Genies 80

Service Manual Part No.
72062
Rev A1
Refer to inside cover for additional serial number information July 2007
(from serial number 966 to 3081)

Introduction Third Edition • First Printing
® S-80
® S-85
Important Contact us:
Read, understand and obey the safety rules and http://www.genielift.com
operating instructions in the Genie S-80 & e-mail: techpub@genieind.com
Genie S-85 Operator's Manual before attempting
any maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills

are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at a Genie dealer service center.
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However, ®
continuous improvement of our products is a Genie Copyright © 1998 by Genie Industries

policy. Therefore product specifications are subject
Third Edition: First Printing, February 2001
to change without notice.
"Genie" and "S" are Registered Trademarks
Readers are encouraged to notify Genie of errors of Genie Industries in the USA and many other
and send in suggestions for improvement. All countries.
communications will be carefully considered for
future printings of this and other manuals. Please Printed on recycled paper
write to the technical publications team in care of
Genie Industries, PO Box 97030, Redmond WA Printed in U.S.A.
98073-97030 U.S.A.
If you have any questions, please contact Genie

Industries.
ii Genie S-80 & Genie S-85 Part No. 72062

Third Edition • First Printing Section 1 • Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-80 & Genie S-85
Operator's Manual will result in death or serious
injury.
Many of the hazards identified in the operator's

manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 72062 Genie S-80 & Genie S-85 iii

Section 1 - Safety Rules Third Edition • First Printing
SAFETY RULES
Personal Safety Workplace Safety

Any person working on or around a machine must Be sure to wear protective eye wear and
be aware of all known safety hazards. Personal other protective clothing if the situation
safety and the continued safe operation of the warrants it.
machine should be your top priority.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
Read each procedure thoroughly. This
placing loads. Always wear approved steel-toed
manual and the decals on the machine
shoes.
use signal words to identify the following:
Be sure to keep sparks, flames and
Safety alert symbol—used to alert
lighted tobacco away from flammable
personnel to potential personal
and combustible materials like battery
injury hazards. Obey all safety
gases and engine fuels. Always have an approved
messages that follow this symbol
fire extinguisher within easy reach.
to avoid possible injury or death.
Be sure that all tools and working areas
Red—used to indicate the
are properly maintained and ready for
presence of an imminently
use. Keep work surfaces clean and free
hazardous situation which, if not
avoided, will result in death or of debris that could get into machine components
serious injury. and cause damage.
Orange—used to indicate the Be sure any forklift, overhead crane or

presence of a potentially other lifting or supporting device is fully
hazardous situation which, if not capable of supporting and stabilizing the
avoided, could result in death or weight to be lifted. Use only chains or straps that
serious injury. are in good condition and of ample capacity.
Yellow with safety alert symbol— Be sure that fasteners intended for one
used to indicate the presence of a time use (i.e., cotter pins and self-locking
potentially hazardous situation nuts) are not reused. These components
which, if not avoided, may result in may fail if they are used a second time.
minor or moderate injury.
Be sure to properly dispose of old oil or
Yellow without safety alert other fluids. Use an approved container.
symbol—used to indicate the Please be environmentally safe.
presence of a potentially
hazardous situation which, if not Be sure that your workshop or work area
avoided, may result in property is properly ventilated and well lit.
damage.
Green—used to indicate operation
or maintenance information.
iv Genie S-80 & Genie S-85 Part No. 72062

Third Edition • First Printing
Table of Contents
Introduction
Important Information ...................................................................................................... ii
Section One Safety Rules

General Safety Rules ..................................................................................................... iii
Section Two Specifications

Machine Specifications ............................................................................................. 2 - 1
Performance Specifications ...................................................................................... 2 - 2
Hydraulic Specifications ............................................................................................ 2 - 3
Ford LRG 425 EFI Engine Specifications ................................................................. 2 - 4
Deutz F4L 1011F Engine Specifications ................................................................... 2 - 5
Perkins 704-30 Engine Specifications ....................................................................... 2 - 6
Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 7
Section Three Theory of Operation

Power Source ........................................................................................................... 3 - 1
Hydraulic System ...................................................................................................... 3 - 1
Electrical System ...................................................................................................... 3 - 1
Limit Switches ........................................................................................................... 3 - 2
Machine Controls ...................................................................................................... 3 - 2
Part No. 72062 Genie S-80 & Genie S-85 v

TABLE OF CONTENTS
Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1
Maintenance Inspection Report ................................................................................ 4 - 3
A-1 Inspect the Operators' and Safety Manuals .................................................... 4 - 5
A-2 Inspect the Decals and Placards ..................................................................... 4 - 5
A-3 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 6
A-4 Check the Engine Oil Level ............................................................................. 4 - 7
A-5 Check the Engine Coolant Level - Liquid Cooled Models ................................ 4 - 8
A-6 Check for Fuel Leaks ...................................................................................... 4 - 8
A-7 Check the Hydraulic Oil Level ......................................................................... 4 - 9
A-8 Check for Hydraulic Leaks ............................................................................ 4 - 10
A-9 Check the Tire Pressure ............................................................................... 4 - 10
A-10 Test the Extendable Axles ............................................................................ 4 - 11
A-11 Test the Platform and Ground Controls ......................................................... 4 - 12
A-12 Test the Auxiliary Power Operation ............................................................... 4 - 13
A-13 Test the Tilt Sensor ....................................................................................... 4 - 14
A-14 Test the Limit Switches ................................................................................. 4 - 14
A-15 Drain the Fuel Filter/Water Separator - Diesel Models .................................. 4 - 17
A-16 Inspect the Engine Air Filter .......................................................................... 4 - 19
A-17 Perform 30 Day Service ................................................................................ 4 - 20
A-18 Inspect the Radiator - Liquid Cooled Models ................................................. 4 - 20
A-19 Check the Battery ......................................................................................... 4 - 21
A-20 Replace the Engine Oil and Filter - Ford Models ........................................... 4 - 22
A-21 Inspect the Electrical Wiring .......................................................................... 4 - 24
A-22 Check the Oil Cooler and Cooling Fins - Deutz Models ................................ 4 - 25
A-23 Check the Engine Belt - Ford and Perkins Models ........................................ 4 - 26
A-24 Replace the Fuel Filters - Ford Models ......................................................... 4 - 28
vi Genie S-80 & Genie S-85 Part No. 72062

TABLE OF CONTENTS
Section Four Scheduled Maintenance Procedures, continued

B-1 Check the Exhaust System ........................................................................... 4 - 30
B-2 Check the Hydraulic Tank Return Filter Condition Indicator .......................... 4 - 31
B-3 Inspect the Tires and Wheels (including lug nut torque) ................................ 4 - 32
B-4 Confirm the Proper Brake Configuration ....................................................... 4 - 33
B-5 Check the Oil Level in the Drive Hubs ........................................................... 4 - 34
B-6 Check and Adjust the Engine RPM ............................................................... 4 - 36
B-7 Test the Key Switch ...................................................................................... 4 - 37
B-8 Test the Emergency Stop Buttons ................................................................. 4 - 38
B-9 Test the Ground Control Override ................................................................. 4 - 38
B-10 Test the Platform Self-leveling ...................................................................... 4 - 39
B-11 Test the Horn ................................................................................................ 4 - 39
B-12 Test the Foot Switch ..................................................................................... 4 - 40
B-13 Test the Engine Idle Select Operation ........................................................... 4 - 40
B-14 Test the Fuel Select Operation - Ford Models ............................................... 4 - 41
B-15 Test the Drive Enable System ....................................................................... 4 - 42
B-16 Test the Drive Brakes ................................................................................... 4 - 43
B-17 Test the Drive Speed - Stowed Position ........................................................ 4 - 44
B-18 Test the Drive Speed - Raised or Extended Position .................................... 4 - 45
B-19 Test the Alarm Package (if equipped) ........................................................... 4 - 46
B-20 Perform Hydraulic Oil Analysis ...................................................................... 4 - 47
B-21 Replace the Hydraulic Tank Return Filter ...................................................... 4 - 47
B-22 Replace the Drive Loop Hydraulic Filter ........................................................ 4 - 48
B-23 Inspect the Fuel Tank Cap Venting System .................................................. 4 - 49
B-24 Replace the Engine Air Filter Element ........................................................... 4 - 50
B-25 Replace the Spark Plugs - Ford Models ........................................................ 4 - 51
Part No. 72062 Genie S-80 & Genie S-85 vii

TABLE OF CONTENTS
Section Four Scheduled Maintenance Procedures, continued

C-1 Check the Engine Belt - Deutz Models .......................................................... 4 - 52
C-2 Check the Engine Valve Clearances - Deutz Models .................................... 4 - 53
C-3 Replace the Fuel Filter/Water Separator Element - Perkins Models .............. 4 - 53
C-4 Replace the Fuel Filter Element - Perkins Models ......................................... 4 - 55
C-5 Replace the Engine Oil and Filter - Perkins Models ...................................... 4 - 56
C-6 Check the Starting Aid - Perkins Models ....................................................... 4 - 57
C-7 Check the Specific Gravity of Engine Coolant - Liquid Cooled Models .......... 4 - 58
C-8 Replace the PCV Valve - Ford Models .......................................................... 4 - 59
D-1 Check the Boom Wear Pads ......................................................................... 4 - 60
D-2 Check the Extendable Axle Wear Pads ........................................................ 4 - 60
D-3 Check the Free-wheel Configuration ............................................................. 4 - 61
D-4 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 62
D-5 Grease the Turntable Rotation Bearing and Rotate Gear .............................. 4 - 63
D-6 Replace the Drive Hub Oil ............................................................................. 4 - 64
D-7 Replace the Engine Oil and Filter - Deutz Models ......................................... 4 - 65
D-8 Clean the Fuel Pump Strainer - Deutz Models .............................................. 4 - 67
D-9 Replace the Diesel Fuel Filter/Water Separator - Deutz & Perkins Models ... 4 - 68
D-10 Replace the Fuel Hoses - Deutz Models ....................................................... 4 - 69
D-11 Check the Engine Valve Clearances - Perkins Models ................................. 4 - 70
D-12 Clean the Engine Breather Assembly - Perkins Models ................................ 4 - 70
E-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 71
E-2 Change or Recondition the Engine Coolant - Liquid Cooled Models ............. 4 - 73
E-3 Change the Fuel Hoses - Ford Models ......................................................... 4 - 74
E-4 Replace the Engine Air Breather - Perkins Models ....................................... 4 - 76
E-5 Grease the Steer Axle Wheel Bearings - 2WD Models ................................. 4 - 76
E-6 Check the Fuel Injectors - Perkins Models .................................................... 4 - 78
viii Genie S-80 & Genie S-85 Part No. 72062

TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts

Introduction ............................................................................................................... 5 - 1
Fault Code Chart ...................................................................................................... 5 - 3
1 Engine Will Not Crank Over ............................................................................ 5 - 8
2 Engine Cranks Over But Will Not Start - Ford Models ................................... 5 - 10
2A Engine Runs While Cranking Then Dies - Ford Models ................................ 5 - 12
3 Engine Cranks Over But Will Not Start - Diesel Models ................................ 5 - 13
4 Engine Will Not Start On LPG, But Will Start On Gasoline -
Ford Models .................................................................................................. 5 - 16
5 Engine Will Not Start On Gasoline, But Will Start On LPG -
Ford Models .................................................................................................. 5 - 18
6 Engine High Idle Inoperative - Ford Models .................................................. 5 - 19
7 Engine Low Idle Inoperative - Ford Models ................................................... 5 - 20
8 Engine High Idle Inoperative - Diesel Models ................................................ 5 - 21
9 Engine Low Idle Inoperative - Diesel Models ................................................. 5 - 23
10 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 24
11 All Lift and Steer Functions Inoperative, Drive Functions Operational ........... 5 - 25
12 Ground Controls Inoperative, Platform Controls Operate Normally ............... 5 - 26
13 Platform Controls Inoperative, Ground Controls Operate Normally ............... 5 - 27
14 Boom Up Function Inoperative ...................................................................... 5 - 28
15 Boom Down Function Inoperative ................................................................. 5 - 31
16 Boom Extend Function Inoperative ............................................................... 5 - 34
17 Boom Retract Function Inoperative ............................................................... 5 - 37
18 Turntable Rotate Left Function Inoperative ................................................... 5 - 39
19 Turntable Rotate Right Function Inoperative ................................................. 5 - 43
Part No. 72062 Genie S-80 & Genie S-85 ix

TABLE OF CONTENTS
Section Five Troubleshooting Flow Charts, continued

20 All Platform Leveling Functions Inoperative .................................................. 5 - 47
21 Platform Level Up Function Inoperative ........................................................ 5 - 48
22 Platform Level Down Function Inoperative .................................................... 5 - 50
23 Platform Rotate Left Function Inoperative ..................................................... 5 - 52
24 Platform Rotate Right Function Inoperative ................................................... 5 - 54
25 Jib Boom Up Inoperative, S-85 Models ......................................................... 5 - 56
26 Jib Boom Down Inoperative, S-85 Models .................................................... 5 - 58
27 Drive Chassis Jack Function Inoperative ...................................................... 5 - 60
28 Axle Extend/Retract Inoperative .................................................................... 5 - 62
29 Steer Left Function Inoperative ..................................................................... 5 - 63
30 Steer Right Function Inoperative ................................................................... 5 - 65
31 All Drive Functions Inoperative, All Other Functions Operate Normally ......... 5 - 67
32 Drive Forward Or Reverse Function Inoperative ........................................... 5 - 70
33 Traction Function Inoperative ........................................................................ 5 - 71
34 Machine Will Not Drive At Full Speed ............................................................ 5 - 72
35 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 73
36 Drive Enable System Is Malfunctioning ......................................................... 5 - 74
37 Auxiliary Functions Inoperative ..................................................................... 5 - 75
x Genie S-80 & Genie S-85 Part No. 72062

TABLE OF CONTENTS
Section Six Schematics

Introduction ............................................................................................................... 6 - 1
Electrical Components .............................................................................................. 6 - 2
Electrical Symbols Legend ....................................................................................... 6 - 4
Abbreviation Legend ................................................................................................. 6 - 5
Engine Wire Harness - Ford Models ......................................................................... 6 - 7
Electrical Schematic - Ford Models .......................................................................... 6 - 8
Ground Control Box Wiring Diagram - Ford Models ................................................ 6 - 10
Platform Control Box Wiring Diagram - Ford Models .............................................. 6 - 11
Electrical Schematic - Deutz Models ...................................................................... 6 - 12
Ground Control Box Wiring Diagram - Deutz Models .............................................. 6 - 14
Platform Control Box Wiring Diagram - Deutz Models ............................................ 6 - 15
Electrical Schematic - Perkins Models .................................................................... 6 - 16
Ground Control Box Wiring Diagram - Perkins Models ........................................... 6 - 18
Platform Control Box Wiring Diagram - Perkins Models .......................................... 6 - 19
Hydraulic Symbols Legend ..................................................................................... 6 - 21
Hydraulic Schematic 2WD ...................................................................................... 6 - 22
Hydraulic Schematic 4WD ...................................................................................... 6 - 23
Part No. 72062 Genie S-80 & Genie S-85 xi

TABLE OF CONTENTS
Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1
Platform Controls
1-1 Joystick Controllers ......................................................................................... 7 - 2
1-2 Horsepower Limiter Board .............................................................................. 7 - 9
1-3 Foot Switch ................................................................................................... 7 - 11
1-4 Toggle Switches ............................................................................................ 7 - 12
Platform Components
2-1 Platform ........................................................................................................ 7 - 13
2-2 Platform Leveling Slave Cylinder .................................................................. 7 - 13
2-3 Platform Rotator ............................................................................................ 7 - 15
Jib Boom Components, S-85 Models
3-1 Jib Boom ....................................................................................................... 7 - 18
3-2 Jib Boom Lift Cylinder ................................................................................... 7 - 19
Boom Components
4-1 Boom Cable Track ........................................................................................ 7 - 21
4-2 Boom ............................................................................................................ 7 - 24
4-3 Boom Lift Cylinder ......................................................................................... 7 - 27
4-4 Extension Cylinders ...................................................................................... 7 - 28
4-5 Platform Leveling Master Cylinder ................................................................ 7 - 30
Turntable Covers
5-1 Turntable Covers .......................................................................................... 7 - 31
xii Genie S-80 & Genie S-85 Part No. 72062

TABLE OF CONTENTS
Section Seven Repair Procedures, continued

Deutz F4L1011F Engine
6-1 RPM Adjustment ........................................................................................... 7 - 32
6-2 Flex Plate ...................................................................................................... 7 - 32
6-3 Oil Temperature and Oil Pressure Gauges ................................................... 7 - 33
Perkins 704-30 Engine
7-1 RPM Adjustment ........................................................................................... 7 - 34
7-2 Flex Plate ...................................................................................................... 7 - 34
7-3 Coolant Temperature and Oil Pressure Gauges ........................................... 7 - 35
Ford LRG 425 EFI Engine
8-1 RPM Adjustment ........................................................................................... 7 - 36
8-2 Flex Plate ...................................................................................................... 7 - 36
8-3 Coolant Temperature and Oil Pressure Gauges ........................................... 7 - 37
Ground Controls
9-1 Control Relays .............................................................................................. 7 - 39
9-2 Power Relay ................................................................................................. 7 - 40
9-3 Toggle Switches, See 1-4, Toggle Switches ................................................. 7 - 12
9-3 Wago® Components ...................................................................................... 7 - 41
9-5 Engine Fault Codes - Ford Models ................................................................ 7 - 41
Hydraulic Pumps
10-1 Lift/Steer Pump ............................................................................................. 7 - 43
10-2 Drive Pump ................................................................................................... 7 - 44
Part No. 72062 Genie S-80 & Genie S-85 xiii

TABLE OF CONTENTS

Manifolds
11-1 Function Manifold Components ..................................................................... 7 - 46
11-2 Valve Adjustments - Function Manifold ......................................................... 7 - 50
11-3 Turntable Rotation Manifold Components ..................................................... 7 - 52
11-4 Chassis Jack Manifold Components ............................................................. 7 - 53
11-5 Axle Extend Dump Manifold Components ..................................................... 7 - 54
11-6 Steer Manifold Components .......................................................................... 7 - 55
11-7 2WD Drive Manifold Components ................................................................. 7 - 56
11-8 Valve Adjustments - 2WD Drive Manifold ...................................................... 7 - 57
11-9 4WD Drive Manifold Components ................................................................. 7 - 58
11-10 Valve Adjustments - 4WD Drive Manifold ...................................................... 7 - 60
11-11 Jib Boom/Platform Rotate Manifold Components - S-85 Models .................. 7 - 61
11-12 Brake/Two Speed Manifold Components ...................................................... 7 - 62
. Fuel and Hydraulic Tanks
12-1 Fuel Tank ...................................................................................................... 7 - 63
12-2 Hydraulic Tank .............................................................................................. 7 - 64
Turntable Rotation Components
13-1 Rotation Hydraulic Motor ............................................................................... 7 - 67
xiv Genie S-80 & Genie S-85 Part No. 72062

TABLE OF CONTENTS

2WD Steering Axle Components
14-1 Yoke and Hub ............................................................................................... 7 - 70
14-2 Steering Cylinders ......................................................................................... 7 - 72
14-3 Tie Rod Cylinder ........................................................................................... 7 - 73
15-1 Yoke and Hub ............................................................................................... 7 - 74
15-2 Steering Cylinders, See 14-2, Steering Cylinders ......................................... 7 - 75
15-3 Tie Rod Cylinder, See 14-3, Tie Rod Cylinder ............................................... 7 - 75
Extendable Axle Components
16-1 Extendable Axles .......................................................................................... 7 - 76
16-2 Drive Chassis Lift Jacks ................................................................................ 7 - 80
16-3 Hydraulic Limit Switches ............................................................................... 7 - 80
Non-steering Axle Components
17-1 Drive Motor REV B........................................................................................ 7 - 82
17-2 Drive Hub REV B........................................................................................... 7 - 83
17-3 Wheel Brake ................................................................................................. 7 - 84
Part No. 72062 Genie S-80 & Genie S-85 xv

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xvi Genie S-80 & Genie S-85 Part No. 72062

Third Edition • First Printing Section 2 • Specifications
Specifications
Machine Specifications Platform dimensions 6 ft 8 ft
(Standard) (Optional)
Stowed dimensions S-80 S-85
Length 72 in 96 in
Length 36 ft 8 in 40 ft 7 in 182.8 cm 243.8 cm
11.2 m 12.4 m Width 30 in 36 in
Width, axles retracted 7 ft 111/2 in 7 ft 111/2 in 76.2 cm 91.4 cm
2.4 m 2.4 m Tires and wheels
Width, axles extended 10 ft 10 ft Tire size 15-22.5 SAT
3m 3m
Tire ply rating 16
Height 9 ft 2 in 9 ft 2 in Tire contact area 71 sq in
2.8 m 2.8 m 458 sq cm
Weight 33,380 lbs 35,860 lbs Overall tire diameter 113 in
15,141 kg 16,266 kg 729 cm
Ground clearance 11 in 11 in Tire pressure 100 psi
27.9 cm 27.9 cm 6.89 bar
Operational dimensions Wheel diameter 221/2 in

57 cm
Maximum platform height 80 ft 85 ft
Wheel width 113/4 in
24.4 m 25.9 m
29.8 cm
Maximum horizontal reach 71 ft 11 in 76 ft 11 in Wheel lugs 10 @ 3/4 -16
21.9 m 23.4 m
Lug nut torque, dry bolts 420 ft-lbs
Maximum turntable tailswing 3 ft 81/2 in 3 ft 81/2 in 569.4 Nm
113 cm 113 cm
Lug nut torque, lubricated bolts 320 ft-lbs
Wheelbase 9 ft 9 ft 433.9 Nm
2.7 m 2.7 m
Fluid capacities
Turning radius, inside 10 ft 71/2
in 10 ft 71 / 2
in Fuel tank 33 gallons
(axles extended) 3.23 m 3.23 m 124.9 liters
Turning radius, outside 23 ft 1 in 23 ft 1 in LPG tank 33.5 pounds
(axles extended) 7.03 m 7.03 m 15.2 kg
Turntable rotation continuous continuous Hydraulic tank 45 gallons
170 liters
Platform rotation 160° 160°
Hydraulic system 55 gallons
Maximum capacity 600 lbs 500 lbs (including tank) 208 liters
6 foot platform 272 kg 227 kg
Drive hubs 50 fl oz
Maximum capacity 500 lbs 500 lbs 1.63 liters
8 foot platform 227 kg 227 kg Turntable rotation 44 fl oz
Maximum allowable 150 lbs 150 lbs drive hub 1.3 liters
side force (ANSI and CSA) 68 kg 68 kg Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice.
Part No. 72062 Genie S-80 & Genie S-85 2-1

Section 2 • Specifications Third Edition • First Printing
SPECIFICATIONS
Performance Specifications Boom function speeds, maximum

from platform controls
Drive speeds, maximum 2WD 4WD
Jib boom up, (S-85 models) 60 to 70 seconds
Drive speed, stowed 3.8 mph 3.1 mph
Gasoline/LPG models 6.1 km/h 4.9 km/h Jib boom down, (S-85 models) 40 to 50 seconds
40 ft/7.2 sec 40 ft/8.8 sec Boom up 89 to 93 seconds
12.2 m/7.2 sec 12.2 m/8.8 sec
Boom down 90 to 94 seconds
Drive speed, stowed 3.3 mph 3 mph
Diesel models 5.3 km/h 4.8 km/h Boom extend 73 to 79 seconds
40 ft/8.3 sec 40 ft/9.1 sec
12.2 m/8.3 sec 12.2 m/9.1 sec Boom retract 79 to 84 seconds
Drive speed, 0.6 mph 0.6 mph Turntable rotate, 360°
raised or extended - 1.0 km/h 1.0 km/h boom fully stowed 80 to 84 seconds
all models 40 ft/40 sec 40 ft/40 sec
12.2 m/40 sec 12.2 m/40 sec Turntable rotate, 360°
boom raised or extended 210 to 220 seconds
Platform rotate, 160° 8 to 12 seconds

Gradeability (boom stowed) 2WD 4WD
Platform level up 50 to 60 seconds
Rough terrain 30% 38%
Platform level down 40 to 50 seconds
2-2 Genie S-80 & Genie S-85 Part No. 72062

SPECIFICATIONS
Hydraulic Specifications Function pump
Hydraulic fluid Dexron equivalent Type: pressure balanced gear
Drive pump Displacement - static 1.4 cu in

19 cc
Type: bi-directional variable displacement piston pump
Displacement 2500 rpm 0 to 14 gpm
Displacement @ 2500 rpm 0 to 30.3 gallons per minute 0 to 53 l/min
0 to 114.7 liters per minute
Hydraulic tank circuit 10 micron with 25 psi
Maximum drive pressure 3500 psi return line filter (1.7 bar) bypass
241.3 bar
Function manifold
Charge pressure
Neutral position 290 psi 20 bar Function relief 2900 psi
Drive position 250 psi 17 bar valve pressure 200 bar
Medium pressure filter 3 micron Boom down 2300 psi

relief valve pressure 158.6 bar
Medium pressure filter 50 psi
bypass pressure 3.4 bar Boom extend 2500 psi
172 bar
Drive manifold
Steer/axle extend 5 gallons per minute
Brake 250 psi flow regulator 18.9 liters per minute
relief pressure 17.2 bar
Steer regulator 3.5 gallons per minute
Steer end drive motors 4WD models 13.2 liters per minute
Displacement 1.52 cu in Auxiliary pump

per revolution 25 cc
Type: fixed displacement gear pump
Non-steer end drive motors
Displacement - static 0.152 cu in
Displacement per revolution, variable 0.16 to 2.8 cu in 2.5 cc
4WD (2 speed motor) 2.62 to 45.9 cc
Displacement 1.4 gallons per minute
Displacement per revolution, variable 1.12 to 2.8 cu in 5.3 liters per minute
2WD 18.4 to 45.9 cc
Auxiliary pump 2500 psi
relief pressure 172 bar

SPECIFICATIONS
Ford Engine LRG-425 EFI Starter motor
Displacement 153 cu in Normal engine cranking speed 200 to 250 rpm

2.5 liters Current draw, normal load 140-200A
Number of cylinders 4 Current draw, maximum load 800A
Bore & stroke 3.78 x 3.4 inches Current draw, minimum 60-80A
96.01 x 86.36 mm
Maximum circuit voltage drop 0.5V DC
Horsepower 70 @ 2500 rpm while starting (normal temperature)
Firing order 1-3-4-2 Brush length, new 0.66 in
Low idle 1600 rpm 16.8 mm
High idle 2500 rpm Brush length wear limit 0.25 in

6.35 mm
Compression ratio 9.4:1
Maximum commutator 0.005 inches
Compression pressure (approx.) run-out 0.127 mm
Pressure (psi) of lowest cylinder must be
at least 75% of highest cylinder Battery
Valve clearances - 0.035 to 0.055 inches Type 12V, Group 31

collapsed tappet 0.889 to 1.397 mm Quantity 1
Lubrication system Cold cranking ampere 1000A
Oil pressure 40 to 60 psi Reserve capacity @ 25A rate 200 minutes
(operating temp. @ 2000 rpm) 2.75 to 4.1 bar
Electronic Fuel pump
Oil capacity 5 quarts
(including filter) 4.7 liters Fuel pressure, static 64 psi
4.4 bar
Oil viscosity requirements
Fuel flow rate 0.58 gpm
below 60°F / 15.5°C 5W-30 2.18 l/min
-10°F to 90°F / -23°C to 32°C 5W-30 Ignition System
above -10°F / -23°C 5W-50 Spark plug type Motorcraft AWSF-52-C
above 25°F / -4°C 10W-30 Spark plug gap 0.042 to 0.046 inches
Use oils meeting API classification SH or SG grade. 1.07 to 1.18 mm
Units ship with 10W-40 CC/SG. Engine coolant
Capacity 111/2 quarts

10.9 liters
Alternator
Output 95A, 14.5VDC

SPECIFICATIONS
Deutz Engine F4L 1011F Injection system
Displacement 166.7 cu in Injection pump make OMAP

2.732 liters Injection pump pressure 4351 psi
Number of cylinders 4 300 bar
Bore and stroke 3.58 x 4.13 inches Injector opening pressure 3626 psi
91 x 105 mm 250 bar
Horsepower 56 @ 3000 rpm Fuel requirement diesel number 2-D
Firing order 1-3-4-2 Alternator output 55A, 14 VDC
Compression ratio 18.5:1 Starter motor
Compression pressure 362 to 435 psi Current draw, no load 90A

25 to 30 bar Brush length, new 0.748 in
Low idle 1500 rpm 19 mm
High idle 2300 rpm Brush length, minimum 0.5 in

12.7 mm
Governor centrifugal mechanical
Battery
Valve clearance, cold
Type 12 VDC, Group 31
Intake 0.012 in
0.3 mm Quantity 1
Exhaust 0.020 in Cold cranking ampere 1000A

0.5 mm Reserve capacity @ 25A rate 200 minutes
Lubrication system Fan belt deflection 3 /8
to 1/2 inch
Oil pressure 26 to 87 psi 9 to 12 mm
1.8 to 6 bar
Oil capacity 11 quarts

(including filter) 10.5 liters
60°F / 15.5°C (synthetic) 5W-30
-10°F to 90°F / -23°C to 32°C 10W-40
above -4°F / -20°C 15W-40
Engine oil should have properties of API classification

CC/SE or CC/SF grades.
Units ship with 10W-40 CC/SG.

SPECIFICATIONS
Perkins Engine 704-30 Injection system
Displacement 183 cu in Injection pump make Zexel PFR-KX

2.9 liters Injection pump pressure 2755 psi 190 bar
Number of cylinders 4 Injector opening pressure 3626 psi 250 bar
Bore and stroke 3.82 x 3.94 inches Fuel requirement diesel number 2-D
97 x 100 mm
Engine coolant
Horsepower 63 @ 2600 rpm
Capacity 111/2 quarts
Firing order 1-3-4-2 10.9 liters
Compression ratio 17.5:1 Alternator output 65A, 12V DC
Compression pressure 300 to 500 psi Battery
20.7 to 34.5 bar
Pressure (psi) of lowest cylinder must be Type 12VDC, Group 31
within 50 psi (3.45 bar) of highest cylinder
Quantity 1
Low idle 1600 rpm
Cold cranking ampere 1000A
High idle 2200 rpm
Reserve capacity @ 25A rate 200 minutes
Governor centrifugal mechanical
Fan belt deflection 3 /8
in
Valve clearance, cold 10 mm
Intake 0.014 in
0.35 mm
Exhaust 0.014 in
0.35 mm
Lubrication system
Oil pressure 41 psi

(at 2600 rpm) 2.8 bar
Oil capacity 7.3 quarts

(including filter) 8.3 liters
below 60°F / 15.5°C 15W-40
-10°F to 90°F / -23°C to 32°C 10W-30
above -4°F / -20°C 15W-40

CF4. Units ship with 10-40 CC/SG.

SPECIFICATIONS
Hydraulic Hose and Fitting Torque Specifications

Your machine is equipped with Parker Seal-Lok® O-ring face seal fittings and hose ends. Machines that
utilize Parker Seal-Lok® O-ring face seal hoses and fittings require that the fittings and hose ends be
torqued to specification when they are removed and installed or when new hoses or fittings are installed.
Hydraulic Hose and Fitting Torque Specifications

SAE O-ring Boss Port - tube fitting Seal-Lok® - hose end
SAE Dash Installing SAE Dash
Size into... ft. lbs. Nm 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
Torque Procedure
1 Replace the O-ring. The O-ring must be 3 Be sure that the face seal O-ring is seated and
replaced anytime the seal has been broken. retained properly.
The O-ring cannot be re-used if the fitting or
4 Position the tube and nut squarely on the face
hose end has been tightened beyond finger
seal end of the fitting and tighten the nut finger
tight.
tight.
The O-rings used in the Parker
Seal Lok® fittings and hose ends 5 Tighten the nut or fitting to the appropriate
are a custom-size O-ring. They torque per given size as shown in the table
are not a standard SAE size above.
O-ring. They are available in the 6 Operate all machine functions and inspect the
O-ring field service kit hoses and fittings and related components to
(Genie part no. 49612). be sure that there are no leaks.
2 Lubricate the O-ring before installation.

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Third Edition • First Printing Section 3 • Theory of Operation
Theory Of Operation
Power Source Electrical System
The Genie S-80 and Genie S-85 are powered by Boom/Steer functions are accomplished by
either a Gasoline/LPG engine or one of two diesel moving a toggle switch or a controller, which
engines. The Gasoline/LPG option uses a Ford sends voltage to the appropriate directional
LRG-425 EFI rated at 70 horsepower @ 2500 control valve. These directional valves determine
rpm. The diesel options include a Deutz which direction the hydraulic fluid will travel. The
F4L1011F rated at 56 horsepower @ 3000 rpm, volume of hydraulic fluid is determined by either
and a Perkins 704-30 rated at 63 horsepower a proportional valve or flow regulator valve.
@ 2600 rpm. A proportional valve receives a variable voltage
signal and delivers more hydraulic fluid as the
Hydraulic System voltage increases. A flow regulator valve is a
mechanical valve and delivers a predetermined
All machine functions are performed by the
amount of hydraulic fluid.
hydraulic system. The hydraulic system is divided
into two groups: Boom/Steer functions and Drive Drive forward or reverse is accomplished by
functions. pressing down the foot switch in the platform and
moving the drive controller (joystick) in the
Boom/Steer functions are powered by a single-
appropriate direction. When activated, the drive
section gear pump, rated at 14 gpm (53 L/min).
controller completes a circuit to the Electronic
When the engine is running, this pump supplies
Displacement Controller (EDC). The EDC
hydraulic fluid under pressure to the function
regulates drive pump displacement in direct
manifold, where the directional and flow control
relation to the drive controller position. A
valves are located. To protect from over-
horsepower limiter printed circuit board
pressurization of the Boom/Steer system, the pump
(located in the platform control box) is provided to
is provided with a pressure relief valve, set at 2900
maintain engine RPM as drive system loads
psi (200 bar).
become greater. This is done by sensing engine
Drive functions are powered by a bi-directional, RPM (via an AC tap on the alternator) and limiting
variable output piston pump rated at 0 to 30.3 gpm the amount of current supplied to the drive
(0 to 114.7 L/min) @ 2500 rpm. Two internal 3500 controller/EDC, which de-strokes the pump,
psi (241 bar) relief valves are used to prevent reducing pump output.
over-pressurization of the closed loop drive system.
The boom lift cylinder, boom extend cylinder,
platform leveling slave cylinder, platform rotator
and jib boom cylinder (S-85 models) incorporate
counterbalance valves to prevent movement in the
event of a hydraulic line failure.

Section 3 • Theory of Operation Third Edition • First Printing
THEORY OF OPERATION
Limit switches Machine Controls

There are two types of limit switches which are The Genie S-80 and Genie S-85 machines are
found in various locations on the machine: drive equipped with operational controls which are found
speed limit switches and a drive enable limit in two locations: the ground controls, located on
switch. The function of a drive speed limit switch the tank side of the machine, and the platform
is to limit the raised or extended drive speed to 0.6 controls, located in the platform. All lift and drive
miles per hour (1 km/h) when the primary boom is functions are available at the platform controls.
raised more than 2 feet (0.6 m) OR when the Only boom functions are available at the ground
primary boom is extended more than 36 inches controls.
(0.9 m). The function of the drive enable limit
switch is to limit the ability of the machine to drive Ground controls are activated by holding the
when the boom is rotated beyond the non-steer function enable toggle switch to either side, then
wheels. moving a boom function toggle switch in the
direction indicated on the control panel decal.
This will determine which boom function will
operate and its direction of travel.
Platform controls use toggle switches and boom
function controllers (joysticks) to operate the boom
functions. The drive controller (joystick) regulates
the drive pump displacement through the EDC in
direct relation to the drive controller position. A
thumb rocker switch on the top of the drive
controller is used for steering.
Washing electronic components is

not suggested. Instead, use
compressed air to remove debris.

Third Edition • First Printing Section 4 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety

warnings and step-by-step instructions.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Safety alert symbol—used to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, annually and every 2
Red—used to indicate the
years as specified on the Maintenance
presence of an imminently
Inspection Report.
Failure to perform each procedure avoided, will result in death or
as presented and scheduled may serious injury.
cause death, serious injury or
Orange—used to indicate the
substantial machine damage.
Immediately tag and remove from service a hazardous situation which, if not
damaged or malfunctioning machine. avoided, could result in death or
serious injury.
Repair any machine damage or malfunction
before operating machine. Yellow with safety alert symbol—
used to indicate the presence of a
Keep records on all inspections for three years. potentially hazardous situation
which, if not avoided, may result
Unless otherwise specified, perform each
in minor or moderate injury.
procedure with the machine in the following
configuration: Yellow without safety alert
· Machine parked on a flat, level surface symbol—used to indicate the
· Boom in the stowed position hazardous situation which, if not
· Turntable rotated with the boom between avoided, may result in property
the non-steering wheels damage.
· Turntable secured with the turntable Green—used to indicate operation
rotation lock pin or maintenance information.
· Key switch in the OFF position with the
Indicates that a specific result is expected after
key removed
performing a series of steps.
· Wheels chocked

Section 4 • Scheduled Maintenance Procedures Third Edition • First Printing
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Maintenance Schedule

The following symbols have been There are five types of maintenance inspections
used in this manual to help that must be performed according to a schedule—
communicate the intent of the daily, quarterly, six months, annual, and two year.
instructions. When one or more of The Scheduled Maintenance Procedures Section
the symbols appear at the and the Maintenance Inspection Report have been
beginning of a maintenance divided into five subsections—A, B, C, D and E.
procedure, it conveys the meaning Use the following chart to determine which
below. group(s) of procedures are required to perform a
scheduled inspection.
Indicates that tools will be required to Inspection Table or Checklist

perform this procedure.
Daily or every 8 hours A
Indicates that new parts will be required Quarterly or every 250 hours A+B
to perform this procedure.
Six month or every 500 hours A+B+C
Annual or every 1000 hours A+B+C+D

Indicates that a cold engine will be
required to perform this procedure. Two year or every 2000 hours A+B+C+D+E
Maintenance Inspection Report

Indicates that a warm engine will be
required to perform this procedure. The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
Indicates that dealer service is required
to use for each inspection. Store completed forms
to perform this procedure.
for three years.

Maintenance Inspection Report

Model Checklist A Y N R Checklist B Y N R
A-1 Manuals B-1 Exhaust system
Serial number A-2 Decals and placards B-2 Hydraulic tank return
A-3 Damage and loose or filter condition
Date
missing parts B-3 Tires and wheels
Hour meter A-4 Engine oil level B-4 Brake configuration
A-5 Engine coolant- B-5 Drive hub oil level
Machine owner Liquid cooled models B-6 Engine RPM
A-6 Fuel leaks B-7 Key switch
Inspected by (print) A-7 Hydraulic oil level B-8 Emergency Stop
A-8 Hydraulic leaks B-9 Ground control override
Inspector signature
A-9 Tire pressure B-10 Platform leveling
Inspector title A-10 Extendable axles B-11 Horn
A-11 Platform and B-12 Foot switch
Inspector company ground controls
B-13 Engine idle select
A-12 Auxiliary power
B-14 Fuel select-Ford models
Instructions A-13 Tilt sensor
B-15 Drive enable system
· Make copies of this report to use for A-14 Limit switches
each inspection. B-16 Drive brakes
A-15 Drain filter/separator
· Select the appropriate checklist(s) for B-17 Drive speed-stowed
Diesel models
the type of inspection to be B-18 Drive speed-raised
A-16 Air filter
performed. or extrended
A-17 30 Day Service
B-19 Alarm package
Daily or 8 hour Perform every 100 hours:
B-20 Hydraulic oil analysis
Inspection: A A-18 Radiator-
B-21 Replace hydraulic
Quarterly or 250 hour Liquid cooled models
tank return filter
Inspection: A+B A-19 Battery
B-22 Drive loop hydraulic filter
Six Month or 500 hour A-20 Replace engine oil and
B-23 Inspect fuel tank cap
Inspection: A+B+C filter-Ford models
venting system
Annual or 1000 hour A-21 Electrical wiring
Perform every 400 hours:
Inspection: A+B+C+D Perform every 125 hours:
B-24 Replace engine air filter
2 Year or 2000 hour A-22 Oil cooler and fins-
B-25 Replace spark plugs-
Inspection: A+B+C+D+E Deutz models
Ford models
Perform every 200 hours:
· Place a check in the appropriate box A-23 Check engine belt -
after each inspection procedure is Ford/Perkins models
completed.
A-24 Fuel filter-Ford models
· Use the step-by-step procedures in
section 4 to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments

MAINTENANCE INSPECTION REPORT
Instructions Checklist C Y N R Checklist E Y N R

· Make copies of this report to use for C-1 Engine belt- E-1 Hydraulic oil
each inspection. Deutz models E-2 Engine coolant-
· Select the appropriate checklist(s) for C-2 Valves-Deutz models Liquid cooled models
the type of inspection to be C-3 Fuel filter/water E-3 Fuel hoses-Ford models
performed. separator-Perkins models E-4 Replace engine
C-4 Fuel filter- breather-Perkins models
Daily or 8 hour
Perkins models E-5 Wheel bearings
Inspection: A
C-5 Replace engine oil and Perform every 3000 hours:
Quarterly or 250 hour filter-Perkins models
Inspection: A+B E-6 Fuel injectors-
C-6 Starting aid- Perkins models
Six Month or 500 hour Perkins models
Inspection: A+B+C
C-7 Check the coolant-
Annual or 1000 hour Liquid cooled models
Inspection: A+B+C+D C-8 PCV valve-Ford models
2 Year or 2000 hour
Inspection: A+B+C+D+E Checklist D Y N R
· Place a check in the appropriate box D-1 Boom wear pads
after each inspection procedure is D-2 Extendable axles
completed. D-3 Free-wheel configuration
· Use the step-by-step procedures in D-4 Turntable bearing bolts
section 4 to learn how to perform D-5 Grease rotation bearing
these inspections.
D-6 Drive hub oil
· If any inspection receives an “N”, tag D-7 Replace engine oil and
and remove the machine from filter-Deutz models
service, repair and re-inspect it. After
D-8 Fuel strainer-
repair, place a check in the “R” box.
Deutz models
Legend D-9 Fuel filter/water
Y = yes, acceptable separator-Diesel models
N = no, remove from service D-10 Change fuel hoses-
R = repaired Deutz models
Comments D-11 Valves-Perkins models
D-12 Clean engine breather-
Perkins models

Table A Procedures
A-1 A-2
Inspect the Operators and Inspect the
Safety Manuals Decals and Placards
Maintaining the operator’s and safety manuals in Maintaining all of the safety and instructional
good condition is essential to safe machine decals and placards in good condition is
operation. Manuals are included with each mandatory for safe machine operation. Decals
machine and should be stored in the container alert operators and personnel to the many possible
provided in the platform. An illegible or missing hazards associated with using this machine. They
manual will not provide safety and operational also provide users with operation and maintenance
information necessary for a safe operating information. An illegible decal will fail to alert
condition. personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to be sure that the storage container is
present and in good condition. 1 Refer to the Decals section in the Genie S-80
& Genie S-85 Operator's Manual and use the
2 Check to make sure that the operator's,
decal list and illustrations to determine that all
responsibilities and safety manuals are present
decals and placards are in place.
and complete in the storage container in the
platform. 2 Inspect all decals for legibility and damage.
Replace any damaged or illegible decal
3 Examine the pages of each manual to be sure
immediately.
that they are legible and in good condition.
Contact your authorized Genie
4 Always return the manuals to the storage
distributor or Genie Industries if
container after use.
replacement decals are needed.
Contact your authorized Genie
distributor or Genie Industries if
replacement manuals are needed.

