PartNo Rev B July ServiceManual. Refertoinsidecover foradditionalserialnumber information. (fromserialnumber 9154)

Transcription

1 ServiceManual Refertoinsidecover foradditionalserialnumber information PartNo. Rev B July 00 (fromserialnumber 9)

2 Introduction July 00 Introduction Important Read, understand and obey the safety rules and operating instructions in the Genie S-0 and Genie S- Operator's Manual before attempting any maintenance or repair procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes and repair procedures for qualified service professionals. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center. Serial Number Information Genie Industries offers the following Service Manuals for these models: Title Part No. S-0 and S- Service Manual (before serial number )... S-0 and S- Service Manual (from serial number to )... S-0 and S- Service Manual (from serial number to 9)... 9 Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals. Contact Us: techsup@genieind.com Copyright 99 by Genie Industries Rev B July 00 Fourth Edition, Second Printing "Genie" and "S" are registered trademarks of Genie Industries in the USA and many other countries. Printed on recycled paper Printed in U.S.A. ii S-0 S- Part No.

3 July 00 INTRODUCTION Serial Number Legend Model: S-0 Serial number: S00- Model year: 00 Manufacture date: 0//0 Electrical schematic number: E0 Machine unladen weight: 0,lbs / 9,0kg Foam Tires add lbs/ kg to weight Rated work load (including occupants): 00 lb / kg Maximum number of platfrm occupants: Maximum allowable side force : 0 lb / 0 N Maximum allowable inclination of the chassis: Air Tires deg / Foam Tires. deg Maximum wind speed : mph/. m/s Maximum platform height : 0 ft in/. m Maximum platform reach : 0 ft in/. m Gradeability: % Country of manufacture: USA This machine complies with: ANSI A9. CAN B.. S Model Model year Sequence number Genie Industries 0 NE th Street Redmond, WA 90 USA PN - 0 Part No. S-0 S- iii

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5 July 00 Section Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie S-0 and Genie S- Operator's Manual will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed. Do Not Perform Maintenance Unless: You are trained and qualified to perform maintenance on this machine. You read, understand and obey: - manufacturer s instructions and safety rules - employer s safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop. Part No. S-0 S- v

6 Section Safety Rules July 00 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority. Read each procedure thoroughly. This manual and the decals on the machine use signal words to identify the following: Safety alert symbol used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. With safety alert symbol used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Without safety alert symbol used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Used to indicate operation or maintenance information. Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Workplace Safety Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity. Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. vi S-0 S- Part No.

7 July 00 Table of Contents Introduction Important Information... ii Serial Number Information... ii Serial Number Legend... iii Section Safety Rules General Safety Rules... iii Section Rev Specifications A Machine Specifications... - A Performance Specifications... - B Hydraulic Specifications... - B Manifold Component Specifications... - A GM.0L Engine Specifications... - A Ford LRG- EFI Engine Specifications... - B Deutz FL-0 Engine Specifications... - B Perkins 0- Engine Specifications... - C Machine Torque Specifications... - B Hydraulic Hose and Fitting Torque Specifications A SAE and Metric Fasteners Torque Charts Section Rev Scheduled Maintenance Procedures Introduction... - Pre-Delivery Preparation... - Maintenance Inspection Report... - C Checklist A Procedures A- Perform Pre-operation Inspection... - A- Perform Function Tests... - A- Perform Engine Maintenance - Deutz Models... - Part No. S-0 S- vii

8 July 00 TABLE OF CONTENTS Section Rev Scheduled Maintenance Procedures, continued A- Perform Engine Maintenance - GM and Ford Models... - A- Perform Engine Maintenance - Perkins Models A- Check the High Pressure Hydraulic Filter Condition Indicator A- Test the Oscillate Axle (if equipped) A- Perform 0 Day Service A-9 Perform Engine Maintenance - GM, Ford and Perkins Models... - A-0 Inspect the Fuel Filter/Water Separator - Diesel Models... - A- Check and Adjust the Engine RPM - Perkins Models... - A- Grease the Turntable Rotation Bearing and Rotate Gear... - A- Perform Engine Maintenance - GM and Ford Models... - A- Perform Engine Maintenance - Perkins Models... - C Checklist B Procedures B- Inspect the Battery... - B- Inspect the Electrical Wiring... - B- Check the Exhaust System... - B- Check the Oil Cooler and Cooling Fins - Deutz Models... - B- Check the Lug Nut Torque (including the tires and wheels) B- Confirm the Proper Brake Configuration B- Check the Oil Level in the Drive Hubs B- Check and Adjust the Engine RPM - Deutz Models B-9 Test the Ground Control Override... - B-0 Check the Oscillate Directional Valve Linkage... - B- Test the Platform Self-leveling... - viii S-0 S- Part No.

