Service M anual - Tuotetietokantatuotteet.ramirent.fi/sites/tuotteet.ramirent/files/product... · A-16 Test the Tilt Sensor and Alarm ... 15 Boom Length Switch Fault..... 5 - 54 16

Service Manual Part No. 62401

Rev A1

October 2004

Genie S-100 & S-105 & S-120 & S-125 Part No. 62401

First Edition • First Printing

ii

Introduction

®

Copyright © 2001 by Genie Industries

First Edition: First Printing, January 2001

"Genie" and "S" are Registered Trademarksof Genie Industries in the USA and many othercountries.

These machines comply withANSI/SIA 92.5-1992.

Printed on recycled paper

Printed in U.S.A.

Important

Read, understand and obey the safety rules andoperating instructions in the Genie S-100 and GenieS-105 Operator's Manual or the Genie S-120 andGenie S-125 Operator's Manual before attemptingany maintenance or repair procedure.

This service manual covers the Genie S-100 andGenie S-105 and Genie S-120 and Genie S-125models.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting andrepair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electrical skills arerequired to perform most procedures. However,several procedures require specialized skills, tools,lifting equipment and a suitable workshop. In theseinstances, we strongly recommend thatmaintenance and repair be performed at a Geniedealer service center.

Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore product specifications are subjectto change without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and other manuals. Pleasewrite to the technical publications team in care ofGenie Industries, PO Box 97030, Redmond WA98073-0069 U.S.A.

If you have any questions, please contact GenieIndustries.

Contact us:

http://www.genielift.come-mail: [email protected]

Part No. 62401 Genie S-100 & S-105 & S-120 & S-125


iii

Safety Rules

Section 1 - Safety Rules

DangerFailure to obey the instructions and safety rules inthis manual, and the Genie S-100 & Genie S-105Operator's Manual or the Genie S-120 & GenieS-125 Operator's Manual will result in death orserious injury.

Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance 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, liftingequipment and a suitable workshop.



SAFETY RULES

iv

Section 1 - Safety Rules

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free of

debris that could get into machine components andcause damage.

Be sure that your workshop or work areais properly ventilated and well lit.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals, on the machine,use signal words to identify the following:

Indicates the presence ofa hazard that will causedeath or serious injury.

Indicates the presence ofa hazard that may causedeath or serious injury.

Indicates the presence ofa hazard that will or maycause serious injury ordamage to the machine.

Indicates specialoperation or maintenanceinformation.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components, and lifting or

placing loads. Always wear approved steel-toedshoes.



Table of Contents

v

Introduction

Important Information ...................................................................................................... ii

Section One Safety Rules

General Safety Rules ..................................................................................................... iii

Section Two Specifications

Machine Specifications, S120 and S-125 Models ...................................................... 2 - 1

Performance Specifications, S120 and S-125 Models ............................................... 2 - 2

Machine Specifications, S100 and S-105 Models ...................................................... 2 - 3

Performance Specifications, S100 and S-105 Models ............................................... 2 - 5

Hydraulic Specifications ............................................................................................ 2 - 6

Perkins Engine 1004-42 Specifications ..................................................................... 2 - 7

Cummins Engine B3.9L Specifications ..................................................................... 2 - 8

Deutz Engine F4L 913 Specifications ........................................................................ 2 - 9

Hydraulic Hose and Fitting Torque Specifications ................................................... 2 - 10

Section Three Theory of Operation

Theory of Operation .................................................................................................. 3 - 1

Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1

Maintenance Inspection Report ................................................................................. 4 - 3

A-1 Inspect the 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 - 6



TABLE OF CONTENTS

vi

Section Four Scheduled Maintenance Procedures, continued

A-5 Check the Engine Coolant Level - Liquid Cooled Models ................................. 4 - 7

A-6 Check the Engine Belt(s) - Cummins Models .................................................. 4 - 8

A-7 Check the Engine Cooling Fan - Liquid Cooled Models .................................... 4 - 9

A-8 Drain the Inline Fuel Filter/Water Separator ................................................... 4 - 10

A-9 Inspect the Engine Air Filter .......................................................................... 4 - 11

A-10 Check for Fuel Leaks .................................................................................... 4 - 12

A-11 Check the Hydraulic Oil Level ....................................................................... 4 - 12

A-12 Check for Hydraulic Leaks ............................................................................. 4 - 13

A-13 Check the Hydraulic Filter Condition Indicators.............................................. 4 - 13

A-14 Test the Platform and Ground Controls .......................................................... 4 - 15

A-15 Test the Auxiliary Power Operation .............................................................. 4 - 16

A-16 Test the Tilt Sensor and Alarm ...................................................................... 4 - 17

A-17 Test the Operating Envelope ......................................................................... 4 - 18

A-18 Perform 30 Day Service ................................................................................ 4 - 19

A-19 Check the Engine Fasteners - Deutz Models ................................................. 4 - 20

A-20 Check the Batteries ....................................................................................... 4 - 21

B-1 Check the Radiator - Liquid Cooled Models ................................................... 4 - 23

B-2 Check the Oil Cooler and Cooling Fins - Deutz Models .................................. 4 - 24

B-3 Check the Engine Belt(s) - Deutz and Perkins Models ................................... 4 - 25

B-4 Replace the Inline Fuel Filter/Water Separator Element ................................. 4 - 26

B-5 Replace the Air Filter ..................................................................................... 4 - 32

B-6 Inspect the Air Intake System ....................................................................... 4 - 33

B-7 Check the Exhaust System ........................................................................... 4 - 33



TABLE OF CONTENTS

vii


B-8 Replace the Hydraulic Tank Return Filters ..................................................... 4 - 35

B-9 Replace the Hydraulic Tank Breather Filter .................................................... 4 - 36

B10 Replace the Medium and High Pressure Hydraulic Filters .............................. 4 - 37

B-11 Inspect the Electrical Wiring .......................................................................... 4 - 38

B-12 Confirm the Proper Brake Configuration ......................................................... 4 - 39

B-13 Inspect the Tires and Wheels (including lug nut torque) ................................. 4 - 39

B-14 Check the Oil Level in the Drive Hubs ........................................................... 4 - 40

B-15 Check and Adjust the Engine RPM ............................................................... 4 - 41

B-16 Test the Key Switches .................................................................................. 4 - 44

B-17 Test the Emergency Stop Buttons ................................................................. 4 - 46

B-18 Test the Ground Control Override .................................................................. 4 - 46

B-19 Test the Safety Envelope and Circuits .......................................................... 4 - 47

B-20 Test the Platform Self-leveling ...................................................................... 4 - 53

B-21 Test the Horn ................................................................................................ 4 - 54

B-22 Test the Foot Switch ..................................................................................... 4 - 54

B-23 Test the Engine Idle Select ........................................................................... 4 - 55

B-24 Test the Drive Enable System ....................................................................... 4 - 56

B-25 Test the Drive Brakes.................................................................................... 4 - 57

B-26 Test the Drive Speed - Stowed Position ........................................................ 4 - 58

B-27 Test the Drive Speed - Raised or Extended Position ..................................... 4 - 58

B-28 Test the Alarm Package (if equipped) ............................................................ 4 - 60

B-29 Replace the Engine Oil and Filter - Cummins Models .................................... 4 - 61

B-30 Inspect the Fuel Tank Cap Venting System .................................................. 4 - 62

B-31 Perform Hydraulic Oil Analysis ...................................................................... 4 - 63



TABLE OF CONTENTS

viii


C-1 Check the Engine Valve Clearances - Deutz Models ..................................... 4 - 64

C-2 Clean the Fuel Pump Strainer - Perkins Models ............................................ 4 - 64

C-3 Replace the Fuel Filter Element - Perkins and Cummins Models ................... 4 - 66

C-4 Replace the Engine Oil and Filter - Deutz and Perkins Models ...................... 4 - 68

C-5 Check the Specific Gravity of the Coolant - Liquid Cooled Models ................. 4 - 70

C-6 Inspect the Boom Extend/Retract Cables ...................................................... 4 - 71

D-1 Check the Boom Wear Pads ......................................................................... 4 - 73

D-2 Check the Extendable Axle Wear Pads ......................................................... 4 - 74

D-3 Check the Free-wheel Configuration .............................................................. 4 - 75

D-4 Check the Turntable Rotation Bearing Bolts .................................................. 4 - 76

D-5 Check the Turntable Rotation Gear Backlash ................................................ 4 - 77

D-6 Grease the Turntable Rotation Bearing and Rotate Gear ................................ 4 - 78

D-7 Replace the Drive Hub Oil ............................................................................. 4 - 78

D-8 Inspect the Engine Belt(s) - Cummin Models ................................................. 4 - 82

D-9 Replace the Fuel Filter/Water Separator - Deutz Models ................................ 4 - 84

D-10 Check the Engine Valve Clearances - Perkins and Cummins Models ............ 4 - 85

E-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 86

E-2 Change or Recondition the Engine Coolant - Liquid Cooled Models................ 4 - 89

E-3 Change the Fuel Hoses ................................................................................. 4 - 90

E-4 Check the Engine Valve Clearances - Cummins Models ............................... 4 - 92

E-5 Check the Fuel Injectors - Deutz Models ....................................................... 4 - 92

E-6 Remove and Inspect the Boom Extend/Retract Cables ................................. 4 - 93



TABLE OF CONTENTS

ix

Section Five Troubleshooting Flow Charts

Introduction ............................................................................................................... 5 - 1

Fault Code Chart ....................................................................................................... 5 - 3

1 Display Not Active ......................................................................................... 5 - 11

2 Engine Will Not Crank Over ........................................................................... 5 - 16

3 Engine Cranks Over But Will Not Start .......................................................... 5 - 22

4 Engine Starts and Runs for 3 Seconds and Dies ........................................... 5 - 25

5 Engine High Idle Inoperative .......................................................................... 5 - 28

6 Engine Low Idle Inoperative ........................................................................... 5 - 30

7 All Functions Inoperative, Engine Starts and Runs ........................................ 5 - 31

8 Boom Up/Down, Extend/Retract, Turntable Rotate andPlatform Functions Inoperative,Drive, Steer and Axle Extend/Retract Functions Operational ......................... 5 - 32

9 All Platform, Steering and Axle Functions Inoperative,All Other Functions Operational ..................................................................... 5 - 33

10 Ground Controls Inoperative, Platform Controls Operate Normally ................. 5 - 38

11 Platform Controls Inoperative, Ground Controls Operate Normally ................. 5 - 40

12 Boom Angle Switch Fault .............................................................................. 5 - 42

13 Boom Up Function Inoperative ...................................................................... 5 - 45

14 Boom Down Function Inoperative .................................................................. 5 - 49

15 Boom Length Switch Fault ............................................................................. 5 - 54

16 Boom Extend Function Inoperative ................................................................ 5 - 58

17 Boom Retract Function Inoperative ............................................................... 5 - 67

18 Boom Envelope Operational Switch Failure, S-100 and S-105 Models ........... 5 - 72

19 Boom Envelope Operational Switch Failure, S-120 and S-125 Models ........... 5 - 77

20 Boom Envelope Safety Switch Failure, S-100 and S-105 Models .................. 5 - 86



TABLE OF CONTENTS

x

Section Five Troubleshooting Flow Charts, continued

21 Boom Envelope Safety Switch Failure, S-120 and S-125 Models .................5 - 104

22 Turntable Rotate Clockwise Function Inoperative .........................................5 - 128

23 Turntable Rotate Counter Clockwise Function Inoperative ............................5 - 133

24 Platform Level Function Inoperative .............................................................5 - 138

25 Platform Level Up Function Inoperative ........................................................5 - 140

26 Platform Level Down Function Inoperative ....................................................5 - 144

27 Platform Level Safety Fault ..........................................................................5 - 148

28 Platform Rotate Clockwise Function Inoperative ...........................................5 - 151

29 Platform Rotate Counter Clockwise Function Inoperative..............................5 - 154

30 Jib Up Function Inoperative ..........................................................................5 - 157

31 Jib Down Function Inoperative ......................................................................5 - 160

32 Auxiliariy Functions Inoperative ....................................................................5 - 163

33 Axle Extend Function Inoperative .................................................................5 - 168

34 Axle Retract Function Inoperative .................................................................5 - 174

35 Blue End Blue Side Steering Function Inoperative ........................................5 - 178

36 Blue End Yellow Side Steering Function Inoperative ....................................5 - 181

37 Yellow End Blue Side Steering Function Inoperative ....................................5 - 184

38 Yellow End Yellow Side Steering Function Inoperative .................................5 - 187

39 Drive Forward Function Inoperative ..............................................................5 - 190

40 Drive Reverse Function Inoperative ..............................................................5 - 196

41 Drive Enable Fault ........................................................................................5 - 202

42 Drive Mode Select Inoperative ......................................................................5 - 204

43 Engine Start Assist Inoperative ....................................................................5 - 210

44 Auxiliary Drive Function Inoperative .............................................................5 - 213



TABLE OF CONTENTS

xi

Section Six Schematics

Introduction ............................................................................................................... 6 - 1

Electrical Components .............................................................................................. 6 - 2

Wire Circuit Legend ................................................................................................... 6 - 4

Limit Switches .......................................................................................................... 6 - 8

Relay Layout ........................................................................................................... 6 - 10

Drive Chassis Controller Pin Legend ....................................................................... 6 - 11

Platform Controller Pin Legend ................................................................................ 6 - 12

Turntable Controller Pin Legend .............................................................................. 6 - 13

Electrical Schematic Legend -Drive Chassis (DCON) and Platform Controls (PCON) ............................................ 6 - 14

Electrical Schematic Legend - Ground Controls (TCON) ......................................... 6 - 15

Electric Symbols Legend ........................................................................................ 6 - 16

Electrical Schematic -Drive Chassis and Platform Controls (Sheet 1 of 2) ................... located at end of manual

Electrical Schematic -Ground Controls (Sheet 2 of 2) ................................................... located at end of manual

Limit Switch Harness Schematic, S-100 & S-105 Models ....................................... 6 - 17

Limit Switch Harness Schematic, S-120 & S-125 Models ....................................... 6 - 18

Safety Circuit Schematic ........................................................................................ 6 - 19

Electrical Schematic - Generators ........................................................................... 6 - 20

Electrical Schematic - Deutz Models ...................................................................... 6 - 21

Electrical Schematic - Cummins and Perkins Models ............................................. 6 - 22



TABLE OF CONTENTS

xii

Section Six Schematics, continued

Hydraulic Symbols Legend ...................................................................................... 6 - 24

Hydraulic Schematic, S-100 Models with 2 Wheel Steer ......................................... 6 - 25




Hydraulic Schematic, S-120 Models ....................................................................... 6 - 33

Hydraulic Schematic, S-125 Models ....................................................................... 6 - 35

Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1

Display Module ......................................................................................................... 7 - 2

Platform Controls

1-1 Circuit Boards .................................................................................................. 7 - 5

1-2 Membrane Decal ............................................................................................. 7 - 6

1-3 Joystick Controllers ......................................................................................... 7 - 7

1-4 Foot Switch ................................................................................................... 7 - 10

1-5 Toggle Switches ............................................................................................ 7 - 10

Platform Components

2-1 Platform ........................................................................................................ 7 - 12

2-2 Platform Leveling Cylinder ............................................................................. 7 - 12

2-3 Platform Rotator ............................................................................................ 7 - 14



xiii

Section Seven Repair Procedures, continued

Jib Boom Components, S-105 and S-125 Models

3-1 Jib Boom, S-105 and S-125 Models .............................................................. 7 - 18

3-2 Jib Boom Lift Cylinder, S-105 and S-125 Models ........................................... 7 - 20

Boom Components

4-1 Cable Track ................................................................................................... 7 - 23

4-2 Boom ............................................................................................................ 7 - 26

4-3 Boom Lift Cylinder ......................................................................................... 7 - 37

4-4 Extension Cylinders ...................................................................................... 7 - 39

4-5 Boom Extend/Retract Cables ........................................................................ 7 - 43

Turntable Covers

5-1 Turntable Covers ........................................................................................... 7 - 47

Engines

6-1 RPM Adjustment ........................................................................................... 7 - 49

6-2 Flex Plate ...................................................................................................... 7 - 49

6-3 Oil Pressure and Coolant Temperature Sending Units,Cummins and Perkins Models ....................................................................... 7 - 50

6-4 Oil Pressure and Temperature Sending Units, Deutz Models ......................... 7 - 51

Ground Controls

7-1 Circuit Boards ................................................................................................ 7 - 52

7-2 Membrane Decal ........................................................................................... 7 - 53

7-3 Control Relays ............................................................................................... 7 - 54

Limit Switches

8-1 Limit Switches ............................................................................................... 7 - 57

TABLE OF CONTENTS




Hydraulic Pumps

9-1 Function Pumps ............................................................................................ 7 - 60

9-2 Drive Pump ................................................................................................... 7 - 61

9-3 Auxiliary Pump .............................................................................................. 7 - 64

9-4 Power Relay .................................................................................................. 7 - 65

Manifolds

10-1 Function Manifold Components, S-100 and S-105 Models ............................. 7 - 66

10-2 Valve Adjustments - Function Manifold, S-100 and S-105 Models ................. 7 - 70

10-3 Proportional Valves - Function Manifold ........................................................ 7 - 71

10-4 Function Manifold Components, S-120 and S-125 Models ............................. 7 - 72

10-5 Valve Adjustments - Function Manifold, S-120 and S-125 Models ................. 7 - 76

10-6 Proportional Valves - Function Manifold ........................................................ 7 - 77

10-7 Distribution Manifold Components ................................................................. 7 - 78

10-8 Valve Adjustments - Distribution Manifold ..................................................... 7 - 80

10-9 Platform Manifold Components, S-100 and S-120 Models ............................. 7 - 82

10-10 Platform Manifold Components, S-105 and S-125 Models ............................. 7 - 84

10-11 Proportional Valves - Platform Manifolds ....................................................... 7 - 86

10-12 Platform Rotate Counterbalance Valve Manifold ............................................ 7 - 86

10-13 Turntable Rotation Manifold Components ...................................................... 7 - 87

10-14 Steer and Axle Extend/Retract Manifold Components - View 1 ...................... 7 - 88

10-15 Steer and Axle Extend/Retract Manifold Components - View 2 ...................... 7 - 92

10-16 Valve Adjustments - Steer and Axle Extend/Retract Manifold ....................... 7 - 96

10-17 Drive Manifold Components ........................................................................... 7 - 98

10-18 Valve Adjustments - Drive Manifold ..............................................................7 - 102

TABLE OF CONTENTS

xiv



TABLE OF CONTENTS

xv


. Fuel and Hydraulic Tanks

11-1 Fuel Tank .....................................................................................................7 - 103

11-2 Hydraulic Tank .............................................................................................7 - 104

Turntable Rotation Components

12-1 Turntable Rotation Hydraulic Motor and Drive Hub ........................................7 - 106

Axle Components

13-1 Steer Sensors ..............................................................................................7 - 110

13-2 Yoke and Hub ...............................................................................................7 - 112

13-3 Drive Motor ...................................................................................................7 - 114

13-4 Drive Hub .....................................................................................................7 - 115

13-5 Steering Cylinders ........................................................................................7 - 116

13-6 Extendable Axles .........................................................................................7 - 117

Appendix Electrical Schematic , Genie part number 62304

Drive Chassis and Platform Control ............................................................... Sheet 1 of 2Ground Controls ............................................................................................ Sheet 2 of 2



TABLE OF CONTENTS

xvi

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Part No. 62401 Genie S-100 & S-105 & S-120 & S-125 2 - 1

Section 2 • SpecificationsFirst Edition • First Printing

Specifications

Machine Specifications,S-120 and S-125 Models

Stowed dimensions S-120 S-125

Length, transport position 39 ft 11 in 39 ft 11 in12.17 m 12.17 m

Length, stowed 42 ft 8 in 46 ft13 m 14 m

Width, axles retracted 8 ft 6 in 8 ft 6 in259 cm 259 cm

Width, axles extended 11 ft 6 in 11 ft 6 in351 cm 351 cm

Height, stowed maximum 10 ft 1 in 10 ft 1 in308 cm 308 cm

Weight 44,340 lbs 44,640 lbs20,112 kg 20,248 kg

Ground clearance 153/4 in 153/4 in40 cm 40 cm

Operational dimensions

Platform height, maximum 120 ft 125 ft36.6 m 38.1 m

Working height, maximum 126 ft 131 ft38.4 m 39.9 m

Horizontal reach maximum 75 ft 80 ft22.9 m 24.4 m

Maximum load capacity 750 lb 500 lb340 kg 227 kg

Turntable tailswing, 66 in 66 inaxles retracted 168 cm 168 cm

Turntable tailswing 48 in 48 inaxles extended 122 cm 122 cm

Wheelbase 12 ft 12 ft366 cm 366 cm

Turning radius, outside, 24 ft 4 in 24 ft 4 inaxles retracted 7.4 m 7.4 m

Turning radius, inside, 16 ft 4 in 16 ft 4 inaxles retracted 4.9 m 4.9 m

Turning radius, outside, 20 ft 8 in 20 ft 8 inaxles extended 6.3 m 6.3 m

Turning radius, inside, 10 ft 1 in 10 ft 1 inaxles extended 3.1 m 3.1 m

Turntable rotation (degrees) 360° continuous

Platform rotation 160°

Maximum allowable 150 lbsside force (ANSI and CSA) 667 N

Maximum allowable 90 lbsside force (CE) 400 N

Controls 12V DC proportional

Platform dimensions

Length 96 in244 cm

Width 36 in91 cm

Tires and wheels

Tire size 18 x 22.5, 18 pr FF

Tire ply rating 18

Overall tire diameter 46.5 in118 cm

Wheel diameter 22.5 in57 cm

Wheel width 13 in33 cm

Wheel lugs 10 @ 3/4 -16

Lug nut torque, dry 420 ft-lbs569.5 Nm

Lug nut torque, lubricated 320 ft-lbs433.9 Nm

2 - 2 Genie S-100 & S-105 & S-120 & S-125 Part No. 62401

Section 2 • Specifications First Edition • First Printing

Performance Specifications,S-120 and S-125 Models

Drive speeds, maximum

Drive speed, stowed 3 mph 4.8 km/h40 ft/9.1 sec 12.2 m/9.1 sec

Drive speed, 0.7 mph 1.1 km/hraised or extended 40 ft/40 sec 12.2 m/40 sec

Drive speed, 0.4 mph 0.6 km/hfully extended 40 ft/70 sec 12.2 m/70 sec

Gradeability (boom stowed) 40%

Boom function speeds, maximumfrom platform controls

Jib boom up (S-125 models) 28 to 32 seconds

Jib boom down (S-125 models) 28 to 32 seconds

Boom up

Boom fully retracted 80 to 88 seconds

Boom extended to >4 ft (>1.2 m) 100 to 110 seconds(time between fully lowered anda fully raised position)

Boom extended to >80 ft (>24.4 m) 50 to 55 seconds(time between 53° envelopelimit and a fully raised position)


Boom down


Boom extended to >4 ft (>1.2 m) 100 to 110 seconds(time between fully raised anda fully lowered position)

Boom extended to >80 ft (>24.4 m) 50 to 55 seconds(time between fully raised andthe 50° envelope limit)


SPECIFICATIONS

Fluid capacities

Hydraulic tank capacity 55 gallons208 liters

Hydraulic system capacity 80 gallons(including tank) 303 liters

Fuel tank capacity 40 gallons151 liters

Airborne noise emissions 80 dBMaximum sound level at normal operating workstations(A-weighted)

Continuous improvement of our products is aGenie policy. Product specifications are subject tochange without notice.