TABLE A PROCEDURES
A-3 Check entire machine for:

Inspect for Damage and Loose or · Cracks in welds or structural components
Missing Parts · Dents or damage to machine
· Battery and connections
· Compartment covers and latches
Daily machine condition inspections are essential Be sure that all structural and other critical
to safe machine operation and good machine components are present and all associated
performance. Failure to locate and repair damage, fasteners and pins are in place and properly
and discover loose or missing parts may result in tightened.
an unsafe operating condition.
After you complete each inspection, be sure that all
1 Inspect the entire machine for damage and compartment covers are in place and secured.
improperly installed or missing parts including:
· Electrical components, wiring and electrical
cables
· Hydraulic hoses, power units, fittings, cylinders
and manifolds
· Fuel and hydraulic tanks
· Drive and turntable motors and drive hubs
· Boom wear pads
· Tires and wheels
· Engine and related components
· Limit switches, alarms, horn and beacon
· Nuts, bolts and other fasteners
· Platform entry mid-rail or gate

TABLE A PROCEDURES
A-4 Deutz F4L 1011F Engine 8.5 quarts

Oil capacity (including filter) 8 liters
Check the Engine Oil Level
below 60°F / 15.5°C (synthetic) 5W-30

Maintaining the proper engine oil level is essential
to good engine performance and service life. -10°F to 90°F / -23°C to 32°C 10W-40
Operating the machine with an improper oil level
can damage engine components. above -4°F / -20°C 15W-40
Check the oil level with the Engine oil should have properties of API classification
engine off. CC/SE or CC/SF grades. Units ship with 10-40 CC/SG.
1 Check the engine oil dipstick. Perkins 704-30 Engine 9.6 quarts
Oil capacity (including filter) 9 liters
Ford Models:
Result: The oil level should be within the "safe" Oil viscosity requirements
marks on the dipstick.
below 60°F / 15.5°C 15W-40
Deutz Models:
-10°F to 90°F / -23°C to 32°C 10W-30
Result: The oil level should be within the two
marks on the dipstick. above -4°F / -20°C 15W-40
Perkins Models:
Result: The oil level should be within the two CF4 grade. Units ship with 10-40 CC/SG.
notches on the dipstick.
Ford LRG-425 EFI Engine 4.5 quarts

Oil capacity (including filter) 4.3 liters
below 60°F / 15.5°C 5W-30
-10° to 90°F / -23° to 32°C 5W-30
above -10°F / -23°C 5W-30
above 25°F / -4°C 10W-30
Use oils meeting API classification SH or SG grade.

Units ship with 10-40 CC/SG.

TABLE A PROCEDURES
A-5 A-6
Check the Engine Coolant Level Check for Fuel Leaks
-
Liquid Cooled Models
Failure to detect and correct fuel leaks will result in
an unsafe condition. An explosion or fuel fire may
cause death or serious injury.
Maintaining the engine coolant at the proper level
is essential to engine service life. Improper coolant Explosion and fire hazard. Engine
level will affect the engine's cooling capability and fuels are combustible. Inspect the
damage engine components. Daily checks will machine in an open, well-
allow the inspector to identify changes in coolant ventilated area away from heaters,
level that might indicate cooling system problems. sparks, flames and lighted
tobacco. Always have an
Burn hazard. Beware of hot approved fire extinguisher within
engine parts and coolant. Contact easy reach.
with hot engine parts and/or
coolant may cause severe burns. 1 Open the shutoff valve on the liquid petroleum
gas (LPG) tank by turning it counterclockwise
1 Check the fluid level in the coolant recovery (if equipped).
tank. Add fluid as needed.
Result: The fluid level should be at the
FULL mark.
Do not remove the radiator cap.

TABLE A PROCEDURES
2 Perform a visual inspection around the following A-7

areas.
Check the Hydraulic Oil Level
Ford models:
· LPG tank, hoses and fittings, solenoid shutoff

valve, LPG regulator and throttle body.
An LPG detector may be Maintaining the hydraulic oil at the proper level is
necessary to locate LPG leaks. essential to machine operation. Improper hydraulic
oil levels can damage hydraulic components. Daily
· Gasoline tank, manual shutoff valve, fuel checks allow the inspector to identify changes in oil
pump, fuel filters, fuel rail and fuel injectors, level that might indicate the presence of hydraulic
hoses and fittings and throttle body. system problems.
Diesel models: 1 Be sure that the boom is in the stowed position,
· Fuel tank, shutoff valve, hoses and fittings, then visually inspect the sight gauge located on
fuel pump, fuel filter, fuel injection pumps and the side of the hydraulic oil tank.
fuel injectors (atomizers). Result: The hydraulic oil level should be within
Explosion and fire hazard. If a fuel the top 2 inches (5 cm) of the sight gauge.
leak is discovered, keep any
2 Add oil as needed.
additional personnel from entering
the area and do not operate the Hydraulic oil specifications
machine. Repair the leak
immediately. Hydraulic oil type Dexron equivalent
Tank capacity 45 gallons

170 liters

(including tank) 208 liters

TABLE A PROCEDURES
A-8 A-9
Check for Hydraulic Leaks Check the Tire Pressure
Detecting hydraulic fluid leaks is essential to Bodily injury hazard. An over-

operational safety and good machine performance. inflated tire can explode and could
Undiscovered leaks can develop into hazardous cause death or serious injury.
situations, impair machine functions and damage
Tip-over hazard. Do not use
machine components.
temporary flat tire repair products.
Bodily injury hazard. Spraying This procedure does not need
hydraulic oil can penetrate and to be performed on machines
burn skin. equipped with the foam-filled
1 Inspect for hydraulic oil puddles, dripping or tire option.
residue on or around the following areas:
To safeguard maximum stability, achieve
· Hydraulic tank—filter, fittings, hoses, auxiliary optimum machine handling and minimize tire
power unit, filters, and turntable surface wear, it is essential to maintain proper pressure
in all air-filled tires.
· Engine compartment—hydraulic filters,
fittings, hoses, pumps, component tray 1 Check each tire with an air pressure gauge. Add
· All hydraulic cylinders air as needed.
· All hydraulic manifolds
Tire specifications
· Primary, and jib booms
· The underside of the turntable Tire size 15-19.5 NHS
· The underside of the drive chassis Pressure 100 psi

· Ground area under the machine 6.9 bar
4 - 10 Genie S-80 & Genie S-85 Part No. 72062

TABLE A PROCEDURES
A-10 6 At the extendable axle controls located at the

non-steer end of the drive chassis, activate the
Test the Extendable Axles steer axle drive chassis lift jack cylinder.
Tip over hazard. Do not raise or Result: The cylinder should extend and the drive
extend the boom unless both axles chassis should raise smoothly, free of
are extended. If the axle extension hesitation.
system is not operating correctly,
the stability of the machine is 7 Continue holding the chassis jack in the
compromised and it may tip over. extended position and activate the steer axle
EXTEND control handle to extend the steer axle.
Be sure the axles are retracted
before performing this procedure. Result: The cylinder should extend and the steer
axle should extend smoothly, free of hesitation.
1 Start the engine from the ground controls.
8 Return the chassis jack control handle to the
2 Hold the function enable switch to either side neutral position.
and activate the boom up function.
Result: The lift jack cylinder should fully retract
Result: The boom should raise to horizontal and when the control handle is returned to neutral.
then stop. The boom should not raise above the
limit switch unless both axles are extended. 9 Activate the non-steer axle drive chassis lift
jack cylinder.
3 Hold the function enable switch to either side
and activate the boom down function. Result: The cylinder should extend and the drive
chassis should raise smoothly, free of
Result: The boom should lower and return to the hesitation.
stowed position.
10 Continue holding the chassis jack in the
4 Hold the function enable switch to either side extended position and activate the non-steer
and activate the boom extend function. axle EXTEND control handle to extend the steer
Result: The boom should extend no more than axle.
36 inches (0.9 m) and then stop. The boom Result: The cylinder should extend and the
should not extend beyond the limit switch non-steer axle should extend smoothly, free of
unless both axles are extended. hesitation.
5 Hold the function enable switch to either side 11 Return the chassis jack control handle to the
and activate the boom retract function. neutral position.
Result: The boom should retract. Result: The lift jack cylinder should fully retract
when the control handle is returned to neutral.
Part No. 72062 Genie S-80 & Genie S-85 4 - 11

TABLE A PROCEDURES
A-11 5 Push in the Emergency Stop button to the OFF

position.
Test the Platform and
Result: No function should operate, the engine
Ground Controls should stop.
Testing the machine functions and the Emergency Machines equipped with Platform
Stop buttons for malfunctions is essential for safe Level Control Disable Function:
machine operation. An unsafe working condition The platform level toggle switch
exists if any function fails to operate properly or will not operate when the boom is
either Emergency Stop button fails to stop all the raised or extended past the drive
machine functions and shut off the engine. Each speed limit switches.
function should activate, operate smoothly and be
free of hesitation, jerking and unusual noise. Diesel models: All functions
should stop immediately. The
1 Pull out the Emergency Stop button at the engine will shut off after 2 to 3
ground controls to the ON position. seconds.
2 Start the engine from the ground controls. 6 Start the engine from the platform controls and
3 Do not hold the function enable switch to either move the lift/drive selector switch to the lift
side. Attempt to activate each boom and position (if equipped).
platform function toggle switch. 7 Do not press down on the foot switch.
Result: All boom and platform functions should 8 Attempt to operate all machine functions.
not operate.
Result: All machine functions should not
4 Hold the function enable switch to either side operate.
and activate each boom and platform function
toggle switch. 9 Press down the foot switch and activate each
machine function.
Result: All boom and platform functions should
operate through a full cycle. Descent alarm (if Result: All machine functions should operate
equipped) should sound while the boom is through a full cycle.
lowering. 10 Push in the Emergency Stop button to the OFF
position at the platform controls.
Result: No function should operate, the engine
should stop.
As a safety feature, selecting
and operating the ground
controls will override the
platform controls, including
the Emergency Stop switch.
Diesel models:
All functions should stop
immediately. The engine will
shut off after 2 to 3 seconds.

TABLE A PROCEDURES
A-12 6 Lift the red auxiliary power toggle switch cover

(if equipped).
Test the Auxiliary Power
7 Simultaneously
Operation hold the
Detection of auxiliary power system malfunctions is auxiliary power
essential for safe machine operation. An unsafe toggle switch
working condition exists if the auxiliary powered ON and activate
functions do not operate in the event of a main each function

power loss. When operating the machine on controller or
engine power, selecting auxiliary power will stop toggle switch.
the engine immediately. Auxiliary power is Result: All boom and steer functions should
designed for short term use only, and excessive operate. Drive functions should not operate with
use will result in battery drain and component auxiliary power.
damage.
To conserve battery power, test
1 Turn the key switch to ground control and pull each function through a partial
out the Emergency Stop button to the ON cycle.
position.
10 Start the engine from the platform controls.
2 Lift the red auxiliary power
toggle switch cover 11 Press down the foot switch, then lift the red
(if equipped). auxiliary power toggle switch cover
(if equipped).
3 Simultaneously hold the
auxiliary power toggle switch 12 Hold the auxiliary power toggle switch in the ON
ON and activate each boom position.
function toggle switch. Result: The engine should stop.
Result: All boom functions should operate. 13 Start the engine from the ground controls.
To conserve battery power, test 14 Lift the red auxiliary power toggle switch cover
each function through a partial (if equipped).
cycle.
15 Hold the auxiliary power toggle switch in the ON
4 Turn the key switch to platform control. position.
5 Pull out the Emergency Stop button to the ON Result: The engine should stop.
position at the platform controls, then press
down the foot switch.

TABLE A PROCEDURES
A-13 A-14
Test the Tilt Sensor Test the Limit Switches
The tilt sensor sounds an alarm located in the
platform when the incline of the turntable exceeds
the rating on the serial plate.
Drive Limit Switches
Select a level test area. The tilt
alarm should not be sounding prior Detecting limit switch malfunctions is essential to
to the test. safe machine operation. The drive limit switches
are used to restrict drive speed when the boom is
1 Start the engine from the platform controls. raised or extended. An improperly functioning drive
2 Open the tank side turntable cover and press limit switch will allow the machine to operate in an
down on one side of the tilt sensor. unsafe position.
Result: The alarm in the platform should sound. 1 Remove the cover from the rear of the turntable
to access the drive limit switch.
Tip-over hazard. The alarm should
be audible at the ground controls. 2 Visually inspect the boom up drive limit switch
If the alarm is not audible at the (LS2) mounted to the turntable riser at the pivot
ground controls, replace the alarm end of the boom. Inspect for the following:
in the platform.
· Broken or missing roller or arm
· Loose or missing fasteners
· Loose wiring
a b
a b c
a fuel tank c
b tilt sensor
c ground control box a turntable riser
b boom
c boom up drive limit switch (LS2)

TABLE A PROCEDURES
3 Manually activate the boom up drive limit 8 Turn the key switch to platform controls and
switch. fully retract the boom.
Result: The boom up drive limit switch arm 9 Move the lift/drive selector switch to the drive
should move freely and spring return to center. position (if equipped).
A distinct click should be felt and heard.
10 Press down the foot switch and slowly move the
4 Visually inspect the boom extend drive limit drive controller off center.
switch located at the end of the cable track on
Result: The machine should move at normal
the boom. Inspect for the following:
drive speeds.
· Broken or missing roller or arm
11 Move the lift/drive selector switch to the lift
· Missing fasteners position (if equipped).
· Loose wiring 12 Raise the boom to just above horizontal.
13 Move the lift/drive selector switch to the drive
position (if equipped).
14 Slowly move the drive controller off center.
Result: The machine should move at a reduced
drive speed.
15 Move the lift/drive selector switch to the lift
16 Lower the boom to the stowed position, then
a b extend the boom 3 feet (0.9 m).
17 Move the lift/drive selector switch to the drive
a boom extend drive limit switch (LS1) position (if equipped).
b cable track
18 Slowly move the drive controller off center.
Result: The machine should move at a reduced
6 Extend the boom approximately 3 feet (0.9 m). drive speed.
7 Manually activate the boom extend drive limit
switch (LS1). Drive speed, maximum,
raised or extended position
Result: The boom extend drive limit switch arm
should move freely and spring return to center. All models 1 foot per second (0.6 mph)
A distinct click should be felt and heard. 0.3 meters per second (0.97 km/h)

TABLE A PROCEDURES
Drive Enable Limit Switch 3 Manually activate the drive enable limit switch.
A properly functioning drive enable limit switch is Result: The drive enable limit switch arm should
essential for safe machine operation and move freely and spring return to center. A
workplace safety. The drive enable limit switch distinct click should be felt and heard.
stops the drive function when the boom is rotated
past a non-steer wheel and alerts the operator that 4 Start the engine from the platform controls, and
the machine may drive in the opposite direction press down the foot switch.
that the drive and steer controller is moved. Result: The drive enable indicator light should
1 Start the engine from the platform controls and be on.
rotate the turntable to the left until the boom is 5 Rotate the turntable so the boom is between the
past the left non-steer wheel. Turn the engine non-steer wheels.
off.
Result: The drive enable indicator light should
2 Visually inspect the drive enable limit switch for be off and drive function should operate.
the following:
6 Rotate the turntable to the left until the boom is
· Broken or missing roller or arm past the left non-steer wheel.
· Missing fasteners
· Loose wiring be on. Drive function should not operate until
a the drive enable override toggle switch is
activated.
7 Rotate the turntable to the right until the boom is
past the right non-steer wheel.
be on. Drive function should not operate until
the drive enable override toggle switch is
activated.
c b
a turntable
b drive enable limit switch (LS3)
c turntable rotation bearing

TABLE A PROCEDURES
A-15 2 Loosen the vent plug located on the fuel filter/

water separator head.
Drain the Fuel Filter/ Water a
Separator - Diesel Models
b
Proper maintenance of the fuel filter/water

separator is essential for good engine
performance. Failure to perform this procedure can d
lead to poor engine performance and component c
damage.
Explosion and fire hazard. Engine

fuels are combustible. Perform this
procedure in an open, well-
ventilated area away from heaters, Fuel filter/water separator
sparks, flames and lighted a head bolt
b vent plug
tobacco. Always have an c drain plug
approved fire extinguisher within d filter bowl
easy reach. e separator head
Perform this procedure with the 3 Loosen the drain plug located at the bottom of
engine off. the bowl. Allow the water to drain into a suitable
container until fuel starts to come out.
Perkins Models: Immediately tighten the drain plug.
1 Open the engine side turntable cover and locate 4 Tighten the vent plug.
the fuel filter/water separator.
If the fuel filter/water separator is
completely drained, you must
prime the fuel filter/water
separator before starting the
engine. Refer to C-4 in this
section, Replace The Fuel Filter
Element - Perkins Models, for
instructions on how to prime the
fuel filter/water separator.

TABLE A PROCEDURES
5 Clean up any fuel that may have spilled. 3 Clean up any fuel that may have spilled.
6 Start the engine from the ground controls and If the fuel filter is completely
check the fuel filter/water separator and vent drained, you must prime the fuel
plug for leaks. filter/water separator before
starting the engine. Refer to D-9
Explosion and fire hazard. If a fuel
in this section, Replace The Fuel
Filter/Water Separator - Deutz
Diesel Models, for instructions on
the area and do not operate the
how to prime the fuel filter/water
separator.
immediately.
4 Start the engine from the ground controls and
Deutz Models:
check the fuel filter/water separator for leaks.
1 Open the engine side cover and locate the fuel
filter/water separator.
2 Loosen the drain plug located at the bottom of additional personnel from entering
the filter. Allow the water to drain into a suitable the area and do not operate the
container until fuel starts to come out. machine. Repair the leak
Immediately tighten the drain plug. immediately.
a fuel filter
b drain plug

TABLE A PROCEDURES
A-16 Perkins models:

Inspect the Engine Air Filter 1 Open the engine side cover and disconnect the
retaining fasteners from the end cap of the air
filter canister. Remove the end cap.
2 Remove the filter element.
Maintaining the engine air filter in good condition is
essential to good engine performance and service 3 Empty dust discharge valve by pressing
life. Failure to perform this procedure can lead to together the sides of the discharge slot. Clean
poor engine performance and component damage. discharge slot as needed.
Perform this procedure with the

engine off.
Ford and Deutz Models: a
1 Open the engine side cover and remove the
retaining ring from the end cap of the air filter
canister.
2 Remove the end cap from the air cleaner b
canister.
3 Remove the air filter retaining fastener. Remove
the filter element.
Perkins diesel models
4 Clean the inside of the canister and the gasket a air filter
with a damp cloth. b dust discharge valve
5 Inspect the filter element. If needed, blow out 4 Clean the inside of the canister and the canister
from inside out using low pressure dry end cap with a damp cloth.
compressed air, or tap dust out taking care not 5 Inspect the filter element. If needed, blow out
to damage the element. from inside out using low pressure dry
6 Install the air filter element and install the compressed air, or tap out dust taking care not
mounting fastener. to damage the element.
7 Install the end cap onto the canister. Install and 6 Install the filter element
tighten the retaining ring. 7 Install the end cap onto the canister. Secure the
retaining fasteners.
Air filters - Genie part numbers

Ford LRG-425 EFI Engine 27916
Deutz F4L 1011F Engine 27916
Perkins 704-30 Engine 62420

TABLE A PROCEDURES
A-17 A-18
Perform 30 Day Service Inspect the Radiator -
The 30 day maintenance procedure is a one time

sequence of procedures to be performed after the Engine specifications require that
first 30 days or 50 hours of usage. After this this procedure be performed every
interval, refer to the maintenance tables for 100 hours. Perform this procedure
continued scheduled maintenance. more often if dusty conditions
1 Perform the following maintenance procedures: exist.
· A-20 Replace the Engine Oil and Filter - Maintaining the radiator in good condition is
Ford Models (if applicable) OR essential for good engine performance. Operating
· C-5 Replace the Engine Oil and Filter - a machine with a damaged or leaking radiator may
Perkins Models (if applicable) OR result in engine damage. Also, restricting air flow
through the radiator (i.e., dirt or debris) will affect
· D-9 Replace the Engine Oil Filter -
the performance of the cooling system. A frequent
Deutz Models (if applicable)
check allows the inspector to identify changes in
· B-3 Inspect the Tires and Wheels the condition of the radiator that might indicate
(including lug nut torque) cooling system problems.
· B-21 Replace the Hydraulic Tank Return
Filter Bodily injury hazard. Do not
inspect while the engine
· D-4 Check the Turnable Rotation Bearing
is running. Remove the key to
Bolts
secure from operation.
Bodily injury hazard. Beware of
hot engine parts and coolant.
Contact with hot engine parts
and/or coolant may cause severe
burns.

TABLE A PROCEDURES
1 Remove the 2 engine pivot plate retaining bolts. A-19

Swing the engine pivot plate away from the
machine to access the radiator. Check the Battery
Genie specifications require that

this procedure be performed every
100 hours.
Proper battery condition is essential to good
engine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component
damage and hazardous conditions.
a b b c
Electrocution hazard. Contact with
hot or live circuits could result in
a engine pivot plate death or serious injury. Remove all
b pivot plate retaining bolts rings, watches and other jewelry.
c air baffle
Bodily injury hazard. Batteries
2 Inspect the radiator for leaks and physical contain acid. Avoid spilling or
damage. contacting battery acid. Neutralize
3 Clean the radiator fins of debris and foreign battery acid spills with baking soda
materials. and water.
4 Inspect all radiator hoses and connections. 1 Put on protective clothing and eye wear.
5 Swing the engine pivot plate back to its original 2 Be sure that the battery cable connections are
position and install the two engine pivot plate free of corrosion.
retaining bolts. 3 Be sure that the battery hold downs and cable
connections are tight.

TABLE A PROCEDURES
4 Remove the battery vent caps and check the A-20

specific gravity of each battery cell with a
hydrometer. Replace the Engine Oil and
Result: If any battery cell displays a specific
Filter - Ford Models
gravity of less than 1.026, the battery must be
replaced.
5 Check the battery acid level of each cell. If Ford engine specifications require
needed, replenish with distilled water to the that this procedure be performed
bottom of each battery fill tube. Do not overfill. every 100 hours. Perform this
6 Install the battery vent caps. procedure more often if dusty
conditions exist or the machine is
Applying a corrosion preventative subjected to extended low idle
sealant will help eliminate operation.
corrosion on the battery terminals
and cables. Periodic replacement of the engine oil and filter
is essential to good engine performance. Operating
the machine with an improper oil level or
neglecting periodic oil and filter changes can
damage engine components. A daily check of
machine hours against the hours noted on the oil
filter will allow the inspector to anticipate and
perform oil and filter changes at the 100 hour
interval.
Bodily injury hazard. Beware of hot
engine parts and oil. Contact with
hot engine oil and/or engine parts
may cause severe burns.
Perform this procedure after
warming the engine to normal
operating temperature.
1 Open the engine side turntable cover and

remove the oil filler cap located on the valve
cover.

TABLE A PROCEDURES
2 Pull the oil drain hose out from underneath the 9 Use a permanent ink marker to write the date
engine. and number of hours from the hour meter on
the oil filter.
3 Open the engine oil drain valve on the engine oil
pan and allow all of the oil from the engine to 10 Fill the engine with new oil per specifications
drain into a suitable container. See and install the filler cap. See capacity
specifications. specifications.
Allow the engine to run for 30 seconds, then
turn the engine off.
12 Check the oil filter, oil pan drain hose and drain
valve for leaks.
13 Swing the engine pivot plate back to its original
position and install the two engine pivot plate
retaining bolts.
14 Check the engine oil level dipstick. Add oil
if needed.
15 Clean up any oil that may have spilled. Properly
dispose of the oil and filter.
a b c b d
Ford LRG-425 EFI Engine 4.5 quarts
a engine pivot plate
b pivot plate retaining bolts
c oil drain hose
d air baffle
below 60°F / 15.5°C 5W-30
4 Close the engine oil drain valve.
-10° to 90°F / -23° to 32°C 5W-30
5 Remove the 2 engine pivot plate retaining bolts.
Pull the engine pivot plate away from the above -10°F / -23°C 5W-30
machine to access the oil filter.
6 Place a container under the oil filter. above 25°F / -4°C 10W-30
7 Use an oil filter wrench and remove the filter. Use oils meeting API classification SH or SG grade.
8 Apply a thin layer of fresh oil on the gasket of
Oil filter - Genie part number 28656
the new oil filter. Install the filter and tighten it
securely by hand.

TABLE A PROCEDURES
A-21 3 Inspect the following areas for burnt, chafed,

corroded and loose wires:
Inspect the Electrical Wiring
· Engine wiring harness
· Hydraulic manifold wiring
4 Open the ground controls side turntable cover.
Genie specifications require that
this procedure be performed every 5 Inspect the following areas for burnt, chafed,
100 hours. corroded and loose wires:
Maintaining electrical wiring in good condition is · Inside of the ground control box
essential to safe operation and good machine · Hydraulic manifold wiring
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in 6 Start the engine from the ground controls and
unsafe operating conditions and may cause raise the boom above the turntable covers.
component damage. 7 Remove the center turntable cover fasteners.
Electrocution hazard. Contact with Remove the cover.
hot or live circuits could result in 8 Inspect the turntable area for burnt, chafed and
death or serious injury. Remove all pinched cables.
rings, watches and other jewelry.
9 Install the center turntable cover and fasteners.
1 Open the engine side turntable cover.
10 Lower the boom to the stowed position and turn
2 Remove the 2 engine pivot plate retaining bolts the engine off.
and swing the engine out away from the
machine to access the wiring. 11 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
· Cable track on the primary boom
· Cables on the primary, and jib booms
· Jib boom/platform rotate manifold
(S-85 models)
· Inside of the platform control box
retaining bolts.
a b b c

c air baffle

TABLE A PROCEDURES
A-22 Oil Cooler

Check the Oil Cooler and 1 Remove the engine side cover mounting
Cooling Fins - fasteners. Remove the engine side cover.
Deutz Models 2 Inspect the oil cooler for leaks and physical
damage.
a b c
Engine specifications require that

125 hours.
Maintaining the oil cooler in good condition is
essential for good engine performance. Operating
a machine with a damaged oil cooler may result in
engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
cooling system.
Bodily injury hazard. Do not a oil cooler
inspect while the engine b cylinder head cooling fins
is running. Remove the key to c fan blower fins
3 Clean the oil cooler of debris and foreign
Bodily injury hazard. Beware of material.
hot engine components. Contact
with hot engine components may
cause severe burns.

TABLE A PROCEDURES
Cooling and Fan Blower Fins A-23

4 Remove the 2 bolts from under the engine pivot Check the Engine Belt -
plate. Swing the engine pivot plate away from Ford and Perkins Models
the machine to access the fan blower.

200 hours.
Maintaining the engine belt is essential to good
engine performance and service life. The machine
will not operate properly with a loose or defective
a b c
belt and continued use may cause component
b
damage.
a engine pivot plate Bodily injury hazard. Do not
b pivot plate retaining bolts inspect while the engine is
c air baffle
running. Remove the key to
5 Inspect the fan blower fins for physical damage. secure from operation.
6 Clean the fan blower fins of debris and foreign Bodily injury hazard. Beware of
material. hot engine components. Contact
7 Inspect the head cooling passages and fins for cause severe burns.
physical damage or foreign material, using a
flashlight.
8 Clean the cylinder head cooling passages and
fins of debris and foreign material.
9 Install the engine side cover.
retaining bolts.

TABLE A PROCEDURES
1 Remove the 2 engine pivot plate retaining Perkins models:

bolts. Swing the engine pivot plate away from
4 Check the engine belt for proper tension.
the machine to access the front engine access
cover mounting fasteners.
Perkins Diesel engine

retaining bolts.
a b b c Belt deflection -
Perkins models 3 /8 inch to 1/2 inch
b pivot plate retaining bolts 9 mm to 12 mm
c air baffle
Engine belts - Genie part numbers
2 Inspect the engine belt for: Ford models 52580
· Cracking Perkins models 62423
· Glazing
· Separation
· Breaks
3 Replace belt if any damage is found.
Ford LRG-425 EFI engines are

equipped with a serpentine belt
and incorporate a self adjusting
belt tensioner. No adjustment is
required.

TABLE A PROCEDURES
A-24 4 Disconnect and plug the fuel hose from the fuel
pre-filter to the fuel pump, then remove the pre-
Replace the Fuel Filters - filter.
Ford Models 5 Install the new fuel pre-filter (Genie part number
52179) and connect the fuel hoses to the filter.
6 Clean up any fuel that may have spilled during
the installation procedure.
this procedure be performed every 7 Remove the 2 engine pivot plate retaining bolts.
200 hours. Swing the engine pivot plate away from the
machine to access the fuel pressure regulator/
Replacing the gasoline fuel filter is essential to
filter.
good engine performance and service life. A dirty
or clogged filter may cause the engine to perform 8 Locate the fuel pressure regulator/filter installed
poorly and continued use may cause component on the engine mounting leg.
damage. Extremely dirty conditions may require
9 Disconnect and plug the hoses from the fuel
that the filter be replaced more often.
pressure regulator/filter.
Explosion and fire hazard.
fuels are combustible. Replace the
Electronic Fuel Injection (EFI)
fuel filter in an open, well-
systems operate at a very high
ventilated area away from heaters,
pressure. Fuel may be expelled
sparks, flames and lighted
under pressure if the hoses are
removed too quickly. Loosen the
approved fire extinguisher within
fuel hoses very slowly to allow the
easy reach.
fuel pressure to dissipate
Perform this procedure with the gradually. Wrap a cloth around
engine off. fuel hoses to absorb leaking fuel
before disconnecting them.
1 Locate the fuel pre-filter to the left of the ground
control box. 10 Remove the fuel pressure regulator/filter
mounting fasteners. Then remove the regulator/
2 Turn the manual shutoff valve, located at the filter from the engine mounting leg.
fuel tank, to the CLOSED position.
3 At the pre-filter, disconnect the fuel hose that
goes to the fuel tank.

TABLE A PROCEDURES
11 Install the new fuel pressure regulator/filter

(Genie part number 58967) onto the engine
mounting leg and connect the hoses to the
regulator/filter.
Component damage hazard. Be
sure the correct regulator/filter is
installed or component damage
may occur.
12 Turn the manual shutoff valve, located at the
fuel tank, to the OPEN position.
13 Start the machine from the ground controls,
then inspect the fuel filters and hoses for leaks.
immediately.
retaining bolts.

Table B Procedures
B-1 2 All models: Be sure that all nuts and bolts are
tight.
Check the Exhaust System
3 Inspect all welds for cracks.
4 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
Maintaining the exhaust system is essential to 5 Diesel models: Swing the engine pivot plate
good engine performance and service life. Running back to its original position and install the two
the engine with a damaged or leaking exhaust engine pivot plate retaining bolts.
system can cause component damage and unsafe
operating conditions.
Bodily injury hazard. Do not
inspect while the engine
is running. Remove the key to
cause severe burns.
1 Diesel models: Remove the 2 bolts from under
the engine pivot plate. Swing the engine pivot
plate away from the machine to access the
exhaust system.
a b b c

c air baffle

TABLE B PROCEDURES
B-2 3 Inspect the filter condition indicator.

Check the Hydraulic Tank Return
Filter Condition Indicator a
Maintaining the hydraulic tank return filter in good

condition is essential to good system performance
b
and safe machine operation. The filter condition
indicator will show when the hydraulic flow is
c
bypassing a clogged filter. If the filter is not
frequently checked and replaced, impurities
will remain in the hydraulic system and cause
component damage.
engine running.
a filter condition indicator
2 Move the engine idle speed select switch to b filter
c hydraulic tank
high idle (rabbit symbol).
Result: The filter should be operating with the
plunger in the green area. If the display shows
the plunger in the red area, this indicates that
the hydraulic filter is being bypassed and the
filter should be replaced. See B-21, Replace the
Hydraulic Tank Return Filter.

TABLE B PROCEDURES
B-3 4 Check the pressure in each air-filled tire. Add air

as necessary.
Inspect the Tires and Wheels
(including lug nut torque) Tires and wheels
Tire size 15-19.5 NHS
Pressure 100 psi

Maintaining the tires and wheels in good 6.9 bar
condition is essential to safe operation and good
Tire ply rating 12
performance. Tire and/or wheel failure could result
in a machine tip-over. Component damage may Wheel lugs 10 @ 3/4 -16
also result if problems are not discovered and
Lug nut torque, dry 420 ft-lbs
repaired in a timely fashion. 569.5 Nm
Bodily injury hazard. An over- Lug nut torque, lubricated 320 ft-lbs
inflated tire can explode and could 433.9 Nm
result in death or serious injury.
Tip-over hazard. Do not use
temporary flat tire repair products.
The tires on some machines are
foam filled and do not need air
added to them.
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque.

TABLE B PROCEDURES
B-4 2 Be sure the free-wheel valve is

closed (clockwise).
Confirm the Proper
The free-wheel valve is located on
Brake Configuration the drive pump.
Proper brake configuration is essential to safe b

operation and good machine performance.
a c
Hydrostatic brakes and hydraulically-released,
spring-applied individual wheel brakes can appear d
to operate normally when they are actually not fully
operational.
1 Check each drive hub disconnect cap to be a drive pump
sure it is in the engaged position. b screwdriver
c lift pump
d free-wheel valve
disengage position
The free-wheel valve should
always remain closed.
engage position

TABLE B PROCEDURES
B-5 4 Apply pipe thread sealant to the plug(s), and

then install the plug(s) in the drive hub.
Check the Oil Level in
5 Repeat this procedure for each drive hub.
the Drive Hubs
Drive hub oil
Capacity 44 fl oz
Failure to maintain proper drive hub oil levels may 1.30 liters
cause the machine to perform poorly and
continued use may cause component damage. Type: SAE 90 multipurpose hypoid gear oil - API service
classification GL5
Drive Hubs
1 Drive the machine to rotate the hub until the

plugs are located one on top and the other at Turntable Rotate Drive Hub
90 degrees. 1 Remove the plug located on the side of the hub
and check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
2 Remove the plug located at 90 degrees and

check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.
a drive hub
b plug

TABLE B PROCEDURES
2 If necessary, add oil until the oil level is even

with the bottom of the side plug hole.
3 Apply pipe thread sealant to the plug, and
install the plug in the drive hub.
Turntable rotate drive hub oil
Capacity 17 fluid ounces

0.51 liters
Type SAE 90 multipurpose hypoid gear oil - API service

classification GL5

TABLE B PROCEDURES
B-6 Skip to step 4 if the low idle rpm is correct.

Check and Adjust the 2 Loosen the low idle lock nut and turn the low
Engine RPM idle adjustment screw clockwise to increase the
rpm, or counterclockwise to decrease the rpm.
Tighten the low idle lock nut and confirm the
rpm.
Maintaining the engine rpm at the proper setting for

both low and high idle is essential to good engine
performance and service life. The machine will not
operate properly if the rpm is incorrect and
f
continued use may cause component damage.
e
Ford Models:
The engine rpm is controlled by the

ECM and can only be adjusted by
re-programming the ECM. If rpm
adjustment or service is required,
a b c d
please contact the Genie
Industries Service Department OR a solenoid boot
your local Ford dealer. b high idle adjustment nut
c yoke lock nut
d yoke
Ford models e low idle adjustment screw
f low idle lock nut
Low idle 1600 rpm
3 Move the function enablerpm select toggle
switch to the high idle (rabbit symbol) position.
High idle 2500 rpm
Result: High idle should be 2300 rpm for Deutz
models, 2200 rpm for Perkins models.
Diesel models:
If high idle rpm is correct, disregard
This procedure will require two adjustment step 4.
people.
1 Connect a tachometer to the engine. Start the
engine from the platform controls.
Result: Low idle should be 1500 rpm for Deutz
models, 1600 rpm for Perkins models.

TABLE B PROCEDURES
4 Loosen the yoke lock nut, then turn the high idle B-7
adjustment nut and solenoid boot
counterclockwise to increase the rpm or Test the Key Switch
clockwise to decrease the rpm. Tighten the Proper key switch action and response is essential
yoke lock nut and recheck the rpm. to safe machine operation. The machine can be
Be sure the solenoid fully retracts operated from the ground or platform controls and
when activating high idle. the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
Deutz models activate the appropriate control panel could cause
a hazardous operating situation.
Low idle 1500 rpm
1 Pull out the Emergency Stop button to the ON
position at both the ground and platform
High idle 2300 rpm
controls.
Perkins models 2 Turn the key switch to ground control, start the
engine and then turn the key switch to platform
Low idle 1600 rpm control.
High idle 2200 rpm 3 Check any machine function from the ground
controls.
Result: The machine functions should not
operate.
4 Turn the key switch to ground control.
5 Check any machine function from the platform
controls.
Result: The machine functions should not
operate.
6 Turn the key switch to the OFF position.
Result: The engine should stop and no
functions should operate.
Diesel models: All functions
engine will shut off after 2 to 3
seconds.

TABLE B PROCEDURES
B-8 B-9
Test the Emergency Test the Ground Control Override
Stop Buttons A properly functioning ground control override is
Properly functioning Emergency Stop buttons essential to safe machine operation. The ground
are essential for safe machine operation. An control override function is intended to allow
improperly operating Emergency Stop button ground personnel to operate the machine from the
will fail to shut off power and stop all machine ground controls whether or not the Emergency
functions, resulting in a hazardous situation for Stop button on the platform controls is in the ON or
OFF position. This function is particularly useful if
ground and platform personnel.
the operator at the platform controls cannot return
As a safety feature, selecting the boom to the stowed position.
and operating the ground controls
will override the platform controls, 1 Push in the platform Emergency Stop button
including the platform Emergency to the OFF position.
Stop button. 2 Start the engine from the ground controls.
1 Start the engine from ground controls. 3 At the ground controls, operate each boom
2 Push in the Emergency Stop button to the OFF function through a partial cycle.
position. Result: All boom functions should operate.
Result: The engine should shut off and no
machine functions should operate.
Diesel models: All functions
engine will shut off after 2 to 3
seconds.
3 Start the engine from platform controls.
4 Push in the Emergency Stop button to the OFF
position.
Result: The engine should shut off and no
machine functions should operate.
The ground control Emergency
Stop button will stop all machine
operation, even if the key switch
is switched to platform control.

TABLE B PROCEDURES
B-10 B-11
Test the Platform Self-leveling Test the Horn
Automatic platform self-leveling throughout A functional horn is essential to safe machine
the full cycle of boom raising and lowering is operation. The horn is activated at the platform
essential for safe machine operation. The controls and sounds at the ground as a warning to
platform is maintained at level by the platform ground personnel. An improperly functioning horn
leveling slave cylinder which operates in a closed will prevent the operator from alerting ground
loop hydraulic circuit with the master cylinder personnel of hazards or unsafe conditions.
located at the base of the boom.
A platform self-leveling failure creates an unsafe 1 Turn the key switch to platform controls and
working condition for platform and pull out the Emergency Stop button to the
ON position at both the ground and
ground personnel.
platform controls.
2 Push down the horn button at the platform
lower the boom to the stowed position.
controls.
2 Hold the function enable toggle switch to either
Result: The horn should sound.
side and adjust the platform to a level position
using the platform level toggle switch. If necessary, the horn can be
adjusted to obtain the loudest
3 Raise and lower the boom through
volume by turning the adjustment
a full cycle.
screw near the wire terminals on
Result: The platform should remain level at the horn.
all times to within ±5 degrees.

