Service Manual: Technical Publications
Service Manual: Technical Publications
Service Manual: Technical Publications
Publications
S-60
S-65
Service
Manual
Introduction
Important
Genie Europe
Telephone (44) 01636-605030
Fax (44) 01636-611090
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-60 & Genie S-65
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.
iii
SAFETY RULES
Personal Safety
Workplace Safety
iv
Table of Contents
Introduction
Important Information ..................................................................................................... ii
Section One
Safety Rules
General Safety Rules .................................................................................................... iii
Section Two
Specifications
Machine Specifications ............................................................................................. 2 - 1
Performance Specifications ...................................................................................... 2 - 2
Hydraulic Specifications ........................................................................................... 2 - 3
Bolt Torque Specifications ........................................................................................ 2 - 4
Ford LRG 423 Engine Specifications ........................................................................ 2 - 5
Deutz F4L Engine Specifications .............................................................................. 2 - 7
Section Three
Section Four
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
TABLE OF CONTENTS
Section Four
B-2
B-3
Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ..................... 4 - 12
B-4
B-5
B-6
B-7
B-8
B-9
TABLE OF CONTENTS
Section Four
C-2
C-3
C-4
C-5
C-6
C-7
C-8
C-9
D-1
D-2
D-3
D-4
D-5
D-6
D-7
Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models .......... 4 - 44
D-8
D-9
vii
TABLE OF CONTENTS
Section Five
viii
Engine Cranks Over But Will Not Start - Gasoline/LPG Models ..................... 5 - 5
Engine Cranks Over But Will Not Start - Deutz Diesel Models ..................... 5 - 11
10
11
All Lift and Steer Functions Inoperative, Drive Functions Operational .......... 5 - 25
12
13
14
15
16
17
18
19
20
21
22
23
TABLE OF CONTENTS
Section Five
Section Six
25
26
27
28
29
30
31
All Drive Functions Inoperative, All Other Functions Operate Normally ........ 5 - 53
32
33
34
35
36
37
Schematics
Introduction ............................................................................................................... 6 - 1
Electrical Symbols Legend ....................................................................................... 6 - 2
Electrical Schematic - Gasoline/LPG Models ........................................................... 6 - 3
Ground Control Box Legend - Gasoline/LPG Models ............................................... 6 - 5
Relay Panel Legend - Gasoline/LPG Models ........................................................... 6 - 6
Platform Control Box Legend - Gasoline/LPG Models ............................................. 6 - 7
Electrical Schematic - Diesel Models ....................................................................... 6 - 8
Ground Control Box Legend - Diesel Models ......................................................... 6 - 10
Platform Control Box Legend - Diesel Models ........................................................ 6 - 11
Hydraulic Symbols Legend ..................................................................................... 6 - 12
2WD Hydraulic Schematic - Non-oscillating axle .................................................... 6 - 13
2WD Hydraulic Schematic - Oscillating axle ........................................................... 6 - 14
4WD Hydraulic Schematic - Non-oscillating axle .................................................... 6 - 15
4WD Hydraulic Schematic - Oscillating axle ........................................................... 6 - 16
ix
TABLE OF CONTENTS
Section Seven
Repair Procedures
Introduction ............................................................................................................... 7 - 1
Platform Controls
1-1
1-2
1-3
1-4
Resistors ......................................................................................................... 7 - 9
1-5
1-6
Platform Components
2-1
Platform ........................................................................................................ 7 - 11
2-2
2-3
3-2
3-3
Boom Components
4-1
4-2
Boom ............................................................................................................ 7 - 17
4-3
4-4
4-5
Turntable Covers
5-1
6-2
6-3
7-1
7-2
TABLE OF CONTENTS
Section Seven
7-4
7-5
7-6
7-7
7-8
Ground Controls
8-1
8-2
8-3
8-4
Resistor ........................................................................................................ 7 - 29
8-5
Hydraulic Pumps
9-1
9-2
Function Manifolds
10-1 Function Manifolds ........................................................................................ 7 - 34
10-2 Valve Adjustments - Function Manifold ......................................................... 7 - 36
Fuel and Hydraulic Tanks
11-1 Hydraulic Tank .............................................................................................. 7 - 39
11-2 Fuel Tank ...................................................................................................... 7 - 40
Turntable Rotation Components
12-1 Rotation Hydraulic Motor .............................................................................. 7 - 41
12-2 Turntable Rotation Manifold Components .................................................... 7 - 43
2WD Steering Axle Components
13-1 Yoke and Hub ............................................................................................... 7 - 44
13-2 Steering Cylinders ........................................................................................ 7 - 45
13-3 Tie Rod ......................................................................................................... 7 - 46
xi
TABLE OF CONTENTS
Section Seven
xii
Section 2 - Specifications
Specifications
Machine Specifications
Stowed dimensions
Platform dimensions
S-60
S-65
27 ft 2 in
8.3 m
30 ft 10 in
9.4 m
8 ft
2.43 m
8 ft
2.43 m
Height
9 ft
2.74 m
9 ft
2.74 m
Weight
26,060 lbs
11,821 kg
28,400 lbs
12,882 kg
12 in
30 cm
12 in
30 cm
Length
Width
Ground clearance
Operational dimensions
Maximum platform height
6 ft
8 ft
(Standard)
(Optional)
Length
6 ft
1.83 m
8 ft
2.44 m
Width
30 in
76.2 cm
36 in
91.4 cm
191/2 in
49.5 cm
121/4 in
31 cm
56 ft 4 in
17.2 m
Wheel width
3 ft 31/2 in
100 cm
3 ft 31/2 in
100 cm
Wheel lugs
9 ft 0 in
2.7 m
9 ft 0 in
2.7 m
12 ft 1 in
3.7 m
12 ft 1 in
3.7 m
continuous
continuous
160
160
Maximum capacity
6 foot platform
600 lbs
272 kg
500 lbs
227 kg
Maximum capacity
8 foot platform
500 lbs
227 kg
500 lbs
227 kg
40 in
102 cm
Wheel diameter
51 ft 3 in
15.6 m
Wheelbase
71 sq in
458 sq cm
85 psi
5.86 bar
65 ft
19.8 m
12
Tire pressure
60 ft
18.3 m
15-19.5 NHS
10 @ 3/4 -16
420 ft-lbs
569.5 Nm
320 ft-lbs
433.9 Nm
Fluid capacities
Fuel tank
30 gallons
114 liters
LPG tank
33.5 pounds
15.2 kg
Hydraulic tank
45 gallons
170 liters
Hydraulic system
(including tank)
55 gallons
208 liters
44 fl oz
1.30 liters
Turntable rotation
torque hub
17 fl oz
0.51 liters
2-1
Section 2 - Specifications
PERFORMANCE SPECIFICATIONS
Performance Specifications
Drive speeds, maximum
Drive speed, stowed
Gasoline/LPG models
Drive speed,
raised or extended
- all models
2WD
4WD
4.4 mph
3.0 mph
7.1 km/h
4.8 km/h
40 ft/6.2 sec 40 ft/9.1 sec
12.2 m/6.2 sec 12.2 m/9.1 sec
4.0 mph
2.8 mph
6.4 km/h
4.5 km/h
40 ft/6.8 sec 40 ft/9.7 sec
12.2 m/6.8 sec 12.2 m/9.7 sec
0.6 mph
0.6 mph
1.0 km/h
1.0 km/h
40 ft/40 sec 40 ft/40 sec
12.2 m/40 sec 12.2 m/40 sec
40 to 60 seconds
50 to 80 seconds
Boom up
55 to 85 seconds
Boom down
90 to 120 seconds
Boom extend
Boom retract
55 to 85 seconds
80 to 120 seconds
120 to 150 seconds
2WD
4WD
Rough terrain
28%
40%
10 to 20 seconds
Platform level up
35 to 65 seconds
25 to 55 seconds
2-2
Section 2 - Specifications
HYDRAULIC SPECIFICATIONS
Hydraulic Specifications
Hydraulic fluid
Dexron II equivalent
Function pump
Drive pump
Displacement - static
3500 psi
241.3 bar
340 psi
250 psi
24 bar
17 bar
3 micron
50 psi
3.4 bar
1.14 cu in
19 cc
0 to 12.3 gallons per minute
0 to 46.6 liters per minute
Function manifold
Function relief valve pressure
S60
S65
2600 psi
2900 psi
179 bar
200 bar
Boom down
relief valve pressure
2100 psi
145 bar
Boom extend
2100 psi
145 bar
Oscillate axle
950 psi
65 bar
Drive manifold
Brake
relief pressure
Steer end drive motors
Displacement
per revolution
250 psi
17.2 bar
4WD models
1.52 cu in
25 cc
Steer regulator
Auxiliary pump
0.16 to 2.8 cu in
2.62 to 45.9 cc
1.12 to 2.8 cu in
18.4 to 45.9 cc
0.152 cu in
2.5 cc
1.4 gallons per minute
5.3 liters per minute
3000 psi
207 bar
2-3
Section 2 - Specifications
Threads
No. 10
/4 inch
5/16
3 /8
7/16
1 /2
9/16
5 /8
3 /4
7 /8
inch
inch
inch
inch
inch
inch
inch
inch
1 inch
Torque - Dry
foot-pounds
Torque - Dry
inch-pounds
Torque - Dry
foot-pounds
Torque - Dry
Newton meters
24
43
60
32
49
68
20
96
11
144
16
28
120
14
168
19
18
17
23
25
34
24
19
28
25
34
16
30
41
45
61
24
35
48
50
68
14
50
68
70
95
20
55
75
80
109
13
75
102
110
149
20
90
122
120
163
12
110
149
150
204
18
120
163
170
231
11
150
204
220
298
18
170
231
240
326
10
260
353
380
515
16
300
407
420
570
430
583
600
814
14
470
637
660
895
640
868
900
1221
12
700
949
1000
1356
Torque specifications for lubricated bolts are 25% less than dry torque specifications for each bolt size.
These bolt torque specifications are for general use only. Specification may vary depending on application of bolt.
2-4
Section 2 - Specifications
140 cu in
2.3 liters
Number of cylinders
Bore & stroke
4
3.781 x 3.126 inches
96.04 x 79.4 mm
Horsepower
63 @ 4000 rpm
Firing order
1-3-4-2
900 rpm
1600 rpm
High idle
2500 rpm
Governor
electronic
Starter motor
Normal engine cranking speed
Current draw, normal load
170A
200A
140A
0.5V DC
0.66 in
16.8 mm
0.25 in
6.35 mm
9.4:1
Oil pressure
(operating temp. @ 2000 rpm)
40 to 60 psi
2.75 to 4.1 bar
45 to 84 inch-pounds
5.08 to 9.5 Nm
Brush mounting
bolt torque
15 to 20 foot-pounds
20 to 27 Nm
5 quarts
4.7 liters
Quantity
Cold cranking ampere
Temperature above
-10F / -23C
10W-40 to 10W-50
Temperature above
20F / -6.6C
20W-40 or 20W-50
0.005 inches
0.127 mm
Battery
Type
Oil capacity
(including filter)
64 ounces
18 Newtons
Bolt torque
through brush
Maximum commutator
run-out
Lubrication system
12V, Group 31
1
1000A
200 minutes
Fuel pump
Electronic solenoid
7 psi
0.48 bar
2-5
Section 2 - Specifications
Ignition System
Motorcraft AWSF-52C
Engine coolant
111/2 quarts
10.9 liters
Capacity
Alternator
Output
95A, 14.5V
torque
ft-lbs
torque
Nm
54 to 64
73 to 87
Intake manifold to
cylinder head bolt or nut (M-8)
15 to 22
20 to 30
11 to 24
20 to 34
10 to 13.5
14 to 18
21 to 26
28 to 35
torque
ft-lbs
torque
Nm
29 to 40
40 to 55
25 to 29
35 to 40
7 to 10
9 to 13
52 to 66
70 to 90
7 to 15
9 to 20
6 to 9
8 to 12
10 to 20
Temperature sending
unit to block (M-14)
8 to 18
11 to 24
Carburetor spacer to
manifold bolt (M-8)
10 to 14
14 to 19
16 to 24
92 to 122
125 to 165
20 to 30
15 to 22
20 to 30
10 to 12
13 to 16
15 to 22
20 to 30
6 to 9
8 to 12
Crankshaft damper
bolt (M-14)
2-6
Section 2 - Specifications
166.7 cu in
2.732 liters
Number of cylinders
Bore and stroke
4
3.58 x 4.13 inches
91 x 105 mm
Horsepower
56 @ 3000 rpm
Firing order
1-3-4-2
Compression ratio
Compression pressure
18.5:1
362 to 435 psi
25 to 30 bar
Low idle
1300 rpm
High idle
2300 rpm
Governor
centrifugal mechanical
4351 psi
300 bar
3626 psi
250 bar
Fuel requirement
Alternator output
55A, 14V
Starter motor
Current draw, no load
90A
0.7480 in
19 mm
0.5 in
12.7 mm
Battery
Type
12V, Group 31
Quantity
Intake
0.012 in
0.3 mm
Exhaust
0.020 in
0.5 mm
1000A
200 minutes
3/8
to 1/2 inch
9 to 12 mm
Lubrication system
Oil pressure
26 to 87 psi
1.8 to 6.0 bar
Oil capacity
(including filter)
11 quarts
10.5 liters
5W-30
torque
ft-lbs
torque
Nm
15 to 18
20 to 24
15 to 18
20 to 24
15 to 18
20 to 24
6 to 7
8 to 10
10W-40
15W-40
33 to 41
45 to 55
15 to 18
20 to 24
Injection system
28 to 34
38 to 46
OMAP
2-7
Section 2 - Specifications
27 to 32
30 to 36
15 to 18
7 to 8
torque
Nm
36 to 44
41 to 49
20 to 24
9 to 11
20 to 24
torque
ft-lbs
torque
Nm
37 to 44
50 to 60
5.5 to 7
7.5 to 9
5.5 to 7
7.5 to 9
14 to 16
19 to 22
14 to 16
19 to 22
15 to 18
15 to 18
20 to 24
15
20
15 to 18
20 to 24
95 to 105
30 to 37
40 to 50
15 to 18
20 to 24
Injection line
10 to 12
13.5 to 16.5
first step
tightening
torque
second step
tightening
angles
15 to 18
20 to 24
20 to 24
27 to 32
36 to 44
28 to 34
38 to 46
50 to 60
68 to 82
15 to 18
20 to 24
37 to 44
50 to 60
2-8
ft-lbs
Nm
1st
2nd
37
50
60
45
22
30
60
60
Flywheel bolts
22
30
60
30
22
59
118
30
80
160
120
NA
Camshaft/central bolt
22
30
150
NA
Crankshaft/central bolt
96
130
210
NA
Cylinder head
studs
step 1
step 2
step 3
New parts
required
The Schedule
Cold
engine
required
engine
required
Dealer
service
suggested
Table or Checklist
Daily
Quarterly
Annual
Two year
A+B
A+B+C
A+B+C+D
Maintenance Tables
3-1
Maintenance Tables
Table A
Tools are
required
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
3-2
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
MAINTENANCE TABLES
Table A, continued
Tools are
required
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
A-16
Table B
B-1
B-2
B-3
Check the Oil Cooler and Cooling Fins Deutz Diesel Models
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-11
B-12
3-3
MAINTENANCE TABLES
Table B, continued
Tools are
required
B-13
B-14
B-15
B-16
B-17
B-18
B-19
B-20
B-21
B-22
B-23
B-24
B-25
B-26
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
3-4
MAINTENANCE TABLES
Table C
Tools are
required
C-1
C-2
C-3
C-4
C-5
C-6
C-7
C-8
C-9
C-10
C-11
C-12
C-13
C-14
C-15
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
3-5
MAINTENANCE TABLES
Table D
Tools are
required
D-1
D-2
D-3
D-4
D-5
D-6
D-7
Check the Fuel Injection Pumps and Injectors Deutz Diesel Models
D-8
D-9
3-6
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
Checklist A
Serial number
Refer to Table A
Y N R
Tools are
required
New parts
required
B-19 Foot
Warmswitch
Cold
required
A-1 Manuals
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Checklist C
Refer to Table C
Inspector company
Instructions
Make copies of this page to use for
each inspection.
