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Self-Propelled Servicing Platform Part No. 107713

July 2011

2

Contact Us:

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

Copyright 2004 by Genie Industries

107713 Rev B July 2011First Edition, Second Printing

"Genie" and "Z" are registered trademarks ofGenie Industries in the USA and many othercountries.

Printed on recycled paper

Printed in U.S.A.

Service Manual Supplement

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November 2011

2

Contact Us:

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

Copyright 2011 Terex Corporation

107713 Rev B July 2011First Edition, Second Printing

"Genie" and "Z" are registered trademarks ofTerex South Dakota, Inc. in the USA and manyother countries.

Printed on recycled paper

Printed in U.S.A.


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Part No. 107713 Self-Propelled Servicing Platform

Service Manual SupplementJuly 2011

3

Table of Contents

Machine Specifications ................................................. 4Scheduled Maintenance Procedure ............................ 9

Maintenance Inspection Report ................................. 10

Maintenance Procedure ............................................. 11

Repair Procedures ..................................................... 16

Steer Axle Components ............................................. 17

Non-steer Axle Components ...................................... 21

Fiberglass Covers ...................................................... 23

Electrical Schematic ................................................... 25

Ground Control Box Terminal Strip Wiring Diagram.. 27

Ground Control Box Switch Panel Wiring Diagram ... 28

Platform Control Box Wiring Diagram ........................ 29

Platform Control Box Switch Panel Wiring Diagram .. 30

Engine Panel Diagram ............................................... 31

Power Cable Diagram ................................................ 32

Hydraulic Schematic .................................................. 33

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Specifications

Machine SpecificationsTires and wheels

Tire size 9-14.5 LT

Wheel diameter 14.5 inches

Wheel width 7 inches

Wheel lugs

Front 8 @ 5/8-18

Rear 9 @ 5/8-18

Lug nut torque 125 ft-lbs

169.5 Nm

Tire size 9-14.5 LT

Tire ply rating Tread 6

Sidewall 6

Tire contact area 43.5 sq in

280 sq cm

Overall tire diameter 28 in

71 cm

Fluid capacities

Fuel tank 9 gallons34.1 liters

Hydraulic tank 8 gallons

30.3 liters

Hydraulic system 11 gallons

(including tank) 41.6 liters

Drive hubs 23 fl oz

0.68 liter

For operational specifications, refer to theOperator's Manual.

Continuous improvement of our products is a

Genie policy. Product specifications aresubject to change without notice.

Performance SpecificationsGradeability (boom stowed) 30%

Boom function speeds, maximum

from platform controls

Jib boom up 35 to 41 seconds

Jib boom down 18 to 24 seconds

Primary boom up 47 to 53 seconds

Primary boom down 34 to 40 seconds

Secondary boom up 35 to 41 seconds

Secondary boom down 22 to 28 seconds

Primary boom extend 7 to 13 seconds

Primary boom retract 9 to 15 seconds

Turntable rotate, 357 94 to 100 seconds

primary boom retracted

Platform rotate, 160 3 to 9 seconds

Platform level up 199 to 205 seconds

Platform level down 127 to 133 seconds

REV A


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Service Manual SupplementJanuary 2006

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Hydraulic SpecificationsHydraulic Oil Specifications

Hydraulic oil type Chevron Rykon MV equivalent

Approximate SAE grade 5W-20

Viscosity index rating 200

Chevron Rykon MV oil is fully compatible and

mixable with Shell Donax TG (Dexron III) oils.

Genie specifications require hydraulic oils which are

designed to give maximum protection to hydraulic

systems, have the ability to perform over a wide

temperature range, and have a minimum viscosity index

rating of 150. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, and

foam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Premium ECO 46

Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046

Quintolubric 822

Mineral based Shell Tellus T32

Shell Tellus T46

Chevron Aviation A

Note: Genie specifications require additionalequipment and special installation instructions for

the approved optional fluids. Consult the GenieIndustries Service Department before use.

Function pump

Type: fixed displacement gear pump

Displacement 0.12 cu in

2 cc

Hydraulic tank circuit 10 micron with

return line filter 25 psi / 1.7 bar bypass

Function manifold

Function relief valve pressure 3200 psi

220.6 bar

Secondary boom down 2000 psirelief valve pressure 138 bar

Auxiliary pump

Type: fixed displacement gear pump

Displacement 0.5 gallons per minute

1.9 liters per minute

Auxiliary pump 3200 psi

relief pressure 220.6 bar

SPECIFICATIONSREV A

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Kubota Z482-E EngineDisplacement 29.23 cu in

0.48 liters

Number of cylinders 2

Bore and stroke 2.64 x 2.68 inches

67 x 68 mm

Horsepower

Gross intermittent 12.5 @ 3600 rpm

Firing order 1 - 2

Compression ratio 23:1

Compression pressure 412 to 469 psi

28.4 to 32.3 bar

Low idle 2000 rpm

High idle 3000 rpm

Governor centrifugal mechanical

Valve clearance, cold 0.0057 to 0.0072 in

0.145 to 0.185 mm

Engine coolant

Capacity 2.9 quarts

2.8 liters

Lubrication system

Oil pressure 36 to 64 psi

2.48 to 4.41 bar

Oil capacity 2.6 quarts

(including filter) 2.5 liters

Oil viscosity 10W-30

requirements

Engine oil should have properties of API classification

CC/SE, CD/SE, CC/SF or CD/SF grades.

Injection system

Injection pump make Bocsh MD

Injection timing 21 BTDC

Injection pump pressure 1991 psi

137 bar

Fuel requirement diesel number 2-D

Alternator

Output 12V, 150 watts

Starter motor

Brush length, new 0.5188 in

13 mm

Brush length, minimum 0.3346 in

8.5 mm

Battery

Type 12V, Group 70

Quantity 1

Cold cranking ampere 450A

Reserve capacity @ 25A rate 125 minutes

Fan belt deflection 1/4to 3/8 inch

7 to 9 mm

SPECIFICATIONS REV A


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Service Manual SupplementJanuary 2006

7

Hydraulic Hose and FittingTorque Specifications

Your machine is equipped with Parker Seal-Lokfittings and hose ends. Genie specifications require

that fittings and hose ends be torqued tospecification when they are removed and installed

or when new hoses or fittings are installed.