TABLE B PROCEDURES
B-12 B-13
Test the Foot Switch Test the Engine Idle Select
A properly functioning foot switch is essential to Operation
safe machine operation. Machine functions should A properly operating engine idle select switch
activate and operate smoothly as long as the foot is essential to good engine performance and safe
switch is pressed down, and promptly stop when machine operation. There are three settings.
the foot switch is released. The foot switch will also
shift the engine into high idle if the idle select is Low idle (turtle symbol) allows the operator to
switched to the rabbit and foot switch symbol. An control individual boom functions only. Drive
improperly functioning foot switch can cause an functions do not operate at low idle.
unsafe working condition and endanger platform
and ground personnel. High idle (rabbit symbol) allows the operator
to control multiple boom and/or drive functions
The engine should not start if the simultaneously. This setting maintains a
foot switch is pressed down. consistent high idle and is usually selected only
when the generator option is being used.
1 Turn the key switch to platform controls and pull
out the Emergency Stop button to the ON Foot switch activated high idle (rabbit and foot
position at both the ground and platform switch symbols) should be used for normal
controls. machine operation. This setting activates high idle
2 Press down the foot switch and attempt to start only when the foot switch is pressed down.
the engine by moving the start toggle switch to 1 Pull out the Emergency Stop button to the
either side. ON position at both the ground and platform
Result: The engine should not start. controls.
3 Do not press down the foot switch and attempt 2 Start the engine from the ground controls. Move
to start the engine. and hold the function enable toggle switch in
Result: The engine should start. the high idle (rabbit symbol) position.
4 Do not press down the foot switch and operate Result: The engine rpm should change to high
the machine functions. idle.
Result: The machine functions should not 3 Release the function enable toggle switch.
operate. Result: The engine rpm should change to low
5 Press down the foot switch and operate the idle.
machine functions.
Result: The machine functions should operate.

TABLE B PROCEDURES
4 Turn the key switch to platform controls. B-14

5 At the platform controls, move the engine idle Test the Fuel Select Operation -
select toggle switch to high idle (rabbit symbol).
Do not press down the foot switch.
Ford Models
Result: The engine rpm should change to high
idle.
6 Move the engine idle select switch to low idle The ability to select and switch between
(turtle symbol). gasoline and LPG fuels as needed is essential to
safe machine operation. A fuel selection can be
Result: The engine rpm should change to low
made while the engine is running or not.
idle.
Switching malfunctions and/or the failure of the
7 Move the engine idle select switch to foot switch engine to start and run properly in both fuel
activated high idle (rabbit and foot switch modes and through all idle speeds can indicate
symbol). fuel system problems that could develop into a
hazardous situation.
Result: The engine rpm should not change to
high idle. Perform this test after checking
the gasoline and LPG fuel levels,
8 Press down the foot switch.
and warming the engine to normal
Result: The engine rpm should change to high operating temperature.
idle.
1 Move the fuel select toggle switch to gasoline
and then move the engine idle select switch to
foot switch activated high idle (rabbit and foot
switch symbol).
2 Start the engine from the platform controls and
allow it to run at low idle.
3 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
4 Release the foot switch and shut the engine off
by pushing the Emergency Stop button in to the
OFF position.

TABLE B PROCEDURES
5 Move the fuel select switch to LPG. B-15

6 Start the engine and allow it to run at low idle. Test the Drive Enable System
7 Press down the foot switch to allow the engine Proper drive enable system operation is
to run at high idle. essential to safe machine operation. When the
Result: The engine should start promptly and boom is past the non-steering wheels, drive
operate smoothly in low and high idle. movement is stopped and the indicator light turns
on. The drive enable switch must be held to either
The engine may hesitate side to reactivate the drive function and should alert
momentarily and then continue the operator that the machine will move in the
to run on the selected fuel if the opposite direction that the drive and steer controls
fuel source is switched while are moved. An improperly functioning drive enable
the engine is running. system may allow the machine to be moved into an
unsafe position.

2 Move the lift/drive selector toggle switch to the
lift position (if equipped).
3 Press down the foot switch.
4 Rotate the turntable to the
right until the boom moves
past the right non-steering
wheel.
Result: The drive enable
indicator light should turn on
and remain on while the
boom is anywhere in the
range shown.
5 Move the lift/drive select toggle switch to the
drive position (if equipped).
6 Slowly move the drive control handle off center.
Result: The drive function should not operate.

TABLE B PROCEDURES
7 Hold the drive enable B-16

toggle switch to
either side and slowly Test the Drive Brakes
move the drive
control handle off
center.
Collision hazard. Always use the Proper brake action is essential to safe machine
color-coded direction arrows on the operation. The drive brake function should operate
platform control panel and the drive smoothly, free of hesitation, jerking and unusual
chassis to identify which direction noise. Hydrostatic brakes and hydraulically-
the machine will travel. released individual wheel brakes can appear to
operate normally when they are actually not fully
Result: The drive function should operate. operational.
8 Rotate the turntable to the left until the boom Collision hazard. Be sure that the
moves past the left non-steering wheel. machine is not in free-wheel or
Result: The drive enable indicator light should partial free-wheel configuration.
come on and remain on while the boom is Refer to B-4 in this section,
anywhere in the range shown. Confirm the Proper Brake
Configuration.
9 Repeat steps 6 and 7.
Select a test area that is firm, level
and free of obstructions.
Be sure the boom is fully retracted
and lowered to the stowed position.
1 Mark a test line on the ground for reference.
3 Move the lift/drive select switch to the drive
4 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the test line.

TABLE B PROCEDURES
5 Bring the machine to top drive speed before B-17

reaching the test line. Release the drive
controller when your reference point on the Test the Drive Speed -
machine crosses the test line. Stowed Position
6 Measure the distance between the test line and
your machine reference point.
Braking: high range, 3 to 5 ft Proper drive function movement is essential to safe

paved surface 0.6 to 1.2 m machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
The brakes must be able to hold hesitation, jerking and unusual noise over the
the machine on any slope it is able entire proportionally controlled speed range.
to climb.
Select a test area that is firm, level
and free of obstructions.
Be sure the boom is fully retracted
and lowered to the stowed position.
1 Create start and finish lines by marking two lines
on the ground 40 feet (12.2 m) apart.
when crossing the start and finish lines.

TABLE B PROCEDURES

reaching the start line. Begin timing when your
reference point on the machine crosses the Test the Drive Speed -
start line. Raised or Extended Position
6 Continue at full speed and note the time when
the machine reference point crosses the finish
line.
Proper drive function movement is essential to
Drive speed: safe machine operation. The drive function should
stowed position 2WD 4WD respond quickly and smoothly to operator control.
Drive performance should also be free of hesitation,
Ford models 40 ft/6.2 sec 40 ft/9.1 sec jerking and unusual noise over the entire
12.2 m/6.2 sec 12.2 m/9.1 sec proportionally controlled speed range.
Diesel models 40 ft/6.8 sec 40 ft/9.7 sec Select a test area that is firm, level
12.2 m/6.8 sec 12.2 m/9.7 sec and free of obstructions.
1 Create start and finish lines by marking two
lines on the ground 40 feet (12.2 m) apart.
3 Move the lift/drive select switch to the lift
4 Move the engine idle select switch to
switch). Press down the foot switch and raise
the boom above horizontal.
when crossing the start and finish lines.

TABLE B PROCEDURES

reaching the start line. Begin timing when your
reference point on the machine crosses the Test the Alarm Package
start line. (if equipped)
8 Continue at full speed and note the time when The alarm package includes:
the machine reference point crosses the finish
line. · Travel alarm
· Descent alarm
9 Move the lift/drive select switch to the lift
position (if equipped). · Flashing beacons
10 Press down the foot switch and lower the boom Alarms and beacons are installed to alert operators
to the stowed position. and ground personnel of machine proximity and
motion. The alarm package is installed on the
11 Extend the boom 3 feet (0.9 m). turntable rear cover. Beacons are installed on both
12 Move the lift/drive select switch to the drive turntable covers.
position (if equipped). The alarms and beacons will
13 Choose a point on the machine; i.e., contact operate with the engine
patch of a tire, as a visual reference for use running or not running.
when crossing the start and finish lines. 1 Turn the key switch to ground controls and pull
14 Bring the machine to top drive speed before out the Emergency Stop button to the ON
reaching the start line. Begin timing when your position at both the ground and platform
reference point on the machine crosses the controls.
start line. Result: Both flashing beacons should be ON and
15 Continue at top speed and note the time when flashing.
the machine reference point crosses the finish 2 Hold the function enable switch to either side
line. and activate the boom toggle switch in the DOWN
position, hold for a moment and then release it.
Drive speed, maximum,
raised or extended position Result: The descent alarm should sound when
the toggle switch is held down.
All models 1 foot per second (0.6 mph)
3 Turn the key switch to platform controls.
0.3 meters per second (0.97 km/h)
Result: The flashing beacons should be ON
and flashing.

TABLE B PROCEDURES
4 Move the lift/drive selector switch to the lift B-21

Replace the Hydraulic Tank
5 Press down the foot switch. Move the boom
controller to the DOWN position, hold for a
Return Filter
moment and then release it.
Result: The descent alarm should sound when
the controller is held down. Genie requires that this procedure
6 Move the lift/drive selector switch to the drive be performed quarterly or every
position (if equipped). 250 hours, whichever comes first.
Perform this procedure more often
7 Press down the foot switch. Move the drive if dusty conditions exist.
controller off center, hold for a moment and
then release it. Move the drive controller off Replacement of the hydraulic tank return filter is
center in the opposite direction, hold for a essential for good machine performance and
moment and then release it. service life. A dirty or clogged filter may cause the
machine to perform poorly and continued use may
Result: The travel alarm should sound when the
cause component damage. Extremely dirty
drive controller is moved off center in either
conditions may require that the filter be replaced
direction.
more often.

B-20 oil. Contact with hot oil may cause
severe burns.
Perform Hydraulic Oil Analysis
engine off.
1 Place a suitable container under the hydraulic
See E-1, Test or Replace the Hydraulic Oil. tank return filter.
2 Remove the filter with an oil filter wrench.
3 Apply a thin layer of fresh oil to the new oil filter
gasket.
4 Install the new filter and tighten it securely by
hand. Clean up any oil that may have spilled
during the installation procedure.

TABLE B PROCEDURES
5 Use a permanent ink marker to write the date 2 Remove the filter housing by using a wrench on
and number of hours from the hour meter on the nut provided on the bottom of the housing.
the oil filter.
3 Remove the filter element from the housing.
4 Inspect the housing seal and replace it if
7 Inspect the filter and related components to necessary.
be sure that there are no leaks.
5 Install the new filter and hand tighten the
housing onto the filter head.
Hydraulic tank return filter
Genie part number 46014
7 Inspect the filter assembly to be sure that there
are no leaks.
8 Clean up any oil that may have spilled during the
installation procedure.
B-22
Drive loop hydraulic filter
Replace the Drive Loop
Hydraulic Filter Genie part number 20880
Replacing the drive loop hydraulic filter is essential

to good machine performance and service life. A
dirty or clogged filter may cause the machine to
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may require that the filter be replaced more often.
oil. Contact with hot oil may cause
severe burns.
engine off.
1 Locate the drive loop hydraulic filter mounted on
the engine near the pump.

TABLE B PROCEDURES
B-23 2 Check for proper venting.

Inspect the Fuel Tank Cap When checking for positive fuel
tank cap venting, air should pass
Venting System freely through the cap.
Result: Air should pass through the fuel tank
cap. Clean or replace the cap.
Genie requires that this procedure 3 Using a mild solvent, carefully wash the cap
be performed quarterly or every venting system. Dry using low pressure
250 hours, whichever comes first. compressed air.
Perform this procedure more often
if dusty conditions exist. 4 Repeat step 2.
A free-breathing fuel tank cap is essential for good 5 Install the fuel tank cap onto the fuel tank.
engine performance and service life. A dirty or
clogged fuel tank cap may cause the engine to
component damage. Extremely dirty conditions
may require that the cap be inspected more often.

easy reach.
engine off.
1 Remove the cap from the fuel tank.

TABLE B PROCEDURES
B-24 5 Install the new air filter element and mounting

fastener.
Replace the Engine Air Filter
6 Install the end cap onto the canister. Install and
Element tighten the retaining ring.
Perkins models:
Engine specifications requires that disconnect the retaining fasteners from the end
this procedure be performed every cap of the air filter canister. Remove the end
400 hours or annually, whichever cap.
comes first. Perform this
procedure more often if dusty 2 Remove the filter element.
conditions exist. 3 Empty the dust discharge valve by pressing
Maintaining the engine air filter in good condition is apart the lips of the discharge valve. Clean
essential to good engine performance and service discharge valve as needed.
life. Failure to perform this procedure can lead to
poor engine performance and component damage.
engine off. a
Ford and Deutz Models:

remove the retaining ring from the end cap of
the air filter canister. b
2 Remove the end cap from the air cleaner

canister.
3 Remove the air filter retaining fastener. Remove a air filter
b dust discharge valve
the filter element.
4 Clean the inside of the canister and the gasket 4 Clean the inside of the canister and the canister
with a damp cloth. end cap with a damp cloth.
5 Install the new filter element.
6 Install the end cap onto the canister. Secure the
retaining fasteners.
Air filters - Genie part numbers

Ford LRG-425 EFI Engine 27916
Deutz F4L 1011F Engine 27916
Perkins 704-30 Engine 62420

TABLE B PROCEDURES
B-25 2 Label, then disconnect the plug wires from the

spark plugs by grasping the handle on the spark
Replace the Spark Plugs - plug boot. Do not pull on the plug wire.
Ford Models 3 Blow out any debris around spark plugs.
4 Remove all the spark plugs from the engine.
5 Adjust the gap on each new spark plug.
Engine specifications requires that
6 Install the new spark plugs, then connect the
wires. Be sure that each spark plug wire is
400 hours.
attached to the correct spark plug.
Periodic replacement of the spark plugs is
essential to good engine performance and
service life. Worn, loose or corroded spark plugs
retaining bolts.
will cause the engine to perform poorly and may
result in component damage.
Ford LRG-425 EFI Engine
Perform this procedure with the Spark plug specifications
engine off.
Spark plug type Motorcraft AWSF-52C
Swing the engine pivot plate away from the Spark plug gap 0.042 to 0.046 inches
machine to access the spark plugs. 1.07 to 1.18 mm
Spark plug torque 5-10 ft-lbs

7-14 Nm
a b b c

c air baffle

Table C Procedures
C-1 2 Remove the front engine access cover mounting
fasteners.
Check the Engine Belt -
3 Inspect the engine belt for:
Deutz Models
· Cracking
· Glazing
· Separation
Maintaining the engine belt is essential to good · Breaks
engine performance and service life. The machine
will not operate properly with a loose or defective 4 Replace belt if any damage is found.
belt and continued use may cause component 5 Check the engine belt for proper tension. Adjust
damage. as necessary.
Bodily injury hazard. Do not
inspect while the engine is
running. Remove the key to
cause severe burns.
1 Remove the 2 engine pivot plate retaining bolts. Deutz Diesel engine
machine to access the engine belt. 6 Install the front engine access cover.
retaining bolts.
Belt deflection -
Deutz models 3/8inch to 1/2 inch
9 mm to 12 mm
Engine belt - Genie part number 32698
a b b c

c air baffle

TABLE C PROCEDURES
C-2 C-3
Check the Engine Valve Replace the Fuel Filter/ Water
Clearances - Separator Element -
Deutz Models Perkins Models
Engine specifications require Replacing the diesel fuel filter/water separator

that this procedure be performed element is essential for good engine performance
initially at 500 hours, at 1000 and service life. A dirty or clogged filter may cause
hours and every 1000 hours the engine to perform poorly and continued use
thereafter. may cause component damage. Extremely dirty
conditions may required that the filter be replaced
Complete information to perform this procedure is more often.
available in the Deutz F4L 1011F Operation
Manual, Deutz part number 0297 7343 (Genie part Explosion and fire hazard. Engine
number 52883). fuels are combustible. Perform this
easy reach.
engine off.
Immediately clean up any fuel that
may have spilled during this
procedure.
1 Open the engine side turntable cover and locate
the fuel filter/water separator.
2 Tag, disconnect and plug the fuel hose from the
fuel tank at the fuel filter/water separator head.

TABLE C PROCEDURES
3 Loosen the vent plug located on the fuel filter/ 8 Apply a thin layer of clean diesel fuel onto the
water separator head. element gasket. Install the filter/bowl assembly
onto the filter head. Tighten the drain plug.
a
9 Tighten the head bolt to 65 in-lbs (7 Nm).
b
10 Tighten the vent plug.
e
11 Clean up any diesel fuel that may have spilled
during the installation procedure.
d 12 Connect the fuel hose from the fuel tank to the

fuel filter/water separator. Tighten the clamp.
c
Bleed the fuel system:
Before bleeding the system, fill the
fuel tank.
Fuel filter/water separator 13 Loosen the vent plug located on the fuel filter/
a head bolt water separator head.
b vent plug
c drain plug 14 Operate the priming lever of the fuel lift pump
d filter bowl until fuel, free from air, comes from the vent
e separator head
plug. Tighten the vent plug.
4 Place a suitable container under the filter bowl. 15 Loosen the air vent screw, located on top of the
Loosen the drain plug located at the bottom of fuel injection pump.
the bowl. Completely drain the fuel.
16 Tighten the air vent screw when air stops
5 Loosen the head bolt. Rotate the filter bowl coming through the air vent.
counterclockwise and remove it from the
element. 17 Clean up any diesel fuel that may have spilled
during the bleeding procedure and dispose of
6 Rotate the filter element counterclockwise and properly.
remove it from the filter head.
18 Start the engine from ground controls and
7 Install the bowl onto the new filter element check for leaks.
(Genie part number 22942).

TABLE C PROCEDURES
C-4 2 Thoroughly clean the outside surfaces of the

fuel filter assembly.
Replace the Fuel Filter Element -
3 Hold the bottom cover of the filter element and
Perkins Models remove the element retaining screw.
a
b
Replacing the diesel fuel filter element is essential
c
for good engine performance and service life. A
dirty or clogged filter may cause the engine to
component damage. Extremely dirty conditions d
may required that the filter be replaced more often.
Explosion and fire hazard. Engine e

ventilated area away from heaters, f
tobacco. Always have an a element retaining screw
b upper seal
approved fire extinguisher within c o-ring
easy reach. d filter element
e lower seal
Perform this procedure with the f bottom cover
engine off.
4 Lower the bottom cover of the filter.
Immediately clean up any fuel that
may have spilled during this 5 Remove the element and dispose of properly.
procedure. 6 Clean the inside surfaces of the filter head and
1 Open the engine side turntable cover and locate the bottom cover.
the fuel filter. 7 Lightly lubricate the upper seal and the o-ring
with clean diesel fuel and install them into the
filter head.

TABLE C PROCEDURES
8 Lightly lubricate the lower seal with clean diesel C-5

fuel and install it into the bottom cover.
Replace the Engine Oil and
9 Put the bottom cover under the new element and
hold the element squarely to the filter head.
Filter - Perkins Models
Ensure that the element is fitted in the center
against the o-ring in the filter head. With the
assembly in this position, install the element
retaining screw. Periodic replacement of the engine oil and
filter is essential to good engine performance.
Bleed the fuel system: Operating the machine with an improper oil level or
10 Loosen the vent plug on the side of the fuel neglecting periodic oil and filter changes can
injection pump. damage engine components. A frequent check
of elapsed machine hours against the hours
11 Operate the priming lever of the fuel lift pump noted on the oil filter will allow the inspector to
until fuel, free from air, comes from the vent anticipate and perform oil and filter changes at
plug. Tighten the vent plug. the 500 hour interval.
12 Clean up any fuel that may have spilled during
this procedure.
hot engine parts and oil. Contact
13 Operate the starter motor for intervals of 15 with hot engine oil and/or engine
seconds until the engine starts. parts may cause severe burns.
It is important to allow the starter Perform this procedure after
motor to cool for 30 seconds warming the engine to normal
between each 15 second interval operating temperature.
of operation.
1 Remove the oil filler cap, located next to the
If the engine runs correctly for a engine oil dipstick.
short time and then stops or runs
2 Pull the end of the engine oil drain hose out
roughly, check for air in the fuel
from under the engine.
system. If there is air in the fuel
system, there is probably a leak in 3 Remove the plug from the end of the drain hose
the low pressure side of the and allow all of the oil from the engine to drain
system. into a suitable container. See capacity
specifications.
Do not remove the drain plug
located on the side of the oil pan.
4 Install and tighten the plug in the drain hose.

TABLE C PROCEDURES
5 Use an oil filter wrench and remove the oil filter C-6
located below the fuel filter. Clean the inside of
the filter head. Check the Starting Aid -
6 Apply a thin layer of clean engine oil to the new
Perkins Models
filter gasket. Install the filter and tighten it
securely by hand.
7 Use a permanent ink marker to write the date Complete information to perform this procedure is
and number of hours from the hour meter on available in the Perkins 700 Series Workshop
the oil filter. Manual, Perkins part number TPD 1359E (Genie
8 Fill the engine with new oil per specifications part number 62424).
and install the oil filler cap.
allow the engine to run for 30 seconds. Stop the
engine.
10 Check the oil filter and drain hose for leaks.
11 Wait 15 minutes after stopping the engine and
check the engine oil level on the dipstick. Add
oil if needed.
12 Dispose of the used oil and filter properly.

Oil capacity (including filter) 9.6 quarts 9 liters
below 60°F / 15.5°C 15W-40
-10°F to 90°F / -23°C to 32°C 10W-30
above -4°F / -34°C 15W-40

CF4 grade.
Oil filter - Genie part number 62422

TABLE C PROCEDURES
C-7 5 Slowly remove the radiator filler cap. Inspect the

cap for wear. Replace as necessary.
Check the Specific Gravity of the
Burn hazard. Allow any pressure
Engine Coolant - to dissipate gradually before
Liquid Cooled Models removing the radiator cap.
6 Drain some coolant from the cooling system
into a suitable container.
The quality of the engine coolant which is used can 7 Use a coolant hydrometer to check the
have a great effect on the efficiency and life of the temperature and specific gravity of the coolant.
cooling system. Old or dirty engine coolant may 8 Adjust the strength of the coolant as necessary
cause the engine to perform poorly and continued for your climate.
use may cause engine damage.
9 Install the radiator filler cap.
Burn hazard. Beware of hot
engine parts and coolant. Contact
with hot engine parts and/or
coolant may cause severe burns.
machine on level ground.
engine off.
1 Put on protective clothing and eyewear.
2 Operate the engine until it is warm enough to
open the thermostat. Continue to run the engine
until the coolant has circulated the cooling
system.
3 Stop the engine.
4 Allow the engine to cool until the temperature of
the coolant is below 140° F (60° C).
Burn hazard. Beware of hot
coolant. Contact with hot coolant

TABLE C PROCEDURES
C-8 3 Locate the PCV valve on the engine under the

intake manifold. Remove the hose from the
Replace the PCV Valve - PCV valve.
Ford Models
Engine specifications require

that this procedure be performed
every 800 hours.
Yearly replacement of the PCV valve is essential to
good engine performance. A malfunctioning PCV
valve can restrict crankcase ventilation and may
cause engine damage.
engine off.
a PCV valve hose
1 Open the engine side turntable cover. b PCV valve
2 Remove the 2 engine pivot plate retaining bolts 4 Remove the PCV valve from the canister.
and swing the engine out away from the Discard the valve.
machine to access the PCV valve. 5 Thoroughly clean the inside and outside of the
hose, tubes and fittings
6 Install the new PCV valve and connect the
hose.
retaining bolts.
PCV Valve - Genie part number 33957
a b b c

c air baffle

Table D Procedures
D-1 D-2
Check the Boom Wear Pads Check the Extendable Axle
Wear Pads
Maintaining the axle wear pads in good condition is
essential to safe machine operation. Wear pads are
Maintaining the boom wear pads in good condition
placed on axle tube surfaces to provice a low
is essential to safe machine operation. Wear pads
friction, replaceable wear pad between moving
are placed on boom tube surfaces to provide a low
parts. Improperly shimmed wear pads or continued
friction, replaceable wear pad between moving
use of worn out wear pads may result in component
parts. Improperly shimmed wear pads or continued
damage and unsafe operating conditions.
use of extremely worn wear pads may result in
component damage and unsafe operating If the wear pads are not worn
conditions. below specification but are still
within specification, see Repair
If the wear pads are still within
Procedure 16-1, Extendable Axles.
specification, see Repair
Procedure 4-2, How to Shim 1 Start the engine from the ground controls and
the Boom. extend the axles.
1 Start the engine from the ground controls. 2 Measure each wear pad. Replace the wear pad if
it is less than specification. If the wear pad is
2 Raise the end of the boom to a comfortable
not less than specification, shim as necessary
working height (chest high), then extend the
to obtain zero clearance and zero drag.
boom 1 foot (30 cm).
3 Extend and retract the axles through the entire
3 Measure each wear pad. Replace the wear pad
range of motion to check for tight spots that
if it is less than specification. If the wear pad is
may cause binding or scraping of the axle
still within specification, shim as necessary to
tubes.
obtain zero clearance and zero drag.
Always maintain squareness
4 Extend and retract the boom through the entire
between the outer and inner
range of motion to check for tight spots that
axle tubes.
may cause binding or scraping of the boom.
Always maintain squareness Extendable axle wear pad specifications
between the outer and inner
boom tubes. Bottom and side wear pads 7/16 inch 11 mm
Boom wear pad specifications
Upper and side wear pads 9/16 inch 14.3 mm

Bottom wear pads 11/16 inch 17.5 mm

D-3 5 Manually rotate each non-steering wheel.

Check the Free-wheel Result: Each non-steering wheel should rotate
with minimum effort.
Configuration
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
remove the blocks.
Proper use of the free-wheel configuration is
essential to safe machine operation. The Collision hazard. Failure to
free-wheel configuration is used primarily for re-engage the drive hubs could
towing. A machine configured to free-wheel without result in death or serious injury
operator knowledge may cause death or serious and property damage.
injury and property damage.
Steer wheels: 4WD models
Collision hazard. Select a work
7 Chock the non-steering wheels to prevent the
site that is firm and level.
machine from rolling.
Component damage hazard. If the
8 Center a lifting jack of ample capacity
machine must be towed, do not
(20,000 lbs/9072 kg) under the drive chassis
exceed 2 mph (3.2 km/h).
between the steer wheels.
Non-steering wheels: All models
9 Lift the wheels off the ground and then place
1 Chock the steer wheels to prevent the machine blocks under the drive chassis for support.
from rolling.
10 Disengage the drive hubs by turning over the
2 Center a lifting jack of ample capacity drive hub disconnect caps on each steer wheel
(20,000 lbs/9072 kg) under the drive chassis hub.
between the non-steer wheels.
disengage position
3 Lift the wheels off the ground and then place
blocks under the drive chassis for support.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
engage position
non-steering wheel hub.
disengage position
engage position

TABLE D PROCEDURES
11 Manually rotate each steer wheel. D-4

Result: Each steer wheel should rotate with Check the Turntable Rotation
minimum effort.
Bearing Bolts
12 Re-engage the drive hubs by turning over
the drive hub disconnect caps. Rotate each
wheel to check for engagement. Lift the
machine and remove the blocks.
Maintaining proper torque on the turntable bearing
Collision hazard. Failure to bolts is essential to safe machine operation.
re-engage the drive hubs could Improper bolt torque could result in an unsafe
result in death or serious injury operating condition and component damage.
and property damage.
1 Raise the boom and place a safety chock on
All models: the lift cylinder rod. Carefully lower the boom
onto the lift cylinder safety chock.
13 Be sure the free-wheel valve on the drive pump
is closed (clockwise). Crushing hazard. Keep hands
away from cylinder and all moving
The free-wheel valve is located on
parts when lowering the boom.
the drive pump, and should always
remain closed. The lift cylinder safety chock is
available through Genie
(part number 33484).
a c
a drive pump
b screwdriver
c lift pump
d free-wheel valve

TABLE D PROCEDURES
2 Be sure that each turntable mounting bolt is D-5

torqued in sequence to 210 ft-lbs (285 Nm).
Grease the Turntable Rotation
20
24
28 1
5
9
Bearing and Rotate Gear
16 13
12 17
8 21
4 25
30 29 Yearly application of lubrication to the turntable
26 3 bearing and rotate gear is essential to good
22 7 machine performance and service life. Continued
18 11 use of an improperly greased bearing and gear will
14 15 result in component damage.
10 19
6 2 27 23
1 Locate the grease fitting on the platform end of
Bolt torque sequence the tank side bulkhead.
3 Raise the boom and remove the safety chock. 2 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments
4 Lower the boom to the stowed position. of 4 to 5 inches (10 to 13 cm) at a time and
repeat this step until the entire bearing has
5 Check to ensure that each bearing mounting bolt
been greased.
under the drive chassis is torqued in sequence
to 210 ft-lbs (285 Nm). 3 Apply grease to each tooth of the drive gear,
located under the turntable.
1 15
10
13 7 Grease type Multipurpose grease
6 12
18 4
3 17
11 5
8 14
16 9
2
Bolt torque sequence

TABLE D PROCEDURES
D-6 Turntable Rotate Drive Hub:

Replace the Drive Hub Oil 1 Secure the turntable from rotating with the
turntable rotation lock pin.
Replacing the drive hub oil is essential for good

machine performance and service life. Failure to
replace the drive hub oil at yearly intervals may
cause the machine to perform poorly and continued
use may cause component damage.
Drive Hubs:
1 Select the drive hub to be serviced. Drive the unlocked locked

machine until one of the two plugs is at the
2 Remove the motor/brake mounting bolts, and
lowest point.
then remove the motor and brake from the drive
2 Remove both plugs and drain the oil into a hub and set them to the side.
suitable container.
Component damage hazard. Hoses
3 Drive the machine until one plug is at the top can be damaged if they are kinked
and the other is at 90 degrees. or pinched.
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Apply pipe thread sealant to the plugs. Install
the plugs.
5 Repeat steps 1 through 4 for all the other drive
hubs.
Oil capacity per hub 44 fl oz a motor

1.30 liters b motor/brake mounting bolts
c brake
d drive hub
Type: SAE 90 multipurpose hypoid gear oil - API
e drive hub mounting bolts
service classification GL5

TABLE D PROCEDURES
3 Remove the drive hub mounting bolts, and use a D-7

lifting device to remove the drive hub from the
machine. Replace the Engine Oil and
4 Remove the plug from the side of the drive hub. Filter - Deutz Models
Then drain the oil from the hub.
5 Install the drive hub. Torque the drive hub
mounting bolts to 180 ft-lbs (244 Nm).
Periodic replacement of the engine oil and
6 Install the brake and motor onto the drive hub. filter is essential to good engine performance.
Torque the motor/brake mounting bolts to Operating the machine with an improper oil level or
180 ft-lbs (244 Nm). neglecting periodic oil and filter changes can
damage engine components. A frequent check
7 Fill the hub with oil from the side hole until the
of elapsed machine hours against the hours
oil level is even with the bottom of the hole.
noted on the oil filter will allow the inspector to
Apply pipe thread sealant to the plug. Install the
anticipate and perform oil and filter changes at
plug.
the 1000 hour interval.
8 Adjust turntable rotation gear backlash. See
13-1, How to Adjust the Turntable Rotation Gear
engine parts and oil. Contact with
Backlash.
hot engine oil and/or engine parts
Turntable rotate drive hub
Perform this procedure after
Oil capacity 17 fluid ounces warming the engine to normal
0.51 liters operating temperature.
Type: SAE 90 multipurpose hypoid gear oil - API 1 Remove the oil filler cap, located next to the
service classification GL5 dipstick.
2 Pull the end of the engine oil drain hose out from
under the engine.
3 Remove the plug from the end of the drain hose
and allow all of the oil from the engine to drain
into a suitable container. See capacity
specifications.
Do not remove the drain plug
located on the side of the oil pan.

TABLE D PROCEDURES
4 Install and tighten the plug in the drain hose. 8 Fill the engine with new oil per specifications
and install the oil filler cap.
5 Use an oil filter wrench and remove the oil filter.
9 Start the engine from the ground controls. Allow
the engine to run for 30 seconds then turn the
engine off.
a
10 Check the oil filter and drain hose for leaks.
11 Check the engine oil level dipstick. Add oil if
needed.
c
b Deutz F4l 1011 Engine 11 quarts
Deutz Diesel engine below 60°F / 15.5°C (synthetic) 5W-30

a engine oil level dipstick
b fuel filter -10°F to 90°F / -23°C to 32°C 10W-40
c oil filter
6 Apply a thin layer of clean engine oil to the new above -4°F / -34°C 15W-40
filter gasket. Install the filter and tighten it
securely by hand.
CC/SE or CC/SF grades.
7 Use a permanent ink marker to write the date
and number of hours from the hour meter on the Oil filter - Genie part number 49924
oil filter.

TABLE D PROCEDURES
D-8 1 Open the engine side turntable cover and locate

the fuel pump, located next to the engine oil dip
Clean the Fuel Pump Strainer - stick.
Deutz Models 2 Turn the manual fuel shutoff valve, located at
the fuel tank, to the CLOSED position.
3 Remove the fuel pump cover retaining fastener.
Cleaning the fuel pump strainer is essential for Remove the cover.
good engine performance and service life. A dirty 4 Gently clean the fuel strainer with clean diesel
or clogged strainer may cause the engine to fuel or a mild solvent.
component damage. Extremely dirty conditions or 5 Install the fuel strainer and pump cover onto the
not operating the machine for extended periods of fuel pump. Install and tighten the fuel pump
time may require that the strainer be cleaned more cover retaining fastener.
often. 6 Turn the manual fuel shutoff valve, located at
Explosion and fire hazard. Engine the fuel tank, to the OPEN position.
fuels are combustible. Perform this 7 Start the engine from the ground controls and
procedure in an open, well- inspect the fuel filter for leaks.
sparks, flames and lighted Explosion and fire hazard. If a fuel
tobacco. Always have an approved leak is discovered, keep any
fire extinguisher within easy reach. additional personnel from entering
Perform this procedure with the machine. Repair the leak
engine off. immediately.
Immediately clean up any fuel that Be sure the fuel filter is full of fuel
may have spilled during this before attempting to start the
procedure. engine.

TABLE D PROCEDURES
D-9 1 Turn the manual fuel shutoff valve, located at

the fuel tank, to the CLOSED position.
Replace the Diesel Fuel
2 Remove the fuel filter/water separator with a
Filter/Water Separator - filter wrench.
Deutz Models
Replacing the diesel fuel filter/water separator is

essential to good engine performance and service
life. A dirty or clogged filter/water separator may
cause the engine to perform poorly and continued a
b
use may cause component damage. Extremely
dirty conditions may require that the filter/water
separator be replaced more often.
fuels are combustible. Replace the a oil filter
fuel filter/water separator in an b fuel filter/water separator
open, well-ventilated area away
3 Fill the new filter with fresh diesel fuel and apply
from heaters, sparks, flames and
a thin layer of diesel fuel to the new fuel filter
lighted tobacco. Always have an
gasket.
easy reach. 4 Install the new filter and tighten it securely by
hand. Clean up any diesel fuel that might have
spilled during the procedure.
engine off.
5 Turn the manual fuel shutoff valve, located at
the fuel tank, to the OPEN position.
inspect the fuel filter for leaks.
immediately.

TABLE D PROCEDURES
D-10 1 Remove the 2 engine pivot plate retaining bolts

and swing the engine out away from the
Change the Fuel Hoses - machine to access the fuel hoses.
Deutz Models
Maintaining the fuel hoses in good condition is

essential to safe operation and good engine
performance. Failure to detect a worn, cracked or
leaking fuel hose may cause an unsafe operating
condition.
Explosion and fire hazard. Engine a b b c
fuels are combustible. Replace the
fuel hoses in an open, well-
sparks, flames and lighted c oil drain hose
tobacco. Always have an d air baffle
easy reach. 2 Place a suitable container under the engine pivot
plate.
sure the fuel hoses are routed the 3 At the fuel pump, disconnect the fuel hose to
same way the original hoses were. the fuel tank and drain the fuel tank into the
container.
engine off and cooled. 4 Remove and replace all of the fuel hoses and
clamps according to the following illustration:
Explosion and fire hazard. Fuel
Injection systems operate at a
very high pressure. Fuel may be
expelled under pressure if the
hoses are removed too quickly.
Loosen the fuel lines very slowly to
allow the fuel pressure to dissipate
gradually. Wrap a cloth around fuel
hoses to absorb leaking fuel before
disconnecting them.

TABLE D PROCEDURES
a b b b b b b b
D-11
Check the Engine Valve
Clearances -
Perkins Models
Complete information to perform this procedure is

available in the Perkins Workshop Manual, (Perkins
part number TPD 1359E) Genie part number 62424.
D-12
Clean the Engine Breather
Assembly -
Perkins Models

f e d c available in the Perkins Workshop Manual,
(Perkins part number TPD 1359E) Genie part
a hose from the injector to
the fuel tank
number 62424.
b hoses connecting injectors
c hose from the fuel shutoff valve
to the fuel pump
d hose from the fuel pump to
the fuel filter
e hose from the fuel filter to the
injection pump
f hose from the injection pump
to the injectors

Table E Procedures
2 Close the two hydraulic shutoff valves located at
E-1 the hydraulic tank.
Test or Replace the Hydraulic Oil
Replacement or testing of the hydraulic oil is

essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and open closed
continued use may cause component damage.
Extremely dirty conditions may require oil changes Component damage hazard. The
to be performed more frequently. engine must not be started with
the hydraulic tank shutoff valves in
The machine uses Dexron the CLOSED position or component
equivalent hydraulic oil. Before damage will occur. If the tank
replacing the hydraulic oil, the oil valves are closed, remove the key
may be tested by an oil distributor from the key switch and tag the
for specific levels of contamination machine to inform personnel of the
to verify that changing the oil is condition.
necessary. If the hydraulic oil is
not replaced at the two year 3 Remove the drain plug from the hydraulic tank.
inspection, test the oil quarterly. 4 Completely drain the tank into a suitable
Replace the oil when it fails the container. See capacity specifications.
test.
5 Tag, disconnect and plug the two suction hoses
Perform this procedure with the that are attached to the hydraulic tank
boom in the stowed position. shutoff valves.
When removing a hose assembly 6 Disconnect and plug the T-fitting located at the
or fitting, the O-ring on the fitting return filter with the 2 hoses connected to it.
and/or hose end must be replaced Cap the fitting on the return filter housing.
and then torqued to specification
during installation. 7 Disconnect and plug the supply hose for the
Refer to Section Two, Hydraulic auxiliary power unit. Cap the fitting on the
Hose and Fitting Torque hydraulic tank.
Specifications. 8 Remove the retaining fasteners from the
1 Remove the fuel tank. See Repair Section 12-1, hydraulic tank hold down straps. Remove the
How to Remove the Fuel Tank. hold down straps from the hydraulic tank.

TABLE E PROCEDURES
9 Support the hydraulic tank with 2 lifting straps. 19 Open the hydraulic tank shutoff valves.
Place one lifting strap at each end of the tank
Component damage hazard.
and attach the lifting straps to an appropriate
Be sure to open the two hydraulic
lifting device.
tank shutoff valves and prime the
10 Remove the hydraulic tank from the machine. pump after installing the hydraulic
Crushing hazard. The hydraulic tank. Refer to Repair Procedure
tank may become unbalanced and 10-2, How to Prime the Pump.
fall if it is not properly supported Always use pipe thread sealant
and secured to the lifting device. when installing the drain plug and
11 Remove the suction strainers from the tank and strainers.
clean them using a mild solvent. Use only Dexron equivalent
12 Rinse out the inside of the tank using a mild hydraulic fluid.
solvent.
13 Install the suction strainers using pipe thread Hydraulic system
sealant on the threads.
Hydraulic tank capacity 45 gallons
14 Install the drain plug using pipe thread sealant 170 liters
on the threads.
15 Install the hydraulic tank onto the machine.
capacity (including tank) 208 liters
16 Install the two suction hoses and the supply
hose for the auxiliary power unit. Hydraulic fluid Dexron equivalent
17 Fill the tank with hydraulic oil until the level is
within the top 2 inches (5 cm) of the sight
gauge. Do not overfill.
18 Clean up any oil that may have spilled.

TABLE E PROCEDURES
E-2 2 Put on protective clothing and eye wear.

