Genie S60/S65 Telescopic Boom Lift Service & Repair Manual

Service Manual Technical Publications Second Edition, First Printing Part No. 48412 (Rev A1) July 2008 S-60 ® S-65 ®

Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition ii Introduction ® Copyright © 1998 by Genie Industries Second Edition: First Printing, June 1998 "Genie" and "S" are Registered Trademarks of Genie Industries in the USA and many other countries. These machines comply with ANSI/SIA 92.5-1992. Printed on recycled paper Printed in U.S.A. Genie North America Telephone (425) 881-1800 Toll Free 800 536-1800 in U.S.A. Toll Free 800 426-8089 in Canada Fax (425) 556-8649 Genie Europe Office Telephone (44) 01636-605030 Office FaxFax (44) 01636-611090 Parts Telephone (44) 01636-605002 Parts Fax (44) 01636-611091 ® ® Important Read, understand and obey the safety rules and operating instructions in the appropriate Genie S-60 & Genie S-65 Operator's Manual before attempting any maintenance or repair procedure. This service manual covers the Genie S-60 and Genie S-65 2WD and 4WD models. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting 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 a Genie dealer service center. Genie Industries 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 other manuals. Please write to the technical publications team in care of Genie Industries, PO Box 69, Redmond WA 98073-0069 U.S.A. If you have any questions, please call Genie Industries.

Part No. 48412 Genie S-60 & Genie S-65 Service Manual - Second Edition iii Safety Rules Section 1 - Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie S-60 & Genie S-65 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.

Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition SAFETY RULES iv 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 that your workshop or work area is properly ventilated and well lit. 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. 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: Indicates the presence of a hazard that will cause death or serious injury. Indicates the presence of a hazard that may cause death or serious injury. Indicates the presence of a hazard that will or may cause serious injury or damage to the machine. Indicates special operation or maintenance information. 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, and lifting or placing loads. Always wear approved steel-toed shoes.

Part No. 48412 Genie S-60 & Genie S-65 Service Manual - Second Edition Table of Contents v Introduction Important Information ..................................................................................................... ii Section One Safety Rules General Safety Rules .................................................................................................... iii Section Two Specifications Machine Specifications ............................................................................................. 2 - 1 Performance Specifications ...................................................................................... 2 - 2 Hydraulic Specifications ........................................................................................... 2 - 3 Ford LRG 423 Engine Specifications ....................................................................... 2 - 4 Deutz F4L 1011F Engine Specifications .................................................................. 2 - 6 Hydraulic Hose and Fitting Torque Specifications .................................................... 2 - 8 Bolt Torque Specifications ........................................................................................ 2 - 9 Section Three Scheduled Maintenance Inspections Introduction ............................................................................................................... 3 - 1 Table A ..................................................................................................................... 3 - 2 Table B ..................................................................................................................... 3 - 3 Table C ..................................................................................................................... 3 - 5 Table D ..................................................................................................................... 3 - 6 Maintenance Inspection Report ................................................................................ 3 - 7 Section Four Scheduled Maintenance Procedures Introduction ............................................................................................................... 4 - 1 A-1 Inspect the Manuals ........................................................................................ 4 - 2 A-2 Inspect the Decals and Placards .................................................................... 4 - 2 A-3 Inspect for Damage, Loose or Missing Parts .................................................. 4 - 2 A-4 Check the Engine Oil Level ............................................................................. 4 - 3 A-5 Check the Engine Coolant Level - Gasoline/LPG Models ............................... 4 - 3 A-6 Check for Fuel Leaks ...................................................................................... 4 - 3 A-7 Check the Hydraulic Oil Level ......................................................................... 4 - 4 A-8 Check for Hydraulic Leaks .............................................................................. 4 - 4

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Genie S60/S65 Telescopic Boom Lift Service & Repair Manual

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