
page.
0V
terminal on BP1.
12V or more
0V
BP1.
Repair Section) OR
OR consult Genie
Industries Service
Department.
4 to 6V
C H A R T 1 8
With key switch in
ground position and
both Emergency Stop
ground panel in the left
direction and check
voltage on
wht/blk wire on boom
coil (itemA).
0V
20V or more
Move the function
side and hold the
ground panel in the left
direction and check
voltage at TB5.
12V or
more
Repair open in wht/blk
turntable rotate left
coil (itemA) OR repair
wire circuit to valve coil.
0V
With key switch in
both Emergency Stop
rotate left/right
(BP1) on platform
direction and check
voltage TB5.
12V or
more
0V
(BP1) on platform
direction and check
voltage TP5.
page.
Troubleshoot turntable
rotate left/right function
repair open in wht/blk
wire circuit fromTS18 to
TB5 OR consult Genie
Industries Service
Department.
Continued fromthe
previous page.
12V or
more Repair open in wht/blk
0V
terminal on BP1.
12V or more
0V
BP1.
Repair Section) OR
OR consult Genie
Industries Service
Department.
C H A R T 1 8
Disconnect wires to
(itemA) and test the
resistance of the valve
coil. See Repair Section.
Continued fromthe
previous page.
0 or
infinite
ohms
2.5 to 3.5 ohms
Replace turntable rotate
left directional valve coil
(itemA).
(345 bar) pressure
gauge at the quick
the boomfunction
engine. Move the
left direction and check
the pressure.
hold the turntable rotate
left/right toggle switch at
the ground controls in
the left direction.
the valve spool.
function
operates
Replace defective
directional valve.
2600
PSI or
more
less than 2600 PSI
Repair cylinder or
valve OR function
Department.
valve (itemI) with a like
function.
function
regulator valve.
page.
C H A R T 1 8
function fromoperating
OR replace shuttle valve
(itemHH) OR consult
Department.
Plumb a 0 to 5000 psi
(0 to 345 bar) pressure
gauge into the hose
fromthe function
manifold to the turntable
rotation brake. Move the
either side and activate
the turntable rotate left
function.
lessthan
250 psi
250 psi or more
Exchange turntable
rotate left and right
counterbalance valves
(items II and J J ).
Activate turntable rotate
left function.
function
operates Replace defective
counterbalance valve.
Function manifold could
have an internal defect.
Service Department.
Continued fromthe
previous page.
Chart 19
Turntable
Rotate Right
Function
Inoperative
n o rm a lly.
With key switch in
ground position and
both Emergency Stop
panel in the right
direction and check
voltage on wht/red wire
on turntable rotate left/
right proportional valve
coil (itemR).
0V
20V or more
Move the function
side and hold the
panel in the right
direction and check
voltage at TB6.
4 to 6V
(itemR) OR repair open
0V
With keyswitch in
both Emergency Stop
rotate left/right
(BP1) on platform
control panel in the right
direction and check
voltage at TP6.
page.
0V
terminal on BP1.
12V or more
0V
BP1.
Repair Section) OR
OR consult Genie
Industries Service
Department.
4 to 6V
C H A R T 1 9
With key switch in
ground position and
both Emergency Stop
ground panel in the right
direction and check
voltage on
wht wire on boom
coil (itemA).
0V
20V or more
Move the function
side and hold the
ground panel in the right
direction and check
voltage at TB4.
12V or
more
circuit fromTB4 to
turntable rotate right
coil (itemA) OR repair
0V
With key switch in
both Emergency Stop
rotate left/right
(BP1) on platform
direction and check
voltage TB4.
12V or
more
0V
(BP1) on platform
direction and check
voltage TP4.
page.
Troubleshoot turntable
rotate left/right function
repair open in wht wire
OR consult Genie
Industries Service
Department.
Continued fromthe
previous page.
12V or
more Repair open in wht/blk
0V
terminal on BP1.
12V or more
0V
BP1.
Repair Section) OR
OR consult Genie
Industries Service
Department.
C H A R T 1 9
Disconnect wires to
(itemA) and test the
coil. See Repair Section.
Continued fromthe
previous page.
0 or
infinite
ohms
2.5 to 3.5 ohms
Replace turntable rotate
right directional valve
coil (itemA).
(345 bar) pressure
gauge at the quick
the boomfunction
engine. Move the
right direction and check
the pressure.
hold the turntable rotate
left/right toggle switch at
the ground controls in
the right direction.
the valve spool.
function
operates
Replace defective
directional valve.
2600
PSI or
more
less than 2600 PSI
Repair cylinder or
valve OR function
Department.
valve (itemI) with a like
function.
function
regulator valve.
page.
C H A R T 1 9
OR replace shuttle valve
(itemHH) OR consult
Department.
gauge into the hose
fromthe function
manifold to the turntable
rotation brake. Move the
either side and activate
the turntable rotate right
function.
lessthan
250 psi
250 psi or more
Exchange turntable
rotate right and left
(items J J and II).
Activate turntable rotate
right function.
function
operates Replace defective
Function manifold could
Service Department.
Continued fromthe
previous page.
Chart 20
All Platform
Leveling
Functions
Inoperative
n o rm a lly.
Remove both hydraulic
hoses fromthe manifold
(ports PL1 &PL2). Plug
the hoses and cap the
manifold fittings. Move
the function enable
activate the boomup
function and check to
see if platformlevels.
no
gauge into master
cylinder rod-end
hydraulic hose (hose
connected to port PL2)
using a tee fitting.
Activate boomup
function and check the
pressure.
less than 2000 PSI
Install a 0 to 5000 psi
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
boomup. Do not allow
the pressure to exceed
2500 PSI.
2000 PSI or more
Repair or replace the
slave cylinder.
Replace the
on function manifold
(items A &B).
yes
2000
PSI
restrictions OR replace
the slave cylinder
counterbalance valves.
less than
2000 PSI Repair or replace the
master cylinder.
Chart 21
Platform Level
Up Function
Inoperative
n o rm a lly.
With the keyswitch
turned to ground control
and both Emergency
to the ON position, move
the function enable
activate the platform
level toggle switch TS16
in the up direction and
check the voltage at org
wire on platformlevel up
(itemS).
0V
With the keyswitch
and both Emergency
to the on position, move
the function enable
TB14.
0V
With the keyswitch
turned to platform
control and both
position, activate the
footswitch and the
switch TS7 in the up
voltage at TB14.
Repair open in org wire
fromTB14 to platform
level up directional valve
coil (itemS) OR repair
12V or
more
0V
Troubleshoot platform
level toggle switches
TS16 and TS7 on
ground and platform
control panels OR repair
open in red power wire
circuit to TS16 and TS7
OR repair open in org
wire circuit fromTS16
and TS7 to TB14 OR
Service Department.
12V or more
on ground control panel
OR repair open in red
power wire circuit to
TS16 OR repair open in
org wire circuit from
TS16 to TB14 OR
Service Department.
12V or more
page.
Disconnect the wires
fromthe platformlevel
up directional valve coil
(itemS) and test the
coil.
0 or
infinite
ohms
level up directional valve
coil (itemS).
6 to 7 ohms
Continued fromthe
previous page.
Exchange platformlevel
up and down directional
valves (items S and U)
and activate the platform
level up function.
function
operates Replace the defective
directional valve.
up and down
(items EE and FF) and
level up function.
function
Install a 0 to 3000
gauge at the quick
the function manifold
level up function.
less than 2600 psi
2600 psi
or more
platformlevel up
OR replace slave
cylinder OR replace
slave cylinder
OR consult Genie
Industries Service
Department.
Test master cylinder
(see Chart 16) OR
repair or replace slave
cylinder or slave
valves OR function
manifold may have an
Department.
C H A R T 2 1
Chart 22
Platform Level
Down Function
Inoperative
n o rm a lly.
With the keyswitch
and both Emergency
the function enable
and check the voltage at
org/blk wire on platform
level down function
directional valve
(itemU).
0V
With the keyswitch
and both Emergency
to the on position, move
the function enable
and check the voltage at
TB15.
0V
With the keyswitch
turned to platform
control and both
footswitch and the
switch TS7 in the down
voltage at TB15.
wire fromTB15 to
platformlevel down
(itemU) OR repair open
12V or
more
0V
level toggle switches
TS16 and TS7 on
ground and platform
control panels OR repair
open in red power wire
circuit to TS16 and TS7
OR repair open in org/
blk wire circuit from
TS16 and TS7 to TB15
OR consult Genie
Industries Service
Department.
12V or more
on ground control panel
OR repair open in red
power wire circuit to
TS16 OR repair open in
org/blk wire circuit from
TS16 to TB15 OR
Service Department.
12V or more
page.
C H A R T 2 2
Disconnect the wires
fromthe platformlevel
down directional valve
coil (itemU) and test the
coil.
0 or
infinite
ohms
level down directional
valve coil (itemU).
6 to 7 ohms
Continued fromthe
previous page.
down and up directional
valves (items U and S)
level down function.
function
directional valve.
down and up
(items FF and EE) and
function
Install a 0 to 3000
gauge at the quick
less than 2600 psi
2600 psi
or more
platformlevel down
OR replace slave
cylinder OR replace
slave cylinder
OR consult Genie
Industries Service
Department.
Test master cylinder
(see Chart 16) OR
repair or replace slave
cylinder or slave
valves OR function
manifold may have an
Department.
Chart 23
Platform Rotate
Left Function
Inoperative
n o rm a lly.
With the keyswitch
and both Emergency
the function enable
rotate toggle switch
TS14 in the left direction
grn/wht wire at TP19 at
the platformcontrols.
0V
With keyswitch turned to
platformcontrol and
both Emergency Stop
footswitch and platform
rotate toggle switch TS5
in the left direction and
check voltage at the grn/
wht wire at the jib delay
capacitor.
12V
Repair open in grn/wht
wire fromTP19 to jib
delay capacitor.
page.
wire fromTS14 to TB19
to TP19 OR test toggle
switch. See Repair
Section.
0V
12V
platformcontrol and
both Emergency Stop
12V
0V
Test toggle switch. See
Repair Section OR
replace platformrotate
toggle switch TS5.
platformrotate toggle
switch TS5 in the left
direction and check
voltage at the grn/wht
wire on TS5.
12V
0V
wire fromTS5 to TP19.
Check voltage on center
terminal of TS5.
0V
12V
Repair open in red
power wire circuit
through controllers and
to TS5.
C H A R T 2 3
Continued fromthe
previous page.
platformcontrol and
both Emergency Stop
check voltage at the red
wire at the jib delay
capacitor.
0V
12V
Replace the jib delay
capacitor OR repair
wire fromcapacitor to
ground.
direction and check
voltage on the red wire
at terminal #86 on
CR14.
fromjib delay capacitor
to CR14.
direction and check
voltage on the red and
black wires at terminal
#87 on CR14.
12V
0V
Replace relay CR14 OR
repair open in power
supply fromP2 to CR14
OR repair open in brown
ground wire to CR14.
0V
12V
direction and check
black wires at the jib/
platformrotate select
valves (itemAM).
12V
0V
Test the resistance of
the valve coils.
0 or
infinite
ohms
5.5 to 6.5
ohms
Replace defective valve
coil.
Repair open in cable
containing red and black
wires fromCR14 to jib
boom/platformrotate
select valves.
page.
C H A R T 2 3
Continued fromthe
previous page.
brown ground wires on
valve coils to ground.
no
continuity
continuity
valve coils.
Exchange jib boom/
valves (itemAM).
platformrotate left
function.
function
operates
valve coils.
Repair or replace
platformrotator OR
0.030" orifice fittings in
jib manifold are plugged
OR jib manifold may
Service Department.
Chart 24
Platform Rotate
Right Function
Inoperative
n o rm a lly.
With the keyswitch
and both Emergency
the function enable
rotate toggle switch
TS14 in the right
direction and check
voltage at grn/wht wire
at TP19 at the platform
controls.
0V
platformcontrol and
both Emergency Stop
in the right direction and
check voltage at the grn/
wht wire at the jib delay
capacitor.
12V
wire fromTP19 to jib
delay capacitor.
page.
to TP19 OR test toggle
switch. See Repair
Section.
0V
12V
platformcontrol and
both Emergency Stop
12V
0V
Test toggle switch. See
Repair Section OR
replace platformrotate
toggle switch TS5.
switch TS5 in the right
direction and check
voltage at the grn/wht
wire on TS5.
12V
0V
wire fromTS5 to TP19.
Check voltage on center
terminal of TS5.
0V
12V
Repair open in red
power wire circuit
through controllers and
to TS5.
C H A R T 2 4
Continued fromthe
previous page.
platformcontrol and
both Emergency Stop
check voltage at the red
wire at the jib delay
capacitor.
0V
12V
Replace the jib delay
capacitor OR repair
wire fromcapacitor to
ground.
direction and check
voltage on the red wire
at terminal #86 on
CR14.
fromjib delay capacitor
to CR14.
direction and check
black wires at terminal
#87 on CR14.
12V
0V
Replace relay CR14 OR
repair open in power
supply fromP2 to CR14
OR repair open in brown
ground wire to CR14.
0V
12V
direction and check
valves (itemAM).
12V
0V
Test the resistance of
the valve coils.
0 or
infinite
ohms
5.5 to 6.5
ohms
Replace defective valve
coil.
Repair open in cable
containing red and black
wires fromCR14 to jib
boom/platformrotate
select valves.
page.
C H A R T 2 4
Continued fromthe
previous page.
brown ground wires on
valve coils to ground.
no
continuity
continuity
valve coils.
Exchange jib boom/
valves (itemAM).
platformrotate right
function.
function
operates
valve coils.
Repair or replace
platformrotator OR
0.030" orifice fitting in jib
manifold are plugged
OR jib manifold may
Service Department.
Jib Boom Up
Function
Inoperative,
S-65 Models
n o rm a lly.
Chart 25
With the keyswitch
and both Emergency
the function enable
activate the jib boom
toggle switch TS15 in
the up direction and
check voltage at the grn
wire on the jib boomup
directional valve
(itemBB).
0V
12V
Move the function
side and activate the jib
boomtoggle switch
TS15 in the up direction
TB17.
12V
0V
Repair open in grn wire
fromTB17 to jib boom
up directional valve OR
repair open in brown
directional valve.
Repair open in red
power wire circuit from
keyswitch to TS15 OR
replace toggle switch
TS15.
With the keyswitch
turned to platform
control and both
pulled out to the ON
footswitch and the jib
boomtoggle switch TS6
check voltage at TB17.
12V
0V
Activate the footswitch
and the jib boomtoggle
switch TS6 in the up
direction and check
voltage at TP17.
fromTP17 to TB17.
12V
0V
With the keyswitch
turned to platform
control and both
footswitch and check the
voltage on the center
terminal of the jib boom
toggle switch TS6.
Check the voltage at
0V
12V
fromTS6 to TP17 OR
replace jib boomtoggle
switch TS6.
0V
12V
fromBP1 to CR13 OR
CR13.
terminal #87a on CR13.
12V
0V
Replace CR13.
fromterminal#87a on
CR13 to TS6 OR
Service Department.
page.
C H A R T 2 5
Continued fromthe
previous page.
jib boomtoggle switch
TS6 in the up direction
the red and black wires
at the jib/platformrotate
select valves (itemAM).
0V
12V
Replace CR13.
Exchange jib boom/
valves (itemAM).
jib boomup function.
2500 psi
or more
less than 2500 psi
Install a 0 to 5000 psi (0
to 345 bar) pressure
gauge at the quick
and activate the jib
boomup function.
function
operates
Replace defective valve.
restrictions keeping jib
boomup function from
operating OR repair or
replace jib boom
cylinder OR replace
counterbalance valve
OR 0.035" orifice may
be plugged OR jib
boom/platformrotate
select manifold has an
internal defect OR
Service Department.
Exchange jib boom
and activate jib boomup
function.
function
operates
Replace defective
Service Department.
Jib Boom Down
Function
Inoperative,
S-65 Models
n o rm a lly.
Chart 26
With the keyswitch
and both Emergency
the function enable
activate the jib boom
toggle switch TS15 in
the down direction and
check voltage at the
grn/blk wire on the jib
valve (itemBB).
0V
12V
Move the function
side and activate the jib
boomtoggle switch
TS15 in the down
direction and check
voltage at TB18.
12V
0V
Repair open in grn/blk
wire fromTB18 to jib
valve OR repair open in
brown ground wire
circuit to directional
valve.
Repair open in red
power wire circuit from
keyswitch to TS15 OR
replace toggle switch
TS15.
With the keyswitch
turned to platform
control and both
footswitch and the jib
boomtoggle switch TS6
TB18.
12V
0V
and the jib boomtoggle
switch TS6 in the down
direction and check
voltage at TP18.
12V
0V
With the keyswitch
turned to platform
control and both
voltage on the center
terminal of the jib boom
toggle switch TS6.
0V
12V
wire fromTS6 to TP18
OR replace jib boom
toggle switch TS6.
0V
12V
fromBP1 to CR13 OR
CR13.
terminal #87a on CR13.
12V
0V
Replace CR13.
fromterminal#87a on
CR13 to TS6 OR
Service Department.
page.
C H A R T 2 6
Continued fromthe
previous page.
jib boomtoggle switch
TS6 in the down
direction and check
valves (itemAM).
0V
12V
Replace CR13.
Exchange jib boom/
valves (itemAM).
jib boomdown function.
2500 psi
or more
less than 2500 psi
Install a 0 to 5000 psi (0
to 345 bar) pressure
gauge at the quick
and activate the jib
boomdown function.
function
operates
Replace defective valve.
restrictions keeping jib
boomdown function
fromoperating OR
repair or replace jib
boomcylinder OR
replace counterbalance
valve OR 0.035" orifice
may be plugged OR jib
boom/platformrotate
select manifold has an
internal defect OR
Service Department.
Exchange jib boom
and activate jib boom
down function.
function
operates
Replace defective
Service Department.
Chart 27
Oscillate
Function
Inoperative
fu n ctio n o p e ra te
n o rm a lly.
Remove the chassis
cover at the non-steer
end. Check the linkage
for damage or improper
linkage adjustment. See
Repair section, 10-6
Howto Set Up the
Directional Valve
Linkage.
bad Re-adjust or replace
linkage.
good
gauge at the quick
the oscillate manifold.
Disconnect the oscillate
linkage fromnon-steer
axle. Start the engine
and manually activate
the directional valve.
Check the pressure.
less
than
950 psi
Adjust the sequence
valve. See Repair
procedure 10-5, Howto
Adjust the Oscillate
Sequencing Valve
Pressure OR consult
Department.
950 psi
Service Department.
Chart 28
Steer Left
Function
Inoperative
n o rm a lly.
With key switch in
both Emergency Stop
footswitch and steer
rocker switch on drive
controller (DP1) in left
direction and check
voltage on TB36.
0V
12V or more
With key switch in
both Emergency Stop
direction and check
voltage at the controller
terminal with the blu
wire attached.
12V or
more
Repair open in blu #36
wire circuit fromdrive
controller (DP1) to TP36
then to TB36.
0V
Repair or replace steer
microswitch on drive
controller. Consult
Department.
page.
With key switch in
both Emergency Stop
direction and check
voltage on blu #36 wire
on steer left directional
valve coil (itemSS) on
steer manifold.
12V or more
0V
Repair open in blu #36
wire circuit that runs
fromTB36 to steer left
directional valve coil on
steer manifold.
Disconnect wires to
steer left directional
steer manifold and test
the resistance of the
valve coil.
0 or
infinite
ohms
Replace steer left
(itemSS) OR repair
wire to steer left valve
coil.
5 to 6 ohms
Continued fromthe
previous page.
gauge at the quick
the boomfunction
manifold and activate
the steer left function.
2600
PSI or
more
less than 2600 PSI
cylinder OR steer
Department.
steer left function from
replace steer cylinder
OR consult Genie
Industries Service
Department.
C H A R T 2 8
Chart 29
Steer Right
Function
Inoperative
n o rm a lly.
With key switch in
both Emergency Stop
controller (DP1) in right
direction and check
voltage on TB37.
0V
12V or more
With key switch in
both Emergency Stop
direction and check
voltage at the controller
terminal with the blu/blk
wire attached.
12V or
more
drive controller (DP1) to
TP37 then to TB37.
0V
microswitch on drive
controller. Consult
Department.
page.
With key switch in
both Emergency Stop
direction and check
voltage on blu/blk #37
wire on steer right
(itemSS) on steer
manifold.
12V or more
0V
#37 wire circuit that runs
fromTB37 to steer right
directional valve coil on
steer manifold.
Disconnect wires to
steer right directional
steer manifold and test
the resistance of the
valve coil.
0 or
infinite
ohms
Replace steer right
(itemSS) OR repair
wire to steer right valve
coil.
5 to 6 ohms
C H A R T 2 9
Continued fromthe
previous page.
gauge at the quick
the boomfunction
manifold and activate
the steer right function.
2600
PSI or
more
less than 2600 PSI
cylinder OR steer
Department.
steer right function from
replace steer cylinder
OR consult Genie
Industries Service
Department.
All Drive
Functions
Inoperative,
All Other
Functions
Operate
Normally
B e su re th e rp m to g g le
switch is in th e
fo o tswitch a ctiva te d
h ig h id le p o sitio n .
B e su re th e h yd ra u lic
ta n k sh u t o ff va lve s a re
in th e O P E N p o sitio n .
B e su re m a ch in e is
n o t in th e fre e wh e e l
co n fig u ra tio n .
Chart 30
With the drive speed
selector toggle switch
(TS8) in the high
footswitch and hold the
drive joystick in the full
forward position and
terminal #10 on the
horsepower limiter
board.
0V
9 to 12V
page.
With the keyswitch
turned to platform
control and both
the drive joystick (DP1).
less
than
12V
to terminal #2 on drive
joystick (DP1).
12V or more
Check continuity of
brown ground wire from
terminal #3 on DP1 to
ground.
continuity
no continuity
ground wire circuit from
ground to DP1.
With the keyswitch
turned to platform
control and both
the horsepower limiter
circuit board.
12V or more
less
than
12V
to terminal #1 on the
horsepower limiter
circuit board.
Check continuity of
brown ground wire from
terminal #2 on the
horsepower limiter
circuit board to ground.
continuity
no continuity
ground to the
horsepower limiter
circuit board.
Replace horsepower
limiter board.
(TS8) in the high
board.
7 to 8V
0V
(TS8) in the high
voltage on the org/blk
wire on the alterator.
7 to 8V
0V
Repair or replace
alternator.
wire fromalternator to
TB41 to TP41 to
terminal #3 on
horsepower limiter
board.
C H A R T 3 0
Continued fromthe
previous page.
Repair open in wire from
terminal #10 on
horsepower limiter
board to terminal #6 on
drive joystick.
and hold the drive
joystick in the full
terminal #6 on the
joystick controller.
9 to 12V
Connect the positve
lead froma voltmeter to
terminal #4 on the
joystick and the negative
lead to terminal #5 on
the joystick. Activate the
check the voltage
across the #4 and #5
terminals on the drive
0V
2V
Replace drive joystick
controller OR consult
Department.
0V
no
continuity
continuity
terminal #3 on drive
joystick to ground.
joystick to ground.
Connect the positve
lead froma voltmeter to
terminal #5 on the
joystick and the negative
lead to terminal #4 on
the joystick. Activate the
reverse position and
check the voltage
across the #5 and #4
terminals on the drive
0V
Replace drive joystick
controller OR consult
Department.
no
continuity
continuity
joystick to ground.
joystick to ground.
2V
page.
Continued fromthe
previous page.
and hold the drive
check the voltage
across the wht #12 wire
and the wht/blk #31 wire
on EDC.
0V
2V
wire fromTS9 to TP12
to TB12.
With the footswitch
activated and the drive
forward position, move
the drive enable toggle
switch (TS9) to either
side and check the
voltage across the wht
#12 wire and the wht/blk
#31on EDC.
2V
0V
fromterminal #4 on
drive joystick to TS9 to
TP30 to TB30 through
drive enable limit switch
(LS3) to TB12 to wht
#12 wire on EDC quick
disconnect plug.
With the footswitch
forward position, move
the drive enable toggle
side and check the
voltage at the blu/wht
wire on TS9.
9 to 12V
0V
Replace drive enable
toggle switch TS9.
0V
9 to 12V
With the footswitch
forward position, check
the voltage on the
center terminal of the
drive enable toggle
switch (TS9).
Repair open in wire from
terminal #4 fromdrive
joystick DP1 OR replace
drive joystick controller
OR consult Genie
Industries Service
Department.
Troubleshoot drive
forward and drive
reverse functions
separately OR replace
pump OR consult Genie
Industries Service
Department.
C H A R T 3 0
Chart 31
Drive Forward
Or Reverse
Function
Inoperative
n o rm a lly in clu d in g
d rive in o p p o site
d ire ctio n o f
m a lfu n ctio n .
Disconnect the EDC
wire connector fromthe
drive pump, start
engine, move the drive
controller to full forward
position and note the
voltage across terminals
TB30 and TB31.
Reverse the volt meter
leads and move the
drive controller to full
reverse position and
note the voltage.
voltage readings different Repair or replace the
drive controller.
voltage readings
the same
Adjust the drive pump
null (neutral). Consult
Department.
no improvement
Defective Sundstrand
drive pump, contact
Sundstrand authorized
repair facility.
symptoms improve
Re-adjust drive joystick
controller OR if problem
still persists, consult
Department.
Check the resistance of
the EDC.
0 or
infinite
ohms
Replace the EDC.
20 to 24 ohms
Chart 32
Traction
Function
Inoperative
n o rm a lly.
Any type of traction
problem, consult Genie
Industries Service
Department.
Chart 33
Machine Will
Not Drive At
Full Speed
n o rm a lly.
