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

Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition TABLE OF CONTENTS vi Section Four Scheduled Maintenance Procedures, continued A-9 Check the Tire Pressure ................................................................................. 4 - 5 A-10 Test the Oscillate Axle (if equipped) ............................................................... 4 - 5 A-11 Test the Platform and Ground Controls .......................................................... 4 - 6 A-12 Test the Auxiliary Power Operation ................................................................ 4 - 6 A-13 Test the Tilt Sensor ........................................................................................ 4 - 7 A-14 Test the Limit Switches ................................................................................... 4 - 8 A-15 Replace the Engine Oil and Filter - Gasoline/LPG Models ........................... 4 - 10 A-16 Drain the Fuel Filter/Water Separator - Deutz Diesel Models ....................... 4 - 11 A-17 Replace the Engine Air Filter ........................................................................ 4 - 12 B-1 Check the Engine Belt .................................................................................. 4 - 13 B-2 Check the Radiator - Gasoline/LPG Models ................................................. 4 - 14 B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ..................... 4 - 14 B-4 Check the Exhaust System .......................................................................... 4 - 15 B-5 Check the Battery ......................................................................................... 4 - 16 B-6 Check the Hydraulic Tank Filter Condition Indicator ..................................... 4 - 16 B-7 Inspect the Electrical Wiring ......................................................................... 4 - 17 B-8 Inspect the Tires and Wheels (including lug nut torque) ............................... 4 - 17 B-9 Confirm the Proper Brake Configuration ....................................................... 4 - 18 B-10 Check the Oil Level in the Torque Hubs ....................................................... 4 - 18 B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models .............. 4 - 19 B-12 Check and Adjust the Engine RPM ............................................................... 4 - 19 B-13 Test the Key Switch ...................................................................................... 4 - 21 B-14 Test the Emergency Stop Buttons ................................................................ 4 - 21 B-15 Test the Ground Control Override ................................................................ 4 - 22 B-16 Check the Directional Valve Linkage ............................................................ 4 - 22 B-17 Test the Platform Self-leveling ...................................................................... 4 - 23 B-18 Test the Horn ................................................................................................ 4 - 23 B-19 Test the Foot Switch ..................................................................................... 4 - 23 B-20 Test the Engine Idle Select ........................................................................... 4 - 24 B-21 Test the Fuel Select Operation - Gasoline/LPG Models ............................... 4 - 24 B-22 Test the Drive Enable System ...................................................................... 4 - 25

Part No. 48412 Genie S-60 & Genie S-65 Service Manual - Second Edition TABLE OF CONTENTS vii Section Four Scheduled Maintenance Procedures, continued B-23 Test the Drive Brakes ................................................................................... 4 - 25 B-24 Test the Drive Speed - Stowed Position ....................................................... 4 - 26 B-25 Test the Alarm Package - Optional Equipment ............................................. 4 - 27 B-26 Perform Hydraulic Oil Analysis ..................................................................... 4 - 27 B-27 Replace the Engine Oil and Filter - Deutz Diesel Models ............................. 4 - 27 C-1 Check the Boom Wear Pads ........................................................................ 4 - 29 C-2 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 29 C-3 Check the Free-wheel Configuration ............................................................ 4 - 30 C-4 Grease the Turntable Rotation Bearing and Rotate Gear ............................. 4 - 31 C-5 Replace the Torque Hub Oil ......................................................................... 4 - 31 C-6 Replace the Hydraulic Tank Filter ................................................................. 4 - 33 C-7 Replace the Drive Loop Hydraulic Filter ....................................................... 4 - 33 C-8 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models ....... 4 - 34 C-9 Replace the Gasoline Fuel Filter - Gasoline/LPG Models ............................. 4 - 34 C-10 Replace the PCV Valve - Gasoline/LPG Models .......................................... 4 - 36 C-11 Replace the Spark Plugs - Gasoline/LPG Models ........................................ 4 - 37 C-12 Check and Adjust the Air/LPG Mixture - Gasoline/LPG Models ................... 4 - 37 C-13 Check and Adjust the Ignition Timing - Gasoline/LPG Models ..................... 4 - 38 C-14 Check the Engine Valve Clearances - Deutz Diesel Models ........................ 4 - 38 C-15 Check the Turntable Rotation Gear Backlash ............................................... 4 - 38 D-1 Test or Replace the Hydraulic Oil ................................................................. 4 - 39 D-2 Change or Recondition the Engine Coolant - Gasoline/LPG Models ............ 4 - 39 D-3 Change the Fuel Lines .................................................................................. 4 - 41 D-4 Check the Engine Valve Clearance - Gasoline/LPG Models ........................ 4 - 42 D-5 Check the Engine Cylinder Compression - Gasoline/LPG Models ............... 4 - 42 D-6 Clean the PCV Hoses and Fittings - Gasoline/LPG Models ......................... 4 - 42 D-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models .......... 4 - 43 D-8 Check the Toothed Belt - Deutz Diesel Models ............................................ 4 - 43 D-9 Replace the Timing Belt - Gasoline/LPG Models .......................................... 4 - 43 D-10 Grease the Steer Axle Wheel Bearings - 2WD Models ................................ 4 - 44

Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition TABLE OF CONTENTS viii Section Five Troubleshooting Flow Charts Introduction ............................................................................................................... 5 - 1 1 Engine Will Not Crank Over ............................................................................ 5 - 3 2 Engine Cranks Over But Will Not Start - Gasoline/LPG Models ..................... 5 - 5 2A Engine Cranks Over But Will Not Start OR Engine Runs While Cranking The Dies- Gasoline/LPG Models ........................................... 5 - 8 2B Engine Runs While Cranking Then Dies ....................................................... 5 - 11 3 Engine Cranks Over But Will Not Start - Deutz Diesel Models ..................... 5 - 12 4 Engine Will Not Start On LPG, But Will Start On Gasoline - Gasoline/LPG Models ................................................................................. 5 - 15 5 Engine Will Not Start On Gasoline, But Will Start On LPG - Gasoline/LPG Models ................................................................................. 5 - 17 6 Engine High Idle Inoperative - Gasoline/LPG Models ................................... 5 - 19 7 Engine Low Idle Inoperative - Gasoline/LPG Models .................................... 5 - 22 8 Engine High Idle Inoperative - Deutz Diesel Models ..................................... 5 - 23 9 Engine Low Idle Inoperative - Deutz Diesel Models ...................................... 5 - 25 10 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 26 11 All Lift and Steer Functions Inoperative, Drive Functions Operational .......... 5 - 27 12 Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 28 13 Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 29 14 Boom Up Function Inoperative ..................................................................... 5 - 30 15 Boom Down Function Inoperative ................................................................. 5 - 33 16 Boom Extend Function Inoperative ............................................................... 5 - 36 17 Boom Retract Function Inoperative .............................................................. 5 - 39 18 Turntable Rotate Left Function Inoperative ................................................... 5 - 42 19 Turntable Rotate Right Function Inoperative ................................................ 5 - 46 20 All Platform Leveling Functions Inoperative .................................................. 5 - 50 21 Platform Level Up Function Inoperative ........................................................ 5 - 51 22 Platform Level Down Function Inoperative ................................................... 5 - 53 23 Platform Rotate Left Function Inoperative .................................................... 5 - 55 24 Platform Rotate Right Function Inoperative .................................................. 5 - 58 25 Jib Boom Up Inoperative, S-65 Models ........................................................ 5 - 61 26 Jib Boom Down Inoperative, S-65 Models .................................................... 5 - 63