Select the appropriate checklist(s) for
the type of inspection to be performed.
Daily Inspection: A
Checklist B
Y N R
Dealer
service
suggested
Y N R
Refer to Table B
B-1 Engine belt(s)
B-2 Engine radiator
B-3 Oil cooler and fins-Deutz
B-4 Exhaust system
B-5 Battery
B-6 Hydraulic tank filter
Checklist D
Refer to Table D
D-4 Valves-gasoline
D-5 Compression-gasoline
Y N R
3-7
Tools are
required
New parts
required
Warm
engine
required
Cold
engine
required
Dealer
service
suggested
3-8
Symbols Legend
4-1
Table A Procedures
2 Inspect all decals for legibility and damage.
Replace any damaged or illegible decal
immediately.
A-1
Inspect the Manuals
Maintaining the operators and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
1 Check to be sure that the storage container is
present and in good condition.
2 Check to make sure that the operator's,
responsibilities and safety manual are present
and complete in the storage container in the
platform.
3 Examine the pages of each manual to be sure
that they are legible and in good condition.
4 Always return the manuals to the storage
container after use.
Contact your authorized Genie
distributor or Genie Industries if
replacement manuals are needed.
A-3
Inspect for Damage, Loose or
Missing Parts
Daily machine condition inspections are essential
to safe machine operation and good machine
performance. Failure to locate and repair damage,
and discover loose or missing parts may result in
an unsafe operating condition.
1 Inspect the entire machine for damage and
improperly installed or missing parts including:
electrical components, wiring and electrical
cables
hydraulic hoses, fittings, cylinders and
manifolds
fuel and hydraulic tanks
drive and turntable rotation motors and
torque hubs
A-2
Inspect the
Decals and Placards
axle components
boom components and wear pads
TABLE
A-4
Check the Engine Oil Level
Maintaining the proper engine oil level is essential
to good engine performance and service life.
Operating the machine with an improper oil level
can damage engine components.
Check the oil level with the
engine off.
PROCEDURES
A-5
Check the Engine Coolant Level
- Gasoline/LPG Models
Maintaining the engine coolant at the proper level
is essential to engine service life. Improper coolant
level will affect the engine's cooling capability and
damage engine components. Daily checks will
allow the inspector to identify changes in coolant
level that might indicate cooling system problems.
5 quarts
4.7 liters
5W-30
10W-30
10W-40 or 10W-50
20W-40 or 20W-50
A-6
Check for Fuel Leaks
Failure to detect and correct fuel leaks will result in
an unsafe condition. An explosion or fuel fire may
cause death or serious injury.
Engine fuels are combustible.
Inspect the machine in an open,
well-ventilated area away from
heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.
11 quarts
10.5 liters
5W-30
10W-40
15W-40
4-3
TABLE
PROCEDURES
A-8
Check for Hydraulic Leaks
Detecting hydraulic fluid leaks is essential to
operational safety and good machine
performance. Undiscovered leaks can develop into
hazardous situations, impair machine functions
and damage machine components.
1 Inspect for hydraulic oil puddles, dripping or
residue on or around the following areas:
hydraulic tankfilter, fittings, hoses, auxiliary
power unit and turntable surface
engine compartmentfittings, hoses,
pumps, filter and turntable surface
all hydraulic cylinders
all hydraulic manifolds
boom(s)
the underside of the turntable
A-7
Check the Hydraulic Oil Level
Dexron II equivalent
Tank capacity
45 gallons
170 liters
Hydraulic system
(including tank)
55 gallons
208 liters
4-4
TABLE
A-9
Check the Tire Pressure
This procedure does not need
to be performed on machines
equipped with the foam-filled
tire option.
An over-inflated tire can explode
and may cause death or serious
injury.
To safeguard maximum stability, achieve
optimum machine handling and minimize tire
wear, it is essential to maintain proper pressure
in all air-filled tires.
1 Check each tire with an air pressure gauge and
add air as needed.
Tire specifications
Tire size
15-19.5 NHS
Pressure
85 psi
5.86 bar
PROCEDURES
A-10
Test the Oscillate Axle
(oscillating axle-equipped
models)
Proper axle oscillation is essential to safe machine
operation. If the axle oscillation system is not
operating correctly, the stability of the machine is
compromised and it may tip over.
1 Start the engine from the platform controls.
2 Drive the right steer tire up onto a 6 inch
(15.2 cm) block or curb.
Result: The three remaining tires should stay in
firm contact with the ground.
3 Drive the left steer tire up onto a 6 inch
(15.2 cm) block or curb.
Result: The three remaining tires should stay in
firm contact with the ground.
4 Drive both steer tires up onto a 6 inch
(15.2 cm) block or curb.
Result: The non-steer tires should stay in firm
contact with the ground.
4-5
TABLE
PROCEDURES
A-11
Test the Platform and
Ground Controls
A-12
Test the Auxiliary Power
Operation
4-6
TABLE
b
a
b
c
PROCEDURES
A-13
Test the Tilt Sensor
fuel tank
tilt sensor
ground control box
4-7
TABLE
PROCEDURES
A-14
Test the Limit Switches
Drive Limit Switches
missing fasteners
loose wiring
4-8
c
drive limit switch
boom
extension cylinder
master cylinder
TABLE
PROCEDURES
missing fasteners
loose wiring
a
b
c
turntable
drive enable limit switch
turntable rotation bearing
4-9
TABLE
PROCEDURES
A-15
Replace the Engine Oil and
Filter - Gasoline/LPG Models
b
a
b
c
4 - 10
TABLE
5 quarts
4.7 liters
PROCEDURES
A-16
Replace the Engine Air Filter
5W-30
10W-30
10W-40 or 10W-50
20W-40 or 20W-50
27916
27916
4 - 11
Table B Procedures
B-1
Check the Engine Belt(s)
Maintaining the engine belt(s) is essential to good
engine performance and service life. The machine
will not operate properly with a loose or defective
belt and continued use may cause component
damage.
Do not inspect while the engine
is running. Remove the key to
secure from operation.
Beware of hot engine
components. Contact with hot
engine components may cause
severe burns.
B-2
Check the Radiator
- Gasoline/LPG Models
Maintaining the radiator in good condition is
essential for good engine performance. Operating
a machine with a damaged or leaking radiator may
result in engine damage. Also, restricting air flow
through the radiator (i.e., dirt or debris) will affect
the performance of the cooling system. A frequent
check allows the inspector to identify changes in
the condition of the radiator that might indicate
cooling system problems.
Do not inspect while the engine
is running. Remove the key to
secure from operation.
separation
breaks
3 Check the engine belt(s) for proper tension.
B-3
Check the Oil Cooler and Cooling
Fins - Deutz Diesel Models
4 - 12
3/8
TABLE B
Oil Cooler
1 Remove the cover from the side of the engine,
then remove the oil cooler top cover.
2 Inspect the oil cooler for leaks and physical
damage.
a
PROCEDURES
B-4
Check the Exhaust System
Maintaining the exhaust system is essential to
good engine performance and service life.
Running the engine with a damaged or leaking
exhaust system can cause component damage
and unsafe operating conditions.
Do not inspect while the engine
is running. Remove the key to
secure from operation.
Beware of hot engine
components. Contact with hot
engine components may cause
severe burns.
a
b
c
oil cooler
cylinder head cooling fins
blower fins
b
a
b
4 - 13
TABLE B
PROCEDURES
B-5
Check the Battery
Proper battery condition is essential to good
engine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component
damage and hazardous conditions.
Batteries contain acid. Avoid
spilling or contacting battery acid.
Neutralize battery acid spills with
baking soda and water.
B-6
Check the Hydraulic Tank Filter
Condition Indicator
Maintaining the hydraulic tank filter in good
condition is essential to good system performance
and safe machine operation. The filter condition
indicator will show when the hydraulic flow is
bypassing a clogged filter. If the filter is not
frequently checked and replaced, impurities
will remain in the hydraulic system and cause
component damage.
1 Start the engine from the platform controls.
2 Move the engine speed control switch to high
idle (rabbit symbol).
3 Inspect the filter condition indicator.
b
c
a
b
c
4 - 14
TABLE B
B-7
Inspect the Electrical Wiring
Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.
Electrocution hazard. Contact with
hot or live circuits may result in
death or serious injury. Remove
all rings, watches and other
jewelry.
1 Inspect the following areas for burnt, chafed,
corroded and loose wires:
PROCEDURES
B-8
Inspect the Tires and Wheels
(including lug nut torque)
Maintaining the tires and wheels in good
condition is essential to safe operation and good
performance. Tire and/or wheel failure could result
in a machine tip-over. Component damage may
also result if problems are not discovered and
repaired in a timely fashion.
An over-inflated tire can
explode and may cause death
or serious injury.
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
15-19.5 NHS
12
Tire pressure
85 psi
5.86 bar
Wheel lugs
10 @ 3/4 -16
420 ft-lbs
569.5 Nm
320 ft-lbs
433.9 Nm
4 - 15
TABLE B
PROCEDURES
B-9
Confirm the Proper
Brake Configuration
B-10
Check the Oil Level
in the Torque Hubs
drive pump
free-wheel valve
screwdriver
lift pump
Capacity
44 fl oz
1.30 liters
4 - 16
TABLE B
B-11
Check and Adjust the Engine Idle
Mixture - Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LRG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: PPD-194287). Genie part number 33907.
a
b
a
b
B-12
Check and Adjust the
Engine RPM
Maintaining the engine rpm at the proper setting
for both low and high idle is essential to good
engine performance and service life. The machine
will not operate properly if the rpm is incorrect and
continued use may cause component damage.
torque hub
plug
Gasoline/LPG Models
Perform this procedure in gasoline
mode with the engine at normal
operating temperature.
PROCEDURES
17 fluid ounces
0.51 liters
4 - 17
TABLE B
PROCEDURES
a
a
900 rpm
1600 rpm
High idle
2500 rpm
4 - 18
TABLE B
f
e
b
a
b
c
d
e
f
PROCEDURES
B-13
Test the Key Switch
Proper key switch action and response is essential
to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could cause
a hazardous operating situation.
1 Pull out the Emergency Stop button to the
position at both the ground and platform
controls.
ON
solenoid boot
high idle adjustment nut
lock nut
yoke
low idle adjustment screw
lock nut
1300 rpm
High idle
2300 rpm
4 - 19
TABLE B
PROCEDURES
B-14
Test the Emergency Stop Buttons
B-15
Test the Ground Control Override
4 - 20
TABLE B
B-16
Check the Directional Valve
Linkage
Proper axle oscillation is essential to safe machine
operation. If the directional valve linkage is not
operating correctly, the stability of the machine is
compromised and it may tip over.
1 Remove the drive chassis cover from the
non-steer end.
2 Inspect the linkage for the following:
PROCEDURES
B-17
Test the Platform Self-leveling
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is
essential for safe machine operation. The
platform is maintained at level by the platform
leveling slave cylinder which is controlled by the
master cylinder located at the base of the boom.
A platform self-leveling failure creates an unsafe
working condition for platform and
ground personnel.
1 Start the engine from the ground controls and
lower the boom into the stowed position.
B-18
Test the Service Horn
b
c
d
a
b
c
d
directional valve
clevis pin with cotter pin (hidden)
yoke
lock nut
4 - 21
TABLE B
PROCEDURES
B-19
Test the Foot Switch
A properly functioning foot switch is essential to
safe machine operation. Machine functions should
activate and operate smoothly as long as the foot
switch is pressed down, and promptly stop when
the foot switch is released. The foot switch will
also shift the engine into high idle if the idle select
is switched to the rabbit and foot switch symbol.
An improperly functioning foot switch can cause
an unsafe working condition and endanger
platform and ground personnel.
The engine should not start if the
foot switch is pressed down.
B-20
Test the Engine Idle Select
Gasoline/LPG models
Low idle
1600 rpm
High idle
2500 rpm
4 - 22
1300 rpm
High idle
2300 rpm
TABLE B
B-21
Test the Fuel Select Operation
- Gasoline/LPG Models
The ability to select and switch between
gasoline and LPG fuels as needed is essential to
safe machine operation. A fuel selection can be
made when the engine is running or not.
Switching malfunctions and/or the failure of the
engine to start and run properly in both fuel
modes and through all idle speeds can indicate
fuel system problems that could develop into a
hazardous situation.
Perform this test after checking
the gasoline and LPG fuel levels,
and warming the engine to normal
operating temperature.
1 Move the fuel select switch to gasoline and
then move the engine idle control switch to foot
switch activated high idle (rabbit and foot
switch symbol).
2 Start the engine from the platform controls and
allow it to run at low idle.
3 Press down the foot switch to allow the engine
to run at high idle.
PROCEDURES
B-22
Test the Drive Enable System
Proper drive enable system operation is
essential to safe machine operation. When the
boom is past the non-steering wheels, drive
movement is stopped and the indicator light turns
on. The drive enable switch must be used
to reactivate the drive function and should inform
the operator that the machine will move in the
opposite direction that the drive and steer controls
are moved. An improperly functioning drive enable
system may allow the machine to be moved into
an unsafe position.
1 Start the engine from the platform controls.
2 Rotate the turntable to the right until the boom
is past the right non-steering wheel.
Result: The drive enable indicator light should
turn on.
3 Slowly move the drive control handle off center.
Result: The drive function should not operate.
4 Hold the drive enable toggle switch to either
side and slowly move the drive control handle
off center.
4 - 23
TABLE B
PROCEDURES
B-23
Test the Drive Brakes
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydrostatic brakes and hydraulicallyreleased individual wheel brakes can appear to
operate normally when they are actually not fully
operational.
Be sure that the machine is not in
free-wheel or partial free-wheel
configuration. Refer to B-9 in this
section, Confirm the Proper Brake
Configuration.
B-24
Test the Drive Speed
- Stowed Position
Proper drive function movement is essential to
safe machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
Select a test area that is firm,
level and free of obstructions.
1 Create start and finish lines by marking two
lines on the ground 40 feet (12.2 m) apart.
2 Start the engine from the platform controls.
Drive speed:
stowed position
Braking:
paved surface
Gasoline/LPG models
Stopping distance
2WD
4WD
3 to 5 ft
0.91 to 1.5 m
5 to 7 ft
1.5 to 2.1 m
2WD
4WD
TABLE B
PROCEDURES
B-25
Test the Alarm Package
- Optional Equipment
travel alarm
descent alarm
flashing beacon
Alarms and a beacon are installed to alert
operators and ground personnel of machine
proximity and motion. The alarm package is
installed on the turntable covers.
The alarms and beacon will
operate with the engine
running or not running.
1 At the ground controls, pull out the Emergency
Stop button to the ON position and turn the key
switch to ground control.
B-26
Perform Hydraulic Oil Analysis
See D-1, Test or Replace the Hydraulic Oil.
4 - 25
TABLE B
PROCEDURES
B-27
Replace the Engine Oil and
Filter - Deutz Diesel Models
Engine specifications require
that this procedure be performed
every 500 hours. Perform this
procedure more often if dusty
conditions exist.
Periodic replacement of the engine oil and
filter is essential to good engine performance.