SAE O-ring Boss Port(tube fitting - installed into Aluminum)

SAE Dash size Torque-4 11 ft-lbs / 14.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 40 ft-lbs / 54.2 Nm

-10 69 ft-lbs / 93.6 Nm

-12 93 ft-lbs / 126.1 Nm

-16 139 ft-lbs / 188.5 Nm

-20 172 ft-lbs / 233.2 Nm

-24 208 ft-lbs / 282 Nm

SAE O-ring Boss Port(tube fitting - installed into Steel)

SAE Dash size Torque

-4 16 ft-lbs / 21.7 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 105 ft-lbs / 142.4 Nm

-12 140 ft-lbs / 190 Nm

-16 210 ft-lbs / 284.7 Nm

-20 260 ft-lbs / 352.5 Nm

-24 315 ft-lbs / 427.1 Nm

Seal-LokFittings(hose end)

SAE Dash size Torque

-4 18 ft-lbs / 24.4 Nm

-6 27 ft-lbs / 36.6 Nm

-8 40 ft-lbs / 54.2 Nm

-10 63 ft-lbs / 85.4 Nm

-12 90 ft-lbs / 122 Nm

-16 120 ft-lbs / 162.7 Nm

-20 140 ft-lbs / 190 Nm

-24 165 ft-lbs / 223.7 Nm

Seal-Lok fittings1 Replace the O-ring. The O-ring must be replaced

anytime the seal has been broken. The O-ringcannot be re-used if the fitting or hose end has

been tightened beyond finger tight.

Note: The O-rings used in the Parker Seal Lok

fittings and hose ends are custom-size O-rings.They are not standard SAE size O-rings. They are

available in the O-ring field service kit (Genie partnumber 49612).

2 Lubricate the O-ring before installation.

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

4 Position the tube and nut squarely on the face

seal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriate

torque per given size as shown in the table.

6 Operate all machine functions and inspect thehoses and fittings and related components to

confirm that there are no leaks.

SPECIFICATIONSREV A

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Service Manual SupplementNovember 2011

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About This SectionThis section contains detailed procedures for eachscheduled maintenance inspection.

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

Symbols Legend

Safety alert symbolused to alertpersonnel to potential personal

injury hazards. Obey all safetymessages that follow this symbol

to avoid possible injury or death.

Used to indicate the presence of animminently hazardous situationwhich, if not avoided, will result in

death or serious injury.

Used to indicate the presence of a

potentially hazardous situationwhich, if not avoided, could result indeath or serious injury.

Used to indicate the presence of apotentially hazardous situation

which, if not avoided, may causeminor or moderate injury.


which, if not avoided, may result inproperty damage.

Indicates that a specific result is expected after

performing a series of steps.

Scheduled Maintenance Procedure

Observe and Obey:

Maintenance inspections shall be completed by a

person trained and qualified on the maintenance

of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, annually and every 2

years as specified on the MaintenanceInspection Report.

Failure to properly complete each

inspection when required maycause death, serious injury or

substantial machine damage.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating machine.

Unless otherwise specified, perform each

procedure with the machine in the followingconfiguration:

Machine parked on a firm, level surface

Boom in the stowed position

Turntable rotated with the boom between the

non-steering wheels

Turntable secured with the turntablerotation lock

Key switch in the off position with the keyremoved

Wheels chocked

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Maintenance Inspection Report

Instructions

Make copies of this report to use for

each inspection. Maintain completed

forms for a minimum of 4 years or in

compliance with employer, jobsite

and governmental regulations and

requirements.

If any inspection receives an N, tag

and remove the machine from

service, repair and reinspect it. After

repair, place a check in the R box.

Legend

Y = yes, acceptable

N = no, remove from service

R = repaired

Comments

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Checklist D Y N R

D-6.1 Temperature sensor

Refer to the Genie Z-45/25 Bi-Energy & Z-45/25J Bi-EnergyServiceManual for scheduled machine maintenance procedures.The following scheduled maintenance procedure will need to be

performed every 1000 hours or annually in addition to regularlyscheduled machine maintenance inspections as outlined in the

Service Manual.


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11

D-6.1Test the Exhaust ManifoldTemperature Sensor

Note: Genie specifications require that thisprocedure be performed every 1000 hours ofoperation or yearly.

Yearly calibration of the exhaust manifold

temperature sensor is essential to safe machine

operation. Continued use of an improperlycalibrated temperature sensor could result infailure to sense an accurate exhaust manifoldtemperature. This could create a hazardous

situation.

Component damage hazard. This

procedure requires specific repairskills and testing equipment.

Dealer service is stronglyrecommended.

1 See How to Program the Temperature Display

and access the TYPEmenu item.2 To change the input type, press the

blank (unmarked) button to scroll through the

available choices until LINis shown on thedisplay. Press the SELbutton to select and

return to the main menu.

3 Press the SELbutton until the OFSETmenu isshown on the display. Change the offset value

to zero.

4 Press and hold the SELbutton for 3 seconds toenter the value and return to the main menu.

Maintenance Procedure

5 Remove the jumper wire from the back of thetemperature display.

Result: The display will show SAVEto indicate the

programming changes are being saved intomemory.

Note: Do not turn the machine off before removing

the jumper from the back of the display. If themachine is turned off before the jumper wire isremoved, all data may not save completely or

correctly. This could result in a fault display of FRIL

the next time the machine is turned on.