9 July 00 TABLE OF CONTENTS Section Rev Scheduled Maintenance Procedures, continued B- Test the Engine Idle Select... - B- Test the Fuel Select Operation - GM and Ford Models... - B- Test the Drive Brakes... - B- Test the Drive Speed - Stowed Position... - B- Test the Drive Speed - Raised or Extended Position... - B- Test the Alarm Package - Optional Equipment... - B- Perform Hydraulic Oil Analysis... - B-9 Replace the Fuel Filter/Water Separator Element - Perkins Models B-0 Replace the Fuel Filter Element - Perkins Models... - B- Perform Engine Maintenance - Deutz Models... - B- Perform Engine Maintenance - GM and Ford Models... - B- Perform Engine Maintenance - Perkins Models... - D Checklist C Procedures C- Perform Engine Maintenance - Deutz Models... - C- Grease the Platform Overload Mechanism (if equipped)... - C- Test the Platform Overload System (if equipped)... - C- Inspect the Boom Extend/Retract Cables... - C- Perform Engine Maintenance - Perkins Models... - C- Perform Engine Maintenance - GM and Ford Models Part No. S-0 S- ix

10 July 00 TABLE OF CONTENTS Section Rev Scheduled Maintenance Procedures, continued C Checklist D Procedures D- Check the Boom Wear Pads D- Check the Turntable Rotation Bearing Bolts D- Inspect for Turntable Bearing Wear... - D- Replace the Drive Hub Oil... - D- Check the Free-wheel Configuration... - D- Replace the Hydraulic Filters... - D- Check and Adjust the Air/LPG Mixture - GM Models... - D- Perform Engine Maintenance - Deutz Models... - D-9 Calibrate the Platform Overload System (if equipped)... - D Checklist E Procedures E- Test or Replace the Hydraulic Oil E- Perform Engine Maintenance - Deutz Models... - E- Perform Engine Maintenance - Deutz Models... - E- Remove and Inspect the Boom Extend/Retract Cables... - Section Rev Repair Procedures Introduction... - A Platform Controls - ALC-00 Circuit Board Joysticks... - B Platform Components - Platform Leveling Slave Cylinder Platform Rotator... - x S-0 S- Part No.

11 July 00 TABLE OF CONTENTS Section Rev Repair Procedures, continued A Jib Boom Components, S- - Jib Boom Jib Boom Lift Cylinder... - B Boom Components - Cable Track Boom Boom Lift Cylinder Boom Extension Cylinder Boom Extend/Retract Cables Platform Leveling Master Cylinder... - C Engines - RPM Adjustment - Deutz Models RPM Adjustment - Perkins Models Flex Plate Engine Fault Codes - GM and Ford Models C Hydraulic Pumps - Function Pump Drive Pump... - Part No. S-0 S- xi

12 July 00 TABLE OF CONTENTS Section Rev Repair Procedures, continued D Manifolds - Function Manifold Components Valve Adjustments - Function Manifold Jib Boom / Platform Rotate Manifold Components Brake/Two-speed Manifold Components Turntable Rotation Manifold Components Oscillate Directional Valve Components Valve Adjustments - Oscillate Relief Valve Traction Manifold Components, WD Valve Adjustments, WD Traction Manifold Traction Manifold Components, WD Valve Adjustments, WD Traction Manifold Valve Coils... - C Turntable Rotation Components - Turntable Rotation Assembly... - C Axle Components 9- Oscillate Axle Cylinders Section Rev Fault Codes Introduction... - A Fault Codes - Control System... - A Fault Codes - Ford Engine... - xii S-0 S- Part No.

13 July 00 TABLE OF CONTENTS Section Rev Schematics Introduction... - A Electrical Symbols Legend... - A Hydraulic Symbols Legend... - A GM.0L Engine Harness... - A Ford LRG- EFI Engine Harness... - B Electrical Schematic, S-0, GM.0L Models... - B Ground Control Box Terminal Strip Wiring Diagram, S-0, GM.0L Models B Ground Control Box Switch Panel Wiring Diagram, S-0, GM.0L Models B Platform Control Box Terminal Strip Wiring Diagram, S-0, GM.0L Models... - B Platform Control Box Switch Panel Wiring Diagram, S-0, GM.0L Models... - C Electrical Schematic, S-, GM.0L Models... - B Ground Control Box Terminal Strip Wiring Diagram, S-, GM.0L Models... - B Ground Control Box Switch Panel Wiring Diagram, S-, GM.0L Models... - B Platform Control Box Terminal Strip Wiring Diagram, S-, GM.0L Models... - B Platform Control Box Switch Panel Wiring Diagram, S-, GM.0L Models... - Part No. S-0 S- xiii