Operating the machine with an improper oil level
or neglecting periodic oil and filter changes can
damage engine components. A frequent check
of elapsed machine hours against the hours
noted on the oil filter will allow the inspector to
anticipate and perform oil and filter changes at
the 500 hour interval.
a
b
c
11 quarts
10.5 liters
5W-30
10W-40
15W-40
4 - 26
Table C Procedures
C-1
Check the Boom
Wear Pads
C-2
Check the Turntable Rotation
Bearing Bolts
9
7
20
24
28
9
13
16
12
8
17
21
25
4
30
29
26
3
7
11
15
22
18
14
/16 inch
/16 inch
14.27 mm
11 mm
10
27 23
19
4 - 27
TABLE C
PROCEDURES
15
7
13
6
engage position
12
18
17
11
14
8
16
C-3
Check the Free-wheel
Configuration
4 - 28
engage position
TABLE C PROCEDURES
C-4
Grease the Turntable Rotation
Bearing and Rotate Gear
Yearly application of lubrication to the turntable
bearing and rotate gear is essential to good
machine performance and service life. Continued
use of an improperly greased bearing and gear will
result in component damage.
1 Locate the grease fitting on the platform end of
the tank side bulkhead.
2 Pump grease into the turntable rotation
bearing. Rotate the turntable in increments
of 4 to 5 inches (10 to 13 cm) at a time and
repeat this step until the entire bearing has
been greased.
3 Apply grease to each tooth of the drive gear,
located under the turntable.
Oil type
a
b
c
d
drive pump
free-wheel valve
screwdriver
lift pump
Multipurpose grease
C-5
Replace the Torque Hub Oil
4 - 29
TABLE C
PROCEDURES
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Apply pipe thread sealant to the plugs, and
then install the plugs.
5 Repeat steps 1 through 4 for all the other drive
torque hubs.
unlocked
locked
44 fl oz
44 fl oz
1.30 liters
1.30 liters
f
c
d
e
a
b
c
d
e
f
TABLE C PROCEDURES
17 fluid ounces
0.51 liters
C-7
Replace the Drive Loop
Hydraulic Filter
Replacing the drive loop hydraulic filter is essential
to good machine performance and service life. A
dirty or clogged filter may cause the machine to
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may require that the filter be replaced more often.
Beware of hot oil. Contact with
hot oil may cause severe burns.
C-6
Replace the Hydraulic Tank Filter
Replacement of the hydraulic tank filter is
essential for good machine performance and
service life. A dirty or clogged filter may cause the
machine to perform poorly and continued use may
cause component damage. Extremely dirty
conditions may require that the filter be replaced
more often.
Beware of hot oil. Contact with
hot oil may cause severe burns.
Perform this procedure with the
engine off.
1 Remove the filter with an oil filter wrench.
2 Apply a thin layer of oil to the new oil filter
gasket.
4 - 31
TABLE C
PROCEDURES
C-8
Replace the Diesel Fuel
Filter - Deutz Diesel Models
Replacing the diesel fuel filter is essential to good
engine performance and service life. A dirty or
clogged filter may cause the engine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filter be replaced more often.
C-9
Replace the Gasoline Fuel
Filter - Gasoline/LPG Models
Replacing the gasoline fuel filter is essential to
good engine performance and service life. A dirty
or clogged filter may cause the engine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filter be replaced more often.
a
b
a
b
4 - 32
fuel filter
oil filter
TABLE C PROCEDURES
a
b
fuel filter
hose from the fuel pump to
the fuel filter
4 - 33
TABLE C
PROCEDURES
C-10
Replace the PCV Valve
- Gasoline/LPG Models
Yearly replacement of the PCV valve is essential
to good engine performance. A malfunctioning
valve can impair crankcase ventilation and may
cause engine damage.
Perform this procedure with the
engine off.
1 Remove the 2 bolts from under the engine pivot
plate. Swing the engine pivot plate away from
the machine to access the PCV valve.
a
a
PCV valve
a
b
4 - 34
TABLE C PROCEDURES
C-11
Replace the Spark Plugs
- Gasoline/LPG Models
Periodic replacement of the spark plugs is
essential to good engine performance and
service life. Worn, loose or corroded spark plugs
will cause the engine to perform poorly and may
result in component damage.
Perform this procedure with the
engine off.
1 Label, then disconnect the plug wires from the
spark plugs by grasping the molded boot. Do
not pull on the plug wire.
2 Blow out any debris around spark plugs.
3 Remove all the spark plugs from the engine.
4 Adjust the gap on each new spark plug.
5 Install the new spark plugs, then connect the
wires. Be sure that each spark plug wire is
attached to the correct spark plug.
Spark plug specifications
Spark plug type
Motorcraft AWSF-52C
5 to 10 foot-pounds
7 to 14 Nm
4 - 35
TABLE C
PROCEDURES
C-12
Check and Adjust the Air/LPG
Mixture - Gasoline/LPG Models
Maintaining the proper air-to-fuel mixture during
LPG operation is essential to good engine
performance.
Engine fuels are combustible.
Perform this procedure in an
open, well-ventilated area away
from heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.
The engine rpm needs to be
preset for gasoline fuel operation
before adjusting the LPG idle
mixture. Refer to B-12, Check and
Adjust the Engine RPM.
a
a
4 - 36
TABLE C PROCEDURES
C-13
Check and Adjust the Ignition
Timing - Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LRG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: PPD-194287). Genie part number 33907.
C-14
Check the Engine Valve
Clearances - Deutz Diesel Models
Complete information to perform this procedure
is available in the Deutz FL 1011 Workshop
Manual (Deutz Number 02611642). Genie part
number 29789.
C-15
Check the Turntable Rotation Gear
Backlash
The turntable rotation torque hub is mounted on
an adjustable plate that controls the gap between
the rotation motor gear and the turntable bearing.
Maintaining proper backlash of the turntable
bearing is essential to safe machine operation.
Improper backlash could result in an unsafe
operating condition and component damage.
See 12-1, How to Adjust the
Turntable Rotation Gear
Backlash.
4 - 37
Table D Procedures
D-1
Test or Replace the Hydraulic Oil
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and
continued use may cause component damage.
Extremely dirty conditions may require oil changes
to be performed more often.
The machine uses Dexron II
equivalent hydraulic oil. Before
replacing the hydraulic oil, the oil
may be tested by an oil distributor
for specific levels of contamination
to verify that changing the oil is
necessary. If the hydraulic oil
is not replaced at the two year
inspection, quarterly testing
(B-26) thereafter should be
completed.
Perform this procedure with the
boom in the stowed position.
1 Close the two hydraulic shutoff valves located
at the hydraulic tank.
open
closed
4 - 38
TABLE D PROCEDURES
D-2
Change or Recondition the
Engine Coolant
- Gasoline/LPG Models
Replacing or reconditioning the engine coolant is
essential to good engine performance and service
life. Old or dirty coolant may cause the engine to
perform poorly and continued use may cause
engine damage. Extremely dirty conditions may
require coolant to be changed more frequently.
Beware of hot engine parts and
coolant. Contact with hot engine
parts and/or coolant will cause
severe burns.
All models:
45 gallons
170 liters
Hydraulic system
capacity (including tank)
55 gallons
208 liters
Hydraulic fluid
Dexron ll equivalent
4 - 39
TABLE D
PROCEDURES
a
a
b
a
b
upper hose
lower hose
4 - 40
11.5 quarts
10.9 liters
TABLE D PROCEDURES
D-3
Change the Fuel Lines
4 - 41
TABLE D
PROCEDURES
D-4
Check the Engine Valve
Clearance - Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LRG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: PPD-194287). Genie part number 33907.
D-5
Check the Engine Cylinder
Compression
- Gasoline/LPG Models
d
a
b
c
d
carburetor
fuel filter
hose from the fuel filter to
the fuel pump
hose from the fuel pump
to the fuel tank (not shown)
4 - 42
TABLE D PROCEDURES
D-6
Clean the PCV Hoses and
Fittings - Gasoline/LPG Models
a
b
c
a
b
4 - 43
TABLE D
PROCEDURES
D-7
Check the Fuel Injection Pumps
and Injectors - Deutz Diesel
Models
Complete information to perform this procedure is
available in the Deutz FL 1011 Workshop Manual
(Deutz number: 0291 1942). Genie part number
29789.
D-8
Check the Toothed Belt
- Deutz Diesel Models
Complete information to perform this procedure is
available in the Deutz FL 1011 Operation Manual
(Deutz number: 0297 4706 EN). Genie part
number 29790.
D-9
Replace the Timing Belt
- Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LRG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: PPD-194287). Genie part number 33907.
4 - 44
5-1
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
problem
solved
Inspect
and test
Perform
repair
5-2
Chart 1
Engine Will Not
Crank Over
Be sure the key switch
is in the appropriate
position.
Be sure the emergency
stop buttons are pulled
up into the on position.
Be sure the circuit
breaker(s) are not
tripped.
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5-4
Chart 2
Engine Cranks
Over But Will
Not Start Gasoline/LPG
Models
Be sure to check the
engine oil level and fill
as needed.
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Chart 2A
Engine Cranks
Over But Will
Not Start Gasoline/LPG
Models
or
Engine Runs
While Cranking
Then Dies
Continuation of good
spark fault path.
Perform these tests in
gasoline mode only.
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5-7
CHART 2A
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INKIQ \URZGMK GZ
ZKXSOTGR :(
<
<
=OZN QK_Y]OZIN UT GTJ
HUZN S[YNXUUS
Y]OZINKY V[RRKJ U[Z
INKIQ \URZGMK GZ HR[]NZ
]OXK GZ ZKXSOTGR UT
)8
<
<
<
=OZN QK_Y]OZIN UT GTJ
HUZN S[YNXUUS
Y]OZINKY V[RRKJ U[Z
IXGTQ KTMOTK GTJ INKIQ
\URZGMK GZ ZKXSOTGR
UT )8
TU MUUJ
MUUJ
8KVRGIK )8
<
)UTZOT[KJ UT ZNK TK^Z
VGMK
5-8
CHART 2A
<
<
TU
<
.URJ YZGXZ Y]OZIN GTJ
INKIQ \URZGMK GZ HR[]NZ
]OXK UT MGYUROTK
YURKTUOJ GZ MGYUROTK
ZGTQ
<
.URJ YZGXZ Y]OZIN JUKY
KTMOTK LOXK%
_KY
-U ZU INGXZ (
VGMK
5-9
Chart 2B
Engine Runs
While Cranking
Then Dies
<
<
ZU <
8KVGOX UVKT OT UXMHRQ
]OXK IOXI[OZ LXUS
GRZKXTGZUX ZU :( ZU
ZKXSOTGR UT YZGXZ
RUIQU[Z SUJ[RK
ZU <
_KY
_KY
<
TU
8KVGOX YNUXZ ZU MXU[TJ
OT ]NZ ]OXK LXUS
YKTJKX ZU :( ZU YZGXZ
RUIQU[Z SUJ[RK ZKXSOTGR
TU
)NKIQ \URZGMK GZ
ZKXSOTGR UT YZGXZ
RUIQU[Z SUJ[RK
<
<
5 - 10
Chart 3
Engine Cranks
Over But Will
Not Start Deutz Diesel
Models
Be sure to check the
engine oil level and fill
as needed.
RKYY
ZNGT
<
NUZ
TUZ NUZ
Be sure to check
fuel level.
TU IUTZOT[OZ_
TU IUTZOT[OZ_
TU IUTZOT[OZ_
8KVGOX YNUXZ OT ]NZ ]OXK
IOXI[OZ LXUS YZGXZ RUIQ
U[Z SUJ[RK ZU :( 58
IUTY[RZ -KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
*OYGHRK YZGXZKX H_
XKSU\OTM HRQ ]OXK GZ ZNK
YZGXZKX YURKTUOJ NURJ
YZGXZ Y]OZIN GTJ INKIQ
\URZGMK GZ VUYOZO\K
ZKXSOTGR UT L[KR
YURKTUOJ
<
)UTZOT[KJ UT ZNK TK^Z
VGMK
<
UX
OTLOTOZK
UNSY
UNSY
9KK *K[Z` YKX\OIK
SGT[GR LUX
ZXU[HRKYNUUZOTM L[KR
Y_YZKS
5 - 11
CHART 3
<
<
)NKIQ \URZGMK GZ XKJ
]OXK UT ZKXSOTGR UL
)8
<
<
.URJ YZGXZ Y]OZIN GTJ
INKIQ \URZGMK GZ
ZKXSOTGR UL )8
<
<
<
)NKIQ \URZGMK GZ
ZKXSOTGR GTJ UT
YZGXZ RUIQU[Z SUJ[RK
<
HGJ
<
)NKIQ MXU[TJ ]OXK
ZKXSOTGR UT YZGXZ
RUIQU[Z SUJ[RK
<
MUUJ
)NKIQ GSV L[YK UT
OMTOZOUT SUJ[RK 58
XKVRGIK ZNK YZGXZ RUIQU[Z
SUJ[RK 58 IUTY[RZ
-KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
)NKIQ MXU[TJ ZU
ZKXSOTGR UT )8
TU MUUJ
MUUJ
)UTZOT[KJ UT ZNK TK^Z
VGMK
5 - 12
CHART 3
<
<
8KVGOX UX XKVRGIK
GRZKXTGZUX 58 IUTZGIZ
-KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
ZU <
8KVGOX UVKT OT UXMHRQ
]OXK IOXI[OZ LXUS
GRZKXTGZUX ZU :( ZU
ZKXSOTGR UT YZGXZ
RUIQU[Z SUJ[RK
ZU <
_KY
_KY
TU
8KVGOX YNUXZ ZU MXU[TJ
]NZ ]OXK LXUS
YKTJKX ZU :( ZU YZGXZ
ZKXSOTGR UT RUIQU[Z
SUJ[RK
TU
)NKIQ \URZGMK GZ
ZKXSOTGR UT YZGXZ
RUIQU[Z SUJ[RK
<
<
<
<
5 - 13
Chart 4
Engine Will Not
Start On LPG,
But Will Start
On Gasoline Gasoline/LPG
Models
Be sure fuel select
switch is switched
to LPG.
Be sure to check
LPG fuel level.
<
<
=OZN QK_Y]OZIN UT GTJ
HUZN S[YNXUUS
Y]OZINKY V[RRKJ U[Z
INKIQ \URZGMK GZ :(
<
<
=OZN QK_Y]OZIN UT GTJ
HUZN S[YNXUUS
Y]OZINKY V[RRKJ U[Z
INKIQ \URZGMK GZ
ZKXSOTGR UT )8
<
<
HGJ
<
)XGTQ KTMOTK LUX
YKIUTJY GTJ INKIQ
\URZGMK GZ ZKXSOTGR
UT )8
<
)NKIQ MXU[TJ ]OXK ZU
ZKXSOTGR UT )8
MUUJ
)UTZOT[KJ UT ZNK TK^Z
VGMK
5 - 14
CHART 4
<
<
.URJ YZGXZ Y]OZIN GTJ
INKIQ \URZGMK GZ HR[XKJ
]OXK UT 26- YURKTUOJ
<
)NKIQ XKYOYZGTIK UL
26- YURKTUOJ
<
UX
OTLOTOZK
UNSY
ZU UNSY
8KIUTTKIZ 26- ZGTQ
GTJ YZGXZKX ZNKT YKK
3GOTZKTGTIK YKIZOUT LUX
26- GJP[YZSKTZY 58
IUTY[RZ -KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
5 - 15
Chart 5
Engine Will
Not Start On
Gasoline,
But Will Start
On LPG Gasoline/LPG
Models
Be sure fuel select
switch is switched
to gasoline.
Be sure to check
gasoline fuel level.
Be sure that engine
choke is operating
properly.