6 Use a precision DC voltage power supply withan output range of -10 mV DC to 60 mV DC

and an accuracy of 0.03% or better. Connectthe negative lead to the TC- terminal and the

positive lead to the TC+ terminal of thetemperature display.

7 Set the power supply to mV DC and turn the

power supply on.

8 Compare the voltage on the temperaturedisplay to that of the power supply over a range

of -10 mV DC to 60 mV DC.

Result: If the voltage differences between thetemperature display and the power supply are

within 0.02 mV DC at all points over the rangeof -10 mV DC to 60 mV DC, the display does

not need to be calibrated.

Result: If the voltage differences between the

temperature display and the power supply are

morethan 0.02 mV DC at one or more pointsover the range of -10 mV DC to 60 mV DC, thedisplay will need to be calibrated. See How to

Calibrate the Temperature Sensor VoltageInput.

REV B

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MAINTENANCE PROCEDURE

How to Program theTemperature Display

There are six items that can be accessed in theprogramming mode.

TYPE- Allows the choice of thermocouple being

used. Genie uses Type K thermocouples.

CJC- Cold Junction Compensation. This feature is

not used on your machine.

DISP- Allows the choice between F or C. Also

allows the choice between whole numbers or

tenths.

FLTER- Used to help stabilize the display if it isdifficult to read due to small process variations or

noise. Choose "0" for no filtering or up to "3" forheavy filtering.

RANGE- The range value determines if the filterwill be applied to the new input sample. If the new

input value is within the range of the previousdisplay, the filter will be applied to the new input.

OFSET- Used to add or subtract a constanttemperature from the display.

1 Push in the red Emergency Stop buttons to the

off position at both the ground and platformcontrols.

2 Open the ground control box and locate the

temperature display.

3 Connect a jumper wire between the PROGRAM

and COMMterminals on the back of the


4 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at the ground controls.

5 Press the SELbutton to scroll to the menu itemyou want to program.

6 Press the blank (unmarked) button to cycle

through available choices for each menu item.

7 Press the SELbutton to make your choice andreturn to the main menu.

8 Repeat steps 5 through 7 for each menu item.

9 Remove the jumper wire from the back of thetemperature display.

Result: The display will show SAVEto indicate

the programming changes are being saved intomemory.


the jumper from the back of the display. If themachine is turned off before the jumper wire isremoved, all data may not save completely or

correctly. This could result in a fault display of FRIL


REV B


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13

MAINTENANCE PROCEDURE

How to Calibrate theTemperature Sensor VoltageInput

Component damage hazard. Thisprocedure requires specific repair

skills and testing equipment.Dealer service is stronglyrecommended.

Note: Calibration of the exhaust manifoldtemperature sensor should only be performed by

individuals experienced in calibrating electronic

equipment.

Note: Allow the temperature sensor to warm up for30 minutes before performing the calibration

procedure.

Note: The calibration procedure should be

performed at an ambient temperature between 59to 95 F / 15 to 35 C.

1 Push in the red Emergency Stop buttons to theoff position at both the ground and platform

controls.

2 Open the ground control box and locate thetemperature display.

3 Connect a jumper wire between the PROGRAMandCOMMterminals on the back of the temperaturedisplay.

4 Tag and disconnect the thermocouple wires fromthe TC+ and TC- terminals of the temperaturedisplay.

5 Use a precision DC voltage power supply withan output range of -10 mV DC to 60 mV DC andan accuracy of 0.03% or better. Connect the

positive and negative leads of the power supplyto the TC+ and TC- terminals on the back the


6 Turn the key switch to ground control and pullout the red Emergency Stop button to the on

position at the ground controls.

7 Turn on the power supply and set it to-10 mV DC.

8 Press theSEL

button untilCAL

is shown on thedisplay.

9 Press the blank (unmarked) button to

select YES.

Result: The display will show "00000".

10 Press the blank (unmarked) button to incrementthe access code until the display shows"00006".

11 Press and hold the SELbutton. After entering thecorrect access code, the display will show IN1.

Follow the table below for the calibration

sequence.

Note: The display will show CALCfor approximately 3

seconds after pressing the SELbutton beforeproceeding to the next input point.

Note: After the calibration sequence is complete,the display will show CAL.

REV B

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MAINTENANCE PROCEDURE REV B


Display Parameter Action

IN1 -10mV DC Apply -10mV DC, wait 5 seconds, press SEL button

IN2 0 mV DC Apply 0 mV DC, wait 5 seconds, press SEL button.







12 Exit the programming mode by removing thejumper wire from the back of the temperaturedisplay.



Note: Do not turn the machine off before removingthe jumper from the back of the display. If themachine is turned off before the jumper wire is

removed, all data may not save completely orcorrectly. This could result in a fault display of FRIL


13 Perform procedure Test the Exhaust Manifold

Temperature Displayto verify voltage calibration.

14 Repeat the calibration procedure if necessary.

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15

MAINTENANCE PROCEDUREREV B

How to Program the TemperatureOffset

Note: This procedure will only need to be performedif the temperature display is being replaced or if the

saved data is corrupted and needs to be reset.

Note: Genie programs a default value of +30 F / -1.1 C for temperature offset.

1 See How to Program the Temperature Displayand access the OFSETmenu item.

2 To enter the offset value, press the

blank (unmarked) button to increment theflashing digit or the sign of the number. To select

a new digit or sign of the number, press the SEL

button.

Note: If no digits are flashing, press the blank button

to toggle the sign of the number or press the SEL

button to wrap around to the LSD.

3 After the desired offset value is on the display,press and hold the SELbutton for 3 seconds to

enter the value and return to the main menu.

4 Remove the jumper wire from the back of the





the jumper from the back of the display. If themachine is turned off before the jumper wire is

removed, all data may not save completely orcorrectly. This could result in a fault display of FRIL


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17

REV B Repair Procedures

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 adamaged 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 theGenie Z-45/25 Bi-Energy & Genie Z-45/25JBi-Energy Operators Manual on your machine.