14 July 00 TABLE OF CONTENTS Section Rev Schematics, continued A Electrical Schematic, S-0, Ford LRG- EFI Models (before serial number 0) A Electrical Schematic, S-0, Ford LRG- EFI Models (after serial number 9)... - A Ground Control Box Terminal Strip Wiring Diagram, S-0, Ford LRG- EFI Models (before serial number 0)... - A Ground Control Box Switch Panel Wiring Diagram, S-0, Ford LRG- EFI Models (before serial number 0)... - A Ground Control Box Terminal Strip Wiring Diagram, S-0, Ford LRG- EFI Models (after serial number 9)... - A Ground Control Box Switch Panel Wiring Diagram, S-0, Ford LRG- EFI Models (after serial number 9)... - A Platform Control Box Terminal Strip Wiring Diagram, S-0, Ford LRG- EFI Models... - A Platform Control Box Switch Panel Wiring Diagram, S-0, Ford LRG- EFI Models... - B Electrical Schematic, S-, Ford LRG- EFI Models (before serial number 0) A Electrical Schematic, S-, Ford LRG- EFI Models (after serial number 9)... - A Ground Control Box Terminal Strip Wiring Diagram, S-, Ford LRG- EFI Models (before serial number 0)... - A Ground Control Box Switch Panel Wiring Diagram, S-, Ford LRG- EFI Models (before serial number 0)... - A Ground Control Box Terminal Strip Wiring Diagram, S-, Ford LRG- EFI Models (after serial number 9)... - A Ground Control Box Switch Panel Wiring Diagram, S-, Ford LRG- EFI Models (after serial number 9)... - A Platform Control Box Terminal Strip Wiring Diagram, S-, Ford LRG- EFI Models... - A Platform Control Box Switch Panel Wiring Diagram, S-, Ford LRG- EFI Models... - xiv S-0 S- Part No.

15 July 00 TABLE OF CONTENTS Section Rev Schematics, continued C Electrical Schematic, S-0, Deutz FL-0 Models (before serial number 0) A Electrical Schematic, S-0, Deutz FL-0 Models (after serial number 9)... - C Electrical Schematic, S-0, CE Models, Deutz FL-0 Models (before serial number 0)... - A Electrical Schematic, S-0, CE Models, Deutz FL-0 Models (after serial number 9)... - B Ground Control Box Terminal Strip Wiring Diagram, S-0, Deutz FL-0 Models (before serial number 0)... - B Ground Control Box Switch Panel Wiring Diagram, S-0, Deutz FL-0 Models (before serial number 0)... - A Ground Control Box Terminal Strip Wiring Diagram, S-0, Deutz FL-0 Models (after serial number 9) A Ground Control Box Switch Panel Wiring Diagram, S-0, Deutz FL-0 Models (after serial number 9) B Ground Control Box Terminal Strip Wiring Diagram, S-0, CE Models, Deutz FL-0 Models (before serial number 0)... - B Ground Control Box Switch Panel Wiring Diagram, S-0, CE Models, Deutz FL-0 Models (before serial number 0)... - A Ground Control Box Terminal Strip Wiring Diagram, S-0, CE Models, Deutz FL-0 Models (after serial number 9)... - A Ground Control Box Switch Panel Wiring Diagram, S-0, CE Models, Deutz FL-0 Models (after serial number 9)... - B Platform Control Box Terminal Strip Wiring Diagram, S-0, Deutz FL-0 Models... - B Platform Control Box Switch Panel Wiring Diagram, S-0, Deutz FL-0 Models... - Part No. S-0 S- xv

16 July 00 TABLE OF CONTENTS Section Rev Schematics, continued D Electrical Schematic, S-, Deutz FL-0 Models (before serial number 0)... - A Electrical Schematic, S-, Deutz FL-0 Models (after serial number 9) D Electrical Schematic, S-, CE Models, Deutz FL-0 Models (before serial number 0)... - A Electrical Schematic, S-, CE Models, Deutz FL-0 Models (after serial number 9)... - B Ground Control Box Terminal Strip Wiring Diagram, S-, Deutz FL-0 Models (before serial number 0)... - B Ground Control Box Switch Panel Wiring Diagram, S-, Deutz FL-0 Models (before serial number 0)... - A Ground Control Box Terminal Strip Wiring Diagram, S-, Deutz FL-0 Models (after serial number 9)... - A Ground Control Box Switch Panel Wiring Diagram, S-, Deutz FL-0 Models (after serial number 9)... - B Ground Control Box Terminal Strip Wiring Diagram, S-, CE Models, Deutz FL-0 Models (before serial number 0) B Ground Control Box Switch Panel Wiring Diagram, S-, CE Models, Deutz FL-0 Models (before serial number 0) A Ground Control Box Terminal Strip Wiring Diagram, S-, CE Models, Deutz FL-0 Models (after serial number 9)... - A Ground Control Box Switch Panel Wiring Diagram, S-, CE Models, Deutz FL-0 Models (after serial number 9)... - B Platform Control Box Terminal Strip Wiring Diagram, S-, Deutz FL-0 Models... - B Platform Control Box Switch Panel Wiring Diagram, S-, Deutz FL-0 Models... - xvi S-0 S- Part No.

