Home

Service Manual - Genie Industries

Contents

1. M L K J H G F E D PLATFORM TURNTABLE JIB BOOM PLATFORM ROTATE VEL x1 ROTATE 1 UP DOWN SLAVE BOOM EXTEND RETRACT Lx eL cora rm PRIMARY m 2 SECONDARY bes oue The TWO SPEED 71 LO M T PN T Ti BRAKE MANIFOLD 83 4 1 T BRAKE 2 SPEED a eR 2 T MASTER 025 L 0 635 mm a ee 17 bar i ly er DE a ee do optionaL A LL b E 21 MANIFOL
2. RED 7 46 27A Ae 21B LIMIT SWITCH POWER 1 GRN WHT EH GRN WHT 1 45 GENERATOR OPTION 44 DUMP VALVES GHN CR5486 GRN t 43 HORN BLK 7 ORG RED 1 42 TURNTABLE ROTATION HIGH oan ORG BLK EH ORG BLK 1 41 ORG BLK 2ISM PULSE PICKUP WHT 6 ORG 1 40 WHT 7 LIMIT SWITCH WHT RED 26 CABLE BLURED 1 39 BLU RED S P LPG BRN GROUND d PNK LGRN FEH BLU WHT 1 38 BLUMHT S P CHECK ENGINE ksi BLU BLK EH BLU BLK 1 37 BLU BLK D B STEER LEFT STACKED CONTAGTS WHT 21A BLU E H BLU 1 36 BLU D B STEER RIGHT GE OPTION ONLY WHT BLK 25A YEULBLU FEH BLK RED 1 35 BLK RED S P RPM REA BLK WHT 1 34 GLOW PLUG CABLE BLK 3 ISM BLK 1 33
3. M L K J H G F E D B A PLATFORM TURNTABLE JIB BOOM PLATFORM ROTATE LEVEL BOOM 1 UP DOWN SLAVE BOOM EXTEND RETRACT x ee ee 4 PRIMARY SECONDARY CRM oe 1 gm Lt TWO SPEED 1200 ps1 eed BRAKE MANIFOLD 83 bar i 035 i2 BRAKE MZ le 0 089 mm 2 osm fe tL 1 Tt T a 9 0 076 MASTER m mm 030 L Famn 78 ae 5 55 PRI PR2 PL2 51 52 1 P2 17 bar a 1 Sa aoa FUNCTION IBN 1 50 PSI OPTION
4. WHT WHT DIV VIA AIAMM D Mj Olivy DI im D W JII d DIC DI DIE allooi lel lolo la a B S v colam ORG BLK 1 B z2z2252222992225mx ajszzszsisx gt 2 9 Tt 5 55 alo Mmaa aaae 3 gizim E 212125 15 5216165 5 0 2 2220 D D gt 2 lt lt 1 lt 0 0 0 5 95212120 20 2 22 samssal S D gt 2 HORSE 52 5 5 5 lt lt 50945305 9 p POWER 3 a8 2 8 75606 ms 53 ag m sz 8 5 E C1 LABEL DESCRIPTION 2 LIMITER 3 9 3 SPSS 2 20 5 x 3 BP1 BOOM PROPORTIONAL CONTROLLER I m im im m PRIMARY BOOM UP DOWN amp TURNTABLE ROTATE T m o 3 Q OIF m 84 gt GRN WHT PIS s m RED OUTPUT BP2 BOOM PROPORTIONAL CONTROLLER RED x BRN EXTEND RETRACT 2 w e s o o lxloleciaixisaxasuseo 5NNNYNSSNsEPSessesgssausggsikts5sbEkS 5 CABLE 1 FROM GROUND CONTRO
5. HIGH IDLE RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID GENERATOR OPTION GLOW PLUG OPTION VOLT METER HOUR METER OIL PRESURE E GAUGE SENDER OIL PRESSURE SWITCH OIL TEMPREATURE SWITCH OIL TEMPERATURE GAUGE SENDER FUEL SOLENOID STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP FLASHING BEACONS LEVEL SENSOR HORN RELAY HORN HYDRAULIC OIL TEMPERATUE SWITCH COOLING FAN OPTION x Q a zr 8 8 a HIGH RPM ENGINE SPEED a s iT BLK RED 1 p le 1 1 D PF FUNCTION ENABLE g q HIGH RPM BLK RED 8 5 p 818 pe i 29 gl BLKRED CR4 EH F OFF GENERATOR a GRN WHT 1 GRN WHT 4 E H S e I e 1 1 e Qa BLK WHT 1 a e GLOW PLUG N I N aLow 5 xs 22 72 9 q PLUG hE BLK WHT 34 E H ele 00000 b N m qv WHT BLK WHT BLK 25 E H E T 5 4 28 3 a 9 t Qe BLK 1 als B WHT 24 E H 8 i SEES gs e s T 28 FS ence ST
6. E M L K J H G F E D PLATFORM TURNTABLE JIB BOOM PLATFORM ROTATE LENE ROTATE BOON 1 UP DOWN SLAVE BOOM EXTEND RETRACT PRIMARY de SECONDARY et ee Pe 6 es A EE OE 0 4 1 Ja Ch EE am i bd Ow 120051 BRAKE MANIFOLD ga Por ne 83 bar Ka LER HL d erae see I EN LAM 030 AEE L 0 635 mm 0 076 ACCUM LL 250 PSI oe ne 31 emm of _ 27 EE I NES ___ FUNCTION PLA 380081 f il L ls 9 _ MANIFOLD ES oben GENERATOR 5 rectas MEDIUM 2100 PSI i 2500 PSI 3 PRESSURE L 73 145 bar 1 1e TF 172 bar 12 L S JIB BOOM sr e 4 EE i baccis su MANIFOLD port 60 i ru 9r j r MAVA AA ERE Aye e SETA a ITO l 1 eae 1 oman fe 1 t 9500 PSI ca con PRESSURE S Limb EFC NE Ei 1 5GPM 11 59 1719 Ost han 4 Ex 6 7 Lmin
7. THROTTLE ACTUATOR POSITION SENSOR POWER FUEL PUMP STARTER 1 CR FA CR FB CR FC FUEL INJECTOR VALVES 6 68 86 Gl M M M 4 3 2 1 5 8 5 8 m 3 nal uL dm gi TN B WATER TEMP r9 d DA J stale 828 8 s E i 5 2 E 8 9 4 2 548 g Sg 5 85 28 9 98 ae 299 58 5286 9585 FORD ENGINE CONTROL MODULE ECM 55 18 i8 8 333 BS 3324 8807 MATING race SN NES 2 an on RoR SHOWN LU 95TW18 X IGNITION COIL 1 qucm F1 NOTUSED ae NOTES 361LR18 lt 5 37BY18 F2 KEEP ALIVE PWR 1 1 ON MACHINES MANUFACTURED BEFORE m M NOTUSED ue FEBRUARY 1 2000 THE WIRE COLOR ganara Gi CRANKSHAFT SENSOR RETURN IE 3 350GY18 I PIN ZIFUEL DS BROWNWHITE 282DB 018 J1 CAMSHAFT SENSOR FEED p d 355GY W18 THROTTLE POSITION SENSOR INPUT 238ADG Y18 FUEL PUMP MONITOR i ss BEONE EN n E Y2 FORD 42 PIN QUICK DISCONNECT wa NOT USED d 555718 S3 FUEL INJECTOR 1 ENGINE HARNESS 2 556W18 S2 FUEL INJECTOR 2 EI ESINE SEE ELECT
8. M L K J H G F E D C B A JIB BOOM PLATFORM TURNTABLE 1 PEATEOBMROTATE LEVEL UP DOWN BOOM EXTEND RETRACT eee 582 PRIMARY uem Es SECONDARY l wogeo 12257 1 t 59 H5 ft TWO SPEED pa zoo est 2 BRAKE MANIFOLD xoi 83 bar EY y BRAKE 2SPEED mm 2 i us T S S2 omm 111 1n MASTER ec te pep i zm ii 1 0 635 0076 1 250 PSI CMS E et r ome mg fe a 207 7 ees TREES SS iei enel e amp FUNCTION 1 aean 50 PSI OPTIONAL 4 J MANIFOLD 200 PSI 0 695 mm GENERATOR fof i i 3 m 4 6 2100 PSI d aussi PRESSURE i 145 bar E i 172 bar n De FILTER JIB BOOM TEST H Ey __ MANIFOLD PORT L eL r AA e Ae a SEIS I 7 p 1 t eee edu poseen pe A aaa 1 E 1 PRESSURE 3 min ECC NS E 1 1 56 ait TIS insam 9 i 4 4 6 7 Limin _ 105 7 L min 7 6 7 Limin T T i FUNCTION PUMP OPTIONAL 0 6GPM 0 6GPM OQ o0
9. CHART 4 Crank engine for 15 no Repair open in dk grn from the seconds and check for continuity wire from ECM to previous pages continuity to ground at gt terminal 86 on OR terminal 86 replace ECM Crank engine for 15 no seconds and check for continuity continuity to ground at Replace LPG relay terminal 30 on CR3 infinite Check resistance of ohms LPG solenoid eee gt Replace LPG solenoid 9 to 10 ohms Reconnect LPG tank and starter then see Maintenance section for LPG adjustments OR consult Genie Industries Service Department Part No 65196 Genie S 60 amp Genie S 65 5 17 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 5 Engine Will Not Start On Gasoline But Will Start On LPG Gasoline LPG Models Be sure fuel select switch is switched to gasoline Be sure to check gasoline fuel level See Repair Section How to Retrieve Fault Codes 1 there a fault code stored in the ECM memory yes Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Refer to the fault code chart in this section for a de
10. RED 7 46 27 218 LIMIT SWITCH POWER GRN WHT 4 E H GRN WHT 1 45 GENERATOR OPTION 44 DUMP VALVES GRN CR5486 GRN 1 43 HORN BLK 7 ORG RED 1 42 TURNTABLE ROTATE HIGH ORG BLK E H ORG BLK 1 41 ORG BLK 2ISM PULSE PICKUP WHT 6 ORG 1 40 WHT 7 LIMIT SWITCH CABLE BLU RED 1 39 BLU RED S P LPG NE BLU WHT BLU WHT 1 38 BLU WHT S P GASOLINE BLU BLK E H BLU BLK 1 37 BLU BLK D B STEER LEFT BLU EH BLU 1 36 BLU D B STEER RIGHT BLK RED 1 35 BLK REDCR3 BLK RED S P RPM N BLK WHT E H BLK WHT 1 34 BLK WHT S P GLOW PLUG CABLE BLK 3 ISM BLK 1 38 BLK S P START 46 WHT RED E H WHT RED 1 32 WHT RED D B BRAKE WHT BLK E H WHT BLK 1 31 E D C RED 5 WHT 1 30 E D C RED WHT E H R W 1 29 RED WHT D B 2WD 4WD RED BLK E H RED BLK 1 28 TILT ALARM RED EH RED 1 27 RED 4 ISM gt _ RED S P AUXILIARY POWER CABLE WHTRED EH 26 WHT RED S P WATER TEMPERATURE SENDER NUS WHT BLK E H 25 WHT BLK S P OIL PRESSURE SENDER WHT 10 ISM WHT E H 24 WARNING SENDER RED WHT E H WHT 2 23 WHT 7 ISM WHTSP 4 KEYSWITCH POWER BLK CR5 30 BLK 2 22 BLK S P POWER TO PLATFORM WHT CR2 87 WHT E H 21 WHT 46A WHT S P IGNITION POWER RED E H RED R17 30 20 RED S P 12V BATTERY SUPPLY GRNMWHT 3 19 GRN WHT S P JIB VALVE GRN BLK 4 GRN BLK 3 18 GRN BLKD B GRN BLK S P PLATFORM ROTATE RIGHT GRN 4 GRN 3 17 GRN DB GRN S P PLATFORM ROTATE LEFT i CABLE 6 OR
11. 4 R1 100 OHMS FOR 4WD R1 150 OHMS FOR 2WD Part No 65196 Genie S 60 amp Genie S 65 6 8 Section 6 Schematics Electrical Schematic Gasoline LPG Models e N Third Edition First Printing ORG BLK 1 BRN 2 E GROUND e 5 E E BLU RED 3 Fi WHT5 Ne S 4 DRIVE ENABLE a m WHT 1 RED 5 LIMIT SWITCH EC S 2 5 x e N 2 amp 1 DRIVE ENABLE E A BLU WHT 3 E 5 B
12. RED 7 46 amp 27 21B L IMIT SWITCH POWER GRNWHT 4 E H GRN WHT 1 45 GENERATOR OPTION 44 DUMP VALVES GRN CR5 86 GRN 1 43 HORN BLK 7 ORG RED 1 42 TURNTABLE ROTATE HIGH ORG BLK E H ORG BLK 1 41 ORG BLK amp 2ISM PULSE PICKUP WHT 6 ORG 1 40 WHT 7 LIMIT SWITCH CABLE BLU RED 1 39 BLU RED S P LPG 7 BLU WHT BLU WHT 1 38 BLU WHT S P GASOLINE BLU BLK E H BLU BLK 1 37 BLU BLK D B STEER LEFT BLU E H BLU 1 36 BLU D B STEER RIGHT BLK RED 1 35 BLK RED CR3 BLK RED S P RPM ud BLKWHT E H BLKWHT 1 34 BLK WHT S P GLOW PLUG BLK 3 ISM BLK 1 33 BLK S P START CABLE wireo n WHT RED 1 32 WHT RED D B BRAKE Ke WHT BLK E H WHT BLK 1 31 E D C RED 5 WHT 1 30 E D C RED WHT E H RW 1 29 RED WHT D B 2WD AWD RED BLK E H RED BLK 1 28 TILT ALARM RED E H RED 1 27 RED 4 ISM RED S P AUXILIARY POWER CABLE WHT RED E H 26 WHT RED S P WATER TEMPERATURE SENDER 5 WHT BLK E H 25 WHT BLK S P OIL PRESSURE SENDER WHT 10 ISM WHT EH 24 WARNING SENDER RED WHT E H WHT 2 23 WHT 7 ISM WHT S P 3 KEYSWITCH POWER BLK CR5 30 BLK 2 22 BLK S P POWER TO PLATFORM WHT CR2 87 WHT E H 21 WHT 46A WHT S P IGNITION POWER RED R17 30 20 RED S P 12V BATTERY SUPPLY GRNWHT 3 19 GRN WHT S P JIB VALVE GRN BLK 4 GRN BLK 3 18 GRN BLK D B GRN BLK S P PLATFORM ROTATE RIGHT GRN 4 GRN 3 17 GRN D B GRN S P PLATFORM ROTATE LEFT BLK 6 ORG RED 3 16 ORG RED D B _ ORG RED S P PLAT
13. Third Edition First Printing ORG BLK 1 ORG RED 1 N Lo lt N BRN 2 t GROUND 2 ET 2 aS BLU RED 3 B WHT 29 g g ote BRNS DRIVE ENABLE WHT 1 REDS BLK 5 LIMIT SWITCH m 3 5 z B 2 E 1 DRIVE ENABLE BLUMHT 3 E 5 Yo E WHT BLK 1 ES WHT BLK 31 E H at OI H 85 amp 1 WHT RED 1 WHT RED 32 E H t Ye BRAKE XT TRAVEL ALARM 5 5 9 4 OPTION E BLU BLK 1 BLU BLK 37 E H z P Ye STEER RIGHT BLU 1 BLU 36 E H steer LEFT y LPITLLL m 1 1 9 v Le NEE x No ME ORG 1 Tel WHT 6 BRN 6 BOOM UP ea c as LIMIT SWITCH WHT 7 BRN 7 BOOM EXTEND 16 4 E 5
14. WHT EMERARA i zz ORG BK 1 255555 25 9 5 2541532192 omma aaa ae omimmimmi mas mm 2 lt 9 2 2mJr i o6o009o0mm9g9ooorz ZaD D 2 j v mir gt XXX5oo is9ozzzzoom 8 S mrs 5 gt C g mE 0 5 gt ems E o LABEL DESCRIPTION HORSE 5605 MelS 5 0 55 2 510 9152 nI rao 3 I ORG 1 POWER E mmm 3 98mhmmmimol Z 3 t 2 rr a 5 x C1 BP1 BOOM PROPORTIONAL CONTROLLER 2 2 LIMITER 2 9 9 9 8 E m m m aga zi m 3 PRIMARY BOOM UP DOWN amp TURNTABLE ROTATE A 1 9 gm 9 ae gt E GRN WHT BP2 BOOM PROPORTIONAL CONTROLLER rmm o e om 2 2 I iz 4 RED OUTPUT EXTEND RETRACT WHT se 2 4 z BRN CABLE 1 FROM GROUND CONTROL BOX TERMINALS 27 45 9 CABLE 2 FROM GROUND CONTROL BOX TERMINALS 22 23 L 11 w www S S 3S IS 1 8S 4S 51 Kal Koad N Kad Kod bmd LAA Kod ba krad DN bid bd kad bm LNA kod baa Kal 5456 AIG CABLE 3 FROM GROUND CONTROL BOX TERMINALS 1 19 BRN TO GROUND STUD GROUND I xuijzzz muujmmuoioi oooo z 5 zxzrmuuwm I z zz uuum O o o o e DECAY CAPACITOR mmm RR lelece RRR mrrrkxkxExcccc 221212 CR13 J
15. 7 74 AWD Steering Axle Components 15 1 Yoke and ce ator esc Eo eee pae eco RR 7 75 15 2 Steering Cylinders See 14 2 Steering Cylinders 7 76 15 3 Tie Rod See 14 3 Tie 292 7 76 Oscillating Axle Components 16 1 Oscillating Axle Lock out Cylinders 0 222 7 77 Non steering Axle Components 17 1 Brive n t o e tendens 7 78 17 2 Drive Hub ww rete ence eae 7 79 17 3 Wheel Brake etc E Pete te tee eee idee 7 80 65196 Genie 5 60 amp Genie 5 65 XV Third Edition First Printing SS This page intentionally left blank Xvi Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 2 Specifications Specifications Machine Specifications Platform dimensions 6 ft 8 ft All Models Standard Optional Length 6 ft 8 ft Stowed dimensions S 60 S 65 1 83 2 44 Length 27 ft 2in 30ft10in Width 30 in 36 in 8 3m 9 4m 76 2 cm 91 4 cm Width 8ft 8 ft Tires and wheels 2 43 m 2 43m Tire size 15 19 5 NHS Height 9 ft 9 ft Tire ply rating 12 2 74m 2 74 Tire contact area 71 sq Weight 26 060 Ibs 28 400 Ibs 458 sq c
16. 1 MANIFOLDS 11 8 Steer Manifold Components Non oscillating Models The steer manifold is located underneath the function manifold Index Schematic No Description Item Function 1 DOS valve 3 position 4 way RR Steer 30 35 in Ibs 3 4 Nm 7 56 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing 11 9 Section 7 Repair Procedures 2WD Drive Manifold Components The drive manifold is mounted inside the drive chassis at the non steer end Index No Description 1 Relief valve 250 psi 17 2 bar 2 Flow divider combiner valve 3 Orifice 0 070 inch 1 78 mm 4 Shuttle valve 3 position 3 way 5 Diagnostic fitting MANIFOLDS Schematic Item Function Torque WW Charge pressure 10 12 ft lbs 14 16 Nm inns XX Controls flow to drive motors in forward and reverse 25 30 ft lbs 34 41 Nm YY Drive circuit m ZZ Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift Testing 15 18 ft lbs 20 24 Nm Plug Torque Specifications Description Hex size Torque SAE No 4 3 16
17. Ly y ES NN gt Part No 65196 Genie S 60 amp Genie S 65 7 47 Section 7 Repair Procedures Third Edition First Printing MANIFOLDS 11 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 345 bar pressure gauge to the diagnostic nipple item 24 on the function manifold 2 Start the engine from the ground controls 3 Hold the function enable switch to either side and activate and hold the retract switch with the boom fully retracted Observe the pressure reading on the pressure gauge System relief valve specifications Pressure S 60 models 2600 psi 179 3 bar S 65 models 2900 psi 200 bar 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 23 on the function manifold 5 Adjust the internal hex socket Turn it clockwise to increase pressure or counterclockwise to decrease pressure Install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 6 Repeat steps 2 through 5 to confirm relief valve pressure How to Adjust the Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect 0 to 5000 psi 0 to 345 bar pressure gauge to the diagnostic nipple item 24 on the function manif
18. WHT WHT 8888 8 247 4844465 85968 5 P ORG BK 1 g EE22J2Hum99ssa5smanAhs SSSR 212 5 lt o 5 5 51421902 ISP YP mme 242 g 2 2 2 5 212 665 00 0 2020 gt 2 2 gt 5 gt 22 42594259 omnim B LABEL DESCRIPTION HORSE 5 MESS Ble 22 52 9194 RJ 9 ORG 1 gt POWER 3 98mim immoJo mrss 9 9 A a 5 d C1 BP1 BOOM PROPORTIONAL CONTROLLER 2 LIMITER zu 8 3 E mmm gt gt aer m 3 PRIMARY BOOM UP DOWN amp TURNTABLE ROTATE z nimm 2 ssamm 9 gt n 9 GRN WHT BP2 BOOM PROPORTIONAL CONTROLLER E ms Zg T M RED OUTPUT EXTEND RETRACT WHT S 2 4X 9 BRN CABLE 1 FROM GROUND CONTROL BOX TERMINALS 27 45 T Lo 11 2 1 re eias Ris Ri 2 FROM GROUND CONTROL BOX TERMINALS 22 23 eee meses lc PF al e ed lic me Eadie Pld ca cl al CABLE 3 FROM GROUND CONTROL BOX TERMINALS 1 19 BRN TO GROUND STUD GROUND d d S gt ID x z z U Uu uuum O oo o e DELAY CARACITOR STUD mimm SPSS aaa rkzzmkm 22252 CR13 JIB LOCKOUT RELAY amp eggSasssS s
19. sessssseeeeeeeeneeeenneenn nen 7 51 11 5 Valve Adjustments Oscillate 2 7 52 11 6 Directional Valve Manifold 7 53 11 7 Steer Manifold Components Oscillating 7 55 11 8 Steer Manifold Components Non oscillating Models 7 56 11 9 2WD Drive Manifold Components 7 57 11 10 Valve Adjustments 2WD Drive 7 58 11 11 4WD Drive Manifold Components 7 60 11 12 Valve Adjustments 4WD Drive 7 62 11 13 Jib Boom Platform Rotate Manifold Components 5 65 Models 7 63 Fuel and Hydraulic Tanks 1271 nei OI dime va dapi 7 64 12 2 Hydraulic Tank lr Lee ehe te Dx e Ede 7 65 Turntable Rotation Components 13 1 Rotation Hydraulic Motor 7 68 Genie 5 60 amp Genie 5 65 Part No 65196 Third Edition First Printing EEE Section Seven TABLE OF CONTENTS Repair Procedures continued 2WD Steering Axle Components 1451 Yoke and Hub betters tee eter ected eae i e e 7 71 14 2 Steering 7 73 14 3 gt
20. 222222 4 10 A 9 Check the Tire Pressure 01222 110000000 nennen nnne nennen nnne 4 10 A 10 Test the Oscillate Axle if equipped 4 11 A 11 Test the Platform and Ground Controls ssssseeeeeeenes 4 12 A 12 Test the Auxiliary Power Operation 22 00 4 13 A 13 Test the Tilt 4 14 A 14 Test the Limit Switches 2442224 1 000 4 14 A 15 Drain the Fuel Filter Water Separator Diesel Models 4 17 A 16 Inspect the Engine Air 4 19 A 17 Perform 30 Day Service 0 0 042244000 4 00 4 20 A 18 Inspect the Radiator Liquid Cooled 4 20 A 19 Check the Battery 4 21 A 20 Replace the Engine Oil and Filter Gasoline LPG Models 4 22 A 21 Inspect the Electrical 0 4 24 A 22 Check the Oil Cooler and Cooling Fins Deutz Diesel Models 4 25 A 23 Check the Engine Belt Gasoline LPG and Perkins Diesel Models 4 26 A 24 Replace the Fuel Filters Gasoline LPG 4 28 vi Genie 5 60 amp Genie S 65 Part No 65196 Third Edition First Printing Eee
21. 30 35 in Ibs 3 4 Nm 3 DOS valve 3 position 4 way Boom 30 35 in Ibs 3 4 Nm 4 Check valve pilot operated D asus Boom extend retract circuit 11 13 ft lbs 15 18 Nm 5 Relief valve 2500 psi 172 bar E Boom extend 25 30 ft lbs 34 41 Nm 6 Relief valve 2100 psi 145 bar Boom down 25 30 ft lbs 34 41 Nm 7 Flow regulator valve 1 5 5 7 L min extend retract circuit prevents overflowing the proportional valve 10 12 ft lbs 14 16 Nm 8 Flow regulator valve 1 5 5 7 L min Boom up down circuit prevents overflowing the proportional valve 10 12 ft lbs 14 16 Nm 9 Flow regulator valve 1 5 5 7 L min tms Turntable rotate left right prevents overflowing the proportional valve 10 12 ft Ibs 14 16 Nm 10 Flow regulator valve 0 1 0 38 L min Bleeds off differential sensing valves to tank 10 12 ft Ibs 14 16 Nm 11 Check sait Differential sensing circuit boom extend retract 11 13 ft Ibs 15
22. 7 E o OPTIONAL J pa i Td E FUNCTION PUMP Coo 0 0 6GPM o0 o 9 KH 14 GPM 53 L min GENERATOR DIG t pi PRESSURE L I MANIFOLD __ Jl S 60 Models 2600 PSI 2 7 t 4 DRIVE PUMP eye 565 Models 2800 PSI TM TIEN le EN 0 TO 30 GPM 114 7 L min lot em aS Ti 1 JH 04 Lmin i TANK ___ ___ d 2500 PSI due o Peg m eu OPTIONAL FAS Fm a i 172 bar SEC REG OIL COOLER E CE to T RESERVOIR AUXILIARY PUMP 3 5 mi IL DO HYDRAULIC COUPLER _STEER MANIFOLD 6 MANIFOLD 1 i 17 1 7 ME REAR NETZ Dlr Tk e n RIGHT E 7 5 l l 6 STEERING 0 070 DC CYLINDER REAR EN LEFT i i CASE DRAIN o Part No 65196 Genie S 60 amp Genie S 65 6 22 Third Edition First Printing Section 6 Schematics 2WD Hydraulic Schematic Oscillating Axle
23. Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform service repair problem solved Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Fault Code Chart 1 Throttle Faulty TP sensor OR Position TP sensor wires shorted to sensor low ground OR poor voltage terminal connection Check for poor terminal connections OR shorted wires from the TP sencor to the ECM OR replace the TP sensor Manifold Absolute Faulty MAP sensor OR nsor wir horted t Pressure jo en eco wires shorted to ground OR replace MAP MAP sensor low voltage m Engine speed T Check for obstructions in the throttle body E exceeded Obstruction In that could cause binding of the throttle 11 12 14 21 22 4 Check for poor terminal connections OR ground OR poor i sensor terminal connection 4000 RPM body OR faulty ECM assembly OR replace ECM The ECM senses a signal from the TP sensor that is greater than 4 9V DC OR the Check for poor terminal connections OR TP sensor wiring is shorted wires from the TP sensor to the shorted to ground OR ECM OR replace the TP sensor there is a poor terminal connection OR the TP sensor is faulty Throttle Position TP sensor high voltage Manifold Absolute Sensoren Check for p
24. dive pump saine replace the Function engine move the drive controller to full forward Inope rative position and note the Be sure all other functions operate normally including drive in opposite direction of manfunction voltage across the wht 12 and the wht blk 31 wire terminals on the EDC Reverse the volt meter leads and move the drive controller to full reverse position and note the voltage voltage readings the same 0 or infinite Check the resistance of ohms Replace the EDC the EDC 20 to 24 ohms no improve Adjust the drive pump ment TA S null neutral repair facility symptoms improve Re adjust horsepower limiter board OR consult Genie Industries Service Department Part No 65196 Genie S 60 amp Genie S 65 5 67 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 32 Tracti on type of roel roblem consult Genie Function Service Inoperative Department Be sure that all other functions operate normally 5 68 Genie 5 60 amp Genie 5 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Machine Will Not Drive At Full Speed Be sure all other functions operate normally Be sure the machine is not raised above or extended beyond the drive limit switche
25. Re adjust controller see Repair Section OR replace controller OR consult Genie Industries Service Department Repair open in power supply circuit from TP24 to boom controller OR repair open in brn ground wire circuit from boom controller to ground 5 28 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts EEE CHART 14 With key switch turned Hold the function enable Repair open in red 4 n gt gt to ground controls and switch to either side and 12V or wire circuit from to p pags both Emergency Stop OV move the boom up down more boom up down buttons pulled out to the P toggle switch in the gt directional valve coil OR ON position hold the direction Check voltage repair open in brn function enable switch to at TB1 ground wire circuit to either side and move the valve coil boom up down toggle switch 7516 in the UP oV direction Check voltage on red 4 wire on boom up down directional With key switch turned Troubleshoot boom up valve coil item B to platform controls and 12V or down toggle switch OR both Emergency Stop more repair open in red wire buttons pulled out to the circuit from TS16 to TB1 ON position press down OR consult Genie the foot switch and Industries Service move t
26. Disconnect wires on turntable rotate right infinite directional valve coil ohms item A and test the resistance of the valve coil See Repair Section 2 5 to 3 5 ohms function Hold function enable switch to either side and BULLY move the turntable rotate toggle switch in the RIGHT direction Manually override the directional valve by pushing in on the end of the valve spool Replace faulty directional valve function inoperative Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the boom function manifold and start the engine Hold the function enable switch to either side and move the turntable rotate toggle switch in the RIGHT direction and check the pressure SEE NOTE 1 gt Exchange flow regulator valve item 1 with boom up down flow regulator valve item H Check turntable rotate right function function inoperative SEE NOTE 2 v Continued on the next page Repair turntable rotation motor OR function manifold may have an internal fault Consult Genie Industries Service Department Third Edition First Printing function operates p 5 Replace faulty flow regulator valve NOTE 1 5 60 2600 PSI or more 5 65 2900 PSI or more NOTE 2 5 60 Less than 2600 PSI S 65 Less than 2900 PSI 5 44 Genie S 60 amp Genie S 65
27. Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures 6 Remove the dust cap from the hub and remove the cotter pin from the castle nut Always replace the cotter pin with new one when removing the castle nut or when checking the torque of the castle nut 7 Tighten the castle nut to 35 ft lbs 47 Nm to seat the bearings 8 Loosen the castle nut then re tighten to 8 ft lbs 11 Nm 9 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result If there is side to side or up and down movement proceed to step 10 to replace the wheel bearings with new ones When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced Result If there is no side to side or up and down movement grease the wheel bearings 10 Remove the castle nut Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut 11 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 12 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the inner bearing 13 Pack both bearings with clean fresh grease TABLE E PROCEDURES 14 Place the large inner bearing into the rear of the hub 15 Install a new bearing grease seal into the hub
28. switch o Check voltage at the blk red wire on the 2 speed solenoid 12V solenoid Check if 2 speed solenoid moves in and out freely moves freely Check adjustment of linkage and fuel injection system low idle See Maintenance section See Deutz OR Perkins workshop manual to troubleshoot fuel injection system OR consult Genie Industries Service Department Isolate the platform and ground RPM select toggle switches TS4 and 512 check individually and replace faulty toggle switch Replace CR4 relay binds m Check linkage or replace solenoid Chart 9 Part No 65196 Genie S 60 amp Genie S 65 5 23 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 10 All Functions inoperative Engine Starts and Runs Check hydraulic fluid level low ok Fill with Dexron equivalent hydraulic fluid Check pump suction line shutoff valves In the open position the valve handles should be parallel with hose closed p Do the pumps feel excessively hot yes open Open valves and start the engine Check all machine functions for correct operation Remove function pump from main pump but leave all hoses connected Disconnect ignition coil connector plug from ignition coils
29. Oil capacity including filter 9 6 quarts 9 liters Cil viscosity requirements below 60 F 15 5 C 15W 40 10 F to 90 F 23 C to 32 C 10W 30 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CF4 grade Units ship with 10 40 CC SG Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE A PROCEDURES A 5 Check the Engine Coolant Level Liquid Cooled Models Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems Burn hazard Beware of hot ACAUTION engine parts and coolant Contact with hot engine parts and or coolant may cause severe burns 1 Check the fluid level in the coolant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark Do not remove the radiator cap A 6 Check for Fuel Leaks Failure to detect and correct fuel leaks will result in an unsafe condition An explosion or fuel fire may cause death or serious injury Explosion and fire hazard Engine ADANGER fam fuels are combustible Inspect the machine in an open well ventilated area away from heaters sparks flames and lighted tobac
30. RED WHT 3 Fr ORG 3 PLATFORM LEVEL n LDOWN ORG BLK 3 ORG 2 D F 1 Eg ORG 4 i a e Te Leje PLAT LEVEL UP lup ORG BLK 8 8 PLATFORM LEVEL LDOWN 4 ORG BEK K ih 2 25 PLAT LEVEL DN 1 1 1 omgaD 8180101 TET T 818 a red N g E ORG RED 3 oz lo ly i BLK6 7 818 PLATFORM LEVEL e H n M z d 5 DISABLE m x vg mrs CE OPTION S a c GRN 3 ez 9 m 2 pee JIB BOOM M 8 A GRN BLK 3 5 GRN 190 4 poke 2 e GRN 4 PLATFORM ROTATE 4 4 P rus GRNIBUR LEFT JIB UP JIB BOOM 4 DOWN GRN BLK 4 t Le PLATFORM ROTATE RIGHT JIB DOWN PLATFORM ROTATE PLATFORM ROTATE LEFT x LEFT e GRNWHT GRN WHT 3 i o m RED 4 gl Pe 8 JIB VALVES J gt HE REDBIK 62 N rp 1 i 1 9 LIFT DRIVE i SELECTOR oe eee iE OPTION a T c E a a a z c m 6 9 Genie 5 60 amp Genie 5 65 Part No 65196 Section 6 Schematics Third Edtion First Printing _ _ __ _ Ground Control Box Wiring Diagram Gasoline LPG Models A B H
31. Repair open in blk red wire circuit from CR3 to CR4 Repair open in brn ground wire circuit to terminal 85 on CR4 good Y Check voltage to oV Repair open in wht wire terminal 30 on CR4 gt circuit from CR2 to TB21 to CR3 to CR4 12V Y Check voltage at the Replace CR4 relay blk red wire on the OR repair open in 2 speed solenoid 12V Check continuity from ground to brn wire at 2 speed solenoid to ground good solenoid Check if 2 speed binds solenoid moves in and out freely moves freely Replace 2 speed solenoid Note resistance across solenoid terminals should be approximately 0 3 ohms bad blk red wire circuit from terminal 87 on CR4 to 2 speed solenoid Repair open in brn ground wire circuit from 2 speed solenoid to ground Check linkage or replace solenoid Third Edition First Printing 5 22 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Engine Low Idle inoperative Diesel Models Check if mechanical linkage from 2 speed solenoid to fuel injection system is binding or defective At the platform controls start the engine and move the RPM select toggle switch TS4 to maintained low idle turtle symbol Check voltage at blk red wire on RPM select toggle 12V
32. BLK 21B BLK S P START 2 KS1 23 6 WHT RED EH WHT RED 1 32 WHT RED D B BRAKE P1 WHT BLK EH WHT BLK 1t 31 E D C ATO RED 5 WHT 1 30 E D C NC REDWHT E H RED WHT 1 29 RED WHT D B 2WD AWD NO NO NO NO TS10 RED BLK EH RED BLK 1 28 TILT ALARM olg PO NC Ale CABLE RED 1 27 RED 4 1SM_ RED S P AUXILIARY POWER gt H WHT RED E H 26 WHT RED S P WATER TEMPERATURE SENDER EDDA WHT BLK E H 25 WHT BLK S P OIL PRESSURE SENDER WHT 10 ISM___ WHT E H 24 WARNING SENDER BLK WHT 8A RED WHTEH WHT 2 23 WHr TS2245 WHT S P KEYSWITCH POWER pem BLK CR5430 2 22 BLK S P POWER TO PLATFORM REDE WHT CR2487 WHT E H 21 BLK 33B WHT 46A IGNITION POWER 5 RED E H RED CR17 20 RED S P 12V BATTERY SUPPLY 3 RED BLK 2A GRN WHT 3 19 GRN WHT S P JIB VALVE GRN BLK 4 GRN BLK 8 18 GRN BLK D B GRN BLK S P PLATFORM ROTATE RIGHT HM GRN 4 GRN 3 17 GRN D B GRN S P PLATFORM ROTATE LEFT TS19 M CABLE ORG RED 3 16 ORG RED D B ORG RED amp P PLATFORM LEVEL FLOW CONTROL 1 ORG BLK 4 ORG BLK 3 15 ORG BLK D B ORG BLK S P PLATFORM LEVEL DOWN TS17 ORG 4 ORG 3 14 ORG D B ORG S P PLATFORM LEVEL UP WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT WERA WHT E H BLU WHT 3 12 BLK 5 DRIVE ENABLE Wie BLU BLK 3 11 BLU BLK S P SECONDARY BOOM DOWN L3 7511 eB TS12 TS15 BLU 3 10 BLU S P SECONDARY BOOM UP 5 BLK RED 4 BLK RED 3 9 BLK RED S P EXTEND RETRACT F C 4
33. BLU RED 3 Fry T g BRN S DRIVE ENABLE z WHT 1 P RED 5 BLK 5 LIMIT SWITCH ay A E e DRIVE ENABLE BLU WHT 3 E E 5 5 WHT BLK 1 Eu WHT BLK 31 E H X E S i E z WHT RED 1 Erg WHT RED 32 E H n YT 4 TRAVEL ALARM M 5 9 Ld m 1 BLU BLK 1 F BLU BLK 37 E H e ej Yo STEER RIGHT 5 BLU 1 x BLU 36 E H 4 STEER LEFT EEEREN 8 8 2 B amp an i PAETE i e x No B e ORG 1 WHT 6 BRN 6 BOOM UP t V LIMIT SWITCH WHT 7 BRN 7 BOOM EXTEND e gees 59 LIMIT SWITCH 9 32 o o Ae BY E RED WHT 1 Y MOTOR STROKE fees Q Q W E E E BLK 3 BLK WHT 3 M BLK 4 a e e BOOM EXTEND EXTEND BLK WHT tr BOOM 4 BLK WHT 4 2 LRETRACT Ye BOOM RETRACT o B 1 BLK RED BLK RED 4 Ye EXTEND RETRACT al BLK RED 3 FLOW CONTROL a WHT BLK 3 e WHT 3 x gt de WHT WHT 4 GUT WATEK TURNTABLE ROTATE RIGHT TURNTABLE ROTATE 4 sath 4 5 4 TURNTABLE ROTATE LEFT m g fa 1 WHT RED 4 5 TURNTABLE ROTATE oo 22 4 FLOW CONTROL E m RED 4 5 ej 4 PRIMARY BOOM UP RED BLK g PRIMARY BOOM 4 P x aM LDOWN ez 4 Jd PRIMARY BOOM DOWN is x 1 DESCENT ALARM st RED WHT 4 n e PRIMARY BOOM n amp AEDS 3 FLOW CONTRO
34. _ 87 30 87 A Ee 85 eo 9 o5 Du 5 OOO 86 COIL 7 D 85 COIL R Y TS1 TS3 TS2 R 30 COMMON COM TS7 TS8 R1 54 87 NORMALLY OPEN NO P3 TS5 TS6 P2 87A NORMALLY CLOSED NC O NOTE R1 RESISTOR IS MOUNTED TO EXTEND RETRACT CONTROLLER O USE 100 OHM RESISTOR FOR 4WD AND 150 OHM RESISTOR FOR 2WD Part No 65196 Genie S 60 amp Genie S 65 6 15 ORG BLK 1 SEE NOTE 1 Third Edition First Printing Electrical Schematic Perkins Diesel Models Section 6 Schematics iz g B s a a c tr a eo T HIGH RPM 3 1 ENGINE SPEED E BLK RED 1 2 1 ce o pc uma amic gt 1 2 FUNCTIONENABLE BLK RED 85 T HIGH HPM s aes HIGH IDLE REL
35. 13037 Microswitch Control Inc 6 TS20 ui Toggle switch DPDT 2 position maintained 27378 Microswitch Control Inc 1 Reun Toggle switch 3 position maintained 13038 Microswitch Control Inc ONT 1515s 1 TS6 7 14 15 Toggle switch position momentary 16397 Microswitch Control Inc ONT 127 ena ee 6 TS3 TS11 Gas LPG Toggle switch DPDT 2 position maintained 27378 Microswitch Control Inc 2NT1 9 ns 2 TS3 TS11 Diesel Toggle switch SPDT position momentary 13037 Microswitch Control Inc TINTI Z iuit ees 2 Part No 65196 Genie S 60 amp Genie S 65 6 3 Section 6 Schematics Third Edition First Printing Electrical Symbols Legend a a a t 15A TB17 Circuit breaker with amperage 178 940 Emergency Stop button 85 normally closed Wire color with cable number E E Coil solenoid or relay Ground QUE supression Toggle switch DPDT circuit Gauge sending unit Terminal H1 Mera p om TN ERI H a orn MEN EN Y Limit switch Control relay contact Oil cooling fan Auxiliary pump
36. KE XO GENERATOR 0 076 mm 1 XC 076mm I i i 14 GPM 53 L min Is te PRESSURE Lt lt L MANIFOLD __ Al 5 60 Models 2600 PSI r 7 ENS r i DRIVE PUMP ee S 65 Models 2900 PSI if 4 5 0454 Pie a teas th i 0 TO 30 GPM 114 7 L min 9 DPA aN Ti _ TANK o o 0 me 2500 PSI L OPTIONAL ES 172 ba SEC REG OIL COOLER PR v 5 RESERVOIR AUXILIARY PUMP p HYDRAULIC ROTARY COUPLER zx 6 STEER MANIFOLD DRIVE MANIFOLD __ __ __ pe i 1 250 PSI i T i M8 ETE E li M METER 1 1 REAR FRONT 7 i i i i i i i STEERING 1 CYLINDER 8 Part No 65196 Genie S 60 amp Genie S 65 6 24 Third Edition First Printing Section 6 Schematics EE 4WD Hydraulic Schematic Oscillating Axle
37. Part No 65196 Third Edition First Printing Continued from the previous page Plumb a 0 to 5000 psi 345 bar pressure gauge into the hose from the function manifold to the turntable rotation brake Hold the function enable switch to either side and move the turntable rotate toggle switch in the RIGHT direction 250 psi or more Exchange turntable rotate right and left counterbalance valves items JJ and KK Activate turntable rotate right function function inoperative Check for mechanical restrictions keeping turntable rotate right function from operating OR replace shuttle valve item Il OR consult Genie Industries Service Department lessthan 250 psi pl function operates mo Section 5 Troubleshooting Flow Charts n u E Function manifold could have an internal fault Consult Genie Industries Service Department Replace faulty counterbalance valve CHART 19 Part No 65196 Genie S 60 amp Genie S 65 5 45 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 20 All Platform Leveling Functions Inoperative Be sure all other functions operate normally Remove both hydraulic hoses from the manifold ports PL1 amp PL2 Plug the hoses and cap the manifold fittings Activate the boom up
38. The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees How to Remove the Platform Rotator CAUTION Component damage hazard Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal If a new rotator is installed or the rotator is disassembled proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform Section 7 Repair Procedures PLATFORM COMPONENTS 2 S 60 models Tag disconnect and plug the hydraulic hoses from the platform rotator Cap the fittings on the rotator AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray S 65 models Tag disconnect and plug the hydraulic hoses from the V1 and V2 ports on platform rotator manifold C
39. fuels are combustible Replace the fuel filter water separator in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Turn the manual fuel shutoff valve located at the fuel tank to the cLosEp position Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE D PROCEDURES 2 Remove the fuel filter water separator with a filter wrench a oil filter b fuel filter water separator 3 Fill the new filter with fresh diesel fuel and apply athin layer of diesel fuel to the new fuel filter gasket 4 Install the new filter and tighten it securely by hand Clean up any diesel fuel that might have spilled during the procedure 5 Turn the manual fuel shutoff valve located at the fuel tank to the open position 6 Startthe engine from the ground controls and inspect the fuel filter for leaks Explosion and fire hazard If a fuel ADANGER 2 leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately D 10 Change the Fuel Hoses Deutz Diesel Models Maintaining the fuel hoses in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or leaking fuel hose may cause an unsa
40. normally open Quick disconnect terminal es Limit switch i BLK WHT 21 ph TBA Flashing beacon normally open held closed Foot switch at terminal P 192 Capacitor Tilt sensor NCHO Limit switch H Hon normally closed T circuits held open DPI connect Horn button J ii ti i i normally open i B 510 KS d Resistor with OTS2 NA Ohm value Connection m No Drive controller no terminal Joystick Hour meter Oil temperature Key switch switch normally open 20 BPI PRA PWM PWM Circuits crossing L3 I ely a a al no connection na x 5 gt E Fig rn 7 8 LED Power relay i Water temperature Boom controller Fuse switch joystick Diode with amperage normally open i 25A am 1 Oil pressure switch Auxiliary lift pump Glow plugs Toggle switch SPDT normally closed Battery or starting aid 6 4 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 6 Schematics E Abbreviation Legend LABEL DESCRIPTION BAT aucun Battery BP oaa Boom proportional controller Capacitor Circuit breaker Control relay DP Lect Drive proportional cont
41. temporary flat tire repair products This procedure does not need to be performed on machines equipped with the foam filled tire option To safeguard maximum stability achieve optimum machine handling and minimize tire wear it is essential to maintain proper pressure in all air filled tires 1 Check each tire with an air pressure gauge Add air as needed Tire specifications Tire size 15 19 5 NHS Pressure 85 psi 5 86 bar Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures TABLE A PROCEDURES A 10 Test the Oscillate Axle if equipped Proper axle oscillation is essential to safe machine operation If the axle oscillation system is not operating correctly the stability of the machine is compromised and it may tip over 1 Start the engine from the platform controls 2 Drive the right steer tire up onto a 6 inch 15 cm block or curb O Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 3 Drive the left steer tire up onto a 6 inch 15 cm block or curb O Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 4 Drive both steer tires up onto a 6 inch 15 cm block or curb O Result The non steer tires should stay in firm contact with the ground If the chassis does
42. 1 2 4 Deutz Engine FAL 1011F Specifications 2 5 Perkins Engine 704 30 Specifications 2 6 Hydraulic Hose and Fitting Torque 2 7 Theory of Operation inn ee du dte die dee o 3 1 Hydraulic SyStem i cett tender i eres 3 1 Electrical System i 3 1 Eimit Switches a e ete certes 3 2 Machine 5 3 2 Part No 65196 Genie S 60 amp Genie S 65 V Third Edition First Printing TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures P 4 1 Maintenance Inspection 4 3 A 1 Inspect the Operator s and Safety Manuals 4 5 2 Inspect the Decals and 4 5 Inspect for Damage and Loose or Missing 4 6 A 4 Check the Engine Oil Level 4 7 A 5 Check the Engine Coolant Level Liquid Cooled Models 4 8 6 Check for Fuel 1 0 2 0110000 nennen nnne nnne nnne 4 8 A 7 Check the Hydraulic 4 9 8 Check for Hydraulic
43. Chart 1 Engine Will Not Crank Over Be sure the key switch is in the appropriate position Be sure that both Emergency Stop buttons are pulled out to the on position Be sure the circuit breakers are not tripped Be sure the battery is fully charged less than Check battery voltage 12V 12V or more With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at the center terminal on the start toggle switch TS11 12V Move the start toggle switch to either side and check the voltage at either side terminal on start toggle switch 12V Move the start toggle switch to either side and check voltage at terminal TB33 12V Move the start toggle switch to either side and check voltage at terminal 3 on ignition start module 12V Check voltage at terminal 6 on the ignition start module 12V Continued on the next page Check battery condition OR check alternator OR check battery cables OR replace the battery Trace circuit back through the key switch Emergency Stop button and CB2 Repair open Replace start toggle switch 1 Repair open in blk wire circuit from start toggle Switch to TB33 Repair open in blk wire circuit from TB33 to terminal 3 on ignition start module Repair open in red power supply wire circuit from CB1 to CR1 to CR2 then to terminal 6 to on ignition s
44. First Printing Platform Controls 1 1 Joystick Controllers Maintaining joystick controllers at the proper settings is essential to safe machine operation Every joystick controller should operate smoothly and provide proportional speed control over its entire range of motion Platform control box horsepower limiter board terminals drive controller extend retract controller boom controller turntable rotate controller 0oo00oo0onmm Boom Up Down Controller Adjustments AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Do not adjust the controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13 6 to 14 5V DC output Individual trim potentiometers trimpots are used to adjust various output signals from the horsepower limiter board and boom function controllers The trimpots will be identified as the following Max out trim potentiometer max out trimpot High range trim potentiometer max out trimpot Lo range trim potentiometer lo range trimpot Dual range trim potentiometer lo range trimpot Threshold trim potentiometer threshold trimpot Ramp rate trim potentiometer ramp rate trimpot Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller Turn the k
45. Genie Service Manual Third Edition First Printing Part No 65196 S 60 S 65 Third Edition First Printing Genie S 60 Genie S 65 Important Read understand and obey the safety rules and operating instructions in the Genie S 60 amp Genie 5 65 Operator s Manualbefore attempting any maintenance or repair procedure 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 97030 Redmond WA 98073 97030 U S A If you have any questions please contact Gen
46. function inoperative Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the boom function manifold and start the engine Hold the function enable switch to either side and move the boom extend retract toggle switch in the EXTEND direction Check the pressure 2500 PSI or more Check for mechanical restrictions keeping the boom from extending OR repair cylinder or cylinder counterbalance valves OR consult Genie Industries Service Department less than 25 00 PSI Exchange boom extend flow regulator valve item G with boom up down flow regulator valve item H Check boom extend function function operates ee S Replace the faulty flow regulator valve function inoperative Repair the cylinder or cylinder counterbalance valve OR function manifold could have an internal fault Consult Genie Industries Service Department CHART 16 Part No 65196 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Chart 17 Boom Retract Function inoperative Be sure all other functions operate normally With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the boom extend retract toggle switch TS15 in the RETRACT direction Check voltage on blk red 4 wire on boom extend
47. 1 78 mm AL Orifice plug 0 070 1 78 mm Ad init 10 Shuttle valve 3 position way AK 11 Diagnostic fitting 2 2 12 Check valve AL ius Plug Torque Specifications Description Hex size Torque SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 8 5 16 50 ft lbs 68 Nm 7 60 Genie 5 60 amp Genie 5 65 Part No 65196 MANIFOLDS 410 U 0 lee gt Section 7 Repair Procedures Third Edition First Printing MANIFOLDS 11 12 Valve Adjustments 4WD Drive Manifold How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the diagnostic nipple index 9 located on the drive manifold 2 Start the engine from the platform controls 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 bar 4 Turn the engine off Hold the charge pressure relief valve with a wrench and remove the cap index 3 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap 6 Start the engine from the platform controls Drive the machine in either direction and confirm the valve pressure 7 Tu
48. 2 Startthe engine from the platform controls 3 Move the lift drive select switch to the drive position if equipped 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 5 Bring the machine to top drive speed before reaching the test line Release the drive controller when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point 3 to 5 ft 0 6 to 1 2 m Braking high range paved surface The brakes must be able to hold the machine on any slope it is able to climb Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures B 18 Test the Drive Speed Stowed Position Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm level and free of obstructions Be sure the boom is fully retracted and lowered to the stowed position 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Start the engine from the platform controls 3 Move the lift drive select switch to the drive position if equipped
49. 20 25 ft lbs 27 33Nm 2 Spool valve nie scie re ER e Directional control Part No 65196 Genie S 60 amp Genie S 65 7 53 Section 7 Repair Procedures Third Edition First Printing MANIFOLDS How to Set Up the Directional Valve Linkage Adjustment of the directional valve linkage is only necessary when the linkage or valve has been replaced 1 Lower the boom to the stowed position 2 Use a bubble type level to be sure the floor is completely level Tip over hazard Failure to perform this procedure on a level floor will compromise the stability of the machine and could result in the machine tipping over 3 Check the tire pressure in all four tires and add air if needed to meet specification 4 Remove the drive chassis cover from the non steer end 5 Disconnect the linkage clevis yoke from the drive chassis if not already disconnected 6 Place a bubble type level across the drive chassis side plates at the non steer end Check to be sure the drive chassis is completely level 7 Tolevel the drive chassis start the engine and push up or pull down on the linkage adjustment rod until the machine is completely level 8 Verify that the ground and drive chassis are completely level 9 Adjust the length of the rod by turning the clevis yoke until the clevis yoke can be pinned to the drive chassis 10 Install the clevis yoke pin and the cotter pin Be sure to bend the cotte