Change or Recondition the 3 Disconnect the coolant return hose at the
radiator and drain the coolant return tank into a
Engine Coolant - suitable container.
4 Slowly remove the radiator cap from the
radiator.
Bodily injury hazard. Allow any
Replacing or reconditioning the engine coolant is pressure to dissipate gradually
essential to good engine performance and service before removing the radiator cap.
life. Old or dirty coolant may cause the engine to 5 Open the drain valve on the radiator and allow
perform poorly and continued use may cause all the coolant to drain into a suitable container.
engine damage. Extremely dirty conditions may
require coolant to be changed more frequently. 6 After all the coolant has drained, close the drain
valve. Connect the coolant return hose to
Bodily injury hazard. Beware of the radiator.
hot engine parts and coolant.
7 Open the drain valve on the engine block and
Contact with hot engine parts
allow the coolant to drain into a suitable
and/or coolant may cause severe
container. After the fluid has drained, close the
burns.
drain valve.
8 Replace all coolant hoses and clamps.
engine off and cooled.
9 Fill the radiator with the proper coolant mixture
(coolant and water) for your climate until it is
full.
machine to access the cooling system.
10 Fill the coolant recovery tank to the NORMAL
range.
11 Clean up any coolant that may have spilled
during this procedure.
let it run for 30 seconds. Turn the engine off
and inspect for leaks.
a b b c
c air baffle

TABLE E PROCEDURES
13 Check the coolant level in the coolant recovery E-3

tank. Add coolant if needed.
Change the Fuel Hoses -
Ford Models
retaining bolts.
15 Start the engine from the ground controls
and let it run until it reaches normal operating
Maintaining the fuel hoses in good condition is
temperature.
essential to safe operation and good engine
16 Turn the engine off. Allow the engine to cool. performance. Failure to detect a worn, cracked or
leaking fuel hose may cause an unsafe operating
17 Check the coolant level in the coolant recovery
condition.
tank. Add coolant if needed.
Coolant capacity fuels are combustible. Replace the
fuel lines in an open, well-
Ford LRG-425 EFI Engine 11.5 quarts 10.9 liters sparks, flames and lighted
Perkins 704-30 Engine 10 quarts 9.5 liters tobacco. Always have an
easy reach.
sure the fuel hoses are routed the
same way the original hoses were.
engine off and cooled.
1 Tag, disconnect and plug the fuel hose from the
fuel tank at the manual shutoff valve.

TABLE E PROCEDURES
2 Remove the 2 engine pivot plate retaining bolts 6 Remove and replace all of the fuel hoses and
and swing the engine out away from the clamps according to the following hose routing
machine to access the fuel hoses. diagram:
a b c
a b b c

c air baffle e d
3 Place a suitable container under the engine a high pressure hose from fuel pump to
pivot plate. See capacity specifications. regulator/filter
b hose from fuel pre-filter to fuel pump
4 Locate the fuel pressure regulator/filter and the c hose from fuel tank to fuel pre-filter
fuel pump on the engine pivot plate behind the d high pressure hose from regulator/
filter to engine
engine. e hose from regulator/filter to tank
5 At the fuel pressure regulator/filter, disconnect 7 Clean up any fuel that may have spilled during
the fuel hose to the fuel tank. this procedure.
Explosion and fire hazard.
Electronic Fuel Injection (EFI)
Inspect the fuel filter and hoses for leaks.
systems operate at a very high
pressure. Fuel may be expelled Explosion and fire hazard. If a fuel
under pressure if the hoses are leak is discovered, keep any
removed too quickly. Loosen the additional personnel from entering
fuel hoses very slowly to allow the the area and do not operate the
fuel pressure to dissipate machine. Repair the leak
gradually. Wrap a cloth around immediately.
fuel hoses to absorb leaking fuel
before disconnecting them.
retaining bolts.

TABLE E PROCEDURES
E-4 E-5
Replace the Engine Air Breather - Grease the Steer Axle Wheel
Perkins Models Bearings - 2WD Models
Complete information to perform this procedure is Maintaining the steer axle wheel bearings is
available in the Perkins 700 Series Workshop essential for safe machine operation and service
Manual, Perkins part number TPD 1359E (Genie life. Operating the machine with loose or worn
part number 62424). wheel bearings may cause an unsafe operating
condition and continued use may result in
component damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure
washing of the machine may require that this
procedure be performed more often.
1 Loosen the wheel lug nuts. Do not remove

them.
2 Block the non-steering wheels. Center a lifting
jack under the steer axle.
3 Raise the machine approximately 6 inches
(15 cm). Place blocks under the drive chassis
for support.
4 Remove the lug nuts. Remove the tire and
wheel assembly.
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: There should be no side to side or up
and down movement.
Skip to step 23 if there is no movement.

TABLE E PROCEDURES
6 Remove the dust cap from the hub and remove 14 Place the large inner bearing into the rear of the
the cotter pin from the castle nut. hub.
Always replace the cotter pin with 15 Install a new bearing grease seal into the hub
a new one when removing the by pressing it evenly into the hub until it is flush.
castle nut or when checking the
Always replace the bearing grease
torque of the castle nut.
seal when removing the hub.
7 Tighten the castle nut to 35 ft-lbs (47 Nm) to
16 Slide the hub onto the yoke spindle.
seat the bearings.
Component damage hazard. Do
8 Loosen the castle nut, then re-tighten to
not apply excessive force or
8 ft-lbs (11 Nm).
damage to the lip of the seal may
9 Check for wheel bearing wear by attempting to occur.
move the wheel hub side to side, then up and
17 Place the outer bearing into the hub.
down.
18 Install the washer and castle nut.
Result: If there is side to side or up and down
movement, proceed to step 10 to replace the 19 Torque the castle nut to 35 ft-lbs (47 Nm)
wheel bearings with new ones. to seat the bearings.
When replacing a wheel bearing, 20 Loosen the castle nut, then torque the castle
both the inner and outer bearings, nut to 8 ft-lbs (11 Nm).
including the pressed-in races,
21 Install a new cotter pin. Bend the cotter pin to
must be replaced.
lock it in place.
Result: If there is no side to side or up and Always replace the cotter pin with
down movement, grease the wheel bearings. a new one when removing the
10 Remove the castle nut. castle nut or when checking the
torque of the castle nut.
Always replace the cotter pin with
a new one when removing the 22 Install the dust cap.
castle nut or when checking the 23 Install the tire and wheel assembly. Torque the
torque of the castle nut. wheel lug nuts to 420 ft-lbs (569.5 Nm).
11 Pull the hub off of the spindle. The washer and 24 Center a lifting jack under the steer axle.
outer bearing should fall loose from the hub.
12 Place the hub on a flat surface and gently pry (15 cm). Remove the blocks from under the
the bearing seal out of the hub. Remove the drive chassis.
inner bearing.
26 Lower the machine.
13 Pack both bearings with clean, fresh grease.

TABLE E PROCEDURES
E-6
Check the Fuel Injectors -
Perkins Diesel Models
Engine specifications require

that this procedure be performed
every 3000 hours or 18 months,
whichever comes first.
available in the Perkins 700 Series Workshop
Manual, Perkins part number TPD 1359E (Genie
part number 62424).

Third Edition • First Printing Section 5 • Troubleshooting Flow Charts
Troubleshooting Flow Charts

Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the Genie S-80
& Genie S-85 Operator’s Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Read each appropiate flow chart thoroughly.
Troubleshooting and repair procedures shall be Attempting shortcuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine.
Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine.
Crushing hazard. When testing
Repair any machine damage or malfunction or replacing any hydraulic
before operating the machine. component, always support
the structure and secure it
Unless otherwise specified, perform each from movement.
repair procedure with the machine in the
following configuration: Electrocution hazard. Contact
with electrically charged circuits
· Machine parked on a flat level surface
could result in death or serious
· Boom in stowed position injury. Remove all rings, watches
· Turntable rotated with the boom between and other jewelry.
the non-steering wheels
Bodily injury hazard. Spraying
· Turntable secured with the turntable hydraulic oil can penetrate and
rotation lock pin burn skin. Loosen hydraulic
· Key switch in the OFF position with the connections very slowly to allow
key removed the oil pressure to dissipate
gradually. Do not allow oil to
· Wheels chocked
squirt or spray.
Perform all troubleshooting on a
firm level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.

Section 5 • Troubleshooting Flow Charts Third Edition • First Printing
TROUBLESHOOTING FLOW CHARTS
About This Section General Repair Process
When a malfunction is discovered, the flow charts

in this section will help a service professional Malfunction Identify Troubleshoot
pinpoint the cause of the problem. To use this discovered symptoms
section, basic hand tools and certain pieces of test
equipment are required—voltmeter, ohmmeter,
pressure gauges. problem
still exists
The location of terminals mentioned in this section
can be found on the appropriate electrical or Return to Inspect Perform
hydraulic schematics provided in Section 6, service problem and test repair
Schematics. solved
Since various degrees of a particular function

loss may occur, selecting the appropriate flow
chart may be troublesome. When a function will not
operate with the same speed or power as a
machine in good working condition, refer to the
flow chart which most closely describes the
problem.

Fault Code Chart

Fault Code Problem Cause Solution
11 -- -- Normal operation
Throttle Faulty TP sensor OR
Check for poor terminal connections OR
Position (TP) sensor wires shorted to
12 shorted wires from the TP sencor to the
sensor low ground OR poor
ECM OR replace the TP sensor.
voltage. terminal connection.
Manifold
Faulty MAP sensor OR
Absolute Check for poor terminal connections OR
sensor wires shorted to
14 Pressure wires shorted to ground OR replace MAP
ground OR poor
(MAP) sensor sensor.
terminal connection.
low voltage.
Engine speed Check for obstructions in the throttle body

Obsrtruction in throttle
21 exceeded that could cause binding of the throttle
body OR faulty ECM.
4000 RPM. assembly OR replace ECM.
The ECM senses a

signal from the TP
sensor that is greater
Throttle
than 4.9V DC OR the Check for poor terminal connections OR
Position (TP)
22 TP sensor wiring is shorted wires from the TP sensor to the
sensor high
shorted to ground OR ECM OR replace the TP sensor.
voltage.
there is a poor terminal
connection OR the TP
sensor is faulty.
Manifold
Faulty MAP sensor OR
Absolute Check for poor terminal connections OR
sensor wires shorted to
24 Pressure shorted wires from the MAP sensor to the
ground OR poor
(MAP) sensor ECM to ground OR replace MAP sensor.
terminal connection.
high voltage.

FAULT CODE CHART

Voltage to fuel pump is Test the fuel pump relay, see the Repair
Fuel pump greater than or equal Section OR check for poor terminal
31
low voltage. to 2V DC below connection from the fuel pump relay to
ignition voltage. fuel pump OR replace the fuel pump.
W ater in the fuel,
misfiring cylinder,
plugged fuel filter OR Check for water in the fuel, misfiring
Heated
the HO2 sensor wiring cylinder or plugged fuel filter OR check for
Oxygen
32 is shorted to ground poor terminal connections or shorted
(HO2) sensor
OR there is a poor wires from the HO2 sensor to the ECM to
low voltage.
terminal connection ground OR replace HO2 sensor.
OR the HO2 sensor is
faulty.
Engine is overheating
Engine
OR sensor wires Check engine coolant level OR check for
Coolant
shorted to ground or shorted wires or poor terminal
33 Temperature
poor terminal connections from the ECT sensor to the
(ECT) sensor
connections OR ECT ECM OR replace the ECT sensor.
high voltage.
sensor is faulty.
Engine is overheating
Intake Air OR sensor wires
Check for poor terminal connections or
Temerature shorted to ground or
35 shorted wires from the IAT sensor to the
(IAT) sensor poor terminal
ECM to ground OR replace IAT sensor.
high voltage. connections OR ECT
sensor is faulty.
Fuel pump is receiving
Test the fuel pump relay, see the Repair
voltage when the ECM
Fuel pump Section OR check for poor terminal
41 is not sending the
high voltage. connection from the fuel pump relay to
signal to the fuel pump
fuel pump OR replace the ECM.
to turn ON.

FAULT CODE CHART

A leaking or
malfunctioning fuel
injector, misfiring
cylinder, faulty TP Test for a leaking or malfunctioning fuel
sensor or injector, misfiring cylinder or bad TP
Heated
contamination of fuel sensor. Remove HO2 sensor and check
Oxygen (HO2)
42 OR use of improper condition of sensor for contamination OR
sensor high
thread sealant on check for poor terminal connections or
voltage.
sensor threads OR shorted wires from the HO2 sensor to the
sensor wires shorted to ECM to ground OR replace HO2 sensor.
ground or poor terminal
connections OR HO2
sensor is faulty.
Engine
ECM detects Check engine coolant level OR check for
Coolant
excessively low signal shorted wires or poor terminal connections
43 Temperature
voltage from the ECT from the ECT sensor to the ECM OR
(ECT) sensor
sensor. replace the ECT sensor.
low voltage.
The IAT sensor shares the same ground
Intake Air ECM detects an wire as the ECT and MAP sensors. Check
Temperature excessively low signal for shorted wires or poor terminal
45
(IAT) sensor voltage from the IAT connections from the IAT sensor to the
low voltage. sensor. ECT and MAP sensors to the ECM OR
replace the IAT sensor.
Faulty oil pressure Check engine oil level OR check for
Low oil switch, wires shorted to shorted wires or poor terminal connections
51
pressure. ground or not enough from the oil pressure switch to the ECM OR
engine oil. replace the oil pressure switch

FAULT CODE CHART

The CKP and CMP
sensors work together;
if one is bad, the other
Crankshaft one won't work
Position correctly and causes Check for shorted wires or poor terminal
(CKP) sensor the ECM to detect a connections from the CKP and CMP
52
senses extra fault. The ECM uses sensors to the ECM OR replace the CKP or
or missing the signal pulses from CMP sensor.
pulses. the CKP and CMP
sensors to initiate
sequential fuel
injection.
The CMP and CKP
sensors work together;
if one is bad, the other
Camshaft one won't work
Position correctly and causes Check for shorted wires or poor terminal
(CMP) sensor the ECM to detect a connections from the CKP and CMP
53
senses fault. The ECM uses sensors to the ECM OR replace the CKP or
unknown the signal pulses from CMP sensor.
pattern. the CKP and CMP
sensors to initiate
sequential fuel
injection.
The ECM received an
illegal instruction signal
ECM Fault - from one or more of the
54 Illegal sensors and has gone Replace the ECM.
Operation. into a default program
and then return to
normal operation

FAULT CODE CHART
The ECM received an

illegal interruption
signal from one or more
ECM - Illegal engine sensors and has
55 Replace the ECM.
Interuption gone into a default
program and then
return to normal
operation.
Under normal operation

ECM -
the ECM will store
Computer
numbers into memory.
56 Operating Replace the ECM.
If this does not happen,
Properly
it will reset itself and set
(COP) failure
fault code 56.
Battery supply voltage Check battery and/or alternator condition

System
61 to the ECM is 8V DC or OR check for shorted wires or poor terminal
voltage low.
less. connections from the battery to the ECM.
Battery supply voltage Check battery and/or alternator condition

System
62 to the ECM is 18V DC OR check for shorted wires or poor terminal
voltage high.
or more. connections from the battery to the ECM.

Chart 1
Engine Will Not less than Check battery condition
Check battery voltage. 12V OR check alternator
Crank Over OR check battery cables
OR replace the battery.
Be sure the key switch
12V or more
is in the appropriate
position.
With key switch turned Trace circuit back
Be sure that both to ground controls and 0V through the key switch,
Emergency Stop both Emergency Stop Emergency Stop button
buttons are pulled out to buttons pulled out to the and CB2. Repair open.
ON position, check
the ON position. voltage at the center
terminal on the start
Be sure the circuit toggle switch TS11.
breakers are not
tripped. 12V
Be sure the battery is Move the start toggle 0V Replace start toggle
fully charged. switch to either side and switch.
check the voltage at
either side terminal on
start toggle switch.
12V
Move the start toggle 0V Repair open in blk wire

switch to either side and circuit from start toggle
check voltage at switch to TB33.
terminal TB33.
12V
Move the start toggle Repair open in blk wire

switch to either side and 0V circuit from TB33 to
check voltage at terminal #3 on ignition/
terminal #3 on ignition/ start module.
start module.
12V
Check voltage at 0V Repair open in red

terminal #6 on the power supply wire circuit
ignition/start module. from CB1 to CR1 to CR2
then to terminal #6 to
on ignition/start module.
12V
Continued on the next

page.

CHART 1
Move the start toggle 0V Check ground wire to bad Repair open in brn
Continued from the switch to either side and terminal #5 on ignition/ ground wire to ignition/
previous page. check voltage at start module. start module.
terminal #1 on ignition/
start module.
good
Consult Genie Industries

Service Department.
12V
Move the start toggle Repair open in blk wire

switch to either side and 0V from terminal #1 on
check voltage at ignition/start module to
terminal #86 on CR1. CR1.
12V
Check voltage at 0V Repair open in red wire

terminal #30 on CR1. circuit from battery to
CB1 to CR1 terminal
#30.
12V
Move the start toggle 0V Check brn ground wire bad Repair open in brn
switch to either side and to terminal #85 on CR1. ground wire circuit to
check voltage at CR1.
terminal #87 on CR1.
good
Replace CR1 relay.

12V
Move the start toggle 0V Repair open in blk wire

switch to either side and circuit from CR1 to
check voltage at the blk starter solenoid.
wire on the starter
solenoid.
12V
Check voltage at starter 0V Repair open in battery

cable. cable to starter.
12V
Repair or replace starter

or starter solenoid.

Chart 2
Engine Cranks See Repair Section, Check for poor terminal Refer to the fault code
How to Retrieve Fault connections OR check chart in this section for
Over But Will Codes. Is there a fault
yes
for shorted or damaged a description of the fault
Not Start - code stored in the ECM wires that go from the and recommended
memory? ECM to the sensor that repairs.
Ford Models is causing the fault OR
replace the sensor OR
consult Genie Industries
Be sure to check the Service Department.
engine oil level and fill no
as needed.
Be sure to check fuel less

With the key switch than Check battery condition
levels and engine turned to ground 11V OR check alternator OR
coolant level. controls and both check for short circuits
Emergency Stop buttons OR check battery cables
Be sure the gasoline pulled out to the ON OR replace the battery.
position, move the start
shut-off valve is in the toggle switch to either
ON or OPEN position. side and check battery
voltage while engine is
Perform following tests cranking.
in gasoline mode only.
more than 11V
Be sure that the coolant
temperature gauge With the key switch Test the fuel pump
turned to the OFF no relay. See Repair
does not show an position and both Section OR replace the
overheated condition. Emergency Stop buttons fuel pump.
pulled out to the ON
position, turn the key
switch to ground
controls and listen for
the fuel pump to turn ON
for approximately 2
seconds and then shut
OFF. Did the fuel pump
turn on?
yes
Remove #1 spark plug good

and ground spark plug spark Consult Genie Industries
body. Crank engine and Service Department.
observe spark.
weak or no spark

page.

CHART 2
Disable starter by See Ford LRG-425 EFI

Continued from the removing blk wire at the Service Manual for
previous page. starter solenoid, move 12V troubleshooting the
the start toggle switch to ignition system OR
either side and check consult Genie Industries
voltage at the light green Service Department.
wire on the ignition coil
plug.
less than
12V
Repair open in light
green wire from the
ECM to ignition coil OR
check for loose or bad
connections from the
ECM to the ignition coil
OR replace the ignition
coil OR consult Genie
Industries Service
Department.

Chart 2A
Engine Runs See Repair Section, Check for poor terminal Refer to the fault code
While Cranking Codes. Is there a fault
yes
Then Dies - code stored in the ECM wires that go from the and recommended
Be sure to check the Service Department.
engine oil level and fill no
as needed.
Be sure to check fuel

Move the start toggle 0V Crank engine and check 0V Check alternator wiring
levels and the engine switch to either side and voltage at org/blk #41 OR repair or replace
coolant level. check voltage at wire on alternator. alternator OR contact
terminal #2 on ignition/ Genie Industries Service
Be sure that the radiator start module. Department.
6 to 7V
overflow tank is at the
FULL mark. Repair open in org/blk
#41 wire circuit from
Perform these tests in alternator to TB41 to
6 to 7V terminal #2 on ignition/
gasoline mode only. start module.
Check voltage at 12V Disconnect red wire Replace ignition/start

terminal #4 on ignition/ from terminal #4 on 12V module OR consult
start module. ignition/start module and Genie Industries Service
check voltage at Department.
terminal #4.
0V
Test auxiliary power

0V toggle switches TS1 and
TS10. See Repair
Section.
Replace ignition/start
module OR consult
Genie Industries Service
Department.

Chart 3
Engine Cranks less
Move the start toggle than Check battery condition
switch to either side and OR check alternator OR
Over But Will check battery voltage
11V
check for short circuits
Not Start - while engine is cranking. OR check battery cables
OR replace the battery.
Diesel Models 11V or more
Be sure to check the
0 or
engine oil level and fill Disable the starter by Turn the machine off infinite
as needed. removing the blk wire at 12V and isolate the fuel ohms Replace the fuel
the starter solenoid. solenoid. Check the solenoid.
Move the start toggle resistance of the
Be sure to check switch to either side and solenoid.
fuel level. check the voltage at
positive terminal on fuel 3.5 ohms Deutz
Be sure the fuel solenoid. 11.5 ohms Perkins
shut-off valve is in
See Deutz or Perkins
the ON position. service manual for
troubleshooting fuel
Be sure that the battery 0V system.
is fully charged.
Move the start toggle Repair open in wht #21

switch to either side and 12V wire from CR2 to fuel
check voltage at wht solenoid.
#21 wire on terminal #87
of CR2.
0V
Check voltage at red 0V Repair open in red wire

wire on terminal #30 of circuit from battery to
CR2. CB1 to CR1 to CR2.
12V

page.

CHART 3
Move the start toggle Move the start toggle Repair open in blk wire
Continued from the 0V switch to either side and 12V from terminal #86 on
previous page. switch to either side and
check voltage at check voltage at CR2 to terminal #9 on
terminal #86 of CR2. terminal #9 on the the ignition/start module.
ignition/start module.
0V
0V
Check voltage at Repair open in power
terminal #6 and #7 on supply wires to terminal
ignition/start module. #6 and #7 on ignition/
start module.
12V
Check continuity from no Repair open in brn

ground to brn wire at continuity ground wire circuit to
12V terminal #5 on ignition/ terminal #5 on ignition/
start module. start module.
continuity
Replace the ignition/

start module OR consult
Department.
no
Check continuity from continuity Repair open in brn
ground to terminal #85 ground wire circuit to
on CR2. CR2.
good
Crank engine and check 0V Crank engine and check 0V Repair or replace
voltage at terminal #2 on voltage at org/blk #41 alternator OR contact
ignition/start module. wire on alternator. Genie Industries Service
Department.
6 to 7V
Repair open in org/blk

#41 wire circuit from
alternator to TB41 to
6 to 7V terminal #2 on ignition/
start module.

page.

CHART 3
While cranking engine Disconnect wht #24 wire Check oil level OR
Continued from the for 15 seconds, check from oil pressure sender replace oil pressure
previous page. continuity to ground on yes and check continuity to yes sending unit OR refer to
terminal #10 on ignition/ ground on signal post of Deutz or Perkins service
start module. Is sender, while cranking manual for
continuity maintained? the engine. Is continuity troubleshooting low oil
maintained? pressure.
no
Disconnect wht #24 wire Check oil level OR

from engine temperature replace engine
sender and check yes temperature sending
continuity to ground on unit OR refer to Deutz or
signal post of sender, Perkins service manual
while cranking the for troubleshooting a
engine. Is continuity overheated engine.
maintained?
no
no
Repair short to ground

in wht #24 wire from
sending units to TB24 to
terminal #10 on ignition/
start module.
Check voltage at 12V Disconnect red wire Replace ignition/start

terminal #4 on ignition/ from terminal #4 on 12V module OR consult
start module. ignition/start module and Genie Industries Service
check voltage at Department.
terminal #4.
0V
Test auxiliary power

0V toggle switches TS1 and
TS10. See Repair
Section.
Replace ignition/start
module OR consult
Department.

Chart 4
Engine Will Not See Repair Section, Check for poor terminal Refer to the fault code
Start On LPG, Codes. Is there a fault
yes
But Will Start code stored in the ECM wires that go from the and recommended
On Gasoline - is causing the fault OR
Ford Models consult Genie Industries
Service Department.
no
Be sure fuel select
switch is switched
to LPG.
Turn OFF the valve on
Be sure the valve on the the LPG tank, then
disconnect LPG supply
LPG tank is fully line from LPG tank and
opened. bleed pressure from
line.
Be sure to check
LPG fuel level.
With key switch turned 0V Check the voltage at the 0V Repair open in power
to ground controls and center terminal of the supply circuit to fuel
both Emergency Stop fuel select toggle switch. select toggle switch.
buttons pulled out to the
ON position, check
voltage at LPG side 12V
(blu/red wire) of fuel
select toggle switch Replace fuel select
TS12. toggle switch.
12V
With key switch turned Repair open in blu/red

to ground controls and 0V wire circuit from fuel
both Emergency Stop select toggle switch to
buttons pulled out to the TB39.
ON position, check
voltage at TB39.
12V
With key switch turned Repair open in red wire

to ground controls and 0V circuit from ECM to
both Emergency Stop terminal #85 on CR3 OR
buttons pulled out to the replace ECM.
ON position, check
voltage at terminal #85
on CR3.
12V

page.

CHART 4
Crank engine for 15 no Repair open in dk grn

Continued from the seconds and check for continuity wire from ECM to
previous page. continuity to ground at terminal #86 on CR3 OR
terminal #86 on CR3. replace ECM.
continuity
Crank engine for 15 no

seconds and check for continuity
continuity to ground at Replace LPG relay CR3.
continuity 0 or
infinite
Check resistance of ohms
LPG solenoid. Replace LPG solenoid.
9 to 10 ohms
Reconnect LPG tank

and starter then see
Maintenance section for
LPG adjustments OR
Service Department.

Chart 5
Engine Will See Repair Section, Check for poor terminal Refer to the fault code
Not Start On Codes. Is there a fault
yes
Gasoline, code stored in the ECM wires that go from the and recommended
But Will Start is causing the fault OR
On LPG - consult Genie Industries
Service Department.
no
Ford Models
Be sure fuel select
switch is switched With key switch turned 12V Replace fuel select
to gasoline. to ground controls and toggle switch.
both Emergency Stop
Be sure to check buttons pulled out to the
ON position, check
gasoline fuel level. voltage at LPG side
(blu/red wire) of fuel
select toggle switch
TS12.
0V
Move the start toggle Replace the fuel pump

switch to either side and 0V relay "B" of the engine
check voltage across harness OR consult
the wires on the fuel Genie Industries Service
pump without Department.
disconnecting the wires.
12V
With key switch turned Repair open in fuel

to the OFF position and no pump wires from fuel
both Emergency Stop pump relay "B" of the
buttons pulled out to the engine harness OR
ON position, turn the key replace the fuel pump.
switch to ground
controls and listen for
the fuel pump to turn ON
for approximately 2
seconds. Did the fuel
pump turn on?
yes
See Ford LRG-425 EFI

service manual for fuel
system troubleshooting
OR consult Genie
Industries Service
Department.

Chart 6
Engine See Repair Section, Check for poor terminal Refer to the fault code
High Idle Codes. Is there a fault
yes
Inoperative - code stored in the ECM wires that go from the and recommended
Service Department.
no
Start the engine then 0V Check voltage at center Repair open in power
terminal on both RPM 0V supply circuit to center
move and hold the RPM
toggle switch to the HIGH select toggle switches. terminal of RPM select
IDLE (rabbit symbol) toggle switch.
position for the following 12V
tests. Check voltage at
blk/red wire on RPM
select toggle switches Replace RPM select
TS4 and TS13. toggle switch.
12V
0V
Check voltage at TB35. Repair open in blk/red
wire circuit from toggle
switch to TB35.
12V
Repair open in tan/blu

wire from TB35 to ECM
OR consult Genie
Industries Service
Department.

Chart 7
Engine Low Idle See Repair Section, Check for poor terminal Refer to the fault code
Inoperative - Codes. Is there a fault
yes
Ford Models code stored in the ECM wires that go from the and recommended
is causing the fault OR
If low idle operates replace the sensor OR
on LPG but not on consult Genie Industries
gasoline, see Ford Service Department.
no
service manual for
troubleshooting.
If low idle operates Start engine and move Isolate the ground and
the RPM select toggle 12V platform RPM toggle
on gasoline but not switch TS13 to low idle switches TS4 and TS13,
on LPG, see Ford (turtle symbol). Check check individually and
service manual for voltage at TB35. replace faulty switch.
troubleshooting.
0V
Replace ECM or consult

Department.

Chart 8
Engine Start engine, move the Check high idle
solenoid adjustment (see
RPM select toggle
High Idle switch TS13 to HIGH IDLE
pulls in Maintenance section)
Inoperative - (rabbit symbol) and OR see Deutz OR
check if 2-speed Perkins workshop
Diesel Models solenoid pulls in. manual to troubleshoot
fuel injection system.
Be sure mechanical solenoid does
linkage is not binding not pull in
or defective.
Check voltage at blk/red Check voltage on red Repair open in circuit
wire on RPM select 0V wire at center terminal of 0V supplying 12V to center
Be sure 2-speed toggle switches TS4 and RPM select toggle terminal of toggle
solenoid grounding TS13. switches. switch.
wires are free of
corrosion and have full 12V
continuity to ground.
12V Replace toggle switch.
0V
Check voltage at TB35. Repair open in blk/red
wire circuit from toggle
switch to TB35.
12V
Check voltage at 0V Repair open in blk/red

terminal #30 on CR3. wire circuit from TB35 to
12V
Check voltage to 0V Repair open in wht wire

terminal #86 on CR3. circuit from terminal #87
on CR2 to TB21 to
12V
no
Check continuity from continuity Repair open in brn
ground to brn wire at ground wire circuit to
terminal #85 on CR3. terminal #85 on CR3.
continuity
0V
Check voltage to Replace CR3 relay.
12V

page.

CHART 8
Continued from the Check voltage at 0V Repair open in blk/red

previous page. terminal #86 on CR4. wire circuit from
CR3 to CR4.
12V
Check continuity from bad Repair open in brn

ground to brn wire at ground wire circuit to
terminal #85 on CR4. terminal #85 on CR4.
good
Check voltage to 0V Repair open in wht wire

terminal #30 on CR4. circuit from CR2 to TB21
to CR3 to CR4.
12V
Check voltage at the 0V Replace CR4 relay

blk/red wire on the OR repair open in
2-speed solenoid. blk/red wire circuit from
terminal #87 on CR4 to
2-speed solenoid.
12V
Check continuity from Repair open in brn

ground to brn wire at bad ground wire circuit from
2-speed solenoid to 2-speed solenoid to
ground. ground.
good
solenoid
Check if 2-speed binds Check linkage or
solenoid moves in and replace solenoid.
out freely.
moves freely
Replace 2-speed
solenoid. Note:
resistance across
solenoid terminals
should be approximately
0.3 ohms.

Chart 9
Engine At the platform controls, Isolate the platform and
start the engine and ground RPM select
Low Idle move the RPM select
12V
toggle switches TS4 and
Inoperative - toggle switch TS4 to TS13, check individually
MAINTAINED LOW IDLE and replace faulty toggle
Diesel Models (turtle symbol). Check switch.
voltage at blk/red wire
Check if on RPM select toggle
switch.
mechanical linkage
from 2-speed solenoid 0V
to fuel injection
12V
system is binding or Check voltage at the Replace CR4 relay.
defective. blk/red wire on the
2-speed solenoid.
0V
solenoid
Check if 2-speed binds Check linkage or
solenoid moves in and replace solenoid.
out freely.
moves freely
Check adjustment of
linkage and fuel injection
system low idle. See
Maintenance section.
ok
See Deutz OR Perkins

workshop manual to
troubleshoot fuel
injection system OR
Service Department.

Chart 10
All Functions Check hydraulic low Fill with Dexron
fluid level. equivalent hydraulic
Inoperative, fluid.
Engine Starts ok
and Runs
Check pump suction line closed Do the pumps feel yes If engine has been run
shutoff valves. In the excessively hot? with valves closed, this
open position, the valve may have damaged one
handles should be no or both pumps. Please
parallel with hose. contact the Genie
Industries Service
Open valves and start Department.
the engine. Check all
machine functions for
open correct operation.
Remove function pump spline Troubleshoot

from main pump but turns inoperative boom
leave all hoses functions and
connected. Disconnect inoperative drive
ignition coil connector functions separately.
plug from ignition coils.
On Deutz or Perkins
diesel models, hold
manual fuel shutoff lever
to the CLOSED position.
Hold start toggle switch
and crank engine while
observing spline drive at
rear of main pump.
spline does not turn
Engine to pump flex

plate coupling is faulty
OR main pump is faulty.
Service Department.

Chart 11
All Lift and 2900
Install a 0 to 5000 PSI psi or Troubleshoot each
(345 bar) pressure function individually or
Steer Functions gauge on the function
more
Inoperative, manifold. Start engine, Service Department.
hold the function enable
Drive Functions toggle switch to either
side and move the boom
Operational retract toggle switch
TS19 in the RETRACT
Be sure the generator direction. Check the
hydraulic pressure.
on/off toggle switch
(if equipped) is in the less than
OFF position. 2900 psi
Adjust the function 2900 Hold the function enable

Be sure the hydraulic manifold system relief switch to either side and
psi or
suction line shutoff valve valve (item Z) all the more move the boom retract
for the lift/steer pump is way in (clockwise) toggle switch in the
counting the number of RETRACT direction and
in the OPEN position. turns. Hold the function adjust the relief pressure
enable switch to either to 2900 psi.
Be sure all grounding side and move the boom
wires for the hydraulic retract toggle switch in
manifold valves are free the RETRACT direction
and check the hydraulic
of corrosion and have pressure.
full continuity to ground.
less than
2900 psi
steering
Check steer functions. operates Repair or replace
differential sensing valve
(item Y) OR repair or
replace priority flow
regulator valve (item
CC) OR manifold has an
steering inoperative internal fault, consult
Department.
Check the function ok Replace the relief valve

pump, see Repair (item Z) OR manifold
section. has an internal fault.
Consult the Genie
Industries Service
Department.
bad
Replace the function

pump.

Chart 12
Ground Does the engine start yes Start the engine from Repair open in red wire
from ground controls? ground controls. Hold circuit from key switch to
Controls the function enable
0V
function enable toggle
Inoperative, toggle switch to either switch to each function
side and check the toggle switch.
Platform voltage on both center
terminals of the platform
Controls rotate toggle switch
TS14.
Operate
no 12V
Normally
Be sure all other Troubleshoot each
function individually.
functions operate
normally, including
the platform
controls. With both Emergency Repair open in red wire
Stop buttons pulled out 0V circuit from Emergency
to the ON position, check Stop button to key
voltage at red wire on switch.
the input side of the
ground controls contact
of the key switch (the
red wire checked should
originate at the
Emergency Stop
button).
12V
With the key switch 0V Check if key switch yes Replace key switch
turned to ground internal cam is activating contact for ground
controls and both ground contact. controls.
Emergency Stop buttons
position, check voltage no
at red wire on the output
side of the ground Replace key switch.
controls contact on the
key switch.
12V
Repair open in red wire

circuit from key switch to
function enable toggle
switch to each function
toggle switch.

Chart 13
Platform Does engine start from yes Start engine from Test or replace foot
platform controls? platform controls, press 0V switch (see Repair
Controls down the foot switch and Section) OR repair open
Inoperative, check voltage at TP24. in wht wire circuit from
foot switch to TP24.
Ground 12V
Controls Repair open in wht wire
no
Operate circuit from TP24 to
function toggle switches
Normally and function controllers.
Be sure all
cables from chassis 0V
through the cable Check voltage at TB22. Repair open in red wire
circuit from key switch to
track are in good TB22 OR replace the
condition with no platform controls contact
12V at the key switch.
kinks or abrasions.
0V
Check voltage at TP22. Repair open in blk-2
wire circuit from TB22
to TP22.
12V
Check voltage at blk 0V Repair open in blk wire

wire on input side of from TP22 to
platform Emergency Emergency Stop button.
Stop button contact.
12V
With key switch turned Check if Emergency yes Replace contact on

0V
to platform controls and Stop button internal cam Emergency Stop button.
both Emergency Stop is activating the contact.
ON position, check the
no
voltage on the output
side of the platform
Emergency Stop button Replace the platform
contact. Emergency Stop button.
12V
0V
Check voltage at TP23. Repair open in wht wire
with diode from
Emergency Stop button
12V to TP23.
Repair open in blk wire

circuit from platform
Emergency Stop button
to TP26 to foot switch
OR replace foot switch
OR consult Genie
Industries Service
Department.

Chart 14
Boom Up With key switch turned Hold the function enable Repair open in red/wht-4
to ground controls and switch to either side and wire circuit from TB3 to
Function both Emergency Stop move the boom up/down 8 to 9V boom up/down
0V
Inoperative buttons pulled out to the toggle switch in the UP proportional valve coil
ON position, hold the direction and check OR repair open in brn
function enable switch to voltage at TB3. ground wire circuit to
Be sure all other either side and move the valve coil.
functions operate boom up/down toggle
normally. switch TS17 in the UP 0V
direction. Check voltage
on red/wht wire on boom
up/down proportional With the key switch 8 to 9V Repair open in red/wht-3
valve coil (item R). turned to platform wire from TP3 to TB3.
controls and both
position, press down the
foot switch and move
the boom controller in
the UP direction. Check
voltage at TP3.
0V
Press down the foot Repair open in power

switch and check 0V supply circuit from TP24
voltage at terminal "+" to boom controller OR
on boom controller. repair open in brn
ground wire circuit from
boom controller to
12V or more ground.
Re-adjust controller (see

Repair Section) OR
12V or more replace controller OR
Service Department.

page.

CHART 14
With key switch turned Hold the function enable Repair open in red-4
Continued from the to ground controls and
previous page. switch to either side and 12V or wire circuit from TB1 to
both Emergency Stop 0V move the boom up/down more boom up/down
buttons pulled out to the toggle switch in the UP directional valve coil OR
ON position, hold the direction. Check voltage repair open in brn
function enable switch to at TB1. ground wire circuit to
either side and move the valve coil.
boom up/down toggle
switch TS17 in the UP 0V
on red-4 wire on boom
up/down directional With key switch turned Troubleshoot boom up/
valve coil (item B). to platform controls and down toggle switch OR
12V or
both Emergency Stop more repair open in red wire
buttons pulled out to the circuit from TS17 to TB1
ON position, press down OR consult Genie
the foot switch and Industries Service
move the boom Department.
controller in the UP
at TB1.
0V
12V or
Press down the foot more Repair open in red-3
switch and move the wire from TP1 to TB1.
boom controller in the
UP direction. Check
voltage TP1.
0V

12V or more switch and check 0V supply circuit from TP24
on the boom controller. repair open in brn
12V or more ground to boom
controller.
Repair Section) OR
replace controller OR
Service Department.

page.

CHART 14
Disconnect wires from 0 or

Continued from the boom up/down infinite
previous page. directional valve coil ohms Replace boom up/down
(item B) and test the directional valve coil.
resistance of the valve
coil. See Repair Section.
2.5 to 3.5 ohms

function
Hold function enable operates Replace the faulty
switch to either side and directional valve.
move the boom up/down
toggle switch in the UP
direction. Manually
override the directional
valve by pushing in on
the end of the valve
spool.
function inoperative
Install a 0 to 5000 PSI Check for mechanical

(345 bar) pressure 2900 restrictions keeping
gauge at the quick psi or boom from moving OR
disconnect coupling on more repair cylinder or
the boom function cylinder counterbalance
manifold and start the valve OR consult Genie
engine. Hold the Industries Service
function enable switch to Department.
either side and move the
boom up/down toggle
switch in the UP direction
and check the pressure.
less than 2900 psi

function
Exchange boom flow operates
regulator valve (item I) Replace the faulty flow
with boom extend/retract regulator valve.
flow regulator valve
(item H). Check boom
up function.
Repair cylinder or
cylinder counterbalance
valve OR boom function
manifold could have an
internal fault. Consult
Department.

Chart 15
Boom Down With key switch turned Hold the function enable Repair open in red/wht-4
Function both Emergency Stop move the boom up/down 6 to 7V boom up/down
0V
Inoperative buttons pulled out to the toggle switch in the proportional valve coil
ON position, hold the DOWN direction and OR repair open in brn
function enable switch to check voltage at TB3. ground wire circuit to
functions operate boom up/down toggle
switch TS17 in the
normally. 0V
DOWN direction. Check
voltage on red/wht wire
on boom up/down
proportional valve coil With key switch turned 6 to 7V Repair open in red/wht-3
(item R). to platform controls and wire from TP3 to TB3.
both Emergency Stop
ON position, press down
the foot switch and
move the boom
controller in DOWN
at TP3.
0V

ground to boom
12V or more controller.
Re-adjust boom
controller (see Repair
12V or more Section) OR replace
boom controller OR
Service Department.

page.

CHART 15
Continued from the With key switch turned Hold the function enable Repair open in red/blk-4
to ground controls and switch to either side and 12V or wire circuit from TB2 to
previous page. 0V
both Emergency Stop move the boom up/down more boom directional valve
buttons pulled out to the toggle switch in DOWN coil OR repair open in
ON position, hold the direction and check brn ground wire circuit to
function enable switch to voltage at TB2. valve coil.
boom up/down toggle
switch TS17 in the 0V
DOWN direction. Check
voltage on red/blk-4 wire
on boom directional With key switch turned Troubleshoot boom up/
valve coil (item B). to platform controls and 12V or down toggle switch OR
both Emergency Stop more repair open in red/blk
buttons pulled out to the wire circuit from TS17 to
ON position, press down TB2 OR consult Genie
move the boom Department.
controller in the DOWN
at TB2.
0V
12V or
Press down the foot more Repair open in red/blk-3
boom controller in the
DOWN direction and
check voltage at TP2.
0V

12V or more switch and check 0V supply circuit from TP24
ground to the boom
12V or more controller.
Re-adjust boom
controller (see Repair
Section) OR replace
boom controller OR
Service Department.

page.