Part No. 48412 Genie S-60 & Genie S-65 Service Manual - Second Edition TABLE OF CONTENTS ix Section Five Troubleshooting Flow Charts, continued 27 Oscillate Function Inoperative ....................................................................... 5 - 65 28 Steer Left Function Inoperative ...................................................................... 5 - 66 29 Steer Right Function Inoperative ................................................................... 5 - 68 30 All Drive Functions Inoperative, All Other Functions Operate Normally .......... 5 - 70 31 Drive Forward Or Reverse Function Inoperative ............................................. 5 - 73 32 Traction Function Inoperative ........................................................................ 5 - 74 33 Machine Will Not Drive At Full Speed ............................................................ 5 - 75 34 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 76 35 Drive Enable System Is Malfunctioning ......................................................... 5 - 77 36 Auxiliary Functions Inoperative ...................................................................... 5 - 78 Section Six Schematics Introduction ............................................................................................................... 6 - 1 Electrical Components .............................................................................................. 6 - 2 Electrical Symbols Legend ........................................................................................ 6 - 4 Abbreviation Legend .................................................................................................. 6 - 5 Electrical Schematic - Gasoline/LPG Models (Rev B) ............................................... 6 - 7 Ground Control Box Legend - Gasoline/LPG Models ................................................. 6 - 9 Ground Control Box Wiring Diagram - Gasoline/LPG Models ................................... 6 - 10 Platform Control Box Legend - Gasoline/LPG Models ............................................. 6 - 11 Platform Control Box Wiring Diagram - Gasoline/LPG Models ................................. 6 - 12 Electrical Schematic - Deutz Diesel Models ............................................................ 6 - 13 Ground Control Box Legend - Deutz Diesel Models ................................................. 6 - 15 Ground Control Box Wiring Diagram - Deutz Diesel Models ..................................... 6 - 16 Platform Control Box Legend - Deutz Diesel Models ............................................... 6 - 17 Platform Control Box Wiring Diagram - Deutz Diesel Models ................................... 6 - 18 Hydraulic Symbols Legend ...................................................................................... 6 - 20 2WD Hydraulic Schematic - Non-oscillating axle ..................................................... 6 - 21 2WD Hydraulic Schematic - Oscillating axle ........................................................... 6 - 22 4WD Hydraulic Schematic - Non-oscillating axle ..................................................... 6 - 23 4WD Hydraulic Schematic - Oscillating axle ........................................................... 6 - 24

Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition TABLE OF CONTENTS x Section Seven Repair Procedures Introduction ............................................................................................................... 7 - 1 Platform Controls 1-1 Joystick Controllers ......................................................................................... 7 - 2 1-2 Horsepower Limiter Board .............................................................................. 7 - 6 1-3 Foot Switch ..................................................................................................... 7 - 8 1-4 Resistors ......................................................................................................... 7 - 9 1-5 Toggle Switches ............................................................................................. 7 - 9 1-6 Control Relays .............................................................................................. 7 - 10 Platform Components 2-1 Platform ........................................................................................................ 7 - 11 2-2 Platform Leveling Slave Cylinder .................................................................. 7 - 11 2-3 Platform Rotator ........................................................................................... 7 - 12 Jib Boom Components, S-65 Models 3-1 Jib Boom, S-65 Models ................................................................................. 7 - 15 3-2 Jib Boom Lift Cylinder, S-65 Models ............................................................. 7 - 16 3-3 Jib Boom / Platform Rotate Manifold Components, S-65 Models ................. 7 - 17 Boom Components 4-1 Boom Cable Track ........................................................................................ 7 - 18 4-2 Boom ............................................................................................................ 7 - 20 4-3 Boom Lift Cylinder ........................................................................................ 7 - 23 4-4 Extension Cylinders ...................................................................................... 7 - 24 4-5 Platform Leveling Master Cylinder ................................................................ 7 - 25 Turntable Covers 5-1 Turntable Covers .......................................................................................... 7 - 26 Deutz Engine F4L 1011F 6-1 RPM Adjustment ........................................................................................... 7 - 27 6-2 Flex Plate ...................................................................................................... 7 - 27 6-3 Oil Temperature and Oil Pressure Gauges ................................................... 7 - 27 Ford LRG-423 Engine 7-1 Governor Actuator ........................................................................................ 7 - 28 7-2 Choke Adjustments ....................................................................................... 7 - 29

Genie S60/S65 Telescopic Boom Lift Service & Repair Manual

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