Supplement - Genie

1 TechnicalPublicationsFirstEdition, S-40Z-45/22S-80&85 Forthefollowingproducts:Z-60/34 Genie SupplementPart No. 35023 First Editionii Copyright 1995 by Genie IndustriesFirst Edition:First Printing, February 1995 Second Printing, March 1995 Third Printing, June 1995 Genie is a registered trademarkof Genie Industries. Registered 2009987 Patents pendingPrinted on recycled paperPrinted in Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is aGenie policy. Therefore product specifications aresubject to change without are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and other manuals. Pleasewrite or fax to the Technical Publications team: Genie IndustriesPO Box 69 Redmond, WA 98073-6900, USAFax Number: (206) you have any questions, call Genie North AmericaTelephone (206) 881-1800 Toll Free in 800 536-1800 Toll Free in Canada 800 426-8089 Fax (206) 883-3475 Genie EuropeTelephone (44) 01636-605030 Fax (44) 01636-611090 Part No.

2 35023 Genie SupplementFirst EditionHow To Use This SupplementThis Supplement is an addition to the servicemanuals listed below. The serial numbers listedbelow mark the first affected machine . Only thefollowing changes are documented in thissupplement:Replacement of the Ford LSG-423 enginewith the Ford LRG-423 engineIf you have any questions about what thissupplements covers or how it fits in to yourexisting documentation, please call the GenieIndustries Service ManualThere are four sections to the service Specifications section contains only thespecifications for Ford LRG-423 maintenance section contains only thosemaintenance procedures that are different for theFord LRG engine. Please note the procedurenumber for your machine, indentified at thebeginning of each procedure in this schematic section contains complete, updatedelectrical schematics for the Gasoline/LPGmachines.

3 The schematics are arranged repair section contains the complete FordLRG engine section. Please note the sectionnumber for your Manuals:ProductPart NumberS-4032222S-80 & S-8534032Z-45/2232960Z-60/3430105iiiSeri al Number Breaks:ProductMachines afterS-40271S-80 & S-85132Z-45/222134Z-60/34481 Genie SupplementPart No. 35023 First EditionTable of ContentsSection OneSpecificationsFord LRG-423 1 Section TwoScheduled Maintenance ProceduresB-1 Check the Engine Belt(s) .. 2B-2 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models .. 2B-3 Check and Adjust the Engine 2C-1 Replace the Gasoline Fuel Filter - Gasoline/LPG Models .. 4C-2 Replace the PCV Valve - Gasoline/LPG Models .. 5C-3 Replace the Spark Plugs - Gasoline/LPG Models .. 6C-4 Check and Adjust the Air/LPG Mixture - Gasoline/LPG Models .. 6C-5 Check and Adjust the Ignition Timing - Gasoline/LPG Models .. 8D-1 Change or Recondition the Engine Coolant - Gasoline/LPG Models.

4 8D-2 Change the Fuel Lines .. 9D-3 Check the Engine Valve Clearance - Gasoline/LPG Models .. 10D-4 Check the Engine Cylinder Compression - Gasoline/LPG Models .. 10D-5 Clean the PCV Hoses and Fittings - Gasoline/LPG Models .. 11D-6 Replace the Timing Belt - Gasoline/LPG Models .. 12 Section ThreeS-40 Electrical SchematicsElectrical Schematic - Gasoline/LPG Models .. 13 Ground Control Box Legend - Gasoline/LPG Models .. 15 Relay Panel Legend - Gasoline/LPG Models .. 16 Platform Control Box Legend - Gasoline/LPG Models .. 17S-80/85 Electrical SchematicsElectrical Schematic - Gasoline/LPG Models .. 18 Ground Control Box Legend - Gasoline/LPG Models .. 20 Relay Panel Legend - Gasoline/LPG Models .. 21 Platform Control Box Legend - Gasoline/LPG Models .. 22Z-45/22 Electrical SchematicsElectrical Schematic - Gasoline/LPG Models .. 23 Ground Control Box Legend - Gasoline/LPG Models.