CHART 15
0 or
Continued from the Disconnect both wires infinite
previous page. from boom down ohms Replace boom down
directional valve coil directional valve coil.
(item B) and test the
2.5 to 3.5 ohms

function
Hold the function enable operates Replace faulty
move the boom up/down
toggle switch in the
DOWN direction.
Manually override the
directional valve by
pushing in on the end of
the valve spool.

(345 bar) pressure restrictions keeping
gauge at the quick 2300 boom from moving OR
disconnect coupling on psi repair cylinder or
manifold and start the valve OR consult Genie
engine. Hold the Industries Service
boom up/down toggle
switch in the DOWN
direction and check the
pressure.
less than 2300 psi
Reset boom down relief

valve (item E) pressure
(see Repair Section) OR
replace boom down
relief valve OR repair
cylinder or cylinder
counterbalance valve
OR function manifold
could have an internal
fault. Consult Genie
Industries Service
Department.

Chart 16
Boom Extend With key switch turned Move the function Repair open in blk/red
to ground controls and enable switch to either wire circuit from TB9 to
Function both Emergency Stop side and hold the boom 9 to 10V boom extend/retract
0V
Inoperative buttons pulled out to the extend toggle switch in proportional valve coil
ON position, move the the EXTEND direction and (item P) OR repair open
function enable switch to check voltage at TB9. in brn ground wire circuit
Be sure all other either side and hold the to valve coil.
functions operate boom extend toggle
switch TS19 in the
normally. 0V
EXTEND direction and
check voltage on blk/red
wire on boom extend/
retract proportional With key switch turned 9 to 10V Repair open in blk/red
valve coil (item P). to platform controls and wire from TP9 to TB9.
both Emergency Stop
the foot switch and
move the boom extend/
retract controller BP2 in
the EXTEND direction and
check voltage at TP9.
0V
Press down the foot 0V Repair open in power

switch and check supply circuit from TP24
voltage at terminal "+" to BP1 to BP2 OR repair
on BP2. open in brn ground wire
circuit from ground to
BP2.
12V or more
12V or more Re-adjust controller (see

Repair Section) OR
replace BP2 OR consult
Department.

page.

CHART 16
Continued from the With key switch turned Hold the function enable Repair open in blk wire
to ground controls and switch to either side and 12V or circuit from TB7 to boom
previous page. more
both Emergency Stop 0V move the boom extend extend directional valve
buttons pulled out to the toggle switch TS19 in coil (item C) OR repair
ON position, hold the the EXTEND direction and open in brn ground wire
function enable switch to check voltage at TB7. circuit to valve coil.
boom extend/retract
toggle switch TS19 in
the EXTEND direction and 0V
check voltage on blk
wire on boom extend
directional valve coil With key switch turned Troubleshoot boom
(item C). to platform controls and extend/retract function
both Emergency Stop 12V or toggle switch TS19 OR
buttons pulled out to the more repair open in blk wire
ON position, press down circuit from TS19 to TB7
the foot switch and OR consult Genie
move boom extend/ Industries Service
retract proportional Department.
controller BP2 in the
EXTEND direction and
check voltage TB7.
0V
12V or
Press down the foot more Repair open in blk wire
switch and move BP2 in from TP7 to TB7.
the EXTEND direction and
check voltage TP7.
0V
12V or more Press down the foot 0V Repair open in power

BP2.
12V or more

Repair Section) OR
replace BP2 OR consult
Department.

page.

CHART 16
Disconnect wires to 0 or
Continued from the boom extend directional infinite
previous page. valve coil (item C) and ohms Replace boom extend
test the resistance of the directional valve coil
valve coil. See Repair (item C).
Section.
2.5 to 3.5 ohms

function
Hold function enable operates Replace defective
move the boom extend
toggle switch (TS19) in
the EXTEND direction.
the valve spool.

(345 bar) pressure restrictions keeping
gauge at the quick 2500 boom from extending
disconnect coupling on PSI OR repair cylinder or
manifold and start the valves OR consult
engine. Hold the Genie Industries Service
boom extend toggle
switch in the EXTEND
direction and check the
pressure.
less than 2500 PSI

function
Exchange flow regulator operates Replace faulty flow
valve (item H) with regulator valve.
boom up/down flow
regulator valve (item I).
Check boom extend
function.
Repair cylinder or
valve OR function
Department.

Chart 17
Boom Retract With key switch turned Hold the function enable Repair open in blk/red-4
Function both Emergency Stop 0V move the boom extend/ 9 to 10V boom extend/retract
Inoperative buttons pulled out to the retract toggle switch in proportional valve coil
ON position, hold the the EXTEND direction. OR repair open in brn
function enable switch to Check voltage at TB9. ground wire circuit to
functions operate boom extend/retract
normally. toggle switch TS19 in 0V
the RETRACT direction.
Check voltage on blk/
red-4 wire on boom With key switch turned 9 to 10V Repair open in blk/red-3
extend/retract to platform controls and wire from TP9 to TB9.
proportional valve coil both Emergency Stop
(item P). buttons pulled out to the
the foot switch and
retract proportional
RETRACT direction.
Check voltage at TP9.
0V
Press down the foot 0V Repair open in power

BP2.
12V or more
12V or more Re-adjust controller (see

Repair Section) OR
replace controller BP2
OR consult Genie
Industries Service
Department.

page.

CHART 17
0 or
Continued from the Disconnect wires to infinite
previous page. boom extend directional ohms Replace boom extend
valve coil (item C) and directional valve coil.
test the resistance of the
valve coil. See Repair
Section.
2.5 to 3.5 ohms

function
Hold the function enable operates Replace faulty
retract toggle switch in
the EXTEND direction.
the valve spool.

(345 bar) pressure 2900 restrictions keeping
gauge at the quick PSI or boom from retracting
disconnect coupling on more OR repair cylinder or
manifold and start the valves OR consult
engine. Hold the Genie Industries Service
boom extend/retract
toggle switch in the
RETRACT direction and
check the pressure.
less than 2900 PSI

function
Exchange extend/retract operates Replace faulty flow
flow regulator valve regulator valve.
(item H) with boom up/
down flow regulator
valve (item I). Check
boom retract function.
Repair cylinder or
valve OR function
Department.

Chart 18
Turntable With key switch turned Hold the function enable Repair open in wht/red-4
Rotate Left both Emergency Stop 0V move the turntable 4 to 6V turntable rotate
Function buttons pulled out to the rotate toggle switch in proportional valve coil
ON position, hold the the LEFT direction and OR repair open in brn
Inoperative function enable switch to check voltage at TB6. ground wire circuit to
turntable rotate toggle
Be sure all other switch TS18 in the LEFT
functions operate direction. Check voltage
normally. on wht/red-4 wire on
turntable rotate
proportional valve coil 0V
(item U).
With key switch turned 4 to 6V Repair open in wht/red

to platform controls and wire from TP6 to TB6.
both Emergency Stop
the foot switch and
move turntable rotate
LEFT direction and check
voltage at TP6.
0V

voltage at terminal "+" to the controller OR
on controller. repair open in brn
12V or more ground wire circuit from
ground to controller.
12V or more

Repair Section) OR
Service Department.

page.

CHART 18
Continued from the With key switch turned Hold the function enable Repair open in wht/blk-4
previous page. 0V more
both Emergency Stop move the turntable turntable rotate left
buttons pulled out to the rotate toggle switch in directional valve coil
ON position, hold the the LEFT direction. (item A) OR repair open
function enable switch to Check voltage at TB5. in brn ground wire circuit
either side and move the to valve coil.
switch TS18 in the LEFT
direction. Check voltage 0V
on wht/blk-4 wire on
turntable rotate
directional valve coil With key switch turned Troubleshoot turntable
(item A). to platform controls and 12V or rotate toggle switch OR
both Emergency Stop more repair open in wht/blk
buttons pulled out to the wire circuit from TS18 to
ON position, press down TB5 OR consult Genie
move the turntable Department.
rotate controller in the
LEFT direction. Check
voltage at TB5.
0V
12V or
Press down the foot more Repair open in wht/blk-3
turntable rotate
controller in the LEFT
at TP5.
0V
12V or more
voltage at terminal "+" to controller OR repair
on controller. open in brn ground wire
controller.
12V or more

Repair Section) OR
Service Department.

page.

CHART 18
0 or
Disconnect wires to infinite
Continued from the turntable rotate left
previous page. ohms Replace turntable rotate
directional valve coil left directional valve coil.
(item A) and test the
2.5 to 3.5 ohms

function
Hold function enable operates
switch to either side and Replace faulty
move the turntable directional valve.
rotate toggle switch
TS18 in the LEFT
direction. Manually
override the directional
valve by pushing in on
the end of the valve
spool.
function
Install a 0 to 5000 PSI Exchange boom rotate operates Replace faulty flow
(345 bar) pressure flow regulator valve regulator valve.
gauge at the quick 2900 (item J) with boom up/
disconnect coupling on psi down flow regulator
the boom function valve (item I). Check
manifold and start the turntable rotate left
engine. Hold the function.
function enable switch to
either side and move the function inoperative
switch in the LEFT
direction and check the Repair turntable rotation
pressure. motor OR function
manifold may have an
Department.
less than 2900 psi

page.

CHART 18
Plumb a 0 to 5000 psi lessthan Function manifold could

Continued from the (0 to 345 bar) pressure 250 psi have an internal fault.
previous page. gauge into the hose Consult Genie Industries
from the function Service Department.
manifold to the turntable
rotation brake. Hold the
switch TS18 in the LEFT
direction. Check the
pressure.
250 psi or more

function
Exchange turntable operates
rotate left and right Replace faulty
counterbalance valves counterbalance valve.
(items LL and KK).
Activate turntable rotate
left function.
Check for mechanical

restrictions keeping
turntable rotate left from
operating OR replace
shuttle valve (item JJ)
OR consult Genie
Industries Service
Department.

Chart 19
Turntable With key switch turned Hold the function enable Repair open in wht/red-4
Rotate Right both Emergency Stop 0V move the turntable 4 to 6V turntable rotate
Function buttons pulled out to the rotate toggle switch in proportional valve coil
ON position, hold the the RIGHT direction. OR repair open in brn
Inoperative function enable switch to Check voltage at TB6. ground wire circuit to
Be sure all other switch TS18 in the RIGHT
functions operate direction. Check voltage
normally. on wht/red wire on
turntable rotate
proportional valve coil 0V
(item U).
With key switch turned 4 to 6V Repair open in wht/red-3

to platform controls and wire from TP6 to TB6.
both Emergency Stop
the foot switch and
move turntable rotate
controller in the RIGHT
at TP6.
0V

12V or more on controller. open in brn ground wire
controller.
12V or more

Repair Section) OR
Service Department.

page.

CHART 19
Continued from the With key switch turned Hold the function enable Repair open in wht-4
previous page.
both Emergency Stop 0V move the turntable more turntable rotate right
buttons pulled out to the rotate left/right toggle directional valve coil OR
ON position, hold the switch in the RIGHT repair open in brn
function enable switch to direction. Check voltage ground wire circuit to
either side and move the at TB4. valve coil.
switch TS18 in the RIGHT
direction. Check voltage 0V
on wht-4 wire on
turntable rotate right
directional valve coil With key switch turned Troubleshoot turntable
(item A). to platform controls and 12V or rotate controller OR
both Emergency Stop more repair open in wht-3 wire
buttons pulled out to the circuit from boom
ON position, press down controller to TB4 OR
the foot switch and consult Genie Industries
move the turntable Service Department.
rotate controller BP1 in
the RIGHT direction.
Check voltage at TB4.
0V
12V or
Press down the foot more Repair open in wht-3
turntable rotate
controller in the RIGHT
at TP4.
0V
12V or more
on controller. open in brn ground wire
controller.
12V or more

Repair Section) OR
Service Department.

page.

CHART 19
Disconnect wires on 0 or Replace turntable rotate

Continued from the infinite
turntable rotate right right directional valve
previous page. ohms
directional valve coil coil.
(item A) and test the
2.5 to 3.5 ohms

function
Hold function enable operates Replace faulty
move the turntable
rotate toggle switch in
the RIGHT direction.
the valve spool.
Install a 0 to 5000 PSI Exchange flow regulator function

(345 bar) pressure 2900 valve (item J) with boom operates Replace faulty flow
gauge at the quick psi up/down flow regulator regulator valve.
disconnect coupling on valve (item I). Check
the boom function turntable rotate right
manifold and start the function.
engine. Hold the
either side and move the function inoperative
switch in the RIGHT Repair turntable rotation
direction and check the motor OR function
pressure. manifold may have an
Department.
less than 2900 psi

page.

CHART 19
Plumb a 0 to 5000 psi lessthan Function manifold could

Continued from the (345 bar) pressure 250 psi have an internal fault.
previous page. gauge into the hose Consult Genie Industries
from the function Service Department.
manifold to the turntable
rotation brake. Hold the
switch in the RIGHT
direction .
250 psi or more

function
Exchange turntable operates Replace faulty
rotate right and left counterbalance valve.
counterbalance valves
(items KK and LL).
Activate turntable rotate
right function.

restrictions keeping
turntable rotate right
function from operating
OR replace shuttle valve
(item JJ) OR consult
Department.

Chart 20
All Platform Remove both hydraulic yes Replace the platform
hoses from the manifold level counterbalance
Leveling (ports PL1 & PL2). Plug valves (items GG & HH).
Functions the hoses and cap the
manifold fittings.
Inoperative Activate the boom up
function. Check to see if
platform levels.
Be sure all other
functions operate no
normally.
Plumb a 0 to 5000 psi 2900 Check for mechanical
(345 bar) pressure psi restrictions OR replace
gauge into master the slave cylinder
cylinder rod-end counterbalance valves.
hydraulic hose (hose
connected to port PL2)
using a tee fitting.
Activate boom up
function and check the
pressure.
less than 2900 psi

less than
Install a 0 to 5000 psi 2900 psi Repair or replace the
(345 bar) pressure master cylinder.
gauge into the barrel-
end hydraulic hose from
the master cylinder and
raise the boom one inch
(2.5 cm) at a time.
Continually monitor the
pressure gauge during
boom up. Do not allow
the pressure to exceed
2900 PSI.
2900 psi or more
Repair or replace the

slave cylinder.

Chart 21
Platform Level With key switch turned With key switch turned Repair open in org-4
to ground controls and to ground controls and wire from TB14 to
Up Function both Emergency Stop both Emergency Stop
12V or
platform level up
more
Inoperative buttons pulled out to the buttons pulled out to the directional valve coil OR
ON position, hold the ON position, hold the repair open in brn
0V
function enable switch to function enable switch to ground wire circuit to
Be sure all other either side and move the either side and move the valve coil.
functions operate platform level toggle platform level toggle
normally. switch TS16 in the UP switch in the UP
direction. Check voltage direction. Check voltage
at org-4 wire on platform at TB14.
level up directional valve
(item V).
0V
With key switch turned Troubleshoot platform

to platform controls and level toggle switches
both Emergency Stop TS16 and TS7 OR
buttons pulled out to the repair open in red power
ON position, press down wire circuit to TS16 and
0V
the foot switch and TS7 OR repair open in
move the platform level org-4 wire circuit from
toggle switch TS7 in the TS16 and TS7 to TB14
UP direction. Check OR consult Genie
voltage at TB14. Industries Service
Department.
12V or more
Troubleshoot platform
level toggle switch TS7
OR repair open in red
power wire circuit to
TS16 OR repair open in
12V or more org-4 wire circuit from
TS16 to TB14 OR
Service Department.

page.

CHART 21
0 or
Continued from the Disconnect the wires infinite Replace the platform
previous page. from platform level up ohms level up directional valve
directional valve coil coil.
(item V) and test the
coil.
6 to 7 ohms
function
Exchange platform level operates Replace the faulty
directional valves (items directional valve.
V and X) and activate
the platform level up
function.
function
Exchange platform level operates Replace the faulty
(items GG and HH) and
activate the platform
level up function.
Install a 0 to 5000 Check for mechanical

(345 bar) pressure 2900 psi restrictions keeping
gauge at the quick or more platform level up
disconnect coupling on function from operating
the function manifold OR replace slave
and activate the platform cylinder OR replace
level up function. slave cylinder
OR consult Genie
Industries Service
less than 2900 psi Department.
Exchange platform level function Replace faulty flow

flow regulator valve operates
(item W) with the jib regulator valve.
boom flow regulator
valve (item FF) and
level up function.
Test master cylinder

(see Chart 20) OR
repair or replace slave
cylinder or slave
valves OR function
Department.

Chart 22
Platform Level With key switch turned With key switch turned Repair open in org/blk-4
Down Function both Emergency Stop both Emergency Stop
12V or
platform level down
more
function enable switch to 0V function enable switch to ground wire circuit to
functions operate platform level toggle platform level toggle
normally. switch TS16 in the switch in the DOWN
DOWN direction. Check direction. Check voltage
voltage at org/blk-4 wire at TB15.
on platform level down
directional valve
(item X). 0V

to platform controls and level toggle switches
0V
move the platform level org/blk wire circuit from
toggle switch TS7 in the TS16 and TS7 to TB15
DOWN direction. Check OR consult Genie
Department.
12V or more
level toggle switch TS16
OR repair open in red
power wire circuit to
12V or more org/blk wire circuit from
TS16 to TB15 OR
Service Department.

page.

CHART 22
Disconnect the wires 0 or

Continued from the infinite
from the platform level
previous page. down directional valve ohms Replace the platform
coil (item X) and test the level down directional
resistance of the valve valve coil.
coil.
6 to 7 ohms
Exchange platform level function

down and up directional operates Replace the faulty
valves (items X and V) directional valve.
and activate the platform
level down function.

down and up operates Replace the faulty
(items GG and HH) and
level down function.

gauge at the quick or more platform level down from
disconnect coupling on operating OR replace
the function manifold slave cylinder OR
and activate the platform replace slave cylinder
level down function. counterbalance valves
OR consult Genie
Industries Service
Department.
less than 2900 psi

flow regulator valve operates Replace faulty flow
(item W) with jib boom regulator valve.
flow regulator valve
(item FF) and activate
the platform level down
function.
Test master cylinder

(see Chart 20) OR
repair or replace slave
cylinder or slave
valves OR function
Department.

Chart 23
Platform Rotate With key switch turned With key switch turned Repair open in grn-4
Left Function both Emergency Stop both Emergency Stop
12V or
platform rotate left
more
Inoperative buttons pulled out to the buttons pulled out to the directional valve coil
ON position, hold the ON position, hold the (item dd) OR repair
function enable switch to 0V function enable switch to open in brn ground wire
Be sure all other either side and move the either side and move the circuit to valve coil.
functions operate platform rotate toggle platform rotate toggle
normally. switch TS14 in the LEFT switch in the LEFT
at grn wire on platform at TB17.
rotate left directional
valve (item DD).
0V

to platform controls and rotate toggle switches
0V
move the platform rotate grn wire circuit from
toggle switch in the LEFT TS14 and TS5 to TB17
direction. Check voltage OR consult Genie
at TB17. Industries Service
Department.
12V or more
red power wire circuit to
12V or more grn wire circuit from
TS14 to TB17 OR
Service Department.

page.

CHART 23
0 or
previous page. from the platform rotate ohms rotate left directional
left directional valve coil valve coil (item DD).
(item DD) and test the
coil.
6 to 7 ohms
Exchange platform function

rotate left and right operates Replace the faulty
directional valves (items directional valve.
DD and EE) and
rotate left function.

rotate left and right operates Replace the faulty
at the counterbalance
valve manifold and

gauge at the quick or more platform rotate left
the function manifold OR repair or replace
and activate the platform platform rotator OR
rotate left function. replace platform rotator
manifold OR consult

rotate flow regulator operates Replace faulty flow
valve (item FF) with the regulator valve.
platform leveling flow
regulator valve (item W)

Service Department.

Chart 24
Platform Rotate With key switch turned With key switch turned Repair open in grn/blk-4
Right Function both Emergency Stop both Emergency Stop
12V or
platform rotate right
more
function enable switch to 0V function enable switch to ground wire circuit to
functions operate platform rotate toggle platform rotate toggle
normally. switch TS14 in the RIGHT switch in the RIGHT
at grn/blk-4 wire on at TB18.
platform rotate right
directional valve
(item EE). 0V

to platform controls and rotate toggle switches
0V
move the platform rotate grn/blk wire circuit from
toggle switch in the TS14 and TS5 to TB18
RIGHT direction. Check OR consult Genie
Department.
12V or more
red power wire circuit to
12V or more grn/blk wire circuit from
TS14 to TB18 OR
Service Department.

page.

CHART 24
0 or
previous page. from the platform rotate ohms rotate right directional
right directional valve valve coil (item EE).
coil (item EE) and test
the resistance of the
valve coil.
6 to 7 ohms
function
Exchange platform operates Replace the faulty
rotate right and left directional valve.
directional valves (items
EE and DD) and
rotate right function.
function
Exchange platform operates Replace the faulty
rotate right and left counterbalance valve.
at the counterbalance
valve manifold and

gauge at the quick or more platform rotate right
the function manifold OR repair or replace
and activate the platform platform rotator OR
rotate right function. replace platform rotator
manifold OR consult
function
Exchange platform operates Replace faulty flow
rotate flow regulator regulator valve.
valve (item FF) with
platform level flow
regulator valve (item W)

Service Department.

Chart 25
Jib Boom Up With the key switch Hold the function enable Repair open in grn-4
turned to ground switch to either side and wire from TB17 to jib
Function controls and both move the jib boom 12V boom up directional
0V
Inoperative, Emergency Stop buttons toggle switch in the UP valve OR repair open in
pulled out to the ON direction and check brn ground wire circuit to
S-85 Models position, hold the voltage at TB17. directional valve.
Be sure all other jib boom toggle switch 0V
functions operate TS15 in the UP direction.
normally. Check voltage at the grn
wire on the jib boom up Repair open in red
directional valve power wire circuit from
(item DD). key switch to TS15 OR
replace TS15.
12V
With the key switch Press down the foot 12V Repair open in grn-3
turned to platform 0V switch and move the jib wire from TP17 to TB17.
controls and both boom toggle switch in
Emergency Stop buttons the UP direction. Check
pulled out to the ON voltage at TP17.
the jib boom toggle 0V
switch TS6 in the UP
at TB17. With the key switch 12V Repair open in grn wire
turned to platform from TS6 to TP17 OR
controls and both replace TS6.
foot switch and check
voltage on the center
terminal of the jib boom
toggle switch.
0V
12V Check voltage at 0V Repair open in red wire

terminal #30 on CR13. from boom controller to
CR13 OR repair open in
brn ground wire circuit to
CR13.
12V
0V
Check the voltage at Replace CR13.
terminal #87a on CR13.
12V
Continued on the next Repair open in red wire

page. from terminal #87a on
CR13 to TS6 OR
Service Department.

CHART 25
Press down the foot 12V

Continued from the switch and move the jib Replace CR13.
previous page. boom toggle switch in
the UP direction. Check
voltage on the red and
black wires at the jib/
boom platform rotate
directional valves (items
DD).
0V
Install a 0 to 5000 psi Exchange jib boom/ function

(345 bar) pressure platform rotate
gauge at the quick 2900 psi directional valves (items operates Replace faulty valve.
disconnect coupling on DD and EE). Press
the function manifold down the foot switch and
and activate the jib activate the jib boom up
boom up function. function.

restrictions keeping jib
boom up function from
operating OR repair or
replace jib boom
cylinder OR replace
less than 2900 psi counterbalance valve
OR 0.030" orifice
may be plugged OR jib
boom/platform rotate
select manifold has an
internal fault OR consult
Department.
function
Exchange jib boom operates Replace faulty
and activate jib boom up
function.

Service Department.

Chart 26
Jib Boom With the key switch Hold the function enable Repair open in grn/blk-4
turned to ground switch to either side and wire from TB18 to jib
Down Function controls and both 0V move the jib boom 12V boom down directional
Inoperative, Emergency Stop buttons toggle switch in the valve OR repair open in
pulled out to the ON DOWN direction. Check brn ground wire circuit to
S-85 Models position, hold the voltage at TB18. directional valve.
Be sure all other jib boom toggle switch 0V
functions operate TS15 in the DOWN
normally. direction. Check voltage
at the grn/blk-4 wire on Repair open in red
the jib boom down power wire circuit from
directional valve key switch to TS14 to
(item EE). TS15 OR replace TS15.
12V
With the key switch Press down the foot 12V Repair open in grn/blk-3
turned to platform 0V switch and move the jib wire from TP18 to TB18.
controls and both boom toggle switch in
Emergency Stop buttons the DOWN direction.
pulled out to the ON Check voltage at TP18.
the jib boom toggle 0V
switch TS6 in the DOWN
at TB18. With the key switch 12V Repair open in grn/blk
turned to platform wire from TS6 to TP18
controls and both OR replace TS6.
foot switch and check
voltage on the center
terminal of the jib boom
toggle switch.
0V
12V Check the voltage at 0V Repair open in red wire

terminal #30 on CR13. from boom controller to
CR13 OR repair open in
brn ground wire circuit to
CR13.
12V
0V
Check the voltage at Replace CR13.
terminal #87a on CR13.
12V
Repair open in red wire

Continued on the next from terminal #87a on
page. CR13 to TS8 OR
Service Department.

CHART 26
Press down the foot 12V Replace CR13.

Continued from the switch and move the jib
previous page. boom toggle switch TS6
in the DOWN direction.
Check voltage on the
red and black wires at
the jib/platform rotate
select valves
(items AP).
0V
function
Install a 0 to 5000 psi Exchange jib boom/ operates Replace faulty valve.
(345 bar) pressure platform rotate
gauge at the quick directional valves (items
disconnect coupling on 2900 psi AP). Press down the
the function manifold foot switch and activate
and activate the jib the jib boom down
boom down function. function.

restrictions keeping jib
boom down function
from operating OR
repair or replace jib
boom cylinder OR
replace counterbalance
less than 2900 psi valve OR 0.035" orifice
may be plugged OR jib
boom/platform rotate
select manifold has an
internal fault OR consult
Department.
function
Exchange jib boom operates Replace faulty
and activate jib boom
down function.

Service Department.

Chart 27
Drive Chassis no
With the boom in the 12V or Check continuity from continuity Repair open in brn
stowed position and brn ground wire on coil ground wire circuit to
Jack Function both axles fully
more
to ground. axle dump valve coil .
Inoperative extended, start the
engine and check the
voltage at the axle dump continuity
Be sure all other valve (item SS) on the 0 or
functions operate axle dump manifold. Disconnect wires to infinite
normally. valve coil and test the ohms Replace the axle dump
resistance of the valve valve coil.
coil.
Be sure machine is in
the stowed position. 6 to 7 ohms
This procedure is
written for the (345 bar) pressure restrictions keeping non-
non-steer end lift jack. gauge onto the test port steer end lift jack from
If the steer end lift on the function manifold. 2900 psi operating OR replace
Start the engine and counterbalance valve
jack is inoperative, operate the non-steer (item OO) in chassis
repeat the procedure end chassis lift jack and jack manifold OR
and substitute steer check the pressure. consult Genie Industries
Service Department.
for non-steer. less than
2900 psi
Replace counterbalance
valve (item OO) in
chassis jack manifold
OR replace axle dump
solenoid valve (item SS)
0V OR repair or replace
non-steer end lift jack
OR chassis jack
manifold or control valve
may have an internal
defect. Consult Genie
Industries Service
Department.

page.

CHART 27
12V or
Start the engine and more Repair open in red wire
Continued from the check the voltage at from TB46 to LS1
previous page. TB46. through blk wire to
TB42, through blk wire
to LS2, through red wire
to axle dump valve
(item SS) OR replace
less than LS1 or LS2.
12V
Start the engine and 12V or Repair open in wht wire

check the voltage at the more from alternator to TB21
wht wire on the to TB46 OR replace
alternator. diodes at TB46.
less than
12V
Repair or replace
alternator.

Chart 28
Axle Extend/ Start the engine and While holding the lift Check for mechanical
raise the non-steer end jack control handle in restrictions keeping axle
Retract of the machine with the no the DOWN direction, yes extend function from
non-steer end lift jack. activate and hold the operating OR replace
Function While holding the lift axle RETRACT control counterbalance valve
jack control handle in handle. Does the axle (item OO) OR repair or
Inoperative the DOWN direction, retract? replace axle extension
activate and hold the cylinder OR control
Be sure all other axle EXTEND control valve may have an
functions operate handle. Does the axle internal defect.
extend?
normally. no
Be sure machine is yes

in the stowed
postion. While holding the lift Install a 0 to 5000 Check for mechanical
jack control handle in no (345 bar) pressure restrictions keeping axle
the DOWN direction, gauge onto the test port from extending or
Be sure that the activate and hold the on the function manifold. retracting OR replace
chassis lift jacks axle RETRACT control Start the engine and 2900 psi counterbalance valve
operate properly. handle. Does the axle while holding the lift jack (item OO) OR repair or
retract? control handle in the replace axle extension
DOWN direction, activate cylinder OR control
This procedure is and hold the axle valve may have an
written for the yes EXTEND control handle internal defect.
non-steer end axle. and check the pressure.
Axle extend/retract
If the steer end axle function is operating less than
is inoperative, correctly. 2900 psi
repeat the procedure
Test the function pump. bad Repair or replace
and substitute steer See Repair Section. function pump.
for non-steer.
good
Replace counterbalance
valve (item OO) in
chassis jack manifold
OR replace flow
regulator (item UU) in
axle dump manifold OR
repair or replace non-
steer axle cylinder OR
chassis jack manifold or
control valve may have
an internal defect.
Service Department.

Chart 29
Steer Left With key switch turned With key switch turned 12V or Repair open in blu wire
to platform controls and to platform controls and circuit from drive
Function both Emergency Stop both Emergency Stop
more
controller terminal 7 to
Inoperative buttons pulled out to the buttons pulled out to the TP36 then blu-1 wire
ON position, press down 0V ON position, press down circuit to TB36.
the foot switch and hold the foot switch and hold
Be sure all other the steer rocker switch the steer rocker switch
functions operate on drive controller in the on drive controller in the
LEFT direction. Check LEFT direction. Check
normally.
voltage on TB36. voltage at the controller
terminal 7.
0V
Repair or replace steer

microswitch on drive
12V or more controller. Consult
Department.
With key switch turned Repair open in blu #36

to platform controls and wire circuit from TB36 to
both Emergency Stop steer left directional
buttons pulled out to the 0V valve coil on steer
ON position, press down manifold OR repair
the foot switch and hold open in brn ground wire
the steer rocker switch circuit to steer left
on drive controller in the directional valve coil.
LEFT direction. Check
voltage on blu #36 wire
on steer left directional
valve coil (item VV) on
steer manifold.
12V or more
Disconnect wires to 0 or Replace steer left

steer left directional infinite directional valve coil OR
valve coil on steer ohms repair open in brn
manifold and test the ground wire circuit to
resistance of the valve steer left valve coil.
coil.
5 to 6 ohms

page.

CHART 29

Continued from the (345 bar) pressure restrictions keeping
previous page. 2900
gauge at the quick psi steer left function from
disconnect coupling on operating OR repair or
the boom function replace steer cylinder
manifold and activate OR replace flow
the steer left function. regulator valve
(item YY) OR consult
Department.
less than 2900 psi

cylinder OR steer
internal defect. Consult
Department.

Chart 30
Steer Right With key switch turned With key switch turned 12V or Repair open in blu/blk
to platform controls and to platform controls and more wire circuit from drive
Function both Emergency Stop both Emergency Stop controller to TP37 then
Inoperative buttons pulled out to the buttons pulled out to the blu/blk-1 to TB37.
ON position, press down 0V ON position, press down
the foot switch and hold the foot switch and hold
Be sure all other the steer rocker switch the steer rocker switch
functions operate on drive controller in the on drive controller in the
RIGHT direction. Check RIGHT direction. Check
normally.
voltage on TB37. voltage at the controller
terminal 8.
0V

microswitch on drive
12V or more controller. Consult
Department.
With key switch turned Repair open in blu/blk

to platform controls and #37 wire circuit that runs
both Emergency Stop from TB37 to steer right
buttons pulled out to the 0V directional valve coil on
ON position, press down steer manifold OR
the foot switch and hold repair open in brn
the steer rocker switch ground wire circuit to
on drive controller in the steer right valve coil.
RIGHT direction. Check
voltage on blu/blk #37
wire on steer right
directional valve coil
(item VV) on steer
manifold.
12V or more
Disconnect wires to 0 or Replace steer right

steer right directional infinite directional valve coil OR
valve coil on steer ohms repair open in brn
manifold and test the ground wire circuit to
resistance of the valve steer right valve coil.
coil.
5 to 6 ohms

page.

CHART 30

Continued from the (345 bar) pressure restrictions keeping
previous page. 2900
gauge at the quick psi steer right function from
disconnect coupling on operating OR repair or
the boom function replace steer cylinder
manifold and activate OR replace flow
the steer right function. regulator valve
(item YY) OR consult
Department.
less than 2900 psi

cylinder OR steer
Department.

Chart 31
All Drive less
With key switch turned than Check continuity of brn Repair open in power
to platform controls and ground wire from continuity supply circuit from TP24
Functions both Emergency Stop
12V
terminal #3 on drive to terminal #2 on drive
Inoperative, buttons pulled out to the controller to ground. controller.
All Other the foot switch and no continuity
check voltage at
Functions terminal #2 on drive
controller. Repair open in brn
Operate ground wire circuit from
ground to drive
Normally controller.
12V or more
Be sure the rpm
toggle switch is in
less
the foot switch With key switch turned than Check continuity of brn Repair open in power
activated high idle to platform controls and 12V ground wire from continuity supply circuit from TP24
both Emergency Stop terminal #2 on the to terminal #1 on the
position. buttons pulled out to the horsepower limiter horsepower limiter
ON position, press down board to ground. board.
Be sure the the foot switch and
hyydraulic tank shut check voltage at
no continuity
terminal #1 on the
off valves are in the horsepower limiter
OPEN position. board. Repair open in brn
Be sure machine is ground to terminal #2 on
not in the free wheel the horsepower limiter
board.
configuration. 12V or more
Press down the foot Press down the foot Adjust the "A" trimpot.
switch and check the 0V switch and check 7 to 8V See repair procedure
voltage at terminal #10 voltage at terminal #3 on 1-2, How to Adjust the
on the horsepower the horsepower limiter Horspower Limiter
limiter board. board. Board OR replace
horsepower limiter
board.
0V
Press down the foot Repair open in org/blk

switch and check 7 to 8V #41 wire from alternator
voltage on the org/blk to TB41 and org/blk-1
9 to 12V #41wire on the alterator. wire from TP41 to
terminal #3 on
horsepower limiter
0V board.
Repair or replace
alternator.

page.

CHART 31
Press down the foot Repair open in wire from

Continued from the switch and hold the terminal #10 on
previous page. 0V
drive controller in the full horsepower limiter
forward position. Check board to terminal #6 on
voltage at terminal #6 on the drive controller.
the drive controller.
9 to 12V
no
Connect the positive 0V Check continuity from continuity Repair open in brn
lead from a voltmeter to terminal #3 on drive ground wire circuit from
terminal #4 on the drive controller to ground. terminal #3 on drive
controller and the controller to ground.
negative lead to terminal
#5 on the drive continuity
controller. Press down
the foot switch and hold Replace drive controller
the drive controller in the OR consult Genie
full FORWARD position. Industries Service
Check voltage across Department.
the #4 and #5 terminals
on the drive controller.
2V
no
Connect the positive 0V Check continuity from continuity Repair open in brn
lead from a voltmeter to terminal #3 on drive ground wire circuit from
terminal #5 on the drive controller to ground. terminal #3 on drive
controller and the controller to ground.
negative lead to terminal
#4 on the drive continuity
controller. Press down
the foot switch and hold Replace drive controller
the drive controller in the OR consult Genie
full REVERSE position. Industries Service
Check voltage across Department.
the terminals #5 and #4
on the drive controller.
2V

page.

CHART 31
Press down the foot Press down the foot Repair open in wht wire
Continued from the switch and hold the switch and hold the from terminal #4 on
previous page. drive controller in the full drive controller in the full drive controller to TS8 to
FORWARD position and 0V FORWARD position. Hold 2V TP30 to TB30 through
check voltage across the drive enable toggle drive enable limit switch
the wht #12 wire and the switch TS9 to either side (LS3) to TB12 to wht
wht/blk #31 wire on and check the voltage #12 wire on EDC quick
EDC. across the wht #12 wire disconnect plug.
and the wht/blk #31 on
EDC.
0V
Connect the positive 2V Repair open in blu/wht

lead from a voltmeter to wire from TS9 to TP12
terminal #5 on the drive to TB12.
controller and the
negative lead from the
voltmeter to the
blu/wht wire on TS9.
Press down the foot
switch and move the
drive controller in the full
FORWARD position. Hold
the drive enable toggle
switch to either side.
and check voltage.
0V
2V
Connect the positive Repair open in wire from
lead from a voltmeter to terminal #4 from drive
terminal #5 on the drive controller to drive enable
controller and the 0V toggle switch OR
negative lead of the replace drive controller
voltmeter on the center OR consult Genie
terminal of the drive Industries Service
enable toggle switch. Department.
Press down the foot
switch and move the
drive controller in the full
FORWARD position. Hold
the drive enable switch
to either side and check
voltage.
2V
Replace drive enable

toggle switch TS9.
Troubleshoot drive
forward and drive
reverse functions
separately OR replace
pump OR consult Genie
Industries Service
Department.

Chart 32
Drive Forward voltage
Disconnect the EDC readings
or Reverse wire connector from the different Repair or replace the
drive pump, start the drive controller.
Function engine, move the drive
controller to full
Inoperative FORWARD position and
note the voltage across
Be sure all other the wht #12 and the wht/
blk #31 wire terminals
functions operate on the EDC. Reverse
normally including the volt meter leads and
drive in opposite move the drive controller
to full REVERSE position
direction of and note the voltage.
manfunction.
voltage readings
the same
0 or
infinite
Check the resistance of ohms Replace the EDC.
the EDC.
20 to 24 ohms
no
improve
ment Faulty drive pump,
Adjust the drive pump contact authorized
null (neutral). repair facility.
symptoms improve
Re-adjust horsepower
limiter board OR consult
Department.

Chart 33
Traction Any type of traction
problem, consult Genie
Function Industries Service
Department.
Inoperative
Be sure that all other
functions operate
normally.

Chart 34
Machine Will With the boom in the Repair short to ground
stowed position, check continuity in wht wires to limit
Not Drive At continuity from TB40 to switches (LS1 and LS2)
Full Speed ground. OR repair or replace
boom lift limit switch or
boom extend limit
Be sure all other switch.
functions operate no continuity
normally.
Be sure the machine is With the boom in the Repair short to ground
not raised above or stowed position, check in orange wire from
extended beyond the terminal #6 on continuity TB40 to TP40 to
horsepower limiter terminal #6 on
drive limit switches. board for continuity to horsepower limiter
ground. board.
Be sure the drive limit
switches are clear of no continuity
any debris and are not
activated when the Re-adjust or replace
boom is in the stowed horsepower limiter
position. board OR check for
misalignment of limit
switches (LS1 and LS2)
Be suire that the boom OR consult Genie
extend limit switch arm Industries Service
is being held down when Department.
the boom is retracted.
Be sure the wiring to
limit switches is intact
and show no signs of
damage or corrosion.
Be sure the free-wheel

valve is closed on the
drive pump.
Be sure the drive speed

select switch in in the
high range position.

Chart 35
Machine Drives EXTEND the boom past Replace horsepower
limit switch (LS1) and limiter board OR re-
At Full Speed check continuity from continuity adjust horsepower
With Platform ground to terminal #6 on limiter board OR consult
the horsepower limiter Genie Industries Service
Raised or board. Department.
Extended no continuity
Be sure boom up drive
Check continuity from continuity Repair open in org wire
limit switch is being ground to TB40. circuit from TB40 to
activated by the cam on TP40 to terminal #6 on
the boom when the horsepower limiter
board.
boom is raised. no continuity
Be sure that the boom
extend drive limit switch
Test limit switches. See bad Replace faulty limit
is not being held down procedure A-14 in the switch contact OR
or being activated when Maintenance Section. replace limit switch.
the boom is extended.
good
Be sure the wiring to
limit switches is intact Repair open from wht
and show no signs of wires at TB40 to limit
damage or corrosion. switches (LS1 and LS2),
then from brn ground
wires to ground.