17 July 00 TABLE OF CONTENTS Section Rev Schematics, continued C Electrical Schematic, S-0, Perkins 0- Models (before serial number 0)... - A Electrical Schematic, S-0, Perkins 0- Models (after serial number 9)... - B Ground Control Box Terminal Strip Wiring Diagram, S-0, Perkins 0- Models (before serial number 0) B Ground Control Box Switch Panel Wiring Diagram, S-0, Perkins 0- Models (before serial number 0) A Ground Control Box Terminal Strip Wiring Diagram, S-0, Perkins 0- Models (after serial number 9)... - A Ground Control Box Switch Panel Wiring Diagram, S-0, Perkins 0- Models (after serial number 9)... - B Platform Control Box Terminal Strip Wiring Diagram, S-0, Perkins 0- Models... - B Platform Control Box Switch Panel Wiring Diagram, S-0, Perkins 0- Models... - D Electrical Schematic, S-, Perkins 0- Models (before serial number 0)... - A Electrical Schematic, S-, Perkins 0- Models (after serial number 9)... - B Ground Control Box Terminal Strip Wiring Diagram, S-, Perkins 0- Models (before serial number 0) B Ground Control Box Switch Panel Wiring Diagram, S-, Perkins 0- Models (before serial number 0) A Ground Control Box Terminal Strip Wiring Diagram, S-, Perkins 0- Models (after serial number 9) A Ground Control Box Switch Panel Wiring Diagram, S-, Perkins 0- Models (after serial number 9) B Platform Control Box Terminal Strip Wiring Diagram, S-, Perkins 0- Models B Platform Control Box Switch Panel Wiring Diagram, S-, Perkins 0- Models D Hydraulic Schematic, WD Models D Hydraulic Schematic, WD Models Part No. S-0 S- xvii

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19 July 00 Section Specifications REV A Specifications Machine Specifications Performance Specifications Tires and wheels Wheel lugs / - Lug nut torque, dry Lug nut torque, lubricated 0 ft-lbs Nm 0 ft-lbs Nm Tire ply rating Overall tire diameter (Rough terrain tires) Overall tire diameter (Hi-flotation tires) Tire pressure (Rough terrain tires) Tire pressure (Hi-flotation tires) Fluid capacities LPG tank Hydraulic tank Hydraulic system (including tank) Drive hubs Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL For operational specifications, refer to the Operator's Manual..9 in 9. cm 0. in 0. cm 0 psi.9 bar 0 psi. bar. pounds. kg gallons 0 liters gallons liters 0 fl oz 0. liters Boom function speeds, maximum from platform controls Jib boom up, S- Jib boom down, S- Boom up Boom down Boom extend Boom retract Turntable rotate, 0 boom stowed Turntable rotate, 0 boom raised or extended Platform rotate, 0 S-0 Platform rotate, 0 S- Braking distance, maximum High range on paved surface Drive speed, maximum stowed position WD models WD models Drive speed, maximum raised or extended position All models 0 to 0 seconds 0 to 0 seconds 0 to 0 seconds 0 to 0 seconds to seconds to seconds to seconds to seconds to seconds to seconds to ft 0.9 to. m 0 ft /. sec. m /. sec 0 ft /. sec. m /. sec 0 ft/0 sec. m/0 sec Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. S-0 S- -

20 Section Specifications July 00 SPECIFICATIONS REV B Hydraulic Specifications Hydraulic Oil Specifications Hydraulic oil type Chevron Rykon MV equivalent Approximate SAE grade W-0 Viscosity index rating 00 Cleanliness level, minimum / Water content, maximum 00 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG (Dexron III) oils. Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems, have the ability to perform over a wide temperature range, and have a minimum viscosity index rating of 0. They should provide excellent antiwear, oxidation, corrosion inhibition, seal conditioning, and foam and aeration suppression properties. Optional fluids Biodegradable Petro Canada Premium ECO Statoil Hydra Way Bio Pa BP Biohyd SE-S Fire resistant Mineral based UCON Hydrolube HP-0 Quintolubric Shell Tellus T Shell Tellus T Chevron Aviation A Drive pump Type: Flow 00 rpm Drive pressure, maximum Charge pump Type: Displacement Flow 00 rpm Charge 00 rpm Function pump Type: Displacement - Pump (inner) Flow 00 rpm Displacement - Pump (outer) bi-directional, variable displacement piston pump. gpm. L/min 0 psi 9 bar gerotor 0. cu in.9 cc 9. gpm. L/min 0 psi. bar section tandem gear pump. cu in cc. gpm L/min 0. cu in cc Use Chevron Aviation A hydraulic oil when in ambient temperatures consistently below 0 F / - C. Use Shell Tellus T hydraulic oil when oil temperatures consistently exceed 0 F / 9 C. Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult the Genie Industries Service Department before use. Flow 00 rpm Auxiliary pump Type: Displacement gpm. L/min gear, fixed displacement. gpm. L/min - S-0 S- Part No.

21 July 00 Section Specifications REV B SPECIFICATIONS Function manifold System relief valve pressure Steer flow regulator 000 psi 0 bar. gpm. L/min Manifold Component Specifications Plug torque SAE No. in-lbs / Nm Jib boom / platform rotate flow regulator Oscillate relief valve pressure 0. gpm. L/min 00 psi bar SAE No. SAE No. SAE No. 0 ft-lbs / Nm ft-lbs / 9 Nm ft-lbs / Nm Drive manifold SAE No. 0 ft-lbs / Nm Hot oil relief valve pressure 0 psi 9. bar SAE No. ft-lbs / Nm Drive motors, WD models Displacement per revolution, 0.9 cu in high speed cc Displacement per revolution,. cu in low speed 0 cc Drive motors, WD models Displacement per revolution,. cu in high speed 0.9 cc Displacement per revolution,. cu in low speed cc Hydraulic filters High pressure filter Beta ³ 00 High pressure filter psi bypass pressure. bar Valve coil resistance specifications Solenoid valve, position way, 0V DC (schematic items D, V and Y) Solenoid valve, position way, 0V DC (schematic item BB) Solenoid valve, position way, 0V DC (schematic items B, C, E, F and FF) to Ω to Ω to Ω Solenoid valve, position way, 0V DC. to.ω (schematic items KK and LL) Proportional solenoid valve, V DC (schematic items M and T) to Ω Proportional solenoid valve, V DC. to.ω (schematic item Q) Medium pressure filter Beta ³ 00 Medium pressure filter bypass pressure Hydraulic return filter psi. bar 0 micron with psi /. bar bypass Part No. S-0 S- -