B e su re th e m a ch in e is
n o t ra ise d a b o ve o r
e xte n d e d b e yo n d th e
d rive lim it switch e s.
B e su re th e b o o m d rive
lim it switch is cle a r o f
a n y d e b ris a n d is n o t
a ctiva te d wh e n th e
b o o m is in th e sto we d
p o sitio n .
B e su re th a t th e b o o m
e xte n d d rive lim it switch
a rm is b e in g h e ld d o wn
wh e n th e b o o m is
re tra cte d .
B e su re th e wirin g to
lim it switch e s is in ta ct
a n d sh o w n o sig n o f
d a m a g e o r co rro sio n .
B e su re th e fre e -wh e e l
va lve is clo se d o n th e
d rive p u m p .
B e su re th e d rive sp e e d
se le ct switch is o n h ig h
ra n g e (m a ch in e o n le ve l
su rfa ce sym b o l).
With the boomin the
stowed position, check
continuity fromTB40 to
ground.
continuity
Check for correct wiring
of limit switches
(LS1 and LS2) OR
repair or replace boom
lift drive limit switch or
boomextend limit
switch.
no continuity
With the boomin the
stowed position, check
terminal #6 on
horsepower limiter
board for continuity to
ground.
continuity
in orange wire shorted
to ground fromTB40 to
TP40 to terminal #6 on
horsepower limiter
circuit board.
no continuity
Re-adjust or replace
horsepower limiter
board OR check for
misalignment of limit
switches (LS1 and LS2)
OR consult Genie
Industries Service
Department.
Chart 34
Machine Drives
At Full Speed
With Platform
Raised or
Extended
B e su re b o o m d rive lim it
switch is b e in g a ctiva te d
b y th e ca m o n th e b o o m
wh e n th e b o o m is
ra ise d .
B e su re th a t th e b o o m
e xte n d d rive lim it switch
is n o t b e in g h e ld d o wn
o r b e in g a ctiva te d wh e n
th e b o o m is e xte n d e d .
B e su re th e wirin g to
lim it switch e s is in ta ct
a n d sh o w n o sig n o f
d a m a g e o r co rro sio n .
Extend the boompast
the drive limit switch and
check continuity from
ground to terminal #6 on
board.
continuity
no continuity
ground to TB40.
continuity Repair open in org wire
circuit fromTB40 to
TP40 to terminal #6 on
horsepower limiter
circuit board.
no continuity
Repair open fromwht
wires at TB40 to drive
limit switches (LS1 and
LS2), then frombrown
ground wires to ground.
bad
good
Test limit switches. See
procedure A-14 in the
Maintenance Section.
Replace defective limit
switch contact OR
replace limit switch.
Replace horsepower
limiter board OR re-
adjust horsepower
limiter board OR consult
Department.
Chart 35
Drive Enable
System Is
Malfunctioning
B e su re th e b o o m is in
th e sto we d p o sitio n .
With keyswitch in
both Emergency Stop
ON position and the
boomrotated between
the non-steer tires,
activate footswitch and
drive controller in
forward direction. Will
unit drive?
no
yes
no continuity
continuity
0V
Repair open from
terminal #4 on DP1 to
center terminal on TS9
OR refer to Chart 30 OR
Service Department.
12V or more
supply circuit from
TP24.
yes
wire fromdrive enable
toggle switch (TS9) to
TP12 to TB12 OR
replace drive enable
toggle switch (TS9).
With keyswitch in
both Emergency Stop
footswitch and drive
controller in forward
direction and check
drive controller (DP1).
With keyswitch in
both Emergency Stop
ON position and the
boomrotated between
the steer end tires,
activate footswitch and
drive controller in
forward direction. Will
unit drive?
yes
no
Hold the drive enable
side and activate the
footswitch and drive
forward function. Will
unit drive?
The machine is
operating correctly. If
machine does not
operate properly,
Service Department.
no
Check for continuity
fromTB30 to TB12.
Replace drive enable
limit switch contact OR
replace drive enable
limit switch (LS3).
Activate limit switch by
hand and check
continuity fromTB30 to
TB12.
continuity
no continuity
Repair open fromTB30
through red wire to LS3
then fromLS3 through
blk wire to TB12.
Please begin
troubleshooting from
beginning of chart OR
Service Department.
Chart 36
Auxiliary
Functions
Inoperative
n o rm a lly.
B e su re ke y switch
is in th e a p p ro p ria te
p o sitio n a n d th e
E m e rg e n cy S to p
b u tto n s a re p u lle d
o u t to th e O N
p o sitio n .
B e su re e n g in e is
n o t ru n n in g wh e n
u sin g a u xilia ry
p o we r.
N o te : O p e ra tin g
a u xilia ry p o we r with
th e e n g in e ru n n in g
sh o u ld im m e d ia te ly
kill th e e n g in e .
Lift the red auxiliary
pump switch cover
switch cover, hold
auxiliary switch and
listen for sound of
auxiliary pump motor
operating.
motor
operates
gauge into the pressure
port of the auxiliary
pump and hold the
auxiliary power toggle
switch and note the
pressure.
2500 psi
Repair or replace pump
OR relief valve is out of
adjustment. Consult
Department.
less than
2500 psi
Reconnect pressure
line and check battery
condition. There is
possibly not enough
battery capacity to
operate both aux. pump
and function valves.
motor does
not operate
With the keyswitch
and both Emergency
to the ON position,
activate the auxiliary
pump toggle switch and
check the voltage on the
red cable on the
auxiliary power unit.
good
Check for a positive
connection between
electric motor and the
pump by removing the
pump fromthe motor,
but leave all the hoses
connected. Visually
check coupling
connection.
bad
Replace the auxiliary
power unit.
12V
0V Test PR1. See Repair
Procedure 8-5.
bad
Replace PR1.
good
Activate the auxiliary
TB27.
12V or
more
0V
Repair open fromTB27
to PR1.
Activate the auxiliary
check the voltage at the
center terminal of TS10.
0V
Repair open from
keyswitch (KS1) to
auxiliary toggle switch
(TS10).
12V or more
Repair open in red #27
OR replace TS10 OR
ground wire to PR1.
page.
negative terminal on
auxiliary power unit to
ground.
Continued fromthe
previous page.
good
bad
Replace negative cable
fromauxiliary pump to
ground.
Replace auxiliary pump
motor.
C H A R T 3 6
Schematics
Observe and Obey:
T ro u b le sh o o tin g a n d re p a ir p ro ce d u re s sh a ll b e
co m p le te d b y a p e rso n tra in e d a n d q u a lifie d o n
th e re p a ir o f th is m a ch in e .
Before Troubleshooting:
a n d o p e ra tin g in stru ctio n s p rin te d in th e
Genie S-60 and Genie S-65 Operator's
Manual.
B e su re th a t a ll n e ce ssa ry to o ls a n d te st
e q u ip m e n t a re a va ila b le a n d re a d y fo r u se .
About This Section
T h e re a re two g ro u p s o f sch e m a tics in th is se ctio n .
A n illu stra tio n le g e n d p re ce d e s e a ch g ro u p o f
d ra win g s.
Electrical Schematics
e le ctrica lly ch a rg e d circu its m a y
re su lt in d e a th o r se rio u s in ju ry.
R e m o ve a ll rin g s, wa tch e s a n d
o th e r je we lry.
Hydraulic Schematics
g ra d u a lly. D o n o t a llo w o il to sq u irt
o r sp ra y.
Malfunction
discovered
Identify
symptoms
Troubleshoot
Perform
repair
Return to
service
problem
solved
problem
still exists
Inspect
and test
S e rvice M a n u a l - S e co n d E d itio n S e ctio n 6 - S ch e m a tics
Item Description Genie Manufacturer Manufacturer Qty
Part Number Part Number
B A T . . . . . . . . . . . . . . . . B a tte ry, 1 0 0 0 C C A , 1 2 V D C . . 3 0 1 4 3 . . . . . . . . . . . T ro ja n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C 3 1 X H -2 . . . . . . . . . . . . . . . . . . . . . . . . 1
B P 1 . . . . . . . . . . . . . . . . J o ystick co n tro lle r
S in g le a xis, u p /d o wn . . . . . . . . . . . . . . 2 4 4 9 5 . . . . . . . . . . . O E M C o n tro ls . . . . . . . . . . . . . . . . . . . . . . E M S 4 M 6 8 8 3 . . . . . . . . . . . . . . . . . . 1
B P 2 . . . . . . . . . . . . . . . . J o ystick co n tro lle r
D u a l a xis, S win g /e xte n d . . . . . . . . 4 0 6 1 3 . . . . . . . . . . . O E M C o n tro ls . . . . . . . . . . . . . . . . . . . . . . E J S 5 M 1 0 0 8 9 . . . . . . . . . . . . . . . . . 1
C B 1 , C B 2 . . . . . . . C ircu it b re a ke r . . . . . . . . . . . . . . . . . . . . . . . 2 4 0 1 8 . . . . . . . . . . . E T A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5 -7 0 0 -I G 1 -P 1 0 . . . . . . . . . . . . . 2
C R 1 th ro u g h
C R 7 . . . . . . . . . . . . . . . . R e la y, S P D T , 1 2 V D C . . . . . . . . . . . 3 4 0 5 2 . . . . . . . . . . . P o tte r-B ru m fie ld . . . . . . . . . . . . . . . . . . V F 4 -1 5 F 1 1 -C O 5 . . . . . . . . . . . . 6
C R 1 3 , 1 4 ,
1 7 a n d 1 8 . . . . . . . R e la y, S P D T , 1 2 V D C . . . . . . . . . . . 1 9 2 7 4 . . . . . . . . . . . P o tte r-B ru m fie ld . . . . . . . . . . . . . . . . . . V F 4 -4 5 F 1 1 -C O 5 . . . . . . . . . . . . 4
D io d e . . . . . . . . . . . . . . D io d e , 6 a m p , 2 0 0 P I V . . . . . . . . . . 4 5 7 8 2 . . . . . . . . . . . M o to ro la . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M O T M R 7 5 2 . . . . . . . . . . . . . . . . . 4 3
D P 1 . . . . . . . . . . . . . . . . J o ystick co n tro lle r-D rive . . . . . . . . 2 0 4 2 4 . . . . . . . . . . . O E M C o n tro ls . . . . . . . . . . . . . . . . . . . . . . M C H 1 1 5 9 A D 1 3 8 6 . . . . . . . . . . 1
F B . . . . . . . . . . . . . . . . . . F la sh in g b e a co n . . . . . . . . . . . . . . . . . . . . 2 0 1 8 9 . . . . . . . . . . . E C C O E le ctro n ic C o n tro ls . . . 6 4 0 0 X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F S 1 . . . . . . . . . . . . . . . . F o o tswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 4 8 2 . . . . . . . . . . . L in e m a ste r S witch C o rp . . . . . . 6 3 2 -S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
G 1 . . . . . . . . . . . . . . . . . . G a u g e - V o lta g e . . . . . . . . . . . . . . . . . . . . 3 0 7 8 9 . . . . . . . . . . . V D O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 2 -5 0 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
G 2 . . . . . . . . . . . . . . . . . . G a u g e - O il P re ssu re . . . . . . . . . . . . . 3 0 7 8 6 . . . . . . . . . . . V D O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 0 -5 1 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
G 3 . . . . . . . . . . . . . . . . . . G a u g e - Wa te r T e m p . . . . . . . . . . . . 3 0 7 8 7 . . . . . . . . . . . V D O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 0 -5 0 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
H 1 . . . . . . . . . . . . . . . . . . A la rm , Wa rb le to n e . . . . . . . . . . . . . . . . 1 9 2 7 0 . . . . . . . . . . . F lo yd B e ll I n c. . . . . . . . . . . . . . . . . . . . . . . M W-0 9 -6 1 6 -Q . . . . . . . . . . . . . . . . 1
H 2 . . . . . . . . . . . . . . . . . . H o rn , 1 2 V D C , 1 3 0 d B . . . . . . . . . . . 1 9 1 4 5 . . . . . . . . . . . S p a rto n E n g in e e re d P ro d . . . . 7 4 3 1 A -2 4 8 2 3 -5 . . . . . . . . . . . . . . 1
H 3 . . . . . . . . . . . . . . . . . . A la rm , in te rm itte n t . . . . . . . . . . . . . . . . . 1 8 9 6 3 . . . . . . . . . . . F lo yd B e ll I n c. . . . . . . . . . . . . . . . . . . . . . . X B -0 9 -6 3 0 -Q . . . . . . . . . . . . . . . . . . 1
H 4 . . . . . . . . . . . . . . . . . . A la rm , ch im e to n e . . . . . . . . . . . . . . . . . 4 5 4 6 2 . . . . . . . . . . . F lo yd B e ll I n c. . . . . . . . . . . . . . . . . . . . . . . C H -0 9 -5 2 5 -Q . . . . . . . . . . . . . . . . . 1
H M . . . . . . . . . . . . . . . . . H o u rm e te r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9 5 0 6 . . . . . . . . . . . E N M C o rp o ra tio n . . . . . . . . . . . . . . . . . T 4 0 A 4 5 0 8 . . . . . . . . . . . . . . . . . . . . . . 1
K S 1 . . . . . . . . . . . . . . . . C o n ta ct - K e yswitch , N . O . . . . . . 4 5 0 8 1 . . . . . . . . . . . T e le m e ca n iq u e . . . . . . . . . . . . . . . . . . . . Z B 2 -B E 1 0 1 . . . . . . . . . . . . . . . . . . . . 2
L 1 . . . . . . . . . . . . . . . . . . . L E D - R e d , 1 2 V D C . . . . . . . . . . . . . . . 3 2 3 3 5 . . . . . . . . . . . A rcto le ctric C o rp . . . . . . . . . . . . . . . . . . L E 1 7 7 C 3 9 0 0 7 . . . . . . . . . . . . . . . . 1
L S 1 , 2 , 3 . . . . . . . . C o n ta ct - L im it switch ,
N . C . H . O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9 4 9 1 . . . . . . . . . . . T e le m e ca n iq u e . . . . . . . . . . . . . . . . . . . . X E S P 2 0 5 1 . . . . . . . . . . . . . . . . . . . . . 3
L e ve l se n so r . . L e ve l se n so r, 4 . 5 . . . . . . . . . . . . . . . . . . 4 4 5 8 6 . . . . . . . . . . . P o we r C o m p . o f M id we st . . . . L S 3 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
This list continues on the next page.
Electrical Components
E L E C T R I C A L C O M P O N E N T S
Item Description Genie Manufacturer Manufacturer Qty
Part Number Part Number
P 1 , P 2 . . . . . . . . . . . . C o n ta ct, N . C . . . . . . . . . . . . . . . . . . . . . . . . . . 2 9 7 3 2 . . . . . . . . . . . T e le m e ca n iq u e . . . . . . . . . . . . . . . . . . . . Z B 2 -B E 1 0 2 . . . . . . . . . . . . . . . . . . . . 4
P 3 . . . . . . . . . . . . . . . . . . . C o n ta ct, N . O . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5 0 8 1 . . . . . . . . . . . T e le m e ca n iq u e . . . . . . . . . . . . . . . . . . . . Z B 2 -B E 1 0 1 . . . . . . . . . . . . . . . . . . . . 1
P R 1 . . . . . . . . . . . . . . . . R e la y, 1 2 V D C co n tin u o u s . . . . 2 7 1 5 5 . . . . . . . . . . . S ta n co r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 0 -9 0 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
R 1 . . . . . . . . . . . . . . . . . . R e sisto r, 1 0 0 2 5 wa tt . . . . . . . . . . 2 7 1 1 6 . . . . . . . . . . . D a le . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R H 2 5 -1 0 0 R -1 % . . . . . . . . . . . . . 1
R e sisto r, 1 5 0 2 5 wa tt . . . . . . . . . . 3 4 7 9 8 . . . . . . . . . . . D a le . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R H 2 5 -1 5 0 -1 % . . . . . . . . . . . . . . . . 1
R 2 . . . . . . . . . . . . . . . . . . R e sisto r, 1 0 2 5 wa tt . . . . . . . . . . . . 2 7 2 8 7 . . . . . . . . . . . D a le . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R H 2 5 -1 0 R -1 % . . . . . . . . . . . . . . . 1
T S 1 , T S 1 0 . . . . . . T o g g le switch , D P S T
2 p o sitio n m o m e n ta ry . . . . . . . . . . . . 1 3 4 8 0 . . . . . . . . . . . M icro switch C o n tro l I n c. . . . . . . 2 N T 1 -8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
T S 2 , 6 , 9 , 1 1 ,
1 3 , 1 5 . . . . . . . . . . . . . T o g g le switch , S P D T
T S 3 , 8 ,
1 2 , 2 0 . . . . . . . . . . . . . T o g g le switch , D P S T
2 p o sitio n m a in ta in e d . . . . . . . . . . . . 2 7 3 7 8 . . . . . . . . . . . M icro switch C o n tro l I n c. . . . . . . 2 N T 1 -3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
T S 4 . . . . . . . . . . . . . . . . T o g g le switch , D P D T
3 p o sitio n m a in ta in e d . . . . . . . . . . . . 1 3 0 3 8 . . . . . . . . . . . M icro switch C o n tro l I n c. . . . . . . 2 N T 1 -1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
T S 5 , 7 , 1 4 , 1 6 ,
1 7 , 1 8 , 1 9 . . . . . . . T o g g le switch , D P D T
V A C . . . . . . . . . . . . . . . . V a cu u m switch . . . . . . . . . . . . . . . . . . . . . . 2 2 2 7 8 . . . . . . . . . . . P e te rso n I n d u stria l . . . . . . . . . . . . . . 1 5 0 1 -L . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Electrical Symbols Legend
+
-
O
R
G
/
B
L
K
-
1
15AMP.
TB20
ALARM
TILT
L4 OP
TP29
B
L
K
G
R
N
/B
L
K
TB17
1
0
BLK #21 TB21
Battery
Wire color
with cable
number
TB=Terminal base
TP=Terminal platform
Dual axis
Ramp up and down
Horsepower
limiter board
Single axis
drive controller
Ignition start
module
Circuit breaker
Connection
no terminal
Spark plug
Terminal
P1
Emergency Stop
button
normally closed
KS1
GRND
PLAT
Key switch
PR4
Relay panel
contactor
Solenoid or
relay coil
Horn
Tilt sensor
NC
LS2
Limit switch
normally closed
held open
NO
LS1
Limit switch
normally open
held closed
HORN P4
Horn button
normally open
T-circuits
connect
T
W
H
T
#
5
1
TR2
1
2
3
6
Time delay relay
O
P
S
1
N
.
C
.
Oil pressure
switch
normally closed
Light
W
T
S
1
N
.
O
.
Water temperature
switch
normally open
Quick disconnect
terminal
Diode
RED
BLK
FS1
Foot switch
C
R
4
Relay contact
normally open
TS3
S
T
A
R
T
E
N
G
IN
E
Toggle switch SPDT
Circuits crossing
no connection
TS6
R
IG
H
T
L
E
F
T
Toggle switch DPDT
Ground
supression
circuit
Glow plug
T-circuits connect
at terminal
R
X
-
+
A
PWM
BP2
Single axis
proportional
controller
Resistor
VAC
Vacuum switch
Auxiliary pump
PUMP
AUX.
2 TACHOMETER
10
7
8
9
KEY PWR.
KEY BYPASS
ENG. FAULT
IGN./FUEL ON
5
6
4
3
AUX. ON
START INPUT
GROUND
BATTERY
1 START RELAY
7
9
8
10
2
4
5
3
6
1
5
6
8
7
DP1
1
3
4
2
Limit switch
W
H
T
-
5
R
E
D
-
5
B
L
K
-
5
NO
G
R
N
-
5
LS3
NC
R
D1
A
-
D2
+
+
R
D1
A
D2
-
BP1
LABEL DESCRIPTION
B A T . . . . . . . . . . . . . B a tte ry
B P . . . . . . . . . . . . . . . P ro p o rtio n a l co n tro lle r
C B . . . . . . . . . . . . . . . C ircu it b re a ke r
C R . . . . . . . . . . . . . . . C o n tro l re la y
D P . . . . . . . . . . . . . . . D rive p ro p o rtio n a l co n tro lle r
F B . . . . . . . . . . . . . . . . F la sh in g b e a co n
F S . . . . . . . . . . . . . . . . F o o t switch
G . . . . . . . . . . . . . . . . . G a u g e
H . . . . . . . . . . . . . . . . . . H o rn o r A la rm
H M . . . . . . . . . . . . . . . H o u r m e te r
K S . . . . . . . . . . . . . . . K e yswitch
L . . . . . . . . . . . . . . . . . . L E D
L S . . . . . . . . . . . . . . . . L im it switch
P . . . . . . . . . . . . . . . . . . P o we r switch
P R . . . . . . . . . . . . . . . P o we r re la y
R . . . . . . . . . . . . . . . . . . R e sisto r
T B . . . . . . . . . . . . . . . . T e rm in a l b a se lo ca tio n
T P . . . . . . . . . . . . . . . . T e rm in a l p la tfo rm lo ca tio n
T S . . . . . . . . . . . . . . . . T o g g le switch
V A C . . . . . . . . . . . . . V a cu u m switch
Abbreviation Legend
Service Manual Section 6 - Schematics
Electrical Schematic-
Gasoline/LPG Models
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
6 - 7 Genie S-60 & Genie S-65 Part No. 48412
REV B
Part No. 48412 Genie S-60 & Genie S-65 6 - 8
Gasoline/LPG Models
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
REV B
Ground Control Box Legend-
Gasoline/LPG Models
Ground Control Box Wiring Diagram-
Gasoline/LPG Models
Platform Control Box Legend-
Gasoline/LPG Models
Platform Control Box Wiring Diagram-
Gasoline/LPG Models
S e rvice M a n u a l S e ctio n 6 - S ch e m a tics
Diesel Models
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
S e rvice M a n u a l S e ctio n 6 - S ch e m a tics
Diesel Models
1
2
3
4
5
6
7
8
Ground Control Box Legend-
Diesel Models
Ground Control Box Wiring Diagram-
Diesel Models
Platform Control Box Legend-
Diesel Models
Platform Control Box Wiring Diagram-
Diesel Models
Hydraulic Symbols Legend
E
Pressure gauge
Filter
Fixed displacement
pump
Bi-directional,
variable
displacement pump
Bi-directional motor
2-speed,
bi-directional motor
Pump prime mover
(engine or motor)
Cylinder
Accumulator
Orifice with size
0.035
Variable orifice
or shut-off valve
Check valve
Relief valve
Priority
flow divider
Solenoid operated
dump valve
Differential
sensing valve
Solenoid operated
proportional valve
Flow regulator valve
Solenoid operated 2 pos.,
3 way, directional valve
4 way, directional valve
4 way, directional valve (DO1)
2 pos., 3 way, shuttle valve
3 pos., 4 way, directional valve
Sequencing valve
Unloader valve
Pressure compensating valve
Counterbalance valve
Pilot operated flow
control valve
1
2
3
4
5
6
7
8
2WD Hydraulic Schematic
Non-Oscillating Axle
3500
14 GPM.
PRESSURE
FILTER
MEDIUM
FUNCTION
RESERVOIR
DRIVE PUMP
3500
PSI
290
PSI
3
PSI
3
PSI
E
25
PSI
PUMP
50
PSI
STEERING
CYLINDER
PSI
AUX. PUMP
SEC
PRESS.
T1
2500
PSI
PSI
REG
TANK
PRESS.
PR2 PR1 PL1
X
PL2
X
P1 P2 S1 S2
3.5
GPM
TEST
.025
REAR
RIGHT
M7
M5
LEFT
REAR
M1
M3
OPTIONAL
GENERATOR
STEER MANIFOLD
MASTER
CYLINDER
ROTATE
BOOM EXTENSION CYLINDER
BOOM UP/DOWN
SLAVE
CYLINDER
FUNCTION
MANIFOLD
MANIFOLD
TURNTABLE
PRIMARY SECONDARY
SELECT
GENERATOR
250
PSI
JIB BOOM
.030
.030
JIB BOOM
MANIFOLD
PLATFORM ROTATE
HYDRAULIC
ROTARY
COUPLER
.035
DRIVE
M
.070
* S-60 Models = 2600 psi
S-65 Models = 2900 psi
OIL
COOLER
OPTIONAL
CASE DRAINS
250 PSI
ACCUM.
1200
PSI
*
GPM
0.6
GPM
0.1
GPM
0.6
PSI
2100
2500
PSI
BRAKE 2 SPEED
TWO SPEED/
BRAKE MANIFOLD
A B
F
G
K
M
L
O
N
T
Q
Y
P
Z
S
U
H I
R
J
V
X
W
C
D
E
GG
AA
CC
BB
EE
II JJ
HH
FF
AN
AM AM
AN
RR
VV
WW
YY
XX
DD
1
1
SECOND COUNTERBALANCE VALVE ADDED
AFTER SERIAL NUMBER 4862
1
2
3
4
5
6
7
8
Oscillating Axle
14 GPM.
PRESSURE
FILTER
MEDIUM
FUNCTION
RESERVOIR
DRIVE PUMP
3500
PSI
290
PSI
3 3
PSI PSI
E
25
PSI
PUMP
50
PSI
STEERING
AUX. PUMP
2500
PSI
REAR
RIGHT
M7
M5
LEFT
REAR
M1
M3
3.5 gpm
OPTIONAL
MOTOR/GEN.
STEER MANIFOLD
MANIFOLD
SELECT
GENERATOR
250
PSI
HYDRAULIC
ROTARY
COUPLER
DRIVE
M
* S-60 Models = 2600 psi
S-65 Models = 2900 psi
.070
OIL
COOLER
OPTIONAL
CASE DRAINS
.030
TEST
T1
PRESS.