5 25 Relay Panel Legend - Gasoline/LPG Models .. 26 Platform Control Box Legend - Gasoline/LPG Models .. 27ivPart No. 35023 Genie SupplementFirst EditionSection Three, continuedZ-60/34 Electrical SchematicsElectrical Schematic - Gasoline/LPG Models .. 28 Ground Control Box Legend - Gasoline/LPG Models .. 30 Relay Panel Legend - Gasoline/LPG Models .. 31 Platform Control Box Legend - Gasoline/LPG Models .. 32 Section FourRepair Procedures7-1 Governor Actuator .. 337-2 Choke Adjustments .. 347-3 Timing 357-4 Carburetor Adjustment .. 357-5 RPM Adjustment .. 357-6 Flex Plate .. 357-7 Water Temperature and Oil Pressure Gauges .. 367-8 Vacuum Switch .. 36vGenie SupplementPart No. 35023 First EditionPart No. 35023 Genie Industries1 First EditionService Manual SupplementSpecificationsFord Engine LRG-423 Displacement140 cu litersNumber of cylinders4 Bore & x x mmHorsepower63 @ 4000 rpmFiring order1 - 3 - 4 - 2S-40 RPM SpecificationsLow idle - carburetor900 rpmLow idle - electronic governor1600 rpmHigh idle2500 rpmS-80/85 RPM SpecificationsLow idle - carburetor900 rpmLow idle - electronic governor1600 rpmHigh idle2500 rpmZ-45/22 RPM SpecificationsLow idle - carburetor900 rpmLow idle - electronic governor1400 rpmHigh idle2150 rpmZ-60/34 RPM SpecificationsLow idle - carburetor900 rpmLow idle - electronic governor1600 rpmHigh idle2500 rpmGovernor electronicCompression :1 Compression pressure (approx.)

6 Pressure (psi) of lowest cylinder must beat least 75% of highest cylinderValve clearances to inchescollapsed to mmLubrication systemOil pressure40 to 60 psi(operating temp. @ 2000 rpm) to barOil capacity5 quarts(including filter) litersOil viscosity requirementsTemperature below 60 F / C5W-30-10 F to 90 F / -23 C to 32 C10W-30 Temperature above10W-40 to 10W-50-10 F / -23 CTemperature above20W-40 or 20W-5020 F / CUse oils meeting API classification SG (labeled SG/CCor SG/CD) as they offer improved wear ship with 10W-40 motorNormal engine cranking speed200 to 250 rpmCurrent draw, normal load170 ACurrent draw, maximum load200 ACurrent draw, minimum140 AMaximum circuit voltage DCwhile starting (normal temperature)Brush length, mmBrush length wear mmBrush spring tension64 ounces18 NewtonsBolt torque45 to 84 inch-poundsthrough to NmBrush mounting15 to 20 foot-poundsbolt torque20 to 27 NmMaximum mmBatteryType12V, Group 31 Quantity1 Cold cranking ampere1000 AReserve capacity @ 25A rate200 minutesFuel pumpElectronic solenoid7 bar2 Genie IndustriesPart No.

7 35023 Service Manual SupplementFirst EditionB-1 Check the Engine Belt(s) Genie S-40 models: Thisprocedure replaces S-80/85 models: Thisprocedure replaces Z-45/22 models: Thisprocedure replaces Z-60/34 models: Thisprocedure replaces the engine belt(s) is essential to goodengine performance and service life. The machinewill not operate properly with a loose or defectivebelt and continued use may cause not inspect while the engineis running. Remove the key tosecure from of hot enginecomponents. Contact with hotengine components may causesevere Inspect the engine belt for: cracking glazing separation breaksFord LRG-423 engines areequipped with a serpentine beltand incorporate a self adjustingpulley tensioner. No adjustment Maintenance ProceduresB-2 Check and Adjust the Engine IdleMixture - Gasoline/LPG ModelsGenie S-40 models: Thisprocedure replaces S-80/85 models: Thisprocedure replaces Z-45/22 models: Thisprocedure replaces Z-60/34 models: Thisprocedure replaces information to perform this procedure isavailable in the Ford LRG-423 Liter IndustrialEngine Service Manual (Ford number: PPD-194-287).