50. 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines TABLE B PROCEDURES 5 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 6 Continue at full speed and note the time when the machine reference point crosses the finish line Drive speed stowed position 2WD 4WD Ford models 40 ft 6 2 sec 40 ft 9 1 sec 12 2 m 6 2 sec 12 2 m 9 1 sec 40 ft 6 8 sec 40 ft 9 7 sec 12 2 m 6 8 sec 12 2 m 9 7 sec Diesel models Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE B PROCEDURES B 19 Test the Drive Speed Raised or Extended Position Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Start the engine from the platform controls 3 Move the lift drive select switch to the lift position if equipped 4 Move the engine idle select switch to foot switch activated high id
51. AA With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the turntable rotate controller in the RIGHT direction Check voltage at TB4 12V or more CHART 19 Repair open in wht 4 wire circuit from TB4 to turntable rotate right directional valve coil OR repair open in brn ground wire circuit to valve coil Troubleshoot turntable rotate controller OR repair open in wht 3 wire circuit from boom controller to TB4 OR consult Genie Industries Service Department o 12V or Press down the foot switch and move the turntable rotate controller in the RIGHT direction Check voltage more Repair open in wht 3 wire from TP4 to TB4 at TP4 w Press down the foot switch and check voltage at terminal on controller oV 12V or more Repair open in power supply circuit from TP24 to controller OR repair open in brn ground wire circuit from ground to controller Re adjust controller see Repair Section OR replace controller OR consult Genie Industries Service Department Continued on the next page Part No 65196 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts 1 CHART 19 Continued from the previous page Replace turntable rotate right directional valve coil
52. BLK WHT 4 BLK WHT 8 BKWHT D B BLKWHT S P BOOM RETRACT __ OO TS18 BLK 4 BLK 3 7 BLK D B BLK S P BOOM EXTEND 4 Qj N CABLE wHT RED 4 WHT RED 3 6 WHT RED S P TURNTABLE ROTATION F C A 2 WHT BLK 4 WHT BLK 3 5 WHT BLK D B WHT BLK S P TURNTABLE ROTATION LEFT TS16 GRN 17A WHT 4 WHT 3 WHT D B WHT S P TURNTABLE ROTATION RIGHT TS13 RED WHT 4 RED WHT 3 3 RED WHT S P PRIMARY BOOM GBN BLK 18A RED BLK 4 RED BLK 3 2 RED BLK D B RED BLI S P PRIMARY BOOM DOWN 4 4 1514 RED 4 RED 3 1 RED D amp RED S P PRIMARY BOOM UP D B A CB1 CB2 GRN WHT 19A ORG BLK 15A ORG BLK 15B T lt gt 6 ORG RED 16B Mi ORG 14A ORG 14B 2 4 GRN 17B Sig ys GRN BLK 188 5 ORG RED 16A CABLE RED WHT 29B 4 a BLK R1 87 M WHT RED 6A 3 BLKAWHT 8B 54 10 BRN GROUND BLK RED 9A BLK 7B 1 6 WHT 21A WHT BLK 5B 2 4 BLU 368 R2 WHT 4B 3 gt 8j BLU BLK 37B RED BLK 2B PN am WHT RED 32B BLK 33A RED 1B 5 10 BRN GROUND BLK RED 35A BLICRI 86 C 1 START RELAY BLU RED 39A A I CABLE ORGIBLK ATE 2 mcuoweren IGNITION START RED 20A 6 4 BLK 33D START INPUT MODULE BLU WHT 38A REDE C 4 AUXILARY ON RED R1 30 C s GRoUND BLUMWHT 38A RED R2 30 LC e WHT TS22 6 C 7 KEY POWER 8 KEY BYPASS WHT R2 86 9 IGN FUEL ON PLATFORM LEVEL DISABLE HYDRAULIC OIL COOLER O 10 ENGINE FAULT OPTION RELAYS OPTION RELAY Satii
53. E B E 950 7 _1 i UT Psi i 5 TI i A r REAR 7 NEZ 7 r k 4 j A VALVE ACYL Le PO 5 i y B varve CYL Neco RE EORR 22044 01 M3 STEERING 5 CYLINDER 0 070 i REAR 1 8 LEFT 8 I CASE DRAIN o Part No 65196 Genie S 60 amp Genie S 65 6 23 Third Edition First Printing Section 6 Schematics p M 1 4WD Hydraulic Schematic Non Oscillating Axle
54. Is continuity maintained E Repair short to ground in wht 424 wire from sending units to TB24 to terminal 10 on ignition start module Check voltage at terminal 4 on ignition start module 12V oV v Disconnect red wire from terminal 4 on ignition start module and check voltage at terminal 4 Test auxiliary power toggle switches TS1 and TS9 See Repair Section Replace ignition start module OR consult Genie Industries Service Department yes replace engine temperature sending unit OR refer to Deutz or Perkins service manual for troubleshooting a overheated engine 12V Replace ignition start module OR consult Genie Industries Service Department Part No 65196 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 4 Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LPG Models Be sure fuel select switch is switched to LPG Be sure the valve on the LPG tank is fully opened Be sure to check LPG fuel level See Repair Section How to Retrieve Fault Codes Is there a fault code stored in the ECM memory yes Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult G
55. Part No 65196 Genie S 60 amp Genie S 65 5 57 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 27 Jib Boom Down Function inoperative Be sure all other functions operate normally With the key switch turned to ground Hold the function enable switch to either side and 12V 12V controls and both oV move the jib boom Emergency Stop buttons 7 toggle switch in the pulled out to the ON DOWN direction Check position hold the voltage at TB18 function enable switch to either side and move the jib boom toggle switch oV TS19 in the DOWN direction Check voltage at the grn blk 4 wire on Repair open in red the jib boom down power wire circuit from directional valve key switch to TS12 to item DD TS19 OR replace TS19 E With the key switch Press down the foot turned to platform switch and move the jib controls and both boom toggle switch in Emergency Stop buttons the DOWN direction pulled out to the on Check voltage at TP18 position press down the foot switch and move the jib boom toggle oV switch TS24 in the DOWN direction Check voltage at TB18 With the key switch 12V turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and check voltage on the center terminal of the jib boom toggle switch 12V Check the vo
56. Remove all rings watches and other jewelry 3 Connectthe negative battery cable to the battery Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 10 1 Lift Steer Pump How to Remove the Lift Steer Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Close the two hydraulic tank valves located at the hydraulic tank open CAUTION closed Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the cLosEp position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition Hydraulic Pumps 2 Tag disconnect and plug the lift steer pump hydraulic hoses Cap the fittings on the pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pump mounting bolts Carefully remove the pump CAUTION Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump See 10 2 How to Prime the Pump
57. Secure the 6 Install the end cap onto the canister Install and retaining fasteners tighten the retaining ring Perkins Diesel models Air filters Genie part numbers Ford LRG 425 EFI Engine 27916 1 Open the engine side turntable cover and Deutz FAL 1011F Engine 27916 disconnect the retaining fasteners from the end Perkins 704 30 Engine 62420 cap of the air filter canister Remove the end 2 Remove the filter element 3 Empty the dust discharge valve by pressing apart the lips of the discharge valve Clean discharge valve as needed a airfilter b dust discharge valve 4 Clean the inside of the canister and the canister end cap with a damp cloth Part No 65196 Genie S 60 amp Genie S 65 4 51 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE B PROCEDURES B 25 Replace the Spark Plugs Gasoline LPG Models Engine specifications requires that this procedure be performed every 400 hours Periodic replacement of the spark plugs is essential to good engine performance and service life Worn loose or corroded spark plugs will cause the engine to perform poorly and may result in component damage Perform this procedure with the engine off 1 Remove the 2 engine pivot plate retaining bolts Swing the engine pivot plate away from the machine to access the spark plugs a engine pivot plate b pivot plate retaining bolts c a
58. by pressing it evenly into the hub until it is flush Always replace the bearing grease seal when removing the hub 16 Slide the hub onto the yoke spindle Component damage hazard Do CAUTION not apply excessive force or damage to the lip of the seal may 17 Place the outer bearing into the hub 18 Install the washer and castle nut 19 Torque the castle nut to 35 ft lbs 47 Nm to seat the bearings 20 Loosen the castle nut then torque the castle nut to 8 ft lbs 11 Nm 21 Install a new cotter pin Bend the cotter pin to lock it in place Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut 22 Install the dust cap 23 Install the tire and wheel assembly Torque the wheel lug nuts to 420 ft lbs 569 5 Nm 24 Center a lifting jack under the steer axle 25 Raise the machine approximately 6 inches 15 cm Remove the blocks from under the drive chassis 26 Lower the machine Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE E PROCEDURES E 6 Check the Fuel Injectors Perkins Diesel Models Engine specifications require that this procedure be performed every 3000 hours or 18 months whichever comes first Complete information to perform this procedure is available in the Perkins 700 Series Workshop Manual Perkins part number TPD 1359E
59. filter should be replaced See B 22 Heplace the Hyaraulic Tank Return Filter Part No 65196 Genie S 60 amp Genie S 65 4 31 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE B PROCEDURES B 3 4 Checkthe pressure in each air filled tire Add Inspect the Tires and Wheels PR including lug nut torque Tires and wheels Tire size 15 19 5 NHS Pressure 85 psi Maintaining the tires and wheels in good 5 86 bar condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may Wheel lugs 10 3 4 16 also result if problems are not discovered and Tire ply rating 12 Lug nut torque dr 420 ft lbs repaired in a timely fashion i 569 5 Nm Bodily injury hazard An over Lug nut torque lubricated 320 ft lbs AWARNING tire explode and could 433 9 Nm result in death or serious injury AWARNING ver hazard Do not use temporary flat tire repair products The tires on some machines are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque 4 32 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures B 4 Conf
60. front to front and back to back using a measuring fixture 9 Center a lifting jack of ample capacity under the non steering axle Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support Loosen the jam nut on the adjustable end of the tie rod Remove the pin retaining fasteners then remove the clevis pin from the adjustable end of the tie rod Slide the tie rod off the yoke and adjust it by turning the end One half turn on the adjustable end equals approximately 1 8 inch 6 4 mm change in the front and rear measurements Slide the tie rod onto the yoke Install the clevis pin then install the retaining fasteners Tighten the jam nut against the tie rod 10 Lower the machine and recheck the Toe in specification front and back measurements step 2 If further adjustment is needed repeat steps 3 through 8 0 1 8 inch 4 mm Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 4WD Steering Axle Components 15 1 Yoke and Hub How to Remove the Yoke and Hub The yoke installation utilizes bushings and a thrust washer that may require periodic replacement The yoke must be removed before the drive hub can be removed 1 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer
61. i WHT 23B C 7 KEY POWER i Key Bypass 1 WHERZSDG HO IGN FUEL i WHT2SD 10 ENGINE FAULT RED 6 ISM WHT 9 ISM BLK RED R4 E H BLK RED 35B RED CB1 arr cene qno CR1 1 i BLK 1 ISM BLK R1 E H BLK D B WHT 21D BLK R5 AH CR2 CR3 CR4 BRN GRD J CR5 BLK 22D GRN 43D LABEL DESCRIPTION CABLE TO PLATFORM CONTROL BOX TERMINAL 27 46 CABLE 2 TO PLATFORM CONTROL BOX TERMINAL 22 23 CABLE 3 TO PLATFORM CONTROL BOX TERMINAL 1 19 CABLE 4 TO CONTROL SOLENIOD 1 CIRCUIT BREAKER CONTROLS 15 CB2 CIRCUIT BREAKER ENGINE 15A CR1 IGNITION START RELAY CR2 IGNITION POWER RELAY CR3 HIGH IDLE RPM CUTOUT RELAY CR4 RPM RELAY CR5 HORN RELAY CR17 HYDRAULIC OIL COOLER OPTION RELAY CR18A amp B CE PLATFORM LEVEL CUTOUT RELAY G1 VOLT METER GAUGE G2 OIL PRESSURE GAUGE G3 ENGINE COOLANT TEMPERATURE GAUGE HM HOUR METER KS1 KEY SWITCH L3 GLOW PLUG LED LS1 CABLE 7 BOOM EXTEND LIMIT SWITCH LS2 CABLE 6 BOOM UP LIMIT SWITCH 153 CABLE 5 DRIVE ENABLE LIMIT SWITCH P1 EMERGENCY STOP BUTTON PR1 IAUXILARY POWER RELAY PR2 GLOW PLUG POWER RELAY R2 RESISTOR 10 OHM BOOM FUNCTIONS TS10 AUXILIARY SWITCH TS11 ENGINE START SWITCH TS12 GLOW PLUG SWITCH TS13 FUNCTION ENABLE SWITCH TS14 PLATFORM ROTATE SWITCH TS15 JIB BOOM UP DOWN SWIT
62. located next to the engine oil dip stick 2 Turn the manual fuel shutoff valve located at the fuel tank to the cLosep position Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures 3 Remove the fuel pump cover retaining fastener Remove the cover 4 Gently clean the fuel strainer with clean diesel fuel or a mild solvent 5 Install the fuel strainer and pump cover onto the fuel pump Install and tighten the fuel pump cover retaining fastener 6 Turn the manual fuel shutoff valve located at the fuel tank to the oPEN position 7 Startthe engine from the ground controls and inspect the fuel filter for leaks Explosion and fire hazard If a fuel 8 leak is discovered keep additional personnel from entering the area and do not operate the machine Repair the leak immediately Be sure the fuel filter is full of fuel before attempting to start the engine TABLE D PROCEDURES D 9 Replace the Diesel Fuel Filter Water Separator Deutz Diesel Models Replacing the diesel fuel filter water separator is essential to good engine performance and service life A dirty or clogged filter water separator may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter water separator be replaced more often Explosion and fire hazard Engine TIVI
63. neutral position 290 psi 20 bar Charge pressure drive position 250 psi 17 bar Medium pressure filter 3 micron Medium pressure filter 50 psi bypass pressure 3 4 bar Drive manifold Brake release pressure 250 psi 17 2 bar Steer end drive motors 4WD models Displacement 1 52 in per revolution 25 cc Non steer end drive motors Displacement per revolution variable 0 16 to 2 8 cu in Section 2 Specifications ET Function pump SPECIFICATIONS Type pressure balanced gear Displacement static 1 4 cu in 23 cc Displacement 2500 rpm 15 2 gom 57 4 l min Hydraulic tank circuit return line filter Function manifold 10 micron with 25 psi 1 7 bar bypass Function relief valve pressure 5 60 2600 psi 179 bar S 65 2900 psi 200 bar Boom down relief 2100 psi valve pressure 145 bar Boom extend relief 2500 psi valve pressure 172 bar Oscillate axle relief 900 psi valve pressure 62 bar Steer regulator Oscillate models Non oscillate models Auxiliary pump 5 gpm 18 9 l min 3 5 gpm 13 2 l min Type fixed displacement gear pump AWD 2 speed motor 2 62 to 45 9 Displacement static 0 152 cu in 2 5 cc Displacement per revolution variable 1 12 to 2 8 cu in 2WD 18 4 to 45 9 cc Displacement 1 4 gpm 5 3 l min Auxiliary pump 2500 psi relief pressure 172 bar Part No 65196 Genie S 60 amp Genie S 65 2 3 Section 2 Specifications T
64. o 12V or Press down the foot more Repair open in wht blk 3 switch and move the wire from TP5 to TBS turntable rotate controller in the LEFT direction Check voltage at TP5 w 12V ome Press down the foot Repair open in power switch and check OV supply circuit from TP24 voltage at terminal to controller OR repair on controller open in brn ground wire circuit from ground to controller 12V or more Re adjust controller see Repair Section OR replace controller OR consult Genie Industries Service Department Y Continued on the next page Part No 65196 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts 1 CHART 18 Continued from the previous page Replace turntable rotate left directional valve coil Replace faulty directional valve 0 or Disconnect wires to infinite turntable rotate left ohms directional valve coil item A and test the resistance of the valve coil See Repair Section 2 5 to 3 5 ohms function Hold function enable switch to either side and operates move the turntable rotate toggle switch in the LEFT direction Manually override the directional valve by pushing in on the end of the valve spool function inoperative Install a 0 to 5000 PSI 345 bar pressure g
65. or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Open the platform control box and remove the platform control box mounting fasteners 2 Disconnect the foot switch wiring from the terminal strip inside the platform control box Remove the cable from the control box and set the control box aside 3 5 65 models Tag disconnect and plug the hydraulic hoses from the V1 and V2 port fittings on the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Tag disconnect and plug the hydraulic hoses from the platform leveling slave cylinder at the union and connect the hoses from the cylinder together using a connector AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray S 65 Models 5 Remove the hose and cable cover from the side of the jib boom Remove the jib boom platform rotate manifold mounting fasteners Do not disconnect the hoses 7 Tag disconne
66. pump 2 Gasoline LPG models Close the valve on the LPG tank then disconnect the hose from the tank Move the fuel select toggle switch to the LPG position sure that the hydraulic tank shutoff 4 5 HYDRAULIC PUMPS Deutz Diesel models Hold the manual fuel shutoff valve clockwise to the cLosep position a manual fuel shutoff valve Perkins Diesel models Disconnect the engine wiring harness from the fuel solenoid at the injector pump Crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 250 psi 17 2 bar Gasoline LPG models Connect the LPG hose to the LPG tank and open the valve on the tank Deutz Diesel models Release the manual shutoff valve Perkins Diesel models Connect the engine wiring harness to the fuel solenoid Start the engine from the ground controls and check for hydraulic leaks Part No 65196 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Third Edition First Printing Manifolds 11 1 Function Manifold Components The function manifold is located on the tank side tray behind the ground control box Index Schematic No Description Item Function Torque 1 valve 3 position 4 way Turntable rotate left right 30 35 in Ibs 3 4 Nm 2 DOS valve 3 position 4 way Basis Boom up down
67. sending unit has limit contacts that are factory set The contacts will close at approximately 221 F 105 C When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Engine coolant temperature will be indicated on the gauge when the key is on and the Emergency Stop Button is pulled out to the on position The engine oil pressure gauge is an electrical gauge The engine oil presure sending unit has limit contacts that are factory set The contacts will close at approximately 4 2 psi 0 3 bar When the contacts close the engine will shut off to prevent damage Engine oil pressure will be indicated on the gauge when the engine is running How to Remove the Coolant Temperature and Oil Pressure Gauge Sending Units Perform this procedure with the engine off 1 Tag and disconnect the wiring from the desired sending unit Remove the sending unit from the engine block 2 Install the new sending unit Do not over tighten 3 Connectthe wires to the new sending unit Burn hazard Contact with hot ACAUTION engine fluids or components may cause severe burns Always use pipe thread sealant when installing a sending unit Coolant temperature sending unit specifications Torque 8 10 ft lbs 11 14 Nm Hex size 7 inch Temperature switch point 221 F 105 Oil pressure sending unit specifications Torque 8 10 ft lbs 11 14 Nm He
68. supply circuit from TP24 to terminal 1 on the horsepower limiter board Adjust the A trimpot See repair procedure 1 2 How to Adjust the Horspower Limiter Board OR replace horsepower limiter board Repair open in org blk 41 wire from alternator to TB41 and org blk 1 wire from TP41 to terminal 3 on horsepower limiter board 5 64 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Continued from the previous page Press down the foot switch and hold the drive controller in the full forward position Check voltage at terminal 6 on the drive controller Section 5 Troubleshooting Flow Charts n U oV gt Repair open in wire from terminal 10 on horsepower limiter board to terminal 6 on the drive controller to 12V Connect the positive lead from a voltmeter to terminal 4 on the drive controller and the negative lead to terminal 5 on the drive controller Press down the foot switch and hold the drive controller in the full forward position Check voltage across the 4 and 5 terminals on the drive controller Connect the positive lead from a voltmeter to terminal 5 on the drive controller and the negative lead to terminal 4 on the drive controller Press down the foot switch an
69. 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 8 5 16 50 ft lbs 68 Nm Part No 65196 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Third Edition First Printing MANIFOLDS 11 10 Valve Adjustments 2WD Drive Manifold How to Adjust the Charge Pressure Relief Valve 1 Connect 0 to 600 psi 0 to 41 bar pressure gauge to the diagnostic nipple index 5 located on the drive manifold 2 Start the engine from the platform controls 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 bar 4 Turn the engine off Hold the charge pressure relief valve with a wrench and remove the cap index 1 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap 6 Startthe engine from the platform controls Drive the machine in either direction and confirm the valve pressure 7 Turn the engine off and remove the pressure gauge 7 58 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures MANIFOLDS This page intentionally left blank Part No 65196 Genie S 60 amp Genie S 65 7 59 Section 7 Repair Procedures Third Edition First Printing MANIFOLDS 11 11 4WD Drive Manifold Components The drive manif
70. 2 Exchange platform level flow regulator valve item T with jib boom flow regulator valve item DD and activate the platform level down function function inoperative Test master cylinder see Chart 20 OR repair or replace slave cylinder or slave cylinder counterbalance valves OR function manifold may have an internal fault Consult Genie Industries Service Department 0 or infinite ohms function operates Bedia function operates ene SEE NOTE 1 o function operates eer Replace the platform level down directional valve coil Replace the faulty directional valve Replace the faulty counterbalance valve Check for mechanical restrictions keeping platform level down from operating OR replace slave cylinder OR replace slave cylinder counterbalance valves OR consult Genie Industries Service Department Replace faulty flow regulator valve Third Edition First Printing NOTE 1 5 60 2600 PSI or more 5 65 2900 PSI or more NOTE 2 5 60 Less than 2600 PSI S 65 Less than 2900 PSI Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Chart 23 Platform Rotate With 2 turned With key switch turned Repair
71. 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures section 4 to learn how to perform these inspections If any inspection receives an tag and remove the machine from Service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service repaired Comments Checklist A YN Checklist B YN R A 1 Manuals B 1 Exhaust system A 2 Decals and placards A 3 Damage and loose or missing parts B 2 Hydraulic tank filter condition B 3 Tires and wheels A 4 Engine oil level B 4 Brake configuration A 5 Engine coolant Liquid cooled models A 6 Fuel leaks A 7 Hydraulic oil level A 8 Hydraulic leaks A 9 Tire pressure A 10 Oscillate axle A 11 Platform and ground controls A 12 Auxiliary power A 13 Tilt sensor A 14 Limit switches A 15 Drain filter separator Diesel models A 16 Air filter A 17 30 Day Service Perform every 100 hours A 18 Radiator Liquid cooled models A 19 Battery A 20 Replace engine oil and filter Ford models A 21 Electrical wiring Perform every 125 hours A 22 Oil cooler and fins Deutz models Perform every 200 hours A 23 Check engine belt Ford Perkins models A 24 Fuel filter Fo
72. 64 seconds Boom extend Max out Cycle time 9 2V DC 55 to 60 seconds Boom retract Lo range Cycle time Ramp rate 3 seconds 7 8 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 1 2 Horsepower Limiter Board The horsepower limiter board HPL is responsible for governing drive pump output Receiving engine rpm signals from the alternator the HPL senses a drop in rpm normally due to increased drive resistance due to operation on an incline or over rough terrain Instantly the HPL decreases voltage to the drive controller which in turn decreases voltage to the drive pump Decreased voltage adjusts the output of the drive pump to maintain peak engine performance For optimum performance three adjustments are required How to Adjust the Horsepower Limiter Board The engine must be correct before performing this procedure See Maintenance Procedure B 6 Check and Adjust the Engine RPM Do not adjust the horsepower limiter board unless the static battery voltage is above 12V DC and the alternator is operating properly with 12 5 to 14 5V DC output Gasoline LPG models Perform this procedure in gasoline mode 1 Remove the fasteners from the platform control box lid 2 Open the control box lid and locate the horsepower limiter board Electrocution hazard Contact AWARNING with electrically charged circuits could result in
73. CONTROL c 5 NOTE SHOWS USED WIRES NOT USED i DIU TOU EA e 359FGY R20 B2 SINGLE RETURN al N1 NOT USED NOTUSED m S 1 D i 743GY20 D1 INTAKE AIR TEMP SENSOR 358LG BK20 B1 MAP SENSOR INPUT 354LG R18 D2 ECT SENSOR 0 T2 NO USAGE ra re 6 342LG P16 L3 STARTER LOCKOUT Et NOTUSED Y 264W LB18 R1 IDLE AIR CONTROL 1 225BK Y20 D3 DRY FUEL SENSOR 2538067020 i 13 Oll PRESSURE 57BK18 i 242DG18 P2 DRYFUEL LOCKOFF MATING FACE 967 018 IGNITION COIL 2 SHOWN 74GY LB18 E2 HO2S SENSOR SIDE R 1 d 1 7 3 RISA 38 gS 958 ae 889 BS 38 as 88 ax 882559 FORD WIRING HARNESS WIRE COLOR CODE EI Or o6 3 gt gt c X MATING FACE 5 525 5 lt a 229 99 8 29 23 55 55 552 8 5 E mE COLOR CODE COLOR CODE SHOWN as z me ao SRS o 55 59 x 885 59 1 5 5 E 5 885 S zo s 8 BL BLUE GY GREY PURPLE L AL A BK BLACK LB LIGHT BLUE R RED Sj BR BROWN LG LIGHT GREEN T TAN pell ep DIAGNOSTIC DB DARK BLUE N NATURAL W WHITE TT z lt LOCATED INSIDE THE CONNECTOR 8 2 d I GROUND CONTROL BOX z DG DARK GREEN ORANGE YELLOW 5 OIL PRESSURE S SWITCH NC GN GREEN PK PINK
74. Drive functions do not operate at low idle High idle rabbit symbol allows the operator to control multiple boom and or drive functions simultaneously This setting maintains a consistent high idle and is usually selected only when the generator option is being used Foot switch activated high idle rabbit and foot switch symbols should be used for normal machine operation This setting activates high idle only when the foot switch is pressed down 1 Pull out the Emergency Stop button to the ON position at both the ground and platform controls 2 Startthe engine from the ground controls Move and hold the function enable toggle switch in the high idle rabbit symbol position O Result The engine RPM should change to high idle 3 Release the function enable toggle switch O Result The engine RPM should change to low idle TABLE B PROCEDURES Turn the key switch to platform controls At the platform controls move the engine idle select toggle switch to high idle rabbit symbol Do not press down the foot switch Result The engine RPM should change to high idle Move the engine idle select switch to low idle turtle symbol Result The engine RPM should change to low idle Move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol Result The engine RPM should not change to high idle Press down the foot switch Result The engine RPM should change to
75. E Replace toggle switch Repair open in blk red wire circuit from toggle switch to TB35 Repair open in blk red wire circuit from TB35 to terminal 30 on Repair open in wht wire circuit from terminal 87 on CR2 to TB21 to terminal 86 Repair open in brn ground wire circuit to terminal 85 on Start engine move the RPM select toggle Tee switch TS12 to high idle PU Sn rabbit symbol and check if 2 speed solenoid pulls in solenoid does not pull in Check voltage at blk red wire on RPM select oV toggle switches TS4 and d 512 12V oV Check voltage at TB35 gt 12V Y Check voltage at oV terminal 30 on CR3 je Check voltage to oV terminal 86 on CR3 4 12V Check continuity from Em ground to brn wire at eon terminal 85 on CR3 oy oV Check voltage to r terminal 87 on CR3 Replace CR3 relay 2V Continued on the next page Chart 8 Repair open in circuit supplying 12V to center terminal of toggle switch Part No 65196 Genie S 60 amp Genie S 65 5 21 Section 5 Troubleshooting Flow Charts 1 CHART 8 Continued from the previous page Check voltage at oV terminal 86 on CR4 12V Check continuity from bad ground to brn wire at o terminal 85 on CR4
76. FUEL AND HYDRAULIC TANKS 9 Remove the retaining fasteners from the hydraulic tank hold down straps Remove the hold down straps from the hydraulic tank 10 Support the hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 11 Remove the hydraulic tank from the machine Crushing hazard The hydraulic AWARNING tank could become unbalanced and fall if it is not properly supported and secured to the overhead crane 12 Remove the suction strainers from the tank and clean them using a mild solvent 13 Rinse out the inside of the tank using a mild solvent 14 Install the suction strainers using pipe thread sealant on the threads 15 Install the drain plug using pipe thread sealant on the threads 16 Install the hydraulic tank onto the machine 17 Install the two suction hoses and the supply hose for the auxiliary power unit 18 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 19 Clean up any oil that may have spilled 20 Open the hydraulic tank shutoff valves CAUTION Component damage hazard Be sure to open the two hydraulic tank shutoff valves and prime the pump after installing the hydraulic tank Always use pipe thread sealant when installing the drain plug and strainers Use only Dexron equivalent hydraulic fluid Hydraulic system Hydraul
77. Flow Charts eee CHART 21 Continued from the previous page Replace the platform level up directional valve coil Disconnect the wires from platform level ohms directional valve coil IL item S and test the resistance of the valve coil to 7 ohms function Exchange platform level directional valves items operates S and U and activate the platform level up function Replace the faulty directional valve function inoperative function Exchange platform level counterbalance valves 99972195 items EE and FF and activate the platform level up function Replace the faulty counterbalance valve function inoperative Install a 0 to 3000 207 bar pressure gauge at the quick disconnect coupling on the function manifold and activate the platform level up function SEE NOTE 2 Check for mechanical restrictions keeping Exchange platform level flow regulator valve item T with the jib boom flow regulator valve item DD and activate the platform level up function SEE NOTE 1 Platform level up gt function from operating OR replace slave cylinder OR replace slave cylinder counterbalance valves OR consult Genie Industries Service Department m Replace faulty fl operates ce Taully Opera e regulator valve function inoperative Test ma
78. Genie part number 62424 4 80 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface Boom in stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock pin Key switch in the orr position with the key removed Wheels chocked Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie S 60 amp Genie S 65 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate flow chart thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from moveme
79. IT eo aoe z REAR f RIGHT 7 7 Ta ACYL i 5 T M3 1 REAR 68m LEFT l 1 STEERING een 2224 LH CYLINDER M1 8 5 Lesen sued I CASE DRAINS Part No 65196 Genie S 60 amp Genie S 65 6 25 Third Edition First Printing Section 7 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the Genie S 60 amp Genie S 65 Operator s Manual Be sure that all necessary tools and parts are available and ready for use Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface in the stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock pin Key switch in the orr position with the key removed Wheels chocked Repair Procedures Abo
80. LE d TS23 mo 1 1 o 6 s 6 tr gt LG N 86 Si 11 EBEN Des La S L1 87 30 87 Ss 85 E A OOG 9 y b 0600 86 COIL 7 NO T9 D 9 NC 85 COIL 9 R 4 TS1 L4 TS2 30 COMMON COM TS7 TS8 R1 TS4 87 NORMALLY OPEN NO 87 NORMALLY CLOSED NC P3 TS5 TS6 P2 NC NOTE R1 RESISTOR IS MOUNTED TO EXTEND RETRACT CONTROLLER USE 100 OHM RESISTOR FOR 4WD AND 150 OHM RESISTOR FOR 2WD Part No 65196 Genie S 60 amp Genie S 65 6 19 Section 6 Schematics Third Edition First Printing Hydraulic Symbols Legend Pressure gauge OF Filter with bypass valve fixed displacement Pump bi directional variable displacement Motor bi directional Motor 2 speed bi directional Om Pump prime mover engine or motor Double acting cylinder www Differential sensing valve es e GIGA Orifice with size Solenoid operated proportional valve Shut off valve lt n Check valve J P outer i 1 Priority eo flow regulator function steer manifold Relief valve WU I T Nl Solenoid operated 2 position ZZ 2 way directional valve Priority flow regulator PEERI Directional valve mec
81. ON position hold the function enable switch to either side and move the boom up down toggle switch TS16 in the DOWN direction Check voltage on red blk 4 wire on boom directional valve coil item B Third Edition First Printing oV gt Hold the function enable switch to either side and move the boom up down toggle switch in DOWN direction and check voltage at TB2 12V or more oV 20V or more v With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the boom controller in the DOWN direction Check voltage 12V or more at TB2 oV 12V or Press down the foot switch and move the boom controller in the DOWN direction and check voltage at TP2 more Press down the foot switch and check voltage at terminal on the boom controller oV 12 Re adjust boom controller see Repair Section OR replace boom controller OR consult Genie Industries Service Department Continued on the next page Repair open in red blk 4 wire circuit from TB2 to boom directional valve coil OR repair open in brn ground wire circuit to valve coil Troubleshoot boom up down toggle switch OR repair open in red blk wire circuit from TS16 to TB2 OR consult Genie Industries Service Department Rep
82. On Deutz or Perkins diesel models hold manual fuel shutoff lever to the closed position Hold start toggle switch and crank engine over while observing spline drive at rear of main pump spline turns Troubleshoot inoperative boom functions and inoperative drive functions separately spline does not turn Engine to pump flex plate coupling is faulty OR main pump is faulty Consult Genie Industries Service Department If engine has been run with valves closed it may have damaged one or both pumps Please contact the Genie Industries Service Department 5 24 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts All Lift and Steer Functions inoperative Drive Functions Operational Be sure the generator on off toggle switch if equipped is in the OFF position Be sure the hydraulic suction line shutoff valve for the lift steer pump is in the oPEN position Be sure all grounding wires for the hydraulic manifold valves are free of corrosion and have full continuity to ground Install a 0 to 5000 PSI 345 bar pressure gauge on the function manifold Start engine hold the function enable toggle switch to either side and move the boom retract toggle switch TS7 in the RETRACT direction Check the hydraulic pressure SEE NOTE 1 Troubleshoot each function i
83. Part No 65196 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Third Edition First Printing HYDRAULIC PUMPS 10 2 Drive Pump The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electronic displacement controller EDC located on the pump The only adjustment that can be made to the pump is the neutral or null adjustment Any internal service to the pump should only be performed at an authorized Sundstrand Sauer service center Call Genie Industries Service Department to locate your local authorized service center How to Remove the Drive Pump CAUTION Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connection at the electronic displacement controller EDC located on the drive pump 2 Close the two hydraulic tank valves located at the hydraulic tank open closed Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the cLosEp position or component damage will
84. Please begin troubleshooting from beginning of chart OR consult Genie Industries Service Department Repair open from TB30 through red 5 wire to LS3 then from LS3 through blk 5 wire to 12 Part No 65196 Genie S 60 amp Genie S 65 5 71 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 36 Auxiliary Functions inoperative Be sure all other functions operate normally Be sure key switch is in the appropriate position and both Emergency Stop buttons are pulled out to the on position Be sure engine is not running when using auxiliary power Note Operating auxiliary power with the engine running should immediately stop the engine Lift the red auxiliary Install a 0 to 5000 psi pump switch cover motor 345 bar pressure move the auxiliary operates gauge into the pressure 2000 psi power toggle switch TS9 port of the auxiliary to either side and listen pump and move the for sound of auxiliary auxiliary power toggle pump motor operating switch to either side and note the pressure less than 2000 psi Check for 7 connection between goo electric motor and the 4 pump by removing the pump from the motor Leave all the hoses motor does connected and visually not operate check coupling connection Replace the auxiliary power unit Y With key switch turned Check continuity from bad to ground controls and 12V nega
85. RED BLK 28 E H i RED WHT 2 RED WHT 23 E H od leM LEVEL SENSOR e 1 I TS UN 5 9 1 ES GRN 858 GRN 1 W HORN RELAY ud i 00 1 o i 9 8 15 BLK CRS 2 BLK 2 a 8 15 BLK CRS5 EH DG m W GS gt 29 x a Ez 315 2 WHT WHT CR17 E H 88 5 2 HYDRAULIC OIL lt 8 TEMPERATURE a SWITCH rape a SI 1 COOLING FAN OPTION ay ORG BLK 1 ORG BLK 41 E H Lm Rue TRECE mter i B 9 E ii q E 1 2 i 1 4 mam 1 idi l ad 052 ads 842 2 g 5 3 amp ttt jus a B i rr i lt E 8 PETERE SERERE MEN RED RED 20 E H 3 ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND THE KEY SWITCH OFF 2 THE FOOTSWITCH POWER IS CONNECTED TO BOTH WHT WIRES WITHOUT THE LIFT DRIVE SELECTOR OPTION 4 R1 100 OHMS FOR 4WD R1 150 OHMS FOR 2WD 1 CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION Part No 65196 Genie S 60 amp Genie S 65 6 16 Section 6 Schematics Electrical Schematic Perkins Diesel Models
86. See Repair Section 0 or infinite Section 5 Troubleshooting Flow Charts n J i CNN ohms Replace boom extend directional valve coil 2 5 to 3 5 ohms Hold the function enable switch to either side and move the boom extend retract toggle switch in the EXTEND direction Manually override the directional valve by pushing in on the end of the valve spool function operates Replace faulty directional valve function inoperative Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the boom function manifold and start the engine Hold the function enable switch to either side and move the boom extend retract toggle switch in the RETRACT direction and check the pressure 2500 PSI or more m Check for mechanical restrictions keeping boom from retracting OR repair cylinder or cylinder counterbalance valves OR consult Genie Industries Service Department less than 2500 PSI Exchange extend retract flow regulator valve item G with boom up down flow regulator valve item H Check boom retract function function operates ee Replace faulty flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal fau
87. The turntable cover could become unbalanced and fall if it is not properly supported and secured to an appropriate lifting device Alignment adjustments may be necessary when a new cover is installed Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures Deutz Engine F4L 1011F 6 1 RPM Adjustment Refer to Maintenance Procedures B 6 Check and Adjust the Engine RPM 6 2 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump pump pump shaft coupler flex plate with raised spline flywheel 3 8 inch 9 5 mm gap How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Supportthe drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 4 Remove the flex plate mounting fasteners then remove the flex plate from the engine flywheel How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump Torque the flex plate mounting bolts to 34 ft Ibs 46 Nm 2
88. at the fuel tank to the cLoseD position 3 Atthe pre filter disconnect the fuel hose that goes to the fuel tank 4 Disconnect and plug the fuel hose from the fuel pre filter to the fuel pump then remove the pre filter 5 Install the new fuel pre filter Genie part number 52179 and connect the fuel hoses to the filter 6 Clean up any fuel that may have spilled during the installation procedure 7 Remove the 2 engine pivot plate retaining bolts Swing the engine pivot plate away from the machine to access the fuel pressure regulator filter 8 Locate the fuel pressure regulator filter installed on the engine mounting leg 9 Disconnect and plug the hoses from the fuel pressure regulator filter Explosion and fire hazard ADANGER f Electronic Fuel Injection EFI systems operate at a very high pressure Fuel may be expelled under pressure if the hoses are removed too quickly Loosen the fuel hoses very slowly to allow the fuel pressure to dissipate gradually Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them 10 Remove the fuel pressure regulator filter mounting fasteners Then remove the regulator filter from the engine mounting leg Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures TABLE PROCEDURES 11 Install the new fuel pressure regulator filter Genie part number 52567 onto the engine m
89. connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the chassis cover from the non steer end of the drive chassis 3 Disconnect the directional valve linkage by removing the clevis yoke from the drive chassis 4 Start the engine from the platform controls 5 With the engine running manually activate the valve and observe the pressure reading on the pressure gauge Sequencing valve specifications Pressure 950 psi 65 5 bar 6 Turn the engine off Hold the unloader valve with a wrench and remove the cap index 4 7 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap Tip over hazard Do not adjust the AWARNING relief valve higher than specified 8 Repeat steps 3 through 6 and manually activate the valve to confirm the valve pressure 9 Turn the engine off remove the pressure gauge and assemble the directional valve linkage 10 Install the cover on the non steer end of the drive chassis Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures MANIFOLDS 11 6 Directional Valve Manifold Components The directional valve manifold is mounted inside the drive chassis at the non steer end Index No Description Function Torque 1 ch eaten aint tete tota t Breather 2
90. continued use may cause component damage Extremely dirty conditions may required that the filter be replaced more often Explosion and fire hazard Engine A DANGER fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Immediately clean up any fuel that may have spilled during this procedure 1 Open the engine side turntable cover and locate the fuel filter water separator 2 Tag disconnect and plug the fuel hose from the fuel tank at the fuel filter water separator head Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures 3 Loosen the vent plug located on the fuel filter water separator head Fuel filter water separator a head bolt b vent plug c drain plug d filter bowl e separator head 4 Place a suitable container under the filter bowl Loosen the drain plug located at the bottom of the bowl Completely drain the fuel 5 Loosen the head bolt Rotate the filter bowl counterclockwise and remove it from the element 6 Rotate the filter element counterclockwise and remove it from the filter head 7 Install the bowl onto the new filter element Genie part number 22942 TABLE C PROCEDURES 8 Applyathin layer of clean diesel fuel onto
91. cylinder rod end pivot pin at the platform end of the number 3 boom tube Use a soft metal drift to remove the pin 13 Support and slide the extension cylinder out of the base end of the number 3 boom tube Place the extension cylinder on blocks for support Crushing hazard The extension AWARNING cylinder may become unbalanced and fall when it is removed from the number 3 boom tube if it is not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 14 Remove and label the wear pads from the extension cylinder Pay careful attention to the location of each wear pad 4 3 Boom Lift Cylinder How to Remove the Boom Lift Cylinder Bodily injury h Thi AWARNING odily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom to a horizontal position 2 Place support blocks under the boom lift cylinder across the turntable 3 Attach an overhead 5 ton 4536 kg crane to the boom Do not lift