22 Section Specifications July 00 SPECIFICATIONS REV A GM.0L EFI Engine Displacement cu in liters Number of cylinders Bore & stroke Horsepower Intermittent Continuous x. inches 0. x rpm 00 rpm Firing order Starter motor Normal engine cranking speed Current draw, normal load Current draw, maximum load Current draw, minimum Battery Type Size 0 rpm 00A 00A 00A V DC x / x 9 / inches x. x. cm Low idle 0 rpm Quantity High idle 00 rpm Cold cranking ampere 000A Compression ratio 9.: Compression pressure - minimum Pressure (psi or bar) of lowest cylinder must be at least % of highest cylinder 00 psi.9 bar Valve clearances Zero lash + full turn Lubrication system Oil pressure, minimum (operating 000 rpm) Oil capacity (including filter) Oil viscosity requirements psi. bar quarts. liters Below 0 F / -. C W-0 Above 0 F / -. C 0W-0 Only use engine oils labeled "For Gasoline Engines" by the American Petroleum Institute (API). Reserve A rate Electronic fuel pump Fuel pressure, static Fuel flow rate Ignition system Spark plug type Spark plug gap Engine coolant Capacity Alternator output Fan belt deflection 00 minutes 9 to psi 0. to 0. bar 0. gpm. L/min AC ACMR--LTS 0.00 inches.0 mm quarts. liters V DC / inch mm - S-0 S- Part No.

23 July 00 Section Specifications REV A SPECIFICATIONS Ford LRG- EFI Engine Displacement cu in. liters Number of cylinders Bore & stroke Horsepower. x. inches 9.0 x. mm 00 rpm 00 rpm Firing order Low idle (computer controlled) High idle (computer controlled) 00 rpm 0 Hz 00 rpm 00 Hz Compression ratio 9.: Compression pressure (approx.) Pressure (psi or bar) of lowest cylinder must be at least % of highest cylinder Valve clearances - collapsed tappet Lubrication system Oil pressure (operating 00 rpm) 0.0 to 0.0 inches 0.9 to.9 mm 0 to 0 psi. to. bar Engine coolant Capacity Starter motor Normal engine cranking speed. quarts 0.9 liters 00 to 0 rpm Current draw, normal load 0-00A Current draw, maximum load Circuit voltage drop while starting, maximum (normal temperature) Brush length, minimum Commutator run-out, maximum Electronic fuel pump Fuel pressure, static Fuel flow rate Alternator Output Battery 00A 0.V DC 0. in. mm 0.00 inches 0. mm psi. bar 0. gpm. L/min 9A,.V DC Oil capacity (including filter) Oil viscosity requirements. quarts. liters Type Size V DC x / x 9 / inches x. x. cm Above - F / - C 0W-0 Quantity Above - F / -0 C W-0 Use oils meeting API classification SJ or SH. Units ship with W-0 SJ. Ignition system Cold cranking ampere Reserve A rate 000A 00 minutes Spark plug type Spark plug gap Motorcraft AGSF--FM 0.0 to 0.0 inches.0 to. mm Part No. S-0 S- -

24 Section Specifications July 00 SPECIFICATIONS REV B Deutz FL 0 Engine Displacement cu in. liters Number of cylinders Bore and stroke Horsepower. x.09 inches 9 x 00 rpm Firing order - - Low idle 00 rpm Oil temperature switch Torque Temperature switch point Oil pressure switch Torque Oil pressure switch point - ft-lbs - Nm 0 F 0 C - ft-lbs - Nm psi bar High idle 00 rpm Fuel injection system Compression ratio.: Injection pump make Bosch Compression pressure to psi to 0 bar Injection pump pressure, maximum 000 psi 0 bar Governor Valve clearance, cold Intake centrifugal mechanical 0.0 in 0. mm Injector opening pressure Fuel requirement Starter motor 0 psi 0 bar # Diesel Exhaust Lubrication system 0.00 in 0. mm Current draw, no load Brush length, new 90A 0. in. mm Oil pressure 0 to psi. to bar Brush length, minimum 0. in mm Oil capacity (including filter) Oil viscosity requirements. quarts liters - F to F/ -0 C to 0 C W-0 (synthetic) - F to 90 F / -0 C to C 0W-0 Above F / - C 0W-0 Engine oil should have minimum properties of API classification CC/SG or CD/SG grades. Units ship with 0W-0 CH- Battery Type Size V DC x / x 9 / inches x. x. cm Quantity Cold cranking ampere Reserve A rate Alternator output Fan belt deflection 000A 00 minutes V DC / to / inch 9 to mm - S-0 S- Part No.

