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Genie Industries S-80, Service Manual

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Summary of Contents for S-80

Page 1: ... e r i a l l i f t e q u i p m e n t c o m A l e x a n d e r E q u i p m e n t S a l e s a n d R e n t a l 1 5 1 1 C o m m e r c e D r i v e B o u r b o n n a i s I L 6 0 9 1 4 G e n i e S 8 5 S E R V I C E MA N U A L R E C OU R C E L I B R A R Y ...

Page 2: ...Service Manual Technical Publications Second Edition First Printing Part No 52270 S 80 S 85 S 80 S 85 ...

Page 3: ...s This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we...

Page 4: ...njury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations...

Page 5: ... locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or other fluids Use an approved container Please be environmentally safe Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each ...

Page 6: ... Fitting Torque Specifications 2 8 Bolt Torque Specifications 2 9 Section Three Scheduled Maintenance Inspections Introduction 3 1 Table A 3 2 Table B 3 3 Table C 3 5 Table D 3 6 Maintenance Inspection Report 3 7 Section Four Scheduled Maintenance Procedures Introduction 4 1 A 1 Inspect the Manuals 4 2 A 2 Inspect the Decals and Placards 4 2 A 3 Inspect for Damage Loose or Missing Parts 4 2 A 4 Ch...

Page 7: ...dels 4 15 B 4 Check the Exhaust System 4 16 B 5 Check the Battery 4 17 B 6 Check the Hydraulic Tank Filter Condition Indicator 4 17 B 7 Inspect the Electrical Wiring 4 18 B 8 Inspect the Tires and Wheels including lug nut torque 4 18 B 9 Confirm the Proper Brake Configuration 4 19 B 10 Check the Oil Level in the Torque Hubs 4 19 B 11 Check and Adjust the Engine Idle Mixture Gasoline LPG Models 4 2...

Page 8: ...5 C 10 Replace the Gasoline Fuel Filter Gasoline LPG Models 4 36 C 11 Replace the PCV Valve Gasoline LPG Models 4 37 C 12 Replace the Spark Plugs Gasoline LPG Models 4 37 C 13 Check and Adjust the Air LPG Mixture Gasoline LPG Models 4 38 C 14 Check and Adjust the Ignition Timing Gasoline LPG Models 4 39 C 15 Check the Engine Valve Clearances Deutz Diesel Models 4 39 C 16 Check the Turntable Rotati...

Page 9: ...el Models 5 23 9 Engine Low Idle Inoperative Deutz Diesel Models 5 25 10 All Functions Inoperative Engine Starts and Runs 5 26 11 All Lift and Steer Functions Inoperative Drive Functions Operational 5 27 11A All Lift Functions Inoperative Steer and Drive Functions Operational 5 28 12 Ground Controls Inoperative Platform Controls Operate Normally 5 30 13 Platform Controls Inoperative Ground Control...

Page 10: ... 80 36 Drive Enable System Is Malfunctioning 5 81 37 Auxiliary Functions Inoperative 5 82 Section Six Schematics Introduction 6 1 Electrical Components 6 2 Electrical Symblos Legend 6 4 Abbreviation Legend 6 5 Electrical Schematic Gasoline LPG Models 6 7 Ground Control Box Legend Gasoline LPG Models 6 9 Ground Control Box Wiring Diagram Gasoline LPG Models 6 10 Platform Control Box Legend Gasoline...

Page 11: ...3 Platform Rotator 7 12 Jib Boom Components S 85 Models 3 1 Jib Boom S 85 Models 7 15 3 2 Jib Boom Lift Cylinder S 85 Models 7 16 3 3 Jib Boom Platform Rotate Manifold Components S 85 Models 7 17 Boom Components 4 1 Boom Cable Track 7 18 4 2 Boom 7 20 4 3 Boom Lift Cylinder 7 22 4 4 Extension Cylinders 7 23 4 5 Platform Leveling Master Cylinder 7 24 Turntable Covers 5 1 Turntable Covers 7 26 Deutz...

Page 12: ...ponents 7 33 8 4 Resistors 7 33 8 5 Power Relay 7 34 Hydraulic Pumps 9 1 Lift Steer Pump 7 35 9 2 Drive Pump 7 35 Manifolds 10 1 Function Manifold Components 7 38 10 2 Valve Adjustments Function Manifold 7 42 10 3 Turntable Rotation Manifold Components 7 45 10 4 Chassis Jack Manifold Components 7 46 10 5 Axle Extend Dump Manifold Components 7 47 10 6 Steer Manifold Components 7 46 10 7 2WD Drive M...

Page 13: ...ering Axle Components 13 1 Yoke and Hub 7 65 13 2 Steering Cylinders 7 66 13 3 Tie Rod Cylinder 7 67 4WD Steering Axle Components 14 1 Yoke and Hub 7 68 14 2 Steering Cylinders 7 69 14 3 Tie Rod Cylinder 7 69 Extendable Axle Components 15 1 Extendable Axles 7 70 15 2 Drive Chassis Lift Jacks 7 72 15 3 Hydraulic Limit Switches 7 72 Non steering Axle Components 16 1 Drive Motor 7 73 16 2 Torque Hub ...

Page 14: ...Part No 52270 Genie S 80 Genie S 85 Service Manual Second Edition This page intentionally left blank xiii ...

Page 15: ...us Platform rotation 160 160 Maximum capacity 600 lbs 500 lbs 6 foot platform 272 kg 227 kg Maximum capacity 500 lbs 500 lbs 8 foot platform 227 kg 227 kg Maximum allowable 150 lbs 150 lbs side force ANSI and CSA 68 kg 68 kg Platform dimensions 6 ft 8 ft Standard Optional Length 72 in 96 in 182 8 cm 243 8 cm Width 30 in 36 in 76 2 cm 91 4 cm Tires and wheels Tire size 15 22 5 SAT Tire ply rating 1...

Page 16: ...ded 210 to 240 seconds Platform rotate 160 8 to 12 seconds Platform level up 50 to 60 seconds Platform level down 40 to 50 seconds Performance Specifications Drive speeds maximum 2WD 4WD Drive speed stowed 3 8 mph 3 1 mph Gasoline LPG models 6 1 km h 4 9 km h 40 ft 7 2 sec 40 ft 8 8 sec 12 2 m 7 2 sec 12 2 m 8 8 sec Drive speed stowed 3 3 mph 3 mph Deutz Diesel models 5 3 km h 4 8 km h 40 ft 8 3 s...

Page 17: ... Displacement per revolution variable 0 16 to 2 8 cu in 4WD 2 speed motor 2 62 to 45 9 cc Displacement per revolution variable 1 12 to 2 8 cu in 2WD 18 4 to 45 9 cc Function pump Type pressure balanced gear Displacement static 1 14 cu in 19 cc Displacement 2500 rpm 0 to 12 3 gallons per minute 0 to 46 6 liters per minute Hydraulic tank circuit 10 micron with 25 psi return line filter 1 7 bar bypas...

Page 18: ...23 C to 32 C 10W 30 Temperature above 10W 40 to 10W 50 10 F 23 C Temperature above 20W 40 or 20W 50 20 F 6 6 C Use oils meeting API classification SG labeled SG CC or SG CD as they offer improved wear protection Units ship with 10W 40 SG CC Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 170A Current draw maximum load 200A Current draw minimum 140A Maximum circui...

Page 19: ...cations torque torque Bolt description size ft lbs Nm Exhaust manifold to cylinder head bolt or nut M 10 torque in sequence first step 14 to 19 19 to 26 second step 35 to 50 47 to 68 Flywheel to crankshaft 54 to 64 73 to 87 bolt M 10 Intake manifold to 15 to 22 20 to 30 cylinder head bolt or nut M 8 Oil pressure sending unit to block 8 to 18 11 to 24 Oil pan drain plug to pan M 14 15 to 25 20 to 3...

Page 20: ... to 7 8 to 10 Blower rotor nut 33 to 41 45 to 55 M 17 Valeo or M 18 Bosch Blower carrier bolts 15 to 18 20 to 24 M 8 x 50 Torx 8 8 V belt pulley bolts 28 to 34 38 to 46 M 10 x 16 8 8 Deutz Engine F4L 1011F Displacement 166 7 cu in 2 732 liters Number of cylinders 4 Bore and stroke 3 58 x 4 13 inches 91 x 105 mm Horsepower 56 3000 rpm Firing order 1 3 4 2 Compression ratio 18 5 1 Compression pressu...

Page 21: ...old bolts 27 to 32 36 to 44 M 10 x 30 Torx 10 9 Starter fastening bolts 28 to 34 38 to 46 M 10 x 28 8 8 Starter carrier bolts 50 to 60 68 to 82 M 12 x 28 8 8 Oil pan bolts 15 to 18 20 to 24 M 8 x 16 Torx 8 8 Oil drain bolts 37 to 44 50 to 60 torque torque ft lbs Nm Oil thermostat housing screw 37 to 44 50 to 60 plug M 38 x 1 5 Oil thermostat housing bolts 5 5 to 7 7 5 to 9 M 6 x 35 Torx 8 8 Oil th...

Page 22: ...k O ring face seal hoses and fittings require that the fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed Torque Procedure 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight The O rings used in ...

Page 23: ...41 48 68 75 102 122 149 163 204 231 353 407 583 637 868 949 60 68 144 168 25 25 45 50 70 80 110 120 150 170 220 240 380 420 600 660 900 1000 7 8 16 19 34 34 61 68 95 109 149 163 204 231 298 326 515 570 814 895 1221 1356 Size Threads SAE Grade 5 Bolts SAE Grade 8 Bolts Bolt Torque Specifications No 10 1 4 inch 5 16 inch 3 8 inch 7 16 inch 1 2 inch 9 16 inch 5 8 inch 3 4 inch 7 8 inch 1 inch Torque ...

Page 24: ...2 10 Genie S 80 Genie S 85 Part No 52270 Section 2 Specifications Service Manual Second Edition This page intentionally left blank ...

Page 25: ... longer than 3 months must complete the quarterly inspection About This Section The Schedule There are four types of maintenance inspections that must be performed according to a schedule daily quarterly annual two year To account for repeated procedures the Maintenance Tables and the Maintenance Inspection Report have been divided into four subsections A B C D Use the following chart to determine...

Page 26: ...t the Decals and Placards A 3 Inspect for Damage Loose or Missing Parts A 4 Check the Engine Oil Level A 5 Check the Engine Coolant Level Gasoline LPG Models A 6 Check for Fuel Leaks A 7 Check the Hydraulic Oil Level A 8 Check for Hydraulic Leaks A 9 Check the Tire Pressure A 10 Test the Extendable Axles A 11 Test the Platform and Ground Controls A 12 Test the Auxiliary Power Operation A 13 Test t...

Page 27: ... A 16 Drain the Fuel Filter Water Separator Deutz Diesel Models A 17 Replace the Engine Air Filter Table B B 1 Check the Engine Belt B 2 Check the Radiator Gasoline LPG Models B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models B 4 Check the Exhaust System B 5 Check the Battery B 6 Check the Hydraulic Tank Filter Condition Indicator B 7 Inspect the Electrical Wiring B 8 Inspect the Tires...

Page 28: ...gency Stop Buttons B 15 Test the Ground Control Override B 16 Test the Platform Self leveling B 17 Test the Horn B 18 Test the Foot Switch B 19 Test the Engine Idle Select B 20 Test the Fuel Select Operation Gasoline LPG Models B 21 Test the Drive Enable System B 22 Test the Drive Brakes B 23 Test the Drive Speed Stowed Position B 24 Test the Alarm Package Optional Equipment B 25 Check the Hydraul...

Page 29: ...iesel Models Table C C 1 Check the Boom Wear Pads C 2 Check the Extendable Axle Wear Pads C 3 Check the Turntable Rotation Bearing Bolts C 4 Check the Free wheel Configuration C 5 Grease the Turntable Rotation Bearing and Rotate Gear C 6 Replace the Torque Hub Oil C 7 Replace the Hydraulic Tank Filter C 8 Replace the Drive Loop Hydraulic Filter C 9 Replace the Diesel Fuel Filter Water Separator De...