SPECIFICATIONS

Boom extendhorizontal, 0 to 80 ft (0 to 24.4 m) 75 to 83 secondsvertical, 0 to 120 ft (0 to 36.6 m) 170 to 190 seconds

Boom retracthorizontal, 80 ft to 0 (24.4 m to 0) 75 to 83 secondsvertical, 120 ft to 0 (36.6 m to 0) 170 to 190 seconds

Turntable rotate, 360°boom horizontal andfully retracted 170 to 190 seconds

Turntable rotate, 360°boom horizontal andextended >0 ft (>0 m) 285 to 315 seconds

Turntable rotate, 360°boom horizontal andextended >80 ft (>24.4 m) 490 to 540 seconds

Platform rotate, 160° 18 to 22 seconds

Machine Specifications,S-100 and S-105 Models

Stowed dimensions S-100 S-105

Length, transport position 39 ft 11 in 39 ft 11 in12.17 m 12.17 m

Length, stowed 42 ft 8 in 46 ft13 m 14 m

Width, axles retracted 8 ft 6 in 8 ft 6 in259 cm 259 cm

Width, axles extended 11 ft 6 in 11 ft 6 in351 cm 351 cm

Height, stowed maximum 10 ft 1 in 10 ft 1 in308 cm 308 cm

Weight 39,700 lbs 40,000 lbs18,007 kg 18,143 kg

Ground clearance 151/2 in 151/2 in39 cm 39 cm

Operational dimensions

Platform height, maximum 100 ft 105 ft30.5 m 32 m

Working height, maximum 106 ft 111 ft32.3 m 33.8 m

Horizontal reach maximum 75 ft 80 ft22.9 m 24.4 m

Maximum load capacity 750 lb 500 lb340 kg 227 kg

Turntable tailswing, 66 in 66 inaxles retracted 168 cm 168 cm

Turntable tailswing 48 in 48 inaxles extended 122 cm 122 cm

Wheelbase 12 ft 12 ft366 cm 366 cm

Turning radius, outside, 24 ft 4 in 24 ft 4 inaxles retracted 7.4 m 7.4 m

Turning radius, inside, 16 ft 4 in 16 ft 4 inaxles retracted 4.9 m 4.9 m



Turning radius, outside, 20 ft 8 in 20 ft 8 inaxles extended 6.3 m 6.3 m

Turning radius, inside, 10 ft 1 in 10 ft 1 inaxles extended 3.1 m 3.1 m

Turntable rotation (degrees) 360° continuous

Platform rotation 160°

Maximum allowable 150 lbsside force (ANSI and CSA) 667 N

Maximum allowable 90 lbsside force (CE) 400 N

Controls 12V DC proportional

Platform dimensions

Length 96 in244 cm

Width 36 in91 cm

Tires and wheels

Tire size 15 x 22.5, 18 pr FF

Tire ply rating 18

Overall tire diameter 43.1 in109.5 cm

Wheel diameter 22.5 in57 cm

Wheel width 11.75 in30 cm

Wheel lugs 10 @ 3/4 -16



Fluid capacities


Hydraulic system capacity 80 gallons(including tank) 303 liters

Fuel tank capacity 40 gallons151 liters

Airborne noise emissions 80 dBMaximum sound level at normal operating workstations(A-weighted)

Continuous improvement of our products is aGenie policy. Product specifications are subject tochange without notice.

SPECIFICATIONS



Performance Specifications,S-100 and S-105 Models

Drive speeds, maximum

Drive speed, stowed 3 mph 4.8 km/h40 ft/9.1 sec 12.2 m/9.1 sec

Drive speed, 0.7 mph 1.1 km/hraised or extended 40 ft/40 sec 12.2 m/40 sec

Drive speed, 0.4 mph 0.6 km/hfully extended 40 ft/70 sec 12.2 m/70 sec

Gradeability (boom stowed) 42%

Boom function speeds, maximumfrom platform controls

Jib boom up (S-105 models) 28 to 32 seconds

Jib boom down (S-105 models) 28 to 32 seconds

Boom up


Boom extended to >4 ft (>1.2 m) 100 to 110 seconds(time between fully lowered anda fully raised position)


Boom down


Boom extended to >4 ft (>1.2 m) 100 to 110 seconds(time between fully raised anda fully lowered position)


Boom extend, boom fully raised0 to 100 ft (0 to 30.5 m) 120 to 140 seconds

Boom retract, boom fully raised100 ft to 0 (30.5 m to 0) 120 to 140 seconds

Turntable rotate, 360°boom horizontal andfully retracted 170 to 190 seconds

Turntable rotate, 360°boom horizontal andextended >0 ft (>0 m) 285 to 315 seconds

Turntable rotate, 360°boom fully raised andextended >80 ft (>24.4 m) 490 to 540 seconds

Platform rotate, 160° 18 to 22 seconds

SPECIFICATIONS



Hydraulic Specifications

Hydraulic fluid Dexron equivalent

Drive pump

Type: bi-directional, variable displacement piston pump

Displacement @ 2350 rpm 28 gpm106 L/min

Maximum drive pressure 4250 psi293 bar

Charge pump

Type: gear

Displacement @ 2350 rpm 5.2 gpm19.7 L/min

Charge pump pressure 290 psi20 bar

Function manifold

Function relief 2600 psivalve pressure 179.3 bar

Boom extend relief 1800 psivalve pressure 124.1 bar

Four wheel steer and axle extend/retract manifold

Steer/axle extend 3 gpmflow regulator 11.4 L/min

Drive manifold

Brake relief pressure 250 psi17.2 bar

Drive motors

Displacement 0.73 to 2.75 cu inper revolution, variable 12 cc to 45 cc

Function pump

Type: two-section gear pump

Displacement (Pump 1) 1.75 cu in28.7 cc

Displacement @ 2350 rpm (Pump 1) 17.8 gpm67.4 L/min

Displacement (Pump 2) 1 cu in16.4 cc

Displacement @ 2350 rpm (Pump 2) 10.2 gpm38.5 L/min

Auxiliary pump

Type: two section gear pump

Displacement (Section 1) 0.159 cu in2.61 cc

Displacement @ 2687 rpm (Section 1) 1.85 gpm7 L/min

Displacement (Section 2) 0.051 cu in0.84 cc

Displacement @ 2687 rpm (Section 2) 0.59 gpm2.2 L/min

Auxiliary pump relief pressureSection 1 2500 psi 172.4 barSection 2 3000 psi 206.8 bar

Hydraulic filters

High pressure filter B3-200

High pressure filter 100 psibypass pressure 6.9 bar

Medium pressure filter B3-200

Medium pressure filter 87 psibypass pressure 6 bar

Hydraulic tank circuit 10 micron with 25 psireturn line filter (1.7 bar) bypass

Drive motor case drain filter 10 micron

SPECIFICATIONS



Perkins Engine 1004-42

Displacement 258 cu in4.23 liters

Number of cylinders 4

Bore & stroke 4.06 x 5 inches103.1 x 127 mm

Horsepower 81 @ 2200 rpm

Firing order 1 - 3 - 4 - 2

Compression ratio 18.5:1

Compression pressurepressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.

Low idle - no load 1300 rpm

High idle - no load 2350 rpm

Valve clearance, cold

Intake 0.008 in0.20 mm

Exhaust 0.018 in0.45 mm

Lubrication system

Oil pressure 51 psi3.45 bar

Oil capacity 8.9 quarts(including filter) 8.4 liters

Oil viscosity requirements

below 32°F / 0°C 0W

-13°F to 68°F / -25°C to 20°C 5W-20

10°F to 104°F / -12°C to 40°C 10W-30

14°F to 122°F / -10°C to 50°C 15W-40

above 23°F / -5°C 20W-50

Engine oil should have properties of API classificationCF4 grade OR ACEA classification E3.

Injection system

Injection pump make Zexel

Injector opening pressure 2204 psi152 bar

Fuel requirement

Summer grade diesel number 2-DWinter grade At operating temperatures below

32°F (0°C), use a special winter fuel.

Alternator output 55A, 12V

Battery - System

Type 12V, Group 27TMQuantity 1AH rating 109AHCold cranking ampere 630AReserve capacity @ 25A rate 160 minutes

Battery - Engine starting

Type 12V, Group 4DQuantity 1AH rating 190AHCold cranking ampere 1020AReserve capacity @ 25A rate 325 minutes

Cooling system

Engine capacity 9.5 quarts9 liters

System capacity 20 quarts18.9 liters

Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

SPECIFICATIONS



Injection system

Injection pump make Bosch

Injection pump pressure 5500 psi379.2 bar


Fuel requirement diesel number 2-D


Battery - System




Cooling system

Engine capacity 8.8 quarts8.3 liters

System capacity 20 quarts18.9 liters

Cummins Engine B3.9L

Displacement 238 cu in3.9 liters


Bore and stroke 4.02 x 4.72 inches102 x 120 mm



Compression ratio 16.5:1







Lubrication system

Oil pressure 50 psi3.45 bar

Oil capacity 9.5 quarts(including filter) 9 liters


below 68°F / 20°C 5W-30

-10° to 68°F / -23° to 20°C 10W-30

above 15°F / -9°C 15W-40

Use oils meeting API classification CE (labeled CE/SG).

SPECIFICATIONS



Injection system

Injection pump make IMSA

Injection pump pressure 8702 psi600 bar


Fuel requirement diesel number 2-D


Battery - System




Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

Deutz Engine F4L 913

Displacement 249.3 cu in4.086 liters


Bore and stroke 4.02 x 4.92 inches102 x 125 mm



Compression ratio 18:1







Lubrication system

Oil pressure 40 to 60 psi2.75 to 4.14 bar

Oil capacity 14.3 quarts(including filter) 13.5 liters


below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C 10W-40

above -4°F / -34°C 15W-40

Engine oil should have properties of API classificationCC/SE or CC/SF grades OR ACEA classification E1-96.

SPECIFICATIONS



Hydraulic Hose and Fitting Torque SpecificationsSAE O-ring Boss Port - tube fitting Seal-Lok® - hose end

SAE Dash Size

Installing into... ft. lbs. Nm

SAE Dash Size ft. lbs. Nm

-4 Aluminum 11 14.9 -4 18 24.4Steel 16 21.7 -6 27 36.6

-6 Aluminum 23 31.2 -8 40 54.2Steel 35 47.5 -10 63 85.4

-8 Aluminum 40 54.2 -12 90 122Steel 60 81.3 -16 120 162.7

-10 Aluminum 69 93.6 -20 140 190Steel 105 142.4 -24 165 223.7

-12 Aluminum 93 126.1Steel 140 190

-16 Aluminum 139 188.5Steel 210 284.7

-20 Aluminum 172 233.2Steel 260 352.5

-24 Aluminum 208 282Steel 315 427.1

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

Torque Procedure1 Replace the O-ring. The O-ring must be

replaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.

The O-rings used in the ParkerSeal Lok® fittings and hose endsare custom-size O-rings. They arenot standard SAE size O-rings.They are available in the O-ringfield service kit(Genie part number 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the tableabove.

6 Operate all machine functions and inspect thehoses and fittings and related components tobe sure that there are no leaks.

SPECIFICATIONS


Section 3 • Theory of OperationFirst Edition • First Printing

Theory of Operation

Power SourceThe Genie S-100, S-105, S-120 and S-125 arepowered by one of three diesel engines:the Cummins B3.9L, the Deutz F4L 913 and thePerkins 1004-42.Auxiliary power is supplied by a hydraulic pumppowered by a 12V battery.

Hydraulic SystemAll machine functions are performed by thehydraulic system. The hydraulic system can bedivided into two groups: Boom and Steer/Axlefunctions and Drive functions.

Boom and Steer/Axle functions are powered bytwo-section gear pumps, rated at 17 gpm (64.4 L/min) and 10 gpm (37.9 L/min). When the engine isrunning, these pumps supply hydraulic fluid underpressure to function manifolds, where thedirectional and flow control valves are located. Toprotect from over-pressurization of the systems,each manifold is provided with a pressure reliefvalve. The Steer and Axle extend/retract manifoldrelief valve is set at 3000 psi (206.8 bar); theFunction manifold relief valve is set at 2600 psi(179.3 bar); the Platform manifold relief valve islocated in the Distribution manifold and is set at3000 psi (206.8 bar).

Drive functions are powered by a bi-directional,variable displacement piston pump rated at 28 gpm(106 L/min) @ 2350 rpm. Two internal 4250 psi(293 bar) relief valves are used to prevent over-pressurization of the closed loop drive system.

The boom lift cylinder, boom extend cylinders,platform leveling slave cylinder, platform rotatorand jib boom cylinder (S-105 and S-125 models)incorporate counterbalance valves to preventmovement in the event of a hydraulic line failure.

A regeneration circuit is used to increase theperformance of the primary boom extensionfunction. This circuit transfers hydraulic fluid fromone end of the primary cylinder into the other endwhen the cylinder is extending or retracting.

The auxiliary pump is a two-section gear pump.One section is rated at 1.85 gpm (7 L/min) and theother is rated at 0.59 gpm (2.2 L/min).The 1.7 gpm (7 L/min) section is supplied with a2500 psi (172.4 bar) relief valve and the 0.59 gpm(2.2 L/min) section is supplied with a 3000 psi(206.8 bar) relief valve.

Electrical SystemTwo separate 12V batteries are used for thissystem. The larger, Group 4D, battery is used tostart the engine and power the auxiliary pump. Thesmaller, Group 31, battery is used to power thethree Electronic Control Modules (ECM's) whichmanage boom functions and engine controls. Thebatteries are charged through a common enginedriven alternator. A battery separator is used tocharge the smaller battery before charging thelarger battery. The control system is protected bytwo circuit breakers that may be manually reset.


Section 3 • Theory of Operation First Edition • First Printing

THEORY OF OPERATION

Service Bypass/RecoveryKey SwitchThe Service Bypass/Recovery key switch is only tobe used by properly trained service personnel.

When the Service Bypass/Recovery key switch isturned to the service bypass position, the boomcan be raised while the axles are retracted. Thisfeature of the machine is especially helpful forstorage purposes or when loading the machine fortransport. When the boom is raised with the axlesretracted, the boom cannot be rotated past eithercircle-end wheel.

When the Service Bypass/Recovery key switch isturned and held to the recovery position, theauxiliary power unit will turn on and fully retract theboom, and then lower the boom to a stowedposition. This feature of the machine is especiallyhelpful if the operator in the platform cannot lowerthe boom, if the platform controls becomeinoperative or for returning the machine to a safeposition when the safety switches have beentripped.

Machine ControlsThree ECMs manage the boom functions. Theyare located at the turntable (ground controls orTCON), the platform (platform controls or PCON)and the drive chassis (drive chassis controller orDCON). Communication between the controllers ismaintained via a high speed data bus (CAN bus).For example, steering inputs from PCON are sentto DCON via the high speed data bus usingmultiplexed signals.

A series of proximity switches and mechanical limitswitches provide information to the controllers.These proximity and mechanical switches maintainand define the safe operating parameters of themachine. In addition, there is a back-up safetysystem using mechanical limit switches which willcut power to selected portions of the controllersshould the operational system fail to operateproperly.

The ground controls (TCON) have membraneoperated switches. They are non-tactile touchswitches for greater durability. When one button ispressed there is an audible beep indicatingoperation. In addition, there is a display on theground control box that is used to show faultcodes, engine condition, machine status andsetup, and the display language selected. Boomspeeds, turntable rotation and ramp rates areadjustable. Also, various options and operatinglimitations can be programmed. For example, theboom extension can be limited to 80 ft (24.4 m) or100 ft (30.5 m).

The platform controls (PCON) has three joystickcontrollers for operational control. Drive and steerfunctions are controlled through one dual-axisjoystick, boom up/down and turntable rotatefunctions are controlled through another dual-axisjoystick, and the boom extend/retract functions arecontrolled through a single axis joystick. Standardtoggle switches are used to control the platformlevel up/down, platform rotate and jib boom up/down functions (S-105 and S-125 models).Membrane type switches are used to select thevarious steering and operating modes.


Section 3 • Theory of OperationFirst Edition • First Printing

The drive chassis controller (DCON) has nooperator accessible controls. The various steeringcontrols, axle status, brake and motor speed ismanaged by this controller. There are status LED'son this module to indicate power, data linkcommunications, system fault and sensor power.

Platform leveling is accomplished withelectrohydraulic controls. An angle sensor ismounted on the platform rotator which senses thelevel of the platform. This signal is processed byPCON and sent to TCON using the data bus. Thesignal from the tilt sensor on the turntable iscompared to the PCON signal and adjustments aremade to level the platform.

For safety, machine drive speed is reduced relativeto the steer angle of the wheels and boom length.

Steering is accomplished using hydraulic cylindersat each wheel. Correct steering geometry ismaintained through the use of four steeringsensors, one at each wheel. Steering angles aresent from the primary steering sensor to DCONand the appropriate adjustments are made to theother three wheels to correspond with the steermode selected. If the machine is equipped withfour wheel steering, there are four steering modesavailable: 2 wheel front steer, 2 wheel rear steer, 4wheel coordinated steer and crab steer. Havingindependent control over each wheel allows themachine to determine the correct wheel geometryin each steering mode.

Washing electronic components isnot suggested. Instead, use lowpressure compressed air toremove debris from thesecomponents.

THEORY OF OPERATION


Section 3 • Theory of Operation First Edition • First Printing

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First Edition • First Printing Section 4 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, semi-annually,annually and every 2 years as specified on theMaintenance Inspection Report.

Failure to perform each procedureas presented and scheduled couldresult in death, serious injury orsubstantial damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating the machine.

Keep records on all inspections for three years.

Machines that have been out of service for aperiod longer than 3 months must complete thequarterly inspection.

Unless otherwise specified, perform eachmaintenance procedure with the machine in thefollowing configuration:

· Machine parked on a flat, level surface

· Boom in stowed position

· Turntable rotated with the boom betweenthe circle-end (yellow arrow) wheels

· Turntable secured with the turntable rotationlock

· Key switch in the OFF position with thekey removed

· Wheels chocked

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetywarnings and step-by-step instructions.

Symbols Legend

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.

Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.

Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.

Yellow without safety alertsymbol—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.

Green—used to indicate operationor maintenance information.

Indicates that a specific result is expected afterperforming a series of steps.


First Edition • First PrintingSection 4 • Scheduled Maintenance Procedures

Maintenance Symbols Legend

The following symbols have beenused in this manual to helpcommunicate the intent of theinstructions. When one or more ofthe symbols appear at thebeginning of a maintenanceprocedure, it conveys the meaningbelow.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold engine will berequired to perform this procedure.

Indicates that a warm engine will berequired to perform this procedure.

Indicates that dealer service will berequired to perform this procedure.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, six months, annual, and two year.The Scheduled Maintenance Procedures Sectionand the Maintenance Inspection Report have beendivided into five subsections—A, B, C, D and E.Use the following chart to determine whichgroup(s) of procedures are required to perform ascheduled inspection.

Inspection Table or Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Semi-annually or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two year or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Store completed formsfor three years.

SCHEDULED MAINTENANCE PROCEDURES



Maintenance Inspection Report

Checklist B Y N R

B-1 Check radiator - Liquid cooled models

B-2 Oil cooler and fins - Deutz models

B-3 Engine belt(s) - Deutz and Perkins models

B-4 Replace inline fuel filter/water separator

B-5 Replace air filter

B-6 Air intake system

B-7 Exhaust system

B-8 Hydraulic tank return filters

B-9 Hydraulic tank breather filter

B-10 Medium and high pressure filters

B-11 Electrical wiring

B-12 Brake configuration

B-13 Tires and wheels

B-14 Drive hub oil level

B-15 Engine RPM

B-16 Key switches

B-17 Emergency Stop

B-18 Ground control override

B-19 Safety envelope

B-20 Platform self leveling

B-21 Horn

B-22 Foot switch

B-23 Engine idle select

B-24 Drive enable system

B-25 Drive brakes

B-26 Drive speed - stowed

B-27 Drive speed - raised or extended

B-28 Alarm package

B-29 Engine oil and filter - Cummins models

B-30 Fuel tank cap vent

B-31 Hydraulic oil analysis

Checklist A Y N R

A-1 Manuals

A-2 Decals and placards

A-3 Damage and loose or missing parts

A-4 Engine oil level

A-5 Engine coolant level - Liquid cooled models

A-6 Engine belt(s) - Cummins models

A-7 Engine cooling fan - Liquid cooled models

A-8 Drain inline fuel filter/water separator

A-9 Inspect air filter

A-10 Fuel leaks

A-11 Hydraulic oil level

A-12 Hydraulic leaks

A-13 Hydraulic filter condition indicators

A-14 Platform and ground controls

A-15 Auxiliary power

A-16 Tilt sensor and alarm

A-17 Operating envelope

Perform after 40 hours:A-18 Perform 30 day service

A-19 Engine fasteners - Deutz models

Perform every 125 hours:A-20 Batteries

Instructions· Make copies of this report to use for

each inspection.

· Select the appropriate checklist(s) forthe type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Semi-annual or 500 hourInspection: A+B+C

Annual or 1000 hourInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

· Place a check in the appropriate boxafter each inspection procedure iscompleted.

· Use the step-by-step procedures inthis section to learn how to performthese inspections.

· If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from service

R = repaired

Comments

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company



MAINTENANCE INSPECTION REPORT

Checklist E Y N RRefer to Table E

E-1 Hydraulic oil

E-2 Engine coolant- Liquid cooled models

E-3 Fuel hoses

E-4 Valves - Cummins models

Perform every 3000 hours:

E-5 Fuel injectors- Deutz models

Perform every 5 years:E-6 Remove and inspect boom extend/ retract cables

Checklist C Y N RRefer to Table C

C-1 Valves - Deutz models

C-2 Fuel pump strainer - Perkins models

C-3 Fuel filter element - Perkins and Cummins

C-4 Engine oil and filter - Deutz and Perkins

C-5 Check the coolant - Liquid cooled modelsC-6 Boom extend/retract cables

Checklist D Y N RRefer to Table D

D-1 Boom wear pads

D-2 Axle wear pads

D-3 Free-wheel configuration

D-4 Turntable bearing bolts

D-5 Turntable gear backlash

D-6 Grease rotation bearing

D-7 Drive hub oil

D-8 Engine Belt(s) - Cummins models

D-9 Fuel filter - Deutz models

D-10 Valves - Cummins and Perkins

Instructions· Make copies of this report to use for

each inspection.

· Select the appropriate checklist(s) forthe type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Semi-annual or 500 hourInspection: A+B+C

Annual or 1000 hourInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

· Place a check in the appropriate boxafter each inspection procedure iscompleted.

· Use the step-by-step procedures inthis section to learn how to performthese inspections.

· If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from service

R = repaired

Comments

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company



A-1Inspect the ManualsMaintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

1 Check to be sure that the storage container ispresent and in good condition.

2 Check to make sure that the operator's,responsibilities and safety manuals are presentand complete in the storage container in theplatform.

3 Examine the pages of each manual to be surethat they are legible and in good condition.

4 Always return the manuals to the storagecontainer after use.

Contact your authorized Geniedistributor or Genie Industries ifreplacement manuals are needed.