25 July 00 Section Specifications REV B SPECIFICATIONS Perkins 0- Engine Displacement cu in. liters Number of cylinders Bore and stroke Horsepower. x.9 inches x 00 mm gross intermittent 000 rpm. Firing order Low idle High idle 00 rpm 00 rpm Compression ratio.: Compression pressure Pressure (psi) of lowest cylinder must be within 0 psi /. bar of highest cylinder Governor Valve clearance, cold Intake Exhaust psi 9. bar centrifugal mechanical 0.00 in 0. mm 0.00 in 0. mm Lubrication system Oil pressure, cold (at 00 rpm) Oil capacity (including filter) Oil viscosity requirements 0 psi. bar 9. quarts. liters Below F / 0 C W-0 - F to 0 F / -0 C to 0 C 0W-0 Above F / -0 C W-0 Engine oil should have minimum properties of API classification CH-. Units ship with CH- Oil pressure sending unit Torque Oil pressure switch point Fuel injection system Injection pump make Injection pressure Fuel requirement Alternator output Fan belt deflection - ft-lbs - Nm. psi bar Zexel psi bar # Diesel V DC / in 0 mm Starter motor Current draw, no load Brush length, new Brush length, minimum 90A 0.0 in 9 mm 0. in. mm Part No. S-0 S- -

26 Section Specifications July 00 SPECIFICATIONS REV C Battery Type Size V DC x / x 9 / inches x. x. cm Quantity Cold cranking ampere Reserve A rate Engine coolant Capacity Coolant temperature sending unit Torque Temperature switch point 000A 00 minutes. quarts. liters - ft-lbs - Nm F 0 C Machine Torque Specifications Platform rotator - center bolt, GR 0 ft-lbs Nm / - bolts, GR ft-lbs 0 Nm Drive motor and hubs Drive hub mounting bolts, lubricated Drive motor mounting bolts, lubricated Turntable bearing Rotate bearing mounting bolts, lubricated Turntable rotation assembly Backlash pivot plate 0 ft-lbs Nm ft-lbs Nm 0 ft-lbs Nm 0 ft-lbs. Nm - S-0 S- Part No.

27 July 00 Section Specifications REV B SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal-Lok fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed. SAE Dash size SAE O-ring Boss Port (tube fitting - installed into Aluminum) Torque - ft-lbs /.9 Nm - ft-lbs /. Nm - 0 ft-lbs /. Nm -0 9 ft-lbs / 9. Nm - 9 ft-lbs /. Nm - 9 ft-lbs /. Nm -0 ft-lbs /. Nm - 0 ft-lbs / Nm SAE O-ring Boss Port (tube fitting - installed into Steel) Seal-Lok fittings Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight. The O-rings used in the Parker Seal Lok fittings and hose ends are custom-size O-rings. They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part number 9). Lubricate the O-ring before installation. Be sure that the face seal O-ring is seated and retained properly. Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight. Tighten the nut or fitting to the appropriate torque per given size as shown in the table. Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks. Seal-Lok Fittings (hose end) SAE Dash size Torque SAE Dash size Torque - ft-lbs /. Nm - ft-lbs /. Nm - 0 ft-lbs /. Nm -0 0 ft-lbs /. Nm - 0 ft-lbs / 90 Nm - 0 ft-lbs /. Nm -0 0 ft-lbs /. Nm - ft-lbs /. Nm - ft-lbs /. Nm - ft-lbs /. Nm - 0 ft-lbs /. Nm -0 ft-lbs /. Nm - 90 ft-lbs / Nm - 0 ft-lbs /. Nm -0 0 ft-lbs / 90 Nm - ft-lbs /. Nm Part No. S-0 S- - 9

28 Section Specifications July 00 SPECIFICATIONS REV A SIZE / / / / / 9/ / / / / / / SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A High Strength THREAD Grade Grade Black Oxide Bolts LUBED DRY LUBED DRY LUBED in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m LUBED DRY LUBED DRY LUBED ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Size Class.. Class.. Class Class.9.9 (mm) LUBED DRY LUBED DRY LUBED DRY LUBED DRY in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm LUBED DRY LUBED DRY LUBED DRY LUBED DRY ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm S-0 S- Part No.