<
<
<
<
HGJ
<
=OZN QK_Y]OZIN UT GTJ
HUZN S[YNXUUS
Y]OZINKY V[RRKJ U[Z
INKIQ \URZGMK GZ :(
<
=OZN QK_Y]OZIN UT GTJ
HUZN S[YNXUUS
Y]OZINKY V[RRKJ U[Z
INKIQ \URZGMK GZ
ZKXSOTGR UT )8
<
)XGTQ KTMOTK LUX
YKIUTJY GTJ INKIQ
\URZGMK GZ ZKXSOTGR
UT )8 ]NORK IXGTQOTM
<
)NKIQ MXU[TJ ]OXK ZU
ZKXSOTGR UT )8
MUUJ
.URJ YZGXZ Y]OZIN GTJ
INKIQ \URZGMK GZ HR[]NZ
]OXK UT GTZOJOKYKR \GR\K
UT IGXH[XKZUX
<
<
)UTZOT[KJ UT ZNK TK^Z
VGMK
5 - 16
CHART 5
<
UX
OTLOTOZK
UNSY
8KVRGIK MGYUROTK
YURKTUOJ
ZU UNSY
)NKIQ MXU[TJ ]OXK ZU
MGY YURKTUOJ
MUUJ
)NKIQ XKYOYZGTIK UL
GTZOJOKYKR \GR\K
HGJ
UX
OTLOTOZK
UNSY
8KVRGIK GTZOJOKYKR
\GR\K
ZU UNSY
.URJ YZGXZ Y]OZIN GTJ
INKIQ \URZGMK GZ HR[]NZ
UT L[KR V[SV TK^Z ZU
L[KR ZGTQ
<
<
)NKIQ MXU[TJ ]OXK ZU
L[KR V[SV
HGJ
MUUJ
/TYZGRR G VXKYY[XK MG[MK
ZU ZNK L[KR V[SV
RKYY ZNGT
VYO
5 - 17
Chart 6
Engine
High Idle
Inoperative Gasoline/LPG
Models
If high idle operates
on LPG but not on
gasoline, see Ford
service manual for
carburetor
troubleshooting.
If high idle operates
on gasoline but not
on LPG, see Repair
section for LPG
regulator adjustments.
Be sure throttle
linkage from governor
to carburetor is not
binding, see Repair
section.
Be sure high idle can
be achieved by
grasping the governor
actuator arm and
momentarily pulling to
throttle the carburetor.
<
<
<
8KVRGIK XVS YKRKIZ
ZUMMRK Y]OZIN
<
)NKIQ \URZGMK GZ :(
<
<
HGJ
<
<
<
<
<
)NKIQ \URZGMK GZ
ZKXSOTGR HRQXKJ UL
)8
<
)NKIQ MXU[TJ ]OXK ZU
ZKXSOTGR UT )8
MUUJ
)NKIQ \URZGMK GZ
ZKXSOTGR UT )8
<
)NKIQ \URZGMK GZ
ZKXSOTGR ' UT )8
<
)NKIQ \URZGMK GZ
ZKXSOTGR UT
KRKIZXUTOI MU\KXTUX
<
)NKIQ \URZGMK GZ
ZKXSOTGR UT )8
<
)UTZOT[KJ UT ZNK TK^Z
VGMK
5 - 18
CHART 6
)NKIQ \URZGMK GZ
ZKXSOTGR UT )8
<
<
)NKIQ MXU[TJ ]OXK ZU
ZKXSOTGR UT )8
HGJ
<
<
MUUJ
)NKIQ \URZGMK ZU
ZKXSOTGR UT )8
<
)NKIQ \URZGMK GZ
ZKXSOTGR XKJ]NZ ]OXK
UT KRKIZXUTOI MU\KXTUX
<
)NKIQ \URZGMK GZ
ZKXSOTGR XKJ]NZ ]OXK
UT MU\KXTUX GIZ[GZUX
<
<
)NKIQ IUTZOT[OZ_ LXUS
ZKXSOTGR UT VXKIOYOUT
MU\KXTUX ZU HR[HRQ
ZKXSOTGR UT MU\KXTUX
GIZ[GZUX
L[RR IUTZOT[OZ_
:[XT SGINOTK ULL
XKSU\K HUZN ]OXKY
LXUS MU\KXTUX GIZ[GZUX
GTJ INKIQ XKYOYZGTIK
GIXUYY MU\KXTUX
GIZ[GZUX ZKXSOTGRY
8KVRGIK MU\KXTUX
GIZ[GZUX
ZU UNSY
8KIUTTKIZ MU\KXTUX
]OXKY GTJ XKYZGXZ KTMOTK
GTJ INKIQ \URZGMK GZ
KRKIZXUTOI MU\KXTUX
ZKXSOTGR GTJ HXU]T
]OXKY
<
<
9KK 3GOTZKTGTIK
YKIZOUT LUX MU\KXTUX
GJP[YZSKTZY 58 XKVRGIK
KRKIZXUTOI MU\KXTUX
5 - 19
Chart 7
Engine Low Idle
Inoperative Gasoline/LPG
Models
If low idle operates
on LPG but not on
gasoline, see Ford
service manual for
carburetor
troubleshooting.
If low idle operates
on gasoline but not
on LPG, see Repair
section for LPG
regulator adjustments.
Be sure throttle
linkage from governor
to carburetor is not
binding, see Repair
section.
<
<
)NKIQ \URZGMK GZ
ZKXSOTGR UT )8
<
<
<
<
<
)NKIQ \URZGMK GZ
ZKXSOTGR ' UT )8
<
)NKIQ \URZGMK GZ
ZKXSOTGR UT
KRKIZXUTOI MU\KXTUX
<
)NKIQ \URZGMK GZ
KRKIZXUTOI MU\KXTUX
ZKXSOTGR GTJ HXU]T
]OXKY
<
:[XT SGINOTK ULL
XKSU\K HR[HRQ ]OXK
LXUS ZKXSOTGR UT
KRKIZXUTOI MU\KXTUX GTJ
XKYZGXZ KTMOTK
8KINKIQ KRKIZXUTOI
MU\KXTUX GJP[YZSKTZY
58 XKVRGIK KRKIZXUTOI
MU\KXTUX
5 - 20
Chart 8
Engine
High Idle
Inoperative Deutz Diesel
Models
Be sure mechanical
linkage is not binding
or defective.
Be sure 2-speed
solenoid grounding
wires are free of
corrosion and have full
continuity to ground.
<
<
)NKIQ \URZGMK GZ
ZKXSOTGR UT )8
<
<
<
)NKIQ \URZGMK GZ :(
<
<
HGJ
<
)NKIQ \URZGMK ZU
ZKXSOTGR UT )8
<
)NKIQ MXU[TJ ]OXK ZU
ZKXSOTGR UT )8
MUUJ
)NKIQ \URZGMK ZU
ZKXSOTGR UT )8
<
<
)NKIQ \URZGMK GZ OTOZOGZK
ZKXSOTGR UT )8
<
<
)UTZOT[KJ UT ZNK TK^Z
VGMK
5 - 21
CHART 8
HGJ
<
<
MUUJ
)NKIQ \URZGMK ZU
ZKXSOTGR UT )8
<
)NKIQ \URZGMK GZ ZNK
HRQXKJ ]OXK UT ZNK
YVKKJ YURKTUOJ
<
)NKIQ OL YVKKJ
YURKTUOJ SU\KY OT GTJ
U[Z LXKKR_
YURKTUOJ
)NKIQ ROTQGMK UX
HOTJY
XKVRGIK YURKTUOJ
SU\KY LXKKR_
8KVRGIK YVKKJ
YURKTUOJ 4UZK
XKYOYZGTIK GIXUYY
YURKTUOJ ZKXSOTGRY
YNU[RJ HK GVVXU^OSGZKR_
UNSY
5 - 22
Chart 9
Engine
Low Idle
Inoperative Deutz Diesel
Models
Check if
mechanical linkage
from 2-speed
solenoid to fuel
injection system is
binding or defective.
<
<
)NKIQ \URZGMK GZ ZNK
XKJ ]OXK UT ZNK
YVKKJ YURKTUOJ
<
<
)NKIQ OL YVKKJ
YURKTUOJ SU\KY OT GTJ
U[Z LXKKR_
YURKTUOJ
HOTJY
)NKIQ ROTQGMK UX
XKVRGIK YURKTUOJ
SU\KY LXKKR_
)NKIQ GJP[YZSKTZ UL
ROTQGMK GTJ L[KR
OTPKIZOUT Y_YZKS RU]
OJRK 9KK 3GOTZKTGTIK
YKIZOUT
UQ
9KK *K[Z` ]UXQYNUV
SGT[GR ZU ZXU[HRKYNUUZ
L[KR OTPKIZOUT Y_YZKS 58
IUTY[RZ -KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
5 - 23
Chart 10
All Functions
Inoperative,
Engine Starts
and Runs
)NKIQ N_JXG[ROI
LR[OJ RK\KR
RU]
UQ
)NKIQ V[SV Y[IZOUT
ROTK YN[ZULL \GR\KY
<GR\K NGTJRKY YNU[RJ
HK VGXGRRKR ]OZN NUYK
IRUYKJ
UVKT
*OYIUTTKIZ IKTZKX IUOR
]OXK LXUS JOYZXOH[ZUX IGV
GTJ OYURGZK LXUS
MXU[TJOTM *K[Z`
SUJKRY NURJ SGT[GR
L[KR YN[ZULL RK\KX
IU[TZKXIRUIQ]OYK
8KSU\K L[TIZOUT V[SV
LXUS SGOT V[SV H[Z
RKG\K GRR NUYKY
IUTTKIZKJ .URJ YZGXZ
Y]OZIN GTJ IXGTQ KTMOTK
U\KX ]NORK UHYKX\OTM
YVROTK JXO\K GZ XKGX UL
SGOT V[SV
YVROTK
Z[XTY
:XU[HRKYNUUZ
OTUVKXGZO\K HUUS
L[TIZOUTY GTJ
OTUVKXGZO\K JXO\K
L[TIZOUTY YKVGXGZKR_
5 - 24
Chart 11
All Lift and
Steer Functions
Inoperative,
Drive Functions
Operational
Be sure the hydraulic
suction line shutoff
valve for the lift/steer
pump is in the open
position.
Be sure all grounding
wires for the hydraulic
manifold valves are free
of corrosion and have
full continuity to ground.
Be sure axles are fully
extended.
VYO UX
SUXK
:XU[HRKYNUUZ KGIN
L[TIZOUT OTJO\OJ[GRR_ UX
IUTY[RZ -KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
VYO UX
SUXK
YZKKXOTM OTUVKXGZO\K
)NKIQ ZNK L[TIZOUT
V[SV YKK 8KVGOX
YKIZOUT
HGJ
UQ
8KVGOX UX XKVRGIK
JOLLKXKTZOGR YKTYOTM
\GR\K OZKS ') 58
XKVGOX UX XKVRGIK LRU]
XKM[RGZUX \GR\K OZKS =
58 SGTOLURJ NGY
OTZKXTGR JKLKIZ IUTY[RZ
-KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
5 - 25
Chart 12
Ground
Controls
Inoperative,
Platform
Controls
Operate
Normally
_KY
<
<
TU
:XU[HRKYNUUZ ZNK
L[TIZOUTY OTJO\OJ[GRR_
<
<
)NKIQ \URZGMK GZ XKJ
]OXK GZ MXU[TJ IUTZXURY
IUTZGIZ UT ZNK QK_
Y]OZIN
<
<
_KY
TU
8KVRGIK QK_ Y]OZIN
5 - 26
Chart 13
Platform
Controls
Inoperative,
Ground
Controls
Operate
Normally
Be sure all
cables are in good
condition with no
kinks or abrasions.
_KY
<
<
TU
<
)NKIQ \URZGMK GZ :6
<
<
)NKIQ \URZGMK GZ HRQ
]OXK UT VRGZLUXS
KSKXMKTI_ YZUV H[ZZUT
<
8KVRGIK IUTZGIZ UT
KSKXMKTI_ YZUV H[ZZUT
<
)NKIQ \URZGMK GZ :6
<
<
5 - 27
Chart 14
Boom Up
Function
Inoperative
Be sure all other
functions operate
normally.
If boom up function
operates normally from
the ground controls but
not from the platform
controls, troubleshoot
the platform controller.
See Repair section.
If boom up function
operates normally from
the platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch or replace
resistor. See Repair
section.
<
ZU <
UX OTLOTOZK UNSY
8KVRGIK IUOR
8KVRGIK JKLKIZO\K
VXUVUXZOUTGR \GR\K
L[TIZOUT OTUVKXGZO\K
.URJ MXU[TJ IUTZXUR
L[TIZOUT Y]OZIN [V
)NKIQ \URZY GZ XKJ ]OXK
UT HUUS L[TIZOUT
JOXKIZOUTGR \GR\K
<
<
8KSU\K HUZN ]OXKY LXUS
\GR\K IUOR )NKIQ
XKYOYZGTIK GIXUYY IUOR
ZKXSOTGRY
UX OTLOTOZK UNSY
8KVRGIK IUOR
ZU UNSY
/TZKXINGTMK LRU]
XKM[RGZUX \GR\K OZKS ?
]OZN G ROQK \GR\K
OZKS >
L[TIZOUT UVKXGZKY
L[TIZOUT OTUVKXGZO\K
)UTZOT[KJ UT ZNK TK^Z
VGMK
5 - 28
CHART 14
UX
OTLOTOZK
UNSY
ZU UNSY
8KVRGIK ZNK \GR\K
L[TIZOUT OTUVKXGZO\K
L[TIZOUT UVKXGZKY
8KVRGIK JKLKIZO\K
INKIQ \GR\K
L[TIZOUT OTUVKXGZO\K
/TYZGRR G ZU 69/
VXKYY[XK MG[MK GZ ZNK
W[OIQ JOYIUTTKIZ
IU[VROTM UT ZNK L[TIZOUT
SGTOLURJ GTJ NURJ ZNK
L[TIZOUT Y]OZIN
VYO UX
SUXK
5 - 29
Chart 15
Boom Down
Function
Inoperative
Be sure all other
functions operate
normally including
boom up function.
If boom down function
operates normally from
the ground controls but
not from the platform
controls, troubleshoot
the platform controller.
See Repair section.
If boom down function
operates normally from
the platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch or replace
resistor. See Repair
section.
<
<
.URJ ZUMMRK Y]OZIN JU]T
GTJ SGT[GRR_ U\KXXOJK
ZNK JU]T JOXKIZOUTGR
\GR\K V[YN OT H[ZZUT UT
KTJ UL \GR\K YVUUR
4UZK U\KXXOJOTM ZNK
\GR\K ]ORR XKW[OXK Z]U
VKUVRK /L G NKRVKX OY TUZ
G\GORGHRK OTZKXINGTMK
ZNK \GR\K OZKS 8 ]OZN G
ROQK \GR\K OZKS 9
UX
OTLOTOZK
UNSY
ZU UNSY
8KVRGIK ZNK \GR\K
L[TIZOUT OTUVKXGZO\K
/TYZGRR G ZU 69/
VXKYY[XK MG[MK GZ ZNK
W[OIQ JOYIUTTKIZ
IU[VROTM UT ZNK L[TIZOUT
SGTOLURJ GTJ NURJ ZNK
L[TIZOUT Y]OZIN
VYO
L[TIZOUT
UVKXGZKY
L[TIZOUT OTUVKXGZO\K
5 - 30
CHART 15
VYO UX
SUXK
5 - 31
Chart 16
Boom Extend
Function
Inoperative
Be sure all other
functions operate
normally.
If boom extend function
operates normally from
the ground controls but
not from the platform
controls, troubleshoot
the platform controller.
See Repair section.
If boom extend function
operates normally from
the platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch or CR16
relay. See Repair
section.