Table A Procedures

A-2Inspect theDecals and PlacardsMaintaining all of the safety and instructionaldecals and placards in good condition ismandatory for safe machine operation. Decalsalert operators and personnel to the many possiblehazards associated with using this machine. Theyalso provide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.

1 Refer to the Decals section in the Genie S-100 &Genie S-105 Operator's Manual or the GenieS-120 & Genie S-125 Operator's Manual anduse the decal list and illustrations to determinethat all decals and placards are in place.

2 Inspect all decals for legibility and damage.Replace any damaged or illegible decalimmediately.

Contact your authorized Geniedistributor or Genie Industries ifreplacement decals are needed.



TABLE A PROCEDURES

A-3Inspect for Damage and Loose orMissing Parts

Daily machine condition inspections are essentialto safe machine operation and good machineperformance. Failure to locate and repair damage,and discover loose or missing parts may result inan unsafe operating condition.

1 Visually inspect the entire machine for damageand improperly installed or missing partsincluding:

· Electrical components, wiring and electrical cables

· Hydraulic hoses, fittings, cylinders and manifolds

· Fuel and hydraulic tanks

· Drive and turntable motors and drive hubs

· Boom and axle wear pads

· Dents or damage to machine

· Tires and wheels

· Engine and related components

· Limit switches and horn

· Alarms and beacon (if equipped)

· Nuts, bolts and other fasteners

· Platform entry mid-rail or gate

· Cracks in welds or structural components

· Compartment covers and latches

A-4Check the Engine Oil Level

Maintaining the proper engine oil level is essentialto good engine performance and service life.Operating the machine with an improper oil levelcan damage engine components.

Check the oil level with theengine off.

1 Check the engine oil dipstick. Add oil asneeded.

Cummins models:Result: The oil level should be within the "L" and"H" marks on the dipstick.

Deutz models:Result: The oil level should be within the twomarks on the dipstick.

Perkins models:Result: The oil level should be within the twonotches on the dipstick.

Cummins B3.9L Engine 11.5 quartsOil capacity (including filter) 10.9 liters

Cummins B3.9L EngineEngine oil viscosity requirements

below 68°F / 20°C 5W-30

-13° to 68°F / -25° to 20°C 10W-30

above 15°F / -9°C 15W-40




TABLE A PROCEDURES

Deutz F4L 913 Engine 14.3 quartsOil capacity (including filter) 13.5 liters

Deutz F4L 913 EngineEngine oil viscosity requirements


-10°F to 90°F / -23°C to 32°C 10W-40

above -4°F / -34°C 15W-40


Perkins 1004-42 Engine 8.9 quartsOil capacity (including filter) 8.4 liters

Perkins 1004-42 EngineEngine oil viscosity requirements


-13°F to 68°F / -25°C to 20°C 5W-20

10°F to 104°F / -12°C to 40°C 10W-30

14°F to 122°F / -10°C to 50°C 15W-40

above 23°F / -5°C 20W-50


A-5Check the Engine Coolant Level -Liquid Cooled Models

Maintaining the engine coolant at the proper levelis essential to engine service life. Improper coolantlevel will affect the engine's cooling capability andcan damage engine components. Daily checks willallow the inspector to identify changes in coolantlevel that might indicate cooling system problems.

1 Check the fluid level in the coolant recoverytank. Add fluid as needed.

Result: The fluid level should be in theNORMAL range.

Bodily injury hazard. Fluids in theradiator are under pressure andextremely hot. Use caution whenremoving cap and adding fluids.



TABLE A PROCEDURES

A-6Check the Engine Belt(s) -Cummins Models

Maintaining the engine belt(s) is essential to goodengine performance and service life. The machinewill not operate properly with a loose or defectivebelt(s) and continued use may cause componentdamage.

Bodily injury hazard. Do notinspect while the engine isrunning. Remove the key tosecure from operation.

Bodily injury hazard. Beware ofhot engine components. Contactwith hot engine components maycause severe burns.

1 Remove the engine pivot plate retainingfastener. Swing the engine pivot plate out awayfrom the machine.

a engine pivot plate anchor holeb engine pivot plate retaining fastener

2 Locate the engine pivot plate anchor hole at thepivot end of the engine pivot plate.

3 Install the bolt that was just removed into theanchor hole to secure the engine pivot platefrom moving.

Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.

4 Inspect the engine belt for:

· Cracking

· Glazing

· Separation

· Breaks

5 Replace the belt if any damage is found. SeeD-8, Inspect the Engine Belt(s).

6 Inspect the generator belt (if equipped) for:

· Cracking

· Glazing

· Separation

· Breaks

a generator (option)b generator belt

ba

a

b



TABLE A PROCEDURES

7 Replace the belt if any damage is found. SeeD-8, Inspect the Engine Belt(s).

Cummins engines are equippedwith a serpentine belt andincorporate a self-adjusting pulleytensioner. No adjustment isrequired.

8 Remove the engine pivot plate retainingfastener from the engine pivot plate anchor holeat the pivot end of the engine pivot plate.

9 Swing the engine pivot plate in towards themachine.

10 Install the bolt that was just removed into theoriginal hole to secure the engine pivot plate.


Belts - Genie part numbers

Cummins engine belt 62437Cummins generator belt 60725

A-7Check the Engine Cooling Fan -Liquid Cooled Models

Maintaining the engine cooling fan is essential togood engine performance and service life. Themachine will not operate properly with a loose ordefective cooling fan and continued use maycause component damage.



1 Open the engine side turntable cover and locatethe engine cooling fan.

2 Inspect the engine cooling fan for:

· Cracking

· Loose rivets (if equipped)

· Bent or loose blades

3 Check the fan to make sure it is securelymounted. Tighten the cooling fan mountingfasteners if necessary.

4 Replace the cooling fan if any damage is found.



TABLE A PROCEDURES

A-8Drain the Inline Fuel Filter/ WaterSeparator

Proper maintenance of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and componentdamage.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Poor fuel quality or very wetconditions may necessitateperforming this procedure moreoften.

Perform this procedure with theengine off.

1 Open the engine side turntable cover and locatethe fuel filter/water separator.

2 Loosen the vent plug located on the fuel filter/water separator head.

a head boltb vent plugc drain plugd filter bowle filter elementf separator head

3 Loosen the drain plug located at the bottom ofthe bowl. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

Do not completely drain the fuelbowl.

4 Tighten the vent plug.

5 Clean up any diesel fuel that may have spilledduring the procedure.

6 Start the engine from the ground controls andcheck the fuel filter/water separator for leaks.

If the engine will not start or runserratically, the fuel system mayneed to be bled. Refer to B-4,Replace The Fuel Filter/WaterSeparator.



TABLE A PROCEDURES

A-9Inspect the Engine Air Filter

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.


1 Open the engine side cover. Empty the dustdischarge valve by pressing together the sidesof the discharge slot. Clean the discharge slotas needed.

a clampb cannister end capc dust discharge valve

2 Release the clamps from the end cap of the airfilter canister. Remove the end cap.

3 Remove the filter element.

4 Clean the inside of the canister and the canisterend cap with a damp cloth.

5 Inspect the filter element. If needed, blow fromthe inside out using low pressure drycompressed air, or tap out dust, taking care notto damage the element.

6 Install the filter element.

7 Install the end cap onto the canister. Secure theclamps.

Air filter element

Genie part number 62425



TABLE A PROCEDURES

A-10Check for Fuel Leaks

Failure to detect and correct fuel leaks will result inan unsafe condition. An explosion or fuel fire couldresult in death or serious injury.

Explosion and fire hazard. Enginefuels are combustible. Inspect themachine in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

1 Perform a visual inspection around the followingareas:

· Fuel tank, shutoff valve, hoses and fittings,fuel pump, fuel filter, fuel injection pumps andfuel injectors.

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.

A-11Check the Hydraulic Oil Level

Maintaining the hydraulic oil at the proper level isessential to machine operation. Improper hydraulicoil levels can damage hydraulic components. Dailychecks allow the inspector to identify changes in oillevel that might indicate the presence of hydraulicsystem problems.

Perform this procedure with theboom in the stowed position andthe axles extended.

1 Visually inspect the sight gauge located on theside of the hydraulic oil tank.

Result: The hydraulic oil level should be 3/4 inch(19 mm) from the top of the sight gauge.

Hydraulic oil specifications

Hydraulic oil type Dexron equivalent

Tank capacity 55 gallons208 liters

Hydraulic system 80 gallons(including tank) 303 liters



A-12Check for Hydraulic Leaks

Detecting hydraulic fluid leaks is essential tooperational safety and good machine performance.Undiscovered leaks can develop into hazardoussituations, impair machine functions and damagemachine components.

1 Inspect for hydraulic oil puddles, dripping orresidue on or around the following areas:

· Hydraulic tank—filter, fittings, hoses,auxiliary power unit and turntable surface

· Engine compartment—fittings, hoses,pumps, filters and turntable surface

· All hydraulic cylinders

· All hydraulic manifolds

· Boom

· The underside of the turntable

· The underside of the drive chassis

· Axles

· Ground area under the machine

A-13Check the Hydraulic FilterCondition Indicators

Maintaining the hydraulic filters in good condition isessential to good system performance and safemachine operation. The filter condition indicatorswill show when the hydraulic flow is bypassing aclogged filter. If the filters are not frequentlychecked and replaced, impurities will remain in thehydraulic system and cause component damage.

There are five hydraulic filterslocated on the machine. There istwo tank return filters, one mediumpressure filter and two highpressure filters. All the filters havecondition indicators on them,except the drive motor case drainreturn filter.

1 Start the engine from the platform controls.

TABLE A PROCEDURES



2 Change the engine idle to high rpm (rabbitsymbol).

a foot switch activated high idleindicator light

b low idle indicator lightc high idle indicator lightd engine idle speed select button

Press the engine idle speed selectbutton until the indicator light nextto foot switch activated high idle(rabbit symbol) is on.

Tank Return Filter

3 Inspect the filter condition indicator gauge.

a filter condition indicator gauge

Result: The needle on the gauge should beoperating in the green area. If the needle is inthe red area, this indicates that the hydraulicfilter is being bypassed and the filter should bereplaced. See B-8, Replace the Hydraulic TankReturn Filters.

Medium and High Pressure Filters

The medium and high pressurefilters are mounted to the engineside bulkhead. A filter conditionindicator is located on the top ofeach filter.

4 Inspect the filter condition indicators.

a high pressure filtersb filter condition indicatorsc medium pressure filter

Result: The filter condition indicators should beoperating with the plungers in the green area. Ifany of the indicators display the plunger in thered area, this indicates that a hydraulic filter isbeing bypassed and the filter should bereplaced. See B-10, Replace the Medium andHigh Pressure Hydraulic Filters.

TABLE A PROCEDURES

a

b

c

a

cb

d

a



A-14Test the Platform andGround ControlsTesting the machine functions and the EmergencyStop buttons for malfunctions is essential for safemachine operation. An unsafe working conditionexists if any function fails to operate properly oreither Emergency Stop button fails to stop all themachine functions and shut off the engine. Eachfunction should activate, operate smoothly and befree of hesitation, jerking and unusual noise.

Tip-over hazard. Do not raise orextend the boom unless bothaxles are extended. If the axleextension system is not operatingcorrectly, the stability of themachine is compromised and itmay tip over.

Be sure the axles are retractedbefore performing this procedure.

1 Turn the key switch to ground controls and pullout the Emergency Stop button to the ON

position at both the ground and platformcontrols.

Result: The LCD screen will come on anddisplay no error messages. The beacon(if equipped) should flash.

In cold climates, the LCD readoutscreen will need to warm upbefore the display appears.

2 Start the engine.

TABLE A PROCEDURES

3 Push and hold a function enable/speed selectbutton and push the boom up button.

Result: The boom should raise to 10° abovehorizontal and then stop. The boom should notraise above the limit switch unless both axlesare extended.

4 Push and hold a function enable/speed selectbutton and push the boom down button.

Result: The boom should lower and return tothe stowed position.

5 Push and hold a function enable/speed selectbutton and press the boom extend button.

Result: The boom will extend approximately 3feet (1 m) and stop. The boom should notextend further unless both axles are extended.

6 Push and hold a function enable/speed selectbutton and push the boom retract button.

Result: The boom should retract.

7 Turn the key switch to platform controls.

8 Press down the foot switch.

9 Move the drive control handle in the forwarddirection and push the extend axle button.

Result: The machine should drive and the axlesshould extend. The indicator light will flashwhile the axles are moving and stay on whenthe axles are fully extended.

The extend axle function will onlywork while the machine is moving.



TABLE A PROCEDURES

10 Stop the machine when the axles are fullyextended.

Test the Ground Controls

11 Turn the key switch to ground controls.

12 Do not press and hold a function enable/speedselect button. Attempt to activate each boomand platform function button.

Result: No boom and platform functions shouldoperate.

13 Press and hold a function enable/speed selectbutton and activate each boom and platformfunction button.

Result: All boom and platform functions shouldoperate through a full cycle. Descent alarm(if equipped) should sound while boom islowering.

Test the Platform Controls


15 Do not press down the foot switch.

16 Attempt to activate each machine functioncontrol handle, toggle switch or button.

Result: No boom and platform functions shouldoperate.


18 Activate each machine function control handle,toggle switch or button.

Result: All functions should operate through afull cycle. Descent alarm (if equipped) shouldsound while boom is lowering.

A-15Test the Auxiliary PowerOperationDetection of auxiliary power system malfunctions isessential for safe machine operation. An unsafeworking condition exists if the auxiliary poweredfunctions do not operate in the event of a mainpower loss. When operating the machine onengine power, selecting auxiliary power will stopthe engine immediately. Auxiliary power isdesigned for short term use only and excessiveuse will result in battery drain and componentdamage.

Perform this procedure with theaxles extended and the engine off.

1 Turn the key switch to ground control and pullout the Emergency Stop button to the ON


2 Simultaneously push and hold the auxiliarypower button and push each boom functionbutton.

To conserve battery power, testeach function through a partialcycle.

Result: All boom functions should operate.



5 Simultaneously press and hold the auxiliarypower button and activate each function controlhandle, toggle switch or button.

To conserve battery power, testeach function through a partialcycle.




A-16Test the Tilt Sensor and AlarmThe tilt sensor sounds an alarm located in theplatform when the incline of the turntable exceedsthe rating on the serial plate.

Select a level test area. The tiltalarm should not be sounding priorto the test.

Be sure the engine is off.

1 Turn the key switch to ground controls and pullout the Emergency Stop buttons out to the ON


2 Push one of the LCDscreen buttons shown untilTURNTABLE LEVEL XAXIS appears.

Result: The LCD screen should display theangle in degrees.

3 Push one of the LCDscreen buttons shown untilTURNTABLE LEVEL YAXIS appears.


TABLE A PROCEDURES

4 Push one of the LCDscreen buttons shown untilPLATFORM LEVELappears.



6 Push a button, such as the engine RPM buttonor the fuel select button.

Result: The alarm should sound at the platformcontrols.



TABLE A PROCEDURES

A-17Test the Operating EnvelopeTesting the machine operating envelope is criticalto safe machine operation. If the boom is allowedto operate outside of the operating envelope, themachine stability is compromised and may tip over.

1 Turn the key switch to ground controls and pullout the Emergency Stop buttons out to the ON


2 Simultaneously push theLCD screen buttonsshown to activate statusmode.

3 Push one of the LCDscreen buttons shown untilBOOM ANGLE isdisplayed.

4 Raise the boom and observe the LCD screen.

Result: The LCD screen should display:<10>10>50>65

5 Push one of the LCDscreen buttons shown untilBOOM LENGTH isdisplayed.

6 Extend the boom and observe the LCD screen.

Result: The LCD screen should display:at 0> 0>80= 100>100

7 Retract the boom.

8 Lower the boom.



A-18Perform 30 Day Service

The 30 day maintenance procedure is a one-timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage. After thisinterval, refer to the maintenance tables forcontinued scheduled maintenance.

1 Perform the following maintenance procedures:Deutz models:

· A-3 Inspect for Damage and Loose orMissing Parts

· A-19 Check the Engine Fasteners -Deutz Models

· B-3 Check the Engine Belt(s) - Deutz andPerkins Models

· B-5 Replace the Air Filter· B-8 Replace the Hydraulic Tank Return

Filters· B-13 Inspect the Tires and Wheels

(including lug nut torque)· C-1 Check the Engine Valve Clearances -

Deutz Models· C-6 Inspect the Boom Extend/Retract

Cables· D-4 Check the Turnable Rotation Bearing

Bolts· D-9 Replace the Fuel Filter/Water

Separator - Deutz Models· B-15 Check and Adjust the Engine RPM· C-4 Replace the Engine Oil and Filter -

Deutz and Perkins Models

Cummins models:· A-3 Inspect for Damage and Loose or

Missing Parts· A-5 Check the Engine Coolant Level -

Liquid Cooled Models· B-5 Replace the Air Filter· B-8 Replace the Hydraulic Tank Return


(including lug nut torque)· C-3 Replace the Fuel Filter Element -

Perkins and Cummins Models· C-6 Inspect the Boom Extend/Retract


Bolts· D-8 Check the Engine Belt(s) -

Cummins Models· D-10 Check the Engine Valve Clearances -

Cummins and Perkins Models· B-15 Check and Adjust the Engine RPM· B-28 Replace the Engine Oil and Filter -

Cummins Models

TABLE A PROCEDURES



Perkins models:· A-3 Inspect for Damage and Loose or

Missing Parts· A-5 Check the Engine Coolant Level -

Liquid Cooled Models· B-3 Check the Engine Belt(s) - Deutz and

Perkins Models· B-5 Replace the Air Filter· B-8 Replace the Hydraulic Tank Return


(including lug nut torque)· C-3 Replace the Fuel Filter Element -

Perkins and Cummins Models· C-6 Inspect the Boom Extend/Retract


Bolts· D-10 Check the Engine Valve Clearances -

Cummins and Perkins Models· B-15 Check and Adjust the Engine RPM· C-4 Replace the Engine Oil and Filter -

Deutz and Perkins Models

A-19Check the Engine Fasteners -Deutz Models

Engine specifications require thatthis procedure be performed after40 hours of use.

Properly torqued engine fasteners are essential togood engine performance and operational safety.Loose or improperly torqued fasteners can result inengine component damage and hazardousconditions.




TABLE A PROCEDURES

ba





4 Tighten all valve cover retaining fasteners.Torque to 108 in-lbs (12 Nm).

5 Tighten all air intake pipe clamps. Torque to 108in-lbs (12 Nm).

6 Tighten all intake manifold retaining fasteners.Torque to 17 ft-lbs (23 Nm).

7 Tighten all exhaust manifold retaining fasteners.Torque to 30 ft-lbs (40 Nm).

8 Tighten all engine mounting fasteners. Torqueengine to bracket mounting fasteners to 54 ft-lbs (73 Nm) and bracket to engine pivot platemounting fasteners to 175 ft-lbs (237 Nm).





A-20Check the Batteries

Genie specifications require thatthis procedure be performed every125 hours.

Proper battery condition is essential to goodengine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and hazardous conditions. There are 2batteries on the machine. One is used for startingthe engine and the other is used to power thecontrol system. The two batteries are charged bythe alternator through a battery separator.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections arefree of corrosion.

3 Be sure that the battery hold downs and cableconnections are tight.

TABLE A PROCEDURES



4 Be sure that the battery separator wireconnections are tight.

5 Remove the battery vent caps from bothbatteries and check the specific gravity of eachbattery with a hydrometer.

Result: If any battery cell displays a specificgravity of less than 1.026, the battery must bereplaced.

6 Check the battery acid level. If needed,replenish with distilled water to the bottom ofthe battery fill tube. Do not overfill.

7 Install the vent caps.

Adding terminal protectors and acorrosion preventative sealant willhelp eliminate corrosion on thebattery terminals and cables.

TABLE A PROCEDURES



B-1Check the Radiator -Liquid Cooled Models

Maintaining the radiator in good condition isessential for good engine performance. Operatinga machine with a damaged or leaking radiator mayresult in engine damage. Also, restricting air flowthrough the radiator (i.e., dirt or debris) will affectthe performance of the cooling system. A frequentcheck allows the inspector to identify changes inthe condition of the radiator that might indicatecooling system problems.


Bodily injury hazard. Beware ofhot engine parts and coolant.Contact with hot engine parts and/or coolant may cause severeburns.



Table B Procedures




4 Inspect the radiator for leaks and physicaldamage.

5 Clean the radiator fins of debris and foreignmaterials.





ba



TABLE B PROCEDURES

B-2Check the Oil Cooler andCooling Fins - Deutz Models

Maintaining the oil cooler in good condition isessential for good engine performance. Operatinga machine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.



Oil Cooler

1 Open the latches from the engine side cover.Remove the cover.

2 Inspect the oil cooler for leaks and physicaldamage.

3 Clean the oil cooler of debris and foreignmaterial.

Cooling and Fan Blower Fins

4 Inspect the fan blower fins for physical damage.

5 Clean the fan blower fins of debris and foreignmaterial.

6 Inspect the cylinder head cooling passages andfins for physical damage or foreign material,using a flashlight.

7 Clean the cylinder head cooling passages ofdebris and foreign material.



TABLE B PROCEDURES

B-3Check the Engine Belt(s) -Deutz and Perkins Models

Maintaining the engine belt(s) is essential to goodengine performance and service life. The machinewill not operate properly with a loose or defectivebelt and continued use may cause componentdamage.


Burn injury hazard. Beware of hotengine components. Contact withhot engine components maycause severe burns.






Deutz models:

4 Remove the front engine access covermounting fasteners and remove the frontengine access cover.

All models:


· Cracking

· Glazing

· Separation

· Breaks

6 Replace the belt if any damage is found.

7 Inspect the generator belt (if equipped) for:

· Cracking

· Glazing

· Separation

· Breaks

Perkins engine Deutz engine

a generator belt

ba

a



TABLE B PROCEDURES

8 Check the engine belt(s) for proper tension.

Perkins engine Deutz engine

Deutz models:

9 Install the front engine access cover mountingfasteners and install the front engine accesscover.

All models:






Deutz Engine Belt 62431Deutz Generator Belt 75053Perkins Engine Belt 62428Perkins Generator Belt 75053

Belt deflection 3/8 inch to 1/2 inch9 mm to 12 mm

B-4Replace the Inline Fuel Filter/Water Separator Element

Replacing the inline fuel filter/water separatorelement is essential for good engine performanceand service life. A dirty or clogged filter may causethe engine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.



1 Tag, disconnect and plug the fuel line from thefuel tank at the inline fuel filter/water separatorhead.



TABLE B PROCEDURES

2 Loosen the vent plug located on the inline fuelfilter/water separator head.

a head boltb vent plugc drain plugd filter bowle filter elementf fuel filter/water separator head

3 Place a suitable container under the filter bowl.

4 Loosen the drain plug located at the bottom ofthe bowl. Completely drain the fuel from thebowl.

5 Loosen the head bolt. Rotate the filter bowlcounterclockwise and remove it from theelement.

6 Install the bowl onto the new inline filter element(Genie part number 62433). Tighten the drainplug.

7 Fill the element and bowl with clean diesel fuel.

8 Apply a thin layer of oil onto the element gasket.

9 Install the filter/bowl assembly onto the filterhead and tighten it securely by hand.

The filter/bowl assembly must befull of fuel when it is installed ontothe filter head or the fuel systemwill have to be bled.