Chart 36
Drive Enable With key switch turned With key switch turned 0V Repair open in power
to platform controls and to platform controls and supply circuit from
System Is both Emergency Stop both Emergency Stop TP24.
Malfunctioning buttons pulled out to the buttons pulled out to the
ON position, and the ON position, press down
no
boom rotated between the foot switch and
Be sure the boom is in the non-steer tires, move the drive controller
the stowed position. press down the foot in FORWARD direction.
switch and move drive Check voltage at
controller in the terminal #2 on drive
FORWARD direction. controller.
Does machine drive?
12V or more
Repair open from

terminal #4 on drive
controller to center
terminal on TS9 OR
yes refer to Chart 28 OR
Service Department.
With key switch turned Hold the drive enable The machine is
to platform controls and toggle switch TS9 to operating properly. If
both Emergency Stop either side and press yes machine does not
buttons pulled out to the no down the foot switch. operate properly,
ON position, and the Move the drive controller consult Genie Industries
boom rotated between in the FORWARD Service Department.
the steer tires, press direction. Does the
down the foot switch and machine drive?
move the drive controller
in FORWARD direction. no
Does the machine
drive?
Repair open in blu/wht
wire from drive enable
toggle switch to TP12 to
TB12 OR replace drive
yes enable toggle switch
TS9.
Check for continuity continuity Activate drive enable Replace drive enable
from TB30 to TB12. limit switch LS3 continuity limit switch contact OR
manually and check replace drive enable
continuity from TB30 to limit switch LS3.
TB12.
no continuity no continuity
Please begin
troubleshooting from
beginning of chart OR
Repair open from TB30 Service Department.
through red-5 wire to
LS3 then from LS3
through blk-5 wire to
TB12.

Chart 37
Auxiliary Lift the red auxiliary Remove the hose from Reconnect pressure
pump switch cover, the pressure port on the hose and check battery
Functions motor
auxiliary pump. Install a
move the auxiliary operates 2500 psi condition. There may
Inoperative power toggle switch 0 to 5000 psi (345 bar) not be enough battery
TS10 to either side and pressure gauge into the capacity to operate both
listen for sound of pressure port of the auxiliary pump and
Be sure all other auxiliary pump motor auxiliary pump and directional valves.
functions operate operating. move the auxiliary
normally. power toggle switch to
either side and note the
pressure.
Be sure key switch
is in the appropriate less than
position and both 2500 psi
Emergency Stop Check for a positive Repair or replace pump
buttons are pulled connection between good OR replace relief valve.
out to the ON electric motor and the Consult Genie Industries
pump by removing the Service Department.
position. pump from the motor.
motor does Leave all the hoses
Be sure engine is not operate connected and visually
not running when check coupling
connection.
using auxiliary
power. bad
Note: Operating
Replace the auxiliary
auxiliary power with power unit.
the engine running
should immediately
stop the engine.
With key switch turned Check continuity from bad Replace negative cable
to ground controls and 12V negative terminal on from auxiliary pump
both Emergency Stop auxiliary pump motor to motor to ground.
buttons pulled out to the ground.
ON position, move the
auxiliary pump toggle
switch to either side and good
check the voltage on the
red cable on the Replace auxiliary pump
auxiliary power unit. motor.
0V

page.

CHART 37
bad
Continued from the Test PR1. See Repair Replace PR1.
previous page. Procedure 8-5.
good
Move the auxiliary pump 12V or Repair open from TB27

toggle switch to either more to PR1 OR repair open
side and check voltage in brn ground wire circuit
at TB27. to PR1 OR replace PR1.
0V
Move the auxiliary pump Repair open in red

toggle switch to either 0V power supply wire from
side and check the key switch to auxiliary
voltage at the center pump toggle switch.
terminal of TS10.
12V or more
Repair open in red #27

wire from TS10 to TB27
OR replace TS10.

Third Edition • First Printing Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey: Electrocution hazard. Contact with

electrically charged circuits may
Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
connections very slowly to allow
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules gradually. Do not allow oil to squirt
and operating instructions printed in the or spray.
appropriate Genie S-80 and Genie S-85 General Repair Process
Operator's Manual.
Be sure that all necessary tools and test
Malfunction Identify Troubleshoot
equipment are available and ready for use. discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved

Section 6 • Schematics Third Edition • First Printing
Electrical Components
Item Description Genie Part Manufacturer Manufacturer Qty

Part Number Part Number
B ..................... Battery, 1000 CCA, 12V DC .. 30143 ........... Trojan ................................... C31XH-2 ........................ 1
BP2 ................ Boom proportional controller (joystick),

Single axis ............................. 24495 ........... OEM Controls ...................... EMS4M6883 .................. 1
BP1 ................ Boom proportional controller (joystick),

Dual axis ................................ 40613 ........... OEM Controls ...................... EJS5M10089 ................. 1
CB1, CB2 ....... Circuit breaker ....................... 24018 ........... ETA ...................................... 45-700-IG1-P10 ............. 2
CR1 through CR8 and CR20

Relay, SPDT, 12V DC ........... 34052 ........... Potter-Brumfield .................. VF4-15F11-CO5 ............ 7
CR13, 14, 17, 18A ,18B and 19

Relay, SPDT, 12V DC ........... 19274 ........... Potter-Brumfield .................. VF4-45F11-CO5 ............ 5
Diode .............. Diode, 6 amp, 200 PIV .......... 45782 ........... Motorola ............................... MOTMR752 ................. 36
DP1 ................ Joystick controller-Drive ........ 20424 ........... OEM Controls ...................... MCH1159AD1386 .......... 1
FB .................. Flashing beacon .................... 20189 ........... ECCO Electronic Controls ... 6400A-GEN ................... 2
FS1 ................ Footswitch .............................. 13482 ........... Linemaster Switch Corp. ..... 632-S ............................. 1
G1 .................. Gauge - Voltage .................... 53761 ........... VDO ..................................... 33203000IC ................... 1
G2 .................. Gauge - Oil Pressure ............. 53758 ........... VDO ..................................... 350030021IC ................. 1
G3 .................. Gauge - Coolant Temp. ......... 53759 ........... VDO ..................................... 310030023C .................. 1
H1 .................. Alarm, Warble tone ................ 45383 ........... Floyd Bell Inc. ...................... MW209-530-Q ............... 1
H2 .................. Horn, 12V DC, 130 dB ........... 56264 ........... Wolo Ind. Horn and Signal .. 300ST-12GEN ............... 1
H3 .................. Alarm, intermittent ................. 18963 ........... Floyd Bell Inc. ...................... XB-09-630-Q .................. 1
H4 .................. Alarm, chime tone ................. 45462 ........... Floyd Bell Inc. ...................... CH-09-525-Q ................. 1
HM ................. Hourmeter .............................. 19506 ........... ENM Corporation ................. T40A4508 ...................... 1
KS1 ................ Contact - Keyswitch, N.O. ..... 45081 ........... Telemecanique .................... ZB2-BE101 .................... 2
L1 ................... LED - Red, 12V DC ............... 32335 ........... Arctolectric Corp. ................. LE177C39007 ................ 3
LS1, 2, 3 ........ Contact - Limit switch,

N.C.H.O. ................................ 19491 ........... Telemecanique .................... XESP2151 ..................... 3
Level sensor .. Level sensor, 4.5° .................. 44586 ........... Power Comp. of Midwest .... LS36-04.5L1.501 ........... 1
P1, P2 ............ Contact, N.C. ......................... 29732 ........... Telemecanique .................... ZB2-BE102 .................... 2

ELECTRICAL COMPONENTS
This list continues on the next page.

Item Description Genie Part Manufacturer Manufacturer Qty
Part Number Part Number
P3 ................... Contact, N.O. ......................... 45081 ........... Telemecanique .................... ZB2-BE101 .................... 1
PR1 ................ Relay, 12V DC continuous .... 27155 ........... Stancor ................................ 70-902 ............................ 1
R1 .................. Resistor,
100Ω 25 watt (4WD) .............. 27116 ........... Dale ..................................... RH25-100R-1% ............. 1
150Ω 25 watt (2WD) .............. 34798 ........... Dale ..................................... RH25-150R-1% ............. 1
R2 .................. Resistor, 14Ω 25 watt ............ 46678 ........... Dale ..................................... RH25-14R-1% ............... 1
R3 .................. Resistor, 10Ω 25 watt ............ 27287 ........... Dale ..................................... RH25-10R-1% ............... 1
TS1, TS10 ...... Toggle switch, DPST

2 position momentary ............ 13480 ........... Microswitch Control Inc. ...... 2NT1-8 ........................... 2
TS2, 6, 9, 11,
13, 15 ............. Toggle switch, SPDT
TS8, TS20 ...... Toggle switch, DPST

2 position maintained ............ 27378 ........... Microswitch Control Inc. ...... 2NT1-3 ........................... 2
TS4 ................ Toggle switch, DPDT

TS5,7,14,16,
17,18, 19 ........ Toggle switch, DPDT
TS3, TS12
(Gas/LPG) ...... Toggle switch, DPST
TS3, TS12
(Diesel) ........... Toggle switch, SPDT

Electrical Symbols Legend

Abbreviation Legend
LABEL DESCRIPTION
B .................. Battery
BP ............... Boom proportional controller (joystick)
C .................. Capacitor, delay
CB ............... Circuit breaker with amperage
CR ............... Control relay
CTS ............. Coolant temperature switch
DP ............... Drive proportional controller (joystick)
F .................. Fuse with amperage
FB ................ Flashing beacon(s)
FS ................ Foot switch
G ................. Gauge
H .................. Horn or Alarm
HM ............... Hour meter
KS ............... Key switch
L .................. LED
LS ................ Limit switch
OPS ............. Oil pressure switch
OTS ............. Oil temperature switch
P .................. Emergency stop button
PR ............... Power relay
R .................. Resistor with ohm value
TB ................ Terminal base location
TP ................ Terminal platform location
TS ................ Toggle switch

Ford LRG-425 EFI

Engine Wiring Harness
N M L K J I H G F E D C B A

Electrical Schematic-
Ford Models
A B C D E F G H I J K L M N

Ford Models

Ground Control Box Wiring Diagram-

Ford Models

Platform Control Box Wiring Diagram-

Ford Models

Deutz Models

Deutz Models


Deutz Models


Deutz Models

Perkins Models

Perkins Models


Perkins Models


Perkins Models

Hydraulic Symbols Legend

2WD Hydraulic Schematic

4WD Hydraulic Schematic

Third Edition • First Printing Section 7 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. Then to
Repair procedures shall be completed by a
re-assemble, perform the disassembly steps in
person trained and qualified on the repair of this
reverse order.
machine.
Immediately tag and remove from service a Symbols Legend
damaged or malfunctioning machine. Safety alert symbol—used to alert
Repair any machine damage or malfunction personnel to potential personal
before operating the machine. injury hazards. Obey all safety
Before Repairs Start: to avoid possible injury or death.
Read, understand and obey the safety rules Red—used to indicate the
and operating instructions in the Genie S-80 & presence of an imminently
Genie S-85 Operator’s Manual. hazardous situation which, if not
avoided, will result in death or
Be sure that all necessary tools and parts are serious injury.
available and ready for use.
Orange—used to indicate the
Read each procedure completely and adhere presence of a potentially
to the instructions. Attempting shortcuts may hazardous situation which, if not
produce hazardous conditions. avoided, could result in death or
Unless otherwise specified, perform each serious injury.
repair procedure with the machine in the Yellow with safety alert symbol—
following configuration: used to indicate the presence of a
· Machine parked on a flat, level surface potentially hazardous situation
· Boom in the stowed position which, if not avoided, may result in
minor or moderate injury.
· Turntable rotated with the boom between
the non-steering wheels Yellow without safety alert
symbol—used to indicate the
· Turntable secured with the turntable
rotation lock pin
· Key switch in the OFF position with the avoided, may result in property
key removed damage.
· Wheels chocked Green—used to indicate operation
or maintenance information.
Indicates that a specific result is expected after
performing a series of steps.

Section 7 • Repair Procedures Third Edition • First Printing
Platform Controls
1-1 Boom Up/Down Controller
Joystick Controllers Adjustments
Electrocution hazard. Contact
Maintaining joystick controllers at the proper
settings is essential to safe machine operation.
Every joystick controller should operate smoothly
injury. Remove all rings, watches
and provide proportional speed control over its
and other jewelry.
entire range of motion.
Do not adjust the controllers
Joystick controller voltage settings
unless the static battery voltage is
are approximate. Some machines
above 12V DC and the alternator
may require slightly different
is operating properly with
voltage settings to obtain the
13.6 to 14.5V DC output.
correct function time range.
Individual trim potentiometers
a b (trimpots) are used to adjust
various output signals from the
horsepower limiter board and
boom function controllers. The
trimpots will be identified as the
following:
• Max out trim potentiometer (max out trimpot)
• High range trim potentiometer (max out trimpot)
• Lo range trim potentiometer (lo range trimpot)
• Dual range trim potentiometer (lo range trimpot)
• Threshold trim potentiometer (threshold trimpot)
f e d c
• Ramp rate trim potentiometer (ramp rate trimpot)
Platform control box 1 Check the battery condition with a volt meter.
a horsepower limiter board The reading should be 12V DC or more to
b terminals
c drive controller
accurately adjust the controller.
d extend/retract controller
2 Turn the key switch to platform controls and
e boom controller
f turntable rotate controller pull out the Emergency Stop button to the
ON position at both the ground and platform
controls. Do not start the engine.

PLATFORM CONTROLS
3 Open the platform control box lid and locate 7 Set the lo range: Press down the foot switch,
the boom up/down controller. then move the controller all the way to the DOWN
position. Adjust the voltage to 8.3V DC. Turn
a b c d e f g h i j
the lo range trimpot adjustment screw
clockwise to increase the voltage or
counterclockwise to decrease
the voltage.
8 Start the engine and move the engine idle
control switch to foot switch activated high
idle (rabbit and foot switch symbol). Lower
the boom to the stowed position.
Engine should be at normal
a ramp rate trimpot 9 Set the threshold: Press down the foot switch,
b lo range trimpot
c terminal "R" activates max out range then slowly move the controller off center until
d (not used) the moment a voltage reading appears. Adjust
e terminal "X" (not used) the voltage until the moment the boom begins to
f terminal "-" ground move. Turn the threshold trimpot adjustment
g terminal "+" positive
h terminal "A" proportional output screw clockwise to increase the voltage or
i threshold trimpot counterclockwise to decrease the voltage.
j max out trimpot
10 Start a timer and record how long it takes for the
4 Set the preliminary ramp rate: Turn the ramp boom to fully raise. Adjust the max out trimpot
rate trimpot adjustment screw counterclockwise to achieve a 90 to 120 second cycle time.
15 turns or until you hear a repeated click. Turn the max out trimpot adjustment screw
clockwise to increase the speed or
5 Connect the red (+) lead from a volt meter to
counterclockwise to decrease the speed.
the “A” terminal on the controller printed circuit
board. Connect the black (-) lead to ground. 11 Start a timer and record how long it takes for
the boom to fully lower. Adjust the lo range
6 Set the max out: Press down the foot switch,
trimpot to achieve an 90 to 120 second cycle
then move the controller all the way to
time. Turn the lo range trimpot adjustment
the UP position. Adjust the voltage to 9.1V DC.
screw clockwise to increase the speed or
Turn the max out trimpot adjustment screw
counterclockwise to decrease the speed.
clockwise to increase the voltage or
counterclockwise to decrease the voltage. If the function cycle time is not
achievable, check the relief valve
pressure. See 11-2, Valve
Adjustments - Function Manifold.

PLATFORM CONTROLS
12 Turn the engine OFF. Turntable Rotation Controller

13 Pull out the Emergency Stop button to Adjustments
the ON position.
14 Press down the foot switch and then move the with electrically charged circuits
controller all the way to the UP position. Record could result in death or serious
the maximum voltage reading. injury. Remove all rings, watches
15 Start the engine. and other jewelry.
16 Start a timer and simultaneously move the Do not adjust the controllers
controller all the way to the UP position. Note unless the static battery voltage is
how long it takes to reach the maximum voltage above 12V DC and the alternator
recorded in step 14. This is the ramp rate. is operating properly with
13.6 to 14.5V DC output.
17 Set the ramp rate: Turn the ramp rate trimpot to
obtain a 2 second ramp speed. Turn the 1 Check the battery condition with a volt meter.
trimpot clockwise to increase the time or The reading should be 12V DC or more to
counterclockwise to decrease the time. accurately adjust the controller.
2 Turn the key switch to platform controls and
Boom up/down specifications
pull out the Emergency Stop button to
Threshold 3.5V DC the ON position at both the ground and
platform controls. Do not start the engine.
Boom up - Max out 9.1V DC
Cycle time 90 to 120 seconds
Boom down - Lo range 8.3V DC

Ramp rate 2 seconds

PLATFORM CONTROLS
3 Open the platform control box lid and locate 5 Connect the red (+) lead from a volt meter to the
the turntable rotation controller. Refer to the “A” terminal on the controller printed circuit
platform control box illustration, page 7-2. board. Connect the black (-) lead to ground.
a b c d e f g h i j 6 Set the threshold: Press down the foot switch,

then slowly move the controller off center until
the moment a voltage reading appears. Adjust
the voltage to 3.5V DC. Turn the threshold
trimpot adjustment screw clockwise to increase
the voltage or counterclockwise to decrease the
voltage.
fully retract the boom, then move the controller
all the way to the left or right. Adjust the voltage
to 5.5V DC. Turn the max out trimpot
adjustment screw clockwise to increase the
voltage or counterclockwise to decrease the
a ramp rate trimpot voltage.
b lo range trimpot
c terminal "R" activates max out range 8 Set the lo range: Press down the foot switch,
d (not used) extend the boom approximately 3 feet (0.9 m),
e terminal "X" (not used) then move the controller all the way to the left
f terminal "-" ground
or right. Adjust the voltage to 4.5V DC. Turn the
g terminal "+" positive
h terminal "A" proportional output lo range trimpot adjustment screw clockwise to
i threshold trimpot increase the voltage or counterclockwise to
j max out trimpot decrease the voltage.
4 Set the preliminary ramp rate: Turn the ramp 9 Start the engine and move the engine idle
rate trimpot adjustment screw counterclockwise control switch to foot switch activated high idle
15 turns or until you hear a repeated click. (rabbit and foot switch symbol).

PLATFORM CONTROLS
10 Fully retract the boom, then start a timer and 12 Turn the engine OFF.
record how long it takes the turntable to rotate
13 Pull out the Emergency Stop button to
through a complete circle. Adjust the max out
the ON position.
trimpot to achieve a 80 to 120 second cycle
time. Turn the max out trimpot adjustment 14 Press down the foot switch and move the
screw clockwise to increase the speed or controller all the way to the left or right.
counterclockwise to decrease the speed. Record the maximum voltage reading.
11 With the boom extended approximately 3 feet 15 Start the engine.
(0.9 m), start a timer and record how long it
takes the turntable to rotate through a complete 16 Start a timer and simultaneously move the
circle. Adjust the lo range trimpot to achieve a controller all the way to the left or right. Note
210 to 240 second cycle time. Turn the lo range how long it takes to reach the maximum voltage
trimpot adjustment screw clockwise to increase recorded in step 14. This is the ramp rate.
the speed or counterclockwise to decrease the 17 Set the ramp rate: Turn the ramp rate trimpot to
speed. obtain a 2 second ramp speed. Turn the ramp
If the function cycle time is not rate trimpot adjustment screw clockwise to
achievable, check the relief valve increase the time or counterclockwise to
pressure. See 11-2, Valve decrease the time.
Turntable rotation specifications
Threshold 3.5V DC
Boom retracted - Max out 5.5V DC

Boom extended - Lo range 4.5V DC

Ramp rate 2 seconds

PLATFORM CONTROLS
Boom Extend/Retract Controller 3 Open the platform control box lid and locate
the boom extend/retract controller.
Adjustments
Electrocution hazard. Contact a b c d e f g h i j
and other jewelry.
Do not adjust the joystick
controllers unless the static battery
voltage is above 12V DC and the
alternator is operating properly
with 13.6 to 14.5V DC output.
1 Check the battery condition with a volt meter.
The reading should be 12V DC or more to
a ramp rate trimpot
accurately adjust the controller. b lo range trimpot
c terminal "R", activates max out range
2 Turn the key switch to platform controls and d terminal unused
pull out the Emergency Stop button to the e terminal "X", auxiliary
ON position at both the ground and platform f terminal "-", ground
controls. Do not start the engine. g terminal "+", battery, positive
h terminal "A", proportional output
i threshold trimpot
j max out trimpot
4 Set the preliminary ramp rate: Turn the ramp

rate trimpot adjustment screw counterclockwise
15 turns or until you hear a repeated click.
5 Connect the red (+) lead from a volt meter to
the “A” terminal on the controller printed circuit
board. Connect the black (-) lead to ground.

PLATFORM CONTROLS
6 Set the threshold: Press down the foot switch, 10 Start a timer and record how long it takes for the
then slowly move the controller off center until boom to fully extend. Adjust the max out trimpot
the moment a voltage reading appears. Adjust to achieve a 140 to 170 second cycle time.
the voltage to 3.5V DC. Turn the threshold
11 Start a timer and record how long it takes for the
trimpot adjustment screw clockwise to increase
boom to fully retract. Adjust the lo range trimpot
the voltage or counterclockwise to decrease the
to achieve a 80 to 110 second cycle time.
voltage.
If the function cycle time is not
achievable, check the relief valve
then move the controller all the way to the
pressure. See 11-2, Valve
EXTEND position. Adjust the voltage to 9.75V DC.
Turn the max out trimpot adjustment screw
clockwise to increase the voltage or 12 Turn the engine off and re-connect the
counterclockwise to decrease the voltage. volt meter.
8 Set the lo range: Press down the foot switch, 13 Pull out the Emergency Stop button to
then move the controller all the way to the the ON position.
RETRACT position. Adjust the voltage to 5.5V DC.
Turn the lo range trimpot adjustment screw 14 Press down the foot switch and move the
clockwise to increase the voltage or controller all the way to the EXTEND position.
counterclockwise to decrease the voltage. Record the maximum voltage reading.
9 Start the engine and move the engine idle Boom extend/retract specifications
control switch to foot switch activated high
Threshold 3.5V DC
idle (rabbit and foot switch symbol). Lower
the boom to the stowed position. Boom extend - Max out 9.75V DC
operating temperature. Boom retract - Lo range 5.5V DC

PLATFORM CONTROLS
1-2
a
Horsepower Limiter Board
The horsepower limiter board (HPL) is responsible
for governing drive pump output. Receiving engine
rpm signals from the alternator, the HPL senses a
drop in rpm normally due to increased drive
Platform control box
resistance due to operation on an incline or over
a horsepower limiter board
rough terrain. Instantly, the HPL decreases voltage
to the drive controller which in turn decreases
voltage to the drive pump. Decreased voltage 3 Connect the black (-) lead from a DC volt meter
adjusts the output of the drive pump to maintain to the number 2 terminal, and the red (+) lead to
peak engine performance. the number 10 terminal.
For optimum performance, three adjustments are
required. a
12V DC or greater
ground b
How to Adjust the Horsepower engine rpm sensor
not used
Limiter Board not used
low drive speed limit switch
not used
The engine rpm must be not used
correct before performing this not used
output to drive controller
procedure. See Maintenance c
Procedure B-6, Check and
Adjust the Engine RPM.
Horsepower limiter board
Do not adjust the horsepower
a "A" trimpot maximum voltage
limiter board unless the static output to the drive controller in the
battery voltage is above 12V DC stowed position
and the alternator is operating (turn counterclockwise to increase
voltage)
properly with 12.5 to 14.5V DC
output. b "B" trimpot maximum voltage
output to the drive controller in the
Ford models: Perform this boom raised or extended position
procedure in gasoline mode. (turn clockwise to increase voltage)
1 Remove the fasteners from the platform c "C" trimpot reaction rate or how
control box lid. fast the voltage output reacts to
the change in engine rpm
2 Open the control box lid and locate the (turn counterclockwise to increase
voltage)
horsepower limiter board.
and other jewelry.

PLATFORM CONTROLS
4 Start the engine from the platform controls. 11 Be sure that the boom is in the stowed position,
then drive the machine and observe how the
5 Move the engine idle control toggle switch to
engine rpm reacts to drive controller movement.
If the engine surges or hunts, adjust the "C"
switch symbol).
potentiometer counterclockwise until surging is
6 Press down the foot switch and turn the "A" minimized.
trimpot adjustment screw counterclockwise to
Under an extreme load, an
increase voltage or clockwise to decrease
excessive counterclockwise
voltage.
adjustment to the "C" trimpot will
cause the engine to stall. The "C"
"A" potentiometer specifications - all models
trimpot adjustment is a
Voltage setting 12V DC compromise between engine
stability (surging) and engine
rpm drop.
7 Move the engine idle control toggle switch to low
idle (turtle symbol). 12 Disconnect the volt meter.
8 Press down the foot switch and turn the "C" 13 Raise the boom above horizontal.
trimpot adjustment screw to obtain a 14 Drive the machine for 40 feet (12 m) and
0.10V DC voltage reading. record the elapsed time. Repeat this step in
9 Move the engine idle control toggle switch to the opposite drive direction.
foot switch activated high idle (rabbit and foot 15 Adjust the "B" trimpot to obtain the correct
switch symbol). raised drive speed of 1 foot per second (0.31 m
10 Press down the foot switch and re-adjust the per second). Turn the "B" trimpot adjustment
"A" trimpot to the previous voltage setting in screw clockwise to increase speed or clockwise
step 6. to decrease speed.
16 Close the platform control box lid and install
the fasteners.
Drive speed: stowed position,

high range 2WD 4WD
Ford models 40 ft/7.2 sec 40 ft/8.8 sec

12.2 m/7.2 sec12.2 m/8.8 sec
Deutz or Perkins models 40 ft/8.3 sec 40 ft/9.7 sec
12.2 m/8.3 sec 12.2 m/9.7 sec
Boom raised or extended 40 ft/40 sec

all models 12.2m/40 sec

PLATFORM CONTROLS
1-3 6 Press down the foot switch. Connect the leads

from an ohmmeter or continuity tester to each
Foot Switch wire combination listed below and check for
continuity.
How to Test the Foot Switch
Test Desired result
key switch in the OFF position. red to black no continuity
(infinite Ω)
1 Remove the foot switch cover plate fasteners
from the platform. red to white no continuity
(infinite Ω)
2 Remove the foot switch guard mounting
fasteners from the platform. black to white continuity
(zero Ω)
3 Remove the foot switch mounting fasteners that
attach the foot switch to the foot switch guard.
4 Remove the cover plate from the bottom of the
foot switch to access the foot switch wire
terminals.
5 Do not press down the foot switch. Connect the
leads from an ohmmeter or continuity tester to
each wire combination listed below and check
for continuity.
Test Desired result
red to black continuity

(zero Ω)
red to white no continuity

(infinite Ω)
black to white no continuity

(infinite Ω)

PLATFORM CONTROLS
1-4 Test Desired result

Toggle Switches Left position
Toggle switches used for single function switching terminal 1 to 2, 3, 4, 5 & 6 no continuity
are single pole double throw (SPDT) switches. (infinite 9)
Dual function switching requires a double pole terminal 2 to 3 continuity
double throw (DPDT) switch. (zero 9)
terminal 2 to 4, 5 & 6 no continuity
(infinite 9)
How to Test a Toggle Switch terminal 3 to 4, 5 & 6 no continuity
(infinite 9)
Continuity is the equivalent of 0 to
3 ohms. A simple continuity tester terminal 4 to 5 & 6 no continuity
may not accurately test the switch. (infinite 9)
This procedure covers fundamental switch testing terminal 5 to 6 continuity

and does not specifically apply to all varieties of (zero 9)
toggle switches. Center position There are no terminal combinations
that will produce continuity
1 Turn the key switch to the OFF position. Tag (infinite 9)
and disconnect all wiring from the toggle switch
Right position
to be tested.
terminal 1 to 2 continuity
2 Connect the leads of an ohmmeter to the switch
(zero 9)
terminals in the following combinations listed to
check for continuity. terminal 1 to 3, 4, 5 & 6 no continuity
(infinite 9)
Left Center Right
terminal 2 to 3, 4, 5 & 6 no continuity
(infinite 9)
terminal 3 to 4, 5 & 6 no continuity
(infinite 9)
(zero 9)
1 3 1 3 1 3 terminal 4 to 6 no continuity
2 2 2
(infinite 9)
Single pole
double throw terminal 5 to 6 no continuity
(SPDT) 1 2 3 1 2 3 1 2 3
(infinite 9)
4 5 6 4 5 6 4 5 6
Double pole
double throw
(DPDT)
1 2 3 1 2 3 1 2 3

Platform Components
2-1 2-2
Platform Platform Leveling Slave Cylinder
How to Remove the Platform The slave cylinder and the rotator pivot are the
two primary supports for the platform. The slave
1 Open the platform control box. cylinder keeps the platform level through the
entire range of boom motion. It operates in a
2 Tag and disconnect the foot switch wiring from
closed-circuit hydraulic loop with the master
the terminal strip inside the platform control
cylinder. The slave cylinder is equipped with
box. Remove the cable from the bottom of the
counterbalance valves to prevent movement
platform control box.
in the event of a hydraulic line failure.
3 Remove the platform control box mounting
fasteners. Lower the control box and set it How to Remove the
aside. Slave Cylinder
If your machine is equipped with
Before cylinder removal is
an airline to platform option, the
considered to correct a
airline must be disconnected from
malfunction, bleed the slave
the platform before removal.
cylinder to be sure there is no
4 Support the platform with an appropriate lifting air in the closed loop
device. hydraulic circuit.
5 Remove the platform mounting fasteners and When removing a hose assembly
remove the platform from the machine. or fitting, the O-ring on the fitting
and/or hose end must be replaced
Crushing hazard. The platform and then torqued to specification
could become unstable and fall during installation.
when it is removed from the Refer to Section Two, Hydraulic
machine if it is not properly Hose and Fitting Torque
supported. Specifications.
1 Extend the boom until the slave cylinder
barrel-end pivot pin is accessible.
2 Raise the boom approximately 3 feet (0.9 m)
and place a structure capable of supporting it
under the platform.
3 Lower the boom until the platform is resting on
the structure just enough to support the
platform.
Do not rest the entire weight of the
boom on the structure.

PLATFORM COMPONENTS
4 Tag, disconnect and plug the hydraulic hoses How to Bleed the Slave Cylinder
from the slave cylinder at the union located near
the platform rotate counterbalance valve Do not start the engine. Use
manifold and connect them together using a auxiliary power for all machine
connector. Cap the fittings on the cylinder. functions in this procedure.
Bodily injury hazard. Spraying 1 Raise the boom to a horizontal position.
hydraulic oil can penetrate and
2 Move the platform level toggle switch up and
burn skin. Loosen hydraulic
down through two platform leveling cycles to
remove any air that might be in the system.
the oil pressure to dissipate
squirt or spray.
5 Remove the pin retaining fastener from
the slave cylinder rod-end pivot pin. Do not
remove the pin.
6 Remove the external retaining ring from the
barrel-end pivot pin.
7 Use a soft metal drift to drive the rod-end pivot
pin out.
8 Use a soft metal drift and drive the barrel-end
pin out.
9 Carefully pull the cylinder out of the boom.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.

PLATFORM COMPONENTS
2-3 2 S-80 models: Tag, disconnect and plug the

hydraulic hoses from the platform rotator
Platform Rotator manifold. Cap the fittings on the rotator.
The platform rotator is a hydraulically activated Bodily injury hazard. Spraying

helical gear assembly used to rotate the platform hydraulic oil can penetrate and
160 degrees. burn skin. Loosen hydraulic
How to Remove the the oil pressure to dissipate
gradually. Do not allow oil to squirt
Platform Rotator or spray.
Component damage hazard. Mark S-85 models: Tag, disconnect and plug the
the platform mounting weldment hydraulic hoses from the "V1" and "V2" ports on
and the rotator flange before platform rotator manifold. Cap the fittings on the
removing the platform mounting manifold.
weldment. The platform mounting
weldment must be replaced in the Bodily injury hazard. Spraying
exact same position on the rotator hydraulic oil can penetrate and
flange as it was before removal. If burn skin. Loosen hydraulic
a new rotator is installed or the connections very slowly to allow
rotator is disassembled, proper the oil pressure to dissipate
alignment can be achieved by gradually. Do not allow oil to squirt
rotating the rotator all the way to or spray.
the left and then installing the 3 S-85 models: Support the platform leveling
platform mounting weldment all the arms and the platform mounting weldment with
way in the left position. an appropriate lifting device. Do not apply any
When removing a hose assembly lifting pressure.
or fitting, the O-ring on the fitting All models:
and then torqued to specification 4 Remove the mounting bolts from the platform
during installation. mounting weldment, then remove the center bolt
Refer to Section Two, Hydraulic and slide the platform mounting weldment off of
Hose and Fitting Torque the platform rotator.
Specifications.
Crushing hazard. The platform
1 Remove the platform. See 2-1, mounting weldment may become
How to Remove the Platform. unbalanced and fall if it is not
properly supported.

PLATFORM COMPONENTS
5 Support the platform rotator with an appropriate How to Bleed the Platform
lifting device. Do not apply any lifting pressure.
Rotator
S-80 Models:
Do not start the engine. Use
6 Support the rod end of the platform leveling auxiliary power for all machine
slave cylinder. Protect the cylinder rod from functions in this procedure.
damage.
1 Connect a clear hose to the top bleed valve.
7 Remove the pivot pin retaining fasteners from Place the other end of the hose in a container
both the slave cylinder rod-end pivot pin and the to collect any drainage. Secure the container to
rotator pivot pin. the boom.
8 Use a soft metal drift to remove both pivot pins.
a
Remove the platform rotator from the machine.
Crushing hazard. The platform
rotator may become unbalanced
and fall if it is not properly
supported.
S-85 Models:
6 Remove the pin retaining fasteners from the jib

boom and jib boom leveling arms to platform
rotator pivot pins. Do not remove the pins.
7 Support the jib boom and leveling arms.
d c b
8 Use a soft metal drift to drive both pins out, then
remove the platform rotator from the machine.
a top bleed valve
Crushing hazard. The platform b bottom bleed valve
c clear hose
rotator may become unbalanced
d container
supported. 2 Move the platform rotate toggle switch to the left
and then to the right through two platform
When installing the center bolt,
rotation cycles, continue holding the switch to
torque the fastener to 200 ft-lbs.
the RIGHT until the platform is fully rotated to the
right.

PLATFORM COMPONENTS
3 Open the top bleed valve, but do not remove it.

4 Move the platform rotate toggle switch to the
LEFT until the platform is fully rotated to the left.
Continue holding the switch until air stops
coming out of the bleed valve. Close the bleed
valve.
Crushing hazard. Keep clear of
the platform during rotation.
5 Connect the clear hose to the bottom bleed
valve. Open the bottom bleed valve, but do not
remove it.
6 Hold the platform rotate toggle switch to the
RIGHT until the platform is fully rotated to the
right. Continue holding the switch until air stops
coming out of the bleed valve. Close the bleed
valve.
Crushing hazard. Keep clear of
the platform during rotation.
7 Remove the hose from the bleed valve and
clean up any hydraulic oil that may have spilled.
8 Rotate the platform full right, then full left and
inspect the bleed valves for leaks.

Jib Boom Components, S-85 Models

3-1 6 Support the barrel end of the cylinder with a
lifting device.
Jib Boom
7 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin.
How to Remove the Jib Boom
8 Use a soft metal drift to remove the pin and lay
Perform this procedure with the the cylinder onto the ground.
boom in the stowed position.
9 Tag, disconnect and plug all the hydraulic hoses
When removing a hose assembly from the jib boom manifold.
or fitting, the O-ring on the fitting
and/or hose end must be replaced Bodily injury hazard. Spraying
and then torqued to specification hydraulic oil can penetrate and
during installation. burn skin. Loosen hydraulic
Refer to Section Two, Hydraulic connections very slowly to allow
Hose and Fitting Torque the oil pressure to dissipate
Specifications. gradually. Do not allow oil to
squirt or spray.
1 Remove the platform. See 2-1,
How to Remove the Platform. 10 Attach a lifting strap from an overhead crane to
the jib boom.
2 Remove the platform mounting weldment
and the platform rotator. See 2-3, How to 11 Remove the pin retaining fastener from the jib
Remove the Platform Rotator. boom pivot pin. Use a soft metal drift to remove
the pin, then remove the jib boom from the
3 Remove the cable cover from the side of the primary boom.
jib boom.
Crushing hazard. If the overhead
4 Support the jib boom with a lifting device. crane is not properly attached, the
5 Tag, disconnect and plug the jib boom lift jib boom may become unbalanced
cylinder hydraulic hoses. Cap the fittings on the and fall when it is removed from
cylinder. the machine.
Bodily injury hazard. Spraying 12 Remove the pin retaining fastener from the jib
hydraulic oil can penetrate and boom lift cylinder rod-end pivot pin. Do not
burn skin. Loosen hydraulic remove the pin.
connections very slowly to allow 13 Slide both of the jib boom leveling arms off of
the oil pressure to dissipate the jib boom pivot pin.
squirt or spray.

JIB BOOM COMPONENTS, S-85 MODELS
14 Support the rod end of the jib boom lift cylinder 3-2
with a lifting device.
Jib Boom Lift Cylinder
15 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin, then remove the jib How to Remove the Jib Boom
boom lift cylinder from the jib boom mounting
weldment. Lift Cylinder
Crushing hazard. If the overhead Perform this procedure with the
crane is not properly attached, the boom in the stowed position.
jib boom lift cylinder may become When removing a hose assembly
unbalanced and fall when it is or fitting, the O-ring on the fitting
removed from the machine. and/or hose end must be replaced
during installation.
Refer to Section Two, Hydraulic
Hose and Fitting Torque
Specifications.
1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Then
lower the jib boom until the platform is resting
on the blocks just enough to support the
platform.
Do not rest the entire weight of the
boom on the blocks.

JIB BOOM COMPONENTS, S-85 MODELS
2 Tag, disconnect and plug the jib boom lift

cylinder hydraulic hoses. Cap the fittings on the
cylinder.
squirt or spray.
3 Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
4 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out. Then
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
5 Attach a strap from an overhead crane to the jib
boom lift cylinder.
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the pin.
7 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pin. Remove the cylinder from
the machine.
Crushing hazard. The jib boom lift
cylinder may become unbalanced
and fall when it is removed from
the machine if it is not properly
supported.

Boom Components
4-1 4 All Models: Tag, disconnect and plug the
hydraulic hoses from the platform leveling
Cable Track slave cylinder at the union and connect the
hoses from the cylinder together using a
The boom cable track guides cables and hoses connector.
running up the boom. It can be repaired link by link
without removing the cables and hoses that run Bodily injury hazard. Spraying
through it. Removing the entire boom cable track is hydraulic oil can penetrate and
necessary when performing major repairs that burn skin. Loosen hydraulic
involve removing the boom. connections very slowly to allow
How to Remove the Cable Track gradually. Do not allow oil to
squirt or spray.
When removing a hose assembly
or fitting, the O-ring on the fitting S-85 Models:
and/or hose end must be replaced 5 Remove the hose and cable cover from the side
and then torqued to specification of the jib boom.
Refer to Section Two, Hydraulic 6 Remove the jib boom/platform rotate manifold
Hose and Fitting Torque mounting fasteners. Do not disconnect the
Specifications. hoses.
1 Open the platform control box and remove the 7 Tag, disconnect and plug the hydraulic hoses
platform control box mounting fasteners. from the jib boom lift cylinder. Cap the fittings
on the cylinder.
2 Disconnect the foot switch wiring from the
terminal strip inside the platform control box. Bodily injury hazard. Spraying
Remove the cable from the control box and set hydraulic oil can penetrate and
the control box aside. burn skin. Loosen hydraulic
3 S-85 Models: Tag, disconnect and plug the the oil pressure to dissipate
hydraulic hoses from the "V1" and "V2" port gradually. Do not allow oil to
fittings on the counterbalance valve manifold squirt or spray.
located on the platform rotator. Cap the fittings
on the manifold. All models:
Bodily injury hazard. Spraying 8 From the ground controls, raise the boom to a
hydraulic oil can penetrate and horizontal position.
squirt or spray.

BOOM COMPONENTS
9 Remove the fasteners from the drive speed limit 17 Remove the cable track from the machine and
switch (LS1) mounted on the side of the cable place it on a structure capable of supporting it.
track at the pivot end of the boom. Do not
Crushing hazard. The cable track
disconnect the wiring.
could become unbalanced and fall
10 Remove the fasteners from the side panel on if it is not properly attached to the
the lower cable track, then remove the panel. overhead crane.
Pull all of the cables and hoses out of the
channel.
Cables and hoses can be
11 Place blocks between the upper and lower damaged if they are kinked or
cable tracks and secure the upper and lower pinched.
tracks together.
Crushing hazard. If the upper and
lower cable tracks are not properly
secured together, the cable track
could become unbalanced and fall
when it is removed from the
machine.
12 Remove the mounting fasteners from the large
cable track guide at the platform end of the
cable track. Remove the guide.
13 Remove the hose and cable clamp at the
platform end of the cable track.
14 Attach a lifting strap from an overhead crane to
the cable track.
15 Remove the cotter pin and clevis pin from the
upper cable track at the platform end.
Always replace the cotter pin with
a new one when removing a clevis
pin.
16 Remove the mounting fasteners that attach the
lower cable track to the boom.

