Genie Industries S-40 Service Manual

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First Edition, First Printing

Part No. 32222

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Page 1 Technical Publications S-40 ® Service Manual First Edition, First Printing Part No. 32222...
Page 2 Service Manual - First Edition ® Important Genie North America Read, understand and obey the safety rules and operating instructions in the Genie S-40 Operator's Telephone (206) 881-1800 Manual before attempting any maintenance or Toll Free 800 536-1800 repair procedure.
Page 3 Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie S-40 Operator's Manual will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
Page 4 Be sure to properly dispose of old oil or such as moving parts, free swinging or other fluids. Use an approved container. unsecured components, and lifting or Please be environmentally safe. placing loads. Always wear approved steel-toed shoes. Genie S-40 Part No. 32222...
Page 5: Table Of Contents
Check the Engine Coolant Level - Gasoline/LPG Models ....... 4 - 3 Check for Fuel Leaks ..................4 - 3 Check the Hydraulic Oil Level ................. 4 - 4 Check for Hydraulic Leaks ................4 - 4 Part No. 32222 Genie S-40...
Page 6 B-18 Test the Service Horn ................... 4 - 21 B-19 Test the Foot Switch ..................4 - 22 B-20 Test the Engine Idle Select ................4 - 22 B-21 Test the Fuel Select Operation - Gasoline/LPG Models ........ 4 - 23 Genie S-40 Part No. 32222...
Page 7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models ... 4 - 44 Check the Toothed Belt - Deutz Diesel Models ..........4 - 44 Replace the Timing Belt - Gasoline/LPG Models .......... 4 - 44 Part No. 32222 Genie S-40...
Page 8 Turntable Rotate Right Function Inoperative ..........5 - 39 All Platform Leveling Functions Inoperative ..........5 - 40 Platform Level Up Function Inoperative ............5 - 41 Platform Level Down Function Inoperative ............ 5 - 42 Genie S-40 Part No. 32222 viii...
Page 9 Platform Control Box Legend - Diesel Models ............6-11 Hydraulic Symbols Legend ..................6-12 2WD Hydraulic Schematic - Non-Oscillating Axle ............. 6-13 2WD Hydraulic Schematic - Oscillating Axle ............6-14 4WD Hydraulic Schematic ..................6-15 Part No. 32222 Genie S-40...
Page 10 Governor Actuator ..................7 - 19 Choke Adjustments ..................7 - 20 Timing Adjustment ..................7 - 21 Carburetor Adjustment .................. 7 - 21 RPM Adjustment ................... 7 - 21 Flex Plate ...................... 7 - 21 Genie S-40 Part No. 32222...
Page 11 12-2 Steering Cylinders ..................7 - 40 12-3 Tie Rod ......................7 - 41 4WD Steering Axle Components 13-1 Yoke and Hub ....................7 - 42 13-2 Steering Cylinders ..................7 - 43 13-3 Tie Rod ......................7 - 43 Part No. 32222 Genie S-40...
Page 12 17-1 2WD Drive Manifold Components ..............7 - 52 17-2 Valve Adjustments ..................7 - 54 4WD Drive Manifold 18-1 4WD Drive Manifold Components ..............7 - 56 18-2 Valve Adjustments ..................7 - 58 Genie S-40 Part No. 32222...
Page 13: Specifications
Product specifications are subject to change 1.83 m 2.44 m without notice. Width 30 in 36 in 76.2 cm 91.4 cm Maximum capacity 500 lbs 500 lbs 227 kg 227 kg Part No. 32222 Genie S-40 2 - 1...
Page 14: Performance Specifications
1.1 km/h 40 ft/40 sec 40 ft/40 sec Platform level up 25 to 50 seconds 12.2 m/40 sec 12.2 m/40 sec Platform level down 15 to 35 seconds Gradeability (boom stowed) Rough terrain 2 - 2 Genie S-40 Part No. 32222...
Page 15: Hydraulic Specifications
0.152 cu in Rear drive motors 2.5 cc Displacement per revolution 2.13 cu in 35 cc Displacement 1.4 gallons per minute 5.3 liters per minute Auxiliary pump 2500 psi relief pressure 176 bar Part No. 32222 Genie S-40 2 - 3...
Page 16: Bolt Torque Specifications
Newton meters No. 10 inch inch inch inch inch inch inch inch inch 1 inch 1221 1000 1356 Torque specification for lubricated bolts is 25% less than dry torque specification for bolt size. 2 - 4 Genie S-40 Part No. 32222...
Page 17: Ford Lsg 423 Engine Specifications
20W-40 or 20W-50 Minimum volume flow 1 pint 25°F / -4°C (in 25 seconds) 473 cc Use oils meeting API classification SF (labeled SF/CC or SF/CD) as they offer improved wear protection. Part No. 32222 Genie S-40 2 - 5...
Page 18 Cylinder head bolt (M-12): torque in sequence Outer timing belt cover 6 to 9 8 to 12 first step 50 to 60 68 to 81 bolt (M-6) second step 80 to 90 108 to 122 2 - 6 Genie S-40 Part No. 32222...
Page 19 Engine oil should have properties of API classification CC/SE, CD/SE, CC/SF or CD/SF grades. V-belt pulley bolts 28 to 34 38 to 46 (M-10 x 16, 8.8) Injection system Injection pump make OMAP Part No. 32222 Genie S-40 2 - 7...
Page 20: Deutz F3L Engine Specifications
68 to 82 Crankshaft/central bolt 210° (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 2 - 8 Genie S-40 Part No. 32222...
Page 21: Scheduled Maintenance Inspections
Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. Part No. 32222 Genie S-40 3 - 1...
Page 22 A-10 Test the Platform and Ground Controls A-11 Test the Auxiliary Power Operation A-12 Test the Tilt Sensor A-13 Test the Limit Switches A-14 Test the Oscillate Axle (oscillating axle equipped models) 3 - 2 Genie S-40 Part No. 32222...
Page 23 Confirm the Proper Brake Configuration B-10 Check the Oil Level in the Torque Hubs B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models B-12 Check and Adjust the Engine RPM Part No. 32222 Genie S-40 3 - 3...
Page 24 Perform Hydraulic Oil Anaysis See D-1 Test or Replace the Hydraulic Oil Every 500 hours, perform the following engine maintenance procedure. B-27 Replace the Engine Oil and Filter - Deutz Diesel Models 3 - 4 Genie S-40 Part No. 32222...
Page 25 Gasoline/LPG Models C-13 Check and Adjust the Air/LPG Mixture - Gasoline/LPG Models C-14 Check and Adjust the Ignition Timing - Gasoline/LPG Models C-15 Check the Engine Valve Clearances - Deutz Diesel Models Part No. 32222 Genie S-40 3 - 5...
Page 26 Clean the PCV Hoses and Fittings - Gasoline/LPG Models Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models Check the Toothed Belt - Deutz Diesel Models Replace the Timing Belt - Gasoline/LPG Models 3 - 6 Genie S-40 Part No. 32222...