Page 30: ... Clearances Deutz Diesel Models C 16 Check the Turntable Rotation Gear Backlash Table D D 1 Test or Replace the Hydraulic Oil D 2 Change or Recondition the Engine Coolant Gasoline LPG Models D 3 Change the Fuel Lines D 4 Check the Engine Valve Clearance Gasoline LPG Models D 5 Check the Engine Cylinder Compression Gasoline LPG Models D 6 Clean the PCV Hoses and Fittings Gasoline LPG Models D 7 Che...

Page 31: ...Engine coolant Gas LPG A 6 Fuel leaks A 7 Hydraulic oil level A 8 Hydraulic leaks A 9 Tire pressure A 10 Extendable axles A 11 Platform and ground controls A 12 Auxiliary power A 13 Tilt sensor A 14 Limit switches Perform every 100 hours A 15 Replace engine oil and filter Gas LPG Models A 16 Drain filter separator Deutz Diesel A 17 Replace air filter Checklist B Y N R Refer to Table B B 1 Engine b...

Page 32: ...Part No 52270 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition Tools are required New parts required Warm engine required Cold engine required Dealer service suggested This page intentionally left blank ...

Page 33: ...ections for three years Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a flat level surface Boom in stowed position Turntable rotated with the boom between the non steering wheels Key switch in the OFF position with the key removed Wheels chocked About This Section This section contains detailed procedures for each sc...

Page 34: ...ovide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Refer to the Decals section in the appropriate Genie S 80 Genie S 85 Operator s Manual and use the decal list and illustrations to determine that all decals and placards are in place Table A Procedures 2 Inspect all decals...

Page 35: ...to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE CD SE SF CC or SF CD grades 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 inspect...

Page 36: ...or to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure that the boom is in the stowed position then visually inspect the sight gauge located on the side of the hydraulic oil tank Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge Hydraulic oil specifications Hydraulic oil type Dexron equivalent Tank capacity...

Page 37: ...limit switch unless both axles are extended 3 Hold the function enable switch to either side and activate the boom down function Result The boom should lower and return to the stowed position 4 Hold the function enable switch to either side and activate the boom extend function Result The boom should extend no more than 6 inches 15 cm and then stop The boom should not extend beyond the limit switc...

Page 38: ...toggle switch Result All boom and platform functions should not operate 4 Hold the function enable switch to either side and activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle Descent alarm if equipped should sound while the boom is lowering 5 Push in the Emergency Stop button to the OFF position Result No function shou...

Page 39: ...imultaneously hold the auxiliary power switch ON and activate each boom function toggle switch To conserve battery power test each function through a partial cycle Result All boom functions should operate 4 Turn the key switch to platform control 5 Pull out the Emergency Stop button to the ON position at the platform controls then press down the foot switch 6 Lift the red auxiliary power switch co...

Page 40: ... 14 Test the Limit Switches Drive Limit Switches Detecting limit switch malfunctions is essential to safe machine operation The drive limit switches are used to restrict drive speed when the boom is raised or extended An improperly functioning drive limit switch will allow the machine to operate at an unsafe drive speed 1 Remove the cover from the rear of the turntable to access the drive limit sw...

Page 41: ...e limit switch Result The boom extend drive limit switch arm should move freely and spring return to center A distinct click should be felt and heard 8 Turn the keyswitch to platform control 9 Start the engine from the platform controls and fully retract the boom 10 Slowly move the drive control handle off center Result The machine should move at normal drive speeds 11 Raise the boom to just above...

Page 42: ... the non steer tires 6 Rotate the turntable to the left until the boom is past the left non steer wheel Result The drive enable indicator light should be on Drive function should not operate until the drive enable toggle switch is activated 7 Rotate the turntable to the right until the boom is past the right non steer wheel Result The drive enable indicator light should be on Drive function should...

Page 43: ...ne parts may cause severe burns 1 Remove the oil filler cap located on the valve cover a b c b 2 Place a suitable container under the engine pivot plate directly below the oil pan drain plug a engine pivot plate b pivot plate retaining bolts c oil drain hose 3 Remove the plug from the oil pan and allow all of the oil from the engine to drain into a suitable container See capacity specifications be...

Page 44: ...LE A PROCEDURES A 16 Drain the Fuel Filter Water Separator Deutz Diesel Models Engine specifications require that this procedure be performed every 500 hours Poor fuel quality or very wet conditions may necessitate performing this procedure more often Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor en...

Page 45: ...edure be performed every 100 hours Perform this procedure more often if dusty conditions exist Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off 1 Remove the retaining ring from the end cap of the air filter...

Page 46: ...ne components may cause severe burns 1 Deutz Diesel models Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the front engine access cover mounting fasteners 2 Remove the front engine access cover mounting fasteners 3 All models Inspect the engine belt for Cracking Glazing Separation Breaks 4 Replace belt if any damage is found Table ...

Page 47: ...e 2 engine pivot plate retaining bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the radiator 2 Inspect the radiator for leaks and physical damage 3 Clean the radiator fins of debris and foreign materials B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models Maintaining the oil cooler in good condition is essential for good engine perfor...

Page 48: ...ssential 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 1 Deutz Diesel models Remove the 2 bolts from under the...

Page 49: ...eeded replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the vent caps Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables B 6 Check the Hydraulic Tank Filter Condition Indicator Maintaining the hydraulic tank filter in good condition is essential to good system performance an...

Page 50: ...s 4 Lower the boom into the stowed position and turn the engine off 5 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable track on the boom Boom to platform cable harness Inside of the platform control box Jib boom cable cover S 85 models B 8 Inspect the Tires and Wheels including lug nut torque Maintaining the tires and wheels in good condition is essential to safe...

Page 51: ...ed TABLE B PROCEDURES B 10 Check the Oil Level in the Torque Hubs Failure to maintain proper torque hub oil levels may cause the machine to perform poorly and continued use may cause component damage Drive Torque Hubs 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees 2 Remove the plug located at 90 degrees and check the oil level Result The oi...

Page 52: ...ce Manual Ford number PPD 194 287 Genie part number 33907 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 Gasoline LPG Models Perform this procedure in gasoline mode with ...

Page 53: ...e to the top of the trimpot screw Apply a bead of silicone to the surface of the back panel prior to re assembly 11 Re assemble the governor and recheck low and high idle Gasoline LPG models Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm Deutz Diesel models 1 Connect an rpm gauge to the engine and then start the engine from the ground controls Result Low idle ...

Page 54: ... ground control 5 Check any machine function from the platform controls Result The machine functions should not operate 6 Turn the key switch to the OFF position Result The engine should stop and no functions should operate Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds B 14 Test the Emergency Stop Buttons Properly functioning Emergency Stop...

Page 55: ...tion 2 Adjust the platform to a level position using the platform level toggle switch 3 Raise and lower the boom through a full cycle Result The platform should remain level at all times to within 5 degrees B 17 Test the Horn A functional horn is essential to safe machine operation The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperl...

Page 56: ...nd platform controls 2 Start the engine from the ground controls Then move the function enable toggle switch to the high idle rabbit symbol position and hold in the ON position Result The engine should change to high idle 3 Release the function enable toggle switch Result The engine should return to low idle 4 Turn the key switch to platform controls 5 At the platform controls move the engine idle...

Page 57: ...ion 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 to either side 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 int...

Page 58: ...and your machine reference point Braking paved surface 2WD 4WD Stopping distance 3 to 5 ft 2 to 3 ft 0 9 to 1 5 m 0 6 to 0 9 m The brakes must be able to hold the machine on any slope it is able to climb B 23 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 per...

Page 59: ...The flashing beacon should be on and flashing 4 Press down the foot switch Move the boom control handle to the DOWN position hold for a moment and then release it Result The descent alarm should sound when the control handle is held down 5 Press down the foot switch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposi...

Page 60: ...se out from under the engine 3 Remove the plug from the end of the drain hose and allow all of the oil from the engine to drain into a suitable container See capacity specifications to the right 4 Install the plug into the drain hose 5 Use an oil wrench and remove the oil filter a engine oil level dipstick b fuel filter c oil filter 6 Apply a thin layer of oil to the new filter gasket Genie part n...

Page 61: ...of the boom tubes Always maintain squareness between the outer and inner boom tubes Boom wear pad specifications Upper and lower wear pads 9 16 inch 14 3 mm Side wear pads 11 16 inch 17 5 mm Table C Procedures C 2 Check the Extendable Axle Wear Pads Maintaining the axle wear pads in good condition is essential to safe machine operation Wear pads are placed on axle tube surfaces to provice a low fr...

Page 62: ...0 foot pounds 285 Newton meters Bolt torque sequence 3 Lower the boom to the stowed position 4 Check to ensure that each bearing mounting bolt under the drive chassis is torqued in sequence to 210 foot pounds 285 Nm Bolt torque sequence C 4 Check the Free wheel Configuration Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used prima...

Page 63: ...0 lbs 9072 kg under the drive chassis between the non steer tires 9 Lift the wheels off the ground and then place jack stands under the drive chassis for support 10 Disengage the torque hubs by turning over the torque hub disconnect caps on each steer wheel hub 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort 12 Re engage the torque hubs by turning over...

Page 64: ...purpose grease C 6 Replace the Torque Hub Oil Replacing the torque hub oil is essential for good machine performance and service life Failure to replace the torque hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage Drive Torque Hubs 1 Select the torque hub to be serviced Then drive the machine until one of the two plugs is at the lowest...

Page 65: ...rque hub mounting bolts and then use a lifting device to remove the torque hub from the machine 4 Remove the plug from the side of the torque hub Then drain the oil from the hub 5 Install the torque hub Torque the hub mounting bolts to 180 foot pounds 244 Newton meters 6 Install the brake and motor onto the torque hub 7 Fill the hub with oil from the side hole until the oil level is even with the ...

Page 66: ...ontrols 6 Inspect the filter and related components to be sure that there are no leaks C 8 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 ...

Page 67: ...e extinguisher within easy reach Perform this procedure with the engine off 1 Turn the manual fuel shutoff valve located at the fuel tank to the CLOSED position 2 Remove the fuel filter with a filter wrench a oil filter b fuel filter water separator Prime the Fuel Pump 3 Fill the new filter Genie part no 29560 with fresh diesel fuel and apply a thin layer of oil or diesel fuel to the new fuel filt...

Page 68: ...ngine off 1 Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the fuel filter located near the carburetor a pivot plate retaining bolts b engine pivot plate 2 Disconnect the fuel hose from the filter then remove the filter from the fitting a fuel filter b hose from the fuel pump to the fuel filter 3 Install the new fuel filter Genie p...

Page 69: ...ngine pivot plate 2 Remove the hose from the PCV valve then remove the valve a PCV valve 3 Install the new PCV valve Connect the hoses 4 Swing the engine pivot plate back to its original position and replace the two retaining bolts C 12 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...

Page 70: ...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 The engine should be warmed to normal operating temperature before performing this procedure 1 Move the fuel select switch to LPG fuel and start the engine from the ground controls 2 Loosen the high idle mixture adjustment ...

Page 71: ... procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 C 15 Check the Engine Valve Clearances Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011F Workshop Manual Deutz Number 0297 7195 Genie part number 52229 C 16 Check the Turntable Rotation Gear Backlash The turntable...

Page 72: ...l 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 equivalent hydraulic oil Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contam...

Page 73: ...er coolant mixture anti freeze and water for your climate into the radiator until it is full TABLE D PROCEDURES 10 Disconnect the hose coupler at the fan end from the tube that is connected to the water pump and hold it until coolant starts to come out of the open hose Then immediately reconnect the hose a tube connected to water pump b hose coupler 11 Fill the radiator and then fill the coolant r...

Page 74: ...co Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Close the manual fuel shutoff valve located next to the fuel tank 2 Remove and replace the fuel line hoses and clamps according to the following illustrations Fuel may be expelled under pressure Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them Deutz Diesel mode...

Page 75: ...for leaks If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately 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 194 287 Genie part number 33907 D 5 Check the Engine ...

Page 76: ...e engine pivot plate away from the machine to access the PCV hoses a pivot plate retaining bolts b engine pivot plate b a a 2 Disconnect the hose from the PCV valve then disconnect the hose from the engine a carburetor to valve cover hose b PCV valve c PCV valve to carburetor hose 3 Disconnect the hose from the carburetor then disconnect the hose from the valve cover 4 Clean the hoses with a mild ...

