Genie Lifts S60&S65 Service Manual

S-60 • S-65 • S-60 HC Part No. 77828 February 2012 ii Introduction Important Read, understand and obey the safety rules and operating instructions in the Genie S-60 and Genie S-65 Operator's Manual or the Genie S-60 HC Operator's Manual before attempting any maintenance or repair procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes and repair procedures for qualified service professionals. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center. Compliance Machine Classification Group B/Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance. Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals. Contact Us: http://www.genielift.com e-mail: awp.techpub@terex.com Serial Number Information Genie offers the following Service Manuals for these models: Title Part No. S-60 and S-65 Service Manual (before serial number 2575) ................................. 34476 S-60 and S-65 Service Manual (from serial number 2575 to 6623) ....................... 48412 S-60 and S-65 Service Manual (from serial number 6624 to 9153) ....................... 65196 S-60 and S-65 Service Manual (from serial number 14782 to 21000) ................ 139188 S-60, S-65, S60 HC and TRAX Service Manual (from serial number 21001) ................................ 147753 Copyright © 2011 Terex Corporation 77828 Rev E February 2012 Fourth Edition, Fifth Printing "Genie" and "S" are registered trademarks of Terex South Dakota, Inc. in the USA and many other countries. Printed on recycled paper Printed in U.S.A. Introduction

Part No. 77828 S-60 • S-65 • S-60 HC February 2012 Revision History Revision Date Section Procedure / Schematic Page / Description E 2/2012 Introduction Revision History Added 3 - Maint. 3-1 E1 1/2013 3 - maint. 3-6, E-4 REFERENCE EXAMPLES: Kubota Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. 3-2, 6-4, 9-1_Section 4_Repair Procedure. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. Electronic Version Click on any procedure or page number highlighted in blue to view the update. iii

S-60 • S-65 • S-60 HC Part No. 77828 February 2012 iv REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description REFERENCE EXAMPLES: Kubota Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. 3-2, 6-4, 9-1_Section 4_Repair Procedure. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. Electronic Version Click on any procedure or page number highlighted in blue to view the update.

Part No. 77828 S-60 • S-65 • S-60 HC February 2012 Serial Number Legend v S60 05 - 12345 Model Sequence number Model year PN - 77055 Country of manufacture: USA This machine complies with: ANSI A92.5 CAN B.354.4 Model: S-60 Serial number: S6005-12345 Electrical schematic number: E0186 Rated work load (including occupants): 500 lb / 227 kg Maximum allowable inclination of the chassis: Air Tires 2 deg / Foam Tires 4.5 deg Gradeability: 45% Maximum allowable side force : 150 lb / 670 N Maximum number of platfrm occupants: 2 Model year: Manufacture date: 04/12/05 2005 Maximum wind speed : 28 mph/ 12.5 m/s Maximum platform height : 60 ft 2 in/ 18.3 m Maximum platform reach : 50 ft 4 in/ 15.3 m Machine unladen weight: 20,736lbs / 9,406kg Foam Tires add 764 lbs/347 kg to weight Serial number tam ed on c a i Serial label (located under cover) Terex South Dakota, Inc. 500 Oak Wood Road PO Box 1150 Watertown, SD 57201 USA Terex South Dakota, Inc. 500 Oak Wood Road PO Box 1150 Watertown, SD 57201 USA

S-60 • S-65 • S-60 HC Part No. 77828 February 2012 Personal Safety Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority. Read each procedure thoroughly. This manual and the decals on the machine use signal words to identify the following: Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Indicates a potentially hazardous situation which, if not avoided, may result in property damage. vi Safety Rules Section 1 • Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie S-60 and Genie S-65 Operator's Manual or the Genie S-60 HC 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. Do Not Perform Maintenance Unless: You are trained and qualified to perform maintenance on this machine. You read, understand and obey: - manufacturer’s instructions and safety rules - employer’s safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop. Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes.

Part No. 77828 S-60 • S-65 • S-60 HC February 2012 SAFETY RULES vii Section 1 • Safety Rules Workplace Safety Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity. Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit.