Page 27: Maintenance Inspection Report
D-4 Valves-gasoline B-13 Key Switch D-5 Compression-gasoline B-14 Emergency Stop D-6 PCV hoses-gasoline B-15 Ground control override D-7 Fuel injection-Deutz B-16 Valve linkage D-8 Toothed belt-Deutz B-17 Platform leveling D-9 Timing belt-Ford Part No. 32222 Genie S-40 3 - 7...
Page 28 Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition Warm Cold Dealer Tools are New parts engine engine service required required required required suggested This page intentionally left blank. 3 - 8 Genie S-40 Part No. 32222...
Page 29: Scheduled Maintenance Procedures
· turntable rotated with the boom between the non-steering wheels · turntable secured with the turntable rotation lock pin · key switch in the position with the key removed · wheels chocked Part No. 32222 Genie S-40 4 - 1...
Page 30: Inspect The Manuals
· compartment covers and latches 1 Refer to the Decals section in the Genie S-40 Operator's Manual and use the decal list and illustrations to determine that all decals and placards are in place. 4 - 2 Genie S-40 Part No.
Page 31: Check The Engine Oil Level
60°F / 15.5°C (synthetic) 5W-30 -10°F to 90°F / -23°C to 32°C 10W-40 above -4°F / -34°C 15W-40 Engine oil should have properties of API classification CC/SE, CD/SE, CC/SF or CD/SF grades. Part No. 32222 Genie S-40 4 - 3...
Page 32: Check The Hydraulic Oil Level
· ground area under the machine Result: The hydraulic oil level should be within the top 2 inches (5 cm) of the sight gauge. 4 - 4 Genie S-40 Part No. 32222...
Page 33: Check The Tire Pressure
4 Push in the Emergency Stop button to the position. Result: No function should operate, the engine should stop. As a safety feature, selecting and operating the ground controls will override the platform controls, including the Emergency Stop button. Part No. 32222 Genie S-40 4 - 5...
Page 34: Test The Auxiliary Power Operation
· boom up/down · extend and retract · turntable rotate right/left Result: Each function should operate smoothly. 3 Turn the key switch to platform control. 4 - 6 Genie S-40 Part No. 32222...
Page 35: Test The Tilt Sensor
· broken or missing actuator arm · missing fasteners · loose wiring fuel tank tilt sensor ground control box drive limit switch boom lift cylinder Part No. 32222 Genie S-40 4 - 7...
Page 36 7 Raise the boom above the drive limit switch. turntable rotation bearing 8 Slowly move the drive control handle off center. Result: The machine should move at a reduced drive speed. 4 - 8 Genie S-40 Part No. 32222...
Page 37: Test The Oscillate Axle
4 Drive both steer tires up onto a 6 inch (15.2 cm) block or curb. Result: The non-steer tires should stay in firm contact with the ground. Part No. 32222 Genie S-40 4 - 9...
Page 38: Replace The Engine Oil And Filter - Gasoline/Lpg Models
6 Use an oil filter wrench and remove the filter. 7 Apply a thin layer of oil to the new oil filter gasket (filter part no. 28656). Then install the filter and tighten it securely by hand. 4 - 10 Genie S-40 Part No. 32222...
Page 39: Replace The Engine Air Filter
20W-40 or 20W-50 Air filters - Genie part numbers Ford LSG-423 Engine 27916 Use oils meeting API classification SF (labeled SF/CC Deutz F3L 1011 29553 or SF/CD) as they offer improved wear protection. Part No. 32222 Genie S-40 4 - 11...
Page 40: Check The Engine Belt(S)
Remove the key to secure from operation. Belt deflection - all models inch to inch 9 mm to 12 mm Beware of hot engine components. Contact with hot engine components may cause severe burns. 4 - 12 Genie S-40 Part No. 32222...
Page 41: Check The Exhaust System
6 Inspect the head cooling passages and fins for physical damage or foreign material, using a flashlight. 7 Clean the cylinder head cooling passages of debris and foreign material. pivot plate retaining bolts engine pivot plate Part No. 32222 Genie S-40 4 - 13...
Page 42: Check The Battery
If the display shows the plunger in the red area, this indicates that the hydraulic filter is being bypassed and the filter should be replaced. See C-6, Replace the Hydraulic Tank Filter. 4 - 14 Genie S-40 Part No. 32222...
Page 43: Inspect The Electrical Wiring
Wheel diameter 16 in 16.5 in 40.6 cm 41.9 cm Wheel width 10 in 9.75 in 25.4 cm 24.7 cm Wheel lugs Lug nut torque 125 ft-lbs 125 ft-lbs 169.5 Nm 169.5 Nm Part No. 32222 Genie S-40 4 - 15...
Page 44: Confirm The Proper Brake Configuration
Drive torque hub oil The free-wheel valve should Capacity 17 fluid ounces always remain closed. 0.51 liters Type: SAE 90 multipurpose hypoid gear oil - API service classification GL5 4 - 16 Genie S-40 Part No. 32222...
Page 45: Check And Adjust The Engine Idle Mixture - Gasoline/Lpg Models
3 Apply pipe thread sealant to the plug, and then governor actuator. install it in the torque hub. Turntable rotate torque hub oil Capacity 8 fluid ounces 0.24 liters TypeSAE 90 multipurpose hypoid gear oil - API service classification GL5 Part No. 32222 Genie S-40 4 - 17...
Page 46 1 Connect an rpm gauge to the engine, and then start the engine from the ground controls. Result: Low idle should be 1300 rpm. Skip to step 3 if the low idle rpm is correct. 4 - 18 Genie S-40 Part No. 32222...
Page 47: Test The Key Switch
Deutz Diesel models: All functions yoke lock nut and recheck the rpm. should stop immediately. The engine will shut off after 2 to 3 Deutz Diesel models seconds. Low idle 1300 rpm High idle 2300 rpm Part No. 32222 Genie S-40 4 - 19...
Page 48: Test The Emergency Stop Buttons
Result: The engine should shut off and no machine functions should operate. The ground Emergency Stop button will stop all machine operation, even if the key switch is switched to platform control. 4 - 20 Genie S-40 Part No. 32222...
Page 49: Check The Directional Valve Linkage
2 Push down the service horn button at the yoke clevis pin with cotter pin platform controls. Result: The service horn should sound. Part No. 32222 Genie S-40 4 - 21...
Page 50: Test The Foot Switch
Deutz Diesel models simultaneously. This setting maintains a consistent high idle and is usually selected only Low idle 1300 rpm when the generator option is being used. High idle 2300 rpm 4 - 22 Genie S-40 Part No. 32222...
Page 51: Test The Fuel Select Operation - Gasoline/Lpg Models
Result: The drive enable indicator light should fuel source is switched while come on. the engine is running. 6 Repeat steps 3 and 4. Part No. 32222 Genie S-40 4 - 23...