Page 77: ...move the lug nuts then remove the tire and wheel assembly 5 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result There should be no side to side or up and down movement Skip to step 10 if there is no movement 6 Remove the dust cap from the hub then remove the cotter pin from the castle nut 7 Tighten the castle nut to 35 foot pounds 47 Nm to seat the...

Page 78: ...the seal may occur 17 Place the outer bearing into the hub 18 Install the washer and slotted nut 19 Tighten the slotted nut to 35 foot pounds 47 Nm to seat the bearings 20 Loosen the slotted nut then re tighten to 8 foot pounds 11 Nm 21 Install a new cotter pin Bend the cotter pin to lock it in 22 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 420 foot pounds 56...

Page 79: ...odily 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 Perform all troubleshooting on a firm level surface Two persons will be required to safely perform some troubleshooting procedures Troubleshooting Flow Charts Observe and Obey Troubleshooting and repair ...

Page 80: ...ter ohmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition ...

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Page 94: ...INKIQ URZGMK GZ ZKXSOTGR UT 8 8KVRGIK 8 XKRG_ URJ ZNK YZGXZ Y OZIN ZU KOZNKX YOJK GTJ INKIQ URZGMK GZ HR XKJ OXK UT 26 YURKTUOJ 8KVGOX UVKT OT HR XKJ OXK IOXI OZ LXUS 8 ZKXSOTGR ZU 26 YURKTUOJ NKIQ XKYOYZGTIK UL 26 YURKTUOJ UX OTLOTOZK UNSY 8KVRGIK 26 YURKTUOJ ZU UNSY 8KIUTTKIZ 26 ZGTQ GTJ YZGXZKX ZNKT YKK 3GOTZKTGTIK YKIZOUT LUX 26 GJP YZSKTZY 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ ...

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Page 96: ... LUX IGXH XKZUX ZXU HRKYNUUZOTM 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ UTZOT KJ LXUS ZNK VXK OU Y VGMK TYZGRR G VXKYY XK MG MK ZU ZNK L KR V SV URJ YZGXZ Y OZIN ZU KOZNKX YOJK GTJ UHYKX K ZNK VXKYY XK UT ZNK MG MK RKYY ZNGT VYO 8KVRGIK L KR V SV 58 INKIQ GTZO JOKYKR GTJ L KR GR K LUX JKLKIZY SUXK ZNGT VYO NKIQ IUTZOT OZ_ LXUS MXU TJ ZU HXU T OXK GZ L KR V SV TU IUTZOT OZ_ 8KVGOX UVKT OT HXU T...

Page 97: ...Z Y_SHUR LUX LURRU OTM ZKYZY NKIQ URZGMK GZ HRQ XKJ OXK UT XVS YKRKIZ Y OZIN 9 GTJ 9 NKIQ URZGMK GZ IKTZKX ZKXSOTGR UT XVS YKRKIZ Y OZIN 9 GTJ 9 8KVGOX UVKT OT VU KX Y VVR_ IOXI OZ ZU IKTZKX ZKXSOTGR UL Y OZIN 8KVRGIK XVS YKRKIZ ZUMMRK Y OZIN NKIQ URZGMK GZ 8KVGOX UVKT OT HRQ XKJ OXK IOXI OZ LXUS ZUMMRK Y OZIN ZU 6 ZU NKIQ URZGMK GZ ZKXSOTGR HRQ XKJ UT 8 8KVGOX UVKT OT HRQ XKJ OXK IOXI OZ LXUS ZU ...

Page 98: ... ZU MU KXTUX GIZ GZUX ZKXSOTGR NKIQ IUTZOT OZ_ LXUS ZKXSOTGR UT VXKIOYOUT MU KXTUX ZU HR HRQ ZKXSOTGR UT MU KXTUX GIZ GZUX TU IUTZOT OZ_ 8KVGOX UVKT OT HR HRQ OXK IOXI OZ LXUS MU KXTUX GIZ GZUX ZU KRKIZXUTOI MU KXTUX L RR IUTZOT OZ_ NKIQ URZGMK GZ ZKXSOTGR UT 8 8KVGOX UVKT OT XJ HRQ 8 OXK IOXI OZ LXUS GI ST Y OZIN ZU 8 ZU 8 ZU ZKXSOTGR UT 8 NKIQ IUTZOT OZ_ LXUS MXU TJ ZU HXU T OXK UT ZKXSOTGR UL 8...

Page 99: ...UX ZKXSOTGRY UX OTLOTOZK UNSY 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 8KVGOX UVKT OT HXU T OXK IOXI OZ LXUS OMTOZOUT IUOR VR M ZU KRKIZXUTOI MU KXTUX 9KK 3GOTZKTGTIK YKIZOUT LUX MU KXTUX GJP YZSKTZY 58 XKVRGIK KRKIZXUTOI MU KXTUX NKIQ URZGMK UT XKJ NZ OXK UT MU KXTUX GIZ GZUX 8KVGOX UVKT OT XKJ NZ ...

Page 100: ...GTJ 9 INKIQ OTJO OJ GRR_ GTJ XKVRGIK JKLKIZO K Y OZIN NKIQ URZGMK GZ ZKXSOTGR UT KRKIZXUTOI MU KXTUX 8KVGOX UVKT OT HRQ XKJ OXK IOXI OZ LXUS 8 ZKXSOTGR ZU KRKIZXUTOI MU KXTUX ZKXSOTGR NKIQ URZGMK GZ KRKIZXUTOI MU KXTUX ZKXSOTGR GTJ HXU T OXKY 8KVGOX UVKT OT HXU T OXK IOXI OZ LXUS OMTOZOUT SUJ RK ZU KRKIZXUTOI MU KXTUX XT SGINOTK ULL XKSU K HR HRQ OXK LXUS ZKXSOTGR UT KRKIZXUTOI MU KXTUX GTJ XKYZGX...

Page 101: ...HRKYNUUZ L KR OTPKIZOUT Y_YZKS YURKTUOJ JUKY TUZ V RR OT NKIQ URZGMK GZ HRQ XKJ OXK UT XVS YKRKIZ Y OZIN 9 GTJ 9 NKIQ URZGMK UT XKJ OXK GZ IKTZKX ZKXSOTGR UL XVS YKRKIZ Y OZIN 8KVGOX UVKT OT IOXI OZ Y VVR_OTM ZU IKTZKX ZKXSOTGR UL Y OZIN 8KVRGIK ZUMMRK Y OZIN NKIQ URZGMK GZ 8KVGOX UVKT OT HRQ XKJ OXK IOXI OZ LXUS ZUMMRK Y OZIN ZU NKIQ URZGMK GZ ZKXSOTGR UT 8 8KVGOX UVKT OT HRQ XKJ OXK IOXI OZ LXUS...

Page 102: ...SU KY OT GTJ U Z LXKKR_ YURKTUOJ HOTJY NKIQ ROTQGMK UX XKVRGIK YURKTUOJ SU KY LXKKR_ 8KVRGIK YVKKJ YURKTUOJ 4UZK XKYOYZGTIK GIXUYY YURKTUOJ ZKXSOTGRY YNU RJ HK GVVXU OSGZKR_ UNSY UTZOT KJ LXUS ZNK VXK OU Y VGMK NKIQ IUTZOT OZ_ LXUS MXU TJ ZU HXU T OXK GZ ZKXSOTGR UT 8 HGJ 8KVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU ZKXSOTGR UT 8 MUUJ NKIQ URZGMK ZU ZKXSOTGR UT 8 8KVGOX UVKT OT NZ OXK IOXI OZ LXUS 8...

Page 103: ...ZGOTKJ RU OJRK Z XZRK Y_SHUR NKIQ URZGMK GZ HRQ XKJ OXK UT XVS YKRKIZ Y OZIN YURGZK ZNK VRGZLUXS GTJ MXU TJ XVS Y OZINKY 9 GTJ 9 INKIQ OTJO OJ GRR_ GTJ XKVRGIK JKLKIZO K Y OZIN NKIQ URZGMK GZ ZNK HRQ XKJ OXK UT ZNK YVKKJ YURKTUOJ 8KVRGIK 8 XKRG_ 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 ...

Page 104: ...KIZUX VR M LXUS OMTOZOUT IUORY 5T K Z JOKYKR SUJKRY NURJ SGT GR L KR YN ZULL RK KX ZU ZNK IRUYKJ VUYOZOUT IRUIQ 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_ YVROTK JUKY TUZ Z XT TMOTK ZU V SV ...

Page 105: ...OTJO OJ GRR_ UX IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ RKYY ZNGT VYO JP YZ ZNK L TIZOUT SGTOLURJ Y_YZKS XKROKL GR K OZKS GRR ZNK G_ OT IRUIQ OYK IU TZOTM ZNK T SHKX UL Z XTY 3U K ZNK L TIZOUT KTGHRK Y OZIN ZU KOZNKX YOJK GTJ NURJ ZNK HUUS XKZXGIZ ZUMMRK Y OZIN GTJ XKINKIQ ZNK VXKYY XK VYO UX SUXK 3U K ZNK L TIZOUT KTGHRK Y OZIN ZU KOZNKX YOJK GTJ NURJ ZNK HUUS XKZXGIZ Y OZIN GTJ XKGJP YZ ZNK XKR...

Page 106: ...KTMOTK GTJ INKIQ ZNK URZGMK GZ UX SUXK RKYY ZNGT 8KVGOX UVKT OT XKJ OXK LXUS ZU 29 ZNXU MN HRQ OXK ZU ZNXU MN HRQ OXK ZU 29 ZNXU MN XKJ OXK ZU ROLZ J SV GR K OZKS 58 XKVRGIK 29 UX 29 9ZGXZ ZNK KTMOTK GTJ INKIQ ZNK URZGMK GZ ZNK NZ OXK UT ZNK GRZKXTGZUX UX SUXK RKYY ZNGT 8KVGOX UVKT OT NZ OXK LXUS GRZKXTGZUX ZU ZU 8KVGOX UX XKVRGIK GRZKXTGZUX OZN ZNK HUUS OT ZNK YZU KJ VUYOZOUT GTJ HUZN G RKY L RR_...

Page 107: ...GR K ZU VYO HGX UTZOT KJ LXUS ZNK VXK OU Y VGMK OZN ZNK QK_Y OZIN Z XTKJ ZU MXU TJ IUTZXURY GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT INKIQ URZGMK GZ ZNK IKTZKX ZKXSOTGR UL ZNK L TIZOUT KTGHRK ZUMMRK Y OZIN 9 UX SUXK 8KVGOX UVKT OT XKJ VU KX Y VVR_ OXK LXUS L TIZOUT KTGHRK ZUMMRK Y OZIN 9 ZU KGIN L TIZOUT ZUMMRK Y OZIN URJ ZNK L TIZOUT KTGHRK ZUMMRK Y OZIN ZU KOZNKX YOJK GTJ INK...

Page 108: ... OZIN XU HRKYNUUZ KGIN L TIZOUT OTJO OJ GRR_ TU OZN HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT INKIQ URZGMK GZ XKJ OXK UT ZNK OTV Z YOJK UL ZNK MXU TJ IUTZXURY IUTZGIZ UL ZNK QK_ Y OZIN 19 ZNK XKJ OXK INKIQKJ YNU RJ UXOMOTGZK LXUS ZNK SKXMKTI_ 9ZUV H ZZUT 8KVGOX UVKT OT XKJ OXK IOXI OZ LXUS KSKXMKTI_ YZUV H ZZUT ZU ZNK QK_ Y OZIN OZN ZNK QK_Y OZIN Z XTKJ ZU MXU TJ IUTZXURY GTJ HUZN S...

Page 109: ...K IOXI OZ LXUS QK_ Y OZIN ZU 58 8KVRGIK ZNK VRGZLUXS IUTZXURY IUTZGIZ GZ ZNK QK_ Y OZIN NKIQ URZGMK GZ 6 8KVGOX UVKT OT HRQ OXK IOXI OZ LXUS 6 NKIQ URZGMK GZ HRQ OXK UT OTV Z YOJK UL VRGZLUXS SKXMKTI_ 9ZUV H ZZUT IUTZGIZ 6 OZN ZNK QK_ Y OZIN Z XTKJ ZU VRGZLUXS IUTZXURY GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK UT VUYOZOUT INKIQ ZNK URZGMK UT ZNK U ZV Z YOJK UL ZNK VRGZLUXS SKXMKTI_ 9ZUV H Z...