92. down the foot switch Result The drive enable indicator light should be on Rotate the turntable so the boom is between the non steer wheels Result The drive enable indicator light should be off and drive function should operate Rotate the turntable to the left until the boom is past the left non steer wheel Result The drive enable indicator light should be on Drive function should not operate until the drive enable override toggle switch is activated Rotate the turntable to the right until the boom is past the right non steer wheel Result The drive enable indicator light should be on Drive function should not operate until the drive enable override toggle switch is activated 4 16 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures TABLE A PROCEDURES A 15 2 Loosen the vent plug located on the fuel filter water separator head Drain the Fuel Filter Water Separator Diesel Models Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and component damage Explosion and fire hazard Engine A DANGER fuels are combustible Perform this procedure in an open well ventilated area away from heaters Fuel filter water separator sparks flames and lighted a head bolt Always have an vent plg tobacco
93. end Check the linkage for damage or improper linkage adjustment See Repair section 11 6 How to Set Up the Directional Valve Linkage good Install a 010 2000 psi 138 bar pressure gauge at the quick disconnect coupling on the oscillate manifold Disconnect the oscillate linkage from non steer axle Start the engine and manually activate the directional valve Check the pressure 950 psi Consult Genie Industries Service Department less than 950 psi Re adjust or replace linkage Adjust the sequence valve See Repair procedure 11 5 How to Adjust the Oscillate Sequencing Valve Pressure OR consult Genie Industries Service Department Chart 25 Part No 65196 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 26 Jib Boom Up Function inoperative Be sure all other functions operate normally With the key switch Hold the function enable turned to ground switch to either side and controls and both move the jib boom Emergency Stop buttons toggle switch in the UP pulled out to the ON direction and check position hold the voltage at TB17 function enable switch to either side and move the jib boom toggle switch oV TS19 in the UP direction Check voltage
94. fitting Drive hub mounting bolts lubricated 90 ft lbs and the bleed valve 122 Nm 3 Loosen the wheel lug nuts Do not remove Drive motor mounting bolts dry 75 ft lbs them 102 Nm 4 Center a lifting jack of ample capacity under the Drive motor mounting bolts lubricated 56 ft lbs non steering axle Raise the machine 76 Nm approximately 6 inches 15 cm and place blocks under the drive chassis for support 5 Remove the wheel lug nuts then the tire and wheel assembly 6 Place a second lifting jack under the drive hub for support and secure the drive hub to the lifting jack Part No 65196 Genie S 60 amp Genie S 65 7 79 Section 7 Repair Procedures Third Edition First Printing NON STEERING AXLE COMPONENTS 17 3 Wheel Brake How to Remove a Wheel Brake When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the drive motor See 17 1 How to Remove a Drive Motor 2 Tag disconnect and plug the hydraulic hose from the brake Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the brake from the machine 7 80 Genie S 60 amp Genie S 65 Part No 65196 California
95. five types of maintenance inspections that must be performed according to a schedule daily quarterly six months annual and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Six month or every 500 hours A B C Annual or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years 4 2 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hour Inspection A B C D
96. from the machine to access the engine belt Table C Procedures Remove the front engine access cover mounting fasteners Inspect the engine belt for Cracking Glazing Separation Breaks Replace belt if any damage is found Check the engine belt for proper tension Adjust as necessary Deutz Diesel engine Install the front engine access cover Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts Belt deflection Deutz Diesel models inch to 1 2 inch 9mmto 12 mm Engine belt Genie part number 32698 a engine pivot plate b pivot plate retaining bolts c air baffle Part No 65196 Genie S 60 amp Genie S 65 4 53 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE C PROCEDURES C 2 Check the Engine Valve Clearances Deutz Diesel Models Engine specifications require that this procedure be performed initially at 500 hours at 1000 hours and every 1000 hours thereafter Complete information to perform this procedure is available in the Deutz FAL 1011F Operation Manual Deutz part number 0297 7343 Genie part number 52883 C 3 Replace the Fuel Filter Water Separator Element Perkins Diesel Models Replacing the diesel fuel filter water separator element is essential for good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and
97. function Check to see if platform levels E Plumb a 0 to 5000 psi 345 bar pressure gauge into master cylinder rod end hydraulic hose hose connected to port PL2 using a tee fitting Activate boom up function and check the NOTE 3 pressure SEE NOTE 2 Install a 0 to 5000 psi 345 bar pressure gauge into the barrel end hydraulic hose from the master cylinder and raise the boom one inch 2 5 cm at a time Continually monitor the pressure gauge during boom up Do not allow the pressure to exceed 2600 PSI NOTE 2 m v Repair or replace the slave cylinder yes Replace the platform level counterbalance valves items FF amp GG SEE Check for mechanical restrictions OR replace the slave cylinder counterbalance valves SEE Repair or replace the master cylinder SEE NOTE 1 NOTE 1 5 60 2600 PSI or more 5 65 2900 PSI or more NOTE2 S 60 Less than 2600 PSI 5 65 Less than 2900 PSI NOTE 3 5 60 2600 PSI 5 65 2900 PSI 5 46 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Chart 21 Platform Level With key switch turned With key switch turned ner open in org 4 to ground controls and to ground control
98. gauge when the engine is running How to Remove the Oil Temperature and Oil Pressure Gauge Sending Units Perform this procedure with the engine off 1 Remove the fasteners from the engine side cover remove the cover 2 Tag and disconnect the wiring from the desired sending unit Remove the sending unit from the engine block 3 Install the new sending unit Do not over tighten 4 Connect the wires to the new sending unit Burn hazard Contact with hot ACAUTION engine fluids or components may cause severe burns Always use pipe thread sealant when installing a sending unit Oil temperature sending unit specifications Torque 8 10 ft Ibs 11 14 Nm Hex size 13 16 inch Temperature switch point 300 F 149 C Oil pressure sending unit specifications Torque 8 10 ft Ibs 11 14 Nm Hex size 11 16 inch Oil pressure switch point 7 psi 0 48 bar Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 7 1 RPM Adjustment Refer to Maintenance Procedures B 6 Check and Adjust the Engine RPM 7 2 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump pump pump shaft coupler flex plate with raised spline flywheel 1 4 inch 6 4 mm gap Perkins Engine 704 30 How to Remove the Flex Plate 1 Disco
99. lways have u c drain plug approved fire extinguisher within d filter bowl easy reach e separator head Perform this procedure with the 3 Loosen the drain plug located at the bottom of engine off the bowl Allow the water to drain into a suitable container until fuel starts to come out Perkins Models Immediately tighten the drain plug 1 Open the engine side turntable cover and locate the fuel filter water separator Den pug If the fuel filter water separator is completely drained you must prime the fuel filter water separator before starting the engine Refer to C 4 in this section Replace The Fuel Filter Element Perkins Diesel Models for instructions on how to prime the fuel filter water separator Part No 65196 Genie S 60 amp Genie S 65 4 17 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE A PROCEDURES 5 Clean up any fuel that may have spilled 6 Start the engine from the ground controls and check the fuel filter water separator and vent plug for leaks ADANGER Deutz Models Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately 1 Open the engine side cover and locate the fuel filter water separator 2 Loosen the drain plug located at the bottom of the filter Allow the water to drain into a suitable container until fuel starts to
100. no continuity infinite terminal 2 to 3 4 5 amp 6 no continuity infinite terminal 3 to 4 5 amp 6 no continuity infinite terminal 4 to 5 continuity zero Q terminal 4 to 6 no continuity infinite terminal 5 to 6 no continuity infinite Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 2 1 Platform How to Remove the Platform 1 Open the platform control box 2 and disconnect the foot switch wiring from the terminal strip inside the platform control box Remove the cable from the bottom of the platform control box 3 Remove the platform control box mounting fasteners Lower the control box and set it aside If your machine is equipped with an airline to platform option the airline must be disconnected from the platform before removal 4 Support the platform with an appropriate lifting device 5 Remove the platform mounting fasteners and remove the platform from the machine Crushing hazard The platform AWARNING could become unstable and fall when it is removed from the machine if it is not properly supported Platform Components 2 2 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of boom motion It operates in a closed circuit hydraulic loop wit
101. not remain level during test see Repair Procedure 11 6 How to Set Up the Directional Valve Linkage OR see Repair Procedure 11 5 How to Adjust the Oscillate Sequencing Valve Pressure Part No 65196 Genie S 60 amp Genie S 65 4 11 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE A PROCEDURES A 11 Test the Platform and Ground Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machine functions and shut off the engine Each function should activate operate smoothly and be free of hesitation jerking and unusual noise 1 Pull out the Emergency Stop button at the ground controls to the on position 2 Startthe engine from the ground controls 3 Do not hold the function enable switch to either side Attempt to activate each boom and platform function toggle switch O Result All boom and platform functions should not operate 4 Hold the function enable switch to either side and activate each boom and platform function toggle switch O Result All boom and platform functions should operate through a full cycle Descent alarm if equipped should sound while the boom is lowering 5 Push in the Emergency Stop button to the position O Result No function should oper
102. occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition CAUTION 3 Tagand disconnect and plug the hydraulic hoses from the drive and lift steer pumps Cap the fittings on the pumps Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Support the pumps with a suitable lifting device and remove the two drive pump mounting fasteners 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 6 Remove the drive pump from the machine CAUTION Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Before installing the pump verify proper pump coupler spacing Refer to the appropriate flex plate installation instructions for your engine How to Prime the Pump CAUTION Component damage hazard Be valves are in the position before priming the pump The engine must not be started with the hydraulic tank shutoff valves in the cLosEp position or component damage will occur 1 Connecta 0 to 600 psi 0 to 41 bar pressure gauge to the diagnostic nipple on the drive
103. oil per specifications and install the oil filler cap 9 Startthe engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off 10 Check the oil filter and drain hose for leaks 11 Check the engine oil level dipstick Add oil if needed Deutz F4I 1011 Engine 11 quarts Oil capacity including filter 10 5 liters Cil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE or CC SF grades Oil filter Genie part number 49924 D 8 Clean the Fuel Pump Strainer Deutz Diesel Models Cleaning the fuel pump strainer is essential for good engine performance and service life A dirty or clogged strainer may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions or not operating the machine for extended periods of time may required that the strainer be cleaned more often Explosion and fire hazard Engine A DANGER fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Immediately clean up any fuel that may have spilled during this procedure 1 Open the engine side turntable cover and locate the fuel pump
104. on red wht wire on boom up down proportional valve coil item P 20V or more v Continued on the next page oV Hold the function enable switch to either side and move the boom up down toggle switch in the DOWN direction and check voltage at TB3 oV With key switch turned 6 to 7V to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the boom controller in DOWN direction Check voltage at TP3 ov Press down the foot switch and check voltage at terminal on the boom controller 12 Re adjust boom controller see Repair Section OR replace boom controller OR consult Genie Industries Service Department 6 to 7V Chart 15 Repair open in red wht 4 wire circuit from TB3 to boom up down proportional valve coil OR repair open in brn ground wire circuit to valve coil Repair open in red wht 3 wire from TP3 to TB3 Repair open in power supply circuit from TP24 to boom controller OR repair open in brn ground wire circuit from ground to boom controller Part No 65196 Genie S 60 amp Genie S 65 5 31 Section 5 Troubleshooting Flow Charts 1 CHART 15 Continued from the previous page With key switch turned to ground controls and both Emergency Stop buttons pulled out to the
105. open in grn 4 1 to ground controls and to ground controls and wire from TB17 to Left Function both Emergency Stop both Emergency Stop d platform rotate left Inoperative buttons pulled out to the buttons pulled out to the directional valve coil ON position hold the ON position hold the item BB OR repair function enable switch to 0V function enable switch to open in brn ground wire Be sure all other either side and move the either side and move the circuit to valve coil functions operate platform rotate toggle platform rotate toggle normally switch TS13 in the LEFT switch in the LEFT direction Check voltage direction Check voltage at grn wire on platform at TB17 rotate left directional valve item BB i With key switch turned Troubleshoot platform to platform controls and rotate toggle switches both Emergency Stop TS13 and TS5 OR buttons pulled out to the repair open in red power ON position press down gy wire circuit to TS13 and the foot switch and gt TS5 OR repair open in move the platform rotate grn wire circuit from toggle switch in the LEFT TS13 and TS5 to TB17 direction Check voltage OR consult Genie at TB17 Industries Service Department 12V or more Troubleshoot platform rotate toggle switch 513 OR repair open in red power wire circuit to TS13 OR repair open in 12V or more grn wire circuit from 151310 TB17 OR consult Genie Industries Service Department Y Continued on the next page Part No 65
106. poor terminal connections or shorted wires from the HO2 sensor to the ECM to ground OR replace HO2 sensor Check engine coolant level OR check for shorted wires or poor terminal connections from the ECT sensor to the ECM OR replace the ECT sensor The IAT sensor shares the same ground wire as the ECT and MAP sensors Check for shorted wires or poor terminal connections from the IAT sensor to the ECT and MAP sensors to the ECM OR replace the IAT sensor Check engine oil level OR check for shorted wires or poor terminal connections from the oil pressure switch to the ECM OR replace the oil pressure switch Part No 65196 Genie S 60 amp Genie S 65 5 5 Section 5 Troubleshooting Flow Charts Third Edition First Printing FAULT CODE CHART Fault Code The CKP and CMP sensors work together if one is bad the other Crankshaft one won t work Position correctly and causes Check for shorted wires or poor terminal CKP sensor the ECM to detect a connections from the CKP and CMP senses extra fault The ECM uses sensors to the ECM OR replace the CKP or or missing the signal pulses from sensor pulses the CKP and CMP sensors to initiate sequential fuel injection The CMP and CKP sensors work together if one is bad the other Camshaft one won t work Position correctly and causes Check for shorted wires or poor terminal CMP sensor the ECM to detect a connections from the CKP and CMP senses fault The ECM use
107. positive fuel tank cap venting air should pass freely through the cap Result Air should pass through the fuel tank cap Clean or replace the cap 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air 4 Repeat step 2 5 Install the fuel tank cap onto the fuel tank B 24 Replace the Engine Air Filter Element Engine specifications requires that this procedure be performed every 400 hours or annually whichever comes first Perform this procedure more often if dusty conditions exist Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off Gasoline LPG and Deutz Diesel Models 1 Open the engine side turntable cover and remove the retaining ring from the end cap of the air filter canister 2 Remove the end cap from the air cleaner canister 3 Remove the air filter retaining fastener Remove the filter element 4 Clean the inside of the canister and the gasket with a damp cloth 4 50 Genie 5 60 amp Genie 5 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures TABLE PROCEDURES 5 Install the new air filter element and mounting 5 Install the new filter element fastener 6 Install the end cap onto the canister
108. promptly and operate smoothly in low and high idle The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running 4 42 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures B 16 Test the Drive Enable System Proper drive enable system operation is essential to safe machine operation When the boom is past the non steering wheels drive movement is stopped and the indicator light turns on The drive enable switch must be held to either side to reactivate the drive function and should alert the operator that the machine will move in the opposite direction that the drive and steer controls are moved An improperly functioning drive enable system may allow the machine to be moved into an unsafe position 1 Start the engine from the platform controls 2 Move the lift drive selector toggle switch to the lift position if equipped Press down the foot switch 4 Rotate the turntable to the right until the boom moves past the right non steering wheel Result The drive enable indicator light should turn on and remain on while the boom is anywhere in the range shown 5 Move the lift drive select toggle switch to the drive position if equipped 6 Slowly move the drive control handle off center Result The drive function should not operate TABLE B PRO
109. spilled 19 Open the hydraulic tank shutoff valves CAUTION Component damage hazard Be sure to open the two hydraulic tank shutoff valves and prime the pump after installing the hydraulic tank Refer to Repair Procedure 10 2 How to Prime the Pump Always use pipe thread sealant when installing the drain plug and strainers Use only Dexron equivalent hydraulic fluid Hydraulic system Hydraulic tank capacity 45 gallons 170 liters Hydraulic system 53 gallons capacity including tank 200 6 liters Hydraulic fluid Dexron equivalent Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures E 2 Change or Recondition the Engine Coolant Liquid Cooled Models Replacing or reconditioning the engine coolant is essential to good engine performance and service life Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage Extremely dirty conditions may require coolant to be changed more frequently Bodily injury hazard Beware of ACAUTION hot engine parts and coolant Contact with hot engine parts and or coolant may cause severe burns Perform this procedure with the engine off and cooled 1 Remove the 2 engine pivot plate retaining bolts Swing the engine pivot plate away from the machine to access the cooling system a engine pivot plate b pivot plate retaining bolts c a
110. sure the wiring to limit switches is intact and show no signs of damage or corrosion Extend the boom past the limit switch LS1 and check continuity from ground to terminal 6 on the horsepower limiter board continuity Replace horsepower limiter board OR re adjust horsepower limiter board OR consult Genie Industries Service Department r continuity Check continuity from ground to TB40 continuity no continuity v Repair open in org wire circuit from TB40 to TP40 to terminal 6 on horsepower limiter board Test limit switches See procedure A 14 in the Maintenance Section Replace faulty limit switch contact OR replace limit switch good Y Repair open from wht wires at TB40 to drive limit switches LS1 and LS2 then from brn ground wires to ground Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Chart 35 Drive Enable With ey switch turned With Key switch turned Repair open n power to platform controls and to platform controls and supply circuit from System Is bon meneno Pn Ue pate SUE 1 j uttons pulled out to the uttons pulled out to the Malfunctio
111. the element gasket Install the filter bowl assembly onto the filter head Tighten the drain plug 9 Tighten the head bolt to 65 in Ibs 7 Nm 10 Tighten the vent plug 11 Clean up any diesel fuel that may have spilled during the installation procedure 12 Connect the fuel hose from the fuel tank to the fuel filter water separator Tighten the clamp Bleed the fuel system Before bleeding the system fill the fuel tank 13 Loosen the vent plug located on the fuel filter water separator head 14 Operate the priming lever of the fuel lift pump until fuel free from air comes from the vent plug Tighten the vent plug 15 Loosen the air vent screw located on top of the fuel injection pump 16 Tighten the air vent screw when air stops coming through the air vent 17 Clean up any diesel fuel that may have spilled during the bleeding procedure and dispose of properly 18 Start the engine from ground controls and check for leaks Part No 65196 Genie S 60 amp Genie S 65 4 55 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE C PROCEDURES C 4 2 Thoroughly clean the outside surfaces of the j fuel filt bly Replace the Fuel Filter Element Perkins Diesel Models 3 Hold the bottom cover of the filter element and remove the element retaining screw Replacing the diesel fuel filter element is essential for good engine performance and service life A CoS dirty o
112. the Engine Air Breather Perkins Diesel Models 4 78 E 5 Grease the Steer Axle Wheel Bearings 2WD Models 4 78 E 6 Check the Fuel Injectors Perkins Diesel Models 4 80 viii Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing EEE Section Five TABLE OF CONTENTS Troubleshooting Flow Charts 5 1 Ea lt Code Chart t iine e rt od ea ed 5 3 1 Engine Will Not Crank Over ssssssssseseeeeeneeeneenneeee nennen entree 5 8 2 Engine Cranks Over But Will Not Start Gasoline LPG Models 5 10 2A Engine Runs While Cranking then Dies Gasoline LPG Models 5 12 Engine Cranks Over But Will Not Start Diesel Models 5 13 Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LPG Models 5 16 5 Engine Will Not Start On Gasoline But Will Start On LPG Gasoline LPG Models 2 22 22 1 0 nennen nennen nnne nnns 5 18 6 Engine High Idle Inoperative Gasoline LPG 5 19 7 Engine Low Idle Inoperative Gasoline LPG Models 5 20 8 Engine High Idle Inoperative Diesel 5 21 9 Engine Low Idle I
113. the PCV valve from the canister Discard the valve 5 Thoroughly clean the inside and outside of the hose tubes and fittings 6 Install the new PCV valve and connect the hose 7 Swingthe engine pivot plate back to its original position and install the two engine pivot plate retaining bolts PCV Valve Genie part number 33957 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures D 1 Check the Boom Wear Pads Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions If the wear pads are still within specification see Repair Procedure 4 2 How to Shim the Boom 1 Start the engine from the ground controls 2 Raise the end of the boom to a comfortable working height chest high then extend the boom 1 foot 30 cm 3 Measure each wear pad Replace the wear pad if itis less than specification If the wear pad is still within specification shim as necessary to obtain zero clearance and zero drag 4 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Always maintain squareness b
114. the boom 4 Support the rod end of the boom lift cylinder with an overhead crane or similar lifting device Crushing hazard The boom lift AWARNING cylinder could become unbalanced and fall when it is disconnected from the machine if it is not properly supported 7 26 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 5 Tag disconnect and plug the boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Remove the pin retaining fastener from the boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin and lower the lift cylinder onto the blocks Protect the cylinder rod from damage Crushing hazard The boom lift AWARNING cylinder could become unbalanced and fall when it is disconnected from the machine if it is not properly supported by the crane 7 Remove the mounting fasteners from the barrel end cylinder pin retaining plates 8 With the lift cylinder being supported by the overhead crane pull the cylinder toward the platform and remove it from the machine Crushing hazard The lift cylinder AWARNING may become unbalanced and fall if itis not properly supported Component damage hazard The cable
115. the foot Switch is pressed down and promptly stop when the foot switch is released The foot switch will also shift the engine into high idle if the idle select is switched to the rabbit and foot switch symbol An improperly functioning foot switch can cause an unsafe working condition and endanger platform and ground personnel The engine should not start if the foot switch is pressed down 1 Turn the key switch to platform controls and pull out the Emergency Stop button to the position at both the ground and platform controls 2 Press down the foot switch and attempt to start the engine by moving the start toggle switch to either side O Result The engine should not start 3 Do not press down the foot switch and attempt to start the engine O Result The engine should start 4 Do not press down the foot switch and operate the machine functions Result The machine functions should not operate 5 Press down the foot switch and operate the machine functions O Result The machine functions should operate Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures B 14 Test the Engine Idle Select Operation A properly operating engine idle select switch is essential to good engine performance and safe machine operation There are three settings Low idle turtle symbol allows the operator to control individual boom functions only
116. to Section Two Hydraulic Hose and Fitting Torque Specifications Remove the pin retaining fasteners from both the steering cylinder and the tie rod clevis pins Remove the pins steer cylinder oscillate cylinder yoke pivot pin drive hub yoke clevis pin tie rod qaroao om 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor AWARNING 2 injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Loosen the wheel lug nuts Do not remove them Block the non steering wheels and center a lifting jack of ample capacity under the steering axle Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support Remove the lug nuts then remove the tire and wheel assembly Remove the hydraulic hose clamp retaining fastener from the top of the yoke 8 Remove the drive motor mounting fasteners 9 Slide the drive motor shaft out of the drive hub and remove the drive motor from the machine 10 Remove the pin retaining fasteners from the upper and lower yoke pivot pins 11 Support and secure the yoke drive hub assembly to a lifting jack Part No 65196 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Third Edition First Printing 4WD STEERING AXLE COMPONEN
117. to carburetor is not binding see Repair section See Repair Section How to Retrieve Fault Codes 1 there a fault code stored in the ECM memory yes Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department r Refer to the fault code chart in this section for a description of the fault and recommended repairs Start engine and move the RPM select toggle switch TS12 to low idle turtle symbol Check voltage at TB35 12V w Isolate the ground and platform RPM toggle switches TS4 and TS12 check individually and replace faulty switch Replace ECM or consult Genie Industries Service Department Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Engine High Idle Inoperative Diesel Models Be sure mechanical linkage is not binding or defective Be sure 2 speed solenoid grounding wires are free of corrosion and have full continuity to ground Check high idle adjustment see Maintenance section OR see Deutz OR Perkins workshop manual to troubleshoot fuel injection system Check voltage on red wire at center terminal of RPM select toggle Switches oV
118. ye Repair or replace starter or starter solenoid Part No 65196 Genie S 60 amp Genie S 65 5 9 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 2 Engine Cranks Over But Will Not Start Gasoline LPG Models Be sure to check the engine oil level and fill as needed Be sure to check fuel levels and engine coolant level Be sure the gasoline shut off valve is in the ON OPEN position Perform following tests in gasoline mode only Be sure that the water temperature gauge does not show an overheated condition See Repair Section How to Retrieve Fault Codes Is there a fault code stored in the ECM memory yes gt gt Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Refer to the fault code chart in this section for a description of the fault and recommended repairs With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position move the start toggle switch to either side and check battery voltage while engine is cranking less than 11V Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery more than 11V With the ke
119. 0 amp Genie S 65 Part No 65196 Third Edition First Printing a ramp rate trimpot b lorange trimpot c terminal activates max out range d not used e terminal X not used f terminal ground g terminal positive h terminal A proportional output i threshold trimpot j max out trimpot 4 Setthe preliminary ramp rate Turn the ramp rate trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click Connect the red lead from a volt meter to the A terminal on the controller printed circuit board Connect the black lead to ground 6 Setthe threshold Press down the foot switch then slowly move the controller off center until the moment a voltage reading appears Adjust the voltage to 3 5V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Section 7 Repair Procedures PLATFORM CONTROLS Set the max out Press down the foot switch fully retract the boom then move the controller all the way to the left or right Adjust the voltage to 6 75V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Set the lo range Press down the foot switch extend the boom approximately 3 feet 0 9 m then move the controller all the way to the left or right Adjust the voltage to 6V DC Turn the lo range trimpot adjustment screw
120. 18 9 L min with oscillate axle 28 Solenoid valve N O Poppet BB Platform rotate left Jib boom up 29 Solenoid valve N O Poppet CC Platform rotate right Jib boom down 30 Flow regulator valve 0 6 2 27 L min DD Platform rotate jib boom 31 Counterbalance valve EE Platform level up 32 Counterbalance valve FR Platform level down 33 Check valve GG Boom extend retract circuit Torque 11 13 ft lbs 15 18 Nm 10 12 ft lbs 14 16 Nm 11 13 ft lbs 15 18 Nm 11 13 ft lbs 15 18 Nm 10 12 ft lbs 14 16 Nm 25 30 ft lbs 34 41 Nm 10 12 ft lbs 14 16 Nm 25 30 ft lbs 34 41 Nm 10 12 ft lbs 14 16 Nm 35 40 ft lbs 47 54 Nm 11 13 ft lbs 15 18 Nm 11 13 ft lbs 15 18 Nm 10 12 ft lbs 14 16 Nm 25 30 ft lbs 34 41 Nm 25 30 ft lbs 34 41 Nm 10 12 ft lbs 14 16 Nm 35 40 ft lbs 47 54 Nm 35 40 ft lbs 47 54 Nm 11 13 ft lbs 15 18 Nm Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures MANIFOLDS 9 Gi 5 29 BB 7 ory Tee O px 4 2 9 9 N
121. 18 Nm 12 Check Valve dieit E uates Differential sensing circuit boom up down 11 13 ft Ibs 15 18 Nm 13 Proportional solenoid valve M Boom extend retract 10 12 ft Ibs 14 16 Nm This list continues Please turn the page Plug Torque Specifications Valve Coil Resistance Description Hex size Torque an y Specifications SAE No 2 1 8 50 in lbs 6 Nm SAE No 4 3 16 13 ft Ibs 18 Nm 3 position 4 way directional valve 10V 2 to 5Q schematic items A B and C SAE No 6 1 4 18 ft lbs 24 Nm Proportional solenoid valve 10V 7 5 to 10 50 SAE No 8 5 16 50 ft lbs 68 Nm schematic item M 7 44 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures MANIFOLDS 9 29 BB 0 ory Tee O O H L3 ST 9 fey M Ly y j 4 Qo ES NN 2 gt Part 65196 Genie 5 60 amp Genie 5 65 7 45 Section 7 Repair Procedures Third Edition First Printing MANIFOLDS Function Manifold Components continued Index Schematic No Description Item Function 14 Check valve eec Nuus Differential sensing circuit turntable rotate left right 15 Proportional solenoid valve Qus Boom u
122. 196 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Third Edition First Printing SSS SSS MANIFOLDS 11 3 Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor on the tank side of the turntable Index Schematic No Description Item Function Torque 1 Shuttle valve 2 position way HH Turntable rotation brake release 10 13 ft lbs 14 18 Nm 2 Counterbalance valve Hh ian Turntable rotate right 35 40 ft Ibs 47 54 Nm 3 Counterbalance valve Ju Turntable rotate 35 40 ft Ibs 47 54 Nm Plug Torque Specifications Description Hex size Torque SAE No 2 1 8 50 in Ibs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm 7 50 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 11 4 Oscillate Manifold Components MANIFOLDS The oscillate manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item 1 Orifice Plug 0 052 inch 1 32 mm KK 2 Differential sensing valve Eb 3 Check valve MM 4 Pilot operated unloader valve 950 psi 65 bar NN 5 Shuttle valve 2 posit
123. 196 Genie S 60 amp Genie S 65 5 51 Section 5 Troubleshooting Flow Charts eee CHART 23 Continued from the previous page Disconnect the wires from the platform rotate left directional valve coil item BB and test the resistance of the valve coil K 7 ohms Exchange platform rotate left and right directional valves items BB and CC and activate the platform rotate left function function inoperative Exchange platform rotate left and right counterbalance valves at the counterbalance valve manifold and activate the platform rotate left function function inoperative Install a 0 to 3000 207 bar pressure gauge at the quick disconnect coupling on the function manifold and activate the platform rotate left function SEE NOTE 2 Exchange platform rotate flow regulator valve item DD with the platform leveling flow regulator valve item T and activate the platform rotate left function function inoperative Consult Genie Industries Service Department 0 or infinite ohms function operates operates function operates gt SEE NOTE 1 gt function rat operates Replace the platform rotate left directional valve coil item BB Replace the faulty directional valve Replace the faulty counterbalance valve Check for mechanical restricti
124. 2 2 m 9 7 sec Diesel models 40 ft 40 sec 12 2m 40 sec Boom raised or extended all models Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 1 3 Foot Switch How to Test the Foot Switch Perform this procedure with the key switch in the position 1 Remove the foot switch cover plate fasteners from the platform PLATFORM CONTROLS 6 Press down the foot switch Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for continuity Test Desired result red to black no continuity infinite Q red to white no continuity infinite Q 2 Remove the foot switch guard mounting fasteners from the platform black to white continuity zero Q 3 Remove the foot switch mounting fasteners that attach the foot switch to the foot switch guard 4 Remove the cover plate from the bottom of the foot switch to access the foot switch wire B terminals 5 Do not press down the foot switch Connect the leads from an ohmmeter or continuity tester to Jc each wire combination listed below and check lt 2 2 for continuity white brown 2 Test Desired result J red to black continuity zero red to white no continuity infinite Q black to white no continuity infinite Q Part No 65196 Genie S 60 amp Genie S 65 7 11 Section 7 Repair Pr
125. 2 and 3 boom tubes out of the number 1 boom tube Place the number 2 and 3 boom tubes on blocks for support Crushing hazard The number 2 AWARNING and 3 boom tubes could become unbalanced and fall when they are removed from the number 1 boom tube if they are not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 7 Remove and label the wear pads from the top side of the number 2 boom tube at the platform end of the boom 8 Remove the trunnion pin retaining fasteners at the base end of the number 2 tube Use a slide hammer to remove the trunnion pins 9 Carefully rotate the base end of the extension cylinder until the pin mounting bore is ina vertical position Part No 65196 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Third Edition First Printing BOOM COMPONENTS 10 Attach a lifting strap from an overhead crane to the number 3 boom tubes at the platform end of the boom for support 11 Support and slide the number 3 boom tube out of the number 2 boom tube Place the number 3 boom tube on blocks for support Crushing hazard The number 3 AWARNING boom tube may become unbalanced and fall when it is removed from the number 2 boom tube if it is not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 12 Remove the external snap rings from the extension
126. 4 Platform Rotate Right Function 5 53 25 Oscillate Function Inoperative 2 2 5 55 26 Jib Boom Up Function Inoperative 5 56 27 Jib Boom Down Function Inoperative 5 58 28 Steer Left Function Inoperative 22 2 2 0 5 60 29 Steer Right Function Inoperative esssesseseeeeeneeeennenenn ee 5 62 30 All Drive Functions Inoperative All Other Functions Operate Normally 5 64 31 Drive Forward Or Reverse Function Inoperative 5 67 32 Traction Function emn 5 68 33 Machine Will Not Drive At Full 5 69 34 Machine Drives At Full Speed With Platform Raised or Extended 5 70 35 Drive Enable System Is Malfunctioning 5 71 36 A Auxiliary Functions Inoperative 4 222222 000 5 72 X Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing u nur Section Six TABLE OF CONTENTS Schematics o 6 1 Electrical Components 6 2 Electrical Symbols 6 4 Abbreviation begend 3 ate 6 5 Engine Wi
127. 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts n U CHART 26 Press down the foot 12V oe d switch and move the jib gt Replace CR13 page boom toggle switch in the UP direction Check voltage on the red and black wires at the jib boom platform rotate directional valves items AC io Install a 0 to 5000 psi Exchange jib boom 845 bar pressure _ platform rotate gauge at the quick 2400 psi directional valves item Replace faulty valve disconnect coupling on AC Press down the the function manifold foot switch and activate and activate the jib the jib boom up function boom up function function inoperative Check for mechanical restrictions keeping jib boom up function from operating OR repair or replace jib boom cylinder OR replace less than 2400 psi counterbalance valve OR 0 030 orifice item AN may be plugged OR jib boom platform rotate select manifold has an internal fault OR consult Genie Industries Service Department ER function eae xchange jib boom erates eplace faulty counterbalance valves counterbalance valve and activate jib boom up function function inoperative Consult Genie Industries Service Department
128. 7C39007 1 This list continues on the next page 6 2 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 6 Schematics ELECTRICAL COMPONENTS Item Description Genie Part Manufacturer Manufacturer Qty Part Number Part Number 120875 Contact Limit switch 19491 Telemecanique XESP2151 use 3 Level sensor Level sensor 4 5 44586 Power Comp of Midwest LS36 04 5L 1 501 1 1 Contact 29732 Telemecanique ZB2 BE102 4 Contact 45081 Telemecanique ZB2 BE101 1 Relay 12V DC continuous 27155 Stancor 40 902 rst 1 R1 4WD Resistor 1000 25 watt 27116 eue RH25 100R 1 1 R1 2WD Resistor 1500 25 watt 34798 Dale nti RH25 150R 1 1 Resistor 100 25 watt 27287 aii nes 825F10R 1 TS1 59 Toggle switch DPDT 2 position momentary 13480 Microswitch Control Inc 2NT1 8 nue 2 TS2 5 8 10 12 195 ue Toggle switch SPDT position momentary
129. 8 Press down the foot switch and turn the C trimpot adjustment screw to obtain a 0 10V DC to 0 13V DC voltage reading 9 Move the engine idle control toggle switch to foot switch activated high idle rabbit and foot switch symbol 10 Press down the foot switch and re adjust the A trimpot to the previous voltage setting in step 6 11 Be sure that the boom is in the stowed position then drive the machine and observe how the engine rpm reacts to drive controller movement If the engine surges or hunts adjust the potentiometer counterclockwise until surging is minimized Under an extreme load an excessive counterclockwise adjustment to the C trimpot will cause the engine to stall The C trimpot adjustment is a compromise between engine stability surging and engine rpm drop 12 Disconnect the volt meter 13 Raise the boom above horizontal 14 Drive the machine for 40 feet 12 m and record the elapsed time Repeat this step in the opposite drive direction 15 Adjust the B trimpot to obtain the correct raised drive speed of 1 foot per second 0 31 m per second Turn the B trimpot adjustment screw counterclockwise to increase speed or clockwise to decrease speed 16 Close the platform control box lid and install the fasteners Drive speed stowed position high range 2WD 4WD Gasoline LPG models 40 ft 6 2 sec 40 ft 9 1 sec 12 2 m 6 2 sec12 2 m 9 1 sec 40 ft 6 8 sec 40 ft 9 7 sec 12 2 m 6 8 sec 1
130. 8A BLK 7A 3 RED 1A RED BLK 2A HM TS19 Y RED WHT 3A 4 ion TS17 WHT BLK 5A TS15 WHT 4A 911 E O less TS18 4 A G TS16 GRN I7A Q GRN BLK 18A 9 6 j TS14 TS13 CB1 CB2 ENAVHT SA CO ORG BLK 15A RA ORG 14A 5 ORG RED 16A WHT RED 6A BLK RED 9A R2 F BLK 33A BLK RED 35A BLU WHT 38A 6 RED 20A RED R1 30 PLATFORM LEVEL DISABLE OPTION RELAYS ORGTBIID HYDRAULIC OIL COOLER 7 OPTION RELAY CR18A F CR17 FUSE INLINE ORG 4 RED TB20C 25 ORG BLK TB15D E WHT CR17 E H CR18B 1 OIL TEMPERATURE SWITCH RED 6 ORG CR17 E H FAN ORGBLK4 6 18 Genie S 60 amp Genie S 65 Part No 65196
131. 9 LIMIT SWITCH 0050 o o AS rang N RED WHT 1 MOTOR STROKE oi LOW B do 9 T Ig glo 88 7 tr N BLK 3 BLK WHT 3 M F BLK 4 e BOOM EXTEND Fs EXTEND BLK WHT BOOM BLK WHT 4 2 1 RETRACT Ps lo BOOM RETRACT Bi a B g 2 1 n EXTEND RETRACT e BLK RED 3 FLOW CONTROL a E WHT BLK 3 WHT 3 5 WHT IE t E Wilts oe TURNTABLE ROTATE RIGHT E RIGHT WHT BLK __ TURNTABLE ROTATE 4 t sc lees WHT BLK 4 n 1 LEERT e Ye TURNTABLE ROTATE LEFT o 1 5 WHT RED 4 5 TURNTABLE ROTATE 1 ao a FLOW CONTROL 21 m E RED 4 e E PRIMARY BOOM UP RED BLK B PRIMARY BOOM RED BLK 4 5 1DOWN e Je 1 PRIMARY BOOM DOWN t A x Yf DESCENT ALARM 10 E x 1 RED WHT 4 x E PRIMARY BOOM FLOW CONTROL RED 3 gt je RED BLK 3 e Baa Er RED WHT 3 n E ORG 3 MC PLATFORM LEVEL E 5 1 DOWN ORG BLK 3 ORG pc E D a P ORG ere PLAT LEVEL UP ORG BLK i 815 o PLATFORM LEVEL 1 DOWN 4 ORGIBEN A noc ee He 1 PLAT LEVEL DN wn QIN Eg ORG RED 818 l si 1 818 e 39 j
132. AL AL J MANIFOLD e 7 0 685 OME doo XT MEDIUM x 1 i 2100 PSI o 3 771 145 bar 7 172 bar a 25 02 JIB BOOM 2 5 Q O r 0 4 HE Lhe 1 S 5 4 Loot Toss L4 E METER ej MANIFOLD PORT b 4 4 4 p Ow WI T 5 0 GPM ea EN 7 E lamt estan PRESSURE 2 3 Limin 1 56PM 1 50 1 Pi rae Li 4 BH 5 7 L min _ 1 7 4 oly OPTIONAL NU i WIN e amp FONCTION peus GENERATOR 0 076 mm 0 076 mm PRESSURE m L MANIFOLD al S 60 Models 2600 PSI 777 4 S 65 Models 2900 PSI epos epa EPEE DRIVE PUMP ah 0 TO 30 GPM 114 7 L min af 6PM Ti 04 Lmin TANK oo wW r5 2500 PSI l OPTIONAL Fr 3PSI 25 PSI d 172 bar SEG yg ee 7 0 2 bar 1 7 bar em OIL COOLER 22 5 RESERVOIR AUXILIARY PUMP 6 HYDRAULIC X 028 mm 13 3 L min Fh rh ROTARY 5 COUPLER 7 J STEER MANIFOLD 1 6 DRIVE MANIFOLD __ x 132 mm P8
133. ART 5 o EEEE aeae ENGINE 8 s e v o e e e S 1 olo olola 55 WHT RED WHT RED 26 E H t START ia ji o 1 S t 4 8 8 1 ji N f t gig WHT 21 E H t ERI Y 4 M N 85 a ORG RED 1 BLK 7 RED 7 e e e 3 8 B o 9 Mi att 858 DII ME 4 c s s 815 BLK CR1 E H e OZ i 5 1 amp 5 AUXILIARY F i AUXILIARY 3 PUMP N PUMP RED RED 27 E H 4 Q8 di RED 1 e i 1 PTS 1 21 Ee 4 4 az i 4 amp 8 x E RED BLK 1 E RED BLK 28 E H e e tn e 1 g g RED WHT 2 RED WHT 23 E H E e esl x e 1 a z ee VN 5 3 E amp Q 1 GRN z GRN 1 z GRN 858 Ys 4 uw m 7 BLK 2 F 8 15 BLK CR5 E H E 2 4 a 52 I gt 8 O WHTCRIZEH 58 o 2 858 E 3 P jS 25 g 6 Q c fp ORG BLK 1 ORG BLK 41 E H a ee 4 w 9 o Du d d E iS T elif Ly ia Be e T o 1 m g ACs 50 o O0 lo 2000 E Baz Ir 08S 1 c x 1 1 lt 1 Ip Rie m i 1 RED RED 20 E H i E 4 plur ie N 1O NOTES 1 CIRCUIT CONNECTION TO TP24 IS FOR U