Page 52: Test The Drive Brakes
Stopping distance 2 to 4 ft 12.2 m/7.8 sec 12.2 m/9.1 sec 0.60 to 1.21 m The brakes must be able to hold the machine on any slope it is able to climb. 4 - 24 Genie S-40 Part No. 32222...
Page 53: Test The Alarm Package - Optional Equipment
3 Turn the key switch to platform control. 4 At the platform controls pull out the Emergency Stop button to the position. Result: The flashing beacon should be on and flashing. Part No. 32222 Genie S-40 4 - 25...
Page 54: Replace The Engine Oil And Filter - Deutz Diesel Models
Temperature below 60°F / 15.5°C (synthetic) 5W-30 -10°F to 90°F / -23°C to 32°C 10W-40 Temperature above -4°F / -34°C 15W-40 Engine oil should have properties of API classification CC/SE, CD/SE, CC/SF or CD/SF grades. 4 - 26 Genie S-40 Part No. 32222...
Page 55: Check The Boom Wear Pads
3 Lower the boom to the stowed position. tubes. 4 Check to ensure that each bearing mounting bolt under the drive chassis is torqued in sequence to 210 foot-pounds (285 Newton meters). Bolt torque sequence Part No. 32222 Genie S-40 4 - 27...
Page 56: Check The Free-Wheel Configuration
Carefully remove the jack stands, lower the machine and remove the jack. Collision hazard. Failure to re-engage the torque hubs may cause death or serious injury and property damage. 4 - 28 Genie S-40 Part No. 32222...
Page 57: Grease The Turntable Rotation Bearing And Rotate Gear
1 Select the drive torque hub to be serviced. Then drive the machine until one of the two plugs is at the lowest point. 2 Remove both plugs and drain the oil. Part No. 32222 Genie S-40 4 - 29...
Page 58 Type: SAE 90 multipurpose hypoid gear oil - API service classification GL5 unlocked locked 2 Remove the motor/brake mounting bolts, and then remove the motor and brake from the torque hub and set them to the side. 4 - 30 Genie S-40 Part No. 32222...
Page 59: Replace The Hydraulic Tank Filter
6 Start the engine from the ground controls. 7 Inspect the filter assembly to be sure that there are no leaks. Part No. 32222 Genie S-40 4 - 31...
Page 60: Replace The Diesel Fuel Filter - Deutz Diesel Models
Replace the fuel filter in an open, well-ventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Perform this procedure with the fuel filter engine off. oil filter 4 - 32 Genie S-40 Part No. 32222...
Page 61 Repair the leak immediately. 6 Swing the engine pivot plate back to its original position and replace the two retaining bolts. Part No. 32222 Genie S-40 4 - 33...
Page 62: Replace The Pcv Valve - Gasoline/Lpg Models
Extremely dirty conditions may require that the cap and rotor be replaced more often. Perform this procedure with the engine off. 4 - 34 Genie S-40 Part No. 32222...
Page 63: Replace The Spark Plugs - Gasoline/Lpg Models
8 Swing the engine pivot plate back to its original position and replace the two retaining bolts. 9 Start the engine from the ground controls and check the engine for proper operation. Part No. 32222 Genie S-40 4 - 35...
Page 64: Check And Adjust The Air/Lpg Mixture - Gasoline/Lpg Models
13.0:1 to 13.2:1, start the engine from the ground controls. using an exhaust gas analyzer. If an exhaust gas analyzer is not available, adjust to obtain peak or optimum rpm. 4 - 36 Genie S-40 Part No. 32222...
Page 65: Check And Adjust The Ignition Timing - Gasoline/Lpg Models
Clearances - Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011 Workshop Manual (Deutz Number 02611642). Genie part number 29789. low idle mixture adjustment screw Part No. 32222 Genie S-40 4 - 37...
Page 66: Test Or Replace The Hydraulic Oil
CLOSED damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 4 - 38 Genie S-40 Part No. 32222...
Page 67: Change Or Recondition The Engine Coolant - Gasoline/Lpg Models
Check the hydraulic tank for leaks. Hydraulic system Hydraulic tank capacity 45 gallons 170 liters Hydraulic system 50 gallons capacity (including tank) 189 liters Hydraulic fluid Dexron ll equivalent Part No. 32222 Genie S-40 4 - 39...
Page 68 Add water if needed. 9 Pour the proper coolant mixture (anti-freeze and water) for your climate into the radiator until it is 11.5 quarts Ford Engine LSG-423 full. Coolant capacity 10.9 liters 4 - 40 Genie S-40 Part No. 32222...
Page 69: Change The Fuel Lines
Part No. 32222 Genie S-40 4 - 41...
Page 70: Check The Engine Valve Clearance - Gasoline/Lpg Models
If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. 4 - 42 Genie S-40 Part No. 32222...
Page 71: Clean The Pcv Hoses And Fittings - Gasoline/Lpg Models
3 Clean the hoses with a mild cleaning solvent. 4 Dry both hoses and inspect them for cracks and damage. Replace the hoses if they are damaged. pivot plate retaining bolts engine pivot plate Part No. 32222 Genie S-40 4 - 43...
Page 72: Check The Fuel Injection Pumps And Injectors - Deutz Diesel Models
Replace the Timing Belt - Gasoline/LPG Models Complete information to perform this procedure is available in the Ford LSG-423 2.3 Liter Industrial Engine Service Manual (Ford number: 194-216). Genie part number 29586. 4 - 44 Genie S-40 Part No. 32222...
Page 73: Troubleshooting Flow Charts
Troubleshooting Flow Charts Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie S-40 Operator’s Manual. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Read each appropiate flow chart thoroughly.
Page 74 When a function will not operate with the same speed or power as a machine in good working condition, refer to the flow chart which most closely describes the problem. 5 - 2 Genie S-40 Part No. 32222...
Page 75: Engine Will Not Crank Over
Check ground wire to Repair open in ground check voltage at terminal #5 on start wire. terminal #1 on start lockout module. lockout module. good Consult Genie Industries Service Department. Continued on the next page. Part No. 32222 Genie S-40 5 - 3...
Page 76 #87 on CR1. good Replace CR1 relay. Check voltage at Repair open in blk wire initiate terminal starter circuit from CR1 to solenoid. starter solenoid. Check, repair or replace starter or starter solenoid. 5 - 4 Genie S-40 Part No. 32222...
Page 77 12V Continued on the next page. Part No. 32222 Genie S-40 5 - 5...
Page 78 #5 on start circuit to start lockout lockout module. module. good Replace the start lockout module OR consult Genie Industries Service Department. Check ground to no good Repair open in ground terminal #85 on CR2. wire to CR2. good Continued on the next page.