Page 110: ... OZIN 9 UT MXU TJ VGTKR OT ZNK V JOXKIZOUT GTJ INKIQ URZGMK GZ ZU 8KVGOX UVKT OT XKJ NZ OXK IOXI OZ LXUS ZU HUUS V JU T VXUVUXZOUTGR GR K IUOR OZKS 8 58 XKVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU GR K IUOR OZN ZNK QK_Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK LUUZY OZIN GTJ HUUS L TIZOUT IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT V JOXKIZOUT GT...

Page 111: ...OZ ZU GR K IUOR OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK LUUZY OZIN GTJ HUUS L TIZOUT IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT V JOXKIZOUT GTJ INKIQ URZGMK UX SUXK IZO GZK LUUZY OZIN GTJ HUUS L TIZOUT IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT V JOXKIZOUT GTJ INKIQ URZGMK 6 UTZOT KJ UT ZNK TK Z VGMK XU HRKYNUUZ HUUS V L TIZOUT ZUMMRK...

Page 112: ...T GTJ INKIQ ZNK VXKYY XK 69 UX SUXK RKYY ZNGT 69 8KVGOX I_ROTJKX UX I_ROTJKX IU TZKXHGRGTIK GR K 58 HUUS L TIZOUT SGTOLURJ IU RJ NG K GT OTZKXTGR JKLKIZ UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM HUUS LXUS SU OTM 58 XKVGOX I_ROTJKX UX I_ROTJKX IU TZKXHGRGTIK GR K 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ 3U K L TIZOUT KTGHRK Y OZIN ZU KOZNKX YOJK GTJ NURJ ZN...

Page 113: ...Y OZIN 9 UT MXU TJ VGTKR OT ZNK JU T JOXKIZOUT GTJ INKIQ URZGMK GZ ZU 8KVGOX UVKT OT XKJ NZ OXK IOXI OZ LXUS ZU HUUS V JU T VXUVUXZOUTGR GR K IUOR OZKS 8 58 XKVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU GR K IUOR OZN ZNK QK_Y OZIN OT ZNK VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK LUUZY OZIN GTJ HUUS L TIZOUT IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT JU T J...

Page 114: ...OXI OZ ZU GR K IUOR OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK LUUZY OZIN GTJ HUUS L TIZOUT IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT JU T JOXKIZOUT GTJ INKIQ URZGMK UX SUXK IZO GZK LUUZY OZIN GTJ HUUS L TIZOUT IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT JU T JOXKIZOUT GTJ INKIQ URZGMK 6 UTZOT KJ UT ZNK TK Z VGMK XU HRKYNUUZ HUUS JU T L ...

Page 115: ...MXU TJ IUTZXURY OT ZNK JU T JOXKIZOUT GTJ INKIQ ZNK VXKYY XK 69 RKYY ZNGT 69 8KYKZ HUUS JU T XKROKL GR K OZKS VXKYY XK YKK 8KVGOX 9KIZOUT 58 XKVRGIK HUUS JU T XKROKL GR K 58 XKVGOX I_ROTJKX UX I_ROTJKX IU TZKXHGRGTIK GR K 58 L TIZOUT SGTOLURJ IU RJ NG K GT OTZKXTGR JKLKIZ UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM HUUS LXUS SU OTM 58 XKVGOX I_ROTJKX UX I_ROTJK...

Page 116: ...9 UT MXU TJ VGTKR OT ZNK K ZKTJ JOXKIZOUT GTJ INKIQ URZGMK GZ ZU 8KVGOX UVKT OT HRQ XKJ OXK IOXI OZ LXUS ZU HUUS K ZKTJ XKZXGIZ VXUVUXZOUTGR GR K IUOR OZKS 6 58 XKVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU GR K IUOR OZN QK_Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK LUUZY OZIN GTJ HUUS K ZKTJ XKZXGIZ VXUVUXZOUTGR IUTZXURRKX 6 UT VRGZLUXS IUTZXUR ...

Page 117: ...UOR OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK LUUZY OZIN GTJ HUUS K ZKTJ XKZXGIZ VXUVUXZOUTGR IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT K ZKTJ JOXKIZOUT GTJ INKIQ URZGMK UX SUXK IZO GZK LUUZY OZIN GTJ HUUS K ZKTJ XKZXGIZ VXUVUXZOUTGR IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT K ZKTJ JOXKIZOUT GTJ INKIQ URZGMK 6 UTZOT KJ UT ZNK TK Z VGM...

Page 118: ...OXKIZOUT GTJ INKIQ ZNK VXKYY XK 69 RKYY ZNGT 69 8KVGOX I_ROTJKX UX I_ROTJKX IU TZKXHGRGTIK GR K 58 L TIZOUT SGTOLURJ IU RJ NG K GT OTZKXTGR JKLKIZ UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM HUUS LXUS K ZKTJOTM 58 XKVGOX I_ROTJKX UX I_ROTJKX IU TZKXHGRGTIK GR KY 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ 3U K L TIZOUT KTGHRK Y OZIN ZU KOZNKX YOJK GTJ NURJ ZNK ...

Page 119: ... OZIN 9 UT ZNK MXU TJ VGTKR OT ZNK XKZXGIZ JOXKIZOUT GTJ INKIQ URZGMK GZ ZU 8KVGOX UVKT OT HRQ XKJ OXK IOXI OZ LXUS ZU HUUS K ZKTJ XKZXGIZ VXUVUXZOUTGR GR K IUOR OZKS 6 58 XKVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU GR K IUOR OZN QK_Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK LUUZY OZIN GTJ HUUS K ZKTJ XKZXGIZ VXUVUXZOUTGR IUTZXURRKX 6 UT VRGZLU...

Page 120: ...IUOR OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK LUUZY OZIN GTJ HUUS K ZKTJ XKZXGIZ VXUVUXZOUTGR IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT ZNK XKZXGIZ JOXKIZOUT GTJ INKIQ URZGMK UX SUXK IZO GZK LUUZY OZIN GTJ HUUS K ZKTJ XKZXGIZ VXUVUXZOUTGR IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT ZNK XKZXGIZ JOXKIZOUT GTJ INKIQ URZGMK 6 UTZOT KJ UT Z...

Page 121: ...JOXKIZOUT GTJ INKIQ ZNK VXKYY XK 69 RKYY ZNGT 69 8KVGOX I_ROTJKX UX I_ROTJKX IU TZKXHGRGTIK GR K 58 L TIZOUT SGTOLURJ IU RJ NG K GT OTZKXTGR JKLKIZ UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM HUUS LXUS XKZXGIZOTM 58 XKVGOX I_ROTJKX UX I_ROTJKX IU TZKXHGRGTIK GR KY 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ 3U K L TIZOUT KTGHRK Y OZIN ZU KOZNKX YOJK GTJ NURJ ZN...

Page 122: ...RK Y OZIN 9 UT MXU TJ VGTKR OT ZNK RKLZ JOXKIZOUT GTJ INKIQ URZGMK GZ ZU 8KVGOX UVKT OT NZ XKJ OXK IOXI OZ LXUS ZU Z XTZGHRK XUZGZK RKLZ XOMNZ VXUVUXZOUTGR GR K IUOR OZKS 58 XKVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU GR K IUOR OZN QK_Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK LUUZY OZIN GTJ Z XTZGHRK XUZGZK RKLZ XOMNZ VXUVUXZOUTGR IUTZXURRKX 6...

Page 123: ... K IUOR OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK LUUZY OZIN GTJ Z XTZGHRK XUZGZK RKLZ XOMNZ VXUVUXZOUTGR IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT ZNK RKLZ JOXKIZOUT GTJ INKIQ URZGMK UX SUXK IZO GZK LUUZY OZIN GTJ Z XTZGHRK XUZGZK RKLZ XOMNZ VXUVUXZOUTGR IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT ZNK RKLZ JOXKIZOUT GTJ INKIQ URZGMK 6 ...

Page 124: ...ZNK Z XTZGHRK XUZGZK RKLZ ZUMMRK Y OZIN GZ ZNK MXU TJ IUTZXURY OT ZNK RKLZ JOXKIZOUT GTJ INKIQ ZNK VXKYY XK 3U K L TIZOUT KTGHRK Y OZIN ZU KOZNKX YOJK GTJ NURJ ZNK Z XTZGHRK XUZGZK RKLZ XOMNZ ZUMMRK Y OZIN GZ ZNK MXU TJ IUTZXURY OT ZNK RKLZ JOXKIZOUT 3GT GRR_ U KXXOJK ZNK JOXKIZOUTGR GR K H_ V YNOTM OT UT ZNK KTJ UL ZNK GR K YVUUR L TIZOUT OTUVKXGZO K L TIZOUT UVKXGZKY 8KVRGIK JKLKIZO K JOXKIZOUTG...

Page 125: ...XK MG MK OTZU ZNK NUYK LXUS ZNK L TIZOUT SGTOLURJ ZU ZNK Z XTZGHRK XUZGZOUT HXGQK 3U K ZNK L TIZOUT KTGHRK Y OZIN ZU KOZNKX YOJK GTJ GIZO GZK ZNK Z XTZGHRK XUZGZK RKLZ L TIZOUT RKYYZNGT VYO VYO UX SUXK INGTMK Z XTZGHRK XUZGZK RKLZ GTJ XOMNZ IU TZKXHGRGTIK GR KY OZKSY 22 GTJ 11 IZO GZK Z XTZGHRK XUZGZK RKLZ L TIZOUT L TIZOUT OTUVKXGZO K L TIZOUT UVKXGZKY 8KVRGIK JKLKIZO K IU TZKXHGRGTIK GR K TIZOUT...

Page 126: ...RK Y OZIN 9 UT MXU TJ VGTKR OT ZNK XOMNZ JOXKIZOUT GTJ INKIQ URZGMK GZ ZU 8KVGOX UVKT OT NZ XKJ OXK IOXI OZ LXUS ZU Z XTZGHRK XUZGZK RKLZ XOMNZ VXUVUXZOUTGR GR K IUOR OZKS 58 XKVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU GR K IUOR OZN QK_Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK LUUZY OZIN GTJ Z XTZGHRK XUZGZK RKLZ XOMNZ VXUVUXZOUTGR IUTZXURRKX ...

Page 127: ... IUOR OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK LUUZY OZIN GTJ Z XTZGHRK XUZGZK RKLZ XOMNZ VXUVUXZOUTGR IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT ZNK XOMNZ JOXKIZOUT GTJ INKIQ URZGMK UX SUXK IZO GZK LUUZY OZIN GTJ Z XTZGHRK XUZGZK RKLZ XOMNZ VXUVUXZOUTGR IUTZXURRKX 6 UT VRGZLUXS IUTZXUR VGTKR OT ZNK XOMNZ JOXKIZOUT GTJ INKIQ URZGMK 6 ...

Page 128: ...NK Z XTZGHRK XUZGZK XOMNZ ZUMMRK Y OZIN GZ ZNK MXU TJ IUTZXURY OT ZNK XOMNZ JOXKIZOUT GTJ INKIQ ZNK VXKYY XK 3U K L TIZOUT KTGHRK Y OZIN ZU KOZNKX YOJK GTJ NURJ ZNK Z XTZGHRK XUZGZK RKLZ XOMNZ ZUMMRK Y OZIN GZ ZNK MXU TJ IUTZXURY OT ZNK XOMNZ JOXKIZOUT 3GT GRR_ U KXXOJK ZNK JOXKIZOUTGR GR K H_ V YNOTM OT UT ZNK KTJ UL ZNK GR K YVUUR L TIZOUT OTUVKXGZO K L TIZOUT UVKXGZKY 8KVRGIK JKLKIZO K JOXKIZOU...

Page 129: ...XK MG MK OTZU ZNK NUYK LXUS ZNK L TIZOUT SGTOLURJ ZU ZNK Z XTZGHRK XUZGZOUT HXGQK 3U K ZNK L TIZOUT KTGHRK Y OZIN ZU KOZNKX YOJK GTJ GIZO GZK ZNK Z XTZGHRK XUZGZK XOMNZ L TIZOUT RKYYZNGT VYO VYO UX SUXK INGTMK Z XTZGHRK XUZGZK XOMNZ GTJ RKLZ IU TZKXHGRGTIK GR KY OZKSY 22 GTJ 11 IZO GZK Z XTZGHRK XUZGZK RKLZ L TIZOUT L TIZOUT OTUVKXGZO K L TIZOUT UVKXGZKY 8KVRGIK JKLKIZO K IU TZKXHGRGTIK GR K TIZOU...