134. AY D 878 e 1 m 848 i E HIGH IDLE e i CUTOUT RELAY 29 gt 8 5 BLK RED CR4 E H t ele I RPM SOLENOID E GRN WHT 1 GRN WHT 4 E H S le GENERATOR B OPTION 1 WATAN T Nav m 5 BLUE WHT GLOW PLUG LED BLUE WHT 1 BLU WHT wo c e 9 8 586 562 GLOW PLUG CONTROLLER wo 8 BLK WHT RED 0001 GLOW PLUG ELEMENTS VOLT METER WHT 2 HOUR METER N B WHT BLK WH BK 25 E H 59 e 1 8625 MA PRESSURE GAUGE E AND SENDER By 58 OIL PRESSURE SWITCH e eg gt A a Og S m as E m WHT 24 EH o BLK 1 XE zB T WATER TEMPERATURE e P i ENGINE SWITCH START 558952526 ET 5 a 215 005 ENGINE 25 START gio o WHT RED 6 WHT RED 26 EH WATER TEMPERATURE m GAUGE AND SENDER a n n 848 S i WHT 21 E H t 419 3 Na o B ORGRED 1 218107 BEDA ay poseen 1 WHT RED 2 i HOLD COIL 3 BLK Foo RP o PULLCOIL 92 BRN iuc FUEL SOLENOID 4 att 8 8 d 8 5 BLK CR1 E H i 224 9 OZ T T t i STARTER MOTOR e FUSE LINK i 8 p Ur ee ae E A E E M 1 RED RED 27 E H t a AUXILIARY POWER RED 1 RELAY j gw t 1 AUXILIARY PUMP FLASHING BEACONS 8 8 7 51 RED BLK 1
135. B E WHT BLK 1 B WHT BLK 31 E H HY bd 1 1 Q N N amp 8 WHT RED 1 WHT RED 32 E H Fie Led Yo BRAKE TRAVEL ALARM 5 5 9 OPTION n 4 BLU BLK 1 BLU BLK 37 E H P Yo STEER RIGHT z BLU 1 BLU 36 E H He EBBERREERE 8 3 4 7 i MERECE i e 83 ORG 1 E 2 WHT 6 BRM6 Boom ue l LIMIT SWITCH ALII WHT 7 22 BRN7 BOOM EXTEND PUER 5 p LIMIT SWITCH EE ooz 22 S958 44 9 9 RED WHT RED WHT 1 B MOTOR STROKE THIGH ooi LOW Nl 9 ri ala tate 58 2 BLK 3 BLK WHT 3 e fo 4 BLA gt BOOM EXTEND 2 EXTEND c BLK WHT BOOM BLK WHT 4 gt 1 RETRACT a BOOM RETRACT E 2 _ 2 BLK RED BLK RED 4 EXTEND RETRACT E BLK RED 3 FLOW CONTROL wo a ual WHT BLK 3 WHT 3 x RIS WHT 4 a WHT 4 E TAGAT 4d TURNTABLE ROTATE RIGHT a TURNTABLE ROTATE id MY WHT BLK 4 n 7 2 e TURNTABLE ROTATE LEFT Ff leo t WHT RED 4 TURNTABLE ROTATE DOE WHTHEDS FLOW CONTROL e m RED 4 E e REDBIR gt PRIMARY BOOM UP PRIMARY BOOM EDA T ed of PRIMARY BOOM DOWN Ei x YT 1 DESCENT ALARM n 10 1 x t RED WHT 4 x n PRIMARY BOOM n MED 8 FLOW CONTROL MN RED BLK 3
136. CEDURES 7 Hold the drive EE enable toggle switch to either side and slowly move the drive control handle off center Collision hazard Always use the ACAUTION color coded direction arrows on the platform control panel and the drive chassis to identify which direction the machine will travel O Result The drive function should operate 8 Rotate the turntable to the left until the boom moves past the left non steering wheel O Result The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown 9 Repeat steps 6 and 7 Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE B PROCEDURES B 17 Test the Drive Brakes Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydrostatic brakes and hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational Collision hazard Be sure that the AWARNING machine is not in free wheel or partial free wheel configuration Refer to B 4 in this section Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions Be sure the boom is fully retracted and lowered to the stowed position 1 Mark a test line on the ground for reference
137. CH TS16 PLATFORM LEVEL SWITCH TS17 PRIMARY BOOM UP DOWN SWITCH TS18 TURNTABLE ROTATE SWITCH TS19 BOOM EXTEND RETRACT SWITCH 86 COIL 4 85 COIL 30 COMMON COM 87 NORMALLY OPEN NO Third Edition First Printing Section 6 Schematics B M 8 Platform Control Box Wiring Diagram Perkins Diesel Models
138. Crushing hazard The boom lift AWARNING cylinder will fall unless it is properly supported 22 Lower the rod end of the lift cylinder onto support blocks Protect the cylinder rod from damage 23 Remove the pin retaining fastener from the boom pivot pin 24 Use a soft metal drift to remove the boom pivot pin then carefully remove the boom from the machine Crushing hazard The boom could AWARNING become unbalanced and fall when it is removed from the machine if it is not supported by the overhead crane How to Disassemble the Boom Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced The extension cylinder can be removed without completely disassembling the boom See 4 4 How to Remove the Extension Cylinders 1 Remove the boom See 4 2 How to Remove the Boom 2 Place blocks under the extension cylinder for support BOOM COMPONENTS 3 Remove the external snap rings from the extension cylinder barrel end pivot pin at the pivot end of the number 1 boom tube Use a soft metal drift to remove the pin 4 Remove and label the wear pads from the top side of the number 1 boom tube at the platform end of the boom Pay careful attention to the location and amount of shims used with each wear pad 5 Attach a lifting strap from an overhead crane to the number 2 and number 3 boom tubes at the platform end of the boom for support 6 Support and slide the number
139. D 2oopsi _ GENERATOR D 20 1 F 3 MEDIUM rem 2100 PSI P 2500 PSI PRESSURE L _ 145 bar 172 bar LJ zE FILTER JIB BOOM TEST AR e RW T Ert MANIFOLD 9 amp 2 r d 71 B M c UM a V 4 ssoPSI 1 ES Mia PRESSURE 1 5GPM IE 11 58 ET ES e en bar N 1 5 7 Lmin 7 15 7 Lmin 167 7 T rap i i 1 1 FumGnoweoun _ OPTIONAL wea PI o9 C 150 WI 14 GPM 53 L min GENERATOR DU Bp 0 t PRESSURE 4 Ls L MANIFOLD __ S 60 Models 2600 PSI 77 DRIVE PUMP 5 65 Models 2900 PSI HIE M a uec cereo E _ 0 TO 30 GPM 114 7 L min 9 PL lt gt OO i i 1 ANK 215 1 oS 5 OPTIONAL 35 3 PSI 25 PSI 7 172 bar L eels na C CELL 0 2 0 2 1 7 bar 1 OIL COOLER 3 zl L 5 RESERVOIR AUXILIARY PUMP lle Fe HYDRAULIC destin es COUPLER TT STEER MANIFOLD _ 6 ATUM 7 0 1 DRIVE 250PSI p MANIFOLD 1y ri 17 bar 1 k 5 1
140. EFT direction Check the pressure 250 function Exchange turntable rotate leftandright 0088 PEE valve counterbalance valves i items JJ and KK Activate turntable rotate left function function inoperative Check for mechanical restrictions keeping turntable rotate left from operating OR replace shuttle valve item 11 OR consult Genie Industries Service Department Part No 65196 Genie S 60 amp Genie S 65 5 41 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 19 Turntable Rotate Right Function inoperative Be sure all other functions operate normally With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the turntable rotate toggle switch TS17 in the RIGHT direction Check voltage on wht red wire on turntable rotate proportional valve coil item S 12V or more v Continued on the next page Hold the function enable Switch to either side and buttons pulled out to the ON position press down the foot switch and move turntable rotate controller in the RIGHT direction Check voltage oV move the turntable 4 to 6V gt rotate toggle switch in the RIGHT direction Check voltage at TB6 oV y With key switch turned 4 to 6V to platform con
141. ENGINE 875 18 COOLANT A EAMUS INTAKE AIR NOTES OXYGEN 020 TEMPERATURE TEMPERATURE SENSOR 3 momo coiL 3 SENSOR MANIFOLD gt SENSOR 1 NES EE LABELLED WITH FORD CIRCUIT NUMBER COLOR AND WIRE GUAGE HO2S 834 25 ECT ABSOLUTE qh 3 2989 AD 59 52 PRESSURE 5 ng 74GY LB18 MEANS CIRCUIT 74 GREY WIRE WITH LIGHT BLUE STRIPE 18 GUAGE WIRE 23 x SENSOR 38239 LPG LOCKOUT RELAY AND VALVE i 52 525 2 INTERNAL SPLICES ARE NOT SHOWN Part No 65196 Genie S 60 amp Genie S 65 6 7 Third Edition First Printing Section 6 Schematics REV B Electrical Schematic Gasoline LPG Models ORG BLK 1 SEE NOTE 1 Y Ek a Aj JA z E W W 9 5 5 8 E Y E BLK RED 1 l M HIGH RPM 2 i N x ENGINE SPEED F FUNCTION ENABLE o ri x E q HIGH RPM pie wo 3 3 GENERATOR o LON GRN WHT 1 GRN WHT 4 E H GENERATOR PTION B E RED WHT 23 E H xg FLASHING BEACONS qN WHT BLK WHT BLK E H OIL PRESSURE WV 1 SENDER AND GAUGE a 8 E n t BLU RED 1 N 9 H gt oag Et a WHT RED WHT RED E H WATER TEMPERATURE 1 GAS SENDER AND GAUGE t FUEL 1 GAS a RED 3S epe amp LED BLU WHT 1 4 E 8 N VOLT METER OR RED 1 3 HOUR METER amp n 3 5 93 58 RED 7 8 Ex 4 4 z ENGINE TEST SW
142. FORM LEVEL F C CABLE ORG BLK CR18B 87 ORG BLK 3 15 ORG BLK D B ORG BLK S P PLATFORM LEVEL DOWN 1 ORG CR18A 87 ORG 3 14 ORG D B ORG S P PLATFORM LEVEL UP WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT WHT EH BLU WHT 3 12 BLK 5 DRIVE ENABLE BLU BLK 3 11 BLU BLK S P SECONDARY BOOM DOWN BLU 3 10 BLU S P SECONDARY BOOM UP BLK RED 4 BLK RED 8 9 BLK RED S P EXTEND RETRACT F C BLK WHT 4 BLK WHT 3 8 BLKWHTD B BLKWHT S P BOOM RETRACT BLK 4 BLK 3 7 BLK D B BLK S P BOOM EXTEND WIR 4 WHT RED 3 6 WHT RED S P TURNTABLE ROTATION F C CABLE 97804 WHT BLK 3 5 wHT BLKD B WHT BLK S P TURNTABLE ROTATION LEFT WHT 4 WHT 8 WHT D B WHT S P TURNTABLE ROTATION RIGHT 2 RED WHT 4 RED WHT 3 3 RED WHT S P PRIMARY BOOM F C RED BLK 4 RED BLK 3 2 RED BLKD B RED BLK S P PRIMARY BOOM DOWN RED 4 RED 3 1 RED D B RED S P PRIMARY BOOM UP D ORG BLK 15B La 5 ORG RED 16B ORG 14B 2 4 1 GRN 17B GRN BLK 18B RED WHT 298 4 gt 9 BLK R1 87 z DIODE BLK WHT 8B 5 10 BRN GROUND M CABLE BLOCK m EE WHT 21A 3 WHT BLK 5B 24 3 BLU 36B WHT 4B 3 8 BLU BLK 37B RED BLK 2B 4 Ee WHT RED 32B RED 1B 54 10 BRN GROUND e BUERT 1 START RELAY ORGIBUCHBE 2 TACHOMETER IGNITION START BLK 33D s stant inpur MODULE CABLE RED 27B 4 4 AUXILARY ON BBN GRD 5 GROUND 6 BATTERY wres __ 17 key power key Bypass 9 IGN FUELON mE 10 ENGINE FAULT RED 6 ISM B
143. G RED 3 16 ORG RED ORG RED S P PLATFORM LEVEL FLOWCONTROL 1 ORG BLK CR18B 87 ORG BLK 3 15 ORG BLK D B ORG BLK SP PLATFORM LEVEL DOWN ORG CR18A 87 ORG 3 14 ORG D B ORG S P PLATFORM LEVEL UP WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT WHT EH BLU WHT 3 12 BLK 5 DRIVE ENABLE BLU BLK 3 11 BLU BLK S P SECONDARY BOOM DOWN BLU 3 10 BLU S P SECONDARY BOOM UP BLK RED 4 BLK RED 3 9 BLK RED S P EXTEND RETRACT F C BLK WHT 4 BLK WHT 3 BLK WHT D B BLKWHTS P BOOM RETRACT BLK 4 BLK 3 7 BLK D B BLK S P BOOM EXTEND CABLE we WHT RED 3 6 WHT RED S P TURNTABLE ROTATION 2 WHT BLK 4 WHT BLK 3 5 WHT LK D B WHT BLK S P TURNTABLE ROTATION LEFT WHT 4 WHT 3 _ WHTD B WHT S P TURNTABLE ROTATION RIGHT RED WHT 4 RED WHT 3 3 RED WHT S P PRIMARY BOOM RED BLK 4 RED BLK 3 2 RED BLKD B RED BLK SP PRIMARY BOOM DOWN RED 4 RED 3 1 RED D B RED S P PRIMARY BOOM UP D B A ORG BLK 15B 1 5 ORG RED 16B ORG 14B 24 GRN 17B Oe 8 GRN BLK 18B RED WHT 298 44 BLK R1 87 uou DIODE 8 54 10 BRN GROUND BLOCK sua Rc WHT 21A WHT BLK 5B 2 4 BLU 36B WHT 4B a BLU BLK 37B RED BLK 2B 44 WHT RED 32B RED 1B 5 4 10 BRN GROUND eee E l BECRIB HO 1 START RELAY QRaiBLUC4TS LC 2 IGNITION START BLK 33D MODULE 4 HO START INPUT HO 4 AUXILARY ON BAN GRO HO 5 GROUND HO 6 BATTERY
144. HORN gt 2 R p RELAY 5895 t t 1 Q 8 5 BLKCR4 E H 5 7 a BLK 2 91 1 HORN a Eo Jo 52 8 SE ES I z fa WHT 04 WHT CR17 E H 8 8 HYDRAULIC OIL ERs zoz MN Saez 2 D TEMPERATURE 9825 2 5 SWITCH 556 amp 6 PU 8 15 ORG CR17 E H COOLING FAN 2 2 ole 4 asec OPTION 9 8 E WHT 21 E H 52 gag 21 E H x 4 510 agg E RED E H 8 ORBEK ORG BLK 41 E H Fag e um Cog 558 d 285 5 823 i acs E Tira lt 9357 Gre oc He Or E a 2 g RED RED 20 E H N e N
145. IB LOCKOUT RELAY STUD oO9 DiZiiassstEess amp kooopzzz A3mua e5v ozzz 29522055653 PIS cmm 2151515 25833 CR14 PLATFORM ROTATOR RELAY 3 BRN 2 RI A9 0 EH o 0 5 mio m IK E DP1 DRIVE PROPORTIONAL CONTROLLER 15 leloj jalo lola jaja STEER LEFT RIGHT 2 zi FS CABLE FROM FOOT SWITCH E 9 5 RED BLK JIB CABLE HORSEPOWER LIMITER BOARD E CR14 H1 TILT ALARM HORN EN JIB CABLE FOR JIB FUNCTION CABLE CABLE CABLE 11 DRIVE ENABLE LED JIB 110 ES 3 2 1 yr t x 4 L4 GLOW PLUG LED 2 EMERGENCY STOP BUTTON 4 H1 P3 HORN BUTTON R1 RESISTOR TS1 AUXILIARY SWITCH TS2 START ENGINE SWITCH lololozso D DD ooo comu oz 0 TS3 GLOW PLUG OPTION D 2 22 m m mim mimim m rz cim m CIZ 2 E Lus 2 3 j3 2 S 1 SII amp 235 3 A 54 HIGH RPM SWITCH gx m mm o9 E Bx 5 2 5 5188 B misi RIESE TS5 PLATFORM ROTATE SWITCH ORIS SS 2 gr 3 F s B s TS6 JIB BOOM UP DOWN SWITCH a e HIE ud e S 6 2 N oe TS7 PLATFORM LEVEL UP DOWN 5 i TS9 TS20 DP1 5 TS8 DRIVE SPEED SELECT SWITCH O O S TS9 DRIVE ENABLE SWITCH q Bid g BP2 5 O O K TS20 GENERATOR SWITCH OPTION lt D cL o TS23 LIFT DRIVE SELECT SWITCH OPTION 1 110 AC POWER CABLE A o D x x x b
146. ITCH z aS 855 868 ae Sle b EXE SEES I 2 u s v e e s s s S w E ioiolelelololo z 9 BLK 1 Z amp ENGINE 3 5 5 5 F ENGINE n START 88 B 1 a Pars i te WT PUR FEH 209 PIN18 9 T go X RED LGRN FEH 16A PIN1 u 2 oO OF IF YEL BLK 674 PIN7 TAN LBLU 306 PIN24 FORD YEL FEH 37B 8 A2 PIN PLUG b YEL FEH 37 PIN9 5 PNK BLK 787 PINS a BLK WHT 570 PIN34 BLK WHT 570E PIN42 aa d FUEL PUMP APT rg 9 RED FEH 361N i u a raz BLU RED LP 888 DGRN FEH 242 2 lt BRN LP MAD n LPG LOCKOUT SOLENOID 8 8 oe 7 re eit i Bt A 212 uri b i EQ oz i _ EH 1 STARTER MOTOR u 2 amp x AUXILIARY IE x AUXILIARY n f PUMP 55 9 PUMP 5 t RED RED 27 E H AUXILIARY POWER N 134 RED 1 KELN 5 RI s iy hd 41414 58 TY 4 1 Pu EBI i AUXILIARY PUMP u d c uz 4 9 lt E BN E 2 X I IY 1 2 RED RED BLK 1 RED BLK 28 E H i E 4 x l amp a 1 in RED WHT 23 E H z i WHT 2 i gt LEVEL SENSOR re g 2022 22 258 E a ji m 696 x ae oO a 2 8 q 4 amp f GRN ET GRN 1 z GRN 858
147. Install the pump coupler onto the pump shaft with the set screw toward the pump Leave a 3 a inch 9 5 mm gap between the pump coupler and pump end plate 3 Apply removable thread locking material to the pump coupler set screw Torque the set screw to 45 ft lbs 61 Nm Component damage hazard Do CAUTION not force the drive pump during installation or the flex plate teeth may become damaged 4 Install the pump and torque the pump mounting plate fasteners to 34 ft Ibs 46 Nm Part No 65196 Genie S 60 amp Genie S 65 7 91 Section 7 Repair Procedures Third Edition First Printing DEUTZ ENGINE F4L 1011F 6 3 Oil Temperature and Oil Pressure Gauges The engine oil temperature gauge is an electrical gauge The engine oil temperature sending unit has limit contacts that are factory set The contacts will close at approximately 300 F 149 C When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Engine oil temperature will be indicated on the gauge when the key is on and the Emergency Stop Button is pulled out to the on position The engine oil pressure gauge is an electrical gauge The engine oil pressure sending unit has limit contacts that are factory set The contacts will close at approximately 7 psi 0 48 bar When the contacts close the engine will shut off to prevent damage Engine oil pressure will be indicated on the
148. L e E RED BLK 3 e RED WHT 3 n E ORG 3 PLATFORM LEVEL e LDOWN ORG BLK 3 NE 21 E i E a i ORGS Lele 4 PLAT LEVEL UP ORG BLK PLATFORM LEVEL 4 11 DOWN 2 ORG BLK 4 rije 4 PLAT LEVEL DN e iD 1 1 ORG RED tn 1 1 E L ee 9 ig z ORG RED 3 2 BLK 6 12 RED6 1 8 PLATFORM LEVEL 4 a po DISABLE 2 ES CE OPTION 53 Erg GRN 3 2 poe JIB BOOM 8 0 DOWN GRN BLK 3 GRN 190 4 pps 2 e GRN 4 g PLATFORM ROTATE 4 2 Top GANIC LEFT JIB UP JIB BOOM 4 Ye PLATFORM ROTATE RIGHT JIB DOWN i RIGHT RIGHT PLATFORM ROTATE PLATFORM ROTATE i LEFT i GRNWHT GRN WHT 3 i 2 m RED i Z LI RED o Le 8 5 JIB VALVES T a ze RED BLK N ps 5 LIFT DRIVE SELECTOR esl Ip OPTION a a a a z T 6 13 Genie 5 60 amp Genie 5 65 Part No 65196 Section 6 Schematics Third Edition e First Printing Ground Control Box Wiring Diagram Deutz Diesel Models A B WHT RED 26A BRN GROUND KS1 STACKED CONTACTS CE MODELS ONLY WHT 21A WHT BLK 25A 2 BLK 22A KS1 WH
149. L BOX TERMINALS1 19 CABLE 2 FROM GROUND CONTROL BOX TERMINALS 22 23 z zzmz xix s owmwmuwoooooo olololo BRN TO GROUND STUD CABLE 3 FROM GROUND CONTROL BOX TERMINALS 27 45 STUD 59285542252555 00222 35440590 Bris DELAY CAPACITOR 2 5oB8m ms SS i8 Bra CR13 JIB LOCKOUT RELAY S 65 ONLY 3 C BRN 2 Sle Ge jejeje 409 E d ZEE 9 XE ESSE CR14 PLATFORM ROTATOR RELAY 1 DRIVE PROPORTIONAL CONTROLLER T STEER LEFT RIGHT 2 BEBBLKJIB CABLE CABLE FROM FOOT SWITCH 5 1 CR14 H P L HORSEPOWER LIMITER BOARD i A H1 TILT ALARM HORN CABLE CABLE CABLE JIB FS JIB CABLE FOR JIB FUNCTION 3 1 ND 4 11 DRIVE ENABLE LED L2 CHECK ENGINE LED 4 H1 P2 EMERGENCY STOP BUTTON P3 HORN BUTTON R1 RESISTOR TS1 AUXILIARY SWITCH TS2 START ENGINE SWITCH Jolololzjo gt 5 2 J3m o o0o uw gt o s 2 J Jf DD D m E EIS 22 DE SIE 2 TS3 FUEL SELECT SWITCH gt 3 21212 X lt 9 Jala ES 2 5 SIS x 15 2 Ot I Im 9 S 2 B3 sm Jls Z3 Sla TS4 HIGH RPM SWITCH ajele om S R Srt gt j N TS5 PLATFORM ROTATE SWITCH E x 8 x x E 85 5 P IEEE TS6 JIB B
150. LK RED R4 E H ISM BLK RED 35B RED CB1 i r eR ij CR1 BLK 1 ISM H BLK R1 E H BLK D B WHT 21D BLK RS A H CR2 CR3 CR4 BRN GRD CR5 I BLK 22D GRN 43D LABEL DESCRIPTION CABLE 1 TO PLATFORM CONTROL BOX TERMINAL 27 46 CABLE 2 TO PLATFORM CONTROL BOX TERMINAL 22 23 CABLE 3 TO PLATFORM CONTROL BOX TERMINAL 1 19 CABLE 4 TO CONTROL SOLENIOD CB1 CIRCUIT BREAKER CONTROLS 15A CB2 CIRCUIT BREAKER ENGINE 15A CR1 IGNITION START RELAY CR2 IGNNITION POWER RELAY CR3 HIGH IDLE RPM CUTOUT RELAY CR4 RPM RELAY CR5 SERVICE HORN RELAY CR17 HYDRAULIC OIL COOLER OPTION RELAY CR18A amp B CE PLATFORM LEVEL CUTOUT RELAY G1 VOLT METER GAUGE G2 OIL PRESSURE GAUGE G3 OIL TEMPERATURE GAUGE HM HOUR METER KS1 KEY SWITCH LS1 CABLE 7 BOOM EXTEND LIMIT SWITCH LS2 CABLE 6 BOOM UP LIMIT SWITCH LS3 CABLE 5 DRIVE ENABLE LIMIT SWITCH P1 EMERGENCY STOP BUTTON PR1 AUXILARY POWER RELAY PR2 GLOW PLUG POWER RELAY R2 RESISTOR 10 OHM BOOM FUNCTIONS TS10 AUXILIARY SWITCH TS11 ENGINE START SWITCH TS12 GLOW PLUG SWITCH TS13 FUNCTION ENABLE SWITCH TS14 PLATFORM ROTATE SWITCH TS15 JIB BOOM SWITCH TS16 PLATFORM LEVEL SWITCH TS17 PRIMARY BOOM UP DOWN SWITCH TS18 TURNTABLE ROTATE SWITCH TS19 BOOM EXTEND RETRACT SWITCH 6 14 Ge
151. NITS WITHOUT GENERATOR OPTION 2 THE FOOTSWITCH POWER IS CONNECTED TO BOTH WHT WIRES WITHOUT THE LIFT DRIVE SELECTOR OPTION 3 ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND THE KEY SWITCH OFF 4 R1 100 OHMS FOR 4WD R1 150 OHMS FOR 2WD Part No 65196 Genie S 60 amp Genie S 65 6 12 Section 6 Schematics Third Edition First Printing Electrical Schematic Deutz Diesel Models ORG BLK 1 N wo N BRN 2 t GROUND S n
152. OOM UP DOWN SWITCH S 65 ONLY 5 id 9 e ejin N Tat e TS7 PLATFORM LEVEL UP DOWN DP1 TS8 DRIVE SPEED SELECT SWITCH 520 TS9 DRIVE ENABLE SWITCH Le BP1 2 oe TS9 7520 GENERATOR SWITCH OPTION lt 2 x O O TS23 LIFT DRIVE SELECT SWITCH OPTION 5 110 AC POWER CABLE E 1 Z ES 1 Doc 15 m 9 LE gt lt L1 Tan EN N Mi 86 TS23 30 87 ar 85 l od rx oo 7 7 NO G4 OO 5 eod 5 NC NC G PRG OWS OOO Q 86 COIL TS1 R1 L2 TS2 85 COIL TS7 E TS8 794 TS3 30 COMMON COM P3 TS5 TS6 P2 87 NORMALLY OPEN NO 87A NORMALLY CLOSED NC C R1 RESISTOR IS MOUNTED TO EXTEND RETRACT CONTROLLER Pet USE 100 OHM RESISTOR FOR 4WD AND 150 OHM RESISTOR FOR 2WD Part No 65196 Genie S 60 amp Genie S 65 6 11 Third Edition First Printing Section 6 Schematics Electrical Schematic Deutz Diesel Models ORG BLK 1 SEE NOTE 1
153. ORM CONTROLS ramp rate trimpot lo range trimpot terminal activates max out range terminal unused terminal X auxiliary terminal ground terminal battery positive terminal A proportional output threshold trimpot max out trimpot 720700009 Set the preliminary ramp rate Turn the ramp rate trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click Connect the red lead from a volt meter to the A terminal on the controller printed circuit board Connect the black lead to ground Set the threshold Press down the foot switch then slowly move the controller off center until the moment a voltage reading appears Adjust the voltage to 3 5V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Part No 65196 Genie S 60 amp Genie S 65 7 7 Section 7 Repair Procedures Third Edition First Printing PLATFORM CONTROLS 7 Set the max out Press down the foot switch then move the controller all the way to the EXTEND position Adjust the voltage to 9 75V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 8 Set the lo range Press down the foot switch then move the controller all the way to the RETRACT position Adjust the voltage to 9 2V DC Turn the lo range trimpot adjustment screw clockwise to incr
154. PROCEDURES D 6 Replace the Drive Loop Hydraulic Filter Replacing the drive loop hydraulic filter is essential to good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Perform this procedure with the engine off 1 Locate the drive loop hydraulic filter mounted on the engine near the pump 2 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing 3 Remove the filter element from the housing 4 Inspect the housing seal and replace it if necessary 5 Install the new filter and hand tighten the housing onto the filter head 6 Start the engine from the ground controls Inspect the filter assembly to be sure that there are no leaks 8 Clean up any oil that may have spilled during the installation procedure Drive loop hydraulic filter Genie part number 20880 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures D 7 Replace the Engine Oil and Filter Deutz Diesel Models Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting p
155. Pressure 7 32 Perkins Engine 704 30 f RPM Adjustment ccc tee e tp eee Ou denote edd a testis 7 33 722 Flex Plate iR Eee cout edo ERES 7 33 7 3 Coolant Temperature and Oil Pressure Gauges 7 34 Ford Engine LRG 425 EFI 8 1 Timing Adjustment iioi ere eg tera ice 7 35 8 2 Fblex Plate ene cine hands ade A 7 35 8 3 Coolant Temperature and Oil Pressure Gauges 7 36 Ground Controls 9 4 a ma atte tec teftc td eee 7 38 9 2 Toggle Switches See 1 4 Toggle Switches esses 7 39 9 3 Wago Components siiip lera aaaea aaa a Eaa 7 39 9 4 Engine Fault Codes Ford 7 39 Hydraulic Pumps 10 1 Lift Steer 7 41 10 2 Drive PUMP veri ER CERE 7 42 Part 65196 Genie 5 60 amp Genie 5 65 xiii Third Edition First Printing TABLE CONTENTS Section Seven Repair Procedures continued Manifolds 11 1 Function Manifold 5 2 0 0 7 44 11 2 Valve Adjustments Function Manifold 7 48 11 3 Turntable Rotation Manifold Components 7 50 11 4 Oscillate Manifold Components
156. Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
157. R check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Chart 6 Refer to the fault code chart in this section for a description of the fault and recommended repairs Repair open in power supply circuit to center terminal of RPM select toggle switch Start the engine then 0 Check voltage at center move and hold the RPM terminal on both RPM toggle switch to the high select toggle switches idle rabbit symbol position for the following 12V tests Check voltage at blk red wire on RPM select toggle switches Replace RPM select TS4 and 1512 toggle switch 12V Check voltage at TB35 9 Repair open blk red wire circuit from toggle 12V switch to TB35 y Repair open in tan blu wire from TB35 to ECM OR consult Genie Industries Service Department Part No 65196 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 7 Engine Low Idle inoperative Gasoline LPG Models If low idle operates on LPG but not on gasoline see Ford service manual for carburetor troubleshooting If low idle operates on gasoline but not on LPG see Repair section for LPG regulator adjustments Be sure throttle linkage from governor
158. RICAL SCHEMATIC FORD EFI 59788 S FUELINJECTOR 3 a TAAN own dO 558BR LB18 n 4 TY TACHLEAD 2 11T Y20 351BR W18 A2 VREF Poe H R GN KEEP ALIVE PWR 1 16AR LG16 e 77DB Y18 R2 DRY FUEL MODULATOR gt Y KEEP ALIVE PWR 8 37BY18 NOT USED J 4 R W WATER TEMPERATURE SWITCH 16 20 iow ROS A SONES GROUND fae K Y VPWR 9 7 570BK W18 i Mind diim au Boe amount 31 BK W BATTERY 34 9 570CBK W12 e 570HBK W18 W2 POWER GROUND BK W BATTERY 42 9 570EBK W12 C3 USED P DATALINK 221 107P20 E3 NOTUSED i DB BK DRIVE BY WIRE SIGNAL INPUT 141 2 151LB BK20 G2 NOTUSED AUXILARY INPUT 37 198DG O20 G3 NOTUSED W P SELF TESTINPUT 18 209W P20 107P20 M1 DATA LINK 71 8 8 T LB GOVERNOR SPEED CONTROL 24 306T LB20 1511 20 A1 DRIVE BY WIRE m a Ba UNA ALARY AT gt i Y BK FUELSELECT 7 674Y BK20 306T LB20 J2 GOVERNOR SELECT 1 M T O DATALINK CONNECTOR 11 914T O20 307BK Y20 K2 GOVERNOR SELECT 2 a DIN 5 BE Ium Lo EE i Laue EES 51 Ej ovn DAWNED S NEUE E BARE de R GN W OIL PRESSURE SWITCH 26 253DG W20 926ALB 016 FUEL PUMP RELAY
159. Section Four TABLE OF CONTENTS Scheduled Maintenance Procedures continued B 1 Check the Exhaust 4 30 B 2 Check the Hydraulic Tank Return Filter Condition Indicator 4 31 B 3 Inspect the Tires and Wheels including lug nut torque 4 32 B 4 Confirm the Proper Brake Configuration 4 33 B 5 Check the Oil Level in the Drive 4 34 B 6 Check and Adjust the Engine RPM sse 4 36 7 Test the Key SwitCh aie eee Bote oven 4 37 B 8 Testthe Emergency Stop 000000 4 38 B 9 Testthe Ground Control Override 20 20404 0 0 0 0 4 38 B 10 Check the Directional Valve Linkage 4 39 B 11 Test the Platform Self leveling 0 4 0 0 4 39 B 12 Testte HOr aaia ute ee BERGE NI DM 4 40 B 13 Test the Foot 0 4 40 B 14 Test the Engine Idle Select Operation 4 41 B 15 Test the Fuel Select Operation Gasoline LPG Models 4 42 B 16 Test the Drive Enable 2 20 4 1 00 4 43 B 17 Test the Drive Brakes 4 44 B 18 Test t
160. Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE E PROCEDURES E 4 Replace the Engine Air Breather Perkins Diesel Models Complete information to perform this procedure is available in the Perkins 700 Series Workshop Manual Perkins part number TPD 1359E Genie part number 62424 E 5 Grease the Steer Axle Wheel Bearings 2WD Models Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steering wheels Center a lifting jack under the steer axle 3 Raise the machine approximately 6 inches 15 cm Place blocks under the drive chassis for support 4 Remove the lug nuts Remove the tire and wheel assembly 5 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result There should be no side to side or up and down movement Skip to step 10 if there is no movement
161. T 23A BLK 7A 3 RED 1A RED BLK 2A TS10 RED 27A BLK WHT 8A RED WHT 3A Qe rs17 WHT BLK 5A WHT 4A TS11 TS18 GRN BLK 18A GRN 17A TS14 GRN WHT 19A T TS13 ORG BLK 15A ORG 14A 5 ORG RED 16A WHT RED 6A BLK RED 9A R2 BLK 33A BLK RED 35A BLK WHT 34A RED 20A 6 RED R1 30 PLATFORM LEVEL DISABLE OPTIONIRELAYS HYDRAULIC OIL COOLER ORG TB14D OPTION RELAY 7 crisa F In INLINE RED TB20C ORG 4 ORG BLK TB15D WHT CR17 E H OIL TEMPERATURE SWITCH RED 6 eran T ORG CR17 EH FAN ORG BLK 4
162. TS 12 Use a slide hammer to remove the upper yoke pivot pin then use a soft metal drift to drive the lower yoke pivot pin down and out Crushing hazard The yoke hub ACAUTION assembly may become unbalanced and fall when the yoke pivot pins are removed if it is not properly secured and supported by the lifting jack 13 Place the yoke drive hub assembly on a flat surface with the drive hub facing down 14 Remove the drive hub mounting fasteners that attach the drive hub to the yoke Remove the drive hub from the yoke Replace the thrust washer when installing the yoke drive hub assembly onto the axle Torque specifications Lug nut torque dry 420 ft lbs 569 5 Nm Lug nut torque lubricated 320 ft lbs 434 Nm Drive hub mounting bolts lubricated 180 ft lbs 122 Nm 15 2 Steering Cylinders How to Remove a Steering Cylinder This procedure is the same as the 2WD procedure See 14 2 How to Remove a Steering Cylinder 15 3 Tie Rod How to Remove the Tie Rod This procedure is the same as the 2WD procedure See 14 3 How to Remove the Tie Rod How to Perform the Toe in Adjustment This procedure is the same as the 2WD procedure See 14 3 How to Perform the Toe in Adjustment Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures Oscillating Axle Components 16 1 Oscillating Axle Lock out Cylinders The oscillating axle cylinders e
163. TS Section Seven Repair Procedures Introductio eie eon ee 7 1 Platform Controls 1 1 Joystick Controllers enne 7 2 1 2 Horsepower Limiter Board 22 22222 0 000 7 9 1 3 FOOt SWIN 7 11 1 4 Toggle ta eae 7 12 Platform Components 2 7 Platform tei mee oe im mb cesis 7 13 2 2 Platform Leveling Slave 2 88 7 13 2 3 Platform Rotator diee eds e tee e eire end in rt 7 15 Jib Boom Components S 65 Models 93 1 dib BOOM ei P a e has p HAERES 7 18 3 2 Jib Boom Lift Cylinder 7 19 Boom Components 4 1 Cable Track E 7 20 4 2 BOOM ee 7 23 4 3 Lift Cylinder 7 26 4 4 Extension Cylinders uiii deine epe i quer terc dg 7 27 4 5 Platform Leveling Master 7 29 Turntable Covers 5bs1 Turntable Covers co eoe eet ee ete e te Dane Dee ua 7 30 Xii Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing TABLE OF CONTENTS Section Seven Repair Procedures continued Deutz Engine FAL 1011F 6 4 RPM Adjustment ie tei e e ep esten beet EA ta 7 81 6 27 Blex Platea enean Den cH 7 31 6 3 Oil Temperature and Oil
164. Y PR2 GLOW PLUG POWER RELAY R2 RESISTOR 10 OHM BOOM FUNCTIONS TS10 AUXILIARY SWITCH TS11 ENGINE START SWITCH TS12 ENGINE FUEL SELECT SWITCH TS13 FUNCTION ENABLE SWITCH TS14 PLATFORM ROTATE SWITCH TS15 JIB BOOM UP DOWN SWITCH TS16 PLATFORM LEVEL SWITCH TS17 PRIMARY BOOM UP DOWN SWITCH TS18 TURNTABLE ROTATE SWITCH TS19 BOOM EXTEND RETRACT SWITCH TS22 ENGINE TEST SWITCH 6 10 Genie S 60 amp Genie S 65 Part No 65196 86 30 zl 85 t 3 4 86 COIL 85 COIL 30 COMMON COM 87 NORMALLY OPEN NO 87A NORMALLY CLOSED NC Third Edition First Printing Section 6 Schematics En SS ss Platform Control Box Wiring Diagram Gasoline LPG Models
165. air open in red blk 3 wire from TP2 to TB2 Repair open in power supply circuit from TP24 to boom controller OR repair open in brn ground wire circuit from ground to the boom controller 5 32 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Continued from the previous page Disconnect both wires from boom down directional valve coil item B and test the resistance of the valve coil See Repair Section 0 infinite Section 5 Troubleshooting Flow Charts n R ohms Replace boom down directional valve coil 2 5 to 3 5 ohms Hold the function enable switch to either side and move the boom up down toggle switch in the DOWN direction Manually override the directional valve by pushing in on the end of the valve spool function operates ee Replace faulty directional valve function inoperative Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the boom function manifold and start the engine Hold the function enable switch to either side and move the boom up down toggle switch in the DOWN direction and check the pressure SEE NOTE 1 o Check for mechanical restrictions keeping boom from moving OR repair cylinder or cylinder
166. alant to the plug s and then install the plug s in the drive hub 5 Repeatthis procedure for each drive hub Drive hub oil Capacity 44 fl oz 1 30 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Turntable Rotate Drive Hub 1 Remove the plug located on the side of the hub and check the oil level Result The oil level should be even with the bottom of the plug hole a drive hub b 4 34 5 60 5 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures TABLE PROCEDURES 2 If necessary add oil until the oil level is even with the bottom of the side plug hole 3 Apply pipe thread sealant to the plug and install the plug in the drive hub Turntable rotate drive hub oil Capacity 17 fluid ounces 0 51 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 65196 Genie S 60 amp Genie S 65 4 35 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE B PROCEDURES B 6 Check and Adjust the Engine RPM Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Gasoline LPG Models The engine rpm is control
167. all a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the boom function manifold and activate the steer left function SEE NOTE 2 Repair or replace steer cylinder OR steer manifold could have an internal defect Consult Genie Industries Service Department SEE NOTE 1 gt Section 5 Troubleshooting Flow Charts n o U EN Check for mechanical restrictions keeping steer left function from operating OR repair or replace steer cylinder OR replace flow regulator valve item WW OR consult Genie Industries Service Department CHART 28 NOTE 1 5 60 2600 PSI or more 5 65 2900 PSI or more NOTE 2 5 60 Less than 2600 PSI S 65 Less than 2900 PSI Part No 65196 Genie S 60 amp Genie S 65 5 61 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 29 Steer Right Function inoperative Be sure all other functions operate normally With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and hold the steer rocker switch on drive controller in the RIGHT direction Check voltage on TB37 12V or more y With key switch turned to platform controls and both Emergency Stop buttons pulled out
168. ap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 S 65 models Support the platform leveling arms and platform mounting weldment with an appropriate lifting device Do not apply any lifting pressure All models 4 Remove the six mounting bolts from the platform mounting weldment Remove the center bolt and slide the plattorm mounting weldment off of the platform rotator Crushing hazard The platform AWARNING mounting weldment could become unbalanced and fall if it is not properly supported Part No 65196 Genie S 60 amp Genie S 65 7 15 Section 7 Repair Procedures Third Edition First Printing PLATFORM COMPONENTS 5 Supportthe platform rotator with an appropriate How to Bleed the Platform lifting device Do not apply any lifting pressure Rotator 6 Supportthe platform leveling slave cylinder Protect the cylinder rod from damage Do not start the engine Use auxiliary power for all machine 7 Remove the pin retaining fasteners from both functions in this procedure the slave cylinder rod end pivot pin and the rotator pivot pin 1 Connect a clear hose to the top bleed valve Place the other end of the hose in a container to collect any drainage Secure the container to the boom 8 Use a soft metal drift to remo
169. at the grn wire on the jib boom up Repair open in red directional valve power wire circuit from item BB key switch to TS19 OR replace TS19 12V With the key switch Press down the foot 12V turned to platform 0 switch and move the jib controls and both gt boom toggle switch in Emergency Stop buttons the UP direction Check pulled out to the ON voltage at TP17 position press down the foot switch and move the jib boom toggle oV switch TS24 in the uP direction Check voltage at TB17 With the key switch 12V turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and check voltage on the center terminal of the jib boom toggle switch oV y 12V Check voltage at oV terminal 30 on CR13 12V v Check the voltage at d terminal 487a on CR13 12V Y Y Continued on the next page Repair open in red wire from terminal 87a on CR13 to TS8 OR consult Genie Industries Service Department 12V gt Repair open grn 4 wire from TB17 to jib boom up directional valve OR repair open in brn ground wire circuit to directional valve Repair open in grn 3 wire from TP17 to TB17 Repair open in grn wire from TS24 to TP17 OR replace TS24 Repair open in red wire from boom controller to CR13 OR repair open in brn ground wire circuit to CR13 Replace CR13 Genie S 60 amp Genie S
170. ate the engine should stop Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the boom is raised or extended past the drive speed limit switches Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds Start the engine from the platform controls Do not press down on the foot switch Attempt to operate all machine functions Result All machine functions should not operate 9 Press down the foot switch and activate each machine function Result All machine functions should operate through a full cycle 10 Push in the Emergency Stop button to the position at the platform controls Result No function should operate the engine should stop As a Safety feature selecting and operating the ground controls will override the platform controls including the Emergency Stop switch Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds 4 12 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures A 12 Test the Auxiliary Power Operation Detection of auxiliary power system malfunctions is essential for safe machine operation An unsafe working condition exists if the auxiliary powered functions do not operate in the event of a main power loss When operati
171. auge at the quick disconnect coupling on the boom function manifold and start the engine Hold the function enable switch to either side and move the turntable rotate toggle switch in the LEFT direction and check the pressure SEE NOTE 1 b gt Exchange boom rotate flow regulator valve item I with boom up down flow regulator valve item H Check turntable rotate left function function inoperative SEE NOTE 2 v Continued on the next page Repair turntable rotation motor OR function manifold may have an internal fault Consult Genie Industries Service Department Third Edition First Printing function operates Replace faulty flow regulator valve NOTE 1 5 60 2600 PSI or more 5 65 2900 PSI or more NOTE 2 5 60 Less than 2600 PSI S 65 Less than 2900 PSI 5 40 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts nT CHART 18 Plumb 0 to 5000 psi lessthan Function manifold could Continued from the 1 9 0 to 345 bar pressure 250 psi have an internal fault previous page gauge into the hose Consult Genie Industries from the function Service Department manifold to the turntable rotation brake Hold the function enable switch to either side and move the turntable rotate toggle switch TS17 in the L
172. ault code chart in this section for a description of the fault and recommended repairs Check alternator wiring OR repair or replace alternator OR contact Genie Industries Service Department Replace ignition start module OR consult Genie Industries Service Department Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Engine Cranks Over But Will Not Start Diesel Models Be sure to check the engine oil level and fill as needed Be sure to check fuel level Be sure the fuel shut off valve is in the on position Be sure that the battery is fully charged Move the start toggle switch to either side and 44y check battery voltage while engine is cranking 11V or more Disable the starter by removing the blk wire at 49y the starter solenoid Move the start toggle switch to either side and check the voltage at positive terminal on fuel solenoid Move the start toggle switch to either side and 12V check voltage at wht 21 wire on terminal 87 of CR2 OV Check voltage at red ov wire on terminal 30 of CR2 12V Y Continued on the next page Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery Turn the machine off mds an
173. boom platform end of the boom Use a soft metal drift to remove the pin AWARNING Crushing hazard The extension cylinder will fall when it is removed 4 Remove the turntable end cover located at the from the extension boom if it is not pivot end of the boom properly supported 5 Tag disconnect and plug the extension cylinder Note the length of the cylinder hydraulic hoses Cap the fittings on the after removal The cylinder must cylinder measure the same length for installation Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Remove the trunnion cover fasteners from both sides of the number 1 boom tube at the pivot end of the boom 7 Remove the trunnion pin retaining fasteners from both sides of the number 2 boom tube at the pivot end of the boom 8 Use a slide hammer to remove the trunnion pins 9 Attach a strap from an overhead crane to the rod end of the lower extension cylinder 10 Remove the external snap rings from both sides of the extension cylinder pivot pin at the pivot end of the boom 11 Use a soft metal drift to remove the extension cylinder pivot pin 7 28 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 4 5 Platform Leveling Master Cylinder The master cylinder acts a
174. bris and foreign material 9 Install the engine side cover 10 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts A 23 Check the Engine Belt Gasoline LPG and Perkins Diesel Models Engine specifications require that this procedure be performed every 200 hours Maintaining the engine belt is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt and continued use may cause component damage AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation ACAUTION Podily injury hazard Beware of hot engine components Contact with hot engine components may cause severe burns Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures TABLE A PROCEDURES 1 Remove the 2 engine pivot plate retaining Perkins Diesel models bolts Swing the engine pivot plate away from the machine to access the front engine access a Check tier nging Del TOC proper tension cover mounting fasteners NN Y a PAS Perkins Diesel engine 5 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts 6 Replace the air baffle and install the air baffle retaining fasteners a engine pivot
175. bs 46 Nm 2 Install the pump coupler onto the pump shaft with the set screw towards the pump Leave a 1 16 inch 1 59 mm gap between the pump coupler and pump end plate 3 Apply removable thread locking material to the pump coupler set screw Torque the set screw to 45 ft lbs 61 Nm Component damage hazard Do CAUTION not force the drive pump during installation or the flex plate teeth may become damaged 4 Install the pump and torque the pump mounting plate fasteners to 34 ft Ibs 46 Nm Part No 65196 Genie S 60 amp Genie S 65 7 35 Section 7 Repair Procedures Third Edition First Printing FORD ENGINE LRG 425 EFI 8 3 Coolant Temperature and Oil Pressure Gauges The engine coolant temperature gauge is an electrical gauge The engine coolant temperture sending unit has limit contacts that are factory set The contacts will close at pproximately 230 F 110 C When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Engine coolant temperature will be indicated on the gauge when the key switch is and the Emergency Stop button is pulled out to the position The oil pressure gauge is an electrical gauge The oil pressure sending unit has limit contacts that are factory set The contacts will open at approximately 8 psi 0 55 bar When the contacts close the engine will shut off to prevent damage Engine oil pr
176. cess Be sure that all necessary tools and test equipment are available and ready for use Malfunction discovered Return to service Identify symptoms problem Still exists problem Solved Troubleshoot Perform repair PartNo 65196 Genie S 60 amp Genie S 65 Section 6 Schematics Third Edition First Printing Electrical Components Item Description Genie Part Manufacturer Manufacturer Qty Part Number Part Number BAT Battery 1000 CCA 12V DC 30143 TROJAN nce he ei ethene ees C31 XH 2 1 BP1 Joystick controller Dual axis 53073 OEM Controls EJS5M1197 1 BP2 Joystick controller Single axis 24495 OEM Controls 54 68 1 CB1 CB2 Circuit breaker 15A 24018 ET ani esito dits 45 700 IG1 P10 2 CR1through CR7 17 18A 18B 19 Relay SPDT 12V DC 34052 Potter Brumfield VF4 15F11 COS 10 Diode Diode 6 amp 200 PIV 45782 Motorola MOTMR752 36 DPT ke Joystick controller Drive 20424 OEM Controls 54 11664 1 EB uu F
177. ch is to limit the ability of the machine to drive when the boom is rotated beyond the non steer wheels Machine Controls The Genie S 60 and Genie S 65 machines are equipped with operational controls which are found in two locations the ground controls located on the tank side of the machine and the platform controls located in the platform All lift and drive functions are available at the platform controls Only boom functions are available at the ground controls Ground controls are activated by holding the function enable toggle switch to either side then moving a boom function toggle switch in the direction indicated on the control panel decal This will determine which boom function will operate and its direction of travel Platform controls use toggle switches and boom function controllers joysticks to operate the boom functions The drive controller joystick regulates the drive pump displacement through the EDC in direct relation to the drive controller position A thumb rocker switch on the top of the drive controller is used for steering Washing electronic components is not suggested Instead use compressed air to remove debris Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the main
178. ck at the platform end Always replace the cotter pin with new one when removing a clevis pin 16 Remove the mounting fasteners that attach the lower cable track to the boom BOOM COMPONENTS 17 Remove the cable track from the machine and place it on a structure capable of supporting it Crushing hazard The cable track AWARNING could become unbalanced and fall if it is not properly attached to the overhead crane Component damage hazard The boom cable track can be damaged if it is twisted CAUTION How to Repair the Cable Track CAUTION Component damage hazard The boom cable track can be damaged if it is twisted A cable track repair kit is available through the Genie Industries Service Parts Department part no 46677 The kit includes a 4 link section of cable track fasteners other miscellaneous parts and detailed instructions 1 Remove the boom cable track See 4 1 How to Remove the Boom Cable Track 2 Visually inspect the cable track and determine which 4 link section needs to be replaced Part No 65196 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Third Edition First Printing BOOM COMPONENTS 3 Drill out the 4 spot welds on each side of the cable track using a 17 64 drill bit Repeat this step for the other end of the 4 link section of cable track CAUTION Component damage hazard Cables and hoses can be damaged if the drill bit comes in contact with them Prot
179. clockwise to increase the voltage or counterclockwise to decrease the voltage Start the engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Engine should be at normal operating temperature 10 Fully retract the boom then start a timer and record how long it takes the turntable to rotate through a complete circle Adjust the max out trimpot to achieve a 80 to 84 second cycle time Turn the max out trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed Part No 65196 Genie S 60 amp Genie S 65 7 5 Section 7 Repair Procedures Third Edition First Printing PLATFORM CONTROLS 11 With the boom extended approximately 3 feet 0 9 m start a timer and record how long it takes the turntable to rotate through a complete circle Adjust the lo range trimpot to achieve a 130 to 134 second cycle time Turn the lo range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed If the function cycle time is not achievable check the relief valve pressure See 11 2 Valve Adjustments Function Manifold 12 Turn the engine orr 13 Pull out the Emergency Stop button to the position 14 Press down the foot switch and move the controller all the way to the left or right Record the maximum voltage reading 15 Start the engine 16 Start a timer and simultaneously m