S-60 • S-65 • S-60 HC Part No. 77828 February 2012 Table of Contents viii Introduction Important Information ................................................................................................... ii Serial Number Information ............................................................................................ ii Revision History .......................................................................................................... iii Serial Number Legend ................................................................................................. v Section 1 Safety Rules General Safety Rules .................................................................................................. vi Section 2 Specifications Machine Specifications .......................................................................................... 2 - 1 Performance Specifications ................................................................................... 2 - 2 Hydraulic Specifications ........................................................................................ 2 - 3 Manifold Component Specifications ....................................................................... 2 - 4 GM 3.0L Engine Specifications .............................................................................. 2 - 5 Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 6 Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 7 Deutz F3L-2011 Engine Specifications ................................................................... 2 - 8 Perkins 404-22 Engine Specifications .................................................................. 2 - 10 Machine Torque Specifications ............................................................................ 2 - 11 Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 12 SAE and Metric Fasteners Torque Charts ............................................................ 2 - 13

Part No. 77828 S-60 • S-65 • S-60 HC February 2012 TABLE OF CONTENTS ix Section 3 Scheduled Maintenance Procedures Introduction ............................................................................................................ 3 - 1 Pre-Delivery Preparation ........................................................................................ 3 - 3 Maintenance Inspection Report .............................................................................. 3 - 5 Checklist A Procedures A-1 Inspect the Manuals and Decals .................................................................. 3 - 7 A-2 Perform Pre-operation Inspection ................................................................. 3 - 8 A-3 Perform Function Tests ................................................................................ 3 - 8 A-4 Perform Engine Maintenance ....................................................................... 3 - 9 A-5 Check the High Pressure Hydraulic Filter Condition Indicator ....................... 3 - 9 A-6 Test the Oscillate Axle (if equipped) ........................................................... 3 - 10 A-7 Perform 30 Day Service ............................................................................. 3 - 10 A-8 Inspect the Engine Air Filter - GM Models .................................................. 3 - 11 A-9 Perform Engine Maintenance - GM, Ford and Perkins Models .................... 3 - 11 A-10 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 12 A-11 Check and Adjust the Engine RPM - Perkins Models ................................. 3 - 14 A-12 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 15 A-13 Replace the Drive Hub Oil .......................................................................... 3 - 15 A-14 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 16 A-15 Perform Engine Maintenance - Perkins Models .......................................... 3 - 16

S-60 • S-65 • S-60 HC Part No. 77828 February 2012 TABLE OF CONTENTS x Section 3 Scheduled Maintenance Procedures, continued Checklist B Procedures B-1 Inspect the Battery ..................................................................................... 3 - 17 B-2 Inspect the Electrical Wiring ....................................................................... 3 - 18 B-3 Check the Exhaust System ....................................................................... 3 - 19 B-4 Inspect the Engine Air Filter - Ford, Deutz and Perkins Models .................. 3 - 20 B-5 Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 20 B-6 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 21 B-7 Confirm the Proper Brake Configuration ...................................................... 3 - 22 B-8 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 22 B-9 Check and Adjust the Engine RPM - Ford and Deutz Models ..................... 3 - 24 B-10 Test the Ground Control Override ............................................................... 3 - 25 B-11 Check the Oscillate Directional Valve Linkage ........................................... 3 - 26 B-12 Test the Platform Self-leveling ................................................................... 3 - 26 B-13 Test the Engine Idle Select ........................................................................ 3 - 27 B-14 Test the Fuel Select Operation - GM and Ford Models ............................... 3 - 28 B-15 Test the Drive Brakes ................................................................................ 3 - 29 B-16 Test the Drive Speed - Stowed Position ..................................................... 3 - 30 B-17 Test the Drive Speed - Raised or Extended Position .................................. 3 - 30 B-18 Test the Alarm Package - Optional Equipment ........................................... 3 - 31 B-19 Perform Hydraulic Oil Analysis ................................................................... 3 - 32 B-20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 33 B-21 Replace the Fuel Filter Element - Perkins Models ...................................... 3 - 34 B-22 Inspect the Boom Extend/Retract Cables ................................................... 3 - 35 B-23 Perform Engine Maintenance - Deutz Models ............................................. 3 - 37 B-24 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 37 B-25 Replace the Engine Air Filter Element - GM and Ford models .................... 3 - 38 B-26 Perform Engine Maintenance - Perkins Models .......................................... 3 - 38

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Genie Lifts S60&S65 Service Manual

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