Page 130: ...GX VXKYY XK MG MK OTZU SGYZKX I_ROTJKX XUJ KTJ N_JXG ROI NUYK NUYK IUTTKIZKJ ZU VUXZ 62 YOTM G ZKK LOZZOTM IZO GZK HUUS V L TIZOUT GTJ INKIQ ZNK VXKYY XK RKYY ZNGT 69 TYZGRR G ZU VYO ZU HGX VXKYY XK MG MK OTZU ZNK HGXXKR KTJ N_JXG ROI NUYK LXUS ZNK SGYZKX I_ROTJKX GTJ XGOYK ZNK VXOSGX_ HUUS UTK OTIN GZ G ZOSK UTZOT GRR_ SUTOZUX ZNK VXKYY XK MG MK J XOTM HUUS V U TUZ GRRU ZNK VXKYY XK ZU K IKKJ 69 ...

Page 131: ... ZUMMRK Y OZIN 9 OT ZNK V JOXKIZOUT GTJ INKIQ ZNK URZGMK GZ OZN ZNK QK_Y OZIN Z XTKJ ZU VRGZLUXS IUTZXUR GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK ZNK LUUZY OZIN GTJ ZNK VRGZLUXS RK KR ZUMMRK Y OZIN 9 OT ZNK V JOXKIZOUT GTJ INKIQ ZNK URZGMK GZ 8KVGOX UVKT OT UXM OXK LXUS ZU VRGZLUXS RK KR V JOXKIZOUTGR GR K IUOR OZKS 58 XKVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU GR K IU...

Page 132: ... TIZOUT L TIZOUT OTUVKXGZO K L TIZOUT UVKXGZKY 8KVRGIK ZNK JKLKIZO K IU TZKXHGRGTIK GR K TYZGRR G ZU ZU HGX VXKYY XK MG MK GZ ZNK W OIQ JOYIUTTKIZ IU VROTM UT ZNK L TIZOUT SGTOLURJ GTJ GIZO GZK ZNK VRGZLUXS RK KR V L TIZOUT RKYY ZNGT VYO VYO UX SUXK NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM VRGZLUXS RK KR V L TIZOUT LXUS UVKXGZOTM 58 XKVRGIK YRG K I_ROTJKX 58 XKVRGIK YRG K I_ROTJKX IU TZKXHGRGTIK G...

Page 133: ...MRK Y OZIN 9 OT ZNK JU T JOXKIZOUT GTJ INKIQ ZNK URZGMK GZ OZN ZNK QK_Y OZIN Z XTKJ ZU VRGZLUXS IUTZXUR GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK ZNK LUUZY OZIN GTJ ZNK VRGZLUXS RK KR ZUMMRK Y OZIN 9 OT ZNK JU T JOXKIZOUT GTJ INKIQ ZNK URZGMK GZ 8KVGOX UVKT OT UXM HRQ OXK LXUS ZU VRGZLUXS RK KR JU T JOXKIZOUTGR GR K IUOR OZKS 58 XKVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ Z...

Page 134: ...L TIZOUT L TIZOUT OTUVKXGZO K L TIZOUT UVKXGZKY 8KVRGIK ZNK JKLKIZO K IU TZKXHGRGTIK GR K TYZGRR G ZU ZU HGX VXKYY XK MG MK GZ ZNK W OIQ JOYIUTTKIZ IU VROTM UT ZNK L TIZOUT SGTOLURJ GTJ GIZO GZK ZNK VRGZLUXS RK KR JU T L TIZOUT RKYY ZNGT VYO VYO UX SUXK NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM VRGZLUXS RK KR JU T L TIZOUT LXUS UVKXGZOTM 58 XKVRGIK YRG K I_ROTJKX 58 XKVRGIK YRG K I_ROTJKX IU TZKXHG...

Page 135: ...K ZUMMRK Y OZIN 9 OT ZNK RKLZ JOXKIZOUT GTJ INKIQ URZGMK GZ ZNK MXT NZ OXK GZ ZNK POH JKRG_ IGVGIOZUX 8KVGOX UVKT OT MXT NZ OXK LXUS 6 ZU POH JKRG_ IGVGIOZUX UTZOT KJ UT ZNK TK Z VGMK 8KVGOX UVKT OT MXT NZ OXK LXUS 9 ZU ZU 6 58 ZKYZ ZUMMRK Y OZIN 9KK 8KVGOX 9KIZOUT OZN QK_Y OZIN Z XTKJ ZU VRGZLUXS IUTZXUR GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK LUUZY OZIN GTJ VRGZLUXS...

Page 136: ... ZNK RKLZ JOXKIZOUT GTJ INKIQ URZGMK UT ZNK XKJ OXK GZ ZKXSOTGR UT 8 8KVGOX UVKT OT XKJ OXK LXUS POH JKRG_ IGVGIOZUX ZU 8 IZO GZK LUUZY OZIN GTJ VRGZLUXS XUZGZK ZUMMRK Y OZIN 9 OT ZNK RKLZ JOXKIZOUT GTJ INKIQ URZGMK UT ZNK XKJ GTJ HRGIQ OXKY GZ ZKXSOTGR UT 8 8KVRGIK XKRG_ 8 58 XKVGOX UVKT OT VU KX Y VVR_ LXUS 6 ZU 8 58 XKVGOX UVKT OT HXU T MXU TJ OXK ZU 8 IZO GZK LUUZY OZIN GTJ VRGZLUXS XUZGZK ZUM...

Page 137: ...IUTZOT OZ_ 8KVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU GR K IUORY INGTMK POH HUUS VRGZLUXS XUZGZK YKRKIZ GR KY OZKS 6 IZO GZK LUUZY OZIN GTJ VRGZLUXS XUZGZK RKLZ L TIZOUT L TIZOUT UVKXGZKY L TIZOUT OTUVKXGZO K 8KVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU GR K IUORY 8KVGOX UX XKVRGIK VRGZLUXS XUZGZUX 58 UXOLOIK LOZZOTMY OT POH SGTOLURJ GXK VR MMKJ 58 POH SGTOLURJ SG_ NG K GT OTZKXTGR JKLKIZ UTY RZ KTO...

Page 138: ...K ZUMMRK Y OZIN 9 OT ZNK XOMNZ JOXKIZOUT GTJ INKIQ URZGMK GZ ZNK MXT NZ OXK GZ ZNK POH JKRG_ IGVGIOZUX 8KVGOX UVKT OT MXT NZ OXK LXUS 6 ZU POH JKRG_ IGVGIOZUX UTZOT KJ UT ZNK TK Z VGMK 8KVGOX UVKT OT MXT NZ OXK LXUS 9 ZU ZU 6 58 ZKYZ ZUMMRK Y OZIN 9KK 8KVGOX 9KIZOUT OZN QK_Y OZIN Z XTKJ ZU VRGZLUXS IUTZXUR GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK UT VUYOZOUT GIZO GZK LUUZY OZIN GTJ VRGZLUX...

Page 139: ...ZNK XOMNZ JOXKIZOUT GTJ INKIQ URZGMK UT ZNK XKJ OXK GZ ZKXSOTGR UT 8 8KVGOX UVKT OT XKJ OXK LXUS POH JKRG_ IGVGIOZUX ZU 8 IZO GZK LUUZY OZIN GTJ VRGZLUXS XUZGZK ZUMMRK Y OZIN 9 OT ZNK XOMNZ JOXKIZOUT GTJ INKIQ URZGMK UT ZNK XKJ GTJ HRGIQ OXKY GZ ZKXSOTGR UT 8 8KVRGIK XKRG_ 8 58 XKVGOX UVKT OT VU KX Y VVR_ LXUS 6 ZU 8 58 XKVGOX UVKT OT HXU T MXU TJ OXK ZU 8 IZO GZK LUUZY OZIN GTJ VRGZLUXS XUZGZK ZU...

Page 140: ...IUTZOT OZ_ 8KVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU GR K IUORY INGTMK POH HUUS VRGZLUXS XUZGZK YKRKIZ GR KY OZKS 6 IZO GZK LUUZY OZIN GTJ VRGZLUXS XUZGZK XOMNZ L TIZOUT L TIZOUT UVKXGZKY L TIZOUT OTUVKXGZO K 8KVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ ZU GR K IUORY 8KVGOX UX XKVRGIK VRGZLUXS XUZGZUX 58 UXOLOIK LOZZOTM OT POH SGTOLURJ GXK VR MMKJ 58 POH SGTOLURJ SG_ NG K GT OTZKXTGR JKLKIZ UTY RZ KTO...

Page 141: ... XKJ VU KX OXK IOXI OZ LXUS QK_Y OZIN ZU 9 58 XKVRGIK ZUMMRK Y OZIN 9 OZN ZNK QK_Y OZIN Z XTKJ ZU VRGZLUXS IUTZXUR GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK ZNK LUUZY OZIN GTJ ZNK POH HUUS ZUMMRK Y OZIN 9 OT ZNK V JOXKIZOUT GTJ INKIQ URZGMK GZ IZO GZK ZNK LUUZY OZIN GTJ ZNK POH HUUS ZUMMRK Y OZIN 9 OT ZNK V JOXKIZOUT GTJ INKIQ URZGMK GZ 6 8KVGOX UVKT OT MXT OXK LXUS 6 Z...

Page 142: ...ZU HGX VXKYY XK MG MK GZ ZNK W OIQ JOYIUTTKIZ IU VROTM UT ZNK L TIZOUT SGTOLURJ GTJ GIZO GZK ZNK POH HUUS V L TIZOUT L TIZOUT UVKXGZKY L TIZOUT OTUVKXGZO K 8KVRGIK JKLKIZO K GR K NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM POH HUUS V L TIZOUT LXUS UVKXGZOTM 58 XKVGOX UX XKVRGIK POH HUUS I_ROTJKX 58 XKVRGIK IU TZKXHGRGTIK GR K 58 UXOLOIK SG_ HK VR MMKJ 58 POH HUUS VRGZLUXS XUZGZK YKRKIZ SGTOLURJ NGY G...

Page 143: ...T OT XKJ VU KX OXK IOXI OZ LXUS QK_Y OZIN ZU 9 58 XKVRGIK ZUMMRK Y OZIN 9 OZN ZNK QK_Y OZIN Z XTKJ ZU VRGZLUXS IUTZXUR GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK ZNK LUUZY OZIN GTJ ZNK POH HUUS ZUMMRK Y OZIN 9 OT ZNK JU T JOXKIZOUT GTJ INKIQ URZGMK GZ IZO GZK ZNK LUUZY OZIN GTJ ZNK POH HUUS ZUMMRK Y OZIN 9 OT ZNK JU T JOXKIZOUT GTJ INKIQ URZGMK GZ 6 8KVGOX UVKT OT MXT HR...

Page 144: ... HGX VXKYY XK MG MK GZ ZNK W OIQ JOYIUTTKIZ IU VROTM UT ZNK L TIZOUT SGTOLURJ GTJ GIZO GZK ZNK POH HUUS JU T L TIZOUT L TIZOUT UVKXGZKY L TIZOUT OTUVKXGZO K 8KVRGIK JKLKIZO K GR K NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM POH HUUS JU T L TIZOUT LXUS UVKXGZOTM 58 XKVGOX UX XKVRGIK POH HUUS I_ROTJKX 58 XKVRGIK IU TZKXHGRGTIK GR K 58 UXOLOIK SG_ HK VR MMKJ 58 POH HUUS VRGZLUXS XUZGZK YKRKIZ SGTOLURJ N...

Page 145: ...ZK UNSY 8KVRGIK ZNK G RK J SV GR K IUOR OZKS 99 TYZGRR G ZU HGX VXKYY XK MG MK UTZU ZNK ZKYZ VUXZ UT ZNK L TIZOUT SGTOLURJ 9ZGXZ ZNK KTMOTK GTJ UVKXGZK ZNK TUT YZKKX KTJ INGYYOY ROLZ PGIQ GTJ INKIQ ZNK VXKYY XK RKYY ZNGT VYO VYO NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM TUT YZKKX KTJ ROLZ PGIQ LXUS UVKXGZOTM 58 XKVRGIK IU TZKXHGRGTIK GR K OZKS 55 OT INGYYOY PGIQ SGTOLURJ 58 IUTY RZ KTOK TJ YZXOKY 9...