Page 79 CR1 to #86 on CR8. no good Repair open in ground Check ground to terminal #85 on CR8. wire to CR8. good If weak spark still exists, contact Genie Industries Service Department. Part No. 32222 Genie S-40 5 - 7...
Page 80: Engine Cranks Over But Will Not Start - Gasoline/Lpg Models
Not Start - Gasoline/LPG Models Check automatic choke Adjust or replace for proper adjustment or automatic choke OR internal damage. consult Genie Industries Service Department. good Engine Runs While Cranking With keyswitch on and Repair open in red/wht both mushroom...
Page 81 Check ground wire on both mushroom terminal #85 of CR6. wire. switches pulled out. Crank engine and check good voltage at terminal #87 on CR6. Replace CR6. Continued on the next page. Part No. 32222 Genie S-40 5 - 9...
Page 82 OR replace anti-diesel valve OR see Ford service manual for Go to chart 2B, troubleshooting fuel page 5 - 11. pump and/or carburetor OR Consult Genie Industries Service Department. 5 - 10 Genie S-40 Part No. 32222...
Page 83 Genie Industries check voltage at Service Department. terminal #4. Repair short to power in red wire circuit from TB27. Replace start lockout module OR consult Genie Industries Service Department. Part No. 32222 Genie S-40 5 - 11...
Page 84: Engine Cranks Over But Will Not Start - Deutz Diesel Models
TB24 to continuity temperature sender. no continuity Repair short in wht wire circuit from start lock out module to TB24 OR consult Genie Industries Service Department. 0 or infinite Disable starter by Turn machine off and Replace the fuel...
Page 85 #5 on start circuit to terminal #5 on lockout module. start lockout module. good Replace the start lockout module OR consult Genie Industries Service Department. Check ground to no good Repair open in ground terminal #85 on CR2. wire to CR2. good Continued on the next page.
Page 86 Continued from the voltage at org/blk #41 alternator OR contact voltage at terminal #2 on previous page. wire on alternator. Genie Industries Service start lockout module. Department. 6 to 7V Repair open in org/blk 6 to 7V #41 wire circuit from...
Page 87: Engine Will Not Start On Lpg, But Will Start On Gasoline - Gasoline/Lpg Models
#86 switch to CR6 to CR7. on CR7. Check ground wire to Repair open in ground terminal #85 on CR7. to terminal #85 on CR7. good Continued on the next page. Part No. 32222 Genie S-40 5 - 15...
Page 88 Check resistance of ohms LPG solenoid. Replace LPG solenoid. 9 to 10 ohms Reconnect LPG tank and starter then see Maintenance section for LPG adjustments OR consult Genie Industries Service Department. 5 - 16 Genie S-40 Part No. 32222...
Page 89: Engine Will Not Start On Gasoline, But Will Start On Lpg
Hold start switch and Repair open in blu/wht check voltage at blu/wht wire circuit from CR6 wire on anti-diesel valve terminal #87 (on carburetor). to anti-diesel valve OR replace CR6. Continued on the next page. Part No. 32222 Genie S-40 5 - 17...
Page 90 0 or infinite ohms Check resistance of Replace anti-diesel anti-diesel valve. valve. 24 to 25 ohms Reconnect starter, check anti-diesel and fuel valve for defects OR see Ford service manual for carburetor troubleshooting. 5 - 18 Genie S-40 Part No. 32222...
Page 91: Engine High Idle Inoperative - Gasoline/Lpg Models
#86 (blk/red) of wire circuit from CR4. CR3 to CR4. Check ground wire to Repair open in ground terminal #85 on CR4. wire to terminal #85 on CR4. good Continued on the next page. Part No. 32222 Genie S-40 5 - 19...
Page 92 3 (brown wire). 6 to 7V See Maintenance section for governor adjustments OR replace electronic governor. 5 - 20 Genie S-40 Part No. 32222...
Page 93: Engine Low Idle Inoperative - Gasoline/Lpg Models
#4 on electronic check and/or replace governor and restart governor actuator OR engine. see Ford service manual for carburetor troubleshooting. engine goes to low idle Recheck electronic governor adjustments OR replace electronic governor. Part No. 32222 Genie S-40 5 - 21...
Page 94: Engine High Idle Inoperative - Deutz Diesel Models
Check voltage to Replace CR3 relay. terminal #87 on CR3. Check voltage at initiate Repair open in blk/red terminal #86 on CR4. wire circuit from CR3 to CR4. Continued on the next page. 5 - 22 Genie S-40 Part No. 32222...
Page 95 2-speed solenoid. solenoid Check if 2-speed Check linkage or binds solenoid moves in and replace solenoid. out freely. moves freely Replace 2-speed solenoid. Note: resistance across solenoid terminals should be approximately 0.3 ohms. Part No. 32222 Genie S-40 5 - 23...
Page 96: Engine Low Idle Inoperative - Deutz Diesel Models
Check adjustment of linkage and fuel injection system low idle. See Maintenance section. See Deutz workshop manual to troubleshoot fuel injection system OR consult Genie Industries Service Department. 5 - 24 Genie S-40 Part No. 32222...
Page 97: All Functions Inoperative, Engine Starts And Runs
Hold start switch and crank engine over while observing spline drive at rear of main pump. spline does not turn Engine to pump flex plate coupling is defective. See Repair section. Part No. 32222 Genie S-40 5 - 25...
Page 98: All Lift And Steer Functions Inoperative, Drive Functions Operational
All Lift and 2400 Troubleshoot each Install a 0 to 3000 PSI function individually or pressure gauge on Steer Functions consult Genie Industries the function manifold. Service Department. Start engine, hold the Inoperative, boom retract function Drive Functions and check the hydraulic pressure.
Page 99: Ground Controls Inoperative, Platform Controls Operate Normally
Replace key switch. Repair open in red wire circuit from key switch to function switches. Part No. 32222 Genie S-40 5 - 27...
Page 100: Platform Controls Inoperative, Ground Controls Operate Normally
Check voltage at TP23. Repair open in blk wire circuit from emergency stop button to TP23. Repair open in blk wire circuit from TP23 to foot switch OR replace foot switch. 5 - 28 Genie S-40 Part No. 32222...
Page 101: Boom Up Function Inoperative
Replace coil. terminals. 4 to 5 ohms Interchange flow regulator valve (item Y) function operates Replace defective flow with a like valve regulator valve. (item X). function inoperative Continued on the next page. Part No. 32222 Genie S-40 5 - 29...
Page 102 OR repair cylinder manifold and hold the OR cylinder function switch. counterbalance valve. less than 2400 psi Repair cylinder OR replace cylinder counterbalance valve OR manifold has internal defect, consult Genie Industries Service Department. 5 - 30 Genie S-40 Part No. 32222...
Page 103: Boom Down Function Inoperative
Disconnecting hydraulic lines or adjusting the Continued on the next cylinder counterbalance page. valve in this situation can be very dangerous Please consult Genie Industries Service Department. Part No. 32222 Genie S-40 5 - 31...