<
<
8KSU\K HUZN ]OXKY LXUS
\GR\K IUOR GTJ INKIQ
XKYOYZGTIK GIXUYY ZNK
IUOR ZKXSOTGRY
UX
OTLOTOZK
UNSY
8KVRGIK IUOR
L[TIZOUT OTUVKXGZO\K
/TZKXINGTMK LRU]
XKM[RGZUX \GR\K OZKS >
]OZN G ROQK \GR\K
OZKS ?
L[TIZOUT OTUVKXGZO\K
.URJ ZUMMRK Y]OZIN GTJ
SGT[GRR_ U\KXXOJK
K^ZKTJ JOXKIZOUTGR \GR\K
V[YN OT H[ZZUT UT KTJ
UL \GR\K YVUUR 4UZK
U\KXXOJOTM ZNK \GR\K ]ORR
XKW[OXK Z]U VKUVRK /L G
NKRVKX OY TUZ G\GORGHRK
OTZKXINGTMK ZNK \GR\K
OZKS 9 ]OZN G ROQK \GR\K
OZKS 6
UX
OTLOTOZK
UNSY
ZU UNSY
8KVRGIK ZNK \GR\K
L[TIZOUT OTUVKXGZO\K
)UTZOT[KJ UT ZNK TK^Z
VGMK
5 - 32
CHART 16
VYO
L[TIZOUT
UVKXGZKY
L[TIZOUT OTUVKXGZO\K
VYO
VYO
5 - 33
Chart 17
Boom Retract
Function
Inoperative
Be sure all other
functions operate
normally including
boom extend function.
If boom retract function
operates normally from
the ground controls but
not from the platform
controls, troubleshoot
the platform controller.
See Repair section.
If boom retract function
operates normally from
the platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch or CR16
relay. See Repair
section.
5 - 34
<
<
.URJ ZUMMRK Y]OZIN JU]T
GTJ SGT[GRR_ U\KXXOJK
ZNK XKZXGIZ JOXKIZOUTGR
\GR\K V[YN OT H[ZZUT UT
KTJ UL \GR\K YVUUR
4UZK U\KXXOJOTM ZNK
\GR\K ]ORR XKW[OXK Z]U
VKUVRK /L G NKRVKX OY TUZ
G\GORGHRK OTZKXINGTMK
ZNK \GR\K OZKS 9 ]OZN G
ROQK \GR\K OZKS 6
L[TIZOUT
UVKXGZKY )NKIQ ZNK XKYOYZGTIK
UL ZNK XKZXGIZ JOXKIZOUTGR
\GR\K IUOR
UX
OTLOTOZK
UNSY
ZU UNSY
8KVRGIK ZNK \GR\K
L[TIZOUT OTUVKXGZO\K
/TYZGRR G ZU VYO
VXKYY[XK MG[MK GZ ZNK
W[OIQ JOYIUTTKIZ
IU[VROTM UT ZNK L[TIZOUT
SGTOLURJ GTJ NURJ ZNK
L[TIZOUT Y]OZIN
VYO
Chart 18
Turntable
Rotate Function
Inoperative
Be sure all other
functions operate
normally.
If turntable rotate
function operates
normally from the
ground controls but
not from the platform
controls, troubleshoot
the platform controller.
See Repair section.
If turntable rotate
function operates
normally from the
platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch or CR16
relay. See Repair
section.
<
ZU <
8KSU\K HUZN ]OXKY
LXUS \GR\K IUOR GTJ
INKIQ XKYOYZGTIK GIXUYY
ZNK IUOR ZKXSOTGRY
UX
OTLOTOZK
UNSY
L[TIZOUT OTUVKXGZO\K
/TZKXINGTMK XUZGZOUT
L[TIZOUT LRU] XKM[RGZUX
\GR\K OZKS > ]OZN G
ROQK \GR\K OZKS ?
L[TIZOUT
UVKXGZKY 8KVRGIK JKLKIZO\K LRU]
XKM[RGZUX \GR\K
L[TIZOUT OTUVKXGZO\K
.URJ ZUMMRK Y]OZIN ZU
RKLZ GTJ SGT[GRR_
U\KXXOJK XUZGZK RKLZ
JOXKIZOUTGR \GR\K V[YN
OT H[ZZUT UT KTJ UL
\GR\K YVUUR 4UZK
U\KXXOJOTM ZNK \GR\K ]ORR
XKW[OXK Z]U VKUVRK /L G
NKRVKX OY TUZ G\GORGHRK
OTZKXINGTMK ZNK \GR\K
OZKS 6 ]OZN G ROQK \GR\K
OZKS 9
UX
OTLOTOZK
UNSY
ZU UNSY
8KVRGIK ZNK \GR\K
L[TIZOUT OTUVKXGZO\K
)UTZOT[KJ UT ZNK TK^Z
VGMK
5 - 35
CHART 18
L[TIZOUT OTUVKXGZO\K
/TYZGRR G ZU VYO
VXKYY[XK MG[MK GZ ZNK
W[OIQ JOYIUTTKIZ
IU[VROTM UT ZNK L[TIZOUT
SGTOLURJ GTJ NURJ ZNK
L[TIZOUT Y]OZIN
VYO UX
SUXK
5 - 36
Chart 19
Turntable
Rotate Left
Function
Inoperative
<
<
UX
OTLOTOZK
UNSY
ZU UNSY
.URJ ZUMMRK Y]OZIN RKLZ
GTJ SGT[GRR_ U\KXXOJK
XUZGZK RKLZ JOXKIZOUTGR
\GR\K V[YN OT H[ZZUT UT
KTJ UL \GR\K YVUUR
4UZK U\KXXOJOTM ZNK
\GR\K ]ORR XKW[OXK Z]U
VKUVRK /L G NKRVKX OY TUZ
G\GORGHRK OTZKXINGTMK
ZNK \GR\K OZKS 6 ]OZN G
ROQK \GR\K OZKS 9
L[TIZOUT
UVKXGZKY 8KVRGIK ZNK XUZGZK
JOXKIZOUTGR \GR\K
L[TIZOUT OTUVKXGZO\K
/TYZGRR G VXKYY[XK MG[MK
GZ ZNK W[OIQJOYIUTTKIZ
IU[VROTM UT ZNK L[TIZOUT
SGTOLURJ GTJ NURJ ZNK
L[TIZOUT Y]OZIN
VYO
VYO
/TZKXINGTMK ZNK
XUZGZK RKLZ GTJ XOMNZ
IU[TZKXHGRGTIK \GR\KY
OZKS ' GTJ OZKS ( UT
Z[XTZGHRK XUZGZOUT
SUZUX
L[TIZOUT
UVKXGZKY
8KVRGIK JKLKIZO\K
IU[TZKXHGRGTIK \GR\K
L[TIZOUT OTUVKXGZO\K
)NKIQ LUX SKINGTOIGR
XKYZXOIZOUTY QKKVOTM
Z[XTZGHRK LXUS XUZGZOTM
RKLZ 58 XKVRGIK
JOXKIZOUTGR \GR\K 58
XKVGOX XUZGZOUT SUZUX
5 - 37
Chart 20
Turntable
Rotate Right
Function
Inoperative
Be sure all other
functions operate
normally including
turntable rotate left
function.
If turntable rotate right
function operates
normally from the
ground controls but
not from the platform
controls, troubleshoot
the platform controller.
See Repair section.
If turntable rotate right
function operates
normally from the
platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch. See
Repair section.
<
<
8KSU\K HUZN ]OXKY LXUS
XUZGZK XOMNZ \GR\K IUOR
GTJ INKIQ XKYOYZGTIK
GIXUYY ZNK IUOR
ZKXSOTGRY
UX
OTLOTOZK
UNSY
ZU UNSY
.URJ ZUMMRK Y]OZIN XOMNZ
GTJ SGT[GRR_ U\KXXOJK
XUZGZK XOMNZ JOXKIZOUTGR
\GR\K V[YN OT H[ZZUT UT
KTJ UL \GR\K YVUUR
4UZK U\KXXOJOTM ZNK
\GR\K ]ORR XKW[OXK Z]U
VKUVRK /L G NKRVKX OY TUZ
G\GORGHRK OTZKXINGTMK
ZNK \GR\K OZKS 6 ]OZN G
ROQK \GR\K OZKS 9
L[TIZOUT
UVKXGZKY 8KVRGIK ZNK XUZGZK
JOXKIZOUTGR \GR\K
L[TIZOUT OTUVKXGZO\K
/TYZGRR G VXKYY[XK MG[MK
GZ ZNK W[OIQJOYIUTTKIZ
IU[VROTM UT ZNK L[TIZOUT
SGTOLURJ GTJ NURJ ZNK
L[TIZOUT Y]OZIN
VYO
/TZKXINGTMK ZNK
XUZGZK XOMNZ GTJ RKLZ
IU[TZKXHGRGTIK \GR\KY
OZKS ' GTJ OZKS ( UT
Z[XTZGHRK XUZGZOUT
SUZUX
L[TIZOUT OTUVKXGZO\K
RKYY ZNGT VYO
VYO
5 - 38
58
)UTY[RZ -KTOK
/TJ[YZXOKY 9KX\OIK
*KVGXZSKTZ
Chart 21
All Platform
Leveling
Functions
Inoperative
Be sure all other
functions operate
normally.
Be sure both automatic
and manual platform
leveling do not operate.
If automatic leveling
operates but manual
leveling does not,
troubleshoot Platform
Leveling Up Function
Inoperative.
<
UX
OTLOTOZK
UNSY
ZU UNSY
8KSU\K HUZN N_JXG[ROI
NUYKY LXUS ZNK SGTOLURJ
VUXZY 62 62 6R[M
ZNK NUYKY GTJ IGV ZNK
SGTOLURJ LOZZOTMY
5VKXGZK HUUS [V
L[TIZOUT GTJ INKIQ OL
VRGZLUXS RK\KRY
_KY
8KVRGIK ZNK
IU[TZKXHGRGTIK \GR\KY
OZKSY ( ) UX \GR\K
HRUIQ '
VYO
TU
6R[SH G VXKYY[XK MG[MK
OTZU ZNK SGYZKX I_ROTJKX
HGXXKRKTJ N_JXG[ROI
NUYK [YOTM G ZKK LOZZOTM
5VKXGZK HUUS [V
L[TIZOUT GTJ XKGJ
ZNK VXKYY[XK
RKYY
ZNGT
VYO 8KVGOX UX XKVRGIK ZNK
SGYZKX I_ROTJKX
5 - 39
Chart 22
Platform Level
Up Function
Inoperative
Be sure all other
functions operate
normally.
If platform level up
function operates
normally from the
ground controls but
not from the platform
controls, troubleshoot
the platform control
toggle switch. See
Repair section.
If platform level up
function operates
normally from the
platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch. See
Repair section.
<
<
8KSU\K HUZN ]OXKY LXUS
\GR\K IUOR GTJ INKIQ
XKYOYZGTIK GIXUYY ZNK
IUOR ZKXSOTGRY
UX
OTLOTOZK
UNSY
ZU UNSY
.URJ ZUMMRK Y]OZIN GTJ
SGT[GRR_ U\KXXOJK ZNK
RK\KR [V JOXKIZOUTGR
\GR\K V[YN OT H[ZZUT
UT KTJ UL \GR\K YVUUR
4UZK U\KXXOJOTM ZNK
\GR\K ]ORR XKW[OXK Z]U
VKUVRK /L G NKRVKX OY TUZ
G\GORGHRK OTZKXINGTMK
ZNK \GR\K OZKS 5 ]OZN
G ROQK \GR\K OZKS 4
L[TIZOUT
UVKXGZKY 8KVRGIK ZNK VRGZLUXS
RK\KROTM JOXKIZOUTGR
\GR\K
L[TIZOUT OTUVKXGZO\K
/TZKXINGTMK INKIQ \GR\K
OZKS 2 ]OZN ROQK \GR\K
OZKS 1
L[TIZOUT
UVKXGZKY 8KVRGIK JKLKIZO\K
INKIQ \GR\K
L[TIZOUT OTUVKXGZO\K
/TYZGRR G VXKYY[XK MG[MK
GZ ZNK W[OIQ JOYIUTTKIZ
IU[VROTM UT ZNK L[TIZOUT
SGTOLURJ GTJ NURJ ZNK
L[TIZOUT Y]OZIN
VYO UX
SUXK
/TZKXINGTMK ZNK
RK\KR [V GTJ JU]T
IU[TZKXHGRGTIK \GR\KY
OZKSY ( )
VYO UX
SUXK
L[TIZOUT UVKXGZKY
RKYY ZNGT VYO
8KVRGIK JKLKIZO\K
IU[TZKXHGRGTIK \GR\K
*OYIUTTKIZOTM N_JXG[ROI
ROTKY UX GJP[YZOTM ZNK
I_ROTJKX IU[TZKXHGRGTIK
\GR\KY OT ZNOY YOZ[GZOUT
IGT HK \KX_ JGTMKXU[Y
6RKGYK IUTY[RZ -KTOK
/TJ[YZXOKY 9KX\OIK
*KVGXZSKTZ
5 - 40
Chart 23
Platform Level
Down Function
Inoperative
Be sure all other
functions operate
normally.
If platform level down
function operates
normally from the
ground controls but
not from the platform
controls, troubleshoot
the platform control
toggle switch. See
Repair section.
If platform level down
function operates
normally from the
platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch. See
Repair section.