Page 146: ...NKIQ ZNK URZGMK GZ UX SUXK RKYY ZNGT 8KVGOX UVKT OT XKJ OXK LXUS ZU 29 ZNXU MN HRQ OXK ZU ZNXU MN HRQ OXK ZU 29 ZNXU MN XKJ OXK ZU G RK J SV GR K OZKS 99 58 XKVRGIK 29 UX 29 9ZGXZ ZNK KTMOTK GTJ INKIQ ZNK URZGMK GZ ZNK NZ OXK UT ZNK GRZKXTGZUX UX SUXK RKYY ZNGT 8KVGOX UVKT OT NZ OXK LXUS GRZKXTGZUX ZU ZU 58 XKVRGIK JOUJKY GZ 8KVGOX UX XKVRGIK GRZKXTGZUX CHART 27 ...

Page 147: ...KYY ZNGT VYO 8KVRGIK IU TZKXHGRGTIK GR K OZKS 55 OT INGYYOY PGIQ SGTOLURJ 58 XKVRGIK LRU XKM RGZUX OZKS OT G RK J SV SGTOLURJ 58 XKVGOX UX XKVRGIK TUT YZKKX G RK I_ROTJKX 58 INGYYOY PGIQ SGTOLURJ UX IUTZXUR GR K SG_ NG K GT OTZKXTGR JKLKIZ UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ _KY NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM G RK K ZKTJ L TIZOUT LXUS UVKXGZOTM 58 XKVRGIK IU TZKXHGRGTIK GR K OZKS 55 ...

Page 148: ...ZNK HR OXK GZZGINKJ UX SUXK 8KVGOX UVKT OT HR OXK IOXI OZ LXUS JXO K IUTZXURRKX 6 ZU 6 ZNKT ZU 8KVGOX UX XKVRGIK YZKKX SOIXUY OZIN UT JXO K IUTZXURRKX UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ UTZOT KJ UT ZNK TK Z VGMK OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK LUUZY OZIN GTJ YZKKX XUIQKX Y OZIN UT JXO K IUTZXURRKX 6 OT RKLZ JOXKIZOUT GT...

Page 149: ...TKIZ IU VROTM UT ZNK HUUS L TIZOUT SGTOLURJ GTJ GIZO GZK ZNK YZKKX RKLZ L TIZOUT 69 RKYY ZNGT 69 8KVGOX UX XKVRGIK YZKKX I_ROTJKX 58 YZKKX SGTOLURJ IU RJ NG K GT OTZKXTGR JKLKIZ UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM YZKKX RKLZ L TIZOUT LXUS UVKXGZOTM 58 XKVGOX UX XKVRGIK YZKKX I_ROTJKX 58 XKVRGIK LRU XKM RGZUX GR K OZKS 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK K...

Page 150: ...R HRQ OXK IOXI OZ LXUS JXO K IUTZXURRKX 6 ZU 6 ZNKT ZU 8KVGOX UX XKVRGIK YZKKX SOIXUY OZIN UT JXO K IUTZXURRKX UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ UTZOT KJ UT ZNK TK Z VGMK OZN QK_ Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK LUUZY OZIN GTJ YZKKX XUIQKX Y OZIN UT JXO K IUTZXURRKX 6 OT ZNK XOMNZ JOXKIZOUT GTJ INKIQ URZGMK UT HR HRQ OXK UT YZK...

Page 151: ...KIZ IU VROTM UT ZNK HUUS L TIZOUT SGTOLURJ GTJ GIZO GZK ZNK YZKKX XOMNZ L TIZOUT 69 RKYY ZNGT 69 8KVGOX UX XKVRGIK YZKKX I_ROTJKX 58 YZKKX SGTOLURJ IU RJ NG K GT OTZKXTGR JKLKIZ UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM YZKKX XOMNZ L TIZOUT LXUS UVKXGZOTM 58 XKVGOX UX XKVRGIK YZKKX I_ROTJKX 58 XKVRGIK LRU XKM RGZUX GR K OZKS 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK ...

Page 152: ...OIQ 6 UX SUXK NKIQ IUTZOT OZ_ UL HXU T MXU TJ OXK LXUS ZKXSOTGR UT 6 ZU MXU TJ IUTZOT OZ_ TU IUTZOT OZ_ 8KVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ LXUS MXU TJ ZU 6 OZN ZNK QK_Y OZIN Z XTKJ ZU VRGZLUXS IUTZXUR GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK ZNK LUUZY OZIN GTJ INKIQ ZNK URZGMK GZ ZKXSOTGR UT ZNK NUXYKVU KX ROSOZKX IOXI OZ HUGXJ UX SUXK RKYY ZNGT 8KVGOX UVKT OT VU ...

Page 153: ...KXSOTGRY UT ZNK JXO K PU_YZOIQ IUTZXURRKX 8KVRGIK JXO K PU_YZOIQ IUTZXURRKX 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ TU IUTZOT OZ_ IUTZOT OZ_ NKIQ IUTZOT OZ_ LXUS ZKXSOTGR UT JXO K PU_YZOIQ ZU MXU TJ 8KVGOX UVKT OT HXU T MXU TJ OXK IOXI OZ LXUS ZKXSOTGR UT JXO K PU_YZOIQ ZU MXU TJ UTTKIZ ZNK VUYOZ K RKGJ LXUS G URZSKZKX ZU ZKXSOTGR UT ZNK PU_YZOIQ GTJ ZNK TKMGZO K RKGJ ZU ZKXSOTGR UT ZNK PU_YZO...

Page 154: ...K RKGJ LXUS G URZSKZKX ZU ZKXSOTGR UT ZNK PU_YZOIQ GTJ OZN ZNK LUUZY OZIN GIZO GZKJ GTJ ZNK JXO K PU_YZOIQ OT ZNK L RR LUX GXJ VUYOZOUT SU K ZNK JXO K KTGHRK ZUMMRK Y OZIN 9 ZU KOZNKX YOJK GTJ NURJ ZNK TKMGZO K RKGJ LXUS ZNK URZSKZKX UTZU ZNK HR NZ OXK UT 9 GTJ INKIQ ZNK URZGMK 8KVRGIK JXO K KTGHRK ZUMMRK Y OZIN 9 8KVGOX UVKT OT OXK LXUS ZKXSOTGR LXUS JXO K PU_YZOIQ 6 ZU JXO K KTGHRK ZUMMRK Y OZIN...

Page 155: ...IXUYY ZNK NZ GTJ ZNK NZ HRQ OXK ZKXSOTGRY UT ZNK 8K KXYK ZNK URZ SKZKX RKGJY GTJ SU K ZNK JXO K IUTZXURRKX ZU L RR XK KXYK VUYOZOUT GTJ TUZK ZNK URZGMK URZGMK XKGJOTMY JOLLKXKTZ 8KVGOX UX XKVRGIK ZNK JXO K IUTZXURRKX 6 URZGMK XKGJOTMY ZNK YGSK JP YZ ZNK JXO K V SV T RR TK ZXGR UTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ TU OSVXU KSKTZ KLKIZO K 9 TJYZXGTJ JXO K V SV IUTZGIZ 9 TJYZXGTJ G ZNUXO KJ XKVGOX...

Page 156: ...t No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Chart 33 Traction Function Inoperative Be sure all other functions operate normally T_ Z_VK UL ZXGIZOUT VXUHRKS IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ ...

Page 157: ...of damage or corrosion 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 OZN ZNK HUUS OT ZNK YZU KJ VUYOZOUT INKIQ IUTZOT OZ_ LXUS ZU MXU TJ IUTZOT OZ_ 8KVGOX YNUXZ ZU MXU TJ OT NZ OXKY ZU ROSOZ Y OZINKY 29 GTJ 29 58 XKVGOX UX XKVRGIK HUUS ROLZ JXO K ROSOZ Y OZIN UX HUUS K ZKTJ ROSOZ Y OZIN TU IUTZOT OZ_ ...

Page 158: ... of damage or corrosion ZKTJ ZNK HUUS VGYZ ZNK JXO K ROSOZ Y OZIN GTJ INKIQ IUTZOT OZ_ LXUS MXU TJ ZU ZKXSOTGR UT ZNK NUXYKVU KX ROSOZKX HUGXJ IUTZOT OZ_ TU IUTZOT OZ_ NKIQ IUTZOT OZ_ LXUS MXU TJ ZU IUTZOT OZ_ 8KVGOX UVKT OT UXM OXK IOXI OZ LXUS ZU 6 ZU ZKXSOTGR UT NUXYKVU KX ROSOZKX IOXI OZ HUGXJ TU IUTZOT OZ_ 8KVGOX UVKT LXUS NZ OXKY GZ ZU JXO K ROSOZ Y OZINKY 29 GTJ 29 ZNKT LXUS HXU T MXU TJ OX...

Page 159: ...MKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK LUUZY OZIN GTJ JXO K IUTZXURRKX OT LUX GXJ JOXKIZOUT GTJ INKIQ URZGMK GZ ZKXSOTGR UT JXO K IUTZXURRKX 6 OZN QK_Y OZIN OT VRGZLUXS VUYOZOUT GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GTJ ZNK HUUS XUZGZKJ HKZ KKT ZNK YZKKX KTJ ZOXKY GIZO GZK LUUZY OZIN GTJ JXO K IUTZXURRKX OT LUX GXJ JOXKIZOUT ORR TOZ JXO K _KY TU URJ ZNK JX...

Page 160: ...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 SUZUX JUKY TUZ UVKXGZK OZN ZNK QK_Y OZIN Z XTKJ ZU MXU TJ IUTZXUR GTJ HUZN SKXMKTI_ 9ZUV H ZZUTY V RRKJ U Z ZU ZNK 54 VUYOZOUT GIZO GZK ZNK G OROGX_ V SV ZUMMRK Y OZIN GTJ INKIQ ZNK URZGMK UT ZNK XKJ IGHRK UT ZNK G OROGX_ VU KX TOZ MUUJ NKIQ LUX G VUYOZO K IUTT...

Page 161: ...l Second Edition Section 5 Troubleshooting Flow Charts CHART 37 NKIQ IUTZOT OZ_ LXUS TKMGZO K ZKXSOTGR UT G OROGX_ VU KX TOZ ZU MXU TJ UTZOT KJ LXUS ZNK VXK OU Y VGMK MUUJ HGJ 8KVRGIK TKMGZO K IGHRK LXUS G OROGX_ V SV ZU MXU TJ 8KVRGIK G OROGX_ V SV SUZUX ...

Page 162: ...5 84 Genie S 80 Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts This page intentionally left blank ...

Page 163: ...Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connectio...

Page 164: ...EM Controls MCH1159AD1386 1 FB Flashing beacon 20189 ECCO Electronic Controls 6400X 2 FS1 Footswitch 13482 Linemaster Switch Corp 632 S 1 G1 Gauge Voltage 30789 VDO 332 502 1 G2 Gauge Oil Pressure 30786 VDO 350 516 1 G3 Gauge Water Temp 30787 VDO 310 502 1 H1 Alarm Warble tone 19270 Floyd Bell Inc MW 09 616 Q 1 H2 Horn 12V DC 130 dB 19145 Sparton Engineered Prod 7431A 24823 5 1 H3 Alarm intermitte...

Page 165: ...0 Toggle switch DPST 2 position momentary 13480 Microswitch Control Inc 2NT1 8 2 TS2 6 9 11 13 15 Toggle switch SPDT 3 position momentary 13037 Microswitch Control Inc 1NT1 7 6 TS8 TS20 Toggle switch DPST 2 position maintained 27378 Microswitch Control Inc 2NT1 3 2 TS4 Toggle switch DPDT 3 position maintained 13038 Microswitch Control Inc 2NT1 1 1 TS5 7 14 16 17 18 19 Toggle switch DPDT 3 position...

Page 166: ...pen NO LS1 Limit switch normally open held closed HORN P4 Horn button normally open T circuits connect T WHT 51 TR2 1 2 3 6 Time delay relay OPS1 N C Oil pressure switch normally closed Light WTS1 N O Water temperature switch normally open Quick disconnect terminal Diode RED BLK FS1 Foot switch CR4 Relay contact normally open TS3 START ENGINE Toggle switch SPDT Circuits crossing no connection TS6 ...