10 Tighten the head bolt to 65 in-lbs (7.3 Nm).

11 Tighten the vent plug.


13 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe filter.

14 Install the fuel tank line onto the inline fuel filter/water separator head. Tighten the hose clamp.

Inline fuel filter/water separator element -Genie part number 62433

Bleed the fuel system:

Before bleeding the fuel system,be sure the fuel tank is full.

Deutz models:

1 Loosen the overflow valve at the injector pump.

a overflow valveb fuel lift pump priming leverc oil filterd filter heade fuel filter



TABLE B PROCEDURES

2 Operate the priming lever of the fuel lift pumpuntil fuel, free from air, comes from the vent.

3 While continuing to operate the priming lever,tighten the overflow valve.

4 Clean up any diesel fuel that might have spilledduring the procedure.

5 Start the engine and inspect for leaks.


Component damage hazard.Damage to the fuel injection pump,battery and starter motor canoccur if the stater motor is usedexcessively to eliminate air fromthe fuel system. Do not engagethe starter motor for more than 30seconds at a time. Wait 120seconds between starter motorengagements.

Component damage hazard.Operate the engine at low idlespeed for a minimum of twominutes immediately after air hasbeen removed from the fuelsystem. This will ensure that thepump is free of air and preventany damage to the pumps bymetal to metal contact.

If the engine does not start or runserratically, refer to the DeutzOperation Manual, Deutz partnumber 0297 7341 (Genie partnumber 62446) for additionalinformation on the fuel system.

Cummins models:

Controlled venting is provided atthe injection pump. Small amountsof air introduced by changing thefilters or injection pump supply linewill be vented automatically. If thefuel filter is changed in accordancewith instructions, no manualbleeding of the fuel system isneeded.






ba



TABLE B PROCEDURES

4 Loosen the fuel filter/water separator filter ventscrew, located on top of the fuel filter/waterseparator head.

a filter head vent screwb fuel filterc lift pumpd priming lever

5 Operate the priming lever on the fuel lift pumpuntil fuel, free from air, comes out from the ventscrew.

6 While continuing to operate the priming lever,tighten the vent screw. Torque the vent screwto 80 in-lbs (9 Nm).


11 Start the engine and inspect for leaks.




If the engine does not start or runserratically, refer to the CumminsOperation and MaintenanceManual, Cummins part number3810205 (Genie part number62448) for additional informationon the fuel system.



TABLE B PROCEDURES





Perkins models:






4 Loosen the fuel filter/water separator filter ventscrew, located on top of the fuel filter/waterseparator head.

a vent screwb fuel filter headc fuel filterba



TABLE B PROCEDURES

5 Operate the priming lever of the fuel lift pumpuntil fuel, free from air, comes from the vent.

If the drive cam of the fuel liftpump is at the point of maximumlift, it will not be possible tooperate the priming lever. In thissituation, rotate the crankshaft onerevolution.

a fuel lift pump

6 While continuing to operate the priming lever,tighten the vent screw.

7 Loosen the union nut on the fuel inlet pipe at theinjection pump.

8 Operate the priming lever of the fuel lift pumpuntil fuel, free from air, comes from theconnection.

9 Tighten the union nut.


11 Start the engine and check for leaks.




If the engine does not start or runserratically, refer to the PerkinsUser's Handbook, Perkins partnumber TPD 1349 (Genie partnumber 62447) for additionalinformation on the fuel system.



TABLE B PROCEDURES





B-5Replace the Air Filter

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.


1 Open the evacuator valve located on the aircleaner cap by squeezing the sides togetherwith your fingers.

2 Open the latches on the air cleaner cap.Remove the end cap from the air cleanercanister.

3 Remove the filter element.

4 Clean the inside of the air cleaner canister andend cap with a damp cloth.

5 Install the new filter element.

6 Replace the end cap on the canister.

Be sure the evacuator valve ispointing in the down direction.

Air filter - Genie part number 62425



TABLE B PROCEDURES

B-6Inspect the Air Intake System

Maintaining the air intake system in good conditionis essential to good engine performance andservice life. Failure to perform this procedure canlead to poor engine performance and componentdamage.


1 Inspect the intake piping for cracked hoses,loose clamps or punctures which can allow dirtand debris to enter the engine.

2 Tighten or replace parts as necessary to makesure the air intake system does not leak.

B-7Check the Exhaust System

Maintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.



Cummins and Perkins models:

1 Be sure that all fasteners are tight.

2 Inspect all welds for cracks.

3 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.



ba

TABLE B PROCEDURES

Deutz models:






4 Be sure that all fasteners are tight.

5 Inspect all welds for cracks.

6 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.







TABLE B PROCEDURES

B-8Replace the Hydraulic TankReturn Filters

Replacement of the hydraulic tank return filter isessential for good machine performance andservice life. A dirty or clogged filter may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.

Burn hazard. Beware of hot oil.Contact with hot oil may causesevere burns.


There are two return filters on themachine. One is the system returnfilter and the other one is thereturn filter for the drive motorcase drains.

1 Open the ground controls side turntable sidecover and locate the tank return filters.

The system return filter is locatednear the top of the hydraulic tankand the drive motor case drainreturn filter is located below thesystem return filter.

2 Place a suitable container under the hydraulictank return filters.

3 Remove each filter with an oil filter wrench.

4 Apply a thin layer of clean oil to the new oil filtergaskets.

5 Install the new system return filter (Genie partnumber 61326) and tighten it securely by hand.

6 Install the drive motor case drain return filter(Genie part number 44207) and tighten itsecurely by hand.

7 Clean up any oil that may have spilled duringthe procedure.

8 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe filters.

9 Start the engine from the ground controls.

10 Inspect the filters and related components tobe sure that there are no leaks.

Hydraulic tank return filters -Genie part numbers

System return filter 61326Drive motor case drain return filter 44207



TABLE B PROCEDURES

B-9Replace the Hydraulic TankBreather Filter

Replacement of the hydraulic tank breather filter isessential for good machine performance andservice life. A dirty or clogged filter may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.



1 Open the ground controls side cover and locatethe tank breather filter.

The tank breather filter is locatedon top of the hydraulic tank.

2 Remove the filter with an oil filter wrench.

3 Apply teflon tape to the threads of the hydraulictank filter mount.

4 Install a new tank breather filter (Genie partnumber 60559) onto the filter mount and tightenit securely by hand.


Hydraulic tank breather filter

Genie part number 60559



TABLE B PROCEDURES

B-10Replace the Medium andHigh Pressure Hydraulic Filters

Replacement of the medium and high pressurefilters is essential for good machine performanceand service life. A dirty or clogged filter may causethe machine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the filters be replacedmore often.


The medium pressure filter is forthe charge pump and the highpressure filters are for the drivecircuit.


1 Open the engine side turntable cover and locatethe three filters mounted to the bulkhead.

a high pressure filtersb medium pressure filter

2 Place a suitable container under the filters.

3 Remove the filter housing by using a wrench onthe nut provided on the bottom of the housing.

4 Remove the filter element from the housing.

5 Inspect the housing seal and replace it ifnecessary.

6 Install the new medium pressure filter elementinto the housing (Genie part number 60858)and tighten it securely.

7 Install the new high pressure filter elements intothe housings (Genie part number 60857) andtighten them securely.

8 Clean up any oil that may have spilled duringthe installation procedure.

9 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter housings.


11 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.

Medium and high pressure filters -Genie part numbers

Medium pressure filter 60858High pressure filter 60857

a

b



TABLE B PROCEDURES

B-11Inspect the Electrical WiringMaintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.

1 Inspect the following areas for burnt, chafed,corroded and loose wires:

· Engine wiring harness

· Ground control box harness connectors

· Turntable manifold wiring

2 Start the engine from the platform controls andextend the axles.

3 Turn the key switch to ground control and raisethe boom above the turntable covers.

4 Install a safety chock (Genie part number75097) onto the hydraulic lift cylinder extensionrod. Carefully lower the boom onto the liftcylinder safety chock.

Crushing hazard. Keep handsaway from the cylinder and allmoving parts when lowering theboom.

The lift cylinder safety chock isavailable through Genie (Geniepart number 75097).

5 Turn the engine off.

6 Remove the boom storage area cover retainingfasteners and remove the boom storage areacover.

7 Inspect the turntable area for burnt, chafed andpinched cables.

8 Install the boom storage area cover and installthe boom storage area cover retainingfasteners.

9 Raise the boom to a horizontal position.

10 Remove the safety chock and lower the boomto the stowed position.

10 Turn the engine off.

11 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

· Cable track on the boom

· Boom to platform cable harness

· Platform control box harness connectors

· Platform manifold wiring



B-12Confirm the ProperBrake Configuration

Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.

1 Check each drive hub disconnect cap to besure it is in the engaged position.

B-13Inspect the Tires and Wheels(including lug nut torque)

Maintaining the tires and wheels in goodcondition is essential to safe operation and goodperformance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired in a timely fashion.

The tires on these machines arefoam filled and do not need airadded to them.

1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracked welds.

3 Check each lug nut for proper torque.

Tires and wheels

Tire size 18-22.5

Tire ply rating 18

Wheel lugs 10 @ 3/4 -16



disengage position

engage position

TABLE B PROCEDURES



TABLE B PROCEDURES

B-14Check the Oil Level in theDrive Hubs

Failure to maintain proper drive hub oil levels maycause the machine to perform poorly andcontinued use may cause component damage.

Drive Hubs

1 Drive the machine to rotate the hub until theplugs are located one on top and the other at90°.

a drive hub plugs

2 Remove the plug located at 90° and check theoil level.

Result: The oil level should be even with thebottom of the plug hole.

3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole.

4 Install the plug into the drive hub.

When removing the drive hub plugon machines before serial number158, replace the drive hub plugwith the new O-ring style drive hubplug (Genie part number 75107).

5 Repeat this procedure for each drive hub.

Drive hub oil

Capacity 83 fl oz2.5 liters

Type: SAE 80W-90 EP multipurpose gear oil

Turntable Rotate Drive Hub

The turntable rotate drive hub islocated under a fixed turntablecover at the ground controls sideof the machine. The cover has tobe removed before the followingprocedure can be completed.

1 Remove the power to platform plug panel upperretaining fasteners and loosen the lowerretaining fasteners. Do not disconnect thewiring.

2 Support the cover with a suitable lifting device.Protect the cover from damage.

3 Remove the cover retaining fasteners. Removethe cover from the machine.

Crushing hazard. The turntablecover may become unbalancedand fall when it is removed fromthe machine if it is not properlysupported.

a



TABLE B PROCEDURES

B-15Check and Adjust theEngine RPM

Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.

Deutz models:


2 Push one of the LCDscreen buttons shown untilengine rpm is displayed.

Result: Low idle should be 1300 rpm.

Skip to step 11 if the low idle rpm is correct.

3 Remove the secondary idle adjustment screwcap from the secondary idle adjustment screwon the injection pump. Loosen the locknut.

Deutz enginea primary idle adjustment screwb secondary idle adjustment screw

4 Remove the plug located on the top of the drivebrake and check the oil level.

Result: The oil level should be even with thebottom of the plug hole.

a plugb turntable rotate drive hubc drive brake

5 If necessary, add oil until the oil level is evenwith the bottom of the plug hole.


Turntable rotate drive hub oil

Capacity (approximately) 92 fl oz2.7 liters

Type SAE 80W-90 EP multipurpose gear oil

a

b

c



TABLE B PROCEDURES

4 Turn the secondary adjustment screwcounterclockwise until the adjustment screw isloose. Tighten the locknut.

Be sure the adjustment screw isloosened until there is no springtension felt.

5 Remove the primary idle adjustment screw capfrom the primary idle adjustment screw on theinjection pump. Loosen the locknut.

6 Adjust the primary idle adjustment screw untillow idle is 1250 rpm. Tighten the locknut.

7 Install the primary idle adjustment screw capand tighten. Do not over tighten.

8 Loosen the secondary idle adjustment screwlocknut.

9 Adjust the secondary adjustment screw until thelow idle is 1300 rpm. Tighten the locknut.

10 Install the secondary idle adjustment screw capand tighten. Do not over tighten.

11 Push and hold the function enable/high speedbutton. Note the engine rpm on the display.

Result: High idle should be 2350 rpm.

If the high idle is correct, disregard adjustmentstep 12.

12 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Be sure the solenoid fully retractswhen activating high idle.

Deutz models

Low idle 1300 rpm

High idle 2350 rpm

Cummins and Perkins models:




ba






5 Push one of the LCD screen buttons shownuntil engine rpm isdisplayed.

Result: Low idle should be1300 rpm.

Skip to step 7 if the low idle rpm is correct.

6 Loosen the low idle lock nut. Turn the low idleadjustment screw clockwise to increase the rpmor counterclockwise to decrease the rpm.Tighten the low idle lock nut and confirm therpm.

Perkins modelsa low idle adjustment screwb yoke lock nutc solenoid bootd high idle adjustment nute yokef low idle lock nut

Cummins modelsa yokeb yoke lock nutc solenoid bootd high idle adjustment nute low idle adjustment screw

TABLE B PROCEDURES



TABLE B PROCEDURES

7 Push and hold the function enable/high speedbutton. Note the engine rpm on the display.

Result: High idle should be 2350 rpm.

Skip to step 9 if the high idle rpm is correct.

8 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Be sure the solenoid fully retractswhen activating high idle.





Cummins and Perkins models

Low idle 1300 rpm

High idle 2350 rpm

B-16Test the Key SwitchesProper key switch action and response is essentialto safe machine operation. Failure of either keyswitch to function properly could cause ahazardous operating situation.

There are two key switches on the machine - theMain key switch and the Service Bypass/Recoverykey switch.

The Main key switch controls machine operationfrom the ground or platform controls.

When the Service Bypass/Recovery key switch isturned to the service bypass position, the boomcan be raised while the axles are retracted. Thisfeature of the machine is especially helpful forstorage purposes or when loading the machine fortransport. When the boom is raised with the axlesretracted, the boom cannot be rotated past eithercircle-end wheel.

When the Service Bypass/Recovery key switch isturned and held to the recovery position, theauxiliary power unit will turn on and fully retract theboom, and then lower the boom to a stowedposition. This feature of the machine is especiallyhelpful if the operator in the platform cannot lowerthe boom, if the platform controls becomeinoperative or for returning the machine to a safeposition when the safety switches have beentripped.

Perform this procedure with theaxles retracted.

1 Open the ground controls side turntable sidecover.



2 Pull out the Emergency Stop button to the ON


3 At the ground controls, turn the servicebypass/recovery key switch to the RUN position.

4 Turn the main key switch to ground control,start the engine and then turn the key switch toplatform control.

5 Check any machine function from the groundcontrols.

Result: The machine functions should notoperate.

6 Turn the main key switch to ground control.

7 Check any machine function from the platformcontrols.


8 Turn the main key switch to the OFF position.

Result: The engine should stop and nofunctions should operate.


10 Turn the main key switch to ground control andstart the engine.

11 Raise the boom.

Result: The boom should raise to 10° abovehorizontal and then stop. The boom should notraise above the limit switch unless both axlesare extended.

12 Remove the key from the main key switch andinsert the key into the service bypass/recoverykey switch.

The key switch should remain inthe GROUND CONTROL position.

13 Turn the service bypass/recovery key switch tothe SERVICE BYPASS position.

14 Raise the boom.

Result: The boom should raise.

15 Remove the key from the servicebypass/recovery key switch and insert the keyinto the main key switch.


17 Remove the key from the main key switch andinsert the key into the service bypass/recoverykey switch.

18 Turn and hold the service bypass/recovery keyswitch to the RECOVERY position.

Result: The boom should return to the stowedposition.

19 Turn the service bypass/recovery key switch tothe run position.

20 Remove the key from the servicebypass/recovery key switch and insert the keyinto the main key switch.


22 Close the turntable side cover.

TABLE B PROCEDURES



B-17Test the EmergencyStop ButtonsProperly functioning Emergency Stop buttonsare essential for safe machine operation. Animproperly operating Emergency Stop buttonwill fail to shut off power and stop all machinefunctions, resulting in a hazardous situation forground and platform personnel.

As a safety feature, selectingand operating the ground controlswill override the platform controls,including the Emergency Stopbutton.


2 Push in the Emergency Stop button to the OFF

position.

Result: The engine should shut off and nomachine functions should operate.


4 Push down the Emergency Stop button to theOFF position.

Result: The engine should shut off and nomachine functions should operate.

The ground Emergency Stopbutton will stop all machineoperation, even if the key switchis switched to platform control.

B-18Test the Ground Control OverrideA properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allowground personnel to operate the machine from theground controls whether or not the EmergencyStop button on the platform controls is in the ON orOFF position. This function is particularly useful ifthe operator at the platform controls cannot returnthe boom to the stowed position.

1 Push in the platform Emergency Stop buttonto the OFF position.


3 Operate each boom function through apartial cycle.


TABLE B PROCEDURES



TABLE B PROCEDURES

B-19Test the Safety Envelope andCircuitsTesting the machine safety envelope is critical tosafe machine operation. If the boom is allowed tooperate when a safety switch is not functioningcorrectly, the machine stability is compromised andmay tip over.

1 Raise the boom to approximately 60°.

For S-100 or S-105 models,proceed to step 15.

101 feet (30.8 m) Length Safety Switch,LSB2RS

2 Extend the boom to more than 80 feet (24.4 m).

3 Disconnect the 68° proximity switch LSB14AOand install a wire jumper between pin 3 and pin4 of the deutsch connector.

Result: ">65 DEG" should be present on thedisplay screen at the ground controls.

4 Activate the function enable/high RPM buttonand extend the boom to 101 feet (30.8 m).

Result: The engine should stop and the boomextend function should be disabled.

Result: If the engine does not stop and theboom continues to extend, the LSB2RS switchis out of adjustment or the wiring circuit is faultyand will need to be replaced or repaired. SeeRepair Section.

Bodily injury hazard. If the boomextends to more than 101 feet(30.8 m) without stopping theengine, stop immediately andretract the boom until the boom isextended to less than 100 feet(30.5 m). Failure to retract theboom could result in death orserious injury.

5 Using auxiliary power, retract the boom until theboom is extended to approximately 95 feet(29 m).

6 Remove the wire jumper installed in step 3 andconnect the deutsch connector to LSB14AO.

65° Angle Safety Switch,LSB9AS

7 Raise the boom to the maximum angle.

8 Fully extend the boom.




10 Start the engine and activate the functionenable/high RPM button and lower the boom to65°.

Result: The engine should stop and the boomdown function should be disabled.

Result: If the engine does not stop and theboom continues to lower to less than 65°, theLSB9AS switch is out of adjustment or thewiring is faulty and will need to be replaced orrepaired. See Repair Section.

Bodily injury hazard. If the boomlowers to less than 65° withoutstopping the engine, stopimmediately and raise the boomuntil the boom is elevated togreater than 68°. Failure to raisethe boom could result in death orserious injury.

11 Measure the angle of the boom.

Result: The angle of the boom should begreater than 65°.

12 Using auxiliary power, raise the boom until theboom angle is greater than 68°.


50° Angle Safety Switch,LSB8AS

14 Raise the boom to approximately 60°.

15 Extend the boom to approximately95 feet (24.4 m).


17 Activate the function enable/high RPM buttonand lower the boom to 50°.

Result: The engine should stop and the boomdown function should be disabled.

Result: If the engine does not stop and theboom continues to lower to less than 50°, theLSB8AS switch is out of adjustment or thewiring circuit is faulty and will need to bereplaced or repaired. See Repair Section.

Bodily injury hazard. If the boomlowers to less than 50° withoutstopping the engine, stopimmediately and raise the boomuntil the boom is elevated togreater than 53°. Failure to raisethe boom could result in death orserious injury.

18 Measure the angle of the boom.

Result: the angle of the boom should be greaterthan 50°.

19 Using auxiliary power, raise the boom until theboom angle is greater than 53°.


TABLE B PROCEDURES



76 feet (30.8 m) Length Safety Switch,LSB4ES

21 Disconnect the 75 feet (22.9 m) proximity switchLSB3EO and install a wire jumper between pin3 and pin 4 of the deutsch connector.

LSB3EO is located on top of boomtube number 2 at the platform endof the machine.

22 Start the engine and activate the functionenable/high RPM button and extend the boomto 76 feet (23.2 m).

Result: The engine should stop and the boomextend function should be disabled.

Result: If the engine does not stop and theboom continues to extend, the LSB4ES switchis out of adjustment or the wiring circuit is faultyand will need to be replaced or repaired. SeeRepair Section.

Bodily injury hazard. If the boomextends to more than 76 feet(23.2 m) without stopping theengine, stop immediately andretract the boom until the boom isextended to less than 75 feet (22.9m). Failure to retract the boomcould result in death or seriousinjury.

23 Using auxiliary power, retract the boom until theboom is extended to less than 75 feet (22.9 m).

24 Remove the wire jumper installed in step 21 andconnect the harness plug to LSB3EO.

Cable Break Safety Switch,LSB6S

25 Start the engine and activate the functionenable/high RPM button and retract the boomuntil the boom is extended to less than 2 feet(0.6 m).

26 Remove the boom end cover from the pivot endof the boom.

27 Remove the arm from the cable break limitswitch LSB6S.

LSB6S is located at the end of theboom tubes at the pivot end of theboom.

28 Using the arm just removed from LSB6S, rotatethe head of the switch 45 degrees clockwiseand activate the function enable/high RPMbutton and attempt to extend the boom.

Result: The boom extend function should bedisabled.

Result: If the boom extends, the LSB6S switchor wiring circuit is faulty and will need to bereplaced or repaired. See Repair Section.

Bodily injury hazard. If the boomextends at all, stop immediatelyand retract the boom until theboom is extended to less than 2feet (0.6 m). Failure to retract theboom could result in death orserious injury.

TABLE B PROCEDURES



29 Activate the function enable/high RPM buttonand attempt to retract the boom.

Result: The boom retract function should beenabled.

Result: If the boom does not retract, the LSB6Sswitch or wiring circuit is faulty and will need tobe replaced or repaired. See Repair Section.

30 Using the arm just removed from LSB6S, rotatethe head of the switch 90 degrees counterclockwise and activate the function enable/highRPM button and attempt to extend the boom.

Result: The boom extend function should bedisabled.

Result: If the boom extends, the LSB6S switchor wiring circuit is faulty and will need to bereplaced or repaired. See Repair Section.

Bodily injury hazard. If the boomextends at all, stop immediatelyand retract the boom until theboom is extended to less than 2feet (0.6 m). Failure to retract theboom could result in death orserious injury.

31 Activate the function enable/high RPM buttonand attempt to retract the boom.

Result: The boom retract function should bedisabled.

Result: If the boom retracts, the LSB6S switchor wiring circuit is faulty and will need to bereplaced or repaired. See Repair Section.

32 Rotate the head of the switch 45 degreesclockwise and install the arm onto LSB6S.

Axle Extend Safety Switch,LSAX1ES and LSAX2ESand

3 feet (0.9 m) Safety Switch,LSB3RSand

11° Angle Safety Switch,LSB7DS

33 Fully retract and lower the boom to the stowedposition.

34 Retract both axles approximately 1 foot (0.3 m).

35 Remove the access cover from each axle.

36 Disconnect the square-end axle extend safetyswitch LSAX1ES and install a wire jumperbetween pin 3 and pin 4 of the deutschconnector.