29 July 00 Section Scheduled Maintenance Procedures Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Observe and Obey: Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. Scheduled maintenance inspections shall be completed daily, quarterly, six months, annually and every years as specified on the Maintenance Inspection Report. Failure to perform each procedure as presented and scheduled may cause death, serious injury or substantial damage. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating machine. Keep records on all inspections for three years. Unless otherwise specified, perform each maintenance procedure with the machine in the following configuration: Machine parked on a firm, level surface Boom in stowed position Turntable rotated with the boom between the non-steer wheels Turntable secured with the turntable rotation lock Key switch in the off position with the key removed Wheels chocked All external AC power disconnected from the machine Each procedure includes a description, safety information and step-by-step instructions. Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. With safety alert symbol used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Without safety alert symbol used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Used to indicate operation or maintenance information. Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. Part No. S-0 S- -

30 Section Scheduled Maintenance Procedures July 00 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below. Indicates that tools will be required to perform this procedure. Indicates that new parts will be required to perform this procedure. Pre-delivery Preparation Report The pre-delivery preparation report contains checklists for each type of scheduled inspection. Make copies of the Pre-delivery Preparation Report to use for each inspection. Store completed forms as required. Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily, quarterly, every six months, annual and two years. The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A, B, C, D and E. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection. Indicates that a cold engine will be required to perform this procedure. Indicates that a warm engine will be required to perform this procedure. Indicates that dealer service is required to perform this procedure. Inspection Daily or every hours Quarterly or every 0 hours Six months or every 00 hours Annual or every 000 hours Two years or every 000 hours Checklist A A + B A + B + C A + B + C + D A + B + C + D + E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. - S-0 S- Part No.

31 Pre-Delivery Preparation July 00 Fundamentals It is the responsibility of the dealer to perform the Pre-delivery Preparation. The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service. A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service. Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications. Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual. Section Scheduled Maintenance Procedures Instructions Use the operator s manual on your machine. The Pre-delivery Preparation consists of completing the Pre-operation Inspection, the Maintenance items and the Function Tests. Use this form to record the results. Place a check in the appropriate box after each part is completed. Follow the instructions in the operator s manual. If any inspection receives an N, remove the machine from service, repair and re-inspect it. After repair, place a check in the R box. Legend Y = yes, completed N = no, unable to complete R = repaired Comments Pre-Delivery Preparation Y N R Pre-operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Genie Industries USA 0 NE th Street PO Box 900 Redmond, WA () -00 Genie UK The Maltings, Wharf Road Grantham, Lincolnshire NG- BH England () - Copyright 00 by Genie Industries. Genie is a registered trademark of Genie Industries. Rev B Part No. S-0 S- -

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33 July 00 Section Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection. Select the appropriate checklist(s) for the type of inspection to be performed. Daily or hour Inspection: A Quarterly or 0 hour Inspection: A+B Six Month or 00 hour Inspection: A+B+C Annual or 000 hours Inspection: A+B+C+D Year or 000 hour Inspection: A+B+C+D+E Place a check in the appropriate box after each inspection procedure is completed. If any inspection receives an N, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the R box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Checklist A - Rev C Y N R A- Pre-operation inspection A- Functions tests A- Engine maintenance - Deutz models A- Engine maintenance - GM and Ford models A- Engine maintenance - Perkins models A- Filter condition indicator A- Oscillate axle Perform after 0 hours: A- 0 day service Perform every 00 hours: A-9 Engine maintenance - GM, Ford and Perkins models A-0 Fuel filter/separator - Diesel models A- Check engine RPM- Perkins models A- Rotation bearing Perform every 00 hours: A- Engine maintenance - GM and Ford models A- Engine maintenance - Perkins models Checklist B - Rev C Y N R B- Inspect battery B- Inspect electrical wiring B- Exhaust system B- Oil cooler and fins- Deutz models B- Lug nut torque B- Brake configuration B- Drive hub oil level B- Engine RPM - Deutz models B-9 Ground control override B-0 Directional valve B- Platform leveling B- Engine idle select B- Fuel select - GM and Ford models B- Drive brakes B- Drive speed - stowed position B- Drive speed - raised position B- Alarm package B- Hydraulic oil analysis B-9 Fuel filter/separator - Perkins models B-0 Fuel filter element - Perkins models Perform every 00 hours: B- Engine maintenance - Deutz models B- Engine maintenance - GM and Ford models B- Engine maintenance - Perkins models Part No. S-0 S- -

34 Section Scheduled Maintenance Procedures July 00 MAINTENANCE INSPECTION REPORT Model Serial number Date Hour meter Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection. Select the appropriate checklist(s) for the type of inspection to be performed. Daily or hour Inspection: A Quarterly or 0 hour Inspection: A+B Six Month or 00 hour Inspection: A+B+C Annual or 000 hours Inspection: A+B+C+D Year or 000 hour Inspection: A+B+C+D+E Place a check in the appropriate box after each inspection procedure is completed. If any inspection receives an N, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the R box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Checklist C - Rev D Y N R C- Engine maintenance - Deutz models C- Grease platform overload (if equipped) C- Test platform overload (if equipped) C- Boom extend/retract cables Perform every 00 hours: C- Engine maintenance - Perkins models Perform every 00 hours: C- Engine maintenance - GM and Ford models Checklist D - Rev C Y N R D- Boom wear pads D- Turntable bearing bolts D- Turntable bearing wear D- Drive hub oil D- Free-wheel configuration D- Hydraulic filters D- Air/LPG mixture - GM models D- Engine maintenance - Deutz models D-9 Calibrate platform overload system (if equipped) Checklist E - Rev D Y N R E- Hydraulic oil Perform every 000 hours: E- Engine maintenance - Deutz models Perform every,000 hours: E- Engine maintenance - Deutz models Perform every years: E- Remove and inspect boom extend/ retract cables - S-0 S- Part No.