Be sure that all necessary tools and parts are

available and ready for use.

Read each procedure completely and adhere

to the instructions. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified, perform each

repair procedure with the machine in thefollowing configuration:

Machine parked on a firm, level surface

Boom in the stowed position

Turntable rotated with the boom between the non-steer wheels

Turntable secured with the turntable

rotation lock

Key switch in the off position with the

key removed

Wheels chocked

About This SectionMost of the procedures in this section should only

be performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshooting

the problem.

Perform disassembly procedures to the point whererepairs can be completed. Then toreassemble, perform the disassembly steps in

reverse order.

Symbols Legend

Safety alert symbolused to alert

personnel to potential personalinjury hazards. Obey all safety

messages that follow this symbolto avoid possible injury or death.

Used to indicate the presence of

an imminently hazardous situationwhich, if not avoided, will result in

death or serious injury.


which, if not avoided, could resultin death or serious injury.

Used to indicate the presence of a

potentially hazardous situationwhich, if not avoided, may cause

minor or moderate injury.


which, if not avoided, may result inproperty damage.

Indicates that a specific result is expected after

performing a series of steps.

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2 Loosen the wheel lug nuts. Do not remove them.3 Block the non-steer wheels, and then center a

lifting jack of ample capacity under the steer

axle.

4 Raise the machine 6 inches / 15 cm and placeblocks under the chassis for support.

5 Remove the lug nuts. Remove the tire and

wheel assembly.

6 Remove the pin retaining fasteners from the

yoke pivot pins. Do not remove the pins.

7 Support and secure the yoke/hub assembly to alifting jack.

8 Place a rod through the upper yoke pivot pin

and twist to remove the pin. Use a soft metaldrift to drive the lower yoke pivot pin down andout.

Crushing hazard. The yoke/hub

assembly may becomeunbalanced and fall when the yoke

pivot pins are removed if notproperly supported and secured to

the lifting jack.

Torque specifications

Lug nut torque, dry 125 ft-lbs

169.5 Nm

Lug nut torque, lubricated 94 ft-lbs127.4 Nm

Steer Axle Components

Yoke and Hub

How to Remove the Yoke

and Hub

The yoke installation utilizes bushings in the axleand a thrust washer that may require periodicreplacement.

1 Remove the cotter pin from the steer cylinder

rod-end clevis pin and remove the cotter pinfrom the tie rod clevis pin. Remove the clevispins.

Note: Always use a new cotter pin when installing aclevis pin.

a tie rodb steer axlec yoke pivot pin

d yokee hubf pivot ping steer cylinder


REV B

a b

e

d

fg

c

f

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Service Manual SupplementNovember 2011

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How to Remove theHub and Bearings

1 Loosen the wheel lug nuts. Do not removethem.

2 Block the non-steer wheels and place a liftingjack of ample capacity under the steering axle.

3 Raise the machine 6 inches / 15 cm and placeblocks under the chassis for support.

4 Remove the lug nuts. Remove the tire andwheel assembly.

5 Remove the dust cap, cotter pin and castle nut.

6 Pull the hub off the spindle. The washer andouter bearing should fall loose from the hub.

7 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.

How to Install theHub and Bearings

Note: When replacing a wheel bearing, both theinner and outer bearings including the pressed-in

races must be replaced.

1 Be sure that both bearings are packedwith clean, fresh grease.

2 Place the large inner bearing into the rear

of the hub.

3 Press the bearing seal evenly into the hub

until it is flush.

4 Slide the hub onto the yoke spindle.

Component damage. Do notapply excessive force or damageto the lip of the seal may occur.

5 Place the outer bearing into the hub.

6 Install the washer and castle nut.

7 Tighten the castle nut to 150 ft-lbs / 203 Nm toseat the bearing.

8 Loosen the slotted nut, then retighten to

35 ft-lbs / 48 Nm.

9 Install a new cotter pin. Bend the cotter pin

to lock it in.

10 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts to

125 ft-lbs / 169.5 Nm.

STEERING AXLE COMPONENTSREV B

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Steer Cylinders

How to Remove a Steer Cylinder

There are two identical steer cylinders thatwork in parallel. They are part of the same hydraulic

circuit, but move in opposite directions. The tie rodmaintains equal movement of the tires.

Note: 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 duringinstallation.

Refer to Section Two, Hydraulic Hose and FittingTorque Specifications.

1 Tag, disconnect and plug the hydraulic hosesfrom the steer cylinder. Cap the fittings on thecylinder.

Bodily injury hazard. Sprayinghydraulic oil can penetrate and burnskin. Loosen hydraulic connections

very slowly to allow the oil pressureto dissipate gradually. Do not allow

oil tosquirt or spray.

2 Remove the cotter pin from the rod-end clevis pin

of the steer cylinder. Remove the clevis pin.

3 Remove the cotter pin from the barrel-end clevispin of the steer cylinder then remove the clevis

pin.

Note: Always use a new cotter pin when installing aclevis pin.

4 Remove the steer cylinder from the machine.

Tie Rod

How to Remove the Tie Rod

1 Remove the cotter pins from the clevis pins ateach end of the tie rod, then remove the clevis

pins.

2 Remove the tie rod.

STEERING AXLE COMPONENTS


REV B

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21

Drive Motor

How to Remove a Drive Motor

1 Disconnect the battery packs.

2 Remove the fasteners from the cover on the non-steer axle. Remove the cover.

3 Tag and disconnect the power cables and relay

wiring from the drive motor.

Electrocution/burn hazard. Contactwith electrically charged circuits

could result in death or seriousinjury. Remove all rings, watches

and other jewelry.

4 Remove the drive motor mounting fasteners.

5 Guide the drive motor shaft out of the brake and

then remove the drive motor from the machine.

Torque Hub

How to Remove a Drive

Torque Hub

Note: The drive motor must be removed in order toaccess the torque hub mounting bolts.