37 Place a metal washer over the target area ofthe axle extend proximity switch LSAX1EO andplace a metal washer over the target area of theaxle extend proximity switch LSAX2EO to closethe contacts.

Result: The axle extend indicator light at theground and platform controls should beilluminated.

Proximity switcha target area

TABLE B PROCEDURES

a



38 Activate the function enable/high RPM buttonand attempt to extend the boom.

Result: The boom should not extend to morethan 3 feet (0.9 m).

Result: If the boom extends to more than 3 feet(0.9 m), the LSAX1ES or LSAX2ES switch areout of adjustment or the wiring circuit is faultyand will need to be replaced or repaired. SeeRepair Section.

Bodily injury hazard. If the boomextends to more than 3 feet(0.9 m), stop immediately andretract the boom until the boom isextended to less than 2 feet(0.6 m). Failure to retract theboom could result in death orserious injury.

39 Activate the function enable/high RPM buttonand attempt to raise the boom.

Result: The boom should not raise to morethan 11°.

Result: If the boom continues to raise, theLSAX1ES or LSAX2ES switch are out ofadjustment or the wiring circuit is faulty and willneed to be replaced or repaired. See RepairSection.

Bodily injury hazard. If the boomraises to more than 11°, stopimmediately and lower the boomuntil the boom is less than 11°.See Repair Section. Failure toretract the boom could result indeath or serious injury.

40 Remove the wire jumper installed in step 36 andconnect the deutsch connector to LSAX1ES.

41 Disconnect the circle-end axle extend safetyswitch LSAX2ES and install a wire jumperbetween pin 3 and pin 4 of the deutschconnector.

42 Activate the function enable/high RPM buttonand attempt to extend the boom.

Result: The boom should not extend to morethan 3 feet (0.9 m).

Result: If the boom extends to more than 3 feet(0.9 m), the LSAX1ES or LSAX2ES switch areout of adjustment or the wiring circuit is faultyand will need to be replaced or repaired. SeeRepair Section.

Bodily injury hazard. If the boomextends to more than 3 feet(0.9 m), stop immediately andretract the boom until the boom isextended to less than 2 feet(0.6 m). Failure to retract theboom could result in death orserious injury.

TABLE B PROCEDURES



43 Activate the function enable/high RPM buttonand attempt to raise the boom.

Result: The boom should not raise to morethan 11°.

Result: If the boom continues to raise, theLSAX1ES or LSAX2ES switch are out ofadjustment or the wiring circuit is faulty and willneed to be replaced or repaired. See RepairSection.

Bodily injury hazard. If the boomraises to more than 11°, stopimmediately and lower the boomuntil the boom is less than 11°.Failure to lower the boom couldresult in death or serious injury.

44 Remove the wire jumper installed in step 41 andconnect the deutsch connector to LSAX2ES.

Reverse Load Moment Switch,LSB20LO

45 Activate the function enable/high RPM buttonand fully retract the boom.

46 Activate the function enable/high RPM buttonand lower the boom onto the boom rest padand continue to hold the boom lower functionbutton for 5 seconds.

47 Activate the function enable/high RPM buttonand extend the boom until ">0" is present onthe display screen at the ground controls.

Result: The alarm should sound and "REVERSE

LOAD MOMENT FAULT" should be present on thedisplay screen at the ground controls.

Result: If the alarm does not sound or if"REVERSE LOAD MOMENT FAULT" is not present onthe display screen at the ground controls, theLSB20LO switch is out of adjustment or thewiring circuit is faulty and will need to bereplaced or repaired. See Repair Section.

Bodily injury hazard. If the alarmdoes not sound or if "REVERSE LOAD

MOMENT FAULT" is not present on thedisplay screen at the groundcontrols, stop immediately andfully retract the boom. Failure toretract the boom could result indeath or serious injury.

48 Activate the function enable/high RPM buttonand raise the boom to clear the alarm.

49 Activate the function enable/high RPM buttonand lower the boom to the stowed position.

50 Turn the key switch to the OFF position.

TABLE B PROCEDURES



B-20Test the Platform Self-levelingAutomatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained level by the communicationbetween the platform level sensor and theturntable level sensor. If the platform becomes outof level, the computer at the ground controls willopen the appropriate solenoid valve(s) at theplatform manifold to maintain a level platform.A platform self-leveling failure creates an unsafeworking condition for platform and groundpersonnel.



3 Push and hold a function enable/speed selectbutton and fully retract the boom.

4 Push and hold a function enable/speed selectbutton and adjust the platform to a level positionusing the platform level up/down buttons.

5 Push and hold a function enable/speed selectbutton and fully raise the boom.

Result: The platform should remain level atall times to within ±2 degrees.

If the platform becomes out oflevel, the tilt alarm will sound andthe Platform Not Level Indicatorwill flash at the ground controls.The platform level up/downbuttons will only work in thedirection that will level theplatform. Level the platform untilthe indicator light turns off.

6 Push and hold a function enable/speed selectbutton and fully lower the boom.

Result: The platform should remain level atall times to within ±2 degrees.

If the platform becomes out oflevel, the tilt alarm will sound andthe Platform Not Level Indicatorwill flash at the ground controls.The platform level up/downbuttons will only work in thedirection that will level theplatform. Level the platform untilthe indicator light turns off.

TABLE B PROCEDURES



B-21Test the HornA functional horn is essential to safe machineoperation. The horn is activated at the platformcontrols and sounds at the ground as a warning toground personnel. An improperly functioning hornwill prevent the operator from alerting groundpersonnel of hazards or unsafe conditions.

1 Turn the key switch to platform control andpull out the Emergency Stop button to theON position at both the ground andplatform controls.

2 Push down the horn button at the platformcontrols.

Result: The horn should sound.

If necessary, the horn can beadjusted to obtain the loudestvolume by turning the adjustmentscrew near the wire terminals onthe horn.

B-22Test the Foot SwitchA properly functioning foot switch is essential tosafe machine operation. Machine functions shouldactivate and operate smoothly as long as the footswitch is pressed down, and promptly stop whenthe foot switch is released. Pressing down the footswitch will also shift the engine into high idle if theengine idle select (rpm) indicates that the rabbitand foot switch symbol is selected. An improperlyfunctioning foot switch can cause an unsafeworking condition and endanger platform andground personnel.

The engine should not start if thefoot switch is pressed down.

1 Turn the key switch to platform controls and pullout the Emergency Stop button to the ON


2 Press down the foot switch and attempt to startthe engine by pushing the engine start button.

Result: The engine should not start.

3 Do not press down the foot switch and start theengine.

4 Do not press down the foot switch and test eachmachine function control handle, toggle switchor button.



6 Activate each machine function control handle,toggle switch or button.

Result: All functions should operate through afull cycle. Descent alarm (if equipped) shouldsound while boom is lowering.

TABLE B PROCEDURES



B-23Test the Engine Idle SelectA properly operating engine idle select functionis essential to good engine performance and safemachine operation. There are three settings.

Low idle (turtle symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously, though at reduced speed. Thissetting maintains a consistent low idle.

High idle (rabbit symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously. This setting maintains aconsistent high idle.

Foot switch activated high idle (rabbit and footswitch symbols) should be used for normalmachine operation. This selection activates highidle only when the foot switch is pressed down.


2 Pull out the Emergency Stop button to theON position at both the ground and platformcontrols.


4 Push and hold the high speed function enable/speed select button (rabbit symbol).

Result: The engine should change to high idle.

5 Release the high speed function enable/speedselect button.

Result: The engine should return to low idle.


7 At the platform controls, press the engine idleselect button until high idle (rabbit symbol) isselected.


a foot switch activated high idleindicator light

b low idle indicator lightc high idle indicator lightd engine rpm select button

8 Press the engine idle select button until low idle(turtle symbol) is selected.

Result: The engine should change to low idle.

9 Press the engine idle select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected.

Result: The engine should not change tohigh idle.



b

d

a c

TABLE B PROCEDURES



B-24Test the Drive Enable SystemProper drive enable system operation isessential to safe machine operation. An improperlyfunctioning drive enable system may allow themachine to be moved into an unsafe position.When the boom is rotated past one of the circle-end wheels while the machine is moving, theindicator light will illuminate and the drive functionwill continue to operate until the drive controljoystick is returned to neutral.The drive enable button must be pressed toreactivate the drive function and should inform theoperator that the machine will move in the oppositedirection that the drive and steer controls aremoved.When the boom is rotated past one of the circle-end wheels and the machine is not moving, theindicator light will illuminate and the drive functionis turned off.


2 Press down the foot switch and lower the boomto the stowed position.

3 Rotate the turntable untilthe boom moves pastone of the circle-endtires.

Result: The drive enable indicator light shouldcome on while the boom is anywhere in therange shown.

4 Move the drive/steer control handle off center.

Result: No drive function should operate.

5 Push the drive enable button and slowly movethe drive/steer control handle off center.

Result: The drive function should operate.

Collision hazard. Always use thecolor-coded direction arrows onthe platform control panel and thedrive chassis to identify whichdirection the machine will travel.

When the drive enable system isin use, the machine may drive inthe opposite direction that thedrive and steer control handle ismoved.

If the drive/steer control handle isnot moved within two seconds ofpushing the drive enable button,the drive function will not operate.

Blue

Yellow

TABLE B PROCEDURES



B-25Test the Drive Brakes

Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydrostatic brakes and hydraulically-released individual wheel brakes can appear tooperate normally when they are actually not fullyoperational.

Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.Refer to B-12 in this section,Confirm the Proper BrakeConfiguration.

Select a test area that is firm, leveland free of obstructions.

1 Mark a test line on the ground for reference.


3 Press the engine rpm select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected, then lower the boom intothe stowed position.

4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.

5 Bring the machine to top drive speed beforereaching the test line. Release the drive joystickwhen your reference point on the machinecrosses the test line.

6 Measure the distance between the test line andyour machine reference point.

Braking, High range 4 to 6 ftpaved surface 1.2 to 1.8 m

The brakes must be able to holdthe machine on any slope it is ableto climb.

TABLE B PROCEDURES



B-26Test the Drive Speed -Stowed Position

Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet (12.2 m) apart.


3 Press the engine rpm select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected, then lower the boom intothe stowed position.

4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

5 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

6 Continue at full speed and note the time whenthe machine reference point crosses the finishline.

Drive speed: 40 ft/9.1 secstowed position 12.2 m/9.1 sec

B-27Test the Drive Speed -Raised or Extended Position

Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet (12.2 m) apart andtwo lines on the ground 10 feet (3 m) apart.


3 Press the engine idle select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected.

4 Raise the boom until the engine rpm switches tolow speed.



TABLE B PROCEDURES




Drive speed: 40 ft/40 secraised position 12.2 m/40 sec

8 Lower the boom below horizontal.

9 Extend the boom approximately 4 feet (1.2 m).




Drive speed: 40 ft/40 secextended position 12.2 m/40 sec


14 Extend the boom until the raise boom LED andenvelope alarm are activated.




Drive speed: 10 ft/18 secfully extended position 3 m/18 sec

TABLE B PROCEDURES



B-28Test the Alarm Package(if equipped)The alarm package includes:

· Travel alarm

· Descent alarm

· Travel and descent alarm

· Motion alarm

· Flashing beacon

Alarms and a beacon are installed to alertoperators and ground personnel of machineproximity and motion. The alarm package isinstalled on the turntable covers.

The alarms and beacon willoperate with the enginerunning or not running.

1 Turn the key switch to ground control and pullout the Emergency Stop button to the ON


Result: The flashing beacon should be on andflashing.

2 Push and hold a function enable/speed selectbutton and the boom down button. Hold for amoment and then release them.

Result: The descent alarm should sound whenthe boom down button is pressed.

3 Turn the key switch to platform control.

Result: The flashing beacon should be onand flashing.

4 Press down the foot switch. Move the boomcontrol handle to the DOWN position, hold for amoment and then release it.

Result: The descent alarm should sound whenthe control handle is held down.

5 Press down the foot switch. Move the drivecontrol handle off center, hold for a momentand then release it. Move the drive controlhandle off center in the opposite direction, holdfor a moment and then release it.

Result: The travel alarm should sound when thedrive control handle is moved off center ineither direction.

TABLE B PROCEDURES



B-29Replace the Engine Oil andFilter -Cummins Models

Periodic replacement of the engine oil andfilter is essential to good engine performance.Operating the machine with an improper oil level orneglecting periodic oil and filter changes candamage engine components. A daily checkof elapsed machine hours against the hoursnoted on the oil filter will allow the inspector toanticipate and perform oil and filter changes atthe 250 hour interval.

Bodily injury hazard. Beware ofhot engine parts and oil. Contactwith hot engine oil and/or engineparts may cause severe burns.

Perform this procedure afterwarming the engine to normaloperating temperature.

1 Remove the oil filler cap from the valve cover.

2 Place a suitable container under the enginetray. See capacity specifications.

3 Remove the drain plug from the oil pan andallow all of the oil from the engine to drain into asuitable container.

Cummins Modela filter headb oil filterc oil filler cap

4 Install the drain plug into the engine and tighten.

5 Use an oil filter wrench and remove the oil filter.

6 Clean inside the filter head.

7 Fill the filter with clean engine oil.

8 Apply a thin layer of clean oil to the new filtergasket (Genie part number 62436). Install thefilter and tighten it securely by hand.



TABLE B PROCEDURES



11 Fill the engine with new oil per specificationsand install the oil filler cap.

12 Start the engine from the ground controls andallow the engine to run for 30 seconds. Stop theengine.

13 Check the oil filter and oil drain plug for leaks.

14 Wait 15 minutes after stopping the engine andcheck the engine oil level on the dipstick. Addoil if needed.

15 Dispose of the used oil and filter properly.

Cummins B3.9L Engine 11.5 quartsOil capacity (including filter) 10.9 liters

Oil filter - Genie part number 62436

Cummins B3.9L EngineEngine oil viscosity requirements

below 68°F / 20°C 5W-30

-13° to 68°F / -25° to 20°C 10W-30

above 15°F / -9°C 15W-40


TABLE B PROCEDURES

B-30Inspect the Fuel Tank Cap VentingSystem

A free-breathing fuel tank cap is essential for goodengine performance and service life. A dirty orclogged fuel tank cap may cause the engine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require that the cap be inspected more often.



1 Remove the cap from the fuel tank.

2 Check for proper venting.

Result: Air should pass through the fuel tankcap.

When checking for positive fueltank cap venting, air should passfreely through the cap.



TABLE B PROCEDURES

If the fuel tank cap vent is working properly,proceed to step 5.

3 Using a mild solvent, carefully wash the fueltank cap. Dry the cap using low pressurecompressed air.

4 Repeat step 2.

5 Install the fuel tank cap onto the fuel tank.

B-31Perform Hydraulic Oil Analysis

See E-1, Test or Replace the Hydraulic Oil.



C-1Check the Engine ValveClearances -Deutz Models

Complete information to perform this procedure isavailable in the Deutz 913 Operation Manual,Deutz part number 0297 9690 (Genie part number62446).

C-2Clean the Fuel Pump Strainer -Perkins Models

Cleaning the fuel pump strainer is essential togood engine performance and service life. A dirtyor clogged strainer may cause the engine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require that the strainer be cleaned moreoften.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel filter in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.



Table C Procedures







Crushing hazard. Failure to installthe bolt into the engine pivot plateanchor hole to secure it frommoving could result in death orserious injury.

TABLE C PROCEDURES

5 Locate the fuel lift pump.

a fuel lift pump

6 Remove the fuel lift pump cover retainingfastener. Remove the cover and seal from thetop of the fuel lift pump.

a cover with retainerb strainerc seald pump bodye priming lever

ba



7 Remove the strainer from the fuel lift pump.

8 Using a mild solvent, carefully wash the insideof the fuel lift pump body.

9 Using a mild solvent, clean the strainer, the sealand the lift pump cover.

10 Install the strainer and seal onto the fuel liftpump body.

11 Install the cover onto the fuel lift pump. Tightenthe fuel lift pump cover retaining fastener.

Be sure that the lift pump bodyand cover are installed correctly.An incorrect fit will let air into thefuel system.

12 Clean up any fuel that might have spilled duringthe procedure.

13 Bleed the fuel system. See MaintenanceProcedure B-4, Replace the Inline Fuel Filter/Water Separator Element.

Before bleeding the system, fill thefuel tank.

C-3Replace the Fuel Filter Element -Perkins and Cummins Models

Replacing the diesel fuel filter element is essentialfor good engine performance and service life. Adirty or clogged filter may cause the engine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay required that the filter be replaced more often.



Immediately clean up any fuel thatmay have spilled during thisprocedure.


TABLE C PROCEDURES








5 Locate the fuel filter. Thoroughly clean theoutside surfaces of the fuel filter assembly.

Cummins modela fuel filterb lift pump

TABLE C PROCEDURES

6 Remove the fuel filter element and dispose ofproperly.

7 Clean the inside surfaces of the filter head.

8 Fill the new fuel filter element with clean dieselfuel. Lightly lubricate the O-ring with cleandiesel fuel and install the element into the filterhead.

Failure to fill the fuel filter elementwith clean diesel fuel beforeinstallation will require bleedingthe fuel system.

9 Clean up any fuel that may have spilled duringthis procedure.





Fuel filter elements -Genie part numbers

Perkins models 62426Cummins models 62435

ba



C-4Replace the Engine Oil andFilter -Deutz and Perkins Models

Periodic replacement of the engine oil andfilter is essential to good engine performance.Operating the machine with an improper oil level orneglecting periodic oil and filter changes candamage engine components. A frequent checkof elapsed machine hours against the hoursnoted on the oil filter will allow the inspector toanticipate and perform oil and filter changes atthe 500 hour interval.

Bodily injury hazard. Beware ofhot engine parts and oil. Contactwith hot engine oil and/or engineparts may cause severe burns.

Perform this procedure afterwarming the engine to normaloperating temperature.

1 Remove the oil filler cap.

2 Remove the drain plug and sealing washer fromthe oil pan and allow all of the oil from theengine to drain into a suitable container. Seecapacity specifications.

Be sure that the sealing washer isnot damaged.

3 Install the sealing washer onto the drain plugand tighten the drain plug.

4 Use an oil filter wrench to remove the oil filter.

Deutz modela oil filler capb oil filterc filter headd fuel filter

Perkins modela oil filler capb oil filterc filter head

TABLE C PROCEDURES



5 Clean inside the filter head.

6 Fill the filter with clean engine oil.

7 Apply a thin layer of clean engine oil to the newfilter gasket. Install the filter and tighten itsecurely by hand.

8 Clean up any oil that may have spilled duringthis procedure.


10 Fill the engine with new oil per specificationsand install the oil filler cap.

11 Start the engine from the ground controls andallow the engine to run for 30 seconds. Stop theengine.

12 Check the oil filter and oil drain plug for leaks.

13 Wait 15 minutes after stopping the engine andcheck the engine oil level on the dipstick. Addoil if needed.

14 Dispose of the used oil and filter properly.

Deutz F4L 913 Engine 14.3 quartsOil capacity (including filter) 13.5 liters

Deutz F4L 913 EngineEngine oil viscosity requirements


-10°F to 90°F / -23°C to 32°C 10W-40

above -4°F / -20°C 15W-40



Perkins 1004-42 Engine 8.9 quartsOil capacity (including filter) 8.4 liters

Perkins 1004-42 EngineEngine oil viscosity requirements


-13°F to 68°F / -25°C to 20°C 5W-20

10°F to 104°F / -12°C to 40°C 10W-30

14°F to 122°F / -10°C to 50°C 15W-40

above 23°F / -5°C 20W-50



TABLE C PROCEDURES



C-5Check the Specific Gravity of theCoolant -Liquid Cooled Models

The quality of the coolant which is used can have agreat effect on the efficiency and life of the coolingsystem. Old or dirty coolant may cause the engineto perform poorly and continued use may causeengine damage.

Burn injury hazard. Beware of hotengine parts and coolant. Contactwith hot engine parts and/orcoolant may cause severe burns.

Perform this procedure with themachine on level ground.


1 Put on protective clothing and eyewear.

2 Operate the engine until it is warm enough toopen the thermostat. Continue to run the engineuntil the coolant has circulated the coolingsystem.

3 Stop the engine.

4 Allow the engine to cool until the temperature ofthe coolant is below 140° F (60° C).

Burn hazard. Beware of hotcoolant. Contact with hot coolantmay cause severe burns.

5 Remove the radiator filler cap. Inspect the capfor wear. Replace as necessary.

Burn hazard. Allow any pressureto dissipate gradually beforeremoving the radiator cap.

6 Drain some coolant from the cooling systeminto a suitable container.

7 Use a special coolant hydrometer to check thetemperature and the specific gravity of thecoolant.

8 Adjust the mixture of the coolant as necessaryto protect the engine to -34°F (-37°C).

9 Install the radiator filler cap.

TABLE C PROCEDURES



C-6Inspect the Boom Extend/RetractCables

The boom extend/retract cables are responsible forthe extension and retraction of the number 3 boomtube. Inspecting for foreign objects, damage and/orimproper adjustment of the boom extend/retractcables on a regular basis is essential to goodmachine performance and safe machine operation.The boom extend and retract functions shouldoperate smoothly and be free of hesitation, jerkingand unusual noise.

Perform this procedure with theboom in the stowed position andthe engine off.

1 Remove the boom end cover from the pivot endof the boom.

a boom end coverb side access coversc cable ends (located

underneath the boom)

TABLE C PROCEDURES

2 Remove the retaining fasteners from the accesscovers located on the side of the boom at theplatform end of the machine. Remove thecovers.

3 Visually inspect the cables and componentsthrough both inspection holes for the following:

· Frayed or broken wire strands

· Kinks or crushed cables

· Corrosion

· Paint or foreign materials on the cables

· Split or cracked cable ends

· Cables are on all pulleys

· Cables have equal tension

· Cables at end of adjustment range

· No Broken or damaged pulleys

· No Unusual or excessive pulley wear

· All fasteners in place and secure

A flashlight and inspection mirrormay be necessary to thoroughlyinspect the above items.

A pulley groove gauge should beused to check the condition of thepulleys.

4 Replace the cables if any damage is found.

5 At the pivot end of the boom, visually inspect forthe following:

· The red locking bracket is securely installed over the cable adjustment bolts

6 Install the plastic cover at the pivot end of theboom and access panels on the sides of theboom.




8 Extend the boom approximately 2 feet (0.6 m).

9 Retract the boom. While retracting the boom,visually inspect the number 2 and number 3boom tubes.

Result: The number 2 should not move morethan 1/2 inch (13 mm) before the number 3boom tube begins to retract.

If the number 2 boom tube movesmore than 1/2 inch (13 mm) beforethe number 3 boom tube begins toretract, the boom extend/retractcables need to be adjusted. SeeRepair Procedure 4-5, How toAdjust the Boom Extend/RetractCables.

TABLE C PROCEDURES



D-1Check the Boom Wear PadsMaintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of worn out wear pads may result incomponent damage and unsafe operatingconditions.


2 Raise the end of the boom to a comfortableworking height (chest high). Stop the engine.

3 Remove the protective covers from the platformend of each boom tube.

4 Measure each wear pad.

Boom wear pad specifications 1/2 inchMinimum thickness 12.7 mm

5 Replace any wear pad if it is less thanspecification. If a wear pad is not less thanspecification, shim as necessary to obtain zeroclearance.

