The "Butchered" Genie - Part 1

On a weekend trip to Columbus, Ohio I stop by a viewer's farm to take a look at his recently-purchased 1995 Genie Z-45 boom lift.
He said that the engine didn't run right, often stalling, and that the platform controls were "modified" by the previous owner. He was not kidding...this poor Genie has been HACKED!
After the preliminary checks it quickly becomes obvious that this Genie was going to take a lot more time to get right than one afternoon call...but we get a good start on it :)
Enjoy!
Ivan

[@kc360awareness]

@PHAD - Great job Ivan. Not just Keeping that Genie working and that families project house moving along....but also keeping us entertained! That you for taking the time to record these cases On a more personal note, thank you for keeping your content clean & “family friendly”

[@elcheapo5302]

The owner is going to need more than three wishes for that Genie.

[@djosbun]

Saturday Post Trophy Winner right here, folks. 👍

[@terrymcconnell6045]

Worked a similar type lift that would , occasionally without warning, stall when you where up and extended....what a fun amusement ride that nobody wanted to ride. It did get fixed, but it was a jinxed device nobody would volunteered to operate. Thanks for sharing, can’t wait for part II.👍😎

[@ChiDraconis]

There is a hydraulic release if you have a scamper that can let it down;

[@quantaearth1]

This lift was featured on the show 1000 ways to die a few years ago.

[@Charles_Mulberry_7977]

It's amazing that nothing got burned up and nobody got hurt! Ivan is the Genius of Genies!

[@TheFirstBigCheese]

@16:30 I like that you primarily judge "going down works" with your testlight in stead of the dodgy human sensation of standing in the basket and physically moving downwards. :D

[@hddm3]

Getting better all the time. Sweet

[@riblets1968]

I hope you enjoyed Columbus! It was my home for 18 years and I rather liked it for a variety of reasons.

[@davidbonnett5441]

Love your videos, your thought process and determination to get it done.

[@stealthg35infiniti94]

Ivan, You have a Sixth Sense for fixing other people's nightmare creations...Some people just make temporary hacks that just blow up to a major repair project...Hard leason I've learned, Fix it right while it's manageable, otherwise it will become expensive and time consuming later....

[@PineHollowAutoDiagnostics]

Haha yes this project became quite expensive and time consuming to restore to factory spec! But customer was very pleased with the results 😁

[@engeneer_ru5827]

@@PineHollowAutoDiagnostics Прежний владелец хорошо потрудился. Так все переделать - это грамотный труд....

[@sinegra30]

That is a nightmare! Ivan, you are the bravest knight I know!

[@Graham_Wideman]

Negative parts required! Hey Ivan -- I can't help thinking that moving the throttle control rod from the inner to the outer hole on the actuator lever would change not just the range of control but also the control loop gain, which potentially affects the loop stability. I'm sure you would have noticed if your result didn't work, so apparently all good. I just thought it was interesting that changing that rod position has those two effects, and possibly hearkens back to your mech eng training.

[@PineHollowAutoDiagnostics]

Great point Graham. It worked fine so I moved on to the bigger fish lol

[@fredandcheryl94]

Does this machine send chills up and down your spine?

[@sixpacksandsrts9122]

Wow. What a mess

[@richardcranium5839]

thats an oldie with a carb. if i was a guessing man i'd guess the level sensor went out so they did a workaround. the level sensor puts all the controls in half speed if it is out more than somewhere about 20 degrees and cuts out basket controls all together around 30 degrees. thus why the enable buttons added because the boom power got cut off. the other thing ive seen is a broken wire to the boom. if you had a spare you are lucky. most dont.

[@jamiewhite838]

Like the " more to come " statement at the end! Can't wait!

[@roxanneabbott8424]

Brilliant with wiring Ivan, I wish I knew half as much as you.

[@andrewdonagher6497]

I'd be only going near that machine with a new OEM basket controls to be sure its safe, doesn't seem to have safely limits just be care full

[@DaveSender66]

Oh sure I'll come over and do a quick diagnosis. 😆😅 7 hours later you get back to your wife. I was hoping you're going to Ohio to do some flying. I miss your flying videos.