.030
SEC
*
PSI
REG
5.0
GPM
0.6
GPM
GPM
0.1
0.6
GPM
PR2 PR1
MANIFOLD
FUNCTION
MANIFOLD
JIB BOOM
2500
PSI
PL1 PL2
MASTER
CYLINDER
.035
JIB BOOM PLATFORM ROTATE
SLAVE
X
X
PSI
1200
PSI
2500
S2 S1 P1
250 PSI
2100
PSI
P2
ACCUM.
PRESS.
TANK
TURNTABLE
ROTATE
PRIMARY SECONDARY
BOOM EXTENSION
CYLINDER
B VALVE
A VALVE
OSCILLATE CYLINDERS
OSCILLATE MANIFOLD
P
B CYL
A CYL
PSI
950
P8 .052
2 SPEED
BRAKE MANIFOLD
TWO SPEED/
P
.025
T
BRAKE
.025
W
Y Z
CC
BB
VV
YY
XX
WW
FF EE
II JJ
HH
AA
DD
RR
LL KK
NN
OO
PP
MM
QQ
UU TT SS
V J
T
U
S
Q P
A
R
H I
G
M O
K L N
F
D
GG
E
C B
X
BOOM UP/DOWN
1
1
1
2
3
4
5
6
7
8
Non-Oscillating Axle
14 GPM.
PRESS.
FILTER
MED.
FUNCTION
RESERVOIR
DRIVE PUMP
3500
PSI
290
PSI
3
PSI
3
PSI
E
25
PSI
PUMP
50
PSI
STEERING
AUXILIARY PUMP
2500
PSI
OPTIONAL
MOTOR/GENERATOR
STEER MANIFOLD
SELECT
GENERATOR
HYDRAULIC
ROTARY
M
* 2900 PSI WITH JIB
* 2600 PSI W/O JIB
OIL
COOLER
OPTIONAL
TURNTABLE
0.030
0.030
0.035
TEST
T1
PRESS.
SEC
*
PSI
REG
3.5
GPM
0.6
GPM
GPM
0.1
0.6
GPM
PR2 PR1
MANIFOLD
FUNCTION
MANIFOLD
JIB BOOM
PLATFORM
LEVEL
3500
PSI
PL1 PL2
MASTER
JIB BOOM PLATFORM ROTATE
SLAVE
X
X
PSI
PSI
1200
1200
PSI
2500
RETRACT
S2 S1
BOOM
P1
250 PSI
EXTEND
2100
PSI
P2
ACCUM.
PRESS.
TANK
TURNTABLE
ROTATE
PRIMARY SECONDARY
BOOM EXTENSION
CYLINDER
2 SPEED
BRAKE MANIFOLD
TWO SPEED/
BRAKE
P
0.025
.052
.070
.070
T
M7
CASE DRAINS
P
LEFT
REAR
RIGHT
REAR
M1
M3
M5
MANIFOLD
DRIVE
A
M8
M2
M4
LEFT
FRONT
M6
RIGHT
FRONT
COUPLER
250
PSI
T
B
H I
R
A
P
EE FF
S
X
Z Y
U
T DD
AM AM
AA
BB
AB
AE
AL
AC
AH
AI
AJ
AF
AG
AD
AK
HH
II JJ
CC
GG
Q
J V
W
SS
F
B C
K
O
L N
E
D
G
M
BOOM UP/DOWN
1
1
1
2
3
4
5
6
7
8
Oscillating Axle
14 GPM.
PRESS.
FILTER
MED.
FUNCTION
RESERVOIR
DRIVE PUMP
3500
PSI
290
PSI
3
PSI
3
PSI
E
25
PSI
PUMP
50
PSI
STEERING
AUX. PUMP
2500
PSI
3.5
OPTIONAL
MOTOR/GEN.
STEER MANIFOLD
SELECT
GENERATOR
HYDRAULIC
ROTARY
COUPLER
M
* 2600 W/O JIB
* 2900 WITH JIB
OIL COOLER
OPTIONAL
B VALVE
A VALVE
P
X
PSI
950
B CYL
A CYL
X
P8
TURNTABLE
ROTATE
T1
TEST
0.030
0.030
PRESS.
PSI
*
5.0
GPM
GPM
0.6
GPM
GPM
0.1
GPM
0.6
PR2 PR1
MANIFOLD
FUNCTION
JIB BOOM
MANIFOLD
PLATFORM
3500
LEVEL
PSI
PL1 PL2
MASTER
0.035
JIB BOOM
PLATFORM ROTATE
SLAVE
X
X
1200
PSI
RETRACT
2500
PSI
S2 S1
BOOM
P1
250 PSI
EXTEND
PSI
2100
P2
ACCUM.
TANK
PRESS.
X
ROTATE
TURNTABLE
PRIMARY SECONDARY
BOOM EXTENSION
SEC REG
2 SPEED
BRAKE MANIFOLD
TWO SPEED/
BRAKE
P
0.025
T
0.025
0.070
0.070 0.052
0.052
RIGHT
REAR
LEFT
REAR
CASE DRAINS
RIGHT
FRONT
FRONT
B
P
M1
M3
M5
M7
M2
M4
LEFT
M6
M8
MANIFOLD
DRIVE
A
250
PSI
T
H I
R
A
P
EE FF
S
X
Z Y
U
T DD
AM AM
AA
BB
AB
AE
AL
AC
AH
AI
AJ
AF
AG
AD
AK
HH
II JJ
CC
GG
Q
J V
W
SS
UU TT
VV
KK
MM
OO
QQ
PP
NN
LL
F
B C
K
O
L N
E
D
G
M
1
BOOM UP/DOWN
1
S e rvice M a n u a l - S e co n d E d itio n S e ctio n 7 - R e p a ir P ro ce d u re s
Repair Procedures
About This Section
M o st o f th e p ro ce d u re s in th is se ctio n sh o u ld o n ly
b e p e rfo rm e d b y a tra in e d se rvice p ro fe ssio n a l
in a su ita b ly e q u ip p e d wo rksh o p . S e le ct th e
a p p ro p ria te re p a ir p ro ce d u re a fte r tro u b le sh o o tin g
th e p ro b le m .
P e rfo rm d isa sse m b ly p ro ce d u re s to th e p o in t
wh e re re p a irs ca n b e co m p le te d . T h e n to
re -a sse m b le , p e rfo rm th e d isa sse m b ly ste p s in
re ve rse o rd e r.
Symbols Legend
th a t will ca u se d e a th
th a t may ca u se d e a th
th a t will o r may ca u se se rio u s
p e rso n a l in ju ry o r
d a m a g e to th e m a ch in e .
I n d ica te s sp e cia l o p e ra tio n o r
m a in te n a n ce in fo rm a tio n .
I n d ica te s th a t a sp e cific re su lt is e xp e cte d
a fte r p e rfo rm in g a se rie s o f ste p s.
Observe and Obey:
R e p a ir p ro ce d u re s sh a ll b e co m p le te d b y a
p e rso n tra in e d a n d q u a lifie d o n th e re p a ir o f th is
m a ch in e .
Before Repairs Start:
a n d o p e ra tin g in stru ctio n s in th e
Genie S-60 & Genie S-65 Operators Manual.
B e su re th a t a ll n e ce ssa ry to o ls a n d p a rts a re
a va ila b le a n d re a d y fo r u se .
R e a d e a ch p ro ce d u re co m p le te ly a n d a d h e re
to th e in stru ctio n s. A tte m p tin g sh o rtcu ts m a y
p ro d u ce h a za rd o u s co n d itio n s.
re p a ir p ro ce d u re with th e m a ch in e in th e
M a ch in e p a rke d o n a fla t, le ve l su rfa ce
ke y re m o ve d
Malfunction
discovered
Identify
symptoms
Troubleshoot
Perform
repair
Return to
service
problem
solved
problem
still exists
Inspect
and test
1-1
Joystick Controllers
M a in ta in in g jo ystick co n tro lle rs a t th e p ro p e r
se ttin g s is e sse n tia l to sa fe m a ch in e o p e ra tio n .
E ve ry jo ystick co n tro lle r sh o u ld o p e ra te sm o o th ly
a n d p ro vid e p ro p o rtio n a l sp e e d co n tro l o ve r its
e n tire ra n g e o f m o tio n .
P la tfo rm co n tro l b o x
a h o rse p o we r lim ite r b o a rd
b te rm in a ls
c d rive p ro p o rtio n a l co n tro lle r
d e xte n d /re tra ct p ro p o rtio n a l co n tro lle r
e b o o m p ro p o rtio n a l co n tro lle r
f tu rn ta b le ro ta te p ro p o rtio n a l co n tro lle r
Boom Up/Down Controller
Adjustments
D o n o t a d ju st th e jo ystick
co n tro lle rs u n le ss th e sta tic b a tte ry
vo lta g e is a b o ve
1 2 V D C a n d th e a lte rn a to r
is o p e ra tin g p ro p e rly with
1 3 . 6 to 1 4 . 5 V D C o u tp u t.
1 C h e ck th e b a tte ry co n d itio n with a vo lt m e te r.
T h e re a d in g sh o u ld b e 1 2 V D C o r m o re to
a ccu ra te ly a d ju st th e co n tro lle r.
co n tro ls. D o n o t sta rt th e e n g in e .
3 O p e n th e p la tfo rm co n tro l b o x lid a n d lo ca te
th e b o o m u p /d o wn co n tro lle r.
a te rm in a l " D 2 " d ire ctio n a l o u tp u t
b te rm in a l " A " p ro p o rtio n a l o u tp u t
c te rm in a l " -" g ro u n d
d te rm in a l " +" p o sitive
e te rm in a l " R " a ctiva te s m a x-o u t ra n g e
f te rm in a l " D 1 " d ire ctio n a l o u tp u t
g ra m p ra te a d ju sta b le trim p o t
h lo ra n g e a d ju sta b le trim p o t
i th re sh o ld a d ju sta b le trim p o t
j h i ra n g e a d ju sta b le trim p o t
4 S e t th e p re lim in a ry ra m p ra te : T u rn th e trim p o t
a d ju stm e n t scre w co u n te rclo ckwise 1 5 tu rn s o r
u n til yo u h e a r a re p e a te d click.
5 C o n n e ct th e re d (+) le a d fro m a vo lt m e te r to
th e A te rm in a l o n th e co n tro lle r p rin te d circu it
b o a rd . C o n n e ct th e b la ck(-) le a d to g ro u n d .
6 S e t th e th re sh o ld : P re ss d o wn th e fo o t switch ,
th e n slo wly m o ve th e co n tro l h a n d le o ff ce n te r
u n til th e m o m e n t a vo lta g e re a d in g a p p e a rs.
A d ju st th e vo lta g e to 3 . 5 V D C . T u rn th e
th re sh o ld trim p o t a d ju stm e n t scre w clo ckwise to
in cre a se th e vo lta g e o r co u n te rclo ckwise to
d e cre a se th e vo lta g e .
Platform Controls
a b c d e f g h i j
b
c
a
d e f
1 6 S ta rt a tim e r a n d sim u lta n e o u sly m o ve th e
co n tro l h a n d le a ll th e wa y to th e U P p o sitio n .
N o te h o w lo n g it ta ke s to re a ch th e m a xim u m
vo lta g e re co rd e d in ste p 1 4 . T h is is th e
ra m p ra te .
1 7 S e t th e ra m p ra te : tu rn th e trim p o t to o b ta in
a 3 to 4 se co n d ra m p sp e e d . T u rn th e
trim p o t clo ckwise to in cre a se th e tim e o r
co u n te rclo ckwise to d e cre a se th e tim e .
Boom up/down specifications
T h re sh o ld 3 . 5 V D C
B o o m u p - h i ra n g e 8 . 5 V D C
C ycle tim e 5 5 to 8 5 se co n d s
B o o m d o wn - lo ra n g e 6 . 2 V D C
C ycle tim e 9 0 to 1 2 0 se co n d s
R a m p ra te 3 to 4 se co n d s
Turntable Rotation Controller
Adjustments
1 2 V D C a n d th e a lte rn a to r is
o p e ra tin g p ro p e rly with
1 3 . 6 to 1 4 . 5 V D C o u tp u t.
p u ll o u t th e E m e rg e n cy S to p b u tto n to
th e O N p o sitio n a t b o th th e g ro u n d a n d
p la tfo rm co n tro ls. D o n o t sta rt th e e n g in e .
7 S e t th e h i ra n g e : P re ss d o wn th e fo o t switch ,
th e n m o ve th e co n tro l h a n d le a ll th e wa y to
th e U P p o sitio n . A d ju st th e vo lta g e to 8 . 5 V D C .
T u rn th e m a x-o u t trim p o t a d ju stm e n t scre w
clo ckwise to in cre a se th e vo lta g e o r
co u n te rclo ckwise to d e cre a se th e vo lta g e .
8 S e t th e lo ra n g e : P re ss d o wn th e fo o t switch ,
th e n m o ve th e co n tro l h a n d le a ll th e wa y to th e
D O WN p o sitio n . A d ju st th e vo lta g e
to 6 . 2 V D C . T u rn th e d u a l ra n g e trim p o t
a d ju stm e n t scre w clo ckwise to in cre a se th e
vo lta g e o r co u n te rclo ckwise to d e cre a se
th e vo lta g e .
9 S ta rt th e e n g in e a n d m o ve th e e n g in e id le
co n tro l switch to fo o t switch a ctiva te d h ig h
id le (ra b b it a n d fo o t switch sym b o l). L o we r
E n g in e sh o u ld b e a t n o rm a l
1 0 S ta rt a tim e r a n d re co rd h o w lo n g it ta ke s fo r
th e b o o m to fu lly ra ise . A d ju st th e
m a x-o u t trim p o t to a ch ie ve a 5 5 to 8 5 se co n d
cycle tim e .
th e b o o m to fu lly lo we r. A d ju st th e d u a l ra n g e
trim p o t to a ch ie ve a n 9 0 to 1 2 0 se co n d cycle
tim e .
I f th e fu n ctio n cycle tim e is n o t
a ch ie va b le , ch e ck th e re lie f va lve
p re ssu re . S e e 1 0 -2 , Valve
Adjustments - Function Manifold.
1 2 T u rn th e e n g in e o ff a n d re -co n n e ct th e
vo lt m e te r.
1 3 P u ll o u t th e E m e rg e n cy S to p b u tto n to
1 4 P re ss d o wn th e fo o t switch a n d th e n m o ve th e
co n tro l h a n d le a ll th e wa y to th e U P p o sitio n .
R e co rd th e m a xim u m vo lta g e re a d in g .
1 5 S ta rt th e e n g in e .
P L A T F O R M C O N T R O L S
th e tu rn ta b le ro ta tio n co n tro lle r. R e fe r to th e
p la tfo rm co n tro l b o x illu stra tio n , p a g e 7 -2 .
a te rm in a l " D 2 " d ire ctio n a l o u tp u t
b te rm in a l " A " p ro p o rtio n a l o u tp u t
c te rm in a l " -" g ro u n d
d te rm in a l " +" p o sitive
e te rm in a l " R " a ctiva te s m a x-o u t ra n g e
f te rm in a l " D 1 " d ire ctio n a l o u tp u t
g ra m p ra te a d ju sta b le trim p o t
h lo ra n g e a d ju sta b le trim p o t
j h i ra n g e a d ju sta b le trim p o t
5 C o n n e ct th e re d (+) le a d fro m a vo lt m e te r to th e
A te rm in a l o n th e co n tro lle r p rin te d circu it
in cre a se th e vo lta g e o r co u n te rclo ckwise
to d e cre a se th e vo lta g e .
a b c d e f g h i j
7 S e t th e h i ra n g e : P re ss d o wn th e fo o t switch ,
fu lly re tra ct th e b o o m , th e n m o ve th e co n tro l
h a n d le a ll th e wa y to th e le ft o r rig h t. A d ju st th e
vo lta g e to 5 . 5 V D C . T u rn th e m a x-o u t trim p o t
vo lta g e o r co u n te rclo ckwise to d e cre a se th e
vo lta g e .
8 S e t th e lo ra n g e : P re ss d o wn th e fo o t switch ,
e xte n d th e b o o m 3 fe e t, th e n m o ve th e co n tro l
h a n d le a ll th e wa y to th e le ft o r rig h t. A d ju st th e
vo lta g e to 4 . 5 V D C . T u rn th e lo ra n g e trim p o t
vo lta g e o r co u n te rclo ckwise to d e cre a se th e
vo lta g e .
co n tro l switch to fo o t switch a ctiva te d h ig h id le
(ra b b it a n d fo o t switch sym b o l).
1 0 F u lly re tra ct th e b o o m , th e n sta rt a tim e r a n d
re co rd h o w lo n g it ta ke s th e tu rn ta b le to ro ta te
th ro u g h a co m p le te circle . A d ju st th e m a x-o u t
trim p o t to a ch ie ve a 8 0 to 1 0 0 se co n d cycle
tim e .
1 1 E xte n d th e b o o m , th e n sta rt a tim e r a n d re co rd
h o w lo n g it ta ke s th e tu rn ta b le to ro ta te th ro u g h
a co m p le te circle . A d ju st th e lo ra n g e trim p o t to
a ch ie ve a 1 3 0 to 1 6 0 se co n d cycle tim e .
vo lt m e te r.
co n tro l h a n d le a ll th e wa y to th e le ft o r rig h t.
a b c d e f g h i j
co n tro l h a n d le a ll th e wa y to th e le ft o r rig h t.
vo lta g e re co rd e d in ste p 1 4 . T h is is th e
ra m p ra te .
1 7 S e t th e ra m p ra te : T u rn th e trim p o t to o b ta in
a 5 se co n d ra m p sp e e d . T u rn th e trim p o t
clo ckwise to in cre a se th e tim e o r
Turntable rotation specifications
T u rn ta b le ro ta tio n -
h i ra n g e (b o o m re tra cte d ) 5 . 5 V D C
C ycle tim e 8 0 to 1 0 0 se co n d s
lo ra n g e (b o o m e xte n d e d ) 4 . 5 V D C
C ycle tim e 1 3 0 to 1 6 0 se co n d s
R a m p ra te 5 se co n d s
Boom Extend/Retract Controller
Adjustments
1 2 V D C a n d th e a lte rn a to r
is o p e ra tin g p ro p e rly with
1 3 . 6 to 1 4 . 5 V D C o u tp u t.
co n tro ls. D o n o t sta rt th e e n g in e .
th e b o o m e xte n d /re tra ct co n tro lle r.
a ra m p ra te a d ju sta b le trim p o t
b d u a l (lo ) ra n g e a d ju sta b le trim p o t
c te rm in a l " R " , a ctiva te s m a x-o u t ra n g e
d te rm in a l u n u se d
e te rm in a l " X " , a u xilia ry
f te rm in a l " -" , g ro u n d
g te rm in a l " +" , b a tte ry, p o sitive
h te rm in a l " A " , p ro p o rtio n a l o u tp u t
j m a x-o u t a d ju sta b le trim p o t
5 C o n n e ct th e re d (+) le a d fro m a vo lt m e te r to
th e A te rm in a l o n th e co n tro lle r p rin te d circu it
in cre a se th e vo lta g e o r co u n te rclo ckwise to
d e cre a se th e vo lta g e .
7 S e t th e m a x-o u t: P re ss d o wn th e fo o t switch ,
th e n m o ve th e co n tro l h a n d le a ll th e wa y to
th e E X T E N D p o sitio n . A d ju st th e vo lta g e to
9 . 7 5 V D C . T u rn th e m a x-o u t trim p o t a d ju stm e n t
scre w clo ckwise to in cre a se th e vo lta g e o r
co u n te rclo ckwise to d e cre a se th e vo lta g e .
8 S e t th e d u a l (lo ) ra n g e : P re ss d o wn th e fo o t
switch , th e n m o ve th e co n tro l h a n d le a ll th e wa y
to th e R E T R A C T p o sitio n . A d ju st th e vo lta g e
to 9 . 2 V D C . T u rn th e d u a l ra n g e trim p o t
vo lta g e o r co u n te rclo ckwise to d e cre a se
th e vo lta g e .
co n tro l switch to fo o t switch a ctiva te d h ig h
id le (ra b b it a n d fo o t switch sym b o l). L o we r
th e b o o m to fu lly e xte n d . A d ju st th e
m a x-o u t trim p o t to a ch ie ve a 6 0 to 8 0 se co n d
cycle tim e .
th e b o o m to fu lly re tra ct. A d ju st th e d u a l ra n g e
trim p o t to a ch ie ve a n 5 5 to 8 5 se co n d cycle
tim e .
I f th e fu n ctio n cycle tim e is n o t
a ch ie va b le , ch e ck th e re lie f va lve
p re ssu re . S e e 1 0 -2 , Valve
Adjustments - Function Manifold.
vo lt m e te r.
co n tro l h a n d le a ll th e wa y to th e E X T E N D p o sitio n .
co n tro l h a n d le a ll th e wa y to th e E X T E N D p o sitio n .
vo lta g e re co rd e d in ste p 1 4 . T h is is th e ra m p
sp e e d .
1 7 S e t th e ra m p ra te : tu rn th e trim p o t to o b ta in
a 3 se co n d ra m p sp e e d . T u rn th e
trim p o t clo ckwise to in cre a se th e tim e o r
Boom extend/retract specifications
B o o m e xte n d - M a x-o u t 9 . 7 5 V D C
B o o m re tra ct - D u a l (lo ) ra n g e 9 . 2 V D C
R a m p ra te 3 se co n d s
1-2
Horsepower Limiter Board
T h e h o rse p o we r lim ite r b o a rd is re sp o n sib le fo r
g o ve rn in g d rive p u m p o u tp u t. I t se n se s e n g in e rp m
fro m th e a lte rn a to r. T h e h o rse p o we r lim ite r b o a rd
se n se s d ro p s in rp m n o rm a lly d u e to in cre a se d
d rive re sista n ce (ro u g h te rra in o r in clin e ), a n d
d e cre a se s vo lta g e to th e d rive co n tro lle r wh ich in
tu rn d e cre a se s vo lta g e to th e d rive p u m p , th e re b y
re d u cin g p u m p o u tp u t to m a in ta in o p tim u m e n g in e
rp m a n d h o rse p o we r. T h re e a d ju stm e n ts a re
re q u ire d fo r o p tim u m p e rfo rm a n ce .
How to Adjust the Horsepower
Limiter Board
T h e e n g in e rp m m u st b e
co rre ct b e fo re p e rfo rm in g th is
p ro ce d u re . S e e M a in te n a n ce
P ro ce d u re B -1 2 , Check and
Adjust the Engine RPM.
D o n o t a d ju st th e h o rse p o we r
lim ite r b o a rd u n le ss th e sta tic
b a tte ry vo lta g e is a b o ve 1 2 V D C
a n d th e a lte rn a to r is o p e ra tin g
p ro p e rly with 1 2 . 5 to 1 4 . 5 V D C
o u tp u t.
Gasoline/LPG models: P e rfo rm
th is p ro ce d u re in g a so lin e m o d e .
1 2 V D C o r g re a te r
g ro u n d
e n g in e rp m se n so r
n o t u se d
n o t u se d
lo w d rive sp e e d lim it switch
n o t u se d
n o t u se d
n o t u se d
o u tp u t to d rive co n tro lle r
b
a
c
a
1 R e m o ve th e fa ste n e rs fro m th e p la tfo rm
co n tro l b o x lid .
2 O p e n th e co n tro l b o x lid a n d lo ca te th e
h o rse p o we r lim ite r b o a rd .
P la tfo rm co n tro l b o x
a h o rse p o we r lim ite r b o a rd
3 C o n n e ct th e b la ck(-) le a d fro m a D C vo lt m e te r
to th e n o . 2 te rm in a l, a n d th e re d (+) le a d to th e
n o . 1 0 te rm in a l.
H o rse p o we r lim ite r b o a rd
a " A " p o te n tio m e te r m a xim u m vo lta g e
o u tp u t to th e co n tro lle r in th e sto we d
p o sitio n
b " B " p o te n tio m e te r m a xim u m vo lta g e
o u tp u t to th e d rive co n tro lle r in th e
b o o m ra ise d p o sitio n
c " C " p o te n tio m e te r re a ctio n ra te o r
h o w fa st th e vo lta g e o u tp u t re a cts to
th e ch a n g e in e n g in e rp m
sym b o l).
6 P re ss d o wn th e fo o t switch a n d a d ju st th e
" A " p o te n tio m e te r co u n te rclo ckwise to in cre a se
vo lta g e o r clo ckwise to d e cre a se vo lta g e .
" A" potentiometer specifications - all models
V o lta g e se ttin g 1 0 . 5 to 1 1 . 5 V D C
(tu rtle sym b o l).
8 P re ss d o wn th e fo o t switch a n d th e n a d ju st
th e " C " p o te n tio m e te r to o b ta in a
0 . 0 1 V D C to 0 . 0 3 V D C vo lta g e re a d in g .
sym b o l).
1 0 P re ss d o wn th e fo o t switch a n d re -a d ju st th e
" A " p o te n tio m e te r to th e p re vio u s vo lta g e
se ttin g in ste p 6 .
1 1 B e su re th a t th e b o o m is in th e sto we d p o sitio n ,
th e n d rive th e m a ch in e a n d o b se rve h o w th e
e n g in e rp m re a cts to d rive co n tro l h a n d le
m o ve m e n t. I f th e e n g in e su rg e s o r h u n ts, a d ju st
th e " C " p o te n tio m e te r co u n te rclo ckwise u n til
su rg in g is m in im ize d .
U n d e r a n e xtre m e lo a d , a n
e xce ssive co u n te rclo ckwise
a d ju stm e n t to th e " C "
p o te n tio m e te r will ca u se
th e e n g in e to sta ll. T h e " C "
p o te n tio m e te r a d ju stm e n t is a
co m p ro m ise b e twe e n e n g in e
sta b ility (su rg in g ) a n d e n g in e
rp m d ro o p .