If the wear pads are still withinspecification, refer to RepairSection 4-2, How to Shim theBoom.

6 Remove the boom end cover retainingfasteners at the pivot end of the boom. Removethe boom end cover from the machine.

7 Remove the boom side inspection coverretaining fasteners from the boom at the pivotend of the boom. Remove the boom inspectioncover from the machine.

8 Repeat step 7 until all boom inspection coversat the pivot end of the boom are removed.

9 Measure each wear pad at the pivot end of theboom.

Boom wear pad specifications 1/2 inchMinimum thickness 12.7 mm

10 Replace any wear pad if it is less thanspecification. If a wear pad is not less thanspecification, shim as necessary to obtain zeroclearance.

11 Extend and retract the boom through the entirerange of motion to check for tight spots thatmay cause binding of the boom tubes.

Always maintain squarenessbetween the outer and innerboom tubes.

Table D Procedures



D-2Check the Extendable AxleWear Pads

Maintaining the axle wear pads in good condition isessential to safe machine operation. Wear padsare placed on axle tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of worn out wear pads may result incomponent damage and unsafe operatingconditions.

Be sure that the axles are fullyextended before attempting thisprocedure.


2 Measure each wear pad.

Extendable axle wear pad specifications 7/16 inchMinimum thickness 11.1 mm

3 Replace any wear pad if it is less thanspecification. If a wear pad is not less thanspecification, shim as necessary to obtain zeroclearance and zero drag.

If the wear pads are still withinspecification, refer to RepairSection 15-1, How to Shim theExtendable Axles.

4 Extend and retract the axles through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the axletubes.

Always maintain squarenessbetween the outer and inneraxle tubes.

TABLE D PROCEDURES



D-3Check the Free-wheelConfiguration

Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily fortowing. A machine configured to free-wheel withoutoperator knowledge may cause death or seriousinjury and property damage.

Collision hazard. Select a worksite that is firm and level.

1 Chock both of the wheels at the circle-end ofthe machine to prevent the machine fromrolling.

2 Center a lifting jack of ample capacity(30,000 lbs/15000 kg) under the drive chassisbetween the wheels at the square-end of themachine.

3 Lift the wheels off the ground and place blocksunder the drive chassis for support.

4 Disengage the drive hubs by turning over thedrive hub disconnect caps on each wheel hubat the square-end of the machine.

TABLE D PROCEDURES

5 Manually rotate each wheel at the square-endof the machine.

Result: Each wheel at the square-end of themachine should rotate with minimum effort.

6 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the blocks. Lower the machine.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injuryand property damage.

7 Chock both of the wheels at the square-end ofthe machine to prevent the machine fromrolling.

8 Center a lifting jack of ample capacity(30,000 lbs/15000 kg) under the drive chassisbetween the wheels at the circle-end of themachine.

9 Lift the wheels off the ground and place jackstands under the drive chassis for support.

10 Disengage the drive hubs by turning over thedrive hub disconnect caps on each wheel hubat the circle-end of the machine.

11 Manually rotate each wheel at the circle-end ofthe machine.

Result: Each wheel at the circle-end of themachine should rotate with minimum effort.

12 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the jack stands. Lower the machine.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injuryand property damage.

disengage position

engage position



D-4Check the Turntable RotationBearing Bolts

Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.


2 Install a safety chock (Genie part number75097) onto the hydraulic lift cylinder extensionrod. Carefully lower the boom onto the liftcylinder safety chock.

Crushing hazard. Keep handsaway from the cylinder and allmoving parts when lowering theboom.

The lift cylinder safety chock isavailable through Genie (Geniepart number 75097).

3 Be sure that each turntable rotation bearingmounting bolt above the turntable is torqued insequence to 190 ft-lbs (258 Nm).

Bolt torque sequence


5 Remove the safety chock and lower the boomto the stowed position.

6 Be sure that each turntable rotation bearingmounting bolt under the drive chassis istorqued in sequence to 190 ft-lbs (258 Nm).

The turntable rotation bearing bolttorque sequence is the same fromabove the turntable and below thedrive chassis.

TABLE D PROCEDURES



2 Mark a test line approximately two feet long(0.6 m), perpendicular to the length to theboom, on the ground under the platform andnear the platform reference point selected.

Choose a point on the machineplatform; i.e., outside edge of theplatform, as a visual reference foruse while performing thisprocedure.

3 Apply approximately 20 lbs (89 N) of side forceto the platform, moving the platform to one sideas far as it will go. Mark a reference point onthe test line where the platform stops moving.

4 Apply approximately 20 lbs (89 N) of side forceto the platform, moving the platform in theopposite direction as far as it will go. Mark areference point on the test line where theplatform stops moving.

5 Measure the distance on the test line betweenthe two reference marks.

Result: The platform movement should notexceed 2 inches (51 mm). If the platformmovement exceeds 2 inches (51 mm), proceedto step 6.

Turntable rotation gear backlashMaximum side to side movement 2 inchesat platform 51 mm

D-5Check the Turntable RotationGear Backlash

Properly adjusted turntable rotation gear backlashis essential for good machine performance andservice life. Improperly adjusted turntable rotationgear backlash will cause the machine to performpoorly and continued use will cause componentdamage. The turntable rotation drive hub ismounted on the swing chassis behind the fixedside cover at the ground controls side.

Be sure to check the backlashwith the machine fully stowed andthe counterweight at the squareend of the machine.


This procedure may require twopeople.

1 Rotate the turntable in a clockwise directionuntil the turntable rotation motor pinion gear isdirectly over the 3 red-painted gear teeth on theturntable rotation bearing.

The 3 red-painted gear teeth onthe turntable rotation bearing arethe teeth closest to the blue arrowside of the drive chassis.

a yellow arrowa blue arrowb red painted teeth

TABLE D PROCEDURES



TABLE D PROCEDURES

Adjusting the backlash:

6 Remove the ground control side fixed turntablecover from the machine. Refer to RepairSection 5-1, How to Remove a Fixed TurntableCover.

7 Loosen the turntable drive hub mounting bolts.Do not remove them.

It may be necessary to raise theboom slightly to access all theturntable drive hub mounting bolts.

a motorb brakec drive hubd pivot bolte mounting boltf adjustment bolt with lock nut

8 Loosen the turntable drive hub pivot bolt. Do notremove it.

9 Loosen the lock nut on the turntable drive hubadjustment bolt.

10 Tighten the turntable drive hub adjustment boltuntil the turntable drive hub gear is fullyengaged and tight into the turntable rotate gear.

11 Turn the adjustment bolt 1/4 turncounterclockwise. Tighten the lock nut on theadjustment bolt.

12 Rotate the drive hub away from the turntableuntil it contacts the adjustment bolt. Torque thedrive hub mounting bolts to 210 ft-lbs (283 Nm).

13 Torque the turntable rotate pivot bolt to210 ft-lbs (283 Nm).

14 Rotate the turntable through an entire rotation.Check for tight spots that could cause binding.Readjust if necessary.

15 Install the ground control side fixed turntablecover onto the machine and tighten theretaining fasteners.



TABLE D PROCEDURES

D-6Grease the Turntable RotationBearing and Rotate Gear

Yearly application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.

1 Remove the turntable rotation gear coverretaining fasteners and remove the gear coverfrom the machine.


3 Locate the grease fitting below the groundcontrol box.

4 Pump grease into the turntable rotation bearing.Rotate the turntable in increments of 4 to 5inches (10 to 13 cm) at a time and repeat thisstep until the entire bearing has been greased.

5 Apply grease to each tooth of the drive gear,located under the turntable.

6 Install the turntable rotation gear cover andretaining fasteners onto the machine.

Bodily injury hazard. Contact withthe turntable rotation gear couldresult in serious injury. Do notoperate the machine if theturntable rotation gear cover is notinstalled.

Grease type Multi-purpose grease

D-7Replace the Drive Hub Oil

Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly andcontinued use may cause component damage.

Drive Hubs:

1 Select the drive hub to be serviced. Drive themachine until one of the two drain plugs is atthe lowest point.

2 Remove both plugs and drain the oil into asuitable container.

3 Drive the machine until one plug hole is at thetop and the other is at 90°.

a drive hub plugs

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.

a



TABLE D PROCEDURES



6 Repeat steps 1 through 5 for all the other drivehubs.

Drive hub oil



Turntable Rotate Drive Hub:

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section Two, HydraulicHose and Fitting TorqueSpecifications.

1 Secure the turntable from rotating with theturntable rotation lock pin.

unlocked locked

2 Remove the ground control side fixed turntablecover. Refer to Repair Section 5-1, How toRemove a Fixed Turntable Cover.

3 Tag, disconnect and plug the turntable rotatedrive motor hoses at the turntable rotate drivemotor and the turntable rotate drive brakehoses at the turntable rotate drive brake. Capthe fittings.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

a drive motorb drive brakec brake drain plugd drive hube pivot boltf mounting boltg adjustment bolt with lock nuth drive hub drain plug



TABLE D PROCEDURES

4 Remove the turntable rotate drive hub mountingbolts and pivot bolt. Remove the turntablerotate drive hub with a suitable lifting device ofample capacity.

Crushing hazard. The turntablerotate drive hub may becomeunbalanced and fall when it isremoved from the machine if it isnot properly supported.

5 Remove the drive brake drain plug from theside of the drive brake and drain the oil from thedrive brake into a suitable container. Seecapacity specifications.

6 Remove the drive hub drain plug from the sideof the drive hub and drain the oil from the drivehub into a suitable container. See capacityspecifications.

7 Fill the drive hub with oil until the oil is levelwith the bottom of the threads. Install the drainplug and tighten.

When removing the drive brakeplug on machines before serialnumber 158, replace the drive hubplug with the new O-ring styledrive hub plug (Genie part number75107).

8 Fill the drive brake with oil until the oil is level withthe bottom of the threads. Install the drain plugand tighten.


9 Install the drive hub onto the machine. Installthe pivot bolt and the mounting bolts andtighten the bolts until they are finger tight.

10 Install the turntable rotate drive motor hosesinto the turntable rotate drive motor and installthe turntable rotate drive brake hose into theturntable rotate drive brake.

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

11 Adjust the turntable rotation gear backlash. SeeD-5, Check the Turntable Rotation GearBacklash.


Turntable rotate drive hub oil





TABLE D PROCEDURES

D-8Inspect the Engine Belt(s) -Cummins Models

Maintaining the engine belt is essential to goodengine performance and service life. The machinewill not operate properly with a loose or defectivebelt and continued use may cause componentdamage.







Crushing hazard. Failure to installthe bolt into the engine pivot plateanchor hole to secure it frommoving could result in death orserious injury.

If the machine is not equipped with thegenerator option, proceed to step 7.

4 Loosen the generator and remove the generatorbelt.

5 Inspect the generator belt for:

· Cracking

· Glazing

· Separation

· Breaks

a generator (option)b generator belt

a

b

ba



TABLE D PROCEDURES


7 Lift the belt tensioner and remove the enginebelt.


· Cracking

· Glazing

· Separation

· Breaks


10 Check the torque of the belt tensioner retainingfastener. Torque to 32 ft-lbs (43 Nm).

11 Lift the belt tensioner and install the engine belt.

Cummins engines are equippedwith a serpentine belt andincorporate a self adjusting pulleytensioner. No adjustment isrequired.

If the machine is not equipped with thegenerator option, proceed to step 13.

12 Install the generator belt.






Cummins Engine Belt 62437Cummins Generator Belt 60725

Generator belt deflection 3/8 inch to 1/2 inch9 mm to 12 mm



D-9Replace the Fuel Filter -Deutz Models

Replacing the diesel fuel filter is essential to goodengine performance and service life. A dirty orclogged filter may cause the engine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more often.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel filter in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.



1 Tag, disconnect and plug the fuel hose from thefuel tank at the inline fuel filter/water separatorhead.

2 Place a suitable container beneath the fuel filter.

a overflow valveb fuel lift pump priming leverc oil filterd filter heade fuel filter

3 Loosen the fuel filter with a filter wrench anddrain the fuel into a suitable container. Removethe fuel filter from the machine when the fuelflow has slowed or stopped.

4 Apply a thin layer of clean diesel fuel to the newfuel filter gasket (Genie part number 29560).

5 Install the new filter and tighten it securely byhand.

6 Clean up any diesel fuel that might have spilledduring the procedure.


TABLE D PROCEDURES



8 Install the fuel tank hose onto the inline fuelfilter/water separator head. Tighten the hoseclamp.



D-10Check the Engine ValveClearances -Perkins and Cummins Models

Perkins models:

Complete information to perform this procedure isavailable in the Perkins User's Handbook,Perkins part number TPD 1349(Genie part number 62447).

Cummins models:

Complete information to perform this procedure isavailable in the Cummins Operation andMaintenance Manual, Cummins part number3810205 (Genie part number 62448).

TABLE D PROCEDURES



E-1Test or Replace the Hydraulic Oil

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more frequently.

The machine uses Dexronequivalent hydraulic oil. Beforereplacing the hydraulic oil, the oilmay be tested by an oil distributorfor specific levels of contaminationto verify that changing the oil isnecessary. If the hydraulic oil isnot replaced at the two yearinspection, test the oil quarterly.Replace the oil when it fails thetest.

Perform this procedure with theboom in the stowed position andthe axles extended.

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section Two, HydraulicHose and Fitting TorqueSpecifications.

1 Remove the ground controls side turntable sidecover. Refer to Repair Section 5-1, How toRemove a Hinged Turntable Cover.

Table E Procedures

2 Close the three hydraulic shutoff valves locatedat the hydraulic tank.

Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe CLOSED position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

3 Remove the drain plug from the hydraulic tankand allow all of the oil from the tank to drain intoa suitable container. See capacityspecifications.

4 Remove the ground controls support bracketretaining fasteners and remove the groundcontrol box assembly from the machine.

Component damage hazard.Be sure to properly support theground control box. Do not allowthe ground control box to hang bythe wiring or cables.

5 Tag and disconnect the wires from the horn.Remove the horn retaining fasteners andremove the horn from the machine.

open closed



TABLE E PROCEDURES

15 Remove the case drain filter from the case drainfilter head.

16 Remove the suction strainers from the tank andclean them using a mild solvent.

17 Rinse out the inside of the tank using a mildsolvent.

18 Install the suction strainers using Loctite® 567on the pipe threads.

Always use Loctite® 567 on allpipe threads.

19 Install the drain plug using Loctite® 567 on thepipe threads.

Always use Loctite® 567 on allpipe threads.

20 Install the hydraulic tank onto the machine.

21 Install the hydraulic tank retaining straps andinstall the hydraulic tank retaining fasteners.

22 Install the horn and horn retaining fastenersonto the machine. Connect the wiring.

23 Install the ground control box assembly andassembly retaining fasteners onto the machine.

24 Install the two suction hoses and the supplyhose for the auxiliary power unit onto themachine.

25 Install the case drain hose onto the return filterhead.

26 Install the T-fitting and 2 hoses connected to itto the hydraulic tank return filter head.

6 Tag, disconnect and plug the two suction hosesthat are attached to the hydraulic tank shutoffvalves. Cap the fittings.

7 Tag, disconnect and plug the supply hose forthe auxiliary power unit. Cap the fitting on thehydraulic tank.

8 Tag, disconnect and plug the case drain hose atthe return filter. Cap the fitting on the returnfilter head.

9 Disconnect and plug the T-fitting located at thereturn filter with the 2 hoses connected to it.Cap the fitting on the return filter head.

10 Remove the hydraulic tank breather filter fromthe tank.

11 Remove the hydraulic tank strap retainingfasteners and remove the hydraulic tank strapsfrom the machine.

12 Support the hydraulic tank with 2 lifting straps.Place one lifting strap at each end of the tankand attach the lifting straps to an overheadcrane.

13 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank could become unbalancedand fall if it is not properlysupported and secured to theoverhead crane when it isremoved from the machine.

14 Remove the hydraulic tank return filter from thehydraulic tank return filter head.



TABLE E PROCEDURES

27 Fill the tank with hydraulic oil until the level is 3/4inch (19 mm) from the top of the sight gauge.Do not overfill.

28 Apply teflon tape to the threads of the hydraulictank filter mount.

29 Install a new tank breather filter (Genie partnumber 60559) onto the filter mount and tightenit securely by hand.


31 Install a new tank case drain return filter (Geniepart number 44207) onto the filter mount andtighten it securely by hand.


33 Install a new tank return filter (Genie partnumber 61326) onto the filter mount and tightenit securely by hand.



36 Open the hydraulic tank shutoff valves.

Component damage hazard.Be sure to open the two hydraulictank shutoff valves and prime thepump after installing the hydraulictank.Refer to Repair Section 10-2, Howto Prime the Pump.

Use only Dexron equivalenthydraulic fluid.

37 Install the turntable side cover.

Hydraulic system


Hydraulic system 80 gallonscapacity (including tank) 303 liters

Hydraulic fluid Dexron equivalent

Hydraulic tank return filters -Genie part numbers

Hydraulic tank breather filter 60559System return filter 61326Drive motor case drain return filter 44207



TABLE E PROCEDURES

E-2Change or Recondition theEngine Coolant -Liquid Cooled Models

Replacing or reconditioning the engine coolant isessential to good engine performance and servicelife. Old or dirty coolant may cause the engine toperform poorly and continued use may causeengine damage. Extremely dirty conditions mayrequire coolant to be changed more frequently.

Bodily injury hazard. Beware ofhot engine parts and coolant.Contact with hot engine partsand/or coolant will cause severeburns.

Perform this procedure with theengine off and cooled.






4 Put on protective clothing and eye wear.

5 Disconnect the coolant return hose at theradiator and drain the coolant return tank into asuitable container. See capacity specifications.

6 Slowly remove the radiator cap from theradiator.

Bodily injury hazard. Allow anypressure to dissipate graduallybefore removing the radiator cap.

7 Open the drain valve on the radiator and allowthe coolant to drain into a suitable container.

8 After all the coolant has drained, close the drainvalve.

9 Open the drain valve on the engine block andallow the coolant to drain into a suitablecontainer.

10 After all the coolant has drained, close the drainvalve.

11 Replace all coolant hoses and clamps.

12 Fill the radiator with the proper coolant mixture(coolant and water) for your climate until it isfull.

ba



TABLE E PROCEDURES

13 Fill the coolant recovery tank to the COLD FULL

line on the tank.

14 Clean up any coolant that may have spilledduring this procedure.

15 Start the engine from the ground controls andlet it run until the engine is up to operatingtemperature. Continue to run the engine untilthe coolant has circulated the cooling system.

16 Stop the engine.

17 Allow the engine to cool.





21 Check the coolant level in the coolant recoverytank. Add coolant if needed.

Coolant capacity 20 quarts 18.9 liters

E-3Change the Fuel Hoses

Maintaining the fuel hoses in good condition isessential to safe operation and good engineperformance. Failure to detect a worn, cracked orleaking fuel hose may cause an unsafe operatingcondition.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel lines in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Bodily injury hazard. Fuel may beexpelled under pressure. Wrap acloth around fuel hoses to absorbleaking fuel before disconnectingthem.



Deutz models:

1 Remove the engine side turntable fixed sidecover. Refer to Repair Section 5-1, How toRemove a Fixed Turntable Cover.




3 Remove and replace the following fuel linehoses and clamps:

· Hose from the fuel tank to the inline fuelfilter/water separator

· Hose from the inline fuel filter/waterseparator to the fuel lift pump

· Hose from the fuel lift pump to the fuel filter· Hose from the fuel filter to the fuel injector

pump· Hose from the fuel injectors to the fuel tank




6 Bleed the fuel system. See B-4, Replace theInline Fuel Filter/ Water Separator Element.


Perkins and Cummins models:

1 Remove the engine side turntable fixed sidecover. Refer to Repair Section 5-1, How toRemove a Fixed Turntable Cover.







ba

TABLE E PROCEDURES



6 Remove and replace the following fuel linehoses and clamps:

Perkins models:


· Hose from the inline fuel filter/water separatorto the fuel lift pump

· Hose from the fuel lift pump to the fuel filterCummins models:


· Hose from the inline fuel filter/water separatorto the fuel lift pump

· Hose from the fuel injectors to the fuel tank






TABLE E PROCEDURES

E-4Check the Engine ValveClearances -Cummins Models

Complete information to perform this procedure isavailable in the Cummins Operation andMaintenance Manual, Cummins part number3810205 (Genie part number 62448).

E-5Check the Fuel Injectors -Deutz Models

Engine specifications requirethat this procedure be performedat 3000 hours.

Complete information to perform this procedure isavailable in the Deutz Workshop Manual, Deutzpart number 297-7293 (Genie part number 62434).



E-6Remove and Inspect theBoom Extend/Retract Cables

Genie specifications require thatthis procedure be performed at5 years or 5000 hours, whichevercomes first and every 2 yearsthereafter until the cables arereplaced.

The boom extend/retract cables are responsible forthe extension and retraction of the number 3 boomtube. Removal and inspection of the boom extend/retract cables at specified intervals is essential togood machine performance and safe machineoperation. The boom extend/retract functionsshould operate smoothlyand be free of hesitation,jerking and unusual noise.

1 Remove the boom extend cylinder from themachine. See Repair Procedure 4-4, How toRemove the Primary Boom Extension Cylinder.

2 Remove the extend cables from the boomextension cylinder assembly and lay them flaton the ground.

3 Visually inspect the boom extend cables andcomponents for the following:


· Kinks in the cables

· Corrosion

· Paint or foreign materials on the cable



4 Replace the boom extend cables if there is anydamage to the cables.

The extend cables must bereplaced in pairs.

If the cables are replaced, thecable sheaves or pulleys shouldalso be replaced.

5 Attach a rope to the boom retract cables at thepivot end of the boom.

6 At the platform end of the boom, pull the boomretract cables out of the boom assembly andlay them on the ground.

7 Using a flashlight, visually inspect the boomretract cables and components inside the boomassembly for the following:


· Kinks in the cables

· Corrosion

· Paint or foreign materials on the cable



8 Replace the cables if there is any damage tothe cables.

The retract cables must bereplaced in pairs.

If the cables are replaced, thecable sheaves or pulleys shouldalso be replaced.

9 At the pivot end of the boom, pull the boomretract cables into the boom assembly using therope.

10 Install the boom extension cylinder assemblyinto the boom.

11 Adjust the boom extend/retract cables. SeeRepair Procedure 4-5, How to Adjust the BoomExtend/Retract Cables.


First Edition • First Printing Section 5 • Troubleshooting Flow Charts

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions printed in the Genie S-100and Genie S-105 Operator's Manual or the GenieS-120 and Genie S-125 Operator's Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate flow chart thoroughly.Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.

Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

Perform all troubleshooting on afirm level surface.

Two persons will be required tosafely perform sometroubleshooting procedures.

Troubleshooting Flow Charts

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

· Machine parked on a flat, level surface

· Boom in stowed position

· Turntable rotated with the boom between the circle-end wheels

· Turntable secured with the turntable rotation lock pin

· Key switch in the OFF position with the key removed

· Welder disconnected from the machine (if equipped with the weld cable to platform option)

· Wheels chocked


First Edition • First PrintingSection 5 • Troubleshooting Flow Charts

General Repair Process

TROUBLESHOOTING FLOW CHARTS

About This SectionWhen a malfunction is discovered, the flow chartsin this section will help a service professionalpinpoint the cause of the problem. To use thissection, basic hand tools and certain pieces of testequipment are required—voltmeter, ohmmeter,pressure gauges.