Page 104 1800 psi Internal defect in manifold OR one of the previous tests involving the pump or manifold components was possibly overlooked or diagnosed incorrectly. Recheck and/or consult Genie Industries Service Department. 5 - 32 Genie S-40 Part No. 32222...
Page 105: Boom Extend Function Inoperative
If a helper is not available, Replace the valve. interchange the valve (item S) with a like valve (item P). function inoperative Continued on the next page. Part No. 32222 Genie S-40 5 - 33...
Page 106 Check for mechanical restrictions and/or the less than 1200 psi cylinder has internal defects. Please consult Genie Industries Service Department. Adjust the boom extend relief valve (item D) in With boom fully 1200 one turn clockwise.
Page 107: Boom Retract Function Inoperative
See Repair section. less than 2400 psi Repair cylinder OR replace cylinder counterbalance valve OR manifold has internal defect, consult Genie Industries Service Department. Part No. 32222 Genie S-40 5 - 35...
Page 108: Turntable Rotate Function Inoperative
If a Replace the valve. helper is not available, interchange the valve (item P) with a like valve (item S). function inoperative Continued on the next page. 5 - 36 Genie S-40 Part No. 32222...
Page 109 OR check rotation brake function switch. OR check rotation torque hub. less than 2400 psi Repair rotation motor OR manifold has internal defect, consult Genie Industries Service Department. Part No. 32222 Genie S-40 5 - 37...
Page 110: Turntable Rotate Left Function Inoperative
Then, with pressure 2400 gauge still attached, operate the function. Repair rotation motor. less than 2400 psi Replace the directional valve OR the manifold has internal defects OR Consult Genie Industries Service Department. 5 - 38 Genie S-40 Part No. 32222...
Page 111: Turntable Rotate Right Function Inoperative
(S1). Then, with pressure Repair rotation motor. gauge still attached, operate the function. less than 2400 psi Replace the directional Consult Genie valve OR the manifold Industries Service has internal defects. Department. Part No. 32222 Genie S-40 5 - 39...
Page 112: All Platform Leveling Functions Inoperative
Continually master cylinder. monitor the pressure gauge during boom up. Do not allow the pressure to exceed 2500 psi. 2400 psi or more Repair or replace the slave cylinder. 5 - 40 Genie S-40 Part No. 32222...
Page 113: Platform Level Up Function Inoperative
Replace defective counterbalance valve. Replace the directional valve OR the manifold has internal defects OR one of the previous tests was possibly overlooked or diagnosed incorrectly. Recheck and/or consult Genie Industries Service Department. Part No. 32222 Genie S-40 5 - 41...
Page 114: Platform Level Down Function Inoperative
Replace defective counterbalance valve. Replace the directional valve OR the manifold has internal defects OR one of the previous tests was possibly overlooked or diagnosed incorrectly. Recheck and/or consult Genie Industries Service Department. 5 - 42 Genie S-40 Part No. 32222...
Page 115: Platform Rotate Left Function Inoperative
Interchange check valve Replace defective (item H) with like valve check valve. (item L). function inoperative Replace directional valve OR manifold has internal defects OR consult Genie Industries Service Department. Part No. 32222 Genie S-40 5 - 43...
Page 116: Platform Rotate Right Function Inoperative
Interchange check valve Replace defective (item I) with like valve check valve. (item L). function inoperative Replace directional valve OR manifold has internal defects OR consult Genie Industries Service Department. 5 - 44 Genie S-40 Part No. 32222...
Page 117: Oscillate Function Inoperative
Sequence Valve chassis and manually Pressure OR consult activate directional Genie Industries valve while engine is Service Department. running. Check the pressure. 900 psi Consult Genie Industries Service Department. Part No. 32222 Genie S-40 5 - 45...
Page 118: Steer Left Function Inoperative
Remove both wires from ohms steer left coil and check Replace steer left resistance across coil valve coil. terminals. 4 to 8 ohms Replace steer valve OR consult Genie Industries Service Department. 5 - 46 Genie S-40 Part No. 32222...
Page 119: Steer Right Function Inoperative
Remove both wires from ohms steer right coil and Replace steer right check resistance across valve coil. coil terminals. 4 to 8 ohms Replace steer valve OR consult Genie Industries Service Department. Part No. 32222 Genie S-40 5 - 47...
Page 120: All Drive Functions Inoperative, All Other Functions Operate Normally
(alternator or battery) board terminal 1. OR repair open in wht wire circuit supplying 12V to terminal 1. 12V or more Continued on the next page. 5 - 48 Genie S-40 Part No. 32222...
Page 121 Repair open in red wire and check voltage at circuit from horse power terminal 6 on drive limiter board to drive controller. control terminal 6. 9 to 12V Continued on the next page. Part No. 32222 Genie S-40 5 - 49...
Page 122 OR repair open in wht the two wires at EDC wire circuit from TB30 to quick disconnect. EDC quick disconnect. 4 to 7V Replace drive pump EDC OR consult Genie Industries Service Department. 5 - 50 Genie S-40 Part No. 32222...
Page 123: Drive Forward Or Reverse Function Inoperative
(neutral). See drive pump, contact Sundstrand Series 40 Sundstrand authorized Service Manual. repair facility. symptoms improve Check all drive speeds and monitor for recurring symptoms. Possible contamination in hydraulic system. Part No. 32222 Genie S-40 5 - 51...
Page 124: Traction Function Inoperative
Section 5 - Troubleshooting Flow Charts Service Manual - First Edition Chart 31 Traction Any type of traction problem, consult Genie Function Industries Service Department. Inoperative Be sure all other functions operate normally. 5 - 52 Genie S-40 Part No. 32222...
Page 125: Machine Will Not Drive At Full Speed
Be sure the free-wheel valve is closed on the no continuity drive pump. Re-adjust or replace horsepower limiter board. See Repair section OR consult Genie Industries Service Department. Part No. 32222 Genie S-40 5 - 53...
Page 126: Machine Drives At Full Speed With Platform Raised Or Extended
Repair limit switch tampering. wiring OR replace boom lift drive limit switch OR Be sure orange wire replace boom extend drive limit switch. (cable 1) is properly attached to horsepower limiter. 5 - 54 Genie S-40 Part No. 32222...
Page 127: Drive Enable System Is Malfunctioning
Will holding the drive enable switch allow boom to drive in stowed position over steer wheels? Repair or replace drive enable toggle switch. Part No. 32222 Genie S-40 5 - 55...
Page 128: Auxiliary Functions Inoperative
Hold the auxiliary power switch and check the voltage at positive Replace PR1 relay. power cable on auxiliary power unit. Check auxiliary power unit grounding cable OR repair or replace electric motor. 5 - 56 Genie S-40 Part No. 32222...