1 2 D isco n n e ct th e vo lt m e te r.
1 3 R a ise th e b o o m a b o ve h o rizo n ta l.
1 4 D rive th e m a ch in e fo r 4 0 fe e t (1 2 m ) a n d
re co rd th e e la p se d tim e . R e p e a t th is ste p in
th e o p p o site d rive d ire ctio n .
1 5 A d ju st th e " B " p o te n tio m e te r to o b ta in th e
co rre ct ra ise d d rive sp e e d o f 1 fo o t p e r se co n d
(0 . 3 1 m p e r se co n d ). T u rn th e " B "
p o te n tio m e te r co u n te rclo ckwise to in cre a se
vo lta g e o r clo ckwise to d e cre a se vo lta g e .
1 6 C lo se th e p la tfo rm co n tro l b o x lid a n d in sta ll
th e fa ste n e rs.
Drive speed specifications
S to we d p o sitio n d ista n ce : 4 0 ft / 1 2 m
2WD 4WD
G a so lin e /L P G m o d e ls 4 0 ft/6 . 2 se c 4 0 ft/9 . 1 se c
1 2 . 2 m /6 . 2 se c 1 2 . 2 m /9 . 1 se c
D e u tz D ie se l m o d e ls 4 0 ft/6 . 8 se c 4 0 ft/9 . 1 se c
1 2 . 2 m /6 . 8 se c 1 2 . 2 m /9 . 1 se c
B o o m ra ise d o r d ista n ce : 4 0 ft / 1 2 m
e xte n d e d 1 fo o t p e r se co n d
A ll m o d e ls 3 0 . 5 cm p e r se co n d
1-3
Foot Switch
How to Test the Foot Switch
1 T u rn th e ke y switch to th e O F F p o sitio n a n d
se p a ra te th e wirin g q u ick d isco n n e ct p lu g fro m
th e p la tfo rm to e b o a rd .
2 D o n o t p re ss d o wn th e fo o t switch . C o n n e ct th e
le a d s fro m a n o h m m e te r o r co n tin u ity te ste r to
e a ch wire co m b in a tio n liste d b e lo w a n d ch e ck
fo r co n tin u ity.
Test Desired result
re d to b la ck co n tin u ity
(ze ro )
re d to wh ite n o co n tin u ity
(in fin ite )
b la ck to wh ite n o co n tin u ity
D o n o t u se th e co lo r o f th e
co n n e cto r a s a g u id e fo r th e se
te sts. U se th e a ctu a l wire co lo r
to id e n tify wh ich wire to u se fo r
te stin g .
3 P re ss d o wn th e fo o t switch . C o n n e ct th e le a d s
fro m a n o h m m e te r o r co n tin u ity te ste r to e a ch
wire co m b in a tio n liste d b e lo w a n d ch e ck fo r
co n tin u ity.
Test Desired result
re d to b la ck n o co n tin u ity
(in fin ite )
re d to wh ite n o co n tin u ity
b la ck to wh ite co n tin u ity
(ze ro )
1-4
Resistors
T h e re sisto rs a re u se d o n 4 WD m a ch in e s to
m a in ta in lo w ra n g e d rive sp e e d . T h e re sisto rs a re
lo ca te d in th e p la tfo rm co n tro l b o x.
R e fe r to th e sch e m a tic le g e n d s
fo r re sisto r lo ca tio n s a n d va lu e s.
How to Test the Resistors
2 D isco n n e ct e ith e r e n d o f o n e o f th e wire s
co n n e cte d to th e re sisto r to b e te ste d .
3 C o n n e ct th e le a d s fro m a n o h m m e te r to e a ch
e n d o r wirin g o f th e re sisto r b e in g te ste d .
4 C o m p a re th e o h m m e te r re a d in g with th e
re sista n ce ra tin g p rin te d o n th e re sisto r.
1-5
Toggle Switches
T o g g le switch e s u se d fo r sin g le fu n ctio n switch in g
a re sin g le p o le d o u b le th ro w (S P D T ) switch e s.
D u a l fu n ctio n switch in g re q u ire s a d o u b le p o le
d o u b le th ro w (D P D T ) switch .
How to Test a Toggle Switch
C o n tin u ity is th e e q u iva le n t o f 0 to
3 o h m s. A sim p le co n tin u ity te ste r
m a y n o t a ccu ra te ly te st th e switch .
T h is p ro ce d u re co ve rs fu n d a m e n ta l switch te stin g
a n d d o e s n o t sp e cifica lly a p p ly to a ll va rie tie s o f
to g g le switch e s.
1 T u rn th e ke y switch to th e O F F p o sitio n . T a g
a n d d isco n n e ct a ll wirin g fro m th e to g g le switch
to b e te ste d .
2 C o n n e ct th e le a d s o f a n o h m m e te r to th e switch
te rm in a ls in th e fo llo win g co m b in a tio n s liste d
b e lo w to ch e ck fo r co n tin u ity.
Test Desired result
Left position
te rm in a l 1 to 2 , 3 , 4 , 5 & 6 n o co n tin u ity
(in fin ite )
te rm in a l 2 to 3 co n tin u ity
(ze ro )
te rm in a l 2 to 4 , 5 & 6 n o co n tin u ity
te rm in a l 4 to 5 & 6 n o co n tin u ity
Center position T h e re a re n o te rm in a l co m b in a tio n s
th a t will p ro d u ce co n tin u ity
(in fin ite )
Right position
(ze ro )
te rm in a l 1 to 3 , 4 , 5 & 6 n o co n tin u ity
(in fin ite )
te rm in a l 2 to 3 , 4 , 5 & 6 n o co n tin u ity
te rm in a l 4 to 6 n o co n tin u ity
te rm in a l 5 to 6 n o co n tin u ity
1
2
3
4 5 6
1 2 3
1
2
3 1
2
3
1 2 3 1 2 3
1 2 3 1 2 3 1 2 3
4 5 6 4 5 6
C e n te r L e ft R ig h t
S in g le p o le
d o u b le th ro w
(S P D T )
D o u b le p o le
d o u b le th ro w
(D P D T )
1-6
Control Relays
R e la ys u se d fo r sin g le fu n ctio n switch in g a re sin g le
p o le d o u b le th ro w (S P D T ) re la ys.
How to Test a Single Pole Double
Throw Relay
E le ctro cu tio n h a za rd .
C o n ta ct with e le ctrica lly ch a rg e d
circu its m a y ca u se d e a th o r
se rio u s in ju ry. R e m o ve a ll rin g s,
wa tch e s a n d o th e r je we lry.
Direct Connection Relay
1 L a b e l a n d th e n d isco n n e ct a ll th e wirin g fro m
th e re la y to b e te ste d .
2 C o n n e ct th e le a d s fro m a n o h m m e te r o r
co n tin u ity te ste r to e a ch te rm in a l co m b in a tio n
a n d ch e ck fo r co n tin u ity. T e rm in a ls 8 5 a n d 8 6
re p re se n t th e co il a n d sh o u ld n o t b e te ste d in
a n y o th e r co m b in a tio n .
Test Desired result
te rm in a l 8 5 to 8 6 with o u t re sisto r 8 5 to 9 5
te rm in a l 8 5 to 8 6 with re sisto r 7 5 to 8 5
te rm in a l 8 7 to 8 7 a & 3 0 n o co n tin u ity
(in fin ite )
te rm in a l 8 7 a to 3 0 co n tin u ity
(ze ro )
3 C o n n e ct 1 2 V D C to te rm in a l 8 5 a n d a g ro u n d
wire to te rm in a l 8 6 , th e n te st th e fo llo win g
te rm in a l co m b in a tio n s.
Test Desired result
te rm in a l 8 7 to 8 7 a & 3 0 n o co n tin u ity
(in fin ite )
te rm in a l 8 7 to 3 0 co n tin u ity
(ze ro )
te rm in a l n o . 8 7 a - N . C .
te rm in a l n o . 8 5 - g ro u n d
te rm in a l n o . 3 0 - co m m o n
te rm in a l n o . 8 6 - co il
te rm in a l n o . 8 7 - N . O .
Control Relay Schematic - without resistor
Control Relay Schematic - with resistor
Platform Components
2-1
Platform
How to Remove the Platform
1 S e p a ra te th e fo o t switch q u ick d isco n n e ct p lu g .
2 S u p p o rt th e p la tfo rm su p p o rt we ld m e n t with a
a p p ro p ria te liftin g d e vice .
3 O p e n th e p la tfo rm co n tro l b o x a n d re m o ve th e
p la tfo rm co n tro l b o x m o u n tin g fa ste n e rs. T h e n
lo we r th e co n tro l b o x a n d se t it a sid e .
I f yo u r m a ch in e is e q u ip p e d with
a n a irlin e to p la tfo rm o p tio n , th e
a irlin e m u st b e d isco n n e cte d fro m
th e p la tfo rm b e fo re re m o va l.
4 R e m o ve th e p la tfo rm m o u n tin g fa ste n e rs a n d
re m o ve th e p la tfo rm fro m th e m a ch in e .
C ru sh in g h a za rd . T h e p la tfo rm
m a y b e co m e u n sta b le a n d fa ll if it
is n o t p ro p e rly su p p o rte d .
2-2
Platform Leveling Slave Cylinder
T h e sla ve cylin d e r a n d th e ro ta to r p ivo t a re th e
two p rim a ry su p p o rts fo r th e p la tfo rm . T h e sla ve
cylin d e r ke e p s th e p la tfo rm le ve l th ro u g h th e
e n tire ra n g e o f b o o m m o tio n . I t o p e ra te s in a
clo se d -circu it h yd ra u lic lo o p with th e m a ste r
cylin d e r. T h e sla ve cylin d e r is e q u ip p e d with
co u n te rb a la n ce va lve s to p re ve n t m o ve m e n t in
th e e ve n t o f a h yd ra u lic lin e fa ilu re .
Leveling Slave Cylinder
B e fo re cylin d e r re m o va l is
co n sid e re d , b le e d th e sla ve
cylin d e r to b e su re th e re is n o
a ir in th e clo se d lo o p .
Wh e n re m o vin g a h o se a sse m b ly
o r fittin g , th e O -rin g o n th e fittin g
a n d /o r h o se e n d m u st b e re p la ce d
a n d th e n to rq u e d to sp e cifica tio n
d u rin g in sta lla tio n .
R e fe r to S e ctio n T wo , Hydraulic
Hose and Fitting Torque
Specifications.
1 E xte n d th e b o o m u n til th e sla ve cylin d e r
b a rre l-e n d p ivo t p in is a cce ssib le .
2 R a ise th e b o o m slig h tly a n d p la ce b lo cks u n d e r
th e p la tfo rm .
3 L o we r th e b o o m u n til th e p la tfo rm is re stin g o n
th e b lo cks ju st e n o u g h to su p p o rt th e p la tfo rm .
D o n o t re st th e e n tire we ig h t o f th e
b o o m o n th e b lo cks.
P L A T F O R M C O M P O N E N T S
4 T a g , d isco n n e ct a n d p lu g th e h yd ra u lic h o se s
fro m th e sla ve cylin d e r a t th e u n io n lo ca te d
n e a r th e p la tfo rm ro ta te co u n te rb a la n ce va lve
m a n ifo ld a n d co n n e ct th e m to g e th e r u sin g a
co n n e cto r. C a p th e fittin g s o n th e cylin d e r.
5 P u ll th e sla ve cylin d e r h o se s th ro u g h th e
p la tfo rm ro ta to r.
6 R e m o ve th e p in re ta in in g fa ste n e r fro m
th e sla ve cylin d e r ro d -e n d p ivo t p in . D o n o t
re m o ve th e p in .
7 R e m o ve th e e xte rn a l re ta in in g rin g fro m th e
b a rre l-e n d p ivo t p in .
8 U se a so ft m e ta l d rift to d rive th e ro d -e n d p ivo t
p in o u t.
9 U se a so ft m e ta l d rift a n d d rive th e b a rre l-e n d
p in o u t.
1 0 C a re fu lly p u ll th e cylin d e r o u t o f th e b o o m .
How to Bleed the Slave Cylinder
D o n o t sta rt th e e n g in e . U se
a u xilia ry p o we r fo r a ll m a ch in e
fu n ctio n s in th is p ro ce d u re .
1 R a ise th e b o o m to a h o rizo n ta l p o sitio n .
2 M o ve th e p la tfo rm le ve l switch u p a n d d o wn
th ro u g h two p la tfo rm le ve lin g cycle s to re m o ve
a n y a ir th a t m ig h t b e in th e syste m .
2-3
Platform Rotator
T h e p la tfo rm ro ta to r is a h yd ra u lica lly a ctiva te d
h e lica l g e a r a sse m b ly u se d to ro ta te th e p la tfo rm
1 6 0 d e g re e s.
How to Remove the
Platform Rotator
C o m p o n e n t d a m a g e h a za rd . M a rk
th e p la tfo rm m o u n tin g we ld m e n t
a n d th e ro ta to r fla n g e b e fo re
re m o vin g th e p la tfo rm m o u n tin g
we ld m e n t. T h e p la tfo rm m o u n tin g
we ld m e n t m u st b e re p la ce d in th e
e xa ct sa m e p o sitio n o n th e ro ta to r
fla n g e a s it wa s b e fo re re m o va l. I f
a n e w ro ta to r is in sta lle d o r th e
ro ta to r is d isa sse m b le d , p ro p e r
a lig n m e n t ca n b e a ch ie ve d b y
ro ta tin g th e ro ta to r a ll th e wa y to
th e le ft a n d th e n in sta llin g th e
p la tfo rm m o u n tin g we ld m e n t a ll
th e wa y in th e le ft p o sitio n .
Specifications.
1 R e m o ve th e p la tfo rm . S e e 2 -1 ,
How to Remove the Platform.
2 S-60 models: T a g , d isco n n e ct a n d p lu g th e
h yd ra u lic h o se s fro m th e p la tfo rm ro ta to r
m a n ifo ld . C a p th e fittin g s o n th e ro ta to r.
o r sp ra y.
S-65 models: T a g , d isco n n e ct a n d p lu g th e
h yd ra u lic h o se s fro m th e " V 1 " a n d " V 2 " p o rts o n
p la tfo rm ro ta to r m a n ifo ld . C a p th e fittin g s o n th e
m a n ifo ld .
o r sp ra y.
3 S u p p o rt th e p la tfo rm m o u n tin g we ld m e n t, b u t d o
n o t a p p ly a n y liftin g p re ssu re .
4 R e m o ve th e six m o u n tin g b o lts fro m th e
p la tfo rm m o u n tin g we ld m e n t, th e n re m o ve th e
ce n te r b o lt a n d slid e th e p la tfo rm m o u n tin g
we ld m e n t o ff o f th e p la tfo rm ro ta to r.
m o u n tin g we ld m e n t m a y b e co m e
u n b a la n ce d a n d fa ll if it is n o t
p ro p e rly su p p o rte d .
5 S u p p o rt th e p la tfo rm ro ta to r. D o n o t a p p ly
a n y liftin g p re ssu re .
S-60 Models:
6 S u p p o rt th e ro d e n d o f th e p la tfo rm le ve lin g
sla ve cylin d e r.
7 R e m o ve th e p in re ta in e r fro m th e sla ve cylin d e r
ro d -e n d p ivo t p in a n d th e ro ta to r p ivo t p in .
8 U se a so ft m e ta l d rift to d rive b o th p in s o u t, th e n
re m o ve th e p la tfo rm ro ta to r fro m th e m a ch in e .
ro ta to r m a y b e co m e u n b a la n ce d
a n d fa ll if it is n o t p ro p e rly
su p p o rte d .
S-65 Models:
6 R e m o ve th e p in re ta in in g fa ste n e rs fro m th e jib
b o o m a n d jib b o o m le ve lin g a rm s to p la tfo rm
ro ta to r p ivo t p in s. D o n o t re m o ve th e p in s.
7 S u p p o rt th e jib b o o m a n d le ve lin g a rm s.
8 U se a so ft m e ta l d rift to d rive b o th p in s o u t, th e n
re m o ve th e p la tfo rm ro ta to r fro m th e m a ch in e .
ro ta to r m a y b e co m e u n b a la n ce d
su p p o rte d .
How to Bleed the Platform
Rotator
D o n o t sta rt th e e n g in e . U se
a u xilia ry p o we r fo r a ll m a ch in e
fu n ctio n s in th is p ro ce d u re .
sid e a n d a ctiva te th e p la tfo rm ro ta te to g g le
switch to th e rig h t th e n th e le ft th ro u g h two
p la tfo rm ro ta tio n cycle s, th e n h o ld th e switch to
th e R I G H T p o sitio n u n til th e p la tfo rm is fu lly
ro ta te d to th e rig h t.
2 C o n n e ct a cle a r h o se to th e to p b le e d va lve .
P la ce th e o th e r e n d o f th e h o se in a co n ta in e r
to co lle ct a n y d ra in a g e . S e cu re th e co n ta in e r to
th e b o o m .
3 O p e n th e to p b le e d va lve o n th e ro ta to r, b u t d o
n o t re m o ve it.
a to p b le e d va lve
b b o tto m b le e d va lve
c cle a r h o se
d co n ta in e r
a
d c b
sid e a n d a ctiva te a n d h o ld th e p la tfo rm ro ta te
switch to th e L E F T p o sitio n u n til th e p la tfo rm is
fu lly ro ta te d . C o n tin u e h o ld in g th e switch u n til
a ir sto p s co m in g o u t o f th e b le e d va lve . T h e n
clo se
th e b le e d va lve .
C ru sh in g h a za rd . K e e p cle a r o f
th e p la tfo rm d u rin g ro ta tio n .
5 C o n n e ct th e cle a r h o se to th e b o tto m b le e d
va lve a n d o p e n th e va lve . D o n o t re m o ve th e
b le e d va lve .
sid e a n d a ctiva te a n d h o ld th e p la tfo rm ro ta te
switch to th e R I G H T p o sitio n u n til th e p la tfo rm is
fu lly ro ta te d . C o n tin u e h o ld in g th e switch u n til
a ir sto p s co m in g o u t o f th e b le e d va lve . T h e n
clo se th e b le e d va lve .
C ru sh in g h a za rd . K e e p cle a r o f
th e p la tfo rm d u rin g ro ta tio n .
7 R e m o ve th e h o se fro m th e b le e d va lve a n d
cle a n u p a n y h yd ra u lic o il th a t m a y h a ve sp ille d .
8 R o ta te th e p la tfo rm fu ll rig h t th e n le ft a n d
in sp e ct th e b le e d va lve s fo r le a ks.
3-1
Jib Boom, S-65 Models
How to Remove the Jib Boom
Specifications.
2 R e m o ve th e p la tfo rm m o u n tin g we ld m e n t
a n d th e p la tfo rm ro ta to r. S e e 2 -3 , How to
Remove the Platform Rotator.
3 R e m o ve th e ca b le tra y fro m th e sid e o f th e
jib b o o m .
4 S u p p o rt th e jib b o o m with a liftin g d e vice .
5 T a g , d isco n n e ct a n d p lu g th e jib b o o m lift
cylin d e r h yd ra u lic h o se s. C a p th e fittin g s o n th e
cylin d e r.
6 S u p p o rt th e b a rre l e n d o f th e cylin d e r with a
liftin g d e vice .
7 R e m o ve th e p in re ta in in g fa ste n e r fro m th e jib
b o o m lift cylin d e r b a rre l-e n d p ivo t p in .
8 U se a so ft m e ta l d rift to re m o ve th e p in a n d la y
th e cylin d e r o n to th e g ro u n d .
9 T a g , d isco n n e ct a n d p lu g a ll th e h yd ra u lic
h o se s fro m th e jib b o o m m a n ifo ld .
1 0 A tta ch a liftin g stra p fro m a n o ve rh e a d cra n e to
th e jib b o o m .
1 1 R e m o ve th e p in re ta in in g fa ste n e r fro m th e jib
b o o m p ivo t p in . U se a so ft m e ta l d rift to re m o ve
th e p in , th e n re m o ve th e jib b o o m fro m th e
p rim a ry b o o m .
C ru sh in g h a za rd . I f th e o ve rh e a d
cra n e is n o t p ro p e rly a tta ch e d , th e
jib b o o m m a y b e co m e u n b a la n ce d
a n d fa ll wh e n it is re m o ve d fro m
th e m a ch in e .
1 2 R e m o ve th e p in re ta in in g fa ste n e r fro m th e jib
b o o m lift cylin d e r ro d -e n d p ivo t p in . D o n o t
1 3 S lid e b o th o f th e jib b o o m le ve lin g a rm s o ff o f
th e jib b o o m p ivo t p in .
1 4 S u p p o rt th e ro d e n d o f th e jib b o o m lift cylin d e r
with a liftin g d e vice .
1 5 U se a so ft m e ta l d rift to re m o ve th e jib b o o m lift
cylin d e r ro d -e n d p ivo t p in , th e n re m o ve th e jib
b o o m lift cylin d e r fro m th e jib b o o m m o u n tin g
we ld m e n t.
cra n e is n o t p ro p e rly a tta ch e d , th e
jib b o o m lift cylin d e r m a y b e co m e
u n b a la n ce d a n d fa ll wh e n it is
re m o ve d fro m th e m a ch in e .
Jib Boom Components, S-65 Models
J I B B O O M C O M P O N E N T S , S -6 5 M O D E L S
3-2
Jib Boom Lift Cylinder,
S-65 Models
How to Remove the Jib Boom
Lift Cylinder
Specifications.
1 R a ise th e jib b o o m slig h tly a n d p la ce b lo cks
u n d e r th e p la tfo rm m o u n tin g we ld m e n t. T h e n
lo we r th e jib b o o m u n til th e p la tfo rm is re stin g
o n th e b lo cks ju st e n o u g h to su p p o rt th e
p la tfo rm .
D o n o t re st th e e n tire we ig h t o f th e
b o o m o n th e b lo cks.
2 T a g , d isco n n e ct a n d p lu g th e jib b o o m lift
cylin d e r.
3 R e m o ve th e p in re ta in in g fa ste n e rs fro m th e jib
b o o m lift cylin d e r ro d -e n d p ivo t p in . D o n o t
4 U se a so ft m e ta l d rift to ta p th e jib b o o m lift
cylin d e r ro d -e n d p ivo t p in h a lf wa y o u t. T h e n
lo we r o n e o f th e le ve lin g a rm s to th e g ro u n d .
T a p th e p in th e o th e r d ire ctio n a n d lo we r th e
o p p o site le ve lin g a rm . D o n o t re m o ve th e p in .
5 S u p p o rt th e jib b o o m lift cylin d e r with a liftin g
d e vice .
6 R e m o ve th e p in re ta in in g fa ste n e r fro m th e jib
b o o m lift cylin d e r b a rre l-e n d p ivo t p in . U se a
so ft m e ta l d rift to re m o ve th e b a rre l-e n d p in .
7 U se a so ft m e ta l d rift to re m o ve th e jib b o o m lift
cylin d e r ro d -e n d p in . R e m o ve th e cylin d e r fro m
th e m a ch in e .
C ru sh in g h a za rd . T h e jib b o o m lift
cylin d e r m a y b e co m e u n b a la n ce d
th e m a ch in e if it is n o t p ro p e rly
su p p o rte d .
J I B B O O M C O M P O N E N T S , S -6 5 M O D E L S
3-3
Jib Boom / Platform Rotate Manifold Components, S-65 Models
1 2 p o sitio n 3 wa y va lve . . . . . . . . . . . . . . . . . . . . . . . A M . . . . . . . . P la tfo rm ro ta te / jib b o o m se le ct . . . . . . . . . . 8 -1 0 ft-lb s / 1 1 -1 4 N m
Plug Torque Specifications
Description Hex Size Torque
S A E N o . 2
1
/8 5 0 in -lb s / 6 N m
S A E N o . 4
3
/1 6 1 3 ft-lb s / 1 8 N m
How to Check the Resistance
of a Valve Coil
d isco n n e ct th e wire s fro m th e va lve co il to
b e te ste d .
2 C o n n e ct th e le a d s fro m a n o h m m e te r to th e
va lve co il te rm in a ls.
Valve coil specification
2 p o sitio n 3 wa y va lve 5 . 9
(sch e m a tic ite m A M )
1
1
AM
AM
4-1
Boom Cable Track
T h e b o o m ca b le tra ck g u id e s ca b le s a n d h o se s
ru n n in g u p th e b o o m . I t ca n b e re p a ire d lin k b y lin k
with o u t re m o vin g th e ca b le s a n d h o se s th a t ru n
th ro u g h it. R e m o vin g th e e n tire b o o m ca b le tra ck is
n e ce ssa ry wh e n p e rfo rm in g m a jo r re p a irs th a t
in vo lve re m o vin g th e b o o m .
How to Remove the Boom
Cable Track
Specifications.
1 O p e n th e p la tfo rm co n tro l b o x a n d re m o ve th e
p la tfo rm co n tro l b o x m o u n tin g fa ste n e rs.
2 S e p a ra te th e fo o tswitch q u ick d isco n n e ct th e n
lo we r th e p la tfo rm co n tro l b o x a n d la y it o ff to
th e sid e .
fro m th e " V 1 " a n d " V 2 " p o rts o n th e
co u n te rb a la n ce va lve m a n ifo ld lo ca te d n e a r th e
p la tfo rm ro ta to r. C a p th e fittin g s o n th e
m a n ifo ld .
Boom Components
fro m th e p la tfo rm le ve lin g cylin d e r a t th e u n io n
a n d co n n e ct th e h o se s fro m th e cylin d e r
to g e th e r u sin g a co n n e cto r.
5 S-65 Models: R e m o ve th e h o se a n d ca b le
co ve r fro m th e sid e o f th e jib b o o m .