180. co Always have an approved fire extinguisher within easy reach 1 Open the shutoff valve on the liquid petroleum gas LPG tank by turning it counterclockwise if equipped 4 8 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures 2 Perform a visual inspection around the following areas Gasoline LPG models LPG tank hoses and fittings solenoid shutoff valve LPG regulator and throttle body An LPG detector may be necessary to locate LPG leaks Gasoline tank manual shutoff valve fuel pump fuel filters fuel rail and fuel injectors hoses and fittings and throttle body Diesel models Fuel tank shutoff valve hoses and fittings fuel pump fuel filter fuel injection pumps and fuel injectors atomizers ADANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak TABLE A PROCEDURES A 7 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure that the boom is in the stowed position then visually inspect the sight gauge located on the side of the hydraulic oi
181. come out Immediately tighten the drain plug a fuel filter b drain plug 3 Clean up any fuel that may have spilled If the fuel filter is completely drained you must prime the fuel filter water separator before starting the engine Refer to D 9 in this section Replace The Fuel Filter Water Separator Deutz Diesel Models for instructions on how to prime the fuel filter water separator 4 Start the engine from the ground controls and check the fuel filter water separator for leaks ADANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures A 16 Inspect the Engine Air Filter Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off Gasoline LPG and Deutz Diesel Models 1 Open the engine side cover and remove the retaining ring from the end cap of the air filter canister 2 Remove the end cap from the air cleaner canister 3 Remove the air filter retaining fastener Remove the filter element 4 Clean the inside of the canister and the gasket with a damp cl
182. counterbalance valve OR consult Genie Industries Service Department SEE NOTE 2 Reset boom down relief valve item F pressure see Repair Section OR replace boom down relief valve OR repair cylinder or cylinder counterbalance valve OR function manifold could have an internal fault Consult Genie Industries Service Department CHART 15 NOTE 1 S 60 2600 PSI S 65 2900 PSI NOTE 2 S 60 Less than 2600 PSI S 65 Less than 2900 PSI Part No 65196 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Chart 16 Boom Extend Function inoperative Be sure all other functions operate normally With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the boom extend toggle switch TS15 in the EXTEND direction Check voltage on blk red 4 wire on boom extend retract proportional valve coil item G 20V or more AA Continued on the next page oV Hold the function enable switch to either side and move the boom extend toggle switch in the EXTEND direction Check 9 to 10V voltage at 9 oV With key switch 9 to 10V to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the boom extend re
183. ct and plug the hydraulic hoses from the jib boom lift cylinder Cap the fittings on the cylinder AWARNING 2 iniury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray All models 8 From the ground controls raise the boom to a horizontal position 7 20 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 9 Remove the fasteners from the drive speed limit switch mounted on the side of the cable track at the pivot end of the boom Do not disconnect the wiring 10 Remove the fasteners from the side panel on the lower cable track then remove the panel Pull all of the cables and hoses out of the channel 11 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and AWARNING lower cable tracks are not properly secured together the cable track could become unbalanced and fall when it is removed from the machine 12 Remove the mounting fasteners from the large cable track guide at the platform end of the cable track Remove the guide 13 Remove the hose and cable clamp at the platform end of the cable track 14 Attach a lifting strap from an overhead crane to the cable track 15 Remove the cotter pin and clevis pin from the upper cable tra
184. ct the bleed valves for leaks Part No 65196 Genie S 60 amp Genie S 65 7 17 Section 7 Repair Procedures Third Edition First Printing Jib Boom Components S 65 Models 3 1 Jib Boom How to Remove the Jib Boom Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the platform mounting weldment and the platform rotator See 2 8 How to Remove the Platform Rotator 3 From the ground controls raise the jib boom to a horizontal position 4 Attach a lifting strap from an overhead crane to the center of the jib boom 5 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the jib boom cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Remove the hose cover hoses and cables from the side of the jib boom and set them aside Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched Remove the pin retaining fastener from the jib boom lift cylinder barre
185. ction 7 Repair Procedures 4 2 Boom How to Shim the Boom 1 Measure each upper and side wear pad Replace the pad if it is less than 9 16 inch 14 3 mm thick If the pad is more than 9 16 inch 14 3 mm thick perform the following procedure 2 Measure the bottom wear pad Replace the pad if it is less than 11 16 inch 17 5 mm thick If the pad is more than 11 16 inch 17 5 mm thick perform the following procedure 3 Extend the boom until the wear pads are accessible 4 Loosen the wear pad mounting fasteners Install the new shims under the wear pad to obtain zero clearance and zero drag 6 Tighten the mounting fasteners 7 Extend and retract the boom through an entire cycle Check for tight spots that could cause binding or scraping Always maintain squareness between the outer and inner boom tubes BOOM COMPONENTS How to Remove the Boom AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torqu
186. d hold the drive controller in the full reverse position Check voltage across the terminals 5 and 4 on the drive controller Check continuity from LANE terminal 43 on drive controller to ground grin Replace drive controller OR consult Genie Industries Service Department Check continuity from onn terminal 3 on drive a controller to ground ony Replace drive controller OR consult Genie Industries Service Department 2V v Continued on the next page CHART 30 Repair open in brn ground wire circuit from terminal 43 on drive controller to ground Repair open in brn ground wire circuit from terminal 43 on drive controller to ground Part No 65196 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts CHART 30 Continued fromthe previous page Press down the foot switch and hold the drive controller in the full forward position and check voltage across the wht 12 wire and the wht blk 31 wire on EDC 2V y Troubleshoot drive forward and drive reverse functions separately OR replace ump OR consult Genie ndustries Service Department Third Edition First Printing Press down the foot switch and hold the drive controller in the full forward position Hold the drive enable toggle switch TS8 to either side and check the voltage across the wht 12
187. d if it is twisted Component damage hazard Hoses can be damaged if they are kinked or pinched CAUTION 13 Remove the turntable end cover 14 Remove the retaining fastener from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin Pull the cylinder back and secure it from moving CAUTION Component damage hazard When pulling the master cylinder back be sure not to damage the master cylinder hoses or fittings 15 Remove the fasteners from the drive speed limit switch mounted to the turntable riser at the pivot end of the boom Do not disconnect the wiring 16 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 17 Attach an overhead 5 ton 4536 kg crane to the center point of the boom 18 Attach a similar lifting device to the boom lift cylinder 19 Use the overhead crane to lift the boom to a horizontal position 20 Place support blocks under the boom lift cylinder across the turntable Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 21 Remove the pin retaining fastener from the boom lift cylinder rod end pin Use a soft metal drift to remove the pin
188. d isolate the fuel ohms solenoid Check the op resistance of the solenoid 3 5 ohms Deutz 11 5 ohms Perkins See Deutz or Perkins service manual for troubleshooting fuel system Repair open in wht 21 wire from CR2 to fuel solenoid Repair open in red wire circuit from battery to CB1 to CR1 to CR2 Chart 3 Replace the fuel solenoid Part No 65196 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts eee CHART 3 Continued from the previous page Third Edition First Printing Repair open in blk wire from terminal 86 on CR2 to terminal 9 on the ignition start module Repair open in power supply wires to terminal 6 and 7 on ignition start module Repair open in brn ground wire circuit to terminal 5 on ignition start module Move the start toggle Move the start toggle switch to either side and gt 5 and 12V check voltage at check voltage a terminal 86 of CR2 terminal 9 on the ignition start module oV Check voltage at Dn terminal 46 and 7 on ignition start module 12 Check continuity from ground to brn wire at continuity 12 terminal 5 on ignition 4 start module continuity Replace the ignition start module OR consult Genie Industries Service Department Y Ch
189. d turn the key switch to the ground controls position O Result The check engine light should turn on The check engine light should begin to blink Part No 65196 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Third Edition First Printing GROUND CONTROLS 5 Continue to hold the run test toggle switch in the test position and count the blinks Fault codes are two digits The check engine light will blink the first digit of a two digit code then will pause for 1 2 seconds and then blink the second digit For example the check engine light blinks 5 consecutive times then pauses for 1 2 seconds and then blinks 1 time That would indicate code 51 The ECM is able to store up to six individual fault codes There will be a 2 4 second pause between codes 6 Referto the Troubleshooting Section for definition of engine fault codes Once a fault code has been retrieved and the repair has been completed the ECM memory must be reset to clear the fault code from the ECM See 9 4 How to Clear Engine Fault Codes How to Clear Engine Fault Codes from the ECM Perform this procedure with the engine off and the key switch in the orr position 1 Open the engine side turntable cover and locate the battery 2 Disconnect the negative battery cable from the battery for a minimum of 20 minutes Electrocution hazard Contact with AWARNING electrically charged circuits could result in death or serious injury
190. death or serious injury Remove all rings watches and other jewelry PLATFORM CONTROLS Platform control box a horsepower limiter board 3 Connect the black lead from a DC volt meter to the number 2 terminal and the red lead to the number 10 terminal 1 12V or greater ground engine rpm sensor not used not used low drive speed limit switch not used not used not used output to drive controller o o o o 0 o o o o gt a e E e 5 Horsepower limiter board a A trimpot maximum voltage output to the drive controller in the stowed position b B trimpot maximum voltage output to the drive controller in the boom raised or extended position c C trimpot reaction rate or how fast the voltage output reacts to the change in engine rpm Part No 65196 Genie S 60 amp Genie S 65 7 9 Section 7 Repair Procedures Third Edition First Printing PLATFORM CONTROLS 4 Start the engine from the platform controls 5 Move the engine idle control toggle switch to foot switch activated high idle rabbit and foot switch symbol 6 Press down the foot switch and turn the A tripmot adjustment screw counterclockwise to increase voltage or clockwise to decrease voltage A potentiometer specifications all models Voltage setting 12 to 12 5V DC 7 Move the engine idle control toggle switch to low idle turtle symbol
191. dirty conditions may require oil changes to be performed more frequently 1 The machine uses Dexron equivalent hydraulic oil Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Remove the fuel tank See Repair Section 12 1 How to Remove the Fuel Tank Table E Procedures 2 Close the two hydraulic shutoff valves located at the hydraulic tank closed Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the cLosEp position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition CAUTION Remove the drain plug from the hydraulic tank Completely drain the tank into a suitable container See capacity specifications Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves Discon
192. dition First Printing Chart 2A Engine Runs While Cranking Then Dies Gasoline LPG Models Be sure to check the engine oil level and fill as needed Be sure to check fuel levels and the engine coolant level Be sure that the radiator overflow tank is at the FULL mark Perform these tests in gasoline mode only See Repair Section How to Retrieve Fault Codes Is there a fault code stored in the ECM memory yes Move the start toggle oV Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Crank engine and check ov switch to either side and voltage at org blk 41 check voltage at wire on alternator terminal 2 on ignition start module 6 to 7V Repair open in org blk 41 wire circuit from alternator to TB41 to 610 7V terminal 2 on ignition start module Y Check voltage at 12V Disconnect red wire terminal 4 on ignition from terminal 4 on 12V start module ov v Replace ignition start module OR consult Genie Industries Service Department ignition start module and check voltage at terminal 4 E Test auxiliary power toggle switches TS1 and TS9 See Repair Section Refer to the f
193. dition is essential for good engine performance Operating a machine with a damaged oil cooler may result in engine damage Also restricting air flow through the oil cooler will affect the performance of the cooling system AWARNING injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns TABLE A PROCEDURES Oil Cooler 1 Remove the engine side cover mounting fasteners Remove the engine side turntable cover 2 Inspect the oil cooler for leaks and physical damage a oilcooler b cylinder head cooling fins fan blower fins 3 Clean the oil cooler of debris and foreign material Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE A PROCEDURES Cooling and Fan Blower Fins 4 Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the fan blower a engine pivot plate b pivot plate retaining bolts c air baffle 5 Inspect the fan blower fins for physical damage 6 Clean the fan blower fins of debris and foreign material 7 Inspect the head cooling passages and fins for physical damage or foreign material using a flashlight 8 Clean the cylinder head cooling passages and fins of de
194. e a pivot plate mounting bolts b adjustment bolt with lock nut c drive hub pivot plate Push the drive hub pivot plate towards the turntable as far as possible this will push the rotation gear into the rotation bearing ring gear Loosen the lock nut on the adjustment bolt 4 Turn the adjustment bolt clockwise until it contacts the pivot plate Turn the adjustment bolt 1 2 turn counterclockwise Tighten the lock nut on the adjustment bolt Rotate the drive hub pivot plate away from the turntable until it contacts the adjustment bolt Then tighten the mounting fasteners on the drive hub pivot plate Rotate the turntable through an entire rotation Check for tight spots that could cause binding Readjust if necessary 7 70 Genie 5 60 amp Genie 5 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 2WD Steering Axle Components 14 1 Yoke and Hub How to Remove the Yoke and Hub 1 Remove the pin retaining fastener from the steering cylinder rod end pivot pin and the tie rod clevis pin Remove the pivot pins tie rod axle yoke pivot pin yoke hub clevis pin steering cylinder qaroao om 2 Loosen the wheel lug nuts Do not remove them 3 Block the non steering wheels and center a lifting jack of ample capacity under the steering axle 4 Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support 5 R
195. e Specifications Remove the platform See 2 1 How to Remove the Platform Remove the platform rotator and leveling slave cylinder See 2 8 How to Remove the Platform Rotator S 65 Models Remove the jib boom See 3 1 How to Remove the Jib Boom Remove the mounting fasteners from the jib boom platform rotate valve manifold on the end of the boom Remove the manifold and set it aside Part No 65196 Genie S 60 amp Genie S 65 7 23 Section 7 Repair Procedures Third Edition First Printing BOOM COMPONENTS 5 Remove the fasteners from the drive speed limit switch mounted on the side of the cable track Do not disconnect the wiring 6 Support the cable track with an overhead crane 7 Remove the hose cable clamp from the pivot end of the boom 8 Remove the hose cable clamp at the platform end of the cable track 9 Remove the fasteners from the large cable track guide at the platform end of the cable track Remove the guide 10 Remove the cotter pin from the clevis pin at the platform end of the cable track Remove the clevis pin Always replace the cotter pin with new one when removing a clevis pin 11 Remove the fasteners from the side panel on the cable track to access the cable track mounting fasteners 12 Remove the cable track mounting fasteners then remove the cable track from the boom and lay it off to the side CAUTION Component damage hazard The boom cable track can be damage
196. e a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist C Third Edition First Printing 2 2 Checklist E C 1 Engine belt Deutz models C 2 Valves Deutz models E 1 Hydraulic oil E 2 Engine coolant Liquid cooled models C 3 Fuel filter water separator Perkins models C 4 Fuel filter Perkins models C 5 Replace engine oil and filter Perkins models C 6 Glow plugs Perkins models E 3 Fuel hoses Ford models E 4 Replace engine breather Perkins models E 5 Wheel bearings Perform every 3000 hours E 6 Fuel injectors Perkins models C 7 Check the coolant Liquid cooled models C 8 PCV valve Ford models ChecklistD YNR D 5 Drive hub oil D 6 Drive loop hydraulic filter D 7 Replace engine oil and filter Deutz models D 8 Fuel strainer Deutz models D 9 Fuel filter water separator Deutz models D 10 Change fuel lines Deutz models D 11 Valves Deutz models D 1 Boom wear pads D 2 Free wheel configuration D 3 Turntable bearing bolts D 4 Grease rotation bearing Comments D 12 Clean engine breather Perkins models 4 4 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures A 1 Inspect the Operators and Safety Manuals Maintaining the operator s and safety manuals in go
197. e boom to the stowed position 1 Pushin the platform Emergency Stop button to the orr position 2 Startthe engine from the ground controls 3 Atthe ground controls operate each boom function through a partial cycle Result All boom functions should operate Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures B 10 Check the Directional Valve Linkage Perform this test only on models equipped with a oscillating axle Proper axle oscillation is essential to safe machine operation If the directional valve linkage is not operating correctly the stability of the machine is compromised and it may tip over 1 Remove the drive chassis cover from the non steer end 2 Inspect the linkage for the following Lock nut is tight against yoke Yoke clevis pins are installed Cotter pins are installed through clevis pins Linkage is properly attached to directional valve a directional valve b clevis pin with cotter pin hidden yoke d lock nut TABLE B PROCEDURES B 11 Test the Platform Self leveling Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located at the base of the boom A platform sel
198. e switch terminal of TS9 2V or more Repair open in red 27 wire from TS9 to TB27 OR replace TS9 Part No 65196 Genie S 60 amp Genie S 65 5 73 Section 5 Troubleshooting Flow Charts Third Edition First Printing This page intentionally left blank 5 74 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 6 Schematics Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry M Immediately tag and remove from service a Hydraulic Schematics damaged or malfunctioning machine Repair any machine damage or malfunction AWARNING before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie S 60 amp Genie S 65 Operator s Manual General Repair Pro
199. e the lift drive selector switch to the drive position if equipped 18 Slowly move the drive controller off center Result The machine should move at a reduced drive speed Drive speed maximum raised or extended position All models 1 foot per second 0 6 mph 0 3 meter per second 0 97 km h Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE A PROCEDURES Drive Enable Limit Switch A properly functioning drive enable limit switch is essential for safe machine operation and workplace safety The drive enable limit switch stops the drive function when the boom is rotated past a non steer wheel and alerts the operator that the machine may drive in the opposite direction that the drive and steer controller is moved 1 Start the engine from the platform controls and rotate the turntable to the left until the boom is past the left non steer wheel Turn the engine off 2 Visually inspect the drive enable limit switch for the following Broken or missing roller or arm Missing fasteners Loose wiring a turntable b drive enable limit switch LS3 c turntable rotation bearing Manually activate the drive enable limit switch Result The drive enable limit switch arm should move freely and spring return to center A distinct click should be felt and heard Start the engine from the platform controls and press
200. e to dissipate gradually Do not allow oil to squirt or spray Section 7 Repair Procedures JIB BOOM COMPONENTS S 65 MODELS 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out Lower one of the leveling arms to the ground Tap the pin the opposite direction and lower the second leveling arm Do not remove the pin 5 Attach a strap from an overhead crane to the jib boom lift cylinder 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin 7 Usea soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the cylinder from the machine Crushing hazard The jib boom lift AWARNING cylinder could become unbalanced and fall when it is removed from the machine if it is not properly supported Part No 65196 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Third Edition First Printing Boom Components 4 1 Cable Track The boom cable track guides cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire boom cable track is necessary when performing major repairs that involve removing the boom How to Remove the Cable Track When removing a hose assembly
201. ease the voltage or counterclockwise to decrease the voltage 9 Start the engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Lower the boom to the stowed position Engine should be at normal operating temperature 10 Start a timer and record how long it takes for the boom to fully extend Adjust the max out trimpot to achieve a 60 to 64 second cycle time 11 Start a timer and record how long it takes for the boom to fully retract Adjust the lo range trimpot to achieve a 55 to 60 second cycle time If the function cycle time is not achievable check the relief valve pressure See 11 2 Valve Adjustments Function Manifold 12 Turn the engine off and re connect the volt meter 13 Pull out the Emergency Stop button to the on position 14 Press down the foot switch and move the controller all the way to the ExTEND position Record the maximum voltage reading 15 Start the engine 16 Start a timer and simultaneously move the control handle all the way to the ExrEND position Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp rate 17 Set the ramp rate turn the ramp rate adjustment trimpot to obtain a 3 second ramp rate Turn the ramp rate trimpot adjustment screw clockwise to increase the time or counterclockwise to decrease the time Boom extend retract specifications Threshold 3 5V DC 9 75V DC 60 to
202. eck continuity from conii Repair open in brn ground to terminal 85 gt ground wire circuit to on CR2 CR2 good Crank engine and check oy Crank engine and check gy voltage at terminal 2 on gt voltage at org blk 41 ignition start module wire on alternator 6 to 7V v Continued on the next page Repair or replace alternator OR contact Genie Industries Service Department Repair open in org blk 41 wire circuit from alternator to TB41 to terminal 2 on ignition start module Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts EEE CHART 3 Continued from the previous page SL While cranking engine for 15 seconds check continuity to ground on terminal 10 on ignition start module Is continuity maintained yes no Y Disconnect wht 24 wire from oil pressure sender and check continuity to ground on signal post of sender while cranking the engine Is continuity yes Check oil level OR replace oil pressure sending unit OR refer to Deutz or Perkins service manual for troubleshooting low oil maintained pressure Disconnect wht 24 wire Check oil level OR from engine temperature sender and check continuity to ground on signal post of sender while cranking the engine
203. ect the hoses and cables with a block of wood to prevent drilling into the hoses and cables 4 Remove the retaining fasteners from the upper black rollers from the 4 link section of cable track to be replaced Remove the rollers 5 Lift up the hoses and cables and carefully remove the damaged 4 link section of cable track CAUTION Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 6 Remove the upper rollers from the replacement section of cable track 7 Lift up the hoses and cables and carefully insert the new 4 link section of cable track CAUTION Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 8 Connect the ends of the replacement cable track section to the existing cable track using the fasteners provided in the kit Do not overtighten the fasteners Component damage hazard CAUTION Over tightening the fasteners will prevent the cable track from rotating and it may kink or bind during operation Be sure that the fasteners are installed from the inside out so that the nuts are on the outside of the cable track Install the black rollers onto the new section of cable track 10 Install cable track onto the machine and operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track 7 22 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Se
204. ection 4 Scheduled Maintenance Procedures D 3 Check the Turntable Rotation Bearing Bolts Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the boom and place a safety chock on the lift cylinder rod Carefully lower the boom onto the lift cylinder safety chock Crushing hazard Keep hands AWARNING away from cylinder and all moving parts when lowering the boom The lift cylinder safety chock is available through Genie part number 33484 TABLE D PROCEDURES 2 Be sure that each turntable mounting bolt is torqued in sequence to 210 ft lbs 285 Nm 10 7 22 9 6 12 8 24 30 027 4 289 59 23 17 E 5 8 0 9 2 16 mL Bolt torque sequence 3 Lower the boom to the stowed position 4 Checkto ensure that each bearing mounting bolt under the drive chassis is torqued in sequence to 210 ft Ibs 285 Nm 1 15 UNS DP Bolt torque sequence Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE D PROCEDURES D 4 Grease the Turntable Rotation Bearing and Rotate Gear Yearly application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an impr
205. emove the lug nuts Remove the tire and wheel assembly 6 Remove the pin retaining fasteners from the yoke pivot pins 7 Support and secure the yoke hub assembly to a lifting jack 8 Use a slide hammer to remove the upper yoke pivot pin 9 Use a soft metal drift to drive the lower yoke pivot pin down and out Crushing hazard The yoke hub ACAUTION assembly could become unbalanced and fall when the yoke pivot pins are removed if it is not properly supported and secured to the lifting jack Torque specifications Lug nut torque dry 420 ft lbs 569 5 Nm Lug nut torque lubricated 320 ft lbs 434 Nm Part No 65196 Genie S 60 amp Genie S 65 7 71 Section 7 Repair Procedures Third Edition First Printing 2WD STEERING AXLE COMPONENTS How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steering wheels Center a lifting jack under the steering axle 3 Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support 4 Remove the lug nuts then remove the tire and wheel assembly 5 Remove the dust cap cotter pin and castle nut Always use a new cotter pin when installing a castle nut 6 Pullthe hub off the yoke spindle The washer and outer bearing should fall loose from the hub 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing Always install a
206. engine to normal operating temperature 1 Remove the oil filler cap located next to the engine oil dipstick 2 Pull the end of the engine oil drain hose out from under the engine 3 Remove the plug from the end of the drain hose and allow all of the oil from the engine to drain into a suitable container See capacity specifications Do not remove the drain plug located on the side of the oil pan 4 Install and tighten the plug in the drain hose Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE C PROCEDURES 5 Use an oil filter wrench and remove the oil filter located below the fuel filter Clean the inside of the filter head 6 Apply a thin layer of clean engine oil to the new filter gasket Install the filter and tighten it securely by hand 7 Usea permanent ink marker to write the date and number of hours from the hour meter on the oil filter 8 Fill the engine with new oil per specifications and install the oil filler cap 9 Startthe engine from the ground controls and allow the engine to run for 30 seconds Stop the engine 10 Check the oil filter and drain hose for leaks 11 Wait 15 minutes after stopping the engine and check the engine oil level on the dipstick Add oil if needed 12 Dispose of the used oil and filter properly Perkins 704 30 Engine Cil capacity including filter 9 6 quarts 9 liter
207. enie Industries Service Department Turn OFF the valve on the LPG tank then disconnect LPG supply line from LPG tank and bleed pressure from line With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at LPG side blu red wire of fuel select toggle switch o Check the voltage at the center terminal of the fuel select toggle switch ye Replace fuel select toggle switch TS11 With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at TB39 oV Repair open in blu red wire circuit from fuel select toggle switch to 2V With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at terminal 85 on CR3 ov Repair open in red wire circuit from ECM to terminal 85 on CR3 OR replace ECM Continued on the next page Refer to the fault code chart in this section for a description of the fault and recommended repairs Repair open in power supply circuit to fuel select toggle switch Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts n
208. enie S 65 7 37 Section 7 Repair Procedures Third Edition First Printing Ground Controls 9 1 Control Relays Relays used for single function switching are single pole double throw SPDT relays How to Test a Single Pole Double Throw Relay AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Label and then disconnect all the wiring from the relay to be tested 2 Connectthe leads from an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other combination Test Desired result terminal 85 to 86 with resistor 75 to 85Q terminal 87 to 87a amp 30 no continuity infinite Q terminal 87a to 30 continuity zero Q 3 Connect 12V DC to terminal 85 and a ground wire to terminal 86 then test the following terminal combinations Test Desired result terminal 87 to 87a amp 30 no continuity infinite Q terminal 87 to 30 continuity zero Q L 3 87 go 9 9 55 90 terminal 87a terminal no 85 coil negative terminal no 30 common terminal no 86 coil positive terminal no 87 N O oQa0 7 9 Control Relay Schematic with resistor Genie S 60 amp Genie S 65 Part No 65196 Thi
209. eriodic oil and filter changes can damage engine components A frequent check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 1000 hour interval Bodily injury hazard Beware of ACAUTION hot engine parts and oil Contact with hot engine oil and or engine parts may cause severe burns Perform this procedure after warming the engine to normal operating temperature 1 Remove the oil filler cap located next to the dipstick 2 Pull the end of the engine oil drain hose out from under the engine TABLE D PROCEDURES Remove the plug from the end of the drain hose and allow all of the oil from the engine to drain into a suitable container See capacity specifications Do not remove the drain plug located on the side of the oil pan Install and tighten the plug in the drain hose Use an oil filter wrench and remove the oil filter Deutz Diesel engine a engine oil level dipstick b fuel filter c filter Apply a thin layer of clean engine oil to the new filter gasket Install the filter and tighten it securely by hand Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter Part No 65196 Genie S 60 amp Genie S 65 4 67 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE D PROCEDURES 8 Fill the engine with new
210. es from ground controls Ground Controls inoperative Platform Controls Operate Normally Be sure all other functions operate normally including the platform controls no With both Emergency Stop buttons pulled out to the ON position check voltage at red wire on Start the engine from ground controls Hold the function enable toggle switch to either side and check the voltage on both center terminals of the platform rotate toggle switch 13 12V Troubleshoot each function individually Repair open in red wire circuit from Emergency Stop button to key switch Repair open in red wire circuit from key switch to function enable toggle switch to each function toggle switch the input side of the ground controls contact of the key switch the red wire checked should originate at the Emergency Stop button With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at red wire on the output side of the ground controls contact on the key switch Check if key switch internal cam is activating Replace key switch contact for ground yes controls ground contact no Replace key switch Repair open in red wire circuit from key switch to function enable toggle switch to each function toggle switch Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troublesh
211. es item disconnect couplingon _ gt AC Press down the the function manifold foot switch and activate and activate the jib the jib boom down boom down function function function inoperative Check for mechanical restrictions keeping jib boom down function from operating OR repair or replace jib boom cylinder OR SEE replace counterbalance NOTE 2 valve OR 0 030 orifice item N may be plugged OR jib boom platform rotate select manifold has an internal fault OR consult Genie Industries Service Department v function Exchange jib boom Operates Replace faulty counterbalance valves counterbalance valve and activate jib boom down function function inoperative Consult Genie Industries Service Department NOTE 1 5 60 2600 PSI 5 65 2900 PSI NOTE 2 5 60 Less than 2600 PSI 5 65 Less than 2900 PSI Part No 65196 Genie S 60 amp Genie S 65 5 59 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 28 Steer Left Function inoperative Be sure all other functions operate normally With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and hold the steer rocker switch on drive controller in the LEFT direction Check voltage on TB36 OV 12V or more v With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON posi
212. essure will be indicated on the gauge when the engine is running How to Remove the Coolant Temperature and Oil Pressure Gauge Sending Units Perform this procedure with the engine off 1 Remove the 2 engine pivot plate retaining bolts Swing the engine pivot plate away from the machine to access the coolant temperature and oil pressure sending units a NN IP a engine pivot plate b pivot plate retaining bolts c air baffle Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 2 Locate the oil pressure and coolant temperature sending units FORD ENGINE LRG 425 EFI 5 Connect the wires to the new sending unit ACAUTION Burn hazard Contact with hot engine fluids or components may cause severe burns Always use pipe thread sealant when installing a sending unit Coolant temperature sending unit specifications Torque 8 10 ft lbs 11 14 Nm Hex size 13 16 inch Temperature switch point 230 F 110 C a pressure sending unit Oil pressure sending unit specifications b coolant temperature sending unit hidded from view Torque 8 10 ft lbs aA j 11 14 Nm 3 Tag and disconnect the wiring from the desired sending unit Remove the sending unit from the Hex size 11 16 inch engine HIER Oil pressure switch point 8 psi 4 Install the new sending unit Do not over tighten 0 55 bar Part No 65196 Genie S 60 amp G
213. etween the outer and inner boom tubes Wear pad specifications 14 3 mm 17 5 mm 9 16 inch 11 46 inch Upper and side wear pads Bottom wear pads Table D Procedures D 2 Check the Free wheel Configuration Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and property damage Collision hazard Select a work AWARNING site that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h CAUTION Non steering wheels All models 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 20 000 1 5 9072 kg under the drive chassis between the non steer wheels 3 Lift the wheels off the ground and then place blocks under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steering wheel hub ip disengage position arg NS engage position Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE D PROCEDURES 5 Manually rotate each non steering wheel O Result Each non steering wheel should rotate with minimum effort 6 Re engage the drive hubs by turning over the
214. etz ep ORG RED 3 2 BLK 6 12 848 PLATFORM LEVEL 7 fj 5 DISABLE 2 9g ES CE OPTION o o RN 2 1 le ens dg UU BTE 8 2 JIB BOOM M GRN BLK 3 GRN m 4 18 7515 TB18 io tDOWN E GRN 4 PLATFORM ROTATE iss vem LEFT JIB UP p JIB BOOM DOWN 7 t e GRN BLK 4 H PLATFORM ROTATE RIGHT JIB DOWN RIGHT RIGHT 1 PLATFORM ROTATE EFT LEFT x L 1 o i a BRN GRNWHT Er GRN WHT 3 4 E gt Fd m ps 4 RED 8 8 8 8 n 8 5 JIB VALVES ze BLK 57 iu 19 x z LIFT DRIVE y SELECTOR pile E P OPTION E a a a z d T c E 6 17 Genie S 60 amp Genie S 65 Part No 65196 Section 6 Schematics Third Edition First Printing Ground Control Box Wiring Diagram Perkins Diesel Models A B D E WHT RED 26A BRN GROUND ML KS1 STACKED CONTACTS CE MODELS ONLY WHT2IA WHT BLK 25A 2 BLK 22A KS1 WHT 23A P1 3 Nc BTS z NO NO NC bs 4 TS10 9 RED 27A BLK WHT
215. evere burns 1 Remove the air baffle retaining fasteners Remove the air baffle Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures 2 Remove the 2 engine pivot plate retaining bolts Swing the engine pivot plate away from the machine to access the radiator a engine pivot plate b pivot plate retaining bolts c air baffle 3 Inspect the radiator for leaks and physical damage 4 Clean the radiator fins of debris and foreign materials 5 Inspect all radiator hoses and connections 6 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts 7 Replace the air baffle and install the air baffle retaining fasteners Co TABLE A PROCEDURES A 19 Check the Battery Genie specifications require that this procedure be performed every 100 hours Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton p
216. ey switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls Do not start the engine 7 2 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 3 Open the platform control box lid and locate the boom up down controller ramp rate trimpot lo range trimpot terminal activates max out range a b d not used e terminal X not used f terminal ground g terminal positive h terminal A proportional output i threshold trimpot j max out trimpot 4 Setthe preliminary ramp rate Turn the ramp rate trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click 5 Connect the red lead from a volt meter to the A terminal on the controller printed circuit board Connect the black lead to ground 6 Setthe threshold Press down the foot switch then slowly move the controller off center until the moment a voltage reading appears Adjust the voltage to 3 5V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage PLATFORM CONTROLS 7 Setthe max out Press down the foot switch then move the controller all the way to the up position Adjust the voltage to 9 2V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to dec
217. f leveling failure creates an unsafe working condition for platform and ground personnel 1 Startthe engine from the ground controls and lower the boom to the stowed position 2 Hold the function enable toggle switch to either side and adjust the platform to a level position using the platform level toggle switch 3 Raise and lower the boom through a full cycle O Result The platform should remain level at all times to within 5 degrees Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE B PROCEDURES B 12 Test the Horn A functional horn is essential to safe machine operation The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform controls and pull out the Emergency Stop button to the ON position at both the ground and platform controls 2 Push down the horn button at the platform controls Result The horn should sound If necessary the horn can be adjusted to obtain the loudest volume by turning the adjustment screw near the wire terminals on the horn B 13 Test the Foot Switch A properly functioning foot switch is essential to safe machine operation Machine functions should activate and operate smoothly as long as
218. f the same hydraulic circuit but move in opposite directions The tie rod maintains equal movement of the tires When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the pin retaining fastener from the rod end clevis pin of the steer cylinder Remove the pin Part No 65196 Genie S 60 amp Genie S 65 7 73 Section 7 Repair Procedures Third Edition First Printing 2WD STEERING AXLE COMPONENTS 14 3 Tie Rod How to Remove the Tie Rod 1 Remove the pin retaining fasteners from the clevis pins at each end of the tie rod then remove the clevis pins 2 Remove the tie rod How to Perform the Toe in Adjustment before serial number 5043 Perform this procedure on a firm level surface Block the non steering tires and be sure that the machine is in the stowed position Machines manufactured after serial number 5042 have non adjustable tie rods 1 Straighten the steer wheels 2 Measure the steer tires
219. fe operating condition Explosion and fire hazard Engine A DANGER fuels are combustible Replace the fuel hoses in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Component damage hazard Be sure the fuel hoses are routed the same way the original hoses were CAUTION Perform this procedure with the engine off and cooled 1 Remove the 2 engine pivot plate retaining bolts and swing the engine out away from the machine to access the fuel hoses engine pivot plate pivot plate retaining bolts oil drain hose air baffle om Genie 5 60 amp Genie 5 65 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures TABLE D PROCEDURES 2 Place a suitable container under the engine b b b b b b b pivot plate 3 Atthe fuel pump disconnect the fuel hose to the fuel tank and drain the fuel tank into the s PT s container a 0 Ry ASS Hd Ser 4 Remove and replace all of the fuel hoses and A SS clamps according to the following illustration i II 2 Explosion and fire hazard Fuel 8 Injection systems operate at all 2 374 ETA 5 very high pressure Fuel be expelled under pressure if the NS cnl amp hoses are removed too quickly Loosen the fuel lines very slowly to allow the f
220. fications Drive speeds maximum 2WD 4WD Drive speed stowed 4 4 mph 3 mph Gasoline LPG models 7 1 km h 4 8 km h 40 ft 6 2 sec 40 ft 9 1 sec 12 2 m 6 2 sec 12 2 m 9 1 sec Drive speed stowed 4 mph 2 8 mph Diesel models 6 4 km h 4 5 km h 40 ft 6 8 40 ft 9 7 sec 12 2 m 6 8 sec 12 2 m 9 7 sec Drive speed 0 6 mph 0 6 mph raised or extended 1 km h 1 km h All models 40 40 sec 40 ft 40 sec 12 2 m 40 sec 12 2 m 40 sec Gradeability stowed Rough terrain 28 40 Third Edition First Printing CREE Boom function speeds maximum from platform controls Boom up 55 to 60 seconds Boom down 90 to 95 seconds Boom extend 60 to 64 seconds Boom retract 55 to 60 seconds Turntable rotate 360 boom fully stowed 80 to 84 seconds Turntable rotate 360 boom extended 130 to 134 seconds Platform rotate 160 10 to 20 seconds Platform level up 35 to 65 seconds Platform level down 25 to 55 seconds Jib boom up S 65 models 40 to 60 seconds Jib boom down S 65 models 50 to 80 seconds Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Hydraulic Specifications Hydraulic fluid Dexron equivalent Drive pump Type bi directional variable displacement piston pump Displacement 2500 rpm 30 3 gpm 114 7 l min Maximum drive pressure 3500 psi 241 3 bar Charge pressure