Page 129: Schematics
Read, understand and obey the safety rules squirt or spray. and operating instructions printed in the Genie General Repair Process S-40 Operator's Manual. Be sure that all necessary tools and test equipment are available and ready for use. Identify Malfunction...
Page 130: Electrical Symbols Legend
Tilt sensor no connection Single axis proportional Vacuum switch controller Relay contact Diode Spark plug normally open Oil pressure Relay panel Dual axis switch Glow plug contactor proportional normally closed Battery controller 6 - 2 Genie S-40 Part No. 32222...
Page 131: Electrical Schematic - Gasoline/Lpg Models
Service Manual Section 6 - Schematics Electrical Schematic - Gasoline/LPG Models...
Page 132 IGN./FUEL ON ENG. FAULT TB21 TB24 RESISTOR CR6 CR7 WIRE IGNITION MODULE VOLT AGE REGULATOR COIL DISTRIBUTOR ALTERNA TOR BAT . ELECTRONIC GOVERNOR GRD. STARTER WTS1 AUX PUMP STA. OPS1 FLD. GOVERNOR ACTUATOR 6 - 3 Genie S-40 Part No. 32222...
Page 133 TP18 TP17 TP16 TP15 TP14 TP40 TP36 TP37 TP32 TP31 TP30 TP12 TP13 TS13 TS14 TS15 TS16 TS17 TB16 TB18 TB15 TB17 TB14 TB37 TB32 TB31 TB30 TB13 TB36 TB40 TB12 WHT#12-E.H. Part No. 32222 Genie S-40 6 - 4...
Page 134: Ground Control Box Legend - Gasoline/Lpg Models
RESISTOR, 10 OHM, BOOM FUNCTIONS RELAY RELAY CUTOUT RELAY RELAY VOLT METER GAGE OIL PRESSURE GAGE WATER TEMP. GAGE HORN FUEL FUEL BALLAST BYPASS RELAY CUTOUT CUTOUT RELAY RELAY RELAY ENGINE HARNESS Part No. 32222 Genie S-40 6 - 5...
Page 135: Relay Panel Legend - Gasoline/Lpg Models
Section 6 - Schematics Service Manual Relay Panel Legend - Gasoline/LPG Models IGNITION COIL VOLTAGE REG. IGNITION MODULE GOVERNOR 6 - 6 Genie S-40 Part No. 32222...
Page 136: Platform Control Box Legend - Gasoline/Lpg Models
Service Manual Section 6 - Schematics Platform Control Box Legend - Gasoline/LPG Models 1 2 3 4 5 6 7 8 9 10 Part No. 32222 Genie S-40 6 - 7...
Page 137: Electrical Schematic - Diesel Models
Service Manual Section 6 - Schematics Electrical Schematic - Diesel Models...
Page 138 START INPUT AUX. ON 15AMP. GROUND TB20 BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT TB21 TB24 ALTERNATOR EXCT. BAT . BAT . STA. STARTER WTS1 AUX PUMP REGULATOR OPS1 IND. 6 - 8 Genie S-40 Part No. 32222...
Page 139 TP18 TP17 TP16 TP15 TP14 TP40 TP36 TP37 TP32 TP31 TP30 TP12 TP13 TS13 TS14 TS15 TS16 TS17 TB16 TB18 TB15 TB17 TB14 TB37 TB32 TB31 TB30 TB13 TB36 TB40 TB12 WHT#12-E.H. Part No. 32222 Genie S-40 6 - 9...
Page 140: Ground Control Box Legend - Diesel Models
CIRCUIT BREAKER, CONTROLS, 15A CIRCUIT BREAKER, ENGINE, 15A HOUR METER START FUEL RESISTOR, 10 OHM, BOOM FUNCTIONS RELAY RELAY CUTOUT RELAY RELAY VOLT METER GAGE OIL PRESSURE GAGE WATER TEMP. GAGE HORN RELAY ENGINE HARNESS Part No. 32222 Genie S-40 6 - 10...
Page 141: Platform Control Box Legend - Diesel Models
Section 6 - Schematics Service Manual Platform Control Box Legend - Diesel Models 1 2 3 4 5 6 7 8 9 10 6 - 11 Genie S-40 Part No. 32222...
Page 142 Service Manual Section 6 - Schematics 2WD Hydraulic Schematic - Non-Oscilating Axle...
Page 143: Hydraulic Symbols Legend
Sequencing valve Bi-directional motor Priority flow divider Counterbalance valve 2-speed, Unloader valve bi-directional motor Pump prime mover (engine or motor) Solenoid operated Pilot operated flow dump valve Pressure compensating valve control valve Part No. 32222 Genie S-40 6 - 12...
Page 144: 2Wd Hydraulic Schematic - Non-Oscillating Axle
HIGH 1950 PRESS. FILTER TEST 3500 PRESS. FUNCTION PUMP 2600 6.4 GPM. PRESS. DRIVE PUMP TANK 2500 RESERVOIR AUX. PUMP TANK STEER MANIFOLD REAR RIGHT REAR LEFT STEERING DRIVE 250 PSI MANIFOLD Part No. 32222 Genie S-40 6 - 13...
Page 145: 2Wd Hydraulic Schematic - Oscillating Axle
Service Manual Section 6 - Schematics 2WD Hydraulic Schematic - Oscilating Axle...
Page 146 DRIVE PUMP TANK 2500 RESERVOIR AUX. PUMP OSCILLATE TANK STEER MANIFOLD REAR RIGHT OSCILLATE DIRECTIONAL VALVE OSCILLATE MANIFOLD REAR LEFT A VALVE A CYL B VALVE B CYL STEERING DRIVE MANIFOLD 250 PSI Part No. 32222 Genie S-40 6 - 14...
Page 147: 4Wd Hydraulic Schematic
Service Manual Section 6 - Schematics 4WD Hydraulic Schematic...
Page 148 AUX. PUMP OSCILLATE TANK STEER MANIFOLD REAR FRONT RIGHT RIGHT OSCILLATE DIRECTIONAL VALVE OSCILLATE MANIFOLD REAR FRONT LEFT LEFT A VALVE A CYL B VALVE B CYL STEERING DRIVE MANIFOLD 250 PSI Part No. 32222 Genie S-40 6 - 15...
Page 150 Before Repairs Start: problem still exists Read, understand and obey the safety rules and operating instructions in the Genie S-40 Operator’s Manual. Return to Inspect Perform service and test repair problem Be sure that all necessary tools and parts are solved available and ready for use.
Page 151: Platform Controls
Remove all rings, watches and other jewelry. 7 - 2 Genie S-40 Part No. 32222...
Page 152 2 Turn the key switch to platform control and Record the maximum voltage reading. pull out the Emergency Stop button to position at both the ground and 15 Start the engine. platform controls. Do not start the engine. Part No. 32222 Genie S-40 7 - 3...
Page 153 15 turns or until Cycle time 70 to 110 seconds you hear a click. This is the only dual range Ramp rate 3 to 4 seconds adjustment for this controller. 7 - 4 Genie S-40 Part No. 32222...