8 Genie part number and Adjust theEngine RPMG enie S-40 models: Thisprocedure replaces S-80/85 models: Thisprocedure replaces Z-45/22 models: Thisprocedure replaces Z-60/34 models: Thisprocedure replaces the engine rpm at the proper settingfor both low and high idle is essential to goodengine performance and service life. The machinewill not operate properly if the rpm is incorrect andcontinued use may cause component this procedure in gasolinemode with the engine at normaloperating Disconnect the blue/black wire from thegovernor No. 35023 Genie Industries3 First EditionService Manual SupplementSCHEDULED MAINTENANCE PROCEDURES2 Connect an rpm gauge to the engine, then startthe engine from the ground : Refer to the RPM Specification chart forthe correct rpm to step 4 if the low idle rpm is Turn the idle adjustment screw on thecarburetor clockwise to increase rpm orcounterclockwise to decrease low idle adjustmentacarburetorbadjustment screw4 Turn the engine off and reconnect theblue/black wire to the governor Start the engine from the ground : Refer to the RPM Specification chart forthe correct rpm Move the engine idle control switch to high idle(rabbit symbol) from the ground.

9 Refer to the RPM Specification chart forthe correct rpm Turn the engine low and high idle rpm s are correct,disregard adjustment steps 8 and Remove the mounting fasteners from theelectronic governor located on the engineside bulkhead, then remove the back panelfrom the Restart the engine, turn the low or high speedset screw clockwise to increase the rpm orcounterclockwise to decrease the not adjust any trimpot otherthan specified in this idle adjustmentalow idle adjustmentbhigh idle adjustment10 Apply a drop of silicone to the top of the trimpotscrew. Apply a bead of silicone to the surfaceof the back panel prior to Re-assemble the governor and recheck lowand high RPM SpecificationsLow idle - carburetor900 rpmLow idle - electronic governor1600 rpmHigh idle2500 rpmS-80/85 RPM SpecificationsLow idle - carburetor900 rpmLow idle - electronic governor1600 rpmHigh idle2500 rpmZ-45/22 RPM SpecificationsLow idle - carburetor900 rpmLow idle - electronic governor1400 rpmHigh idle2150 rpmZ-60/34 RPM SpecificationsLow idle - carburetor900 rpmLow idle - electronic governor1600 rpmHigh idle2500 rpmba4 Genie IndustriesPart No.

10 35023 Service Manual SupplementFirst EditionC-1 Replace the Gasoline FuelFilter - Gasoline/LPG ModelsGenie S-40 models: Thisprocedure replaces S-80/85 models: Thisprocedure replaces Z-45/22 models: Thisprocedure replaces Z-60/34 models: Thisprocedure replaces the gasoline fuel filter is essential togood engine performance and service life. A dirtyor clogged filter may cause the engine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more fuels are the fuel filter in an open,well-ventilated area away fromheaters, sparks, flames andlighted tobacco. Always have anapproved fire extinguisher withineasy this procedure with theengine Remove the 2 bolts from under the engine pivotplate. Swing the engine pivot plate away fromthe machine to access the fuel filter, locatednear the plate retaining boltsbengine pivot plate2 Disconnect the fuel hose from the filter, thenremove the fitting from the Remove the filter from the filterbhose from the fuel pump tothe fuel filter4 Install the fitting into the new fuel filter, theninstall the fiter into the MAINTENANCE PROCEDURESPart No.