<
<
8KSU\K HUZN ]OXKY LXUS
\GR\K IUOR GTJ INKIQ
XKYOYZGTIK GIXUYY ZNK
IUOR ZKXSOTGRY
UX
OTLOTOZK
UNSY
ZU UNSY
.URJ ZUMMRK Y]OZIN GTJ
SGT[GRR_ U\KXXOJK ZNK
RK\KR JU]T JOXKIZOUTGR
\GR\K V[YN OT H[ZZUT
UT KTJ UL \GR\K YVUUR
4UZK U\KXXOJOTM ZNK
\GR\K ]ORR XKW[OXK Z]U
VKUVRK /L G NKRVKX OY TUZ
G\GORGHRK OTZKXINGTMK
ZNK \GR\K OZKS 5 ]OZN
G ROQK \GR\K OZKS 4
L[TIZOUT
UVKXGZKY 8KVRGIK ZNK VRGZLUXS
RK\KROTM JOXKIZOUTGR
\GR\K
L[TIZOUT OTUVKXGZO\K
/TZKXINGTMK INKIQ \GR\K
OZKS 2 ]OZN ROQK \GR\K
OZKS 1
L[TIZOUT
UVKXGZKY 8KVRGIK JKLKIZO\K
INKIQ \GR\K
L[TIZOUT OTUVKXGZO\K
/TYZGRR G VXKYY[XK MG[MK
GZ ZNK W[OIQ JOYIUTTKIZ
IU[VROTM UT ZNK L[TIZOUT
SGTOLURJ GTJ NURJ ZNK
L[TIZOUT Y]OZIN
VYO UX
SUXK
VYO UX
SUXK
L[TIZOUT UVKXGZKY
RKYY ZNGT VYO
8KVRGIK JKLKIZO\K
IU[TZKXHGRGTIK \GR\K
*OYIUTTKIZOTM N_JXG[ROI
ROTKY UX GJP[YZOTM ZNK
I_ROTJKX IU[TZKXHGRGTIK
\GR\KY OT ZNOY YOZ[GZOUT
IGT HK \KX_ JGTMKXU[Y
6RKGYK IUTY[RZ -KTOK
/TJ[YZXOKY 9KX\OIK
*KVGXZSKTZ
5 - 41
Chart 24
Platform Rotate
Left Function
Inoperative
)NKIQ OL POH
HUUS [V
OY UVKXGZOUTGR
9 SUJKRY VXUIKKJ
JU]T ZU TK^Z YZKV
<
<
8KSU\K HUZN ]OXKY LXUS
\GR\K IUOR GTJ INKIQ
XKYOYZGTIK GIXUYY ZNK
IUOR ZKXSOTGRY
UX
OTLOTOZK
UNSY
ZU UNSY
8KVGOX 58 XKVRGIK ZNK
JKLKIZO\K \GR\K 58
INKIQ LUX SKINGTOIGR
XKYZXOIZOUTY QKKVOTM
VRGZLUXS LXUS XUZGZOTM
58 XKVGOX N_JXG[ROI
XUZGZUX
POH HUUS [V
OTUVKXGZO\K
<
<
8KSU\K HUZN ]OXKY LXUS
\GR\K IUOR GTJ INKIQ
XKYOYZGTIK GIXUYY ZNK
IUOR ZKXSOTGRY
UX
OTLOTOZK
UNSY
ZU UNSY
)UTZOT[KJ UT ZNK TK^Z
VGMK
5 - 42
CHART 24
L[TIZOUT
UVKXGZKY 8KVRGIK ZNK VRGZLUXS
XUZGZK JOXKIZOUTGR \GR\K
L[TIZOUT OTUVKXGZO\K
/TYZGRR G VXKYY[XK MG[MK
GZ ZNK W[OIQ JOYIUTTKIZ
IU[VROTM UT ZNK XUZGZK
L[TIZOUT SGTOLURJ GTJ
NURJ ZNK L[TIZOUT Y]OZIN
L[TIZOUT
UVKXGZKY 8KVRGIK JKLKIZO\K LRU]
IUTZXUR \GR\K
L[TIZOUT OTUVKXGZO\K
L[TIZOUT VYO
/TZKXINGTMK INKIQ
OZKS . ]OZN ROQK \GR\K
OZKS 2
L[TIZOUT
UVKXGZKY 8KVRGIK JKLKIZO\K
INKIQ \GR\K
L[TIZOUT OTUVKXGZO\K
8KVRGIK ZNK JOXKIZOUTGR
\GR\K 58 ZNK SGTOLURJ
NGY OTZKXTGR JKLKIZY 58
UTK UL ZNK VXK\OU[Y
ZKYZY ]GY VUYYOHR_
U\KXRUUQKJ UX
JOGMTUYKJ OTIUXXKIZR_
8KINKIQ GTJUX IUTY[RZ
-KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
5 - 43
Chart 25
Platform Rotate
Right Function
Inoperative
)NKIQ OL POH
HUUS JU]T OY
UVKXGZOUTGR
9 SUJKRY VXUIKKJ
JU]T ZU TK^Z YZKV
POH HUUS
.URJ VRGZLUXS XUZGZK RKLZ
JU]T
UVKXGZKY L[TIZOUT Y]OZIN GTJ
INKIQ \URZGMK GZ MXT]NZ
]OXK UT HUZN \GR\KY UT
POH HUUS SGTOLURJ
<
<
8KSU\K HUZN ]OXKY LXUS
\GR\K IUOR GTJ INKIQ
XKYOYZGTIK GIXUYY ZNK
IUOR ZKXSOTGRY
POH HUUS JU]T
OTUVKXGZO\K
UX
OTLOTOZK
UNSY
ZU UNSY
8KVGOX 58 XKVRGIK
JKLKIZO\K \GR\KY 58
INKIQ LUX SKINGTOIGR
XKYZXOIZOUTY QKKVOTM
VRGZLUXS LXUS XUZGZOTM
58 XKVGOX N_JXG[ROI
XUZGZUX
<
<
8KSU\K HUZN ]OXKY LXUS
\GR\K IUOR GTJ INKIQ
XKYOYZGTIK GIXUYY ZNK
IUOR ZKXSOTGRY
UX
OTLOTOZK
UNSY
ZU UNSY
.URJ ZUMMRK Y]OZIN XOMNZ
GTJ SGT[GRR_ U\KXXOJK
ZNK XUZGZK XOMNZ
JOXKIZOUTGR \GR\K V[YN
OT H[ZZUT UT KTJ UL
\GR\K YVUUR 4UZK
U\KXXOJOTM ZNK \GR\K ]ORR
XKW[OXK Z]U VKUVRK /L G
NKRVKX OY TUZ G\GORGHRK
OTZKXINGTMK ZNK \GR\K
OZKS 4 ]OZN G ROQK
\GR\K OZKS 5
L[TIZOUT
UVKXGZKY 8KVRGIK ZNK VRGZLUXS
XUZGZK JOXKIZOUTGR \GR\K
L[TIZOUT OTUVKXGZO\K
)UTZOT[KJ UT ZNK TK^Z
VGMK
5 - 44
CHART 25
VYO UX
SUXK
L[TIZOUT
UVKXGZKY 8KVRGIK JKLKIZO\K
INKIQ \GR\K
L[TIZOUT OTUVKXGZO\K
8KVRGIK ZNK JOXKIZOUTGR
\GR\K 58 ZNK SGTOLURJ
NGY OTZKXTGR JKLKIZY 58
UTK UL ZNK VXK\OU[Y
ZKYZY ]GY VUYYOHR_
U\KXRUUQKJ UX
JOGMTUYKJ OTIUXXKIZR_
8KINKIQ GTJUX IUTY[RZ
-KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
5 - 45
Chart 26
Jib Boom Up
Function
Inoperative S65 Models
Be sure all other
functions operate
normally.
If jib boom up function
operates normally
from the ground
controls but not
from the platform
controls, troubleshoot
the platform control
toggle switch or CR13.
See Repair section.
If jib boom up function
operates normally
from the platform
controls but not from
the ground controls,
troubleshoot the
ground control toggle
switch. See Repair
section.
<
<
<
)NKIQ \URZGMK GZ MXT
]NZ ]OXK UT )8 XKRG_
<
<
<
XUZGZK RKLZ
UVKXGZKY 8KVGOX 58 XKVRGIK
JKLKIZO\K \GR\KY 58
INKIQ POH HUUS LUX
SKINGTOIGR XKYZXOIZOUTY
58 XKVGOX POH HUUS
I_ROTJKX 58 XKVRGIK
XUZGZK RKLZ
POH HUUS I_ROTJKX
OTUVKXGZO\K
IU[TZKXHGRGTIK \GR\KY
<
<
8KSU\K HUZN ]OXKY LXUS
\GR\K IUOR GTJ INKIQ
XKYOYZGTIK GIXUYY ZNK
IUOR ZKXSOTGRY
UX
OTLOTOZK
UNSY
ZU UNSY
)UTZOT[KJ UT ZNK TK^Z
VGMK
5 - 46
CHART 26
L[TIZOUT OTUVKXGZO\K
/TYZGRR G VXKYY[XK MG[MK
GZ ZNK W[OIQ JOYIUTTKIZ
IU[VROTM UT ZNK L[TIZOUT
SGTOLURJ GTJ NURJ ZNK
L[TIZOUT Y]OZIN
VYO UX
SUXK
/TZKXINGTMK VXKYY[XK
IUSVKTYGZOTM LRU]
IUTZXUR \GR\K OZKS ;
]OZN ROQK \GR\K OZKS <
L[TIZOUT
UVKXGZKY 8KVRGIK JKLKIZO\K LRU]
IUTZXUR \GR\K
L[TIZOUT OTUVKXGZO\K
RKYY ZNGT
VYO
/TZKXINGTMK INKIQ
OZKS . ]OZN ROQK \GR\K
OZKS 2
L[TIZOUT OTUVKXGZO\K
8KVRGIK ZNK JOXKIZOUTGR
\GR\K 58 ZNK SGTOLURJ
NGY OTZKXTGR JKLKIZY 58
UTK UL ZNK VXK\OU[Y
ZKYZY ]GY VUYYOHR_
U\KXRUUQKJ UX
JOGMTUYKJ OTIUXXKIZR_
8KINKIQ GTJUX IUTY[RZ
-KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
5 - 47
Chart 27
Jib Boom Down
Function
Inoperative S65 Models
Be sure all other
functions operate
normally.
If jib boom down
function operates
normally from the
ground controls but
not from the platform
controls, troubleshoot
the platform control
toggle switch or CR13.
See Repair section.
If jib boom down
function operates
normally from the
platform controls but
not from the ground
controls, troubleshoot
the ground control
toggle switch. See
Repair section.
XUZGZK
8KVGOX 58 XKVRGIK
XOMNZ
JKLKIZO\K \GR\KY 58
UVKXGZKY INKIQ POH HUUS LUX
SKINGTOIGR XKYZXOIZOUTY
58 XKVGOX POH HUUS
I_ROTJKX 58 XKVRGIK
XUZGZK XOMNZ
POH HUUS I_ROTJKX
OTUVKXGZO\K
IU[TZKXHGRGTIK \GR\KY
)NKIQ OL VRGZLUXS
XUZGZK XOMNZ OY
UVKXGZOUTGR
<
<
8KSU\K HUZN ]OXKY LXUS
\GR\K IUOR GTJ INKIQ
XKYOYZGTIK GIXUYY ZNK
IUOR ZKXSOTGRY
UX
OTLOTOZK
UNSY
ZU UNSY
.URJ ZUMMRK Y]OZIN GTJ
SGT[GRR_ U\KXXOJK ZNK POH
HUUS JU]T JOXKIZOUTGR
\GR\K V[YN OT H[ZZUT UT
KTJ UL \GR\K YVUUR
4UZK U\KXXOJOTM ZNK
\GR\K ]ORR XKW[OXK Z]U
VKUVRK /L G NKRVKX OY TUZ
G\GORGHRK OTZKXINGTMK
ZNK \GR\K OZKS 4 ]OZN G
ROQK \GR\K OZKS 5
L[TIZOUT
UVKXGZKY 8KVRGIK ZNK POH HUUS
JOXKIZOUTGR \GR\K
L[TIZOUT OTUVKXGZO\K
)UTZOT[KJ UT ZNK TK^Z
VGMK
5 - 48
CHART 27
VYO
UX SUXK 8KVRGIK ZNK POH HUUS
JOXKIZOUTGR \GR\K
L[TIZOUT
UVKXGZKY 8KVRGIK JKLKIZO\K
INKIQ \GR\K
L[TIZOUT OTUVKXGZO\K
8KVRGIK ZNK JOXKIZOUTGR
\GR\K 58 ZNK SGTOLURJ
NGY OTZKXTGR JKLKIZY 58
UTK UL ZNK VXK\OU[Y
ZKYZY ]GY VUYYOHR_
U\KXRUUQKJ UX
JOGMTUYKJ OTIUXXKIZR_
8KINKIQ GTJUX IUTY[RZ
-KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
5 - 49
Chart 28
Oscillate
Function
Inoperative
Be sure all other
function operate
normally.
HGJ
8KGJP[YZ UX XKVRGIK
ROTQGMK
MUUJ
/TYZGRR G VXKYY[XK MG[MK
GZ ZNK W[OIQ JOYIUTTKIZ
IU[VROTM UT ZNK UYIORRGZK
SGTOLURJ *OYIUTTKIZ
ROTQGMK LXUS JXO\K
INGYYOY GTJ SGT[GRR_
GIZO\GZK JOXKIZOUTGR
\GR\K ]NORK KTMOTK OY
X[TTOTM )NKIQ ZNK
VXKYY[XK
RKYY
ZNGT
VYO
VYO
)UTY[RZ -KTOK
/TJ[YZXOKY 9KX\OIK
*KVGXZSKTZ
5 - 50
Chart 29
Steer Left
Function
Inoperative
Be sure all other
functions operate
normally.
<
<
<
<
.URJ ZNK YZKKX Y]OZIN
RKLZ GTJ INKIQ \URZGMK
GZ :(
<
.URJ ZNK YZKKX Y]OZIN
RKLZ GTJ INKIQ \URZGMK GZ
HR[ ]OXK UT YZKKX \GR\K
<
8KSU\K HUZN ]OXKY LXUS
YZKKX RKLZ IUOR GTJ INKIQ
XKYOYZGTIK GIXUYY IUOR
ZKXSOTGRY
UX
OTLOTOZK
UNSY
ZU UNSY
8KVRGIK YZKKX \GR\K 58
IUTY[RZ -KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
5 - 51
Chart 30
Steer Right
Function
Inoperative
Be sure all other
functions operate
normally.
<
<
<
<
.URJ ZNK YZKKX Y]OZIN
XOMNZ GTJ INKIQ \URZGMK
GZ :(
<
.URJ ZNK YZKKX Y]OZIN
XOMNZ GTJ INKIQ \URZGMK
GZ HR[HRQ ]OXK UT
YZKKX \GR\K
<
8KSU\K HUZN ]OXKY LXUS
YZKKX XOMNZ IUOR GTJ
INKIQ XKYOYZGTIK GIXUYY
IUOR ZKXSOTGRY
UX
OTLOTOZK
UNSY
ZU UNSY
8KVRGIK YZKKX \GR\K 58
IUTY[RZ -KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
5 - 52
Chart 31
All Drive
Functions
Inoperative,
All Other
Functions
Operate
Normally
Be sure the hydraulic
suction line valve is in
the open position.
Be sure machine is
not in the free wheel
configuration.
SGINOTK SU\KY
3U\K ZU VRGZLUXS
VXKYY JU]T LUUZ Y]OZIN
NURJ JXO\K KTGHRK
Y]OZIN ZU KOZNKX YOJK
GTJ ZX_ ZU JXO\K
TU JXO\K
8KVGOX UVKT OT
]NZ ]OXK IOXI[OZ LXUS
:6 ZU :(
SGINOTK JXO\KY
8KVRGIK JXO\K KTGHRK
ROSOZ Y]OZIN 58 XKVGOX
UVKT OT ]OXK IOXI[OZY
LXUS ZKXSOTGR :( ZU
ROSOZ Y]OZIN GTJ LXUS
ROSOZ Y]OZIN ZU :(
TU JXO\K
UX
OTLOTOZK
UNSY
8KVRGIK +*)
ZU UNSY
6XKYY JU]T LUUZ Y]OZIN
GTJ INKIQ \URZGMK GZ
NUXYKVU]KX ROSOZKX
HUGXJ ZKXSOTGR
< UX SUXK
)UXXKIZ OTY[LLOIOKTZ
\URZGMK Y[VVR_
GRZKXTGZUX UX HGZZKX_
58 XKVGOX UVKT OT ]NZ
]OXK IOXI[OZ Y[VVR_OTM
< ZU ZKXSOTGR
5 - 53
CHART 31
<
ZU <
ZU <
<
)NKIQ \URZGMK GZ
UXMHRQ ]OXK UT KTMOTK
GRZKXTGZUX
<
ZU <
8KVGOX UX XKVRGIK
GRZKXTGZUX
6XKYY JU]T LUUZ Y]OZIN
GTJ INKIQ \URZGMK GZ
ZKXSOTGR UT
NUXYKVU]KX ROSOZKX
<
8KVRGIK NUXYKVU]KX
ROSOZKX HUGXJ
ZU <
6XKYY JU]T LUUZ Y]OZIN
GTJ INKIQ \URZGMK GZ
ZKXSOTGR UT JXO\K
IUTZXURRKX
<
ZU <
)UTZOT[KJ UT ZNK TK^Z
VGMK
5 - 54
CHART 31
<
ZU <
6XKYY JU]T LUUZ Y]OZIN
NURJ JXO\K IUTZXURRKX OT
L[RR LUX]GXJ VUYOZOUT
GTJ INKIQ \URZGMK
GIXUYY ZKXSOTGRY
:6 GTJ :6
<
ZU <
6XKYY JU]T LUUZ Y]OZIN
NURJ JXO\K IUTZXURRKX OT
L[RR LUX]GXJ VUYOZOUT
GTJ INKIQ \URZGMK
GIXUYY ZKXSOTGRY
:( GTJ :(
<
ZU <
6XKYY JU]T LUUZ Y]OZIN
NURJ JXO\K IUTZXURRKX OT
L[RR LUX]GXJ VUYOZOUT GTJ
INKIQ \URZGMK GIXUYY
ZNK Z]U ]OXKY GZ +*)
W[OIQ JOYIUTTKIZ
<
ZU <
8KVRGIK JXO\K V[SV
+*) 58 IUTY[RZ -KTOK
/TJ[YZXOKY 9KX\OIK
*KVGXZSKTZ
5 - 55
Chart 32
Drive Forward
Or Reverse
Function
Inoperative
Be sure all other
functions operate
normally including
drive in opposite
direction of
malfunction.