Page 154: Horsepower Limiter Board
5 Move the engine idle control switch to foot injury. Remove all rings, watches switch activated high idle (rabbit and foot and other jewelry. switch symbol). Part No. 32222 Genie S-40 7 - 5...
Page 155 40 ft/7.8 sec 40 ft/9.1 sec 12.2 m/7.8 sec 12.2 m/9.1 sec Boom raised or distance: 40 ft / 12 m extended 1 foot per second All models 30.5 cm per second 7 - 6 Genie S-40 Part No. 32222...
Page 156: Foot Switch
Test Desired result green to black no continuity (infinite Ω) green to white no continuity black to white continuity (zero Ω) Part No. 32222 Genie S-40 7 - 7...
Page 157: Toggle Switches
3 to 4, 5 & 6 no continuity terminal 4 to 5 continuity terminal 4 to 6 no continuity terminal 5 to 6 no continuity Single pole double throw (SPDT) Double pole double throw (DPDT) 7 - 8 Genie S-40 Part No. 32222...
Page 158: Platform Components
1 Remove the platform. See 2-1, How to Remove the Platform. 2 Extend the boom until the slave cylinder barrel-end pivot pin is accessible. 3 Support the platform rotator, but do not apply Part No. 32222 Genie S-40 7 - 9...
Page 159: Platform Rotator
4 Remove the six mounting bolts from the platform mounting weldment, then remove the center bolt and slide the platform mounting weldment off of the platform rotator. 5 Support the platform rotator. Do not apply any lifting pressure. 7 - 10 Genie S-40 Part No. 32222...
Page 160 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled. 8 Rotate the platform full right then left and inspect the bleed valves for leaks. Part No. 32222 Genie S-40 7 - 11...
Page 161: Boom Components
1 Remove the platform. See 2-1, How to Remove the Platform. 2 Remove the platform rotator and leveling slave cylinder. See 2-3, How to Remove the Platform Rotator. 7 - 12 Genie S-40 Part No. 32222...
Page 162 How to Remove the Boom. gradually. Do not allow oil to 2 Place blocks under the extension cylinder for squirt or spray. support. 14 Attach an overhead crane to the center point of the boom. Part No. 32222 Genie S-40 7 - 13...
Page 163: Boom Lift Cylinder
6 Use the crane to lift the boom to a horizontal position. 7 Remove the turntable end cover to access the lift cylinder mounting bracket (label and disconnect the alarm wiring, if equipped). 7 - 14 Genie S-40 Part No. 32222...
Page 164: Extension Cylinder
1 Raise the boom to a horizontal position. cylinder will fall when it is removed 2 Extend the boom until the extension cylinder from the extension boom if it is rod-end mounting pins are accessible. not properly supported. Part No. 32222 Genie S-40 7 - 15...
Page 165: Platform Leveling Master Cylinder
Do not allow oil to squirt or spray. 4 Remove the pin retaining fasteners from both master cylinder pins. 5 Use a soft metal drift to remove the pins. 7 - 16 Genie S-40 Part No. 32222...
Page 166: Turntable Covers
If a turntable cover must be replaced, be sure that all appropriate safety and instructional decals are applied to the new cover. Alignment adjustments may be necessary when a new cover is installed. Part No. 32222 Genie S-40 7 - 17...
Page 167: Deutz Engine F3L 1011
Leave a inch Do not continue to run the engine (4.7 mm) gap between the coupler and pump with the low oil pressure light on. end plate. 7 - 18 Genie S-40 Part No. 32222...
Page 168: Ford Lsg-423 Engine
Rotate the actuator arm until it is at a Tighten the fastener on the actuator arm 110 degree angle to the linkage rod. without releasing the shaft. Part No. 32222 Genie S-40 7 - 19...
Page 169: Choke Adjustments
The choke functions in both gasoline and LPG mode. The choke butterfly may be adjusted to a fully closed (rich) position for colder climates and the poppet valve will provide a flow path during LPG fueled operation. rich lean 7 - 20 Genie S-40 Part No. 32222...
Page 170: Timing Adjustment
Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged. 4 Assemble the engine and torque the pumpmountint plate to 34 ft-lbs (46 Nm). Part No. 32222 Genie S-40 7 - 21...
Page 171: Water Temperature And Oil Pressure Gauges
(infinite Ω). 2 Apply mild suction to the vacuum port. Result: The switch should close and show full continuity (zero Ω). Component damage hazard. Do not short the vacuum switch terminals to ground. 7 - 22 Genie S-40 Part No. 32222...
Page 172: Ground Controls
5 to 9 continuity (zero Ω) terminal no. 5 terminal no. 1 relay terminal no. 13 terminal no. 9 terminal no. 12 terminal no. 14 terminal no. 4 terminal no. 8 Part No. 32222 Genie S-40 7 - 23...
Page 173 5 to 9 continuity (zero Ω) terminal no. 5 terminal no. 1 relay terminal no. 13 terminal no. 9 terminal no. 14 7 - 24 Genie S-40 Part No. 32222...
Page 174: Wago Components
86, then test the following on the tab of the component and remove it. terminal combinations. Test Desired result terminal 87 to 87a & 30 no continuity (infinite Ω) terminal 87 to 30 continuity (zero Ω) Part No. 32222 Genie S-40 7 - 25...
Page 175: Resistor
Test Desired result 2 small posts 13 to 17Ω 2 large posts no continuity (infinite Ω) Any small post to no continuity (infinite Ω) any large post 7 - 26 Genie S-40 Part No. 32222...
Page 176: Hydraulic Pumps
Remove all rings, watches and other jewelry. 4 Turn the key switch to ground control and pull out the Emergency Stop button to the position. Part No. 32222 Genie S-40 7 - 27...
Page 177: Drive Hydraulic Pump
CLOSED component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 7 - 28 Genie S-40 Part No. 32222...
Page 178 3 Crank the engine with the starter motor for 15 seconds, wait 15 seconds, then crank the engine an additional 15 seconds or until the pressure reaches 320 psi (22 bar). Part No. 32222 Genie S-40 7 - 29...
Page 179: Function Manifold
Check valve ........H ... Platform rotate left - differential sensing .......... 11-13 ft-lbs / 15-18 Nm Check valve ........L ... Platform level - differential sensing .......... 11-13 ft-lbs / 15-18 Nm 7 - 30 Genie S-40 Part No. 32222...
Page 180 Service Manual - First Edition Section 7 - Repair Procedures FUNCTION MANIFOLD Part No. 32222 Genie S-40 7 - 31...
Page 181: Valve Adjustments - Function Manifold
6 Restart the engine. Hold the retract switch with Pressure 2200 psi the boom fully retracted, and recheck the valve 152 bar pressure. Main relief valve specifications Pressure 2600 psi 179 bar 7 - 32 Genie S-40 Part No. 32222...