BOOM COMPONENTS
How to Repair the Cable Track 5 Lift up the hoses and cables and carefully
remove the damaged 4 link section of cable
Component damage hazard. track.
The boom cable track can be
damaged if it is twisted. Component damage hazard.
Hoses and cables can be
A cable track repair kit is available damaged if they are kinked or
through the Genie Industries pinched.
Service Parts Department,
part no. 46677. The kit includes a 6 Remove the upper rollers from the replacement
4 link section of cable track, section of cable track.
fasteners, other miscellaneous 7 Lift up the hoses and cables and carefully insert
parts and detailed instructions. the new 4 link section of cable track.
1 Remove the boom cable track. See 4-1, How to Component damage hazard.
Remove the Boom Cable Track. Hoses and cables can be
2 Visually inspect the cable track and determine damaged if they are kinked or
which 4 link section needs to be replaced. pinched.
3 Drill out the 4 spot welds on each side of the 8 Connect the ends of the replacement cable track
cable track using a 17/64" drill bit. Repeat this section to the existing cable track using the
step for the other end of the 4 link section of fasteners provided in the kit. Do not overtighten
cable track. the fasteners.
Component damage hazard. Component damage hazard.

Cables and hoses can be Over tightening the fasteners will
damaged if the drill bit comes in prevent the cable track from
contact with them. Protect the rotating and it may kink or bind
hoses and cables with a block of during operation.
wood to prevent drilling into the Be sure that the fasteners are
hoses and cables. installed from the inside out so
4 Remove the retaining fasteners from the upper that the nuts are on the outside of
black rollers from the 4 link section of cable the cable track.
track to be replaced. Remove the rollers. 9 Install the rollers onto the new section of cable
track.
10 Install cable track onto the machine and operate
the boom extend/retract function through a full
cycle to ensure smooth operation of the new
section of cable track.

BOOM COMPONENTS
4-2 How to Remove the Boom

Boom Bodily injury hazard. This
procedure requires specific repair
How to Shim the Boom skills, lifting equipment and a
suitable workshop. Attempting this
1 Measure each side wear pad. procedure without these skills and
Replace the pad if it is less than tools could result in death or
11/16 inch (14.3 mm) thick. If the serious injury and significant
pad is more than 11/16 inch component damage. Dealer
(14.3 mm) thick, perform the service is strongly recommended.
following procedure. Perform this procedure with the
2 Measure each bottom and top wear pad. boom in the stowed position.
Replace the pad if it is less than When removing a hose assembly

9/16 inch (17.5 mm) thick. If the or fitting, the O-ring on the fitting
pad is more than 9/16 inch and/or hose end must be replaced
(17.5 mm) thick, perform the and then torqued to specification
following procedure. during installation.
3 Extend the boom until the wear pads are Hose and Fitting Torque
accessible. Specifications.
4 Loosen the wear pad mounting fasteners. 1 Remove the platform. See 2-1, How to Remove
5 Install the new shims under the wear pad to the Platform.
obtain zero clearance and zero drag. 2 Remove the platform rotator and leveling slave
6 Tighten the mounting fasteners. cylinder. See 2-3, How to Remove the Platform
Rotator.
7 Extend and retract the boom through an entire
cycle. Check for tight spots that could cause 3 Remove the cable track. See 4-1, How to
binding or scraping. Remove the Cable Track.
Always maintain squareness S-85 Models:

between the outer and inner 4 Remove the jib boom. See 3-1,
boom tubes. How to Remove the Jib Boom.
5 Raise the boom to a horizontal position high
enough that the boom lift cylinder rod-end can
clear the boom lift cylinder mounting boss.
6 Remove the turntable end cover.

BOOM COMPONENTS
7 Tag, disconnect and plug the hydraulic hoses 15 Remove the pin retaining fastener from the
from the master cylinder. Cap the fittings on the boom lift cylinder rod-end pin. Use a soft metal
cylinder. drift to remove the pin.
Bodily injury hazard. Spraying Crushing hazard. The boom lift
hydraulic oil can penetrate and cylinder will fall unless it is
burn skin. Loosen hydraulic properly supported.
16 Lower the rod end of the lift cylinder onto
support blocks. Protect the cylinder rod from
damage.
squirt or spray.
17 Remove the pin retaining fastener from the
boom pivot pin.
master cylinder barrel-end pivot pin. Place a rod
through the pin and twist to remove the pin. 18 Use a soft metal drift to remove the boom pivot
pin, then carefully remove the boom from the
9 Remove the fasteners from the drive speed limit
machine.
switch (LS2) mounted to the turntable riser at
the pivot end of the boom. Do not disconnect Crushing hazard. If the overhead
the wiring. crane is not properly attached,
the boom may become unbalanced
10 Tag, disconnect and plug the extension cylinder
and fall when it is removed from
hydraulic hoses. Cap the fittings on the cylinder.
the machine.
hydraulic oil can penetrate and How to Disassemble the Boom
Complete disassembly of the
boom is only necessary
if the outer or inner boom tubes
must be replaced. The extension
squirt or spray.
cylinder can be removed without
11 Attach an overhead 5 ton (4536 kg) crane to the completely disassembling the
center point of the boom. boom. See 4-4, How to Remove
the Extension Cylinders.
12 Attach a similar lifting device to the boom lift
cylinder. 1 Remove the boom. See 4-2, How to Remove the
Boom.
13 Remove the center turntable cover fasteners.
Remove the cover. 2 Remove the external snap rings from the
extension cylinder barrel-end pivot pin at the
14 Place support blocks under the boom lift pivot end of the number 1 boom tube. Use a
cylinder, across the turntable. soft metal drift to remove the pin.

BOOM COMPONENTS
3 Remove and label the wear pads from the top, 10 Attach a lifting strap from an overhead crane to
side, and bottom of the 1 boom tube at the the number 3 boom tube at the platform end of
platform end of the boom. the boom for support.
Pay careful attention to the 11 Support and slide the number 3 boom tube out
location and amount of shims of the number 2 boom tube. Place the number 3
used with each wear pad. boom tube on blocks for support.
4 Remove the two wear pad stop bolts from each Crushing hazard. The number 3
side of the number 1 boom tube (located on the boom tube may become
outside). unbalanced and fall when it is
removed from the number 2 boom
tube if it is not properly supported.
the number 2 and number 3 boom tubes at the
platform end of the boom for support. During removal, the overhead
crane strap will need to be
6 Support and slide the number 2 and 3 boom
carefully adjusted for proper
tubes out of the number 1 boom tube. Place the
balancing.
number 2 and 3 boom tubes on blocks for
support. 12 Remove the external snap rings from the
extension cylinder rod-end pivot pin at the
Crushing hazard. The number 2
platform end of the number 3 boom tube. Use a
and 3 boom tubes could become
soft metal drift to remove the pin.
unbalanced and fall when they are
removed from the number 1 boom 13 Support and slide the extension cylinder out of
tube if they are not properly the base end of the number 3 boom tube. Place
supported. the extension cylinder on blocks for support.
During removal, the overhead Crushing hazard. The extension
crane strap will need to be cylinder may become unbalanced
carefully adjusted for proper and fall when it is removed from
balancing. the number 3 boom tube if it is not
properly supported.
7 Remove and label the wear pads from the top,
side, and bottom of the number 2 boom tube at During removal, the overhead
the platform end of the boom. crane strap will need to be
carefully adjusted for proper
8 Remove the trunnion pin retaining fasteners at
balancing.
the base end of the number 2 boom tube. Use a
slide hammer to remove the trunnion pins. 14 Remove and label the wear pads from the
extension cylinder.
9 Carefully rotate the base end of the extension
cylinder until the pin mounting bore is in a Pay careful attention to the
vertical position. location of each wear pad.

BOOM COMPONENTS
4-3 5 Support the rod end of the boom lift cylinder with
an overhead crane or similar lifting device.
Boom Lift Cylinder
Crushing hazard. The boom lift
cylinder could become unbalanced
How to Remove the Boom and fall when it is disconnected
Lift Cylinder from the machine if it is not
properly supported.
Bodily injury hazard. This
procedure requires specific repair 6 Tag, disconnect and plug the boom lift cylinder
skills, lifting equipment and a hydraulic hoses. Cap the fittings on the cylinder.
suitable workshop. Attempting this Bodily injury hazard. Spraying
procedure without these skills and hydraulic oil can penetrate and
tools could result in death or burn skin. Loosen hydraulic
serious injury and significant connections very slowly to allow
component damage. Dealer the oil pressure to dissipate
service is strongly recommended. gradually. Do not allow oil to
When removing a hose assembly squirt or spray.
or fitting, the O-ring on the fitting 7 Remove the pin retaining fastener from the
and/or hose end must be replaced boom lift cylinder rod-end pivot pin. Use a soft
and then torqued to specification metal drift to remove the pin, and lower the lift
during installation. cylinder onto the blocks. Protect the cylinder
Refer to Section Two, Hydraulic rod from damage.
Specifications. Crushing hazard. The boom lift
1 Raise the boom to a horizontal position high
and fall when it is disconnected
enough that the boom lift cylinder rod-end can
from the machine if it is not
clear the boom lift cylinder mounting boss.
properly supported.
2 Remove the center turntable cover fasteners. 8 Remove the mounting fasteners from the
Remove the cover. barrel-end cylinder pin retaining plates.
3 Place support blocks under the boom lift 9 With the lift cylinder being supported by the
cylinder across the turntable. overhead crane, pull the cylinder toward the
4 Attach an overhead 5 ton (4536 kg) crane to the platform and remove it from the machine.
boom. Do not lift the boom. Crushing hazard. The lift cylinder
may become unbalanced and fall if
it is not properly supported.
Component damage hazard. The
cables and hydraulic hoses can be
damaged if the lift cylinder is
pulled across them.

BOOM COMPONENTS
4-4 3 Place a 4 in x 4 in x 6 ft (183 cm) block on top

of the number 3 boom tube and place one end
Extension Cylinders of the block against the weldment at the
platform end of the boom.
The extension cylinder consists of two cylinders
that are fastened together. The first cylinder 4 Retract the boom until the number 2 boom tube
extends and retracts the number 2 boom tube. The is fully retracted into the number 1 boom tube.
second cylinder extends and retracts the number 3 The number 3 boom tube will
boom tube.The extension cylinders are equipped remain extended 6 feet (183 cm).
with counterbalance valves to prevent movement
in the event of a hydraulic line failure. 5 Remove the external snap rings from the
extension cylinder rod-end pin at the platform
How to Remove the end. Use a soft metal drift to remove the pin.
Extension Cylinders 6 Remove the turntable end cover.
This procedure requires specific 7 Support the barrel end of the master cylinder
repair skills, lifting equipment and with a lifting device.
a suitable workshop. Attempting
this procedure without these skills
master cylinder barrel-end pivot pin. Place a rod
and tools could result in death or
through the pin and twist to remove the pin.
serious injury and significant
component damage. Dealer Use the platform level toggle
service is strongly recommended. switch to relieve pressure on the
master cylinder barrel-end pivot
pin.
Specifications.
1 Raise the boom to a horizontal position, fully
extend the boom and fully lower the platform.
2 Remove the 2 bolts that are located on each 9 Lay the master cylinder down. Protect the
side of the number 3 boom tube near the cylinder rod from damage.
platform end of the number 2 boom tube.

BOOM COMPONENTS
10 Remove the external snap rings from the 16 Remove the trunnion pin retaining fastener and
extension cylinder rod-end pivot pin at the pivot use a slide hammer to remove the pins.
end of the boom. Use a soft metal drift to
17 Support and slide the extension cylinder out of
remove the pin through the access holes in the
the pivot end of the boom.
turntable riser.
Crushing hazard. The extension
11 Cut and remove the plastic ties from the
cylinder will fall when it is removed
hydraulic hoses.
from the extension boom if it is not
12 Activate auxiliary power and move the boom properly supported.
extend toggle switch in the EXTEND direction and
Note the length of the cylinder after
extend the extension cylinder out the pivot end
removal. The cylinder must be at
of the boom approximately 1 foot (0.3 m).
the same length for installation.
13 Tag, disconnect and plug the extension cylinder
squirt or spray.
the rod end of the extension cylinder and lift
slightly to relieve the pressure on the trunnion
pins.
15 Remove the trunnion pin access covers from
both sides of the number 1 boom tube at the
pivot end of the boom.

BOOM COMPONENTS
4-5 4 Remove the pin retaining fastener from the

master cylinder barrel-end pivot pin.
Platform Leveling
5 Place a rod through the barel-end pivot pin and
Master Cylinder twist to remove the pin.
The master cylinder acts as a pump for the slave
cylinder. It is part of the closed loop hydraulic
circuit that keeps the platform level through the
entire range of boom motion. The master cylinder
is located inside the pivot end of the boom.
How to Remove the Platform

Leveling Master Cylinder
When removing a hose assembly 6 Attach a lifting strap from an overhead crane to
or fitting, the O-ring on the fitting the lug on the barrel end of the master cylinder.
and then torqued to specification 7 Remove the pin retaining fastener from the
during installation. barrel-end pivot pin.
Refer to Section Two, Hydraulic 8 Place a rod through the rod-end pivot pin and
Hose and Fitting Torque twist to remove the pin.
Specifications.
1 Raise the boom until the master cylinder
rod-end pivot pin is accessible.
2 Remove the turntable end cover to access the
master cylinder.
3 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying Crushing hazard. The master
hydraulic oil can penetrate and cylinder could become unbalanced
burn skin. Loosen hydraulic and fall if it is not properly
connections very slowly to allow supported by the lifting device.
squirt or spray.

Turntable Covers
5-1 5 Carefully lift and remove the cover from
the machine.
Turntable Covers
Bodily injury hazard. Safety decals
are essential to safe machine
How to Remove a operation. Failure to replace all
Turntable Cover safety and instructional decals
1 Raise the turntable cover. Support and secure
injury. If a turntable cover must be
the open cover with an overhead crane or
replaced, be sure that all
forklift. Do not lift the cover.
appropriate safety and
Crushing hazard. Due to its heavy instructional decals are applied to
weight, do not attempt to support the new cover.
the cover by hand.
Crushing hazard. The turntable
Component damage hazard. cover could become unbalanced
Protect the cover from damage by and fall if it is not properly
using carpet or padding on the supported and secured to an
crane or forkliftforks. appropriate lifting device.
2 Remove the upper retaining clip from the gas Alignment adjustments may be
strut. necessary when a new cover
is installed.
3 Gently pry the strut pivot socket off of the ball
stud and lower the strut. Protect the strut
cylinder rod from damage.
Mark the location of the hinge
support bracket on the bulkhead to
ensure proper cover alignment
4 Remove the cover hinge bolts that fasten the
hinge support bracket to the bulkhead.

Deutz F4L 1011F Engine

6-1 How to Remove the Flex Plate
RPM Adjustment 1 Disconnect the wiring plug at the electronic
displacement controller (EDC), located on
Refer to Maintenance Procedures, B-6, the drive pump.
Check and Adjust the Engine RPM.
2 Support the drive pump with an appropriate
6-2 lifting device. Remove all of the pump mounting
plate to engine bell housing bolts.
Flex Plate
3 Carefully pull the pump away from the engine
The flex plate acts as a coupler between the and secure it from moving.
engine and the pump. It is bolted to the engine Component damage hazard.
flywheel and has a splined center to drive Hoses can be damaged if they
the pump. are kinked or pinched.
a b c d e 4 Remove the flex plate mounting fasteners,
then remove the flex plate from the engine
flywheel.
How to Install the Flex Plate

1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump.
f Torque the flex plate mounting bolts to 34 ft-lbs
(46 Nm).
a pump
b pump shaft 2 Install the pump coupler onto the pump shaft
c coupler with the set screw toward the pump. Leave a
d flex plate with raised spline 3/8 inch (9.5 mm) gap between the pump
e flywheel
f 3/8 inch (9.5 mm) gap coupler and pump end plate.
3 Apply removable thread locking material to the
pump coupler set screw. Torque the set screw
to 45 ft-lbs (61 Nm).
not force the drive pump during
installation or the flex plate teeth
may become damaged.
4 Install the pump and torque the pump mounting
plate fasteners to 34 ft-lbs (46 Nm).

DEUTZ F4L 1011F ENGINE
6-3 How to Remove the Oil

Oil Temperature and Oil Pressure Temperature and Oil Pressure
Gauges Gauge Sending Units
The engine oil temperature gauge is an electrical
engine off.
gauge. The engine oil temperature sending unit
has limit contacts that are factory set. The contacts 1 Remove the fasteners from the engine side
will close at approximately 300o F (149o C). When cover, remove the cover.
the contacts close, the engine will shut off to
prevent damage and will not start until the 2 Tag and disconnect the wiring from the desired
temperature drops below the contact point. Engine sending unit. Remove the sending unit from the
oil temperature will be indicated on the gauge engine block.
when the key is ON and the Emergency Stop Button 3 Install the new sending unit. Do not over tighten.
is pulled out to the ON position.
4 Connect the wires to the new sending unit.
The engine oil pressure gauge is an electrical
gauge. The engine oil pressure sending unit has Burn hazard. Contact with hot
limit contacts that are factory set. The contacts will engine fluids or components may
close at approximately 7 psi (0.48 bar). When the cause severe burns.
contacts close, the engine will shut off to prevent Always use pipe thread sealant
damage. Engine oil pressure will be indicated on when installing a sending unit.
the gauge when the engine is running.
Oil temperature sending unit specifications
Torque 8-10 ft-lbs

11-14 Nm
Hex size 13/16 inch
Temperature switch point 300° F

149° C
Oil pressure sending unit specifications
Torque 8-10 ft-lbs

11-14 Nm
Hex size 11/16 inch
Oil pressure switch point 7 psi

0.48 bar


RPM Adjustment 1 Disconnect the wiring plug at the electronic
Refer to Maintenance Procedures, B-6, the drive pump.
Check and Adjust the Engine RPM.
2 Support the drive pump with an appropriate
7-2 lifting device. Then remove all of the pump
mounting plate to engine bell housing bolts.
Flex Plate
3 Carefully pull the pump away from the engine
The flex plate acts as a coupler between the and secure it from moving.
engine and the pump. It is bolted to the engine Component damage hazard.
flywheel and has a splined center to drive Hoses can be damaged if they are
the pump. kinked or pinched.
a b c d e 4 Remove the flex plate mounting fasteners,
then remove the flex plate from the engine
flywheel.

f Torque the flex plate mounting bolts to 34 ft-lbs
(46 Nm).
a pump
b pump shaft 2 Install the pump coupler onto the pump shaft
c coupler with the set screw toward the pump. Leave a
d flex plate with raised spline 1/4 inch (6.4 mm) gap between the pump
e flywheel
f 1/4 inch (6.4 mm) gap coupler and pump end plate.
3 Apply removable thread locking material to the
pump coupler set screw. Torque the set screw
to 45 ft-lbs (61 Nm).
may become damaged.

PERKINS 704-30 ENGINE
7-3 How to Remove the Coolant

Coolant Temperature and Oil Temperature and Oil Pressure
Pressure Gauges Gauge Sending Units
The engine coolant temperature gauge is an
engine off.
electrical gauge. The engine coolant temperature
sending unit has limit contacts that are factory set. 1 Tag and disconnect the wiring from the desired
The contacts will close at approximately 221o F sending unit. Remove the sending unit from the
(105o C). When the contacts close, the engine will engine block.
shut off to prevent damage and will not start until
the temperature drops below the contact point. 2 Install the new sending unit. Do not over tighten.
Engine coolant temperature will be indicated on the 3 Connect the wires to the new sending unit.
gauge when the key is ON and the Emergency Stop
Button is pulled out to the ON position. Burn hazard. Contact with hot
engine fluids or components may
The engine oil pressure gauge is an electrical cause severe burns.
gauge. The engine oil presure sending unit has
limit contacts that are factory set. The contacts will Always use pipe thread sealant
close at approximately 4.2 psi (0.3 bar). When the when installing a sending unit.
contacts close, the engine will shut off to prevent
Coolant temperature sending unit specifications
damage. Engine oil pressure will be indicated on
the gauge when the engine is running. Torque 8-10 ft-lbs
11-14 Nm
Hex size 7/8 inch

105° C
Oil pressure sending unit specifications
Torque 8-10 ft-lbs

11-14 Nm
Hex size 7/8 inch
Oil pressure switch point 4.2 psi

0.3 bar

Ford LRG-425 EFI Engine

Timing Adjustment 1 Disconnect the wiring plug at the electronic
The ignition timing is controlled by the drive pump.
the ECM and can only be adjusted
by re-programming the ECM. If 2 Support the drive pump with an appropriate
timing adjustment or service is lifting device. Then remove all of the pump
required, please contact Genie mounting plate to engine bell housing bolts.
Industries Service Department OR 3 Carefully pull the pump away from the
your local Ford dealer. engine and secure it from moving.
8-2 Component damage hazard.
Flex Plate Hoses can be damaged if they are
kinked or pinched.
The flex plate acts as a coupler between the 4 Remove the flex plate mounting fasteners,
engine and the pump. It is bolted to the engine then remove the flex plate from the engine fly
flywheel and has a splined center to drive wheel.
the pump.
a b c d e
Torque the flex plate mounting bolts to
34 ft-lbs (46 Nm).
2 Install the pump coupler onto the pump shaft
with the set screw towards the pump. Leave a
1/16 inch (1.59 mm) gap between the pump
f
coupler and pump end plate.
a pump
b pump shaft 3 Apply removable thread locking material to the
c coupler pump coupler set screw. Torque the set screw
d flex plate with raised spline
e flywheel to 45 ft-lbs (61 Nm).
f 1/16 inch gap
may become damaged.

FORD LRG-425 EFI ENGINE
8-3 How to Remove the Coolant

Coolant Temperature and Oil Temperature and Oil Pressure
Pressure Gauges Gauge Sending Units
The engine coolant temperature gauge is an
engine off.
electrical gauge. The engine coolant temperture
sending unit has limit contacts that are factory set. 1 Remove the 2 engine pivot plate retaining bolts.
The contacts will close at approximately 230° F Swing the engine pivot plate away from the
(110° C). When the contacts close, the engine will machine to access the coolant temperature and
shut off to prevent damage and will not start until oil pressure sending units.
the temperature drops below the contact point.
Engine coolant temperature will be indicated on the
gauge when the key switch is ON and the
Emergency Stop button is pulled out to the ON
position.
The oil pressure gauge is an electrical gauge. The
oil pressure sending unit has limit contacts that
are factory set. The contacts will close at
approximately 8 psi (0.55 bar). When the contacts
close, the engine will shut off to prevent damage.
Engine oil pressure will be indicated on the gauge
when the engine is running.
a b b c

c air baffle

FORD LRG-425 EFI ENGINE
2 Locate the oil pressure and coolant temperature 5 Connect the wires to the new sending unit.
sending units.
Burn hazard. Contact with hot
engine fluids or components may
cause severe burns.
a Always use pipe thread sealant

when installing a sending unit.
b Coolant temperature sending unit specifications
Torque 8-10 ft-lbs

11-14 Nm
Hex size 13/16 inch

110° C
a oil pressure sending unit Oil pressure sending unit specifications

b coolant temperature sending unit
(hidded from view) Torque 8-10 ft-lbs
11-14 Nm
3 Tag and disconnect the wiring from the desired
sending unit. Remove the sending unit from the Hex size 11/16 inch
engine block.
Oil pressure switch point 8 psi
4 Install the new sending unit. Do not over tighten. 0.55 bar

Ground Controls
9-1
Control Relays
Relays used for single function switching are single
pole double throw (SPDT) relays.
How to Test a Single Pole Double

Throw Relay
Electrocution hazard. Contact with a terminal no. 87a - N.C.
electrically charged circuits could b terminal no. 85 - coil negative (-)
c terminal no. 30 - common
result in death or serious injury. d terminal no. 86 - coil positive (+)
Remove all rings, watches and e terminal no. 87 - N.O.
other jewelry.
1 Label and then disconnect all the wiring from
the relay to be tested. Control Relay Schematic - with resistor
2 Connect the leads from an ohmmeter or
continuity tester to each terminal combination
and check for continuity. Terminals 85 and 86
represent the coil and should not be tested in
any other combination.
Test Desired result

terminal 85 to 86 with resistor 75 to 85Ω
terminal 87 to 87a & 30 no continuity
(infinite Ω)
terminal 87a to 30 continuity
(zero Ω)
3 Connect 12V DC to terminal 85 and a ground

wire to terminal 86, then test the following
terminal combinations.
Test Desired result

terminal 87 to 87a & 30 no continuity
(infinite Ω)
(zero Ω)

GROUND CONTROLS
9-2 2 Connect 12V DC to one of the small posts and a

ground wire to the other small post, then test
Power Relay the following terminal combination.
Electrocution hazard. Contact with Test Desired result

electrically charged circuits may
2 large posts continuity (zero Ω)
Remove all rings, watches and
other jewelry. a b
The power relay is mounted on the
backside of the ground control box.
How to Test the Power Relay

Electrocution hazard. Disconnect
the ground cable from the battery a
before performing this procedure.
1 Connect the leads from an ohmmeter to each b
terminal combination and check for continuity.
Test Desired result

a solenoid activate coil terminal
2 small posts 12 to 16Ω (small post)
2 large posts no continuity b high amp power contact terminal
(infinite Ω) (large post)
Any small post to no continuity

any large post (infinite Ω)

GROUND CONTROLS
9-3 9-5
Toggle Switches Engine Fault Codes -
Ford Models
See 1-4, Toggle Switches.
9-4 How to Retrieve Engine Fault

Wago® Components Codes
When a engine malfunction is detected by the
How to Remove a Wago® Electronic Control Module (ECM), a fault code is
Component recorded and the check engine light will turn ON at
the ground and platform controls. Use the following
Electrocution hazard. Contact with procedure to retrieve the engine fault code to
electrically charged circuits could determine the engine malfunction.
cause death or serious injury.
Remove all rings, watches and Perform this procedure with the
other jewelry. key switch in the OFF position.
Wago® tools are available from 1 Open the ground controls side turntable cover.
the Genie Service Parts 2 Open the ground control box and locate the
Department (Genie part number run/test toggle switch inside of the ground
33996). control box.
1 Label the wiring from the component to be 3 Pull out the ground controls Emergency Stop
removed. button to the ON position.
2 Use a small screwdriver to push in and release 4 Hold the run/test toggle switch to the test
the wire from the component. position and turn the key switch to the ground
3 Locate the removal tab on the bottom or top controls position.
of the component. Result: The check engine light should turn on.
4 Use a small screwdriver to gently pry up on the The check engine light should begin to blink.
tab of the component and remove it.

GROUND CONTROLS
5 Continue to hold the run/test toggle switch in the How to Clear Engine Fault
test position and count the blinks.
Codes from the ECM
Fault codes are two digits. The
check engine light will blink the Perform this procedure with the
first digit of a two digit code then engine off and the key switch in
will pause for 1.2 seconds and the OFF position.
then blink the second digit. For 1 Open the engine side turntable cover and locate
example: the check engine light the battery.
blinks 5 consecutive times then
pauses for 1.2 seconds and then 2 Disconnect the negative battery cable from the
blinks 1 time. That would indicate battery for a minimum of 20 minutes.
code 51. The ECM is able to store
Electrocution hazard. Contact with
up to six individual fault codes.
electrically charged circuits could
There will be a 2.4 second pause
between codes.
Remove all rings, watches and
6 Refer to the Troubleshooting Section for other jewelry.
definition of engine fault codes.
3 Connect the negative battery cable to the
Once a fault code has been battery.
retrieved and the repair has been
Result: The check engine light should not turn
completed, the ECM memory must
on.
be reset to clear the fault code
from the ECM. See 9-5, How to 4 Start the engine and allow it to idle for
Clear Engine Fault Codes. approximately ten minutes.
Result: The check engine light should not turn
on.

Hydraulic Pumps
10-1 2 Tag, disconnect and plug the lift/steer pump
hydraulic hoses. Cap the fittings on the pump.
Lift/Steer Pump
How to Remove the burn skin. Loosen hydraulic
Lift/Steer Pump connections very slowly to allow
squirt or spray.
and then torqued to specification 3 Remove the pump mounting fasteners. Carefully
during installation. remove the pump.
Specifications.
tank valves and prime the pump
1 Close the two hydraulic tank valves located at after installing the pump.
the hydraulic tank. See 10-2, How to Prime the
Pump.
open closed

engine must not be started with
the CLOSED position or component
damage will occur.
If the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.

HYDRAULIC PUMPS
10-2 2 Close the two hydraulic tank valves located at

the hydraulic tank.
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electronic displacement controller
(EDC), located on the pump. The only adjustment
that can be made to the pump is the neutral or null
adjustment. Any internal service to the pump
open closed
should only be performed at an authorized
Sundstrand-Sauer service center. Call Genie
Industries Service Department to locate your local
authorized service center.
How to Remove the Drive Pump damage will occur. If the tank
Component damage hazard. The valves are closed, remove the key
work area and surfaces where this from the key switch and tag the
procedure will be performed must machine to inform personnel of the
be clean and free of debris that condition.
could get into the hydraulic system 3 Tag, disconnect and plug the hydraulic hoses
and cause severe component from the drive and lift/steer pumps. Cap the
damage. Dealer service is fittings on the pumps.
recommended.
When removing a hose assembly hydraulic oil can penetrate and
or fitting, the O-ring on the fitting burn skin. Loosen hydraulic
and/or hose end must be replaced connections very slowly to allow
and then torqued to specification the oil pressure to dissipate
during installation. gradually. Do not allow oil to
Refer to Section Two, Hydraulic squirt or spray.
Specifications. 4 Support the pumps with a suitable lifting device
and remove the two drive pump mounting
1 Disconnect the electrical connection at the fasteners.
electronic displacement controller (EDC)
located on the drive pump. 5 Carefully pull the drive pump out until the pump
coupler separates from the flex plate.

HYDRAULIC PUMPS
6 Remove the drive pump from the machine. Deutz Diesel models: Hold the manual fuel
shutoff valve counterclockwise to the CLOSED
position.
tank valves and prime the pump a
after installing the pump.
Before installing the pump, verify
proper pump coupler spacing.
Refer to the appropriate flex plate
installation instructions for your
engine.
How to Prime the Pump

sure that the hydraulic tank shutoff
valves are in the OPEN position
before priming the pump. The
engine must not be started with a manual fuel shutoff valve
the hydraulic tank shutoff valves in Perkins Diesel models: Disconnect the engine
the CLOSED position or component wiring harness from the fuel solenoid at the
damage will occur. injector pump.
1 Connect a 0 to 600 psi (0 to 41 bar) pressure 3 Crank the engine with the starter motor for
gauge to the diagnostic nipple on the drive 15 seconds, wait 15 seconds, then crank the
pump. engine an additional 15 seconds or until the
2 Gasoline/LPG models: Close the valve on the pressure reaches 300 psi (20.68 bar).
LPG tank, then disconnect the hose from the 4 Gasoline/LPG models: Connect the LPG
tank. Move the fuel select toggle switch to the hose to the LPG tank and open the valve on the
LPG position. tank.
Deutz Diesel models: Release the manual
shutoff valve.
Perkins Diesel models: Connect the engine
wiring harness to the fuel solenoid.
check for hydraulic leaks.

Manifolds
11-1
Function Manifold Components
The function manifold is located on the tank side tray, behind the ground control box.
Index Schematic
No. Description Item Function Torque
1 3 position 4 way DO3 valve .............. A ........... Turntable rotate left/right ..................... 30-35 in-lbs (3-4 Nm)
2 3 position 4 way DO3 valve .............. B ........... Boom up/down .................................... 30-35 in-lbs (3-4 Nm)
3 3 position 4 way DO3 valve .............. C ........... Boom extend/retract ............................ 30-35 in-lbs (3-4 Nm)
4 Check valve, pilot operated .............. D ........... Boom extend/retract circuit ............... 11-13 ft-lbs (15-18 Nm)
5 Relief valve, 2300 psi (158 bar) ........ E ........... Boom down ....................................... 25-30 ft-lbs (34-41 Nm)
6 Relief valve, 2500 psi (172 bar) ........ F ........... Boom extend .................................... 25-30 ft-lbs (34-41 Nm)
7 Solenoid valve - N.O. poppet ............ G ........... Hydraulic limit switch circuit ............. 35-40 ft-lbs (47-54 Nm)
8 Flow regulator valve,
1.5 gpm (5.7 l/min) ............................ H ........... Boom extend/retract circuit
(prevents overflowing
the proportional valve) ..................... 10-12 ft-lbs (14-16 Nm)
1.5 gpm (5.7 l/min) ............................ I ............ Boom up/down circuit
the proportional valve) ..................... 10-12 ft-lbs (14-16 Nm)
1.5 gpm (5.7 l/min) ............................ J ............ Turntable rotate left/right
the proportional valve) ....................... 10-12 ft-lbs (14-6 Nm)
0.2 gpm (0.78 l/min) .......................... K ........... Hydraulic limit switch circuit ............. 10-12 ft-lbs (14-16 Nm)
0.1 gpm (0.37 l/min) ......................... L ............ Bleeds off differential
sensing valves to tank ........................ 10-12 ft-lbs (14-6 Nm)
13 2 position 2 way directional valve ..... M .......... Hydraulic limit switch circuit ............. 25-30 ft-lbs (34-41 Nm)
14 Check valve ....................................... N ........... Differential sensing circuit,
boom extend/retract .......................... 11-13 ft-lbs (15-18 Nm)
15 Check valve ....................................... O ........... Differential sensing circuit,
boom up/down .................................. 11-13 ft-lbs (15-18 Nm)
16 Proportional solenoid valve .............. P ........... Boom extend/retract ......................... 10-12 ft-lbs (14-16 Nm)
17 Check valve ....................................... Q ........... Differential sensing circuit,
turntable rotate left/right .................... 11-13 ft-lbs (15-18 Nm)
18 Proportional solenoid valve .............. R ........... Boom up/down ................................. 10-12 ft-lbs (14-16 Nm)
19 Check valve ....................................... S ........... Differential sensing circuit,
platform level up ............................... 11-13 ft-lbs(15-18 Nm)

MANIFOLDS

MANIFOLDS
Function Manifold Components, continued

Index Schematic
20 Check valve ....................................... T ........... Differential sensing circuit,

platform level down .......................... 11-13 ft-lbs (15-18 Nm)
21 Proportional solenoid valve .............. U ........... Turntable rotate left/right .................. 10-12 ft-lbs (14-16 Nm)
22 Solenoid valve - N.O. poppet ............ V ........... Platform level up ............................... 25-30 ft-lbs (34-41 Nm)
0.6 gpm (2.27 l/min) .......................... W .......... Platform level circuit ......................... 10-12 ft-lbs (14-16 Nm)
24 Solenoid valve - N.O. poppet ............ X ........... Platform level down .......................... 25-30 ft-lbs (34-41 Nm)
25 Differential sensing valve .................. Y ........... Meters flow to functions .................... 10-12 ft-lbs (14-16 Nm)
26 Relief valve, 2900 psi (200 bar) ........ Z ........... System relief ..................................... 35-40 ft-lbs (47-54 Nm)
27 Diagnostic nipple ............................................. Testing
28 Check valve ....................................... AA ......... Differential sensing circuit
Platform rotate left ............................. 11-13 ft-lbs (15-18 Nm)
29 Check valve ....................................... BB ......... Differential sensing circuit
Platform rotate right .......................... 11-13 ft-lbs (15-18 Nm)
30 Priority flow regulator valve, .............. CC ........ Steering ............................................ 10-12 ft-lbs (14-16 Nm)
5 gpm (18.9 l/min)
31 Solenoid valve - N.O. poppet ........... DD ........ Platform rotate left/Jib boom up ........ 25-30 ft-lbs (34-41 Nm)
32 Solenoid valve - N.O. poppet ........... EE ......... Platform rotate right/Jib boom down 25-30 ft-lbs (34-41 Nm)
0.6 gpm (2.27 l/min) .......................... FF ......... Platform rotate .................................. 10-12 ft-lbs (14-16 Nm)
34 Counterbalance valve ....................... GG ........ Platform level up ............................... 35-40 ft-lbs (47-54 Nm)
35 Counterbalance valve ....................... HH ........ Platform level down .......................... 35-40 ft-lbs (47-54 Nm)
36 Check valve ....................................... II ............ Boom extend/retract circuit ............... 11-13 ft-lbs (15-18 Nm)
Valve Coil Resistance

Plug Torque Specifications Specifications
3 position 4 way directional valve, 10V 3.2Ω
Description Hex size Torque
(schematic items A, B and C)
SAE No. 2 1/8 50 in-lbs (6 Nm)
Solenoid valve - N.O. poppet 5.4Ω
SAE No. 4 3/16 13 ft-lbs (18 Nm) (schematic item G)
SAE No. 6 1/4 18 ft-lbs (24 Nm) Proportional solenoid valve, 10V 4.7Ω
(schematic items P, R and U)
SAE No. 8 5/16 50 ft-lbs (68 Nm)
Solenoid valve - N.O. poppet 5.6Ω
SAE No. 10 9/16 55 ft-lbs (75 Nm) (schematic items V, X, DD and EE)

MANIFOLDS

MANIFOLDS
11-2 How to Adjust the Boom Down

Valve Adjustments - Relief Valve
Function Manifold Perform this procedure with the
boom in the stowed position.
How to Adjust the System 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure
Relief Valve gauge to the diagnostic nipple (index 27) on the
function manifold.
boom in the stowed position. 2 Start the engine from the ground controls.
1 Connect a 0 to 5000 psi (0 to 345 bar) pressure 3 Hold the function enable switch to the high idle
gauge to the diagnostic nipple (index 27) on the side and activate and hold the boom down
function manifold. toggle switch with the boom fully lowered.
Observe the pressure reading on the pressure
2 Start the engine from the ground controls. gauge.
3 Hold the function enable switch to the high idle
side and activate and hold the retract switch Boom down relief valve specifications
with the boom fully retracted. Observe the Pressure 2300 psi
pressure reading on the pressure gauge. 158.5 bar
System relief valve specifications
Pressure 2900 psi

4 Turn the engine off. Use a wrench to hold the
200 bar relief valve and remove the cap (index 5) on
the function manifold.
5 Adjust the internal hex socket. Turn it clockwise
4 Turn the engine off. Use a wrench to hold the to increase pressure or counterclockwise to
relief valve and remove the cap (index 26) on decrease pressure. Install the relief valve cap.
the function manifold.
Tip-over hazard. Do not adjust
5 Adjust the internal hex socket. Turn it clockwise the relief valves higher than
to increase pressure or counterclockwise to specified.
decrease pressure. Install the relief valve cap.
6 Repeat steps 2 through 5 and confirm relief
Tip-over hazard. Do not adjust valve pressure.
the relief valves higher than
specified.
6 Repeat steps 2 through 5 to confirm relief valve
pressure.

MANIFOLDS
How to Adjust the Boom Extend How to Override a Valve

Relief Valve A hydraulic valve may need to be manually
Perform this procedure with the overridden to troubleshoot a malfunction. The
boom in the stowed position. proportional boom functions (boom up/down,
extend/retract and turntable rotate) use a variable
1 Connect a 0 to 3000 psi (0 to 207 bar) pressure position proportional valve and a three position
gauge to the diagnostic nipple (index 27) on the directional valve. Example: one position for boom
function manifold. up, one position for neutral and one position for
boom down. The platform rotate function uses a
three position valve. The platform level uses a
3 Hold the function enable switch to either side three position and a two position valve. The three
and hold the boom extend toggle switch with position valves and the proportional valves can be
the boom fully extended. Observe the pressure manually overridden. To identify the manifold
reading on the pressure gauge. valves see 11-1, Function Manifold, in this section.
Boom extend relief valve specifications 1 Push the button on the end of the valve in
¼ inch (6 mm).
Pressure 2500 psi
172 bar
4 Turn the engine off. Use a wrench to hold the

relief valve and remove the cap
(index 6) on the function manifold.
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Then install the relief
valve cap.
Tip-over hazard. Do not adjust 2 Hold the function enable switch to either side
the relief valves higher than and move the ground control toggle switch for
specified. the function being overridden to operate the
function.
6 Repeat steps 2 through 5 to confirm relief valve
pressure. Collision hazard. Impact with
moving boom components could
Use extreme caution when
overriding a machine function.
Identify the direction of machine
movement before overriding a
valve.