TU OSVXU\KSKTZ
*KLKIZO\K 9[TJYZXGTJ
JXO\K V[SV IUTZGIZ
9[TJYZXGTJ G[ZNUXO`KJ
XKVGOX LGIOROZ_
Y_SVZUSY OSVXU\K
)NKIQ GRR JXO\K YVKKJY
GTJ SUTOZUX LUX
XKI[XXOTM Y_SVZUSY
6UYYOHRK IUTZGSOTGZOUT
OT N_JXG[ROI Y_YZKS
5 - 56
Chart 33
Traction
Function
Inoperative
5 - 57
Chart 34
Machine Will
Not Drive At
Full Speed
Be sure all other
functions operate
normally.
Be sure the free-wheel
valve is closed on the
drive pump.
Be sure the drive speed
select switch is on high
range (machine on level
surface symbol).
5 - 58
L[RR
8KVGOX UX XKVRGIK HUUS
IUTZOT[OZ_ ROLZ JXO\K ROSOZ Y]OZIN UX
HUUS K^ZKTJ ROSOZ
Y]OZIN
TU IUTZOT[OZ_
=OZN HUUS L[RR_ YZU]KJ
INKIQ NUXYKVU]KX
ROSOZKX HUGXJ ZKXSOTGR
LUX IUTZOT[OZ_ ZU MXU[TJ
TU IUTZOT[OZ_
8KGJP[YZ UX XKVRGIK
NUXYKVU]KX ROSOZKX
HUGXJ 9KK 8KVGOX
YKIZOUT 58 IUTY[RZ
-KTOK /TJ[YZXOKY
9KX\OIK *KVGXZSKTZ
Chart 35
Machine Drives
At Full Speed
With Platform
Raised or
Extended
Remove machine from
service immediately.
Be sure boom lift drive
limit switch or boom
extend drive limit switch
is not being held down
or up.
Be sure wiring to limit
switches is intact and
shows no sign of
tampering.
Be sure orange wire
(cable 1) is properly
attached to horsepower
limiter.
L[RR
*OYIUTTKIZ KRKIZXUTOI
IUTZOT[OZ_ JOYVRGIKSKTZ IUTZXURRKX
+*) ]OXKY UT JXO\K
V[SV SU\K JXO\K
IUTZXURRKX ZU L[RR LUX]GXJ
VUYOZOUT GTJ INKIQ
\URZGMK HKZ]KKT
ZKXSOTGRY GTJ
UT JXO\K IUTZXURRKX
ZU <
*KLKIZO\K 9[TJYZXGTJ
JXO\K V[SV 8KVRGIK UX
XKVGOX GZ G[ZNUXO`KJ
9[TJYZXGTJ XKVGOX
LGIOROZ_
ZU <
TU IUTZOT[OZ_
8KVRGIK NUXYKVU]KX
ROSOZKX HUGXJ
)NKIQ IUTZOT[OZ_
HKZ]KKT MXU[TJ
GTJ :(
L[RR
IUTZOT[OZ_ 8KVGOX UVKT OT UXM ]OXK
IOXI[OZ LXUS :( ZU
NUXYKVU]KX ROSOZKX
HUGXJ ZKXSOTGR
TU IUTZOT[OZ_
8KVGOX ROSOZ Y]OZIN
]OXOTM 58 XKVRGIK HUUS
ROLZ JXO\K ROSOZ Y]OZIN 58
XKVRGIK HUUS K^ZKTJ
JXO\K ROSOZ Y]OZIN
5 - 59
Chart 36
Drive Enable
System Is
Malfunctioning
TU
TU
:XU[HRKYNUUZ
NUXYKVU]KX ROSOZ HUGXJ
JXO\K IUTZXURRKX UX
JXO\K V[SV 9KK INGXZ
_KY
_KY
_KY
TU
=ORR NURJOTM ZNK JXO\K
KTGHRK Y]OZIN GRRU]
HUUS ZU JXO\K OT
YZU]KJ VUYOZOUT U\KX
YZKKX ]NKKRY%
TU
8KVGOX UX XKVRGIK JXO\K
KTGHRK ZUMMRK Y]OZIN
5 - 60
Chart 37
Auxiliary
Functions
Inoperative
V[SV
X[TY
*KGJNKGJ G VXKYY[XK
MG[MK OTZU ZNK VXKYY[XK
ROTK UL ZNK G[^OROGX_
V[SV GTJ NURJ ZNK
G[^OROGX_ VU]KX Y]OZIN
VYO
8KIUTTKIZ VXKYY[XK
ROTK GTJ INKIQ HGZZKX_
IUTJOZOUT :NKXK OY
VUYYOHR_ TUZ KTU[MN
HGZZKX_ IGVGIOZ_ ZU
UVKXGZK HUZN G[^ V[SV
GTJ L[TIZOUT \GR\KY
<
8KVRGIK JKLKIZO\K
G[^OROGX_ VU]KX
ZUMMRK Y]OZIN
<
<
.URJ ZNK G[^OROGX_ VU]KX
Y]OZIN GTJ INKIQ ZNK
\URZGMK GZ OTOZOGZK
ZKXSOTGR XKJ ]OXK UT
68 SUZUX YZGXZ
YURKTUOJ
<
.URJ ZNK G[^OROGX_ VU]KX
Y]OZIN GTJ INKIQ ZNK
\URZGMK GZ VUYOZO\K
VU]KX IGHRK UT G[^OROGX_
VU]KX [TOZ
<
<
)NKIQ G[^OROGX_ VU]KX
[TOZ MXU[TJOTM IGHRK
58 XKVGOX UX XKVRGIK
KRKIZXOI SUZUX
5 - 61
5 - 62
Section 6 - Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Hydraulic Schematics
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the Genie
S-60 & Genie S-65 Operator's Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
problem
solved
Inspect
and test
Perform
repair
6-1
Section 6 - Schematics
TB17
BLK
ORG/BLK-1
GRN/BLK
Circuit breaker
Water temperature
switch
normally closed
Wire color
with cable
number
Solenoid or
relay coil
Ground
supression
circuit
Starter motor
relay
WHT #51
TB20
PR5
WTS1 N.O.
15AMP.
FS1
BLK
RED
TR2
1
2
Foot switch
Terminal
TP29
LS4
NC
NO
1
Quick disconnect
terminal
Horn
Limit switch
KS1
GRND
BLK #21
Key switch
TB21
T-circuits connect
at terminal
PLAT
TR1
LS1
NO
L4 OP
TS3
Light
HORN
ENGINE
START
Limit switch
normally open
held closed
P4
T-circuits
connect
10
Horn button
normally open
Resistor
TS6
LS2
NC
Limit switch
normally closed
held open
RIGHT
LEFT
Connection
no terminal
P1
BP2
PWM
A
+
Circuits crossing
no connection
Tilt sensor
VAC
CR4
Vacuum switch
Diode
Single axis
proportional
controller
Relay contact
normally open
Spark plug
BP1
OPS1 N.C.
+
-
Battery
6-2
Glow plug
Oil pressure
switch
normally closed
PWM
A
PR4
Relay panel
contactor
PWM
A
Dual axis
proportional
controller
Section 6 - Schematics
Service Manual
6-3
Service Manual
Section 6 - Schematics
6-4
Service Manual
Section 6 - Schematics
6-5
Section 6 - Schematics
Service Manual
6-6
Service Manual
Section 6 - Schematics
6-7
Section 6 - Schematics
Service Manual
6-8
Service Manual
Section 6 - Schematics
6-9
Service Manual
Section 6 - Schematics
6 - 10
Section 6 - Schematics
Service Manual
6 - 11
Section 6 - Schematics
Cylinder
Pressure gauge
Differential
sensing valve
Accumulator
Filter
Solenoid operated
proportional valve
Variable orifice
or shut-off valve
Check valve
Relief valve
Sequencing valve
Bi-directional motor
Priority
flow divider
Counterbalance valve
2-speed,
bi-directional motor
Unloader valve
Solenoid operated
dump valve
6 - 12
Service Manual
Section 6 - Schematics
6 - 13
Service Manual
Section 6 - Schematics
6 - 14
Service Manual
Section 6 - Schematics
6 - 15
Service Manual
Section 6 - Schematics
6 - 16
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
wheels chocked
Perform
repair
OFF
Inspect
and test
Symbols Legend
problem
solved
7-1
Platform Controls
1-1
Joystick Controllers
b
a
a
b
c
d
e
f
g
h
i
j
PLATFORM CONTROLS
3 to 4 seconds
6.2V DC
90 to 120 seconds
8.5V DC
55 to 85 seconds
3.5V DC
7-3
PLATFORM CONTROLS
a
b
c
d
e
f
g
h
i
j
7-4
PLATFORM CONTROLS
3.5V DC
5.5V DC
80 to 120 seconds
4.5V DC
120 to 150 seconds
5 seconds
a
b
c
d
e
f
g
h
i
j
7-5
PLATFORM CONTROLS
9.75V DC
100 to 130 seconds
9.2V DC
55 to 85 seconds
Ramp rate
3 seconds
1-2
Horsepower Limiter Board
The horsepower limiter board is responsible for
governing drive pump output. It senses engine
rpm from the alternator. The horsepower limiter
board senses drops in rpm normally due to
increased drive resistance (rough terrain or
incline), and decreases voltage to the drive
controller which in turn decreases voltage to the
drive pump, thereby reducing pump output to
maintain optimum engine rpm and horsepower.
Three adjustments are required for optimum
performance.
3.5V DC
PLATFORM CONTROLS
10.5 to 11.5V DC
7-7
PLATFORM CONTROLS
1-3
Foot Switch
How to Test the Foot Switch
1 Turn the key switch to the OFF position and
separate the wiring quick disconnect plug from
the platform toe board.
2 Do not press down the foot switch. Connect the
leads from an ohmmeter or continuity tester to
each wire combination listed below and check
for continuity.
Test
a
b
Desired result
green to black
continuity
(zero W)
green to white
no continuity
(infinite W)
black to white
no continuity
7-8
distance: 40 ft / 12 m
2WD
4WD
40 ft/6.2 sec 40 ft/9.1 sec
12.2 m/6.2 sec 12.2 m/9.1 sec
40 ft/6.8 sec 40 ft/9.1 sec
12.2 m/6.8 sec 12.2 m/9.1 sec
Test
Desired result
green to black
no continuity
(infinite W)
green to white
no continuity
black to white
continuity
(zero W)
distance: 40 ft / 12 m
1 foot per second
30.5 cm per second
PLATFORM CONTROLS
Left
1-4
Resistors
Center
Right
Single pole
double throw
(SPDT)
3
2
3
2
Double pole
double throw
(DPDT)
3
2
Desired result
Left position
terminal 1 to 2, 3, 4, 5 & 6
1-5
Toggle Switches
terminal 2 to 3
no continuity
(infinite W)
continuity
(zero W)
terminal 2 to 4, 5 & 6
no continuity
terminal 3 to 4, 5 & 6
no continuity
terminal 4 to 5 & 6
no continuity
terminal 5 to 6
Center position
continuity
There are no terminal combinations
that will produce continuity
(infinite W)
Right position
terminal 1 to 2
continuity
(zero W)
terminal 1 to 3, 4, 5 & 6
no continuity
(infinite W)
terminal 2 to 3, 4, 5 & 6
no continuity
terminal 3 to 4, 5 & 6
no continuity
terminal 4 to 5
continuity
terminal 4 to 6
no continuity
terminal 5 to 6
no continuity
7-9
PLATFORM CONTROLS
1-6
Control Relays
Relays used for single function switching are
single pole double throw (SPDT) relays.
a
b
c
d
e
85
87A
87
86
30
Test
terminal 85 to 86 without resistor
terminal 87 to 87a & 30
terminal 87a to 30
Desired result
85 to 95W
no continuity
(infinite W)
continuity
(zero W)
7 - 10
Desired result
no continuity
(infinite W)
continuity
(zero W)
Platform Components
3 Remove the pin retainer fastener from
the rod-end pin.
2-1
Platform
How to Remove the Platform
1 Remove the cable harness from the cable
clamp located on the platform mounting
bracket and separate the foot switch quick
disconnect plug.
2 Remove the platform control box mounting
bolts, then lower the control box and
set it aside.
If your machine is equipped with
an airline to platform option, the
airline must be disconnected from
the platform before removal.
2-2
Platform Leveling Slave Cylinder
7 - 11
PLATFORM COMPONENTS
2-3
Platform Rotator
7 - 12
PLATFORM COMPONENTS
7 - 13
3-1
Jib Boom - S-65 Models
7 - 14
3-2
Jib Boom Lift Cylinder S-65 Models
How to Remove the Jib Boom
Lift Cylinder
Perform this procedure with the
boom in the stowed position.
1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Then
lower the jib boom until the platform is resting
on the blocks.
7 - 15
3-3
Jib Boom / Platform Rotate Manifold Components - S-65 Models
1
2 position 3 way valve ....................... A ........... Platform rotate select ....................... 8-10 ft-lbs / 11-14 Nm
2 position 3 way valve ....................... B ........... Platform rotate select ....................... 8-10 ft-lbs / 11-14 Nm
Hex Size
Torque
SAE No. 2
1/ 8
50 in-lbs / 6 Nm
SAE No. 4
3/16
13 ft-lbs / 18 Nm
SAE No. 6
1/ 4
18 ft-lbs / 24 Nm
SAE No. 8
5/16
50 ft-lbs / 68 Nm
SAE No. 10
9/16
55 ft-lbs / 75 Nm
SAE No. 12
5/ 8
75 ft-lbs / 102 Nm
7 - 16
6.3W
Boom Components
4-1
Plastic Cable Track
4-2
Boom
a
b
a
b
How to Remove
the Boom
7 - 17
BOOM COMPONENTS
How to Disassemble
the Boom
BOOM COMPONENTS
7 - 19
BOOM COMPONENTS
4-3
Boom Lift Cylinder
How to Remove the Boom
Lift Cylinder
This procedure requires specific
repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools may result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
4-4
Extension Cylinders
The extension cylinder consists of two cylinders
that are fastened together. The first cylinder
extends and retracts the number 2 boom tube.
The second cylinder extends and retracts the
number 3 boom tube.The extension cylinders are
equipped with counterbalance valves to prevent
movement in the event of a hydraulic line failure.
BOOM COMPONENTS
4-5
Platform Leveling
Master Cylinder
The master cylinder acts as a pump for the slave
cylinder. Its part of the closed circuit hydraulic
loop that keeps the platform level through the
entire range of boom motion. The master cylinder
is located at the base of the boom.
7 - 21
Turntable Covers
5-1
Turntable Covers
How to Remove a
Turntable Cover
1 Raise the turntable cover. Support the open
cover with an overhead crane or forklift.
Do not lift it.
Crushing hazard. Due to its heavy
weight, do not attempt to support
the cover by hand.
2 Remove the upper and lower retaining clips
from the gas strut.