Note: 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 duringinstallation.Refer to Section Two, Hydraulic Hose and Fitting

Torque Specifications.

1 Remove the drive motor. See, How to Remove aDrive Motor.

2 Disconnect the hydraulic hose from the brakeand plug it. Remove the hydraulic fitting and thebleed valve.

Bodily injury hazard. Sprayinghydraulic oil can penetrate and burnskin. Loosen hydraulic connections

very slowly toallow the oil pressure to

dissipate gradually. Do notallow oil to squirt or spray.

3 Chock the steer wheels.

4 Loosen the wheel lug nuts. Do not remove them.

5 Center a lifting jack of ample capacity under thenon-steer axle. Raise the machine approximately

6 inches / 15.2 cm and place blocks under thechassis for support.

6 Remove the wheel lug nuts, then the tire andwheel assembly.

Non-steer Axle ComponentsREV B

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7 Place a second lifting jack under the torquehub for support. Secure the torque hub to thelifting jack.

8 Remove the torque hub mounting bolts thatattach the torque hub to the non-steer axle.

9 Remove the torque hub from the machine.

Crushing hazard. The torque

hub may become unbalanced andfall when the mounting fasteners

are removed if not properlysupported and secured to the

lifting jack.

Torque specifications

Lug nut torque, dry 125 ft-lbs

169.5 Nm

Lug nut torque, lubricated 94 ft-lbs

127.4 Nm

Drive torque hub mounting bolts 210 ft-lbs

285 Nm

NON-STEER AXLE COMPONENTS REV B

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Repair or Replacement of aFiberglass Cover

Repair:Minor damage, including small holes,cracks and chips in a fiberglass cover may be

repaired by a qualified repair facility.

Replacement:Replacement of a fiberglass coverwhen the structural integrity has been compromiseddue to excessive damage is required.

REV A Fiberglass Covers

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E

S

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Electrical Schematic

1

2

3

4

5

6

7

8

A B C D E F G H I

November 2011

25 Self-Propelled Servicing Platform Part No. 107713

86 CB-AP1 M- B+F1 F2

CR16

F2

+24V DC

GROUND

RIGHTBOX

OR-GEN POS

OR-GEN NEG 30

87

LEFTMOTOR

CHARGERALTERNATORPUMP PUMP

-

+

-

+ A1

A2

A1

A2

F1F2

AC POWER

BK

WH

48VDCCHARGER

PR2PR3

48VDCALTERNATOR

PRIMARYLIFTPUMP

AUXILIARYPUMP

AP1

MOTORMAIN

CONTACTOR

RELAYPR1

BRAKERELEASE

RELAYCR5

BRN

RIGHTMOTOR

87

30

85

86

+

F1

BRN

BK

WH

RD

TILTSENSOR

CR4

TEMPERATURE

DISPLAY

HORNRELAY

HOURMETER

BRN

87

+

(12V DC)

STARTERRELAYCR11

BK

-

+

+12V

STARTER

FB

48VDCPOWER

RELAYCR2

FLASHING

BEACON

OPTION

48VDCPOWER

RELAYCR1

2

C30FWDWH

+48V DC

LEFTBOX

F2

F510A

F1200A

RD/WH

WH/RD

WH/BK

WHOR/RD

48V DCAP2

PR1

14

16

1191 10

REVERSE

POT.HI

+48VDCINPUT

DIODERETURN

POT.LOW

FORWARD

200 A

24V DC

AP2

RD20

C1P-4

CB110A

CONTROLLERFAULT

INDICATORLEDL2

85

86

21

22

21

22

CR5

20

OR/RD

C6-39CR5RD/BK

OR/RD

RD/BK

TB23

LS2(PRI)

OR/RD

BL/WH

LS4(SEC)

BK-4

BK/RD

C39-3GR

17

3 5

INTERLOCK

OFF-LMTSPDINP

COIL-PR1

BRN

BRN

8530

85

86

87

30

86

85 87

30

C23PWR WH

RD/WH

TB42

CR2

C5-11 C21IGN2 WH

CB315A

CR1

OR/RD

BK-(FS)

P20BAT RD

RD +

C9P-1 BK

RD

P2

P3HORN

TB22

KS1P1

GROUND

PLATFORM

RD-(FS) P25BAT RD

H1

FS1

WH-(FS)

RD

TILTALARM

BK

PR2

PR3

C1P-5

C31REVWH/BK

C1P-6

C32JSLWH/RD

C1P-3

C29JSHRD/WH

C3P-9

C9HRNBK/RD

C1P-2

C28TTARD/BK

C3P-3

C3BATRD/WH

C2P-4

R42BATOR/RD

C9P-3P24BAT WHC9P-2

C1B-6

C1B-5

C1B-4

C1B-3

C1B-2

C3B-3

C2B-4

P20BATRD

C7B-4

C6-30

C6-31

C6-32

C6-29

C6-28

C6-9BK/RD

C6-34

BK-7

BK

BK

C10-3

C10-4

C10-1

C10-2

C11-2

C11-1

C11-4

C11-3

C6-20RD

BK

C6-12

C6-22

C6-25CFILBK

P42BAT OR/RD

C8-C

C8-A

C8-B

HORN

C7P-1P22BAT

1

14

LS1(EXT)

13

WH-6

P26BAT

BK

RD/BK

RD

BK-5

WH-5

WH-4

RD-5

BK-5

WH-7

BK-6

BK2GA

TB40

C2B-2

C2P-2

C40LSOR

C6-24

C6-40OR

OR

812

5

76

4

31

P23BATWH

C7P-2

C7B-2

C7B-1

C132 PLI BL/WH

TB134

GR/BK

H2

D2

C1B

-12

C3B-9

F4500A

U6ACURTIS 1244

SEPEX CONTROLLER

C32

C7B-2

C7P-2

P23BATWH

+

+

+

+

-

-

-

-

+

+

+

+

-

-

-

-

SW33

SW33

1

3

2

TS44DUALBEACO

FB2

FB2

GROUNDPANEL

ILLUMINATION

BRN

NOTES:1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.2. ALL SOLENOID AND RELAY COILS ARE 24V DC EXCEPT WHERE NOTED.

SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.2

SWITCH SHOWN WITH BOOM EXTENDED.1

BRN

AC POWER

BATTERYBLANKET

BLOCKHEATER

BK

+

_HM

5

4

THERMOCOUPLE WIRE

(ENGINE EXHAUST MAINIFOLD)

C39-1

C39-2

C39-8

C38-9

C38-10

C39-11

C5-4

BRN

C39-12

C5-6

TEMPERATURE

DISPLAY ( F)

TC+

TC-

GND PWR

PGM

RELAY CR24 ADDED PER CAMPAIGN BULLETIN 080008.3

L49

87

30

85

86CR4

18

C6B-3

3

L48


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N M L K J I H G F

P

N

REV C

C6-4WH

BK

(GND)

TURNTABLEROTATE

LEFTCOIL

SECONDARYBOOMUPCOIL

SECONDARYBOOM

DOWNCOIL

DESCENTALARM

OPTION(A3)

C12DRE BL/WH

RD

TS55 FUNCTIONENABLE

TB5 TB11 TB10TB4

TURNTABLEROTATE

RD

TS62 TS60

SECONDARYBOOM

C32JSL WH/RD

C31REV WH/BK

C29JSH RD/WH

TS12

TURNTABLE

ROTATESECONDARYBOOMTS10 TS11

PRIMARYBOOM

C30FWD WH

PRIMARYBOOMDOWNCOIL

PLATFORMLEVELUPCOIL

PRIMARYBOOM

EXTENDCOIL

PRIMARYBOOM

RETRACTCOIL

PRIMARYBOOMUPCOIL

PLATFORMLEVEL

DOWNCOIL

FLOW

CONTROLCOIL

JIBBOOM

MANIFOLD

RETRACT

TB7TB2 TB1 TB8 TB15 TB14

TS61

PRIMARYBOOM

TS63

PRIMARYBOOM

TS59

PLATFORMLEVEL

TB18

TB

GR/WH

TB17

TS57 TS58

JIBBOOM

TS7TS9

PRIMARYBOOMTS13

PLATFORMLEVEL

PLATFORM

ROTATE

BRN

RD

BK/RD

ROTARY

OEMFLOW

CONTROL

BP1

CR7

PLATFORMLEVEL

CUTOUTDOWN

RELAYCOILCR10B

TS8

JIB

BOOM

PLATFORM

ROTATELEFT/

JIBBOOMUP

RIGHT

LEFT

DOWN

UP

UP

DOWN

EXTEND

UP

DOWN

LEFT

UP

RIGHT

DOWN

DOWN

UP

PLATFORM

ROTATERIGHT/

JIBBOOMDOWN

UP

DOWN

EXTEND

RETRACT

UP

DOWN

UP

DOWN

RIGHT

LEFT

LEFT

RIGHT

TURNTABLEROTATE

RIGHTCOIL

30

87a

86

85

87a

85

86

SE

CR19A

BRN

8

BK

85

86 CR19B

CR19A30

87

30

87 CR19B

P42BAT OR/RD

BK

PR2

PR3

CR5

TB44

C3P-4

C4TRLWH

C3P-5

C4TRRWH/BK

C3P-11

C11SBDBL/BK

C3P-10

C10SBUBL

C3P-2

C2PBDRD/BK

C3P-1

C1PBURD

C3P-8

C8PBRBK/WH

C3P-7

C7PBEBK

C4P-2

C14PLUOR

C4P-3

C15PLDOR/BK

C45JSVGR/WH

C6LFCWH/RD

C2P-7

C3P-6

C2P-6

C44JDAGR/BK

C4P-6

C18PRRGR/BK

C4P-5

C17PRLGR

C3B-4

C3B-5

C3B-10

C3B-11

C3B-2

C3B-1

C3B-7

C3B-8

C4B-2

C4B-3

C6-5WH/BK

C6-10BL

C6-11BL/BK

C6-1RD

C6-2RD/BK

C6-7BK

C6-8BK/WH

C6-14OR

C6-15OR/BK

C6-18GR/BK

C6-17GR

C4B-5GR

C4B-6GR/BK

C2B-6

C3B-6WH/RD

C6-6WH/RD

C2B-7

GR/WH

C13-1

C12-1

C13-2

C12-2

C16-1

C17-1

C18-2

C16-2

C20-1

C21-1

C21-2

C20-2

C23-1

C22-1

C22-2

C23-2

C18-1

C19-1

C19-2

C18-2

C15-1

C14-1

C14-2

C15-2

P24BAT WH

R42BAT OR/RD

C40LS OR

RD

BRN

WH

BK

PLATFORM

ROTATE

PR2

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Electrical Schematic

November 2011 Service Manual Supplement

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G

S

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N M L K J I H G F

P

N

REV C

TS54

RPM

HIGH/L

OW

TS51

PUMP

AUXILIARY

P1STO

P

EMERG

ENCY

RD

RD

RD

1

2

NC

BK/RD

KS1

RD

D2

WH

RD

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Ground Control Box Switch Panel Wiring Diagram


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P

S

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Platform Control Box Wiring Diagram