[@rugrataudio]

It's not supposed to have a throttle stop on that set up. When you shut unit down the throttle blades should shut completely to stop backfire and engine run on. throttle actuator rod length should be adjusted so blades are completely shut when off Also the controller box has pots to set gain and engine speed for hi & low speed settings

[@PineHollowAutoDiagnostics]

You are probably right, but this solution worked fine 👍🙂

[@rugrataudio]

@@PineHollowAutoDiagnostics I know you got it covered no matter what! lol

[@throttlebottle5906]

i'd imagine it shouldn't be out on the arm end hole, sees like way to fast and sudden movement at the blades

[@TheCrazy243]

Seeing wires hurt my brain!! Crazy! 🤯

[@porky7753]

Great video Ivan but i'm addicted to bonus footage. lol

[@SmittySmithsonite]

Wow, what a wiring nightmare there! Always fun fixing someone else's brainstorms, lol! 😂

[@VigilanceTech]

How many diagnostics did you bill this for, or did you just go by the hour?

[@PineHollowAutoDiagnostics]

Many hours... Over one full day lol

[@stojansimke4130]

Hey Ivan are you coming in Kentucky soon, I need help with my VW jetta 2008 2.0t it has check engine light but works fine except when it starts has bit louder engine noise and from time to time shows fuel cap is open.

[@robertmccully2792]

Been stuck up high in those more than once. And smart ass can switch kill switch from below and trap you up high. And have had arm break loose and swing 50 feet. Not a fan, in fact stop going up in them unless I had a rope to climb down. This was all in my construction days.

[@aminejan5241]

THANKS FOR MAKING THIS VIDEO

[@PineHollowAutoDiagnostics]

THANK YOU FOR WATCHING 😁

[@kc360awareness]

Pine Hollow Auto Diagnostics - ALL CAPS RESPONSE!!! Gotta love a little subtle humor. Good one.

[@HandyC]

Even the brand new genies occasionally stall. Thankfully they've always started again after though. (Steel erector/fabricator welder, used them a lot and abused them using it as a crane to fit steel 🤣🙈 never seen one with so many bodged wiring and buttons though 😳😳

[@georgeswindolljr1980]

I work as a mechanic for one of the largest equipment rental companies, it always amazes me how our customers misuse and abuse equipment, however it is job security for me!!!!!

[@jamesmcgraw9570]

Andy C you are right. None of those bypass buttons are supposed to be there. Any wire that is spliced or jumpered, is a visual give away, something just isn’t right.

[@HandyC]

James Mcgraw there should be one and it's to allow you to either lower it or drive it (can't remember which) after it cuts out due to tilt switch (or on the newer ones overloading the basket ) activation.

[@georgeswindolljr1980]

Andy C there is a override switch that allows you to drive with the turntable rotated out of normal rotation. Also as you said newer ones have a platform load sensor, but I don’t think there is a override for that!!!!

[@jamesmcgraw9570]

Andy C true that is the only override and it only allows you to move back to a “safe” position. It has been several years since I used one but I could install the lighting for high school football fields. 120-160’ reach. Could not reach far from the base unless you were at a higher angle.

[@matthewjuhlin4628]

4:35 a little Eric O action there... with the camera off

[@billziegmond4943]

You have to love those wire monkeys. Bad sign when you see wire nuts. Sometime I'll tell you a story about a monkey who screwed up 350 camera security system. You know it was going to be bad day when the guy hands you a diagram points to shield twisted pair wire ask what does that mean.

[@gillgetter3004]

Five point harness clipped to bucket when running!

[@opl500]

WIRE NUTS, YES

[@boomer9900]

The thing needs a new boom electrical cable set. Besides that I would use a serial link between the boom and the main panel so you were just sending serial commands down a pair of wires, making the boom cable replacement cost trivial. However you have to give credit to the guys who hotwired the thing to work.

[@PineHollowAutoDiagnostics]

Those guys must have spent days rewiring this thing... Surprised that it worked at all with all the mods 😂

[@mikechiodetti4482]

Good luck with this one!

[@caduceus33]

Ivan, you are a Genie genie!

[@cjames4957]

I want to add that some laws require us to remove from service and lock machine out if repairs cannot be made according to OEM Specs.

[@randy1ization]

Ivan u need to be very careful working on this type of stuff, because if it kills somebody, your the guy they will come after.. scary.. I admire your tenacity, but this is insane. I would definitely get a control panel with all functions legible marked, then run down every wire against a diagram. test any and all safety components, and replace any that are missing.,,. leave no chance for a liability.