35 July 00 REV C Section Scheduled Maintenance Procedures Checklist A Procedures A- Perform Pre-operation Inspection Completing a Pre-operation Inspection is essential to safe machine operation. The Pre-operation Inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests. The Pre-operation Inspection also serves to determine if routine maintenance procedures are required. Complete information to perform this procedure is available in the Genie S-0 and Genie S- Operator's Manual on your machine. A- Perform Function Tests Completing the function tests is essential to safe machine operation. Function tests are designed to discover any malfunctions before the machine is put into service. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service. Complete information to perform this procedure is available in the Genie S-0 and Genie S- Operator's Manual on your machine. Part No. S-0 S- -

36 Section Scheduled Maintenance Procedures July 00 CHECKLIST A PROCEDURES REV C A- Perform Engine Maintenance - Deutz Models A- Perform Engine Maintenance - GM and Ford Models Engine specifications require that this procedure be performed daily or every 0 hours, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Deutz FL 0 Operation Manual (Deutz part number ). Deutz FL 0 Operation Manual Genie part number 9 To access the engine: Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Engine specifications require that this procedure be performed daily or every hours, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the GM.0L Operator Handbook (GM part number 0000) or the Ford LRG- EFI Operator Handbook (Ford part number FPP 9-0). GM.0L Operator Handbook Genie part number 009 Ford LRG EFI Operator Handbook Genie part number 9 To access the engine: Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. - S-0 S- Part No.

37 July 00 Section Scheduled Maintenance Procedures REV C CHECKLIST A PROCEDURES A- Perform Engine Maintenance - Perkins Models Engine specifications require that this procedure be performed daily or every hours, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Perkins 00 Series Operation Manual (Perkins part number TPD S). Perkins 00 Series Operation Manual Genie part number 990 To access the engine: Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. A- Check the High Pressure Hydraulic Filter Condition Indicator Maintaining the hydraulic return filter in good condition is essential to good system performance and safe machine operation. The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter. If the filter is not frequently checked and replaced, impurities will remain in the hydraulic system and cause component damage. Open the engine side turntable cover. Start the engine from the ground controls. Change the engine idle to high rpm (rabbit symbol). Visually inspect the filter condition indicator. Result: The filter condition indicator should be operating with the plunger in the green area. Result: If the indicator displays the plunger in the red area, this indicates that the hydraulic filter is being bypassed and the filter should be replaced. See D-, Replace the Hydraulic Filters. Part No. S-0 S- - 9

38 Section Scheduled Maintenance Procedures July 00 CHECKLIST A PROCEDURES REV C A- Test the Oscillate Axle (if equipped) A- Perform 0 Day Service Proper axle oscillation is essential to safe machine operation. If the axle oscillation system is not operating correctly, the stability of the machine is compromised and it may tip over. Start the engine from the platform controls. Drive the right steer tire up onto a inch / cm block or curb. Result: The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times. Drive the left steer tire up onto a inch / cm block or curb. Result: The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times. Drive both steer tires up onto a inch / cm block or curb. Result: The non-steer tires should stay in firm contact with the ground. If the chassis does not remain level during test, see Repair Procedure -, How to Set Up the Oscillate Directional Valve. The 0 day maintenance procedure is a one time sequence of procedures to be performed after the first 0 days or 0 hours of usage, whichever comes first. After this interval, refer to the maintenance tables for continued scheduled maintenance. Perform the following maintenance procedures: A-9 Perform Engine Maintenance - GM, Ford and Perkins Models A- Grease the Turntable Bearing and Rotate Gear B- Check the Lug Nut Torque (including tires and wheels) B- Check the Oil Level in the Drive Hubs C- Perform Engine Maintenance - Deutz Models D- Check the Turnable Rotation Bearing Bolts D- Replace the Hydraulic Filters - 0 S-0 S- Part No.

39 July 00 Section Scheduled Maintenance Procedures REV C CHECKLIST A PROCEDURES A-9 Perform Engine Maintenance - GM, Ford and Perkins Models A-0 Inspect the Fuel Filter/Water Separator - Diesel Models Engine specifications require that this procedure be performed every 00 hours. Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the GM.0L Operator Handbook (GM part number 0000) or the Ford LRG- EFI Operator Handbook (Ford part number FPP 9-0) or the Perkins 00 Series Operation Manual (Perkins part number TPD S). GM.0L Operator Handbook Genie part number 009 Ford LRG EFI Operator Handbook Genie part number 9 Perkins 00 Series Operation Manual Genie part number 990 Engine specifications require that this procedure be performed every 00 hours. Proper maintenance of the fuel filter/water separator is essential for good engine performance. Failure to perform this procedure can lead to poor engine performance and component damage. Perkins Models: Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Perform this procedure with the engine off. Put on protective clothing and eye wear. Open the engine side turntable cover and locate the fuel filter/water separator next to the hydraulic return filter on the bulkhead. Inspect the filter bowl for water buildup. Result: If water is present in the filter bowl continue with steps through. Part No. S-0 S- -