221. from an overhead crane to the barrel end of the oscillating cylinder 6 Remove the pin retaining fasteners from the barrel end pivot pin Use a soft metal drift to remove the pin 7 Remove the oscillate cylinder from the machine Crushing hazard The oscillate AWARNING cylinder could become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane Part No 65196 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Third Edition First Printing Non steering Axle Components 17 1 2 Tag disconnect and plug the hydraulic hoses Dri Mot from the drive motor Cap the fittings on the rive Motor drive motor Bodily injury hazard Spraying How to Remove a Drive Motor AWARNING ii oil can penetrate and Component damage hazard burn skin Loosen hydraulic CAUTION Repairs to the motor should only connections very slowly to allow be performed by an authorized the oil pressure to dissipate Sundstrand Sauer dealer gradually Do not allow oil to squirt or spray Component damage hazard The PE CAUTION work area and surfaces where this 3 Remove the drive motor mounting fasteners procedure will be performed must 4 Slide the drive motor shaft out of the brake be clean and free of debris that Remove the drive motor from the machine could get into the hydraulic system and cause severe component Torque specifications damage Dealer service is recommended Drive motor moun
222. fuel shutoff valve clockwise to the cLosep position Deutz model a manual fuel shutoff valve Part No 65196 Genie S 60 amp Genie S 65 7 67 Section 7 Repair Procedures Third Edition First Printing Turntable Rotation Components 13 1 Rotation Hydraulic Motor How to Remove the Rotation Hydraulic Motor When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin Locked position 2 Tag disconnect and plug the hydraulic hoses from the motor brake and manifold Cap the fittings on the motor brake and manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the motor brake mounting fasteners then remove the motor from the brake a motor b motor brake mounting bolts brake d drive hub e drive hub mounting bolts 7 68 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures How to Remove the Turntable Rotation Brake or Drive Hub 1 Secure the turntable from rotating with the turntable rotation l
223. g cannot be re used if the fitting or hose end has been tightened beyond finger tight The O rings used in the Parker Seal Lok fittings and hose ends are a custom size O ring They are not a standard SAE size O ring They are available in the O ring field service kit Genie part number 49612 2 Lubricate the O ring before installation Be sure that the face seal O ring is seated and retained properly Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight Tighten the nut or fitting to the appropriate torque per given size as shown in the table above Operate all machine functions and inspect the hoses and fittings and related components to be sure that there are no leaks Part No 65196 Genie S 60 amp Genie S 65 Section 2 Specifications Third Edition First Printing This page intentionally left blank 2 8 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 3 Theory of Operation Power Source The Genie S 60 and Genie S 65 are powered by either a Gasoline LPG engine or one of two diesel engines The Gasoline LPG option uses a Ford LRG 425 EFI rated at 70 horsepower 2500 rpm The diesel options include a Deutz F4L1011F rated at 56 horsepower 3000 rpm and a Perkins 704 30 rated at 63 horsepower 2600 rpm Hydraulic System All machine functions are performed by the hydraulic system The hydraul
224. h the master cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Slave Cylinder Before cylinder removal is considered to correct a malfunction bleed the slave cylinder to be sure there is no air in the closed loop hydraulic circuit When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Adjust the platform to a level position 2 Extend the boom until the slave cylinder barrel end pivot pin is accessible Part No 65196 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Third Edition First Printing PLATFORM COMPONENTS 3 Raise the boom slightly and place blocks under the platform 4 Lower the boom until the platform is resting on the blocks just enough to support the platform Do not rest the entire weight of the boom on the blocks 5 Support the slave cylinder with an appropriate lifting device Protect the cylinder rod from damage 6 5 60 models Tag disconnect and plug the hydraulic hoses from the slave cylinder at the union located near the platform rotate counterbalance valve manifold Plug the hoses from the slave cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loose
225. hanically activated Pilot operated 3 position 3 way shuttle valve Flow divider combiner valve with pressure balancing orifice High speed divider bypass valve it AES LA Solenoid operated 3 position 4 Way directional valve lt gt 2 position 3 way shuttle valve Oil cooler Pilot operated unloader valve oscillate sequence Differential sensing valve oscillate circuit Brake Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 6 Schematics SS sez 2WD Hydraulic Schematic Non Oscillating Axle
226. he Drive Speed Stowed 4 45 B 19 Test the Drive Speed Raised or Extended Position 4 46 B 20 Test the Alarm Package if 4 47 B 21 Perform Hydraulic Oil 2 00 4 48 B 22 Replace the Hydraulic Tank Return Filter 4 48 B 23 Inspect the Fuel Tank Cap Venting System 4 49 B 24 Replace the Engine Air Filter 2 4 50 B 25 Replace the Spark Plugs Gasoline LPG Models 4 51 Part No 65196 Genie S 60 amp Genie S 65 vii Third Edition First Printing TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued C 1 Check the Engine Belt Deutz Diesel 4 52 C 2 Check the Engine Valve Clearances Deutz Diesel Models 4 53 C 3 Replace the Fuel Filter Water Separator Element Perkins Diesel Models 4 53 C 4 Replace the Fuel Filter Element Perkins Diesel Models 4 55 C 5 Replace the Engine Oil and Filter Perkins Diesel Models 4 57 C 6 Check the Glow Plugs Perkins Diesel Models 4 58 C 7 Check the Specific Gravity of Engi
227. he boom Department controller in the UP direction Check voltage at TB1 oV 12V or Press down the foot more Repair open in red 3 switch and move the wire from TP1 to TB1 boom controller in the uP direction Check voltage TP1 oV Press down the foot Repair open in power 20V or more switch and check ov Supply circuit from TP24 voltage at terminal to boom controller OR on the boom controller repair open in brn ground wire circuit from ground to boom 12V more controller Re adjust controller see Repair Section OR replace controller OR consult Genie Industries Service Department Y Continued on the next page Part No 65196 Genie S 60 amp Genie S 65 5 29 Section 5 Troubleshooting Flow Charts 1 CHART 14 Continued from the previous page Disconnect wires from 0 or boom up down infinite directional valve coil ohms item B and test the resistance of the valve coil See Repair Section 2 5 to 3 5 ohms function Hold function enable operates switch to either side and gt move the boom up down toggle switch in the UP direction Manually override the directional valve by pushing in on the end of the valve spool function inoperative Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the boom function manifold and start the engine Hold the function enable switch to either side and mo
228. hen the incline of the turntable exceeds the rating on the serial plate Drive Limit Switches Select a level test area The tilt alarm should not be sounding prior Detecting limit switch malfunctions is essential to to the test safe machine operation The drive limit switches are used to restrict drive speed when the boom is 1 Startthe engine from the platform controls raised or extended An improperly functioning drive 2 Openthe tank side turntable cover and press limit switch will allow the machine to operate in an down on one side of the tilt sensor unsafe position O Result The alarm in the platform should sound 1 Remove the cover from the rear of the turntable Ti h d The al poua to access the drive limit switch ip over hazard The alarm shou AWARNING be audible at the ground controls 2 Visually inspect the boom up drive limit switch If the alarm is not audible at the mounted to the turntable riser at the pivot end ground controls replace the alarm of the boom Inspect for the following in the platform Broken or missing roller or arm Missing fasteners Loose wiring a fueltank b til sensor ground control box a turntable riser b boom C boom up drive limit switch LS2 4 14 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures 3 Manually activate the boom up drive limit switch Result The boom up drive limit sw
229. high idle Part No 65196 Genie S 60 amp Genie S 65 4 41 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE B PROCEDURES B 15 Test the Fuel Select Operation Gasoline LPG Models The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made while the engine is running or not Switching malfunctions and or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation Perform this test after checking the gasoline and LPG fuel levels and warming the engine to normal operating temperature 1 Move the fuel select toggle switch to gasoline and then move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol 2 Startthe engine from the platform controls and allow it to run at low idle 3 Press down the foot switch to allow the engine to run at high idle O Result The engine should start promptly and operate smoothly in low and high idle Release the foot switch and shut the engine off by pushing the Emergency Stop button in to the position Move the fuel select switch to LPG 6 Start the engine and allow it to run at low idle Press down the foot switch to allow the engine to run at high idle Result The engine should start
230. hird Edition First Printing SPECIFICATIONS Ford Engine LRG 425 EFI Displacement 153 cu in 2 5 liters Number of cylinders 4 3 78 x 3 4 inches 96 01 x 86 36 mm Bore amp stroke Horsepower 70 2500 rpm Firing order 1 3 4 2 Low idle 1600 rpm High idle 2500 rpm Compression ratio 9 4 1 Compression pressure Pressure psi of lowest cylinder must be at least 75 of highest cylinder 0 035 to 0 055 inches 0 889 to 1 397 mm Valve clearances collapsed tappet Lubrication system Oil pressure operating temperature 2000 rpm 40 to 60 psi 2 75 to 4 1 bar Oil capacity 5 quarts including filter 4 7 liters Cil viscosity requirements Temperature below 60 F 15 5 C 5W 30 10 F to 90 F 23 C to 32 10W 30 Temperature above 10W 40 or 10W 50 10 F 23 C Temperature above 20W 40 or 20W 50 20 F 6 6 C Use oils meeting API classification SG labeled SG CC or SG CD as they offer improved wear protection Units ship with 10W 40 SG CC Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 140 200A Current draw maximum load 800A Current draw minimum 60 80A Maximum circuit voltage drop 0 5V DC while starting normal temperature Brush length new 0 66 in 16 8 mm Brush length wear limit 0 25 in 6 35 mm Maximum commutator 0 005 inches run out 0 127 mm Battery Type 12VDC Group 31 Quant
231. hould 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 Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Workplace Safety Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards 3l such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire exti
232. hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the blocks TS ET AWARNING CUllision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage Steer wheels 4WD models 7 Chockthe non steering wheels to prevent the machine from rolling 8 Center a lifting jack of ample capacity 20 000 Ibs 9072 kg under the drive chassis between the steer wheels 9 Liftthe wheels off the ground and then place blocks under the drive chassis for support 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort 12 Re engage the drive hubs by turning over the drive hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the blocks llision h AWARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage All models 13 Be sure the free wheel valve on the drive pump is closed clockwise The free wheel valve is located on the drive pump and should always remain closed hub mo disengage position qus arg engage position a drive pump b free wheel valve c pump d screwdriver 4 62 Genie 5 60 amp Genie 5 65 Part No 65196 Third Edition First Printing S
233. ic system is divided into two groups Boom Steer functions and Drive functions Boom Steer functions are powered by a single section gear pump rated at 12 3 gom 46 6 L min When the engine is running this pump supplies hydraulic fluid under pressure to the function manifold where the directional and flow control valves are located To protect from over pressurization of the Boom Steer system the pump is provided with a pressure relief valve set at 2900 psi 200 bar on S 65 Models and 2600 psi 179 bar S 60 Models Drive functions are powered by a bi directional variable output piston pump rated at 0 to 30 3 0 to 114 7 L min 2500 rpm Two internal 3500 psi 241 bar relief valves are used to prevent over pressurization of the closed loop drive system The boom lift cylinder boom extend cylinder platform leveling slave cylinder platform rotator and jib boom cylinder S 65 models incorporate counterbalance valves to prevent movement in the event of a hydraulic line failure Theory Of Operation Electrical System Boom Steer functions are accomplished by moving a toggle switch or a controller which sends voltage to the appropriate directional control valve These directional valves determine which direction the hydraulic fluid will travel The volume of hydraulic fluid is determined by either a proportional valve or flow regulator valve A proportional valve receives a variable voltage signal and delivers mo
234. ic tank capacity 45 gallons 170 liters Hydraulic system 55 gallons capacity including tank 208 liters Hydraulic fluid Dexron equivalent Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures ee SSS SSS SSeS FUEL AND HYDRAULIC TANKS How to Prime the Pump Perkins Diesel models Disconnect the engine wiring harness from the fuel solenoid at the Component damage hazard Be injector pump CAUTION sure that the hydraulic tank shutoff valves are in the position before priming the pump The engine must not be started with the hydraulic tank shutoff valves in Crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 250 psi 17 2 bar the position or component 4 Gasoline LPG models Connect the LPG damage will occur hose to the LPG tank and open the valve on the 1 Connect a 0 to 600 psi 0 to 41 bar pressure tank gauge to the diagnostic nipple on the drive Deutz Diesel models Release the manual pump shutoff valve 2 Gasoline LPG models Close the valve on the Perkins Diesel models Connect the engine LPG tank then disconnect the hose from the wiring harness to the fuel solenoid tank Move the fuel select toggle switch to the l LPG position 5 Start the engine from the ground controls and check for hydraulic leaks Deutz Diesel models Hold the manual
235. icate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 65196 Genie S 60 amp Genie S 65 4 1 Section 4 Scheduled Maintenance Procedures Third Edition First Printing SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service is required to perform this procedure E LEE Maintenance Schedule There are
236. ie Industries Contact us http Awww genielift com e mail techpub genieind com Genie Industries Copyright 2000 by Genie Industries Third Edition First Printing September 2001 Genie and S are Registered Trademarks of Genie Industries in the USA and many other countries 4 gt Tae Printed on recycled paper Printed in U S A Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie S 60 amp 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 Part No 65196 Genie S 60 amp Genie S 65 Section 1 Safety Rules Third Edition First Printing SAFETY RULES 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 s
237. ilter head With the assembly in this position intsall the element retaining screw Bleed the system 10 Loosen the vent plug on the side of the fuel injection pump 11 Operate the priming lever of the fuel lift pump until fuel free from air comes from the vent plug Tighten the vent plug 12 Clean up any fuel that may have spilled during this procedure 13 Operate the starter motor for intervals of 15 seconds until the engine starts It is important to allow the starter motor to cool for 30 seconds between each 15 second interval of operation If the engine runs correctly for a short time and then stops or runs roughly check for air in the fuel system If there is air in the fuel system there is probably a leak in the low pressure side of the system TABLE C PROCEDURES C 5 Replace the Engine Oil and Filter Perkins Diesel Models Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A frequent check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 500 hour interval Bodily injury hazard Beware of ACAUTION hot engine parts and oil Contact with hot engine oil and or engine parts may cause severe burns Perform this procedure after warming the
238. intenance Procedures B 20 Test the Alarm Package if equipped The alarm package includes Travel alarm Descent alarm Flashing beacons Alarms and beacons are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable rear cover Beacons are installed on both turntable covers The alarms and beacons will operate with the engine running or not running 1 Turn the key switch to ground controls and pull out the Emergency Stop button to the position at both the ground and platform controls Result Both flashing beacons should be on and flashing 2 Hold the function enable switch to either side and activate the boom toggle switch in the pown position hold for a moment and then release it Result The descent alarm should sound when the toggle switch is held down 3 Turn the key switch to platform controls Result The flashing beacons should be on and flashing TABLE B PROCEDURES Move the lift drive selector switch to the lift position if equipped Press down the foot switch Move the boom controller to the position hold for a moment and then release it Result The descent alarm should sound when the controller is held down Move the lift drive selector switch to the drive position if equipped Press down the foot switch Move the drive controller off center hold for a moment and then release it Mo
239. ion First Printing Injection system Injection pump make Zexel PFR KX Injection pump pressure 2755 psi 190 bar Injector opening pressure 3626 psi 250 bar Fuel requirement Engine coolant diesel number 2 D Capacity 111 2 quarts 10 9 liters Alternator output 65A 12VDC Battery Type 12VDC Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Fan belt deflection 3 8 in 10 mm Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 2 Specifications SSS SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok O ring face seal fittings and hose ends Machines that utilize Parker Seal Lok O ring face seal fittings and hose ends require that the fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed Hydraulic Hose and Fitting Torque Specifications SAE O ring Boss Port tube tting SAE Dash Installing SAE Dash Ae a7 e 7z mnm 40 52 lea 3 45 OC e mnm 40 842 12 90 12 ges 83 6 5 17 _ 9 Aumnm 69 20 w 39 24 6 297 Torque Procedure 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O rin
240. ion way OO 6 jo E Check valve PP 8 Shuttle valve 2 position way QQ 9 Diagnostic fitting 2 2 11 Function Torque Differential sensing circuit Differential sensing 10 12 ft lbs 14 16 Nm 35 40 ft lbs 47 54 Nm Oscillate check left 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm Check valve circuit the piston is located between index numbers 3 and 7 Oscillate check right 35 40 ft lbs 47 54 Nm Unloading 35 40 ft Ibs 47 54 Nm Testing Plug Torque Specifications Description Hex size Torque SAE No 2 1 8 50 in Ibs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm Part No 65196 Genie S 60 amp Genie S 65 7 51 Section 7 Repair Procedures Third Edition First Printing MANIFOLDS 11 5 Valve Adjustments Oscillate Manifold How to Adjust the Oscillate Sequencing Valve Pressure When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Connect a 0 2000 psi 0 to 138 bar pressure gauge to the diagnostic nipple index 9 located on the oscillate manifold Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic
241. ir baffle a A C Label then disconnect the plug wires from the spark plugs by grasping the handle on the spark plug boot Do not pull on the plug wire Blow out any debris around spark plugs Remove all the spark plugs from the engine Adjust the gap on each new spark plug Install the new spark plugs then connect the wires Be sure that each spark plug wire is attached to the correct spark plug Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts Ford LRG 425 EFI Engine Spark plug specifications Spark plug type Motorcraft AWSF 52C Spark plug gap 0 042 to 0 046 inches 1 07 to 1 18 mm Spark plug torque 5 10 ft Ibs 7 14 Nm Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures C 1 Check the Engine Belt Deutz Diesel Models Maintaining the engine belt is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt and continued use may cause component damage AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation ACAUTION Podily injury hazard Beware of hot engine components Contact with hot engine components may cause severe burns 1 Remove the 2 engine pivot plate retaining bolts Swing the engine pivot plate away
242. ir baffle 3 Place a suitable container under the engine pivot plate See capacity specifications 4 Locate the fuel pressure regulator filter and the fuel pump on the engine pivot plate behind the engine 5 Atthe fuel pressure regulator filter disconnect the fuel hose to the fuel tank ADANGER Explosion and fire hazard Electronic Fuel Injection EFI systems operate at a very high pressure Fuel may be expelled under pressure if the hoses are removed too quickly Loosen the fuel hoses very slowly to allow the fuel pressure to dissipate gradually Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them TABLE E PROCEDURES 6 Remove and replace all of the fuel hoses and clamps according to the following hose routing diagram From tank Fuel Pump To engine I Return to tank a high pressure hose from fuel pump to regulator filter b hose from fuel pre filter to fuel pump hose from fuel tank to fuel pre filter d high pressure hose from regulator filter to engine e hose from regulator filter to tank 7 Clean up any fuel that may have spilled during this procedure 8 Startthe engine from the ground controls Inspect the fuel filter and hoses for leaks ADANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately 9
243. ir baffle TABLE E PROCEDURES Put on protective clothing and eye wear Disconnect the coolant return hose at the radiator and drain the coolant return tank into a suitable container Slowly remove the radiator cap from the radiator Bodily injury hazard Allow an ACAUTION 2277717 Y pressure to dissipate gradually before removing the radiator cap Open the drain valve on the radiator and allow all the coolant to drain into a suitable container After all the coolant has drained close the drain valve Connect the coolant return hose to the radiator Open the drain valve on the engine block and allow the coolant to drain into a suitable container After the fluid has drained close the drain valve Replace all coolant hoses and clamps Fill the radiator with the proper coolant mixture coolant and water for your climate until it is full 10 Fill the coolant recovery tank to the NoRMAL range 11 Clean up any coolant that may have spilled during this procedure 12 Start the engine from the ground controls and let it run for 30 seconds Turn the engine off and inspect for leaks Part No 65196 Genie S 60 amp Genie S 65 4 75 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE E PROCEDURES 13 Check the coolant level in the coolant recovery tank Add coolant if needed 14 Swing the engine pivot plate back to its original position and install the two engine p
244. irm the Proper Brake Configuration Proper brake configuration is essential to safe operation and good machine performance Hydrostatic brakes and hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each drive hub disconnect cap to be sure it is in the engaged position CREE brake disengage position MEE aorg es u brake engage position TABLE B PROCEDURES 2 Be sure the free wheel valve is closed clockwise The free wheel valve is located on the drive pump a drive pump b free wheel valve c lift pump d screwdriver The free wheel valve should always remain closed Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE B PROCEDURES B 5 Check the Oil Level in the Drive Hubs Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage Drive Hubs 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the plug hole 3 If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole 4 Apply pipe thread se
245. itch arm should move freely and spring return to center A distinct click should be felt and heard 4 Visually inspect the boom extend drive limit switch located at the end of the cable track on the boom Inspect for the following Broken or missing roller or arm Missing fasteners Loose wiring a extend drive limit switch LS1 b cable track 5 Startthe engine from the ground controls Extend the boom approximately 3 feet 0 9 m 7 Manually activate the boom extend drive limit Switch Result The boom extend drive limit switch arm should move freely and spring return to center A distinct click should be felt and heard TABLE A PROCEDURES 8 Turn the key switch to platform controls and fully retract the boom 9 Move the lift drive selector switch to the drive position if equipped 10 Press down the foot switch and slowly move the drive controller off center Result The machine should move at normal drive speeds 11 Move the lift drive selector switch to the lift position if equipped 12 Raise the boom to just above horizontal 13 Move the lift drive selector switch to the drive position if equipped 14 Slowly move the drive controller off center Result The machine should move at a reduced drive speed 15 Move the lift drive selector switch to the lift position if equipped 16 Lower the boom to the stowed position then extend the boom 3 feet 0 9 m 17 Mov
246. ity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Electronic fuel pump Fuel pressure static 64 psi 4 4 bar Fuel flow rate 0 58 gpm 2 18 liters per minute Ignition System Spark plug type Motorcraft AWSF 52 C 0 042 to 0 046 inches 1 07 to 1 18 mm Spark plug gap Engine coolant Capacity 111 2 quarts 10 9 liters Alternator Output 95A 14 5VDC Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Deutz Engine F4L 1011F Section 2 Specifications I Injection system SPECIFICATIONS Displacement 166 7 cu in Injection pump make OMAP 2 732 liters Injection pump pressure 4351 psi Number of cylinders 4 300 bar Bore and stroke 3 58 x 4 13 inches Injector opening pressure 3626 psi 91 x 105 mm 250 bar Horsepower 56 3000 rpm Fuel requirement diesel number 2 D Firing order 1 3 4 2 Alternator output 55A 14VDC Compression ratio 18 51 Starter motor Compression pressure 362 to 435 psi Current draw no load 90A 25 to 30 bar Brush length new 0 748 in Low idle 1500 rpm 19 mm m Brush length minimum 0 5 in High idl 2 igh idle 300 rpm 35 7 nim Governor centrifugal mechanical Battery Valve clearance cold Type 12VDC Group Intake 0 012in 31 0 3 mm Quantity 1 Exhaust 0 020 in 0 5 mm Cold cranking ampere 1000A Lubrication system Reserve capacity 25A rate 200 minutes Oil pressure 26 to 87 p
247. ivot plate retaining bolts 15 Start the engine from the ground controls and let it run until it reaches normal operating temperature 16 Turn the engine off Allow the engine to cool 17 Check the coolant level in the coolant recovery tank Add coolant if needed Coolant capacity Ford LRG 425 EFI Engine Perkins 704 30 Engine 10 9 liters 9 5 liters 11 5 quarts 10 quarts E 3 Change the Fuel Hoses Gasoline LPG Models Maintaining the fuel hoses in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or leaking fuel hose may cause an unsafe operating condition Explosion and fire hazard Engine ADANGER fuels are combustible Replace the fuel lines in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Component damage hazard Be sure the fuel hoses are routed the same way the original hoses were CAUTION Perform this procedure with the engine off and cooled 1 Tag disconnec and plug the fuel hose from the fuel tank at the manual shutoff valve Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures 2 Remove the 2 engine pivot plate retaining bolts and swing the engine out away from the machine to access the fuel hoses a engine pivot plate b pivot plate retaining bolts c a
248. l and filter changes at the 100 hour interval Perform this procedure after warming the engine to normal operating temperature Bodily injury hazard Beware of ACAUTION hot engine parts and oil Contact with hot engine oil and or engine parts may cause severe burns 1 Open the engine side turntable cover and remove the oil filler cap located on the valve cover Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures 2 Pull the oil drain hose out from underneath the engine 3 Open the engine oil drain valve on the engine oil pan and allow all of the oil from the engine to drain into a suitable container See specifications engine pivot plate pivot plate retaining bolts oil drain hose air baffle 4 Close the engine oil drain valve Remove the 2 engine pivot plate retaining bolts Pull the engine pivot plate away from the machine to access the oil filter Place a container under the oil filter 7 Use oil filter wrench and remove the filter 8 Apply a thin layer of fresh oil on the gasket of TABLE A PROCEDURES 9 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 10 Fill the engine with new oil per specifications and install the filler cap See capacity specifications 11 Start the engine from the ground controls Allow the engine to run for 30 seconds then
249. l end pivot pin Do not remove the pin Support the jib boom lift cylinder then use a soft metal drift to remove the pivot pin Lower the barrrel end of the cylinder toward the ground Remove the pin retaining fastener from the jib boom pivot pin Use a soft metal drift to remove the pin 10 Remove the jib boom from the bell crank AWARNING C ushing hazard The jib boom could become unbalanced and fall when it is removed from the machine if it is not properly supported 7 18 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing nn NH 3 2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder 1 Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Raise the jib boom slightly and place blocks under the platform mounting weldment Lower the jib boom until the platform is resting on the blocks just enough to support the platform Do not rest the entire weight of the boom on the blocks 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressur
250. l tank Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge 2 Add oil as needed Hydraulic oil specifications immediately Hydraulic oil type Dexron equivalent Tank capacity 45 gallons 170 liters Hydraulic system 53 gallons including tank 200 6 liters Part No 65196 Genie S 60 amp Genie S 65 4 9 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE A PROCEDURES A 8 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develop into hazardous situations impair machine functions and damage machine components Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin 1 Inspect for hydraulic oil puddles dripping or residue on or around the following areas Hydraulic tank filter fittings hoses auxiliary power unit filters and turntable surface Engine compartment hydraulic filters fittings hoses pumps component tray All hydraulic cylinders All hydraulic manifolds Primary and jib booms The underside of the turntable The underside of the drive chassis Ground area under the machine A 9 Check the Tire Pressure Bodily injury hazard An over AWARNING inflated tire can explode and could cause death or serious injury Tip over hazard Do not use AWARNING
251. l valve item With key switch turned Troubleshoot platform to platform controls and rotate toggle switches both Emergency Stop TS13 and TS5 OR buttons pulled out to the repair open in red power ON position press down gy wire circuit to TS13 and the foot switch and gt 195 OR repair open in move the platform rotate grn blk wire circuit from toggle switch in the TS13 and TS5 10 TB18 RIGHT direction Check OR consult Genie voltage at TB18 Industries Service Department 12V or more Troubleshoot platform rotate toggle switch 513 OR repair open in red power wire circuit to 513 OR repair Sen in grn blk wire circuit from 7513 to TB18 OR consult Genie Industries Service Department Y Continued on the next page Part No 65196 Genie S 60 amp Genie S 65 5 53 Section 5 Troubleshooting Flow Charts eee CHART 24 Continued from the previous page Disconnect the wires from the platform rotate right directional valve coil item CC and test the resistance of the valve coil K 7 ohms Exchange platform rotate right and left directional valves items BB and CC and activate the platform rotate right function function inoperative Exchange platform rotate right and left counterbalance valves at the counterbalance valve manifold and activate the platform rotate right function function inoperative Install a 0 to 3000 207 bar pressure gauge at
252. lashing beacon 20189 ECCO Electronic Controls 6400A GEN 2 EST os ead Foot switch 13482 Linemaster Switch Corp 632 9 1 arit tetas 1 Gauge Voltage 53761 E 332 0300010 1 32 de its Gauge Oil Pressure 53758 ene en ete tid 350 0300210 1 Water Temp 59759 VDO aiii 310 0300230 1 ET iis Alarm Warble tone 19270 Floyd Bell Inc MW09 530 Q 1 H2 ees Horn 12V 54506 Sparton Engineered Prod 300LJ 12 1 ae Alarm intermittent 18963 Floyd Bell Inc XB 09 630 Q S 1 isse Alarm chime tone 45462 Floyd Bell Inc CH 09 525 Q 1 ine 19506 ENM Corporation 40 4508 1 Contact Key switch 45081 Telemecanique ZB2 BE101 2 E eiim LED Red 12V DC 32335 Arctolectric Corp LE17
253. latform controls and level toggle switches both Emergency Stop TS14 and TS6 OR buttons pulled out to the repair open in red power ON position press down gy wire circuit to TS14 and the foot switch and gt TS6 OR repair open in move the platform level org blk wire circuit from toggle switch TS6 in the 7514 and TS6 to TB15 DOWN direction Check OR consult Genie voltage at TB15 Industries Service Department 12V or more Troubleshoot platform level toggle switch TS14 OR repair open in red power wire circuit to 514 OR repair ed in org blk wire circuit from TS14 to TB15 OR consult Genie Industries Service Department Y Continued on the next page Part No 65196 Genie S 60 amp Genie S 65 5 49 Section 5 Troubleshooting Flow Charts eee CHART 22 Continued from the previous page Disconnect the wires from the platform level down directional valve coil item U and test the Scd of the valve coil E 7 ohms Exchange platform level down and up directional valves items U and S and activate the platform level down function function inoperative Exchange platform level down and up counterbalance valves items FF and EE and activate the platform level down function function inoperative Install a 0 to 3000 207 bar pressure gauge at the quick disconnect coupling on the function manifold and activate the platform level down function SEE NOTE
254. le rabbit and foot switch Press down the foot switch and raise the boom above horizontal 5 Move the lift drive select switch to the drive position if equipped 6 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 7 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 8 Continue at full speed and note the time when the machine reference point crosses the finish line 9 Move the lift drive select switch to the lift position if equipped 10 Press down the foot switch and lower the boom to the stowed position 11 Extend the boom 1 foot 30 cm 12 Move the lift drive select switch to the drive position if equipped 13 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 14 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 15 Continue at top speed and note the time when the machine reference point crosses the finish line Drive speed maximum raised or extended position All models 1 foot per second 0 6 mph 0 3 meter per second 0 97 km h Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Ma
255. led by the ECM and can only be adjusted by re programming the ECM If rpm adjustment or service is required please contact the Genie Industries Service Department OR your local Ford dealer Gasoline LPG models Low idle 1600 rpm High idle 2500 rpm Diesel models This procedure will require two people 1 Connecta tachometer to the engine Start the engine from the ground controls O Result Low idle should be 1500 rpm for Deutz models 1600 rpm for Perkins models Skip to step 4 if the low idle rpm is correct 2 Loosen the low idle lock nut and turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and confirm the rpm solenoid boot high idle adjustment nut yoke lock nut yoke low idle adjustment screw low idle lock nut 3 Move the function enable toggle switch to the high idle rabbit symbol position Result High idle should be 2300 rpm for Deutz models 2200 rpm for Perkins models If high idle rpm is correct disregard adjustment step 4 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures 4 Loosen the yoke lock nut then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Be sure the solen
256. lity and damage Replace any damaged or illegible decal immediately Contact your authorized Genie distributor or Genie Industries if replacement decals are needed Part No 65196 Genie S 60 amp Genie S 65 4 5 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE A PROCEDURES A 3 Inspect for Damage and Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage and discover loose or missing parts may result in an unsafe operating condition 1 Inspect the entire machine for damage and improperly installed or missing parts including Electrical components wiring and electrical cables Hydraulic hoses power units fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Boom wear pads Tires and wheels Engine and related components Limit switches alarms horn and beacon Nuts bolts and other fasteners Platform entry mid rail or gate Check entire machine for Cracks in welds or structural components Dents or damage to machine Battery and connections Compartment covers and latches Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened After you complete each inspection be sure that all compartment cove
257. lt Consult Genie Industries Service Department CHART 17 Part No 65196 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 18 Turntable Rotate Left Function inoperative Be sure all other functions operate normally With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the turntable rotate toggle switch TS17 in the LEFT direction Check voltage on wht red 4 wire on turntable rotate proportional valve coil item S 12V or more v Continued on the next page oV Hold the function enable switch to either side and move the turntable rotate toggle switch in the LEFT direction and 4 to 6V _ check voltage at TB6 oV Y With key switch turned 4 to 6V to platform controls and d both Emergency Stop buttons pulled out to the ON position press down the foot switch and move turntable rotate controller in the LEFT direction and check voltage at TP6 io Press down the foot switch and check voltage at terminal on controller 12V or more Re adjust controller see Repair Section OR replace controller OR consult Genie Industries Service Department Repair open in wht red 4 wire circuit from TB6 to turntable rotate proportional va
258. ltage at oV terminal 30 on CR13 12V Check the voltage at BY terminal 487a on CR13 E v Continued on the next page Repair open in red wire from terminal 87a on CR13 to TS8 OR consult Genie Industries Service Department Repair open in grn blk 4 wire from TB18 to jib boom down directional valve OR repair open in brn ground wire circuit to directional valve Repair open in grn blk 3 wire from TP18 to TB18 Repair open in grn blk wire from TS24 to TP18 OR replace TS24 Repair open in red wire from boom controller to CR13 OR repair open in brn ground wire circuit to CR13 Replace CR13 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts n U CHART 27 Press down the foot 12V Replace CR13 2 m the switch and move the jib k p pags boom toggle switch TS6 in the DOWN direction Check voltage on the red and black wires at the jib platform rotate select valves item AC w function Install a 0 to 5000 psi Exchange jib boom operates Replace faulty valve 345 bar pressure SEE platform rotate P gauge at the quick NOTE 1 directional valv
259. lve coil OR repair open in brn ground wire circuit to valve coil Repair open in wht red wire from TP6 to TB6 Repair open in power supply circuit from TP24 to the controller OR repair open in brn ground wire circuit from ground to controller Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts EEE CHART 18 i With key switch turned Hold the function enable Repair open in wht blk 4 2 nm the 5 5 to ground controls and switch to either side and 12Vor wire circuit from TB5 to page both Emergency Stop move the turntable more turntable rotate left buttons pulled out to the rotate toggle switch in directional valve coil ON position hold the the LEFT direction item A OR repair open function enable switch to Check voltage at TB5 in brn ground wire circuit either side and move the to valve coil turntable rotate toggle switch TS17 in the LEFT direction Check voltage on wht blk 4 wire on boom rotate directional valve coil item A With key switch turned Troubleshoot turntable to platform controls and 12Vor rotate toggle switch OR both Emergency Stop more repair open in wht blk buttons pulled out to the wire circuit from TS17 to ON position press down TB5 OR consult Genie the foot switch and Industries Service move the turntable Department rotate controller in the LEFT direction Check voltage at TB5
260. m 11 821 kg 12 882 kg Overall tire diameter 40 in Ground clearance 12 in 12 in 102 cm 30 cm 30cm Tire pressure 85 psi 5 86 bar Operational dimensions Wheel diameter 191 2 Maximum platform height 60 ft 65 ft 49 5 cm 18 3m 19 8 m Wheel width 121 4 in Maximum horizontal reach 51 ft 3 in 56 ft 4 in 31 cm 15 6m 17 2 m Wheel lugs 10 3 4 16 Maximum turntable tailswing ft 31 2 in 3 ft 31 2 in Lug nut torque dry 420 ft lbs 100 cm 100 cm 569 5 Nm Wheelbase 9 ft O in 9ftOin Lug nut torque lubricated 320 ft lbs 2 7 m 2 7 m 433 9 Nm Minimum turning radius 12 ft 1 in 12 ft 1 in Fluid capacities insi 7 inside Som Sm Fuel tank 33 gallons Minimum turning radius 22 ft2 in 22 ft 2 in 125 liters outside 6 76 m 6 76 m LPG tank 33 5 pounds Turntable rotation continuous continuous 15 2 kg Hydraulic tank 45 gallons Platform rotation 160 160 rial Maximum capacity 600 Ibs 500 lbs Hydraulic system 53 gallons 6 foot platform 272 kg 227kg including tank 200 6 liters Maximum capacity 500 Ibs 500 Ibs Drive hubs 44 fl oz 8 foot platform 227 kg 227 kg 1 3 liters Maximum allowable side force Turntable rotation 17 fl oz ANSI and CSA 150 Ibs 150 Ibs drive hub 0 5 liters 667 N 667 N Continuous improvement of our products is a Genie CE 90 Ibs 90lbs policy Product specifications are subject to change 400N 400N without notice Part No 65196 Genie S 60 amp Genie S 65 Section 2 Specifications SPECIFICATIONS Performance Speci
261. m Emergency Stop button to TP26 to foot switch OR replace foot switch OR consult Genie Industries Service Department Part No 65196 Genie S 60 amp Genie S 65 5 27 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 14 Boom Up Function inoperative Be sure all other functions operate normally With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the boom up down toggle switch TS16 in the uP direction Check voltage on red wht wire on boom up down proportional valve coil item P oV 20V or more v Continued on the next page Hold the function enable switch to either side and move the boom up down toggle switch in the UP direction and check voltage at TB3 8 to 9V mo oV Repair open in red wht 4 wire circuit from TB3 to boom up down proportional valve coil OR repair open in brn ground wire circuit to valve coil With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the boom controller in the uP direction Check voltage at TP3 8 to 9V Repair open in red wht 3 wire from TP3 to TB3 o Press down the foot switch and check voltage at terminal on boom controller 2V or more