[@spinb]

Not only do these lift makers put on control decals that wear off, their "symbols" for operation are nonsense to the operator.

[@davidcraven277]

I just love the wire nuts

[@throttlebottle5906]

work reliably again, replace the whole umbilical cord to the basket, probably a dozen other parts lol.

[@jimhaines8370]

I'm guessing there is no part number from Genie for those wire nuts HA!!!

[@BoB4jjjjs]

I thought you would just have fixed it properly when you were there. Ph well, a return is in order.

[@PineHollowAutoDiagnostics]

My wife didn't have two days to sit around and wait for me 😂

[@zx8401ztv]

So hacked about, i guess that some of the controls had faulty contacts and rather than get a replacement control someone added bypass buttons. I bet a second hand control plate and switches are kidney selling money :-( I do redesign things (bodge lol) that are causing problems , but never to that degree!!.

[@PineHollowAutoDiagnostics]

We'll get this machine back to factory specs almost no parts required 👍😉

[@workinprogress3942]

You should do a live call. Maybe we all can help you out.

[@progandy]

With that wiring I'd be tempted to rip everything out and start from scratch.

[@justinhayward5027]

Ivan the genie 🧞‍♂️ master

[@sergeyspirin4539]

Привет, Иван! Весёлый мужик! Надо на Кан шину его и впрыск на мотор. Покрасить и новый будет. А всё потому там на капоте слово ВООМ написано 😉

[@engeneer_ru5827]

Аппарату 25 лет, а он работает! Кто из современных "цифровых" машин столько прослужит...

[@baxrok2.]

1995 - Holy shit.

[@Familyfleet]

Thats not a control panel, its the secret ritual to achieve Grand Poohbah at the raccoon lodge

[@hatfez]

Whoever wired that modified control panel used the "by system" of wiring. By guess & by golly!

[@piperjohn_3]

Ivan not intimidated at all by the rat's nest of jerry rigged platform wiring. Brutal logic triumphs again.

[@cjames4957]

The Liability from working on these things, so many people have been killed on these machines when they operate perfectly, I stay away from them if the customer won't let me repair it properly back to OEM, be careful Ivan.

[@baxrok2.]

He's young and brave. I remember those days!

[@ChiDraconis]

@@baxrok2. Apparently Mr Pine Hollow has not realized paying for legal drawing $3,400 is not motivated to "git 'er done" → It is legal to refuse work; $230,000 just for Dog Bite ??? Walk away dude!!

[@tallbrian100]

Those terminal blocks on the boom are crap. LOL

[@gillgetter3004]

Twenty five years old? I think it’s service life is over. I’m retired now but usually that would be taken out of service.

[@jamesfenton7338]

I see this allot, "I don't understand this thing, lets add some hot wires and make it work" Regarding the previous tech, they had tools, but ideally they should leave them in the box.

[@justincase3880]

“Ground Control to Major Ivan” ...

[@litz13]

I used to fix arcade games. Often they would come in "customized" like this. We charged an unfix fee.

[@heyitsdrew]

if I had one wish, I wish for the video of the guy who butchered this in the first place, with explaining exactly why each wire went where.

[@PineHollowAutoDiagnostics]

That would be cringe worthy to watch lol

[@heyitsdrew]

@@PineHollowAutoDiagnosticsI can see myself slapping my head saying but why!?

[@45AMT]

Somebody with some extra switches and a white paint maker had to much time on there hands...

[@AP9311]

That's so real Russian hack lol. At least you got it fixed to semi factory. It needs more unhacking to do. Haha, more or less no parts required!! Lmao!

[@charlesmiller5078]

Ground Control to Major Tom, your stuck up in your box and you cant get home.

[@fredandcheryl94]

At least it’s not 12” from a wall can’t get to the control panel.

[@jamesmcgraw9570]

Ivan, run away as fast as you can. Those are not supposed to have that many bypasses. They are engineered to not rotate a certain amount due to instability. That machine is a death trap at worst and a lawsuit at best. Actually are supposed to be repaired by certified tech due to variable degree of height, reach out and rotation. Side load is the worst. They are supposed to stop when the bucket commands move the bucket outside of safe operating conditions. Study up on requirements to work on industrial equipment. Your own investigation has shown this machine is a total hack job. And every safety has an illegal bypass.