6 S-65 Models: R e m o ve th e jib /ro ta te m a n ifo ld
m o u n tin g fa ste n e rs. D o n o t d isco n n e ct a n y o f
th e h o se s.
7 S-65 Models: T a g , d isco n n e ct a n d p lu g th e
h yd ra u lic h o se s fro m th e jib b o o m lift cylin d e r.
C a p th e fittin g s o n th e cylin d e r.
9 R e m o ve th e fa ste n e rs fro m th e d rive sp e e d lim it
switch m o u n te d o n th e sid e o f th e ca b le tra ck a t
th e p ivo t e n d o f th e b o o m . D o n o t d isco n n e ct
th e wirin g .
1 0 R e m o ve th e fa ste n e rs fro m th e sid e p a n e l o n
th e lo we r ca b le tra ck, th e n re m o ve th e p a n e l.
P u ll a ll o f th e ca b le s o u t o f th e ch a n n e l.
1 1 P la ce b lo cks in b e twe e n th e u p p e r a n d lo we r
ca b le tra cks a n d se cu re th e u p p e r a n d lo we r
tra cks to g e th e r.
C ru sh in g h a za rd . I f th e u p p e r a n d
lo we r ca b le tra cks a re n o t p ro p e rly
se cu re d to g e th e r, th e ca b le tra ck
m a y b e co m e u n b a la n ce d a n d fa ll
wh e n it is re m o ve d fro m th e
m a ch in e .
B O O M C O M P O N E N T S
1 2 R e m o ve th e m o u n tin g fa ste n e rs fro m th e la rg e
ca b le tra ck g u id e a t th e p la tfo rm e n d o f th e
ca b le tra ck. R e m o ve th e g u id e .
1 3 R e m o ve th e h o se a n d ca b le cla m p a t th e
p la tfo rm e n d o f th e ca b le tra ck.
1 4 A tta ch a liftin g stra p fro m a n o ve rh e a d cra n e to
th e ca b le tra ck.
1 5 R e m o ve th e co tte r p in a n d cle vis p in fro m th e
u p p e r ca b le tra ck a t th e p la tfo rm e n d .
1 6 R e m o ve th e ca b le tra ck m o u n tin g fa ste n e rs th a t
a tta ch th e lo we r ca b le tra ck to th e b o o m .
1 7 R e m o ve th e ca b le tra ck fro m th e m a ch in e a n d
p la ce it o n a stru ctu re ca p a b le o f su p p o rtin g it.
C ru sh in g h a za rd . T h e ca b le tra ck
if it is n o t p ro p e rly a tta ch e d to th e
o ve rh e a d cra n e .
C a b le s a n d h o se s ca n b e
d a m a g e d if th e y a re kin ke d o r
p in ch e d .
How to Repair the Boom
Cable Track
T h e b o o m ca b le tra ck ca n b e
d a m a g e d if it is twiste d .
A ca b le tra ck re p a ir kit is a va ila b le
th ro u g h th e G e n ie I n d u strie s
S e rvice P a rts D e p a rtm e n t,
P a rt n o . 4 6 6 7 7 . T h e kit in clu d e s a
4 lin k se ctio n o f ca b le tra ck,
fa ste n e rs, o th e r m isce lla n e o u s
p a rts a n d d e ta ile d in stru ctio n s.
1 R e m o ve th e b o o m ca b le tra ck. S e e 4 -1 , How to
Remove the Boom Cable Track.
2 V isu a lly in sp e ct th e ca b le tra ck a n d d e te rm in e
wh ich 4 lin k se ctio n n e e d s to b e re p la ce d .
3 D rill o u t th e 4 sp o t we ld s o n e a ch sid e o f th e
ca b le tra ck u sin g a
1 7
/6 4 " d rill b it. R e p e a t th is
ste p fo r th e o th e r e n d o f th e 4 lin k se ctio n o f
ca b le tra ck.
C a b le s a n d h o se s ca n b e
d a m a g e d if th e d rill b it co m e s in
co n ta ct with th e m . P ro te ct th e
h o se s a n d ca b le s with a b lo ck o f
wo o d to p re ve n t d rillin g in to th e
h o se s a n d ca b le s.
4 R e m o ve th e re ta in in g fa ste n e rs fro m u p p e r
b la ck ro lle rs fro m th e 4 lin k se ctio n o f ca b le
tra ck to b e re p la ce d . R e m o ve th e ro lle rs.
5 L ift u p th e h o se s a n d ca b le s a n d ca re fu lly
re m o ve th e d a m a g e d 4 lin k se ctio n o f ca b le
tra ck.
H o se s a n d ca b le s ca n b e
p in ch e d .
6 R e m o ve th e u p p e r ro lle rs fro m th e re p la ce m e n t
se ctio n o f ca b le tra ck.
7 L ift u p th e h o se s a n d ca b le s a n d ca re fu lly in se rt
th e n e w 4 lin k se ctio n o f ca b le tra ck.
H o se s a n d ca b le s ca n b e
p in ch e d .
8 C o n n e ct th e e n d s o f th e re p la ce m e n t ca b le
tra ck se ctio n to th e e xistin g ca b le tra ck u sin g
th e fa ste n e rs p ro vid e d in th e kit. D o n o t
o ve rtig h te n th e fa ste n e rs.
O ve r tig h te n in g th e fa ste n e rs will
re su lt in th e ca b le tra ck n o t
ro ta tin g a n d m a y b in d d u rin g
o p e ra tio n .
B e su re th a t th e fa ste n e rs a re
in sta lle d fro m th e in sid e o u t so th e
n u ts a re o n th e o u tsid e o f th e
ca b le tra ck.
9 I n sta ll th e b la ck ro lle rs o n to th e n e w se ctio n o f
ca b le tra ck.
1 0 I n sta ll ca b le tra ck o n to th e m a ch in e a n d o p e ra te
th e b o o m /e xte n d fu n ctio n fu lly to e n su re
sm o o th o p e ra tio n o f th e n e w se ctio n o f ca b le
tra ck.
4-2
Boom
How to Shim the Boom
1 M e a su re e a ch to p we a r p a d .
R e p la ce th e p a d if it is le ss th a n
9
/1 6 in ch (1 4 . 3 m m ) th ick. I f th e
p a d is m o re th a n
9
/1 6 in ch
(1 4 . 3 m m ) th ick, p e rfo rm th e
fo llo win g p ro ce d u re .
2 M e a su re e a ch b o tto m a n d sid e we a r p a d .
R e p la ce th e p a d if it is le ss th a n
1 1
/1 6 in ch (1 7 . 5 m m ) th ick. I f th e
p a d is m o re th a n
1 1
/1 6 in ch
(1 7 . 5 m m ) th ick, p e rfo rm th e
fo llo win g p ro ce d u re .
3 E xte n d th e b o o m u n til th e we a r p a d s a re
a cce ssib le .
4 L o o se n th e we a r p a d m o u n tin g fa ste n e rs.
5 I n sta ll th e n e w sh im s u n d e r th e we a r p a d to
o b ta in ze ro cle a ra n ce a n d ze ro d ra g .
6 T ig h te n th e m o u n tin g fa ste n e rs.
7 E xte n d a n d re tra ct th e b o o m th ro u g h a n e n tire
cycle . C h e ck fo r tig h t sp o ts th a t m a y ca u se
b in d in g o r scra p in g o f th e b o o m .
A lwa ys m a in ta in sq u a re n e ss
b e twe e n th e o u te r a n d in n e r b o o m
tu b e s.
T h is p ro ce d u re re q u ire s sp e cific
re p a ir skills, liftin g e q u ip m e n t a n d
a su ita b le wo rksh o p . A tte m p tin g
th is p ro ce d u re with o u t th e se skills
a n d to o ls m a y ca u se d e a th o r
se rio u s in ju ry a n d sig n ifica n t
co m p o n e n t d a m a g e . D e a le r
se rvice is stro n g ly re co m m e n d e d .
Specifications.
2 R e m o ve th e p la tfo rm ro ta to r a n d le ve lin g sla ve
cylin d e r. S e e 2 -3 , How to Remove the Platform
Rotator.
S-65 Models: R e m o ve th e jib b o o m . S e e 3 -1 ,
How to Remove the Jib Boom.
3 R e m o ve th e m o u n tin g fa ste n e rs fro m th e jib
b o o m /jib ro ta te va lve m a n ifo ld o n th e e n d o f th e
b o o m . T h e n re m o ve th e m a n ifo ld a n d se t it
a sid e .
4 R e m o ve th e fa ste n e rs fro m th e d rive sp e e d lim it
switch m o u n te d o n th e sid e o f th e ca b le tra ck.
D o n o t d isco n n e ct th e wirin g .
5 S u p p o rt th e ca b le tra ck with a n o ve rh e a d cra n e .
6 R e m o ve th e h o se /ca b le cla m p fro m th e p ivo t
e n d o f th e b o o m .
7 R e m o ve th e h o se a n d ca b le cla m p a t th e
p la tfo rm e n d o f th e ca b le tra ck.
8 R e m o ve th e fa ste n e rs fro m th e la rg e ca b le
tra ck g u id e a t th e p la tfro m e n d o f th e ca b le
tra ck. R e m o ve th e g u id e .
9 R e m o ve th e co tte r p in fro m th e cle vis p in a t th e
p la tfo rm e n d o f th e ca b le tra ck a n d re m o ve th e
cle vis p in .
1 0 R e m o ve th e fa ste n e rs fro m th e sid e p a n e l o n
th e ca b le tra ck to a cce ss th e ca b le tra ck
m o u n tin g fa ste n e rs.
1 1 R e m o ve th e ca b le tra ck m o u n tin g fa ste n e rs,
th e n re m o ve th e ca b le tra ck fro m th e
b o o m a n d la y it o ff to th e sid e .
T h e b o o m ca b le tra ck
ca n b e d a m a g e d if it is twiste d .
1 2 R e m o ve th e tu rn ta b le e n d co ve r.
1 3 R e m o ve th e re ta in in g fa ste n e r fro m th e m a ste r
cylin d e r ro d -e n d p ivo t p in . U se a so ft m e ta l d rift
to re m o ve th e p in . P u ll th e cylin d e r b a ck a n d
se cu re it fro m m o vin g .
Wh e n p u llin g th e m a ste r cylin d e r
b a ck, b e su re n o t to d a m a g e th e
m a ste r cylin d e r h o se s o r fittin g s.
1 4 R e m o ve th e fa ste n e rs fro m th e d rive sp e e d lim it
switch m o u n te d to th e tu rn ta b le rise r a t th e
p ivo t e n d o f th e b o o m . D o n o t d isco n n e ct th e
wirin g .
1 5 T a g , d isco n n e ct a n d p lu g th e e xte n sio n cylin d e r
h yd ra u lic h o se s. C a p th e fittin g s o n th e
cylin d e r.
1 6 A tta ch a n o ve rh e a d 5 to n (4 5 3 6 kg ) cra n e to th e
ce n te r p o in t o f th e b o o m .
1 7 A tta ch a sim ila r liftin g d e vice to th e lift cylin d e r.
1 8 U se th e cra n e to lift th e b o o m to a h o rizo n ta l
p o sitio n .
1 9 P la ce su p p o rt b lo cks u n d e r th e lift cylin d e r,
a cro ss th e tu rn ta b le .
2 0 R e m o ve th e p in re ta in in g fa ste n e r fro m th e
b o o m lift cylin d e r ro d -e n d p in . U se a so ft m e ta l
d rift to re m o ve th e p in .
C ru sh in g h a za rd . T h e b o o m lift
cylin d e r will fa ll u n le ss it is
2 1 L o we r th e ro d e n d o f th e lift cylin d e r o n to
su p p o rt b lo cks. P ro te ct th e cylin d e r ro d fro m
d a m a g e .
2 2 R e m o ve th e p in re ta in in g fa ste n e r fro m th e
b o o m p ivo t p in .
2 3 R e m o ve th e b o o m p ivo t p in with a so ft m e ta l
d rift, th e n ca re fu lly re m o ve th e b o o m fro m th e
m a ch in e .
cra n e is n o t p ro p e rly a tta ch e d ,
th e b o o m m a y b e co m e
re m o ve d fro m th e m a ch in e .
How to Disassemble the Boom
C o m p le te d isa sse m b ly o f th e
b o o m is o n ly n e ce ssa ry
if th e o u te r o r in n e r b o o m tu b e s
m u st b e re p la ce d . T h e e xte n sio n
cylin d e r ca n b e re m o ve d with o u t
co m p le te ly d isa sse m b lin g th e
b o o m . S e e 4 -4 , How to Remove
the Extension Cylinder.
1 R e m o ve th e b o o m . S e e 4 -2 ,
How to Remove the Boom.
2 P la ce b lo cks u n d e r th e e xte n sio n cylin d e r fo r
su p p o rt.
3 R e m o ve th e e xte rn a l sn a p rin g s fro m th e
e xte n sio n cylin d e r b a rre l-e n d p ivo t p in a t th e
b a se o f th e n u m b e r 1 b o o m tu b e . U se a so ft
m e ta l d rift to re m o ve th e p in .
4 R e m o ve a n d la b e l th e we a r p a d s fro m th e to p
sid e o f th e n u m b e r 1 b o o m tu b e a t th e p la tfo rm
P a y ca re fu l a tte n tio n to th e
lo ca tio n a n d a m o u n t o f sh im s
u se d with e a ch we a r p a d .
5 R e m o ve th e two we a r p a d sto p b o lts fro m e a ch
sid e o f th e n u m b e r 1 b o o m tu b e (lo ca te d o n th e
o u tsid e ).
6 S u p p o rt th e n u m b e r 2 a n d 3 b o o m tu b e s with a
liftin g stra p a tta ch e d to a n o ve rh e a d cra n e a t
th e p la tfo rm e n d o f th e b o o m .
7 S u p p o rt a n d slid e th e n u m b e r 2 a n d 3 b o o m
tu b e s o u t o f th e n u m b e r 1 b o o m tu b e . P la ce th e
2 a n d 3 b o o m tu b e s o n b lo cks fo r su p p o rt.
C ru sh in g h a za rd . T h e n u m b e r 2
a n d 3 b o o m tu b e s m a y b e co m e
u n b a la n ce d a n d fa ll wh e n th e y a re
re m o ve d fro m th e n u m b e r 1 b o o m
tu b e if th e y a re n o t p ro p e rly
su p p o rte d .
D u rin g re m o va l, th e o ve rh e a d
cra n e stra p will n e e d to b e
ca re fu lly a d ju ste d fo r p ro p e r
b a la n cin g .
8 R e m o ve a n d la b e l th e we a r p a d s fro m th e to p
sid e o f th e n u m b e r 2 b o o m tu b e a t th e p la tfo rm
9 R e m o ve th e tru n n io n ca p m o u n tin g fa ste n e rs a t
th e b a se o f th e n u m b e r 2 b o o m tu b e . T h e n u se
a slid e h a m m e r to re m o ve th e tru n n io n ca p s.
1 0 C a re fu lly ro ta te th e th e b a se e n d o f th e
e xte n sio n cylin d e r u n til th e p in m o u n tin g b o re is
in a ve rtica l p o sitio n .
1 1 S u p p o rt th e n u m b e r 3 b o o m tu b e with a liftin g
stra p a tta ch e d to a n o ve rh e a d cra n e a t th e
p la tfo rm e n d o f th e b o o m .
1 2 S u p p o rt a n d slid e th e n u m b e r 3 b o o m tu b e o u t
o f th e n u m b e r 2 b o o m tu b e . P la ce th e n u m b e r 3
b o o m tu b e o n b lo cks fo r su p p o rt.
C ru sh in g h a za rd . T h e n u m b e r 3
b o o m tu b e m a y b e co m e
re m o ve d fro m th e n u m b e r 2 b o o m
tu b e if it is n o t p ro p e rly su p p o rte d .
b a la n cin g .
1 3 R e m o ve th e e xte rn a l sn a p rin g s fro m th e
e xte n sio n cylin d e r ro d -e n d p ivo t p in a t th e
p la tfo rm e n d o f th e n u m b e r 3 b o o m tu b e . U se a
so ft m e ta l d rift to re m o ve th e p in .
1 4 S u p p o rt a n d slid e th e e xte n sio n cylin d e r o u t o f
th e b a se e n d o f th e n u m b e r 3 b o o m tu b e . P la ce
th e e xte n sio n cylin d e r o n b lo cks fo r su p p o rt.
C ru sh in g h a za rd . T h e e xte n sio n
th e n u m b e r 3 b o o m tu b e if it is n o t
b a la n cin g .
1 5 R e m o ve a n d la b e l th e we a r p a d s fro m th e
e xte n sio n cylin d e r.
P a y ca re fu l a tte n tio n to th e
lo ca tio n o f e a ch we a r p a d .
4-3
Boom Lift Cylinder
Lift Cylinder
a n d to o ls m a y re su lt in d e a th o r
Specifications.
1 R a ise th e b o o m u n til th e b o o m is h o rizo n ta l.
2 P la ce su p p o rt b lo cks u n d e r th e cylin d e r a cro ss
th e tu rn ta b le .
3 A tta ch a n o ve rh e a d 5 to n (4 5 3 6 kg ) cra n e to th e
b o o m . D o n o t lift th e b o o m .
4 S u p p o rt th e ro d e n d o f th e b o o m lift cylin d e r
with a n o ve rh e a d cra n e o r sim ila r liftin g d e vice .
cra n e is n o t p ro p e rly a tta ch e d ,
th e lift cylin d e r m a y b e co m e
d isco n n e cte d fro m th e m a ch in e .
5 T a g , d isco n n e ct a n d p lu g th e b o o m lift cylin d e r
cylin d e r.
6 R e m o ve th e p in re ta in in g fa ste n e r fro m th e lift
cylin d e r ro d -e n d p ivo t p in . U se a so ft m e ta l d rift
to re m o ve th e p in , th e n lo we r th e lift cylin d e r
o n to th e b lo cks. P ro te ct th e cylin d e r ro d fro m
d a m a g e .
C ru sh in g h a za rd . T h e lift cylin d e r
if it is n o t p ro p e rly su p p o rte d .
7 R e m o ve th e m o u n tin g fa ste n e rs fro m th e b a rre l-
e n d cylin d e r p in re ta in in g p la te s.
8 With th e lift cylin d e r b e in g su p p o rte d b y th e
o ve rh e a d cra n e , p u ll th e cylin d e r to wa rd th e
p la tfo rm u n til it is o u t.
C ru sh in g h a za rd . T h e lift cylin d e r
if it is n o t p ro p e rly su p p o rte d .
C o m p o n e n t d a m a g e h a za rd . T h e
ca b le s a n d h yd ra u lic h o se s ca n b e
d a m a g e d if th e lift cylin d e r is
p u lle d a cro ss th e m .
4-4
Extension Cylinders
T h e e xte n sio n cylin d e r co n sists o f two cylin d e rs
th a t a re fa ste n e d to g e th e r. T h e first cylin d e r
e xte n d s a n d re tra cts th e n u m b e r 2 b o o m tu b e . T h e
se co n d cylin d e r e xte n d s a n d re tra cts th e n u m b e r 3
b o o m tu b e . T h e e xte n sio n cylin d e rs a re e q u ip p e d
with co u n te rb a la n ce va lve s to p re ve n t m o ve m e n t
in th e e ve n t o f a h yd ra u lic lin e fa ilu re .
How to Remove the
Extension Cylinders
a n d to o ls m a y ca u se d e a th o r
Specifications.
1 E xte n d th e b o o m u n til th e e xte n sio n cylin d e r
ro d -e n d p in is a cce ssib le in th e n u m b e r 3 b o o m
tu b e .
2 R e m o ve th e p la tfo rm . S e e 2 -1 , How to Remove
the Platform.
3 R e m o ve th e p la tfo rm le ve lin g sla ve cylin d e r.
S e e 2 -2 , How to Remove the Slave Cylinder.
S-65 Models: R e m o ve th e jib b o o m . S e e 3 -1 , How
to Remove the Jib Boom.
5 R e m o ve th e e xte rn a l sn a p rin g s fro m th e
e xte n sio n cylin d e r ro d -e n d p in (a t th e p la tfo rm
e n d ). U se a so ft m e ta l d rift to re m o ve th e p in .
6 R e m o ve th e tu rn ta b le e n d co ve r.
7 T a g , d isco n n e ct a n d p lu g th e e xte n sio n cylin d e r
cylin d e r.
8 R e m o ve th e tru n n io n p in co ve rs fro m b o th sid e s
o f th e n u m b e r 1 b o o m tu b e a t th e p ivo t e n d o f
th e b o o m .
9 R e m o ve th e tru n n io n p in re ta in in g fa ste n e r a n d
u se a slid e h a m m e r to re m o ve th e p in s.
1 0 R e m o ve th e p in re ta in in g fa ste n e rs fro m b o th
sid e s o f th e e xte n sio n cylin d e r a t th e p ivo t e n d
o f th e b o o m .
1 1 U se a slid e h a m m e r to re m o ve th e p in s.
1 2 S u p p o rt a n d slid e th e e xte n sio n cylin d e r o u t o f
th e p ivo t e n d o f th e b o o m .
C ru sh in g h a za rd . T h e e xte n sio n
cylin d e r will fa ll wh e n it is re m o ve d
fro m th e e xte n sio n b o o m if it is n o t
N o te th e le n g th o f th e cylin d e r
a fte r re m o va l. T h e cylin d e r m u st
b e a t th e sa m e le n g th fo r
in sta lla tio n .
4-5
Platform Leveling
Master Cylinder
T h e m a ste r cylin d e r a cts a s a p u m p fo r th e sla ve
cylin d e r. I ts p a rt o f th e clo se d circu it h yd ra u lic lo o p
th a t ke e p s th e p la tfo rm le ve l th ro u g h th e e n tire
ra n g e o f b o o m m o tio n . T h e m a ste r cylin d e r is
lo ca te d a t th e b a se o f th e b o o m .
Leveling Master Cylinder
Specifications.
1 R a ise th e b o o m u n til th e ro d -e n d p ivo t p in is
a cce ssib le .
2 R e m o ve th e tu rn ta b le e n d co ve r to a cce ss th e
m a ste r cylin d e r.
3 T a g , d isco n n e ct a n d p lu g th e m a ste r cylin d e r
cylin d e r.
4 R e m o ve th e p in re ta in in g fa ste n e rs fro m th e
m a ste r cylin d e r b a rre l-e n d p ivo t p in .
5 P la ce a ro d th ro u g h th e b a re l-e n d p ivo t p in a n d
twist to re m o ve th e p in .
6 A tta ch a liftin g stra p fro m a n o ve rh e a d cra n e to
th e lu g o n th e ro d e n d o f th e m a ste r cylin d e r.
7 R e m o ve th e p in re ta in in g fa ste n e r fro m th e ro d -
e n d p ivo t p in .
8 U se a so ft m e ta l d rift to re m o ve th e p in .
C ru sh in g h a za rd . T h e m a ste r
su p p o rte d b y th e liftin g d e vice .
5-1
Turntable Covers
How to Remove a
Turntable Cover
1 R a ise th e tu rn ta b le co ve r. S u p p o rt th e o p e n
co ve r with a n o ve rh e a d cra n e o r fo rklift.
D o n o t lift it.
C ru sh in g h a za rd . D u e to its h e a vy
we ig h t, d o n o t a tte m p t to su p p o rt
th e co ve r b y h a n d .
P ro te ct th e co ve r fro m d a m a g e b y
u sin g ca rp e t o r p a d d in g o n th e
cra n e o r fo rklift fo rks.
2 R e m o ve th e u p p e r a n d lo we r re ta in in g clip s
fro m th e g a s stru t.
3 G e n tly p ry th e stru t p ivo t so cke ts o ff o f th e b a ll
stu d s a n d re m o ve th e stru t. P ro te ct th e stru t
cylin d e r ro d fro m d a m a g e .
M a rk th e lo ca tio n o f th e h in g e
su p p o rt b ra cke t o n th e b u lkh e a d to
e n su re p ro p e r co ve r a lig n m e n t
4 R e m o ve th e co ve r h in g e b o lts, th a t fa ste n th e
h in g e su p p o rt b ra cke t to th e b u lkh e a d .
5 C a re fu lly lift a n d re m o ve th e co ve r fro m
th e m a ch in e .
C ru sh in g h a za rd . T h e tu rn ta b le
co ve r m a y b e co m e u n b a la n ce d
su p p o rte d a n d se cu re d to a
a p p ro p ria te liftin g d e vice .
I f a tu rn ta b le co ve r m u st b e
re p la ce d , b e su re th a t a ll
a p p ro p ria te sa fe ty a n d
in stru ctio n a l d e ca ls a re
a p p lie d to th e n e w co ve r.
A lig n m e n t a d ju stm e n ts m a y b e
n e ce ssa ry wh e n a n e w co ve r
is in sta lle d .
Turntable Covers
6-1
RPM Adjustment
R e fe r to M a in te n a n ce P ro ce d u re s, B -1 2 ,
Check and Adjust the Engine RPM.
6-2
Flex Plate
T h e fle x p la te a cts a s a co u p le r b e twe e n th e
e n g in e a n d th e p u m p . I t is b o lte d to th e e n g in e
flywh e e l a n d h a s a sp lin e d ce n te r to d rive
th e p u m p .
a p u m p
b p u m p sh a ft
c co u p le r
d fle x p la te with ra ise d sp lin e
e flywh e e l
f
1
/2 in ch g a p
How to Remove the Flex Plate
1 D isco n n e ct th e wirin g p lu g a t th e e le ctro n ic
d isp la ce m e n t co n tro lle r (E D C ), lo ca te d o n
th e d rive p u m p .
2 S u p p o rt th e d rive p u m p with a n a p p ro p ria te
liftin g d e vice . T h e n re m o ve a ll o f th e p u m p
m o u n tin g p la te to e n g in e b e ll h o u sin g b o lts.