Page 167: ... beacon FS Foot switch G Gauge H Horn or Alarm HM Hour meter KS Keyswitch L LED LS Limit switch P Power switch PR Power relay R Resistor TB Terminal base location TP Terminal platform location TS Toggle switch VAC Vacuum switch Part No 52270 Genie S 80 Genie S 85 6 5 Service Manual Second Edition Section 6 Schematics Abbreviation Legend ...

Page 168: ...Service Manual Second Edition Section 6 Schematics 6 6 Genie S 80 Genie S 85 Part No 52270 ...

Page 169: ...Service Manual Section 6 Schematics Electrical Schematic Gasoline LPG Models 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N 6 7 Genie S 80 Genie S 85 Part No 52270 ...

Page 170: ...Service Manual Section 6 Schematics Part No 52270 Genie S 80 Genie S 85 6 8 Electrical Schematic Gasoline LPG Models 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A ...

Page 171: ...Service Manual Second Edition Section 6 Schematics Part No 52270 Genie S 80 Genie S 85 6 9 Ground Control Box Legend Gasoline LPG Models ...

Page 172: ...Service Manual Second Edition Section 6 Schematics Ground Control Box Wiring Diagram Gasoline LPG Models 6 10 Genie S 80 Genie S 85 Part No 52270 ...

Page 173: ...Service Manual Second Edition Section 6 Schematics Part No 52270 Genie S 80 Genie S 85 6 11 Platform Control Box Legend Gasoline LPG Models ...

Page 174: ...Service Manual Second Edition Section 6 Schematics Platform Control Box Wiring Diagram Gasoline LPG Models 6 12 Genie S 80 Genie S 85 Part No 52270 ...

Page 175: ...Service Manual Section 6 Schematics Electrical Schematic Diesel Models 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M N 6 13 Genie S 80 Genie S 85 Part No 52270 ...

Page 176: ...Service Manual Section 6 Schematics Part No 52270 Genie S 80 Genie S 85 6 14 Electrical Schematic Diesel Models 1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A ...

Page 177: ...Service Manual Second Edition Section 6 Schematics Part No 52270 Genie S 80 Genie S 85 6 15 Ground Control Box Legend Diesel Models ...

Page 178: ...Service Manual Second Edition Section 6 Schematics Ground Control Box Wiring Diagram Diesel Models 6 16 Genie S 80 Genie S 85 Part No 52270 ...

Page 179: ...Service Manual Second Edition Section 6 Schematics Part No 52270 Genie S 80 Genie S 85 6 17 Platform Control Box Legend Diesel Models ...

Page 180: ...Service Manual Second Edition Section 6 Schematics Platform Control Box Wiring Diagram Diesel Models 6 18 Genie S 80 Genie S 85 Part No 52270 ...

Page 181: ...Service Manual Second Edition Section 6 Schematics Part No 52270 Genie S 80 Genie S 85 6 19 ...

Page 182: ...size 0 035 Variable orifice or shut off valve Check valve Relief valve Priority flow divider Solenoid operated dump valve Differential sensing valve Solenoid operated proportional valve Flow regulator valve Solenoid operated 2 pos 3 way directional valve Solenoid operated 2 pos 4 way directional valve Solenoid operated 3 pos 4 way directional valve DO1 2 pos 3 way shuttle valve 3 pos 4 way directi...

Page 183: ...1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A Service Manual Section 6 Schematics Part No 52270 Genie S 80 Genie S 85 6 21 2WD Hydraulic Schematic ...

Page 184: ...1 2 3 4 5 6 7 8 N M L K J I H G F E D C B A Service Manual Section 6 Schematics Part No 52270 Genie S 80 Genie S 85 6 22 4WD Hydraulic Schematic ...

Page 185: ... steps Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate Genie S 80 Genie S 8...

Page 186: ...e to accurately adjust the controller 2 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls Do not start the engine 3 Open the platform control box lid and locate the boom up down controller a terminal D2 directional output b terminal A proportional output c terminal ground d terminal positive e terminal R activ...

Page 187: ...Do not start the engine 7 Set the hi range Press down the foot switch then move the control handle all the way to the UP position Adjust the voltage to 8 5V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 8 Set the lo range Press down the foot switch then move the control handle all the way to the DOWN position Adjust the v...

Page 188: ...wn the foot switch fully retract the boom then move the control handle all the way to the left or right Adjust the voltage to 5 5V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 8 Set the lo range Press down the foot switch extend the boom 3 feet then move the control handle all the way to the left or right Adjust the volt...

Page 189: ... controller 2 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls Do not start the engine 3 Open the platform control box lid and locate the boom extend retract controller a ramp rate adjustable trimpot b dual lo range adjustable trimpot c terminal R activates max out range d terminal unused e terminal X auxilia...

Page 190: ...ing 15 Start the engine 16 Start a timer and simultaneously move the control handle all the way to the EXTEND position Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp speed 17 Set the ramp rate turn the trimpot to obtain a 3 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Boom extend retract specifi...

Page 191: ...om the platform controls 5 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 6 Press down the foot switch and adjust the A potentiometer counterclockwise to increase voltage or clockwise to decrease voltage A potentiometer specifications all models Voltage setting 10 5 to 11 5V DC 7 Move the engine idle control switch to low idle turtle symbol 8 P...

Page 192: ...foot per second All models 30 5 cm per second 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 Do not use the color of the connector a...

Page 193: ...er may not accurately test the switch This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches 1 Turn the key switch to the OFF position Tag and disconnect all wiring from the toggle switch to be tested 2 Connect the leads of an ohmmeter to the switch terminals in the following combinations listed below to check for continuity Test Desire...

Page 194: ...ty tester to each terminal combination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other combination Test Desired result terminal 85 to 86 without resistor 85 to 95W terminal 85 to 86 with resistor 75 to 85W terminal 87 to 87a 30 no continuity infinite W terminal 87a to 30 continuity zero W 3 Connect 12V DC to terminal 85 and a ground wire to ter...

Page 195: ...o primary supports for the platform The slave cylinder keeps the platform level through the entire range of boom motion It operates in a closed circuit hydraulic loop with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling Slave Cylinder Before cylinder removal is considered ...

Page 196: ... to Bleed the Slave Cylinder Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Raise the boom to a horizontal position 2 Move the platform level switch up and down through two platform leveling cycles to remove any air that might be in the system 2 3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the p...

Page 197: ...ix mounting bolts from the platform mounting weldment then remove the center bolt and slide the platform mounting weldment off of the platform rotator Crushing hazard The platform mounting weldment may become unbalanced and fall if it is not properly supported 5 Support the platform rotator Do not apply any lifting pressure S 80 Models 6 Support the rod end of the platform leveling slave cylinder ...

Page 198: ...ottom bleed valve c clear hose d container 4 Hold the platform rotate switch to the LEFT position until the platform is fully rotated Continue holding the switch until air stops coming out of the bleed valve Then close the bleed valve Crushing hazard Keep clear of the platform during rotation 5 Connect the clear hose to the bottom bleed valve and open the valve Do not remove the bleed valve PLATFO...

Page 199: ...rel end pivot pin 8 Use a soft metal drift to remove the pin and lay the cylinder onto the ground 9 Tag disconnect and plug all the hydraulic hoses from the jib boom 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 10 Attach a lifting strap f...

Page 200: ...e fittings on the cylinder 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 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end...

Page 201: ...ib boom select 8 10 ft lbs 11 14 Nm Plug Torque Specifications Description Hex Size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm How to Check the Resistance of a Valve Coil 1 Turn the key switch to the OFF position and disconnect the wires from the valve coil to be tested 2 Connect the leads from an ohmmeter to the valve coil terminals Valve coil specification 2 position 3 way ...

Page 202: ...plug the hydraulic hoses from the from the platform leveling cylinder at the union and connect the hoses from the cylinder together using a connector 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 5 S 85 Models Remove the hose and cable cover from t...

Page 203: ... Remove the Boom Cable Track 2 Visually inspect the cable track and determine which 4 link section needs to be replaced 3 Drill out the 4 spot welds on each side of the cable track using a 17 64 drill bit Repeat this step for the other end of the 4 link section of cable track Component damage hazard Cables and hoses can be damaged if the drill bit comes in contact with them Protect the hoses and c...

Page 204: ...uareness between the outer and inner boom tubes How to Remove the Boom This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may cause death or serious injury and significant component damage Dealer service is strongly recommended Perform this procedure with the boom in the stowed position When removing a h...

Page 205: ...l drift then carefully remove the boom from the machine Crushing hazard If the overhead crane is not properly attached the boom may become unbalanced and fall when it is removed from the machine How to Disassemble the Boom Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced The extension cylinder can be removed without completely disassembling the b...

Page 206: ...3 boom tube Place the extension cylinder on blocks for support Crushing hazard The extension cylinder may become unbalanced and fall when it is removed from the number 3 boom tube if it is not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 15 Remove and label all of the wear pads from the extension cylinder Pay careful attention t...

Page 207: ...e 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 How to Remove the Extension Cylinders This procedure requires specific rep...

Page 208: ...y Do not allow oil to squirt or spray 13 Attach a lifting strap from an overhead crane to the rod end of the extension cylinder and lift slightly to relieve the pressure on the trunnion pins BOOM COMPONENTS 14 Remove the trunnion pin access covers from both sides of the number 1 boom tube at the pivot end of the boom 15 Remove the trunnion pin retaining fastener and use a slide hammer to remove th...

Page 209: ...w the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the pin retaining fasteners from the master cylinder barrel end pivot pin 5 Place a rod through the barell end pivot pin and twist to remove the pin 6 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder 7 Remove the pin retaining fastener from the rod end pivot pin 8 Pl...

Page 210: ...ry the strut pivot sockets off of the ball studs and remove the strut Protect the strut cylinder rod from damage Mark the locationof the hinge support bracket on the bulkhead to ensure proper cover alignment during installation 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 Crushing hazard The turntable co...

Page 211: ... with the set screw toward the pump Leave a 1 2 inch 12 7 mm gap between the coupler and pump end plate 3 Apply Loctite removable thread sealant to the coupler set screw Torque the set screw to 45 ft lbs 61 Nm Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged 4 Install the pump and torque the pump mounting plate fasteners to 34 ft lb...

Page 212: ...uator arm Rotate the actuator arm until it is at a 110 degree angle to the linkage rod Then tighten the actuator arm fastener Governor actuator and linkage a clevis yoke b linkage rod c carburetor d throttle plate shaft e governor actuator f actuator shaft g actuator arm 4 Position the linkage rod so that the throttle is in the idle position Then adjust the clevis yoke on the linkage rod to obtain...

Page 213: ...ree of friction and obstruction Do not let it rub against the engine brackets or hoses FORD LRG 423 ENGINE 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 clim...

Page 214: ...wheel and has a splined center to drive the pump a pump b pump shaft c coupler d flex plate with raised spline e flywheel f 1 4 inch gap Flex Plate Removal 1 Disconnect and remove the hose between the carburetor venturi and the air cleaner 2 Disconnect the linkage from the governor then remove the governor linkage from the carburetor Do not alter the length of the linkage 3 Disconnect the wiring p...

Page 215: ...e fasteners to 34 ft lbs 46 Nm 7 7 Water Temperature and Oil Pressure Gauges The water temperature gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 230 F 109 C When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Temperature will be indicated when the...

Page 216: ...c vacuum switch d normally open terminal ING 1 Connect the leads from an ohmmeter or continuity tester to the common and normally open terminals Result There should be no continuity infinite W 2 Apply mild suction to the vacuum port Result The switch should close and show full continuity zero W Component damage hazard Do not short the vacuum switch terminals to ground FORD LRG 423 ENGINE ...

Page 217: ...he removal tab on the bottom or top side of the component 3 Use a small narrow flat blade screwdriver to push in and release the wire from the component 4 Use the small narrow flat blade screwdriver to gently pry up on the tab of the component and remove it 8 4 Resistors How to Test the Resistor The resistor is used to maintain proper control of boom function speeds A 10 ohm resistor reduces volta...

Page 218: ...rd Disconnect the ground cable from the battery before performing this procedure 1 Connect the leads from an ohmmeter to each terminal combination and check for continuity Test Desired result 2 small posts 12 to 16W 2 large posts no continuity infinite W Any small post to no continuity any large post infinite W a b a b 2 Connect 12V DC to one of the small posts and a ground wire to the other small...