[@kraschsclassics]

Yes run, insist on an inspection by a certified tech after repair to remove any liability. You should have tested the aux function before letting them run machine. Ground controls are bang-bang and platform joysticks are proportional. Does the foot pedal work or bypassed? Level switch lockout? Boom limits work? If you did do this you could have shown it.

[@PineHollowAutoDiagnostics]

I always do a full test drive after repairs, and verify safety of the machine 👍

[@mplante7352]

@@kraschsclassics A "certified" tech wouldn't touch this boom with a 10 foot pole, also I it would take many hours and lots of cash to put that boom back up to code for it to pass an annual inspection and even then it's not worth it due to liability and state of repair of this unit and surely someone competent wouldn't sign off on it without knowing the full extent of the can of worms being opened up. Also i'd want a structural NDT inspection as well. If the owner chooses to use this on his own property that's one thing but the second that MEWP is used on a job site he's on OHSA's jurisdiction and if there's an accident he's in severe shit. Kudos to Ivan for wanting to get things right but there is much liability involved here and he should take steps to protect himself as a business repairing a MEWP, and I think he should give the owner a disclosure statement of no warrantee and will not assume any liability on any work he's done and have him sign it as this boom is modified against the manufacturer's original design and doesn't meet safety code. Also lots of the safety and info decals are missing as well, and the operators manual and manual of responsibilities is required to be in the booms platform document box. This is not a talk down to Ivan he's doing a great job but there are standards and guidelines when working on MEWPs especially customer owned ones that have not been maintained properly. Lastly fall protection check the state laws a fall arrest harness is required to be worn when operating the MEWP.

[@engeneer_ru5827]

This is all very serious! But I see how this is not respected. I thought only in Russia complete chaos ...

[@georgeswindolljr1980]

Pine Hollow Auto Diagnostics Ivan he is correct, I work as a mechanic for one of the largest equipment rental companies and aerial work platforms (AWP) can be dangerous at best when all the manufacturers safeties are intact and work as designed!!!!! Any one who could potentially be injured on this type equipment could legally hold you liable for being the last person to work on it!!!!!!!! Please think sbout the that before you do this type of work in the future!!!!!!!!!!

[@Nudnik1]

Lol I seen machines like this before..lol Little Rascals labeled basket controls

[@neilmurphy845]

Why they didn't just keep the stock set up it would be cheaper and easier

[@justincase3880]

Pull it to ground with your test light LOL ...

[@justincase3880]

When in doubt, read the “White Out” ...

[@kevinbyrne4538]

If Ivan had been stranded on Gilligan's Island aboard the S.S. Minnow, they would have left the island in a day -- 2 days at the most.

[@randy1ization]

HOPE HE GOT THAT MESS CHEAP, because he would get a very large bill to untangle all of that hackjob if I was fixing it. Just ridiculous..

[@neilmurphy845]

I feel sorry for that machine 😞 and it's mechanic iven

[@Garth2011]

Obviously some "construction electrician" got involved with that unit. The fact that he used solid core twist connectors explains much plus, no wiring diagram which is likely why all the wiring was rigged so he could avoid wiring the unit as intended. This is so childish and you see this often when unskilled folks get their hand on equipment vs. stick to their profession and in some cases, their profession exhibits the same quality ! What a bold move...rewire the entire basket control board and then hand carve a new nameplate for all of the controls. LOL. You just don't work on other peoples property that way...maybe the previous owner did all of this since he was going to be using it for himself only. Some folks just stray off and never learn...stick with the original design.

[@donnierobertson3088]

Ok

[@aleskyfinis1025]

Somebody invite the rest of that wire and that’s when I Apple

[@on-site4094]

What a rats nest thats wiring nightmare

[@publicmail2]

I'm sure you've a customer that bitched about you making a video and charging them time. How do you handle this? They don't realize it's a video log of their actual repair and I am sure you don't tack time on for video, It's those customers that you can never please.

[@engeneer_ru5827]

An interesting moment! Deserves an explanation.

[@PineHollowAutoDiagnostics]

Actually the video doesn't add too much time to the process, and the documentation is worth its weight in gold as reference material. Customers usually enjoy watching the videos after the repairs 🙂

[@publicmail2]

@@PineHollowAutoDiagnostics Imagine a shop offering, for a small fee, a raw unedited recording of a customers repair. I usually do repairs myself but on occassion I'm the guy standing on the yellow line observing with an occasion comment like yelling "hand thread! first", "star pattern"...

[@paddycooper2682]

First