3 C a re fu lly p u ll th e p u m p a wa y fro m th e e n g in e
a n d se cu re it fro m m o vin g .
4 R e m o ve th e fle x p la te m o u n tin g fa ste n e rs,
th e n re m o ve th e fle x p la te fro m th e flywh e e l.
How to Install the Flex Plate
1 I n sta ll th e fle x p la te o n to th e flywh e e l with th e
ra ise d sp lin e to wa rd s th e p u m p . T o rq u e th e fle x
p la te m o u n tin g b o lts to 3 4 ft-lb s (4 6 N m ).
2 I n sta ll th e co u p le r o n to th e p u m p sh a ft with th e
se t scre w to wa rd th e p u m p . L e a ve a
1
/2 in ch
(1 2 . 7 m m ) g a p b e twe e n th e co u p le r a n d p u m p
e n d p la te .
3 A p p ly L o ctite
re m o va b le th re a d se a la n t to th e
co u p le r se t scre w. T o rq u e th e se t scre w to
4 5 ft-lb s (6 1 N m ).
C o m p o n e n t d a m a g e h a za rd . D o
n o t fo rce th e d rive p u m p d u rin g
in sta lla tio n o r th e fle x p la te te e th
m a y b e co m e d a m a g e d .
4 I n sta ll th e p u m p a n d to rq u e th e p u m p m o u n tin g
p la te fa ste n e rs to 3 4 ft-lb s (4 6 N m ).
6-3
Oil Temperature and Pressure
Gauges
T h e o il te m p e ra tu re g a u g e is a n e le ctrica l g a u g e .
T h e se n d in g u n it h a s lim it co n ta cts th a t a re fa cto ry
se t. T h e co n ta cts will clo se a t 3 0 0
o
F (1 4 7
o
C ).
Wh e n th e co n ta cts clo se , th e e n g in e will sh u t o ff to
p re ve n t d a m a g e a n d will n o t sta rt u n til th e
te m p e ra tu re d ro p s b e lo w th e co n ta ct p o in t.
T e m p e ra tu re will b e in d ica te d wh e n th e ke y is o n
a n d th e E m e rg e n cy S to p B u tto n is p u lle d o u t to th e
O N p o sitio n .
D o n o t cra n k th e e n g in e with
th e o ve r-te m p e ra tu re lig h t o n .
T h e o il p re ssu re g a u g e is a n e le ctrica l g a u g e . T h e
se n d in g u n it h a s lim it co n ta cts th a t a re fa cto ry se t.
T h e co n ta cts will clo se a t 7 p si (0 . 4 8 b a r). Wh e n
th e co n ta cts clo se , th e e n g in e will sh u t o ff to
p re ve n t d a m a g e . O il p re ssu re will b e in d ica te d
wh e n th e e n g in e is ru n n in g .
D o n o t cra n k th e e n g in e with th e
lo w o il p re ssu re lig h t o n .
a b c d e
f
e
b c
f
g
7-1
Governor Actuator
How to Set Up the Governor
Actuator and Linkage
A d ju stm e n t o f th e g o ve rn o r
a ctu a to r is o n ly n e ce ssa ry wh e n
th e g o ve rn o r a ctu a to r o r th e
lin ka g e h a s b e e n re p la ce d .
1 C o n n e ct th e lin ka g e ro d to th e th ro ttle p la te
sh a ft, th e n tig h te n th e lo ck n u t.
2 F a ste n th e lo ck n u t a n d cle vis yo ke to th e
lin ka g e ro d . D o n o t tig h te n th e lo ck n u t
a g a in st th e cle vis yo ke .
3 L o o se n th e fa ste n e r o n th e a ctu a to r a rm . R o ta te
th e a ctu a to r a rm u n til it is a t a 1 1 0 d e g re e a n g le
to th e lin ka g e ro d . T h e n tig h te n th e a ctu a to r
a rm fa ste n e r.
G o ve rn o r a ctu a to r a n d lin ka g e
a cle vis yo ke
b lin ka g e ro d
c ca rb u re to r
d th ro ttle p la te sh a ft
e g o ve rn o r a ctu a to r
f a ctu a to r sh a ft
g a ctu a to r a rm
4 P o sitio n th e lin ka g e ro d so th a t th e th ro ttle is in
th e id le p o sitio n . T h e n a d ju st th e cle vis yo ke o n
th e lin ka g e ro d to o b ta in th e p ro p e r le n g th .
I n sta ll th e yo ke o n to th e a ctu a to r a rm .
5 With th e th ro ttle in th e id le p o sitio n a n d th e
a ctu a to r a rm a t a 1 1 0 d e g re e a n g le to th e
lin ka g e , ro ta te th e cle vis yo ke o n th e lin ka g e
ro d two tu rn s co u n te rclo ckwise to p re -lo a d th e
sp rin g . T ig h te n th e lo ck n u t o n th e lin ka g e ro d .
d
110
a
Ford LRG-423 Engine
6 M a n u a lly p u ll th e a ctu a to r a rm th ro u g h a fu ll
cycle to b e su re th a t th e lin ka g e m o ve s fre e ly.
B e su re th a t th e lin ka g e a ctiva te s th e th ro ttle
sh a ft to a p p ro xim a te ly h a lf th ro ttle .
I f th e th ro ttle lin ka g e is im p ro p e rly
a d ju ste d a n d a llo we d to re a ch fu ll
th ro ttle , th e e n g in e will o ve r-re v
a n d ca u se co m p o n e n t d a m a g e .
T h e lin ka g e m u st b e fre e o f frictio n
a n d o b stru ctio n . D o n o t
le t it ru b a g a in st th e e n g in e ,
b ra cke ts o r h o se s.
F O R D L R G -4 2 3 E N G I N E
7-2
Choke Adjustments
T h is e n g in e is e q u ip p e d with a n e le ctrica lly h e a te d
a u to m a tic ch o ke . T h e ch o ke h a s a p o p p e t va lve to
e n h a n ce co ld sta rtin g a b ility o n L P G fu e l.
C h o ke a d ju stm e n ts a re a ffe cte d
b y clim a te . R ich e r a d ju stm e n t
will b e n e ce ssa ry in co ld e r
clim a te s, le a n e r a d ju stm e n t
in wa rm e r clim a te s.
Automatic Choke with
Poppet Valve
T h e ch o ke fu n ctio n s in b o th g a so lin e a n d L P G
m o d e . T h e ch o ke b u tte rfly m a y b e a d ju ste d to a
fu lly clo se d (rich ) p o sitio n fo r co ld e r clim a te s a n d
th e p o p p e t va lve will p ro vid e a flo w p a th d u rin g
L P G fu e le d o p e ra tio n .
rich le a n
a b c d e
f
7-3
Timing Adjustment
7-4
Carburetor Adjustment
7-5
RPM Adjustment
R e fe r to M a in te n a n ce P ro ce d u re s, B -1 2 , Check
and Adjust the Engine RPM.
7-6
Flex Plate
T h e fle x p la te a cts a s a co u p le r b e twe e n th e
e n g in e a n d th e p u m p . I t is b o lte d to th e e n g in e
flywh e e l a n d h a s a sp lin e d ce n te r to d rive
th e p u m p .
a p u m p
b p u m p sh a ft
c co u p le r
d fle x p la te with ra ise d sp lin e
e flywh e e l
f
1
/4 in ch g a p
Flex Plate Removal
1 D isco n n e ct a n d re m o ve th e h o se b e twe e n
th e ca rb u re to r ve n tu ri a n d th e a ir cle a n e r.
2 D isco n n e ct th e lin ka g e fro m th e g o ve rn o r,
th e n re m o ve th e g o ve rn o r lin ka g e fro m
th e ca rb u re to r. D o n o t a lte r th e le n g th o f
th e lin ka g e .
3 D isco n n e ct th e wirin g p lu g a t th e e le ctro n ic
d isp la ce m e n t co n tro lle r (E D C ), lo ca te d o n
th e d rive p u m p .
4 R e m o ve th e m o u n tin g fa ste n e rs fro m th e
re g u la to r m o u n tin g b ra cke t, th e n p u ll th e
b ra cke t u p p a st th e b e ll h o u sin g . S e cu re
th e b ra cke t b e fo re co n tin u in g .
5 S u p p o rt th e d rive p u m p with a n a p p ro p ria te
liftin g d e vice . T h e n re m o ve a ll o f th e p u m p
m o u n tin g p la te to e n g in e b e ll h o u sin g b o lts.
6 C a re fu lly p u ll th e p u m p a wa y fro m th e
e n g in e a n d se cu re it fro m m o vin g .
7 R e m o ve th e fle x p la te m o u n tin g fa ste n e rs,
th e n re m o ve th e fle x p la te fro m th e fly wh e e l.
How to Install the Flex Plate
1 I n sta ll th e fle x p la te o n to th e flywh e e l with th e
ra ise d sp lin e to wa rd s th e p u m p . T o rq u e th e fle x
p la te m o u n tin g b o lts to 3 4 ft-lb s (4 6 N m ).
2 I n sta ll th e co u p le r o n to th e p u m p sh a ft with th e
se t scre w to wa rd s th e p u m p . L e a ve a
1
/4 in ch
(6 . 3 5 m m ) g a p b e twe e n th e co u p le r a n d p u m p
e n d p la te .
3 A p p ly L o ctite
re m o va b le th re a d se a la n t to th e
co u p le r se t scre w. T o rq u e th e se t scre w to
4 5 ft-lb s (6 1 N m ).
C o m p o n e n t d a m a g e h a za rd . D o
n o t fo rce th e d rive p u m p d u rin g
in sta lla tio n o r th e fle x p la te te e th
m a y b e co m e d a m a g e d .
4 I n sta ll th e p u m p a n d to rq u e th e p u m p m o u n tin g
p la te fa ste n e rs to 3 4 ft-lb s (4 6 N m ).
7-7
Water Temperature and Oil
Pressure Gauges
T h e wa te r te m p e ra tu re g a u g e is a n e le ctrica l
g a u g e . T h e se n d in g u n it h a s lim it co n ta cts th a t a re
fa cto ry se t. T h e co n ta cts will clo se a t 2 3 0 F
(1 0 9 C ). Wh e n th e co n ta cts clo se , th e e n g in e will
sh u t o ff to p re ve n t d a m a g e a n d will n o t sta rt u n til
th e te m p e ra tu re d ro p s b e lo w th e co n ta ct p o in t.
T e m p e ra tu re will b e in d ica te d wh e n th e ke y is o n
a n d th e E m e rg e n cy S to p B u tto n is p u lle d o u t to th e
O N p o sitio n .
D o n o t cra n k th e e n g in e with
th e o ve r-te m p e ra tu re lig h t o n .
T h e o il p re ssu re g a u g e is a n e le ctrica l g a u g e . T h e
se n d in g u n it h a s lim it co n ta cts th a t a re fa cto ry se t.
T h e co n ta cts will clo se a t 8 p si (0 . 5 5 b a r). Wh e n
th e co n ta cts clo se , th e e n g in e will sh u t o ff to
p re ve n t d a m a g e . O il p re ssu re will b e in d ica te d
wh e n th e e n g in e is ru n n in g .
D o n o t cra n k th e e n g in e with th e
lo w o il p re ssu re lig h t o n .
a b
c d
7-8
Vacuum Switch
How to Test the Vacuum Switch
a o h m m e te r
b co m m o n te rm in a l (S O L . )
c va cu u m switch
d n o rm a lly o p e n te rm in a l (I N G . )
1 C o n n e ct th e le a d s fro m a n o h m m e te r o r
co n tin u ity te ste r to th e co m m o n a n d n o rm a lly
o p e n te rm in a ls.
R e su lt: T h e re sh o u ld b e n o co n tin u ity
(in fin ite ).
2 A p p ly m ild su ctio n to th e va cu u m p o rt.
R e su lt: T h e switch sh o u ld clo se a n d sh o w fu ll
co n tin u ity (ze ro ).
D o n o t sh o rt th e va cu u m switch
te rm in a ls to g ro u n d .
Ground Controls
8-1
Control Relays
S e e 1 -6 , Control Relays
8-2
Toggle Switches
S e e 1 -5 , Toggle Switches.
8-3
Wago
Components
How to Remove a Wago
Component
A sm a ll scre wd rive r is p ro vid e d
a n d sh o u ld b e u se d wh e n
re m o vin g a Wa g o
co m p o n e n t.
T h is scre wd rive r is lo ca te d in th e
o p e ra to rs m a n u a l sto ra g e b o x in
th e p la tfo rm .
1 L a b e l th e wirin g fro m th e co m p o n e n t to b e
re m o ve d .
2 L o ca te th e re m o va l ta b o n th e b o tto m o r to p
sid e o f th e co m p o n e n t.
3 U se a sm a ll n a rro w fla t b la d e scre wd rive r to
p u sh in a n d re le a se th e wire fro m th e
co m p o n e n t.
4 U se th e sm a ll n a rro w fla t b la d e scre wd rive r to
g e n tly p ry u p o n th e ta b o f th e co m p o n e n t a n d
re m o ve it.
8-4
Resistors
How to Test the Resistor
T h e re sisto r is u se d to m a in ta in p ro p e r co n tro l o f
b o o m fu n ctio n sp e e d s. A 1 0 o h m re sisto r re d u ce s
vo lta g e to a ll th e b o o m fu n ctio n switch e s a t th e
g ro u n d co n tro ls.
R e fe r to th e sch e m a tic le g e n d s fo r
re sisto r lo ca tio n s a n d va lu e s.
2 D isco n n e ct e ith e r e n d o f o n e o f th e wire s
co n n e cte d to th e re sisto r to b e te ste d .
e n d o r wirin g o f th e re sisto r b e in g te ste d .
4 C o m p a re th e o h m m e te r re a d in g with th e
re sista n ce ra tin g p rin te d o n th e re sisto r.
G R O U N D C O N T R O L S
8-5
Power Relay
e le ctrica lly ch a rg e d circu its m a y
re su lt in d e a th o r se rio u s in ju ry.
R e m o ve a ll rin g s, wa tch e s a n d
o th e r je we lry.
T h e p o we r re la y is m o u n te d o n th e
b a cksid e o f th e g ro u n d co n tro l
b o x.
How to Test the Power Relay
E le ctro cu tio n h a za rd . D isco n n e ct
th e g ro u n d ca b le fro m th e b a tte ry
b e fo re p e rfo rm in g th is p ro ce d u re .
te rm in a l co m b in a tio n a n d ch e ck fo r co n tin u ity.
Test Desired result
2 sm a ll p o sts 1 2 to 1 6
2 la rg e p o sts n o co n tin u ity
(in fin ite )
A n y sm a ll p o st to n o co n tin u ity
a n y la rg e p o st (in fin ite )
a b a b
2 C o n n e ct 1 2 V D C to o n e o f th e sm a ll p o sts a n d
a g ro u n d wire to th e o th e r sm a ll p o st, th e n te st
th e fo llo win g te rm in a l co m b in a tio n .
Test Desired result
2 la rg e p o sts co n tin u ity (ze ro )
a h ig h a m p p o we r co n ta ct te rm in a l
(la rg e p o st)
b so le n o id a ctiva te co il te rm in a l
(sm a ll p o st)
Hydraulic Pumps
9-1
Lift/Steer Pump
How to Remove the
Lift/Steer Pump
Specifications.
1 C lo se th e two h yd ra u lic ta n k va lve s lo ca te d a t
th e h yd ra u lic ta n k.
d a m a g e will o ccu r.
I f th e ta n k va lve s a re clo se d ,
re m o ve th e ke y fro m th e ke y
switch a n d ta g th e m a ch in e to
in fo rm p e rso n n e l o f th e co n d itio n .
2 T a g , d isco n n e ct a n d p lu g th e lift/ste e r p u m p
h yd ra u lic h o se s. C a p th e fittin g s o n th e p u m p .
3 R e m o ve th e p u m p m o u n tin g b o lts. C a re fu lly
re m o ve th e p u m p .
B e su re to o p e n th e two h yd ra u lic
ta n k va lve s a n d p rim e th e p u m p
a fte r in sta llin g th e p u m p .
9-2
Drive Pump
T h e d rive p u m p is a b i-d ire ctio n a l va ria b le
d isp la ce m e n t p isto n p u m p . T h e p u m p o u tp u t is
co n tro lle d b y th e e le ctro n ic d isp la ce m e n t co n tro lle r
(E D C ), lo ca te d o n th e p u m p . T h e o n ly a d ju stm e n t
th a t ca n b e m a d e to th e p u m p is th e n e u tra l o r n u ll
a d ju stm e n t. A n y in te rn a l se rvice to th e p u m p
sh o u ld o n ly b e p e rfo rm e d a t a n a u th o rize d
S u n d stra n d -S a u e r se rvice ce n te r. C a ll G e n ie
I n d u strie s S e rvice D e p a rtm e n t to lo ca te yo u r lo ca l
a u th o rize d se rvice ce n te r.
How to Remove the Drive Pump
wo rk a re a a n d su rfa ce s wh e re th is
p ro ce d u re will b e p e rfo rm e d m u st
b e cle a n a n d fre e o f d e b ris th a t
co u ld g e t in to th e h yd ra u lic syste m
a n d ca u se se ve re co m p o n e n t
d a m a g e . D e a le r se rvice is
re co m m e n d e d .
Specifications.
1 D isco n n e ct th e e le ctrica l co n n e ctio n a t th e
e le ctro n ic d isp la ce m e n t co n tro lle r (E D C )
lo ca te d o n th e d rive p u m p .
o p e n clo se d
H Y D R A U L I C P U M P S
2 C lo se th e two h yd ra u lic ta n k va lve s lo ca te d a t
th e h yd ra u lic ta n k.
co n d itio n .
3 T a g a n d d isco n n e ct a n d p lu g th e h yd ra u lic
h o se s fro m th e d rive a n d lift/ste e r p u m p s. C a p
th e fittin g s o n th e p u m p s.
4 S u p p o rt th e p u m p with a liftin g d e vice a n d
re m o ve th e two d rive p u m p m o u n tin g fa ste n e rs.
5 C a re fu lly p u ll th e d rive p u m p o u t u n til th e p u m p
co u p le r se p a ra te s fro m th e fle x p la te .
6 R e m o ve th e d rive p u m p fro m th e m a ch in e .
a fte r in sta llin g th e p u m p .
o p e n clo se d
How to Prime the Pump
1 C o n n e ct a 0 to 6 0 0 p si (0 to 4 1 b a r) p re ssu re
g a u g e to th e te st p o rt o n th e d rive p u m p .
2 Gasoline/LPG models: D isco n n e ct th e
e le ctrica l co n n e cto r a t th e ig n itio n co ils. T h e
ig n itio n co ils a re lo ca te d a b o ve th e a lte rn a to r.
Deutz Diesel models: H o ld th e m a n u a l fu e l
sh u to ff va lve clo ckwise to th e C L O S E D p o sitio n .
a m a n u a l fu e l sh u to ff va lve
3 C ra n k th e e n g in e with th e sta rte r m o to r fo r
1 5 se co n d s, wa it 1 5 se co n d s, th e n cra n k th e
e n g in e a n a d d itio n a l 1 5 se co n d s o r u n til th e
p re ssu re re a ch e s 3 2 0 p si (2 2 b a r).
4 Gasoline/LPG models: C o n n e ct th e ig n itio n
co il wirin g a n d sta rt th e e n g in e fro m th e g ro u n d
co n tro ls. C h e ck fo r h yd ra u lic le a ks.
a
Manifolds
10-1
Function Manifold Components
T h e fu n ctio n m a n ifo ld is lo ca te d o n th e ta n k sid e tra y, b e h in d th e g ro u n d co n tro l b o x.
I ndex Schematic
No. Description Item Function Torque
1 3 p o sitio n 4 wa y D 0 3 va lve . . . . . . . . . . . . . . . . A . . . . . . . . . . . T u rn ta b le ro ta te le ft/rig h t . . . . . . . . . . . . . . . . . . . . . . . 3 0 -3 5 in -lb s / 3 -4 N m
2 3 p o sitio n 4 wa y D 0 3 va lve . . . . . . . . . . . . . . . . B . . . . . . . . . . . B o o m u p /d o wn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 -3 5 in -lb s / 3 -4 N m
3 3 p o sitio n 4 wa y D 0 3 va lve . . . . . . . . . . . . . . . . C . . . . . . . . . . . B o o m e xte n d /re tra ct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 -3 5 in -lb s / 3 -4 N m
4 C h e ck va lve , p ilo t o p e ra te d . . . . . . . . . . . . . . . D . . . . . . . . . . . B o o m e xte n d /re tra ct circu it . . . . . . . . . . . . . . . . 1 1 -1 3 ft-lb s / 1 5 -1 8 N m
5 R e lie f va lve , 2 5 0 0 p si (1 7 2 b a r) . . . . . . . . E . . . . . . . . . . . B o o m e xte n d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 -3 0 ft-lb s / 3 4 -4 1 N m
6 R e lie f va lve , 2 1 0 0 p si (1 4 5 b a r) . . . . . . . . F . . . . . . . . . . . B o o m d o wn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 -3 0 ft-lb s / 3 4 -4 1 N m
7 F lo w re g u la to r va lve ,
1 . 5 g p m (5 . 7 l/m in ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . G . . . . . . . . . . . B o o m e xte n d /re tra ct circu it
(p re ve n ts o ve r flo win g
th e p ro p o rtio n a l va lve ) . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
1 . 5 g p m (5 . 7 l/m in ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . H . . . . . . . . . . . B o o m u p /d o wn circu it
th e p ro p o rtio n a l va lve ) . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
1 . 5 g p m (5 . 7 l/m in ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . I . . . . . . . . . . . . T u rn ta b le ro ta te le ft/rig h t
th e p ro p o rtio n a l va lve ) . . . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -6 N m
1 0 F lo w re g u la to r va lve ,
0 . 1 g p m (0 . 3 8 l/m in ). . . . . . . . . . . . . . . . . . . . . . . . . . . J . . . . . . . . . . . . B le e d s o ff d iffe re n tia l
se n sin g va lve s to ta n k . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
1 1 C h e ck va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K . . . . . . . . . . . D iffe re n tia l se n sin g circu it,
b o o m e xte n d /re tra ct . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -1 3 ft-lb s / 1 5 -1 8 N m
1 2 C h e ck va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L . . . . . . . . . . . D iffe re n tia l se n sin g circu it,
b o o m u p /d o wn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -1 3 ft-lb s / 1 5 -1 8 N m
1 3 P ro p o rtio n a l so le n o id va lve . . . . . . . . . . . . . . . M . . . . . . . . . . B o o m e xte n d /re tra ct . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
1 4 C h e ck va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N . . . . . . . . . . . D iffe re n tia l se n sin g circu it,
tu rn ta b le ro ta te le ft/rig h t . . . . . . . . . . . . . . . . . . . . 1 1 -1 3 ft-lb s / 1 5 -1 8 N m
1 5 P ro p o rtio n a l so le n o id va lve . . . . . . . . . . . . . . . O . . . . . . . . . . . B o o m u p /d o wn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
1 6 C h e ck va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P . . . . . . . . . . . D iffe re n tia l se n sin g circu it,
p la tfo rm le ve l u p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -1 3 ft-lb s / 1 5 -1 8 N m
1 7 C h e ck va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q . . . . . . . . . . . D iffe re n tia l se n sin g circu it,
p la tfo rm le ve l d o wn . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -1 3 ft-lb s / 1 5 -1 8 N m
This list continues. Please turn the page
M A N I F O L D S
Function Manifold Components, co n tin u e d
I ndex Schematic
1 8 P ro p o rtio n a l so le n o id va lve . . . . . . . . . . . . . . . R . . . . . . . . . . . T u rn ta b le ro ta te le ft/rig h t . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
1 9 S o le n o id va lve - N . O . P o p p e t . . . . . . . . . . . . S . . . . . . . . . . . P la tfo rm le ve l u p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 -3 0 ft-lb s / 3 4 -4 1 N m
0 . 6 g p m (2 . 2 7 l/m in ). . . . . . . . . . . . . . . . . . . . . . . . . . . T . . . . . . . . . . . P la tfo rm le ve l circu it . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
2 1 S o le n o id va lve - N . O . P o p p e t . . . . . . . . . . . . U . . . . . . . . . . . P la tfo rm le ve l d o wn . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 -3 0 ft-lb s / 3 4 -4 1 N m
2 2 D iffe re n tia l se n sin g va lve . . . . . . . . . . . . . . . . . . V . . . . . . . . . . . M e te rs flo w to fu n ctio n s . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
2 3 R e lie f va lve ,
2 6 0 0 p si (1 7 9 b a r), S -6 0 m o d e ls
2 9 0 0 p si (2 0 0 b a r), S -6 5 m o d e ls . . . . . . . W . . . . . . . . . . S yste m re lie f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 -4 0 ft-lb s / 4 7 -5 4 N m
2 4 D ia g n o stic n ip p le . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X . . . . . . . . . . . T e stin g
2 5 C h e ck va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Y . . . . . . . . . . . D iffe re n tia l se n sin g circu it
P la tfo rm ro ta te le ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -1 3 ft-lb s / 1 5 -1 8 N m
2 6 C h e ck va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z . . . . . . . . . . . D iffe re n tia l se n sin g circu it
P la tfo rm ro ta te rig h t . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -1 3 ft-lb s / 1 5 -1 8 N m
2 7 P rio rity flo w re g u la to r va lve , . . . . . . . . . . . . . . A A . . . . . . . . . S te e rin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
3 . 5 g p m (1 3 . 2 l/m in ), with o u t o scilla te a xle
5 g p m (1 8 . 9 l/m in ), with o scilla te a xle
2 8 S o le n o id va lve - N . O . P o p p e t . . . . . . . . . . . B B . . . . . . . . . P la tfo rm ro ta te le ft/J ib b o o m u p . . . . . . . . 2 5 -3 0 ft-lb s / 3 4 -4 1 N m
2 9 S o le n o id va lve - N . O . P o p p e t . . . . . . . . . . . C C . . . . . . . . P la tfo rm ro ta te rig h t/J ib b o o m d o wn . 2 5 -3 0 ft-lb s / 3 4 -4 1 N m
0 . 6 g p m (2 . 2 7 l/m in ). . . . . . . . . . . . . . . . . . . . . . . . . . . D D . . . . . . . . P la tfo rm ro ta te . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
3 1 C o u n te rb a la n ce va lve . . . . . . . . . . . . . . . . . . . . . . . . E E . . . . . . . . . P la tfo rm le ve l u p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 -4 0 ft-lb s / 4 7 -5 4 N m
3 2 C o u n te rb a la n ce va lve . . . . . . . . . . . . . . . . . . . . . . . . F F . . . . . . . . . P la tfo rm le ve l d o wn . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 -4 0 ft-lb s / 4 7 -5 4 N m
3 3 C h e ck va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G G . . . . . . . . B o o m e xte n d /re tra ct circu it . . . . . . . . . . . . . . . 1 1 -1 3 ft-lb s / 1 5 -1 8 N m
M A N I F O L D S
Description Hex size Torque
S A E N o . 2
1
/8 5 0 in -lb s / 6 N m
S A E N o . 4
3
/1 6 1 3 ft-lb s / 1 8 N m
S A E N o . 6
1
/4 1 8 ft-lb s / 2 4 N m
S A E N o . 8
5
/1 6 5 0 ft-lb s / 6 8 N m
S A E N o . 1 0
9
/1 6 5 5 ft-lb s / 7 5 N m
M A N I F O L D S
10-2
Valve Adjustments -
Function Manifold
How to Adjust the System
Relief Valve
1 C o n n e ct a 0 to 5 0 0 0 p si (0 to 3 4 5 b a r) p re ssu re
g a u g e to th e te st p o rt (ite m 2 3 ) o n th e fu n ctio n
m a n ifo ld .
a n d a ctiva te a n d h o ld th e re tra ct switch with th e
b o o m fu lly re tra cte d . O b se rve th e p re ssu re
re a d in g o n th e p re ssu re g a u g e .