1

2

3

4

5

6

7

8

A B C D E F G H I

November 2011


OR/BK

OR/BK-R6

GR/WH-R7

RD-J7

GR/WH-45

GR/WH

C27AUXRD

C29JSHRD/WH

C30FWDWH

C31REVWH/BK

C32JSLWH/RD

C33STRBK

C34SABK/WH

C35HRPMBK/RD

C36STCCBL

C37STCBL/BK

R41DREOR/BK

C44JDAGR/BK

C45JSVGR/WH

C1PBURD

C2PBDRD/BK

C3BATRD/WH

C4TRLWH

C5TRRWH/BK

C6LFCWH/RD

C7PBEBK

C8PBRBK/WH

C9HRNBK/RD

C11SBDBL/BK

C10SBUBL

C12DREBL/WH

C13DRELBL/RD

C14PLUOR

C15PLDOR/BK

C16DREOR/RD

C17PRLGR

C18PRRGR/BK

C19LPMPGR/WH

P26BATBK

P25BATRD

P24BATWH

BK-JIBGND

GR/WH-45

GR/WH-45

BRN-J1

BRN-BATGND

BRN-JIBGND

C28TTARD/BK

C1P-1

C1P-3

C1P-4

C1P-5

C1P-2

C1P-6

C1P-7

C1P-9

C1P-8

C1P-10

C1P-11

C2P-3

C2P-6

C2P-7

C3P-1

C3P-2

C3P-3

C3P-4

C3P-5

C3P-6

C3P-7

C3P-8

C3P-9

C3P-10

C3P-11

C3P-12

C4P-1

C4P-2

C4P-3

C4P-4

C4P-5

C4P-6

C4P-7

C9P-1

C9P-2

C9P-3

R42BATOR/RD

C2P-4

C1P

(GY)

C2P

(BK

)

C4P

(BR

)

C3P

(GR)

19/18 CONTROLCABLE

C9PC7P

12V DC BATTERY FOOT SWITCH

LS18JIB

BK

WH

C134PWRRD

TILT ALARM

PLATFORM CONTROL BOX

BRN-BATGND

P22BATBK

P23SWBATWH

C7P-1

C7P-2

C7P-3

OR/RD

RD/BK-R6

BRN-RELAY

BP1

BK/RD

RD

GR

C9HRNBK/RD

RD-HRN

C27AUXRD

RD-AUX

RD-DRE

BK/WH-DRE

C13DRELBL/RD

C44JDAGR/BK

C18PRRGR/BK

C17PRLGR

C15PLDOR/BK

C14PLUOR

P25BATRD

C34SABK/WH

C33STRBK

RD-AUX

RD-RPM

C35HRPM

BK/RD

C5TRRW

H/BK

C4TRLW

H

C10SBU

BL

C2PBDR

D/BK

C8PBRB

K/WH

C7PBEB

K

RD-SW

C19LPMPGR/WH

C6LFCW

H/RD

TS12TURNTABLE

ROTATE

TS10SECONDARY

BOOM

TS11PRIMARY

BOOMTS13

EXTEND/RETRACT

TS8JIB BOOM

TS7PLATFORM

ROTATE

TS9PLATFORM

LEVEL

TS1AUXILIARY

POWER

P3HORN TS6

GLOW PLUG

TS2ENGINESTART

TS4RPM SELECT

TS15DRIVEENABLE

RD

BRN-BCI

GR-LFC

GR/WH-45

L1

GR1

2

3

4

5

6

7

8

9

1

FWD

REV

20k

LIFT

DRIVE

RIGHT

LEFT 0

OR

WH

BK

RD

YL

PRPL

BL

WH/YL

WH/RD

WH/GR

DP1

34 N

O

BRN-J1

C1PBUR

D

C11SBD

BL/BK

PLATFORM CONTROL BOX LID

GR/WH-R7

1 1 11

1 1 1

RD

CR7CR6

RD/BKL48

D40

H1

C2P-5

OPT.

8


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N M L K J I H G F

P

N

REV C

C

1P(GY)

C

2P(BK)

C

4P(BR)

C

3P(GR)

19/18 CONTROLCABLE

C9PC7P

12V DC BATTERY FOOTSWITCH

JIB

TILTALARM

PLATFORM CONTROL BOX

BRN-RELAY

BP1

BK/RD

RD

GR

TS12TURNTABLE

ROTATE

TS10SECONDARY

BOOM

TS11PRIMARY

BOOM

TS13EXTEND/RETRACT

TS8JIB BOOM

TS7PLATFORM

ROTATE

TS9PLATFORM LEVEL

TS1AUXILIARY

POWER

P3HORN

TS6GLOW PLUG

TS2ENGINESTART

TS4RPM SELECT

TS15DRIVE ENABLE

L1

FWD

REV

20k

LIFT

DRIVE

RIGHT

LEFT

DP1

34 N

O

PLATFORM CONTROL BOX LID

1

2

34

5

6

7

8

LVI/BCI

53 4

LVI

RESET IS SET TO "B",DISCHARGE IS SET TO "N"

RD-LVI

RD-LR19B

BL-L10

BL-LR19A

R42BATOR/RD

OR-LVI

OR/BK-LVI

OR/RD-LVI

P24BATWH

BRN-LVI

C3P-1

C2P-4

C3P-10

WHWH

OR/RD

OR/BK

OR

OR/RD

CR19BCR19ACR7CR6

O

R-LVI

OR/BK-LVI

OR/R

D-LVI

RD-LR19B

BL-LR19A

C2P-6

GR/BKC133PLA

RDLS18

D39

H1

GR/BKL4

TS44BEACON ON

TS46FUNCTIONOVERIDE

WHCR51#85

GNDLITEC2P-5

OR

C2P-2

WH-PLAT.BE

ACON

WH

-DP1

BK/W

HDP1

WH-BASEBE

ACON

AIRCRAFT

PROTECTION

PROXIMITY SENSOR

PLATFORM

BEACON

BASE

BEACON

BKGND

WHTS44

WHTS44

CR51

WHCR51#86

BKTS4

BKGND

BN

ORTS44C2P-2

BKA.C.PROX

BK

8

RD

LEFT

WORKLIGHT

WH

BN TO RIGHT

WORK LIGHT

WH

7A

8685

30

87

WH P24 BAT11

WHP24BAT

WHTS46

WHAIRCRAFTPROX.