MANIFOLDS
11-3
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor on the tank side of the turntable.
ndex Schematic
1 Shuttle valve, 2 position 3 way ......... JJ .......... Turntable rotation brake release ...... 10-13 ft-lbs (14-18 Nm)
2 Counterbalance valve ....................... KK ......... Turntable rotate left ........................... 35-40 ft-lbs (47-54 Nm)
3 Counterbalance valve ....................... LL ......... Turntable rotate right ........................ 35-40 ft-lbs (47-54 Nm)
1 2 3
KK
LL
JJ
Plug Torque Specifications

SAE No. 4 3/16 13 ft-lbs (18 Nm)
SAE No. 6 1/4 18 ft-lbs (24 Nm)

MANIFOLDS
11-4
Chassis Jack Manifold Components
The chassis jack manifold is mounted next to the drive manifold at the non-steer end.
Index Schematic
1 Check valve ....................................... MM ....... Hydraulic limit switch circuit ............. 35-40 ft-lbs (47-54 Nm)
2 Relief valve, 350 psi (24.1 bar) ......... NN ........ Chassis jack auto retract circuit ........ 25-30 ft-lbs (34-41 Nm)
3 Counterbalance valve ....................... OO ........ Steer end chassis jack circuit ........... 35-40 ft-lbs (47-54 Nm)
4 Counterbalance valve ....................... PP ......... Non-steer end chassis jack circuit ... 35-40 ft-lbs (47-54 Nm)
OO
PP
NN
MM

SAE No. 4 3/16 13 ft-lbs (18 Nm)
SAE No. 6 1/4 18 ft-lbs (24 Nm)

MANIFOLDS
11-5
Axle Extend Dump Manifold Components
The axle extend dump manifold is mounted to the tank tray underneath the function manifold.
Index Schematic
1 Check valve ....................................... QQ ........ Blocks flow back to pump ............ 85-90 ft-lbs (115-122 Nm)
2 Relief valve, 200 psi (13.8 bar) ......... RR ........ Chassis jack relief circuit when
boom is raised or extended .............. 25-30 ft-lbs (34-41 Nm)
3 Solenoid valve - N.O. ........................ SS ......... Allows chassis jacks to lift chassis
when boom is in stowed position ..... 25-30 ft-lbs (34-41 Nm)
4 Check valve ....................................... TT ......... Prevents flow from chassis jacks
through auxiliary pump ..................... 25-30 ft-lbs (34-41 Nm)
5 Flow regulator, 0.3 gpm (1.14 l/min) . UU ........ Regulates flow to steer manifold ...... 10-12 ft-lbs (14-16 Nm)
1 2
RR
QQ
5
UU 3
TT SS
4
SAE No. 2 1/8 50 in-lbs (6 Nm) Specification
SAE No. 4 3/16 13 ft-lbs (18 Nm)
Solenoid valve, 10V 4.5 to 7.5Ω
SAE No. 6 1/4 18 ft-lbs (24 Nm) (schematic item SS)

MANIFOLDS
11-6
Steer Manifold Components
The steer manifold is mounted underneath the function manifold.
Index Schematic
1 3 position 4 way solenoid valve ........ VV ......... Steer left/right ...................................... 30-35 in-lbs (3-4 Nm)
2 Check valve ....................................... WW ....... Priority flow regulator circuit ............. 10-12 ft-lbs (14-16 Nm)
3 Orifice plug, 0.025 inch (0.635 mm) .. XX ......... Priority flow regulator circuit
4 Priority flow regulator valve,
3.5 gpm (13.2 l/min) ......................... YY ......... Regulates flow to axle
extend dump manifold ..................... 10-12 ft-lbs (14-16 Nm)
VV
WW
XX
4 2
YY
3

1/8
SAE No. 2 50 in-lbs (6 Nm) Specification
SAE No. 4 3/16 13 ft-lbs (18 Nm)
3 position 4 way solenoid valve, 10V 4.5 to 7.5Ω
SAE No. 6 1/4 18 ft-lbs (24 Nm) (schematic item VV)

MANIFOLDS
11-7
2WD Drive Manifold Components
The drive manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Relief valve, 260 psi (18 bar) ............ ZZ ......... Charge pressure circuit .................... 10-12 ft-lbs (14-16 Nm)
2 Flow divider/combiner valve ............. AB ......... Controls flow to drive motors
in forward and reverse ..................... 25-30 ft-lbs (34-41 Nm)
3 Orifice, 0.07 in (1.8 mm) .................... AC ........ Drive circuit
4 Shuttle valve, 3 position 3 way ......... AD ........ Charge pressure circuit that
gets hot oil out of low pressure
side of drive pump. ........................... 15-18 ft-lbs (20-24 Nm)
5 Diagnostic nipple ............................................. Testing

SAE No. 4 3/16 13 ft-lbs (18 Nm)
SAE No. 6 1/4 18 ft-lbs (24 Nm)
SAE No. 8 5/16 50 ft-lbs (68 Nm)

MANIFOLDS
11-8 6 Start the engine from the platform controls and

drive the machine slowly in the forward
Valve Adjustments, direction. Note the pressure reading on the
2WD Drive Manifold pressure gauge.
7 Turn the engine off and remove the hot oil
How to Adjust the Hot Oil Shuttle shuttle relief valve cap (index 1). Adjust the
Relief Valve internal hex socket counterclockwise one full
turn. Install the valve cap.
The pressure differential between
the charge pump relief valve
Drive the machine slowly in the forward direction
(located in the drive pump) and the
and note the pressure reading on the pressure
hot oil shuttle relief valve (located
gauge.
in the drive manifold) is necessary
to return hot oil from the closed 9 Turn the engine off, and remove the hot oil
loop drive circuit to the hydraulic shuttle relief valve cap (index 1). Adjust the
tank for cooling. This pressure internal hex socket clockwise to increase the
differential must be maintained at pressure or counterclockwise to decrease the
40 psi (14.5 bar). pressure. Install the valve cap.
The following procedure will require 10 Repeat steps 6 through 9 until a pressure
two people. differential (between the charge pump reading
and the hot oil shuttle relief valve) of 40 psi
1 Hold the hot oil shuttle relief valve with a wrench
(14.5 bar) is obtained.
and remove the cap (index 1).
2 Turn the internal hex socket clockwise until it is Hot Oil Shuttle Relief valve specifications
fully seated. Install the valve cap.
Pressure 260 psi
3 Open the engine side turntable cover and 18 bar
connect a 0 to 600 psi (0 to 41 bar) pressure
gauge to the diagnostic nipple on the drive
pump.
allow the engine to run at low idle. Note the
pressure reading on the pressure gauge.
5 Turn the engine off and connect a 0 to 600 psi
(0 to 41 bar) pressure gauge to the diagnostic
nipple (index 5) located on the drive manifold.

MANIFOLDS
11-9
4WD Drive Manifold Components
The drive manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Directional valve, 2 position 2 way ... AE ......... High speed divider bypass
N.C. Pilot to open ............................. 25-30 ft-lbs (34-41 Nm)
2 Flow divider/combiner valve ............. AF ......... Controls flow to flow
divider/combiner valves 6 and 7 ..... 25-30 ft-lbs (34-41 Nm)
3 Relief valve, 260 psi (18 bar) ............ AG ........ Charge pressure circuit ................... 10-12 ft-lbs (14-16 Nm)
4 Check valve, pilot to close ................ AH ........ Works in conjunction with
Index no.12 in the high speed
divider bypass circuit ....................... 10-12 ft-lbs (14-16 Nm)
5 Orifice - plug, 0.052 inch (1.32 mm) .. AI .......... Steer end drive motor circuit
6 Flow divider/combiner valve ............. AJ ......... Controls flow to steer end
drive motors in forward
and reverse ...................................... 25-30 ft-lbs (34-41 Nm)
7 Flow divider/combiner valve ............. AK ......... Controls flow to non-steer end
drive motors in forward
and reverse ...................................... 25-30 ft-lbs (34-41 Nm)
8 Orifice, 0.07 in (1.8 mm) .................... AL ......... Non-steer end drive motor circuit
9 Orifice, 0.07 in (1.8 mm) .................... AM ........ Equalizes pressure on both sides
of flow divider combiner valve
Index no. 2
10 Shuttle valve, 3 position 3 way ......... AN ........ Charge pressure circuit
that gets hot oil out of low pressure
side of drive pump ........................... 15-18 ft-lbs (20-24 Nm)
11 Diagnostic fitting ............................................... Testing
12 Check valve ....................................... AO ........ Works in conjunction with
Index no. 4 in the high speed
divider bypass circuit ....................... 10-12 ft-lbs (14-16 Nm)

SAE No. 4 3/16 13 ft-lbs (18 Nm)
SAE No. 6 1/4 18 ft-lbs (24 Nm)
SAE No. 8 5/16 50 ft-lbs (68 Nm)

MANIFOLDS

MANIFOLDS
11-10 6 Start the engine from the platform controls and

drive the machine slowly in the forward
Valve Adjustments, direction. Note the pressure reading on the
4WD Drive Manifold pressure gauge.
7 Turn the engine off and remove the hot oil
How to Adjust the Hot Oil Shuttle shuttle relief valve cap (index 3). Adjust the
Relief Valve internal hex socket counterclockwise one full
turn. Install the valve cap.
The pressure differential between
the charge pump relief valve
Drive the machine slowly in the forward direction
(located in the drive pump) and the
and note the pressure reading on the pressure
hot oil shuttle relief valve (located
gauge.
in the drive manifold) is necessary
to return hot oil from the closed 9 Turn the engine off, and remove the hot oil
loop drive circuit to the hydraulic shuttle relief valve cap (index 3). Adjust the
tank for cooling. This pressure internal hex socket clockwise to increase the
differential must be maintained at pressure or counterclockwise to decrease the
40 psi (14.5 bar). pressure. Install the valve cap.
The following procedure will require 10 Repeat steps 6 through 9 until a pressure
two people. differential (between the charge pump reading
and the hot oil shuttle relief valve) of 40 psi
1 Hold the hot oil shuttle relief valve with a wrench
(14.5 bar) is obtained.
and remove the cap (index 3).
2 Turn the internal hex socket clockwise until it is Hot Oil Shuttle Relief valve specifications
fully seated. Install the valve cap.
Pressure 260 psi
3 Open the engine side turntable cover and 18 bar
connect a 0 to 600 psi (0 to 41 bar) pressure
pump.
allow the engine to run at low idle. Note the
pressure reading on the pressure gauge.
5 Turn the engine off and connect a 0 to 600 psi
(0 to 41 bar) pressure gauge to the diagnostic
nipple (index 11) located on the drive manifold.

MANIFOLDS
11-11
Jib Boom / Platform Rotate Manifold Components, S-85 Models
The jib boom/platform rotate manifold is mounted on the platform end of the boom.
Index Schematic
1 2 position 3 way valve ....................... AP ......... Platform rotate select .......................... 8-10 ft-lbs (11-14 Nm)
2 Orifice fitting, 0.030 inch (0.76 mm) .. AQ ........ Platform rotate circuit

Specification
2 position 3 way solenoid valve, 10V 4.5 to 7.5Ω
(schematic item AP)

MANIFOLDS
11-12
Brake/Two Speed Manifold Components
The brake/two speed manifold is mounted on the engine tray.
Index Schematic
1 2 position, 3 way valve ...................... AR ........ Brake release ..................................... 8-10 ft-lbs (11-14 Nm)
2 2 position, 3 way valve ...................... AS ......... 2-Speed wheel motors,
(energized in high range to
destroke the rear motor
swash plates) .................................... 8-10 ft-lbs (11-14 Nm)
3 Orifice fitting, 0.025 inch (0.63 mm) .. AT ......... Two speed/Brake circuit

Specification
Solenoid valve, 2 position 3 way , 10V 5.9 to 6.4Ω
(schematic items AR and AS)

Fuel and Hydraulic Tanks

12-1 5 Support the fuel tank with 2 lifting straps. Place
one lifting strap at each end of the tank and
Fuel Tank attach the lifting straps to an overhead crane.
6 Remove the fuel tank from the machine.
How to Remove the Fuel Tank
Crushing hazard. The fuel tank
Explosion and fire hazard. Engine could become unbalanced and fall
fuels are combustible. Remove the when it is removed from the
fuel tank in an open, well- machine if it is not properly
ventilated area away from heaters, supported and secured to the
sparks, flames and lighted overhead crane.
When installing the plastic fuel
easy reach.
tank, do not overtighten the
Explosion and fire hazard. When retaining fasteners.
transferring fuel, connect a
Clean the fuel tank and inspect
grounding wire between the
for rust and corrosion before
machine and pump or container.
installing.
1 Turn the manual fuel shutoff valve to the
CLOSED position.
2 Remove the tank side turntable cover. See 5-1,

How to Remove a Turntable Cover.
3 Ford models: Disconnect, drain and plug the
fuel hose.
Diesel models: Disconnect, drain and plug the
supply and return fuel hoses. Cap the fuel
return fitting on the fuel tank.
4 Metal tank: Remove the fuel tank hold down
straps retaining fasteners. Remove the straps
from the fuel tank.
Plastic tank: Remove the fuel tank retaining
fasteners.

FUEL AND HYDRAULIC TANKS
12-2 3 Close the two hydraulic shutoff valves located

at the hydraulic tank.
Hydraulic Tank
The primary functions of the hydraulic tank are to
cool, clean and deaerate the hydraulic fluid during
operation. The tank utilizes internal suction
strainers for the pump supply hoses and has an
external return filter equipped with a filter condition
indicator.
open closed
How to Remove the
Hydraulic Tank Component damage hazard. The
Component damage hazard. the hydraulic tank shutoff valves in
The work area and surfaces the CLOSED position or component
where this procedure will be damage will occur. If the tank
performed must be clean and valves are closed, remove the key
free of debris that could get from the key switch and tag the
into the hydraulic system. machine to inform personnel of the
condition.
or fitting, the O-ring on the fitting 4 Remove the drain plug from the hydraulic tank.
5 Completely drain the tank into a suitable
container. See capacity specifications.
Refer to Section Two, Hydraulic 6 Tag, disconnect and plug the two suction hoses
Hose and Fitting Torque that are attached to the hydraulic tank
Specifications. shutoff valves.
1 Lower and retract the boom to the stowed 7 Disconnect and plug the T-fitting located at the
position. return filter with the 2 hoses connected to it.
Cap the fitting on the return filter housing.
2 Remove the fuel tank. See 12-1, How to
Remove the Fuel Tank. 8 Disconnect and plug the supply hose for the
auxiliary power unit. Cap the fitting on the
hydraulic tank.

9 Remove the retaining fasteners from the 19 Clean up any oil that may have spilled.
hydraulic tank hold down straps. Remove the
20 Open the hydraulic tank shutoff valves.
hold down straps from the hydraulic tank.
10 Support the hydraulic tank with 2 lifting straps. Component damage hazard.
Place one lifting strap at each end of the tank Be sure to open the two hydraulic
and attach the lifting straps to an overhead tank shutoff valves and prime the
crane. pump after installing the hydraulic
tank.
11 Remove the hydraulic tank from the machine.
Always use pipe thread sealant
Crushing hazard. The hydraulic when installing the drain plug and
tank could become unbalanced strainers.
supported and secured to the Use only Dexron equivalent
overhead crane. hydraulic fluid.
12 Remove the suction strainers from the tank and Hydraulic system
clean them using a mild solvent.
Hydraulic tank capacity 45 gallons
13 Rinse out the inside of the tank using a mild
170 liters
solvent.
14 Install the suction strainers using pipe thread Hydraulic system 55 gallons
capacity (including tank) 208 liters
sealant on the threads.
15 Install the drain plug using pipe thread sealant Hydraulic fluid Dexron equivalent
on the threads.
16 Install the hydraulic tank onto the machine.
17 Install the two suction hoses and the supply
hose for the auxiliary power unit.
18 Fill the tank with hydraulic oil until the level is
within the top 2 inches (5 cm) of the sight
gauge. Do not overfill.

How to Prime the Pump a

sure that the hydraulic tank shutoff
valves are in the OPEN position
before priming the pump. The
damage will occur.
1 Connect a 0 to 600 psi (0 to 41 bar) pressure
pump.
Deutz model
2 Ford models: Close the valve on the LPG tank, a manual fuel shutoff valve
then disconnect the hose from the tank. Move
the fuel select toggle switch to the LPG
position. 3 Crank the engine with the starter motor for
Deutz models: Hold the manual fuel shutoff 15 seconds, wait 15 seconds, then crank the
valve counterclockwise to the CLOSED position. engine an additional 15 seconds or until the
pressure reaches 250 psi (17.2 bar).
Perkins models: Disconnect the engine wiring
harness from the fuel solenoid at the injector 4 Ford models: Connect the LPG hose to the
pump. LPG tank and open the valve on the tank.
Deutz models: Release the manual shutoff
valve.
Perkins models: Connect the engine wiring
harness to the fuel solenoid.
check for hydraulic leaks.

Turntable Rotation Components

13-1 2 Tag, disconnect and plug the hydraulic hoses
from the motor, brake and manifold. Cap the
Rotation Hydraulic Motor fittings on the motor, brake and manifold.
How to Remove the Rotation hydraulic oil can penetrate and
Hydraulic Motor burn skin. Loosen hydraulic
squirt or spray.
during installation. Refer to 3 Remove the motor/brake mounting fasteners,
Section Two, Hydraulic Hose and then remove the motor from the brake.
Fitting Torque Specifications.
1 Secure the turntable from rotating with the
Unlocked position
a motor
b motor/brake mounting bolts
c brake
d drive hub
Locked position

TURNTABLE ROTATION COMPONENTS
How to Remove the Turntable 3 Loosen the backlash pivot plate and adjustment
bolts.
Rotation Brake or Drive Hub
4 Remove the drive hub mounting bolts, then use
1 Secure the turntable from rotating with the an appropriate lifting device to remove the drive
turntable rotation lock pin. hub from the machine.
Crushing hazard. The turntable
rotate drive hub could become
unbalanced and fall when it is
removed from the machine if it is
not properly supported.
5 Install the drive hub. Torque the drive hub
mounting bolts to 180 ft-lbs (244 Nm).
6 Install the brake, then motor onto the drive hub.
unlocked locked Torque the brake/motor mounting bolts to
75 ft-lbs (102 Nm).
2 Remove the motor, See 13-1, How to Remove
the Rotation Hydraulic Motor. 7 Adjust turntable rotation gear backlash. See
13-1, How to Adjust the Turntable Rotation
Component damage hazard. Gear Backlash.
Hoses can be damaged if they are
kinked or pinched.
a motor
b motor/brake mounting bolts
c brake
d drive hub
f pivot plate mounting bolts
g adjustmetnt bolt with lock nut

TURNTABLE ROTATION COMPONENTS
How to Adjust the

Turntable Rotation Gear Backlash
The turntable rotation drive hub is mounted on an
adjustable plate that controls the gap between the
rotation motor gear and the turntable bearing ring
gear.
Be sure to check the backlash

with the machine on a flat level
surface.
1 Secure the turntable from rotating with the
a drive hub pivot plate

b pivot plate mounting bolts
c adjustment bolt with lock nut
2 Push the drive hub pivot plate towards the

turntable as far as possible (this will push the
unlocked locked rotation gear into the turntable bearing ring
2 Loosen the mounting fasteners on the drive hub gear).
pivot plate. 3 Loosen the lock nut on the adjustment bolt.
4 Turn the adjustment bolt clockwise until it
contacts the pivot plate.
5 Turn the adjustment bolt 1/2 turn
counterclockwise. Tighten the lock nut on the
adjustment bolt.
6 Rotate the drive hub pivot plate away from the
turntable until it contacts the adjustment bolt.
Then tighten the mounting fasteners on the
drive hub pivot plate.
7 Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
Readjust if necessary.


14-1 2 Loosen the wheel lug nuts. Do not
remove them.
Yoke and Hub
3 Block the non-steering wheels, and center a
lifting jack of ample capacity under the steering
How to Remove the Yoke axle.
and Hub
1 Remove the pin retaining fastener from the (15 cm) and place blocks under the chassis for
steering cylinder rod-end pivot pin and the tie support.
rod clevis pin. Remove the pivot pins.
5 Remove the lug nuts. Remove the tire and
wheel assembly.
6 Remove the pin retaining fasteners from the
yoke pivot pins.
7 Support and secure the yoke/hub assembly to a
lifting jack.
8 Use a slide hammer to remove the upper yoke
pivot pin.
9 Use a soft metal drift to drive the lower yoke
pivot pin down and out.
Crushing hazard. The yoke/hub
assembly could become
unbalanced and fall when the yoke
pivot pins are removed if it is not
properly supported and secured to
the lifting jack.
Torque specifications
Lug nut torque, dry 420 ft-lbs

a tie rod 569.5 Nm
b axle
c yoke pivot pin Lug nut torque, lubricated 320 ft-lbs
d yoke 434 Nm
e hub
f clevis pin
g steering cylinder

2WD STEERING AXLE COMPONENTS
How to Remove the How to Install the

Hub and Bearings Hub and Bearings
1 Loosen the wheel lug nuts. Do not remove them. When replacing a wheel bearing,
both the inner and outer bearings
2 Block the non-steering wheels. Center a lifting
including the pressed-in races
jack of ample capacity under the steering axle.
must be replaced.
(15 cm) and place blocks under the chassis for 1 Be sure that both bearings are packed
support. with clean, fresh grease.
4 Remove the lug nuts, then remove the tire 2 Place the large inner bearing into the rear
and wheel assembly. of the hub.
5 Remove the dust cap, cotter pin and 3 Press the bearing seal evenly into the hub
castle nut. until it is flush.
Always use a new cotter pin when 4 Slide the hub onto the yoke spindle.
installing a castle nut.
Component damage. Do not
6 Pull the hub off the yoke spindle. The washer apply excessive force or damage
and outer bearing should fall loose from the to the lip of the seal may occur.
hub.
5 Place the outer bearing into the hub.
7 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the 6 Install the washer and castle nut.
inner bearing. 7 Torque the castle nut to 35 ft-lbs (47 Nm)
Always install a new bearing seal to seat the bearings.
when removing a hub. 8 Loosen the castle nut, then torque the castle
nut to 8 ft-lbs (11 Nm).
9 Install a new cotter pin. Bend the cotter pin
to lock it.
Always use a new cotter pin when
installing a castle nut.
10 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
420 ft-lbs (569.5 Nm).

14-2 3 Remove the pin retaining fasteners from the

steer cylinder pivot pins. Then remove the pivot
Steering Cylinders pin from each end of the steering cylinder.
4 Remove the steering cylinder from the machine.
How to Remove a
Steering Cylinder
There are two identical steering cylinders that
work in parallel. They are part of the same
hydraulic circuit, but move in opposite directions.
The tie rod maintains equal movement of the tires.

Specifications.
1 Tag, disconnect and plug the hydraulic hoses
from the steering cylinder. Cap the fittings on
the cylinder.
squirt or spray.
2 4WD Models: Remove the hose bracket
mounting fastener on the steer cylinder barrel-
end pivot pin.

14-3 1 Straighten the steer wheels.

Tie Rod Cylinder 2 Measure the steer tires, front to front and back
to back, using a measuring fixture.
How to Remove the
Tie Rod Cylinder
1 Tag, disconnect and plug the hydraulic hoses
from the tie rod cylinder. Cap the fittings on the
cylinder.
squirt or spray.
2 Support the tie rod cylinder with a lifting jack. 3 Center a lifting jack of ample capacity under the
steering axle, then raise the machine.
3 Remove the pin retaining fasteners, then remove
the pivot pin from each end of the tie rod 4 Loosen the jam nut on the adjustable end
cylinder. of the tie rod cylinder.
4 Remove the tie rod cylinder. 5 Remove the pin retaining fasteners, then remove
the pivot pin from the adjustable end of the tie
Crushing hazard. The tie rod rod cylinder.
and fall if it is not properly 6 Slide the tie rod cylinder off of the yoke and
supported and secured to the lifting adjust it by turning the end.
jack when it is removed from the One half turn on the adjustable end
machine. equals approximately 1/4 inch
(6.4 mm) change in the front
How to Perform the Toe-in and rear measurements.
Adjustment
7 Slide the tie rod cylinder onto the yoke. Install
Perform this procedure on a the pivot pin, then install the retaining bolt.
firm, level surface. Block the
8 Tighten the jam nut against the tie rod cylinder.
non-steering tires and be sure
that the machine is in the 9 Lower the machine and recheck the
stowed position. front and back measurements (step 2).
If further adjustment is needed, repeat
steps 3 through 8.
Toe-in specification 0 ± 1/8 inch (6.35 mm)


from the drive motor. Cap the fittngs on the
Yoke and Hub drive motor.
How to Remove the Yoke hydraulic oil can penetrate and
and Hub burn skin. Loosen hydraulic
The yoke installation utilizes bushings and a thrust
washer that may require periodic replacement. The
yoke must be removed before the drive hub can be
squirt or spray.
removed.
3 Loosen the wheel lug nuts. Do not
When removing a hose assembly remove them.
and/or hose end must be replaced 4 Block the non-steering wheels, and center a
and then torqued to specification lifting jack of ample capacity under the steering
during installation. axle.
Refer to Section Two, Hydraulic 5 Raise the machine approximately 6 inches
Hose and Fitting Torque (15 cm) and place blocks under the chassis for
Specifications. support.
1 Remove the pin retaining fasteners from both 6 Remove the lug nuts, then remove the tire and
the steering cylinder and the tie rod cylinder wheel assembly.
pivot pins. Remove the pins.
7 Remove the hydraulic hose clamp retaining
fastener from the top of the yoke pivot pin.
8 Remove the drive motor mounting fasteners.
9 Slide the drive motor shaft out of the drive hub
and then remove the drive motor from the
machine.
10 Remove the pin retaining fasteners from the
upper and lower yoke pivot pins.
11 Support and secure the yoke/drive hub
assembly to a lifting jack.
a steer cylinder
b yoke king pin
c drive hub
d yoke
e clevis pin
f tie rod cylinder

12 Use a slide hammer to remove the upper yoke 15-2

pivot pin, then use a soft metal drift to drive the
lower yoke pivot pin down and out. Steering Cylinders
Crushing hazard. The yoke/hub
assembly may become
How to Remove a
unbalanced and fall when the yoke Steering Cylinder
pivot pins are removed if it is not
This procedure is the same as the 2WD procedure.
properly secured and supported by
See repair procedure 14-2,
the lifting jack.
How to Remove a Steering Cylinder.
13 Place the yoke/drive hub assembly on a flat
surface with the drive hub facing down. 15-3
14 Remove the drive hub mounting fasteners that Tie Rod Cylinder
attach the drive hub to the yoke. Remove the
drive hub from the yoke. How to Remove the
Replace the thrust washer when Tie Rod Cylinder
installing the yoke/drive hub
assembly onto the axle. This procedure is the same as the 2WD procedure.
See Repair Procedure 14-3,
Torque specifications How to Remove the Tie Rod Cylinder.
Lug nut, dry 420 ft-lbs How to Perform the Toe-in

569.5 Nm
Adjustment
Lug nut torque, lubricated 320 ft-lbs
434 Nm This procedure is the same as the 2WD procedure.
See Repair Procedure 14-3,
Drive hub mounting bolts, dry 120 ft-lbs How to Perform the Toe-in Adjustment.
163 Nm
Drive hub mounting bolts, lubricated 90 ft-lbs

122 Nm
Drive motor mounting bolts, dry 75 ft-lbs

102 Nm
Drive motor mounting bolts, lubricated 56 ft-lbs

76 Nm

Extendable Axle Components

16-1 1 Remove the drice chassis cover.
Extendable Axles 2 Retract the axle, then extend the axle
approximately 8 inches (203 mm).
The extendable axles are used to widen the foot 3 Loosen the wear pad mounting fasteners on the
print of the drive chassis for stability. top and side wear pads.
How to Shim the Outer Axle 4 Install the new shims under the wear pads to
obtain zero clearance and zero drag. Tighten the
Measure each wear pad. Replace wear pad fasteners.
the wear pad if it is less than
7/16 inch (11 mm) thick. If the pad 5 Extend and retract the axle through an entire
is more than 7/16 inch (11 mm) cycle. Check for tight spots that could cause
thick, perform the following binding or scraping.
procedure. 6 Install the drive chassis cover and fasteners.
Always maintain squareness
1 Extend the axle, then retract it 1 inch (25.4 mm). between the inner and outer axle
tubes.
2 Loosen the wear pad mounting fasteners.
Non-steer end:
3 Install the new shims under the wear pads to
obtain zero clearance and zero drag. 1 Remove the drive chassis cover.
4 Use a round punch to align the shim to the wear 2 Retract the axle, then extend the axle
pad. Tighten the mounting fasteners. approximately 4 inches (101 mm).
5 Extend and retract the axle through an entire 3 Loosen the wear pad mounting fasteners on the
cycle. Check for tight spots that could cause top and side wear pads.
binding or scraping. 4 Install the new shims under the wear pads to
Always maintain squareness obtain zero clearance and zero drag. Tighten the
between the inner and outer axle wear pad fasteners.
tubes. 5 Extend and retract the axle through an entire
cycle. Check for tight spots that could cause
How to Shim the Inner Axle binding or scraping.
Steer end: 6 Install the drive chassis cover and fasteners.
Measure each wear pad. Replace Always maintain squareness
the wear pad if it is less than between the inner and outer axle
7/16 inch (11 mm) thick. If the pad
tubes.
is more than 7/16 inch (11 mm)
thick, perform the following
procedure.

EXTENDABLE AXLE COMPONENTS
How to Remove the Inner Axle 7 Block the wheels on the non-steer end of the
machine, then center a lifting jack under the
When removing a hose assembly axle to be removed.
and/or hose end must be replaced 8 Raise the machine 15 inches (38 cm) and place
and then torqued to specification blocks under the chassis for support.
during installation. 9 Remove the lug nuts, then remove the tire and
Refer to Section Two, Hydraulic wheel assembly.
Specifications. 10 Remove the yoke and hub assembly. See 15-1,
How to Remove the Yoke and Hub.
hydraulic oil can penetrate and 11 Remove the steer cylinder. See 14-2, How to
burn skin. Loosen hydraulic Remove a Steering Cylinder.
connections very slowly to allow 12 Remove the steer cylinder mounting lug from the
the oil pressure to dissipate inner axle.
or spray. 13 Remove the pin retaining fasteners from the tie
rod cylinder. Remove the pins.
Steer end:
14 Remove the external snap ring from the axle
1 Remove the drive chassis cover. extension cylinder pivot pin. Use a soft metal
2 Retract the axle and remove the shims from the drift to remove the pin.
top wear pads of the inner axle. 15 Tag, disconnect and plug the axle extension
Pay careful attention to the cylinder hydraulic hoses at the tee next to the
location and number of shims chassis lift jack.
used when removing the shims. Bodily injury hazard. Spraying
3 Extend the axle, then retract the axle hydraulic oil can penetrate and
approximately 1 inch (25 mm). burn skin. Loosen hydraulic
4 Loosen the axle limit switch actuator rod. the oil pressure to dissipate
Remove the mounting hardware from the gradually. Do not allow oil to squirt
linkage pivot plate. or spray.
5 Remove the actuator rod assembly and set it 16 Attach a strap from a lifting device to the inner
aside. axle for support.
6 Loosen the wheel lug nuts. Do not remove
them.

17 Remove all wear pads between the inner and 8 Raise the machine 15 inches (38 cm) and place
outer axle. blocks under the chassis for support.
Pay careful attention to the 9 Remove the drive motor covers from both sides
location and number of shims used of the axle.
when removing the wear pads.
10 Tag, disconnect and plug the hoses on the drive
18 Carefully pull the inner axle out of the outer axle motor and brake. Cap the fittings on the motor
tube. and brake.
Crushing hazard. The inner axle Bodily injury hazard. Spraying
may become unbalanced and fall if hydraulic oil can penetrate and
it is not properly supported when it burn skin. Loosen hydraulic
is removed from the outer axle connections very slowly to allow
tube. the oil pressure to dissipate
Non-steer end:
or spray.
1 Remove the drive chassis cover.
11 Remove the pin retaining fasteners from the axle
2 Retract the axle and remove the shims from the extension cylinder at the axle that is to be
top wear pads of the inner axle. removed. Use a soft metal drift to remove the
pin.
Pay careful attention to the
location and number of shims used 12 Attach a strap from a lifting device through the
when removing the shims. inner axle close to the drive hub for support.
3 Extend the axle, then retract the axle 13 Remove all wear pads between the inner and
approximately 1 inch (25 mm). outer axles.
4 Loosen the axle limit switch actuator rod. Pay careful attention to the
Remove the mounting hardware from the linkage location and number of shims used
pivot plate. when removing the wear pads.
5 Remove the actuator rod assembly and set it 14 Carefully remove the inner axle from the outer
aside. axle.
6 Loosen the wheel lug nuts. Do not remove them. Crushing hazard. The inner axle
may become unbalanced and fall if
7 Block the wheels on the steer end of the it is not properly supported when it
machine, then center a lifting jack under the is removed from the outer axle
axle to be removed. tube.

How to Remove the Axle Non-steer end:

Extension Cylinder 1 Remove the drice chassis cover.
1 Steer end: Remove the yoke and hub 2 Remove the drive motor access covers from
assembly. See 14-1 2WD or 15-1 4WD, How to both sides of the axle.
Remove the Yoke and Hub. 3 Support the axle extension cylinder with a lifting
2 Remove the steering cylinder. See 14-2, How to device.
Remove a Steering Cylinder. 4 Remove the pin retaining fasteners from the axle
3 Remove the inner axle. See 16-1, How to extension cylinder pivot pins. Use a soft metal
Remove the Inner Axle. drift to remove the pins.
Remove the inner axle at the barrel 5 Start the engine and retract the axle extension
end of the axle extend cylinder. cylinder.
4 Remove the drive chassis cover. 6 Tag, disconnect and plug the axle extension
cylinder hydraulic hoses at the control valve.
5 Tag, disconnect and plug the axle extend Cap the fittings on the control valve.
cylinder hoses and fittings at the tee junction on
top of the outer axle. Plug the cylinder ports. Bodily injury hazard. Spraying
Bodily injury hazard. Spraying burn skin. Loosen hydraulic
hydraulic oil can penetrate and connections very slowly to allow
burn skin. Loosen hydraulic the oil pressure to dissipate
connections very slowly to allow gradually. Do not allow oil to squirt
the oil pressure to dissipate or spray.
or spray. 7 Remove the cylinder from the machine.
6 Support the axle extension cylinder with a lifting Crushing hazard. The axle
device. extension cylinder may become
unbalanced and fall if it is not
7 Remove the external snap ring from the rod end properly supported when it is
of the axle extension cylinder pin. Use a soft removed from the axle.
metal drift to remove the pin.
8 Carefully remove the cylinder from the machine.
Crushing hazard. The axle
extension cylinder may become
properly supported when it is
removed from the axle.

16-2 16-3
Drive Chassis Lift Jacks Hydraulic Limit Switches
The drive chassis lift jacks are used to lift the drive The hydraulic limit switches are 2 position, 2 way
chassis for axle extension. The lift jacks should not valves. These switches sense full axle extension,
be used to support the machine during maintenance then allow the boom functions to operate.
or repair procedures.
How to Set Up the Hydraulic
How to Remove a Chassis Limit Switch Linkage
Lift Jack
Adjustment of the hydraulic limit
1 Remove the drive chassis cover. switch linkage is only necessary
when the switch or linkage has
2 Tag, disconnect and plug the chassis lift jack
been replaced or the axle wear
pads are worn or have been
Bodily injury hazard. Spraying replaced.
1 Install the hydraulic switch and connect the
hydraulic hoses.
the oil pressure to dissipate 2 Install the linkage rod and leave the lock nut
gradually. Do not allow oil to squirt loose.
or spray.
the cylinder.
a b c d e
4 Remove the chassis lift jack mounting
fasteners, then remove the lift jack cylinder a locknut
from the machine. b linkage rod
c spring
Crushing hazard. The chassis lift d valve actuator
jack cylinder may become e limit switch valve
3 Use the drive chassis lift jack to raise the
properly attached to the overhead
machine.
crane when it is removed from the
machine. 4 Extend the axles completely, then lower the
machine.

5 Turn the linkage rod clockwise until it completely

compresses the valve actuator.
6 Raise the machine.
7 Extend and retract both axles through 2 cycles
and check boom functions.
Result: If the boom will not raise past the drive
limit switch with both axles extended, readjust
the hydraulic limit switches as necessary.
8 Perform procedure A-10, Test the Extendable
Axles.

Non-steering Axle Components REV B

from the drive motor. Cap the fittings on the
Drive Motor drive motor.
How to Remove a Drive Motor hydraulic oil can penetrate and
Component damage hazard. burn skin. Loosen hydraulic
Repairs to the motor should only connections very slowly to allow
be performed by an authorized the oil pressure to dissipate
Sundstrand-Sauer dealer. gradually. Do not allow oil to squirt
or spray.
work area and surfaces where this 5 Remove the drive motor mounting fasteners.
procedure will be performed must 6 Slide the drive motor shaft out of the brake or
be clean and free of debris that drive hub, and remove the drive motor from the
could get into the hydraulic system machine.
and cause severe component
damage. Dealer service is Torque specifications
recommended.
Drive motor mounting bolts, dry 110 ft-lbs
When removing a hose assembly 149 Nm
and/or hose end must be replaced Drive motor mounting bolts, lubricated 80 ft-lbs
108 Nm
Specifications.
1 Remove the fasteners from drive chassis cover
at the non-steer end. Remove the cover.
2 Extend the axle.
3 Remove the drive motor access covers from
both sides of the inner axle.

REV B NON-STEERING AXLE COMPONENTS
17-2 Torque specifications

Drive Hub Lug nut, dry 420 ft-lbs
569.5 Nm
How to Remove a Drive Hub Lug nut torque, lubricated 320 ft-lbs
When removing a hose assembly 434 Nm
or fitting, the O-ring on the fitting Drive hub mounting bolts, dry 210 ft-lbs
and/or hose end must be replaced 284 Nm
during installation. Drive hub mounting bolts, lubricated 160 ft-lbs
Refer to Section Two, Hydraulic 217 Nm
Hose and Fitting Torque Drive motor mounting bolts, dry 110 ft-lbs
Specifications. 149 Nm
1 Remove the drive motor. See 17-1, How to Drive motor mounting bolts, lubricated 80 ft-lbs
Remove a Drive Motor. 108 Nm
2 Loosen the wheel lug nuts. Do not remove them.
3 Center a lifting jack of ample capacity under the
non-steering axle. Raise the machine and place
blocks under the drive chassis for support.
4 Remove the wheel lug nuts, then the tire and
wheel assembly.
5 Place a second lifting jack under the drive hub
for support and secure the drive hub to the
lifting jack.
6 Remove the drive hub mounting bolts that attach
the drive hub to the axle. Remove the drive hub.
Crushing hazard. The drive
hub may become unbalanced and
fall if it is not properly supported
and secured to the lifting jack.

NON-STEERING AXLE COMPONENTS
17-3
Wheel Brake
How to Remove a Wheel Brake

Specifications.
1 Remove the drive motor. See 17-1, How to
Remove a Drive Motor.
2 Tag, disconnect and plug the hydraulic hose
from the brake.
or spray.
3 Remove the brake from the machine.

California Proposition 65
WARNING
The exhaust from this product contains chemicals
known to the State of California to cause cancer,
birth defects or other reproductive harm.
Genie North America

Phone 425.881.1800
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Distributed By:
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Genies 80

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Service Manual Part No.

(from serial number 966 to 3081)

Basic mechanical, hydraulic and electrical skills

continuous improvement of our products is a Genie Copyright © 1998 by Genie Industries

If you have any questions, please contact Genie

ii Genie S-80 & Genie S-85 Part No. 72062

Many of the hazards identified in the operator's

Do Not Perform Maintenance

Part No. 72062 Genie S-80 & Genie S-85 iii

Personal Safety Workplace Safety

Orange—used to indicate the Be sure any forklift, overhead crane or

iv Genie S-80 & Genie S-85 Part No. 72062

Section One Safety Rules

Section Two Specifications

Section Three Theory of Operation

Part No. 72062 Genie S-80 & Genie S-85 v

Section Four Scheduled Maintenance Procedures

vi Genie S-80 & Genie S-85 Part No. 72062

Section Four Scheduled Maintenance Procedures, continued

Part No. 72062 Genie S-80 & Genie S-85 vii

Section Four Scheduled Maintenance Procedures, continued

viii Genie S-80 & Genie S-85 Part No. 72062

Section Five Troubleshooting Flow Charts

Part No. 72062 Genie S-80 & Genie S-85 ix

Section Five Troubleshooting Flow Charts, continued

x Genie S-80 & Genie S-85 Part No. 72062

Section Six Schematics

Part No. 72062 Genie S-80 & Genie S-85 xi

Section Seven Repair Procedures

xii Genie S-80 & Genie S-85 Part No. 72062

Section Seven Repair Procedures, continued

Part No. 72062 Genie S-80 & Genie S-85 xiii

Section Seven Repair Procedures, continued

xiv Genie S-80 & Genie S-85 Part No. 72062

Section Seven Repair Procedures, continued

Part No. 72062 Genie S-80 & Genie S-85 xv

This page intentionally left blank.

xvi Genie S-80 & Genie S-85 Part No. 72062

Operational dimensions Wheel diameter 221/2 in

Part No. 72062 Genie S-80 & Genie S-85 2-1

Performance Specifications Boom function speeds, maximum

Platform rotate, 160° 8 to 12 seconds

2-2 Genie S-80 & Genie S-85 Part No. 72062

Hydraulic Specifications Function pump

Hydraulic fluid Dexron equivalent Type: pressure balanced gear

Drive pump Displacement - static 1.4 cu in

Medium pressure filter 3 micron Boom down 2300 psi

Displacement 1.52 cu in Auxiliary pump

Part No. 72062 Genie S-80 & Genie S-85 2-3

Ford Engine LRG-425 EFI Starter motor

Displacement 153 cu in Normal engine cranking speed 200 to 250 rpm

High idle 2500 rpm Brush length wear limit 0.25 in

Valve clearances - 0.035 to 0.055 inches Type 12V, Group 31

Capacity 111/2 quarts

Output 95A, 14.5VDC

2-4 Genie S-80 & Genie S-85 Part No. 72062

Deutz Engine F4L 1011F Injection system

Displacement 166.7 cu in Injection pump make OMAP

Horsepower 56 @ 3000 rpm Fuel requirement diesel number 2-D

Firing order 1-3-4-2 Alternator output 55A, 14 VDC

Compression ratio 18.5:1 Starter motor

Compression pressure 362 to 435 psi Current draw, no load 90A

High idle 2300 rpm Brush length, minimum 0.5 in

Exhaust 0.020 in Cold cranking ampere 1000A