4 T u rn th e e n g in e o ff. U se a wre n ch to h o ld th e
re lie f va lve a n d re m o ve th e ca p
(ite m 2 3 , fu n ctio n m a n ifo ld ).
5 A d ju st th e in te rn a l h e x so cke t. T u rn it clo ckwise
to in cre a se th e p re ssu re o r co u n te rclo ckwise to
d e cre a se th e p re ssu re . T h e n in sta ll th e re lie f
va lve ca p .
T ip -o ve r h a za rd . D o n o t a d ju st
th e re lie f va lve s h ig h e r th a n
sp e cifie d .
6 R e p e a t ste p s 2 th ro u g h 5 a n d re ch e ck re lie f
va lve p re ssu re .
System relief valve specifications
P re ssu re
S -6 0 m o d e ls 2 6 0 0 p si 1 7 9 . 3 b a r
S -6 5 m o d e ls 2 9 0 0 p si 2 0 0 b a r
M A N I F O L D S
How to Adjust the Boom Down
Relief Valve
m a n ifo ld .
a n d a ctiva te a n d h o ld th e b o o m d o wn switch
with th e b o o m fu lly lo we re d . O b se rve th e
p re ssu re re a d in g o n th e p re ssu re g a u g e .
(ite m 6 , fu n ctio n m a n ifo ld ).
va lve ca p .
sp e cifie d .
Boom down relief valve specifications
P re ssu re 2 1 0 0 p si
1 4 5 b a r
M A N I F O L D S
How to Adjust the Boom Extend
Relief Valve
m a n ifo ld .
a n d a ctiva te a n d h o ld th e e xte n d switch with th e
b o o m fu lly e xte n d e d . O b se rve th e p re ssu re
re a d in g o n th e p re ssu re g a u g e .
(ite m 5 , fu n ctio n m a n ifo ld ).
va lve ca p .
sp e cifie d .
Boom extend relief valve specifications
P re ssu re 2 5 0 0 p si
1 7 2 b a r
How to Override a Valve
A h yd ra u lic va lve m a y n e e d to b e m a n u a lly
o ve rrid d e n to tro u b le sh o o t a m a lfu n ctio n . T h e
p ro p o rtio n a l b o o m fu n ctio n s (b o o m u p /d o wn ,
e xte n d /re tra ct a n d tu rn ta b le ro ta te ) u se a va ria b le
p o sitio n p ro p o rtio n a l va lve a n d a th re e p o sitio n
d ire ctio n a l va lve . E xa m p le : o n e p o sitio n fo r b o o m
u p , o n e p o sitio n fo r n e u tra l a n d o n e p o sitio n fo r
b o o m d o wn . T h e p la tfo rm ro ta te fu n ctio n u se s a
th re e p o sitio n va lve . T h e p la tfo rm le ve l u se s a
th re e p o sitio n a n d a two p o sitio n va lve . T h e th re e
p o sitio n va lve s a n d th e p ro p o rtio n a l va lve s ca n b e
m a n u a lly o ve rrid d e n . T o id e n tify th e m a n ifo ld
va lve s se e 1 0 -1 , Function Manifold, in th is se ctio n .
1 P u sh th e b u tto n o n th e e n d o f th e va lve in
in ch (6 m m ).
a n d m o ve th e g ro u n d co n tro l fu n ctio n switch fo r
th e fu n ctio n b e in g o ve rrid d e n to o p e ra te
fu n ctio n .
C o llisio n h a za rd . I m p a ct with
m o vin g b o o m co m p o n e n ts m a y
ca u se d e a th o r se rio u s in ju ry. U se
e xtre m e ca u tio n wh e n o ve rrid in g a
m a ch in e fu n ctio n . I d e n tify th e
d ire ctio n o f m a ch in e m o ve m e n t
b e fo re o ve rrid in g a va lve .
M A N I F O L D S
How to Check the Resistance
of a Valve Coil
d isco n n e ct th e wire s fro m th e va lve co il to b e
te ste d .
2 C o n n e ct th e le a d s fro m a n o h m m e te r to th e
va lve co il te rm in a ls.
Valve coil specifications
P ro p o rtio n a l so le n o id va lve , 1 2 V 8 . 6
(sch e m a tic ite m s M , O a n d R )
3 p o sitio n 4 wa y d ire ctio n a l va lve , 1 0 V 3 . 2
(sch e m a tic ite m s A , B a n d C )
N o rm a lly o p e n p o p p e t va lve 6 . 4
(sch e m a tic ite m S , U , B B a n d C C )
10-3
Turntable Rotation Manifold Components
T h e tu rn ta b le ro ta tio n m a n ifo ld is m o u n te d to th e tu rn ta b le ro ta tio n m o to r o n th e ta n k sid e o f th e tu rn ta b le .
Index Schematic
1 S h u ttle va lve 2 p o sitio n 3 wa y . . . . . . . . . . . H H . . . . . . . . T u rn ta b le ro ta tio n b ra ke re le a se . . . . . . . 1 0 -1 3 ft-lb s / 1 4 -1 8 N m
2 C o u n te rb a la n ce va lve . . . . . . . . . . . . . . . . . . . . . . . . I I . . . . . . . . . . . T u rn ta b le ro ta te rig h t . . . . . . . . . . . . . . . . . . . . . . . . 3 5 -4 0 ft-lb s / 4 7 -5 4 N m
3 C o u n te rb a la n ce va lve . . . . . . . . . . . . . . . . . . . . . . . . J J . . . . . . . . . . T u rn ta b le ro ta te le ft . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 -4 0 ft-lb s / 4 7 -5 4 N m
3 2 1
S A E N o . 2
1
/8 5 0 in -lb s / 6 N m
S A E N o . 4
3
/1 6 1 3 ft-lb s / 1 8 N m
S A E N o . 6
1
/4 1 8 ft-lb s / 2 4 N m
M A N I F O L D S
HH
II
JJ
10-4
Oscillate Manifold Components
T h e o scilla te m a n ifo ld is m o u n te d in sid e th e d rive ch a ssis a t th e n o n -ste e r e n d .
Index Schematic
1 O rifice P lu g , 0 . 0 5 2 in ch (1 . 3 2 m m ) . . . . K K . . . . . . . . . D iffe re n tia l se n sin g circu it
2 D iffe re n tia l se n sin g va lve . . . . . . . . . . . . . . . . . . L L . . . . . . . . . D iffe re n tia l se n sin g . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
3 C h e ck va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M M . . . . . . . O scilla te ch e ck - le ft . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 -4 0 ft-lb s / 4 7 -5 4 N m
4 P ilo t o p e ra te d u n lo a d e r va lve
9 5 0 p si (6 5 b a r) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N N . . . . . . . . S e q u e n cin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
5 S h u ttle va lve 2 p o sitio n 3 wa y . . . . . . . . . . . O O . . . . . . . . P ilo t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
6 P isto n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C h e ck va lve circu it
(th e p isto n is lo ca te d b e twe e n
in d e x n u m b e rs 3 a n d 7 )
7 C h e ck va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P P . . . . . . . . . O scilla te ch e ck - rig h t . . . . . . . . . . . . . . . . . . . . . . . 3 5 -4 0 ft-lb s / 4 7 -5 4 N m
8 S h u ttle va lve 2 p o sitio n 3 wa y . . . . . . . . . . . Q Q . . . . . . . . U n lo a d in g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 -4 0 ft-lb s / 4 7 -5 4 N m
9 D ia g n o stic fittin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T e stin g
S A E N o . 2
1
/8 5 0 in -lb s / 6 N m
S A E N o . 4
3
/1 6 1 3 ft-lb s / 1 8 N m
S A E N o . 6
1
/4 1 8 ft-lb s / 2 4 N m
M A N I F O L D S
1 2
3
6
7
8 4
9
5
KK
LL
MM
NN
OO
PP
QQ
10-5
Valve Adjustments -
Oscillate Manifold
How to Adjust the Oscillate
Sequencing Valve Pressure
Specifications.
g a u g e to th e te st p o rt lo ca te d o n th e o scilla te
m a n ifo ld .
2 D isco n n e ct th e d ire ctio n a l va lve lin ka g e , b y
re m o vin g th e cle vis yo ke fro m th e d rive
ch a ssis.
4 With th e e n g in e ru n n in g , m a n u a lly a ctiva te th e
va lve a n d o b se rve th e p re ssu re re a d in g o n th e
p re ssu re g a u g e .
5 T u rn th e e n g in e o ff. H o ld th e u n lo a d e r va lve
a n d re m o ve th e ca p (ite m 4 ).
to in cre a se th e p re ssu re o r co u n te rclo ckwise
to d e cre a se th e p re ssu re . T h e n in sta ll th e
va lve ca p .
T ip -o ve r h a za rd . D o n o t a d ju st th e
re lie f va lve h ig h e r th a n sp e cifie d .
7 R e p e a t ste p s 3 th ro u g h 6 a n d m a n u a lly a ctiva te
th e va lve a n d re ch e ck th e va lve p re ssu re .
8 T u rn th e e n g in e o ff, th e n re m o ve th e
p re ssu re g a u g e a n d a sse m b le th e d ire ctio n a l
va lve lin ka g e .
Sequencing valve specifications
P re ssu re 9 5 0 p si
6 5 . 5 b a r
M A N I F O L D S
10-6
Directional Valve Manifold Components
T h e d ire ctio n a l va lve m a n ifo ld is m o u n te d in sid e th e d rive ch a ssis a t th e n o n -ste e r e n d .
Index
No. Description Function Torque
1 C a p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B re a th e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 -2 5 ft-lb s / 2 7 -3 3 N m
2 S p o o l va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D ire ctio n a l co n tro l
1
2
M A N I F O L D S
How to Set Up the Directional
Valve Linkage
A d ju stm e n t o f th e d ire ctio n a l va lve
lin ka g e is o n ly n e ce ssa ry wh e n
th e lin ka g e o r va lve h a s b e e n
re p la ce d .
1 L o we r th e b o o m to th e sto we d p o sitio n .
2 U se a " b u b b le typ e " le ve l to b e su re th e flo o r is
co m p le te ly le ve l.
F a ilu re to p e rfo rm th is p ro ce d u re
o n a le ve l flo o r will co m p ro m ise
th e sta b ility o f th e m a ch in e a n d
m a y re su lt in th e m a ch in e tip p in g
o ve r.
3 C h e ck th e tire p re ssu re in a ll fo u r tire s a n d a d d
a ir if n e e d e d to m e e t sp e cifica tio n .
4 R e m o ve th e d rive ch a ssis co ve r fro m th e
n o n -ste e r e n d .
5 D isco n n e ct th e lin ka g e cle vis yo ke fro m th e
d rive ch a ssis (if n o t a lre a d y d isco n n e cte d ).
6 P la ce a " b u b b le typ e " le ve l a cro ss th e d rive
ch a ssis n o n -ste e r e n d . C h e ck to b e su re th e
d rive ch a ssis is co m p le te ly le ve l.
7 T o le ve l th e d rive ch a ssis, sta rt th e e n g in e a n d
p u sh u p o r p u ll d o wn o n th e lin ka g e a d ju stm e n t
ro d u n til th e m a ch in e is co m p le te ly le ve l.
8 V e rify th a t th e g ro u n d a n d d rive ch a ssis a re
co m p le te ly le ve l.
9 A d ju st th e le n g th o f th e ro d b y tu rn in g th e cle vis
yo ke u n til th e cle vis yo ke ca n b e p in n e d to th e
d rive ch a ssis.
1 0 I n sta ll th e cle vis yo ke p in th e n th e co tte r p in . B e
su re to b e n d th e co tte r p in .
1 1 M e a su re th e d ista n ce b e twe e n th e d rive
ch a ssis a n d th e n o n -ste e r a xle o n b o th sid e s
(fro m th e in sid e o f th e d rive ch a ssis).
I f th e d ista n ce is n o t e q u a l a n d th e
a d ju stm e n t to th e lin ka g e wa s
co m p le te d with th e g ro u n d a n d
d rive ch a ssis le ve l, co n su lt G e n ie
I n d u strie s S e rvice D e p a rtm e n t.
M A N I F O L D S
10-7
Steer Manifold Components, S-60/65 Oscillating Models
T h e ste e r m a n ifo ld is u n d e rn e a th th e fu n ctio n m a n ifo ld .
Index Schematic
1 3 p o sitio n 4 wa y so le n o id va lve . . . . . . . . . S S . . . . . . . . . S te e r le ft/rig h t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 -3 5 in -lb s / 3 -4 N m
2 C h e ck va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T T . . . . . . . . . P rio rity flo w re g u la to r circu it . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
3 O rifice P lu g , 0 . 0 2 5 in ch (0 . 6 3 5 m m ) . . U U . . . . . . . . P rio rity flo w re g u la to r circu it
4 P rio rity flo w
re g u la to r va lve , 3 . 5 g p m (1 3 . 2 l/m in ) . V V . . . . . . . . . R e g u la te s flo w to
o scilla te m a n ifo ld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
1
2
M A N I F O L D S
SS
TT
UU
VV
3
4
S A E N o . 2
1
/8 5 0 in -lb s / 6 N m
S A E N o . 4
3
/1 6 1 3 ft-lb s / 1 8 N m
S A E N o . 6
1
/4 1 8 ft-lb s / 2 4 N m
10-8
2WD Drive Manifold Components
T h e d rive m a n ifo ld is m o u n te d in sid e th e d rive ch a ssis a t th e n o n -ste e r e n d .
Index Schematic
1 R e lie f va lve , 2 5 0 p si (1 7 . 2 b a r) . . . . . . . . . WW . . . . . . . C h a rg e p re ssu re circu it . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
2 F lo w d ivid e r/co m b in e r va lve . . . . . . . . . . . . . . X X . . . . . . . . . C o n tro ls flo w to d rive m o to rs
in fo rwa rd a n d re ve rse . . . . . . . . . . . . . . . . . . . . . . 2 5 -3 0 ft-lb s / 3 4 -4 1 N m
3 O rifice 0 . 0 7 0 in (1 . 7 8 m m ) . . . . . . . . . . . . . . . . . Y Y . . . . . . . . . D rive circu it
4 S h u ttle va lve 3 p o sitio n 3 wa y . . . . . . . . . . . Z Z . . . . . . . . . C h a rg e p re ssu re circu it th a t
g e ts h o t o il o u t o f lo w p re ssu re
sid e o f d rive p u m p a n d a llo ws
lo w p re ssu re flo w p a th fo r
b ra ke re le a se a n d 2 -sp e e d
m o to r sh ift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 -1 8 ft-lb s / 2 0 -2 4 N m
5 D ia g n o stic fittin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T e stin g
M A N I F O L D S
S A E N o . 8
5
/1 6 5 0 ft-lb s / 6 8 N m
S A E N o . 1 0
9
/1 6 5 5 ft-lb s / 7 5 N m
S A E N o . 1 2
5
/8 7 5 ft-lb s / 1 0 2 N m
M A N I F O L D S
10-9
Valve Adjustments, 2WD
Drive Manifold
How to Adjust the Charge
Pressure Relief Valve
g a u g e to th e te st p o rt lo ca te d o n th e d rive
m a n ifo ld .
3 D rive th e m a ch in e slo wly in e ith e r d ire ctio n a n d
o b se rve th e p re ssu re re a d in g o n th e p re ssu re
g a u g e .
4 T u rn th e e n g in e o ff. H o ld th e ch a rg e p re ssu re
re lie f va lve a n d re m o ve th e ca p (ite m 1 ).
va lve ca p .
6 R e sta rt th e e n g in e . D rive th e m a ch in e in e ith e r
d ire ctio n a n d re ch e ck th e va lve p re ssu re .
Charge Pressure Relief valve specifications
1 7 . 2 b a r
M A N I F O L D S
M A N I F O L D S
10-10
4WD Drive Manifold Components
T h e d rive m a n ifo ld is m o u n te d in sid e th e d rive ch a ssis a t th e n o n -ste e r e n d .
Index Schematic
1 D ire ctio n a l va lve , 2 p o sitio n 2 wa y . . . . A B . . . . . . . . . H ig h sp e e d d ivid e r b yp a ss
N . C . P ilo t to o p e n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 -3 0 ft-lb s / 3 4 -4 1 N m
2 F lo w d ivid e r/co m b in e r va lve . . . . . . . . . . . . . . A C . . . . . . . . C o n tro ls flo w to flo w
d ivid e r/co m b in e r va lve s 6 a n d 7 . . . . . . . 2 5 -3 0 ft-lb s / 3 4 -4 1 N m
3 R e lie f va lve , 2 5 0 p si (1 7 . 2 b a r) . . . . . . . . . A D . . . . . . . . C h a rg e p re ssu re circu it . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
4 C h e ck va lve , p ilo t to clo se . . . . . . . . . . . . . . . . . A E . . . . . . . . . Wo rks in co n ju n ctio n with
I n d e x n o . 1 2 in th e h ig h sp e e d
d ivid e r b yp a ss circu it . . . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
5 O rifice - p lu g , 0 . 0 5 2 in ch (1 . 3 2 m m ) . . A F . . . . . . . . . F ro n t d rive m o to r circu it
6 F lo w d ivid e r/co m b in e r va lve . . . . . . . . . . . . . . A G . . . . . . . . C o n tro ls flo w to ste e r e n d
d rive m o to rs in fo rwa rd
a n d re ve rse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 -3 0 ft-lb s / 3 4 -4 1 N m
7 F lo w d ivid e r/co m b in e r va lve . . . . . . . . . . . . . . A H . . . . . . . . C o n tro ls flo w to n o n -ste e r e n d
d rive m o to rs in fo rwa rd
a n d re ve rse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 -3 0 ft-lb s / 3 4 -4 1 N m
8 O rifice 0 . 0 7 0 in (1 . 7 8 m m ) . . . . . . . . . . . . . . . . . A I . . . . . . . . . . R e a r d rive m o to r circu it
9 O rifice 0 . 0 7 0 in (1 . 7 8 m m ) . . . . . . . . . . . . . . . . . A J . . . . . . . . . E q u a lize s p re ssu re o n b o th sid e s
o f flo w d ivid e r co m b in e r va lve
I n d e x n o . 2
1 0 S h u ttle va lve , 3 p o sitio n 3 wa y . . . . . . . . . . A K . . . . . . . . . C h a rg e p re ssu re circu it
th a t g e ts h o t o il o u t o f lo w p re ssu re
sid e o f d rive p u m p a n d a llo ws lo w
p re ssu re flo w p a th fo r b ra ke
re le a se a n d 2 -sp e e d m o to r sh ift . . . . . . . 1 5 -1 8 ft-lb s / 2 0 -2 4 N m
1 1 D ia g n o stic fittin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T e stin g
1 2 C h e ck va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A L . . . . . . . . . Wo rks in co n ju n ctio n with
I n d e x n o . 4 in th e h ig h sp e e d
d ivid e r b yp a ss circu it . . . . . . . . . . . . . . . . . . . . . . . . 1 0 -1 2 ft-lb s / 1 4 -1 6 N m
S A E N o . 2
1
/8 5 0 in -lb s / 6 N m
S A E N o . 4
3
/1 6 1 3 ft-lb s / 1 8 N m
S A E N o . 6
1
/4 1 8 ft-lb s / 2 4 N m
S A E N o . 8
5
/1 6 5 0 ft-lb s / 6 8 N m
S A E N o . 1 0
9
/1 6 5 5 ft-lb s / 7 5 N m
S A E N o . 1 2
5
/8 7 5 ft-lb s / 1 0 2 N m
M A N I F O L D S
M A N I F O L D S
10-11
Valve Adjustments, 4WD
Drive Manifold
How to Adjust the Charge
Pressure Relief Valve
g a u g e to th e te st p o rt lo ca te d o n th e d rive
m a n ifo ld .
3 D rive th e m a ch in e slo wly in e ith e r d ire ctio n a n d
o b se rve th e p re ssu re re a d in g o n th e p re ssu re
g a u g e .
4 T u rn th e e n g in e o ff. H o ld th e ch a rg e p re ssu re
re lie f va lve a n d re m o ve th e ca p (in d e x 3 ).
va lve ca p .
6 R e sta rt th e e n g in e . D rive th e m a ch in e in e ith e r
d ire ctio n a n d re ch e ck th e va lve p re ssu re .
Charge Pressure Relief valve specifications
1 7 . 2 b a r
M A N I F O L D S
Fuel and Hydraulic Tanks
11-1
Fuel Tank
How to Remove the Fuel Tank
E xp lo sio n h a za rd . E n g in e fu e ls
a re co m b u stib le . R e m o ve th e fu e l
ta n k in a n o p e n , we ll-ve n tila te d
a re a a wa y fro m h e a te rs, sp a rks,
fla m e s a n d lig h te d to b a cco .
A lwa ys h a ve a n a p p ro ve d fire
e xtin g u ish e r with in e a sy re a ch .
E xp lo sio n h a za rd . Wh e n
tra n sfe rrin g fu e l, co n n e ct a
g ro u n d in g wire b e twe e n th e
m a ch in e a n d p u m p o r co n ta in e r.
1 T u rn th e m a n u a l fu e l sh u to ff va lve to th e
C L O S E D p o sitio n .
2 R e m o ve th e ta n k sid e tu rn ta b le co ve r. S e e 5 -1 ,
How to Remove a Turntable Cover.
3 Gasoline/LPG models: D isco n n e ct, d ra in a n d
p lu g th e fu e l h o se .
Deutz Diesel models: D isco n n e ct, d ra in a n d
p lu g th e su p p ly a n d re tu rn fu e l lin e s. C a p th e
fu e l re tu rn fittin g o n th e fu e l ta n k.
4 R e m o ve th e re ta in in g fa ste n e rs fro m th e fu e l
ta n k h o ld d o wn stra p s. R e m o ve th e stra p s fro m
th e fu e l ta n k.
5 S u p p o rt th e fu e l ta n k with 2 liftin g stra p s. P la ce
o n e liftin g stra p a t e a ch e n d o f th e ta n k a n d
a tta ch th e liftin g stra p s to a n o ve rh e a d cra n e .
6 R e m o ve th e fu e l ta n k fro m th e m a ch in e .
C ru sh in g h a za rd . T h e fu e l ta n k
if it is n o t p ro p e rly su p p o rte d a n d
se cu re d to th e o ve rh e a d cra n e .
C le a n th e fu e l ta n k a n d in sp e ct
fo r ru st a n d co rro sio n b e fo re
in sta llin g .
11-2
Hydraulic Tank
T h e p rim a ry fu n ctio n s o f th e h yd ra u lic ta n k a re to
co o l, cle a n a n d d e a e ra te th e h yd ra u lic flu id d u rin g
o p e ra tio n . I t u tilize s in te rn a l su ctio n stra in e rs fo r
th e p u m p su p p ly lin e s a n d h a s a n e xte rn a l re tu rn
lin e filte r with a filte r co n d itio n in d ica to r.
How to Remove the
Hydraulic Tank
T h e wo rk a re a a n d su rfa ce s
wh e re th is p ro ce d u re will b e
p e rfo rm e d m u st b e cle a n a n d
fre e o f d e b ris th a t co u ld g e t
in to th e h yd ra u lic syste m .
Specifications.
1 R e m o ve th e fu e l ta n k. S e e 1 1 -1 , How to
Remove the Fuel Tank.
F U E L A N D H Y D R A U L I C T A N K S
2 C lo se th e two h yd ra u lic sh u to ff va lve s lo ca te d
a t th e h yd ra u lic ta n k.
co n d itio n .