262. n hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray S 65 Models Tag disconnect and plug the hydraulic hoses from the slave cylinder at the union located near the platform rotate counterbalance valve manifold Plug the hoses from the slave cylinder Pull the slave cylinder hoses through the platform rotator AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Do not remove the pin 8 Remove the external snap ring from the barrel end pivot pin 9 Use a soft metal drift to remove the rod end pivot pin 10 Use a soft metal drift and remove the barrel end pivot pin 11 Carefully pull the cylinder out of the boom CAUTION Component damage hazard Hoses can be damaged if they are kinked or pinched How to Bleed the Slave Cylinder Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Raise the boom to a horizontal position 2 Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing 2 3 Platform Rotator
263. ndividually or consult Genie Industries Service Department SEE NOTE 2 Adjust the function manifold system relief valve item X all the way in clockwise counting the number of turns Hold the function enable switch to either side and move the boom retract toggle switch in the RETRACT direction and check the hydraulic pressure SEE NOTE 1 c Hold the function enable switch to either side and move the boom retract toggle switch in the RETRACT direction and adjust the relief pressure to 2600 psi SEE NOTE 2 v steering Check steer functions operates steering inoperative Repair or replace differential sensing valve item W OR repair or replace priority flow regulator valve item BB OR manifold has an internal fault consult Genie Industries Service Department Y Check the function ok pump see Repair section bad Replace the relief valve item X OR manifold has an internal fault Consult the Genie Industries Service Department Replace the function pump Chart 11 NOTE 1 5 60 2600 PSI or more 5 65 2900 PSI or more NOTE2 5 60 Less than 2600 PSI S 65 Less than 2900 PSI Part No 65196 Genie S 60 amp Genie S 65 5 25 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 12 Does the engine start y
264. ne Coolant Liquid Cooled Models 4 59 C 8 Replace the PCV Valve Gasoline LPG 4 60 D 1 Check the Boom Wear 5 4 61 D 2 Check the Free wheel Configuration sessseeeeeeneeeneee 4 61 D 3 Check the Turntable Rotation Bearing Bolts 4 63 D 4 Grease the Turntable Rotation Bearing and Rotate 4 64 D 5 Replace the Drive Hub Oil nnne enne 4 64 D 6 Replace the Drive Loop Hydraulic 4 66 D 7 Replace the Engine Oil and Filter Deutz Diesel Models 4 67 D 8 Clean the Fuel Pump Strainer Deutz Diesel Models 4 68 D 9 Replace the Diesel Fuel Filter Water Separator Deutz Diesel Models 4 69 D 10 Change the Fuel Hoses Deutz Diesel 4 70 D 11 Check the Engine Valve Clearances Perkins Diesel Models 4 72 D 12 Clean the Engine Breather Assembly Perkins Diesel Models 4 72 E 1 Testor Replace the Hydraulic 4 73 E 2 Change or Recondition the Engine Coolant Liquid Cooled Models 4 75 E 3 Change the Fuel Hoses Gasoline LPG 4 76 E 4 Replace
265. nect and plug the T fitting located at the return filter with the 2 hoses connected to it Cap the fitting on the return filter housing Disconnect and plug the supply hose for the auxiliary power unit Cap the fitting on the hydraulic tank Remove the retaining fasteners from the hydraulic tank hold down straps Remove the hold down straps from the hydraulic tank Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE E PROCEDURES 9 Support the hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 10 Remove the hydraulic tank from the machine Crushing hazard The hydraulic AWARNING tank may become unbalanced and fall if it is not properly supported and secured to the overhead crane 11 Remove the suction strainers from the tank and clean them using a mild solvent 12 Rinse out the inside of the tank using a mild solvent 13 Install the suction strainers using pipe thread sealant on the threads 14 Install the drain plug using pipe thread sealant on the threads 15 Install the hydraulic tank onto the machine 16 Install the two suction hoses and the supply hose for the auxiliary power unit 17 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 18 Clean up any oil that may have
266. new bearing seal when removing a hub How to Install the Hub and Bearings When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Place the large inner bearing into the rear of the hub 3 Press the bearing seal evenly into the hub until it is flush 4 Slide the hub onto the yoke spindle CAUTION Component damage Do not apply excessive force or damage to the lip of the seal may occur Place the outer bearing into the hub Install the washer and castle nut 7 Torque the castle nut to 35 ft Ibs 47 Nm to seat the bearings 8 Loosen the castle nut then torque the castle nut to 8 ft Ibs 11 Nm 9 Install a new cotter pin Bend the cotter pin to lock it Always use a new cotter pin when installing a castle nut 10 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 420 ft Ibs 569 5 Nm Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures SSS SSS SSS n 2WD STEERING AXLE COMPONENTS 14 2 3 Remove the pin retaining fastener from the barrel end clevis of the steer cylinder Steering Cylinders Remove the pin How to Remove a 4 Remove the steering cylinder from the machine Steering Cylinder There are two identical steering cylinders that work in parallel They are part o
267. ng the machine on engine power selecting auxiliary power will stop the engine immediately Auxiliary power is designed for short term use only and excessive use will result in battery drain and component damage 1 Turn the key switch to ground control and pull out the Emergency Stop button to the position 2 Liftthe red auxiliary power toggle switch cover if equipped 3 Simultaneously hold the auxiliary power toggle switch and activate each boom function toggle switch Result All boom functions should operate To conserve battery power test each function through a partial cycle 4 Turn the key switch to platform control Pull out the Emergency Stop button to the oN position at the platform controls then press down the foot switch TABLE A PROCEDURES Lift the red auxiliary power toggle switch cover if equipped Simultaneously hold the auxiliary power toggle switch ON and activate each function controller or toggle switch Result All boom and steer functions should operate Drive functions should not operate with auxiliary power To conserve battery power test each function through a partial cycle Part No 65196 Genie S 60 amp Genie S 65 4 13 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE A PROCEDURES A 13 A 14 Test the Tilt Sensor Test the Limit Switches The tilt sensor sounds an alarm located in the platform w
268. nguisher within easy reach Be sure to keep sparks flames and 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 d 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 is 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 P Be sure to properly dispose of old oil or 2 other fluids Use an approved container Please be environmentally safe Be Sure that your workshop or work area is properly ventilated and well lit iv Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Introduction Section One Section Two Section Three Table of Contents Important Information Safety Rules General Safety 2 444 0 iii Specifications Machine Specifications 2 cite ette bee iden enin e c da 2 1 Performance Specifications sessssssssssseeses esee nennen nnns 2 2 Hydraulic Specifications et t eene 2 3 Ford Engine LRG 425 EFI Specifications
269. ni CR17 E CHECK ENGINE TOGGLE SWITCH FUSE 7 RUNE TS22 CR18A i RED Te20G 25AMP A Gaag WHPISMET m BRN R1 2 sto WHT 29B ORG 4 WHT CR17 E H BRN GROUND 140 33 OIL TEMPERATURE SWITCH __ WHT PUR FEH CR2487 ORG BLK TB15D OROORIREH RED LGRN FEH FAN CR18B 1 L RED 6 ISM GRN 43D BLK 22D Rene WHT 9 ISM BRN LP SOLENOID CR2 BLK38B CR4 ENGINE CR1 8 HARNESS i2 BLK 1 ISM 1 BLK CR1 E H WHT 21D BLK D B DKGRN FEH WHT TS22 4 EA E BLK CR4 E H Es LABEL DESCRIPTION 1 TO PLATFORM CONTROL BOX TERMINAL 27 46 CABLE 2 TO PLATFORM CONTROL BOX TERMINAL 22 23 CABLE 3 TO PLATFORM CONTROL BOX TERMINAL 1 19 CABLE 4 TO CONTROL SOLENIOD CB1 CIRCUIT BREAKER CONTROLS 15A CB2 CIRCUIT BREAKER ENGINE 15A CR1 IGNITION START RELAY CR2 IGNNITION POWER RELAY CR3 HIGH IDLE RPM CUTOUT RELAY CR4 RPM RELAY CR5 SERVICE HORN RELAY CR17 HYDRAULIC OIL COOLER OPTION RELAY CR18A amp B CE PLATFORM LEVEL CUTOUT RELAY G1 VOLT METER GAUGE G2 OIL PRESSURE GAUGE G3 ENGINE COOLANT TEMPERATURE GAUGE HM HOUR METER KS1 KEY SWITCH L3 CHECK ENGINE LED LS1 CABLE 7 EXTEND LIMIT SWITCH 152 CABLE 6 UP LIMIT SWITCH 153 CABLE 5 ENABLE LIMIT SWITCH P1 EMERGENCY STOP BUTTON PR1 AUXILARY POWER RELA
270. ni ng ON position and the no ON position press down nox boom rotated between the foot switch and Be sure the boom is in the non steer tires move the drive controller the stowed position press down the foot in forward direction switch and move drive Check voltage at controller in the forward terminal 42 on drive direction Does machine controller drive 2V or more Repair open from terminal 4 on drive controller to center Sd terminal on 58 OR y refer to Chart 28 OR consult Genie Industries Service Department Y With key switch turned Hold the drive enable The machine is to platform controls and toggle switch TS8 to operating properly If both Emergency Stop either side and press yes machine does not buttons pulled out to the no down the foot switch operate poren ON position and the Move the drive controller consult Genie Industries boom rotated between in the forward direction Service Department the steer tires press Does the machine down the foot switch and drive move the drive controller in forward direction no Does the machine Repair open in blu wht wire from drive enable toggle switch to TP12 to TB12 OR replace drive yes ed toggle switch Check for continuity continuity Activate limit switch by Replace drive enable from TB30 to TB12 gt hand and check continuity limit switch contact OR continuity from TB30 to gt replace drive enable TB12 limit switch LS3 continuity no continuit
271. nie S 60 amp Genie S 65 Part No 65196 86 30 d xl 85 86 COIL 85 COIL 30 COMMON COM 87 NORMALLY OPEN NO 87A NORMALLY CLOSED NC Third Edition First Printing Section 6 Schematics LXXX Platform Control Box Wiring Diagram Deutz Diesel Models
272. nnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Supportthe drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 4 Remove the flex plate mounting fasteners then remove the flex plate from the engine flywheel How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump Torque the flex plate mounting bolts to 34 ft Ibs 46 Nm 2 Install the pump coupler onto the pump shaft with the set screw toward the pump Leave a 1 4 inch 6 4 mm gap between the pump coupler and pump end plate 3 Apply removable thread locking material to the pump coupler set screw Torque the set screw to 45 ft lbs 61 Nm Component damage hazard Do CAUTION not force the drive pump during installation or the flex plate teeth may become damaged 4 Install the pump and torque the pump mounting plate fasteners to 34 ft Ibs 46 Nm Part No 65196 Genie S 60 amp Genie S 65 7 33 Section 7 Repair Procedures Third Edition First Printing PERKINS ENGINE 704 30 7 3 Coolant Temperature and Oil Pressure Gauges The engine coolant temperature gauge is an electrical gauge The engine coolant temperature
273. nning Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns 1 Diesel models Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the exhaust system a engine pivot plate b pivot plate retaining bolts c air baffle 4 30 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures B 2 Check the Hydraulic Tank Return Filter Condition Indicator Maintaining the hydraulic tank return filter in good condition is essential to good system performance and safe machine operation The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter If the filter is not frequently checked and replaced impurities will remain in the hydraulic system and cause component damage Perform this procedure with the engine running 1 Start the engine from the platform controls 2 Move the engine idle speed select switch to high idle rabbit symbol TABLE B PROCEDURES 3 Inspect the filter condition indicator a filter condition indicator b filter c hydraulic tank O Result The filter should be operating with the plunger in the green area If the display shows the plunger in the red area this indicates that the hydraulic filter is being bypassed and the
274. noperative Diesel 5 23 10 All Functions Inoperative Engine Starts and 5 24 11 All Lift and Steer Functions Inoperative Drive Functions Operational 5 25 12 Ground Controls Inoperative Platform Controls Operate Normally 5 26 13 Platform Controls Inoperative Ground Controls Operate Normally 5 27 14 Boom Up Function 5 28 15 Down Function Inoperative 2 5 31 16 Extend Function Inoperative 5 34 17 Retract Function Inoperative 5 36 18 Turntable Rotate Left Function Inoperative 5 38 19 Turntable Rotate Right Function Inoperative 5 42 Part No 65196 Genie S 60 amp Genie S 65 ix Third Edition First Printing TABLE OF CONTENTS Section Five Troubleshooting Flow Charts continued 20 All Platform Leveling Functions Inoperative 5 46 21 Platform Level Up Function Inoperative 5 47 22 Platform Level Down Function Inoperative 5 49 23 Platform Rotate Left Function Inoperative 5 51 2
275. nsor is faulty Fuel pump is receiving voltage when the ECM is not sending the signal to the fuel pump to turn ON Engine Coolant Temperature ECT sensor high voltage Check for poor terminal connections or shorted wires from the IAT sensor to the ECM to ground OR replace IAT sensor Test the fuel pump relay see the Repair Section OR check for poor terminal connection from the fuel pump relay to fuel pump OR replace the ECM Fuel pump high voltage 5 4 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts FAULT CODE CHART Fault Code Heated Oxygen HO2 sensor high voltage Engine Coolant Temperature ECT sensor low voltage Intake Air Temperature IAT sensor low voltage Low oil pressure A leaking or malfunctioning fuel injector misfiring cylinder faulty TP sensor or contamination of fuel OR use of improper thread sealant on sensor threads OR sensor wires shorted to ground or poor terminal connections OR HO2 sensor is faulty ECM detects excessively low signal voltage from the ECT sensor ECM detects an excessively low signal voltage from the IAT sensor Faulty oil pressure switch wires shorted to ground or not enough engine oil Test for a leaking or malfunctioning fuel injector misfiring cylinder or bad TP sensor Remove HO2 sensor and check condition of sensor for contamination OR check for
276. nt Electrocution hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Perform all troubleshooting firm level surface Two persons will be required to safely perform some troubleshooting procedures Part No 65196 Genie S 60 amp Genie S 65 5 1 Section 5 Troubleshooting Flow Charts Third Edition First Printing TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem General Repair Process
277. ocedures Third Edition First Printing PLATFORM CONTROLS 1 4 Toggle Switches Toggle switches used for single function switching are single pole double throw SPDT switches Dual function switching requires a double pole double throw DPDT switch How to Test a Toggle Switch Continuity is the equivalent of 0 to 3 ohms A simple continuity tester may not accurately test the switch This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches 1 Turn the key switch to the orr position Tag and disconnect all wiring from the toggle switch to be tested 2 Connect the leads of an ohmmeter to the switch terminals in the following combinations listed to check for continuity Left Center Right Single pole double throw SPDT 0119 00919 Ez Double pole double throw Test Left position Desired result terminal 1 to 2 3 4 5 amp 6 no continuity infinite terminal 2 to 3 continuity zero Q terminal 2 to 4 5 amp 6 no continuity infinite terminal 3 to 4 5 amp 6 no continuity infinite terminal 4 to 5 amp 6 no continuity infinite terminal 5 to 6 continuity zero Q Center position There are no terminal combinations that will produce continuity infinite Right position terminal 1 to 2 continuity zero Q terminal 1 to 3 4 5 amp 6
278. ock pin unlocked locked 2 Remove the motor See 13 1 How to Hemove the Rotation Hydraulic Motor Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched motor motor brake mounting bolts brake drive hub drive hub mounting bolts TURNTABLE ROTATION COMPONENTS 3 Remove the drive hub mounting bolts then use an appropriate lifting device to remove the drive hub from the machine Crushing hazard The turntable AWARNING rotate drive hub could become unbalanced and fall when it is removed from the machine if it is not properly supported 4 Install the drive hub Torque the drive hub mounting bolts to 57 ft lbs 77 3 Nm 5 Install the brake then motor onto the drive hub Torque the brake motor mounting bolts to 75 ft lbs 102 Nm 6 Adjust turntable rotation gear backlash See 13 1 How to Adjust the Turntable Rotation Gear Backlash Part No 65196 Genie S 60 amp Genie S 65 7 69 Section 7 Repair Procedures Third Edition First Printing TURNTABLE ROTATION COMPONENTS How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor gear and the turntable bearing ring gear Be sure to check the backlash with the machine on a flat level surface 1 Loosen the mounting fasteners on the drive hub pivot plat
279. od condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition 1 Check to be sure that the storage container is present and in good condition 2 Check to make sure that the operator s responsibilities and safety manuals are present and complete in the storage container in the platform 3 Examine the pages of each manual to be sure that they are legible and in good condition 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed Table A Procedures A 2 Inspect the Decals and Placards Maintaining all of the safety and instructional decals and placards in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Refer to the Decals section in the Genie 5 60 amp Genie 5 65 Operator s Manual and use the decal list and illustrations to determine that all decals and placards are in place 2 Inspect all decals for legibi
280. oid fully retracts when activating high idle Deutz Diesel models TABLE B PROCEDURES B 7 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause Low idle 1500 rpm High idle 2300 rpm Perkins Diesel models Low idle 1600 rpm High idle 2200 rpm a hazardous operating situation 1 Pull out the Emergency Stop button to the on position at both the ground and platform controls Turn the key switch to ground control start the engine and then turn the key switch to platform control Check any machine function from the ground controls Result The machine functions should not operate Turn the key switch to ground control Check any machine function from the platform controls Result The machine functions should not operate Turn the key switch to the position Result The engine should stop and no functions should operate Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds Part No 65196 Genie S 60 amp Genie S 65 4 37 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE B PROCEDURES B 8 Test the Emergency Stop Buttons P
281. old 2 Start the engine from the ground controls 3 Hold the function enable switch to either side and activate and hold the boom down toggle switch with the boom fully lowered Observe the pressure reading on the pressure gauge Boom down relief valve specifications Pressure 2100 psi 145 bar 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 6 on the function manifold 5 Adjust the internal hex socket Turn it clockwise to increase pressure or counterclockwise to decrease pressure Install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 6 Repeat steps 2 through 5 and confirm relief valve pressure Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures How to Adjust the Boom Extend Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 207 bar pressure gauge to the diagnostic nipple item 24 on the function manifold Start the engine from the ground controls 3 Hold the function enable switch to either side and hold the boom extend toggle switch with the boom fully extended Observe the pressure reading on the pressure gauge Boom extend relief valve specifications Pressure 2500 psi 172 bar 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 5 functi
282. old is mounted inside the drive chassis at the non steer end Function Torque High speed divider bypass N C Pilot to open 25 30 ft lbs 34 41 Nm Controls flow to flow divider combiner valves 6 and 7 25 30 ft lbs 34 41 Nm Charge pressure circuit 10 12 ft lbs 14 16 Nm Works in conjunction with check valve 12 in the high speed divider bypass circuit 10 12 ft lbs 14 16 Nm Front drive motor circuit Controls flow to steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm Controls flow to non steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm Rear drive motor circuit Equalizes pressure on both sides of flow divider combiner valve 2 Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift 15 18 ft lbs 20 24 Nm Testing Works in conjunction with check valve 4 in the high speed divider bypass circuit 10 12 ft lbs 14 16 Nm Index Schematic No Description Item 1 Directional valve 2 position 2 way AB 2 Flow divider combiner valve AC 3 Relief valve 250 psi 17 2 bar AD 4 Check valve pilot to close AE Orifice plug 0 052 inch 1 32 mm AF Flow divider combiner valve AG 7 Flow divider combiner valve AH s Orifice plug 0 070 in
283. om the previous page Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the boom function manifold and activate the steer right function SEE NOTE 2 Repair or replace steer cylinder OR steer manifold could have an internal fault Consult Genie Industries Service Department SEE NOTE 1 gt Section 5 Troubleshooting Flow Charts n Check for mechanical restrictions keeping steer right function from operating OR repair or replace steer cylinder OR replace flow regulator valve item WW OR consult Genie Industries Service Department CHART 29 NOTE 1 5 60 2600 PSI or more 5 65 2900 PSI or more NOTE 2 5 60 Less than 2600 PSI S 65 Less than 2900 PSI Part No 65196 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 30 All Drive Functions inoperative All Other Functions Operate Normally Be sure the rpm select switch is in the foot switch activated high idle position Be sure the hyydraulic tank shut off valves are in the OPEN position Be sure machine is not in the free wheel configuration With key switch turned Check con
284. on hazard Contact 14 Press down the foot switch and then move the with electrically charged circuits controller all the way to the ur position Record could result in death or serious the maximum voltage reading injury Remove all rings watches 15 Start the engine and other jewelry 16 Start a timer and simultaneously move the Do not adjust the controllers controller all the way to the position Note unless the static battery voltage is how long it takes to reach the maximum voltage above 12V DC and the alternator recorded in step 14 This is the ramp rate is operating properly with 13 6 to 14 5V DC output 17 Set the ramp rate turn the ramp rate trimpot to obtain a 3 to 4 second ramp speed Turn the 1 Check the battery condition with a volt meter trimpot clockwise to increase the time or The reading should be 12V DC or more to counterclockwise to decrease the time accurately adjust the controller 2 Turn the key switch to platform control and pull out the Emergency Stop button to Threshold 3 5V DC the position at both the ground and platform controls Do not start the engine Boom up down specifications Boom up Max out 9 2V DC Cycle time 55 to 60 seconds 3 Open the platform control box lid and locate the turntable rotation controller Refer to the Boom down Lo range 6 5V DC platform control box illustration page 7 2 Cycle time 90 to 94 seconds Ramp rate 3 to 4 seconds 7 4 Genie S 6
285. on manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 6 Repeat steps 2 through 5 to confirm relief valve pressure MANIFOLDS How to Override a Valve A hydraulic valve may need to be manually overridden to troubleshoot a malfunction The proportional boom functions up down extend retract and turntable rotate use a variable position proportional valve and a three position directional valve Example one position for boom Up one position for neutral and one position for boom down The platform rotate function uses a three position valve The platform level uses a three position and a two position valve The three position valves and the proportional valves can be manually overridden To identify the manifold valves see 11 1 Function Manifold in this section 1 Push the button on the end of the valve in inch 6 mm 2 Hold the function enable switch to either side and move the ground control toggle switch for the function being overridden to operate the function AWARNING Collision hazard Impact with moving boom components could result in death or serious injury Use extreme caution when overriding a machine function Identify the direction of machine movement before overriding a valve Part No 65
286. ons keeping platform rotate left function from operating OR repair or replace platform rotator OR replace platform rotator counterbalance valve manifold OR consult Genie Industries Service Department Replace faulty flow regulator valve Third Edition First Printing NOTE 1 5 60 2600 PSI or more 5 65 2900 PSI or more NOTE2 5 60 Less than 2600 PSI S 65 Less than 2900 PSI 5 52 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Chart 24 Platform Rotate With key switch turned With key switch turned open in grn blk 4 1 1 to ground controls and to ground controls and wire from TB18 to Right Function both Emergency Stop both Emergency Stop d platform rotate right Inoperative buttons pulled out to the buttons pulled out to the gt gt gt directional valve coil OR ON position hold the ON position hold the repair open in brn function enable switch to 0V function enable switch to ground wire circuit to Be sure all other either side and move the either side and move the valve coil functions operate platform rotate toggle platform rotate toggle normally switch TS13 in the RIGHT switch in the RIGHT direction Check voltage direction Check voltage at grn blk 4 wire on at TB18 platform rotate right directiona
287. oor terminal connections OR sensor wires shorted to 2 Pressure shorted wires from the MAP sensor to the MAP sensor 9 ECM to ground OR replace MAP sensor high voltage terminal connection Part No 65196 Genie S 60 amp Genie S 65 5 3 Section 5 Troubleshooting Flow Charts Third Edition First Printing FAULT CODE CHART Fault Code Voltage to fuel pump is Test the fuel pump relay see the Repair Fuel pump greater than or equal to Section OR check for poor terminal low voltage 2 DC below ignition connection from the fuel pump relay to fuel voltage pump OR replace the fuel pump Water in the fuel misfiring cylinder Heated plugged fuel filter OR Oxygen HO2 the HO2 sensor wiring sensor low is shorted to ground O voltage there is a poor terminal connection OR the HO2 sensor is faulty Check for water in the fuel misfiring cylinder or plugged fuel filter OR check for pg Poor terminal connections or shorted wires from the HO2 sensor to the ECM to ground OR replace HO2 sensor Engine is overheating OR sensor wires Check engine coolant level OR check for shorted to ground or shorted wires or poor terminal connections poor terminal from the ECT sensor to the ECM OR connections OR ECT the ECT sensor sensor is faulty Engine is overheating Intake Air OR sensor wires Temerature shorted to ground or IAT sensor poor terminal high voltage connections OR ECT se
288. ooting Flow Charts Chart 13 Platform Start engin rom Testor replace fot platform controls platform controls press switch see Repair Controls down the foot switch and Section OR repair open i check voltage at TP24 in wht wire circuit from Inope rative foot switch to TP24 Ground 12V Controls epair open wht wire Operate circuit from TP24 to function toggle switches Normally and function controllers Be sure all cables from chassis TUN ae FF eck voltage a epair open in red wire through the cane circuit from key switch to track are in good TB22 OR replace the condition with no 2V platform controls contact kinks or abrasions at the key switch Check voltage at TP22 oy Repair open in blk 2 wire circuit from TB22 to TP22 12V Check voltage at blk Repair open in blk wire wire on input side of from TP22 to platform Emergency Emergency Stop button Stop button contact 12V With key switch turned Check if Emergency yes Replace contact on to platform controls and Stop button internal cam Emergency Stop button both Emergency Stop is activating the contact buttons pulled out to the ON position check the no voltage on the output side of the platform Emergency Stop button Replace the platform contact Emergency Stop button 12V Check voltage at TP23 Repair open in wht wire with diode from 12 Emergency Stop button to TP23 Repair open in blk wire circuit from platfor
289. operly greased bearing and gear will result in component damage 1 Locate the grease fitting on the platform end of the tank side bulkhead 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 3 Apply grease to each tooth of the drive gear located under the turntable Grease type Multipurpose grease D 5 Replace the Drive Hub Oil Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage Drive Hubs 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Apply pipe thread sealant to the plugs Install the plugs 5 Repeat steps 1 through 4 for all the other drive hubs 44 fl oz 1 30 liters Cil capacity per hub Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Main
290. ormed after the first 30 days or 50 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures A 20 Replace the Engine Oil and Filter Gasoline LPG Models if applicable OR C 5 Replace the Engine Oil and Filter Perkins Diesel Models if applicable OR D 7 Replace the Engine Oil Filter Deutz Diesel Models if applicable B 3 Inspect the Tires and Wheels including lug nut torque B 22 Replace the Hydraulic Tank Return Filter D 3 Check the Turnable Rotation Bearing Bolts A 18 Inspect the Radiator Liquid Cooled Models Engine specifications require that this procedure be performed every 100 hours Perform this procedure more often if dusty conditions exist Maintaining the radiator in good condition is essential for good engine performance Operating a machine with a damaged or leaking radiator may result in engine damage Also restricting air flow through the radiator i e dirt or debris will affect the performance of the cooling system A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems AWARNING P dily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine parts and coolant Contact with hot engine parts and or coolant may cause s
291. oth 5 Inspect the filter element If needed blow out from inside out using low pressure dry compressed air or tap dust out taking care not to damage the element 6 Install the air filter element and install the mounting fastener 7 Install the end cap onto the canister Install and tighten the retaining ring TABLE A PROCEDURES Perkins Diesel models 1 Open the engine side cover and disconnect the retaining fasteners from the end cap of the air filter canister Remove the end cap 2 Remove the filter element 3 Empty dust discharge valve by pressing together the sides of the discharge slot Clean discharge slot as needed Perkins diesel models a air filter b dustdischarge valve 4 Clean the inside of the canister and the canister end cap with a damp cloth 5 Inspect the filter element If needed blow out from inside out using low pressure dry compressed air or tap out dust taking care not to damage the element 6 Install the filter element 7 Install the end cap onto the canister Secure the retaining fasteners Air filters Genie part numbers Ford LRG 425 EFI Engine 27916 Deutz F4L 1011F Engine 27916 Perkins 704 30 Engine 62420 Part No 65196 Genie S 60 amp Genie S 65 4 19 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE A PROCEDURES A 17 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be perf
292. ounting leg and connect the hoses to the regulator filter Component damage hazard Be CAUTION sure the correct regulator filter is installed or component damage may occur 12 Turn the manual shutoff valve located at the fuel tank to the open position 13 Start the machine from the ground controls then inspect the fuel filters and hoses for leaks Explosion and fire hazard If a fuel POTNIT leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately 14 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts Part No 65196 Genie S 60 amp Genie S 65 4 29 Section 4 Scheduled Maintenance Procedures Third Edition First Printing Table B Procedures B 1 2 All models Be sure that all nuts and bolts are Check the Exhaust System Inspect all welds for cracks 3 4 Inspect for exhaust leaks i e carbon buildup around seams and joints Maintaining the exhaust system is essential to _ 5 Diesel models Swing the engine pivot plate good engine performance and service life Running back to its original position and install the two the engine with a damaged or leaking exhaust engine pivot plate retaining bolts system can cause component damage and unsafe operating conditions Bodily injury h Do not AWARNING 202 injury hazard Do no inspect while the engine is ru
293. ove the controller all the way to the left or right Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp rate 17 Set the ramp rate Turn the ramp rate trimpot to obtain a 5 second ramp speed Turn the ramp rate trimpot adjustment screw clockwise to increase the time or counterclockwise to decrease the time Turntable rotation specifications Threshold 3 5V DC Turntable rotation Max out boom retracted 6 75V DC Cycle time 80 to 84 seconds Lo range boom extended 6V DC Cycle time 130 to 134 seconds Ramp rate 5 seconds Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures Boom Extend Retract Controller Adjustments Electrocution hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13 6 to 14 5V DC output 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller 2 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls Do not start the engine 3 Open the platform control box lid and locate the boom extend retract controller PLATF
294. p down 16 Check valve Pius Differential sensing circuit platform level up 17 Check valVe sert Differential sensing circuit platform level down 18 Proportional solenoid valve Fun Turntable rotate left right 19 Solenoid valve N O Poppet S edens Platform level up 20 Flow regulator valve 0 6 2 27 L min Platform level circuit 21 Solenoid valve Poppet Usus Platform level down 22 Differential sensing valve M cesis Meters flow to functions 23 Relief valve 2600 psi 179 bar S 60 models 2900 psi 200 bar 5 65 models W System relief 24 Diagnostic nipple P Testing 25 Check valve Mese Differential sensing circuit Platform rotate 26 Check Differential sensing circuit Platform rotate right 27 Priority flow regulator valve NAA Steering idi ded 3 5 gpm 13 2 L min without oscillate axle 5 gpm
295. plate b pivot plate retaining bolts z c air baffle Belt deflection Perkins Diesel models 3 8 inch to 1 2 inch 9 mm to 12 mm 2 Inspect the engine belt for Cracking Engine belts Genie part numbers Glazing Ford models 52580 Separation Perkins Diesel models 62423 Breaks 3 Replace belt if any damage is found Ford LRG 425 EFI engines are equipped with a serpentine belt and incorporate a self adjusting belt tensioner No adjustment is required Part No 65196 Genie S 60 amp Genie S 65 4 27 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE A PROCEDURES A 24 Replace the Fuel Filters Gasoline LPG Models Engine specifications require that this procedure be performed every 200 hours Replacing the gasoline fuel filter is essential to good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Explosion and fire hazard Engine FUTT 4 fuels are combustible Replace the fuel filter in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Locate the fuel pre filter to the left of the ground control box 2 Turn the manual shutoff valve located
296. r 3 Gasoline LPG models Disconnect drain and plug the fuel hose Diesel models Disconnect drain and plug the supply and return fuel hoses Cap the fuel return fitting on the fuel tank 4 Metal tank Remove the fuel tank hold down straps retaining fasteners Remove the straps from the fuel tank Plastic tank Remove the fuel tank retaining fasteners 6 Support the fuel tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane Remove the fuel tank from the machine AWARNING Crushing hazard The fuel tank could become unbalanced and fall when it is removed from the machine if it is not properly supported and secured to the overhead crane Component damage hazard CAUTION When installing the plastic fuel tank do not overtighten the retaining fasteners Clean the fuel tank and inspect for rust and corrosion before installing 7 64 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures 12 2 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and deaerate the hydraulic fluid during operation The tank utilizes internal suction strainers for the pump supply hoses and has an external return filter equipped with a filter condition indicator How to Remove the Hydraulic Tank Component damage hazard CAUTION The work area and surfaces where this procedu
297. r and tighten it securely by hand Clean up any oil that may have spilled during the installation procedure 5 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 6 Start the engine from the ground controls Inspect the filter and related components to be sure that there are no leaks Hydraulic tank return filter Genie part number 46014 TABLE B PROCEDURES B 23 Inspect the Fuel Tank Cap Venting System Genie requires that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist A free breathing fuel tank cap is essential for good engine performance and service life A dirty or clogged fuel tank cap may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the cap be inspected more often Explosion and fire hazard Engine A DANGER fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Remove the cap from the fuel tank Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE B PROCEDURES 2 Check for proper venting When checking for
298. r clogged filter may cause the engine to f B perform poorly and continued use may cause component damage Extremely dirty conditions may required that the filter be replaced more often Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well CA ventilated area away from heaters sparks flames and lighted e VNG tobacco Always have element ener screw approved fire extinguisher within dne sea reach filter element F lower seal Perform this procedure with the engine off 4 Lower the bottom cover of the filter Immediately clean up any fuel that may have spilled during this 5 Remove the element and dispose of properly procedure 6 Clean the inside surfaces of the filter head and 1 Open the engine side turntable cover and locate the bottom cover me Tue miter 7 Lightly lubricate the upper seal and the o ring with clean diesel fuel and install them into the filter head 4 56 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures 8 Lightly lubricate the lower seal with clean diesel fuel and install it into the bottom cover 9 Putthe bottom cover under the new element and hold the element squarely to the filter head Ensure that the element is fitted in the center against the o ring in the f
299. r pin 11 Measure the distance between the drive chassis and the non steer axle on both sides from the inside of the drive chassis If the distance is not equal and the adjustment to the linkage was completed with the ground and drive chassis level consult Genie Industries Service Department i ecu cao qq 7 54 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures MANIFOLDS 11 7 Steer Manifold Components Oscillating Models The steer manifold is located underneath the function manifold Index Schematic No Description Item Function Torque 1 Solenoid valve 3 position 4 way SS Steer 2 2 2 422222 30 35 in Ibs 3 4 Nm 2 Check Priority flow regulator 10 12 ft lbs 14 16 Nm 3 Orifice Plug 0 025 inch 0 635 mm UU Priority flow regulator circuit 4 Priority flow regulator valve 3 5 13 2 L min VV Regulates flow to oscillate manifold 10 12 ft lbs 14 16 Nm Valve Coil Resistance Specifications Description Measurement Solenoid valve 3 position 4 way 10V 4 5 to 7 50 schematic item SS Part No 65196 Genie S 60 amp Genie S 65 7 55 Section 7 Repair Procedures Third Edition First Printing pu
300. rd Edition First Printing Section 7 Repair Procedures 9 2 Toggle Switches See 1 4 Toggle Switches 9 3 Wago Components How to Remove a Wago Component Electrocution hazard Contact with electrically charged circuits could cause death or serious injury Remove all rings watches and other jewelry AWARNING Wago tools are available from the Genie Service Parts Department Genie part number 33996 1 Label the wiring from the component to be removed 2 Useasmall screwdriver to push in and release the wire from the component 3 Locate the removal tab on the bottom or top of the component 4 Usea small screwdriver to gently pry up on the tab of the component and remove it GROUND CONTROLS 9 4 Engine Fault Codes Gasoline LPG Models How to Retrieve Engine Fault Codes When a engine malfunction is detected by the Electronic Control Module ECM a fault code is recorded and the check engine light will turn ow at the ground and platform controls Use the following procedure to retrieve the engine fault code to determine the engine malfunction Perform this procedure with the key switch in the orr position 1 Open the ground controls side turntable cover 2 Open the ground control box and locate the run test toggle switch inside of the ground control box 3 Pull out the ground controls Emergency Stop button to the on position 4 Hold the run test toggle switch to the test position an
301. rd models B 5 Drive hub oil level B 6 Engine RPM B 7 Key switch B 8 Emergency Stop B 9 Ground control override B 10 Directional valve B 11 Platform leveling B 12 Horn B 13 Foot switch B 14 Engine idle select B 15 Fuel select Ford models B 16 Drive enable system B 17 Drive brakes B 18 Drive speed stowed B 19 Drive speed raised B 20 Alarm package B 21 Hydraulic oil analysis B 22 Replace hydraulic tank return filter B 23 Inspect fuel tank cap venting system Perform every 400 hours B 24 Replace engine air filter B 25 Replace spark plugs Ford models Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures MAINTENANCE INSPECTION REPORT Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hour Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in section 4 to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair plac
302. re Harness Gasoline LPG Models 6 7 Electrical Schematic Gasoline LPG Models 6 8 Ground Control Box Wiring Diagram Gasoline LPG Models 6 10 Platform Control Box Wiring Diagram Gasoline LPG Models 6 11 Electrical Schematic Deutz Diesel 6 12 Ground Control Box Wiring Diagram Deutz Diesel 6 14 Platform Control Box Wiring Diagram Deutz Diesel Models 6 15 Electrical Schematic Perkins Diesel Models 6 16 Ground Control Box Wiring Diagram Perkins Diesel Models 6 18 Platform Control Box Wiring Diagram Perkins Diesel Models 6 19 Hydraulic Symbols Legend sessesssssseseeeeeeeeneeennenne 6 21 2WD Hydraulic Schematic Non oscillating axle 6 22 2WD Hydraulic Schematic Oscillating 22 6 23 4WD Hydraulic Schematic Non oscillating axle 6 24 AWD Hydraulic Schematic Oscillating axle 6 25 Part No 65196 Genie S 60 amp Genie S 65 xi Third Edition First Printing TABLE OF CONTEN
303. re burns 9 Install the radiator filler cap Perform this procedure with the machine on level ground Perform this procedure with the engine off 1 Puton protective clothing and eyewear 2 Operate the engine until it is warm enough to open the thermostat Continue to run the engine until the coolant has circulated the cooling system 3 Stopthe engine 4 Allow the engine to cool until the temperature of the coolant is below 140 F 60 C Burn hazard Beware of hot A CAUTION coolant Contact with hot coolant may cause severe burns Part No 65196 Genie S 60 amp Genie S 65 4 59 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE C PROCEDURES C 8 Replace the PCV Valve Gasoline LPG Models Engine specifications require that this procedure be performed every 800 hours Yearly replacement of the PCV valve is essential to good engine performance A malfunctioning PCV valve can restrict crankcase ventilation and may cause engine damage Perform this procedure with the engine off 1 Open the engine side turntable cover 2 Remove the 2 engine pivot plate retaining bolts and swing the engine out away from the machine to access the PCV valve v a engine pivot plate b pivot plate retaining bolts c air baffle 3 Locate the PCV valve on the engine under the intake manifold Remove the hose from the PCV valve a PCV valve hose b PCV valve 4 Remove