The location of terminals mentioned in this sectioncan be found on the appropriate electrical orhydraulic schematics provided in Section 6,Schematics.

Since various degrees of a particular functionloss may occur, selecting the appropriate flowchart may be troublesome. When a function will notoperate with the same speed or power as amachine in good working condition, refer to theflow chart which most closely describes theproblem.

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test



Fault Code Chart

Continued on next page

Diagnostic code displayed Condition Possible Causes SolutionAXLE EXT/RET BUTTONS FAULT Axles will not extend or retract. Shorted axle extend or retract

membrane on platform membrane panel.

Consult Genie Industries Service Department. The platform membrane panel may need to be replaced.

AXLE VALVE FAULT Axle extend or axle retract inoperative.

Axle extend or axle retract valve coils circuits open or shorted to ground or the coils are bad.

Refer to charts 33 and 34 to troubleshoot.

UP/DOWN JOYSTICK NOT CALIBRATED

Up/down functions inoperative from platform.

Up/down joystick not calibrated. Calibrate up/down joystick refer to repair section.

UP/DOWN JOYSTICK SHORTED TO 0V


Open circuit between platform control card and up/down joystick.


UP/DOWN JOYSTICK SHORTED TO 5V


Shorted circuit between platform control card and up/down joystick.


UP/DOWN JOYSTICK VALUE TOO HIGH


Damaged circuit between platform control card and up/down joystick or Joystick may need to be replaced.


UP/DOWN JOYSTICK VALUE TOO LOW


Damaged circuit between platform control card and up/down joystick or Joystick may need to be replaced.


UP/DOWN BUTTONS FAULT Up/down functions inoperative from turntable.

Shorted boom up/down membrane on turntable membrane panel.

Consult Genie Industries Service Department. The turntable membrane panel may need to be replaced.

BOOM UP/DOWN SPEED NOT CALIBRATED

Up/down function speeds to fast or to slow.

Up/down speed calibration set from display or Reset Boom up/down flow valve defaults set from display. Refer to Display module section.

Calibrate Boom up/down speed refer to repair section.

BOOM UP/DOWN FLOW VALVE NOT CALIBRATED

No movement on up/down functions until joystick is moved past half stroke.

Reset Boom up/down flow valve defaults set from display. Refer to Display module section.

Calibrate Boom up/down Thresholds refer to repair section.

BOOM UP/DOWN FLOW VALVE FAULT

Up/down functions inoperative. Boom up/down flow valve coil circuit open or shorted to ground or the coil itself is bad.


BOOM UP VALVE FAULT Up function inoperative. Boom up valve coil circuit open or shorted to ground or the coil itself is bad.

Refer to chart 13 to troubleshoot.

BOOM DOWN VALVE FAULT Down function inoperative. Boom down valve coil circuit open or shorted to ground or the coil itself is bad.


BOOM ANGLE SWITCHES FAULT Extend and up functions inoperative and boom down function operative only when boom is fully retracted.

Boom angle operational switches out of sequence.


EXTEND/RETRACT JOYSTICK NOT CALIBRATED

Extend/retract functions inoperative from platform.

Extend/retract joystick not calibrated. Calibrate extend/retract joystick refer to repair section.

EXTEND/RETRACT JOYSTICK SHORTED TO 0V


Open circuit between platform control card and extend/retract joystick.


EXTEND/RETRACT JOYSTICK SHORTED TO 5V


Shorted circuit between platform control card and extend/retract joystick.


EXTEND/RETRACT JOYSTICK VALUE TOO HIGH


Damaged circuit between platform control card and extend/retract joystick or Joystick may need to be replaced.




Diagnostic code displayed Condition Possible Causes Solution

FAULT CODE CHART


EXTEND/RETRACT JOYSTICK VALUE TOO LOW


Damaged circuit between platform control card and extend/retract joystick or Joystick may need to be replaced.

Refer to charts 16 and 17 to troubleshoot

EXTEND/RETRACT BUTTONS FAULT

Extend/retract functions inoperative from turntable.

Shorted boom extend/retract membrane on turntable membrane panel.


BOOM EXT/RET SPEED NOT CALIBRATED

Extend/retract function speeds to fast or to slow.

Extend/retract speed calibration set from display or Reset Boom ext/ret flow valve defaults set from display. Refer to Display module section.

Calibrate Boom extend/retract speed refer to repair section.

BOOM EXT/RET FLOW VALVE NOT CALIBRATED

No movement on extend/retract functions until joystick is moved past half stroke.

Reset Boom extend/retract flow valve defaults set from display. Refer to Display module section.

Calibrate Boom extend/retract Thresholds refer to repair section.

BOOM EXT/RET FLOW VALVE FAULT

Extend/retract functions inoperative. Boom extend/retract flow valve coil circuit open or shorted to ground or the coil itself is bad.


BOOM EXT VALVE FAULT Extend function inoperative. Boom extend valve coil circuit open or shorted to ground or the coil itself is bad.


BOOM RET VALVE FAULT Retract function inoperative. Boom retract valve coil circuit open or shorted to ground or the coil itself is bad.


LOCK OUT VALVE P1 FAULT Retract function inoperative when boom length is <100’.

Boom retract lockout valve coil circuit open or shorted to ground or the coil itself is bad.

Refer to chart 16 to troubleshoot

LOCK OUT VALVE P2 FAULT Extend function inoperative when boom length = or >100’

Boom extend lockout valve coil circuit open or shorted to ground or the coil itself is bad.


BOOM LENGTH SWITCHES FAULT Extend, up, and down functions inoperative.

Boom length operational switches out of sequence.


TURNTABLE ROTATE JOYSTICK NOT CALIBRATED

Turntable rotate functions inoperative from platform.

Turntable rotate joystick not calibrated.

Calibrate turntable rotate joystick refer to repair section.

TURNTABLE ROTATE JOYSTICK SHORTED TO 0V


Open circuit between platform control card and turntable rotate joystick.


TURNTABLE ROTATE JOYSTICK SHORTED TO 5V


Shorted circuit between platform control card and turntable rotate joystick.


TURNTABLE ROTATE JOYSTICK VALUE TOO HIGH


Damaged circuit between platform control card and turntable rotate joystick or Joystick may need to be replaced.


TURNTABLE ROTATE JOYSTICK VALUE TOO LOW


Damaged circuit between platform control card and turntable rotate joystick or Joystick may need to be replaced.


TURNTABLE ROTATE BUTTONS FAULT

Turntable rotate functions inoperative from turntable.

Shorted turntable rotate membrane on turntable membrane panel.





FAULT CODE CHART


TURNTABLE ROTATE SPEED NOT CALIBRATED

Turntable rotate function speeds to fast or to slow.

Turntable rotate speed calibration set from display or Reset turntable rotate flow valve defaults set from display. Refer to Display module section.

Calibrate Turntable rotate speed refer to repair section.

TURNTABLE ROTATE FLOW VALVE NOT CALIBRATED

No movement on Turntable rotate functions until joystick is moved past half stroke.

Reset turntable rotate flow valve defaults set from display. Refer to Display module section.

Calibrate turntable rotate Thresholds refer to repair section.

TURNTABLE ROTATE FLOW VALVE FAULT

Turntable rotate functions inoperative.

Turntable rotate flow valve coil circuit open or shorted to ground or the coil itself is bad.


TURNTABLE ROTATE CW VALVE FAULT

Turntable rotate CW function inoperative.

Turntable rotate CW valve coil circuit open or shorted to ground or the coil itself is bad.


TURNTABLE ROTATE CCW VALVE FAULT

Turntable rotate CCW function inoperative.

Turntable rotate CCW valve coil circuit open or shorted to ground or the coil itself is bad.


MULTI FUNCTION VALVE FAULT Multiple functions inoperative. Boom up/dwn,ext/ret, and turntable rotate auxiliary functions inoperative.

Multi function valve coil circuit open or shorted to ground or coil may be bad


STEERING JOYSTICK NOT CALIBRATED

Steering functions inoperative. Steering joystick not calibrated. Calibrate steering joystick refer to repair section.

STEERING JOYSTICK SHORTED TO 0V

Steering functions inoperative from platform.

Open circuit between platform control card and steering joystick.

Refer to charts 35,36,37, and 38 to troubleshoot.

STEERING JOYSTICK SHORTED TO 5V


Shorted circuit between platform control card and steering joystick.


STEERING JOYSTICK VALUE TOO HIGH

steering functions inoperative from platform.

Damaged circuit between platform control card and steering joystick or Joystick may need to be replaced.


STEERING JOYSTICK VALUE TOO LOW


Damaged circuit between platform control card and steering joystick or Joystick may need to be replaced.


BLUE END BLUE SIDE STEER SENSOR SHORTED TO 0V

Blue end blue side steering functions inoperative.

Open circuit between blue end blue side steering sensor and DCON box.


BLUE END BLUE SIDE STEER SENSOR SHORTED TO 5V


Shorted circuit between blue end blue side steering sensor and DCON box.


BLUE END BLUE SIDE STEER SENSOR VALUE TOO HIGH


Damaged circuit between blue end blue side steering sensor and DCON box or steering sensor may need to be replaced.


BLUE END BLUE SIDE STEER SENSOR VALUE TOO LOW


Damaged circuit between blue end blue side steering sensor and DCON box or steering sensor may need to be replaced.


BLUE END YELLOW SIDE STEER SENSOR SHORTED TO 0V

Blue end yellow side steering functions inoperative.

Open circuit between blue end yellow side steering sensor and DCON box.


BLUE END YELLOW SIDE STEER SENSOR SHORTED TO 5V


Shorted circuit between blue end yellow side steering sensor and DCON box.





FAULT CODE CHART


BLUE END YELLOW SIDE STEER SENSOR VALUE TOO HIGH


Damaged circuit between blue end yellow side steering sensor and DCON box or steering sensor may need to be replaced.


BLUE END YELLOW SIDE STEER SENSOR VALUE TOO LOW


Damaged circuit between blue end yellow side steering sensor and DCON box or steering sensor may need to be replaced.


YELLOW END BLUE SIDE STEER SENSOR SHORTED TO 0V

Yellow end blue side steering functions inoperative.

Open circuit between yellow end blue side steering sensor and DCON box.


YELLOW END BLUE SIDE STEER SENSOR SHORTED TO 5V


Shorted circuit between yellow end blue side steering sensor and DCON box.


YELLOW END BLUE SIDE STEER SENSOR VALUE TOO HIGH


Damaged circuit between yellow end blue side steering sensor and DCON box or steering sensor may need to be replaced.


YELLOW END BLUE SIDE STEER SENSOR VALUE TOO LOW


Damaged circuit between yellow end blue side steering sensor and DCON box or steering sensor may need to be replaced.


YELLOW END YELLOW SIDE STEER SENSOR SHORTED TO 0V

Yellow end yellow side steering functions inoperative.

Open circuit between yellow end yellow side steering sensor and DCON box.


YELLOW END YELLOW SIDE STEER SENSOR SHORTED TO 5V


Shorted circuit between yellow end yellow side steering sensor and DCON box.


YELLOW END YELLOW SIDE STEER SENSOR VALUE TOO HIGH


Damaged circuit between yellow end yellow side steering sensor and DCON box or steering sensor may need to be replaced.


YELLOW END YELLOW SIDE STEER SENSOR VALUE TOO LOW


Damaged circuit between yellow end yellow side steering sensor and DCON box or steering sensor may need to be replaced.


BLUE END BLUE SIDE STEER VALVE FAULT

Blue end blue side CW or blue end blue side CCW functions inoperative.

Blue end blue side CW or CCW valve coils circuits open or shorted to ground or the coils are bad.

Refer to charts 35 to troubleshoot.

BLUE END YELLOW SIDE STEER VALVE FAULT

Blue end yellow side CW or blue end yellow side CCW functions inoperative.

Blue end yellow side CW or CCW valve coils circuits open or shorted to ground or the coils are bad.


YELLOW END BLUE SIDE STEER VALVE FAULT

Yellow end blue side CW or yellow end blue side CCW functions inoperative.

Yellow end blue side CW or CCW valve coils circuits open or shorted to ground or the coils are bad.


YELLOW END YELLOW SIDE STEER VALVE FAULT

Yellow end yellow side CW or yellow end yellow side CCW functions inoperative

Yellow end yellow side CW or CCW valve coils circuits open or shorted to ground or the coils are bad.


DRIVE JOYSTICK NOT CALIBRATED

Drive functions inoperative. Drive joystick not calibrated. Calibrate drive joystick refer to repair section.

DRIVE JOYSTICK SHORTED TO 0V Drive functions inoperative. Open circuit between platform control card and drive joystick.


DRIVE JOYSTICK SHORTED TO 5V Drive functions inoperative. Shorted circuit between platform control card and drive joystick.





FAULT CODE CHART


DRIVE JOYSTICK VALUE TOO HIGH

Drive functions inoperative. Damaged circuit between platform control card and drive joystick or Joystick may need to be replaced.


DRIVE JOYSTICK VALUE TOO LOW

Drive functions inoperative. Damaged circuit between platform control card and drive joystick or Joystick may need to be replaced.


DRIVE VALVE NOT CALIBRATED No movement on Drive forward or reverse functions until joystick is moved past half stroke.

Reset propel valve defaults set from display. Refer to Display module section.

Calibrate propel thresholds refer to repair section.

DRIVE VALVE FAULT Drive forward and drive reverse functions inoperative.

Drive forward or drive reverse valve coils circuits open or shorted to ground or the coils are bad.


BRAKE VALVE FAULT Drive forward or drive reverse functions inoperative.

Brake valve circuit open or shorted to ground or coil is bad.


MOTOR COIL FAULT High drive inoperative. Motor coil circuit open or shorted to ground or the coil is bad.


AUX PROPEL VALVE FAULT Auxiliary drive forward or reverse inoperative (Only seen if Aux. Drive option is enabled from display. Refer to display module section.).

Auxiliary propel valve coils circuits open or shorted to ground or the coils are bad.

Refer to chart 44 To troubleshoot.

PLATFORM LEVEL TOGGLE SWITCHES FAULT

Manual platform level inoperative from platform or turntable controls.

Shorted platform level toggle switch on the platform control box or shorted platform level up or down membrane switch on the turntable membrane panel.


PLATFORM LEVEL SENSOR DEGREES SHORTED TO 0V

Platform level and boom up/down functions inoperative.

Open circuit between platform level sensor and platform control box.


PLATFORM LEVEL SENSOR DEGREES SHORTED TO 5V


Shorted circuit between platform level sensor and platform control box.


PLATFORM LEVEL SENSOR DEGREES VALUE TOO HIGH


Damaged circuit between platform level sensor and platform control box or platform level sensor may need to be replaced.


PLATFORM LEVEL SENSOR DEGREES VALUE TOO LOW


Damaged circuit between platform level sensor and platform control box or platform level sensor may need to be replaced.


PLATFORM LEVEL VALVE FAULT Platform level up or platform level down function inoperative.

Platform level up or platform level down coils circuits open or shorted to ground or the coils are bad.


PLATFORM ROTATE TOGGLE SWITCHES FAULT

Platform rotate functions inoperative from platform or turntable controls.

Shorted platform rotate toggle switch on the platform control box or shorted platform rotate CW or CCW membrane switch on the turntable membrane panel.


PLATFORM ROTATE VALVE FAULT

Platform rotate CW or CCW inoperative.

Platform rotate cw or ccw coils circuits open or shorted to ground or the coils are bad.


JIB UP/DOWN TOGGLE SWITCHES FAULT

Jib functions inoperative. Shorted jib toggle switch on the platform control box or shorted jib up or down membrane switch on the turntable membrane panel.





FAULT CODE CHART


JIB VALVE FAULT Jib up or jib down inoperative. Jib up or jib down coils circuits open or shorted to ground or coils are bad.


ENGINE SPEED NO RESPONSE Engine runs then dies. Engine RPM signal from alternator below 100RPM.


ENGINE SPEED VALUE TOO HIGH Engine runs then dies. Engine RPM signal from alternator above 3500RPM.


ENGINE OIL PRESSURE VALUE TOO LOW

Engine runs then dies. Engine oil pressure below 12psi. Refer to chart 4 to troubleshoot.

ENGINE OIL PRESSURE SENSOR SHORTED TO 0V

Engine runs then dies. Engine oil pressure sensor circuit shorted to ground.


ENGINE OIL PRESSURE SENSOR SHORTED TO 5V

Engine runs then dies. Engine oil pressure sensor circuit open.


ENGINE OIL PRESSURE SENSOR VALUE TOO HIGH

Engine runs then dies. Engine oil pressure sensor circuit damaged or sensor may need to be replaced.


ENGINE OIL PRESSURE SENSOR VALUE TOO LOW

Engine runs then dies. Engine oil pressure sensor circuit damaged or sensor may need to be replaced.


ENGINE TEMPERATURE VALUE TOO HIGH

Engine runs then dies. Engine temperature above maximum allowable temp for engine.


ENGINE TEMPERATURE SENSOR SHORTED TO 0V

Engine runs then dies. Engine temperature sensor circuit shorted to ground.


ENGINE TEMPERATURE SENSOR SHORTED TO 5V

Engine runs then dies. Engine temperature sensor circuit open.


ENGINE TEMPERATURE SENSOR VALUE TOO HIGH

Engine runs then dies. Engine temperature sensor circuit damaged or sensor may need to be replaced.


ENGINE TEMPERATURE SENSOR VALUE TOO LOW

Engine runs then dies. Engine temperature sensor circuit damaged or sensor may need to be replaced.


TURNTABLE LEVEL SENSOR X-DIRECTION SHORTED TO 0V

Unit out of level LED, icon and alarm active.

Open circuit in turntable level sensor X-direction wiring.

Repair open in circuit. Refer to electrical schematic to troubleshoot.

TURNTABLE LEVEL SENSOR X-DIRECTION SHORTED TO 5V


Short in turntable level sensor X-direction circuit wiring.

Repair short in circuit. Refer to electrical schematic to troubleshoot.

TURNTABLE LEVEL SENSOR X-DIRECTION VALUE TOO HIGH


Damaged circuit in turntable level sensor X-direction wiring or turntable level sensor may need to be replaced.

Repair damage in circuit wiring. Refer to electrical schematic to troubleshoot or consult Genie Industries Service Department to determine if turntable level sensor needs to be replaced.

TURNTABLE LEVEL SENSOR X-DIRECTION VALUE TOO LOW


Damaged circuit in turntable level sensor X-direction wiring or turntable level sensor may need to be replaced.


TURNTABLE LEVEL SENSOR Y-DIRECTION SHORTED TO 0V


Open circuit in turntable level sensor Y-direction wiring.

Repair open in circuit. Refer to electrical schematic to troubleshoot.




FAULT CODE CHART


TURNTABLE LEVEL SENSOR Y-DIRECTION SHORTED TO 5V


Short in turntable level sensor Y-direction circuit wiring.

Repair short in circuit. Refer to electrical schematic to troubleshoot.

TURNTABLE LEVEL SENSOR Y-DIRECTION VALUE TOO HIGH


Damaged circuit in turntable level sensor Y-direction wiring or turntable level sensor may need to be replaced.


TURNTABLE LEVEL SENSOR Y-DIRECTION VALUE TOO LOW


Damaged circuit in turntable level sensor Y-direction wiring or turntable level sensor may need to be replaced.


DCON CAN NO RESPONSE All drive chassis functions inoperative.

Open or shorted wires in CAN bus circuits between DCON and TCON control box’s.

Repair damage in circuit wiring. Refer to electrical schematic to troubleshoot or consult Genie Industries Service Department.

CAN BUS NO RESPONSE No functions from platform control box and all platform functions inoperative when using turntable controls.

Open or shorted wires in CAN bus circuits between PCON and TCON control box’s.


SAFETY SWITCH P3 FAULT All functions inoperative. Open circuit in tether Emergency stop wiring.


SAFETY SWITCH P6R1 FAULT Boom extend and boom down functions inoperative. This fault creates Safety switch P9A,P10,P11, and P18 fault.

Bad K4 relay inside turntable control box.

Replace K4 relay or consult Genie Industries Service Department.

SAFETY SWITCH P6R2 FAULT Engine cranks but won’t start. Bad K3 relay inside turntable control box.

Replace K3 relay or consult Genie Industries Service Department.

SAFETY SWITCH P7 FAULT No boom functions. Fault creates safety switch P7R,P22,P14,P12 and P22R faults.

Bad K5 relay inside turntable control box or bad K1 relay inside platform control box.

Replace K5 or K1 relays or consult Genie Industries Service Department.

SAFETY SWITCH P7R FAULT No boom functions. Fault creates safety switch P22,P22R,P14, and P12 faults.

Bad K2 relay inside turntable control box or bad K2 relay inside platform control box.

Replace relays or consult Genie Industries Service Department.

SAFETY SWITCH P9A FAULT Boom extend and boom down functions inoperative. This fault creates Safety switch P10 and P18 faults.

Open in Boom envelope safety circuits or operational limit switches LSB3EO,LSB13AO,LSB4EO, or LSB14AO have failed.

Refer to chart 18 or 19 to troubleshoot.

SAFETY SWITCH P9B FAULT Engine cranks but won’t start. Open in Boom envelope safety circuits or operational limit switches LSB3EO,LSB13AO,LSB4EO, or LSB14AO have failed.


SAFETY SWITCH P10 FAULT Boom extend inoperative. Boom extension cables out of adjustment or LSB6S limit switch is bad or there is an open in the safety circuit wiring.


SAFETY SWITCH P11 FAULT Boom up inoperative. Open in axle safety switch circuit or limit switch LSB7DS,LSAX1ES, or LSAX2ES have failed or operational limit switch LSB1DO has failed.

Refer to chart 18 or 19 and chart 20 or 21 to troubleshoot.




FAULT CODE CHART

SAFETY SWITCH P12 FAULT Axle retract inoperative. Open in stowed safety circuit or limit switch LSB7DS or LSB3RS have failed or operational limit switches LSB1DO or LSB3RO have failed.


SAFETY SWITCH P14 FAULT Axle retract inoperative. Open in stowed safety circuit or limit switch LSB7DS has failed or limit switch LSB1DO has failed.


SAFETY SWITCH P18 FAULT Boom extend inoperative. Open in axle safety switch circuit or limit switch LSB3RS,LSAX1ES, or LSAX2ES have failed or operational limit switch LSB3RO has failed.


SAFETY SWITCH P22 FAULT Platform level inoperative. Fault creates a safety switch P22R fault.

Platform out of level >10degrees out of stowed position or platform level sensor is bad or there is an open in the platform level sensor circuit or limit switches LSB1DO or LSB3RO are bad.


SAFETY SWITCH P22R FAULT Platform level and Boom up/down inoperative.

Platform out of level >10degrees out of stowed position or platform level sensor is bad or there is an open in the platform level sensor circuit or limit switches LSB1DO or LSB3RO are bad.


DCON SAFETY SWITCH P7R FAULT

Steering and axle functions inoperative.

Open in Red S56PRV wire circuit that runs from the turntable control box to the DCON control box.


PROX. KILL SW. FAULT All functions inoperative unless spare membrane on platform control box is activated.

Proximity Kill Bumper under platform has run into an obstruction or is out of adjustment.

Activate spare membrane and carefully move away from obstruction or readjust proximity kill limit switch.

PLTFRM OVERLOAD SEN. FAULT All functions inoperative red LED above spare membrane flashing.