Page 219: ...e the pump mounting bolts Carefully remove the pump Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump 9 2 Drive Pump The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electronic displacement controller EDC located on the pump The only adjustment that can be made to the pump is t...

Page 220: ...ners 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate 6 Remove the drive pump from the machine Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump open closed How to Prime the Pump 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump 2 Gasoline LPG models Disconn...

Page 221: ...Part No 52270 Genie S 80 Genie S 85 7 37 Service Manual Second Edition Section 7 Repair Procedures This page intentionally left blank ...

Page 222: ...lbs 14 16 Nm 9 Flow regulator valve 1 5 gpm 5 7 l min I Boom up down circuit prevents overflowing the proportional valve 10 12 ft lbs 14 16 Nm 10 Flow regulator valve 1 5 gpm 5 7 l min J Turntable rotate left right prevents overflowing the proportional valve 10 12 ft lbs 14 6 Nm 11 Flow regulator valve 0 2 gpm 0 78 l min K Hydraulic limit switch circuit 10 12 ft lbs 14 16 Nm 12 Flow regulator valv...

Page 223: ...Part No 52270 Genie S 80 Genie S 85 7 39 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS ...

Page 224: ...c nipple Testing 28 Check valve AA Differential sensing circuit Platform rotate left 11 13 ft lbs 15 18 Nm 29 Check valve BB Differential sensing circuit Platform rotate right 11 13 ft lbs 15 18 Nm 30 Priority flow regulator valve CC Steering 10 12 ft lbs 14 16 Nm 5 gpm 18 9 l min 31 Solenoid valve N O Poppet DD Platform rotate left Jib boom up 25 30 ft lbs 34 41 Nm 32 Solenoid valve N O Poppet EE...

Page 225: ...Part No 52270 Genie S 80 Genie S 85 7 41 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS ...

Page 226: ...ust the relief valves higher than specified 6 Repeat steps 2 through 5 and recheck relief valve pressure System relief valve specifications Pressure 2900 psi 200 bar MANIFOLDS How to Adjust the Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 345 bar pressure gauge to the test port item 27 on the function manifold 2 Start the engine ...

Page 227: ...re Boom extend relief valve specifications Pressure 2300 psi 159 bar How to Override a Valve A hydraulic valve may need to be manually overridden to troubleshoot a malfunction The proportional boom functions boom up down extend retract and turntable rotate use a variable position proportional valve and a three position directional valve Example one position for boom up one position for neutral and...

Page 228: ...witch to the OFF position and disconnect the wires from the valve coil to be tested 2 Connect the leads from an ohmmeter to the valve coil terminals Valve coil specifications Proportional solenoid valve 12V 8 6W schematic items P R and U 3 position 4 way directional valve 10V 3 2W schematic items A B and C Normally open poppet valve 6 4W schematic item G V X DD and EE ...

Page 229: ...e Index Schematic No Description Item Function Torque 1 Shuttle valve 2 position 3 way JJ Turntable rotation brake release 10 13 ft lbs 14 18 Nm 2 Counterbalance valve KK Turntable rotate right 35 40 ft lbs 47 54 Nm 3 Counterbalance valve LL Turntable rotate left 35 40 ft lbs 47 54 Nm 3 2 1 Plug Torque Specifications Description Hex size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 4 3 16 13 ft lbs 1...

Page 230: ...ck valve MM Hydraulic limit switch circuit 35 40 ft lbs 47 54 Nm 2 Relief valve 350 psi 24 1 bar NN Chassis jack auto retract circuit 25 30 ft lbs 34 41 Nm 3 Counterbalance valve OO Non steer end chassis jack circuit 35 40 ft lbs 47 54 Nm 4 Counterbalance valve PP Steer end chassis jack circuit 35 40 ft lbs 47 54 Nm Plug Torque Specifications Description Hex size Torque SAE No 2 1 8 50 in lbs 6 Nm...

Page 231: ...r RR Chassis jack relief circuit when boom is raised or extended 25 30 ft lbs 34 41 Nm 3 Solenoid valve N O pilot operated SS Allows chassis jacks to lift chassis when boom is in stowed position 25 30 ft lbs 34 41 Nm 4 Check valve TT Prevents flow from chassis jacks through auxiliary pump 25 30 ft lbs 34 41 Nm 5 Flow regulator 0 3 gpm 1 14 l min UU Regulates flow to steer manifold 10 12 ft lbs 14 ...

Page 232: ...es How to Check the Resistance of a Valve Coil 1 Turn the key switch to the OFF position and disconnect the wires from the valve coil to be tested 2 Connect the leads from an ohmmeter to the valve coil terminals Valve coil specifications Normally open poppet valve 6 4W schematic item SS MANIFOLDS ...

Page 233: ...onents The steer manifold is mounted underneath the function manifold Index Schematic No Description Item Function Torque 1 3 position 4 way solenoid valve VV Steer left right 30 35 in lbs 3 4 Nm 2 Check valve WW Priority flow regulator circuit 10 12 ft lbs 14 16 Nm 3 Orifice plug 0 025 inch 0 635 mm XX Priority flow regulator circuit 4 Priority flow regulator valve 3 5 gpm 13 2 l min YY Regulates...

Page 234: ... How to Check the Resistance of a Valve Coil 1 Turn the key switch to the OFF position and disconnect the wires from the valve coil to be tested 2 Connect the leads from an ohmmeter to the valve coil terminals Valve coil specifications 3 position 4 way solenoid valve 5 7W schematic item VV MANIFOLDS ...

Page 235: ...Part No 52270 Genie S 80 Genie S 85 7 51 Service Manual Second Edition Section 7 Repair Procedures This page intentionally left blank ...

Page 236: ...Index Schematic No Description Item Function Torque 1 Relief valve 250 psi 17 2 bar ZZ Charge pressure circuit 10 12 ft lbs 14 16 Nm 4 Flow divider combiner valve AB Controls flow to drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 3 Orifice 0 070 in 1 78 mm AC Drive circuit 2 Shuttle valve 3 position 3 way AD Charge pressure circuit that gets hot oil out of low pressure side of drive pum...

Page 237: ...Part No 52270 Genie S 80 Genie S 85 7 53 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS ...

Page 238: ...machine slowly in either direction and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the charge pressure relief valve and remove the cap item 1 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 6 Restart the engine Drive the machine in either direction and recheck the v...

Page 239: ...Part No 52270 Genie S 80 Genie S 85 7 55 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS This page intentionally left blank ...

Page 240: ...r circuit 6 Flow divider combiner valve AJ Controls flow to steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 7 Flow divider combiner valve AK Controls flow to non steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 8 Orifice 0 070 in 1 78 mm AL Non steer end drive motor circuit 9 Orifice 0 070 in 1 78 mm AM Equalizes pressure on both sides of flow divider combine...

Page 241: ...Part No 52270 Genie S 80 Genie S 85 7 57 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS ...

Page 242: ...machine slowly in either direction and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the charge pressure relief valve and remove the cap index 3 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 6 Restart the engine Drive the machine in either direction and recheck the ...

Page 243: ... the fuel tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 6 Remove the fuel tank from the machine Crushing hazard The fuel tank may become unbalanced and fall if it is not properly supported and secured to the overhead crane Clean the fuel tank and inspect for rust and corrosion before installing 11 2 Hydraulic Tank The ...

Page 244: ...ith 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 10 Remove the hydraulic tank from the machine Crushing hazard The hydraulic may become unbalanced and fall if it is not properly supported and secured to the overhead crane 11 Remove the suction strainers from the tank and clean them using a mild solvent 12 Rinse out the inside o...

Page 245: ... pressure gauge to the test port on the drive pump 2 Gasoline LPG models Disconnect the electrical connector at the ignition coils The ignition coils are located above the alternator Electrocution hazard Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry a Deutz Diesel models Hold the manual fuel shutoff valve clockwise to the CL...

Page 246: ...ake mounting fasteners then remove the motor from the brake a motor brake mounting bolts b motor c brake d torque hub mounting bolts e torque hub f plug 12 1 Rotation Hydraulic Motor How to Remove the Rotation Hydraulic Motor When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two...

Page 247: ...g bolts and then use a lifting device to remove the torque hub from the machine b c d e f a 4 Remove the plug from the side of the torque hub Then drain the oil from the hub 5 Install the torque hub Torque the hub mounting bolts to 180 foot pounds 244 Newton meters 6 Install the brake and motor onto the torque hub 7 Fill the hub with oil from the side hole until the oil level is even with the bott...

Page 248: ...ts b adjustment bolt with lock nut c torque hub pivot plate 2 Push the torque hub pivot plate towards the turntable as far as possible this will push the rotation gear into the rotation bearing 3 Loosen the lock nut on the adjustment bolt 4 Turn the adjustment bolt clockwise until it contacts the pivot plate 5 Turn the adjustment bolt 1 2 turn counterclockwise Then tighten the lock nut on the adju...

Page 249: ...eering axle 3 Raise the machine 6 inches 15 cm and place blocks under the chassis for support 4 Remove the lug nuts Then remove the tire and wheel assembly 5 Remove the dust cap cotter pin and slotted nut 6 Pull the hub off the spindle The washer and outer bearing should fall loose from the hub 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing...

Page 250: ...0 foot pounds 569 5 Nm 2WD STEERING AXLE COMPONENTS 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 cylinder maintains equal movement of the tires When removing a hose assembly or fitting the O ring on the fitting and or hose end must be...

Page 251: ...rform the Toe in Adjustment Perform this procedure on a firm level surface Block the non steering tires and be sure that the machine is in the stowed position 1 Straighten the steer wheels 2 Measure the steer tires front to front and back to back using a measuring fixture 3 Center a lifting jack of ample capacity under the steering axle then raise the machine 4 Loosen the jam nut on the adjustable...

Page 252: ...wer yoke pivot pins 11 Support the yoke torque hub assembly with a lifting jack Secure the yoke torque hub assembly to the lifting jack 12 Use a slide hammer to remove the upper yoke pivot pin then use a soft metal drift to drive the lower yoke pivot pin down and out 13 Remove the yoke torque hub assembly from the machine Crushing hazard The yoke hub assembly may become unbalanced and fall when th...

Page 253: ...bs 569 5 Nm lubricated 320 ft lbs 433 9 Nm Torque hub mounting bolts dry 120 ft lbs 163 Nm lubricated 90 ft lbs 122 Nm Drive motor mounting bolts dry 75 ft lbs 102 Nm lubricated 56 ft lbs 76 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 14 3 Tie Rod Cylinder How to Remove the ...

Page 254: ...s How to Remove the Inner Axle When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dis...

Page 255: ...on the drive motor 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 14 Attach a strap from a lifting device to the inner axle for support 15 Use a soft metal drift to remember to remove the axle extension cylinder pivot pin 16 Remove the lock plate fr...

Page 256: ...en remove the lift jack cylinder from the machine Crushing hazard The chassis lift jack cylinder may become unbalanced and fall if it is not properly attached to the overhead crane when it is removed from the machine EXTENDABLE AXLE COMPONENTS 15 3 Hydraulic Limit Switches The hydraulic limit switches are 2 position 2 way valves The switches sense full axle extension and allow the boom functions t...

Page 257: ...ic 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 Non steering Axle Components 4 Remove the drive motor mounting fasteners 5 Slide the drive motor shaft out of the brake and then remove the drive motor from the machine Torque specifications Drive motor mounting bolts 75 ft lbs 102 Nm 16 2...

Page 258: ...to the axle Remove the torque hub Crushing hazard The torque hub may become unbalanced and fall if it is not properly supported and secured to the lifting jack Torque specifications Lug nut dry 420 ft lbs 569 5 Nm lubricated 320 ft lbs 433 9 Nm Torque hub mounting bolts dry 120 ft lbs 163 Nm lubricated 90 ft lbs 122 Nm Drive motor mounting bolts dry 75 ft lbs 102 Nm lubricated 56 ft lbs 76 Nm ...

Page 259: ...Genie North America 18340 NE 76th Street P O Box 97030 Redmond Washington 98073 9730 Genie Europe Brunel Drive Newark Nottinghamshire NG24 2EG England Distributed By ...

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