Page 182 Collision hazard. Impact with moving boom components may cause death or serious injury. Use extreme caution when overriding a machine function. Identify the direction of machine movement before overriding a valve. Part No. 32222 Genie S-40 7 - 33...
Page 183 2 Connect the leads from an ohmmeter to the valve coil terminals. Valve coil specifications Proportional solenoid valve 5Ω 3 position 4 way directional valve 4.5Ω Normally closed poppet valve 7Ω 7 - 34 Genie S-40 Part No. 32222...
Page 184: Fuel And Hydraulic Tanks
3 Completely drain the oil from the tank by pressure reaches 320 psi (22 bar). removing the drain plug located in the bottom of the tank. Burn hazard. Contact with hot oil may cause severe burns. Part No. 32222 Genie S-40 7 - 35...
Page 185: Fuel Tank
3 Remove the mounting fasteners from the bottom of the tank. 4 Use an appropriate lifting device to remove the tank from the machine. Clean the fuel tank and inspect for rust and corrosion before installing. 7 - 36 Genie S-40 Part No. 32222...
Page 186: Turntable Rotation Components
How to Remove the Turntable Rotation Brake or Torque Hub Locked position Refer to Maintenance Procedures, C-5, How to Replace the Torque Hub Oil. Part No. 32222 Genie S-40 7 - 37...
Page 187: Turntable Rotation Manifold Components
SAE No. 6 18 ft-lbs / 24 Nm SAE No. 8 50 ft-lbs / 68 Nm SAE No. 10 55 ft-lbs / 75 Nm SAE No. 12 75 ft-lbs / 102 Nm 7 - 38 Genie S-40 Part No. 32222...
Page 188: 2Wd Steering Axle Components
3 Block the non-steering wheels, and then center a lifting jack under the steering axle. 4 Raise the machine 6 inches (15 cm) and place blocks under the chassis for support. Part No. 32222 Genie S-40 7 - 39...
Page 189: Steering Cylinders
3 Remove the steering cylinder. 5 Place the outer bearing into the hub. 7 - 40 Genie S-40 Part No. 32222...
Page 190: Tie Rod
2 Measure the steer tires, front to front and back If further adjustment is needed, repeat to back, using a measuring fixture. steps 3 through 8. Toe-in specification 0 ± inch (6.35 mm) Part No. 32222 Genie S-40 7 - 41...
Page 191: 4Wd Steering Axle Components
13 Attach a strap from a lifting device to the yoke/torque hub assembly for support. oscillate cylinder king pin torque hub yoke pivot pin steer cylinder tie rod 3 Disconnect and plug the hydraulic hoses 7 - 42 Genie S-40 Part No. 32222...
Page 192: Steering Cylinders
75 ft-lbs 102 Nm 13-2 Steering Cylinders How to Remove a Steering Cylinder This procedure is the same as the 2WD procedure. See repair procedure 12-2, How to Remove a Steering Cylinder. Part No. 32222 Genie S-40 7 - 43...
Page 193 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. 7 - 44 Genie S-40 Part No. 32222...
Page 194: Steer And Oscillate Manifolds
SAE No. 10 55 ft-lbs / 75 Nm SAE No. 4 13 ft-lbs / 18 Nm SAE No. 6 18 ft-lbs / 24 Nm SAE No. 12 75 ft-lbs / 102 Nm Part No. 32222 Genie S-40 7 - 45...
Page 195: Valve Adjustments
7 Restart the engine. manually activate the valve and recheck the valve pressure. 8 Turn the engine off, then remove the pressure gauge and assemble the directional valve linkage. Unloader valve specifications Pressure 1200 psi 82.7 bar 7 - 46 Genie S-40 Part No. 32222...
Page 196: Directional Valve Manifold Components
Section 7 - Repair Procedures STEER AND OSCILLATE MANIFOLDS 15-3 Directional Valve Manifold Components Index Schematic Description Item Function Torque Cap ..............Breather ..........20-25 ft-lbs / 27-33 Spool valve ............Directional control Part No. 32222 Genie S-40 7 - 47...
Page 197 (from the inside of the drive chassis). If the distance is not equal and the adjustment to the linkage was completed with the ground and drive chassis level, consult Genie Industries Service Department. 7 - 48 Genie S-40 Part No. 32222...
Page 198: Steer Manifold Components
SAE No. 10 55 ft-lbs / 75 Nm SAE No. 4 13 ft-lbs / 18 Nm SAE No. 12 75 ft-lbs / 102 Nm SAE No. 6 18 ft-lbs / 24 Nm Part No. 32222 Genie S-40 7 - 49...
Page 199: Non-Steering Axle Components
169.5 Nm Drive torque hub mounting bolts 120 ft-lbs Torque specifications 163 Nm Drive motor mounting bolts 75 ft-lbs Drive motor mounting bolts 75 ft-lbs 102 Nm 102 Nm 7 - 50 Genie S-40 Part No. 32222...
Page 200 Service Manual - First Edition Section 7 - Repair Procedures This page intentionally left blank. Part No. 32222 Genie S-40 7 - 51...
Page 201: 2Wd Drive Manifold
SAE No. 4 13 ft-lbs / 18 Nm SAE No. 10 55 ft-lbs / 75 Nm SAE No. 6 18 ft-lbs / 24 Nm SAE No. 12 75 ft-lbs / 102 Nm 7 - 52 Genie S-40 Part No. 32222...
Page 202 Service Manual - First Edition Section 7 - Repair Procedures 2WD DRIVE MANIFOLD Part No. 32222 Genie S-40 7 - 53...
Page 203: Valve Adjustments
6 Restart the engine. Drive the machine in either direction and recheck the valve pressure. 7 Turn the engine off, then remove the pressure gauge. Relief valve specifications Pressure 250 psi 17 bar 7 - 54 Genie S-40 Part No. 32222...
Page 204 Service Manual - First Edition Section 7 - Repair Procedures This page intentionally left blank. Part No. 32222 Genie S-40 7 - 55...
Page 205: 4Wd Drive Manifold
Flow control valve ......P ... RF flow regulator in reverse ..15-18 ft-lbs / 20-24 Nm Flow control valve ......T ... RF flow regulator in forward ..15-18 ft-lbs / 20-24 Nm 7 - 56 Genie S-40 Part No. 32222...
Page 206 Service Manual - First Edition Section 7 - Repair Procedures 4WD DRIVE MANIFOLD Part No. 32222 Genie S-40 7 - 57...
Page 207: Valve Adjustments
4 Turn the engine off. Hold the relief valve and remove the cap (index 13). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the valve cap. 7 - 58 Genie S-40 Part No. 32222...
Page 208 Genie North America 18340 NE 76th Street P.O. Box 97030 Redmond, Washington 98073-9730 Distributed By: Genie Europe Brunel Drive Newark Nottinghamshire NG24 2EG England...

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