Load in platform is above rated load or load sensor is out of adjustment.

Unload excessive weight out of platform or readjust load sensor.

BOOM UP OVERLOAD FAULT All functions except Boom retract inoperative.

Load in platform is above rated load or boom has run into an obstruction or boom up overload switch is out of adjustment.

Unload excessive weight out of platform or readjust limit switch or move away from obstruction.

BOOM DOWN OVERLOAD FAULT All functions except Boom up and retract inoperative.

Boom has been lowered into an obstruction with boom extended or boom down overload switch is out of adjustment or there is an open in boom down overload circuit.


PRESS PLATFORM ESTOP Code displayed whenever engine is running and controller is waiting for engine to be shut off to save calibrations or any parameter changes made with the display to memory.

Just finished a speed calibration for boom up/dwn, ext.ret, or turntable rotate or Joysticks were calibrated with engine running or a function parameter was changed with the display while the engine was running.

Turn key switch to platform control position and depress platform Emergency stop.



Display NotActiveBe sure the key switchis in the appropriateposition.

Be sure that bothEmergency Stopbuttons are pulled out tothe ON position.

Be sure the circuitbreakers are nottripped.

Be sure the batteriesare fully charged andproperly connected.

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Engine Startsand Runs for 3Seconds andDiesBe sure to check theengine oil level and fillas needed.

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Be sure to checkcoolant level and fill asneeded.

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Engine Low IdleInoperativeBe sure that mechanicallinkage from 2-speedsolenoid to fuel injectionsystem is not binding oris defective.


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Chart 7

All FunctionsInoperative,Engine Startsand RunsBe sure the hydraulicsuction line shutoffvalves for the pumpsare in the OPEN position.

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Chart 8

Boom Up/Down,Extend/Retract,Turntable Rotateand PlatformFunctionsInoperative,Drive, Steer andAxle Extend/RetractFunctionsOperationalBe sure the hydraulicsuction line shutoff valvefor the lift/steer pump is inthe OPEN position.

Be sure the hydraulic tankis filled to the correctlevel.

Be sure the batteries arefully charged and properlyconnected.

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Chart 9

All Platform,Steering andAxle FunctionsInoperative,All OtherFunctionsOperationalBe sure the hydraulicsuction line shutoffvalve for the lift/steerpump is in the OPEN

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Chart 10

GroundControlsInoperative,PlatformControlsOperateNormallyBe sure all otherfunctions operatenormally, includingthe platformcontrols.

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Chart 11

PlatformControlsInoperative,GroundControlsOperateNormallyBe sure allcables from chassisthrough the cabletrack are in goodcondition with nokinks or abrasions.


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Chart 12

Boom AngleSwitch FaultBe sure the machineis on level ground.

Be sure the boomangle limit switchesare properlyconnected to thecorrect wiringharness leads.


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Chart 13

Boom UpFunctionInoperativeBe sure all otherfunctions operatenormally.

Be sure the axles arefully extended.

Be sure the platform islevel to gravity within7 degrees.


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Chart 14

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Boom LengthSwitch FaultBe sure all otherfunctions operatenormally.

Be sure the boom lengthlimit switches areproperly connected tothe correct wiringharness leads.


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Chart 16

Boom ExtendFunctionInoperativeBe sure all otherfunctions operatenormally.


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Chart 18

Boom EnvelopeOperationalSwitch Failure,S-100 andS-105 ModelsA boom envelope safetyfault is the result of theboom exceeding theoperational limits andactivating the safetyswitches OR when thesafety switches aretripped within theoperational range.

Press the (+) and (-)keys together to accessthe status screen. Thestatus screen candisplay the followinginformation:- Hydraulic pressure- Boom Length- Boom Angle- Axle status

Boom lengths are givenin feet. The first numberis the length for a S-100,the second number isfor a S-105. Forexample, 75.5/80.5 feet.

Greater than or equal tois indicated by >= on thedisplay.

A digital protractorwill be needed toproperly troubleshootthe machine.


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Boom EnvelopeOperationalSwitch Failure,S-120 andS-125 ModelsA boom envelope safetyfault is the result of theboom exceeding theoperational limits andactivating the safetyswitches OR when thesafety switches aretripped within theoperational range.

Press the (+) and (-)keys together to accessthe status screen. Thestatus screen candisplay the followinginformation:- Hydraulic pressure- Boom Length- Boom Angle- Axle status

Boom lengths are givenin feet. The first numberis the length for a S-120,the second number isfor a S-125. Forexample, 75.5/80.5 feet.

Greater than or equal tois indicated by >= on thedisplay.

A digital protractorwill be needed toproperly troubleshootthe machine.


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Chart 24

Platform LevelFunctionInoperativeBe sure all otherfunctions operatenormally.

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Chart 25

Platform LevelUp FunctionInoperativeBe sure all otherfunctions operatenormally.

Be sure the platformout of level LED andICON are not flashingatthe ground control box.


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Chart 26

Platform LevelDown FunctionInoperativeBe sure all otherfunctions operatenormally.

Be sure the platform outof level LED and ICONare not flashing at theground control box.


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Chart 27

Platform LevelSafety Fault

"SAFETY SWITCH

P22 FAULT""SAFETY SWITCH

P22R FAULT"Be sure all otherfunctions operatenormally.


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Chart 28

Platform RotateClockwiseFunctionInoperativeBe sure all otherfunctions operatenormally.



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Platform RotateCounterClockwiseFunctionInoperativeBe sure all otherfunctions operatenormally.



Chart 29

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Chart 30

Jib UpFunctionInoperativeBe sure all other functionsoperate normally.

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Chart 31

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Chart 32

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Chart 33

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Chart 34

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Yellow EndYellow SideSteeringFunctionInoperativeBe sure all otherfunctions operatenormally.


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Drive ForwardFunctionInoperativeBe sure all otherfunctions operatenormally.

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Chart 40

Drive ReverseFunctionInoperativeBe sure all otherfunctions operatenormally.

Be sure the engine isrunning.

Be sure the drive hubsare not in the free wheelconfiguration.


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Schematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions printed in the GenieS-100 and Genie S-105 Operator's Manual orGenie S-120 and Genie S-125 Operator'sManual.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.

Electrical Schematics

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

Hydraulic Schematics

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test


First Edition • First Printing Section 6 • Schematics

First Edition • First PrintingSection 6 • Schematics

Electrical Components


Item Description Genie Manufacturer Manufacturer QtyPart Number Part Number

B1 ...........................Battery,12V DC, 105AH ................. 57159 ............ Allied ......................................Group 27TM ............. 1

B2 ...........................Battery,12V DC, 190AH ................. 57160 ............ Allied ......................................Group 4D .................. 1

B3 ...........................Battery separator ............... 61343 ............ Surepower Industries .............1314 .......................... 1

CB1 ........................Circuit breaker, 40A ........... 61188 ............ Klixon .....................................7851-37-40-I ............. 1

CB2 ........................Circuit breaker, 20A ........... 61187 ............ Klixon .....................................7851-37-20-I ............. 1

CR6, CR7,CR10 throughCR17 ......................Relay, SPDT, 12V DC ....... 34052 ............ Potter-Brumfield .....................VF4-15F11-CO5 ..... 10

F1 ...........................Fuse, 20A, Maxi(Deutz models) .................. 75433 ............ Bussman ................................MAX 20 ..................... 1

F2 ...........................Fuse, 70A, Maxi ................. 61116 ............ Bussman ................................MAX 70 ..................... 1

FB ..........................Flashing beacon ................ 20189 ............ ECCO Electronic Controls .....6400A-GEN .............. 2

FS1 ........................Foot switch ........................ 13482 ............ Linemaster Switch Corp. ........632-S ........................ 1

H1, H2 ....................Alarm - Audio ..................... 62379 ............ Sauer Danfoss .......................K27631 ..................... 2

H3 ..........................Horn,12V DC, 112 dB ................. 54506 ............ Wolo Industries ......................300LJ-12 ................... 1

JC1, JC3 ................ Joystick controller,Dual axis ............................ 62390 ............ Sauer Danfoss .......................K26519(1090332) ..... 2

JC2 .........................Joystick controller,Single axis ......................... 62391 ............ Sauer Danfoss .......................K26520(1090333) ..... 1

KS1, KS2 ...............Contact, N.O. ..................... 45081 ............ Telemecanique ......................ZB2-BE101 ............... 5Contact, N.C. ..................... 29732 ............ Telemecanique ......................ZB2-BE102 ............... 6



ELECTRICAL COMPONENTS

Item Description Genie Manufacturer Manufacturer QtyPart Number Part Number

Proximity switch .....Proximity switch ................. 60987 ............ Power Components ................FP-2000 .................. 10

Relay ......................Relay, SPDT, 12V DC(Deutz models) .................. 60521 ............ Potter-Brumfield .....................VF4-65F11-S01 ........ 4(Cummins andPerkins models) ................. 60521 ............ Potter-Brumfield .....................VF4-65F11-S01 ........ 3

Relay ......................Relay, SPDT, 12V DC(Deutz models) .................. 61225 ............ Potter-Brumfield .....................VF7-41F11-C05 ........ 2(Cummins andPerkins models) ................. 61225 ............ Potter-Brumfield .....................VF7-41F11-C05 ........ 1

SS1 throughSS4 ........................Steer sensor ...................... 50159 ............ Power Components ................HP-NRPS ................. 4

TS1, TS2,TS3 ........................Toggle switch, DPDT,

3 position momentary ........ 16397 ............ Microswitch Control Inc. .........2NT1-7 ...................... 3



Circuit numbering1 Circuit numbers consist of three parts: the

circuit prefix, circuit number and circuit suffix.The circuit prefix indicates the type of circuit.The circuit number describes the function of thecircuit. The circuit suffix provides anabbreviation for the number or may be used tofurther define the function of this portion of thecircuit. It also may be used to indicate the finalend of the circuit, i.e., LS or limit sw.

2 The circuit number may be used more thanonce in a circuit.

For Example:

C 74 PRLO – This is the circuit for the lockoutvalve #1. C stands for control, 74 is the number ofthe circuit for the primary #1 lock out valve. PRLOstands for Primary Lockout.

S 62 BSTO – This is the circuit that communicatesto the onboard computers of the machine that theboom is fully stowed. S stands for safety, 62 is thenumber of the circuit for boom stowed and BSTOstands for Boom Stowed.

P 48 LP – P stands for power. 48 is the circuitnumber for work lamps and LP stands for Lamp.

R 48 LP – R stands for relay. In this case it is thewire that feeds the relay coil for the work lamp. Allother numbers remain the same.

V 61 AXRT – V stands for valve power. 61 standsfor axle retracted circuit and AXRT is themnemonic for Axle Retracted.

Circuit suffixDefinition suffixAC Generator GENAngle ANGAuxiliary Boom Valve ABVAuxiliary Forward Valve AFVAuxiliary Platform Valve APVAuxiliary Reverse Valve AREVAuxiliary Reverse Valve AREVAuxiliary Steer/Drive Valve ASVAxle Extend Valve AXEXAxle Oscillate AXOSAxle Retract Valve AXRTBattery BATBoom Extended BEXBoom Stowed BSTBrake BRKBypass Valves BVCAN High Signal CAN+CAN Low Signal CAN-CAN Shield SHLDChain Break CNBKData High DTA+Data Low DTA-Drive Chassis Controller DCONDrive Enable DREElectrical Displacement Control EDCEngine Speed Select ESPDEngine Status Lamp ESLFilter Restricted FLRFilter Switch FLTRFloat Switch FSFoot switch Signal FTSForward FWDFuel Select (gas/LP) FUEL

Wire Circuit Legend

Section 6 • SchematicsFirst Edition • First Printing


Fuel Solenoid FSOLGround Control TCONHorn HRNIgnition IGNJib Down JDJib Flow Control JFCJib Select Valve JSVJib Up JULamps LPSLeft Front LFLeft Front Steer Sensor LFSLeft Rear LRLeft Rear Steer Sensor LRSLimit Switch LSLoad Sensor LDSLow fuel LOFMotor Shift (Speed) MSMulti Function Valve MFVPlatform Control PCONPlatform Level Down PLDPlatform Level Flow Control PLFPlatform Level Up PLUPlatform Rotate Flow Control PRFPlatform Rotate Left (CCW) PRLPlatform Rotate Right (CW) PRRPlatform Tilt Alarm PTAPlatform Tilt Sensor PTSPressure Sender PSRPressure Switches PSPri Boom down PBDPrimary Boom Down PBDPrimary Boom Extend/Retract Lockout Valve PBLPrimary Boom Extend PBEPrimary Boom Extend/Retract Flow Control PERFPrimary Boom Retract PBRPrimary Boom Up PBU

Primary Boom Up/Down Flow Control PBFPrimary Lockout #1 P1LPrimary Lockout #2 P2LProportional Valve PRVProximity Sensor PXSReceptacle RECReverse REVRight Front RFRight Front Steer Sensor RFSRight Rear RRRight Rear Steer Sensor RRSRPM RPMSec Boom Down SBDSec Boom Extend SBESec Boom Extend/Retract Flow Control SERFSec Boom Retract SBRSec Boom Up SBUSec Boom Up/Down Flow Control SBFCSecondary Boom SBSecondary Boom Lockout Valve SBLOSpare SPStart Aid (Glow Plug or choke) SAStarter STRSteering Valve (CW) STCSteering Valve (CCW) STCCTemp Sender TSRTemp Switches TSTether TETTilt Alarm X axis TAXTilt Alarm Y axis TAYGround Control Panel TCONTurntable Rotate Flow Control TRFTurntable Rotate Right (CW) TRRTurntable Tilt Alarm TTATurntable Tilt Sensor TTSRTest Switch TSW

WIRE CIRCUIT LEGEND

Wire Coloring1 All cylinder extension colors are solid and all

retract functions are striped black. When usingblack wire, the stripe shall be white.

2 All rotations that are LEFT or CW are solid,RIGHT or CCW are striped and black. When thewire is black, the stripe is white.

3 All proportional valve wiring is striped.

Wire Color LegendBL BlueBL/BK Blue/BlackBL/RD Blue/RedBL/WH Blue/WhiteBK BlackBK/RD Black/RedBK/WH Black/WhiteBR BrownGRN GreenGR/BK Green/BlackGR/WH Green/WhiteRD RedRD/BK Red/BlackRD/WH Red/WhiteOR OrangeOR/BL Orange/BlueOR/BK Orange/BlackOR/RD Orange/RedWHT WhiteWH/BK White/BlackWH/RD White/RedYL Yellow

Color, Circuit #, and Primary functionRD 1 Primary boom up driveRD/BK 2 Primary boom down driveRD/WH 3 Primary boom up/down FC

proportional valve driveWH 4 Turntable rotate left valve driveWH/BK 5 Turntable rotate right valve driveWH/RD 6 Turntable rotate FC proportional

valve driveBK 7 Primary boom extendBK/WH 8 Primary boom retractBK/RD 9 Primary boom Extend/Retract

proportional valve driveBL 10 Secondary boom up valve driveBL/BK 11 Secondary boom down valve driveBL/WH 12 Secondary boom up/down FC

proportional valve driveBL/RD 13 Drive enableOR 14 Platform level up valveOR/BK 15 Platform level down valveOR/RD 16 Platform up/down FC

proportional valve driveGR/RD 17 Platform rotate left valve driverGR/BK 18 Platform rotate right valve driverGR/WH 19 Jib select valve driver circuitRD 20 12 battery supplyWH 21 12 ignition supplyBK 22 Key switch power to platform

Emergency StopWH 23 Power to platformWH 24 Power to warning sendersWH/BK 25 Power to oil pressure senderWH/RD 26 Power to temp senderRD 27 Auxiliary PowerRD/BK 28 Platform level alarmRD/WH 29 Drive Motor shift (speed)WH 30 ForwardWH/BK 31 ReverseWH/RD 32 BrakeBK 33 StartBK/WH 34 Start Aid (glow plug or choke)BK/RD 35 Engine speed selectBL 36 Steer clockwise



WIRE CIRCUIT LEGEND

BL/BK 37 Steer counterclockwiseBL/WH 38 GasBL/RD 39 LPOR 40 Limit switch signal stowedOR/BK 41 RPM signalOR/RD 42 Boom retracted signalGR 43 Jib UpGR/BK 44 Jib DownGR/WH 45 AC GeneratorWH 46 Drive HornWH/BK 47 Output Power EnableWH/RD 48 Work LampWH/BK 49 Motion LampBL 50 Auxiliary BoomBL/WH 51 Auxiliary SteerBL/RD 52 Auxiliary PlatformWH/BK 53 Boom envelope safety valve cutoffBK/WH 54 Power to safety interlock

switches (engine)GR/BK 55 Axle oscillationRD 56 Foot switch/TCON

Emergency Stop powerRD/WH 57 Boom down safety interlockRD/BK 58 Safety interlock to engineGR/WH 59 Chain break circuitGR/WH 60 Axle extendGR 61 Axle retractOR 62 Boom stowed (safety)OR/RD 63 Power to boom envelope

safety switchOR/BL 64 Power for operational switchesBL/WH 65 Low fuel indicationBL 66 Drive EnableBL 67 Secondary boom not stowedRD 68 Pri Boom lowered (operational)BL 69 Pri boom #1 extendedBL/WH 70 Pri boom #2 retractedBL/BK 71 Pri boom #2 extendedBL/WH 72 Secondary boom extendedBL/RD 73 Secondary boom retractedRD 74 Pri #1 LockoutRD/WH 75 Pri #2 LockoutBL 76 Pri boom #3 extended



WIRE CIRCUIT LEGEND

WH 77 Lower Angle #1 operationalWH/BK 78 Upper Angle #2 operationalBK 79 power from TCON ESTOP

80Can 2.0/J1939 ShieldGR 81 Can 2.0/J1939 LowYL 82 Can 2.0/J1939 HighGR/WH 83 Tilt signal x axisGR/BK 84 Tilt signal y axisGR 85 Tilt sensor powerOR 86 Hydraulic Filter restrictedRD 87 Platform Level Safety PowerRD/BK 88 Platform Level Safety OutputBR 89 Platform Level Safety GroundRD/BK 90 Proximity KillRD/WH 91 Gate InterlockWH/BK 92 Motor Speed (LO/HI)WH/RD 93 Motor BypassWH 94 Load SensorOR 95 Tether ESTOP returnRD 96 Tether PowerBK 97 Tether ESTOP PowerWH 98 J1708 + (high)BK 99 J1708- (low)WH/RD 100 Outrigger loweredWH/BK 101 Outrigger raisedOR 102 Pothole protector upOR/RD 103 Pothole protector downBK/WH 104 Proprietary Data buss -BK/RD 105 Proprietary Data buss +GR 106 SpareRD 107 Alternator FieldBK/RD 108 Engine StatusGR/WH 109 Sensor PwrBK 110 Sensor ReturnOR 111 Steer SignalRD 112 Steer Signal to Solenoid ValveOR/RD 113 Multi Function ValveBK/RD 114 Load Moment OverweightRD/BK 115 Load Moment UnderweightGRN 116 AC Power GroundWHT 117 AC Power Neutral Wire (-)BK 118 AC Power Hot Wire (+)BL 119 Hydraulic Pressure Sensor Output



Limit Switches

Types of Limit SwitchesThere are two types of limit switches, which arefound in various locations throughout the machine:mechanical-type operational or safety switchesand magnetic proximity switches. As in aircraft,which features redundant safety systems, eachmechanical safety switch is backed up with anindependently functioning proximity switch.

The mechanical-type operational or safetyswitches are used to sense a positive displacementor movement of the limit switch actuator, or arm, asthe machine moves through its range of operationalfunctions. Included in this group are envelope limitswitches, which sense the extended length andangle of the boom, position of the axles androtational position of the turntable.For example, when the 53° operational switch isactivated by achieving a 53° boom angle, the boommay then be extended beyond 75 feet (22.9 m).Another example is the drive enable limit switch,which disables the drive function anytime the boomis rotated past the rear axles, indicated by the'square' end of the drive chassis.In some cases, the engine will be stopped if safetyparameters are exceeded.

Magnetic proximity switches are used to sensevery specific positions of a part of the machine inrelation to the remainder of the machine. Proximityswitches must be correctly aligned for the machinefunctions to operate. Proximity switches are foundat the front and rear axle, the turntable and severallocations on the boom.

Limit Switch NumberingLSAX1RO Front axle retract proximityLSAX2RO Rear axle retract proximityLSAX1EO Front axle extend proximityLSAX2EO Rear axle extend proximityLSAX1ES Front axle extend safetyLSAX2ES Rear axle extend safetyLSB6S Cable tension safetyLSB7DS Boom 11° angle safetyLSB3RS Boom 3 foot (0.9 m) extend safetyLSB2RS •• Boom 101 feet (30.8 m) extend

safetyLSB9AS •• Boom 65° angle safetyLSB8AS Boom 50° angle safetyLSB4ES Boom 76 feet (23.2 m) extend

safetyLST1O Drive enable mechanicalLSB1DO Boom 10° mechanicalLSB2RO •• Boom >100 feet (30.5 m)

retract proximityLSB3RO Boom >3 feet (0.9 m) stowed

mechanicalLSB3EO Boom 75 feet (22.9 m)

extend proximityLSB4EO •• Boom 100 feet (30.5 m)

extend proximityLSB13AO Boom 53° angle proximityLSB14AO •• Boom 68° angle proximityLSB19LO Load moment mechanicalLSB20LO Reverse load moment proximity

(•• S-120 and S-125 models only)



LIMIT SWITCHES

S-100 & S-105 Models(S-100 shown)

S-120 & S-125 Models(S-120 shown)



Relay Layout

a Fuel solenoid relay (Deutz models only).b Oil cooler relay (Deutz models only).c Engine cold start relay.d Starter relay.e Horn relay.f Flashing beacon relay.g CR17 relay (K7) - powers C35RPM

circuit (Hi/low solenoid).h CR16 relay (K8) - powers C34SA

circuit (Engine cold start).i CR12 relay (K4) - powers primary valves 1 and

2, ignition, glow plug, starter relay, generator,and the boom retract, multifunction andplatform rotate valve coils.

j CR14 relay (K2) - powers P7R or S56PRVcircuit including the auxiliary valve, boomextend/retract and turntable rotate valve coils.

k CR10 relay (K6) - powers C21IGN and C107AFcircuits (Fuel on/off solenoid and alternatorfield).

l CR15 relay (K1) - powers P22R or C03PBFcircuit (Boom up/down valve coil).

m CR13 relay (K5) - powers P_7 and throttlerelay.

n CR11 relay (K3) - powers P-6R2 or P54ENGcircuits.



Drive Chassis Controller Pin Legend



Platform Controller Pin Legend



Turntable Controller Pin Legend


Electrical Schematic Legend -Drive Chassis (DCON) and Platform Controls (PCON)




Electrical Schematic Legend -Ground Controls (TCON)


Electrical Symbols Legend



Limit Switch Harness Schematic,S-100 & S-105 Models

1

2

3

4

5

6

7

8

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


Limit Switch Harness Schematic,S-120 & S-125 Models

1

2

3

4

5

6

7

8




Safety Circuit Schematic

1

2

3

4

5

6

7

8




Documents

Service M anual - Tuotetietokantatuotteet.ramirent.fi/sites/tuotteet.ramirent/files/product... · A-16 Test the Tilt Sensor and Alarm ... 15 Boom Length Switch Fault..... 5 - 54 16