3 R e m o ve th e d ra in p lu g fro m th e h yd ra u lic ta n k.
4 C o m p le te ly d ra in th e ta n k in to a su ita b le
co n ta in e r. S e e ca p a city sp e cifica tio n s.
5 T a g , d isco n n e ct a n d p lu g th e two su ctio n h o se s
th a t a re a tta ch e d to th e h yd ra u lic ta n k
sh u to ff va lve s.
6 D isco n n e ct a n d p lu g th e T -fittin g lo ca te d a t th e
re tu rn filte r with th e 2 h o se s co n n e cte d to it.
C a p th e fittin g o n th e re tu rn filte r h o u sin g .
7 D isco n n e ct a n d p lu g th e su p p ly h o se fo r th e
a u xilia ry p o we r u n it. C a p th e fittin g o n th e
h yd ra u lic ta n k.
8 R e m o ve th e re ta in in g fa ste n e rs fro m th e
h yd ra u lic ta n k h o ld d o wn stra p s. R e m o ve th e
stra p s fro m th e h yd ra u lic ta n k.
9 S u p p o rt th e h yd ra u lic ta n k with 2 liftin g stra p s.
P la ce o n e liftin g stra p a t e a ch e n d o f th e ta n k
a n d a tta ch th e liftin g stra p s to a n o ve rh e a d
cra n e .
1 0 R e m o ve th e h yd ra u lic ta n k fro m th e m a ch in e .
C ru sh in g h a za rd . T h e h yd ra u lic
if it is n o t p ro p e rly su p p o rte d a n d
se cu re d to th e o ve rh e a d cra n e .
1 1 R e m o ve th e su ctio n stra in e rs fro m th e ta n k a n d
cle a n th e m u sin g a m ild so lve n t.
1 2 R in se o u t th e in sid e o f th e ta n k u sin g a m ild
so lve n t.
1 3 I n sta ll th e su ctio n stra in e rs u sin g a th re a d
se a la n t o n th e th re a d s.
1 4 I n sta ll th e d ra in p lu g u sin g a th re a d se a la n t o n
th e th re a d s.
1 5 I n sta ll th e h yd ra u lic ta n k o n to th e m a ch in e .
1 6 I n sta ll th e two su ctio n h o se s a n d th e su p p ly
h o se fo r th e a u xilia ry p o we r u n it.
1 7 F ill th e ta n k with h yd ra u lic o il u n til th e le ve l is
with in th e to p 2 in ch e s (5 cm ) o f th e sig h t
g a u g e . D o n o t o ve rfill.
1 8 C le a n u p a n y o il th a t m a y h a ve sp ille d a n d o p e n
th e h yd ra u lic ta n k va lve s.
a fte r in sta llin g th e h yd ra u lic ta n k.
A lwa ys u se p ip e th re a d se a la n t
wh e n in sta llin g th e d ra in p lu g .
U se o n ly D e xro n I I e q u iva le n t
h yd ra u lic flu id .
Hydraulic system
H yd ra u lic ta n k ca p a city 4 5 g a llo n s
1 7 0 lite rs
ca p a city (in clu d in g ta n k) 2 0 8 lite rs
H yd ra u lic flu id D e xro n e q u iva le n t
o p e n clo se d
How to Prime the Pump
C o m p o n e n t d a m a g e h a za rd . B e
su re th a t th e h yd ra u lic ta n k sh u to ff
va lve s a re in th e O P E N p o sitio n
b e fo re p rim in g th e p u m p . T h e
co n d itio n .
g a u g e to th e te st p o rt o n th e d rive p u m p .
2 Gasoline/LPG models: D isco n n e ct th e
e le ctrica l co n n e cto r a t th e ig n itio n co ils. T h e
ig n itio n co ils a re lo ca te d a b o ve th e a lte rn a to r.
a
Deutz Diesel models: H o ld th e m a n u a l fu e l
sh u to ff va lve clo ckwise to th e C L O S E D p o sitio n .
a m a n u a l fu e l sh u to ff va lve
3 C ra n k th e e n g in e with th e sta rte r m o to r fo r
1 5 se co n d s, wa it 1 5 se co n d s, th e n cra n k th e
e n g in e a n a d d itio n a l 1 5 se co n d s o r u n til th e
p re ssu re re a ch e s 3 2 0 p si (2 2 b a r).
4 C o n n e ct th e wirin g a n d sta rt th e e n g in e fro m
th e g ro u n d co n tro ls. C h e ck fo r h yd ra u lic le a ks.
F U E L A N D H Y D R A U L I C T A N K S
fro m th e m o to r, b ra ke a n d m a n ifo ld . C a p th e
fittin g s o n th e m o to r, b ra ke a n d to rq u e h u b .
B o d ily in ju ry h a za rd .
S p ra yin g h yd ra u lic o il ca n
p e n e tra te a n d b u rn skin . L o o se n
h yd ra u lic co n n e ctio n s ve ry slo wly
to a llo w th e o il p re ssu re to
d issip a te g ra d u a lly. D o n o t
a llo w o il to sq u irt o r sp ra y.
3 R e m o ve th e m o to r/b ra ke m o u n tin g fa ste n e rs,
th e n re m o ve th e m o to r fro m th e b ra ke .
a m o to r/b ra ke m o u n tin g b o lts
b m o to r
c b ra ke
d to rq u e h u b m o u n tin g b o lts
e to rq u e h u b
f p lu g
12-1
Rotation Hydraulic Motor
How to Remove the Rotation
Hydraulic Motor
d u rin g in sta lla tio n . R e fe r to
S e ctio n T wo , Hydraulic Hose and
Fitting Torque Specifications.
U n lo cke d p o sitio n
L o cke d p o sitio n
Turntable Rotation Components
b a
d
f
e
c
How to Remove the Turntable
Rotation Brake or Torque Hub
u n lo cke d lo cke d
2 R e m o ve th e m o to r/b ra ke m o u n tin g b o lts, a n d
th e n re m o ve th e m o to r a n d b ra ke fro m th e
to rq u e h u b a n d se t th e m to th e sid e .
a m o to r/b ra ke m o u n tin g b o lt
b m o to r
c to rq u e h u b
d to rq u e h u b m o u n tin g b o lt
e p lu g
f b ra ke
3 R e m o ve th e to rq u e h u b m o u n tin g b o lts, a n d
th e n u se a liftin g d e vice to re m o ve th e to rq u e
h u b fro m th e m a ch in e .
b
c
d
e
f
a
4 R e m o ve th e p lu g fro m th e sid e o f th e to rq u e
h u b . T h e n d ra in th e o il fro m th e h u b .
5 I n sta ll th e to rq u e h u b . T o rq u e th e h u b m o u n tin g
b o lts to 1 8 0 fo o t-p o u n d s (2 4 4 N e wto n m e te rs).
6 I n sta ll th e b ra ke a n d m o to r o n to th e to rq u e h u b .
7 F ill th e h u b with o il fro m th e sid e h o le u n til th e
o il le ve l is e ve n with th e b o tto m o f th e h o le .
8 A d ju st tu rn ta b le ro ta tio n g e a r b a ckla sh . S e e
R e p a ir P ro ce d u re 1 8 -1 , How to Adjust the
Turntable rotate torque hub
C a p a city 1 7 flu id o u n ce s
0 . 5 1 lite rs
T U R N T A B L E R O T A T I O N C O M P O N E N T S
a
b
c
T U R N T A B L E R O T A T I O N C O M P O N E N T S
How to Adjust the
Turntable Rotation Gear Backlash
T h e tu rn ta b le ro ta tio n to rq u e h u b is m o u n te d o n a
a d ju sta b le p la te th a t co n tro ls th e g a p b e twe e n th e
ro ta tio n m o to r g e a r a n d th e tu rn ta b le b e a rin g .
B e su re to ch e ck th e b a ckla sh
with th e m a ch in e o n a fla t le ve l
su rfa ce .
1 L o o se n th e m o u n tin g fa ste n e rs o n th e to rq u e
h u b p ivo t p la te .
a p ivo t p la te m o u n tin g b o lts
b a d ju stm e n t b o lt with lo ck n u t
c to rq u e h u b p ivo t p la te
2 P u sh th e to rq u e h u b p ivo t p la te to wa rd s th e
tu rn ta b le a s fa r a s p o ssib le (th is will p u sh th e
ro ta tio n g e a r in to th e ro ta tio n b e a rin g ).
3 L o o se n th e lo ck n u t o n th e a d ju stm e n t b o lt.
4 T u rn th e a d ju stm e n t b o lt clo ckwise u n til it
co n ta cts th e p ivo t p la te .
5 T u rn th e a d ju stm e n t b o lt
1
/2 tu rn
co u n te rclo ckwise . T h e n tig h te n th e lo ck n u t o n
th e a d ju stm e n t b o lt.
6 R o ta te th e to rq u e h u b p ivo t p la te a wa y fro m th e
tu rn ta b le u n til it co n ta cts th e a d ju stm e n t b o lt.
T h e n tig h te n th e m o u n tin g fa ste n e rs o n th e
to rq u e h u b p ivo t p la te .
7 R o ta te th e tu rn ta b le th ro u g h a n e n tire ro ta tio n .
C h e ck fo r tig h t sp o ts th a t co u ld ca u se b in d in g .
R e a d ju st if n e ce ssa ry.
yo ke p ivo t p in s.
7 S u p p o rt th e yo ke /h u b a sse m b ly with a liftin g
ja ck.
8 U se a slid e h a m m e r to re m o ve th e u p p e r yo ke
p ivo t p in , th e n u se a so ft m e ta l d rift to d rive th e
lo we r yo ke p ivo t p in d o wn a n d o u t.
C ru sh in g h a za rd . T h e yo ke /h u b
a sse m b ly m a y b e co m e
u n b a la n ce d a n d fa ll wh e n th e yo ke
p ivo t p in s a re re m o ve d if it is n o t
p ro p e rly se cu re d a n d su p p o rte d
b y th e liftin g ja ck.
Torque specifications
L u g n u t to rq u e , d ry 4 2 0 ft-lb s
5 6 9 . 5 N m
L u g n u t to rq u e , lu b rica te d 3 2 0 ft-lb s
4 3 3 . 9 N m
How to Remove the
Hub and Bearings
th e m .
2 B lo ck th e n o n -ste e rin g wh e e ls a n d p la ce a
liftin g ja ck o f a m p le ca p a city u n d e r th e ste e rin g
a xle .
b lo cks u n d e r th e ch a ssis fo r su p p o rt.
4 R e m o ve th e lu g n u ts. T h e n re m o ve th e tire
a n d wh e e l a sse m b ly.
5 R e m o ve th e d u st ca p , co tte r p in a n d
slo tte d n u t.
6 P u ll th e h u b o ff th e sp in d le . T h e wa sh e r a n d
o u te r b e a rin g sh o u ld fa ll lo o se fro m th e h u b .
7 P la ce th e h u b o n a fla t su rfa ce a n d g e n tly p ry
th e b e a rin g se a l o u t o f th e h u b . R e m o ve th e
re a r b e a rin g .
13-1
Yoke and Hub
How to Remove the Yoke
and Hub
1 R e m o ve th e p in re ta in in g fa ste n e rs fro m b o th
th e ste e rin g cylin d e r a n d th e tie ro d p ivo t p in s.
R e m o ve th e p in s.
a tie ro d
b a xle
c yo ke p ivo t p in
d yo ke
e h u b
f p ivo t p in
g ste e rin g cylin d e r
2 L o o se n th e wh e e l lu g n u ts. D o n o t
re m o ve th e m .
3 B lo ck th e n o n -ste e rin g wh e e ls, a n d th e n
ce n te r a liftin g ja ck o f a m p le ca p a city u n d e r th e
ste e rin g a xle .
b lo cks u n d e r th e ch a ssis fo r su p p o rt.
5 R e m o ve th e lu g n u ts. T h e n re m o ve th e tire
a n d wh e e l a sse m b ly.
a b
e
d
f g
c
f
How to Install the
Hub and Bearings
Wh e n re p la cin g a wh e e l b e a rin g ,
b o th th e in n e r a n d o u te r b e a rin g s
in clu d in g th e p re sse d -in ra ce s
m u st b e re p la ce d .
1 B e su re th a t b o th b e a rin g s a re p a cke d
with cle a n , fre sh g re a se .
2 P la ce th e la rg e in n e r b e a rin g in to th e re a r
o f th e h u b .
3 P re ss th e b e a rin g se a l e ve n ly in to th e h u b
u n til it is flu sh .
4 S lid e th e h u b o n to th e yo ke sp in d le .
C o m p o n e n t d a m a g e . D o n o t
a p p ly e xce ssive fo rce o r d a m a g e
to th e lip o f th e se a l m a y o ccu r.
5 P la ce th e o u te r b e a rin g in to th e h u b .
6 I n sta ll th e wa sh e r a n d slo tte d n u t.
7 T ig h te n th e slo tte d n u t to 3 5 fo o t-p o u n d s
(4 7 N m ).
8 L o o se n th e slo tte d n u t, th e n re -tig h te n to
8 fo o t-p o u n d s (1 1 N m ).
9 I n sta ll a n e w co tte r p in . B e n d th e co tte r p in
to lo ck it in .
1 0 I n sta ll th e d u st ca p , th e n th e tire a n d wh e e l
a sse m b ly. T o rq u e th e wh e e l lu g n u ts to
4 2 0 fo o t-p o u n d s (5 6 9 . 5 N m ).
2 WD S T E E R I N G A X L E C O M P O N E N T S
13-2
Steering Cylinders
How to Remove a
Steering Cylinder
T h e re a re two id e n tica l ste e rin g cylin d e rs th a t
wo rk in p a ra lle l. T h e y a re p a rt o f th e sa m e
h yd ra u lic circu it, b u t m o ve in o p p o site d ire ctio n s.
T h e tie ro d m a in ta in s e q u a l m o ve m e n t o f th e tire s.
Specifications.
fro m th e ste e rin g cylin d e r. C a p th e fittin g s o n
th e cylin d e r.
2 R e m o ve th e p in re ta in in g fa ste n e rs. T h e n
re m o ve th e p ivo t p in fro m e a ch e n d o f th e
ste e rin g cylin d e r.
3 R e m o ve th e ste e rin g cylin d e r fro m th e m a ch in e .
13-3
Tie Rod
How to Remove the Tie Rod
1 R e m o ve th e p in re ta in in g fa ste n e rs, th e n
re m o ve th e p ivo t p in fro m e a ch e n d o f th e tie
ro d .
2 R e m o ve th e tie ro d .
How to Perform the Toe-in
Adjustment
P e rfo rm th is p ro ce d u re o n a
firm , le ve l su rfa ce . B lo ck th e
n o n -ste e rin g tire s a n d b e su re
th a t th e m a ch in e is in th e
sto we d p o sitio n .
1 S tra ig h te n th e ste e r wh e e ls.
2 M e a su re th e ste e r tire s, fro n t to fro n t a n d b a ck
to b a ck, u sin g a m e a su rin g fixtu re .
3 C e n te r a liftin g ja ck o f a m p le ca p a city u n d e r th e
ste e rin g a xle , th e n ra ise th e m a ch in e .
4 L o o se n th e ja m n u t o n th e a d ju sta b le e n d
o f th e tie ro d .
5 R e m o ve th e p in re ta in in g fa ste n e rs, th e n
re m o ve th e p ivo t p in fro m th e a d ju sta b le e n d o f
th e tie ro d .
6 S lid e th e tie ro d o ff th e yo ke a n d a d ju st it b y
tu rn in g th e e n d .
O n e h a lf tu rn o n th e a d ju sta b le
e n d e q u a ls a p p ro xim a te ly
1
/4 in ch
(6 . 4 m m ) ch a n g e in th e fro n t
a n d re a r m e a su re m e n ts.
7 S lid e th e tie ro d o n to th e yo ke . I n sta ll th e
p ivo t p in , th e n in sta ll th e re ta in in g b o lt.
8 T ig h te n th e ja m n u t a g a in st th e tie ro d .
9 L o we r th e m a ch in e a n d re ch e ck th e
fro n t a n d b a ck m e a su re m e n ts (ste p 2 ).
I f fu rth e r a d ju stm e n t is n e e d e d , re p e a t
ste p s 3 th ro u g h 8 .
Toe-in specification 0
1
/8 in ch (6 . 3 5 m m )
fro m th e d rive m o to r. C a p th e fittn g s o n th e
d rive m o to r.
3 L o o se n th e wh e e l lu g n u ts. D o n o t
re m o ve th e m .
4 B lo ck th e n o n -ste e rin g wh e e ls, a n d th e n
ce n te r a liftin g ja ck o f a m p le ca p a city u n d e r th e
ste e rin g a xle .
5 R a ise th e m a ch in e 6 in ch e s (1 5 . 2 cm ) a n d
p la ce b lo cks u n d e r th e ch a ssis fo r su p p o rt.
6 R e m o ve th e lu g n u ts, th e n re m o ve th e tire a n d
7 R e m o ve th e h yd ra u lic h o se cla m p re ta in in g
fa ste n e r fro m th e to p o f th e yo ke .
8 R e m o ve th e d rive m o to r m o u n tin g fa ste n e rs.
9 S lid e th e d rive m o to r sh a ft o u t o f th e to rq u e h u b
a n d th e n re m o ve th e d rive m o to r fro m th e
m a ch in e .
1 0 R e m o ve th e p in re ta in in g fa ste n e rs fro m th e
u p p e r a n d lo we r yo ke p ivo t p in s.
1 2 S u p p o rt th e yo ke /to rq u e h u b a sse m b ly with a
liftin g ja ck. S e cu re th e yo ke /to rq u e h u b
a sse m b ly to th e liftin g ja ck.
1 3 U se a slid e h a m m e r to re m o ve th e u p p e r yo ke
p ivo t p in , th e n u se a so ft m e ta l d rift to d rive th e
lo we r yo ke p ivo t p in d o wn a n d o u t.
C ru sh in g h a za rd . T h e yo ke /h u b
a sse m b ly m a y b e co m e
u n b a la n ce d a n d fa ll wh e n th e yo ke
p ivo t p in s a re re m o ve d if it is n o t
p ro p e rly se cu re d a n d su p p o rte d
b y th e liftin g ja ck.
14-1
Yoke and Hub
How to Remove the Yoke
and Hub
T h e yo ke in sta lla tio n u tilize s b u sh in g s a n d a th ru st
wa sh e r th a t m a y re q u ire p e rio d ic re p la ce m e n t. T h e
yo ke m u st b e re m o ve d b e fo re th e to rq u e h u b ca n
b e re m o ve d .
Specifications.
1 R e m o ve th e p in re ta in in g fa ste n e rs fro m b o th
th e ste e rin g cylin d e r a n d th e tie ro d p ivo t p in s.
R e m o ve th e p in s.
a o scilla te cylin d e r
b kin g p in
c to rq u e h u b
d yo ke
e p ivo t p in
f tie ro d
g ste e r cylin d e r
a
b
c
d e f g
1 4 P la ce th e yo ke /to rq u e h u b a sse m b ly o n a fla t
su rfa ce with th e to rq u e h u b fa cin g d o wn .
1 5 R e m o ve th e to rq u e h u b m o u n tin g fa ste n e rs th a t
a tta ch th e yo ke to th e to rq u e h u b . R e m o ve th e
yo ke we ld m e n t fro m th e to rq u e h u b .
R e p la ce th e th ru st wa sh e r wh e n
in sta llin g th e yo ke /to rq u e h u b
a sse m b ly o n to th e a xle .
L u g n u t,
d ry 4 2 0 ft-lb s 5 6 9 . 5 N m
lu b rica te d 3 2 0 ft-lb s 4 3 3 . 9 N m
T o rq u e h u b m o u n tin g b o lts,
d ry 1 2 0 ft-lb s 1 6 3 N m
lu b rica te d 9 0 ft-lb s 1 2 2 N m
D rive m o to r m o u n tin g b o lts,
d ry 7 5 ft-lb s 1 0 2 N m
lu b rica te d 5 6 ft-lb s 7 6 N m
14-2
Steering Cylinders
How to Remove a
Steering Cylinder
T h is p ro ce d u re is th e sa m e a s th e 2 WD p ro ce d u re .
S e e re p a ir p ro ce d u re 1 3 -2 ,
How to Remove a Steering Cylinder.
14-3
Tie Rod
How to Remove the Tie Rod
S e e R e p a ir P ro ce d u re 1 3 -3 ,
How to Remove the Tie Rod.
How to Perform the Toe-in
Adjustment
S e e R e p a ir P ro ce d u re 1 3 -3 ,
How to Perform the Toe-in Adjustment.
15-1
Oscillating Axle
Lock-out Cylinders
T h e o scilla tin g a xle cylin d e rs e xte n d a n d re tra ct
b e twe e n th e d rive ch a ssis a n d th e o scilla tin g a xle .
T h e cylin d e rs a re e q u ip p e d with co u n te rb a la n ce
va lve s to p re ve n t m o ve m e n t in th e e ve n t o f a
h yd ra u lic lin e fa ilu re . T h e va lve s a re n o t
a d ju sta b le .
How to Remove an Oscillating
Axle Cylinder
re p a ir skills a n d a su ita b le
wo rksh o p . A tte m p tin g th is
p ro ce d u re with o u t th e se skills
a n d to o ls m a y re su lt in d e a th o r
P e rfo rm th is p ro ce d u re o n a firm ,
le ve l su rfa ce with th e b o o m in
th e sto we d p o sitio n .
Specifications.
1 R o ta te th e b o o m u n til th e b o o m is b e twe e n th e
ste e r tire s.
2 R e m o ve th e fa ste n e rs fro m d rive ch a ssis co ve r
a t th e ste e r e n d . R e m o ve th e co ve r.
Oscillating Axle Components
3 T a g , d isco n n e ct a n d p lu g th e o scilla tin g a xle
o scilla te cylin d e r.
o r sp ra y.
ro d -e n d p ivo t p in . U se a so ft m e ta l d rift to
5 A tta ch a liftin g stra p fro m a n o ve rh e a d cra n e to
th e b a rre l e n d o f th e o scilla tin g cylin d e r.
b a rre l-e n d p ivo t p in . U se a so ft m e ta l d rift to
C ru sh in g h a za rd . T h e o scilla te
th e m a ch in e if it is n o t p ro p e rly
a tta ch e d to th e o ve rh e a d cra n e .
7 R e m o ve th e cylin d e r fro m th e m a ch in e .
16-1
Drive Motor
How to Remove a Drive Motor
R e p a irs to th e m o to r sh o u ld o n ly
b e p e rfo rm e d b y a n a u th o rize d
S u n d stra n d -S a u e r d e a le r.
wo rk a re a a n d su rfa ce s wh e re th is
p ro ce d u re will b e p e rfo rm e d m u st
b e cle a n a n d fre e o f d e b ris th a t
co u ld g e t in to th e h yd ra u lic syste m
a n d ca u se se ve re co m p o n e n t
d a m a g e . D e a le r se rvice is
re co m m e n d e d .
Specifications.
1 R e m o ve th e fa ste n e rs fro m d rive ch a ssis co ve r
a t th e n o n -ste e r e n d . R e m o ve th e co ve r.
fro m th e d rive m o to r. C a p th e fittin g s o n th e
d rive m o to r.
o r sp ra y.
3 R e m o ve th e d rive m o to r m o u n tin g fa ste n e rs.
Non-steering Axle Components
4 S lid e th e d rive m o to r sh a ft o u t o f th e b ra ke a n d
th e n re m o ve th e d rive m o to r fro m th e m a ch in e .
D rive m o to r m o u n tin g b o lts 7 5 ft-lb s
1 0 2 N m
16-2
Torque Hub
How to Remove a Drive
Torque Hub
Specifications.
1 R e m o ve th e d rive m o to r. S e e 2 2 -1 , How to
Remove a Drive Motor.
2 T a g , d isco n n e ct a n d p lu g th e h yd ra u lic h o se
fro m th e b ra ke . T h e n re m o ve th e h yd ra u lic
fittin g a n d th e b le e d va lve .
th e m .
4 C e n te r a liftin g ja ck o f a m p le ca p a city u n d e r th e
n o n -ste e rin g a xle . R a ise th e m a ch in e a n d p la ce
b lo cks u n d e r th e d rive ch a ssis fo r su p p o rt.
5 R e m o ve th e wh e e l lu g n u ts, th e n th e tire a n d
6 P la ce a se co n d liftin g ja ck u n d e r th e to rq u e h u b
fo r su p p o rt a n d se cu re th e to rq u e h u b to th e
liftin g ja ck.
N O N -S T E E R I N G A X L E C O M P O N E N T S
7 R e m o ve th e to rq u e h u b m o u n tin g b o lts th a t
a tta ch th e to rq u e h u b to th e ch a ssis. R e m o ve
th e to rq u e h u b .
C ru sh in g h a za rd . T h e to rq u e
h u b m a y b e co m e u n b a la n ce d a n d
fa ll if it is n o t p ro p e rly su p p o rte d
a n d se cu re d to th e liftin g ja ck.
L u g n u t,
d ry 4 2 0 ft-lb s 5 6 9 . 5 N m
lu b rica te d 3 2 0 ft-lb s 4 3 3 . 9 N m
T o rq u e h u b m o u n tin g b o lts,
d ry 1 2 0 ft-lb s 1 6 3 N m
lu b rica te d 9 0 ft-lb s 1 2 2 N m
D rive m o to r m o u n tin g b o lts,
d ry 7 5 ft-lb s 1 0 2 N m
lu b rica te d 5 6 ft-lb s 7 6 N m
Genie North America
1 8 3 4 0 N E 7 6 th S tre e t
P . O . B o x 9 7 0 3 0
R e d m o n d , Wa sh in g to n
9 8 0 7 3 -9 7 3 0
Genie Europe
B ru n e l D rive
N e wa rk
N o ttin g h a m sh ire
N G 2 4 2 E G E n g la n d
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