86 85

30

8787

86

30

85

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Platform Control Box Switch Panel Wiring DiagramLVI/BCI Options


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E

S

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Engine Panel Diagram

1

2

3

4

5

6

7

8

A B C D E F G H I

November 2011


VOLTAGE REGULATOR12V DC

BL

BK

BL

RD

BL

-E.H.

BRN

-VOLT

BL

-E.H.

BL

-ISM2

RD

-J10

YEL

GR

WH

-R14

C5

-1P20BAT

RD

85

CR11START RELAY

OR

-GENPOS

OR

-GENNEG

BRN

-VOLT

WH

-R11

BK

-ISM

-1

BK

-START

86

30

CR16

RELAYFIELD

8587a

87

WH-J5

BRN-J4

WH-BATT

C35HRPM BK/RD

BRN-J4

RD-J6

WH-J6

WH-J4

BRN-VOLT

RD

-J10

BK-ISM1

BL-ISM2

WH-R14

30

87a

87

86

BRN-J4

WH-J5

WH-J4

BRN-J4

30

WH-J4

CR12ENGINE POWER

RELAY

WH-J6

BRN-J4

87

87a85 86

WH-J4

WH

-R14

30

CR13RPM CUTOUT

RELAY

87a

87

85 86

BRN-J4

BK/RD

30

WH-J6

CR14RPM RELAY

BK/RD

BRN-J4

87a85

87

86

NOTE: RELAY SOCKETS ARE SHOWN FROM THE RELAY SOCKET SIDE.

C21IGN2 WH

ENGINE HARNESS

ENGINE HARNESS

BK/RD

-35

RD-J6

BRN

C5MALE DEUTSCH

CONNECTOR

C5

-2GNDBRN

C5

-3C23PWRWH

C5

-5C33STRBK

C5

-11C21IGN2

WH

C5

-18C35HRPMBK/RD

C5

-22C34SABK/WH

WH

-BATT

ENGINE HARNESSONOFF

BRN

-ISM5

B+STARTER

STARTER B-


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N M L K J I H G F

P

N

REV C

DC AMME

AC POWE

CONT

BAT

BK-FROMCHARGER

LEFTSIDEDRIVE MOTOR

GROUNDISOLATOR

F1

A1

BK-2GA

BK-2GA

BRN-J8

BK-FROM CHARGER

BK-2GA

BK-2GA

RD-2GA

RD-10GA

F2

A2

RD-2GA

RD-10GA

F1200A

48V DC

RD-2GA

BK-2GA

BK-2GA

BK-2GA

BRN-J8

23

C31REVWH/BK

R27AUX RD

12

OR/RD

BRN-J8

BK-2GA

RD-2GA

RD-10GA

BRN-J8

24

RD-2GA

RD-10GA

OR/RD

RD-2GA

4 3 1267 511 10 9 8

F1 F2

SEP-EX DC MOTOR CONTROLLER

B- M- B+

CFILBK

R42BATOR/RD

C30FWDWH

R42BATOR/RD

C12DREBL/WH

C40LSOR

GR

CR5

RD/BK

2022 21 19 18

C29JSHRD/WH

C32JSLWH/RD

1617 15 1314

BRN-J8

RD

GR/BK-BATTISM-9

AP-2

+

-

WH-BATT

WH-BATT

+

-

+

-

+

+

_

WH-BATTR12

LEFTSIDEBATTERYPACK

+

-

R42BAT OR/RD

R42BAT OR/RD

P42BAT OR/RD

WH-FROM CHARGER TO BK 12/2

RD-20-12GA

LIFTCONTACTOR

PR-2

DIODE

GR/WH-19

BK-2GA

BK-2GA

FUNCTIONHARNESS

BK-2GA

BK-2GA

RD-2GA

R42BAT OR/RD

PR-1

DRIVE CONTACTOR

FUSE-F510A

PR-1

TOPVIEW OFDRIVE CONTA

AUXILIARYLIFTPUMP

A2D1

D1

A1

TO GROUND CONTROLBOXCONNECTOR C6

ACBATTERYCHARGER

RD-2GA

BK BKBK

DIODE

TO ENGINE PANEL

F4500A

P42BATOR/RD

ON

PRIMARYLIFT

PUMP

RD-2GA

BK-12/2

WH

12/2

WH12/2

87

87a8586

30

CR24

C108PLP

33

1

-

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Power Cable Diagram


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N M L K J I H G F

N

P

REV C

PR1PR2

RESERVOIR

T

PRIMARYPUMP(2cc)1.5 gpm /5.7 L/min

AUXILIARYPUMP0.5 gpm /1.89 L/min

M M

3200 psi /220.6 bar

TEST

BRAKE

0.060 inch /1.52 mm

0.4 gpm /1.5 L/min

PS

COMN.C.

N.O.

ST1 PR1ST2 PR2

MM

BRAKES STEER

1.5:13800 psi /262 bar

J1 J2

JIB BOOM

PL1 PL2

MASTERCYLINDER

3:13500 psi /241 bar

S1

SW1

V

0.030 inch /0.76 mm

SLAVE CYLINDERTURNT

3:13000 psi /207 bar

PLATFORM ROTATE

V2 V1

0.030 inch /0.76 mm

P

2500 psi /172 bar

JIB BOOM MANIFOLD

FUNCTION MANIFOLD

PR1PR2RE

RL

TOW BAR OPTION

0.030 inch /0.76 mm

0.020 inch /0.51 mm

0.020 inch /0.51 mm

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Hydraulic Schematic


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Genie North America

Genie Australia Pty Ltd.

Genie China

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Genie Korea

Phone

Toll Free

Fax

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

Phone +

Fax +

ribut

edBy:

California Proposition 65

W RNIN

The exhaust from this product contains chemicals

known to the State of California to cause cancer,birth defects or other reproductive harm.

Genie Holland

Genie Scandinavia

Genie France

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Phone +

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Documents

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