304. re hydraulic fluid as the voltage increases A flow regulator valve is a mechanical valve and delivers a predetermined amount of hydraulic fluid Drive forward or reverse is accomplished by pressing down the foot switch in the platform and moving the drive controller joystick in the appropriate direction When activated the drive controller completes a circuit to the Electronic Displacement Controller EDC The EDC regulates drive pump displacement in direct relation to the drive controller position A horsepower limiter printed circuit board located in the platform control box is provided to maintain engine RPM as drive system loads become greater This is done by sensing engine RPM via an AC tap on the alternator and limiting the amount of current supplied to the drive controller EDC which destrokes the pump reducing pump output Part No 65196 Genie S 60 amp Genie S 65 3 1 Section Theory of Operation Third Edition First Printing THEORY OF OPERATION Limit switches There are two types of limit switches which are found in various locations on the machine drive speed limit switches and a drive enable limit switch The function of a drive speed limit switch is to limit the raised or extended drive speed to 0 6 miles per hour 1 km h when the primary boom is raised more than 2 feet 0 6 m OR when the primary boom is extended more than 18 inches 45 7 cm The function of the drive enable limit swit
305. re will be performed must be clean and free of debris that could get into the hydraulic system When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Lower and retract the boom to the stowed position 2 Remove the fuel tank See 12 1 How to Remove the Fuel Tank FUEL AND HYDRAULIC TANKS Close the two hydraulic shutoff valves located at the hydraulic tank open closed Component damage hazard The CAUTION engine must not be started with the hydraulic tank shutoff valves in the cLosEp position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition Remove the drain plug from the hydraulic tank Completely drain the tank into a suitable container See capacity specifications Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves Disconnect and plug the T fitting located at the return filter with the 2 hoses connected to it Cap the fitting on the return filter housing Disconnect and plug the supply hose for the auxiliary power unit Cap the fitting on the hydraulic tank Part No 65196 Genie S 60 amp Genie S 65 7 65 Section 7 Repair Procedures Third Edition First Printing
306. rease the voltage 8 Setthe lo range Press down the foot switch then move the controller all the way to the Down position Adjust the voltage to 6 5V DC Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 9 Startthe engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Lower the boom to the stowed position Engine should be at normal operating temperature 10 Start a timer and record how long it takes for the boom to fully raise Adjust the max out trimpot to achieve a 55 to 60 second cycle time Turn the max out trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed 11 Start a timer and record how long it takes for the boom to fully lower Adjust the lo range trimpot to achieve an 90 to 94 second cycle time Turn the lo range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed If the function cycle time is not achievable check the relief valve pressure See 11 2 Valve Adjustments Function Manifold Part No 65196 Genie S 60 amp Genie S 65 7 3 Section 7 Repair Procedures Third Edition First Printing PLATFORM CONTROLS 12 Turn the engine Turntable Rotation Controller 13 Pull out the Emergency Stop button to Adjustments the on position AWARNING Electrocuti
307. retract proportional valve coil item G 12V or more AA Continued on the next page oV Hold the function enable switch to either side and move the boom extend retract toggle switch in the EXTEND direction Check voltage at TB9 oV With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the boom extend retract toggle switch TS7 in the RETRACT direction Check voltage at TP9 E Press down the foot switch and check voltage at center terminal of TS7 12 Test extend retract bad toggle switch see Repair Section good Repair open in blk red wire circuit from TS7 to TP9 Third Edition First Printing 9 to 10V Repair open in blk red 4 wire circuit from TB9 to boom extend retract proportional valve coil OR repair open in brn ground wire circuit to valve coil Sto tov Repair open in blk red 3 wire from TP9 to TB9 Repair open in power supply circuit from TP24 to TS7 Replace extend retract toggle switch Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Continued from the previous page Disconnect wires to boom extend directional valve coil item C and test the resistance of the valve coil
308. rn the engine off and remove the pressure gauge 7 62 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures SSS SSS SSeS MANIFOLDS 11 13 Jib Boom Platform Rotate Manifold Components S 65 Models The jib boom platform rotate manifold is mounted on the platform end of the boom Index Schematic No Description Item Function Torque 1 2 position way valve AM Platform rotate select 8 10 ft Ibs 11 14 Nm 2 Orifice fitting 0 030 inch 0 76 mm AN Platform rotate circuit Valve Coil Resistance Specification 2 position 3 way solenoid valve 10V 4 5 to 7 50 schematic item AM Part No 65196 Genie S 60 amp Genie S 65 7 63 Section 7 Repair Procedures Third Edition First Printing Fuel and Hydraulic Tanks 12 1 Fuel Tank How to Remove the Fuel Tank Explosion and fire hazard Engine fuels are combustible Remove the fuel tank in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container 1 Turn the manual fuel shutoff valve to the CLOSED position 2 Remove the tank side turntable cover See 4 1 How to Remove a Turntable Cove
309. roller 1 Flashing beacons ES naues Foot switch c Gauge Horn or Alarm KS RW Key switch MUN LED ES satius Limit switch OP Shirai Oil pressure switch iau Oil temperature switch P asso Emergency Stop Button PER dd quens Power relay Fi EREMO Resistor Terminal base location TN Terminal platform location T9 iota Toggle switch WTS Water temperature switch Part No 65196 Genie S 60 amp Genie S 65 6 5 Third Edition First Printing Section 6 Schematics Ford LRG 425 EFI Engine Wire Harness
310. roperly functioning Emergency Stop buttons are essential for safe machine operation An improperly operating Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation for ground and platform personnel As a safety feature selecting and operating the ground controls will override the platform controls including the platform Emergency Stop button 1 Start the engine from ground controls 2 Push the Emergency Stop button to the position Result The engine should shut off and no machine functions should operate Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds 3 Startthe engine from platform controls Push in the Emergency Stop button to the position Result The engine should shut off and no machine functions should operate The ground control Emergency Stop button will stop all machine operation even if the key switch is switched to platform control B 9 Test the Ground Control Override A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is in the oN or position This function is particularly useful if the operator at the platform controls cannot return th
311. rotective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion Be sure that the battery hold downs and cable connections are tight Part No 65196 Genie S 60 amp Genie S 65 4 21 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE A PROCEDURES 4 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer O Result If any battery cell displays a specific gravity of less than 1 026 the battery must be replaced 5 Check the battery acid level of each cell If needed replenish with distilled water to the bottom of each battery fill tube Do not overfill 6 Install the battery vent caps Applying a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables A 20 Replace the Engine Oil and Filter Gasoline LPG Models Ford engine specifications require that this procedure be performed every 100 hours Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A daily check of machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oi
312. rs are in place and secured Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures A 4 Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life Operating the machine with an improper oil level can damage engine components Check the oil level with the engine off 1 Check the engine oil dipstick Ford Models Result The oil level should be within the safe marks on the dipstick Deutz Models Result The oil level should be within the two marks on the dipstick Perkins Models Result The oil level should be within the two notches on the dipstick Ford LRG 425 EFI Engine Oil capacity including filter 4 5 quarts 4 3 liters Oil viscosity requirements below 60 F 15 5 C 5W 30 10 to 90 F 23 to 32 C 5W 30 above 10 F 23 C 5W 30 above 25 F 4 C 10W 30 Use oils meeting API classification SH or SG grade Units ship with 10 40 CC SG TABLE A PROCEDURES Deutz F4L 1011F Engine Oil capacity including filter 8 5 quarts 8 liters Oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE or CC SF grades Units ship with 10 40 CC SG Perkins 704 30 Engine
313. s Be sure the drive limit switches are clear of any debris and are not activated when the boom is in the stowed position Be sure the wiring to limit switches is intact and show no signs of damage or corrosion Be sure the free wheel valve is closed on the drive pump With the boom in the stowed position check continuity from TB40 to ground continuity no continuity Repair short to ground in wht wires to limit switches LS1 and LS2 OR repair or replace boom lift limit switch or boom extend limit switch With the boom in the stowed position check terminal 6 on horsepower limiter board for continuity to ground continuity je continuity Repair short to ground in orange wire from TB40 to TP40 to terminal 6 on horsepower limiter board Re adjust or replace horsepower limiter board OR check for misalignment of limit switches LS1 and LS2 OR consult Genie Industries Service Department Chart 33 Part No 65196 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Third Edition First Printing Chart 34 Machine Drives At Full Speed With Platform Raised or Extended Be sure boom up drive limit switch is being activated by the cam on the boom when the boom is raised Be sure that the boom extend drive limit switch is not being held down or being activated when the boom is extended Be
314. s Cil viscosity requirements below 60 F 15 5 15W 40 10 F to 90 F 23 C to 32 10W 30 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CF4 grade Oil filter Genie part number 62422 C 6 Check the Glow Plugs Perkins Diesel Models Complete information to perform this procedure is available in the Perkins 700 Series Workshop Manual Perkins part number TPD 1359E Genie part number 62424 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures ee I TABLE C PROCEDURES C 7 5 Slowly remove the radiator filler cap Inspect the ig f Repl Check the Specific Gravity of the M MA QAI 5 Burn hazard Allow any pressure Engine Coolant ACAUTION to dissipate gradually before Liquid Cooled Models removing the radiator cap 6 Drain some coolant from the cooling system into a suitable container The quality of the engine coolant which is used can 7 Use a coolant hydrometer to check the have a great effect on the efficiency and life of the temperature and specific gravity of the coolant cooling system Old or dirty engine coolant may 8 Adjustthe strength of the coolant as necessary cause the engine to perform poorly and continued for your climate use may cause engine damage Burn hazard Beware of hot ACAUTION engine parts and coolant Contact with hot engine parts and or coolant may cause seve
315. s a pump for the slave cylinder It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of boom motion The master cylinder is located inside the pivot end of the boom How to Remove the Platform Leveling Master Cylinder When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom until the master cylinder rod end pivot pin is accessible 2 Remove the turntable end cover to access the master cylinder 3 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray BOOM COMPONENTS Remove the pin retaining fastener from the master cylinder barrel end pivot pin Place a rod through the barel end pivot pin and twist to remove the pin Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder Remove the pin retaining fastener from the rod end pivot pin Use a soft metal drift to remove the pivot pin and remove the master cylinder from the machine hing h Th t AWARNING Crushing hazard The master c
316. s and hydraulic hoses can be damaged if the lift cylinder is pulled across them CAUTION BOOM COMPONENTS 4 4 Extension Cylinders The extension cylinder consists of two cylinders that are fastened together The first cylinder extends and retracts the number 2 boom tube The second cylinder extends and retracts the number 3 boom tube The extension cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Extension Cylinders This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Extend the boom until the extension cylinder rod end pivot pin is accessible in the number 3 boom tube 2 Raise the boom to a horizontal position Part No 65196 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Third Edition First Printing SSS BOOM COMPONENTS 3 Remove the external snap rings from the 12 Carefully slide the extension cylinder out of the extension cylinder rod end pivot pin at the pivot end of the
317. s and wire from TB14 to Up Function both Emergency Stop both Emergency Stop aes platform level up Inoperative buttons pulled out to the buttons pulled out to the gt gt gt directional valve coil OR ON position hold the ov ON position hold the repair open in brn function enable switch to function enable switch to ground wire circuit to Be sure all other either side and move the either side and move the valve coil functions operate platform level toggle platform level toggle normally switch TS14 in the UP switch in the UP i direction Check voltage direction Check voltage at org 4 wire on platform at TB14 level up directional valve item io With key switch turned Troubleshoot platform to platform controls and level toggle switches both Emergency Stop TS14 and TS6 OR buttons pulled out to the repair open in red power ON position press down wire circuit to TS14 and the foot switch and gt TS6 OR repair open in move the platform level org 4 wire circuit from toggle switch in the UP TS14 and TS6 to TB14 direction Check voltage OR consult Genie at TB14 Industries Service Department 12V or more Troubleshoot platform level toggle switch TS14 OR repair open in red power wire circuit to TS14 OR repair open in 12V or more org 4 wire circuit from TS14 to TB14 OR consult Genie Industries Service Department v Continued on the next page Part No 65196 Genie S 60 amp Genie S 65 5 47 Section 5 Troubleshooting
318. s sensors to the ECM OR replace the CKP or unknown the signal pulses from CMP sensor pattern the CKP and CMP sensors to initiate sequential fuel injection The ECM received an illegal instruction signal ECM Fault from one or more of the Illegal sensors and has gone Replace the ECM Operation into a default program and then return to normal operation 5 6 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts FAULT CODE CHART Fault Code ECM Illegal Interuption ECM Computer Operating Properly COP failure System voltage low System voltage high The ECM received an illegal interruption signal from one or more engine sensors and has gone into a default program and then return to normal operation Replace the ECM Under normal operation the ECM will store numbers into memory If this does not happen it will reset itself and set fault code 56 Battery supply voltage Check battery and or alternator condition to the ECM is 8V DC or OR check for shorted wires or poor terminal connections from the battery to the ECM Battery supply voltage Check battery and or alternator condition to the ECM is 18V DC OR check for shorted wires or poor terminal connections from the battery to the ECM Part No 65196 Genie S 60 amp Genie S 65 5 7 Section 5 Troubleshooting Flow Charts Third Edition First Printing
319. scription of the fault and recommended repairs With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at LPG side blu red wire of fuel select toggle switch TS11 12V Replace fuel select toggle switch iv Move the start toggle switch to either side and check voltage across the wires on the fuel pump without disconnecting the wires Replace the fuel pump relay B of the engine harness OR consult Genie Industries Service Department With key switch turned to the OFF position and both Emergency Stop buttons pulled out to the ON position turn the key switch to ground controls and listen for the fuel pump to turn ON for approximately 2 seconds Did the fuel pump turn on Repair open in fuel pump wires from fuel pump relay B of the engine harness OR replace the fuel pump ys See Ford LRG 425 EFI service manual for fuel system troubleshooting OR consult Genie Industries Service Department Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Engine High Idle inoperative Gasoline LPG Models See Repair Section How to Retrieve Fault Codes 1 there a fault code stored in the ECM memory yes Check for poor terminal connections O
320. si Fan belt deflection 3 to 1 2 inch 1 8 to 6 bar Oil capacity 11 quarts including filter 10 5 liters Oil viscosity requirements Temperature below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 Temperature above 4 F 34 C 15W 40 Engine oil should have properties of API classification SG CC or CD SG grades Units ship with 10W 40 SG CC Part No 65196 Genie S 60 amp Genie S 65 2 5 Section 2 Specifications SPECIFICATIONS Perkins Engine 704 30 Displacement 183 cu in 2 9 liters Number of cylinders 4 Bore and stroke 3 82 x 3 94 inches 97 x 100 mm Horsepower 63 Q 2600 rpm Firing order 1 3 4 2 Compression ratio 17 5 1 Compression pressure 300 to 500 psi 20 7 to 34 5 bar Pressure psi of lowest cylinder must be within 50 psi 3 45 bar of highest cylinder Low idle 1600 rpm High idle 2200 rpm Governor centrifugal mechanical Valve clearance cold Intake 0 014 in 0 35 mm Exhaust 0 014 in 0 35 mm Lubrication system Oil pressure 41 psi at 2600 rpm 2 8 bar Oil capacity 7 3 quarts including filter 8 3 liters Oil viscosity requirements below 68 F 20 C synthetic 5W 20 5 F to 104 F 15 C to 40 10W 30 above 14 F 10 C 15W 40 Engine oil should have properties of API classification CC SE API classification CD SE or CCMC D4 can be used but is not recommended during the first 50 hours or for light load applications Third Edit
321. ssssszst s3gSSSS35S5s5 oz2z2 o Bsoss zd Pirz ss ss z s x g CR14 PLATFORM ROTATOR RELAY 3 2 RE REB i6 ii B io io i 11 xB A9 ENS a xu DP1 DRIVE PROPORTIONAL CONTROLLER olal 195 ele amp eG L A A fala STEER LEFT RIGHT 2 FS CABLE FROM FOOT SWITCH S RED BLK JIB CABLE H P L HORSEPOWER LIMITER BOARD E CR14 H1 TILT ALARM HORN Eh JIB CABLE FOR JIB FUNCTION CABLE CABLE CABLE JIB 110 11 DRIVE ENABLE LED 3 2 1 d 4 P2 EMERGENCY STOP BUTTON P3 HORN BUTTON 4 H1 1 RESISTOR TS1 AUXILIARY SWITCH TS2 START ENGINE SWITCH TS3 GLOW PLUG OPTION o lololol gt 5 5 322 oo 2 mom olola olsa o s v TS4 HIGH RPM SWITCH 2 58653465 i d 58852283 5 amp 588 4 TS5 PLATFORM ROTATE SWITCH E Baza so B i Bx 5 m i E 8 8 m m ae 5 S I TS6 JIB BOOM UP DOWN SWITCH 5 ele sig xs 8r x xa I s x TS7 PLATFORM LEVEL UP DOWN a ols i 47471 9 S 6 2 gir amp TS8 DRIVE SPEED SELECT SWITCH 5 f TS9 TS20 1 gt TS9 DRIVE ENABLE SWITCH Oo x TS20 GENERATOR SWITCH OPTION 1 9 2 Yo o M TS23 LIFT DRIVE SELECT SWITCH OPTION lt che o 110 AC POWER CABLE x x 2 4A 2 TS23 CR13 CE 6 c gt 4 4 lt N 86 e O O SH S lt 5 L1
322. ster cylinder see Chart 20 OR repair or replace slave cylinder or slave cylinder counterbalance valves OR function manifold may have an internal fault Consult Genie Industries Service Department Third Edition First Printing NOTE 1 5 60 2600 PSI or more 5 65 2900 PSI or more NOTE 2 5 60 Less than 2600 PSI S 65 Less than 2900 PSI 5 48 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Platform Level Chart 22 With 2 With key switch turned open in org blk 4 1 to ground controls an to ground controls and wire from TB15 to Down Function both Emergency Stop both Emergency Stop d platform level down Inoperative buttons pulled out to the buttons pulled out to the gt gt gt directional valve coil OR ON position hold the ON position hold the repair open in brn function enable switch to 0V function enable switch to ground wire circuit to Be sure all other either side and move the either side and move the valve coil functions operate platform level toggle platform level toggle normally switch TS14 in the switch in the DOWN i DOWN direction Check direction Check voltage voltage at org blk 4 wire at TB15 on platform level down directional valve 0 item 0 With key switch turned Troubleshoot platform to p
323. tart module Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts eee CHART 1 Move the start toggle Check ground wire to Repair open in brn 2 4 the switch to either side and La terminal 5 on ignition bad y ground wire to ignition pags J check voltage at start module start module terminal 1 on ignition start module d Consult Genie Industries 12V Service Department Move the start toggle Repair open in blk wire switch to either side and 0V from terminal 41 on check voltage at 4 ignition start module to terminal 86 on CR1 CRI jn Check voltage at OV Repair open in red wire terminal 30 on CR1 circuit from battery to 1 to CR1 terminal 30 12V Move the start toggle ov Check brn ground wire bad Repair open in brn switch to either side and to terminal 85 on CR1 ground wire circuit to check voltage at CRI terminal 87 on CR1 good 12V Replace CR1 relay Move the start toggle 0 Repair open in blk wire switch to either side and gt circuit from CR1 to check voltage at the blk starter solenoid wire on the starter solenoid E Check voltage at starter OV Repair open in battery cable cable to starter
324. tenance Procedures Turntable Rotate Drive Hub 1 Secure the turntable from rotating with the turntable rotation lock pin unlocked locked 2 Remove the motor brake mounting bolts and then remove the motor and brake from the drive hub and set them to the side Component damage hazard CAUTION 9 Hoses can be damaged if they are kinked or pinched a motor b motor brake mounting bolts c brake d drive hub e drive hub mounting bolts TABLE D PROCEDURES 3 Remove the drive hub mounting bolts and use a lifting device to remove the drive hub from the machine 4 Remove the plug from the side of the drive hub Then drain the oil from the hub 5 Install the drive hub Torque the drive hub mounting bolts to 180 ft Ibs 244 Nm 6 Install the brake and motor onto the drive hub Torque the motor brake mounting bolts to 180 ft lbs 244 Nm 7 Fill the hub with oil from the side hole until the oil level is even with the bottom of the hole Apply pipe thread sealant to the plug Install the plug 8 Adjust turntable rotation gear backlash See 13 1 How to Adjust the Turntable Rotation Gear Backlash Turntable rotate drive hub Oil capacity 17 fluid ounces 0 51 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 65196 Genie S 60 amp Genie S 65 4 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE D
325. tenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to perform each procedure AWARNING as presented and scheduled may cause death serious injury or substantial machine damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a flat level surface Boom in the stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock pin Key switch in the orr position with the key removed Wheels chocked About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend 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 Red used to indicate the A DANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to ind
326. the engine side turntable cover 2 Remove the 2 engine pivot plate retaining bolts and swing the engine out away from the machine to access the wiring MI a engine pivot plate b pivot plate retaining bolts c air baffle 3 Inspect the following areas for burnt chafed corroded and loose wires Engine wiring harness Hydraulic manifold wiring 4 Open the ground controls side turntable cover 5 Inspect the following areas for burnt chafed corroded and loose wires Inside of the ground control box Hydraulic manifold wiring 6 Startthe engine from the ground controls and raise the boom above the turntable covers 7 Inspect the turntable area for burnt chafed and pinched cables 8 Lower the boom to the stowed position and turn the engine off 9 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable track on the primary boom Cables on the primary and jib booms Jib boom platform rotate manifold Inside of the platform control box 10 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures A 22 Check the Oil Cooler and Cooling Fins Deutz Diesel Models Engine specifications require that this procedure be performed every 125 hours Maintaining the oil cooler in good con
327. the quick disconnect coupling on the function manifold and activate the platform rotate right function SEE NOTE 2 Exchange platform rotate flow regulator valve item DD with platform level flow regulator valve item T and activate the platform rotate right function function inoperative Consult Genie Industries Service Department 0 or infinite ohms function rat operates function rat operates SEE NOTE 1 function rat operates Replace the platform rotate right directional valve coil item CC Replace the faulty directional valve Replace the faulty counterbalance valve Check for mechanical restrictions keeping platform rotate right function from operating OR repair or replace platform rotator OR replace platform rotator counterbalance valve manifold OR consult Genie Industries Service Department Replace faulty flow regulator valve Third Edition First Printing NOTE 1 5 60 2600 PSI or more 5 65 2900 PSI or more NOTE2 5 60 Less than 2600 PSI S 65 Less than 2900 PSI 5 54 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Oscillate Function inoperative Be sure all other functions operate normally Remove the chassis cover at the non steer
328. ting bolts dry 75 ae 102 Nm When removing a hose assembly f or fitting the O ring on the fitting Drive motor mounting bolts lubricated 56 ft lbs and or hose end must be replaced 76 Nm and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the fasteners from the drive chassis cover on the non steer axle Remove the cover 7 78 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing 17 2 Drive Hub How to Remove a Drive Hub When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Section 7 Repair Procedures NON STEERING AXLE COMPONENTS 7 Remove the drive hub mounting bolts that attach the drive hub to the chassis Remove the drive hub Crushing hazard The drive hub CAUTION may become unbalanced and fall if it is not properly supported and secured to the lifting jack Torque specifications Lug nut torque dry 125 ft lbs Refer to Section Two Hydraulic 169 5 Nm Hose and Fitting Torque Specifications Lug nut torque lubricated 94 ft lbs 127 4 Nm 1 Remove the drive motor See 17 1 How to Remove a Drive Motor Drive hub mounting bolts dry 120 ft lbs 163 Nm 2 Tag disconnect and plug the hydraulic hose from the brake Remove the hydraulic
329. tinuity of brn to platform controls and joy ground wire from both Emergency Stop gt 55 terminal 3 on drive buttons pulled out to the controller to ground a ee the foot switch an check voltage at no continuity terminal 2 on drive controller Repair open in brn ground wire circuit from ground to drive controller 12V or more less With key switch turned than Check continuity of brn to platform controls and yoy ground wire from both Emergency Stop terminal 2 on the buttons pulled out to the horsepower limiter ON position press down board to ground the foot switch and check voltage at terminal 1 v the continuity horsepower limiter board Repair open in brn ground wire circuit from ground to terminal 2 on the horsepower limiter 12V or more board Y Press down the foot Press down the foot switch and check the oV switch and check voltage at terminal 10 voltage at terminal 3 on on the horsepower limiter board the horsepower limiter board 9 to 12V v oV Press down the foot switch and check voltage on the org blk 41wire the alterator oV Repair or replace alternator Continued on the next page continuity o continuity gt 7 to 8V 7 to 8V Repair open in power supply circuit from TP24 to terminal 2 on drive controller Repair open in power
330. tion press down the foot switch and hold the steer rocker switch on drive controller in the LEFT direction Check voltage at the controller terminal with the blu wire attached 12V or mor more Repair open in blu wire circuit from drive controller to TP36 then blu 1 wire circuit to TB36 E Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and hold the steer rocker switch on drive controller in the LEFT direction Check voltage on blu 36 wire on steer left directional valve coil item TT on steer manifold ov Repair open in blu 36 wire circuit from TB36 to steer left directional valve coil on steer manifold OR repair open in brn ground wire circuit to steer left directional valve coil h 2V or more Disconnect wires to steer left directional valve coil on steer manifold and test the resistance of the valve coil 0 or infinite ohms Replace steer left directional valve coil OR repair open in brn ground wire circuit to steer left valve coil 5 to 6 ohms AA Continued on the next page Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Continued from the previous page Inst
331. tive terminal on bad y both Emergency Stop auxiliary pump motor to buttons pulled out to the ground ON position move the auxiliary pump toggle d switch to either side and goo check the voltage on the red cable on the Replace auxiliary pump auxiliary power unit motor ov v Continued on the next page Reconnect pressure hose and check battery condition There may not be enough battery capacity to operate both auxiliary pump and directional valves Repair or replace pump OR replace relief valve Consult Genie Industries Service Department Replace negative cable from auxiliary pump motor to ground 5 72 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts n o U EN CHART 36 Continued from the N Test PR1 See Repair Replace PR1 previous page Procedure 8 5 Move the auxiliary pump 12Vor Repair open from TB27 toggle switch to either more to PR1 OR repair open side and check voltage in brn ground wire circuit at TB27 to PR1 OR replace PR1 Move the auxiliary pump Repair open in red toggle switch to either oV power supply wire from side and check the key switch to auxiliary voltage at the center pump toggl
332. to the ON position press down the foot switch and hold the steer rocker switch on drive controller in the RIGHT direction Check voltage on blu blk 37 wire on steer right directional valve coil item TT on steer manifold 12V or more Disconnect wires to steer right directional valve coil on steer manifold and test the resistance of the valve coil 5 to 6 ohms AA Continued on the next page ov With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and hold the steer rocker switch on drive controller in the RIGHT direction Check voltage at the controller terminal with the blu blk wire attached E Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department ov Repair open in blu blk 37 wire circuit that runs from TB37 to steer right directional valve coil on steer manifold OR repair open in brn ground wire circuit to steer right valve coil 0 or infinite ohms r Replace steer right directional valve coil OR repair open in brn ground wire circuit to steer right valve coil 12V or more Repair open in blu blk wire circuit from drive controller to TP37 then blu blk 1 to TB37 5 62 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Continued fr
333. tract toggle switch TS7 in the EXTEND direction Check voltage at TP9 iv Third Edition First Printing Repair open in blk red 3 wire circuit from TB9 to boom extend retract proportional valve coil OR repair open in brn ground wire circuit to valve coil Repair open in blk red 3 wire from TP9 to TB9 Press down the foot Repair open in power switch and check gt supply circuit from TP24 voltage at center to TS7 terminal of TS7 h 2V or more Test toggle switch TS7 bad Replace toggle switch see Repair Section TS7 good Repair open in blk red wire circuit from TS7 to TP9 5 34 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Continued from the previous page N N 7 0 Disconnect wires to boom extend directional valve coil item C and test the resistance of the valve coil See Repair Section 0 or infinite ohms Replace boom extend directional valve coil 2 5 to 3 5 ohms Hold the function enable switch to either side and move the boom extend retract toggle switch TS15 in the EXTEND direction Manually override the directional valve by pushing in on the end of the valve spool function operates gt Replace faulty directional valve
334. trols both Emergency Stop at TP6 i Press down the foot switch and check voltage at terminal on controller 12V or more Re adjust controller see Repair Section OR replace controller OR consult Genie Industries Service Department Repair open in wht red 4 wire circuit from TB6 to turntable rotate proportional valve coil OR repair open in brn ground wire circuit to valve coil Repair open in wht red 3 wire from TP6 to TB6 Repair open in power supply circuit from TP24 to controller OR repair open in brn ground wire circuit from ground to controller 5 42 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Continued from the previous page With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the turntable rotate toggle switch TS17 in the RIGHT direction Check voltage on wht 4 wire on turntable rotate right directional valve coil item A Section 5 Troubleshooting Flow Charts n U oV m Hold the function enable switch to either side and move the turntable rotate left right toggle switch in the RIGHT direction Check voltage at TB4 12V or more oV 12V or more
335. turn the engine off 12 Check the oil filter oil pan drain hose and drain valve for leaks 18 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts 14 Check the engine oil level dipstick Add oil if needed 15 Clean up any oil that may have spilled Properly dispose of the oil and filter Ford LRG 425 EFI Engine 4 5 quarts capacity including filter 4 3 liters Cil viscosity requirements below 60 F 15 5 C 5W 30 10 to 90 F 23 to 32 C 5W 30 above 10 F 23 C 5W 30 above 25 F 4 C 10W 30 Use oils meeting API classification SH or SG grade the new oil filter Install the filter and tighten it ee ly securely by hand Part No 65196 Genie S 60 amp Genie S 65 4 23 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE A PROCEDURES A 21 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 100 hours Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Open
336. uel pressure to dissipate gradually Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting MI AS them PN 2 0 9 5 9 a hose from the injector to the fuel tank b hoses connecting injectors hose from the fuel shutoff valve to the fuel pump d X hose from the fuel pump to the fuel filter e hose from the fuel filter to the injection pump f hose from the injection pump to the injectors Part No 65196 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE D PROCEDURES D 11 Check the Engine Valve Clearances Perkins Diesel Models Complete information to perform this procedure is available in the Perkins Workshop Manual Perkins part number TPD 1359E Genie part number 62424 D 12 Clean the Engine Breather Assembly Perkins Diesel Models Complete information to perform this procedure is available in the Perkins Workshop Manual Perkins part number TPD 1359E Genie part number 62424 4 72 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures E 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely
337. ut This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend 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 Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 65196 Genie S 60 amp Genie S 65 7 1 Section 7 Repair Procedures Third Edition
338. ve both pivot pins Remove the platform rotator from the machine Crushing hazard The platform AWARNING rotator could become unbalanced and fall if it is not properly supported a top bleed valve b bottom bleed valve C clear hose d container 2 Move the platform rotate toggle switch to the left and then to the right through two platform rotation cycles continue holding the switch to the RIGHT until the platform is fully rotated to the right 7 16 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures PLATFORM COMPONENTS 3 Open the top bleed valve but do not remove it 4 Move the platform rotate toggle switch to the LEFT until the platform is fully rotated to the left Continue holding the switch until air stops coming out of the bleed valve Close the bleed valve Crushing hazard Keep clear of AWARNING the platform during rotation 5 Connect the clear hose to the bottom bleed valve Open the bottom bleed valve but do not remove it 6 Hold the platform rotate toggle switch to the RIGHT until the platform is fully rotated to the right Continue holding the switch until air stops coming out of the bleed valve Close the bleed valve Crushing hazard Keep clear of AWARNING the platform during rotation 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled 8 Rotate the platform full right then full left and inspe
339. ve the boom up down toggle switch in the UP direction and check the pressure SEE NOTE2 Exchange boom flow regulator valve item H with boom extend retract flow regulator valve item G Check boom up function function inoperative Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal fault Consult Genie Industries Service Department Replace boom up down directional valve coil Replace the faulty directional valve Check for mechanical restrictions keeping NOE boom from moving OR repair cylinder or gt cylinder counterbalance valve OR consult Genie Industries Service Department function operateg Replace the faulty flow regulator valve Third Edition First Printing NOTE 1 S 60 2600 PSI or more S 65 2900 PSI or more NOTE 2 S 60 Less than 2600 PSI S 65 Less than 2900 PSI Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Boom Down Function inoperative Be sure all other functions operate normally With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the boom up down toggle switch TS16 in the DOWN direction Check voltage
340. ve the drive controller off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive controller is moved off center in either direction Part No 65196 Genie S 60 amp Genie S 65 4 47 Section 4 Scheduled Maintenance Procedures Third Edition First Printing TABLE B PROCEDURES B 21 B 22 Perform Hydraulic Oil Analysis Replace the Hydraulic Tank Return Filter See E 1 Test or Replace the Hydraulic Oil Genie requires that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist Replacement of the hydraulic tank return filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Perform this procedure with the engine off 1 Place a suitable container under the hydraulic tank return filter 2 Remove the filter with an oil filter wrench 3 Apply a thin layer of fresh oil to the new oil filter gasket 4 48 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 4 Scheduled Maintenance Procedures 4 Install the new filte
341. wire and the wht blk 31 on 2V Repair open in wht wire from terminal 4 on drive controller to TS8 to TP30 to TB30 through drive enable limit switch LS3 to TB12 to wht 12 wire on EDC quick disconnect plug EDC o Connect the positive lead from a voltmeter to terminal 5 on the drive controller and the negative lead from the voltmeter to the blu wht wire on TS8 Press down the foot switch and move the drive controller in the full forward position Hold the drive enable toggle switch to either side and check voltage 2V Repair open in blu wht wire from TS9 to TP12 to TB12 o Connect the positive lead from a voltmeter to terminal 5 on the drive controller and the negative lead of the voltmeter on the center terminal of the drive enable toggle switch Press down the foot switch and move the drive controller in the full forward position Hold the drive enable switch to either side and check oV Repair open in wire from terminal 4 from drive controller to drive enable toggle switch OR replace drive controller OR consult Genie Industries Service Department voltage Replace drive enable toggle switch TS8 Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 5 Troubleshooting Flow Charts Chart 31 Drive Forward Disconnect the EDC wire connector from the
342. x size 7 3 inch Oil pressure switch point 4 2 psi 0 3 bar Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Section 7 Repair Procedures Ford Engine LRG 425 EFI 8 1 Timing Adjustment The ignition timing is controlled by the ECM and can only be adjusted by re programming the ECM If timing adjustment or service is required please contact Genie Industries Service Department OR your local Ford dealer 8 2 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump OO pump a b pump shaft coupler d flex plate with raised spline e flywheel f 1 gap How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Supportthe drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 4 Remove the flex plate mounting fasteners then remove the flex plate from the engine fly wheel How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump Torque the flex plate mounting bolts to 34 ft I
343. xtend and retract between the drive chassis and the oscillating axle The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic hose failure How to Remove an Oscillating Axle Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Perform this procedure on a firm level surface with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Rotate the turntable until the boom is between the steer tires 2 Remove the fasteners from drive chassis cover at the steer end Remove the cover 3 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the oscillate cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the pin retaining fasteners from the rod end pivot pin Use a soft metal drift to remove the pin 5 Attach a lifting strap
344. y switch turned to the OFF position and both Emergency Stop buttons pulled out to the ON position turn the key switch to ground controls and listen for the fuel pump to turn ON for approximately 2 seconds and then shut OFF Did the fuel pump turn on Test the fuel pump relay See Repair Section OR replace the fuel pump Remove 1 spark plug and ground spark plug body Crank engine and observe spark good spark Consult Genie Industries Service Department y weak or no spark Continued on the next page Genie S 60 amp Genie S 65 Part No 65196 Third Edition First Printing Continued from the previous page Disable starter by removing blk wire at the starter solenoid move the start toggle switch to either side and check voltage at the light green wire on the ignition coil plug less than 12V Repair open in light green wire from the ECM to ignition coil OR check for loose or bad connections from the ECM to the ignition coil OR replace the ignition coil OR consult Genie Industries Service Department 12V Section 5 Troubleshooting Flow Charts eee See Ford LRG 425 EFI Service Manual for troubleshooting the ignition system OR consult Genie Industries Service Department CHART 2 Part No 65196 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Third E
345. ylinder could become unbalanced and fall if it is not properly supported by the lifting device Part No 65196 Genie S 60 amp Genie S 65 7 29 Section 7 Repair Procedures Third Edition First Printing Turntable Covers 5 1 Turntable Covers How to Remove a Turntable Cover 1 Raise the turntable cover Support and secure the open cover with an overhead crane or forklift Do not lift the cover AWARNING CAUTION Crushing hazard Due to its heavy weight do not attempt to support the cover by hand Component damage hazard Protect the cover from damage by using carpet or padding on the crane or forkliftforks 2 Remove the upper and lower retaining clips from the gas strut 3 Gently pry the strut pivot sockets off of the ball studs and remove the strut Protect the strut cylinder rod from damage Mark the location of the hinge support bracket on the bulkhead to ensure proper cover alignment during installation 4 Remove the cover hinge bolts that fasten the hinge support bracket to the bulkhead 5 Carefully lift and remove the cover from the machine AWARNING AWARNING Bodily injury hazard Safety decals are essential to safe machine operation Failure to replace all safety and instructional decals could result in death or serious injury If a turntable cover must be replaced be sure that all appropriate safety and instructional decals are applied to the new cover Crushing hazard

Download Pdf Manuals

Related Search

Related Contents

Your HTC EVO 3D  User Manual Edition 5a  Télécharger  Samsung AS09W8WE/AFR Manual de Usuario  Atlas Sound SIREN HPG-370GA User's Manual  Neighborhood Patrol Drone - The University of Texas at Arlington    OPTOCODE-II-CAN  35298_TSD bettery charge IM L-O A4.indd  Cypress NoBL CY7C1471V25 User's Manual  

Copyright © All rights reserved. Failed to retrieve file