3 Gently pry the strut pivot sockets off of the ball
studs and remove the strut. Protect the strut
cylinder rod from damage.
4 Remove the cover hinge bolts, that fasten the
hinge support bracket to the bulkhead.
5 Carefully lift and remove the cover from
the machine.
If a turntable cover must be
replaced, be sure that all
appropriate safety and
instructional decals are
applied to the new cover.
Alignment adjustments may be
necessary when a new cover
is installed.
7 - 22
6-1
RPM Adjustment
Refer to Maintenance Procedures, B-12,
Check and Adjust the Engine RPM.
6-2
Flex Plate
The flex plate acts as a coupler between the
engine and the pump. It is bolted to the engine
flywheel and has a splined center to drive
the pump.
a
6-3
Oil Temperature and Pressure
Gauges
a
b
c
d
e
f
f
pump
pump shaft
coupler
flex plate with raised spline
flywheel
1
/2 inch gap
7 - 23
110
f
7-1
Governor Actuator
7 - 24
7-2
Choke Adjustments
This engine is equipped with an electrically heated
automatic choke. The choke has a poppet valve to
enhance cold starting ability on LPG fuel.
Choke adjustments are affected
by climate. Richer adjustment
will be necessary in colder
climates, leaner adjustment
in warmer climates.
rich
lean
7 - 25
7-3
Timing Adjustment
7-4
Carburetor Adjustment
Complete information to perform this procedure is
available in the Ford LRG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: PPD-194287). Genie part number 33907.
7-5
RPM Adjustment
Refer to Maintenance Procedures, B-12, Check
and Adjust the Engine RPM.
7-6
Flex Plate
The flex plate acts as a coupler between the
engine and the pump. It is bolted to the engine
flywheel and has a splined center to drive
the pump.
a
a
b
c
d
e
f
7 - 26
f
pump
pump shaft
coupler
flex plate with raised spline
flywheel
1/4 inch gap
7-7
Water Temperature and Oil
Pressure Gauges
7-8
Vacuum Switch
How to Test the Vacuum Switch
d
a
b
c
d
ohmmeter
common terminal (SOL.)
vacuum switch
normally open terminal (ING.)
7 - 27
Ground Controls
8-1
Control Relays
Relays used for single function switching are
single pole double throw (SPDT) relays.
a
b
c
d
e
85
87A
87
Test
terminal 85 to 86 with resistor
75 to 85W
85 to 95W
7 - 28
85
87A
87
no continuity
(infinite W)
continuity
(zero W)
30
Desired result
86
30
Desired result
no continuity
(infinite W)
continuity
(zero W)
GROUND CONTROLS
8-2
Toggle Switches
8-4
Resistors
8-3
Wago Components
Electrocution hazard.
Contact with electrically charged
circuits may cause death or
serious injury. Remove all rings,
watches and other jewelry.
A small screwdriver is provided
and should be used when
removing a Wago component.
This screwdriver is located in the
operators manual storage box in
the platform.
7 - 29
GROUND CONTROLS
8-5
Power Relay
a
b
Desired result
2 small posts
13 to 17W
2 large posts
no continuity
(infinite W)
no continuity
(infinite W)
7 - 30
Desired result
continuity (zero W)
Hydraulic Pumps
9-1
Lift/Steer Pump
9-2
Drive Pump
closed
open
closed
HYDRAULIC PUMPS
7 - 32
7 - 33
Function Manifold
10-1
Function Manifold
The function manifold is located on the tank side tray, behind the ground control box.
Index
No.
Description
Schematic
Item
3 position 4 way D03 valve ............... N ........... Platform rotate .................................. 30-35 in-lbs / 3-4 Nm
Counterbalance valve ........................ B ........... Platform level up ............................... 35-40 ft-lbs / 47-54 Nm
3 position 4 way D03 valve ............... O ........... Platform level .................................... 30-35 in-lbs / 3-4 Nm
3 position 4 way D03 valve ............... P ........... Turntable rotate ................................ 30-35 in-lbs / 3-4 Nm
Function
Torque
3 position 4 way D03 valve ............... R ........... Boom up/down .................................. 30-35 in-lbs / 3-4 Nm
3 position 4 way D03 valve ............... S ........... Boom extend/retract ......................... 30-35 in-lbs / 3-4 Nm
Counterbalance valve ........................ C ........... Platform level down .......................... 35-40 ft-lbs / 47-54 Nm
10
11
Check valve ....................................... M .......... Boom up/down differential sensing .. 11-13 ft-lbs / 15-18 Nm
12
Flow regulator valve .......................... Y ........... Boom up/down .................................. 10-12 ft-lbs / 14-16 Nm
13
Relief valve, 2100 psi (145 bar) ........ D ........... Boom extend ..................................... 25-30 ft-lbs / 34-41 Nm
14
Relief valve, 2100 psi (145 bar) ........ F ........... Boom down ....................................... 25-30 ft-lbs / 34-41 Nm
15
Proportional solenoid valve ............... AA ......... Boom ................................................. 10-12 ft-lbs / 14-16 Nm
16
17
Normally closed poppet valve ........... J ............ Platform level .................................... 25-30 ft-lbs / 34-41 Nm
18
19
Flow regulator valve .......................... V ........... Platform level .................................... 10-12 ft-lbs / 14-16 Nm
20
Differential sensing valve .................. AC ........ All functions ....................................... 10-12 ft-lbs / 14-16 Nm
21
Flow regulator valve .......................... U ........... Platform rotate .................................. 10-12 ft-lbs / 14-16 Nm
22
Flow regulator valve .......................... W .......... Differential sensing circuit ................. 10-12 ft-lbs / 14-16 Nm
23
24
25
Priority flow regulator valve ............... T ........... Steering ............................................. 10-12 ft-lbs / 14-16 Nm
26
Check valve ....................................... I ............ Platform rotate right differential sensing ............................ 11-13 ft-lbs / 15-18 Nm
27
Check valve ....................................... H ........... Platform rotate left differential sensing ............................ 11-13 ft-lbs / 15-18 Nm
28
Check valve ....................................... L ........... Platform level - differential sensing .. 11-13 ft-lbs / 15-18 Nm
7 - 34
FUNCTION MANIFOLD
9
10
11
28
12
27
26
25
13
14
24
15
16
23
22
21
20
19
18
17
7 - 35
FUNCTION MANIFOLD
10-2
Valve Adjustments Function Manifold
2100 psi
145 bar
7 - 36
S-60
2600 psi
179 bar
S-65
2900 psi
200 bar
FUNCTION MANIFOLD
2100 psi
145 bar
7 - 37
FUNCTION MANIFOLD
7 - 38
5W
4.5W
7W
open
closed
7 - 39
11-2
Fuel Tank
How to Remove the Fuel Tank
Explosion hazard. Engine fuels
are combustible. Remove the fuel
tank in an open, well-ventilated
area away from heaters, sparks,
flames and lighted tobacco.
Always have an approved fire
extinguisher within easy reach.
Explosion hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
1 Turn the manual fuel shutoff valve to the
CLOSED position.
2 Gasoline/LPG models: Disconnect, drain and
plug the fuel hose.
Deutz Diesel models: Disconnect, drain and
plug the supply and return fuel lines. Cap the
fuel return fitting on the fuel tank.
3 Remove the mounting fasteners from the
bottom of the tank.
4 Use an appropriate lifting device to remove the
tank from the machine.
Clean the fuel tank and inspect
for rust and corrosion before
installing.
7 - 40
12-1
Rotation Hydraulic Motor
Unlocked position
d
f
a
b
c
d
e
f
Locked position
7 - 41
b
c
a
b
c
7 - 42
12-2
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor on the tank side of the
turntable.
Index
No.
Description
Schematic
Item
Shuttle valve 2 position 3 way ........... C ........... Turntable rotation brake release ...... 10-13 ft-lbs / 14-18 Nm
Counterbalance valve ........................ A ........... Turntable rotate - right ...................... 35-40 ft-lbs / 47-54 Nm
Counterbalance valve ........................ B ........... Turntable rotate - left ........................ 35-40 ft-lbs / 47-54 Nm
1
Function
Torque
Hex size
Torque
SAE No. 2
1/8
50 in-lbs / 6 Nm
SAE No. 4
3/16
13 ft-lbs / 18 Nm
SAE No. 6
1/4
18 ft-lbs / 24 Nm
SAE No. 8
5/16
50 ft-lbs / 68 Nm
SAE No. 10
9/16
55 ft-lbs / 75 Nm
SAE No. 12
5/8
75 ft-lbs / 102 Nm
7 - 43
13-1
Yoke and Hub
Torque specifications
a
b
c
d
e
f
g
420 ft-lbs
569.5 Nm
320 ft-lbs
433.9 Nm
tie rod
axle
king pin/retaining bolt
yoke
hub
pivot pin/retaining bolt
steering cylinder
7 - 44
13-2
Steering Cylinders
How to Remove a
Steering Cylinder
There are two identical steering cylinders that
work in parallel. They are part of the same
hydraulic circuit, but move in opposite directions.
The tie rod maintains equal movement of the tires.
Bushings are used at both ends of each steering
cylinder clevis.
1 Disconnect and plug the hydraulic hoses from
the steering cylinder. Cap the fittings.
7 - 45
13-3
Tie Rod
How to Remove the Tie Rod
1 Remove the pin retaining fasteners, then
remove the pivot pin from each end of the tie
rod.
7 - 46
14-1
Yoke and Hub
e
a
b
c
d
e
f
g
oscillate cylinder
king pin
torque hub
yoke
pivot pin
tie rod
steer cylinder
7 - 47
14-3
Tie Rod
How to Remove the Tie Rod
This procedure is the same as the 2WD
procedure. See Repair Procedure 13-3,
How to Remove the Tie Rod.
Torque specifications
Lug nut - dry bolts
420 ft-lbs
569.5 Nm
320 ft-lbs
433.9 Nm
120 ft-lbs
163 Nm
75 ft-lbs
102 Nm
14-2
Steering Cylinders
How to Remove a
Steering Cylinder
This procedure is the same as the 2WD
procedure. See repair procedure 13-2,
How to Remove a Steering Cylinder.
7 - 48
15-1
Oscillating Axle
Lock-out Cylinders
7 - 49
Description
Schematic
Item
Differential sensing valve .................. A ........... Differential sensing ........................... 10-12 ft-lbs / 14-16 Nm
Check valve ....................................... D ........... Oscillate check - left ......................... 35-40 ft-lbs / 47-54 Nm
Shuttle valve 2 position 3 way ........... C ........... Pilot ................................................... 10-12 ft-lbs / 14-16 Nm
Check valve ....................................... E ........... Oscillate check - right ....................... 35-40 ft-lbs / 47-54 Nm
Shuttle valve 2 position 3 way ........... F ........... Unloading .......................................... 35-40 ft-lbs / 47-54 Nm
Function
Torque
4
8
7
6
Hex size
Torque
Description
Hex size
Torque
SAE No. 2
50 in-lbs / 6 Nm
SAE No. 8
50 ft-lbs / 68 Nm
SAE No. 4
13 ft-lbs / 18 Nm
SAE No. 10
55 ft-lbs / 75 Nm
SAE No. 6
18 ft-lbs / 24 Nm
SAE No. 12
75 ft-lbs / 102 Nm
7 - 50
/8
/16
/4
/16
/16
/8
16-2
Valve Adjustments
How to Adjust the Sequencing
Valve Pressure
1 Connect a 0 to 600 psi (0 to 41 bar) pressure
gauge to the test port located on the oscillate
manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
2 Disconnect the directional valve linkage, by
removing the clevis yoke from the drive
chassis.
3 Start the engine from the platform controls.
4 With the engine running, manually activate the
valve and observe the pressure reading on the
pressure gauge.
5 Turn the engine off. Hold the valve and remove
the cap (index 4).
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise
to decrease the pressure. Then install the
valve cap.
7 Restart the engine. manually activate the valve
and recheck the valve pressure.
8 Turn the engine off, then remove the
pressure gauge and assemble the directional
valve linkage.
Unloader valve specifications
Pressure
950 psi
65 bar
7 - 51
16-3
Directional Valve Manifold Components
The directional valve manifold is mounted inside the drive chassis at the non-steer end.
Index
No.
Description
Schematic
Item
Function
Torque
7 - 52
7 - 53
16-4
Steer Manifold Components
The steer manifold is mounted to the engine side tray.
Index
No.
Description
Schematic
Item
3 position 4 way D03 valve .............................. Steering ............................................. 30-35 in-lbs / 3-4 Nm
Function
Torque
Hex size
Torque
Description
Hex size
Torque
SAE No. 2
50 in-lbs / 6 Nm
SAE No. 8
50 ft-lbs / 68 Nm
SAE No. 4
13 ft-lbs / 18 Nm
SAE No. 10
55 ft-lbs / 75 Nm
SAE No. 6
18 ft-lbs / 24 Nm
SAE No. 12
75 ft-lbs / 102 Nm
7 - 54
/8
/16
/4
/16
/16
/8
17-2
Torque Hub
Torque specifications
Torque specifications
Drive motor mounting bolts
75 ft-lbs
102 Nm
420 ft-lbs
569.5 Nm
320 ft-lbs
433.9 Nm
120 ft-lbs
163 Nm
75 ft-lbs
102 Nm
7 - 55
Description
Schematic
Item
Relief valve, 250 psi (17 bar) ............ B ........... Charge pressure circuit .................... 15-18 ft-lbs / 20-24 Nm
Shuttle valve 3 position 3 way ........... A ........... Charge pressure circuit that
Function
Torque
7 - 56
Hex size
Torque
SAE No. 2
1/8
50 in-lbs / 6 Nm
SAE No. 4
3/16
13 ft-lbs / 18 Nm
SAE No. 6
1/4
18 ft-lbs / 24 Nm
SAE No. 8
5/16
50 ft-lbs / 68 Nm
SAE No. 10
9/16
55 ft-lbs / 75 Nm
SAE No. 12
5/8
18-2
Valve Adjustments
How to Adjust the Charge
Pressure Relief Valve
1 Connect a 0 to 600 psi (0 to 41 bar) pressure
gauge to the test port located on the drive
manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
75 ft-lbs / 102 Nm
250 psi
7 - 57
Description
Schematic
Item
Function
Torque
Relief valve, 250 psi (17 bar) ............ E ........... Charge pressure circuit ................... 15-18 ft-lbs / 20-24 Nm
Orifice 0.052 in (1.32 mm) ................ H ........... Drive circuit, non-steer end
Orifice 0.070 in (1.78 mm) ................ F ........... Drive circuit, steer end
Orifice 0.070 in (1.78 mm) ................ G ........... Drive circuit, non-steer end
7 - 58
7 - 59
Hex size
Torque
SAE No. 2
1/ 8
50 in-lbs / 6 Nm
SAE No. 4
3/16
13 ft-lbs / 18 Nm
SAE No. 6
1/ 4
18 ft-lbs / 24 Nm
Pressure
17 bar
SAE No. 8
5/16
50 ft-lbs / 68 Nm
SAE No. 10
9/16
55 ft-lbs / 75 Nm
SAE No. 12
5/ 8
250 psi
75 ft-lbs / 102 Nm
19-2
Valve Adjustments
How to Adjust the Charge
Pressure Relief Valve
1 Connect a 0 to 600 psi (0 to 41 bar) pressure
gauge to the test port located on the drive
manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
2 Start the engine from the platform controls.
3 Drive the machine slowly in either direction
and observe the pressure reading on the
pressure gauge.
4 Turn the engine off. Hold the relief valve and
remove the cap (index 2).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise
to decrease the pressure. Then install the
valve cap.
7 - 60
7 - 61
Distributed By:
Genie Europe
Brunel Drive
Newark
Nottinghamshire
NG24 2EG England